Thermal Safety in Manufacturing Tunnels with Infrared Cameras

More than 100 Simultaneously Monitoring Infrared Cameras Protect Entire Production Facilities from Fires

Challenge

In automotive paint drying tunnels, high ambient temperatures and flammable materials create significant fire hazards. Traditional detection methods like smoke sensors or manual checks cannot react fast enough to sudden, localized temperature spikes, risking safety, production downtime, and costly damage.

Solution

By installing over 100 infrared cameras along the drying tunnels, continuous, non-intrusive surface temperature monitoring was achieved. The automated system detects critical heat buildup early, triggering alarms to allow immediate response, minimizing fire risk and ensuring uninterrupted production without disturbing the drying process.

Benefits

Immediate response to critical heat buildup enhances workplace safety and fire prevention.
Continuous monitoring helps maintain uninterrupted production and avoid costly downtime.
Reduced dependence on manual inspection lowers labor costs and human error.
Seamless integration into existing systems simplifies deployment and long-term use.
Enables scalable application in other high-temperature automotive processes.

Dangers in Automotive Production Due to High Temperatures

In automotive production, painting is one of the most critical processes. Before vehicle bodies are fully assembled, they go through multiple stages of priming and coating. These procedures require a final drying phase, which takes place in long, enclosed drying tunnels. These tunnels range from 20 to 50 meters in length and reach high temperatures of up to 900°C to ensure fast and uniform curing of the coatings. The drying systems are often housed in large factory halls.

A major challenge in these tunnel systems is the fire hazard. Due to the materials and high temperatures involved, there is always a risk of uncontrolled heating or fire. Traditional fire detection methods, such as smoke detectors or manual visual inspections, are insufficient to respond immediately to critical temperature changes.

For this reason, the automotive manufacturer in this application chose a more precise solution: monitoring tunnel temperatures using infrared cameras from Optris. The goal was to detect critical temperatures early to immediately initiate safety measures and prevent fires. Another important aspect was ensuring operational continuity, as production downtimes caused by fire or heat damage could have severe financial consequences.

Effective Monitoring with 100+ Networked Ethernet IR Cameras

To minimize safety risks, more than 100 Optris Xi 410 infrared cameras were installed along the drying tunnels inside the manufacturing hall. These cameras continuously measure the temperatures on the tunnel’s outer surface without interfering with the actual drying process inside. The Xi 410 was selected for its high resolution, fast capture rate, and easy integration into existing systems.

The cameras operate autonomously at a frequency of 1.5 Hz. Each camera captures a large measurement field with an 80° wide-angle optic, providing a comprehensive image of the tunnel structure. The recorded temperature data is transmitted via an analog output and monitored by a central control system. Critical temperature changes automatically trigger alarms, allowing responsible personnel to respond immediately.

The cameras are connected via Ethernet with PoE switches and can be directly controlled via the easyCom interface. This enables operators to access images from individual cameras when needed and perform detailed analyses. The customer deliberately chose not to display all camera images in real-time continuously, as this was unnecessary and would have placed additional strain on the system.

A key advantage of the Xi 410 is its simple installation. The cameras can be flexibly mounted at various points along the tunnels. However, it was important to consider hot metal structures in the environment, as these could heat the camera housings. In such cases, Optris water-cooling enclosures could be used as a protective measure.

All Xi cameras run in parallel and simultaneously to ensure complete coverage of the entire factory hall and drying tunnels. The simultaneous monitoring of all areas ensures that temperature changes can be detected and localized immediately.

Automated Temperature Monitoring Saves Costs and Increases Safety

The implementation of the Optris Xi 410 infrared cameras has proven to be highly efficient. Since the initial test installation with eight cameras, the system has been gradually expanded until the entire production line was secured. The automatic detection of temperature changes significantly reduces the risk of fires, greatly improving the safety of the production facility and its employees.

The Xi 410 cameras have proven to be a cost-effective and reliable alternative to conventional fire protection systems. While competing solutions often require high investment and maintenance costs, the Optris Xi 410 stands out with its ease of use, low operating costs, and robust performance.

The system operates fully automatically and requires minimal manual intervention. When a critical temperature is detected, the corresponding camera image is displayed and can be stored for documentation purposes. The easy integration into existing control systems and the high resolution of the measurement data were additional key advantages that convinced the automotive manufacturer.

In the long term, the Optris solution not only provides increased safety but also holds potential for similar applications in other areas of automotive production, such as battery manufacturing or material handling. This makes the Xi 410 a future-proof choice for manufacturers seeking precise, automated, and cost-efficient temperature monitoring.

Downloads

DATASHEET

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Xi 410 Datasheet (US)

DATASHEET

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