Automated casting machines require complete automation of the various elements for control and monitoring, as well as a display system for driving the machine. The basic components of the GAPCast system are a PLC and a SCADA system (Siemens WinCC) installed on an industrial PC.
This Hardware and Software package allows the following functions to be performed:
The solution to straightening out the filling of the moulds is to measure the level as soon as the metal enters the mould. This requires using a sensor that has a larger measuring range, specifically around 200 mm. The GLS (GAP LEVEL SENSOR) is designed with an inductive sensor attached to a linear axis for vertical movement. As a result of this movement, by means of control electronics as well as the position measurement of the inductive head, the measuring range is increased to 200 mm.
For casting machines with automatic level regulation, the metal level in the mould must be taken into account when introducing liquid metal. Depending on metal requirements, a plug regulates such introduction of liquid metal. In case of a problem and, more particularly, in the event of an emergency stop, even without electrical power, the plug must prevent the inflow of metal.
For casting machines with automatic level regulation, it is essential to know the metal level in the casting channels. This information is necessary at certain points in the installation, such as:
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