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Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE 1 THE WAY TO LOOK.

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Presentation on theme: "Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE 1 THE WAY TO LOOK."— Presentation transcript:

1 Tissue World conference, Istanbul, , Vesterinen/controlEYE 1 THE WAY TO LOOK

2 Tissue World conference, Istanbul, , Vesterinen/controlEYE 2 Tissue World conference, Istanbul, September , 2014 THE WAY TO LOOK

3 Tissue World conference, Istanbul, , Vesterinen/controlEYE 3 Convergence of converting and technology trends 1990’s2000’s2010’s Converting operating crew size Event capturing solution cost Event capturing complexity Converting speed Quality requirements Cost of production upset Cost of accident

4 Tissue World conference, Istanbul, , Vesterinen/controlEYE 4 Digital Cameras No weak links Operator friendly Instant download. Long video history Non proprietary Full web inspection integration Millwide information system (MIS) integration Required features

5 Tissue World conference, Istanbul, , Vesterinen/controlEYE 5 26/9/2014 Improper setup – notice billowing web Improper setup Holes in base sheet causing breaks Two cores inserted Bottom ply break Improper setup – log released too soon Typical events captured with controlEYE

6 Tissue World conference, Istanbul, , Vesterinen/controlEYE 6 AccuLog ™ Proven log diameter measurement within ±1 mm accuracy Eliminates manual measurement Immediate alarming if off specification Automated Log Diameter Measurement Helps eliminate post re-winder problems on the packaging line. Reduces customer claims for out of specification product

7 Tissue World conference, Istanbul, , Vesterinen/controlEYE 7 Automated accurate off-line measurement eliminating human judgment in rating embossing quality. Allows input of customer defined quality scale. Has been already adopted by a major tissue producer as their essential quality control step. Embossing Clarity Tester Quality control

8 Tissue World conference, Istanbul, , Vesterinen/controlEYE 8 Various Application Matched Architectures Mobile/Distributed/Fixed Systems

9 Tissue World conference, Istanbul, , Vesterinen/controlEYE 9 Large holes (> 10 mm 2 )

10 Tissue World conference, Istanbul, , Vesterinen/controlEYE 10 Small holes (≤10 mm 2 )

11 Tissue World conference, Istanbul, , Vesterinen/controlEYE 11 Rewinder break

12 Tissue World conference, Istanbul, , Vesterinen/controlEYE 12 Position Camera Amount Camera Type Illumination SideFunctionNotes Unwinding 2 + 2monoSynchronized Flash LEDs Cross webInspectionPixel size 0.78 mm Standoff ≥ 851 mm Printing* 1 (2) ColorFlash LEDMiddle (edges) Monitoring Event Capture Camera amount depends on visibility Embossing* 1 (2) ColorFlash LEDMiddle (edges) Monitoring Event Capture Camera amount depends on visibility Rewinding 2Ultra high speed mono Synchronized Flash LEDs OperatorMonitoring Event Capture Cutting 1ColorFlash LEDOperatorMonitoring Event Capture Event Capturing cameras on typical converting line FUTURA CONSUMER LINE #

13 Tissue World conference, Istanbul, , Vesterinen/controlEYE 13 Results Unwind output optimization

14 Tissue World conference, Istanbul, , Vesterinen/controlEYE 14 Rewinding Event Capture – image examples

15 Tissue World conference, Istanbul, , Vesterinen/controlEYE 15 controlEYE – Intuitive – effective THE WAY TO LOOK

16 Tissue World conference, Istanbul, , Vesterinen/controlEYE 16 Unwind break due to a hole

17 Tissue World conference, Istanbul, , Vesterinen/controlEYE 17 Converting Handkerchief stacker has a problem  GC 1290M 1280x460 pixel 60 Hz 1/10,000 sec  One WebLED 28 F1 (taken from existing position)  GC 680M 656x Hz 1/25,000 sec  One WebLED 28 F1

18 Tissue World conference, Istanbul, , Vesterinen/controlEYE 18 Converting Handkerchief Bundler problem located and fixed in 30 min  GC 1290M 1280x460 pixel 60 Hz 1/10,000 sec  One WebLED 28 F1 (taken from existing position)  GC 680M 656x Hz 1/25,000 sec  One WebLED 28 F1 Indicating problem After repair

19 Tissue World conference, Istanbul, , Vesterinen/controlEYE 19 Tissue Converting Line Solutions Unwind Intelligent product allocation and machine operation based on knowledge of incoming product quality (assumes web inspection on base paper machine), or Incoming product inspection with optional poor quality log ejection Determine if process interruptions occur at the unwind Printer Online monitoring of print quality Determine if process interruptions occur at the printer Possible measurement of print-to- perforation distance (feasibility study required) Laminator / Embosser Offline & possible online monitoring of embossing quality Online monitoring of glue presence on applicator roll (if visible) Determine if process interruptions occur at the laminator/embosser Rewinder Determine if process interruptions occur at the rewinder Measure log diameter at +/- 1mm accuracy Log Saw Monitor log saw blade to determine maintenance requirements Safety – Improve overall line safety by providing visibility to inaccessible machine areas. Efficiency – Improve overall line efficiency by solving the root causes of process interruptions via synchronized visibility of the web across all camera views. Quality – Improve product quality by providing tools to identify quality problems and to reject poor quality product. Service – Improve service capabilities with remote service offerings that include picture-by-picture visibility of stored events at up to 400 images per second.

20 Tissue World conference, Istanbul, , Vesterinen/controlEYE 20 The future FUTURA CONSUMER LINE #2 LocationCamera typeNotes 1.Crane1 x Color – HD (Wifi) 2. Unwinding2 x Color – HD 3. Unwinding2 x 2 B&W – HD – HFR 4. Printing1 x Color – HD – HFR? 5. Embossing2 x Color – HD – HFR 6. Rewinder2 x B&W – HFR 7. Log Saw2 x Color – HD 8. Core Area1 x Color – HD 9. Core Trim Cutting2 X B&W – HFR

21 Tissue World conference, Istanbul, , Vesterinen/controlEYE 21 The mobile operator / maintenance station

22 Tissue World conference, Istanbul, , Vesterinen/controlEYE 22 24/7: Real-time window to the process & automatic controls Before event: Early warning After event: Immediate review and possibility to drill down to history State of the art o Easy, intuitive, modern user interface o WIS + Event capturing = controlEYE o Digital application specific cameras and enclosures o Large database of event examples to refer to o Flexible MIS integration conclusions

23 Tissue World conference, Istanbul, , Vesterinen/controlEYE 23  30 systems installed on various diaper lines  Many repeat orders  Latest digital GigE 120 to 1000 images/second cameras operating at full VGA+ resolution  Typical line configuration uses 8 to 15 cameras with the needed connection points (junction boxes)  Quickly improve OEE (Overall Equipment Effectiveness) by faster start-ups and reduced downtime And there are more verticals: Diaper Line Solutions

24 Tissue World conference, Istanbul, , Vesterinen/controlEYE 24 THE WAY TO LOOK


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