Image processing and Grid-Based analysis for detection of non-uniform Heat Distribution: A comparative study

This paper presents a detailed comparative analysis of detecting non-uniform heat distribution over a metal disk, which serves as a baffle for a custom-designed heat exchanger, using thermocouples and a thermal camera (FLIR Lepton 2.5, 60x80 pixels). The experimental setup involves placing K-Type thermocouples in a grid pattern over the surface and positioning the thermal camera at a fixed height/distance. The thermal camera has a stated accuracy of ±5 degrees Celsius. Controlled non-uniform heating is applied to the metal disk, and temperature data are recorded using both the thermocouples and the thermal camera. The study aims to assess the accuracy, spatial resolution, and effectiveness of each method for detecting non-uniform heat distribution over metal surfaces. The findings offer valuable insights into the strengths and limitations of thermocouples and thermal cameras in both industrial processes and academic research. In our case, we gained an in-depth understanding of the thermal distribution of the baffle, providing guidance for process optimization, design refinement, and quality control.