PYROVIPER FURNACE LENS PROBE

Transcription

1 PYROVIPER FURNACE LENS PROBE 1 ST, 2 ND, 3 RD AND 4 TH EDITION LENS DESIGNS Comparison-Lens-PyroViper-4thEdition.AC doc Page 1 of 10 Specifications are subject to change without prior notice.

2 Contents Contents 2 Pictures st edition (FE) probe optics nd edition (SE) probe optics rd edition (TE) probe optics 5 4 th edition (4E) probe optics 8 Pictures Pic. 1 PyroViper Lens 1 st Edition 3 Pic. 2 PyroViper Lens 1 st Edition disassembled 3 Pic. 3 PyroViper lens 2 nd edition 4 Pic. 4 PyroViper lens 2 nd edition disassembled 4 Pic. 5 PyroViper Camera head 3 rd edition assembled 6 Pic. 6 PyroViper Camera head 3 rd edition with dismounted protection shroud 6 Pic. 7 PyroViper Camera head 3 rd edition with dismounted probe optics 6 Pic. 8 Details of adjustable protection shroud 6 Pic. 9 Lens Tip detail - optical zoom Pic. 10 Lens Tip detail focus through third lens 7 Pic. 11 Lens Tip detail adjustable bearers Pic. 12 Detail of adjustable probe optics flange 7 Pic. 13 Easy access to the camera electronics without risk 7 Pic. 14. Camera overview 4 th edition optics with separate air intakes 9 Pic. 15 Electrical isolation of mounting flange Pic. 16 Sideways mounting of measuring transducers 9 Pic. 17 Centering unit Pic. 18 Focusing unit 9 Pic. 19 Integrated thermoelement in probe optics via compliant plug on clamp ring 10 Pic. 20 Lens tip with tight fits for easy adjustment 10 Pic. 21 Additional plug for add-on sensor features Pic. 22 Smaller air purging hole 10 Comparison-Lens-PyroViper-4thEdition.AC doc Page 2 of 10

3 1 1 st edition (FE) probe optics The original PyroViper Imager had a plain design in which the different components were assembled in one piece. Although inexpensive, this layout suffered from disadvantages in functionality and maintenance: The maintenance can only be carried out by expert personnel. It is necessary to dismantle the whole unit (Fig. 2) in order to access the parts that usually require maintenance: o Optics cleaning/replacement o Protection shroud replacement Thus, the unit takes long maintenance time and implies the risk of damaging cables or sensors o The camera requires only low pressure, low flow for cooling, the lens tip needs high pressure, high flow for cooling+purging. The air intake (Fig. 1) is placed at the back of the unit. o The camera(s) is(are) cooled with pressure air, which results in pollution through unclean air (oil, water, particles) allows only a one-way cooling/purging air flow for both camera and optics All optical and mechanical elements are fixed. There is no adjustment possibility. Air Intake Air Exhaust Pic. 1 PyroViper Lens 1 st Edition Shroud Lens Lens Tip Pic. 2 PyroViper Lens 1 st Edition disassembled Comparison-Lens-PyroViper-4thEdition.AC doc Page 3 of 10

4 2 2 nd edition (SE) probe optics The SE probe optics addressed the above-mentioned limitations to allow easier maintenance of the optic and reduce the air flow on the camera sensors. The air intake (fig 3) is located on the side of the front plate of the PyroViper o Air flow can be regulated (fig 3 regulated housing air exhaust), higher flow can be provided to the lens tip, lower flow to the housing. o Maximum air flow affects only the lens system, while the delicate electronic parts receive less possible pollution in the housing. Maintenance of lens or lens tip does not require dismantling the unit o Maintenance time is much shorter o No special training required to clean the optic tip o replace lens tip or protection shroud o No risk of damaging delicate parts Regulated Housing Air Exhaust Air Intake Lens Air Exhaust Pic. 3 PyroViper lens 2 nd edition Shroud Lens Tip Shroud Pic. 4 PyroViper lens 2 nd edition disassembled Although a great breakthrough, there was room for improvement: Still, all optical and mechanical elements are fixed. There is no adjustment possibility. Access to the electronics still implies a risk to damage cables or sensors. Comparison-Lens-PyroViper-4thEdition.AC doc Page 4 of 10

5 3 3 rd edition (TE) probe optics The release of our 3 rd edition probe optics (see Fig. 5) implied a complete re-design of the PyroViper concept. Our goal, to deliver a furnace probe camera which delivers a sharp and detailed image of the high-temperature scenario. reduces the maintenance cycles and efforts allows fine adjustments to optimize optical and mechanical properties With these key ideas in mind, the following improvements have been realized with respect to the 2 nd edition (which already included quick-change probe optics and protection shroud, see this again in Figs. 6 and 7): The protection shroud is adjustable (Fig. 8). This allows to change the size of the opening at the lens tip, regulating the relation pressure/air flow to achieve an optimum between cooling and purging o In order to adjust it, pull off the shroud loosen the two allen headless screws loosen the lock ring that keeps the flange in place. Turn the flange to the desired position and do these steps backwards o An optimum balance in the air flows guarantees long maintenance-free periods The lens tip o is screwed to the probe optics. o Is equipped with an optical zoom (See Fig. 9) Loosen the two allen headless screws Turn the nodal in and out, to zoom in and out respectively o Has a small optical bank inside (see Fig. 10) Rotate the last lens holder to help focus o Includes adjustable bearers to center the lens tip with the opening of the protection shroud (see Fig. 11). The inner flange o Is screwed to the probe optics o Has a more stable and accurate fixing to the housing o Allows a continuous adjustment of the optical axis (see Fig. 12) Loosen the three allen screws Turn to the desired position Fix the screws o o The air intake has completely separate ways for camera and lens tip, allowing to divide not only the flows, but also the pressures The new housing design allows accessing the camera electronics without risk for the cables and sensors. (Fig. 13) o The lens tip and probe optics are optimized through computer-simulated models to achieve a sharp image rich in details. The Interface to retraction system o is attached to the front plate o allows access to the camera electronics while monitoring the kiln / boiler / cooler Comparison-Lens-PyroViper-4thEdition.AC doc Page 5 of 10

6 Conclusion: The 3 rd edition probe optics keeps and enhances all maintenance/cleaning advantages of the 2 nd edition, but also offers more versatile adjustments for an optimal performance. This covers also small changes of the kiln/cooler/boiler that may happen during full maintenance stops at the plant, like geometry changes or changes in the performance (kiln running at a higher temperature, more dust in the cooler, etc.). Moreover, the imaging properties have been improved. Pic. 5 PyroViper Camera head 3 rd edition assembled Pic. 6 PyroViper Camera head 3 rd edition with dismounted protection shroud Pic. 7 PyroViper Camera head 3 rd edition with dismounted probe optics Headless screws Shroud flange Lock ring Pic. 8 Details of adjustable protection shroud Comparison-Lens-PyroViper-4thEdition.AC doc Page 6 of 10

7 Nodal Last Lens Holder Headless screws Pic. 9 Lens Tip detail - optical zoom Pic. 10 Lens Tip detail focus through third lens Centering bearers Pic. 11 Lens Tip detail adjustable bearers Pic. 12 Detail of adjustable probe optics flange Pic. 13 Easy access to the camera electronics without risk Comparison-Lens-PyroViper-4thEdition.AC doc Page 7 of 10

8 4 th edition (4E) probe optics The experience gathered with many successful 3 rd edition cameras working reliably all around the globe showed that there was still some room for improvement by polishing up a few details in various areas: a) Electrics Full electrical isolation of the sensors to avoid eventual ground loops (see Pic. 15). b) Housing 1. Sideways mounting of the measuring transducers to optimize the housing space (Pic. 16). 2. Newly developed centering and focusing units, intuitive and easy to adjust (Pics. 17&18) c) Interface housing-probe 1. Complete separation of the probe optics from the camera housing (Pics. 14, 19) Feed-through system for the thermocouple by means of a compliant plug to fully detach the probe. 2. New flange-mount system for the probe optics via clamp ring for more flexible optical designs. d) Probe 1. Tight fit for most optical and mechanical parts (e.g., lens tip), minimizing the amount of threaded pieces for a faster and cleaner maintenance (Pic. 20) inch compliant optical system while keeping the same camera interfaces The optic tube and achromat holders re-designed to house industry-standard 1-inch lenses improving SWIR imaging without compromising the air flow. Integration of thermocouple with probe optics: permanently fixed to groove on optic tube. 3. Engraving on mechanical elements holding the optics together Clear marks indicate how to put the unit together after maintenance. 4. Fixed end-position of achromats in the achromat holders The previously introduced optical bank for achromats in their holders proved to be too much of a good thing, since some users were not able to put them back together properly. e) PyroViper Interfaces 1. Universal size: standardized 145mm housing: simple upgrade from entry-level to high-end. 2. The separate air-intake for housing and probe optics becomes standard for all models (Pic. 14). Extremely useful for on-site adjustments, possible fine-tuning while in operation. 3. Introduction of a carrying handle (Pic. 14) 4. Introduction of additional sensors for process control (Pic. 15&21) An extra 19-pin plug expands the possibilities to monitor the status of the Pyroviper camera. a. A differential pressure switch in the housing gives an alarm if the air supply to the lens tip is insufficient, covering thus failures like hose break or similar. b. Upgrade of additional sensors is possible any time f) Protection shroud 1. Minimized air consumption with maximum air purging/cooling effect and optics protection. Computer-aided optics optimization leads to smaller air purging holes (Pic. 22). In short, the 4 th edition probe optics offers more features and is even more reliable, easier to adjust, use and service, with more add-on functionality, lower consumption and improved maintenance periods. Comparison-Lens-PyroViper-4thEdition.AC doc Page 8 of 10

9 Pic. 14. Camera overview 4 th edition optics with separate air intakes Pic. 15 Electrical isolation of mounting flange and new pressure switch Pic. 16 Sideways mounting of measuring transducers Pic. 17 Centering unit Pic. 18 Focusing unit Comparison-Lens-PyroViper-4thEdition.AC doc Page 9 of 10

10 Pic. 19 Integrated thermoelement in probe optics via compliant plug on clamp ring Pic. 20 Lens tip with tight fits for easy adjustment Pic. 21 Additional plug for add-on sensor features Pic. 22 Smaller air purging hole Note: The design is subject to improvement without previous notice. The pictures are only illustrative and the actual appearance of the product may vary. Comparison-Lens-PyroViper-4thEdition.AC doc Page 10 of 10