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PINHOLE DETECTOR for process line CSM20

General characteristics

Schema 1

 

The CSM 20 - 1 is a high performance, opto-electronic system, based on laser technology, specifically designed and engineered for the detection of pinholes from 10 microns in diameter on a non transparent web of speeds up to 2000 M/min. Other characteristics of the system include the comprehensive, real-time reporting package, high reliability and sophisticated self-diagnostics functions.

The system produces real-time digital output signals that can be used for driving external rejection or marking devices and gives comprehensive real time production information for operators and/or quality control uses.

A real-time Rolling Map giving the cross and down web position and the size (different colours) of the detected holes - and signal-outputs representing these defects are also be provided for driving sorting operations.

Non-contact, high-speed edge tracking devices (diaphragms), are present on both sides for automatic setting of the detector in case of web size/position change. These diaphragms prevent the possibility of erroneous hole detection adjacent to the web extents – thus ensuring accurate pinhole data extending very closed to the web edges. (within 3 mm standard or 2 mm optional).  

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Self-diagnostic system

The system includes an on line self-diagnostics system test that gives the following messages:

  • Transmitter emitted energy
  • Receiver performance
  • Diaphragm performance
  • The system also includes an off-line calibration test which is used to test the system at simulated process conditions to verify its calibration.

The equipment is of static concept; all solid-state and uses structured monochromatic bundles generated by laser transmitters together with sophisticated optics and highly sensitive, semi conductor diode detectors. In consequence, distinctive characteristics of this system are:

  • Constant and highly sensitive cross-web detection
  • High web speed
  • High immunity to ambient light sources
  • Narrow uninspected edge zone
  • High tolerance for detector-to-web distance (30-80 mm)
  • Minimal downtime-maintenance (solid-state emitter and receiver elements with MTBF in excess of 100.000 hours)
  • Stable reliable operation

Specifications

Minimum Hole size: 10 micron (5 micro optional)
Web speed: Up to 2000 m/min
Web width: Standard up to 1760 mm (larger optional)
Web size change: Auto-controlled by diaphragm
Non inspected edge zone: 3.5 mm
Cross web resolution: ±11 mm (±5 mm optional)
Holes ranking: Programmable size thresholds - 2 standard. (4 optional)

System characteristics

  • Compact size, rugged construction allowing installation on pre-existing plants
  • Easy installation and removal
  • Real time continuous 100% inspection
  • Detection of 10 microns holes at web speeds up to 2000 m/min
  • Alarm based on size and density
  • Auto diagnostics facilities
  • Easy setting of detection parameters (size, density)
  • Inputs / outputs and serial port for connection to switches, PLC and computers
  • Real-time product quality monitoring
  • Low maintenance, no calibration required

Application fields

The system, being modular, is compatible with all production plants.

Systems based on this standard configuration have been designed to satisfy the needs of customers plants in the following industries :

  • Aluminium
  • Copper, electrolytic copper,
  • Steel, Tinplate
  • Other metals
  • Paper
  • Rubber
  • Plastic
  • Laminated film (food and pharmaceutical industry)

Autotest facilities

On line auto test - Detector

The On line auto test is designed as a simple, effective and reliable device for verification of correct operation and to identify faults in detector head. The test is performed internally in the detection device itself and therefore, the material being processed does not have to be cut, nor is it necessary to move the detection system off-line to make the diagnosos. When an auto test start signal is entered, the diaphragms are automatically driven accross the inspection line in order to make the scan. Flashing LED's mounted on the receiver sides of the diaphragms simulate the presence of pre-calibrated holes. The system can detect whether there are one or more defective cells and transmits the cross-web position of the failed cell via the serial link from the HDE microprocessor to the HDI C.P.U. The Operator panel displays a detailed report of system status when the test is completed.

online autotest

Off line calibration test (Quality Assurance certification)

HDL off line test system designed to satisfy ISO 9000 testing and certification.

This test is designed to confirm the correct calibration of the inspection system under controlled test conditions across the full range of the application.

To run this test there must be no strip between the transmitter and receiver heads. This can be achieved by either removal the strip or by moving the inspection to an off-line position by local means - or by using the optionally supplied EDS Head Extraction Frame.

To prepare for the test the calibration test device (HDL) is firstly mounted onto diaphragm #1 by using the supplied locking screws. The HDL motor is switched on and this drives an internal disk containing a pre-calibrated hole of known size. The hole is located at exactly the point on the disk radius such that its speed precisely simulates the maximum web-speed of the processing line.

When the off line test is started from the auto-test sub-menu, diaphragm #1 moves across the inspection head from edge to centre.

As diaphragm #1 traverses, all of the cells are tested in sequence.

The same test is repeated on diaphragm #2 in order to check all the other cells.

At the end of the test, the system gives a comprehensive report of cell condition, with the complete test only taking about fifteen minutes.

HDX Extraction Frame

Consist of a frame supporting two slideways. The detection head is mounted on the removable plates of the slideways in order to guarantee the possibility of removing the detector from the operating position for test and maintenance activity, without production stop. Four taper-pins are used to set the system in the standard operation position. Electrical connections are properly protected against mechanical damage during extraction operation.

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REPORTS - Summary

Real-time reports (displayed on the computer monitor):

  • Rolling map
  • Cross web distribution (for each class)
  • Down web alarms trend (for each class)
  • Periodic defects monitoring (optional)
  • Quality reports (optional automatically printed at the end of each coil)
  • Coil identification and defect summary (for each coil)
  • Database reports (printed on operator request)
  • Coil identification and defect summary for all produced coil

INPUT / OUTPUT

The following dedicated inputs/outputs are available as an interface to production plant:

INPUT

  • Inspection Enable: Starts full inspection, monitoring and alarming operation
  • Auto test start: Start auto test cycle
  • Inspection pause: Stops inspection, monitoring and alarming operation
  • Coil Change: Resets length and outputs coil report
  • Encoder: Coil length and speed data source

OUTPUT

  • System Alarm: Active in presence of system failure
  • Defect Alarm: Active when defects exceed alarm thresholds
  • Markers Drive: Active to appropriate marker input

Note: I/O can be open contacts or PLC type

REPORTS - Details

Rolling Map

In the rolling map windows on the x-axis, the cross web positions are represented. A coloured spot in the corresponding cross web position represents each detected hole. The down web position is indicated in the left side. The colour code used for holes classification is indicated on the right side. The rolling map is updated in real time. Cross web distribution:- For each cross-web zone, the histogram represents the actual holes count from coil head. The size colour-code is indicated on the right side. The histogram is updated in real time.

Rolling Map 1

FIG. 2

Rolling Map 2

FIG. 3

Rolling Map 3

FIG. 3

Technical Specifications

 Transmitters:

 Multiple Lasers

 Sensors:

 Multiple Semiconductor diode detectors.

 Minimum holes size:

 10 micron

 Web speed:

 Up to 2000 m. /min.

 Web width:

 Up to 1760 mm. (10 modules at 176 mm each)

 Cross web movement:

 No limits within detector sensitive area.

 Vertical jitter:

 ± 2 mm. (higher figures can slowly affect system   performance)
(Note 1)

 Cross web resolution:

 ± 11 mm. (± 5 mm optional)

 Down web resolution:

 1 mm. (Note 2)

 Holes ranking:

Two class standard

   

Four class optional

Class A = Th1 < Ø < Th2

   

Class A = Th1 < Ø < Th2

Class B = Ø > Th4

   

Class B = Th2 < Ø < Th3

 

   

Class C = Th3 < Ø < Th4

 

   

Class D = Ø > Th4

(Th1, Th2, Th3, Th4 = user programmable thresholds)

 Programmable thresholds range:

For class

   

Two class

Th1 = 10 ÷ 25 micron

   

10 ÷ 25 micron

Th2 = 26 ÷ 99 micron

   

26 ÷ 200 micron

Th3 = 100 ÷ 399 micron

   

 

Th4 = 400 ÷ 800 micron

   

 

 Inspection width change:

 Automatic diaphragm

 Diaphragm edge Overlapping:

 3.5 mm

 Defects monitoring:

 Real-time on PC display

 System status monitoring:

 Real-time on PC display

 Dedicated Outputs (opto-coupled):

 System alarm
 Defect alarm (500 m.sec standard) (Note 3)

 Dedicated Inputsn(Opto-coupled):

 Inspection Enable (500 m.sec min.)
 Coil Change (500 m.sec min.)
 Inspection Pause (500 m.sec min.)
 Auto test start (500 m.sec min., 2 sec. max.)

 Auto test:

 Continuous on transmitter On request on receiver

 Temperature:

 +5°C ÷ +50°C(extended range optional)

 Humidity:

 30 to 95% RH

 Power supply:

 110/220 V AC ± 10% 50 Hz 180 VA

 Transmitter HDT:

 Dimensions dependant on number of modules (width)  required.

 Detector HDR:

 Electronic Cabinet HDI:

 700 x 500 x 250 mm. / Weight ~ 40 Kg

Note 1: Jitter = web movement along the axis perpendicular the web plane. Variations up to ± 5 mm can be accepted whit small reduction in sensitivity.

Note 2: Two holes, on the same zone, are detected as one hole if the longitudinal distance between them is < 1 mm. at a speed of 2 m/sec.

Note 3: Defect alarm on time can be changed if required

 

EDS