Casting Unit Management Based on a Digital Model

The paper identifies the existing disadvantages of typical control systems for casting units for the production of aluminum ingots. Local control algorithms for individual components of a foundry unit (mixer, metallograft, casting machine) based on previously developed proprietary mathematical models are presented. Based on individual models, a comprehensive control algorithm has been developed that allows for the coordinated functioning of all components of the unit. Special attention is paid to controlling the thickness of the ingot’s cortical zone, which allows for timely response to a critical decrease in thickness and automatic adjustment of control actions to avoid breakthroughs of the ingot wall and subsequent metal explosions. Also, based on the heat distribution obtained by the mathematical model, the Niyama criterion is monitored in real time, which makes it possible to assess the quality of the microstructure of the ingot and the casting speed to ensure the absence of cold and hot cracks in the ingots. This makes it possible to switch from reactive stabilizing control to proactive predictive control, which increases the yield of usable products, process stability and industrial safety. The developed set of models and algorithms is the basis for creating a digital twin of the unit and predictive control systems.

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