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PINHOLE DETECTOR for cutting line CSM10

General characteristics

csm10

 

The CSM10 is a high performance, opto-electronic system, specifically designed and engineered for the detection of the presence of holes from 20 microns in diameter (15 micron optional) on a non-transparent web of speed ranging up to 2000 m/min. Other characteristics of the system include real time detection and sophisticated self-diagnostics functions.

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

Non-contact, high-speed edge tracking devices (diaphragms) are present on each side of the detector for automatic edge 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.

In case of system failure, on line self-diagnostics immediately alerts the line operator.

An off line calibration test performs a complete system check under simulated, standard process conditions.

The operator panel has the facility for display of status messages and setting of operating parameters.

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The equipment is of static concept; all solid-state and uses structured monochromatic bundles generated by Light Emission Diodes 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 (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:

20 micron diameter (15 micron optional)

Web speed:

up to 2000 m/min

Inspection width:

From 0 mm to 2112 mm (4 to 12 modules x 176 mm.)

Web size change:

Auto-controlled by diaphragm

Non inspected edge zone:

3.5 mm

System characteristics

  • Compact size, rugged construction allowing installation on pre-existing plants
  • Easy installation and removal
  • Real time continuous 100% inspection
  • Detection of 20 micron (15 micron optionak)  diameter holes at web speed in up to 2000 m/min
  • Alarm based on adjustable threshold detection
  • Serial-link auto-diagnostics facilities
  • Easy setting of detection parameters (size, density)
  • Inputs / outputs interface to switches, PLC and computers
  • Low maintenance, no calibration required

Application fields

These systems have been designed according to customer needs and are compatible with all production plants. Strip manufacturing and processing:

  • 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 -- the complete test only taking about ten minutes.

INPUT / OUTPUT

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

INPUT

  • Inspection Enable: Starts inspection, monitoring and alarming when active
  • Inspection pause: Pauses inspection (inhibits defect detection) when active.

OUTPUT

  • System Alarm: Active in presence of any system or sub-system failure
  • Defect Alarm: Active when defects exceed alarm thresholds
  • Markers Drive: (Optional)

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

TECHNICAL SPECIFICATIONS

 Transmitters:

 Multiple LED arrays

 Detectors:

 Multiple opto-electric detectors

 Minimum holes size:

 20 micron diameter (15 micron optional)

 Web speed:

 Up to 2000 m. /min.

 Inspection width:

 From 0 to 2112 mm (4 to 12 modules x 176 mm.) (Note 1)

 Cross web movement:

 ± 20 mm.

 Vertical jitter:

 ± 2 mm. (Note 2)

 Rejection threshold:

 Minimum 25 micron (Defined at order placement)

 Inspection width change:

 Automatic diaphragm

 Diaphragm edge overlapping:

 3.5 mm

 Dedicated Outputs (opto-coupled):

 System alarm: Serial output
 Hole detection: 500 m.sec (Note 3)
 Marker drive: to suit application

 Dedicated Inputs (Opto-coupled):

 Inspection Enable (500 m.sec min.)
 Inspection Pause (500 m.sec min.)

 Temperature:

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

 Humidity:

 30 to 95% RH

 Power supply:

 110/220 V AC ± 10% 50 Hz 180 VA

 Web Width (No. Modules):

 4

7

10

12

 Max. Web Width (mm):

 704

1252

1760

2112

 Overall Head Width (mm):

 994

1522

2050

2402

 Head Length (Line space required) (mm):

 300

 Electronic Cabinet HDI:

 500 x 400 x 210 mm. Weight ~ 10 Kg.

Note 1: Different sizes optional

Note 2: Jitter = web movement along the axis perpendicular the web plane. Variations of ± 2 mm in specification but variations up to ± 5 mm can be tolerated with a little reduction in sensitivity.

Note 3: The duration of the alarm time is adjustable.

 

EDS