Cast Lead Thickness.
Locked In.
See the true thickness of every strip coming off the drum, edge to edge, in real time. Every coil, every shift, with closed-loop control back to casting speed.
2 µm
Typical Accuracy
7 strips
Measured Individually
0.5 µm
Resolution
508 mm
Max Strip Width
Built For The Caster.
Designed around a chill drum caster, not adapted from a general purpose gauge. Three things it does that a hand mic cannot.
It Reads Every Strip, Not The Trim Edge
Trim edge checks taken during a cast do not represent the average thickness of the main strip. The C-frame travels edge to edge across the full 508 mm and reports each strip separately, up to seven in a single pass, without touching the lead.
It Tells You Which Problem You Have
The group average against target says whether the drum is off. The per-strip spread says whether one lane is off. Two different problems with two different fixes, and both answers are on one screen with the mean, min, max, standard deviation and width of every strip.
It Holds The Target On Its Own
Optional closed loop writes a corrected speed target straight back to the caster. With the loop off, thickness sits heavy and wanders. With it on, the distribution recentres on target and tightens, which is the difference between an operator chasing the number between coils and a line that holds it.
Catches Drum Drift As It Happens
Drum surface, lead height and speed all move the strip. Continuous measurement sees it start.
Survives The Casting Floor
Shield assembly, air purge, and an automatic thickness reference for thermal drift.
Stops You Running Heavy
That safety margin is lead given away on every coil. Knowing the real number removes it.
What Is Your Variation
Actually Costing?
Put in your line speed, your strip width, your lead price, and your own standard deviation. The estimator shows the math it used, so you can check every number rather than take ours on faith.
No sign-up. Runs in your browser.
The Software Is The Difference.
mgOS filters and processes the thickness waveform to extract and record measurements and KPIs, published continuously to a 15″ touchscreen HMI on the floor, and to your PLC.
What an operator reads off it
- Every strip, side by sideMean, max, min, standard deviation and width for each strip, plus the group average, from one pass.
- Centring, then spreadThe average against target says whether the caster is on nominal. The per-strip spread says whether the strips agree with each other. Two problems, two different fixes.
- Cross-section by locationThe profile shows strip edges and widths where they actually sit across the drum, not where they are meant to be.
- Proof the loop is workingControl mode sits next to manual slitter voltage and automatic slitter voltage, so the correction the gauge is applying is visible against what the operator dialled in.
Closed-Loop Control
Automatic adjustment of casting speed based on live thickness data, keeping strip on target without operator intervention.
Full Thickness Profile
Edge-to-edge thickness and width on every scan, with mean, min, max, and standard deviation reported individually for up to seven strips in a single pass.
Live Data Visualization
Real-time displays designed for operator ease: live, daily, and monthly views of key production metrics on the touchscreen.
Alarms & Alerts
Configurable alerts against your spec and action limits, raised on the HMI or as a PLC signal the instant strip drifts.
PDF & CSV Reporting
Data file downloads for offline analysis and trend tracking over run-time. Zero manual data entry.
PLC & API Integration
Connects to your production control system over Ethernet/IP, with support for Allen-Bradley, Siemens, and Omron controllers.
Your Hand Mic. Upgraded.
Everything your operators know about micrometers, in digital form. Inline, continuous, logged automatically, and with zero contact pressure, so nothing deforms soft cast lead and nothing depends on operator technique. Configure every detail to match the checks you already run.
Configurable Anvil Size.
Set the virtual anvil to match the hand mic your operators already use. Flat, disk, or point, each one averages over a different footprint. Larger anvils give more stable readings on textured surfaces, smaller ones give finer point-by-point detail, and every VMic across the strip can carry its own size.
MG-CLS. The Numbers.
Engineered for the cast lead environment. Class 2 lasers, 1–5 kHz sampling, sub-micron resolution, and an automatic thickness reference that compensates for thermal expansion.
System Includes
- 2× laser sensors (Class 2)
- Scanning C-frame, belt-driven actuator
- Shield assembly (included)
- Caster mounting bracket (included)
- 15″ touchscreen HMI
- Automatic thickness reference (TR)
- NIST-traceable calibration block
- Automatic strip edge detection
Ordered separately: replacement sandblaster arm, analog thickness controller for legacy analog speed control casters, and commissioning (remote or on-site).
- Resolution0.5 µm
- Accuracy (Typical)2 µm
- Thickness Range0 – 8 mm
- Stroke508 mm [20 in]
- Max Strip Width508 mm [20 in]
- Scanning Speed150 mm/sec
- Measurement Frequency1 – 5 kHz
- Laser ClassClass 2
- Operating Temperature5 – 50 °C
- System Weight67 kg [148 lbs]
Mounts Right To Your Existing Caster.
The bracket fixes the gauge to the caster side-wall and retracts for maintenance, so the system takes no extra floor space. A retrofit drawing package is issued ahead of the install, and a Mate Gauge engineer commissions the system on site.
-
01
Caster-Wall Mounting
The mounting bracket fixes to the caster side-wall and retracts to simplify maintenance. Side-plate, top roller shield, and top guard modifications are covered by drawings issued before the install, so the work is defined ahead of your shutdown.
-
02
Shield Assembly
Protects the C-frame and threads the strip at start-up. Built for the heat, fume, and splash of a casting line.
-
03
PLC & Network Compatibility
Connects to your production control system for real-time data transfer and closed-loop speed control. Modern casters use PLC speed control. The optional analog thickness controller is only needed on legacy casters running analog speed control.
-
04
Automated Operation
Once installed, the system runs continuously with minimal manual intervention, ensuring uninterrupted production monitoring around the clock.
From Line to Live Data.
Once installed on your caster, MG-CLS runs continuously. The Strips App in mgOS handles scanning, measurement, processing, display, and alerts, with optional closed-loop output back to the line.
Strip Scanning Begins
The Strips App continuously scans the incoming lead strip from the caster, no operator input required.
Cross-Sectional Measurement
Laser sensors traverse the strip, capturing thickness data at multiple points in real time.
Live Data Processing
The system calculates thickness profile, min / max thickness, standard deviation, and width on the fly.
Display & Analysis
Data is visualized on the HMI, giving operators real-time insights without leaving the line.
Alerts & Reports
Deviations from set tolerances trigger alerts. Optional closed-loop output adjusts casting speed automatically.
More From Mate Gauge.
MG3-RLS · Rolled Lead
Rolled Lead Strip
Continuous thickness monitoring after the rollers, with the same VMic system in a compact form factor.
Learn More →
MG3 · Pasted Plate
Lead Pasting
Pasted plate thickness monitoring after the dryer, with 50 mm sensors built for the pasting environment.
Learn More →
MGX · Benchtop
Battery Separators
Benchtop measurement of rib and backweb thickness on lead-acid battery separators.
Learn More →Reduce Waste. Improve Consistency.
Automate Control.
We will spec the right system for your caster, your strip layout, and your control system. Send us these six things and an engineer will come back with a configuration, not a brochure.
Tell us about your caster
- Strip thickness and target
- Number of strips
- Strip and trim width
- Caster make and model
- Speed control, PLC or analog
- Space beside the caster
Cast Lead Thickness.
Locked In.
See the true thickness of every strip coming off the drum, edge to edge, in real time. Every coil, every shift, with closed-loop control back to casting speed.
2 µm
Typical Accuracy
7 strips
Measured Individually
0.5 µm
Resolution
508 mm
Max Strip Width
Built For The Caster.
Designed around a chill drum caster, not adapted from a general purpose gauge. Three things it does that a hand mic cannot.
It Reads Every Strip, Not The Trim Edge
Trim edge checks taken during a cast do not represent the average thickness of the main strip. The C-frame travels edge to edge across the full 508 mm and reports each strip separately, up to seven in a single pass, without touching the lead.
It Tells You Which Problem You Have
The group average against target says whether the drum is off. The per-strip spread says whether one lane is off. Two different problems with two different fixes, and both answers are on one screen with the mean, min, max, standard deviation and width of every strip.
It Holds The Target On Its Own
Optional closed loop writes a corrected speed target straight back to the caster. With the loop off, thickness sits heavy and wanders. With it on, the distribution recentres on target and tightens, which is the difference between an operator chasing the number between coils and a line that holds it.
Catches Drum Drift As It Happens
Drum surface, lead height and speed all move the strip. Continuous measurement sees it start.
Survives The Casting Floor
Shield assembly, air purge, and an automatic thickness reference for thermal drift.
Stops You Running Heavy
That safety margin is lead given away on every coil. Knowing the real number removes it.
What Is Your Variation
Actually Costing?
Put in your line speed, your strip width, your lead price, and your own standard deviation. The estimator shows the math it used, so you can check every number rather than take ours on faith.
No sign-up. Runs in your browser.
The Software Is The Difference.
mgOS filters and processes the thickness waveform to extract and record measurements and KPIs, published continuously to a 15″ touchscreen HMI on the floor, and to your PLC.
What an operator reads off it
- Every strip, side by sideMean, max, min, standard deviation and width for each strip, plus the group average, from one pass.
- Centring, then spreadThe average against target says whether the caster is on nominal. The per-strip spread says whether the strips agree with each other. Two problems, two different fixes.
- Cross-section by locationThe profile shows strip edges and widths where they actually sit across the drum, not where they are meant to be.
- Proof the loop is workingControl mode sits next to manual slitter voltage and automatic slitter voltage, so the correction the gauge is applying is visible against what the operator dialled in.
Closed-Loop Control
Automatic adjustment of casting speed based on live thickness data, keeping strip on target without operator intervention.
Full Thickness Profile
Edge-to-edge thickness and width on every scan, with mean, min, max, and standard deviation reported individually for up to seven strips in a single pass.
Live Data Visualization
Real-time displays designed for operator ease: live, daily, and monthly views of key production metrics on the touchscreen.
Alarms & Alerts
Configurable alerts against your spec and action limits, raised on the HMI or as a PLC signal the instant strip drifts.
PDF & CSV Reporting
Data file downloads for offline analysis and trend tracking over run-time. Zero manual data entry.
PLC & API Integration
Connects to your production control system over Ethernet/IP, with support for Allen-Bradley, Siemens, and Omron controllers.
Your Hand Mic. Upgraded.
Everything your operators know about micrometers, in digital form. Inline, continuous, logged automatically, and with zero contact pressure, so nothing deforms soft cast lead and nothing depends on operator technique. Configure every detail to match the checks you already run.
Configurable Anvil Size.
Set the virtual anvil to match the hand mic your operators already use. Flat, disk, or point, each one averages over a different footprint. Larger anvils give more stable readings on textured surfaces, smaller ones give finer point-by-point detail, and every VMic across the strip can carry its own size.
MG-CLS. The Numbers.
Engineered for the cast lead environment. Class 2 lasers, 1–5 kHz sampling, sub-micron resolution, and an automatic thickness reference that compensates for thermal expansion.
System Includes
- 2× laser sensors (Class 2)
- Scanning C-frame, belt-driven actuator
- Shield assembly (included)
- Caster mounting bracket (included)
- 15″ touchscreen HMI
- Automatic thickness reference (TR)
- NIST-traceable calibration block
- Automatic strip edge detection
Ordered separately: replacement sandblaster arm, analog thickness controller for legacy analog speed control casters, and commissioning (remote or on-site).
- Resolution0.5 µm
- Accuracy (Typical)2 µm
- Thickness Range0 – 8 mm
- Stroke508 mm [20 in]
- Max Strip Width508 mm [20 in]
- Scanning Speed150 mm/sec
- Measurement Frequency1 – 5 kHz
- Laser ClassClass 2
- Operating Temperature5 – 50 °C
- System Weight67 kg [148 lbs]
Mounts Right To Your Existing Caster.
The bracket fixes the gauge to the caster side-wall and retracts for maintenance, so the system takes no extra floor space. A retrofit drawing package is issued ahead of the install, and a Mate Gauge engineer commissions the system on site.
-
01
Caster-Wall Mounting
The mounting bracket fixes to the caster side-wall and retracts to simplify maintenance. Side-plate, top roller shield, and top guard modifications are covered by drawings issued before the install, so the work is defined ahead of your shutdown.
-
02
Shield Assembly
Protects the C-frame and threads the strip at start-up. Built for the heat, fume, and splash of a casting line.
-
03
PLC & Network Compatibility
Connects to your production control system for real-time data transfer and closed-loop speed control. Modern casters use PLC speed control. The optional analog thickness controller is only needed on legacy casters running analog speed control.
-
04
Automated Operation
Once installed, the system runs continuously with minimal manual intervention, ensuring uninterrupted production monitoring around the clock.
From Line to Live Data.
Once installed on your caster, MG-CLS runs continuously. The Strips App in mgOS handles scanning, measurement, processing, display, and alerts, with optional closed-loop output back to the line.
Strip Scanning Begins
The Strips App continuously scans the incoming lead strip from the caster, no operator input required.
Cross-Sectional Measurement
Laser sensors traverse the strip, capturing thickness data at multiple points in real time.
Live Data Processing
The system calculates thickness profile, min / max thickness, standard deviation, and width on the fly.
Display & Analysis
Data is visualized on the HMI, giving operators real-time insights without leaving the line.
Alerts & Reports
Deviations from set tolerances trigger alerts. Optional closed-loop output adjusts casting speed automatically.
More From Mate Gauge.
MG3-RLS · Rolled Lead
Rolled Lead Strip
Continuous thickness monitoring after the rollers, with the same VMic system in a compact form factor.
Learn More →MG3 · Pasted Plate
Lead Pasting
Pasted plate thickness monitoring after the dryer, with 50 mm sensors built for the pasting environment.
Learn More →MGX · Benchtop
Battery Separators
Benchtop measurement of rib and backweb thickness on lead-acid battery separators.
Learn More →Reduce Waste. Improve Consistency.
Automate Control.
We will spec the right system for your caster, your strip layout, and your control system. Send us these six things and an engineer will come back with a configuration, not a brochure.
Tell us about your caster
- Strip thickness and target
- Number of strips
- Strip and trim width
- Caster make and model
- Speed control, PLC or analog
- Space beside the caster