Description:TECHNICAL FIELD
The present disclosure generally relates to a field of die casting process. More particularly, the present disclosure relates to a system and a method for monitoring a level of molten metal in a furnace reservoir during the die casting process.
BACKGROUND
During die casting process, the molten metal is fed into the die cavity under pressure to rapidly form moulded products. At present, die casting machines are used for this purpose. The casting machine owners receives raw material (i.e., metals) from third-party sources. Further, the metal received from the third-party sources is provided to furnaces for melting the metal. Conventionally, in case of any issue such as failure of a machine, if the raw material (i.e., metals) could not reach to the casting machine owners on time, then it has a significant impact on the casting machine owners. The problem is pronounced when there is a delay in communication about the aforementioned event between the casting machine owners and the third-party owners. In many situations, the casting machine owners could not be able to maintain the level of molten metal required for running the production. To cope up with such situations, the casting machine owners have to keep few stocks of molten metal in reserve. These reserve molten metal stock further increases rejection during the casting process.
Thus, there is a need for a new system and method that facilitates in monitoring the level of molten metal in the furnace reservoir in real time.
SUMMARY
In an embodiment of the present disclosure, a monitoring system is disclosed. The system includes a robotic arm, an encoder, a probe, a processing unit, and a data processing apparatus, coupled to each other. The encoder is configured to determine a degree of motion of the robotic arm. The probe is configured to sense signals associated with position of surface of molten metal contained in a furnace reservoir. The processing unit is configured to determine a fill level status associated with the furnace reservoir based on the degree of motion of the robotic arm and the position of the surface of the molten metal in the furnace reservoir. The data processing apparatus includes processing circuitry. The processing circuitry is configured to, based on the fill level status, determine (i) consumption rate of the molten metal by a casting machine of a plurality of casting machines and (ii) operative status of a casting machine of the plurality of casting machines.
In some embodiments of the present disclosure, the operative status comprising (i) idleness state of a casting machine of the plurality of casting machines and (ii) active state of a casting machine of the plurality of casting machines.
In some embodiments of the present disclosure, wherein the robotic arm further comprising a ladle such that the robotic arm is inserted within the furnace reservoir to collect the molten metal in the ladle.
In some embodiments of the present disclosure, the robotic arm, upon collection of the molten metal in the ladle, is configured to pour the molten metal in at least one casting machine of the plurality of casting machines.
In some embodiments of the present disclosure, the processing circuitry is further configured to generate a dashboard that represents (i) the consumption rate of the molten metal by each casting machine of the plurality of casting machines and (ii) the operative status of each casting machine of the plurality of casting machines.
In some embodiments of the present disclosure, the monitoring system further includes a user device coupled to the data processing apparatus, and configured to display the dashboard to a user.
In another embodiment of the present disclosure, a method for monitoring is disclosed. The method includes the step of determining, by way of an encoder coupled to the robotic arm, a degree of motion of the robotic arm. The method further includes the step of sensing, by way of a probe coupled to the robotic arm, signals associated with position of surface of molten metal contained in a furnace reservoir. The method further includes the step of determining, by way of a processing unit coupled to the encoder and the probe, a fill level status associated with the furnace reservoir based on the degree of motion of the robotic arm and the position of the surface of the molten metal in the furnace reservoir. The method further includes the step of determining by way of processing circuitry of a data processing apparatus coupled to the processing unit, (i) consumption rate of the molten metal by each casting machine of the plurality of casting machines and (ii) operative status of each casting machine of the plurality of casting machines, wherein the processing circuitry determines the consumption rate and the operative status based on the fill level status.
In some embodiments of the present disclosure, the method further includes the step of generating, by way of the processing circuitry, a dashboard that represents (i) the consumption rate of the molten metal by each casting machine of the plurality of casting machines and (ii) the operative status of each casting machine of the plurality of casting machines.
In some embodiments of the present disclosure, the method further includes displaying, by way of a user device coupled to the data processing apparatus, the dashboard to a user.
BRIEF DESCRIPTION OF DRAWINGS
Other objects, features, and advantages of the embodiments will be apparent from the following description when read with reference to the accompanying drawings. In the drawings, wherein like reference numerals denote corresponding parts throughout the several views:
The diagrams are for illustration only, which thus is not a limitation of the present disclosure, and wherein:
FIG. 1 illustrates a block diagram of a monitoring system that facilitate in monitoring level of molten metal contained in a furnace reservoir during a die casting process, in accordance with an embodiment of the present disclosure;
FIG. 2 illustrates a block diagram of a data processing apparatus of the system of Fig, 1, in accordance with an embodiment of the present disclosure; and
FIG. 3 illustrates a flow chart of a method that facilitate in monitoring level of molten metal contained in a furnace reservoir during a die casting process, in accordance with an embodiment of the present disclosure.
To facilitate understanding, like reference numerals have been used, where possible to designate like elements common to the figures.
DETAILED DESCRIPTION
Various embodiments of the present disclosure provide a system and a method that facilitates in monitoring the level of molten metal in the furnace reservoir during a die casting process. The following description provides specific details of certain embodiments of the disclosure illustrated in the drawings to provide a thorough understanding of those embodiments. It should be recognized, however, that the present disclosure can be reflected in additional embodiments and the disclosure may be practiced without some of the details in the following description.
The various embodiments including the example embodiments are now described more fully with reference to the accompanying drawings, in which the various embodiments of the disclosure are shown. The disclosure may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure is thorough and complete, and fully conveys the scope of the disclosure to those skilled in the art. In the drawings, the sizes of components may be exaggerated for clarity.
As mentioned, there remains a need for a new system and method that facilitates in monitoring the level of molten metal in the furnace reservoir in real time. The present aspect, therefore, provides a system, and a method that facilitates in monitoring the level of molten metal in the furnace reservoir in real time.
The aspects herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting aspects that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the aspects herein. The examples used herein are intended merely to facilitate an understanding of ways in which the aspects herein may be practiced and to further enable those of skill in the art to practice the aspects herein. Accordingly, the examples should not be construed as limiting the scope of the aspects herein.
FIG. 1 is a block diagram of a system 100 that facilitates in monitoring level of molten metal contained in a furnace reservoir during a die casting process (hereinafter referred to as “the system 100”), in accordance with an embodiment of the present disclosure. The system 100 may include a robotic arm 102, a user device 104 and a data processing apparatus 106. The data processing apparatus 106 may be communicatively coupled to the robotic arm 102 and the user device 104, by way of a communication network 108. In some embodiments of the present disclosure, the robotic arm 102, the user device 104, and the data processing apparatus 106 may be communicatively coupled through separate communication networks established therebetween that may be wired and/or wireless.
The robotic arm 110 may be configured to collect molten metal via a furnace reservoir. Examples of the robotic arm 102 may include, but are not limited to, a cartesian robotic arm, a collaborative robotic arm, a cylindrical robotic arm, a spherical robotic arm, a SCARA robotic arm, and/or an articulated robotic arm. Aspects of the present disclosure are intended to include or otherwise cover any type of the robotic arm including known, related art, and/or later developed technologies, without deviating from the scope of the present disclosure. In some embodiments of the present disclosure, the robotic arm 102 may be configured to collect the molten metal via a ladle attached with the robotic arm 102. Further, upon collection of the molten metal in the ladle, the robotic arm 102 with the ladle may be configured to pour the molten metal in a casting machine of a plurality of casting machine. As illustrated, the robotic arm 102 may include an encoder 110, a probe 112, and a processing unit 114. In some embodiment of the present disclosure, the encoder 110, the probe 112, and the processing unit 114 may be communicatively coupled to each other.
The encoder 110 may be coupled to the robotic arm 102 and configured to determine a degree of motion of the robotic arm 102. The encoder 110 may be further configured to generate pulse signals corresponding to the degree of motion of the robotic arm 102. In a preferred embodiment of the present disclosure, the generated pulse signals are direct current (hereinafter “DC”) signals. Examples of the encoder 110 may include, but are not limited to, a linear encoder, a rotary encoder, a magnetic encoder, an optical encoder, an inductive encoder, a capacitive encoder and/or a laser encoder. Aspects of the present disclosure are intended to include or otherwise cover any type of the encoder including known, related art, and/or later developed technologies, without deviating from the scope of the present disclosure.
The probe 112 may be coupled to the robotic arm 102 and configured to sense signals associated with position of surface of the molten metal contained in the furnace reservoir. In some embodiment of the present disclosure, the probe 112 may be configured to sense signals associated with position of surface of the molten metal contained in the furnace reservoir when the probe 112 comes in contact with the molten metal.
The processing unit 114 may be coupled to the encoder 110 and the probe 112. The processing unit 114 may include suitable logic, instructions, circuitry, interfaces, and/or codes for executing various operations, such as the operations associated with various operations of the encoder 110, the probe 112, and the like. Specifically, the processing unit 114 may be configured to determine a fill level status associated with the furnace reservoir based on the degree of motion of the robotic arm 102 and the position of the surface of the molten metal in the furnace reservoir. Examples of the processing unit 114 may include, but are not limited to, an application-specific integrated circuit (ASIC) processor, a reduced instruction set computing (RISC) processor, a complex instruction set computing (CISC) processor, a field-programmable gate array (FPGA), a Programmable Logic Control unit (PLC), and the like. Aspects of the present disclosure are intended to include or otherwise cover any type of processing unit including known, related art, and/or later developed processing units.
The user device 104 may be configured to facilitate a user to input data, receive data, and/or transmit data within the system 100. Specifically, the user device 104 may be configured to receive and display a processed data from the processing unit 114 and/or from the data processing apparatus 106. Examples of the user device 104 may include, but are not limited to, a smart phone, a desktop, a notebook, a laptop, a handheld computer, a touch sensitive device, a computing device and/or a smart watch. Aspects of the present disclosure are intended to include or otherwise cover any type of the user device 104 including known, related art, and/or later developed technologies, without deviating from the scope of the present disclosure. Although FIG. 1 illustrates that the system 100 includes a single user device (i.e., the user device 104), it will be apparent to a person skilled in the art that the scope of the present disclosure is not limited to it. In various other aspects, the system 100 may include multiple user devices without deviating from the scope of the present disclosure. In such a scenario, each user device is configured to perform one or more operations in a manner similar to the operations of the user device 104 as described herein.
The communication network 108 may include suitable logic, circuitry, and interfaces that may be configured to provide a plurality of network ports and a plurality of communication channels for transmission and reception of data related to operations of various entities (such as the robotic arm 102, the user device 104 and the data processing apparatus 106) of the system 100. Each network port may correspond to a virtual address (or a physical machine address) for transmission and reception of the communication data. For example, the virtual address may be an Internet Protocol Version 4 (IPV4) (or an IPV6 address) and the physical address may be a Media Access Control (MAC) address. The communication network 108 may be associated with an application layer for implementation of communication protocols based on one or more communication requests from the robotic arm 102, the user device 104 and the data processing apparatus 106. The communication data may be transmitted or received, via the communication protocols. Examples of the communication protocols may include, but are not limited to, Hypertext Transfer Protocol (HTTP), File Transfer Protocol (FTP), Simple Mail Transfer Protocol (SMTP), Domain Network System (DNS) protocol, Common Management Interface Protocol (CMIP), Transmission Control Protocol and Internet Protocol (TCP/IP), User Datagram Protocol (UDP), Long Term Evolution (LTE) communication protocols, or any combination thereof.
In an aspect of the present disclosure, the communication data may be transmitted or received via at least one communication channel of a plurality of communication channels in the communication network 108. The communication channels may include, but are not limited to, a wireless channel, a wired channel, a combination of wireless and wired channel thereof. The wireless or wired channel may be associated with a data standard which may be defined by one of a Local Area Network (LAN), a Personal Area Network (PAN), a Wireless Local Area Network (WLAN), a Wireless Sensor Network (WSN), Wireless Area Network (WAN), Wireless Wide Area Network (WWAN), a metropolitan area network (MAN), a satellite network, the Internet, a fiber optic network, a coaxial cable network, an infrared (IR) network, a radio frequency (RF) network, and a combination thereof. Aspects of the present disclosure are intended to include or otherwise cover any type of communication channel, including known, related art, and/or later developed technologies.
The data processing apparatus 106 may be a network of computers, a framework, or a combination thereof, that may provide a generalized approach to create a server implementation. In some embodiments of the present disclosure, the data processing apparatus 106 may be a server. Examples of the data processing apparatus 106 may include, but are not limited to, personal computers, laptops, mini-computers, mainframe computers, any non-transient and tangible machine that can execute a machine-readable code, cloud-based servers, distributed server networks, or a network of computer systems. The data processing apparatus 106 may be realized through various web-based technologies such as, but not limited to, a Java web-framework, a .NET framework, a personal home page (PHP) framework, or any other web-application framework. The data processing apparatus 106 may include one or more processing circuitries of which processing circuitry 116 is shown and a database 118.
The processing circuitry 116 may be configured to execute various operations associated with the system 100. The processing circuitry 116 may be coupled to the database 118 and configured to execute the one or more operations associated with the system 100 by communicating one or more commands and/or instructions over the communication network 108. Examples of the processing circuitry 116 may include, but are not limited to, an ASIC processor, a RISC processor, a CISC processor, a FPGA, and the like. Embodiments of the present disclosure are intended to include and/or otherwise cover any type of the processing circuitry 116 including known, related art, and/or later developed technologies.
The database 118 may be configured to store the logic, instructions, circuitry, interfaces, and/or codes of the processing circuitry 116 for executing various operations. The database 118 may be further configured to store therein data associated with the robotic arm 102. It will be apparent to a person having ordinary skill in the art that the database 122 may be configured to store various types of data associated with the system 100, without deviating from the scope of the present disclosure. Examples of the database 122 may include but are not limited to, a Relational database, a NoSQL database, a Cloud database, an Object-oriented database, and the like. Further, the database 118 may include associated memories that may include, but is not limited to, a ROM, a RAM, a flash memory, a removable storage drive, a HDD, a solid-state memory, a magnetic storage drive, a PROM, an EPROM, and/or an EEPROM. Embodiments of the present disclosure are intended to include or otherwise cover any type of the database 122 including known, related art, and/or later developed technologies.
In operation, the level of the molten metal contained in the furnace reservoir is determined by the system 100. In some embodiment of the present disclosure, the level of the molten metal contained in the furnace reservoir is determined by the system 100, when the robotic arm 102 starts moving to collect the molten metal via the ladle attached to the robotic arm 102. Further, with the movement of the robotic arm 102, the encoder 110 may simultaneously start generating pulse signals corresponding to each movement of the robotic arm. The generated pulse signals may be transmitted to the processing unit 114 till the probe 112 comes in contact with the surface of the molten metal contained in the furnace reservoir. In some embodiments of the present disclosure, a Digital to Analog card (hereinafter “DA card”) may be configured to receive the transmitted pulse signals, convert the transmitted pulse signals into corresponding Analog signals via an analog to Modbus converter, and transmit the converted analog signals to the processing unit 114. Further, the processing unit 114, upon receiving the analog signals determine the fill level status associated with the furnace reservoir based on the degree of motion of the robotic arm 102 and the position of the surface of the molten metal in the furnace reservoir.
In some other embodiment of the present disclosure, the system 100 may employ a plurality of level sensors that may be communicatively coupled to the processing unit 114 that determines the level of the molten metal contained in the furnace reservoir.
Further, the processing unit 114 may transmit data related to the determined level of the molten metal in the furnace reservoir to the data processing apparatus 106. Upon receiving the data, the data processing apparatus 106 may be configured to determine consumption rate of the molten metal by the casting machine of the plurality of casting machines and operative status of a casting machine of the plurality of casting machines. Furthermore, the data processing apparatus 106 may be configured to generate and display a dashboard representing, the determined consumption rate of the molten metal by the casting machine and the determined operative status of the casting machine, via the user device 104.
FIG. 2 illustrates a block diagram of the data processing apparatus 106 of the system 100 of FIG.1, in accordance with an aspect of the present disclosure. The data processing apparatus 106 may include the processing circuitry 116, the database 118, a network interface 200, and an input-output (I/O) interface 202 communicatively coupled to one another by way of a communication bus 204.
The network interface 200 may include suitable logic, circuitry, and interfaces that may be configured to establish and enable a communication between the data processing apparatus 106, and the user device 104 via the communication network 108. The network interface 200 may be implemented by use of various known technologies to support wired or wireless communication of the data processing apparatus 106 with the communication network 108. The network interface 200 may include, but is not limited to, an antenna, a radio frequency (RF) transceiver, one or more amplifiers, a tuner, one or more oscillators, a digital signal processor, a coder-decoder (CODEC) chipset, a subscriber identity module (SIM) card, and a local buffer circuit.
The I/O interface 202 may include suitable logic, circuitry, interfaces, and/or code that may be configured to receive inputs (e.g., orders) and transmit outputs via a plurality of data ports in the data processing apparatus 106. The I/O interface 202 may include various input and output data ports for different I/O devices. Examples of such I/O devices may include, but are not limited to, a touch screen, a keyboard, a mouse, a joystick, a projector audio output, a microphone, an image-capture device, a liquid crystal display (LCD) screen and/or a speaker.
In some embodiments of the present disclosure, the processing circuitry 120 may include a data collection engine 206, a processing engine 208, and a display engine 210. The data collection engine 206, the processing engine 208, and the display engine 210 may be coupled to each other by way of a second communication bus 216.
The data collection engine 206 may be configured to receive the data from the processing unit 114. The processing engine 208 may be configured to receive data from the data collection engine 206 and configured to process the received data to determine the operative status of the casting machine of the plurality of casting machines and the consumption rate of the molten metal by the casting machine of the plurality of casting machines. In some embodiments of the present disclosure, the processing engine 208 may be configured to determine the operative status of the casting machine that includes idleness state of the casting machine and the active state of a casting machine. Further, the processing engine 208 may be configured to determine an on time in full (OTIF) number that represents the efficiency of the system (100) based on the fill level status associated with the furnace reservoir and the operative status of a casting machine of the plurality of casting machines. Specifically, the OTIF number represents the total amount of molten metal required in the furnace reservoir to keep the plurality of casting machines in operative state.
The display engine 210 may be configured to receive the determined consumption rate of the molten metal by the casting machine and the operative status of the casting machine from the processing engine 208, and thereby generates a dashboard representing the determined consumption rate of the molten metal by the casting machine and the operative status of the casting machine. Furthermore, the display engine 210 may be configured to display the dashboard to a user via the user device 204.
FIG. 3 illustrates a flow chart of a method 300 that facilitate in monitoring level of molten metal contained in a furnace reservoir during a die casting process, in accordance with an embodiment of the present disclosure.
At step 302, an encoder 110 coupled to the robotic arm 102, may determine a degree of motion of the robotic arm 102.
At step 304, a probe 112 coupled to the robotic arm 102 may sense signals associated with position of surface of molten metal contained in a furnace reservoir.
At step 306, a processing unit 114 coupled to the encoder 110 and the probe 112, may determine a fill level status associated with the furnace reservoir based on the degree of motion of the robotic arm 102 and the position of the surface of the molten metal in the furnace reservoir.
At step 308, processing circuitry 116 of a data processing apparatus 106 coupled to the processing unit 114, may determine (i) consumption rate of the molten metal by each casting machine of the plurality of casting machines and (ii) operative status of each casting machine of the plurality of casting machines, wherein the processing circuitry 116 determines the consumption rate and the operative status based on the fill level status.
At step 310, the processing circuitry 116 may determine an on time in full (OTIF) number. The on time in full (OTIF) number may represent the efficiency of the system (100) based on the fill level status associated with the furnace reservoir and the operative status of a casting machine of the plurality of casting machines.
At step 312, the processing circuitry 116 may generate a dashboard that represents, (i) the consumption rate of the molten metal by each casting machine of the plurality of casting machines and (ii) the operative status of each casting machine of the plurality of casting machines, and display the dashboard via a user device 104 to a user.
The foregoing discussion of the present disclosure has been presented for purposes of illustration and description. It is not intended to limit the present disclosure to the form or forms disclosed herein. In the foregoing Detailed Description, for example, various features of the present disclosure are grouped together in one or more aspects, configurations, or aspects for the purpose of streamlining the disclosure. The features of the aspects, configurations, or aspects may be combined in alternate aspects, configurations, or aspects other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention the present disclosure requires more features than are expressly recited in each aspect. Rather, as the following aspects reflect, inventive aspects lie in less than all features of a single foregoing disclosed aspect, configuration, or aspect. Thus, the following aspects are hereby incorporated into this Detailed Description, with each aspect standing on its own as a separate aspect of the present disclosure.
Moreover, though the description of the present disclosure has included description of one or more aspects, configurations, or aspects and certain variations and modifications, other variations, combinations, and modifications are within the scope of the present disclosure, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative aspects, configurations, or aspects to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those disclosed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.
As one skilled in the art will appreciate, the system 100 includes a number of functional blocks in the form of a number of units and/or engines. The functionality of each unit and/or engine goes beyond merely finding one or more computer algorithms to carry out one or more procedures and/or methods in the form of a predefined sequential manner, rather each engine explores adding up and/or obtaining one or more objectives contributing to an overall functionality of the system 100. Each unit and/or engine may not be limited to an algorithmic and/or coded form, rather may be implemented by way of one or more hardware elements operating together to achieve one or more objectives contributing to the overall functionality of the system 100. Further, as it will be readily apparent to those skilled in the art, all the steps, methods and/or procedures of the system 100 are generic and procedural in nature and are not specific and sequential.
Certain terms are used throughout the following description and aspects to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not structure or function. While various aspects of the present disclosure have been illustrated and described, it will be clear that the present disclosure is not limited to these aspects only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the spirit and scope of the present disclosure. , Claims:1. A monitoring system (100) comprising:
a robotic arm (102);
an encoder (110) coupled to the robotic arm (102), and configured to determine a degree of motion of the robotic arm (102);
a probe (112) coupled to the robotic arm (102), and configured to sense signals associated with position of surface of molten metal contained in a furnace reservoir;
a processing unit (114) coupled to the encoder (110) and the probe (112), and configured to determine a fill level status associated with the furnace reservoir based on the degree of motion of the robotic arm (102) and the position of the surface of the molten metal in the furnace reservoir;
a data processing apparatus (106) coupled to the processing unit (114), the data processing apparatus (106) comprising:
processing circuitry (116) configured to, based on the fill level status, determine (i) consumption rate of the molten metal by a casting machine of a plurality of casting machines and (ii) operative status of a casting machine of the plurality of casting machines.

2. The monitoring system (100) as claimed in claim 1, wherein the operative status comprising (i) idleness state of a casting machine of the plurality of casting machines and (ii) active state of a casting machine of the plurality of casting machines.

3. The monitoring system (100) as claimed in claim 1, wherein the processing circuitry (116) is further configured to determine an on time in full (OTIF) number that represents the efficiency of the system (100) based on the fill level status associated with the furnace reservoir and the operative status of a casting machine of the plurality of casting machines.
4. The monitoring system (100) as claimed in claim 1, wherein the robotic arm (102) further comprising a ladle such that the robotic arm (102) is inserted within the furnace reservoir to collect the molten metal in the ladle.

5. The monitoring system (100) as claimed in claim 3, wherein the robotic arm (102), upon collection of the molten metal in the ladle, is configured to pour the molten metal in at least one casting machine of the plurality of casting machines.

6. The monitoring system (100) as claimed in claim 1, wherein the processing circuitry (116) is further configured to generate a dashboard that represents (i) the consumption rate of the molten metal by each casting machine of the plurality of casting machines, (ii) the operative status of each casting machine of the plurality of casting machines and (iii) the on time in full (OTIF) number.

7. The monitoring system (100) as claimed in claim 5, further comprising a user device (104) coupled to the data processing apparatus (106) and configured to display the dashboard to a user.

8. A method for monitoring (300) comprising:
determining (302), by way of an encoder (110) coupled to the robotic arm (102), a degree of motion of the robotic arm (102);
sensing (304), by way of a probe (112) coupled to the robotic arm (102), signals associated with position of surface of molten metal contained in a furnace reservoir;
determining (306), by way of a processing unit (114) coupled to the encoder (110) and the probe (112), a fill level status associated with the furnace reservoir based on the degree of motion of the robotic arm (102) and the position of the surface of the molten metal in the furnace reservoir;
determining (308), by way of processing circuitry (116) of a data processing apparatus (106) coupled to the processing unit (114), (i) consumption rate of the molten metal by each casting machine of the plurality of casting machines and (ii) operative status of each casting machine of the plurality of casting machines, wherein the processing circuitry (116) determines the consumption rate and the operative status based on the fill level status.

9. The method (300) as claimed in claim 7, further comprising determining (310), by way of the processing circuitry (116), an on time in full (OTIF) number that represents the efficiency of the system (100) based on the fill level status and the operative status of a casting machine of the plurality of casting machines.

10. The method (300) as claimed in claim 7, further comprising generating (312), by way of the processing circuitry (116), a dashboard that represents (i) the consumption rate of the molten metal by each casting machine of the plurality of casting machines, (ii) the operative status of each casting machine of the plurality of casting machines, and (iii) the on time in full (OTIF) number.

11. The method (300) as claimed in claim 7, further comprising displaying (310), by way of a user device (104) coupled to the data processing apparatus (106), the dashboard to a user.