DIAS Infrared provides the universal multilingual software PYROSOFT Compact, Professional and Professional IO for all thermal imagers PYROVIEW and infrared line cameras PYROLINE. PYROSOFT Compact is supplied free of charge to all DIAS cameras.
With different software versions, you can record thermographic data and represent, analyze and control and evaluate and document.Selected features of our universal software solutions PYROSOFT Compact, Professional and Professional IO
In addition to these universal software versions, a comprehensive application-specific thermography software is available.
We realize complete customized system solutions based on our infrared cameras PYROVIEW, infrared line camera PYROLINE and pyrometers PYROSPOT.
The DIAS system solution for foundries, consists of pyrometers, display and evaluation unit and software can compensate differences by using an algorithm, in measurement results caused by a fluctuating iron stream.The advantages of the PYROCAST Pyrometer System made by DIAS
Using DIAS infrared cameras PYROVIEW and thermography software PYROSOFT the temperature of the steel is measured during the production and the position, size and number of hot workpieces can be identified and evaluated.
The DIAS PYROVIEW thermal imaging cameras can be used not only fornon-contact measurement of temperatures in metallurgy. The fields of application of IR cameras are much more varied. So also position, size and number of hot objects can be determined and evaluated on thermal images. For example, using our PYROVIEW thermal imaging cameras in the context of quality assurance industrial robots can be controlled sofaulty parts are sorted out.
The partial and short heating of metallic workpieces during induction hardening places high demands on the test instruments. Our robust DIAS pyrometers are suitable excellent manner with very short setting times and very small spot to do so.
The induction hardening is a heat treatment for surface hardening, mainly used for complicated shaped workpieces or for partially hardening of specific parts of an item. One of the most important parameters at induction hardening is the correct temperature of the item to guarantee the required quality of the product. This temperature is approximately 900 °C depending on the material.
In the most cases the item will be quenched with water after having reached the correct hardening temperature. Pyrometers enable a fast and very accurate measurement and a complete documentation of the surface temperature of each single part. The output of the pyrometer is used for the controlling of this very fast heating process. Pyrometers with very short response times and small spotsizes are used for these applications so that the correct measurement of the item can be done even between the windings of the induction coil.
The robust stationary pyrometers PYROSPOT DS 40N, DS 42N, DS 44Nor DS 10N are used here. Depending on the process and the measuring task often fibre optic pyrometers are used. As the optic head and the fibre optic cable do not contain any electronics these parts can be mounted very close to the induction coil without any interference of the strong electromagnetic field.
To monitor the development of the temperature of the forging blank, DIAS pyrometer for contactless temperature measurement during heating and pre-forming can be used.
Measurement of the forming temperature during forging of metals: steel, iron and alloys
When industrial forging metal components mainly for shipbuilding, automotive, aerospace, mechanical engineering and plant constructionare made, for example in so-called forging. Using the non-contact temperature measurement, the correct shaping temperature of steel, iron, and their alloys are checked when hot forging.
Because the temperature of the workpiece before forging is one of the most important parameters and thus decisive for the quality in the production of many safety-related components. The temperature is depending on the material and process between 950 °C and 1250 °C. The forged blanks are preheated to gas-fired or induction heated furnaces and therefore can not be measured directly with conventional thermocouples. For gas stoves only the internal temperature of the furnace is measured, but not the workpiece itself. In inductively heated furnaces also thermocouple measurement does not apply.Pyrometers replace conventional thermoelements for non-contact temperature measurement
That is the reason why it is essential to check the work pieces for thecorrect forging temperature directly at the exit of the furnace with pyrometers before it will be taken into the forging press. These pyrometers must have a very short response time, very small spot sizes, and a peak picker as the parts are always moving. Only the combination of these 3 properties enables a very exact measurement even if the work piece has scale on the surface.
To avoid that reinforcing steel becomes brittle in the production, a temperature band in steel production must not be exceeded or undershot. The DIAS Infrared Line Camera PYROLINE provides the ability to measure the temperatures of the steel contactlessly and represent the result as a thermal image with temperature profile.
For the production of reinforced concrete reinforcing bars made of steel are used to make the concrete resistant of occurrent drag and compressive forces. Scrap metal is being melted for the production of reinforcing bars and is casted in continuous casting to steel billets.
The steel billets are then rolled and stretched . In this form they are continued processing in other industries. In order that the reinforcing steel has the appropriate strength and does not get brittle it is important that a certain temperature band is not fell below or gets exceeded.Non-contact measurement of the temperature band with infrared line cameras
An infrared line camera PYROLINE 128M with a special spectral range from 3 µm to 5 µm is in a temperature range from 400 °C to 1200°C is used to detect this. The camera with a IP65 protected industry housingwas equipped with an additional air purge to keep the lense free of dustand dirt. A bridge over the band conveyor was chosen as a location for installation. So the access to the camera in a case of maintenance is guaranteed.
The data is sent via fibre optics to a computer in the control room to fulfill the hard electromagnetic requirements. The computer with thesoftware PYROSOFT Automation records continuously a thermographic picture of the passing steel billets. The picture is played on a screen in the control room and is available for the user immediately. In addition there is a data storage to make the pictures available for quality controlat a later date.
Because different sizes and amounts of collateral legs of reinforcing bars are produced, the software allows the switching of saved templates per touch-screen. In this way it is guaranteed that the right settings are used.
Too low or too high temperatures in the strand casting of steel can lead to significant quality problems and thus result in high costs. In order to monitor the homogeneity in the casting of steel, non-contact temperature measurement can be used in the production process for quality control.
High temperatures are mostly coupled to a high energy input. The quality of the final goods quite often depends on the temperature
The product quality as well as the energy demand can be deciding affected with the appropriate measurement devices. The measurement system amortizes very fast in many cases, so that a better quality is achieved with a less energy input.
Typical applications can be found for instance in the steel industry. A mostly rectangular strand profile is formed out of liquid steel with a mold. Afterwards, the strand profile has to be cooled down in several levels.
By means of the DIAS pyrometers PYROSPOT the temperatures within the float glass process can be measured on liquid glass as well as on solid glass (cooling down process). In this way the quality of the float glass can be monitored.Versatile possible application of digital pyrometers in the float glass industry
Float glass is produced in the so called float glass process. It is the base for insulation glass, window glass, safety glass, mirror glass or automobile glass. During the process the glass melt is leaded continuously from the melting furnace on to a liquid tin bath where the glass spreads out. By means of DIAS pyrometers PYROSPOT thetemperatures in the float glass process can be measured on liquid glassas well as on solid glass and so the quality of the glass can be monitored.
The image on the right side shows the production process of the float glass production:
(3) Tin bath
(5) Glass cutting zone
The DIAS PYROSPOT pyrometers of series 3x with fiber optic cable are specifically designed for the non-contact temperature measurement on glass. In contrast to thermocouples they are a well-priced and long-term stable alternative.Replacement of thermocouples by pyrometers in the production of container glass
Individual Section machines are used for the production of container glass. In different production processes in the feeder and the melting furnace glass drops are produced whose temperature has to be monitored in the line of process control and quality assurance. Digital pyrometers with fiber optic specifically for the non-contact temperature on glass can be used instead of the common thermocouples. Pyrometers have a lot of advantages regarding price and long-term stability.
Glass ampules are heated by a burner to a particular temperature that is crucial for the further processing of the glass. DIAs has developed special pyrometers for the temperature measurement through the flame of the burner.
Glass ampoules in medical technology and cosmetic industries serve mainly as containers for the respective products. They are also used as thermal release element in fire detection systems in sprinkler systems and other temperature-controlled release mechanisms. In the manufacturing of these glass ampoules a finished glass raw body is heated and then reshaped to the respetive form.Pyrometers measure through the flame on the surface of the glass ampoule
These usually full automated processes are proceeding in a horizontal rotating table with several gas burners. The ampoules are heated by the burner to a certain temperature that is crucial for the further processing.
An important part in the process control is to capture the temperatures exactly and quickly. Temperature measurement devices used for this purpose need to be quick, exact and especially unaffected when they are measuring the glass temperature through the gas burner. Theparticular DIAS pyrometer PYROSPOT DT 40F and DT 44F offer exactly these features. With measurement ranges between 300 °C and 2500 °C,mutable optical proportions and fast acquistion times from 10 ms, thepyrometers measure through the burner flame to the glass surface.High-End pyrometer DIAS PYROSPOT for very fast production processes in the manufacturing of glass ampoules
For extremely small ampoules or very fast production processes thehigh-end pyrometer PYROSPOT DPE 10 MF kann be used. This pyrometers measures in ranges between 50 °C and 2500 °C with a acquistion time of only 1.5 ms and can realize measuring fields smaller than 1 mm. The burner flame has no influence on the measurement.
Before glass panes can be bended the furnace has to have the correct temperature for the heating process. Elsewise quality problems can occur. The DIAS Infrared Line Camera PYROLINE can measure this temperature without contact precisely.
The infrared line camera PYROLINE camera made by DIAS can be used to monitor the glass temperature at the exit of a rotary furnace just prior to the bending press.Even heating of the glass before the bending is important for the quality
The rotary furnace has 10 arms each holding 2 sections of the mirror which will later be sandwiched together annealing. The objective of the measurement is to ensure that the glass on each of the 10 arms is uniformly heated as they exit the furnace just prior to bending in a press. Quality issues can occur if the glass blanks are non-uniformly heated prior to bending or if there are variations in glass temperature from arm to arm as they exit the furnace.An air purge unit prevents dirt, the water cooling keeps the operation temperature of the IR camera stable at the glass bending furnace
The glass rests on a flexible fabric mesh on a hoop at the end of each of the 10 rotating arms. At the exit of the furnace the glass is pressed into shape between 2 solid cloth surfaces, Boron Nitride powder is used as a lubricating agent during pressing. An air purge is used to keep the powder from settling on the lens. Water cooling is also employed to keep the camera at the proper operating temperature.
The PYROLINE camera is placed to view the glass as it exits the furnace, just prior to pressing. Below is an image of the furnace with one hoop exiting, moving into position to be pressed.
The PYROLINE camera is placed just out of view at the top of the image above. It is positioned to look down at the hoop and glass as it leaves the furnace. The line speed on the camera is set to 256 Hz, with the line oriented perpendicular to the direction of travel of the rotary arm.
The thermal image from the infrared line camera PYROLINE with a ROI (Region Of Interest) is shown below. A sequence trigger was used to acquire up to 256 lines per data record. The trigger temperature setting of > 985 °F, starts the acquisition of lines. This level setting was chosen to trigger on the edge of the hoop as it entered the field of view.
For the production of wafers, for example for the solar industry, crystals are needed that are pulled out of a melt in so called crystal growing factories.
The crystal growth from a melt is activated by the slow cooling of the melt that crystalizes thereby. It is important to measure the temperature of the melt in this process, but also the temperature of the heating elements that control the process Both has to be cordinated to guarantee an optimal crystal growth.
DIAS pyrometers of series 10,40 or 44 are used for the measurement of the melting temperature. The suitable devices of series 40 and 44 are the types PYROSPOT DS 40N and DS 44N that are short-wave spectral pyrometers in the measurement range between 800 °C and 2500 °C. Depending on the type of system, ratio pyrometersof type PYROSPOT DSR 10N can be used as well. Besides the devices of the series 44 and 10 provide the advantage of a bus-compatible interface for the simplified integration in existing control systems.
In order to be able to produce robust linoleum floor coverings it is important that all process parameters are correct.
In the first step of production dryers and resins are admixed intolinoleum cement that gets heated and filling materials and several pigments are added for coloring. This mixture has to be heated up to aspecified temperature range. Because this mixture moves on a broad band coveyor with increased speed a contact temperature measurement is not possible.
In the course of a modernisation of the machine old canning pyrometers have been replaced by new, up-to-date infrared line cameras of the typePYROLINE of the German manufacturer DIAS Infrared GmbH. This camera enables a fast, non-contact and high-precision temperature measurement in the necessary temperature range of 100 °C to 200 °C.
Average peaks of 4 zones, that are made out of the measured temperatures, are passed to the process control system so thetemperature control can be made. In this way the camera is an integral part of a closed loop system which is very important for the product quality.
After the temperature measurement raw materials are milled into plates and get coated with hot wax in order to make them robust against mechanical influence.
In the next step the coated plates are cooled with spray. Directly after the cooling an additional camera can be used for detecting the temperature and the temperature distributions on the product. In addition the plates are cutted or blanked into the size demanded by the end customer.
Very high damage of persons and objects can be caused by burning vehicles in regions of high security requirements like road tunnels..
Fires of vehicles are often caused by overheated parts (like tires) that can be detected by the PYROLINE FireCheck system before they catch fire. Vehicles with a risk of fire or already burning vehicles can be stopped early enough by such a system to prevent an entering of regions with high security requirements.
Two fast uncooled infrared line cameras PYROLINE per traffic line are scanning the running traffic to measure the temperature distribution of the vehicles.
The image processing software determines dangerous overheating of tires and cargo load, triggers alert if thresholds are exceeded and identifies the vehicle by a video image.
Traffic supervision and information systems can stop affected vehicles in good time for a manual inspection.
The challange: Reliable systems for surveillance and recognition of spontaneous fires inside bunkers or free air dumps of waste or combustible materials like paper, waste or charcoal are neccessary to detect and reduce undesirable fires. Since dumped materials are mostly inflammable the probability of spontaneous combustions is high with disastrous effects for man and environment.Applications:
Many insurance policies recommend the usage of a fire early warning system where easily flammable material is stored. Environments that are prone to fires can also be monitored and protected by our fire surveillance system. These are for example: