Non-Visible Imaging

By Paul Sacker FLIR Systems Ltd.

In Cooperation with:

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Agenda

What is Infrared? Infrared Detector Technologies Different Types of Imaging Qualitative vs. Quantitative
Qualitative Applications Quantitative Applications Many Others

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What is Infrared?

SW

MW

LW

0.9 to 1.7m

1.0 to 5.0m

8.0 to 13.0m

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Infrared Detectors Technologies

Compound Semiconductors
(Photon Detectors Higher Performance)

InGaAs
SWIR

InSb
MWIR
5.0m

QWIP
Thermal Bands

UV Visible
0.4m

NIR
1.0m

LWIR
8.0m 14.0m

1.7m 2.5m 3.0m

Silicon CCD

Silicon-Based Detectors
(Thermal Detectors Lower Cost)

Bolometer

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Detector Technologies
Detectors are made from a wide variety of

Materials, but fundamentally work in 2 ways:

Photon Detectors InSb / QWIP / InGaAs / MCT/ PtSi Based on energy filling a well in a given time period Variable time period Typically cooled cameras used for R&D or demanding applications Focal Plane Arrays (FPAs) VOx / ASi / Based on energy arriving on a resistance bridge in a specific time period Typically uncooled cameras Majority of industrial cameras work this way

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Cameras Come in all Shapes and Sizes

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Interfacing to FLIR Cameras Product Interface Supported

LVDS IEEE1394 (Firewire) GigE CameraLink

A10 A20 A40 SC4000/ 6000

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Typical Vision Imaging Applications

Enhance Image Calibrate Images Filters Check for Presence Measure Intensity Analyze Particles Match Colors

Locate Features Match Patterns Detect Edges

Measure Features Gauge Geometry

Identify Parts Read characters (OCR) Read 1D Barcodes Read Data Matrix codes Read PDF417 codes Classification NEW!

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Typical IR Imaging Applications

Machine Monitoring Predictive maintenance Vessel monitoring Medical

Imaging
Fever

detection Fluid transfer Diagnosis

Food Inspection Checking meat temperature Looking for bruises

Semiconductor Hot spots Bad solder

Telecommunications Laser inspection

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Qualitative vs. Quantitative

113.7F 157.9F Diff. =44.2F

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Qualitative Applications

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Production (De-Barking Process)

Steam

Challenge
Operators can not see through

the steam cloud caused by condensation in cooler air temperatures.

Solution
IR offers another pair of eyes to

see through the steam into the Log Vat for proper log alignment.

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Quality Control (Defroster Element Integrity Check)

Challenge
Optional features in vehicles cannot

be inspected without some type of contact. 100% inspection is tedious and expensive.

Solution
IR can be permanently mounted to

Unable to see with visible system.

inspect these items. IR can be used in a non-contact method.

Broken defroster element

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Quality Control (Heated Seat Check)

Challenge
Optional features in vehicles cannot

be inspected without some type of contact. This slows production down. 100% inspection is tedious.

Solution
IR can be permanently mounted to

inspect these items. IR can be used in a non-contact method.

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Quantitative Applications

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Manufacturing Test (Mini Hot Surface Igniter Crack Detector)

Challenge
Design a system detect cracks in the ceramic element. Most cracks are not visible.

Solution
FLIR ThermoVision A-10 IR Camera NI Vision Software NI Compact Vision System

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Manufacturing Test (Mini Hot Surface Igniter Crack Detector)

Details
14 Bit Thermal Image Data Sample each ROI every 5 pixels for a difference in temperature peaks along a line Failing igniters do not have even heating Overlay pass/fail text

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Product Validation (Motherboard Video Chip Temperature)

Challenge

Validate temperature for fan to start Long Term staring application

Solution

FLIR ThermoVision A-10 IR Camera NI Vision Software

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Temperature Monitoring (Critical Vessel Monitoring)

Challenge
Monitor the temperature around the entire circumference Alarm on high temperature to avoid a potential failure and catastrophic damage.

Hemispherical Area to be monitored

T-couples

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Temperature Monitoring (Critical Vessel Monitoring)

Solution
Four A20 cameras networked via Ethernet. NI Software (NI Vision, LabVIEW) Images analyzed via PC Trigger alarms and record log 24x7

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Temperature Monitoring (Critical Vessel Monitoring)

Courtesy of FLIR Systems

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Remote Monitoring (Sub-Station Preventative Maintenance)

Transformer Disconnect LA

Circuit Breaker

PTs, CTs

G N R LE E T IC E E A L CR

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Remote Monitoring (Sub-Station Preventative Maintenance)

Challenge
Travel time and remote locations do

not allow for continuous 24x7x365 monitoring of critical components.

Goal
Provide a solution that can be easily

set up, monitored, and controlled from anywhere.

Solution
IR, combined with visible and

SCADA technology offer customers real-time data from anywhere in the world over an IP network.

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Industrial Automation (Slag Detection in Molten Steel) Challenge

Develop system to detect the

presence of slag in molten steel stream as it is poured from the BOF to the transfer ladle.

Goal
Provide a solution that can

consistently and safely determine when the slag from the top of the furnace begins to pour into the ladle.

Solution
IR in the long-wave length can

effectively see the differences in emmissivity of the slag vs. the steel.

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Industrial Automation (Refractory Brick Degradation)

Challenge
The refractory brick linings of transfer
858.9F
AR01

ladles can deteriorate to a point that destroys the ladle and potentially people and machinery around it.

800

600

Goal
Provide an automated 360 degree view of

400
SP01

LI01

200

the ladle shell temperatures with real-time response.

72.4F

869.5F 800
SP02 LI01 SP01

Solution
Four (4) IR cameras are strategically

600

placed around the ladle to provide 24x7 operation to the crane operator and maintenance team.

400

200

62.2F

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Thermal Vision Network Layout (Refractory Brick Degradation) Cab Crane

Plant Network
VMT

Cisco 350 Workgroup Bridge

Cisco 2950C-XL Switch

Cisco 350 Workgroup Bridge Cisco 1200 Access Points

Camera Station
Camera Station PC Trango Receiver

Cisco 350 Workgroup Bridge

Legend:
2.4 GHz 802.11b Wireless Ethernet 2.4 GHz 802.11b Wireless Ethernet (Conner) 5.8 GHz Wireless Realtime Video (Trango)

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Industrial Automation (Torpedo Car Monitoring)

Challenge
Identify wear to patch Look for hot areas Look for areas that cool faster than

421.7F 400

300

normal. May indicate steel leaking thru refractory.

SP01

200

100 84.9F

Solution
Two (2) cameras mounted on either

side of the car can indicate potential breakouts within the refractory linings.

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Simple Demo

Demo Set-up A40M CVS Simple application

Examine the image Find the hottest temperature in the Zone of Interest Take the 16 bit linear output of the camera Convert to 8 bit image and display.

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Many Others

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Many Others

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Thank You!
Questions? Paul Sacker FLIR Systems +44 (0)1732 221291 Paul.sacker@flir.uk.com