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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
September 2, 2021
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
Temperature Monitoring during Container Glass Gob cutting
Infrared camera monitors temperature during container glass gob cutting. Production quality was improved and reject ratio was minimized. Earlier issue of cracks in container glass was resolved and it maintained consistent thickness throughout the container glass. Home Case Studies Temperature Monitoring during Container Glass Gob cutting Temperature Monitoring during Container Glass Gob cutting 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 Improved quality of production Lower reject ratio Challenges Temperature monitoring during container glass gob cutting phase is critical. The glass strand gets cut as it exits through the feeder. Temperature of the molten glass needs to be maintained around 1000⁰C to ensure the cutting is done appropriately without defects to the gob. The customer was facing a challenge with high reject ratio due to – • Cracks in the container glass• Thickness variation throughout the container glass Furthermore, temperature monitoring with pyrometers gave only single point temperatures Solution Infrared thermal imaging cameras with a short wavelength and spectral response of 1 µm was ideally suited for the multipoint temperature measurement of the gob. Feedback of temperature was used as a reference to increase or decrease the heat of the melting furnace. Products and Accessories Thermal Imaging 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 Solutions in other industries 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: Container glass, Glass, gob, Hot spot detection, Temperature
Easy visualization of the weak refractory hot spots
Thermal imaging camera was installed to monitor temperature of kiln shell and identify hot spots there. It enables real time temperature measurement. It delivers sharp images and videos, thereby increasing efficiency and safety. Modular system approach saves power. Home Case Studies Easy visualization of the weak refractory hot spots Easy visualization of the weak refractory hot spots 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 camera to be installed for capturing hidden area Challenges The refractory-lined lower part of the kiln reaches temperatures of up to 2,000 C making it prone to refractory damage. Localized hot spots of the kiln shell may occur, that can lead to extensive damage and warp the kiln. Solution In order to enable real time temperature measurement and identify hot spots in the kiln shell, a thermal imaging camera Pi640 from Optris was installed. 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 it is ideal to be installed where space is limitedThe wide optic lens enabled continuous scanning of the entire kiln from 60-100mtrs relaying a thermal map to plant operations System features include 4-20Ma output signal Data logging Alarm and alert Temperature range of -20 °C to 900 °C (optional up to 1 500 °C) Spectral range: 8 to 14 µm Frame rate: 32Hz 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 Cement 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: Cement, Hot spot detection, Kiln shell monitoring, Temperature
Measuring displacement of rollers on kiln
Inductive analog sensors from Proxitron offer an efficient solution for measuring displacement of rollers on kiln of cement plants. It accurately measures up to 100 °C ambient temperature. Manual operation is minimized with the help of RS485 or software program. Home Case Studies Measuring displacement of rollers on kiln Measuring displacement of rollers on kiln 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 Measuring range 0 -200 mm, 0-10V, 4-20mA output signal • Waterproof plug connection• Measuring accuracy up to 0.01 mm• Variations up to 100°C ambient temperature• Comfortable RS485 interface Challenges In modern cement plants, cement production is a continuous dry process, where the rotary kiln plays a key role. In the first step raw materials such as limestone, clay, sand, and iron ore are crushed in a cone mill and dried. This raw meal, or slurry, is then fed to a rotary kiln – an enormous rotating pipe – and heated at a temperature of 1.400–1.450°C to become clinker; in the cooling equipment the new compound is quickly cooled down to a temperature under 200°C. In the second step Gipsum or anhydrite are added to these grey-brown grains and ground in a ball mill to obtain cement as final product. Solution Inductive analogue sensors from Proxitron are mainly used at the drive of the rotary kiln or of the cone mill to check the rollers wear condition; to do this they continuously measure a defined distance: if this distance is not reached, rollers replacement or service is required. Inductive measuring sensors from Proxitron can be programmed via software to deliver an analogue output corresponding to a freely adjustable measuring range. According to sensor size, measurement range can go from 0 up to 200 mm max, and ambient temperature up to 100°C. Parameters can be set via RS485 interface and software, or directly at the device. Products and Accessories Large sensing distance proximity 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: Cement, Displacement, Kiln
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