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A Rotalec Company Head Office & Canadian Sales

Montreal, Canada E : info@rotalec.com

T : 514-341-3685

UK Manufacturing & Sales Hertfordshire SG3 6JP

E: sales@moduloc-intl.com T: +44 (0) 845-873-6501

USA Sales Minneapolis MN55344

E : sales@moduloc-usa.com T : 952-238-8453

Moduloc Control Level Sensor MDCLS

® MODULOC

® Control Systems

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The MDCLS Digital Laser Level Sensors are compact units with integrated optics and signal processor for pre-cise measurement of the liq-uid level. A focused laser spot is illuminated on the molten metal surface and the image distance determined by inter-nal CCD Camera. Installation software is provided for con-nection to a PC and to display measured values. Measurement of data is via both RS232 and 4-20 mA an-alogue output. The MDCLS operates at a measuring

KEY FEATURES

• Non-contact measurement on Launder and Head Box

• Internal Camera determines level via Laser spot position

• Operates off mirror like sur-faces regardless of angle

• Single nozzle keeps out con-taminate an reflections

• Configurable filtering with ability to remove bad read-ings

• Auto-gain circuit brightens laser when heavy fumes

• Operates off molten metal surfaces at up to 2,200°C

• Compact unit for confined space well away from heat

• Single purged aperture view-ing penetrates heavy steam.

• Various Stand-off clearances and working ranges

• Measurement frequency of 1 k Hz and 0.3 mm resolution

• Serial, Analogue and Digital Outputs

• Digital Out-of-range and overheating Alarms

• Gate, Vertical, Pin Position & Tap-Out Actuators available

LEVEL CONTROL ON HEAD BOX AND LAUNDER Typical Applications - Aluminium Casting Industry - Die Cast Aluminium Moulders - Lead, brass and Copper Foundries – Iron and Steel Plants.

In all Industries there is a need for reliable precise level control on the Launders, Troughs and Head boxes that are in use throughout the typical casting plant. With this in mind the Mod-uloc Level Sensors incorporate digital outputs confirming level measurement is being transmitted and the internal temperature is within limits. The illustrations below show the various areas in the Casting House where these Laser Level Sensors pro-vide the ideal solution for measurement of molten metal level, be it on Ingot Casters, Sheet or Rod Casters.

frequency of 1000 measurements per second a serial output update frequency of 1000 measurement points per sec. or lower. The La-ser unit is protected by in a Sec-ondary robust stainless enclosure provided with air inlet with Vortex cooling option as Air purge vent-ing out of the protective nozzle. This enables replacement of the Camera without disturbing mounting configuration. The con-nection cable is encased in a stainless flexible conduit to pro-tect it from metal splash. Vortex Air Purging via a Single Purged Aperture aids viewing through heavy steam.

'We have been using Moduloc lasers in recent years in the casting centre of our Grande-Baie factory and we are delighted with the results. The Moduloc Lasers have demonstrated an excellent level of reliability and accuracy and meet our needs in terms of technology solution to an automated system.'

Éric Fortin, ing.

Rio Tinto Alcan

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CASE STUDY Brocks Metals Improve Ingot Casting Lines Using

This new technology has been introduced with a focus on meeting the needs of the Casting House. For instance, automatic gain (AGC) on both the Laser transmitter and receiver optics, as well as the most effective purging with protective baffling measures to prevent the optics being contaminated. All this has meant robust level measurement is ensured even at start of the pour where heavy fumes normally generated.

Brock Metals produces zinc alloy ingots by use of speed controlled metallic pumps to transfer molten alloy from melt-ing pits to head boxes and from the head boxes the molten alloy goes to in troughs to casting ladles that pours into ingot moulds. To produce uniformed ingots the level in the head boxes needs to be very accurate and Brocks Metals achieved that by overfilling the head boxes and returned the surplus alloy to the melting pit. The returned alloy created a lot of dross which couldn`t be used for ingots. After contacting MODULOC Control Systems we advised a MODULOC LASER TRIANGULATION level sensor be used to measure the level in the head boxes and to use the infor-mation to maintain the pump speed to achieve an accurate level in the head boxes and thus avoid overfilling. MODULOC provided a drawing on how to connect the sen-sor to existing pump speed converters. MODULOC technical consultant “Rolf Backberg” attended Brock Metals for a trial installation and programming of the speed converter and subsequently installed the Moduloc laser sensor as well as assisting the manager of Brocks Metals “Mr Pavel Urban” in designing a new 2 chamber head box which was installed.

This procedure was carried out on all 3 casting lines.

“Level control keeps the constant metal flow to moulds and we achieve ingots of even height in melt, which is most important for special ingots with claws; as the level of molten metal in the casting box is constant we got rid of the overflow of molten material back into the pot and we achieve substantial savings on dross loss-es say from 2% to 1% in addition only one operator is needed to operate a casting as the pimp speeds are maintained by the Moduloc Triangulation Sensor”.

Pavel Urban—Manager Brock Metals

Moduloc Control Systems as manufactur-ers of Optical Sensors and Lasers have been suppliers to the Steel Industry for many years and from our experience on numerous installations monitoring molten aluminium level in North America we have implemented important technical advances that ensure robust level meas-urement for nonferrous molten metal and have introduced blue Lasers for molten ferrous metal level control.

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“With a big research we identify a couple of solution, one of which was MODULOC, in particular its periscope system; the solution needed to have good performance with high temperature, problems of reflection and small spaces. Actually the system has been working on the plant since 6 months and the feedback was quite good; we think that with some months more, we will be able to collect some more indication to optimize something more the complete system. PRSE agreed with MODULOC to design directly the struc-

ture, starting from the dimension of the MDCLS box.” PRSE Emanuele Rubini

An issue had occurred which was related to an application on a continuous brass casting, where PRSE were called to design and con-struct the level control system. Due to an ini-tial problem in choosing a laser measurement level sensor, PRSE had now had the respon-sibility of finding the solution to their problem.

Once PRSE contacted Moduloc, a repre-sentative visited their site to determine what product would best suit their needs; an MDCLS was then advised. After an initial test period, PRSE have concluded that this was the best solution for them.

Due to the extreme heat of the product, a per-iscope system must be used with a first reflec-tor.

PRSE have decided that they will continue to use Moduloc with some alterations; after the tests, they have realised that some optimisa-tion in certain parts such as the air refresh, mirror dimension and type, the periscope structure stiffness.

CASE STUDY PRSE

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A Rotalec Company Head Office & Canadian Sales

Montreal, Canada E : info@rotalec.com

T : 514-341-3685

UK Manufacturing & Sales Hertfordshire SG3 6JP

E: sales@moduloc-intl.com T: +44 (0) 845-873-6501

USA Sales Minneapolis MN55344

E : sales@moduloc-usa.com T : 952-238-8453

Alternative models with a variety of ranges and accuracies are available, the below are the most common.

General Specification.

Configurable Filters - All Models have a programming/select functionality. In Group Mode a running average is cal-culated over a user specified number of measuring points. The user also programs the sensor to disregard a num-ber of, usually all, bad (zero) measuring points before calculating the average value. The average values are calcu-lated at full measuring frequency and are used for converting the analogue signals. Several other filters are availa-ble to ensure robust measurement values are provided.

Laser Model Short Stand Off (SSO) Long Stand Off (LSO)

MDCLS-230 (SSO)

MDCLS-455 (LSO)

MDCLS-510 (LSO)

MDCLS-775 (LSO)

Measuring range (mm)

180-280 400 - 500 400-600 400-1150

Stand-off (mm) 230 450 500 775

Resolution Short Range (SR) Long Range (LR)

0.01 mm 0.01 mm (SR) 0.02 mm (LR)

0.01 mm (SR) 0.02 mm (LR)

0.01 mm (SR) 0.12 mm (LR)

Linearity ±0.03mm ±0.03mm ± 0.04mm ± 0.30mm

Laser Spot Size Ø 0.6 mm Ø 0.5 mm ± Ø 0.7 mm ± Ø 2.0 mm

Material Temperature Up to 2,200° C Up to 2,200° C Up to 2,200° C Up to 2,200° C

Serial Output RS232 Baud Rate 38400 Supply Voltage 22—36 VDC

Serial Output RS422/485 (optional) Power Consumption 4.5 Watt

Digital Output RS232/RS422/Ethernet Operating Temperature 0° C (32° F) to ± 45°C (113°F)

Analog Output2 4-20mA or 1-9V Storage Temperature -20° C (-4° F) to ± 70°C (158°F)

Measuring Frequency 1000Hz—10,000Hz Product Temp. Limit Standard 500° C (932° F) HT 1000° C (1832° F) VHT 1300° C (2372° F) VVHT Max 2200° C (3992°F)

Temperature Deviation ±0.03% of F.S./°C Laser Class Options Class II, IEC 2, Class 2/3R, Blue Laser Diode

Light Source 665nm Communication Language TCP/IP