Non-invasive real-time level sensing and feedback system for the precision sand casting process

A level sensing system for a casting mold comprising:

• a casting mold forming a mold cavity for receiving a conductive material therein;
• a drive circuit;
• and
• an inductive component coupled to the drive circuit and disposed adjacent the casting mold, wherein the inductive component is an electromagnetic coil having a generally C-shaped core with an aperture formed therein, the aperture interposed between at least a portion of the core and the casting mold, and wherein a magnetic field generated by the inductive component causes a change in an electrical characteristic of the drive circuit when a conductive material is caused to flow through the magnetic field.

A method of determining the position of a conductive material in a casting mold, the method comprising the steps of:

• providing a casting mold forming a mold cavity for receiving a conductive material therein;
• providing an inductive component disposed adjacent the casting mold a, wherein the inductive component is an electromagnetic coil having a C-shaped core with an aperture formed therein;
• providing a drive circuit in electrical communication with the inductive component to cause to the inductive component to generate a magnetic field in the mold cavity, wherein a flow of the conductive material through the magnetic field causes a change in an electrical characteristic of the drive circuit;
• introducing a conductive material into the mold cavity of the casting mold;
• and
• measuring a change in an electrical characteristic of the drive circuit as the conductive material fills the mold cavity, the change in the electrical characteristic indicating a position of the conductive material within the mold cavity.