Start with the process decision

Define what the operator or machine must do differently: hold a part for review, record a temperature trend or request a maintenance check. Choose a specific station, part family and operating condition. A colourful thermal image alone is not an acceptance criterion.

For a heated assembly process, the question might be whether a defined surface region follows an agreed temperature profile while the visible camera confirms the part is correctly positioned. For a motor, it might be whether its thermal pattern has changed under a comparable load. These are different measurement and validation tasks.

Choose a thermal camera for measurement, not just an image

If the decision depends on temperature values, evaluate radiometric output and the camera’s supported operating conditions. Emissivity, reflected apparent temperature, distance and any infrared window affect the measurement setup. Document these settings together with the calibration procedure. A bright region is not automatically an overheating component.

Confirm the smallest feature that must be measured, working distance, field of view and how much the part moves during acquisition. Verify the selected lens, sensor and mounting arrangement using representative parts before fixing the enclosure design. See the FLIR measurement parameter guidance and OEM radiometry integration guidance.

Give thermal and visible images distinct jobs

The visible camera can locate the part, check its assembly or identify the region to inspect. The thermal channel adds information about surface temperature patterns. Align the fields of view and timestamps, and test how motion or a change in part orientation affects the correspondence. Do not treat an attractive overlay as proof that both sensors measured the same point.

Use the simplest analysis that supports the decision. A temperature threshold or defined region may be sufficient. Evaluate an AI model when variation makes fixed rules inadequate, using examples from different loads, shifts and relevant defect conditions.

Connect local processing to the existing line

An edge computer can acquire the sensor data, run the chosen analysis and record the evidence needed for review. Specify how it exchanges results with the PLC, operator interface or maintenance system. Agree the permitted delay, trigger behaviour and response to a missing frame, sensor fault or lost connection.

Electronics, embedded software, connectors, cooling, the enclosure and service access should be designed together. Alvexis can scope this as a custom engineering project around selected third-party thermal sensors. Camera selection, supply and integration are agreed within the project scope.

Validate a small pilot before scaling

  • Record the process conditions and a repeatable reference measurement.
  • Agree acceptance criteria and review false alarms as well as missed events.
  • Test startup, interruptions, reconnection and operation at the intended line speed.
  • Define who reviews an alert, what evidence is stored and how settings are maintained.

A thermal anomaly is evidence to investigate, not a fault diagnosis by itself. Keep the maintenance decision tied to process context and other measurements.

Bring the measurement problem to engineering

Share the material, temperature range, target feature, working distance, line speed and required interfaces. Include representative samples or data where available. We can then agree the sensor selection work, prototype scope and validation responsibilities.