THE WAY TO LOOK
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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Tissue World conference, Istanbul, September 25 - 26, 2014
Tissue Converting Lines Integrated
with Smart imaging Achieve New
Levels of Efficiency & Product Quality
Anttoni Vesterinen
ControlEYE
Espoo, Finland
THE WAY TO LOOK
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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Convergence of converting and technology trends
Converting operating crew size
Event capturing solution cost
Event capturing complexity
1990’s
2000’s
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
Converting speed
Quality requirements
Cost of production upset
Cost of accident
2010’s
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Required features
•
Digital Cameras
•
No weak links
•
Operator friendly
•
Instant download.
•
Long video history
•
Non proprietary
•
Full web inspection integration
•
Millwide information system (MIS) integration
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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Typical events captured with controlEYE
Holes in base sheet causing breaks
Improper setup
Improper setup – notice billowing web
26/9/2014
Bottom ply break
Improper setup – log released too soon
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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Two cores inserted
Automated Log Diameter Measurement
AccuLog™
Proven log diameter measurement within ±1 mm accuracy
Eliminates manual measurement
Immediate alarming if off specification
Helps eliminate
post re-winder
problems on the
packaging line.
Reduces
customer claims
for out of
specification
product
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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Embossing Clarity Tester
Quality control
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.
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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Various Application Matched Architectures
Mobile/Distributed/Fixed Systems
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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Large holes (> 10 mm2)
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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Small holes (≤10 mm2)
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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Rewinder break
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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Event Capturing cameras on typical converting line
Position
Unwinding
Printing*
Embossing*
Rewinding
Cutting
Camera
Amount
Camera
Type
Illumination
Side
Function
Notes
2+2
mono
Synchronized
Flash LEDs
Cross web
Inspection
Pixel size 0.78 mm
Standoff ≥ 851 mm
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1
(2)
Color
Flash LED
Middle
(edges)
Monitoring
Event Capture
Camera amount
depends on visibility
13
1
(2)
Color
Flash LED
Middle
(edges)
Monitoring
Event Capture
Camera amount
depends on visibility
2
Ultra high speed
mono
Synchronized
Flash LEDs
Operator
Monitoring
Event Capture
1
Color
Flash LED
Operator
Monitoring
Event Capture
1
14
15
1
12
13
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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15
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Results
Unwind output optimization
Typical reduction in
unwanted process
interruptions due to
poor incoming product
100%
50%
10 to 50%
REDUCTION
Initial
Post event capturing system
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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Rewinding Event Capture – image examples
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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controlEYE – Intuitive – effective
THE WAY TO LOOK
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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Unwind break due to a hole
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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Converting Handkerchief stacker has a problem
GC 680M 656x492 pixel @ 200 Hz
1/25,000 sec
One WebLED 28 F1
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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Converting Handkerchief Bundler problem located and fixed in 30 min
GC 680M 656x256 pixel @ 399Hz
1/25,000 sec
One WebLED 28 F1
Indicating problem
After repair
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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Tissue Converting Line Solutions
•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.
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-toperforation
distance
(feasibility study
required)
Laminator /
Embosser
•Offline & possible
online monitoring of
embossing quality
•Online monitoring of
glue presence on
applicator roll (if
visible)
Rewinder
•Determine if
process
interruptions
occur at the
rewinder
Log Saw
•Monitor log saw
blade to determine
maintenance
requirements
•Measure log
diameter at +/1mm accuracy
•Determine if process
interruptions occur at
the
laminator/embosser
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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The future
Location
Camera type
1. Crane
1 x Color – HD (Wifi)
2. Unwinding
2 x Color – HD
3. Unwinding
2 x 2 B&W – HD – HFR
4. Printing
1 x Color – HD – HFR?
5. Embossing
2 x Color – HD – HFR
6. Rewinder
2 x B&W – HFR
7. Log Saw
2 x Color – HD
8. Core Area
1 x Color – HD
9. Core Trim Cutting
2 X B&W – HFR
Notes
18
19
1
17
15
12
12
14
13
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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The mobile operator / maintenance station
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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conclusions
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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
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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And there are more verticals: Diaper Line Solutions




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
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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THE WAY TO LOOK
Tissue World conference, Istanbul, 26.9.2014, Vesterinen/controlEYE
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