Array Infrared Temperature Sensor: Redefining Temperature Measurement

In the era of Industry 4.0 and smart manufacturing, temperature monitoring has evolved from single-point measurement to heat-field distribution analysis. Traditional single-point infrared thermometers cannot capture localized anomalies, while contact sensors struggle in high-temperature, high-pressure, or high-speed environments. The Nexisense 600-400 array infrared temperature sensor, with a 16×4 array design, provides multi-point, non-contact thermal imaging, offering comprehensive and safe temperature solutions for power, metallurgy, chemical, and food industries. This article details its technical principles, key advantages, and typical applications, helping engineers rethink temperature measurement strategies.

Introduction: From Single-Point to Array Measurement

Industrial temperature anomalies often manifest as localized hotspots rather than uniform changes. Traditional infrared guns or single-point sensors can only "point measure," easily missing potential hazards. Contact probes are limited by installation difficulty and safety risks.

The Nexisense 600-400 array infrared temperature sensor uses a high-sensitivity infrared array detector, acquiring 16×4=64 independent temperature points in a single scan to create a regional heat distribution map. This array design greatly enhances monitoring dimensions, making it ideal for uneven heat sources, moving targets, or hard-to-access environments.

Technical Principles and Core Performance Advantages

The array infrared temperature sensor is based on thermal radiation: each pixel independently receives infrared radiation from the target area, converts it into an electrical signal via a micro thermopile array, and calculates temperature in real time using internal algorithms. Compared with single-point sensors, it functions like a miniature thermal imager but with smaller size, lower cost, and faster response.

The Nexisense 600-400 measures from -20℃ to +300℃, with accuracy ±2℃ or ±2% (whichever is larger), resolution 0.1℃, and millisecond-level response time. The 16×4 pixel layout offers a wide field of view (customizable), suitable for mid- to close-range area scanning.

Its housing is made of premium 304 stainless steel, rated IP65, resistant to corrosion, high temperature, dust, and water. The wide voltage supply range of 5–30V ensures compatibility with common industrial power sources. The RS485 interface supports Modbus/RTU protocol for PLC, SCADA, or IoT integration, enabling remote data acquisition and multi-device networking.

Value of Multi-Point Heat Distribution Monitoring

Single-point measurement only indicates "overheating," while the array shows "where and how heat is distributed." This provides richer information for fault diagnosis:

• Identify hotspot location and area to determine causes like poor contact, uneven load, or insulation aging;

• Monitor temperature gradients to warn of thermal runaway;

• Support independent threshold alarms for multiple zones for precise management.

In practice, this multi-dimensional data significantly improves alert accuracy, reducing false alarms and missed detections.

Typical Applications and Project Value

• Power Equipment Monitoring: High-voltage switchgear, busbar joints, and transformer windings are prone to localized overheating. The 600-400 can be installed inside cabinets for real-time multi-point scanning, triggering alarms when hotspots exceed thresholds, preventing arc flash accidents.

• Chemical and Metallurgical Reactors: Uneven temperature distribution in reactors or furnace walls may cause local overheating or coking. The array sensor covers large areas, providing comprehensive thermal maps to support process optimization.

• Food and Pharmaceutical Consistency Control: Drying tunnels and sterilization equipment require uniform temperatures. Array monitoring detects dead spots, ensuring product quality.

• Mechanical Equipment and High-Speed Components: Bearings, gearboxes, and rotating parts are hard to contact; array non-contact monitoring captures temperature anomalies for preventive maintenance.

System Integration and Expansion Potential

The RS485 interface supports Modbus/RTU and up to 32 devices on a bus. Users can view real-time thermal maps, historical trends, and alarm logs. AI algorithms can later enable automatic hotspot recognition and fault classification for predictive maintenance.

Flexible installation options: standard threaded or bracket mount, customizable viewing angles (horizontal/vertical), achieving true plug-and-play deployment.

FAQ: Common Questions

What is the difference between array and conventional infrared sensors?
Conventional infrared sensors measure a single point, while array sensors capture 64 temperature points simultaneously, creating a regional heat distribution map for more comprehensive monitoring.

Is 16×4 pixel resolution sufficient for industrial use?
For mid- to close-range monitoring (e.g., inside switchgear or pipe sections), 64 pixels are enough to clearly identify hotspot positions and trends. Higher resolution arrays can be custom ordered if needed.

Does the sensor get affected by high ambient temperature?
The stainless steel housing and internal thermal isolation support stable operation from -20℃ to +85℃, ensuring high-temperature measurements are not influenced by sensor temperature.

Does it support remote monitoring and alarms?
Yes. Through Modbus integration, multiple threshold alarms can be configured, with notifications via SMS/email for unattended monitoring.

Conclusion: Array Measurement Unlocks Industrial Temperature Management

The Nexisense 600-400 array infrared temperature sensor, with its non-contact, multi-point, and durable design, redefines temperature measurement in complex industrial environments. It overcomes the limitations of traditional methods and provides reliable data for equipment safety, process optimization, and preventive maintenance.

Choosing a field-adapted array sensor today means lower failure risks, higher production continuity, and smarter operational modes. Nexisense continues to innovate in sensor technology, helping industries achieve precise and comprehensive temperature monitoring.