Fiber-Optic Temperature-Measurement System

The HERAEUS ELECTRO-NITE Chameleon Foundry is a comprehensive portfolio of sensors and accessories for precise control of metallurgical processes, including measuring temperature, oxygen, and carbon content, as well as other quality-critical parameters in molten metal.

Chameleon Foundry sets new standards in the temperature measurement of iron melts. Instead of traditional disposable temperature probes, the system uses a fiber-optic wire for direct measurement in the melt. It was developed specifically for iron foundries and meets the highest standards of accuracy, reliability and process safety.

Unlike conventional methods, where operators must manually insert the probes into the ladles or pouring channel, the measurement can be triggered either fully automatically via a PLC-controlled signal exchange or, if required, simply at the press of a button on the control panel.

The system automatically immerses the fiber optic probe, records temperature data, and transmits the measured values without exposing staff to extreme heat or metal splashes.

The conventional measurement methods using disposable thermocouples require additional effort in terms of maintenance, as well as higher logistics and storage costs, and they involve significant material costs, as the thermocouples must be disposed of as waste. Chameleon Foundry's FIMT (Fiber in Metal Tube), on the other hand, dissolves in the melt.

By using Chameleon Foundry at high-frequency or critical measurement points, this effort can be significantly reduced. A single coil weighing just 25 kilograms enables up to 6,000 measurements and replaces several pallets of conventional sensors. This saves storage space, lowers freight costs and significantly reduces the environmental footprint. Avoiding the use of cardboard tubes means lower resource consumption, less waste and a significant step towards more sustainable foundry operations.

As fewer components need to be replaced, maintenance requirements are also significantly reduced, leading to higher system availability and minimized unplanned downtime.

One benefit of the new technology is increased workplace safety. In environments involving high temperatures, molten metal, radiant heat, and the risk of splashes, any manual intervention is risky. Fully automatable immersion measurement using optical fiber technology prevents direct contact with the melt, thereby reducing the risk of accidents and creating safer working conditions.

Automated control enables more precise measurements, which are always carried out under the same conditions. This helps to optimize casting quality and energy consumption and to achieve target temperatures more accurately. Overheating, energy wastage, and rework are reduced.

The result is more stable processes and optimized energy consumption, contributing to consistently high product quality in iron casting.

Learn more at www.heraeus-electro-nite.com/en/