CAM-361

The ladle stream has missed and molten metal is running across the floor

Half past nine at night, casting bay. The crane ladle has tipped over the mould car and the stream has missed: it falls outside, splashes the floor and leaves a pool of molten metal beside the car. Sparks reach as far as the yellow railing. More than a dozen people are around it: some step back, some shield their face with an arm. On the right, the cooled ingots are stacked on pallets.

CAM-361 · CASTING BAY · MOLTEN SPILL

What IRIS understands

What it recognises in this scene

molten metal outside the mould
ladle tipping
mould car under the pour
person inside the railing
cooled ingots on pallets

What this camera measures

An alert says something is happening. The reading says how much.

11 sSince the first splash
16People in the bay
3People inside the railing
2Pours this shift
21:40Time of the alert

The figures on this screen are an example from the illustration, not any client's measurement.

The rule

You decide once. IRIS applies it always.

glowing metal shows up outside the ladle, the runner or the mould

Then

alert the control room and the bay supervisor with the camera and the time
save the video from the moment the ladle started tipping
log how many people were inside the railing at that moment

The instruction that set it up«Alert me the moment metal falls outside the mould or the runner, and tell me how many people are in the bay right then.»

What changes

What changes for whoever answers for the plant

A metal spill gets told afterwards, and every person tells it differently. Here the bay supervisor gets the alert while the metal is still running, with the camera, the time and the video from before the tipping started. That is good for two things: sending somebody to close off that side, and, the next day, seeing on screen whether the ladle was badly lined up or whether the problem was the car. And splashes stop being a locker-room story: they get counted.

What people usually ask

Does IRIS tell a normal splash apart from a spill?

Yes, but the plant draws the line. IRIS sees where the glowing metal is and how long it has been outside the vessel. If a stray spark while tipping is normal for that pour, it stays out of the rule; if metal reaches the floor or crosses the painted line, it alerts. What counts as normal for that pour is decided by the people who run it, not by the camera, which is why the rule is written with the plant in the room.

Can IRIS stop the pour?

No. IRIS does not command the crane or any other machine. It alerts the control room with the camera and the time, saves the video from the moment the ladle started tipping and logs how many people were inside the railing. Stopping the pour, closing off the walkway or clearing the bay is decided by a person, following the plant procedure.

Does it work with the smoke and the glare of the pour?

Yes, because metal outside the vessel is exactly the thing that shows: a glowing mass where there was dark floor a second earlier. That contrast is easy for a camera. What a camera does not do is measure the temperature of the bath or state the composition of the steel: that comes from furnace instrumentation and the heat analysis. IRIS brings where the metal landed, at what time and who was nearby.

Other cameras

Demo · IRIS at work

You set the rule once. IRIS applies it every time.

You will see a summary of the interface, played step by step and hands-free. Each round starts with another case. The complete tool does not fit in a demo.