Documente Academic
Documente Profesional
Documente Cultură
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September 4
2005
Infrared
Brought to you by – Ritesh Bhusari
application in
Mechanical
Industry
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ABSTRACT:
This exciting seminar is designed for anyone interested in making the most
of a predictive maintenance program. The peculiarities of infrared photography lie in the
ability of the film to record what the eye cannot see (permitting, for instance,
photography in the dark); in the fact that many materials reflect and transmit infrared
radiation in a different manner than visible radiation (light); in the ability of infrared
radiation to penetrate certain kinds of haze in the air so that photographs can be taken of
distant objects that cannot be seen or photographed on normal films; and in the ability to
photograph hot objects by the long-wavelength radiation that they emit. This can be
useful in a various applications such as monitoring the condition of electrical machinery
and checking the efficiency of the building insulation.
A typical system will display an image in different colours, each colour band
has its specific meaning, which indicates different temperatures. In this article I would
like to present an overview of infrared imaging and thermography.There is no other
technology that can compare to the versatility of infrared Thermography with its
immediate playback. Whether you are in management or in a technical position, this
seminar will help you understand the immense role Infrared Thermography can play
important role in your Maintenance program. Reduce downtime, increasing profits,
predict failure before they occur. A properly designed and implemented infrared program
can increase employee safety as well as equipment reliability.
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INTRODUCTION:-
WHAT IS INFRARED?
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X-rays and ultraviolet are examples of short wavelength radiation. Longer wavelength
radiation is of lower energy and is usually less harmful - examples include radio,
Microwaves and infrared. A rainbow shows the optical (visible) part of the
Electromagnetic Spectrum and infrared (if you could see it) would be located just beyond
the red side of the rainbow.
Although infrared radiation is not visible, humans can sense it - as heat. Put
your hand next to a hot oven if you want to experience infrared radiation "first-hand!
THE ATMOSPHERE — A FILTER:
Just as sunlight is scattered by smoke, the atmosphere reduces Infrared energy
by absorption and scattering. However, there are several "windows" in the spectrum
where this effect is minimized. Selection of detectors that operate in these windows in the
NEAR INFRARED (NIR), MIDDLE INFRARED (MIR), and FAR INFRARED (FIR)
permit practical operation.
HOW HOT IS IT ?
It is helpful to understand the relationship between wavelength and object
temperature. Photographers refer to lighting effects on film by "effective color
temperature." Objects heated to temperatures which radiate at short wavelengths will
become visible; for example a light bulb filament. As objects become cooler, the
wavelength becomes longer and the object visible darkens. Objects at normal
temperatures radiate in the FIR portion of the spectrum. A hot soldering iron, although
not visible, would be considered NIR. A hot coal on a fire would have its peak radiation
level in the MIR portion of the spectrum. Thus, selection of systems is related to the kind
of detection required.
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Every object whose surface temperature is above absolute zero (-273 °C)
radiates energy at a wavelength corresponding to its surface temperature. Utilizing our
highly sensitive infrared cameras, it is possible to convert this radiated energy into a
thermal image of the object being surveyed.
All of our thermal images feature extremely accurate embedded temperature
measurement systems for fast, precise quantitative documentation of the object's thermal
characteristics.
violet RED
Sensor Technology :
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Types of sensors :
It can be measured by a thermocouple with the hot junction on the platelet and
the reference junction on the substrate the thermoelectric sensor. Or it can be measured
by an electrical capacitance effect the pyroelectric sensor. The microbolometer and
thermoelectric sensors were developed by Honeywell and are effectively used in Infrared
cameras.
A) Microbolometer sensors :
Individual sensor elements use the change in electrical resistance of a vanadium
oxides (Vox) resistor deposited onto the tiny “platelets” fabricated by silicon micro-
machining in a silicon foundry. Incoming target radiation heats the VOx causing a change
in electrical resistance, which is readout by measuring the resulting change in current.
80,000 and more sensors can be fabricated together into a two-dimensional array.
The structure can be dimensioned to operate at 30 Hertz. That is, the thermal conductance
of the isolating legs can be adjusted to match the time-constant for 30-hertz operation. An
example of a microbolometer element is pictured below. It consists of a two-layer
structure. An interconnecting readout circuitry is applied to the silicon process wafer and
then the microbolometer structure is built on top of the readout circuitry. First a pattern of
islands wavelength thick are deposited on the readout circuitry.
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The islands are made of a material that can be selectively etched away later to form a
bridge structure. Three layers silicon nitride, vanadium oxide, and silicon nitride are
deposited over the sacrificial islands. The sacrificial islands are then etched away leaving
the thermally isolated bridge structure of vanadium oxide. A photo of an early Honeywell
microbolometer element is shown in the picture below followed by a photo of one corner
of a 320 by 240 microbolometer array.
Most of today’s camera manufacturers use the 320 by 240 microbolometer array.
However there is an excellent alternative for many commercial applications the 160 by
120 array. The smaller array and its resulting camera can be produced at a much lower
cost. Far more arrays can be produced on a single wafer and the yield is higher for the
smaller array. In addition, one of the most expensive components of an infrared camera is
the lens and its cost is proportional to the array size.
The only advantage of the larger array is field of view (FOV). With the same
focal length lens and the same detector size, a camera with 320 by 240 or 160 by 120 will
have identical spatial resolution. But the target size for a fixed distance between the
camera and target will be twice as large in both dimensions for the camera with the larger
array. For many commercial applications the cost savings of the smaller array size over
shadows the advantage of a larger FOV.
B) Thermoelectric sensors :
Individual sensor elements use thermocouples to measure temperature
change of the tiny platelet. The platelet, typically 50-micron square by 0.5-micron thick,
is fabricated by silicon micro machining in a silicon foundry similar to, but easier than,
the microbolometer.
Up to five series-connected thermocouples are deposited on each platelet.
They produce a small voltage caused by the target radiation heating the platelet. 120
sensing elements are fabricated together into a linear array. We have exclusively used this
Honeywell array for the IR Snapshot camera.
Moving the sensor array in the focal plane of the camera lens produces a two-
dimensional image. The resulting thermal image consists of 14,400 pixels (120 by 120).
A cross section diagram of a thermoelectric sensor is pictured below.
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Disadvantages :
2) Expensive.
3) Less expensive digital cameras uses cryo-coolers for cooling which are expensive.
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Industrial Application :
1 } Building Envelope
The primary diagnostic procedure for determining the thermal performance of
a building envelope is infrared thermography. It can be used to identify heating and
cooling loss due to poor construction, missing or inadequate insulation and moisture
intrusion. Correcting the defects plays a significant role in increasing building efficiency
and structural integrity.
Conductive Losses
Problems identified as conductive losses are: missing insulation, improperly
installed or compressed insulation, shrinkage or settling of various insulating materials;
excessive thermal bridging in joints between walls and the top and bottom plates.
Air Leakage
Air leakage is the passage of air through a building envelope, wall, window,
joint, etc. Leakage to the interior is referred to as infiltration and leakage to the exterior is
referred to as exfiltration.
2 } Food Industries
The food industry must maintain tight control of food temperatures during
the transportation of perishable food materials, during preparation and processing, and all
the way through storage in wholesale and retail environments.
3} Manufacturing
Infrared cameras and accessories meet and exceed the most stringent
monitoring and inspection requirements in the demanding manufacturing environment.
IR thermography has been used for decades by predictive/preventive maintenance
professionals and process and quality assurance engineers to solve the tough problems as
well as day-to-day maintenance challenges.
4 } R&D/Testing
As the global leader in infrared cameras, the most advanced infrared
temperature measurement systems for applications that demand superior thermal
uniformity and/or controlled heat dissipation: micro-electronics, paper processing,
automotive, plastics, injection molding, consumer appliance design, telecommunications,
target heat signatures, mechanical testing, R&D and much more. IR cameras capture and
record thermal distribution in real time helping engineers visualize and quantify heat
patterns in the devices they create and events they monitor.
5 } Steel
Infrared cameras save money and help produce quality steel products and save
time and money by enabling routine thermal surveys of ladles, torpedo cars, and other
refractory equipment and/or components, as well as the large, high horsepower motors
running the finishing mill stands. Unscheduled downtime for only one of these motors
can result in production losses that are estimated at $6,000 per minute.
Infrared cameras are designed to provide fast, reliable, accurate monitoring
and control. They enable steel mills to routinely achieve and verify temperature.
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6 } Mechanical Systems
We have a few examples of thermography for mechanical systems. The first
two thermograms, P) and Q) below show electric motors at 30C (54F) and 40C (72F)
above ambient, respectively. Thermogram R) shows a motor coil under test. The camera
operator is looking for shorts, which will show up as temperature anomalies.
Thermogram S) is a coupling for a high horse power motor and is 6C (10F) below the
motor bearing temperature and 12C (20F) below the machine bearing temperature. It is
well within its normal operating temperature.
Thermogram T) is an oil field natural gas compressor where the cylinder head
in the lower left of the picture shows signs of a valve problem. Not counting the bolt head
parts of the images, this cylinder head shows a 25C (45F) temperature gradient. This
gradient was felt to be excessive and it resulted in a tear down and servicing of the
compressor. Thermogram U) is an image of a rotating one-foot diameter 3 feet long
pinion gear that drives a 50-foot diameter drum in a molybdenum mining operation. By
monitoring the lengthwise temperature gradient, the technician could monitor the gear
alignment and its life expectancy. Thermograms V) and W) are images of pipe with band
heaters. V) shows the heaters on and functioning and W) shows them not working.
7 } Glass Manufacturing
Since the nature of the glass manufacturing process is thermal, the quality of
the glass manufactured is dependent on obtaining accurate temperature readings of
various elements such as the glass mold, “gob”, steel conveyor belt and the furnace.
Using easily deployable infrared equipment to monitor these temperatures as well as
preventing electrical and mechanical failure by carrying out traditional predictive
maintenance with such equipment can result in a higher quality product and minimize
costs by averting failures.
8 } Condition Monitoring:
Industrial pumps are known to work continuously for many hours. If a
pump stops working or starts to wear, this can cost a factory much needed time. Using an
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IR camera to monitor the temperature of these type pumps, a maintenance worker can
spot troubled pumps before the failure and address with little or no down time - saving
you time and money.
9 } Predictive Maintenance:
Monitor temperatures of bearings and other moving components. Friction is a
machine’s nightmare, and an engineer or technician would do anything to avoid it. As
bearings wear with time, they begin to slow machinery and create unnecessary heat.
Monitoring changes over time can help predict when maintenance needs to be performed.
Neither too soon, nor too late. Saving the costs of unnecessary maintenance.
10 } Roofing Inspection:
Infrared inspection of this industrial roof reveals water saturation due to
leaks or condensation under the roof membrane. The heat generated by sunlight
dissipates much slower where moisture saturated insulation exists. As a result, the
moisture soaked roof areas appear quite clearly when performing an infrared scan
Conclusion :
So, finally we conclude that the Infrared is very effective in analysis of the
objects having some specific temperature and analysis will be an easy task by using
thermographs shown by Infrared camera. The infrared camera industry has experienced
huge changes in the last 5 to 10 years and we can expect more changes in the future. We
will find more uses for the technology and camera costs will continue to drop. The
cameras will also have higher performance and be simpler to operate.
References :
1 ) www.infrared.com
2 ) www.infraredsolutions.com
3) www.flirthermography.com
4) A textbook on optics (Fourth Edition) By Eugene Hecht
v THANKING YOU