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

Home  Case Studies Benefits of using a thermal imaging camera in a cast iron foundry

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

  • Continuous temperature monitoring
  • Optimum process control achieved resulting in reduced electricity wastage
  • Reduces safety hazard for operator
  • One time investment with no recurring costs

Challenges

Accurate temperature monitoring is critical to ensure high quality and efficiency of the casting process as the quality of casting is highly dependent on the temperature of the molten metal.

Low temperatures result in poor quality of casting whereas too high temperatures results in energy wastage and may cause damage to the ladle refractory.

Mostly commonly thermocouples are used to measure temperature by dipping it in the molten metal in the ladle.

Although thermocouples can be used to measure the final tapping temperatures after the liquid has been poured into moulds, they cannot measure temperature of the pouring stream.

By the dipping approach, the operator needs to manually take the measurement and requires him to be in close proximity.

Thermocouples only give temperature readings at specific time points (when dipped).

Furthermore, tips need to be continually replaced resulting in ongoing consumables cost.

 

Solution

Thermal imaging cameras provide a more accurate alternative to thermocouples by measuring the temperature of the liquid tapping stream as it is being poured into the mould to make the final product. The solution has the following benefits –

    • No alignment issue: Hot spot detector automatically differentiates between slag and hot metal
    • Increases productivity: Non-contact measurement does not interrupt tapping / casting process
    • Provide traceability: Each melt temperature is recorded with image
    • Improved product quality: with precise temperature control
    • No recurring consumable cost: One time investment, with payback in few months.

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