Mercury Marine · company speakers →
Precision temperature control is critical in foundry operations, particularly when melting and pouring from stainless steel ingots. Leveraging a two-color pyrometer system integrated with a PLC, a method was developed to observe and respond to the thermal behavior of liquid metal in real time. The pyrometer continuously monitors the temperature within a ceramic crucible, and once a defined heating slope and temperature threshold are detected, the PLC automatically transitions the furnace into a hold state. This ensures that the metal is poured at an optimal temperature, improving consistency and quality. The defined heating slope was established through extensive data analysis and iterative trials, allowing thermal patterns to be identified consistently that precede ideal pouring conditions. By analyzing historical pyrometer data, key inflection points were isolated coupled with control logic that reliably predicts when the melt reaches its optimal state. This presentation will detail the instrumentation setup, control strategy, slope detection methodology, and the resulting improvements in process efficiency and product quality. The use of pyrometer data exemplifies the potential for data-driven optimization in traditional foundry environments.
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