Con-Trol-Cure, Inc. provides an entire line of solutions to determine critical
information on UV Lamp conditions while the lamp is operating within the
curing application. The LM-9000 CONTINUOUS LAMP MONITOR SYSTEM, the
flagship of this technology, is a highly modular, computer-based, full spectrum UV data
acquisition and management system providing both Real-Time Display and Data
Storage of UV Lamp output characteristics. Our exclusive Optical Probe and
Fiber Optic sub-systems will allow permanent sensor placement inside the
curing zone, reflector housing, or even directly on the lamp.
WHY CONTINUOUS LAMP MONITORING?
The UV lamp itself is a critical variable in the entire UV curing process. Lamp
performance has classically been tested by two distinct methods: The Mechanical Testing
of the product after it has been cured and The Radiometric Measurement method. Both
methods serve their purpose, however the Mechanical Test measures only after the curing
process has been completed. While the Radiometric Method only takes an occasional
snapshot of lamp output. While both of these methods can provide valuable information,
the Continuous Monitoring of Lamp Performance throughout the Curing Process allows
you to avoid costly product failures and produce a more consistent end-product without
incident.
WHAT IS THE CONTINUOUS LAMP MONITOR?
The LM-9000 Lamp Monitor System is a computer hardware and software based
Data Acquisition System. Data is captured through the installation of our exclusive
Optical Probes within the Lamp Reflector Housing that are coupled to our Optical Bench
(mounted on an Internal PC Card, or in an External Housing) via Fiber Optic Cabling.
This data is displayed and managed by the custom Windows 3.1x / Win'95 Lamp Monitor
Software package.
1) The LM-9000 Instrument is available in two forms:
The Internal LM-9000 Instrument is a PC card (ISA or PCI Bus), mounted directly inside
the PC.
The External LM-9000 Instrument is housed in an impact resistant case that is connected
to the PC’s USB port.
Both units allow direct connection of the UV enhanced Fiber Optic Cable (below)
to the PC, bringing the full spectrum of UV light (200nm to 450nm other ranges available
on special order) into the system. The incoming "Light Sample" is broken up into
individual wavelengths and reflected onto a CCD array containing 2000 individual
sensors. Data from each sensor (and wavelength) is then displayed by the computer and
maintained in an MS-SQL DataBase. Multiple lamp configurations can be created by
incorporating the additional card units and adding additional instrument units to the
system.
2) The LM-9000 Lamp Monitor Software is Windows compatible featuring real-time
display of the Wavelength Intensity Distribution between 200 and 450 nanometers
sampled every 5 seconds, Selective Wavelength Monitoring, and a Saved Baseline
display. The LM-9000 captures all the performance characteristics of your UV Lamp
output throughout the course of each job, not just when the operator pushes a button. The
LM-9000 even saves information for later, so you can keep Process and Machine
Settings, Job Characteristics and System State information to help duplicate the exact
conditions that job required. "Events" for Selected Wavelengths can be defined to alert
operators to changes in lamp intensity.
3) The Basic Optical Probes are available as small as 1/4" diameter by 3/4" long,
intrude only 3/8" into the curing system, and are easily installed inside the curing zone,
anywhere around the lamp. Using a proprietary lens system that interface with the
connecting Fiber Optic cabling, Basic Probes will withstand up to 400° C, and come in 4
levels of Optical Attenuation, designed to address very high UV light levels when used in
High Energy (300+ watt) lamp systems.
4) The connecting Fiber Optic Cabling is designed for industrial applications, and is
specially UV enhanced to transmit all the UV energy in the 200nm to 450nm range
without loss of signal. Jacketed and encased within a flexible stainless steel covering, the
Fiber is designed to function at up to 300° C continuous operation and will not solarize
over long term UV exposure. Cables feature easy installation on Industrial Processing
equipment without fear of damage to the fiber. Cables are available in 2 meter, 10 meter
and in Custom lengths.
WHY DO I NEED CONTINUOUS LAMP MONITORING?
Many factors influence the level of cure within the UV Curing Process. As we
develop Higher Power Lamps, Newer Coating Formulations, new trends in Cooling
and IR/UV filtering, as we try to implement Higher Quality Control Standards
and Process Controls, we push the envelope of technology in the hopes of Higher
Profits, Better Throughput, and Less Wasted Time and Product. But, if the UV
Lamp itself is not providing Long Term, Reliable, Stable output at the required
Wavelengths, the entire process is compromised, or even completely inhibited.
Over the actual life of your UV Lamp, it's output varies, and declines, over
time. When your lamps are Brand New, they should produce perfectly stable, and
repeatable results. But, if that were the case, why do you suffer from product
failures? Whether occasionally (in the midst of a job), or periodically whole
jobs just don't pass Quality Control, it might be that your Lamp Itself is the
responsible agent. The LM-9000 can spot problems such as these before they
cost you time and money.
We have seen that an individual lamp loses intensity at various wavelengths
and different rates over the operating life of the lamp. We have also observed
two lamps, with the same specifications, same arc-length, on the same machine,
perform with different Wavelength Intensity Distributions. We have even seen
some older lamps perform fractionally better than a brand new lamp of the
same specifications.
OTHER CONCERNS IN THE UV CURING PRODCESS
At differing power settings, a lamp may not perform in a linear manner at every
frequency. When your electric service fluctuates, whether from natural causes,
power cutbacks, or when the shop across the street switches on the Big Machine,
your UV Curing System may be experiencing Specific Frequency Events that
can have profound effects on your production runs. Even differences in Cooling
Air temperature and how it is applied affects lamp output intensity at certain
critical wavelengths. As the power supply warms up, its output can fluctuate,
causing changes in intensity at different wavelengths. As the Lamp itself
warms up to operating temperature, output intensity at particular wavelengths
can climb to 150% of the operating maximum before settling back down. This
"Warm Up" period changes from lamp to lamp, and machine to machine as well.
BENEFITS FROM USING THE LM-9000 MONITOR
Install a new Lamp into your Curing System, and the LM-9000 Lamp Monitor will
establish the Baseline Performance Characteristics of the lamp. It will then
keep track of Lamp Performance as you run jobs, and as lamp hours accrue, it can
show when to replace the lamp with a new one.
Turn on your Curing System, and the LM-9000 Lamp Monitor will let you know when
your system has Stabilized and is ready for use. No more wasted time or product
run before the system could properly cure it.
While running a job, the LM-9000 can alert operators to Energy Output Events at
the instant they occur, allowing mid-job correction of press characteristics or
temporary pausing of the job until the problem can be corrected. Setting
intensity levels on any monitored wavelength allows output fluctuations of 25% or 50%
of the baseline to trigger an alarm. Once the LM-9000 is in place, you will no longer
suffer from inconsistent production runs, wasted product or wasted time.
You can enter pertinent data for later retrieval and tracking such as: Lamp Data, Process
Info, Machine / Location, Operator, Job Description and Settings, Coating Data, etc.
These criteria can all be saved with the actual data to help clear up any discrepancies
before they become problems.
If your client requires ISO-9000 level reporting of job Quality Control, the
LM-9000 provides it on demand. The only limit to the number of job baselines or the
length of time you can keep information on-line is your available hard disk storage space.
In addition, by running the system on MS-SQL, it can be networked locally or over the
internet for added flexibility.
_____________________________________________________________________
So, you need Mutliple Lamp, Multiple System Monitoring Capabilities? What about
Process Control Interfacing with the LM-9000 to make production line control
a reality? A visible light, as well as UV monitoring capacity is available, making control
of other aspects of product creation possible.
Do you need Temperature information as well? What about Color Process Control,
Speed Data, Product Counting, Thickness or Registration monitoring? We have
Custom Hardware and Custom Software solutions to fit all of your needs. Let Us Know
About Your Requirements and We Can Help Make It Happen.
LM-9000 SYSTEM FEATURES:
-> Continuous Monitoring of Lamp Energy
-> Full Spectral Range Sensitivity From 200nm through 450nm Range
-> Selective Wavelength Monitoring
-> Full Capabilities At Any Intensity with No Wattage Limitations
-> Automatic Calibration At Startup
-> Completely Modular Component Designs
Single or Multiple Lamp Configurations Are Available
Simultaneous Multi-Lamp Monitoring And Event Storage Capabilities
-> Choice of View Angle To the Lamp
No Environmental Barriers To Probe Installation: Temp 400ø C Max.
Probes May Be Installed Anywhere Around The Lamp, or Anywhere Along It
Small Probe Profile: 1/4" (6mm) Diameter, 3/8" intrusion into curing area
Focal Plane Positioning using the Optional Right Angle Probe
-> Long Range Positioning of Central Station to Monitored Lamps
Up To 20 meters from Central Station (Longer Ranges Are Available)
-> Selective Sampling By Hour, Minute, Day, Week or Month
-> History of Lamp Performance With:
Full Range Data Storage
Maintains All Lamp Operation Information
Records All Lamp Operating Parameters
Event Data Storage By Job, Skid, Hour, Day, Operation, Operator, Machine
Event Recording By Critical Wavelength / Critical Energy Level
-> Completely Software Controlled: Windows 3.11 or Windows '95
LM-9000 DATA COLLECTION FEATURES:
-> Lamp Data:
Date & Time of Lamp Installation
Lamp Serial Number (for tracking)
Number of Hours On (in use) and Number of Lamp Starts
Peak Irradiance at Each Wavelength
Baseline Performance of New Lamp
-> Process Data:
Operating Temperature, Power and Speed Settings
Output Energy Events
User Defined Data Collection
-> Data Storage:
Lamp & Job Baselines
Lamp & Job Description Information
-> Data Reporting Capabilities:
ISO-9000 Level Reporting
Lamp Performance Over Time
Process Data Reports On Demand
Ink/Coating, Job, Lot & Skid
-> I/O Interfacing Options for Extended Process Controls and Data Logging
-> Optional Accessories
Computer: 486 or Pentium
Light, Medium & Heavy Duty Probes
Probe & Fiber Optic Lengths
Temperature Monitoring Sensors
Visible Spectrum Optical Bench 200-1000nm
Modular System Expansion for Additional Lamps or Probes