PYROCAST – Temperature measurement in foundries

PYROCAST – The made-to-measure measurement system for your foundry

DIAS Infrared offers a system solution for the use in foundries. A special algorithmcounteracts the differences of the measurement results that occur because of a fluctuating casting stream.

PYROCAST – The DIAS pyrometer system solution specifically for the non-contact temperature measurement on the casting stream with fiber optic cable
PYROCAST – The DIAS pyrometer system solution specifically for the non-contact temperature measurement on the casting stream with fiber optic cable. Image source: Shutterstock.de/Jordache, DIAS Infrared GmbH
PYROCAST PRO – The ratio pyrometer is equipped with an integrated color video camera and has a rectangular measurement spot.
PYROCAST PRO – The ratio pyrometer is equipped with an integrated color video camera and has a rectangular measurement spot.
PYROCAST PRO – Detailed view of the video image with rectangular measurement spot for the precise temperature measurement of the casting stream.
PYROCAST PRO – Detailed view of the video image with rectangular measurement spot for the precise temperature measurement of the casting stream.

The casting stream measurement system is based on digital ratio pyrometers of the PYROSPOT series, combined with a display and evaluation unit and parameterizable software. It is specifically designed for industrial purpose in foundries for temperature measurements of the casting stream.

Depending on application conditions you can chose between an infrared pyrometer with fiber optic cable and special optics (PYROCAST) and an infrared thermometer with integrated color video camera and a special rectangular measurement field (PYROCAST PRO).

The temperature linear output signal of 0/4 to 20 mA is available. The measurement temperature can be viewed on a large LED display. The special optics guarantees an exact temperature measurement even when the measurement field is not filled completely or when the casting stream is moving.

The advantages of the PYROCAST Pyrometer System made by DIAS

  • A reliable temperature measurement even at very low or fluctuating emissivity
  • The special optics compensate the movement of the casting stream and need only a little filling of the measurement field
  • To avoid dust effects the optics can be protected with an air purge unit and a sighting tube
  • The precise aiming of the pyrometer to the measurement object is made with the integrated laser aiming light or a video image in real-time

Easy access via Software at any time


The system is controlled via the integrated web server. Even in a running process it is possible to optimize settings in the web browser that contains the temperature profile and the value table. The web server allows the adjustment of different parameters to the respective casting process. Besides the detection of a relevant average value via whom signal variations (e.g. at the sprue) can be faded out, the beginning and the end of a casting process can be detected automatically.

The web server allows the adjustment of different parameters of the ratio pyrometer to the respective casting process.
The web server allows the adjustment of different parameters of the ratio pyrometer to the respective casting process.

The special software allows the adjustment of different parameters to the respective casting process. For every casting process a relevant average value over the temperature is output and occuring troubles, for example at the sprue, are faded out. The controller is programmed via Ethernet interface and it can be integrated into the remote maintenance. It is possible to access to the device in a running process to optimize settings and to solve a problem. The software is multilingual. You can switch between English, German and Spanish. Further languages are available on request.

As a specialist for customized system solutions in the field of temperature measurement technology DIAS Infrared realizes complex projects including project plannung, software, installation and maintenance.

Overview: All components of the casting stream measurement system, technical data

Components of the casting stream system

Overview: All components of the casting stream measurement system “PYROCAST” and “PYROCAST PRO”
Version 1 (PYROCAST):
Ratio pyrometer with fiber optics cable
– Digital ratio pyrometer
– Temperature measurement range: 700 °C to 1800 °C
– With special optic
– Fiber optic cable made of stainless steel in different lengths
– Optional: with air purge unit and sighting tube
Version 2 (PYROCAST PRO):
Ratio pyrometer with color video camera
– Digital ratio pyrometer
– Temperature measurement range: 700 °C to 1800 °C
– With rectangular measurement spot and video camera
– Optional: air purge unit and cooling jacket
Junction box with LED display

Junction box with large LED display
Junction box with large LED display
– Dimensions junction box: 380 mm x 300 mm (W x H)
– Weight junction box: approx. 9 kg
– Display: 4 numerics, temperature unit/3.5″ video image
– Dimensions digit field: approx. 135 mm x 38 mm (W x H)
– Ethernet interface
– Power supply: 230 V AC
– Operating temperature: 0 °C to 55 °C
Software– Special evaluation and parameterization software
– Available via website
– Multilingual: German, English, Spanisch (further on request)

Technical data ratio pyrometer

Technical data of DIAS ratio pyrometer
TypePYROCASTPYROCAST PRO
Temperature range700 °C to 1800 °C
Sub temperature rangeAdjustable via RS-485 interface within temperature range, minimum span 50 °C
Spectral range0.7 µm to 1.1 µm
OpticsSpecial opticsOptics with rectangular measurement field, measurement distance 2 m
Measurement uncertainty0.5 % of measured value
Reproducibility0.2 % of measured value0.1 % of measured value
NETD0.1 K
Response time t955 ms, adjustable up to 100 s, adjustable via RS-485 interface
Emissivity ε0.050 of 1.000, adjustable via RS-485 interface
Ratio correction K0.800 of 1.200
Output0/4 to 20 mA, switchable, temperature linear, max. burden: 700 Ω at 24 V0/4 to 20 mA, switchable, temperature linear, max. burden: 500 Ω at 24 V
Pyrometer interfaceRS-485 (galvanically isolated), half duplex, max. baud rate 115 kB, Modbus RTU
AimingLaser aiming lightColor video camera,FBAS-Signal PAL (B), 50 Hz (galvanically isolated), optional NTSC (M) 60 Hz
SoftwarePYROSOFT Spot for Windows ® , software for parameterization of the casting stream parameters
ParametersRatio correction K, emissivity ε, response time, data storage, sub temperature range, baud rate, address, measurement mode 1- or 2-channel
Power supply24 V DC ± 25 %24 V DC ± 25 %, residual ripple 500 mV
Power consumptionmax. 1.5 W
Operating temperature0 °C to 70 °C (pyrometer),
0 °C to 250 °C (fiber optic cable and optical head)
0 °C to 70 °C
Storage temperature–20 °C to 70 °C
Weightapprox. 450 g (without fiber optic cable and optics)approx. 600 g
DimensionsThread M40 x 1.5, length 125 mmLength approx. 105 mm, diameter 50 mm
HousingStainless steel housing with plug connectorRound stainless steel housing with plug connector
Protection classIP65 (according to DIN EN 40050)
CE symbolaccording to EU regulations

PDF

A detailed overview of the composition of the casting stream system as well as technical data can be found in our broschure Broschure “Non-contact temperature measurement of the casting stream”