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
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
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