Cyclops Meltmaster delivers return on investment for Indian foundry liquid metal temperature measurement

3 min read

The Cyclops 055L-2F Meltmaster portable non-contact thermometer from AMETEK Land offers high-quality castings producer, PSG Foundries, accurate temperature measurement of liquid metal, while providing a much higher level of operator safety and achieving significant savings on consumables.

PSG Foundries, the foundry division of PSG and Sons based in Coimbatore, India, was established in 1974 to supply high-quality castings for engineering industries both at home and overseas. The foundry produces a wide range of grey iron, SG Iron (nodular / ductile) and Ni-hard castings of high integrity, creating a niche for itself in the global market. In total, PSG Foundries produces approximately 600 tons of high-quality castings per month.

PSG Foundries required an effective solution for accurately measuring the temperature of liquid metals at its foundry.  The business purchased over 10,000 DIP thermocouple consumables each year and was looking for a solution that was both safer and more cost effective. Its aim was to optimise the quality of the molten metal, whilst achieving significant annual savings on consumables.

AMETEK Land recommended the Cyclops 055L-2F Meltmaster, a high-precision portable non-contact thermometer that provides accurate measurement of liquid metal temperatures in the range 1000o to 2000 °C /1832o to 3632 °F.

Cyclops Measurement PSG FoundriesHow does is work?

The operator stands 3-4 metres away from the molten metal and points the Cyclops Meltmaster at the liquid.  The operator pulls the trigger to take a measurement. That measurement is then displayed in four simultaneous modes, including Continuous, Peak, Valley and a unique advanced Meltmaster measurement mode to meet users’ specific requirements.

A clear, wide angle field of view and small, clearly defined measurement area help to ensure accurate sighting.  All processed temperature values are shown continuously on the display when the trigger is pressed.

Return on Investment

PSG Foundries already has achieved an annual saving on DIP thermocouples, which the plant had used previously to measure the temperature of molten metal at a cost of about $6,000 per annum. The AMETEK Meltmaster represents a good return on investment, since its purchase it has paid for itself in less than 6 months, plus the instrument uses no consumables.

In addition, the Meltmaster will accrue greater value to the foundry over the years by enabling it to deliver the best and most consistent mould value by accurately measuring liquid metal temperatures using a single instrument.

The Advantages

In addition to a relatively quick return on investment, the Cyclops 055L-2F Meltmaster offers PSG Foundries several other advantages.  Because of the non-contact nature of its measurement, there are health and safety benefits to using the Meltmaster. It is much safer from an operational point of view. The temperature readings are triggered from a distance of 3 to 4 metres away from the molten metal, providing a much higher level of operator safety.

There is the high accuracy of the Cyclops 055L-2F Meltmaster, even while taking the temperature of the pouring of the last mould. The instrument is renowned for its ability to measure real liquid metal temperatures, regardless of high-temperature sparks, low-temperature water vapour, dust and smoke, which can cause errors in temperature measurement.

PSG Foundries 3The instrument features four trigger operating modes for datalogging.  Modes are available from logging a measurement for each trigger release to precisely executed pre-configured routes for consistent, repeated long-term readings. This innovative pyrometer can store up to 9,999 readings.

Emissivity compensation is provided via an icon-based menu system.  The operating waveband is carefully chosen to minimise errors due to uncertainty in emissivity and the effects of atmospheric vapour components, such as steam or hot sparks. Consistency of measurement is assured as the Cyclops Meltmaster offers excellent repeatability.

With on-board storage, the Cyclops 055L-2F provides fast, simple data logging with Bluetooth® and USB connectivity to download this data to PC or mobile device for analysis and trending.

Its rugged instrument casing is designed to withstand harsh environments for extended periods.  It also features a lens protector that maintains the optics in good condition.

The ergonomically friendly equipment is designed for single-hand operation, with contact-free measurement for better safety and easier use in hazardous environments.

“AMETEK Land’s Cyclops Meltmaster infrared, non-contact thermometer is a highly effective solution for accurate temperature measurement of molten metal. It provides easy, accurate point-and-measure temperature readings. Since its introduction, our plant has significantly reduced our expenditure on disposable DIP type thermocouples,” comments Mr. S Kuppusamy, Vice President of PSG Foundries.

“Foundries in India have come to recognize the major advantages of our Cyclops Meltmaster both in terms of cost savings and in safer plant operation,” notes Prasath Venkatasamy, National Service Manager for AMETEK Land in India.  “Also, since the equipment is made in India and calibrated in our own NABL-accredited laboratory, our customers benefit from an easier transaction, shorter delivery times, local technical support, and access to annual calibration services.”