Caster Package Checker: Automatic Testing of Caster Technological Packages

The Caster Package Checker software automatically tests all the functions of the technological packages of a continuous caster in both the maintenance area and the pre-cast configuration. Steel producers require the maintenance workshop to provide mechanical systems in a pre-tested condition, as evidenced by test protocols, in order to maintain the operational efficiency of continuous casting machines.

To achieve operational efficiency, the test unit must:

• monitor all measurements related to the mechanical components
• operate easily
• run repeatable, automatic tests of the entire functionality
• provide test certificates for maintenance to ensure proper operation

The Caster Package Checker is a testing and monitoring software solution that is installed on a laptop. It verifies the functionality of technological packages on casters by running predefined test sequences and generating test certificates. It was developed as an add-on feature for the Primetals Technologies maintenance packages, Mold Box, and OsciBox.

Maintenance engineers can use either an existing laptop or a preconfigured Caster Package Checker notebook provided by Primetals Technologies to control and document the testing of technological packages, such as MoldCon and OsciCon.

Automated Maintenance

The Mold Box and the OsciBox are not dependent on the Caster Package Checker. However, using them together provides a complete, fully automated set of repeatable tests with predefined sequences, which reduces testing time. Additionally, functionality tests can be performed online right before casting begins. This ensures accurate calibration and functionality, resulting in fewer failures, early detection of mechanical problems, and reduced maintenance costs. Test certificates and reports are provided after each testing run is complete. To optimize the user experience, Primetals Technologies offers an optional preconfigured laptop with pre-installed Caster Package Checker software.

Intuitive Software Interface for Smart Maintenance of Casters

The Caster Package Checker software features a clearly structured, intuitive interface that lets new employees efficiently operate it with minimal training. Its ease of use allows for faster troubleshooting and targeted issue resolution, thereby improving maintenance effectiveness and operational efficiency.

The Caster Package Checker Enables Automatic Testing of Hydraulic Mold Oscillators

• Electrical connection
• Sensors and removal of air
• Pressure test
• Position sensor calibration
• Hydraulic valve offset
• Endurance test
• Breakaway and friction force
• Oscillation with various setpoints

The Caster Package Checker Allows for Fully Automated Testing of Width-Adjustable Molds

• Configuration check and calibration
• Electrical connection and electrical offset search
• Mold spreading/clamping and soft clamping
• Lateral strand guide
• Removal of cylinder air and cylinder connection
• Backlash measurement (bottom/top)
• Test of mechanical limits and endurance
• Automatic adjustments

Benefits of the Caster Package Checker

• Standardized testing: consistent, thorough, and reliable testing of mold technological packages
• Comprehensive documentation: test certificates and reports in PDF format
• Comprehensive functional testing: checks of position sensors, pressure, and temperature transmitters with an intuitive interface for easy operation
• Enhanced maintenance and efficiency: early fault detection extends the equipment lifecycle and reduces maintenance costs through targeted repairs
• Improved operational efficiency through pre-cast testing