Presentation is loading. Please wait.

Presentation is loading. Please wait.

Presented by: Les Jenson Chief Engineer Beta LaserMike

Similar presentations

Presentation on theme: "Presented by: Les Jenson Chief Engineer Beta LaserMike"— Presentation transcript:

1 Presented by: Les Jenson Chief Engineer Beta LaserMike
2011 AIMCAL Technical Conference Non-Contact, Laser-Based Technology for Accurately Measuring the Length and Speed of Product in Web Coating and Lamination Presented by: Stuart Manser, Beta LaserMike Presented by: Les Jenson Chief Engineer Beta LaserMike BETA LaserMike

2 Introduction Technology of a Non-Contact Length and Speed gauge
Describe how it works Three applications examples: Coating and Lamination Control Continuous Length Stretch and Draw

3 Traditional Length & Speed Measurements
Accomplished by using a roller that contacts the material being measured The material turns the roller as the material moves An encoder or tachometer is attached to the roller Generates pulses as the wheel or roller rotates Relies on friction between the material and roller

4 Disadvantages Tachometers/Encoders
Error caused by slippage Dependent on friction Wheel pressure Product surface Lubricant on surface Recalibration Diameter change because of wear Diameter change because of build-up Maintenance Bearings and other mechanical parts wear out

5 LaserSpeed History LaserSpeed technology was developed in 1984
Aluminum/Steel Mills Small integrated gauge developed in 2001 Smaller Cheaper Easy to Install High Accuracy – 0.05%

6 System Concept FPGA- Signal processing PCB
Laser diode assembly with temperature control Proprietary beams steering optics and receiving optics Measuring region

7 Non-Contact Gauge Technology

8 Non-Contact Gauge Technology
Two laser beams cross at an angle 2K K bisects the two laser beams Constructive and Destructive Interference cause a Fringe Pattern The Fringe Pattern consists of light (constructive) and dark (destructive) stripes

9 Fringe Pattern Expanded
Constructive Interference occurs when two laser beams are in phase and add together to equal the original laser density - light stripe Destructive Interference occurs when two laser beams are out of phase and the two laser beams cancel each other out - dark stripe

10 Fringe Pattern Generation
Fringe Pattern looks like an elongated football Measuring region (Depth of Field) is where the fringe pattern exist Project this fringe pattern on the surface of the product to be measured

11 Laser Doppler Velocimetry (LDV) Theory
Fringe direction

12 No Calibration Required
Wave length of the laser is fixed and constant Laser diode based system Laser diode is temperature controlled Crossing angle is created optically No moving parts in optics package Crossing angle is permanently fixed Fringe Spacing ‘d’ is fixed and cannot change

13 No Calibration Required
Frequency measurement uses an all Digital Signal Processor Autocorrelation algorithm High measurement rate High measurement accuracy High measurement repeatability Signal processor is all digital and has no drift or measurement error

14 No Calibration Required
Length is achieved by numerically integrating the speed Permanently calibrated with very high accuracy

15 Non-Contact Gauge Block Diagram - Dual-Beam Laser Interferometer
Diode Laser Acusto-Optical Modulator Product Optical Beam Splitter Photo -Detector Received Light Receiving Lens (15mm) Fringe Direction Measurement Region

16 Coating and Lamination Control Application
Manufactures label products Depends on accuracy of line’s drive speed and contact encoder to: Apply adhesive and easy release coatings to backing Apply varnishes to face of label Control speed of two or more materials during lamination of clear material to printed face stock Measures product length to apply exact quantity of coatings and lamination

17 Problem Inaccurate length and speed measurements
2% error Slippage due to texture, slick coatings, lubricants, etc. Contact method relies on wheel circumference and # of rotations Contact measurement wheel: Rides on product Builds-up debris or wears down Requires recalibration

18 Scrap Cost Calculation
2% length and speed inaccuracy 20,000 foot roll 400 feet of uncertainty Each roll costs a significant amount in unnecessary expense Scrap = roll length x material cost/ft x contact encoder accuracy (2%)

19 Solution Install non-contact laser gauge at specific measurement points on the line Control length and speed of lamination line and coating application +/- 0.05% speed accuracy Instead of 400 foot per every 20,000 feet of uncertainty Lowers error to a max of 10 ft on a 20,000 foot roll Coating Control Lamination Control

20 Continuous Length Application
Manufactures diapers, pads, liners and pull-on style disposable underwear Slitting and cut-to-length requirements

21 Problem Lubricants caused slippage errors – 2.5%
Slippage errors always make the product length long 2.5% slippage error on a 1000 foot makes the actual length 1025 foot Give away 25 foot for every 1000 foot produced

22 Scrap Cost Calculation
Manufacture produces between $2 to $4M of product on this line per year Over length error of 2.0% cost between $40,000 and $80,000/year/machine

23 Solution Non-contact laser gauge was installed on in-feed side of parent roll Non-contact gauge has no slippage errors Potential saving of $40,000 to 80,000/Year Reduced maintenance costs No recalibration No moving parts to wear out

24 Stretch and Draw Application
Manufacturers require: Draw down of thin sheet to consistent thickness Draw and drive rollers pull product down at same speed Draw down to specific controlled thickness with minimal variance and breakage

25 Problem Drive speeds and contact encoders do not provide accurate measurements Tension problems, product composition, and texture cause slippage errors Slippage error - 1% to 2% Wheel wear, dirt buildup causes calibration errors Calibration is directly proportional to the circumference of the wheel Down time for recalibration

26 Solution Install non-contact laser gauge at each critical measurement point along the line Non-contact laser gauge directly measures product Slippage is not a problem +/-0.05% accuracy provides reliable, precise stretch and draw measurements Eliminates any measurement guesswork and uncertainty

27 Summary Non-Contact Laser Gauge Advantages No slippage error - optical system and does not contact the product Permanently calibrated – Laser Interferometer Optical system No moving parts to wear out Accuracy: +/-0.05% Repeatability: +/-0.02%

28 Summary Continued Complete System in one small rugged package
Sensor Processor I/O Power Supply 24 VDC operation IP67 protection Built-in water cooling ports 26.25 X X 10.5 cm 2.54 Kilograms

29 Thank You -- Questions

Download ppt "Presented by: Les Jenson Chief Engineer Beta LaserMike"

Similar presentations

Ads by Google