Safety for all process steps in metallurgy thanks to DIAS Infared system solutions

The industrial heat treatment of metals is very manifold. High quality requirements meet the melting, casting, forging, hardening, preheating depending on the production and the materials such as aluminum, iron, cast iron, steel, lead, brass and nickel, platinum, copper or zinc. The accurate control of the temperature is a very important parameter for the material characteristics and so thus the fulfillment of the use claims of the produced goods. Who wants to keep up here in competition especially in the automotive supply chain, must invest in precise and reliable process control. The thermal imagers, pyrometers and complete system solutions from DIAS Infrared from Saxony are flexible helpers. Just as a chameleon changes its color in the appropriate environment, the measuring systems of DIAS to the manufacturing processes of the customers can be customized.

Multiple spectral ranges and therefore different measuring devices are necessary for non-contact temperature measurement of metals and their different temperature ranges. DIAS has specialized to manufacture according to the customer-specific challenges and thus the respective temperature ranges and process framework conditions, appropriate systems based on a variety of its own standard equipment.

DIAS will present several innovative system solutions at THERMPROCESS from June 16-20, 2015 in Dusseldorf. The fair takes place every four years, together with GIFA, METEC and NEWCAST and regularly attracts thousands of experts from iron, steel and nonferrous metals industry, mechanical engineering and other economic and research areas. For accurate process monitoring in metal industry, often very different temperatures between 75 °C and 3000 °C have to be measured. At high temperatures thermal imagers with a large measuring range, without the need to switching, meet this challenge. In addition to the standard range from 600 °C to 1500 °C, e.g. the PYROVIEW 512N of DIAS can be factory set to a continuous range from 1400 °C to 3000 °C. These high-end temperatures are reached for example in the blast furnaces of steel mills in the reduction of unwanted substances from the liquid melts.

For non-contact temperature measurement of the casting stream, DIAS offers the system solution PYROCAST, which is based on two digital ratio pyrometers. Combined with a display and evaluation unit, and also configurable software, this measuring system is specially designed for foundry use. The special optics used requires only a small filling of the measuring field and still accurately measures the temperature between 700 °C to 1800 °C. The system is controlled via the integrated web server. Even during the current process, it is possible to optimize settings via web browser, which shows the temperature curve and the table of values. The PYROCAST system is available in two variants.

During forging, the temperature between 950 °C and 1250 °C is decisive for the quality in the production of many safety-relevant components such as for the automotive industry. The temperature measurement of the forged blanks takes place directly at the furnace outlet. Because the parts are in motion, DIAS has developed a system solution with pyrometers, which realizes a very short response time, a maximum value memory and very small spot sizes. The solution based on the pyrometer DS 44N has an online digital RS-485 interface that enables networking of multiple devices in a bus system. Even with oxidized forged blanks very accurate measurements and thus sorting out to hot or cold parts are guaranteed. Furthermore, all to be forged parts are complete documented.

The long-established and manifold used compact pyrometers PYROSPOT series 44 of DIAS Infrared now also detects temperatures starting at 75 °C. Thus, they are the basis for system solutions in processes such as preheating, tempering, annealing and hardening in the metal and steel industry. The measurement with the PYROSPOT DGE 44N takes place at short wavelengths to minimize emissivity related errors even in harsh environmental conditions.

The four examples in Dusseldorf with the associated system components (e.g. special optics, purging units, protection tubes, housing, interfaces and software) exhibit high solution competence of DIAS developers and engineers which enables a very flexible and quality secure integration of non-contact temperature measurement in respective customer processes.

Technical details of the devices:

Hochtemperatur-Wärmebildkamera PYROVIEW 512N
• High dynamic Si-NIR array
• Resolution of 512 x 384 pixels
• Up to 60 images per second measurement frequency
• Measurement range: 600 °C to 1500 °C or 1400 °C to 3000 °C
• Spectral range: 0,8 µm to 1,2 µm
• Housing: aluminum compact housing or stainless steel industrial housing
Technical data thermal imaging camera PYROVIEW 512N | Overview of the DIAS infrared camera series PYROVIEW

Casting stream temperature measurement system PYROCAST and PYROCAST PRO
• Variant 1 (PYROCAST): Ratio pyrometer with fibre optic
• Variant 2 (PYROCAST PRO): Ratio pyrometer with Quotienten-Pyrometer with color video camera and a rectangular measuring field
• Temperature range from 700 °C to 1800 °C
• Optional: air purge unit, sighting tube and cooling jacket
• Connection box with 7-segment display
• Measurement results accessible via website

Ratio Pyrometer System for Foundries | Overview of the DIAS pyrometer series PYROSPOT

Pyrometers PYROSPOT DGE 44N for temperatures from 75 ° C
• Compact IP 65 stainless steel housing
• Integrated laser aiming light for accurate alignment
• Different optics with distance ratios from up to 200:1
• Spot sizes from up to 1,5 mm.
• Response time of only 5 ms
• Standard analog interface 0/4 to 20 mA
• Bus-capable RS-485 interface with Modbus RTU protocol
• Real-time data recording by the pc software PYROSOFT Spot
Technical data pyrometer PYROSPOT DGE 44N | Overview of the DIAS pyrometer series PYROSPOT

DIAS Infrared GmbH is exhibitor at the THERMPROCESS from June 16.20, 2015
Messe Düsseldorf
Am Staad, 40474 Düsseldorf
Hall 10, booth D78, opened daily from 10:00 a.m. to 6 p.m.

Picture credit: Jordache, Shutterstock.de