MoldCon: Automatic Mold Width Adjustment During Casting

MoldCon from Primetals Technologies is a fast and accurate software solution that automatically adjusts the width of slab caster molds.

Slow mold width adjustments limit productivity, reduce operational flexibility, and increase costs. During width adjustment, the mold’s copper plates are exposed to considerable deformation forces, leading to increased wear, high maintenance demands, and downtime. These issues make it difficult for plants to achieve consistent and efficient production.
MoldCon is the perfect solution for quickly and automatically adjusting the width of slab caster molds. Its high-speed, low-force adjustment method decreases wear and maintenance demands by minimizing deformation and copper wear. The width is adjusted by four hydraulic or electric drives per mold, which are directly linked to the mold’s narrow faces and controlled by the MoldCon software. This solution can even be implemented in existing molds. Furthermore, MoldCon detects disturbances within the width-change sequence and automatically initiates countermeasures to ensure the solution remains in a fail-safe condition.

Compatibility of the MoldCon Automatic Mold Width Adjustment System

MoldCon offers outstanding compatibility and integration flexibility. Its standardized interfaces have undergone rigorous testing to ensure reliable 24/7 operation and seamless integration with existing caster automation systems. Designed for future expansion, this software solution can also be used with existing molds to ensure seamless upgrades and long-term adaptability.

Adjustment Models of MoldCon

The S-Mode adjustment significantly increases the speed of warm adjustments. This reduces deformation forces on the strand shell, minimizing copper wear and maintenance requirements. Additionally, it requires less force on the narrow-side drives than conventional methods.

Mold Box for Maintenance

The optional Mold Box is a portable, standardized control device designed for width-adjustable molds. It enables operators to manually inspect molds for damage in the maintenance area prior to operation.

Benefits of the MoldCon Automatic Mold Width Adjustment System

• Reduced maintenance costs: the low-force adjustment method decreases wear and maintenance demands by minimizing deformation and copper wear.
• Increased productivity and operational flexibility: fast dynamic response, automatic adjustment of control parameters, and high adjustment speed allow width changes during operation without interrupting casting, while offline calibration and adjustment eliminate the need for readjustments during production.
• Increased operational safety: an integrated expert system automatically detects and responds to critical operating conditions, ensuring smooth and safe casting processes.
• Fast overall adjustment process: high adjustment accuracy, fast response rates, and efficient operation enable quick and reliable mold width adjustment.
• Higher yield (up to 4%): precise and stable mold adjustments improve casting quality and consistency, reducing losses and increasing output.
• No additional equipment needed, as retrofitting is possible: the system is designed for easy integration into existing molds, with standardized interfaces and compatibility with caster automation systems and EMS/EMBR.