Electromagnetic Automatic Metal Level Sensor for Billet Caster

Electromagnetic Automatic Metal Level Sensor for Billet Caster


Sensor is designed to be used as a component of Mould Molten Metal Level Control System of a Billet Caster.

Use of Electromagnetic advantages:

  • Non-sensitivity towards slag powder. Whereas in radio-isotopic sensor based control systems there are 10 - 20 mm level jumps at the time of manual powder addition.
  • Better precision of level stabilization due to lesser noises and better response time from electromagnetic sensor.
  • Simpler installation and operation of sensor, since no calibration is required as compared to radio-isotopic sensor (ageing of the radiation source), safe operation and utilization.

Device and its Principle of Operation

Design of the attachable Electromagnetic level sensor consists of the system of coils, which is hermetically immersed in the compound inside the steel body with the outgoing cable provision.

Level Sensor is fixed inside the Mould on the outer surface of the Cooling Jacket. Mould body shall have a cable hole provision. Sealing of this hole is done with the help of two sealing rings.

Inside the sensor there is alternate electromagnetic field generated along the Mould axis. It penetrates through the Mould Jacket and Copper Tube into the molten metal. Eddy currents created inside Copper Mould and molten metal form the secondary field that alters at the change in metal level the mould. This secondary field and its alterations carry the information about the changed metal level value. Calculation algorithms can define metal level suppressing response time lags related to heat transfer processes in the copper tube.

Main Technical Parameters

Liquid metal level measurement range (from top of copper mould), mm

60*to 300*

  1. Dimensions without cable (lengthwidthheight), mm


  1. Weight without cable, kg, not exceeding

  1. Power Supply AC Voltage, V, not exceeding

  1. Power Consumption, W, not exceeding


* Level measuring range depends on its length as well as mould design

These pictures display typical trends at simultaneous operation of Electromagnetic and Radio-Isotopic Sensors in the Mould. Level was stabilized as per Radio-Isotopic Sensors signals.

Beginning of Casting


Time from the start of casting, s Slag PE


Jump in the value indicated by Electromagnetic Sensors shows undesirable change in the level caused by sensitivity of the radio-isotopic sensor towards the powder thickness. The new sensor is designed for use in the Mould with electro-magnetic stirring (EMS) facility.

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