Auto Parts Inspection
Auto Parts Manufacturing Applications
Motor Thermal Sleeve Temperature Measurement
[Application Requirements]
Electric compressors are core components of the thermal management system for new energy vehicles. The pump casing of the electric compressor is heated (expanded) and cooled (contracted) to a temperature range of 80°C to 200°C. The stator, which is fixed to the motor, is then placed into the pump casing during the heating process.
[Technical Route]
The pump casing is measured in real time using thermal imaging technology. This technology connects to the production PLC system via the Modbus-TCP protocol to obtain the thermal imaging temperature measurement results, which are then linked to the PLC system for production line execution.
[Advantages of Thermal Imaging Applications]
Non-contact visual temperature measurement allows for comprehensive temperature measurement of the casing, enabling image traceability and improving shrink-fit process quality.
Nylon Air Suspension Hot Air Welding Application
[Application Background]
Air suspension, as an advanced automotive suspension technology, has gained widespread adoption in the high-end automotive market due to its advantages in improving vehicle comfort and handling. Its core component is the air spring, a sealed airbag structure typically made of rubber, nylon, and other composite materials. During production, the airbag is welded by heating and melting the halves of the airbag, then closing the cover and applying a certain amount of pressure.
[Pain Points]
The process uses a hot air plate with a hot air duct that matches the shape of the nylon part to heat and melt the workpiece, achieving welding. Occasionally, the hot air duct can become clogged, resulting in insufficient heating in some areas and poor welds. The existing production process lacks effective means to inspect the weld quality of nylon parts. Direct testing after welding results in a high defect rate, necessitating optimization and improvement of this process.
[Thermal Imaging Applications]
1. Technical Route: Install a thermal imaging camera at appropriate locations on the hot air welding tooling. Within 1-2 seconds after the hot air plate finishes heating, the camera captures a thermal image (image + full-screen temperature data) and uploads it to the host computer integrated software for temperature analysis.This determines whether the workpiece is fully heated and assists in determining weld pass/failure.
2. Product Recommendation: Select 4-6 thermal imaging 640 high-resolution temperature measurement cameras based on the actual tooling configuration.
3. User Benefit: Thermal imaging enables visual temperature measurement, and combined with analysis software, it assists in determining weld pass/failure for testing, effectively improving production process yield.
Laser Welding, Friction Stir Welding
[Application Background]
Laser welding technology, due to its high precision and efficiency, is widely used in the automotive, aerospace, and electronics industries. However, a key challenge lies in precisely controlling the temperature distribution during the welding process. Excessive temperatures can lead to excessive melting or vaporization of the material, while insufficient temperatures can cause defects such as holes and cracks. Furthermore, the diversity of weld materials (such as metals, thermoplastics, and composites) further complicates quality control. Infrared thermography, through non-contact temperature monitoring and thermal distribution analysis, has become a key tool in addressing these challenges.
[Advantages of Thermal Imaging Applications]
(1) Real-time temperature monitoring and control: Monitor the temperature of the welding area to ensure it is within the set range, and adjust parameters such as laser power and welding speed in real time through a closed-loop feedback system.
(2) Welding defect detection: Identify defects such as pores, cracks, and insufficient fusion through abnormal temperature distribution.
(3) Process optimization and energy efficiency improvement: By analyzing temperature data, laser power, welding path, and material selection can be optimized.
Rubber Tire Mileage Test Application
[Application Requirements]
Temperature measurement is a crucial step in rubber tire mileage testing, primarily used for tire performance evaluation, fault warning, and design optimization.
1. Performance Evaluation: Tires generate heat during driving. This heat primarily comes from hysteresis loss in the rubber material caused by the tire’s cyclical deformation and frictional heat from the contact patch. Increased temperature degrades the rubber’s chemical and physical properties, thereby affecting the tire’s strength and lifespan. Temperature measurement can assess the tire’s thermal stability under different driving conditions, ensuring its safety and reliability in actual use.
2. Fault Warning: High temperatures can lead to serious accidents such as tire blowouts. Real-time tire temperature monitoring can proactively detect potential overheating issues and enable timely action to prevent accidents.
3. Design Optimization: Temperature data can help engineers better understand the thermal behavior of tires under different operating conditions, thereby optimizing tire design and improving durability and performance.
[Pain Points]
Traditional contact temperature measurement methods (such as thermocouples) require direct contact with the tire surface, which not only affects the tire’s normal driving performance but can also lead to measurement errors. This prevents real-time and comprehensive monitoring of the tire’s surface temperature distribution, making data recording and analysis difficult.
[Advantages of Thermal Imaging]
Non-contact, visual temperature measurement maintains the tire’s normal rotation during mileage testing and generates a temperature distribution map of the tire surface, visually displaying temperature variations across different areas. This helps engineers gain a more comprehensive understanding of the tire’s thermal behavior and optimize design and performance. Real-time monitoring and early warning of accident risks, such as explosions, are also provided. When the temperature exceeds a preset threshold, the system automatically issues an alarm, prompting operators to take action.
Temperature Measurement of Rubber Extrusion Roller Belt
[Application Requirements]
Temperature measurement is a critical step in the production of rubber extrusion and roll-forming tapes, primarily used for quality control, process optimization, and equipment protection.
1. Quality Control: During the rubber extrusion and roll-forming process, temperature has a direct impact on the rubber’s fluidity and molding quality. Appropriate temperature ensures uniform rubber flow and excellent molding results, while excessively high or low temperatures can degrade the rubber’s properties, impacting the quality of the final product.
2. Process Optimization: Precise temperature measurement and control can optimize the production process, improve efficiency, and reduce scrap. For example, during extrusion, an appropriate die head temperature can increase the rubber’s fluidity and relaxation speed, reducing extrusion distortion.
3. Equipment Protection: High temperatures can cause equipment damage. Real-time temperature monitoring can proactively detect potential overheating issues, allowing timely measures to prevent equipment failure and extend equipment life.
[Pain Points]
Traditional contact temperature measurement methods (such as thermocouples) require direct contact with the rubber surface, which impacts production and cannot fully monitor the temperature distribution on the tire surface in real time. Data recording and analysis are also difficult.
[Advantages of Thermal Imaging Applications]
This non-contact method does not interfere with the tape roll extrusion process. Visual temperature measurement generates a tape temperature distribution map, visually displaying temperature variations across different areas. This helps engineers more comprehensively analyze the tape’s thermal uniformity and optimize design and performance.
Automobile Steering Wheel, Seat, Rearview Mirror Heating Inspection Application
[Background]
The primary reason for heated steering wheels, seats, and rearview mirrors in vehicles is to improve driving comfort and safety. The primary purpose of heated steering wheels and seats is to provide warmth in cold weather. Heated rearview mirrors prevent frost or water accumulation on the mirror surface, ensuring a clear view of the road behind and avoiding potential visual obstruction.
[Pain Points]
Traditional handheld thermopile temperature sensors cannot quickly and comprehensively measure the entire temperature of a target, resulting in low overall efficiency.
[Thermal Imaging Application Introduction]
1. Technical Route: Real-time imaging of the heat distribution (temperature field) of a heated object allows detection of any abnormalities and prompt on-site repairs.
2. Product Selection: Handheld Thermal Imaging Temperature Sensor.
3. User Benefit: Thermal imagers accurately capture the thermal radiation signals generated by seat heating elements during operation. Using advanced image processing technology and algorithms, thermal imagers convert these signals into intuitive thermal images. Simply by observing these images, technicians can quickly locate the fault location, such as a damaged heating element or poor wiring connection. This significantly improves troubleshooting efficiency and reduces repair costs and time.
