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The 3D Laser System uses t

combination of a line laser a

custom video receiver. The se

views the cup at an angle, and

determine the metal level in

cup by reading the position o

line.

Because the line laser and 3

sensor are on opposite sides o

iron stream, the 3D Laser Sys

is insensitive to variations in

iron stream.

ombining Vision and Laser Pouring for High Performance

undry

ran Lowback

oran Lowback

2010-01-22 (All day)

gh-volume metalcasting demands bottom-pouring technology with closed-loop control, and metal-level feedback from t

ur cup to control the pour.

uring the last 50 years, pouring processes have evolved from manual (hand) pouring, via

mi-automated systems to completely automated systems. Although hand and

mi-automatic pouring is still common, high-volume production facilities use bottom-uring technology (featuring a stopper rod and nozzle) featuring closed-loop control, with

etal-level feedback from the pour cup to control the pour.

the 1980s, two technologies were introduced to provide this level feedback, vision

meras and laser systems. In 2004, KOINS Co. Ltd, introduced its pourTECH system

d a new approach to pouring, the 3D Laser System. The 3D Laser uses a combination of

er and vision to provide the most reliable real-time level data in the industry.

e 3D Laser System uses the combination of a line laser and a custom video receiver. On

e side of the pour cup is a line laser, projecting a green laser line across the cup. On the

posite side, the 3D sensor picks up the image of the line, as it reflects in the metalrface. The sensor views the cup at an angle, and can determine the metal level in the cup

reading the position of the line.

r vertically parted molding lines, traditional laser systems require a modification of the

ur cup to provide an area for the laser to measure the metal level while still keeping the

p size down, but since the 3D Laser projects a line across the entire cup, the system is

le to collect level data from both sides of the pour stream, so it can provide more accurate

formation to the pourTECH, allowing it to optimize its pouring control decisions.

traditional vision-based system depends on the illumination from the iron in the pour cup

make a level interpretation. The light contribution from the iron stream must however bescarded (since it doesnt represent level), a sometimes difficult task as the iron stream can

ander from side to side during the pour, or fan out if the nozzle condition deteriorates.

ith its green light source, the 3D Laser System is completely insensitive to the light from

e iron (thanks to the difference in wave length) and because the line laser and 3D sensor

e on opposite sides of the iron stream, the sensor will see a break in the laser line where

e stream enters the cup, making it possible for the sensor to ignore that part of the

ading. This makes the 3D Laser System insensitive to variations in the iron stream (side-

-side movement and fanning of the stream). As long as the 3D sensor can see a small

rtion of the line, the system can continue to operate even with severely fanning iron

eams.

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While a traditional vision sys

often requires additional

equipment and mold feature

locate the cup, the 3D Lase

point laser uses a combinatio

an active light source and sim

triangulation to locate the c

addition to the 3D sensor, the device opposite the line laser houses a point laser to

sition the pouring vessel over the mold on vertical molding lines, or to perform a cup

eck on flask lines, verifying the flask has both sand and a cup before pouring starts. While

raditional vision system often requires additional equipment and mold features to locate

e cup (lights and mold notches, as it is difficult to see a black hole in black sand), the 3D

sers point laser uses a combination of an active light source and simple triangulation to

cate the cup.

e 3D-Lasers camera features a specialized C-Mos detector. This detector is

ogrammable, which allows the system to decide which part of the detector to read and

ly view the area of the pour cup. This allows for higher data rates (traditional CCD

tectors must have every cell read before a new image can be collected) and higher

ecision.

e 3D Laser is designed for use with small pour cups and does not require any

odifications of the cup. Initially designed for pouring furnaces, the 3D-Laser has been

ccessfully adapted for use with heated and unheated pouring ladles such as KOINS

wn pouring units. PourTECH systems with 3D Lasers can be used together in pairs, allowing for simultaneous pouring o

olds without any interference between the two systems.

e level data from the 3D Laser is further processed by the pourTECH system controller, which in turn controls the posi

KOINS actuator and the opening of the stopper rod. This unit features an electric servo drive unit that moves at speed

ore than 100mm/sec.

e pourTECHs controller has been designed to handle a multitude of external sensors, such as run-out detectors, pyrom

d final level sensors, to provide the foundry with additional production data.

ith its mold-mapping feature, pourTECH will track each mold as it moves down the cooling line and allows the operato

ew key data, such as pouring status, iron temperature and final level on the operators panel. The data displayed on the sc

n be augmented with batch numbers, lab analyses and other pattern and pour specific information. The collected data ca

nt to an external database, where it can be kept as a quality record for each pour, fully accessible by the plant engineers.

old mapping, it is possible to provide cooling time control (CTC), to ensure that each mold is sufficiently cooled before it

e cooling line, while optimizing the production rate for the highest possible mold rate, taking advantage of line stoppages

breakdowns, pattern changes, etc., to keep the mold rate up.

oran Lowback is the president of Viking Technologies. Visitwww.viking-technologies.com.

ource URL:http://foundrymag.com/feature/combining-vision-and-laser-pouring-high-performance

ining Vision and Laser Pouring for High Performance http://foundrymag.com/print/feature/combining-vision-and-laser-po