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Roll Change Detection: High temperature proximity for wet areas with heat radiation proximity fo
Short circuit protected proximity switch for 10 – 55 V DC with 3-wire technology was used for the accurate detection of roll change in very harsh operating conditions. The high temperature electronics can withstand ambient temperature of up to 100⁰C Home Case Studies Roll change detection on work roll backup roll in mill stand Roll Change Detection: High temperature proximity for wet areas with heat radiation proximity 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 Best solution for roll change proximity under most aggressive environment Reduction in roll change time to maximize production/ equipment availability High ambient temperature electronics (1000C and 1200C) Cable protection system from flying scales, sparks PBT housing material prevent corrosion of the housing easy to replace during shutdown Challenges Delays/interruptions in roll change as the feedback from proximity was not reliable Detection in harsh operating environment continuous water from spray headers; high ambient heat from the strips. Cable damage due to flying chips / scale PVC cable crackling from temp. cycling Solution Improvised field proven proximity used by SMS-Siemag | Primetals by high temperature electronics PBT housing designed to reduce impact of temperature cycling Silicone cable withstand 1800C Reduce damage from mechanical play by higher sensing 15|20|25mm Integrated cable protection Higher IP rating Inductive Proximity Switch Cable Protection 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 – Finishing 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
Tags: backup roll, HRM Flat, Proximity, Roll Change, Work roll
September 3, 2021
Online condition based monitoring of Tundish
IR camera continuously monitors the ROI of tundish, generating an alarm if temperature exceeded 300⁰ thereby improving ladle lifetime with early detection and selective repairs. Home Case Studies Online condition based monitoring of Tundish Online condition based monitoring of Tundish 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: Prevented breakouts and reduced risk of damage to personnel & plant equipment Predictive 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 Cracking as a result of the puncture in the refractory which was causing machine downtime, interrupting operations and creating safety hazards. Solution Compact spot finder IR camera was installed. The Hot spot detector scanned the entire tundish Each ROI (region of interest) temperature was continuously monitored If zone temperature exceeds above 300⁰C, an alarm was generated Easy identification of the spot with maximum refractory erosion was made possible 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
Tags: Steel Making, Temperature, Tundish
September 2, 2021
Temperature Measurement of Caster for Billet | Bloom | Slab
Thermal imaging camera provides accurate temperature profile of the slab eliminating the need of multiple point temperature measurement from a single sensor. Home Case Studies Temperature Measurement of Caster for Billet Bloom Slab Temperature Measurement of Caster for Billet | Bloom | Slab 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 Consistent metallurgical properties: Scales, water do not impact measurement Energy Saving: Optimized heating pattern can be controlled Homogenize temperature: At discharge uniform temperature distribution across length, breadth and thickness Accurate: Scales have no impact on temperature readings Challenges The customer needed the profile measurement for the slab to ensure uniform heating from edge to edge. It was difficult to install and maintain one single sensor for each billet / bloom. Solution Thermal imaging camera allows simultaneous measurement of multiple objects in different locations Measured temperature profile over the entire metal object Could be easily integrated into 24/7 control and monitoring systems System features included 450-1800°C 768*428 pixels 1µm wavelength 1Khz capture rate 3|4|8 nos of Analog 4-20mA Excel data logging (optional) 3nos of Analog 4-20mA Excel data logging 315C of ambient temperature Process visualization: Accurately gauge metallurgical cooling requirements Low maintenance cost: Multiple point temperature measurement from single sensor Highly durable: IR Camera installed 10m away from heat zone Products and Accessories For Secondary Steel Processing Cooling Jacket High Temperature Cables 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
Tags: Billet, Bloom, Caster, Slab, Steel Making, Temperature
Condition Based Monitoring of Kiln Shell
Home Case Studies Condition Based Monitoring of Kiln Shell Condition Based Monitoring of Kiln Shell Thermal imaging camera provides real time temperature measurement and identifies hot spots in the kiln shell. Wide optic lens enabled continuous scanning of the entire kiln from 60-100mtrs relaying a thermal map to plant operations. Improved safety level: Automatic hot spot detection could be done hence avoiding costly damage and subsequent downtime. Reduced power: 3nos of analog/ digital output were available to activate the cooling fans. Shadow monitoring of Slip rings: Modular system approach that enabled additional thermal cameras to be installed for capturing hidden areas. 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: Scanning of the entire kiln from 60-100mtrs was now feasible. Improved safety level: Automatic hot spot detection could be done hence avoiding costly damage and subsequent downtime. Save power: 3nos of analog/ digital output were available to activate the cooling fans. Shadow monitoring of Slip rings: Modular system approach that enabled additional thermal cameras to be installed for capturing hidden areas. Challenges The refractory-lined lower part of the kiln reaches temperatures of up to 2,000 ⁰C making it prone to refractory damage. Localized hot spots of the kiln shell may occur, that can lead to extensive damage to the kiln and unexpected breakdowns Solution In order to enable real time temperature measurement and identify hot spots in the kiln shell, a thermal imaging camera was used.With a very small measuring VGA and an optical resolution of 640×480 pixels, the PI 640 delivers pin-sharp radiometric pictures and videos in real time.It has a compact design, with a body sized 45x56x90 mm and weight of 269 – 340 g making it ideal to be installed where space is limited.The wide optic lens enabled continuous scanning of the entire kiln from 60-100mtrs relaying a thermal map to plant operations. 4-20Ma output signal Data logging Alarm and alert Temperature range of 50 °C to 600 °C Additional cameras were used for shadow monitoring Products and Accessories Thermal Imaging Cooling Jacket Laminar Air Purge Protective Housing High Temperature Cables 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
Tags: Kiln, Pellet, Temperature, Thermal Imaging
Temperature monitoring to ensure uniform heating of sinter bed
Home Case Studies Temperature monitoring to ensure uniform heating of sinter bed Temperature monitoring to ensure uniform heating of sinter bed A non-contact thermal imaging camera was used to monitor the temperature profile of the sinter cake and ensure uniform heating. Hot spots could be detected in time and avoid damage to conveyor and subsequent downtime was avoided. 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: Precise control of burner section to ensure uniform heating Improved safety level: Hot spot detection to avoid damage to conveyor and subsequent downtime Process visualization: Monitoring sinter caking on a PC Challenges The sintered material of desired chemical composition and grain size is charged into the Blast furnace. Iron ore fines, limestone, waste, scale and slag particles and dolomites are mixed together. As the mixture is baked and the sinter cake moves on the conveyor, it becomes critical to ensure that the sinter is homogenous through the cake. Proper sintering removes unwanted Sulphur and makes down-stream processes efficient in the blast furnace. Solution In order to ensure uniform heating and to monitor the temperature profile of the sinter cake, a non-contact thermal imaging camera was used. The robust and compact design made it ideal for this application. System features included Temperature Range: 150⁰C – 1500⁰C Wide optic lens. 4-20mA output signal Data logging feature Alarm and alert function Rugged outdoor housing: for installing the camera for high ambient temperature environment 80 Hz frame rate for the monitoring of fast thermal processes Optical resolution of 382 x 288 pixels Products and Accessories Thermal Imaging Cooling Jacket Laminar Air Purge USB to Ethernet High Temperature Cables 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 Iron Making 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
Tags: Iron Making, Sinter, Temperature, Thermal Imaging, uniform heating, Xi400
Pilger mill in tube rolling mills hot and cold pipe detection
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
Monitoring of a strip roller path
Hot metal detector from Proxitron was installed to detect objects precisely and safely, even if tube diameters were changing. It accurately monitored strip roller path. It offered high repeatability and reliability, while having adjustable measuring rate. Home Case Studies Monitoring of a strip roller path Monitoring of a strip roller path 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 Hot metal detector from Proxitron was installed to detect objects precisely and safely, even if tube diameters were changing. It accurately monitored strip roller path. It offered high repeatability and reliability, while having adjustable measuring rate. Challenges Accuracy of tube length measurement depends upon the ability to detect the beginning and ending of tubes. A tube rolling mill required length measurement directly at the conveyor track. Simple commissioning, high repeatability and a integrated error monitoring system were needed. Furthermore, tubes of different sizes were in production Solution Different tube diameters lead in a V-conveyor to a very divergent height position of the pipe. Therefore the tube beginning and end couldn’t be detected with a light barrier. However, HMD from Proxitron detects objects in a field within the barrier height. This ensures the safe detection of the tubes, even if the tube diameters are changing. If a tube is detected by the light grid, the counter in the system control is set to zero. By means of an incremental rotary transmitter which runs with the tube, exact length measuring up to +/- 1mm is possible. The HMD works as a light barrier with 10 single lines in the grid of 8 mm. The invisible infrared radiation between transmitter and receiver scans a height of 75 mm on entering material. A contamination output at the light grid ensures a reliable production even under extremely dusty or dirty conditions. The intermittent short circuit protection protects both outputs in case of overload. Proxitron HMDs are available with a barrier width from up to 1400 mm. Products and Accessories Light Barriers 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
Tags: presence detection, strip roller path, Tubes and pipes
Quality Assurance in Induction Welding in Tube Mill using fast response IR camera / pyrometer
Infrared camera or ratio pyrometer are ideally suited for quality assurance in induction welding in tube mill. It offers fast response and ensures optimal seam during the welding process. Being tolerant to dirty environment, it can withstand high temperature and is ideal for hard to access areas. Home Case Studies Quality Assurance in Induction Welding in Tube Mill using fast response IR camera / pyrometer Quality Assurance in Induction Welding in Tube Mill using fast response IR camera / 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 c Challenges Ensuring optimal seam during the welding process Solution Temperature Monitoring using Ratio Pyrometer Ratio Pyrometer with temperature Range: 500⁰-1800⁰C Tolerant to dirty environment: 5% FOV coverage is sufficient Withstands high ambient temperature: 250⁰C for optic head /Fibre Optic Separate electronics: Electronic module is sperate. Ideal for hard to access area: Small sensor head dimensions Temperature Monitoring using thermal imaging Products and Accessories Next Generation Pyrometer: Dirt & Steam Resistant, for high ambient environment Thermal Camera 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 Tubes and Pipes Industry 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
Tags: Induction welding, Quality Assurance, Temperature, Tubes and pipes
September 1, 2021
Wind positioning with relay outputs on ship loader / unloader
Process indicators along with two relay outputs , and an anemometer are installed to measure position of wind. They have precise control, giving optimum productivity and maintaining safety. Monitors speed safely in accordance with SIL3/PLe. Home Case Studies Wind positioning with relay outputs on ship loader / unloader Wind positioning with relay outputs on ship loader / unloader 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 Speed monitors enable safe monitoring in accordance with SIL3/PLe. These safety relays have 2 synchronous relays and 4×2 control outputs. The speed monitors can work with both digital and SinCos signal Challenges Precise control for machines running at optimum productivity. Strike a balance between productivity and safety. Solution Process indicators equipped with two relay outputs can be used with an anemometer as a wind warning device. Multiple solutions for wind monitoring are possible. Simple monitoring of the wind speed Basic wind speed monitoring can be achieved by connecting a process Indicator with two 16 bit Analog Inputs to an anemometer with an analog output. Alternatively a digital indicator is required to work with an anemometer with frequency output. Safe operation of the wind speed Better operating safety can be achieved by the parallel operation of two analog or two digital indicators. If a cable break occurs, the second signal path remains intact and continues to reliably monitor the wind speed. Maximum security of monitoring wind speed. even greater security of the monitoring is possible by connecting a digital and analog anemometer + process indicator.With an analog anemometer connected to a digital indicator and a digital anemometer connected to a digital indicator, a wide range of measurement approaches are possible resulting in limited error margins. Products and Accessories Anemometer 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
Tags: Anemometer, Ports and cranes, ship loader unloader, Wind positioning
Temperature Monitoring during Tablet Coating process
Non contact infra red pyrometer, with cable and sensor head is used for temperature monitoring during the process of tablet coating. It solves the serious problem of overheating, blistering and cratering. The rugged optics allows it to operate it at very high ambient temperature without cooling, with accurate temperature control. Reliable coats and minimum injections are produced as the output. Home Case Studies Temperature Monitoring during Tablet Coating process Temperature Monitoring during Tablet Coating 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 Continuous temperature measurement during the table and capsules coating process resulted in reliable coats and minimum rejections. Sensor output was used as a feedback signal to the air supply for air and temperature control Improved operational efficiency with reduced risks of defects during the tablet coating process Highly accurate and precise temperature control during the coating process Increases process efficiency and consequent production quality, yield and speed Challenges Overheating during the tablet coating process can cause various challenges such as blistering, cratering, pitting, blushing, sticking and picking. High temperature can cause gases to be trapped under the film during the spraying process or at the end of the coating run. Other defects such as cratering may appear exposing the surface of the tablet. High coating temperatures can also cause white specks or haziness to appear on the film. Sometimes pits may occur in the tablet core without a noticeable defect on the on the coating. Tablets may stick to each other and to pan walls. Solution Compact series, contactless IR pyrometer with electronics inside the cable and M12 construct sensor head is ideally suited for this application. The sensor has an object temperature detection range of -50⁰C to 1030⁰ C and offers a fast response of 150ms. With a rugged coated silicon optics it can operate at high ambient temperature of 180⁰C without cooling. It also offers a LED alarm indication, analog (0-5/10V , 4020 mA) with simultaneous alarm outputs Easy programming via smartphone or windows software 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 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
Tags: Pharma, Tablet coating, Temperature
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