WO2019227224A1

WO2019227224A1 - System for measuring level and quality of a metal in a furnace

Info

Publication number: WO2019227224A1
Application number: PCT/CA2019/050749
Authority: WO
Inventors: Jean-François DESMEULES; Maxime FAUCHER-BOIVIN; François GRAVEL; Erik TREMBLAY
Original assignee: Dynamic Concept Inc.
Priority date: 2018-06-01
Filing date: 2019-05-30
Publication date: 2019-12-05

Abstract

A system for generating scan values regarding a surface of molten metal contained in a reservoir comprises a sensor unit, driving means, inclinometer, processing means and display means. The sensor unit measures distances to the surface of the molten metal. The driving means controls inclination of the sensor unit to aim the sensor unit at areas of the surface of the molten metal, whereby measuring a distance for each of the areas on the surface of the molten metal. The inclinometer detects the inclination and associates an inclination value with each of the measured distances. The processing means receives and processes the measured distances and the inclination values, and establishes a scan value, wherein the scan value comprises at least one of: a level for the surface of the molten metal; and a quality factor for the surface of the molten metal. The display means displays the scan value.

Description

SYSTEM FOR MEASURING LEVEL AND QUALITY OF A METAL IN A FURNACE

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority from US provisional patent application 62/679,354 filed

June 1st, 2018, the specification of which is hereby incorporated herein by reference in its entirety.

BACKGROUND

(a) Field

[0002] The subject matter disclosed generally relates to metallurgy, in particular to a systems and methods for measuring level and controlling level of molten metal.

(b) Related Prior Art

[0003] Molten metal, used in various casting processes, is contained in reservoirs of various shapes and sizes. For various purposes, including alloying element addition, inventory and process calculations, it is desired to measure accurately the quantity of metal stored in the container. One common method is measuring the level of the surface and computing the metal quantity knowing the shape of the container.

[0004] Various level measurement methods are actually used, including lasers, radars or ultrasound. These methods are more or less accurate depending on the sensor location and other issues.

[0005] One issue with most measurement systems is that the metal surface is often polluted with dross that floats as chunks randomly dispersed on the surface. If the level measurement device points on one of these chunks, a measurement error occurs, however the nature of the measure, namely an erroneous measurement, is undetectable by the measurement device.

[0006] Another issue is that the measurement systems are often located on the roof of the containers (most of the time, gas fired furnaces) and this reduces the access for maintenance and adjustment. It also can cause overheating problems due to hot gases and radiation escaping from the furnace roof.

[0007] Accordingly, there is a need for improvement in the field that would overcome at least some of the listed shortcomings of the prior art.

SUMMARY

[0008] According to an embodiment, there is provided a system for generating a scan value regarding a surface of molten metal contained in a reservoir. The system comprises a sensor unit for measuring distances to the surface of the molten metal; driving means for controlling inclination of the sensor unit to aim the sensor unit at a plurality of areas of the surface of the molten metal, whereby the sensor unit measures a distance for each of the plurality of areas on the surface of the molten metal; an inclinometer for detecting the inclination and for associating an inclination value with each of the measured distances; processing means for receiving and processing the measured distances and the inclination values, and for establishing the scan value comprising at least one of: 1- a level for the surface of the molten metal, and 2- a quality factor for the surface of the molten metal; and display means for displaying the scan value.

[0009] According to an aspect, the sensor unit of the system comprises an optic sensor.

[0010] According to an aspect, the sensor unit of the system comprises a light emitting component.

[0011] According to an aspect, the sensor unit of the system provides signals to the processing means indicative of distance values and associated timestamps.

[0012] According to an aspect, the driving means of the system moves the sensor unit between a plurality of inclinations, wherein the driving means is adapted for stopping at each of the plurality of inclinations.

[0013] According to an aspect, the inclinometer of the system provides signals to the processing means indicative of inclination values and associated timestamps.

[0014] According to an aspect, the system comprises a cooler component cooling down the sensor unit.

[0015] According to an aspect, the system comprises a casing enclosing the sensor unit and the inclinometer.

[0016] According to an aspect, the system comprising a casing has the casing comprises thermal insulation component insulating thermally the sensor unit and the inclinometer.

[0017] According to an aspect, the system comprising a casing wherein the casing comprises a window through which the sensor unit aims toward the reservoir.

[0018] According to an aspect, the system comprising the window comprises a thermal shield and a shutter controllably displacing the thermal shield for opening up and shutting down the window, whereby the sensor unit is being controllably thermally insulated.

[0019] According to an aspect, the system comprises an end-of-course sensor communicatively linked to the driving means, wherein the driving means ends displacement of the sensor unit upon reception of a signal from the end-of-course sensor.

[0020] According to an embodiment, there is provided a system for performing measurements associated with a plurality of areas of a surface of molten metal contained in a reservoir. The system comprises a casing mountable to the reservoir: a driving means mounted to the casing; a sensor unit movable by the driving means; an inclinometer collecting inclination values at the plurality of distinct aiming inclinations; and a controller transmitting the measurements and the inclination values associated to the plurality of areas to a processing means. The sensor unit is adapted to perform a plurality of measurements at a plurality of distinct aiming inclinations with each one of the plurality of measurements comprising a distance of an aimed area at one of the plurality of distinct aiming inclinations

[0021] According to an aspect, the processing means of the system is receiving and processing the measurements and inclinations values associated with the plurality of areas and establishing a scan value associated with a quality of the surface of the molten metal, with the quality comprising at least one of: 1- a level for the surface of the molten metal, and 2- a quality factor for the surface of the molten metal. The display means is displaying the scan value indicative of the quality associated with the surface of the molten metal.

[0022] According to an aspect, the sensor unit of the system comprises a laser.

[0023] According to an aspect, the system comprises a cooler component cooling down the sensor unit.

[0024] According to an aspect, the casing of the system comprises thermal insulation component insulating thermally the sensor unit and the inclinometer.

[0025] According to an aspect, the casing of the system casing comprises a window through which the sensor unit aims toward the reservoir, a thermal shield and a shutter controllably displacing the thermal shield for opening up and shutting down the window, whereby the sensor unit is being controllably thermally insulated.

[0026] According to an embodiment, there is provided a system for establishing a value indicative of a quality associated with a surface of molten metal contained in a reservoir. The system comprises a sensor unit performing measurements of a plurality of distinct areas of the surface of molten wherein each one of the measurements comprises a distance to one of the plurality of distinct areas; processing means receiving and processing the measurements as area values, and compiling the area values into a scan value indicative the quality of the surface of the molten metal, wherein the quality is one of: 1- a level for the surface of the molten metal, and 2- a quality factor for the surface of the molten metal; and display means displaying the scan value.

[0027] According to an aspect, the system comprises a driving means mounted to the reservoir, wherein the sensor unit is movable by the driving means to aim to the plurality of distinct areas.

[0028] Features and advantages of the subject matter hereof will become more apparent in light of the following detailed description of selected embodiments, as illustrated in the accompanying figures. As will be realized, the subject matter disclosed and claimed is capable of modifications in various respects, all without departing from the scope of the claims. Accordingly, the drawings and the description are to be regarded as illustrative in nature and not as restrictive and the full scope of the subject matter is set forth in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Further features and advantages of the present disclosure will become apparent from the following detailed description, taken in combination with the appended drawings, in which: [0030] Fig. 1 is a sectional elevation view of an empty reservoir adapted to contain molten metal, with a measuring unit mounted thereto in accordance with an embodiment;

[0031] Fig. 2 is a right-side partial view from an external point of view of the reservoir of Fig. 1 without the measuring unit mounted thereto.

[0032] Fig. 3 is a sectional elevation view of the reservoir of Fig. 1 having molten metal therein, with an illustration of the detection field in accordance with an embodiment;

[0033] Figure 3A is a close up sectional view of a measuring unit and the reservoir of Fig. 3;

[0034] Fig. 4 is a perspective view of a measuring unit in accordance with an embodiment;

[0035] Fig. 5 is a perspective view of the measuring unit of Fig. 4 with the cover removed;

[0036] Fig. 6 is a front view of the measuring unit of Figs. 4-5;

[0037] Fig. 7 is a top sectional view along cutting line A-A of Fig. 6 of the measuring unit of

Figs. 4-6;

[0038] Fig. 8 is a right-side view of the measuring unit of Figs. 4-7;

[0039] Fig. 9 is a left-side sectional view along cutting line B-B of Fig. 6 of the measuring unit of Figs. 4-8;

[0040] Fig. 10 is a perspective view of a sub-assembly of components of the measuring unit of Figs. 4-9;

[0041] Fig. 11 is a front view of the sub-assembly of Fig. 10;

[0042] Fig. 12 is a top view of the sub-assembly of Figs. 10-11 ;

[0043] Fig. 13 is a right-side sectional view along cutting line A-A of Fig. 11 of the sub- assembly of Figs. 10-12; and

[0044] Fig. 14 is a flow chart of steps performed by the measuring unit in accordance with an embodiment.

[0045] It will be noted that throughout the appended drawings, like features are identified by like reference numerals.

DETAILED DESCRIPTION

[0046] The realizations will now be described more fully hereinafter with reference to the accompanying figures, in which realizations are illustrated. The foregoing may, however, be embodied in many different forms and should not be construed as limited to the illustrated realizations set forth herein.

[0047] With respect to the present description, references to items in the singular should be understood to include items in the plural, and vice versa, unless explicitly stated otherwise or clear from the text. Grammatical conjunctions are intended to express any and all disjunctive and conjunctive combinations of conjoined clauses, sentences, words, and the like, unless otherwise stated or clear from the context. Thus, the term "or" should generally be understood to mean "and/or" and so forth.

[0048] Recitation of ranges of values and of values herein or on the drawings are not intended to be limiting, referring instead individually to any and all values falling within the range, unless otherwise indicated herein, and each separate value within such a range is incorporated into the specification as if it were individually recited herein. The words "about," "approximately," or the like, when accompanying a numerical value, are to be construed as indicating a deviation as would be appreciated by one of ordinary skill in the art to operate satisfactorily for an intended purpose. Ranges of values and/or numeric values are provided herein as examples only, and do not constitute a limitation on the scope of the described realizations. The use of any and all examples, or exemplary language ("e.g.," "such as," or the like) provided herein, is intended merely to better illuminate the exemplary realizations and does not pose a limitation on the scope of the realizations. No language in the specification should be construed as indicating any unclaimed element as essential to the practice of the realizations.

[0049] In the following description, it is understood that terms such as "first", "second", "top",

"bottom", "above", "below", and the like, are words of convenience and are not to be construed as limiting terms.

[0050] The terms "top", “up”, “upper”, "bottom", “lower”, “down”, “vertical”, “horizontal”,

“interior” and“exterior” and the like are intended to be construed in their normal meaning in relation with normal installation of the present measuring unit.

[0051] Referring now to the drawings, and more particularly to Figs. 1-3A, a measuring unit

100 is mounted to a reservoir 50 (e.g. a furnace, an oven, a tundish, etc.) for molten metal 90. The measuring unit 100 is more precisely mounted to the exterior face 56 of a mounting wall 52. The reservoir 50 thus comprises the mounting wall 52 having an interior face 54 and the exterior face 56, with the measuring unit 100 mounted to the exterior face 56 for thermic insulation from heat dissipated by the molten metal 90. A window 60 defines a visual opening between the exterior face 56 and the interior face 54, with the window 60 extending equally or larger than the detection field 110 (see Fig. 3) used in operation of the measuring unit 100.

[0052] As illustrated on Fig. 1 , the window 60 spans between a sloped bottom wall 62 and a sloped top wall 64, the top wall 64 and the bottom wall 62 being sloped toward the interior, hence having the detection field 110 pointing towards the bottom 58 of the reservoir 50. Further, the configuration of the window 60 allows the window 60 to remain at any time above the level of molten metal 90, preventing the molten metal 90 to attack the window 60.

[0053] According to an embodiment, the angle of the sloped top wall 64 and bottom wall 62 are about around 45 degrees, that angle ensures that the window remains above the level of molten metal 90 while keeping an operating distance relatively to the surface of molten metal 90. [0054] Referring additionally to Fig. 2, the reservoir 50 comprises mounting components (the mounting components comprising a mounting plate 70) to mount the measuring unit 100 thereto. The mounting components are adapted to mount the measuring unit 100 to the reservoir 50 and to grossly orientate the detection field 110 to pass through the window 60 and to aim toward the bottom 58 of the reservoir 50.

[0055] Referring additionally to Figs. 3 and 3A, the detection field 110 spans over a span angle

DELTA 112 toward the bottom 58. The detection field 110 defines the limits in which the measuring unit 100 operates. Accordingly, the measuring unit 100 collects data, aka measurements, on the level of molten metal 90 at different distances from the mounting wall 52. On Fig. 3, a maximum level 82 molten metal 90 is illustrated with an illustration of the minimum width 114 of the area of detection, aka width of detection, for the detection field 110 associated therewith. In the situation where no molten metal 90 is present in the reservoir 50, i.e. , at a minimum level 84 of molten metal 90, it results in a maximum width 116 of detection for the detection field 110.

[0056] One must understand, in relation to the detection field 110, that multiple measures are taken corresponding to a plurality of areas of the surface within the limits of the detection field 110, with the measures being taken at different angles within the span angle DELTA 112. Hence, measures of areas of the surface are taken at different distances from the mounting wall 52.

[0057] According to an embodiment, the measuring unit 100 comprises a shutter (not shown) adapted to controllably shut down the window 60 (e.g., by displacing the thermal shield 190) when the measuring unit 100 is in an idle mode. Accordingly, upon initiation of a measuring operation to be performed by the measuring unit 100, the shutter opens, freeing the window 60 and hence the detection field 110 from obstacles. According to an embodiment, the shield 190 (see Figs. 9-11) operates in combination with the shutter to controllably take place between the window 60 and the sensor unit 140 (see Fig. 7).

[0058] Referring now to Figs. 4-9, the measuring unit 100 comprises a main casing 120 to which is mounted a motor unit 130, a.k.a. a driving means, which drives inclination of an optic sensor emitting light (i.e., a light emitting component), e.g. a laser-based sensor unit 140, that rotates relatively to a rotation axis 105. The motor unit 130 is connected to a controller 150 (e.g. a Programmable Logic Controller or PLC) transmitting command signals to the motor unit 130 to set and/or change the inclination, a.k.a. orientation, of the sensor unit 140 during a measuring phase (i.e., the motor unit 130 / driving means stops at each of the plurality of inclinations). The measuring unit 100 further comprises cooling component 160 to maintain the temperature inside the main casing 120 in an operating range that is required for maintaining precision and preventing premature fatigue of components, comprising the motor unit 130 and the sensor unit 140.

[0059] The main casing 120 comprises a base plate 122 and a cover 124 removable from the base plate 122. The operative components of the measuring unit 100 are mounted to the base plate 122, with the base plate 122 being mounted to the reservoir 50. Therefore, an operator may remove the cover 124 to access the operative components for maintenance. [0060] The motor unit 130 comprises a servo motor 132 such as a step motor. The measuring unit 100 further comprises an end-of-course sensor 134 detecting when the sensor unit 140 has reached a limit position and to transmit signals to the controller 150 and/or the servo motor 132 accordingly.

[0061] The controller 150, according to an embodiment, comprises a motion controller (not shown) and an encoder (not shown) which are adapted to control the movement of the servo motor 132 and to translate for instance end-of-course sensor signals into motion controller usable information. The controller 150 further comprises a command console (not shown) comprising command controls (not shown) and interface means (not shown) and/or is adapted to communicate with a generic command device (e.g. a processing means such as a computer) comprising program designed for exchanging signals and data (e.g., receiving and forwarding signals, data, values, measurements, etc.). According to the computer embodiment, the signals and data comprise command signals relative to the operation of the measuring unit 100, and reading data collected by the measuring unit 100 and transmitted to the computer to be processed and displayed, e.g. on a display means such a monitor, to an operator.

[0062] According to embodiments, the components of the controller 150 are in part located inside the main casing 120.

[0063] According to an embodiment, the cooling component 160 comprises a cooler component comprising a plurality of vortex coolers 162 each generating a vortex of air inside the casing 120 to cool down sensitive components, comprising the servo motor 132, the sensor unit 140 and the junction box (not shown per se). Each of the vortex coolers 162 comprise a solenoid valve 164 mounted on an air control panel 166 dedicated to control the vortex coolers 162.

[0064] According to an embodiment, the cooling component 160 is a pneumatic system, and more precisely a pneumatic system for distribution of compressed air to vortex coolers 162. According to this embodiment, compressed air is forced onto or in the vicinity of some critical components, which cools down the critical components along with other components located inside the casing 120.

[0065] According to an embodiment, the laser-based sensor unit 140 is a sensor made specifically for foundries, such as one made by Precimeter (www.precimeter.com). The laser-based sensor unit 140, according to an embodiment, collects information over a plurality of aimed areas of the surface of molten metal, with the information, aka area values, being compiled over the plurality of areas into a scan value indicative of a quality of the surface of molten metal. One such quality is a level of molten metal 90. One other quality is a quality factor providing an indication on the cleanliness on the surface, which is indicative of the cleanliness of the molten metal 90 as a whole.

[0066] Referring now additionally to Figs. 10-13, there is shown a sensor casing 170 comprising a base 172 and a cover 174. The sensor casing 170 is designed to be mounted to the main casing 120 through side mounting plates 182 and 184. The sensor unit 140 is housed by the sensor casing 170 with thermal insulation side walls 188 and bottom wall 186 (i.e. , thermal insulation components) located between the sensor unit 140 and the sensor casing 170. Furthermore, there is a ceramic-based sheet material 180 between the thermal insulation side walls 188 and the sensor unit 140. The combination of the sensor casing 170, the thermal insulation side walls 188 and 186, and ceramic-based sheet material 180 insulates the sensor unit 140 from the high-temperature environment in which it operates. A thermal shield 190 is located under the sensor unit 140, the thermal shield 190 protects the bottom of the sensor unit 140. An inclinometer 200 is mounted to the sensor casing 170, e.g., on the top of the sensor casing 170, for providing signals indicative of the current inclination of the sensor casing 170 relative to axis 105, hence the inclination of the sensor unit 140 and accordingly the orientation of detection. An end-of-course sensor 134 (see Fig. 5) mounted to the main casing 120 collaborates with an abutment on the sensor casing 170 to detect one of the end-of- course positions and transmit a signal accordingly.

[0067] According to an embodiment, a single end-of-course sensor 134 is present and able to detect a critical end-of-course position. The other end-of-course position is an end-of-operating position beyond which the sensor unit 140 does not operate properly, the sensor unit 140 being oriented outside the detection field 110. According to one embodiment, the controller 150 stores the parameters relative to the end-of-operating position and limits the course of the sensor unit 140 under the end-of-operating position.

[0068] According to an embodiment, the controller 150 is able to detect that the sensor unit

140 moves beyond the end-of-operating position, thus exiting the detection field 110, using the readings of the sensor unit 140. When the sensor unit 140 points outside the detection field 110, the distance reading (i.e. the measured distance) drops to an out-of-operation range since the sensor unit 140, rather than reading the distance of the surface of molten metal 90 through the window 60, reads the distance of the mounting wall 52 or of a component of the measuring unit 100, both being close to the sensor unit 140.

[0069] According to alternative embodiments, a plurality of end-of-course sensors 134 are used to detect end-of-course positions, or no end-of-course sensor 134 is used, using information transmitted by the sensor unit 140 and/or the inclinometer 200 to determine critical inclination and thus to control the extend of the course of the sensor casing 170.

[0070] Back to the Fig. 5, the sensor casing 170 is rotatably mounted to the main casing 120 about the axis 105, with the servo motor 132 aligned with the axis 105 controlling the rotation of the sensor casing 170.

[0071] Reverting now to Figs. 10-13, the measuring unit 100 further comprises mounting components (with no numerical references attached thereto) and connection components (with no numerical references attached thereto) for mounting and interconnecting components of the measuring unit 100. Possible options and selection of appropriate mounting components and connection components are deemed well known to a person skill in the art.

[0072] Referring now back to Figs 2, 3 and 3A for the operation of the measuring unit 100, the measuring unit 100 is designed for the sensor unit 140 to scan a plurality of areas of the surface of molten metal 90 over a detection field 110 varying between the minimum width 114 of detection and the maximum width 116, to take measurements at a plurality of aimed areas on the surface of molten metal 90 within the detection field 110, and to transmit the data to be processed to determine a level of molten metal 90 in the reservoir 50 for each of the scanned areas. In order to scan the surface, the servo motor 132 rotates, a.k.a. changes the inclination of, the sensor casing 170, hence the sensor unit 140, between a first inclination and a second inclination. The sensor unit 140 aims towards distinct areas of the surface of molten metal 90 through the window 60 according to distinct inclination values (i.e. , distinct aiming inclinations). The inclinometer 200 further also transmits inclination data. By processing the combination of inclination data and distance data, level data of the molten metal 90 may be determined for each measurement during the scan. Further, statistical values, e.g., an average value, using the distance data of plurality of areas of the surface provides more precise information on the surface of molten metal 90. By processing the level data over angles, thus a plurality of areas, and time, additional information on the level of molten metal 90 are generated, for instance an increase or decrease of the level of molten metal 90 over time, disturbance in the molten metal 90 visible as variation in the level data over location and/or over time.

[0073] According to an embodiment, the data from a plurality of scanned areas are processed over a combined surface to obtain an instant quality factor for the surface of molten metal 90. The quality factor is indicative of the cleanliness of the surface of the molten metal 90. Since lack of cleanliness due to impurities in the molten metal 90 is generating irregularities over the surface due to dross, the processing of level data of a plurality of areas, and more particularly the processing of the data to establish a level of evenness of the surface, provides an indication of the cleanliness of the surface of molten metal 90.

[0074] According to an embodiment, the angle of the sensor unit 140 when scanning the detection field 110 varies from about 47 degrees to 50 degrees, with the extend of the detection field 110, for an exemplary level of molten metal 90, resulting in distances read by the sensor unit 140 varying from about 3900 mm to about 4200 mm.

[0075] Therefore, the present measuring unit 100 is adapted to provide a list of useful information to an operator comprising:

a first scan value comprising the level of the surface of molten metal 90 in the reservoir 50;

a second scan value comprising the processed quality factor based on the evenness of the surface of molten metal 90 in the reservoir 50 as scanned by the sensor unit 140; and

error signals indicative of the sensor unit 140 being outside a temperature range, an operating range, the servo motor 132 being unable to orientate the sensor unit 140 appropriately, loss of communication, cooling conditions, etc. [0076] In order to operate, the measuring unit 100 is initially provided the height of the reservoir

50 and performs mathematical operations on collected data to obtain the metal level using the following formulas:

OPPOSITE = TAN 0 * RESERVOIR HEIGHT

METAL LEVEL = RESERVOIR HEIGHT - OPPOSITE

[0077] Where X refers to the angle at which the data is collected.

[0078] The quality factor is typically calculated with the five (5) lowest measurements collected during a scanning operation. Then a counter determines the number of these readings that are within a range of, typically, three (3) mm off from the calculated average, or in other words ± 3 mm. Therefore, the quality factor is calculated using the following formula:

(NB TOTAL READINGS - NB OFF READINGS)

QUALITY FACTOR = 100 *

NB TOTAL READINGS

[0079] Where NB TOTAL READINGS refers to the number of readings collected during the scan and used for the calculation; and

[0080] NB OFF READINGS refers to the number of readings from the NB TOTAL READINGS that are off the acceptable range of values.

[0081] The table below provides exemplary measurements performed by the laser-based sensor unit 140 of the measuring unit 100. These measurements can be used in the above-mentioned formulas.

ANGLE” DISTANCE (mm)

47Ά 3933

47.77 3963.85

48.14 3994.70

48.51 4025.55

48.88 4056.40

49.25 4087.25

49.62 41 18.1

50.00 4149

[0082] Referring now to Fig. 14, a method of measuring the level of a surface of molten metal

90 as performed by the present measuring unit 100 comprises the steps of:

[0083] S102: Orientating a sensor unit 140 towards a first location of the surface of molten metal 90, hence according to a first inclination value. [0084] S112: Measuring the distance of the surface of molten metal 90 at the current inclination of the sensor unit 140.

[0085] S114: Detecting the current inclination of the sensor unit 140 and associating the inclination value to the distance value as determined by the sensor unit 140.

[0086] S116: Transmitting distance data and inclination data to a processing component.

[0087] S120: Detecting if the sensor unit 140 has reached an inclination limit, hence if the limit of the detection field 110 has been reached.

[0088] S122: If no inclination limit has been reached, changing the inclination of the sensor unit 140 according to an increment. Afterwards, repeating the step of measuring distance (step S112) and detecting an inclination (step S114).

[0089] S124a-b: Else, if an inclination limit has been reached, either a) changing increment orientation (step S124a), or b) restoring the sensor unit 140 in a start-of-scan position (step S124b).

[0090] It should be noted that the term“increment” in the present context encompass both

“inclination increment” and“time increment” depending on realizations involving either step-by-step inclination of the sensor unit 140 or continuous inclination of the sensor unit 140 between two limit inclination values with the measurements being collected at different time increments (e.g. each 1/10^th of a second). For instance, the processing of the latter example may comprise the encoding of timestamps along the distance and inclination data, whereby association of the distance values and inclination values may be performed upon processing to correctly interpret and process the data into valid scan value(s).

[0091] S132: The method further comprises processing the transmitted distance data and inclination data to obtain a measure, the measure being at least one of a) a level for the surface of molten metal 90, and b) a quality factor of the molten metal 90 and providing the processed measure (surface level and/or quality factor) to the operator. Step S132 is herein illustrated to take place once the sensor unit 140 having performed over the whole detection field 110. However, step S132 may take place during the scan process with the measure being refined as the number of readings increases.

[0092] One must note that the present disclosure of the measuring unit 100 is in relation with a reservoir 50. The expression“reservoir” is intended to cover any type of container to store, to be fed with, to feed others with or for a flow of molten metal 90 to take place. The potential embodiments of reservoirs present distinct sources of variations in their volume of molten metal 90, which may result in variations in the applicable configuration of the measuring unit 100 as in the processing algorithm processing the collected data. Nevertheless, these alternative embodiments are also intended to be enclosed within the present disclosure since these variations are perceived as easily accessible by a person skilled in the art.

[0093] While preferred embodiments have been described above and illustrated in the accompanying drawings encompassing a plurality of components and sub-system, it will be evident to those skilled in the art that alternative realizations may be made from the described embodiment without departing from this disclosure. Such alternative realizations comprise a measuring unit 100 comprising the essential components as identified in the following claims with a combination of“m” out of“n” non-essential components as described therein, wherein“m” may vary from 0 to“n”, and“n” is an ensemble enclosing all the components described herein before, and wherein no specific association of components are mandatory unless expressly stated in the description.

[0094] While preferred embodiments have been described above and illustrated in the accompanying drawings, it will be evident to those skilled in the art that modifications may be made without departing from this disclosure. Such modifications are considered as possible variants comprised in the scope of the disclosure.

Claims

CLAIMS:

1. A system for generating a scan value regarding a surface of molten metal contained in a reservoir, comprising:

a sensor unit for measuring distances to the surface of the molten metal;

driving means for controlling inclination of the sensor unit to aim the sensor unit at a plurality of areas of the surface of the molten metal, whereby the sensor unit measures a distance for each of the plurality of areas on the surface of the molten metal;

inclinometer for detecting the inclination and for associating an inclination value with each of the measured distances;

processing means for receiving and processing the measured distances and the inclination values, and for establishing the scan value comprising at least one of:

a level for the surface of the molten metal; and

a quality factor for the surface of the molten metal;

and

display means for displaying the scan value.

2. The system of claim 1 , wherein the sensor unit comprises an optic sensor.

3. The system of claim 2, wherein the sensor unit comprises a light emitting component.

4. The system of claim 1 , wherein the sensor unit provides signals to the processing means indicative of distance values and associated timestamps.

5. The system of claim 1 , wherein the driving means moves the sensor unit between a plurality of inclinations, wherein the driving means is adapted for stopping at each of the plurality of inclinations.

6. The system of claim 1 , wherein the inclinometer provides signals to the processing means indicative of inclination values and associated timestamps.

7. The system of claim 1 , further comprising a cooler component cooling down the sensor unit.

8. The system of claim 1 , further comprising a casing enclosing the sensor unit and the inclinometer.

9. The system of claim 8, wherein the casing comprises thermal insulation component insulating thermally the sensor unit and the inclinometer.

10. The system of claim 8, wherein the casing comprises a window through which the sensor unit aims toward the reservoir.

11. The system of claim 10, further comprising:

a thermal shield; and

a shutter controllably displacing the thermal shield for opening up and shutting down the window,

whereby the sensor unit is controllably thermally insulated.

12. The system of claim 1 , further comprising an end-of-course sensor communicatively linked to the driving means,

wherein the driving means ends displacement of the sensor unit upon reception of a signal from the end-of-course sensor.

13. A system for performing measurements associated with a plurality of areas of a surface of molten metal contained in a reservoir, comprising:

a casing mountable to the reservoir;

a driving means mounted to the casing;

a sensor unit movable by the driving means, wherein the sensor unit performs a plurality of measurements at a plurality of distinct aiming inclinations, and wherein each one of the plurality of measurements comprises a distance of an aimed area at one of the plurality of distinct aiming inclinations;

inclinometer collecting inclination values at the plurality of distinct aiming inclinations;

a controller transmitting the measurements and the inclination values associated to the plurality of areas to a processing means.

14. The system of claim 13, further comprising:

the processing means receiving and processing the measurements and inclinations values associated with the plurality of areas, and establishing a scan value associated with a quality of the surface of the molten metal, wherein the quality comprises at least one of: a level for the surface of the molten metal; and

a quality factor for the surface of the molten metal;

and

display means displaying the scan value indicative of the quality associated with the surface of the molten metal.

15. The system of claim 13, wherein the sensor unit comprises a laser.

16. The system of claim 13, further comprising a cooler component cooling down the sensor unit.

17. The system of claim 13, wherein the casing comprises thermal insulation component insulating thermally the sensor unit and the inclinometer.

18. The system of claim 13, wherein the casing comprises:

a window through which the sensor unit aims toward the reservoir;

a thermal shield; and

whereby the thermal shield insulates thermally the sensor unit.

19. A system for establishing a scan value indicative of a quality associated with a surface of molten metal contained in a reservoir, the system comprising:

a sensor unit performing measurements of a plurality of distinct areas of the surface of molten wherein each one of the measurements comprises a distance to one of the plurality of distinct areas;

processing means receiving and processing the measurements as area values, and compiling the area values into the scan value indicative of the quality of the surface of the molten metal, wherein the quality is one of:

a level for the surface of the molten metal; and

a quality factor for the surface of the molten metal;

and

display means displaying the scan value.

20. The system of claim 19, further comprising a driving means mounted to the reservoir, wherein the sensor unit is movable by the driving means to aim to the plurality of distinct areas.