SICS: A Sensor-Based In-Line Control System for the Surfaces of Continuously Cast Slabs
The goal of this project was to develop and demonstrate a SICS test unit that meet the need of the steel industry for enhancing the continuous casting process for improved surface quality for the targeted benefits and that is composed of an In-line Imaging Module and a Hybrid Predictive Control Module. The In-line Imaging Module provides the real-time or near real-time Product Information to the Hybrid Predictive Control Module. The latter is able to fuse the Product Information with the Process Information. In order to support the goal, this project had the technical objectives for indexes such as inspection accuracy and in-line service life, based on the inspection coverage of the entire cast slab. The deployment of the SICS systems has the potential to provide benefits in reduction of energy waste, CO 2 emission, waste water amount, toxic waste, and so forth. It will help to uphold the competitiveness of the industry that employs approximately 150,000 people nationwide and consumes about 3% of the energy in the country. The Phase II project has been carried out in accordance to the proposed tasks and budget, based on the original and extended schedule. The R&D team designed and implemented the test unit for the full width coverage, installed the unit in a caster. The development work further included enhanced image processing, in-depth defect study and process control models. The function, operation, and maintenance of the SICS was thoroughly studied during the Phase II research. The experience indicates additional hardware and procedures are required to make the SICS a commercially ready product in operation and maintenance aspect. Such developments have been finished and the team is contacting potential customers for the first commercial installation of SICS. Additionally, OGT is exploring the possibility to team up with a US company that specializes in surface cleaning for slabs/blooms/billets such that the in-line surface inspection can be integrated with in-line surface clean up for the maximum benefit to the steel industry.