Infralytic NGO3-W Online Infrared Water & Oil Film Thickness Gauge

Overview

The Infralytic NGO3-W is a high-precision, non-contact online thickness gauge engineered for real-time quantification of residual water and rolling emulsion (oil) films on moving metal or ceramic strip surfaces during continuous hot or cold rolling and post-rolling processing. Utilizing calibrated near-infrared (NIR) absorption spectroscopy in the 1.4–1.9 µm spectral region—where H₂O and hydrocarbon bonds exhibit strong, distinct absorption features—the NGO3-W delivers trace-level film mass measurement without physical contact, thermal disturbance, or process interruption. Designed specifically for integration into high-speed production lines (up to 2,500 m/min), it operates at ≤120 Hz sampling frequency, enabling millisecond-scale response to dynamic film thickness variations across strip widths up to 2,200 mm. Its fixed 200 mm working distance and ±20 mm vertical tolerance accommodate typical mechanical vibrations and strip flutter in industrial coil winding stations, ensuring stable optical alignment under harsh plant conditions.

Key Features

• Non-contact NIR spectroscopic measurement—no calibration drift from wear, contamination, or temperature-induced sensor deformation
• Dual-parameter output: simultaneous, independent quantification of water (H₂O) and hydrocarbon-based lubricant (e.g., mineral oil, synthetic ester) mass per unit area (mg/m² or g/m²)
• Robust optomechanical housing (IP65-rated) with thermally stabilized detector and reference channel for long-term signal stability
• Integrated real-time display module showing live film mass values directly on operator HMIs—no external PC required for basic operation
• Modular mounting design compatible with standard roll stand frames or coil winder interstices; installation depth ≤100 mm
• Factory-calibrated for common rolling emulsions and deionized water films; optional user-specific calibration kits available for specialty lubricants

Sample Compatibility & Compliance

The NGO3-W is validated for use on all electrically conductive and non-conductive strip substrates—including carbon steel, stainless steel, aluminum alloys, nickel-based superalloys, and technical ceramics—without requiring surface preparation or reflective coating. Its NIR-based methodology eliminates interference from substrate emissivity, surface roughness (Ra ≤ 6.3 µm), or ambient lighting fluctuations. The instrument complies with EU Machinery Directive 2006/42/EC, Electromagnetic Compatibility Directive 2014/30/EU, and RoHS 2011/65/EU. Manufacturing adheres to ISO 9001:2015 quality management standards. While not a medical or pharmaceutical device, its data traceability architecture supports GLP/GMP-aligned process documentation when integrated with validated SCADA or MES systems.

Software & Data Management

The NGO3-W communicates via standard industrial protocols including EtherNet/IP, PROFINET, and Modbus TCP. Raw spectral data and processed film mass values are timestamped and transmitted with 16-bit resolution. Optional Infralytic AnalyzeSuite software provides spectral visualization, batch trend analysis, alarm threshold configuration (e.g., >15 mg/m² water trigger), and automated report generation compliant with FDA 21 CFR Part 11 requirements—including electronic signatures, audit trails, and data integrity controls. Historical measurements are stored in SQLite or SQL Server databases with configurable retention policies (default: 90 days). All firmware updates are digitally signed and delivered via secure HTTPS.

Applications

• Optimization of post-rolling drying sections: reducing energy consumption by eliminating over-drying via closed-loop feedback to radiation heater banks and high-volume air knives
• Rolling emulsion consumption monitoring: correlating measured oil film mass with emulsion flow rate, concentration, and nozzle performance to detect degradation or clogging
• Surface cleanliness validation prior to annealing, galvanizing, or painting—ensuring <5 mg/m² residual moisture to prevent blistering or adhesion failure
• Process deviation detection: identifying upstream issues such as defective emulsion recirculation, uneven spray bar distribution, or strip edge thinning
• Energy balance auditing: quantifying water removal load (kW·h/t) across multiple coil batches for ISO 50001 energy management reporting

FAQ

Can the NGO3-W distinguish between free water and bound emulsion?
Yes—its multi-wavelength NIR algorithm separates absorption contributions from O–H stretching (water) and C–H stretching (hydrocarbons), enabling independent quantification even in mixed-phase films.
Does ambient temperature affect measurement accuracy?
Internal thermal stabilization maintains detector and optical path temperature within ±0.5 °C of setpoint; compensation algorithms correct for minor substrate temperature gradients up to 150 °C.
Is recalibration required after mechanical repositioning?
No—factory calibration is geometry-independent; only verification using certified reference foils (provided annually) is recommended per ISO/IEC 17025 guidelines.
What maintenance does the NGO3-W require?
None beyond quarterly optical window cleaning with lint-free wipes and isopropyl alcohol; no consumables or moving parts are present.
Can it be retrofitted onto existing rolling mills?
Yes—its compact footprint (519 × 264 × 100 mm) and flexible mounting brackets enable integration into space-constrained locations, including between tension reels and entry looper pits.