Although single, static IR images of moving machinery or a dynamic process are useful for recognizing many problems, real-time thermal imaging systems allow machine cycles to be recorded and analyzed easily. This capability speeds accurate problem recognition while eliminating potential misdiagnoses that could lead to costly delays or inappropriate remedies. The call for more sophisticated application of IR imaging is often initiated after production and engineering departments have battled quality or efficiency problems. The problems may range from poor adhesion of hot-set glues to quality variations in plastic films or poor uniformity in glass products. Invariably, the production equipment has been designed to provide a uniform level of heating to one or more components.
Heat is supplied using a system that maintains temperatures based on a simple control mechanism.
It is not uncommon that as management pushes for increased quality, the new levels cannot be maintained over time. At other times, the equipment may have been tuned for a higher level of performance, but the product has recently deviated for reasons not explained by the existing process data. Attaching a thermocouple is seldom an option because the equipment moves too fast, or there are too many points to measure. In these production situations, the new real-time IR thermal imaging systems are most useful. A key feature is the digital video interface, which transmits every temperature measurement pixel generated by the camera.