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Thermal Profiling System
Introduction
A thermal profiling system is an advanced temperature monitoring solution that is used to check and measure temperature distribution during the heating process. Tempsens Instruments specializes in thermal profiling systems using thermocouple probes, data loggers, thermal barrier boxes, and analytical software to create comprehensive temperature profiles, similar to industry-recognized solutions such as Datapaq, revealing how heat distributes throughout ovens, furnaces, and kilns.
Manufacturers have been utilizing Tempsens thermographic data to analyze and optimize their heating process(es), enhance their product quality and conserve energy for multiple years. The equipment manufactured by Tempsens collects temperature readings at multiple locations on the same surface; thereby, providing the end-user with a comprehensive set of data regarding the uniformity, presence of ‘hot-spots’ and ‘cold-zones’ produced throughout their manufacturing process.
About Thermal Profiling System
Tempsens thermal profiling equipment is a comprehensive measurement solution used to monitor and optimize heating processes across various industries. The system tracks temperature variations and creates detailed thermal profiles that help engineers produce a better quality of product and to improve the efficiency of their production operation.
Tempsens Temperature Profiling Systems are vital to businesses within the automotive industry, electronic manufacturing industry, food processing industry, pharmaceutical industry, and heat treatment applications due to the fact that accurate temperature management of your production process directly correlates with both the final product’s quality and the consistency of your production processes.
How Thermal Profiling System Works
The Tempsens thermal profiling system operates by placing thermocouple probes at critical measurement points on products or within process chambers. Each thermocouple is connected to a SmarTrack 10 Data Logger located inside the Tempsens thermal barrier box, which protects the electronics from high heat. Each thermocouple records temperature data every few seconds during the assembly’s passage through the furnace/oven. After collection, the data can be analyzed with Tempsens SmarTrack 10 software to develop a detailed thermal profile for process optimization.
Key Thermal Profiling Equipment
- Thermocouple Probes: Tempsens offers temperature sensors in various configurations including magnetic clamp, sheet clamp, surface mount as well as air temperature, and mineral insulated types. Equipment can be connected through cables that are capable of measuring temperatures from 250°C up to (and including) 1200°C.
- Data Logger: The Tempsens SmarTrack 10 data logger features 10 channels with K-type thermocouple inputs, 0.1°C resolution, ±1.0°C accuracy. Each channel stores 50,000 readings, the logger may be programmed to take readings every 100 milliseconds or up to 1 hour apart depending on the user’s requirements.
- Thermal Barrier Box: Tempsens protective enclosures available in multiple models (TBB-045 to TBB-W-300)with options of different size enclosures and different thermal capabilities from 150 to 1100°C, lasting between 9minutes to 130 hours depending on the type selected.
- Software: Tempsens SmarTrack 10 software provides multi-channel data comparison, import and export data to/from MS Excel, generate one page PDF reports and reports in Word format, monitor battery life, choose multiple triggers for starting and stopping data collection, and offset and graphical display of data which provide a complete database analysis capability.
Thermal Profiling System Applications
- Circuit Board Assembly and PCB Solder Type to Optimize Solder Joint Quality
- Manufacturing Semiconductors – Solder Reflow, Die Attachment, and Adhesive Cure
- Surface Mount Technology (SMT) provides for the ability to monitor the temperature of the solder paste in a reflow operation.
- Paints and Powder Coatings Cured in Automotive and Other Industrial Applications
- Food Processing (Baking, Roasting, Cooking) – Temperature Verification
- Heat Treatment and Annealing of Metals, Polymers, and Composites
- Glass Manufacturing and Tempering to obtain the properties of desired products.
- Ceramics and Refractories manufactured in High-Temperature Kilns
- Polymer processing – Injection Molding, Extrusion, Blow Molding
- Aluminum Aging and Alloy Casting Temperature Monitoring
- Vacuum Annealing Furnaces with Air Quenching Capability.
- Environmental Chambers for Simulating Condition and Aging of Products.
- Aerospace Manufacturing and Processing of Advanced Materials.
Specifications of Thermal Profiling System
| Parameter | Specification |
| Number of Channels | 10 |
| Input Type | K-Type Thermocouple (other types on order) |
| Accuracy | ±1.0°C (sampling interval ≥ 1 second) |
| Resolution | 0.1°C |
| Memory Capacity | 50,000 readings per channel with date & time |
| Sample Interval | 100 milliseconds to 1 hour |
| Communication | USB 2.0 |
| Operating Temperature | 70°C (Rechargeable), 100°C (Non-Rechargeable) |
| Weight | 500 gm (data logger) |
| Barrier Box Range | TBB-045 to TBB-W-300 models |
| Temperature Range | 150°C to 1100°C (depending on barrier model) |
| Duration Range | 9 minutes to 130 hours (temperature dependent) |
| Reference Junction | Internal compensation |
| Battery Options | Rechargeable and Non-Rechargeable |
Why Tempsens for Thermal Profiling Systems?
- 35+ years of experience in thermal engineering solutions.
- Advanced Tempsens SmarTrack 10 data logger with 10-channel capability and high-precision measurement.
- Complete Tempsens system integration including hardware, software, and thermocouple probes.
FAQ
Frequently Asked Questions
Find answers to frequently asked questions related to Thermal Profiling System.
The thermal profile encompasses all the temperatures associated with a given product/process as it travels through the heating system. The thermal profile also graphically represents the time-temperature relationship, which is essential for validating/optimising the heating process, using Tempsens thermal profiling equipment.
In a Tempsens thermal profiling system, a thermograph records data about the temperature continuously and at the same time from multiple thermocouple sensors. The records of temperature with timestamps are stored in the memory of the SmarTrack 10 Data Logger. The temperature data is then analyzed and used to create a thermal profile.
In a Tempsens thermal profiling system, thermocouples generate a voltage that is proportional to the difference in temperature between their measurement junction and the reference junction. The SmarTrack 10 data logger uses this voltage to accurately convert it into a measured temperature with a resolution of 0.1°C within the specified measurement capacity of the thermocouple.
