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Background

Infrared thermal imaging can monitor the temperature field and solidification state of the mold and melt during roller centrifugal casting, warn of casting defects and equipment thermal damage, and optimize process parameters to improve casting quality and production stability.

Solution Description

HIRDA-R Roller Centrifugal Casting Thermal Imager Camera Detection System is a high-tech system specially used to detect the temperature changes during centrifugal roll casting and conduct intelligent analysis. The system consists of a high-temperature thermographic camera control cabinet, an algorithm server, and client management software. It centrally monitors and manages the equipment on the job site, and realizes functions such as temperature data collection, analysis, high temperature point positioning, and automatic alarm for the rolls through a digital transmission network. After actual use, this system has successfully increased the qualified rate of rolls produced by a certain roll factory from 70% to 93%.

System Features
IR thermal camera has all-weather passive thermal imaging function;
Real-time measurement of the temperature of the high-speed rotating rollers during the casting process of the roller centrifuge;
The temperature data detected by the system is associated with the roller centrifuge stop system, and the centrifuge stop time can be controlled according to the temperature;
Adopts self-developed temperature measurement and correction algorithm to achieve accurate temperature measurement;
Strong environmental adaptability, can be used in harsh environments such as high temperature and high dust;
High protection level, up to IP66;
Adopts high frame rate design, the highest frame rate can reach 125Hz, and can observe fast-moving targets;
Temperature data can be connected to LED screens and PLCs;
Temperature measurement accuracy is better than ±1%;
Open interface, SDK development kit is provided, and it can be connected to DCS, PLC and other systems.

Benefits brought

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  Monitor the temperature uniformity of the casting mold to improve the molding quality of the casting, dynamically monitor the circumferential and axial temperature distribution of the roller casting mold, and avoid casting wall thickness deviation, cold shut or shrinkage defects caused by uneven heating.

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  Monitor the solidification process of molten metal, optimize the centrifugal casting process, track the solidification path of molten metal under centrifugal force through thermal imaging, analyze the influence of radial temperature gradient on grain growth, assist in adjusting parameters such as rotation speed (200~3000rpm) and cooling water volume, and reduce shrinkage and porosity.

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  Warning of abnormalities in key equipment components to ensure production continuity, scan the temperature of high-speed running parts such as drum spindle bearings and gear boxes, and promptly discover abnormal temperature rise caused by insufficient lubrication and assembly deviations to prevent equipment from getting stuck or fatigued and to extend maintenance cycles.