Application Scenario
In a modern steel plant, maintaining precise mold level during the continuous casting process is critical for ensuring casting quality and process stability. This application demonstrates how OpenPLC can be integrated with industrial-grade hardware to realize high-precision mold level control.
System Configuration
Y-AI Analog Input Board (for receiving radiation-type level sensor signals)
X-DO Digital Output Board (for controlling the stopper rod servo mechanism)
Implementation
The Y-AI board collects real-time signals from a radiation-type level sensor (4–20 mA, range: 0–300 mm), providing accurate liquid steel level data in the mold.
OpenPLC executes a PID control algorithm that calculates adjustments needed to maintain target levels. The system outputs PWM signals to the servo drive to precisely adjust the position of the stopper rod.
The X-DO board is responsible for controlling emergency gate actuators via hardwired safety circuits, ensuring rapid response during abnormal conditions.
Key Advantages
Engineers can remotely tune PID parameters to adapt to different steel grades and casting conditions, increasing flexibility and reducing downtime.
The Y-AI board provides galvanic isolation for all input channels, offering robust performance in high-EMI environments like steel plants.
This solution showcases the flexibility and industrial-grade reliability of OpenPLC when paired with modular hardware in demanding steel manufacturing environments.
