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Rolls,Of,Metal,Sheet.,Zinc,,Aluminium,Or,Steel,Sheet,Rolls

Air knife positioning system

Cold Rolling Mill (CRM), Steel & Rolling Mills

Air knife positioning system

Cold Rolling Mill (CRM), Steel & Rolling Mills

Continuous high temperature poses serious challenges to the proximity. 70 °C proximity is unable to survive in this environment, and it fails. Proximity from Proxitron was used for the application of air knife positioning. Home Case Studies Air knife positioning Air knife positioning system Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Efficient positioning Protective housing M30 diameter available for 100 °C and 120 °C High degree of protection Challenges Continuous high temperature poses serious challenges to the proximity. 70 °C proximity is unable to survive in this environment, and it fails. Solution Proximity from Proxitron was used for the application of air knife positioning. Products and Accessories Inductive Proximity Sensors Key Specifications Cable length: 2,5,10,15,20 m Cable MOC: Silicone cable No. of wires: 2-wire, 3-wire Housing (Ǿ): M30 available for 100 °C and 120 °C Cable conduit protection available (Pg X) Sn: 30 mm IP 68 Temp: -25 to +120 °C Supply voltage: 20-260 V AC/DC Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All

Hot Rolling Mill / Screw downs: Replacing of old resolver technology

Hot Rolling Mill (HRM), Steel & Rolling Mills

Hot Rolling Mill / Screw downs: Replacing of old resolver technology

Hot Rolling Mill (HRM), Steel & Rolling Mills

For precise speed control in rolling mills the main drives of the roll stands and the coilers need to be equipped with an encoder. In addition, it is often necessary to provide increased protection for personnel during special operating modes, such as: For this application Johannes Hübner Giessen has been working with Motor OEMs for many decades to provide complete solution ie. Electrical and mechanical components. Home Case Studies Hot Rolling Mill / Screw downs: Replacing of old resolver technology Hot Rolling Mill / Screw downs: Replacing of old resolver technology Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Assembly of hollow shaft absolute encoder ASSH 60 K-16 / 50P (SSI interface) Improved final quality of the rolled material due to increased thickness accuracy Direct assembly to the screw down spindle Before: The old resolver transducer Challenges The customer needed to replace the old resolver technology to improve the thickness control precision and thereby, the material quality. For this purpose they attempted a solution using a linear transducer, which did not give satisfactory results due to its mechanical weakness. Finally, they came to the conclusion to use a high resolution absolute encoder suitable for heavy duty applications. Solution Due to the required robustness, a hollow shaft absolute encoder model ASSH 60 K-16 / 50P with corresponding torque bracket was chosen. The SSI interface with a resolution of 16 bit provides highly accurate signals for the thickness control. At the customer‘s request, the Hübner Giessen engineering department helped in the design of the mounting materials, which were produced by themself. After: Hollow shaft absolute encoder type ASSH 60 K-16 / 50Pwith torque bracket (directly mounted) Products and Accessories Main mill motor encoder Tether Adapter Shaft Heavy duty programmable overspeed switch Speed feedback for main drives Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions in Hot Rolling Mills – Roughing Mills View All

Iron,Pipe,Centrifugal,Pipe,Casting,Machine,At,The,Foundry

Pilger mill in tube rolling mills hot and cold pipe detection

Tubes and Pipes

Pilger mill in tube rolling mills hot and cold pipe detection

Tubes and Pipes

Hot metal detector provided optimum adaptation to operating conditions and performed efficient detection in pilger mill in tube rolling mills. It offers increased flexibility high ambient temperature conditions also. The compact model with stainless steel housing is maintenance free and self adjusting. Home Case Studies Pilger mill in tube rolling mills hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Challenges The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Products and Accessories Hot Metal Detector Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All

289 Condition Monitoring of both Movable & Fixed Dies in Casting Process

Infrared sensors, Infrared temperature sensors, Thermal Cameras

289 Condition Monitoring of both Movable & Fixed Dies in Casting Process

Infrared sensors, Infrared temperature sensors, Thermal Cameras

Condition Monitoring of Movable & Fixed Dies in Casting via Infrared Thermography IR Thermal Camera Challenges Needed precise temperature control of movable & fixed dies. Variations caused warping, cracking, and surface defects. Overheating reduced die life; undercooling led to poor bonding. No real-time data made quality control reactive. Solution Uniform heating, and reduced rejections Clear temperature layout – better insights into die conditions. Early detection of overheating and undercooling Extend die life and ensure material flow. Specifications Temperature Range : -20 °C – 900 °C Distance to spot ratio : 390:1 Customer’s Benefit Prominent temperature layout provides the user more specific idea about die condition Best Prise to performance Motorized focus Mid level resolution Suggested Products IR Thermal Camera Related case Studies Slab Detection on Transfer Table Uninterrupted sensor performance on hot / cold slab in high ambient temperature upto 290°C at charging transfer table without any water cooling. Width Confirmation / Camber Detection Precise laser distance sensor with 0.5mm accuracy working on both hot (upto 1300°C) and cold (black with scale) surface rated for high ambient temperature 60°C. Air/ water cooling options available. Temperature-Sensitive Slab Width Measurement: The Role of IR Cameras in Accurate Data Collection Combined software and IR camera data to provide temperature-compensated width measurements. Both width and temperature can be measured simultaneously Get In Touch 9818400356 enquiry@manglamelectricals.com Tower C, 12, Yamuna Marg, Civil Lines, Delhi – 110054 Get In Touch Mobile Number Email Message/Requirements (optional) Page URL Company Name Thank You …

The,Welding,Robot,Machine,For,Welding,Automotive,Part,In,The

Monitoring of temperature profile of weld pool during welding process

R&D

Monitoring of temperature profile of weld pool during welding process

R&D

Monitoring of temperature profile of weld pool during welding process. Welding spot / process temperature measurement using thermal imaging camera Home Case Studies Monitoring of temperature profile of weld pool during welding process Monitoring of temperature profile of weld pool during welding process Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Monitoring of temperature profile of weld pool during welding process Welding spot / process temperature measurement using thermal imaging camera Challenges Monitoring of temperature profile of weld pool during welding process https://www.manglamelectricals.com/wp-content/uploads/2021/10/Media1.wmv Solution Thermal imaging camera was used for the measurement of welding spot / process temperature Products and Accessories For Laser additive manufacturing Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All

Heating,Steel,By,Induction,Heating,Furnace,For,Hot,Forging

Profile (Multi-point) Temperature on Induction Heating

Casting and Forging

Profile (Multi-point) Temperature on Induction Heating

Casting and Forging

High rejection rate due to inaccurate temperature. Due to moving process difficult define measuring point, where the temperature has to measured. Thermal camera provides multiple ROIs (areas) for full profile measurement. Auto HOT SPOT tracker for max process temperature. Home Case Studies Profile (Multi-point) Temperature on Induction Heating Profile (Multi-point) Temperature on Induction Heating Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Heat treatment process : Induction Heating Special wavelength camera to minimize the influence of emissivity adjustment No alignment required even for moving job process Wide temperature range : 450 to 1800°C Analog outputs (4-20ma) for multiple region of interest Challenges High rejection rate as not accurate temperature Due to moving process can not define measuring point, where the temperature has to measured. Oxidation / scales reduces real temperature Existing ratio pyrometer not sufficient for the process Solution Special spectral range applicable for heat treatment process Multiple ROIs (areas) for full profile measurement Auto HOT SPOT tracker for max process temperature Water cool jacket for ambient temperature 315°C Single image on screen (left and right) from two camera Products and Accessories Thermal Cameras Cooling Jacket Other Solutions for Molten Metal Melt IR System Portable pyrometer for molten metal Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions in Casting and Forging Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All

Pinch roll rod detection before laying head

Steel & Rolling Mills

Pinch roll rod detection before laying head

Steel & Rolling Mills

Hot Metal Detector was used for the detection of long product rolling. The sensor’s small spot size is big enough to capture bar fluttering but without sensing crop ends. No water cooling was required as the sensor was provided with a fibre optic cable between the optics and the electronics. Electronics were kept 2m away from the heat zone Home Case Studies Pinch roll rod detection before laying head Pinch roll rod detection before laying head Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Dual (Hystersis) Threshold: Customer could now create band to control signal on/off (Son and Soff. Avoid false triggering when temperature dropped for short durations due to presence of steam. Maintenance free modular design: Three-piece design (Optics, fiber optic cable, electronics) parts can be each purchased separately. Compact size: Optics are 25mx85mm. Possibility to implement redundancy and shadow mode operations to compare the results. Flexibility for variable response temperature threshold (400C..10000C) as per site: The object temperature can range from 1000C to 18000C. On special request model can start as low as 250⁰C to 600⁰C Standard-function, offset-function, alarm-function and jump-detection 2 free adjustable switching outputs Challenges The existing solution suffered from various problems Oversensing Scanning technology detected hot crops/ tail ends fallen on the track Flickering at water box exit: Bar temperature used to drop from 900⁰C to ~600⁰C with existing solution’s fixed triggered threshold. Expensive maintenance: Water cooling line had to be ON all times to avoid electronics failure. Redundancy not feasible Existing solution had a bulky design therefore it was not feasible to implement dual HMDs. Solution HMD optical sensor is ideal for this application. The sensor’s small spot size is big enough to capture bar fluttering but without sensing crop ends. (Optics 20 has 55mm spot size) No water cooling was required as the sensor was provided with a fibre optic cable between the optics and the electronics. With the FOC system, the sensor can operate at ambient temperatures upto 2900C without any water / air cooling. Electronics were kept 2m away from the heat zone. All components were housed in protective rugged stainless steel for protection against moisture, steam, shock and vibration. Optical filters protected against spurious radiation. Variable Response Temperature threshold could be set as per site requirement from 4000C to 10000C. Note: Other models that start as low as 1000C response temperature are also possible Products and Accessories Compact HMD for TMT bars Flicker free HMD for long and flat rolling Flicker free compact HMD for high ambient environment Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions in Hot Rolling Mills Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All

Hot,Rolling,Coil,Before,Machine,Skin,Pass,Mill,In,Steel

114 Down coiler: Strip detection after laminar cooling

Hot Rolling Mill (HRM), Hot Rolling Mill (HRM)

114 Down coiler: Strip detection after laminar cooling

Hot Rolling Mill (HRM), Hot Rolling Mill (HRM)

Down Coiler: Strip Detection After Laminar Cooling Light Barrier Challenges Stable performance was required while strip detection after laminar cooling, in harsh environment conditions Due to low temperature of the strip at the laminar table, the response from a standard scanning type HMD was unstable. Moreover the environment conditions were challenging:- High ambient temperature and fumes under the strip. Presence of scales and dust generating from them, led to degraded performance of light barrier. Continuous water falling on the conveyor table Solution Proxitron light barrier was installed at the down coiler. It provided higher functional reserve up to 750 m. Higher the functional reserve, better is the stability of performance against pollutions such as water, steam, fumes. Customer Benefit Resistant to contamination due to steam, dust, fumes. Stable and uninterrupted performance Accurate and reliable Schematic of Solution Suggested Products & Accessories Light Barrier Cable Protection System High Temperature Reflectors- 150 °C to 500 °C Stand For Pan, Tilt and Height Adjustment Related case Studies Slab Detection on Transfer Table Uninterrupted sensor performance on hot / cold slab in high ambient temperature upto 290°C at charging transfer table without any water cooling. Width Confirmation / Camber Detection Precise laser distance sensor with 0.5mm accuracy working on both hot (upto 1300°C) and cold (black with scale) surface rated for high ambient temperature 60°C. Air/ water cooling options available. Temperature-Sensitive Slab Width Measurement: The Role of IR Cameras in Accurate Data Collection Combined software and IR camera data to provide temperature-compensated width measurements. Both width and temperature can be measured simultaneously Get In Touch 9818400356 enquiry@manglamelectricals.com Tower C, 12, Yamuna Marg, Civil Lines, Delhi – 110054 Get In Touch Mobile Number Email Message/Requirements (optional) Page URL Company Name Thank You …

Tank,Pours,Liquid,Metal,At,The,Steel,Mill

Benefits of using a thermal imaging camera in a cast iron foundry

Casting and Forging

Benefits of using a thermal imaging camera in a cast iron foundry

Casting and Forging

Home Case Studies Benefits of using a thermal imaging camera in a cast iron foundry Benefits of using a thermal imaging camera in a cast iron foundry Continuous temperature monitoring Optimum process control achieved resulting in reduced electricity wastage Reduces safety hazard for operator One time investment with no recurring costs Challenges Accurate temperature monitoring is critical to ensure high quality and efficiency of the casting process as the quality of casting is highly dependent on the temperature of the molten metal. Low temperatures result in poor quality of casting whereas too high temperatures results in energy wastage and may cause damage to the ladle refractory. Mostly commonly thermocouples are used to measure temperature by dipping it in the molten metal in the ladle. Although thermocouples can be used to measure the final tapping temperatures after the liquid has been poured into moulds, they cannot measure temperature of the pouring stream. By the dipping approach, the operator needs to manually take the measurement and requires him to be in close proximity. Thermocouples only give temperature readings at specific time points (when dipped). Furthermore, tips need to be continually replaced resulting in ongoing consumables cost. Solution Thermal imaging cameras provide a more accurate alternative to thermocouples by measuring the temperature of the liquid tapping stream as it is being poured into the mould to make the final product. The solution has the following benefits – No alignment issue: Hot spot detector automatically differentiates between slag and hot metal Increases productivity: Non-contact measurement does not interrupt tapping / casting process Provide traceability: Each melt temperature is recorded with image Improved product quality: with precise temperature control No recurring consumable cost: One time investment, with payback in few months. Products and Accessories Thermal Imaging Protective Housing Cooling Jacket Laminar Air purge Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions in Hot Rolling Mills Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All

Accurate Temperature measurement in Induction Heating using Ratio Pyrometer

Casting and Forging

Accurate Temperature measurement in Induction Heating using Ratio Pyrometer

Casting and Forging

High rejection rate due to inaccurate temperature. Due to moving process difficult define measuring point, where the temperature has to measured. Thermal camera provides multiple ROIs (areas) for full profile measurement. Auto HOT SPOT tracker for max process temperature. Home Case Studies Accurate Temperature measurement in Induction Heating using Ratio Pyrometer Accurate Temperature measurement in Induction Heating using Ratio Pyrometer Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Next generation Ratio pyrometer for accurate temperature measurement Accurate temperature even at recycled/oxidized billet No EMC effect, hence minimized measurement errors Compact size and Easy to install: No need of cooling arrangement High temperature ( 315°C) sensing head with Fiber optics cable Ratio pyrometer installed for accurate temperature measurement Challenges Scales get formed on the surface of billet when hot metal comes in contact with air due to oxidation. Presence of scales leads to inaccurate temperature measurement. Previous pyrometer faced frequent problems due to the EMC effect. High rejection rate due to inaccurate billet temperature. Billet coming out of furnace Solution Ratio Pyrometer was installed for accurate temperature measurement even at 5% object visibility. It comes with focusable optics and high temperature ( 315°C) sensing head with Fiber optics cable. It comprises of green laser for alignment on red hot metal, because it is easily visible on the burning red-hot metal Hot Billet entering on the conveyor Key Specifications Temperature range: 1-channel : 450-3000°C; 2-channel: 525-3000°C Output: 2x 0/4-20 mA Power supply: 8 – 30 V DC Optical resolution: 100:1 Spectral range: 0.8 – 1.1 µm Response time: 1 ms – 10 s Products and Accessories Ratio Pyrometer Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions in Casting and Forging Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All

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424 Detection of hot and cold tubes at heat treatment (wet environment)

Infrared sensors, Infrared temperature sensors, Thermal Cameras

424 Detection of hot and cold tubes at heat treatment (wet environment)

Infrared sensors, Infrared temperature sensors, Thermal Cameras

Detection of Hot and Cold Tubes in Wet Heat Treatment Processes Using Light Barriers and Inductive Switches Through-Beam Light Barrier, Inductive Proximity Switch Challenges Heavy water spray during hardening and high heat from untreated supports pose a serious threat to nearby sensors, leading to frequent failures. Solution Infrared light barrier placed before the hardening head detects tubesearly with minimal water exposure. Staggered signal enables upstream detection, improving processcontrol and safety. Inductive proximity switches mounted underneath supports, activatedonly after hardening to avoid heat damage. Compact design ensures reliable performance in harsh environmentswith water and steam. Specifications Light Barrier : Range 2500 m, adjustable Ambient temperature -20 to +70 °C without cooling, up to +200 °C with cooling Inductive Proximity Switch : Aluminum housing 212 x 212 x 75 Rated operating distance (Sn) 100 mm AC/DC 2 wire normally open A light barrier made of transmitter and receiver was installed at furnace exit (red arrow), presence of tube inside the hardening head (blue arrow). Suggested Products & Accessories Through-Beam Light Barrier Inductive Proximity Switch Related case Studies Slab Detection on Transfer Table Uninterrupted sensor performance on hot / cold slab in high ambient temperature upto 290°C at charging transfer table without any water cooling. Width Confirmation / Camber Detection Precise laser distance sensor with 0.5mm accuracy working on both hot (upto 1300°C) and cold (black with scale) surface rated for high ambient temperature 60°C. Air/ water cooling options available. Temperature-Sensitive Slab Width Measurement: The Role of IR Cameras in Accurate Data Collection Combined software and IR camera data to provide temperature-compensated width measurements. Both width and temperature can be measured simultaneously Get In Touch 9818400356 enquiry@manglamelectricals.com Tower C, 12, Yamuna Marg, Civil Lines, Delhi – 110054 Get In Touch Mobile Number Email Message/Requirements (optional) Page URL Company Name Thank You …

Blast,Furnace,Smelting,Liquid,Steel,In,Steel,Mills

Critical Assets Preventative Maintenance: Pre-heat station

Steel & Rolling Mills, Steel Making

Critical Assets Preventative Maintenance: Pre-heat station

Steel & Rolling Mills, Steel Making

Condition based monitoring using thermal imaging cameras is an effective approach to monitor temperature and prevent long term damage to the ladle refractory. The compact IR camera can automatically identify hot spots and generates alarm if temperatures exceeds thresholds. This allows for early detection of potential damage and for selective repairs Home Case Studies Critical Assets Preventative Maintenance: Pre-heat station Critical Assets Preventative Maintenance: Pre-heat station Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Increased efficiency: Ladle lifetime improvement with early detection allowing for selective repairs as opposed to full lining replacement Improved safety level: Prevents breakouts and reduces risk of damage to personnel & plant equipment Enabled Preventive Maintenance: Real time system running 365 / 24/ 7 days, with warning of excessive shell temperature from refractory degradation Avoided unscheduled downtime: Avoided costly machinery damage and days to clean-up mess Challenges The customer wanted to measure the temperature of the inner surface of the ladle to ensure it is sufficiently heated during the pre-heating process before the hot metal is added. Overheating can cause long term damage to the ladle refractory and result in high replacement costs. Solution Condition based monitoring using thermal imaging cameras is an effective approach to monitor temperature and prevent long term damage. The compact IR camera can automatically identify hot spots and provides analog or digital output signals. Products and Accessories Thermal Imaging Camera Cooling Jacket Laminar Air purge Protective Housing High Temperature Cables USB to LAN Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions in Hot Rolling Mills Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All

Cost Effective Temperature Measurement in Infrared Heaters using Compact Pyrometers

Casting and Forging

Cost Effective Temperature Measurement in Infrared Heaters using Compact Pyrometers

Casting and Forging

High rejection rate due to inaccurate temperature. Due to moving process difficult define measuring point, where the temperature has to measured. Thermal camera provides multiple ROIs (areas) for full profile measurement. Auto HOT SPOT tracker for max process temperature. Home Case Studies Profile (Multi-point) Temperature on Induction Heating Cost Effective Temperature Measurement in Infrared Heaters using compact pyrometers Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection Pilger mill in tube rolling mills – hot and cold pipe detection Special Features of CT LT Pyrometer : It is equipped with one of the world’s smallest infrared sensors. It boasts a high optic resolution of 22:1, ensuring precise and accurate measurements Additionally, it offers a high level of variability. This is due to selectable analog outputs, as well as several digital interfaces in the electronics box. Customers Benefits : Cost-Effective: Our products offer a cost-effective solution for your needs. Plug and Play: Easy to set up and use, requiring minimal installation time. Immediate Availability: Products are readily available for immediate use. Products start at an affordable price point of Rs 12,500 Specifications Temperature range: -50°C to 975°C Spectral range: 8 to 14 µm Response time: 150 ms Products and Accessories Pyrometer Case Study Number TP3 Challenge The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity. In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C. After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter. Previous solution / Competitor product N/A Solution The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19. The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase. An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions. The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C. Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling. Customer Benefits Maintenance-free High temperature stability Recognition of hot objects at big distances Self adjustment with Auto-Teach or step switch for the response temperature Product Part number OKA 2038.38 G Brand Proxitron Accessories Piros swivel stand HM2 Tube OL 19 Pilot light unit (for alignment) DAK 308 + OL 26 Different cable lengths (e.g. 15 m) Customer Testimonial compared to previous solution or competition Case Studies Other Solutions in Casting and Forging Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE Sample case study title lorem ipsum here Short description of the problem solved, maybe include the client name. READ MORE View All

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