The K show is a great place to learn about new technology, and even about older, but possibly underutilized ones such as thermography. Thermal energy is an internal, direct process variable, which makes it a critical component of molding processing. There are many ways to measure temperatures, including thermography, and this hot runner manufacturer’s executive welcomes you to his stand for Thermography 101.

Thermography has been around for quite awhile, but not many in the plastics industry are too familiar with it. PSG Plastic Service Group Inc. (Stand 10/H67) has implemented this technology and evaluated it over an extended period of time as a suitable method for measuring the heat variables in injection molds. The result is that Rich Oles, president and CEO of PSG North America, feels that this is a technology whose time has come.

Oles began following thermography back in 2002-2003. While his background and expertise is in hot runner/manifold systems, controllers and mold making, he thought thermographic imaging was an underdeveloped concept. However, at that time cost was a major consideration as thermography cameras cost upwards of $60,000-$70,000. Because of the expense, penetration was limited and typically a company trained just one person in the technology.

“A person with one of these cameras would be the thermographic god,” says Oles. “If he had access to this camera and the software, this knowledge would all be locked up with him – he wielded the magic wand. However, if the company did not mainstream the technology, the full benefits would never be realized.”

Things changed, and Oles notes that thermography equipment is now more reasonably priced ($3000 - $12,000 price range) and thermography, when used to study the molding process, is a great communications tool that provides technical thermal graphic images recorded during the molding process to people who may not be technical or processing savvy, “but who have to make major financial decisions about their company and its operations.”

Using thermography can help provide useful information so informed decisions can be made to change process parameters, or to guide maintenance operations when necessary. Colors appearing in the thermographic image provide the thermal roadmap of the part or the mold being evaluated.

“The better you can communicate with customers and suppliers, the better off you are,” says Oles. “In 2004 I wanted to implement thermography, so I went to a design show where I first met people from North Coast Industrial Imaging, and began learning about thermography.”

John Lefeber, partner in North Coast Industrial Imaging, taught Oles about thermography, and Lefeber learned about plastics from Oles. “Today, we have several thermographic imaging cameras, which are used either for troubleshooting new system build-ups, process evaluations at the molder or for tooling audits,” explains Oles. “We have lots of other uses for them as well.”
Oles is currently working on advanced concepts for thermography including the development of a process he calls “Thermal to 3d”, but that one is still in the development stage.

Oles adds that one of the primary advantages of thermography is reducing the number of hours it takes technicians to diagnose and fix a problem. “We’re diagnosing problems quickly, and keeping the man-hours down because we’re using technology as opposed to man hours, and helping our customers make good decisions about the problem and how to fix it based on what the technology has revealed to us,” he says.

“The thermal data you get is dependent on two things. First, the person recording and presenting the data must be well-trained in the technology,” Oles explains. “For example, emissivity (the relative ability of a surface to emit radiation) is a critical variable when shooting thermal images, and lack of due diligence in preparing to record a thermal image can negate the value of the technical data being recorded.”

Second, the value of the data is dependent on the character of the person doing the recording. “You can easily manipulate the images (i.e. data) – sometimes it’s done intentionally, but usually it’s done through inexperience or lack of training,” Oles says. “When shooting steel, as one example, proper steps need to be taken to minimize the effects of emissivity.”

Thermography gives you a “thermal map” or “profile of the surface” so that you’re only recording the temperature on the surface, Oles explains. “That’s why it’s critical that you set up the testing or the diagnostics in a way that you’ll get accurate data. Remember, ambient air movement can also change the temperature which will change the appearance of the data.”

So, check your closets, dust off that expensive camera, get your team trained and begin taking advantage of thermography’s benefits. If you haven’t yet invested in thermography, Oles believes now is the time, and will be at the K show ready to tell you more.