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CONTROL OF APPEARANCE AND DIMENSIONAL OF REFRACTORY BRICKS FOR INDUSTRY

Refractory bricks are essential for the construction and maintenance of industrial furnaces used in sectors such as steelmaking, glassmaking, cement production, or incineration. Designed to withstand extreme temperatures, thermal shocks, and chemical corrosion, they must meet rigorous standards for quality and performance.

A PRECISE CONTROL IS ESSENTIAL FOR:


  • Ensure a perfect fit to guarantee the sealing and stability of structures.
  • Prevent thermal losses that can compromise energy efficiency.
  • Meet resistance standards and avoid cracks or premature wear.
  • Optimize industrial performance, directly influencing thermal efficiency and the lifespan of equipment.

THE CHALLENGE


Before the installation of a control system, several issues were affecting the quality of the refractory bricks:

  • Lack of material leading to structural defects.
  • Breaks and flaws affecting the durability of the material.
  • Aesthetic defects compromising the product's compliance.
  • Multiplicity of simultaneous controls, making the process complex and demanding.

The implementation of a suitable industrial vision system was intended to allow for the precise inspection of each brick without slowing down production.

THE METHODOLOGY


To address these challenges, CODA Systems has deployed a multi-modal online control solution, combining several technologies:

Installation of an automated test bench, optimized for a demanding industrial environment.

Three Keyence profilometers coupled with an XG-X controller, performing simultaneously:

  • Dimensional measurement (height, width, length) of the bricks.
  • Detection of material defects with a precision of 5 mm (breakage, onset of rupture…).
  • Inspection of stains and aesthetic anomalies.
  • Adaptive program, capable of automatically managing different brick references without recalibration.
  • Ultra-fast processing capability, with 2000 profiles analyzed per second and a control speed of 1.6 meters per second.

THE RESULTS


Thanks to this innovative solution, the refractory brick manufacturer now benefits from automated and efficient quality control:

  • Transition from a non-existent control to a 100% online inspection.
  • Increased reliability through precise detection of dimensional and appearance defects.
  • Reduction of defects and losses, optimizing the profitability of the industrial process.
  • Intelligent automation, ensuring rapid adaptation to different brick references.

The integration of this industrial vision technology allows refractory brick manufacturers to optimize their production and ensure products that meet industry standards. CODA Systems supports manufacturers in implementing tailored solutions that combine precision, speed, and advanced automation.

ANY QUESTIONS ?

If you would like to share a project or need more information, our team is at your disposal.

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