Paper manufacturers cannot afford to manufacture defective products in this globally competitive market. Web inspection and monitoring is becoming increasingly important. Paper manufacturers can rely on working with a specialist with extensive industry know-how to bring appropriate technology improving production.
This is the case with the Web Inspection System and the Web Break Monitoring from ISRA PARSYTEC, which unifies the tasks of line inspection and event capturing in a single platform. The Web Break Monitoring system uses robust sensors consisting of ruggedized housing with integrated cameras, LED illumination, and embedded PC and one or more Web Inspection Systems connected to a server and a control unit via a Gigabit Ethernet. A platform thus includes it all: inspection, process monitoring and analyzing for web breaks and events. This design idea saves installation costs by eliminating many duplicate costs.
All information with one mouse click
A paper manufacturer can access all inspection and monitoring information on the control panel, enabling him to make the right decisions. If an event is detected, the Web Monitoring System automatically opens the event, displays the analyzer, moves to the camera positions on the paper machine and presents the corresponding image and status information.
This flexibility of the Web Inspection System is supported by a wide variety of sensors being dependent upon the type of paper as well as the inspection task and providing very clear images of defects. The systems support the group of all current and future cameras up to a frequency of 640 MHz per camera. The CombiSensor uses high-performance cameras in a pulsed mode, while the lighting functions work in flash mode in two different geometric arrangements for transmission and reflection recording. These sensors combine the expertise of countless inspection system installations with high-quality technology in the paper industry. CombiSensor detects any defects in the web using reflection and transmission illumination. The CompactSensor brings further value added to the concept by integrating the lighting in the camera beam thus reducing space requirements as well as the required number of beams from 3 to 2. The sensors are insensitive to contamination, as they are mounted above the production line.
This innovation enables for example the inspection of packaging cartons with only two sensors: The CombiSensor using CompactSensor design detects all defects on the web with reflection and transmission lighting using only 2 beams.
For board or further coated applications the recommended add-on is the low angle CoatingSensor to find microscopic defects on coated surface. Important software options, such as defect tracking, defect marking, slitting analyses, statistical tools or the process analysis expert extend and complete the inspection system, turning them into universal tools for process optimization.
Efficient algorithms and advanced computer technology enable reliable detection of all relevant defects - resulting as a worst case in a web break - and provide optimal, robust defect classification. An integrated database stores inspection results and thus represents objective and comprehensive information for complete quality documentation. The Web Inspection System makes it possible to carry out cost-effective inspections with world-class results.
Perfect combination in one platform
The Web Inspection System can be combined with the Web Break Monitoring (WBM) which takes over the task of event capturing. The newly-developed sensors in the system bring together a camera, LED lighting and an embedded PC in one robust stainless steel housing. Sensors provide all the essential and detailed results information, including video data which is provided over a Gigabit Ethernet connection allowing secure transfer over long distances to a remote, central evaluation computer. Sensors are optimized for harshest environmental conditions. The screen is cleaned automatically by a flush with windscreen wipers guaranteeing the clearest possible images with low maintenance requirement. Hence, contamination of the visual field is impossible.
Valuable options complement the Web Break Monitoring system. The Trim Squirt Analysis Module gives a signal to the operator if contamination of the water nozzles has reached the edge of the contamination section in the screening area of the paper machine such that clumps fall onto the line which could cause web breaks. The Release Point Analysis Module monitors the release point of the center rolls or yankee cylinder. Should the release point no longer be in a specific tolerance area, the operator receives an alarm to prevent web break. The Tail Threading Analysis Module provides for fast and efficient start-up of paper production. The software module monitors the quality and progress of tails at critical points and thus provides clear acceleration to the start-up of the paper machine. A further module, the - Edge Analysis - unit, provides easy control of paper edges for line fluttering, movement and more.
Versatile in application
The all-in-one-platform for quality and process control covers all paper requirements including applications of coated and uncoated paper, newsprint, specialty papers, such as decorative, parchment, cigarette filter paper or even pulp and tissue, for v arious applications in packaging and for PE and metal coatings with an extruder. Paper manufacturers benefit from significant yield maximization. They can systematically improve their processes based on the results of analytical processes of inspection and monitoring platforms. But the end of the quest to complete inspection and monitoring has not yet been achieved. ISRA PARSYTEC has already more innovations in the pipeline. Stay tuned.