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Ladle Movement Tracking

Track molten metal movement with precision. Prevent spills, reduce risk, and enhance casting control.

Ladle Movement

SAFE POURING. CONTROLLED FLOW. NO SLIPPAGE.

Production Line Health

In steel plants, ladles carry molten metal at extreme temperatures. Any delay, misalignment, or deviation during transfer can result in accidents, production loss, or structural damage. AI-powered Ladle Movement Tracking ensures real-time visual tracking of ladles from furnace to caster, monitoring position, speed, alignment, and stoppage. It reduces manual dependency and boosts safety during the most hazardous phase of steelmaking.

OUR HOLISTIC VIEW TO CHALLENGES & FEATURES

Challenges

Manual Monitoring Limitations

Manual Monitoring Limitations

Human oversight during ladle movement is inconsistent, especially in high-heat, low-visibility areas.

Pouring Delays & Inaccuracies

Pouring Delays & Inaccuracies

Improper ladle alignment or delay can lead to defective casting or spillage.

High-Risk Work Zones

High-Risk Work Zones

The area around ladle transfer is among the most dangerous, errors can be catastrophic.

Lack of Real-Time Location Tracking

Lack of Real-Time Location Tracking

No centralized way to track ladle movement from furnace to pouring station.

Features

Real-Time Position Tracking

Real-Time Position Tracking

Constant location visibility of each ladle along transfer paths using AI-based vision.

Pouring Zone Alignment Alerts

Pouring Zone Alignment Alerts

The system notifies operators when ladles deviate from preset alignment zones.

Movement Speed Analysis

Movement Speed Analysis

Detects unusual speed variations that indicate mechanical issues or operator error.

Night & Smoke-Ready Imaging

Night & Smoke-Ready Imaging

Designed to function accurately under low lighting, glare, and smoky environments.

WHO BENEFITS FROM LADLE MOVEMENT TRACKING?

Steel-8 copy 2
  • Casting Supervisors – Get real-time data on ladle arrival, delays, or flow disruptions.
  • Safety Officers – Monitor risky zones and detect abnormal movement before incidents happen.
  • Melt Shop Engineers – Optimize the ladle path and pouring schedule for maximum output.
  • Control Room Operators – View all movement data via integrated dashboards and alarms.

BUILDING AND DEPLOYING PROCESS

Surface Defect
Plant Route Mapping

Plant Route Mapping

Every steel plant has unique ladle paths, from furnace, through transfer bays, to casting points. We start by mapping your ladle track layouts, transfer intervals, and critical zones (e.g., turning points, elevation changes).

Camera Grid Design for 360° Coverage

Camera Grid Design for 360° Coverage

Specialized thermal-resistant cameras are placed along the route to cover overhead cranes, rail paths, and pouring bays, ensuring no blind spots in motion tracking.

Movement Behavior Modelling

Movement Behavior Modelling

We collect video data of standard vs. abnormal ladle movements (e.g., misaligned pour, idle time, speed spikes). This is used to train a motion-pattern AI model specifically for your plant’s environment.

Alert Integration with Safety Systems

Alert Integration with Safety Systems

The AI model is connected with your SCADA or DCS system. When unusual ladle behavior is detected (e.g., excessive vibration, drift, or delay), alerts are triggered on operator screens, with optional auto-shutdown triggers.

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