Bottom-Up GIS 640i G7

Low-emissivity (Low-E) glass is often used for windows and facade components to improve energy efficiency in buildings. However, it creates significant challenges for traditional infrared (IR) devices. This glass type is multi-pane insulating glass with a coated side that has very low emissivity. Infrared devices usually measure the glass temperature from above as the panes come out of the furnace. Because of the coated side’s low emissivity, these devices often struggle to get accurate temperature readings. This can lead to inefficiencies and potential quality problems in production.

The Bottom-Up Glass Inspection System (GIS) from Optris offers a new solution to this problem. By placing multiple infrared imagers underneath the tempering line, the system can measure the temperature consistently on the non-coated, high-emissivity side of the glass. This method ensures accurate temperature readings, which are crucial for maintaining glass quality. Recent advancements in IR technology have made it possible to create smaller, uncooled imagers that are suitable for tight installations. Earlier, bulky line scanners typically used in the industry were not feasible for this setup. The new imagers’ compact design and small accessories allow for an innovative bottom-up package that greatly improves the accuracy and reliability of glass temperature measurements.

The Optris infrared cameras , PI 450i G7 and PI 640i G7, are specialized models within the PI series, designed specifically for the glass industry. These cameras have a spectral response of 7.9 μm and can measure temperatures from 150 °C to 1500 °C. This wide range makes them useful in various applications throughout the production, refining, and further processing of glass panes.

The Bottom-Up Glass Inspection System (GIS) uses two VGA imagers with a maximum field of view of 111°, achieving a remarkable 1600-pixel scan line resolution over a maximum scan width of 4.3 m. Combining the two VGA imagers gives a high-resolution scan line across a broad area, ensuring detailed and precise temperature data. This feature is vital for maintaining the quality and consistency of glass products, which are sensitive to temperature variations during production. The high resolution ensures accurate temperature mapping across the entire width of the glass pane. In addition to measuring temperature distribution, the system can calculate the glass surface area, offering useful data for process control and quality assurance.

The compact Bottom-Up system allows for coating-independent measurement, ensuring continuous and accurate temperature readings regardless of the glass coating. This is essential for maintaining product quality across different applications. The system includes an ultra-fast CTlaser 4M pyrometer, which has a 90 μs exposure time, paired with a Digitally Controlled Lens Protection (DCLP) system. This combination offers reliable protection for the infrared cameras in case of glass breakage, ensuring ongoing operation and reducing downtime.

Optris thermal cameras come with the license-free PIX Connect software, allowing the cameras to function as line-scan cameras. Traditional line scanners used in the glass industry for various measurement tasks are often bulky, costly, and require considerable manual setup. In contrast, the infrared camera system is compact, cost-effective, and easy to set up. The software enables flexible positioning and adjustment of the scan line, providing complete IR images for valuable additional details, especially during system setup.

infrared cameras can accurately measure the surface temperatures of moving objects using minimal apertures, which is particularly important in the glass industry. The temperature of glass directly affects its quality, so measuring temperature accurately at multiple points during production is critical. The data is sent straight to the process control system, allowing for quick adjustments and ensuring optimal product quality.

The Bottom-Up Glass Inspection System (GIS) is a pre-assembled system that installs easily on glass tempering furnaces. This turnkey solution simplifies the implementation process, enabling manufacturers to quickly integrate the system into their production lines. Its design minimizes disruption during installation while providing immediate benefits in temperature measurement accuracy and process control.

Thermography software optris PIX Connect is included and license-free.All infrared cameras are delivered with the thermography software optris PIX Connect, developed specifically for the extensive documentation and analysis of thermal images. The Windows-based PIX Connect software enables users to tailor the infrared cameras to meet specific requirements. It analyses live and recorded temperature data and triggers alarm signals for process integration.The key to leveraging the Optris infrared camera is a correct configuration. This includes detailed device-specific configurations such as frame rate, measurement range adjustments, external communication settings, and USB/Ethernet configurations. Moreover, PIX Connect facilitates firmware updates and the download of configuration files over the Internet. PIX Connect Optris offers several different SDKs for our Xi and PI thermal imaging cameras. Depending on the operating platform, the infrared camera, the coding language, and the hardware platform, different software interfaces can be utilized: SDK The Optris IRmobile allows users to set up and commission an Optris infrared pyrometer or infrared camera with an Android smartphone or tablet. This tool becomes handy for commissioning and aligning the infrared camera‘s field of view or adjusting the configuration. The app analyzes the connected infrared camera‘s live infrared image stream with auto hot and cold spot detection. For pyrometers, a temperature-time diagram or the video signal is displayed. This app works on most Android devices running 5.0+ with a USB port supporting USB-OTG (On The Go). Google Play

How do I install the system?

The Bottom-Up GIS is a pre-assembled system designed for straightforward installation on glass tempering furnaces. Optris or distributors are available to handle the installation and monitoring during the commissioning phase, ensuring a smooth process. For the first commissioning of the entire system, all components must be correctly positioned. Since all components are already pre-wired, they must only be brought into the correct position. The camera must be focused. After connecting the hardware, the configuration in the PIX Connect software can be done.

Where do I install the system?

A suitable position for glass measurement is between the furnace and the immediately following annealing furnace. In most cases, there is a small slit there, as the glass is transported on the glass is transported on conveyor belts, allowing a contactless temperature measurement. After leaving the furnace, the glass must be cooled down relatively quickly. The annealing furnace follows the heating furnace at a very short distance.

What is the package containing?

The whole system consists of three main components: two infrared cameras with shutters, an additional pyrometer that detects broken glass approaching the infrared cameras , and a switch cabinet with a complete electronic unit and control unit.

Do I need a computer?

Yes, Optris recommends a Windows OS Windows 10 or higher with 16GB RAM and an i7 processor.

Shall an input signal to trigger recordings be integrated?

It is recommended to start triggering the line scan of the system with an additional input. Therefore, the cabinet must opened to integrate the furnace’s input signal with the glass inspection system.

What kind of maintenance should be carried out?

The system requires a maintenance check at regular intervals. Here, it should be checked whether the camera’s optics are clean and correctly focused and whether the shutter systems still function properly. This includes a complete opening and closing of the shutters. These points must be observed, as they directly influence the temperature measurement. Never use cleaning compounds containing solvents (neither for the lens nor the housing). The lens surface can be cleaned with a soft, humid tissue (moistened with water) or a lens cleaner.

Does the temperature reading depend on the measurement angle?

Angle dependence is another important factor to consider when measuring temperature. On the uncoated side, the values are constant up to an angle of 45°. On the coated side (Low-E), the 60° optics is preferred since the influence of the emissivity change is negligiblehere.

Why should I measure glass with a G7 infrared camera?

Accurate temperature measurement relies significantly on the emissivity of glass, a crucial determinant affected by multiple factors and tailored to specific applications. The narrowband G7 spectral range, peaking at 7.9 µm, aligns with the highest emissivity of glass, facilitating remote temperature measurement by minimizing issues related to reflectivity and transmissivity. Additionally, within this wavelength range, the angle dependency of glass surface emissivity is reduced, enabling temperature measurement irrespective of reflection, even at inclined viewing angles.

How do I align the camera?

The G7 infrared camera offers a sighting mode in which an infrared image is shown, but no temperature values are measured.

The stated accuracy in that range for the PI 640i LT is +-2 C, but I was wondering if the accuracy could be further improved with surface emissivity information or calibrated to +-1 C or better

No, the actual temperature accuracy could not be further improved by information on surface emissivity. This is for the PI640i camera ±2 °C or ±2 %.
However, accurate surface information regarding the emissivity is necessary in order to measure the correct temperature based on the reflection ratio on the surface to be measured. An incorrectly set emissivity results in a temperature deviation.

I have a PI 640i and would like to connect it with the USB cable. What do I do if I’m not receiving a signal in the software?

• Check in the WINDOWS device manager that the USB driver was recognized correctly
• Go to Settings/Camera or via search and type in „camera“ and then activate the button “allow apps to access your camera”. Due to an Windows Update this could happen.
• If you have a black screen on PIXConnect software, this could be because of the bad performance of your graphic chip and hardware acceleration. Regarding this case, reduce the screen resolution of the monitor.
• Check the USB cable and the connector pins on camera and PC side
• Try another USB port of the PC or another PC (if available) to check that the USB cable has no issue
• Maybe the USB power supply of the camera supporting PC is too low
• Using a too long USB cable / a not provided USB cable by Optris or an USB extension cable could be the reason that the software PIXConnect does not get any signal
• Use a PC where you have administrative rights or check with your local administrator

Will optris PIX Connect Software for optris IR Cameras run on my iPad?

No, PIXConnect currently cannot be run on an iOS system (Apple).

Is your infrared camera long-wave (LWIR) or short-wave (SWIR/MWIR)? What’s the typical frame rate? What’s the IFOV (instantaneous field of view / pixel size)? And does it connect to a PC via USB, or what other platforms/interfaces are supported (e.g., Ethernet, etc.)?

Optris provides different types of IR cameras with different wavelengths. Here you can find an overview of the different camera types regarding the spectral ranges, the typical frame rates and the interface versions (USB or Ethernet (ETH)):

Long-wave (LWIR) cameras (spectral range 8-14 µm):

• PI400i LT (80Hz, switchable to 27 Hz),
• PI450i LT (80Hz, switchable to 27 Hz),
• PI640i LT (32 Hz (640×120 px @ 125 Hz),
• Xi80 LT ETH (50 Hz),
• Xi400 LT USB (80Hz, switchable to 27 Hz),
• Xi410 LT ETH (25 Hz (connected via Ethernet,4 Hz connected via USB),
• Xi640 LT USB (32 Hz)

Long-wave (LWIR) cameras (spectral range 7,9 µm):

• PI450iG7 (80Hz, switchable to 27 Hz),
• PI640iG7 (32 Hz (640×120 px @ 125 Hz)

Middle-wave (MWIR) cameras (spectral range 3,9 µm):

• Xi320MT (30 Hz)

Short-wave (SWIR) cameras:

• PI1M (0,85-1,1µm), 32 Hz (382×268 px @ 80 Hz, (switchable to 27 Hz)/ 72×56 px/ 764×8 px @1 kHz)),
• PI08M (780-820 µm), 32 Hz (382×268 px @ 80 Hz, (switchable to 27 Hz)/ 72×56 px/ 764×8 px @1 kHz)) ,
• PI05M (500-540 µm), 764×480 px @ 32 Hz/ 382×288 px @ 80 Hz (switchable to 27 Hz)/ 72×56 px/ 764×8 px @ 1 kHz,
• Xi1M ETH (0,85-1,1µm), 396×300 px, 20 Hz, 396×8 px (auton.: 396×1 px), 500 Hz, 0,85-1,1 μm, Ethernet, USB 2.0 (only 20 Hz), Auton. operation,
• Xi05M ETH (500-540 µm), 396×300 px, 20 Hz, 396×8 px (auton.: 396×1 px), 500 Hz, 500-540 nm, Ethernet, USB 2.0 (only 20 Hz), Auton. operation

The following digital interface kits are for the Xi 80/ 410/ 05M/ 08M cameras available:

• Ethernet TCP/IP / Modbus TCP interface kit
• EtherNet/IP interface kit
• Profinet kit

You can see the IFOV (instantaneous field of view / pixel size) for your IR camera with the different available optics in the optics calculator on the Optris website: Optris IR Camera Calculator (https://optris.com/optris-calculator/camera/)
Example:

What is the bit depth of our camera?

The bit depth of our cameras is 14 bit. The data has 16 bit but only 14 bit are used for the Temperature Data and the other 2 bits are not used

Can we send the raw ADU data from the camera to another commercial software for processing?

As a rule, we do not disclose any information about raw data. The only option is to use the Connect SDK to output the camera’s ADU values as a matrix. However, these ADU values are uninterpreted. The cameras can send the temperature information and the color information to another commercial software for processing.

Does changing the mode from Temperature to ADU in the Connect SDK change the way that the image is displayed?

No, the way the image is displayed does not change. You can see this in the software examples provided with the PIXConnect software (See the menu HELP => Connect SDK => Examples). Under the configuration menu => External communication => ConnectSDK. You can change the mode from “Temperatures” to “ADU”. This has no influence on the displayed image.

Our company designs and supplies camera systems for steelmaking processes and is exploring different camera types. For this application, would you recommend long-range, near-infrared, or short-wave infrared models?

For steelmaking processes we recommend short-wave infrared cameras as the PI 1M camera, PI 08M camera, PI05M camera , Xi1M camera or Xi 05M camera. Use the lowest wavelength / spectral range as possible!

I’m using the SDK to run SimpleViewer on Linux and have PI Connect installed on Windows. After performing calibration, the thermal image appears entirely black and displays an incorrect temperature reading of 257°F. Which setup or calibration steps could I have overlooked to make this work correctly?

• Regaring the black display in the software PIXConnect , this could be caused by a bad performance of your graphic chip e.g. the hardware acceleration. Reduce the screen resolution of your monitor or if possible reduce the hardware acceleration
• Set the Optimization to “Performance” and remove the hook from “High Speed temperature calculation”

Does the PI 640i support external triggering? Specifically, can I connect a relay output or a controller’s digital output to trigger image acquisition on the camera?

• Yes , the PI 640i camera supports via the software PIXConnect external triggering to record an image.
• You can use an analog input or a digital input signal via the Process Interface (PIF) to trigger the camera.
• In the configuration menu, PIF setting menu , you can set the voltage signal for the analog signal to trigger the camera or you can set the edges conditions for the digital signal to trigger the camera.
• Another possibility to trigger a snapshot via a controller’s digital output is to use the serial communication (if available at the PLC). For this you can use the command list of the serial communication to send the command to take a snapshot.

Which Optris infrared cameras support integration with machine learning frameworks? Do they provide raw thermal image data access via SDK/API (e.g., the OTC SDK), allowing developers to apply custom ML models for tasks like segmentation, classification, or predictive thermal analysis?

The IR cameras do not provide any raw thermal image data access. You get the temperature data via the SDK (OTC SDK) from the camera to your process.

Which Optris infrared camera is best for measuring temperatures during welding processes?

• The choose of the correct Optris infrared camera depends on the temperature range and the type of the welding process.
• For plastic welding , a PI/Xi LT camera can be used (8-14 µm)
• For metal (e.g. steel applications) a short wavelength camera PI 1M/08M/05M , Xi 1M , Xi05M should be used (0.85-1.1 µm , 780-820 µm , 500-540 µm)
• For laser welding applications Optris provides IR cameras with a blocking filter.

• 2x PI 640i infrared cameras
• 2x Industrial Process Interface
• CTlaser 4ML glass breakage sensor with USB interface
• 2x DCLP Shutter system with mounting brackets for imagers
• 2x USB Server Gigabit
• Control cabinet with cable set (10 m each) and remote control box
• Software package
• 100-230 V AC/ 24 V DC power supply for initial start-up