“FOMET” radar system for level measurement and continuous pouring channel control
FOMET’s radar systems are now widely used to improve level control in its automatic casting furnaces. These radar systems have been successfully installed in numerous FOMET furnaces in Italy, Europe and around the world, including at Renault, Tupy and Brembo.
The radar system replaces the previous laser measurement technology, whilst the electrode remains in place as a safety backup.
Following initial trials and subsequent field tests in 2021 with trusted foundries, FOMET successfully installed and integrated its first radar system into an existing FOMET casting furnace in November 2021.
In 2022, FOMET further expanded its radar systems, integrating five systems: one in the first quarter, one in the second quarter, one in the third quarter and two in the final quarter.
In 2023 and 2024, further FOMET radar systems were installed and integrated into casting systems for other loyal customers.
The purpose of this article is to inform customers that, whilst the radar system is not exclusively supplied by FOMET, it must be correctly configured and integrated into the casting system’s control logic to ensure optimum performance. It is therefore not recommended to purchase the radar system without full integration by FOMET.
As with any piece of equipment, full integration is essential for the system to function optimally.
FOMET’s radar sensors are designed for the non-contact measurement of metal levels. These sensors provide reliable readings even under difficult conditions, such as the presence of insulating mats, slag, dust and noise, and are unaffected by deposits or condensation.
Principle of measurement
The measuring device transmits short microwave signals through the antenna system towards the medium. When these signals strike the iron surface, they are reflected back and received by the antenna system. The time taken for the signal to travel from transmission to reception is directly proportional to the level in the casting siphon.
A unique time-stretching method ensures accurate and reliable measurement of the very short transmission times and converts them into level values.
The radar sensors operate at low transmission power in the C- and K-band frequency ranges.
Advantages
Non-contact radar technology offers exceptional measurement accuracy. The system is unaffected by changes in the properties of the iron or process conditions such as temperature, pressure or heavy dust generation. The user-friendly setup eliminates the need to fill and empty the channel, saving time, and the sensors require no maintenance.
The radar system is housed in a protective enclosure cooled by a vortex air system and is mounted on a special bracket above the casting channel.
System components:
- Radar sensor for continuous measurement of iron content (A)
- Antenna extension (B)
- Cone antenna (C)