Infrared Sensors for Metal Processing Industry

Temperature monitoring and control are crucial steps in metal processing and manufacturing to prevent defects in the final product. For this purpose, engineers install a remote measurement system to continuously monitor the process temperature in the blast furnace, rolling mills, die forming, and hardening process. Data monitoring is done in the central control room to ensure workplace safety and identify areas for process optimization. For example, defects can be controlled by monitoring and maintaining the process temperature during the hot rolling process.

Typically, metal production involves operating the processing machine at high temperatures. Therefore, using non-contact infrared sensors such as pyrometers or thermal imaging cameras is more suitable for continuous monitoring as they measure from a reasonably safe distance to the object. A thermal imaging camera can measure temperature distribution on hot metals with high accuracy and precision over a wide temperature range from 400oC to 2000oC.

Question to ask While Choosing the IR sensors 

Infrared pyrometers are not newly developed technologies. Infrared sensors have crowded the industrial test and measurement market, which adds to the confusion in selecting suitable products. Engineers must understand the purpose of conducting the measurement and the outcome they expect before they can proceed with choosing the sensors. Our engineers have compiled the checklists to consider when buying infrared sensors.

  1. What is the temperature measurement range needed for the application?
  2. What objects are to be measured? Is it shiny, reflective, etc.?
  3. Do you require single reading of temperature or are you looking for hot spots?
  4. Is it static or continuous measurement?
  5. What are the ambient operating temperature and conditions?

Measurement Solutions for Various Metal Processing Applications

Bestech Australia has provided expertise and solutions for industrial test and measurement applications for the local manufacturing and engineering industry in Oceania. We partner with the global sensor manufacturers to supply the local industry with high-precision measurement technology and offer full local technical support from system design to commissioning.

For measuring hot metals, the TIM M1 compact thermal imaging camera from Micro-Epsilon operates at a near-infrared wavelength of 0.85 to 1.1µm to offer reliable measurement. This thermal camera is programmed to operate at this wavelength band due to reduced measurement error. This phenomenon happens as the higher radiation intensity from the hot metal at high temperature is neglected and temperature differences due to metal oxides are minimized at this wavelength band. This thermal imager also offers a wide measurement range from 400oC to 1800oC. A jacketed cooling system can be optionally equipped to the camera for operation in high-temperature environments up to 315oC.

Moreover, this infrared camera offers a fast-sampling rate of 1kHz, enabling the detailed thermal analysis of rapid thermodynamic processes during metal processing and temperature adjustment in the real-time process. The system can be configured to output temperature values or alarm values via the process interface.

In the real-world application, the TIM M1 can be permanently installed for early detection of wear in the refractory lining of torpedo cars, slag cards, and ladles. It can be connected to PLC and programmed to send automated warning messages whenever hot spots are detected on the outer wall of the furnaces. This enables the engineers to perform preventive maintenance actions to minimize risk and prevent failures.

In addition, a thermal imager can also be used for continuous measurements, such as monitoring forming temperature in rolling mills or within the die-forming process. However, an infrared pyrometer with a short wavelength offers a cost-effective alternative if the users are only interested in obtaining the single-point temperature data.

The CTRatio M1 high-speed ratio pyrometer from Micro-Epsilon is a single-point pyrometer specifically designed to measure red-hot and glowing metal objects. It operates at a wavelength of 0.7 to 1.1 µm and offers a fast response time for in-line measurement in the production line. The measurement performed by this glass-fiber ratio pyrometer is not affected by interference such as smoke, fogs, or dust that may partially or fully conceal the moving objects. This makes it suitable for application in an industrial environment.

For example, the CTRatio high-speed pyrometer has been previously installed in the rolling mill to measure forming temperature between individual rolls continuously. This configuration allows the engineer to optimize process parameters and prevent temperature shifts to ensure high product quality. The sensor is also suitable for measuring temperature during the die-forming process as the blank’s temperature needs to be precise before it is getting hot formed. Additionally, it is also required to measure the temperature after forming and before being sent for storage.

In induction hardening processes, an optimum temperature-time profile is essential to produce metals with the desired microstructure. This high-speed pyrometer can be permanently installed for continuous monitoring. Optionally, the operators can use a handheld pyrometer used for sporadic measurement.

There are other different types of IR sensors available that are suitable for various applications fulfilling the measurement requirements. For more information, browse into the range of our infrared sensors or speak with one of our engineers

Click here to browse our range of Infrared Temperature Sensors  

 

 

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