Hardware
- Zynq FPGA/ARM platforms
- Six-layer custom PCB systems
- Electromagnetic sensing hardware
- Class-AB push-pull driver systems
- Siemens S7-1200 PLC
- Industrial HMI systems
- STM32H7 proof-of-concept controller
- Industrial cabinet and backplane systems
Industrial Automation
Electromagnetic Slag Detection and Steel Casting Optimization System
Developed an industrial electromagnetic slag-detection platform for molten-steel casting optimization using FPGA-based signal analysis, custom six-layer PCBs, industrial PLC systems, and real-time electromagnetic sensing.
Summary
Engineering context
Developed an industrial electromagnetic slag-detection platform for molten-steel casting optimization using FPGA-based signal analysis, custom six-layer PCBs, industrial PLC systems, and real-time electromagnetic sensing.
- Category
- Industrial Automation
- Year
- Jan 2021 - Dec 2024
- Status
- Industrial Deployment
- Context
- Barman Afzar Fidar (Jan 2021 - Dec 2024) / Iran Alloy Steel Company
My Role
Industrial Systems and Embedded Electronics Engineer
Technical Stack
System Architecture
- Electromagnetic transformer-based sensing structure surrounded molten-steel flow
- Push-pull Class-AB amplifier excited the primary sensing winding
- Secondary winding measurements captured electromagnetic phase-shift behavior
- Molten metal and slag acted as the magnetic core of the sensing structure
- FPGA and ARM systems processed electromagnetic signal characteristics in real time
- Industrial PLC and HMI systems integrated process monitoring and operator interaction
Engineering Challenges
- Measuring electromagnetic phase differences in harsh industrial environments
- Designing stable mixed-signal high-power analog systems
- Developing real-time industrial signal-processing architecture
- Integrating FPGA, PLC, and industrial telemetry systems
- Designing reliable six-layer industrial PCB systems
- Maintaining sensing stability in molten-steel environments
Hardware / Firmware / Software
Firmware
- ARM-core embedded firmware
- Embedded signal acquisition systems
- FPGA-integrated processing systems
- STM32H7 embedded firmware
- Industrial telemetry firmware
Software
- Industrial HMI systems
- Process monitoring systems
- Industrial signal-analysis systems
- PLC process-control logic
Sensors
- Electromagnetic transformer-based slag sensor
- Industrial process sensing systems
Protocols
- Industrial Ethernet
- PLC communication systems
- Embedded serial communication
Results / Outcomes
- Achieved approximately 88% slag-detection accuracy
- Saved approximately 2 tons of steel per casting cycle
- Successfully deployed industrial slag-detection platform
- Integrated FPGA, PLC, and embedded telemetry systems into a unified industrial solution
- Demonstrated real-time molten-steel process monitoring and optimization
Gallery
Engineering Notes
Electromagnetic Sensing Principle
The sensing system used a transformer-like electromagnetic structure surrounding the molten-steel flow path.
The sensor consisted of:
- primary excitation winding
- secondary sensing winding
- electromagnetic excitation driver
- signal-analysis electronics
A push-pull Class-AB amplifier generated sinusoidal excitation signals through the primary winding.
The molten metal and slag acted as the magnetic core of the transformer system, affecting electromagnetic coupling characteristics and phase relationships between the primary and secondary windings.
The system measured phase differences in the received sine-wave signals to detect slag conditions during casting operations.
FPGA and Signal Processing Architecture
The system used Zynq FPGA/ARM platforms for:
- signal acquisition
- real-time processing
- telemetry integration
- industrial communication
- electromagnetic signal analysis
The FPGA/ARM architecture enabled reliable real-time analysis of electromagnetic phase behavior in harsh industrial environments.
I contributed to ARM-core software development and embedded integration using Vivado workflows.
Industrial Automation and PLC Integration
The sensing platform was integrated into industrial process-control infrastructure using:
- Siemens S7-1200 PLC systems
- industrial HMI interfaces
- telemetry systems
- industrial cabinet architectures
The HMI system visualized process conditions and slag-detection states for industrial operators.
Industrial Impact
The deployed system achieved:
- approximately 88% slag-detection accuracy
- savings of approximately 2 tons of steel per casting cycle
The project demonstrated real-world deployment of advanced industrial sensing and signal-processing systems within heavy-industry steel-manufacturing environments.
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