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Infrared thermographic inspection.

Examples in a factory environment

Area1Min Mean Max 20.7 36.9 50.0

Area1Min Mean Max 20.7 36.9 50.0

*>50.0°C

*<10.2°C

15.0

20.0

25.0

30.0

35.0

40.0

45.0

50.0

Here we have an example of a single overheated diodeon a MIG welder.

22.3°C

153.0°C

40

60

80

100

120

140

AR01: 166.9°C

This is an example of a bad connection on atransformer. Note the joint temperature is at 166.9°C.

16.1°C

29.7°C

18

20

22

24

26

28

Orange Bus: 28.1°C

This example shows a section of bus with a bad joint.Bus failures are often very expensive in terms of

PDC Systems23-25 Windermere RdBlackpool FY4 2BX

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safety and plant downtime.

19.5°C

64.8°C

20

30

40

50

60

Shunt: 63.3°C

Another example of an overheated/damaged shunt.

29.9°C

88.3°C

40

60

80

F18: 91.0°C

Here we have an example of a bad fuse connection ina pump supply cabinet.

18.5°C

37.0°C

20

25

30

35

SP01

AR02: 41.4°C

Here was have an example of thermal striping of thepower cable to the weld gun. This type of defect isresponsible for a great deal of individual gundowntime and quality defects.

PDC Systems23-25 Windermere RdBlackpool FY4 2BX

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19.7°C

47.7°C

20

30

40SP01: 41.0°C

AR01: 41.4°C

This example shows an increased robot drive motortemperature.

20.6°C

60.2°C

30

40

50

60

Motor Body: 58.8°C

Ambient: 21.0°C

This example is of a DC motor. This motor isoperating at a much higher temperature than normalcaused by over tension of the drive belt.

33.2°C

65.7°C

40

50

60

AR01: 71.4°C

Here we see a single termination on a contactor whichis overheating. This defect would be virtuallyimpossible to identify using conventional techniques.

PDC Systems23-25 Windermere RdBlackpool FY4 2BX

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29.4°C

103.1°C

40

60

80

100

F2 right phase: 103.9°C

Another example of a resistance joint on a contactor.Even though there are many cables and connectionsthe defect is still easy to spot.

32.2°C

65.3°C

40

50

60

Fuse F13: 74.7°C

In this example we see a fuse bank with a badconnection at the bottom of one of the fuses.

22.4°C

100.7°C

40

60

80

100

AR01: 101.1°C

Panel fires are often caused by overheating contactorcoils.

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17.1°C

59.2°C

20

30

40

50

LI01: 59.6°C

Remote investigation of cables (even in a cable pit) arerelatively straight forward using the IR camera.

15.6°C

59.0°C

20

30

40

50

Conn Box Top: 57.3°C

Cable: 22.4°C

Transformer Body Top: 26.9°C

In this example of an HV transformer we see internalheating - probably due to a loose connection - withpotentially catastrophic consequences.