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Pouring Stream Measurement
Monitoring the temperature of the pouring melt in foundries is a challenging task due to the varying measuring conditions and characteristics of the metal.
In most foundries, the temperature of the metal melt is usually measured by thermocouple immersion probes. These immersion measurements can only be made in the crucibles or the transfer ladles where the melt is stationary, but not in the pouring stream where insertion of a probe would disturb the flow into the cast.
The Challenge
In foundries non-contact temperature measurement techniques are increasingly replacing the use of conventional thermocouples. Specially designed pyrometers satisfy the specific requirements of the measurement of pouring streams.
In contrary to the measurement with thermocouples, the use of pyrometers allows non-contact temperature measurement of the pouring stream directly when the mold is being filled. It is possible to measure the exact cast temperature, which is crucial for the quality of the cast-product.
The surface of a pouring stream produces thin oxide films. This has to be taken into account for non-contact temperature measurements on pouring streams, because the emissivity of the oxide film varies significantly from the emissivity of the cast-material.
For this reason it is advisable to use multi-color-, respectively ratio-pyrometers. They detect the emitted infrared radiation in two different wavelengths and the measurement becomes mainly independent of the emissivity of the object.
With spectral band pyrometers, which only detect the infrared radiation in a single spectral range, valid measurement results will be achieved, if the slag- or oxide film on the liquid metal is torn open constantly.
Solutions for the following processes
Pouring stream measurement with fixed installation ratio pyrometer with special "pouring stream measuring mode"
Automatic measurement of the pouring stream: Calculation of the average temperature value of the cast. Temperatures at the beginning and the end of the cast are omitted. A line shaped field of view guarantees, that the pouring stream does not move out of scope. The system can easily be connected to existing data base systems.
- ISR 12-LO/GS
Pouring stream measurement with fixed installation ratio pyrometers
Continuous measurement of the pouring stream with average temperature value calculation.
- ISR 6 Advanced
- IGAR 6 Advanced
- ISR 12-LO
- ISQ 5
- ISQ 5-LO
Pouring stream measurement with spectral band portable pyrometer
Special foundry pyrometer for handheld non-contact temperature measurements of molten metals in the range between 1000 and 2000 °C.
Measurements in different productions steps possible, if the slag- or oxide film on the liquid metal is torn open.
Automatic measurement of the pouring stream and calculation of the average temperature value of the cast. An online connection to the PC is possible.
- IS 8-GS pro
With the InfraWin software (included in delivery or available as free download) the measured temperature data can be displayed and processed on a PC in realtime.
The TQCS (Temperature Quality Control System) software can be used in combination with digital or analog pyrometers for complete recording and documentation of temperatures for every single processed piece on up to 30 machines simultaneously.
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Key Products for this Application
Your Benefits
- Direct, accurate measurement of the pouring stream
- Automatic recording of the pouring temperature
- Comprehensive documentation of the temperature of each single pouring process and by large data storage
- Replacement or reduction of immersion lance measurements with thermocouples
- Minimum system maintenance required
- Increased safety with reduced employee interactions
- Special design for mobile deployment in foundries available
- Measurements can be taken at all production steps provided that the layer of slag on the liquid metal is torn open
- Compliance with quality specifications thanks to reproducible processes