Furnace Thermal Camera
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Thermal Camera for Furnace Metal Temperature
Introducing the new Ultra Compact thermal Camera for Secondary Steel Processing
Short wavelength camera for temperature measurement of metal surfaces
The optris PI 1M is a thermal camera for furnace, optimized to measure metal temperatures at a 1 μm wavelength, where metals exhibit higher emissivity than in the usual 8-14 μm range. The camera features an advanced set of sensor electronics that deliver a rapid 1 ms reaction time, accurately displaying the center pixel’s temperature. This enables precise real-time monitoring and adjustments during thermal processes.
Thermal furnace camera systems are used to observe combustion and flame patterns to detect burner malfunctions. They also monitor process flow to verify accurate material positioning, alignment, and movement. These cameras evaluate melter material composition and formation patterns, determine melting points, and assess the condition of refractories. This device provides accurate readings that help in achieving superior production quality
Specifications :
- High dynamic CMOS detector with up to 764 x 480 pixels resolution
- Wide measurement ranges from 842 °F to 3272 °F without sub-ranges
- Up to 1 kHz frame rate for fast processes
- Real-time analog output with 1 ms response time
- Extensive software package and SDK included
- 1 kHz linescanning function possible
Applications of Furnace Thermal Camera
Melting Furnace
Real time IR based thermal imager provides highly accurate temperature profile in the melting furnace. Temperature measurement becomes a challenge due to presence of slag and harsh ambient conditions like high ambient temperature and smoke. Thermocouples have high consumable cost and measurement is dependent on human assessment resulting in chance of errors. Overheating causes high power consumption because of delayed measurement.
Short wavelength IR camera provides auto hot spot tracker continuously tracks hot metal even in presence of scale. With the option of different kinds of cooling jackets for harsh environments, the thermal camera for furnace continuously measures temperature which can be used to control the power of the furnace.
Precise temperature profiling in melting furnaces is instrumental in optimizing power consumption, cutting down operational costs, and boosting the overall efficiency of the melting process. With the provided precise temperature data, it aids in preventing overheating and ensures consistent quality of the molten material.
Open Die Forging
In Open Die Forging target alignment during moving process can be a challenge. Errors in measurement can occur due to scale presence on surface because of oxidation. Further there maybe obstacles due to moving hammer. Short measurement wavelength camera provides precise temperature measurement during deforming of metal piece between multiple dies. No alignment required as >3.5 lacs pixels working with auto hot spot tracker.Multiple ROIs and longer FOV provide accurate shape analysis and temperature measurement. Auto HOT SPOT tracker penetrates through scale. Longer FOV provide shape analysis and temperature. Water cooling jacket for ambient temperature upto 315°C. Analog/ USB 2.0 and Ethernet GgE/ PoE.
The precise temperature measurement and shape analysis improve product quality by ensuring uniform temperature throughout the workpiece, reducing the risk of cracks or uneven forging.
Induction Heating
During Induction Heating, high rejection rate may result as temperature is not accurate. Due to moving. Process defining measuring point becomes difficult. In the measurement process, scales temperature may also get recorded. Defects and product cracks can occur at the head end due to temperature variations.
Short wavelength thermal camera provides profile temperature during heat treatment process on induction heating. High Special spectral range applicable for heat treatment process. Multiple ROIs (areas) for full profile measurement. Auto HOT SPOT tracker for max process temperature. Water cooling jacket for ambient temperature upto 315°C.
Captured data analysis and reporting are enhanced by features such as software for emissivity correction and temperature data analysis.
FAQ on Furnace Thermal Imaging Camera
Yes, safety is irreplaceable while working with furnaces. Here are some precautions:
∙ Always follow the manufacturer’s instructions for safe operation of the thermal camera.
∙ Ensure the camera housing and any cables are rated for the high temperatures within the furnace.
∙ Wear appropriate personal protective equipment (PPE) when working near the furnace.
∙ Be aware of potential hazards like hot surfaces, flames, and electrical components.
Absolutely! By monitoring temperature trends over time, thermal cameras for furnaces can help identify potential issues before they cause any sort of collateral damage to the production units. For instance, gradual temperature increases in specific areas might indicate refractory wear or burner inefficiencies. Early detection allows for timely maintenance, preventing costly breakdowns and production delays.
While thermocouples are widely used for point temperature measurements, they have limitations. Thermal cameras offer several advantages:
∙ Non-contact measurement: Eliminates the risk of damaging thermocouples in harsh environments.
∙ Area monitoring: Provides a complete picture of temperature distribution within the furnace.
∙ Early detection of anomalies: Can identify subtle temperature variations that might go unnoticed with point measurements.
