Recognized globally for its excellence in instrument development, Heraeus is launching Chameleon Foundry, an automated temperature measurement system with fiber optic-based technology, at Metallurgy 2025. The company’s portfolio includes sensors and accessories for controlling metallurgical processes, with a focus on applications such as measuring temperature, oxygen content, carbon content and other parameters critical to foundry quality.
Chameleon Foundry is a totally innovative temperature measurement system that uses fiber optics to take temperature readings in liquid metals, eliminating the need for disposable cardboard-based sensors and conventional thermocouples. The solution was developed especially for use in cast iron foundries, meeting the highest requirements for precision and reliability.
Unlike traditional technologies, in which the operator needs to approach the furnace or ladle containing liquid metal to insert lances with single-use sensors, Chameleon Foundry allows the entire operation to be controlled remotely from the control pulpit. Fully automated, the temperature measurement system injects the optical fiber into the metal bath, collects the temperature reading in real time and returns the data with maximum precision, all without exposing the operator to the risk of splashes or extreme heat.
DIFFERENTIALS OF THE FIBER OPTIC TEMPERATURE MEASUREMENT SYSTEM
Traditionally, temperature measurement in foundries is done with disposable thermocouples mounted on cardboard tubes, which require not only direct contact with the metal, but also constant maintenance of cables, immersion lances and frequent replacement of parts. This model generates a high volume of waste, requires considerable storage space and also entails high logistical costs for transporting the sensors, which generally occupy three to four pallets per load.
With Chameleon Foundry, all this is drastically reduced. A single 10 kg fiber optic coil can measure up to 6,000 times and replace several pallets of conventional sensors, resulting in space savings in the warehouse, reduced freight costs and, above all, less environmental impact. The elimination of paper tubes means fewer trees cut down, less waste generated and a significant step towards cleaner and more sustainable processes within the foundry.
In addition, as the temperature measurement system eliminates the need to constantly replace components, there is less need for maintenance, which translates into more operational availability and less downtime on production lines.
Operator safety is one of the main advantages of this technology. In environments with high temperatures, the risk of metal splashes and intense radiant heat, every human approach represents a potential incident. With the Heraeus fiber optic immersion measurement system, direct worker exposure to liquid metal is eliminated, which reduces accidents and improves the working environment.
In addition, automated control via the pulpit allows the operator to take readings more frequently and accurately, optimizing melting cycles and reducing thermal energy losses due to inefficient measurements. This also means that the ideal temperature is reached more precisely, avoiding overheating, energy waste and rework. This integrated automation contributes to more reliable and consistent process control, which in turn has a direct impact on the quality of the end product, whether it’s the manufacture of iron castings, steel components or copper alloys.
ABOUT HERAEUS
With decades of experience and a solid global reputation, Heraeus is one of the world’s leading suppliers of industrial instrumentation for process control in foundries and steel mills. Its sensors, equipment and systems are used by major industrial groups around the world, always with a focus on efficiency, safety and innovation. The company maintains research, development and technical support centers in different countries, guaranteeing local service, team training and ongoing support for Brazilian customers, such as the launch of the fiber optic temperature measurement system.
Its global presence, combined with its proximity to local markets, allows Heraeus to offer customized solutions for different production realities, from medium-sized foundries to large industrial operations.
