Thermal Imaging and High-Frequency Vibration Sensing
Azitec combines thermal imaging with 24/7 Oscillot ultrahigh frequency vibration sensing to monitor IsaMills™ during disc upgrades. Thermal imaging provides a useful visual reference, while Oscillot acts as the primary observation platform for identifying abnormal mill behaviour.
About this Project
Challenge
Thermal images can be misleading when viewed alone. Hot spots do not automatically mean abnormal wear or failure, so thermal data must be interpreted with mill history, operating context and supporting monitoring data.
Solution
Azitec recommends daily thermal imaging during disc upgrades, captured at the same time each day with a fixed temperature range. Images are reviewed alongside Oscillot vibration data to support faster, more informed investigation.
Outcome
During a November 2025 review, Oscillot detected elevated and erratic vibration readings at sensor MIDA06. A thermal inspection confirmed unusual heat activity in the same area, despite no abnormal noise being detected. Investigation found excessive media loading caused by the IsaCharger being left operating in manual media mode. Once several tonnes of media were removed, both vibration and thermal patterns returned to normal.
Key Metrics
- 24/7 Oscillot vibration sensing as primary monitoring.
- Thermal imaging used as a supporting diagnostic tool.
- Daily thermal checks recommended during upgrades.
- FLIR C5 and FLIR E8 cameras used in recent trials.
- Elevated MIDA06 vibration triggered investigation.
- Thermal imaging confirmed abnormal heat activity.
- Several tonnes of excess media removed.
- Vibration and thermal patterns returned to normal.
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