PDC Systems

23-25 Windermere Rd
Blackpool FY4 2BX

Thermography
Examples in an Automotive Body Shop
*>46.6C
46.0
44.0
42.0
40.0
38.0
36.0
34.0

Hot Cable Connection

Min Mean Max
34.6 38.6 48.4

32.0
*<31.3C

Bad connection on an isolator. Contact was slightly

burnt causing an increase in resistance resulting in
localised power consumption at the terminal.
*>108.7C

100.0
90.0
80.0
70.0
60.0
50.0

Area1
Min Mean Max
28.4 64.4 116.3

40.0
30.0
*<24.8C

Top connection on manual welder kickless cable. The

connection was not tight, causing a resistance joint.

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Page 1 of 6

PDC Systems
23-25 Windermere Rd
Blackpool FY4 2BX
*>126.1C
120.0
110.0
100.0
90.0
80.0
70.0
60.0
50.0
40.0
30.0
20.0

Area1
Min Mean Max
34.6 91.1 143.5

*<17.8C

This shot shows a resistance joint at the weld gun end

of a kickless cable.
*>99.3C

90.0
80.0
70.0
60.0
50.0
40.0
30.0

Area1
Min Mean Max
24.8 60.4 106.9

20.0
*<18.3C

Here we see overheating of a laminar shunt on a robot

welder.
*>86.2C
85.0
80.0
75.0
70.0
65.0
60.0
55.0
50.0
45.0
40.0
35.0
30.0
25.0

Area1
Min Mean Max
28.4 63.7 86.3

*<21.3C

Bad connection on a weld gun weld cable.

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Page 2 of 6

PDC Systems
23-25 Windermere Rd
Blackpool FY4 2BX
*>76.7C
75.0
70.0
65.0
60.0
55.0
50.0
45.0
40.0
35.0
30.0
25.0
20.0
15.0

Area1
Min Mean Max
25.2 44.7 71.4

Spot 1
58.3

*<12.4C

In this kickless cable example we see localised heating

at the connection but we also see thermal striping of
the cable. This is caused by an inadequate cooling
water supply.
*>50.0C
50.0
45.0
40.0
35.0
Area1
Min Mean Max
20.7 36.9 50.0

30.0
25.0
20.0
15.0

*<10.2C

Here we have an example of a single overheated diode

on a MIG welder.

AR01: 166.9C

153.
14
12
10
80
60
40
22 3

This is an example of a bad connection on a

transformer. Note the joint temperature is at 166.9C.

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Fax (01253) 400552
Page 3 of 6

PDC Systems
23-25 Windermere Rd
Blackpool FY4 2BX

Orange Bus: 28.1C

29.7
28
26
24
22
20
18
16 1

This example shows a section of bus with a bad joint.

Bus failures are often very expensive in terms of
safety and plant downtime.
64.8C

60
Shunt: 63.3C

50

40

30

20
19.5C

Another example of an overheated/damaged shunt.

88.3C

80
F18: 91.0C

60

40

29.9C

Here we have an example of a bad fuse connection in

a weld water pump supply cabinet.

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Page 4 of 6

PDC Systems
23-25 Windermere Rd
Blackpool FY4 2BX
29.8C

28
26

SP01: 27.6C

24
22
20
19.8C

Bad connections in transgun power supply cable.

37.0C
35
AR02: 41.4C
30

SP01

25

20
18.5C

Here was have an example of thermal striping of the

power cable to the weld gun. This type of defect is
responsible for a great deal of individual gun
downtime and quality defects.
47.7C

AR01: 41.4C
40

SP01: 41.0C

30

20
19.7C

This example shows an increased robot drive motor

temperature.

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Page 5 of 6

PDC Systems
23-25 Windermere Rd
Blackpool FY4 2BX
60.2C
60

50
Motor Body: 58.8C
40

30
Ambient: 21.0C
20.6C

This example is of a body sides gate motor. This

motor is operating at a much higher temperature than
normal caused by over tension of the drive belt.

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Page 6 of 6