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This paper deals with the problem of molten metal level control in continuous casting. Under normal circumstances, proportional integral derivative (PID) control performs quite well, but abnormal conditions (in particular nozzle clogging/unclogging) require manual intervention. Indeed, when the flow of matter into the mold increases suddenly, the PID controller is not always able to prevent large level variations that can even lead to mold overflow. So, a fuzzy controller has been designed using the expert knowledge of the operators for controlling the process during disturbed phases. The paper discusses both the design of the fuzzy logic controller and its integration with the PID in a global control architecture. Results from simulation and successful online implementation are presented.

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