Edge Inspection Made Easy

• Smart Camera Solution where all image acquisition and processing is done onboard the camera

• No moving parts with camera-based, real-time edge tracking

• Web Based Operator Interface – any computer can access the data and host the playback experience

• Wi-Fi Capable to eliminate costly cable runs from camera to operator interface location

• Auto Suspend Image Processing logic to eliminate need for any connection to sheet break system

• One-sided image acquisition (does not require a jaw design or any exposed sheet)

• Ideal for Tissue Installations where there is no exposed sheet

  • System can run against a foil

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WHY?

Edge crack issues are costly downtime events for all grades of paper manufacture. Edge cracks can cause paper breaks on the paper machines.

Worse – edge cracks that do not break the sheet at the paper machine can cause downtime on more value-add and downstream converting operations.

What is Edge Crack Detection?

• Edge cracks are structural weakness points at critical areas of web-based manufacturing processes

• This problem effects all grades of paper and when left undiagnosed it will contribute to increased downtime, waste and lower product output

• This quality issue will contribute to efficiency decreases at both the parent machine and any downstream value-add systems (converting)

It is essential to develop high ROI solutions to identify this issue

Existing Solutions

Current solutions are costly as they require extensive installation requirements and may require mechanical hardware to allow the edge crack sensor to follow the cross direction (CD) movement of the sheet. Other edge crack detection systems may require the installation of a full cross direction beam of cameras (WIS – web inspection system). Both of these options involve a wide range of project management requirements and a high long-term cost of ownership. Neither option presents a rapid deployment of the technology.

Past Solutions: WIS – Web Inspection Systems

• Camera Based

• Limited to installation requirements

  • In most cases the camera is positioned above the sheet

  • Cannot be installed on machines that have foils (tissue)

• Limited resolution depending on number of cameras and age of system (pixel density)

• Cost

• Requires extensive infrastructure

• Opportunity cost in time to design, install and commission

• Capital Project – requires multiple interconnected systems for complete solution

Past Solutions: Sensor Based with Mechanical Head

• Requires mechanical hardware (hydraulics) for sensor to track the edge

• No picture of sheet defect – sensor based only

• No control room operator interface

• Requires close proximity to sheet edge

• Requires coverage on both sides of the sheet – will not work with tissue foils

• Requires extensive infrastructure: Sensor Head, hydraulics and mounting hardware, separate junction box and connections for break signal

• Opportunity cost in time to design, install and commission

• Capital Project

Past Solutions: A Common Theme

• Missed Opportunities

• Problem must be extreme for the ROI model to work

• The means significant potential loss to the mill as the problem is often times tolerated but not capture and solved