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BETA LaserMike Presented by: Les Jenson Chief Engineer Beta LaserMike Non-Contact, Laser-Based Technology for Accurately Measuring the Length and Speed.

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Presentation on theme: "BETA LaserMike Presented by: Les Jenson Chief Engineer Beta LaserMike Non-Contact, Laser-Based Technology for Accurately Measuring the Length and Speed."— Presentation transcript:

1 BETA LaserMike Presented by: Les Jenson Chief Engineer Beta LaserMike 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 2011 AIMCAL Technical Conference

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

7 Non-Contact Laser Gauge Non-Contact Gauge Technology

8 Non-Contact Laser Gauge 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 Non-Contact Laser Gauge 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 Non-Contact Laser Gauge 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 Non-Contact Laser Gauge Laser Doppler Velocimetry (LDV) Theory Fringe direction

12 Non-Contact Laser Gauge 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 Non-Contact Laser Gauge 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 Non-Contact Laser Gauge No Calibration Required Length is achieved by numerically integrating the speed Permanently calibrated with very high accuracy

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

16 Non-Contact Laser Gauge 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 Non-Contact Laser Gauge 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 Non-Contact Laser Gauge 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 Non-Contact Laser Gauge 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 Non-Contact Laser Gauge Continuous Length Application Manufactures diapers, pads, liners and pull-on style disposable underwear Slitting and cut-to-length requirements

21 Non-Contact Laser Gauge 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 Non-Contact Laser Gauge 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 Non-Contact Laser Gauge 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 Non-Contact Laser Gauge 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 Non-Contact Laser Gauge 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 Non-Contact Laser Gauge 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 Non-Contact Laser Gauge Summary 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% Non-Contact Laser Gauge Advantages

28 Non-Contact Laser Gauge 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 X X 10.5 cm 2.54 Kilograms

29 Non-Contact Laser Gauge Thank You -- Questions


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