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- Page 1 $29.95 IR Automation Guidebook: Temperature Monitoring and Control with IR Cameras...
- Page 3 IR Automation Guidebook: Temperature Monitoring and Control with IR Cameras...
- Page 4 Tel: +32 3 287 87 10 The thoughts, ideas, opinions, and recommendations expressed in this book are intended for informational purposes only. FLIR accepts no liability for actions taken by readers in their individual businesses or circumstances. Published by FLIR Systems Incorporated This booklet may not be reproduced in any form without the permission in writing from FLIR Systems Incorporated.
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Page 5: Table Of Contents
Real-Time Control Issues Appendix A Glossary Appendix B Thermographic Measurement Techniques Appendix C History and Theory of Infrared Technology Appendix D Command Syntax Examples for A320 Resource Socket Services Appendix E Quick Summary of FLIR IR Cameras Inside Back Cover... -
Page 6: Preface
Preface Some of the major topics that will be covered include: Manufacturing and process engineers • Integration of IR cameras into are under constant pressure to make automation systems production systems and processes more efficient and less costly. Frequently, their •... -
Page 7: Typical Monitoring And Control Applications
Typical Monitoring and Chapter 1 Control Applications Typical Monitoring and temperature can be used for alarm and control functions. In addition, a smart Control Applications IR camera is a calibrated thermographic instrument capable of accurate non- Temperature Measurements contact temperature measurements. with IR Cameras IR cameras with these capabilities Infrared (IR) radiation is not detectable... - Page 8 Chapter 1 • Environmental, machine, and safety Production Testing of Car Seat Heaters monitoring Problem: Using contact temperature • Temperature monitoring as a proxy for sensors to assure proper operation of other variables optional car seat heaters slows down The examples below demonstrate a wide production and is inaccurate if sensors range of applications that can be served are not properly placed.
- Page 9 Typical Monitoring and Control Applications Packaging Operations application method has a good deal of variability that must be monitored and Problem: On a high-speed packaging recorded with statistical quality control line, efficient methods for non- routines. destructive testing of a glued box seal Solution: Since the glue is heated prior are scarce, and most tend to be very cumbersome.
- Page 10 Chapter 1 locations on the box lid can be monitored that smart IR cameras can serve. In with an IR camera. Moreover, the image the following chapters, more detailed can be digitized in a way that allows this examples will be presented along information to be stored in a statistical with practical information on the quality control database for trend analysis...
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Page 11: Remote Ir Monitoring
In FLIR IR cameras, the A/D converters that digitize the pixel IR Camera Operation output have resolutions that range from 8 bits (2 or 0–255 pixels) up to 14 bits... - Page 12 Depending on the software packages, such as those situation, the target objects may need available from FLIR. to be in the same position consistently within the camera’s FOV. Other application variables related to the...
- Page 13 In contrast, stand-alone IR cameras example, the digital I/O output from a monitoring the facility can detect a FLIR A320 camera is 10–30VDC for loads temperature rise within their FOV before of 100mA or less. Typically, the digital fire occurs (Figures 2a and 2b).
- Page 14 Figure 4 illustrates a system using the PLC, which treats that event just as if the FLIR A320’s Ethernet and TCP/IP a temperature had reached the setpoint, communication protocols in conjunction thereby causing an alarm.
- Page 15 The FLIR IP CONFIG readings for any point or area (minimum, software can be used to set up each maximum, and average) in that image.
- Page 16 PoE uses a power supply connected to this purpose. Alternatively, the program the network with spare signal leads not Figure 5. Masking functionality of the FLIR A320 IR camera, which is also available in some third party software programs.
- Page 17 Remote IR Monitoring otherwise used in 10/100baseT Ethernet Additional Asset Monitoring Situations systems. Various PoE configurations are Bulk Material Storage. Many bulk possible. Figure 6 depicts one in which materials are stored in open yards where the power source is located at one end air and moisture can help promote of the network.
- Page 18 Chapter 2 Figure 7. Control room for waste pile processing, and screen capture of the zone monitoring layout, which uses a FLIR IR camera on a pan-tilt mount for fire hazard warning. In most cases, prevention is less costly for reliable operation in harsh industrial than a cure, and the best prevention is environments.
- Page 19 Remote IR Monitoring Figure 8. Visible light and IR images of a coal pile – the thermographic image clearly identifies a hot spot that is a fire about to erupt. on the application environment, an explosion proof housing for the camera may be a requirement.
- Page 20 Chapter 2 Figure 10. Visible light and IR images of a substation showing a transformer with excessive temperature. before an unplanned outage happens. Exel consider IR monitoring a strategic (See Figure 10.) investment in automation, which is part of a common SCADA (Supervisory The cameras can be installed on a pan/ Control And Data Acquisition) platform tilt mounting mechanism to continually...
- Page 21 Remote IR Monitoring Smarter surveillance for a smarter grid Meet ScadaCam Intelligent Surveillance, the only system in its price range that can automatically perform site patrols, monitor equipment temperature, and scan for security breaches without human supervision. By combining visual, thermal imaging, and thermographic cameras into a multifunctional operations and security automation tool, ScadaCam can detect, validate, and alarm you of problems that could otherwise result in a major outage –...
- Page 22 IR cameras are more than adequate for As noted in the text, IR camera temperature data may be used for alarm and control systems. Figure 12. Ngaro’s IRIS® Watchman forest fire early warning system uses a FLIR IR camera.
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Page 23: Temperature Measurement For Automated Processes
For example, the FLIR A320 camera into an IR camera, and when the supports up to four spots and four areas. threshold is reached an alarm is triggered through a PLC. - Page 24 Chapter 3 Figure 2. Gray scale images of a car engine – the left view has white as the hottest temperature and the right view shows black as the hottest. temperatures. Therefore, images will better illustrate smaller temperature differences. On the other hand, a broader scale and/or higher maximum temperature range may be needed to prevent saturation of the portion of the...
- Page 25 Temperature Measurement for Automated Processes 1 Computer or PLC 2 CAT-6 Ethernet cable with RJ45 connectors 3 Industrial Ethernet switches with fiber optic ports 4 Fiber optic cable 5 ThermoVision™ A320 or A325 cameras 6 Industrial process to be monitored, e.g., items on a conveyor belt Figure 4.
- Page 26 FOV and machinery. typically much cooler. This occurs when the parts are not in the proper position. A In one such application, FLIR photoelectric detector tells the PLC when customized the camera firmware to the parts enter the press area; otherwise...
- Page 27 While a visible light camera may be able The only physical interface for digital to detect broken fiber strands, an IR data transfer from the FLIR A320 is the camera can also provide temperature Ethernet port. Only TCP/IP is supported,...
- Page 28 Appendix D.) trend analysis and statistical process control purposes are stored on a separate The system designer or FLIR would server connected to the network, which create the message instructions that is running transaction manager software...
- Page 29 Temperature Measurement for Automated Processes 2008-9522-221-101-D 4/29/08 10:25 AM Page 1 Inspect Faster with NI Vision Builder AI National Instruments Vision Builder for Automated Inspection (AI) now features an innovative state machine editor, taking you from initial design to deployed vision application faster than ever. Easily integrate with existing industrial control hardware –...
- Page 30 Microsoft COM/DCOM. All essential ® on a PC, there are a few options. FLIR’s measurement, analysis, and control Researcher package supports OLE-2, functions for FLIR IR cameras are directly the Microsoft standard for linking and programmable using macro commands.
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Page 31: Combining Machine Vision And Temperature Measurement
Combining Machine Vision and Chapter 4 Temperature Measurement Combining Machine matching). Moreover, the electronics in newer IR cameras provide fast signal Vision and Temperature processing that allows high video frames Measurement rates (60Hz or higher) to capture relatively fast-moving parts on a production line. Background Their A/D converters combine short integration times with 14- to 16-bit... - Page 32 Chapter 4 are typically captured afterward to reveal so the X-rays were taken a few hours after heat dissipation characteristics. part production. If the X-rays showed a significant problem in parts coming from In other applications of this sort, a good a particular mold, this information was image can be stored and compared to relayed to the production area so that...
- Page 33 Combining Machine Vision and Temperature Measurement IR cameras that make for practical use in as the ability to use relatively long cable machine vision applications are Gigabit runs where required. Ethernet (GigE) connectivity, GigE Vision™ The GigE Vision standard, which is based compliance, a GenICam™...
- Page 34 Chapter 4 use the Windows or Linux IP stack, which • GenApi: configuring the camera may lead to unpredictable behavior, • Standard Feature Names: such as data transmission delays. By recommended names and types for using more efficient dedicated drivers common features compatible with the GigE Vision •...
- Page 35 SDK, Active GigE SDK from A&B Software, ease integration tasks. For example, the etc.) for those creating source code for FLIR A325 comes with three packages that custom applications within programming run on a PC controller: environments such as Visual Basic, C++, Delphi, etc.
- Page 36 Chapter 4 hamburger patties. This can be done by Acquire with IEEE 1394 Find circular edges Measure intensity defining measurement spots or areas and GigE cameras Communicate with corresponding to the locations of burgers Find and match Find and measure external devices such patterns straight edges...
- Page 37 IR cameras like the FLIR A325 provide a stream of digitized IR images at fast frame rates for relatively high-speed processes, which can be transmitted over GigE networks to Figure 7.
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Page 38: Real-Time Control Issues
Chapter 5 Real-Time Control Issues Hardware and Software Platform Considerations Background In most cases, a PC with a Microsoft Real-time control is an important issue in Windows operating system (OS) isn’t most IR machine vision systems used for well suited for controlling fast, real-time automated temperature monitoring and applications. - Page 39 Real-Time Control Issues office PC. Often, a system based on a PLC these tools, a programmer can take with 115VAC control I/O is much more advantage of Windows events and appropriate for real-time applications messaging functionality to create a (Figure 1). PLC processors are designed more deterministic application that to operate with deterministic control runs relatively fast and provides tight...
- Page 40 IR machine vision systems. The control. This can become even more of digitized streaming video from FLIR’s an issue when the World Wide Web is A325 camera allows near-real-time involved. Again, there are work-arounds data acquisition of thermal images to minimize inherent weaknesses.
- Page 41 IR Camera Hardware and with detectivity that varies strongly Firmware Issues with IR wavelength. FLIR has made Thermal Time Constants for Cooled and recent improvements to its uncooled Uncooled IR Cameras. In general, time broadband microbolometer detectors...
- Page 42 FLIR A320 Series. The spotmeter finds the target objects, atmospheric attenuation, temperature at a particular point whereas reflected ambient temperature, and the the area function isolates a selected area camera’s ambient temperature drift.
- Page 43 1.0. This adjustment consumes processor particularly if multiple areas are selected. time. To avoid this, the FLIR A325 uses a This also means that more data is being global emissivity value (input by the user) transmitted over a machine vision for the camera’s entire FOV.
- Page 44 FLIR Software Developers Total Radiation Law Kit. The routine that’s developed sets up the system to read the FLIR proprietary 1 = α + ρ + τ. stream of data coming out of the A/D The coefficients α, ρ, and converter and applies emissivity values τ...
- Page 45 Real-Time Control Issues Filter Adaptation 3.45µm NBP lter Polyethylene transmission Resulting transmission Wavelength, µm Figure 8. Application of a narrow bandpass (NBP) filter to achieve nearly complete absorption and high emittance (green curve) from polyethylene film, allowing its temperature measurement. In the last two cases, spectral filters that (or near-real-time) response requires are selective at specific wavelengths...
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Page 46: Appendix A Glossary
Appendix A Glossary all the time, continuously adjusting brightness and contrast according to the absorption (absorption factor). The image content. amount of radiation absorbed by an object relative to the received radiation. A convection. The process that makes hot number between 0 and 1. air or liquid rise. - Page 47 Glossary image correction (internal or external). which the measurement of an object A way of compensating for sensitivity was made and the object itself (such differences in various parts of live images as emissivity, ambient temperature, and also of stabilizing the camera. distance, etc.) infrared.
- Page 48 Appendix A relative humidity. Percentage of water blackbody temperatures that limit the in the air relative to what is physically current calibration. possible. Air temperature dependent. temperature scale. The way in which an IR image currently is displayed. Expressed saturation color. The areas that contain as two temperature values limiting temperatures outside the present level/ the colors.
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Page 49: Thermographic Measurement Techniques
Thermographic Appendix B Measurement Techniques Thermographic polished (mirror) surface falls below 0.1, while an oxidized or painted surface Measurement Techniques has much higher emissivity. Oil-based paint, regardless of color in the visible Introduction spectrum,has an emissivity of over 0.9 in the infrared. Human skin exhibits an An infrared camera measures and images emissivity close to 1. - Page 50 Other Parameters reflected object, it is important to In addition, some cameras and analysis set and compensate for the reflected programs from FLIR Systems allow temperature correctly. you to compensate for the following parameters: Distance Parameter •...
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Page 51: History And Theory Of Infrared Technology
History and Theory of Appendix C Infrared Technology History and Theory of experiment with the objective of finding a single material that would give the Infrared Technology desired reduction in brightness as well as the maximum reduction in heat. Less than 200 years ago the existence He began the experiment by actually of the infrared portion of the repeating Newton’s prism experiment,... - Page 52 Appendix C Moving the thermometer into the to the infrared. The result was that dark region beyond the red end of the rock salt became the principal infrared spectrum, Herschel confirmed that optical material and remained so for the heating continued to increase. The the next hundred years until the art of maximum point, when he found it, lay synthetic crystal growing was mastered...
- Page 53 Wheatstone the photon detector. At first, the image bridge circuit upon which the infrared converter received the greatest attention radiation was focused and to which a by the military, because it enabled an sensitive galvanometer responded.
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Page 54: Theory Of Thermography
(no search beam) distinguished by the methods used to systems around the extremely sensitive produce and detect the radiation. There photon detector. During this period, is no fundamental difference between military secrecy regulations completely radiation in the different bands of the prevented disclosure of the status of electromagnetic spectrum. - Page 55 FLIR Systems camera, for capable in the emission of radiation. example. If the temperature of blackbody radiation increases to more than 525°C (977°F), the...
- Page 56 Appendix C Planck’s Law 900 K 800 K 700 K 600 K 500 K Figure 7. Max Planck (1858–1947) Wavelength (µm) Max Planck (Figure 7) was able to describe the spectral distribution of the radiation Figure 8. Blackbody spectral radiant emittance from a blackbody by means of the according to Planck’s law, plotted for various following formula:...
- Page 57 History and Theory of Infrared Technology light, radiates with the peak of spectral radiant emittance occurring within the invisible ultraviolet spectrum at wavelength 0.27 µm. The sun (approx. 6,000 K) emits yellow light, peaking at about 0.5 µm in the middle of the visible light spectrum.
- Page 58 Appendix C approximately the amount of the sun’s • The spectral reflectance ρ = the ratio λ radiation that lies inside the visible light of the spectral radiant power reflected spectrum. by an object to that incident upon it. • The spectral transmittance τ...
- Page 59 History and Theory of Infrared Technology According to Kirchhoff’s law, for any material the spectral emissivity and Blackbody spectral absorptance of a body are equal at any specified temperature and wavelength. That is: Selective radiator ε = α λ λ From this we obtain, for an opaque Graybody material (since α...
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Page 60: The Measurement Formula
Appendix C This last relation is a particularly neglected. In case they are not negligible, convenient one, because it is often easier the measurement configuration is likely to measure reflectance than to measure to be such that the risk for disturbance emissivity directly. - Page 61 , where (1 – ε) is the refl reflectance of the object. The ambient This is the general measurement sources have the temperature T formula used in all the FLIR Systems refl It has here been assumed that the thermographic equipment. The voltages temperature T is the same for all of the formula are given in Table 1.
- Page 62 Appendix C This task can sometimes be a heavy Object Temperature burden for the operator since there are 0°C (32°F) 20°C (68°F) 50°C (122°F) normally no easy ways to find accurate values of emittance and atmospheric transmittance for the actual case. The two temperatures are normally less of a Emittance problem provided the surroundings do...
- Page 63 4.1 volts, extreme extrapolation, particularly provided the calibration algorithm is when considering that the video based on radiation physics, like the FLIR amplifier might limit the output to 5 Systems algorithm. Of course there must volts. Note, though, that the application...
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Page 64: Appendix D Command Syntax Examples For A320 Resource Socket Services
TCP/IP with exposed services such as example the “level” command. telnet, ftp, http, CIFS, FLIR resource It is possible to run independent socket, and FLIR RTP. More than one instances of the command shell with the service and possibly more than one... - Page 65 FLIR Resource Socket is packetized according to RFC 3016. It is possible to directly read and write On the receiver side, FLIR supplies a nodes of the software resource tree from DirectShow component (Win32, PC a PC. Standard sockets are used, but there platform) which is able to receive the are no standard client programs available.
- Page 66 RFC 4175 (RTP Payload Format for Uncompressed Video). Remote Detection Multicast DNS (Bonjour) The raw image frame rates are up to To query Bonjour for local FLIR IR about 7.8 Hz. cameras, use: These raw formats are provided: •...
- Page 67 Appendix E Quick Summary of FLIR IR Cameras Photon A320 A325 Sensor Type μbolometer μbolometer μbolometer Pixel Resolution 324×256 320×240 320×240 Pixel Pitch 38μm 25μm 25μm Spectral Ranges 7.5μm – 13.5μm 7.5μm – 13.0μm 7.5μm – 13.0μm 14-bit, Signal +...
- Page 68 Published by FLIR Systems Incorporated www.goinfrared.com...