Recent Advances
1. Laser-Guided Mould Level Control System
A high-precision laser displacement unit is mounted above each mould and connected directly to the PLC. For sow casting, the laser is angled approximately 1 metre above the mould and references the mould base as a zero point before each cycle. Upon reaching the target fill height, the system signals the tilting tundish to retract, ensuring consistent sow weights regardless of mould variations.
In multi-ingot casting, each mould receives an individually air-cooled laser sensor. These sensors monitor molten metal height in real time and send direct shutoff signals to servo-controlled stopper rods once the desired level is reached. This ensures volumetric accuracy across multiple moulds poured simultaneously, even under uneven flow conditions.
2. Pouring Wheel Collision Avoidance System (Mechanical Sensing Arm)
WORSWICK’s pouring wheel obstruction response system uses a mechanical sensing arm that scans each mould cavity immediately before the pouring sequence. If an obstruction (such as a previously un-ejected ingot or foreign object) is detected, the arm triggers a countdown timer, allowing operator override or system response. Upon expiry, the pouring wheel automatically diverts away from the blocked mould, preventing mechanical damage to the wheel, nozzles, or pouring orifices. This system preserves tundish integrity and supports uninterrupted multi-cavity casting.
3. Stuck Ingot Detection System
Located at the ingot exit station, a mechanical sensing arm swings across the ejection path after each demoulding cycle. If an ingot fails to clear the mould cavity (due to shrink fit, surface tension, or alignment issues), the arm detects the obstruction and generates a visual and/or audible alarm on the operator interface. While the casting process continues, the system enables timely operator intervention, preventing downstream accumulation or damage.
4. Robotic Skimming System
A high-temperature-resistant robotic skimming unit removes slag and dross from the molten metal surface before casting. Equipped with a graphite or Inconel paddle and guided by pre-set path logic, the robot performs consistent, low-disturbance skimming of the furnace surface or tundish inlet. This automation reduces operator exposure, enhances metal cleanliness, and improves casting reliability.
5. Nitrogen Purge Hood System
A sealed nitrogen injection hood is positioned over the mould fill area, delivering a controlled inert atmosphere during pouring. The system uses stainless steel nozzles to distribute nitrogen across the mould surface, displacing oxygen and minimizing oxide formation. The hood is linked to the pour cycle via a servo-actuated lift mechanism, ensuring precise activation and retraction timing.
6. Cross-Flow Water Cooling System (Under-Mould Cooling)
This system consists of a cross-flow laminar water bath located directly beneath the casting moulds. Water is circulated via VFD-controlled pumps through spray manifolds and submerged jets that deliver consistent, controlled cooling. This accelerates solidification, reduces surface cracking, and improves metallurgical grain structure. The cooling rate is adjustable based on alloy type and ingot geometry, with all parameters managed via PLC.
7. Certified In-Line Weighing System
WORSWICK casting lines are now equipped with OIML-certified load cell modules that record the post-cast weight of each ingot or sow. The system logs weight data in real time, enabling batch traceability, quality documentation, and statistical process control (SPC). Output is available via Ethernet/IP, Modbus TCP, or SQL database integration, aligning with ISO 9001 quality management systems.
8. Multi-Zone Tundish Flow
The proprietary multi-zone tundish design incorporates flow-restricting elements to regulate metal distribution to each mould. Internal inserts optimize flow paths, while outlet ports are calibrated for uniform delivery. This results in improved fill balance, consistent alloy properties, and reduced porosity across all cast products.
9. Real-Time Data Acquisition and Diagnostic Interface
An integrated SCADA/HMI platform provides real-time insight into all casting parameters—metal height, cooling flow, skimming cycles, stuck ingot alerts, nitrogen purge status, and ingot weights. Operators are equipped with diagnostic tools and trend graphs, enabling predictive maintenance, rapid troubleshooting, and continuous process optimization.