NZ628746B2 - Bleedout detection system - Google Patents

Abstract

Disclosed is a semi-continuous or continuous casing mold with a bleedout detection system. The casting mold comprises a casting mold framework, a molten metal casting mold with a mold inlet and a mold outlet and a bleedout detection system (177). The bleedout detection system (178) includes a signal generator (181) that provides a balanced current to a bleedout sensor (182) at or near the mold outlet perimeter, means (183) for monitoring bleedout sensor impedance, and a programmable controller (180) configured to receive an electrical signal from the bleedout detection system (177) regarding the status of the sensor (182). generator (181) that provides a balanced current to a bleedout sensor (182) at or near the mold outlet perimeter, means (183) for monitoring bleedout sensor impedance, and a programmable controller (180) configured to receive an electrical signal from the bleedout detection system (177) regarding the status of the sensor (182).

Description

BLEEDOUT DETECTION SYSTEM This invention is relevant to the use of a sensor with inputs and/or s in the detection and notification to a control system of an undesired molten metal escape from a mass of solidifying metal being cast with a semi-continuous or continuous casting molten metal mold. This invention pertains to an improved bleedout detection system.

Metal ingots, billets, and other castparts are typically formed by a casting s which utilizes a vertically oriented mold ed above a large g pit beneath the floor level of the metal casting facility, although this invention may also be utilized in horizontal molds. The lower component of the vertical casting mold is a starting block. When the casting process begins, the starting blocks are in their upward-most position and in the molds. As molten metal is poured into the mold bore or cavity and cooled ally by water), the starting block is slowly lowered at a predetermined rate by a hydraulic cylinder or other device. As the starting block is lowered, solidified metal or aluminum emerges from the bottom of the mold and , rounds or billets of various geornetries are formed, which may also be referred to herein as castparts.

While the invention pertains to the casting of metals in general. including t limitation um, brass, lead, zinc, magnesium, copper, steel, etc.. the examples given and the preferred embodiment disclosed may be directed to aluminum, and therefore the term aluminum or molten metal may be used throughout for consistency even though the invention applies more generally to metals.

While there are numerous ways to achieve and configure a vertical casting arrangement, Figure 1 illustrates one example of a billet table casting arrangement.

In Figure 1 the vertical casting of aluminum generally occurs h the ion level ofthe factory floor in a casting pit. ly beneath the casting pit floor [Ola is a caisson 103, in which the hydraulic er barrel 102 for the hydraulic cylinder is placed.

As shown in Figure 1, the components of the lower portion of a typical vertical aluminum g apparatus, shown within a casting pit 101 and a caisson 103, are a hydraulic cylinder barrel 102, a ram 106, a mounting base housing 105, a platen 107 and a starting block base 108 (also referred to as a ng head or bottom block base), all shown at elevations below the casting facility floor 104.

The ng base housing 105 is mounted to the floor 101a ofthe casting pit 101, below which is the caisson 103. The caisson 103 is defined by its side walls 103b and its floor 103a.

A typical mold table assembly 110 is also shown in Figure I, which can be tilted as shown by hydraulic cylinder 111 pushing mold table tilt arm 110a such that it pivots about point 112 and thereby raises and rotates the main casting frame ly, as shown in Figure 1. There are also mold table carriages which allow the mold table assemblies to be moved to and from the casting position above the casting pit.

Figure 1 further shows the platen 107 and starting block base 108 partially descended into the casting pit 101 with eastpart or billet 113 being partially Formed.

Castpart 113 is on the starting block basc 108, all of which is known in the art and need not therefore be shown or described in greater detail. While the term starting block is used for item 114, it should be noted that the terms bottom block and starting head are also used in the ry to refer to item114, bottom block is typically used when an ingot is being cast and starting head when a billet is being cast.

While the starting block base 108 in Figure 1 only shows one starting block 114 and pedestal 115, there are typically several of each mounted on each ng block base, which simultaneously cast billets, l shapes or ingots as the starting block is lowered during the casting process, as shown in later Figures and as is known.

When hydraulic fluid is introduced into the hydraulic cylinder at sufficient pressure, the ram 106, and consequently the starting 14, are raised to the desired elevation start level for the casting process, which is when the starting blocks are within the mold table assembly 110.

The lowering of the starting block base 108 is accomplished by metering thc hydraulic fluid from the cylinder at a predetermined rate5 thereby lowering the ram 106 and consequently the starting block at a predetermined and controlled rate. The mold is controllably cooled during the process to assist in the solidification of the emerging ingots or billets, lly using water cooling means.

There are numerous mold and casting technologies that fit into mold tables, and no one in particular is ed to practice the various ments of this invention, since they are knowu by those of ordinary skill in the art.

Mold tables come in all sizes and configurations because there are numerous and ently sized and configured casting pits over which mold tables are placed.

The needs and requirements for a mold table to fit a particular application therefore depends on numerous factors, some of which include the dimensions of the casting pit, the location(s) of the sources of water and the practices of the entity Operating the pit.

The upper side of the typical mold table operativcly connects to, or interacts with, the metal distribution system. The typical mold table also operativeiy ts to the molds which it .

When metal is cast using a semi-continuous or continuous cast al mold, the molten metal is cooled in the mold and continuously emerges from the lower end of the mold as the starting block base is lowered. The emerging billet 113, ingot, or other configuration is intended to be sufficiently solidified such that it maintains its d shape. There is an air gap between the emerging solidified metal and the ble ring wail. Below that, there is also a mold air cavity between the emerging solidified metal and the lower n ofthe mold and related equipment.

Since the casting process generally utilizes fluids, including lubricants, there is necessarily ts and/or piping designed to deliver the fluid to the desired locations around the mold cavity. Although the term lubricant will be used through this specification, it is understood that this also means fluids of all types, whether a lubricant or not, and may also include release agents.

Working in and around a casting pit and molten metal can be potentially dangerous and it is desired to continually find ways to increase safety and minimize the danger or accident potential to which operators of the equipment are exposed. In addition, it is an advantage to reduce the probability of potential damages and associated costs to the equipment and surrounding facilities.

The ion es a semi-continuous or continuous casting mold with a blecdorit detection system comprising: a casting mold framework; a molten metal casting mold with a mold inlet and a mold outlet. the mold outlet having a mold cavity perimeter; and a ut detection system comprising: a Signal generator that provides a balanced current to a bleedout sensor/conductor: at or near the mold outlet perimeter; means for monitoring ut sensor/conductor impedance: and a programmable controller configured to receive an electrical signal from the bleedout detection system regarding the status of the sensor/conductor.

The ion also provides a method for detecting a bleedout condition in a semi~contimious or continuous casting molten metal mold, sing: providing an electrically conducting ut sensor/conductor configured at or near the mold outlet perimeter; providing a balanced alternating current from a signal generator to the bleedout sensor/conductor; monitoring bleedout sensor/conductor impedance; and receiving at a programmable controller an electrical signal regarding the status ol‘the bleedout sensor/conductor The present invention will now be described, by way of non-limiting example only‘ with reference to the accompanying drawings as briefly described below: Figure l is an elevation view of a typical vertical casting pit, caisson and metal casting apparatus; Figure 2 is a perSpective view of one oftlic numerous mold frameworks with which embodiments ofthis invention may be utilized.

Figure 2A is a perspective view of one of the us mold frameworks with which embodiments of this invention may be ed, showing a ut of molten metal from the east product.

Figure 3 is a tic top view depiction of a mold table with four rows and seven columns of molten metal molds; Figure 4 Figure illustrates an exemplary schematic box diagram layout of a bleedout detection system connected to a programmable controller. The bleedout ion system consists of a signal generator and current detector and a sensor/conductor.

Figure 4A illustrates how a programmable controller may be operably connected to a bleedout sensor and a signal generator, n the mmable controller may perform the function of providing the signal current detection functions.

Figure 48 illustrates how a programmable controller may be operably connected to a bleedout sensor and a current detector, wherein the programmable controller may perform the function of providing the signal generation functions.

Figure 4C an exemplary configuration of how the programmable controller or “PLC” may be operably ted to the sensor 194, wherein the programmable ller may be configured to provide both the current detection, sensing or monitoring and the signal generation functions.

Figure 4D rates an exemplary box layout or schematic of a programmable controller operably connected to an alarm system and a SCADA system.

Figure 4E rates an exemplary box diagram of how a programmable controller may be operably connected to a user notification system and also to other system components.

Figure 4F rates through a schematic box diagram a configuration wherein a bleedout detection system is Operably connected to an alarm, SCADA= user notification or other system.

Figure 5 illustrates the various possible impacts of bleedouts on electrical circuit paths in closing an open circuit, opening a closed circuit, or ing an operating level of resistance or impedance.

Figure 5A provides a showing of a circuit consisting of a wire, bleedout detection system, and the mold surface.

Figure 6 is a View of several possible rms selected from numerous le waveforms that could be used in the bleedout detection system.

Figure 7 is a perspective view of the exit side of a mold g One of the many possible embodiments of a bleedout sensor consisting of one plate separated from a mold by a layer of tion.

Figure 8 is a perspective view of the exit side of a mold showing one of the many possible embodiments of a bleedout sensor consisting of two plates Separated from each other by a layer of insulation.

Figure 9 is a perspective View of a main component housing representative of one which may house a programmable controller, and remote system components; Figure 9A shows a block diagram of a programmable controller where the system is contained in one location.

Figure 9B shows a block diagram of a programmable controller system where the system may consist ofa main l location and remote system components.

Figure 10 shows a block diagram indicating a general relationship between a bleedout sensor, signal tor, current detector, and remote system components.

Many of the fastening, connection, manufacturing and other means and components utilized in this invention are widely known and used in the field of the invention described, and their exact nature or type is not necessary for an understanding and use of the invention by a person skilled in the art or science; therefore, they will not be discussed in significant detail. Furthermore, the various components shown or described herein for any specific application ofthis invention can be varied or altered as anticipated by this invention and the practice ofa specific application or embodiment of any element may already be widely known or used in the art or by persons skilled in the art or science; therefore, each will not be sed in significant detail.

The terms “a”, “an”, and “the” as used in the claims herein are used in conformance with long-standing claim drafting ce and not in a limiting way.

Unless specifically set forth herein, the terms “a”, “an”, and “the” are not limited to one of such elements, but instead mean “at least one”.

It is to be understood that this invention applies to and can be utilized in tion with various types of metal pour technologies and configurations. it is further to be understood that this invention may be used on horizontal or vertical casting devices.

The mold ore must be able to receive molten metal from a source of molten metal, whatever the ular source type is. The mold cavities in the mold must therefore be oriented in fluid or molten metal receiving position relative to the source of molten metal.

It will be iated by those nary skill in the art that embodiments of this invention may and will be combined with new systems and/or retrofits to existing Operating casting systems, all within the scope ofthis invention. Applicant hereby incorporates by reference, US. Pat. No. 6,446,704 and U.S. Pat. No~ 7,296,6l3, as though fully set forth herein.

Figure I is an elevation view of a vertical casting pit, n and metal g apparatus, and is described in more detail above.

In semi—continuous or continuous cast molding ofmetnls such as aluminum, it is ble to more reliably monitor for what may be referred to as a blecdout or run out condition, from the confines of either the mold cavity or through the solidifying shell of the castpart. This ion can create significant issues in the molding s (such as personnel safety and destruction of equipment), ng molten metal to escape into the casting area.

Figure 2 is a perspective view of one ofthc numerous mold frameworks with which embodiments of this ion may be ed, illustrating refractory trough 135, mold inlet 134, mold outlet 136, permeable perimeter wall, 130, typically a graphite ring, water inlet ts 133 and mold framework 131. Figure 2 further illustrates a round castpart 137 ng from the mold outlet 136.

Figure 2A is a perspective view of the same items as described for Figure 2, but exhibits a representative Opening 138 in the outer shell of the castpart [37, resulting in molten metal l39 escaping from the normal boundaries, or in the condition represented by the term “bleedout.” As would be understood by one of ordinary skill in the art, such crack appearances and bleedout conditious can vary, so that shown in Figure 2A represents the various possible bleedout ions.

The casting environment is harsh and c and tends to create significant corrosion and deterioration of exposed components. While electrically based and/or electronic components may provide more precise and controllable sensors and detectors, they are at times more susceptible to the harsh casting environment. It is therefore one object of some embodiments of this invention to e a bleedout detection system with improved corrosion properties in the casting environment.

Figure 3 is a schematic top view depiction of a mold table 150 with four rows 152 and seven columns 15] of molten metal molds, illustrating exemplary two dimensional X-Y coordinates. Figure 3 show mold table with x dimension 153 and y ion 154.

It has been found as part of this invention that if an ating or fluctuating signal such as an alternating current/voltage is used instead of a direct or constant current/voltage, and the balanced current or voltage is maintained or balanced within a range or tolerance around zero, the corrosion on the bleedout detection components is reduced, minimized and/0r eliminated. it is also an object of some embodiments of this invention to e an electrically based signal generator which provides balanced alternating current or voltage which essentially balances to a predetermined value such as zero, or within a reasonable range about zero.

Figure 4 provides a simple box diagram representing several of the main components of an embodiment of the invention, and generally illustrates ments of a bleedout detection systeml77 and a bleedout detection control system 178. A programmable controller 180 sends output to, and receives input from, a signal generator 181. The signal generator sends the ed current to a current detector 183 with ponding information provided to the programmable controller 180. Figure 4 illustrates bleedout sensor Operably connected to current detector 183 and further illustrates programmable controller 180 operably connected to the alarm component 179, which may be an alarm, a SCADA system or other system component configured to receive such a signal and provide an alarm, notification, data or actions as a .

Figure 4A illustrates an exemplary configuration wherein ut sensor and/or conductor 182 may be connected to the programmable controller 180 components and to a signal generator 181, which is a uration wherein the programmable controller 180 may perform the function of the current detector.

Figure 4B shows how the programmable controller i90 may be connected to a bleedout sensor 191 and a current detector l92, which is also a configuration wherein the programmable controller (which may also be referred to as a programmable logic controller or “PLC”), may perform the function of signal tion.

Figure 4C an exemplary configuration of how the programmable ller 193 or programmable logic controller (“PLO”) is Operably connected to the sensor 194 and wherein the programmable controller may be configured to provide both the current detection and the signal generation functions. As appreciated by those of ordinary skill in the art, such system arrangements could be structured in a variety of ways physically and electronically.

Figure 4D illustrates an exemplary box layout or schematic of a mmable controller 180 ly connected to an alarm system l85 and n\l SCADA system 186. Figure 4E illustrates an exemplary box diagram of how a programmable controller 180 may be operably connected to a user notification system 196 and also to other system ents. Figure 4F illustrates h a schematic box diagram a configuration wherein a bleedout detection system is ly connected to an alarm, SCADA, a user notification or other system 199. gh bleedout detection systems in an embodiment of this invention are described wherein a bleedout sensor is configured at or near the mold outlet perimeter, it will be appreciated by those of ordinary skill in the art that the other components and elements of said system may be located either at or near the mold outlet perimeter or remote in any other location, all within the contemplation ofthis invention. In another embodiment of this invention, a sensor/conductor device may be d at or near the mold outlet perimeter, or could alternatively be located at the same, or a different location relative to the sensor/conductor. The sensor/conductor, as appreciated by one of ordinary skill in the art, could be arranged to form an open circuit, closed circuit, or otherwise set to operate at some expected level of normal impedance that can thus alter in a bleedout condition to show some other characteristic, such as changing from open to closed circuit, a IO closed to open circuit, or in changing its overall impedance in some other fashion.

Figure 5 provides es of a bleedout sensor/conductor that ly ‘is in an open condition 20l, is normally in a closed condition 202, or is otherwise arranged with some amount of impedance 203 as ented by the amounts of resistance.

The bleedout condition can thus lead to altering the expected current levels based on normal Operating conditions. Figure 5A provides an indication of how one wire 205 may be used for an electrical connection n the bleedout detection system 206, or bleedout detector circuitry, with the use of the conducting al of the mold 207 and mold assembly to complete that path. One of ordinary skill of the art would recognize that such electrical loops could be completed using wires or various other forms of conducting material.

When the term balanced t is used herein, it is intended to be broadly construed to refer to a t which is oscillating or fluctuating about an e reference line or point range. Figure 6 provides several examples of possible rms, which is not exhaustive as one of ordinary skill in the art would recognize that such waveforms could be structured or varied in a high number of ways. In a typical embodiment this would be a sinusoidal current wave 20l balanced about a zero value neutral reference, but it may also refer to a square wave 202 or other shape of waveform, and that the waves or area within the square, sinusoidal, or other shaped waveform need not be identical in shape, peak value, or on in time period in order to be balanced Other such es include a pulse waveform 203, rectangular waveform 204 that could be identical or of different shapes on the positive or negative sides of the average, and a triangular waveform 205. The mean or e value of the waveform, as understood by those of ordinary skill in the art, could also be referred to as, without limitatioa, a DC bias or DC coefficient that may or may not be at the value of zero. For one of ordinary skill in the art, the waveform could also be described as the anode or cathode values relative to time.

When the term signal generator is used herein it is used in its st sense to refer to any device or element that is providing, generating, or transmitting an electrical current, signal or other ical potential or conductive energy to and/or through a bleedout /conductor, which may be the bleedout sensor, or be in electrical connection with the bleedout sensor. As would be understood by one of ordinary skill in the art, the location of the bleedout signal generator can vary both physically and electronically, and could be arranged as a separate assembled electronic unit, a portion of the controller itself, or as components otherwise arranged to provide the electrical signal used by the ut detection system. in partial contemplation of this invention, the use of frequency from the signal generator could be employed over a wide range of values, with the possible frequencies typically being selected depending on electronic advantages such as, the desired characteristics which may result from the impedance of the sensor/conductor coolant interaction, or the resulting corrosion ion. Similarly, the embodiments of this invention could be used with a variety of ating waveforms provided by the signal generator as usly described.

Depending on the conductivity of the liquid used as part ofthe casting coolant ses, the output of the signal generator that provides the balanced current may need adjustment For l potential with resulting current levels. In contemplated ments of the invention, the output of the signal generator could be adjusted manually, set to certain values through the programmable controller, or automatically adjusted via the programmable controller. The conductivity of the liquid coolant affects the corrosion because as it runs outside over the two rings, one ring is negative and one ring is positive, and the liquid t has enough conductivity or the ability to allow the charge to pass there-through and thereby causing ion.

In an electrolytic corrosion cell ions are removed from one of the components, erred in solution, and deposited on the other component. By using AC we effectively neutralize the electrolysis on thereby reducing or eliminating the resulting corrosion.

When the term bleedout sensor is used herein, it may be any one of a number of different arrangements of ting materials, elements or components within the contemplation of this ion, such as, without limitation, a metal plate or , wiring, or other materials creating a conducting path with intentional normal operation levels of impedance or conductance between conducting materials. The level of impedance or conductance between the conducting materials could be set in a variety of ways known of those of ry skill in the art. Some embodiments within the contemplation of this ion for a ut sensor/conductor could include the conductivity of matter placed between the conducting metal portions, or components between the conducting materials providing resistance or reactance, or some combination forming levels of impedance, as described with Figure 5.

Figure 7 shows one embodiment ofthis invention that uses an insulation layer 220 between the bottom of the mold 221 and a plate 222 (a ut /conductor) that can be attached. In this embodiment, a resistor or other impedance component 223 is installed bypassing or passing through the insulation layer 220. The plate and mold body are electrically connected in what could be viewed as an instantaneous alternating positive and negative voltage relative to the mold body is obtained. Impedance levels that can be present due to the coolant and/or molten metal 225 are also represented in Figure 7.

Another embodiment uses two plates, 222a and 222b, as shown in Figure 8 attached to the bottom of the mold 221, with an insulation layer 220 n the plates, and a resistor 223 put in place connecting the plates. The plates are electrically connected in what may be viewed as an instantaneous ating positive and negative voltage between the two plates. impedance levels that can be t due to the coolant and/or molten metal 225 are also represented in Figure 8.

Contemplated paths for the ical current could include the embodiment of two or more wires to the bleedout sensor/conductor path, thus allowing its connection to the, signal generator, PLC controller and/or current detector. An onal embodiment using one wire to the bleedout sensor/conductor has also been contemplated, where the mold, and assembled mold equipment could provide one ol‘ the current paths.

When the term controller or programmable controller is used , it may be referring to any number of different types ofcontrolling structures, such as, without limitation, a programmable logic controller consisting ofa main component housing 240 as shown in Figures 9 and 9A, or with a combination of a main component housing 240 and remote system components 241, as illustrated in s 9 and 9B.

The programmable controller could refer to a controlling t containing adjustable components, or prewired onics arranged to e the desired lling functions. One of ordinary skill in the art would appreciate that the while the use of a programmable logic ller, PLC, is common, it would not be the only alternatiVe in the setup of a controller.

White embodiments of this ion include or utilize an electronic current detector, it should be noted that this may include: a circuit designed with a component or components that switch or otherwise change ion when facing various electrical current or potential levels, a module or component considered a part of a programmable controller, or any other material arranged to change its output in the presence of electrical potential or currents at various levels. Figure 10 provides a sketch of an embodiment of the relationship between a bleedout sensor/conductor 261, current detector 262, and programmable controller 263. In one embodiment as shown, the current detector 262 in operation would be located to receive current or potential based on the current flow through the blecdout sensor/conductor 26I, and that ses that current depending on thresholds set manually or on input from the controller, and provides output From the electronic current or to the programmable centroller based on threshold levels. A old latch in this embodiment is represented by an internal switch 264 that latches on when detecting a current threshold level. The current detector output to the programmable controller 263 thus changes depending on present conditions, providing information to the programmable controller ing the state of the current detector. As considered for this invention, the term ofthrcshold can refer to any positive or negative magnitude vaiuc that is sufficient to trigger some change in the current detector output. As known by one of ordinary skill in the art, depending on the circuit structure, such thresholds could be adjustable with the use of different components, adjustable components, or in changes in the programmable controller settings. As usly indicated and understood by those ol’ordinary skill in the art, the current or could be located physically and electronically in a variety of locations. Such embodiments considered could be ured in examples of a separate assembled electronic unit, a portion of the controller itself, or components otherwise arranged to change status when faced with various levels of current.

Those of ordinary skill in the art would understand that the programmable controller could be configured for a variety of functions in connection with the other elements of the bleedout detection system in operation. Programmable controller function embodiments envisioned relative to this invention include, but are not limited to, several functions that may be used independently or individually, or in s combinations of some or all of the functions. e inputs, not to be ered an exhaustive list of all potential and considered inputs, that the programmable controller may be setup to receive could include one or more of: a signal or signals from a current or, the magnitude of the waveform being provided by the signal generator, and fication of the mold or molds whosa bleedout sensor/conductor, is the source of the information. As appreciated by one of ry skill in the art, these inputs from other portions of the system may effectively be an actual electrical signal, or may be the absence of an electrical signal. Examples of contemplated outputs for the programmable controller, again not an exhaustive list, include: a command to the signal generator regarding the characteristics of the signal it provides such as magnitude, frequency, and/or waveform; and reset commands to the current detector based on the current detector status. In operation, a current detector could reach the threshold previously described. The programmable controller can be used to alter the status ofthe current or set by reaching the threshold. As known by those of ordinary skill in the art, the programmable controller may be arranged reSpond to and/or reset the current detector, when to ignore its signal, or when use it to initiate other processes.

Additional possible programmable controller outputs as contemplated as part of this ion, the programmable controller could be arranged to provide an alarm or other notification to the operator, or commands to other equipment in response to the bleedout condition. The cation” term will be used to refer to any of these functions of an alarm, either providing of information, or in the linking to additional process steps.

Another e envisioned in various embodiments of the invention includes a g function, allowing the determination of the bleedout /conductor current path status and llity prior to casting, during casting operations, or at any other point when d by the user. In line with one of ordinary skill in the art, this process could be arranged in a variety of ways, but for some of the embodiments envisioned for this invention, the programmable controller directs the signal generator to modify the signal provided to the ut sensor/conductor, such as in the areas of magnitude, ncy, or waveform, so that the t to the current or would meet the old settings of the current or. The current detector would correspondingly send the programmable controller the information, or lack of information, which the programmable controller, in accordance with its settings, could recognize as the Operability status of the bleedout /conductor and its electrical connection status. As previously described in the potential programmable controller outputs, the programmable controller can then be used for one or more of the functions of cting the signal generator to normal operation levels, resetting of the current detector in onship to its thresholds. In addition, the programmable controller can be arranged to recognize signals received, or not received, to be during testing processes, or e of testing processes.

As would be understood by one of ordinary skill in the art, electrical tion could be referring to a solid, liquid, gas, or some other form of electrical separation. As would similarly be tood, the magnitude of the wave form could vary considerably, but would ideally be kept at reasonably low levels for safety and circuit designs, but still be substantial enough to perform the desired function.

While various embodiments of the present invention have been described abOVe, it should be understood that they have been presented by way of example only. and not by way of limitation. It will be apparent to a person skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention.

Thus, the present invention should not be limited by any of the above described exemplary embodiments.

Throughout this specification and the claims which follow, unless the context es otherwise, the word ”comprise", and variations such as "comprises“ and "comprising". will be understood to imply the ion of a stated integer 01' step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

The reference in this specificatiou to any prior publication (or information derived from it), 01' to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

II gu‘hucmmcu \‘Rl’onl'l DCCGWIINVKHKJ don.” II? Into THE

Claims (19)

CLAIMS NG THE ION ARE AS FOLLOWS:

1. A ontinuous or uous casting mold with a bleedout detection system comprising: a casting mold framework; a molten metal g mold with a mold inlet and a mold outlet. the mold outlet having a mold cavity perimeter: and a bleedout detection system comprising: a signal generator that provides a balanced t to a bleedout sensor/conductor. at or near the mold outlet perimeter; means for monitoring bleedout sensor/conductor nce: and a programmable controller configured to receive an electrical signal from the bleedout detection system regarding the status ot’the sensor/conductor.

2. A casting mold with a bleedout detection system as recited in claim 1. further comprising an electronic current detector operatively connected between the programmable controller and the bleedout sensor/conductor: and configured to receive signals from the bleedout sensor/conductor and provide the programmable controller a bleedout status signal.

3. A casting mold with a bleedout detection system as recited in claim 1. wherein the programmable controller receives information in the form of a lack oi‘signal from the bleedout sensor/conductor.

4. A casting mold with a bleedout detection system as d in claim 3. wherein the programmable ller is configured to te a reset signal to the electronic current detector-after receiving a bleedout status signal.

5. A casting mold with a bleedout detection system as recited in claim 4. wherein the programmable controller is configured to periodically direct the signal generator to raise the magnitude of its output signal to the bleedout sensor/conductor and detect or generate a reset signal to the onic current detector after receiving a bleedout status signal.

6. A casting mold with a bleedout detection system as recited in claim 1‘ wherein the ll mn'lmcrumcn NRPonbl DCF‘OWIUJ'IXNX _I don-2110mm: programmable controller is configured to automatically adjust the magnitude ol‘ the signal generator output signal.

7. A casting mold with a bleedout detection system as recited in claim 1. wherein the programmable controller is configured to automatically provide a notification or alarm to the user of the bleedout ion system.

8. A g mold with a bleedout detection system as recited in claim l._ wherein the programmable ller is configured to provide outputs to other system components. comprising: a notification or alarm to the user ofthe bleedout detection system: a command to other equipment to contain bleedout effects.

9. A g mold with a bleedout detection system as recited in claim I. wherein the balanced current is a square wave form ol’alternating current.

10. A casting mold with a bleedout detection system as recited in claim 1, wherein the alternating t waveform is in the fi'equency range of 1 kHz to 100 kHz and preferably in the frequency range of 20 kHz to 50 kHz.

1 1. A casting mold with a bleedout detection system as recited in claim 1. wherein the programmable controller is a programmable logic controller.

12. A casting mold with a bleedout detection system as recited in claim it wherein an electrical connection to each molten metal casting mold position includes one wire. 1.3.

A casting mold with a bleedout detection system as recited in claim 1. wherein: the bleedout /conductor is an ically conducting ut sensor/conductor: the signal generator provides a balanced alternating current to the bleedout sensor/conductor.

14. A g mold with a bleedout detection system as recited in claim 1. n the system further comprises: -I6— ll \gn‘Jntcnwwn‘NRPonleCC GW' llu'mNRJ dxv |0 "71211“. a wire to the electrically conducting bleedout sensor/conductor: conductor and the a set impedance between the electrically ting bleedout sensor/ mold outlet perimeter; and a mold table assembly as part of the current path.

1 S. A casting mold with a bleedout detection system as recited in claim 14. n the system also comprises a wire to the electrically conducting bleedout sensor/conductor. the electrically conducting bleedout sensor/conductor comprising two pieces of conducting materials separated by a set amount of impedance. one ofthe pieces oi'conducting materials in electrical contact with a mold, and a mold and mold table assembly as part ofthe current path.

16. A method for detecting a ut condition in a semi-continuous or continuous casting molten metal mold, comprising: providing an electrically conducting bleedout sensor/conductor configured at or near the mold outlet perimeter; providing a ed ating current from a signal generator to the bleedont sensor/conductor; monitoring bleedout sensor/conductor impedance: and receiving at a programmable controller an electrical signal regarding the status oi’the bleedout sensor/conductor.

17. A method for ing a bleedout condition in a semi~continuous or continuous molten metal mold as recited in claim 16. further comprising ing a current detector in connection with the programmable controller and the hlecdout /conductor. n the current detector is set with a threshold current level‘ and wherein the threshold t level of the current detector triggers an output to the mmable controller.

18. A method for ing a bleedout condition in a semi—continuous or continuous molten metal mold as recited in claim 16, wherein the programmable controller provides a notification.

19. A method for detecting a bleedout condition in a semi-continuous or continuous molten metal mold as recited in claim 16, wherein a test process is performed. comprising: ll lnullnltmotcn‘NRPAnbl'nCC Guam-mm; uxvl‘m'mulh ing a programmable controller and sending a command from the programmable controller to the signal generator to modify the magnitude of its alternating t output: providing a current detector that electrically sends an output to the programmable controller when detecting set current levels: and providing settings of the programmable controller to recognize a signal received from the current detector as results ofthe test process.