고객 사례

고객 프로필

• Industry: Steel Manufacturing
• Country: India
• Company Type: Large-scale steel rolling mill (producing 200,000 tons of hot-rolled steel annually)
• Core Need: A reliable 비접촉식 적외선 온도 센서 to enable safe, real-time monitoring of moving steel billets (800–1200°C) during the rolling process, reduce manual inspection risks, and optimize production efficiency by ensuring consistent temperature control.

도전 과제

• Dangerous manual inspections: Workers had to use handheld thermometers to measure billet temperatures, exposing them to extreme heat (up to 1200°C) and moving machinery—resulting in 3 minor burn injuries in 12 months.
• Inaccurate contact measurements: Physical contact with hot billets caused rapid sensor degradation and inconsistent readings, leading to 15% of steel batches failing quality standards due to incorrect rolling temperatures.
• Production delays: Manual checks took 5–10 minutes per billet, slowing production lines and reducing output by 8% during peak shifts.
• Harsh environment limitations: Existing sensors couldn’t withstand the mill’s dusty, high-temperature environment, failing within 3 months and requiring frequent replacements (costing $35,000 annually in parts and labor).

솔루션

• Safe non-contact measurement: As a premium infrared temperature sensor, it uses 8–14μm infrared radiation to measure moving billet temperatures (0–1200°C) without physical contact—eliminating worker exposure to extreme heat and machinery risks entirely.
• High-precision performance: ±1% accuracy (at 300°C) and 20:1 optical resolution (D:S) ensure consistent, reliable readings even at 1000mm distance, with built-in temperature compensation to maintain accuracy in the mill’s harsh environment.
• Durable industrial design: 304 stainless steel housing (IP54-rated) resists dust, heat, and minor moisture, extending sensor lifespan to 2+ years (vs. 3 months for legacy units). Optional cooling jackets protect sensors from direct heat exposure near rolling mills.
• Seamless production integration: RS485 (Modbus RTU) and 4–20mA analog outputs connect directly to the mill’s PLC system, enabling real-time data-driven adjustments to rolling speeds and furnace temperatures.
• Flexible installation: M18×1 threaded interface and adjustable mounting brackets allow easy positioning of sensors to target moving billets, with laser sight accessories (single-point or ring two-dot) ensuring precise alignment for accurate measurements.

결과

• Worker safety improved: 0 workplace injuries related to temperature monitoring in 18 months post-deployment, eliminating all manual inspection risks and complying with OSHA safety standards.
• Production quality boosted: Consistent ±1% accuracy from the infrared temp sensor reduced steel batch failure rates from 15% to 1.2%, saving $280,000 annually in rework and material waste.
• Operational efficiency increased: Real-time non-contact monitoring cut production line delays by 90%, increasing annual steel output by 12% (24,000 tons) and generating $1.2M in additional revenue.
• Maintenance costs cut by 85%: Rugged stainless steel design eliminated frequent sensor replacements, reducing annual maintenance labor and parts costs from $35,000 to $5,250.