OsciCon: Casting Mold Oscillation Control

OsciCon is a software product that enables the adjustment of the stroke, frequency, and oscillation pattern of the mold oscillators online during flat or long product casting. This enables the highest possible surface quality.

The performance of the mold oscillator is critical to continuous casting because it directly affects product quality. Surface defects can result from irregular movement of the oscillator, so maintaining tight oscillation tolerances is essential for stable operation. Furthermore, oscillation behavior affects casting powder consumption, which is a key factor in lubrication, heat transfer, and overall casting performance.
OsciCon improves product quality and casting performance by offering advanced oscillation control. This includes non-sinusoidal and inverse oscillation, which optimize casting powder utilization. The Iterative Learning Control Algorithm compensates for wear on hydraulic components, ensuring long-term precision. OsciCon offers the highest level of flexibility and can be seamlessly integrated with existing oscillation systems through control cabinet upgrades. This solution is designed to operate with different types of oscillators found in flat and long product casters.

Inverse Oscillation for Optimized Casting Powder Utilization

As casting speed increases, the oscillator stroke increases while the frequency decreases. OsciCon maintains a low, stable negative strip time within a stable region of mold oscillation and increases positive strip time as casting speed increases. Different oscillation curves are applied to specific steel grades, which are defined using process information from Level 2 automation. This optimizes mold powder consumption where it is needed most.

Model-Based Control for High-Quality Products

The Feed-Forward Position Control feature, with its model-based design, allows for faster and more accurate attainment of setpoints. In double-cylinder configurations, it significantly reduces phase shifts between cylinders for smoother, more synchronized movement. It also prevents non-sinusoidal oscillation jerking, which is essential for powder utilization and the production of high-quality products.

Compatibility with Existing Units and Systems

OsciCon offers outstanding flexibility. It can be integrated with existing oscillation units and automation systems with a simple upgrade to the control cabinet. This seamless pairing optimizes performance for flat or long product casters.

Iterative Learning Control Enables Precise Control and Reliable Performance

The Iterative Learning Control Algorithm continuously compensates for wear on hydraulic components, such as valves and cylinders, in real time. Applicable across all stroke lengths and oscillation frequencies, it ensures precise control by reducing the deviation between the setpoint and actual cylinder positions. This feature results in smoother, more reliable oscillator performance and consistently high casting quality.

OsciBox Optimizes Maintenance

The OsciBox is an optional, compact, standardized testing device designed for oscillation systems. It allows operators to manually verify the functionality of molds in the maintenance area, ensuring they are ready for casting.

Benefits of OsciCon Mold Oscillation Control

• Substantial improvements in operation and metallurgy, such as minimizing mark depth and optimizing powder consumption
• Increased operating range and wear compensation
• Improved surface quality, especially at low casting speeds
• Potential for use with existing oscillators through targeted repairs