A Novel Flow Rate Estimation Method Using Extended Kalman Filter and Sensor Dynamics Compensation with Automatic Casting Pouring Process

We describe here a method for estimating the pouring flow rate for tilting-ladle-type automatic pouring systems used in casting industries. To precisely pour molten metal into the mold, controlling the flow rate of liquid flowing out of the ladle is mandatory. However, it is difficult to directly measure the pouring flow rate by using a conventional flow meter, because the flow meter is damaged by the molten metal. Therefore, in this study, we used a soft sensing technique as part of the pouring flow rate estimation system. For estimation of the flow rate, the weight of liquid in the ladle and the tilting angle of the ladle are measured by a load cell and an encoder, respectively. Then, the flow rate is estimated by using an extended Kalman filter and sensor dynamics of the load cell, since in this study, the flow rate model was built as a nonlinear model. The advantage of the proposed system is that the flow rate can be precisely estimated by the load cell and the encoder. The system is easy to construct, and the load cell is not damaged easily, because it does not come in direct contact with the molten metal. The effectiveness of the proposed flow rate estimation method is demonstrated through experiments.