Ultra compact Optris infrared camera was used to measure pouring temperature for Sand/Investment/Die/Billet (ingot) casting. It measured molten metal temperature efficiently and accurately, along with avoiding slag. It increased productivity, yield, product quality, and reduced the cost.
Measurement of Pouring Temperature for Sand |Investment |Die |Billet (Ingot) Casting
Pilger mill in tube rolling mills - hot and cold pipe detection
- Increase productivity: Ladle pre-heat temperature of 800C and furnace/ Tapping temperature of 1500C
- Traceability: Each melt temperature could be recorded with image and data logged in excel
- Increased yield: Increased mold life and lower rejected rate was obtained
- Improved product quality: with precise temperature control
- No recurring consumable cost: One time investment, with payback within months
Challenges
The pour stream temperature needed to be measured at the same avoiding the temperature of the slag
Solution
A short wavelength and ultra compact infrared camera Optris PI 05 M –was installed. With a continuous measurement range from 900 to 2450 °C and a spectral range of 500 to 540 nm it is especially designed for temperature measurement of molten metal.
The hot spot detector efficiently catches pour stream temperature and avoids slag.
It has a high dynamic CMOS detector with up to 764 x 480 pixels resolution. With up to 1 kHz frame rate it is ideal for fast processes. Furthermore 3 numbers of real-time analog output is available with 1 ms response time
Increase productivity was obtained: Laddle pre-heat temperature of 800C and furnace/ tapping temperature of 1500C
Pouring to mold was possible within acceptable temperature limits
Provided traceability: Each melt temperature could be recorded with image and data logged in excel
Increased yield: Increased mold life and lower rejected rate was obtained
Improved product quality: with precise temperature control
No recurring consumable cost: One time investment, with payback within months
In addition non contact measurement does not interrupt casting process
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
Other Solutions in Hot Rolling Mills
Sample case study title lorem ipsum here
Short description of the problem solved, maybe include the client name.
Sample case study title lorem ipsum here
Short description of the problem solved, maybe include the client name.
Sample case study title lorem ipsum here
Short description of the problem solved, maybe include the client name.
