Unique Advantages of Thermal Cameras in Plate Electrode Monitoring in Electrolytic Tanks to Assist the Metallurgy Industry

In an electrolytic tank, metal purification is implemented by electrolyzing metal materials. In the purification process, metal impurities often accumulate between the plate electrodes, causing short circuits in between. If short circuits occur, a large amount of heat is produced, melting and damaging the plate electrodes and causing device faults. Traditional manual inspection is of low efficiency and can possibly cause omission and incorrect results. The thermal camera can comprehensively and quickly scan the measurement target and automatically capture high-temperature points, helping staff quickly locate the heat defect location, improving maintenance efficiency, lowering maintenance cost, and ensuring manufacturing safety.

I.  Main Applications of Thermal Cameras in Plate Electrode Monitoring in Electrolytic Tanks

1.  Accurately Locating the High-Temperature Points on the Plate Electrode

Thermal cameras collect the thermal image of the electrolytic tank, and the computer processes the thermal image to capture the pixels with exceptional temperature and determine the specific location of the faulty plate electrode. In this way, the short circuit location of the plate electrode in the monitored area is determined.

2.  Determining Whether the Plate Electrode Is Short-Circuited and Failed

Thermal cameras are used to monitor the plate electrode temperature, in order to determine the short circuit location in between.

3.  Improving the Efficiency and Accuracy of Batch Plate Electrode Inspection

Thermal cameras greatly improve the inspection efficiency compared with that of manual inspection. They reduce the manpower cost and provide a convenient and efficient way for monitoring the electrolytic tank operation.

II.  Unique Advantages of Thermal Cameras in Electrolytic Tank Monitoring

1.  Non-contact real-time online temperature measurement, with optional lenses, to monitor every corner in the electrolytic tank and the temperature of the narrow space between the positive and negative plate electrodes, missing no high-temperature points in between.

2.  If the plate electrodes are not evenly distributed or the positive plate electrode is attached to the negative plate electrode, short circuits occur, causing excessive current and temperature rise on the plate. On the thermal image, the color of the short circuit point is obviously different from surrounding area, staff can quickly locate the fault location, facilitating fault and potential risk troubleshooting and prompt handling.

3.  Due to the difficulty in locating high-temperature points on plate electrodes in electrolytic tanks, a second analysis can be implemented on thermal image data, helping staff to accurately determine the failed plate electrode caused by short circuits and high-temperature position of the plate electrode.

III.  Recommended Models

1.  AT31F/61F Thermal Camera

①  It is of small size and for easy integration. SDK is provided for external development. It can be connected to the back-end of automatic inspection machines, to promptly locate the high-temperature point

②  Networked use of multiple devices is supported, implementing online remote monitoring and control and reducing installation costs

③  The software supports high-temperature point location and thermal image capturing, facilitating fault troubleshooting and prompt handling of the fault

2.  AT31/61 Thermal Camera

①  It supports the electrical focusing, to clearly display the temperature between plate electrodes, missing no high-temperature points in between

②  The patented smart temperature compensation algorithm is equipped to accurately identify the root of the plate electrode fault, quickly discovering the fault point

③  It supports secondary analysis of images, helping detecting staff to accurately locate the high-temperature position, avoiding omissions

IV.  How Can I Use a Thermal Camera to Produce a Thermal Image of Premium Quality?

Please refer to the following suggestions for using a thermal imager to produce a thermal image of premium quality:

1.  Onsite environment temperature and sunlight will have different effects on plate electrodes in different locations. Direct sunlight will heat up the plate electrode. It is recommended that sunshades be installed to avoid the impact of environmental factors

2.  Select thermal imagers with high thermal sensitivity for scenarios with a small regional temperature difference

3.  Select thermal cameras or levels of proper measurement ranges for different scenarios and temperature

4.  Use automatic measurement first, and then enable the temperature width stretch function. Manually set the temperature width to the minimum and include the previously measured temperature range to enrich the image details