CROSS-REFERENCE TO RELATED APPLICATION [0001] This application claims the benefit of and priority to U.S. Provisional Application No. 62/705,945, filed on July 23, 2020, and titled “DETECTING METAL SEPARATION FROM CASTING MOLD” and U.S. Provisional Application No. 62/705,947, filed on July 23, 2020, and titled “Monitoring Casting Environment,” the contents of both of which are herein incorporated by reference in their entireties for all purposes.

FIELD

[0002] The present disclosure generally relates to metal casting and more specifically to associated processes and systems for monitoring the metal casting process.

BACKGROUND

[0003] Molten metal may be deposited into a mold to create a metal ingot. These metal ingots may be formed using, for example, direct chill (DC) casting or electromagnetic casting (EMC).

In DC casting, molten metal is typically poured into a shallow water-cooled mold. The mold may include a bottom block mounted on a telescoping hydraulic table to form a false bottom. The bottom block may be positioned at or near the bottom of the mold prior to the molten metal being deposited into the mold. As molten metal is deposited into the mold, the molten metal may fill the mold cavity, and the outer and lower portions of the mold can be cooled. The molten metal may cool and begin to solidify, forming a shell of solid or semi-solid metal around a molten core. As the bottom block is lowered, additional molten metal can be fed into the mold cavity.

[0004] During solidification, the metal undergoing cooling may contract and pull away from the mold walls, leaving a gap. When additional molten metal is fed into the mold cavity, the newly added molten metal may flow through the gap between the mold wall and the ingot shell and down the exterior of the ingot. If the molten metal contacts and/or entraps the cooling liquid, it may cause an explosion. Additionally, if the molten metal solidifies in the gap, it may cause the ingot to jam in the mold as the bottom block continues to lower, leaving space between the bottom of the ingot and the bottom block. Eventually, the weight of the ingot may cause the ingot to fall out of the mold onto the lowered bottom block, causing molten metal to splash out of the mold into the casting environment. [0005] To mitigate risk associated with gaps between the ingot and the mold, an operator or operators may observe the edge of the mold during the casting process looking for such gaps, either in person or via a video monitoring system. However, the operator or operators may miss or overlook a gap because it is small or hard to see. Additionally, several molds may be in use at the same time, requiring the operator or operators to split his or her attention between molds or requiring a number of operators to be monitoring the various molds.

SUMMARY

[0006] The term embodiments and like terms are intended to refer broadly to all of the subject matter of this disclosure and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the claims below. Embodiments of the present disclosure covered herein are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the disclosure and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this disclosure, any or all drawings, and each claim.

[0007] Certain examples herein address systems and methods for detecting metal separating from a casting mold during a casting process. Various examples utilize one or more molds for containing molten and/or solidifying metal during the casting process. At least one of the molds may have a number of sidewalls spanning between a top and a bottom of the mold. The top and bottom of the mold may be open, allowing molten metal to be deposited through the open top and allowing solidifying metal to exit through the open bottom. The system may include one or more cameras with at least one camera having a field of vision including at least a portion of the mold. For example, the field of vision of the one or more cameras may include the top of the mold. A light source may be positioned adjacent to the mold, for example, on the opposite side of the mold as the one or more cameras. The light source may be positioned to direct light toward the mold. For example, the light source may be positioned to shine light from the bottom of the mold toward a camera at the top of the mold. A computer system may be used to detect whether the light is visible between the solidifying metal in the mold and a sidewall of the mold, based on image data received from the camera. The computer system may determine whether the metal in the mold has separated from a side wall of the mold, for example, based on whether the system has detected that light is visible between the solidifying metal in the mold and the sidewall of the mold.

[0008] In various examples, a system for detecting an unanticipated gap between solidifying metal and a mold sidewall is provided. The system may include a mold, a camera, a light source, a processor, and memory. The mold may have a first side, a second side opposite the first side, and a number of walls spanning between the first side and the second side. The camera may be positioned adjacent to the first side of the mold and have a field of vision including the first side of the mold. The light source may be positioned adjacent to the second side of the mold and pointed toward the second side of the mold so that light from the light source may be visible to the camera through the first side of the mold when the solidifying metal has separated from at least one of the mold walls. The memory may include instructions that, when executed by the processor, may cause the system to detect light between a mold side wall and the solidifying metal, based at least in part on data from the camera, and determine whether separation of the mold side wall and the solidifying metal has occurred, based at least in part on the detected light.

[0009] In various examples, a computer-implemented method for detecting solidifying metal separating from a mold is provided. The method may include receiving molten metal into a mold with two opposing faces and a plurality of side walls spanning between the two opposing faces. The mold may have at least one side wall contacting the molten metal as it cools and solidifies. Light may be detected between at least one side wall of the mold and the solidifying metal, based on at least data received from a camera having a field of view of at least a portion of a first face of the mold. The source of the light may be positioned adjacent to a second face of the mold and direct the light towards the second face of the mold. The method may further include determining whether the solidifying metal has pulled away from a side wall of the mold based on the detected light.

[0010] In various examples, a system for detecting metal separating from a casting mold is provided. The system may include a mold, a launder, a camera, a light, and a computer system. The mold may receive and contain metal. The mold may have a first side, a second side opposite the first side, and a plurality of side walls spanning between the first side and the second side. The launder may be positioned above the mold and include a channel for containing molten metal and one or more openings for transferring molten metal from the launder to the mold. The camera may have a field of view that includes the first side of the mold. The light may be positioned adjacent to the second side of the mold and may direct light toward the second side of the mold. The light may be visible to the camera through the first side of the mold when solidifying metal separates from at least one of the mold walls. The computer system may include one or more processors, memory, and computer executable instructions stored in the memory and executable by the one or more processors. The computer executable instructions may cause the computer system to detect whether light is visible between a mold side wall and the solidifying metal based at least in part on data from the camera, determine whether separation of the mold side wall and the solidifying metal has occurred based at least in part on the detected light, and adjust the flow of molten metal from the channel to the mold.

[0011] In various examples, a system for detecting metal separating from a mold is provided. The system may include a mold configured to receive and contain the metal, the mold including a first side, a second side opposite the first side, and a plurality of side walls spanning between the first side and the second side; a container positioned above the mold having a bottom and defining a channel for containing the metal, the bottom of the mold defining one or more apertures for flow of the metal from the container to the mold; a camera having a field of view that includes the first side of the mold; and a light positioned adjacent to the second side of the mold for directing light toward the second side of the mold, the light visible to the camera through the first side of the mold when the metal is separated from at least one of the plurality of side walls. The system may detect whether light is visible between at least one of the plurality of side walls and the metal based at least in part on data from the camera, determine whether separation of at least one of the plurality of side walls and the metal has occurred based at least in part on whether light is detected as visible between at least one of the plurality of side walls and the metal, and adjust the flow of the metal from the container to the mold based at least in part if it is determined that separation of at least one of the plurality of side walls and the metal has occurred.

[0012] Other objects and advantages will be apparent from the following detailed description of non-limiting examples. BRIEF DESCRIPTION OF THE FIGURES

[0013] The specification makes reference to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components.

[0014] FIG. 1 is a cross-sectional side view of a system for detecting solidifying metal separating from a mold, according to various embodiments.

[0015] FIG. 2 is a front view of the system of FIG. 1, with multiple molds included, according to various embodiments.

[0016] FIG. 3 is a top view of the mold of FIG. 1 after molten metal has been added to the mold and started to solidify and pull away from the mold side walls, according to various embodiments.

[0017] FIG. 4 is a flowchart illustrating a process of detecting if solidifying metal has separated from a mold such as by use of the systems of FIGS. 1-3, according to various embodiments.

[0018] FIG. 5 illustrates an example computer system of FIGS. 1 and 2, according to various embodiments.

DETAILED DESCRIPTION

[0019] As used herein, the terms “invention,” “the invention,” “this invention,” and “the present invention” are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. As used herein, the meaning of “a,” “an,” and “the” includes singular and plural references unless the context clearly dictates otherwise. [0020] While certain aspects of the present disclosure may be suitable for use with any type of material, such as metal, certain aspects of the present disclosure may be especially suitable for use with aluminum.

[0021] All ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, e.g. 1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10.

[0022] The following examples will serve to further illustrate the present invention without, at the same time, however, constituting any limitation thereof. On the contrary, it is to be clearly understood that references may be made to various embodiments, modifications and equivalents thereof which, after reading the description herein, may suggest themselves to those skilled in the art without departing from the spirit of the invention.

[0023] FIGS. 1 and 2 depict a detection system 100 for detecting solidifying metal 114 separating from at least one side wall of a mold 120 and associated components, according to certain embodiments. The detection system 100 can include any number of components, however, in various embodiments the detection system 100 includes an ingot 110, a mold 120, a camera 140, a light source 150, and a computer system 160. As depicted in FIGS. 1 and 2, the detection system 100 is depicted as further including a launder 130, however, the detection system 100 may include additional or alternative components.

[0024] The ingot 110 may include molten metal 112 and solidifying metal 114. In various examples, the solidifying metal 114 is molten metal 112 that has met the walls of the mold 120 and cooled. In an illustrative example, molten metal 112 is deposited into the mold 120 and begins to solidify, forming solidifying metal 114. The bottom block 122 of the mold 120 can be steadily lowered while molten metal 112 is added to the top of the mold 120. The addition of the molten metal 112 can create a pocket of molten metal 112 surrounded by walls of solidifying metal 114 and continuously lengthen the ingot 110.

[0025] The ingot 110 may be formed from any metal or combination of metals capable of being heated to a melting temperature. In a non-limiting example, the metal used to form the ingot 110 includes aluminum. Additionally or alternatively, the metal used to form the ingot 110 may include iron, magnesium, or a combination of metals.

[0026] One or more molds 120 (hereinafter referred to individually or collectively as a “mold”) may be provided as part of the detection system 100. The mold 120 may receive molten metal 112 into one or more mold openings. The molten metal 112 may be contained and formed into a shape by the mold 120 as the molten metal 112 cools and becomes solidifying metal 114. The solidifying metal 114 (e.g., once cooled) may exit the mold 120 through one or more mold exits. In various embodiments, the mold 120 may be rectangular with four side walls, an open top for receiving molten metal 112, and an open bottom through which solidifying metal 114 can exit. The mold 120 may additionally or alternatively have or cooperate with a bottom block 122 for forming the ingot 110, such as may commonly be the case in a mold 120 used in direct chill casting. The bottom block 122 may be moveable or stationary. In some embodiments, the bottom block 122 may be a starting head mounted on a telescoping hydraulic table. In alternative embodiments, the mold 120 can be any type and shape suitable for casting molten metal 112.

[0027] The mold 120 may additionally or alternatively aid in the cooling of the molten metal 112 to form solidifying metal 114. In a non-limiting example, the mold 120 is a water-cooled mold. However, the mold 120 may have heated walls to retard mold wall cooling (e.g., an Ohno Continuous Caster (OCC) mold). The mold 120 may also be or include a cooling system that uses one or more of air, glycol, or any suitable cooling medium.

[0028] The molten metal 112 can be deposited by one or more launders 130 positioned adjacent to the mold 120. The launder 130 may contain one or more openings for dispensing the molten metal 112 into the mold 120. In various embodiments, the launder 130 may be positioned above the mold 120 and deposit the molten metal 112 into the mold 120 from the one or more openings. The launder 130 may be any size and shape suitable for containing and dispensing the molten metal 112. As depicted, the launder 130 has a rectangular shape with a u-shaped channel for containing the molten metal 112.

[0029] The launder 130 may further include a flow control device 132. The flow control device 132 may control the flow rate of the molten metal 112 from the launder 130 to the mold 120. As an illustrative example, the flow control device 132 can include a pin 134. The pin 134 can be positioned in an opening 136 in the launder 130. The opening 136 and/or the pin 134 can be tapered such that moving the pin downwards relative to the opening makes the annulus between the pin and the opening smaller. The pin 134 can be raised and/or lowered to adjust the flow of molten metal 112 out of the launder 130. For example, the pin 134 can be raised to enlarge the annulus between the pin and the opening 136, increasing the molten metal 112 flowing out of the launder 130 (e.g., as shown in solid lines). Further, the pin 134 can be lowered to shrink the annulus between the pin and the opening 136, decreasing and/or stopping the flow of the molten metal 112 out of the launder 130 (e.g., as shown in dashed lines).

[0030] The pin 134 can be automatically raised and/or lowered by the computer system 160. For example, the pin 134 may be automatically raised and/or lowered to maintain the level of the molten metal 112 in the mold 120 within a range of a setpoint. The pin 134 may additionally or alternatively be automatically raised and/or lowered in response to detecting the size of the gap 116 is within a certain range. However, the pin 134 may be raised and/or lowered manually. In some examples, the manual raising and/or lowering of the pin 134 may be prompted by the computer system 160. In various embodiments, the pin 134 can be raised and lowered at timed intervals (e.g., the pin can be pulsed) to adjust the flow of molten metal 112 into the mold 120. Pulsing the pin 134 can cause the molten metal 112 flowing into the mold 120 to disrupt the surface tension of the molten metal in the mold 120. Disrupting the surface tension of the molten metal 112 in the mold 120 can cause molten metal to flow more readily along the surface of the molten metal in the mold, for example, into gap 116. In further embodiments, the flow control device 132 can additionally or alternatively include a valve, a stop, a funnel, or other suitable structure.

[0031] The detection system 100 may further include one or more cameras 140 capable of capturing still or moving images. The camera 140 may be positioned facing the mold 120 or otherwise have a field of view 142 including at least a portion of the mold 120. In various embodiments, a camera 140 is positioned above the mold 120 with a field of view 142 that includes at least a portion of the top of the mold 120. A camera 140 may additionally or alternatively be positioned beneath the mold 120 with a field of view that includes at least a portion of the bottom of the mold 120. In various embodiments, the camera 140 is moveable and/or has a changing field of view 142. [0032] The detection system 100 may include multiple cameras 140 working in conjunction. The multiple cameras 140 may be positioned to have adjacent or overlapping fields of view 142. For example, two cameras 140 may be mounted at different heights above the mold 120 and may have overlapping fields of view 142 of the top of a mold 120. As another example, two cameras 140 may be mounted so that each camera 140 has a field of view 142 of a portion of one side of the mold 120. Each field of view 142 may be combined to form an image of the entire side of the mold 120 or other aggregate areas of interest.

[0033] The light source 150 may be positioned on the opposite side of the mold 120 as the camera 140. As described further below when discussing FIG. 3, the light source 150 may be positioned to emit light directly toward the mold 120 such that, if a gap 116 (as shown, the gap 116 has been exaggerated in size for ease of viewing) exists between at least one side wall of the mold 120 and the solidifying metal 114, the emitted light will shine through the gap 116. In a non-limiting example, the camera 140 is positioned above the mold 120 and the light source 150 is positioned below the mold 120 to emit light directed upwards. The light source 150 may alternatively be positioned above the mold 120 to emit light directed downwards and the camera 140 positioned below the mold 120. In a further example, the light and the camera may be positioned on the same side of the mold. If present, the emitted light visible through the gap 116 may be captured, registered, and/or detected by the camera 140. The emitted light can be or can include light that has traveled indirectly and been bounced, reflected, and/or refracted when traveling from the light source 150, through the gap 116, and to the camera 140. For example, the light may reflect off of the solidifying metal 114 and/or the mold 120 when traveling through the gap 116. However, the light may be or include light that has traveled directly from the light source 150, through the gap 116, and to the camera 140 with little or no reflection or refraction.

[0034] The light source 150 may emit light in a single color or may be capable of changing between multiple colors. The color may be in the visible spectrum or in the infrared spectrum. In a non-limiting example, the light source 150 includes LEDs that are able to change colors. The light source 150 can include incandescent lamps, compact fluorescent lamps, halogen lamps, metal halide lamps, light emitting diodes (LEDs), fluorescent tubes, neon lamps, high intensity discharge lamps, or other light emitter, individually or in combination. Moreover, the light source 150 may directly emit light and correspond to a component capable of producing light and/or may additionally or alternatively indirectly emit light and include one or more reflective surfaces or other elements capable of reflecting or directing light toward a target focal area. Further non-limiting examples include mirrors or fiber-optic cables for directing the light.

[0035] The detection system 100 may include a computer system 160. The computer system 160 may include hardware and software for executing computer-executable instructions. For example, the computer system 160 may include memory, processors, and an operating system for executing the computer-executable instructions (FIG. 5). The computer system 160 may have hardware or software capable of communicating with other devices through a wired connection or a wireless connection (e.g., Bluetooth). The computer system 160 may be in communication with one, some combination, or all of: the flow control device 132, the camera 140, the light source 150, an alarm 170 (FIG. 2), or a sensor 180 (FIG. 2).

[0036] In embodiments, the computer system 160 is in a single physical location. For example, the computer system 160 may be hardware and software located in the same manufacturing facility as the mold 120 and communicating with the camera 140 and/or light source 150 over a local communication network (e.g., Wi-Fi or Bluetooth). Additionally or alternatively, multiple computer systems 160 may be in communication with the camera 140 and/or light source 150 and/or located in multiple physical locations. For example, the computer system 160 may be a cloud computing system including any number of internet connected computing components.

[0037] The computer system 160 may contain hardware and software capable of enabling execution of the steps of: receiving data from the camera 140, analyzing the received data to detect light between the mold 120 and the solidifying metal 114, and determining whether the metal 114 has separated from the mold 120. Some or all of these steps may be performed by a single computer system 160 or multiple computer systems.

[0038] The detection system 100 as depicted in FIG. 2 includes additional elements of an alarm 170 and a sensor 180. However, the detection system 100 of FIG. 2 may include additional or alternative elements.

[0039] The computer system 160 may alert a user after it has been determined that the solidifying metal 114 has separated from the mold 120 (e.g., a gap, such as gap 116, exists between the mold 120 and the solidifying metal 114, such that light from the light source 150 is detected by the camera 140). The computer system 160 may also be in communication with the alarm 170. For example, the computer system 160 may activate the alarm 170 in response to a determination (e.g., made by the computer system 160) that a gap 116 exists between one or more side walls of the mold 120 and the solidifying metal 114 (such as when the camera 140 captures, registers and/or detects light through the gap 116). The alarm 170 may correspond to or include a bell, a light, a siren, display, speaker, or any other object capable of getting the attention of a user and/or conveying information to the user.

[0040] Other actions may be prompted in addition to or in lieu of activating the alarm 170. In various embodiments, a change in the flow of the molten metal 112 into the mold 120 may be introduced along with or instead of activation of the alarm 170. For example, the flow control device 132 may be controlled to increase, decrease, or otherwise change the flow rate, amount, or other characteristic of the flow of molten metal 112 into the mold 120. In various embodiments, an alert additionally or alternatively may be displayed, logged, sent, or otherwise communicated to a user or another aspect of the system (e.g., and may be independent of or performed in conjunction with activating the alarm 170 and/or changing the flow of the molten metal 112).

[0041] In various embodiments, the light source 150 may utilize a color of light that is different from other colors present in the environment of the detection system 100. Such functionality may be facilitated by the sensor 180. The sensor 180 may detect light in the surrounding manufacturing environment and communicate such data to the computer system 160. In a non-limiting example, the surrounding environment contains a red-light. The sensor 180 detects the red-light and sends that data to the computer system 160. Based on that data, the computer system 160 sends a signal to the light source 150 to produce a green light color and/or a light color other than red. In various embodiments, the light source 150 may be tuned during setup by a technician to produce a light color that differs from a color of other lights and/or other objects in a relevant surrounding environment, such as an environment around the mold 120 that may affect colors that will appear in the field of vision of the camera 140 and could otherwise negatively impact the ability of the camera 140 to collect light that can be distinguished for determining the presence of a gap 116 between the solidifying metal 114 and the side of the mold 120. Additionally or alternatively, in some embodiments, ambient light and/or colors or types of light that may be present in the surrounding manufacturing environment may be detected by the sensor 180 or other suitable input and filtered out by the computer system 160, e.g., to facilitate detection of relevant emitted light for determining the presence of a gap 116.

[0042] As depicted in FIG. 2, the detection system 100 may include multiple molds 120 A, 120B, 120C. The multiple molds 120A, 120B, 120C may be positioned to receive molten metal 112 from a launder 130. The multiple molds 120A, 120B, 120C may alternatively receive molten metal 112 from multiple launders 130. The multiple molds 120 A, 120B, 120C may all receive the same type, alloy, and/or combination of molten metal 112, however, each mold 120A, 120B, 120C may receive a different type, alloy, and/or combination of molten metal.

[0043] In various embodiments, one or more cameras 140 and/or one or more light sources 150 are positioned around the multiple molds 120A, 120B, 120C. For example, two cameras 140 may be positioned with overlapping fields of view 142 that include at least a portion of a first mold 120A. An additional camera 140 may be positioned to have a field of view 142 that includes at least a portion of the first mold 120A and a second mold 120B. A moveable camera 140 may additionally be positioned with a field of view 142 that includes at least a portion of a third mold 120C. The one or more light sources 150 may be positioned on an opposing side of the multiple molds 120 A, 120B, 120C as the one or more cameras 140.

[0044] Turning to FIG. 3, an example of a field of view 142 of the camera 140 of FIGS. 1 and 2 is depicted. The field of view 142 may include the mold 120, the molten metal 112, and the solidifying metal 114. The field of view 142 may also include the gap 116, if present, between at least one side wall of the mold 120 and the light 152 (e.g., from the light source 150) shining through the gap 116. As depicted, the field of view 142 includes one side of a mold 120 (e.g., a top side) and an entire perimeter of the mold 120. However, the field of view 142 may include a sub-portion of a perimeter of a mold 120, portions of multiple molds, for example, molds 120A, 120B, and 120C, multiple sides of a mold 120, or multiple sides of multiple molds 120A, 120B, and 120C.

[0045] By way of example, the field of view 142 is depicted as being split into four quadrants (e.g., I, II, III, IV). However, the field of view 142 may include more or less quadrants. A single camera 140 can have a field of view 142 that includes all four quadrants. However, a single camera 140 may have a field of view 142 that corresponds to a single quadrant. Additionally or alternatively, a single camera 140 may have a field of view 142 that corresponds to a combination of quadrants. In some embodiments, a single camera 140 may have multiple fields of view 142 (e.g., each quadrant is a different field of view 142) that the camera 140 can switch between. For example, a moveable camera 140 may switch between fields of view 142 as the camera 140 pans around the top of the mold 120.

[0046] In various embodiments, the quadrants can include indicia that correspond to coordinates of locations on the ingot 110 and/or mold 120. In some embodiments, the computer system 160 can determine the gap 116 exists and then determine a location of the gap 116 using the coordinates.

[0047] FIG. 4 is a flow chart representing an example of a process 400 for using the detection system 100 to identify a gap 116 between a side wall of the mold 120 and the solidifying metal 114 in accordance with some embodiments. Some or all of the process 400 (or any other processes described herein, or variations, and/or combinations thereof) may be performed under the control of one or more computer systems configured with executable instructions and may be implemented as code (e.g., executable instructions, one or more computer programs, or one or more applications) executing collectively on one or more processors, by hardware or combinations thereof. The code may be stored on a computer-readable storage medium, for example, in the form of a computer program comprising a plurality of instructions executable by one or more processors. The computer-readable storage medium may be non-transitory. Moreover, unless indicated otherwise, acts shown in the processes are not necessary performed in the order shown and/or some acts can be omitted in embodiments.

[0048] The process 400 at 402 can include depositing metal, such as molten metal 112 into one or more molds, such as mold 120. The molten metal 112 may be deposited into the mold 120 by a launder 130 as described herein. The launder 130 may deposit the molten metal 112 into the mold 120 through one or more openings in the launder 130. The amount or flow rate of the molten metal 112 entering the mold 120 may be adjusted by controlling the flow control device 132. The molten metal 112 may enter the mold 120 through one or more openings in the mold 120. The molten metal 112 contained by the mold 120 may contact one or all side walls of the mold 120. The temperature of the molten metal 112 may decrease after entering the mold 120 and the molten metal 112 may cool and become solidifying metal 114. The solidifying metal 114 may contract away from the sidewalls of the mold 120 causing one or more gaps 116 to form between the solidifying metal 114 and a side wall of the mold 120.

[0049] The process 400 at 403 can include emitting light, such as light 152, from a light source, such as light source 150 described above. The light source 150 can be positioned on the opposite side of the mold 120 and oriented to emit light 152 toward the lens of a camera, such as camera 140. The solidifying metal 114 in the mold 120 can block the emitted light 152 if the solidifying metal 114 is touching all sides of the mold 120. However, if there is a gap, such as the gap 116, between the solidifying metal 114 and the mold 120, the emitted light can travel through the gap 116 and be seen by the camera 140. The light source 150 may emit light 152 containing multiple colors. For example, the light source 150 can emit a certain color of light that is different than the color of light visible in the surrounding environment. In some embodiments, a sensor 180 is used to detect the light source in the surrounding environment. In some cases, the sensor 180 sends the detected light data to a computer, such as computer system 160, which sends instructions to the light source 150 to shine light 152 at a color other than the color of the detected light.

[0050] The process 400 at 404 can include detecting light between a side wall of the mold 120 and the solidifying metal 114. The detected light may be the light 152 emitted by the light source 150. In some embodiments, the detected light 152 is ambient light in the surrounding environment. The light 152 can be detected after traveling through the gap 116 between the mold 120 and the solidifying metal 114. The camera 140 can see the light through the gap 116. The camera 140 can then send data to the computer system 160 indicating light is visible between the mold 120 and the solidifying metal 114. The computer system 160 can process the data and determine that light has been detected between a side wall of the mold 120 and the solidifying metal 114.

[0051] The process 400 at 406 can include determining the solidifying metal 114 has separated from the mold 120. The computer system 160 determines the solidifying metal 114 has separated from the mold 120 by determining if light 152 has been detected between a side wall of the mold 120 and the solidifying metal 114. In some embodiments, the computer system 160 can process data received from the camera 140 to determine if the solidifying metal 114 has separated from at least one side wall of the mold 120. The computer system 160 can process that data and determine if the visible data includes light 152 between the mold 120 and the solidifying metal 114. If there is light 152 between the mold 120 and the solidifying metal 114, the computer system 160 can make a determination that the solidifying metal 114 has pulled away from the sidewalls of the mold 120. In an illustrative example, the computer system 160 receives visual data from the camera 140 and processes the data using a machine vision application. The machine vision application analyzes the visual data to determine if light 152 is visible and/or if certain defined conditions are present in the visual data. The machine vision application can then send that data to another application and/or make a determination that the solidifying metal 114 has pulled away from the sidewalls of the mold 120.

[0052] The computer system 160 may make the determination that the solidifying metal 114 has pulled away from the mold 120 using additional or alternative data received from the camera 140. In some embodiments, the computer system 160 can receive information about the mold 120 and/or the solidifying metal 114 from a data source (e.g., a database) to aid in determining whether the solidifying metal 114 has separated from the mold 120. In an illustrative example, a first mold 120A and a second mold 120B are monitored by a camera 140. The computer system 160 receives information that the solidifying metal 114 in the first mold 120A has a greater probability of separating from the first mold 120A than the solidifying metal 114 in the second mold 120B (e.g., the first mold 120A may be located in an area that is closer to a cooling source than the second mold 120B, causing the solidifying metal 114 in the first mold to have a higher chance of cooling more rapidly and contracting away from the walls of the first mold 120A). In response to the received information, the computer system 160 directs the camera 140 to keep more of the first mold 120A in the field of view 142 of the camera 140.

[0053] The process 400 at 408 can include responding to the determination of the computer system 160 that the solidifying metal 114 has separated from the sidewalls of the mold 120. The response can include sending an alert to a user. The alert may be sent by the computer system 160 to a user to inform them of the solidifying metal 114 separating from the mold 120. For example, the alert may be to activate an alarm, such as alarm 170 described above, and alert a user that separation has occurred. The alert may also or alternatively be a message, a visual indication, or an audio indication that draws the attention of the user and/or informs them of the separation. [0054] The computer system 160 may additionally or alternatively respond to the separation of the solidifying metal 114 and the mold 120 by changing the flow rate of the molten metal 112 into the mold 120. As molten metal 112 is deposited into the mold 120, it may flow into the gap 116 caused by the contracting of the solidifying metal 114 away from the mold. The gap 116 may be small, e.g., such that molten metal 112 can be added to the mold 120 to fill the gap. In contrast, the gap 116 may be large, e.g., such that molten metal 112 may be added to the mold 120, flow through the gap 116, and exit the bottom of the mold 120. In some embodiments, the molten metal 112 that flows through the gap 116 may contact water and/or a cooling solution, which can cause an explosion. Accordingly, the computer system 160 may determine a size of the gap 116 and use that information to determine whether to change the flow rate in response to the gap 116.

[0055] In various embodiments, the gap 116 can be filled by adjusting the flow of molten metal 112 into the mold 120. For example, the flow rate of molten metal 112 into the mold 120 may be adjusted with flow control device 132. In response to the computer system 160 detecting the gap 116 (and/or detecting that the gap 116 is sufficiently small to permit filling), the flow of molten metal 112 into the mold 120 can be increased, for example, by raising the pin and increasing the flow rate of molten metal through the opening in the launder 130. Additionally or alternatively, the height of the pin can be pulsed to vary the flow rate of the molten metal 112 into the mold 120. The increased and/or varied flow rate of the molten metal 112 can cause molten metal 112 to flow into the gap 116. The molten metal 112 can cool and become solidifying metal 114. The solidifying metal 114 can substantially or completely fill the gap 116. The filled gap 116 can stop or prevent additional molten metal 112 from flowing through the gap. If the gap 116 is large, the computer system 160 may send instructions to the flow control device 132 to decrease or stop the flow of molten metal 112 into the mold 120. The computer system 160 may also prompt or cause a change in the rate of flow by sending instructions to a user.

[0056] In some embodiments, the process 400 includes steps 410 through 414 for responding to the solidifying metal 114 separating from the mold 120. The process 400 at 410 can include determining the size of the gap 116 between the solidifying metal 114 and the mold 120. In various examples, the computer system 160 receives data from the camera 140 comprising or containing the amount of light 152 the camera 140 has captured in the gap 116 between the solidifying metal 114 and the mold 120. The computer then uses the amount of light 152 detected in the received data to determine the size of the gap 116.

[0057] The process 400 at 412 can include comparing the size of the gap 116 between the solidifying metal 114 and the mold 120 to a threshold value. The threshold value can be received by the computer system 160 and may be based on at least the type of ingot 110 being formed, the type of mold 120, and/or other characteristics of the detection system 100. The process 400 at 414 can include increasing or decreasing the flow of molten metal 112 into the mold 120 based on the comparison of the gap 116 to the threshold value. For example, if the gap 116 is below the threshold value, the flow of molten metal 112 into the mold 120 can be increased. Additionally or alternatively, if the gap 116 is greater than the threshold value, the flow of molten metal 112 into the mold 120 can be decreased and/or stopped.

[0058] FIG. 5 is an example computer system 500 for use with the system for detecting solidifying metal 114 separating from a mold 120, as shown in FIG. 1. In some embodiments, the computer system 500 performs one, some, or all of the steps of process 400. However, the computer system 500 may perform additional and/or alternative steps. In various embodiments, the computer system 500 includes a controller 510 that is implemented digitally and is programmable using conventional computer components. The controller 510 may be used in connection with certain examples (e.g., including equipment such as shown in FIG. 1) to carry out the processes of such examples. The controller 510 includes a processor 512 that can execute code stored on a tangible computer-readable medium in a memory 518 (or elsewhere such as portable media, on a server or in the cloud among other media) to cause the controller 510 to receive and process data and to perform actions and/or control components of equipment such as shown in FIG. 1. The controller 510 may be any device that can process data and execute code that is a set of instructions to perform actions such as to control industrial equipment. As non- limiting examples, the controller 510 can take the form of a digitally implemented and/or programmable PID controller, a programmable logic controller, a microprocessor, a server, a desktop or laptop personal computer, a laptop personal computer, a handheld computing device, and a mobile device. [0059] Examples of the processor 512 include any desired processing circuitry, an application- specific integrated circuit (ASIC), programmable logic, a state machine, or other suitable circuitry. The processor 512 may include one processor or any number of processors. The processor 512 can access code stored in the memory 518 via a bus 514. The memory 518 may be any non-transitory computer-readable medium configured for tangibly embodying code and can include electronic, magnetic, or optical devices. Examples of the memory 518 include random access memory (RAM), read-only memory (ROM), flash memory, a floppy disk, compact disc, digital video device, magnetic disk, an ASIC, a configured processor, or other storage device.

[0060] Instructions can be stored in the memory 518 or in the processor 512 as executable code. The instructions can include processor-specific instructions generated by a compiler and/or an interpreter from code written in any suitable computer-programming language. The instructions can take the form of an application that includes a series of setpoints, parameters for detecting light, and programmed steps which, when executed by the processor 512, allow the controller 510 to determine if solidifying metal 114 has separated from the mold 120, such as by detecting light 152 between the mold 120 and the solidifying metal 114 using the camera 140 to capture light emitted by the light source 150. Additionally or alternatively, the instructions can include instructions for a machine vision application.

[0061] The controller 510 shown in FIG. 5 includes an input/output (I/O) interface 516 through which the controller 510 can communicate with devices and systems external to the controller 510, including components such as the flow control device 132, the camera 140, the light source 150, the alarm 170, and/or the sensor 180. The input/output (I/O) interface 516 can also, if desired, receive input data from other external sources. Such sources can include control panels, other human / machine interfaces, computers, servers or other equipment that can, for example, send instructions and parameters to the controller 510 to control its performance and operation; store and facilitate programming of applications that allow the controller 510 to execute instructions in those applications to determine if solidifying metal 114 has separated from the mold 120 such as in connection with the processes of certain examples of the invention; and other sources of data necessary or useful for the controller 510 in carrying out its functions to detect light 152 between the mold 120 and the solidifying metal 114 and/or determine if solidifying metal 114 has separated from the mold 120, such as in the detection system 100 of FIG. 1. Such data can be communicated to the input/output (I/O) interface 516 via a network, hardwire, wirelessly, via bus, or as otherwise desired.

[0062] All patents, publications and abstracts cited above are incorporated herein by reference in their entirety. The foregoing description of the embodiments, including illustrative aspects of embodiments, has been presented only for the purpose of illustration and description and is not intended to be exhaustive or limiting to the precise forms disclosed. Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art.

ILLUSTRATIVE ASPECTS

[0063] All patents, publications and abstracts cited above are incorporated herein by reference in their entirety. The foregoing description of the embodiments, including illustrative aspects of embodiments, has been presented only for the purpose of illustration and description and is not intended to be exhaustive or limiting to the precise forms disclosed. Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art.

[0064] Aspect 1 is a system for detecting metal contraction in a mold, comprising: a mold for receiving and containing metal, the mold comprising a first side, a second side opposite the first side, and a plurality of walls spanning between the first side and the second side; a camera facing the first side of the mold and having a field of vision including at least a portion of the first side of the mold; a light source facing the second side of the mold for emitting light directed toward the second side of the mold, the emitted light visible to the camera through the first side of the mold when the metal is separated from at least one of the plurality of walls; wherein the system is configured to: detect light visible between the at least one of the plurality of walls and the metal based at least in part on data from the camera; and determine whether separation of the metal from the at least one of the plurality of walls has occurred based at least in part on the light detected as visible between the at least one of the plurality of walls and the metal.

[0065] Aspect 2 is the system of aspect(s) 1 (or of any other preceding or subsequent aspects individually or in combination), wherein the first side of the mold is an open top for receiving the metal and the second side of the mold is an open bottom allowing the metal to exit the mold or wherein the first side of the mold is an open bottom allowing metal to exit the mold and the second side of the mold is an open top for receiving the metal. [0066] Aspect 3 is the system of aspect(s) 1 (or of any other preceding or subsequent aspects individually or in combination), wherein the mold is a first mold and the field of vision of the camera includes the first mold and a second mold such that the system can detect separation of the metal from at least one of the plurality of walls in either or both of the first mold and the second mold and wherein the system is further configured to send a response based at least in part on determining whether separation of at least one of the plurality of walls and the metal has occurred.

[0067] Aspect 4 is the system of any one of aspects 1 through 3 (or of any other preceding or subsequent aspects individually or in combination), wherein the light source is a plurality of light emitting diodes capable of emitting light at a wavelength of 380 to 740 nm.

[0068] Aspect 5 is the system of aspect(s) 1 (or of any other preceding or subsequent aspects individually or in combination), further comprising a container positioned above the mold having a bottom and defining a channel for containing the metal, the bottom of the container defining one or more apertures for flow of the metal from the container to the mold, wherein the system is further configured to adjust the flow of the metal from the container to the mold based at least in part if it is determined that separation of at least one of the plurality of walls and the metal has occurred.

[0069] Aspect 6 is the system of aspect(s) 5 (or of any other preceding or subsequent aspects individually or in combination), wherein the camera is a first camera and the system further comprises a second camera with a field of vision that differs from the field of vision of the first camera, and wherein detecting whether light is visible between at least one of the plurality of walls and the metal is based on data from one or both of the first camera or the second camera.

[0070] Aspect 7 is the system of aspect(s) 6 (or of any other preceding or subsequent aspects individually or in combination), wherein the mold is a first mold and the system further comprises a second mold comprising a first side, a second side opposite the first side, and a plurality of side walls spanning between the first side and the second side, wherein the second camera has a field of vision that includes the first side of the second mold.

[0071] Aspect 8 is the system of aspect(s) 7 (or of any other preceding or subsequent aspects individually or in combination), wherein the system is further configured to detect whether light is visible between at least one of the plurality of side walls of the first mold and the metal based at least in part on data from the first camera and whether light is visible between at least one of the plurality of side walls of the second mold and the metal based at least in part on data from the second camera.

[0072] Aspect 9 is the system of aspect(s) 1 (or of any other preceding or subsequent aspects individually or in combination), wherein the system further comprises a launder positioned above the mold and configured for depositing the metal into the mold, the launder defining a channel for receiving the metal and comprising a flow control device configured to control a flow rate of the metal into the mold.

[0073] Aspect 10 is the system of aspect(s) 9 (or of any other preceding or subsequent aspects individually or in combination), wherein the system is further configured to control the flow rate of the metal into the mold based on at least determining whether separation of at least one of the plurality of walls and the metal has occurred.

[0074] Aspect 11 is the system of aspect(s) 10 (or of any other preceding or subsequent aspects individually or in combination), wherein at least a portion of the flow control device is positionable adjacent to an aperture defined by a bottom of the launder and controlling the flow rate of the metal into the mold comprises at least changing a position of the flow control device relative to the aperture.

[0075] Aspect 12 is the system of aspect(s) 5 (or of any other preceding or subsequent aspects individually or in combination), wherein adjusting the flow of the metal from the channel to the mold further comprises: determining a size of the separation between at least one of the plurality of walls and the metal; comparing the size of the separation to a threshold value; and increasing the flow of the metal if the size of the separation is less than the threshold value or stopping or decreasing the flow of the metal if the size of the separation is greater than the threshold value.

[0076] Aspect 13 is the system of aspect(s) 12 (or of any other preceding or subsequent aspects individually or in combination), further comprising a flow control device at least partially positioned adjacent to an aperture of the one or more apertures, wherein increasing the flow of the metal or stopping or decreasing the flow of the metal comprises adjusting a position of a flow control device to change a size of the aperture. [0077] Aspect 14 is the system of aspect(s) 13 (or of any other preceding or subsequent aspects individually or in combination), wherein increasing the flow of the metal comprises adjusting the flow control device to increase the size of the aperture or stopping or decreasing the flow comprises adjusting the flow control device to decrease the size of the aperture.

[0078] Aspect 15 is the system of any one of aspects 9 through 14 (or of any other preceding or subsequent aspects individually or in combination), wherein the flow control device comprises at least one of a pin, a valve, a stop, or a funnel.

[0079] Aspect 16 is a method for detecting metal separating from a mold, the method comprising: causing the metal to be received into the mold, the mold comprising a first face, a second face opposing the first face, and a plurality of side walls spanning between the first and second faces, where at least one of the plurality of side walls contacts the metal; detecting if light is present between at least one of the plurality of side walls of the mold and the metal based on at least data received from a camera having a field of view of at least a portion of the first face, a light source emitting the light and positioned adjacent to the second face and directing the light towards the second face; and determining if the metal has pulled away from at least one of the plurality of side walls of the mold based on at least detecting if the light is present.

[0080] Aspect 17 is the method of aspect(s) 16 (or of any other preceding or subsequent aspects individually or in combination), further comprising sending a response based on at least determining the metal has pulled away from at least one of the plurality of side walls of the mold.

[0081] Aspect 18 is the method of aspect(s) 17 (or of any other preceding or subsequent aspects individually or in combination), wherein the response includes sending at least one of an alert message or activating an alarm.

[0082] Aspect 19 is the method of aspect(s) 16 (or of any other preceding or subsequent aspects individually or in combination), wherein causing the metal to be received into the mold comprises operating a flow control device configured for depositing the metal into the mold, the flow control device operable to change a flow rate of the metal into the mold.

[0083] Aspect 20 is the method of aspect(s) 19 (or of any other preceding or subsequent aspects individually or in combination), further comprising operating the flow control device to adjusting the flow rate of the metal into the mold based on at least determining the metal has pulled away from at least one of the plurality of side walls of the mold.

[0084] Aspect 21 is the method of aspect(s) 20 (or of any other preceding or subsequent aspects individually or in combination), wherein adjusting the flow rate of the metal into the mold comprises: determining a size of a separation between at least one of the plurality of side walls and the metal; comparing the size of the separation to a threshold value; and increasing the flow rate of the metal if the size of the separation is less than the threshold value or stopping or decreasing the flow rate of the metal if the size of the separation is greater than the threshold value.

[0085] Aspect 22 is the method of aspect(s) 16 (or of any other preceding or subsequent aspects individually or in combination), further comprising identifying a location where the metal has pulled away from at least one of the plurality of side walls of the mold.

[0086] Aspect 23 is the method of aspect(s) 16 (or of any other preceding or subsequent aspects individually or in combination), further comprising: identifying colors of environmental light in an environment outside of the mold based on data from the camera or data from a light sensor disposed in the environment outside of the mold; and controlling the light source to generate light with a color or colors that differ from the identified colors.

[0087] Aspect 24 is the method of aspect(s) 16 (or of any other preceding or subsequent aspects individually or in combination), wherein detecting light between at least one of the plurality of side walls of the mold and the metal further comprises receiving data from a second camera having a field of view of at least a portion of the first face of the mold.

[0088] Aspect 25 is the method of aspect(s) 16 (or of any other preceding or subsequent aspects individually or in combination), wherein detecting light between at least one of the plurality of side walls of the mold further comprises moving the camera to change the field of view.

[0089] Aspect 26 is the method of aspect(s) 25 (or of any other preceding or subsequent aspects individually or in combination), wherein moving the camera comprises changing the field of view to include at least: one or more portions of the first or second face of one or more of a plurality of molds. [0090] Aspect 27 is the method of aspect(s) 16 (or of any other preceding or subsequent aspects individually or in combination), wherein determining the metal has pulled away from at least one of the plurality of side walls of the mold is further based on information received about the mold or the metal.