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公开(公告)号：US12030114B2
公开(公告)日：2024-07-09
申请号：US17907161
申请日：2021-03-25
申请人： NOVELIS INC.
发明人： Phillip Wilson , John Robert Buster McCallum , Aaron David Sinden , Brent Opdendries , Jason Dell Hymas , Todd F. Bischoff
IPC分类号： B22D11/049 , B22D11/00 , B22D11/112 , B22D11/22
CPC分类号： B22D11/049 , B22D11/003 , B22D11/112 , B22D11/22
摘要： Systems and associated methods are provided for controlling the shape of an ingot head during formation. At the end of a cast, prior to forming the ingot head, chill bars or other cooling structure may be lowered into an ingot mold and define a reduced casting footprint for forming the ingot head. Supplemental molten metal may be fed into the reduced casting footprint, and the chill bars may be moved laterally towards the center of the ingot, further reducing the casting footprint. As additional molten metal fills the reduced mold footprint, the ingot may be lowered relative to the chill bars to further increase the height of the ingot head. Additional molten metal may be added until the desired shape of the ingot head is formed.
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公开(公告)号：US20230286036A1
公开(公告)日：2023-09-14
申请号：US18005885
申请日：2021-07-23
申请人： Novelis Inc.
发明人： John Robert Buster McCallum , Phillip Wilson , Larry Hudson , Richard Shockley , Todd F. Bischoff , Adwait Thakur
IPC分类号： B22D11/16 , B22D11/049
CPC分类号： B22D11/16 , B22D11/049
摘要： Systems and methods are disclosed for an event detection system that captures data associated with events while a DC casting system forms an ingot, determines characteristics of the events, and improves the casting system based on the events. Example systems and methods may include initiating a casting operation using one or more pieces of equipment of a casting system including a casting apparatus; capturing sensor data associated with one or more acoustic signals captured relative to the one or more pieces of equipment performing the casting operation; comparing the sensor data with a set of acoustic profiles; determining whether a particular type of event has occurred; causing an adjustment to the casting system or to the casting operation based on whether the particular type of event has occurred; and initiating a second casting operation using the adjusted casting system or casting operation.
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公开(公告)号：US20240207924A1
公开(公告)日：2024-06-27
申请号：US18596071
申请日：2024-03-05
申请人： Novelis Inc.
发明人： John Robert Buster McCallum , Phillip Wilson , Larry Hudson , Richard Shockley , Todd F. Bischoff , Adwait Thakur
IPC分类号： B22D11/16 , B22D11/049
CPC分类号： B22D11/16 , B22D11/049
摘要： Systems and methods are disclosed for an event detection system that captures data associated with events while a DC casting system forms an ingot, determines characteristics of the events, and improves the casting system based on the events. Example systems and methods may include initiating a casting operation using one or more pieces of equipment of a casting system including a casting apparatus; capturing sensor data associated with one or more acoustic signals captured relative to the one or more pieces of equipment performing the casting operation; comparing the sensor data with a set of acoustic profiles; determining whether a particular type of event has occurred; causing an adjustment to the casting system or to the casting operation based on whether the particular type of event has occurred; and initiating a second casting operation using the adjusted casting system or casting operation.
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公开(公告)号：US11951536B2
公开(公告)日：2024-04-09
申请号：US18005749
申请日：2021-07-23
申请人： Novelis Inc.
IPC分类号： B22D11/18 , B22D11/049
CPC分类号： B22D11/185 , B22D11/049
摘要： A monitoring system may monitor a gap between an ingot and a bottom block of a mold. The monitoring system may include a camera and a computer system. The camera may be positioned to capture or detect optical data associated with one or more molds positioned in a casting environment and send the optical data to the computer system. The computer system may compare the optical data with a baseline profile. Based on the comparison between the optical data and the baseline profile, the computer system may determine if the ingot has separated from the bottom block and the height of the separation. The computer system may generate operating instructions based on the separation. The operating instructions may be used to adjust the casting process.
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公开(公告)号：US20240042518A1
公开(公告)日：2024-02-08
申请号：US18258670
申请日：2021-12-13
申请人： Novelis Inc.
IPC分类号： B22D27/00
CPC分类号： B22D27/003 , B22D27/006
摘要： Disclosed herein are gas control systems and associated methods of controlling gas in a mold in casting, such as aluminum casting. The system may have a first mass controller, a second mass controller, and a control device capable of switching the gas control system between a first operating state and a second operating state. The first mass controller and the second mass controller may have different flow rate ranges. In the first operating state, the gas control system may deactivate one of the first or second mass controllers, and in the second operating state, the gas control system may activate both first and second mass controllers.
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公开(公告)号：US20240189863A1
公开(公告)日：2024-06-13
申请号：US18556144
申请日：2022-06-06
申请人： Novelis, Inc.
CPC分类号： B07C5/3412 , B07C5/3416 , B07C5/342 , B07C5/363
摘要： Methods and systems for sorting mixed metal scrap may first determine a sorting attribute of each article of metal scrap, and subsequently mark each article with a machine-readable or visually identifiable mark according to the sorting attribute. The articles of mixed metal scrap can be sorted along a high throughput conveyance using a series of sensors to scan the articles for the machine-readable marks, and rapidly sorting marked articles to appropriate sorting destinations based on detecting the machine-readable marks, and without requiring repeat identification by metal analyzers at the sorting step.
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公开(公告)号：US20230286037A1
公开(公告)日：2023-09-14
申请号：US18005712
申请日：2021-07-23
申请人： Novelis Inc.
IPC分类号： B22D11/18 , B22D11/049 , B22D11/14 , B22D7/06
CPC分类号： B22D11/185 , B22D11/049 , B22D11/147 , B22D7/06 , B22D11/141 , B22D9/003
摘要： A monitoring system may monitor the level of molten metal in a mold. The monitoring system may include a camera and a computer system. The camera may be positioned to capture or detect optical data associated with one or more molds positioned in a casting environment and send the optical data to the computer system. For example, the computer system may determine the level of the molten metal in the mold. The level of the molten metal in the mold may be compared with a baseline level. The computer system may generate operating instructions based on the comparison between the current level and the baseline level. The operating instructions may be used to adjust the casting process.
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公开(公告)号：US20190143402A1
公开(公告)日：2019-05-16
申请号：US16190761
申请日：2018-11-14
申请人： Novelis Inc.
IPC分类号： B22D11/18
摘要： Automated processes and systems dynamically control the delivery rate of molten metal to a mold during a casting process. Such automated processes and systems can include automatically controlling a flow control device (such as a control pin) during a first phase of casting to modulate molten metal flow or flow rate, moving the flow control device in a transition time between the first phase and a second phase toward a substitute flow control device position determined based on a difference between a first projected flow rate of the first phase and a second projected flow rate of the second phase, and resuming automatic control of the flow control device during the second phase based on the detected metal level and the metal level setpoint. Overshoot and/or undershoot can additionally or alternatively be mitigated by translating the mold or altering the cast speed.
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公开(公告)号：US11951534B2
公开(公告)日：2024-04-09
申请号：US18005885
申请日：2021-07-23
申请人： Novelis Inc.
发明人： John Robert Buster McCallum , Phillip Wilson , Larry Hudson , Richard Shockley , Todd F. Bischoff , Adwait Thakur
IPC分类号： B22D11/16 , B22D11/049
CPC分类号： B22D11/16 , B22D11/049
摘要： Systems and methods are disclosed for an event detection system that captures data associated with events while a DC casting system forms an ingot, determines characteristics of the events, and improves the casting system based on the events. Example systems and methods may include initiating a casting operation using one or more pieces of equipment of a casting system including a casting apparatus; capturing sensor data associated with one or more acoustic signals captured relative to the one or more pieces of equipment performing the casting operation; comparing the sensor data with a set of acoustic profiles; determining whether a particular type of event has occurred; causing an adjustment to the casting system or to the casting operation based on whether the particular type of event has occurred; and initiating a second casting operation using the adjusted casting system or casting operation.
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公开(公告)号：US20230286038A1
公开(公告)日：2023-09-14
申请号：US18005937
申请日：2021-07-23
申请人： Novelis Inc.
发明人： John Robert Buster McCallum , Michael R. Kosmicki , Adwait Thakur , William M. Betts , Phillip Wilson , Adarsh Gupta , Augusto-Cesar Silva
IPC分类号： B22D11/18 , B22D11/14 , B22D11/20 , B22D11/049
CPC分类号： B22D11/185 , B22D11/141 , B22D11/204 , B22D11/049
摘要： A monitoring system may monitor a casting environment, for example, including a mold. The monitoring system may include a camera and a computer system. The camera may be positioned to capture or detect optical data associated with one or more components in a casting environment. The camera may send the optical data to the computer system and the computer system may generate a profile associated with the casting environment. The profile may be compared with a baseline profile to determine whether a particular event has occurred. Based on the event that may have occurred, operating instructions can be generated. The operating instructions may be used to adjust the casting process.
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