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The present paper is an exploration of six sigma in foundry adopt for the refinement of green sand casting process by decreasing the defects for getting sufficiently good casting improvement. An approach based on case study is applied for reducing defects by implementing six sigma techniques. Proposed technique is used for optimizing the various factors which are responsible for controlling quality,...
Aiming at the problem about the nonlinear function and the mechanical zero offset in the vibration system of continuous casting mold driven by servo motor, a discrete auto disturbance rejection control (ADRC) with nonlinear function processing algorithm is proposed. Firstly, for the nonlinear multi solutions problem existing between rotation angle and displacement of mold, a nonlinear algorithm is...
This study focuses on providing a framework to assist the technology evaluation to produce stable arsenic compounds in mining in Chile. Technological processes offer different attributes to show consideration for the environment, arsenic capacity reduction, process viability and efficiency. The objective is to determine the most appropriate technology for arsenic abatement that comes from the casting...
The utilization of dual power control in a directional solidification system (DSS) is shown to help grow higher quality multi-crystalline ingots, particularly high performance ingots with seeded growth. Since the power ratio to the top and the side heaters is tunable, this allows optimal control of the power profile and the solidification front throughout the entire casting process. A dual power controlled...
This paper deals with the control of the preheating process of a casting mould formulated as a distributed parameter system and using a programmable logic controller (PLC). The control process is first optimized by a simulation procedure using a distributed parameter control loop. The temporal part of the control synthesis is implemented on the PLC in order to control the preheating of the casting...
In this paper, a new fuzzy-adaptive mould level control to improve the steel guality in the continuous casting process will be described. The concept does not reguired additional hardware. The presented commissioning results show a better control behaviour e.g. in case of worn stoppers.
Mold level control is an important part of continuous casting process, and is an indispensable part to keep the process safe and make the quality of slab stable. As for the problem of poor performance in the mold level disturbance when the traditional PID controller is applied to mold level control, a fuzzy predictive PID control method is introduced based on the analysis of the controlling object's...
A Model Predictive Control (MPC) is a system designed to control a production plant. These systems are composed by several phases, being one of the most important ones the phase for the prediction of the plant situation in a given time. In a previous work, we presented a machine-learning approach for this prediction phase that replaced the need of developing a single mathematical function with a more...
In [1], the authors introduced a novel control law for the single-phase Stefan problem, a nonlinear partial differential equation, with the eventual goal of applying the result to control of cooling in continuous steel casting. In this paper, the previously published method of controlling the Stefan problem is extended in two key ways that improve the fidelity of the nonlinear PDE as a model of the...
The production process of steelmaking-continuous casting is a complex process which is high temperature, continuous, and uncertain. A multi-agent based simulation model is proposed to simulate the complex production process. Firstly, we present a simulation system architecture based on multi-agent technique. Secondly, we present the functional structure of agent and the communication / storage mechanism...
Through analyzing the effect factors of error in rapid glass mould manufacturing process, the rapid tooling precision control system has be researched. Using of computer simulation of metal casting process to compensate size changes, and using electrical discharge machining eliminate mold roughcast making process of size change, the rapid mould manufacturing process chain error can be considered as...
Controlling and eliminating defects, such as macro-porosity, in die casting processes is an on-going challenge for manufacturers. Current strategies focus on the execution of a pre-set casting cycle and die structure design. To respond to process variability and mitigate its negative effects, advanced process control methodologies may be employed to dynamically adjust the operational parameters of...
The mold level control is one of most important control loops in a steel continuous casting process, since level variations higher than 10−2m may impair the quality of the steel. The goal of this paper is to apply the Hammerstein Generalized Predictive Controller (HGPC) technique to control the mold level, considering the effects of external disturbs and random noises. The parameters of the controller...
Mold level control is a crucial part in the continuous casting process. However, uncomfortable uncertainties and nonlinearities of this system lead considerable challenges and difficulties for a traditional PID controller. The model of AC servo electric cylinder, stopper flow characteristics, characteristics of the casting speed, mold and liquid level detection device were established. A new mold...
A control model of the steel casting process will be proposed using fractional order differential equations (FDE) and the orthogonal distance fitting (ODF). These two mathematical approaches will be used for creating a relationship between the speed of steel casting and the measured temperature of the steel strand in a critical place of the continuous steel casting machine. To obtain the required...
This paper is concerned with the modeling of a plastic film manufacturing process and the development and implementation of a model-based Cross-Directional (CD) controller. The model is derived from first-principles and some empirical relationships. The final validated nonlinear model could provide a useful offline platform for developing control and monitoring algorithms. A new controller is designed...
In this paper it is presented a design procedure for identification and control of the metal level on the aluminium casting process. This process is the final step of the aluminium production and is extremely related to the product quality issues. The automatic control of the metal level allows operators focus on other activities and reduces product variability due to disturbances. This avoid production...
The goal of this paper is to apply the Generalized Predictive Controller (GPC) to control the mold level in a continuous casting process, considering the effects of the clogging disturb and the argon gas noise. Using a linear mathematical model of a real plant, it is shown by simulation the necessity of including the recursive identification and the Kalman filter in the control loop, in order to satisfy...
This paper, the third in a series, completes the presentation of a proposed set of modifications and extensions to the IMS Learning Design specification with the goal of enabling better support for adaptivity in collaborative learning settings. The extensions presented here target advanced adaptation features that build upon previous work and include: adapting control flows, controlling adaptations...
Aiming to improve the control system performance, the product quality and productivity for a bloom caster, the modified control system was designed and implemented in an Specialty Steel plant. Programmable logic controller (PLC) based Level I automation control system was developed to control level, frequency, flow rate, speed, pressure, etc. in the continuous casting process. Level II supervisory...
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