CLASSROOM TODAY’S LESSON: SPEEDBOOST

Faster Start-up Direct Control of Heater Surfaces and Product Temperature Reduces Adjustments Required 8 hr 1 hr Conventional Control IR Control

Reduced Scrap Less Product is Scrapped for Adjustments $1000 per set-up Conventional Control IR Control $100 per set-up

Increasing Speeds via Non- Invasive IR-Monitored Heat Balance

Frontiers Principles of the Heat Balance in Time and Space The Speed Boost Equation Balanced Heat Input via IR Control Applications – Laminating, Drying, Printing, Heat Sealing, Color Copying High Speed Event Detection

Principles of the IRt/c: With Heat Balance Automatically Computes Heat Balance, Using Material Properties Alone Can be Configured for Unpowered or Powered Configurations

Non-Invasive Fluid Temperature in Tubing via IRt/c Heat Balance T a T s T f R f R t R o T w Radiation + Convection Heat Transfer q  T RRR R TTT f fto o saa   

Thermal Energy Balance in Space and Time: The Time Domain Thermal Energy Balance in Space and Time: The Time Domain

Jean Baptiste Joseph Fourier Fourier’s Equation of Heat Conduction Unsteady State Heat Conduction for Moving Materials

Pierre Simon Marquis de LaPlace Laplace Transform Method of Solution Converts Partial Differential Equation to Ordinary Differential Equation

Francesco Pompei New Method of Solution Leads to a General Equation for Non-Contact Temperature Monitoring of Internal Temperatures of Moving Materials

Which simplifies to

Deriving The Speed Boost Equation Set the surface temperature equal to the center temperature, then the equation reduces to Since K 2 /K 1 is a function only of material properties and speed:

The Speed Boost Equation General Equation for Non-Contact IR Temperature Monitoring of Internal Temperatures of Moving Materials is Combined with Surface TemperatureGeneral Equation for Non-Contact IR Temperature Monitoring of Internal Temperatures of Moving Materials is Combined with Surface Temperature Leads to Uniform Material Temperature When Controlled via the Speed Boost EquationLeads to Uniform Material Temperature When Controlled via the Speed Boost Equation Which Forces the Control System to Apply Heat at an Optimally Balanced RateWhich Forces the Control System to Apply Heat at an Optimally Balanced Rate The ratio can be formed, which then becomes:

Applying The Speed Boost Equation

Speed Boost Equation is Generally Linear for Most Applications Speed % Increase % Increase

Implementing Speed Boost to Include Non-Linearities Speed % Increase % Increase Apply step-wise speed increases in accordance with speed boost equation, and renormalize at new operating condition to account for property changes. For variable speed systems, program to follow the characteristic curve. Speed Changes Followed by Renormalization

Existing Set-up: T oo = 105 C T s = 85 C T o = 25C New Set-up: T oo = 120 C T s = 85 C T o = 25C Potential Speed Increase*:  25% Example Speed Boost: Laminating *Assuming all other factors are permitting T oo ToToToTo TsTsTsTs

Existing Set-up:Existing Set-up: T oo = 260 C T s = 85 C T o = 25 C New Set-up:New Set-up: T oo = 260 C T s = 85 C T o = 40 C (with preheat) Potential Speed Increase*:Potential Speed Increase*:  33% Example Speed Boost: Drying *Assuming all other factors are permitting ToToToTo T oo TsTsTsTs

Precision Drying Control for Maximum Production Speed Relative Temperatures at IRt/c Locations Dry-Out Point (Phase Change)

Example Speed Boost: Heat Sealing Existing Set-up: T oo = 150 C T s = 120 C T o = 25 C New Set-up: T oo = 150 C T s = 120 C T o = 45 C (with preheat added) Potential Speed Increase:  27% ToToToTo T oo TsTsTsTs

Example: High Speed Color Copy Process Paper Flow Energy Flow ToToToTo T oo TsTsTsTs

Overcoming Thermal Delays due to Mass of Rollers Tw Ts IRt/c. SV To Ts

Speed Boost Equation Above Can Be a Simplified Control Algorithm Keep Equation Balanced to Within a Few % to Avoid Non-Uniformity in Material Temperature Heat Source Temperature Control Loop Gain Product Surface - setpoint Product Input

Existing Set-up: T oo = 105 C T s = 85 C T o = 25C New Set-up: T oo = 120 C T s = 85 C T o = 25C Potential Speed Increase*:  25% Example Speed Boost: Laminating *Assuming all other factors are permitting T oo ToToToTo TsTsTsTs

Existing Set-up:Existing Set-up: T oo = 260 C T s = 85 C T o = 25 C New Set-up:New Set-up: T oo = 260 C T s = 85 C T o = 40 C (with preheat) Potential Speed Increase*:Potential Speed Increase*:  33% Example Speed Boost: Drying *Assuming all other factors are permitting ToToToTo T oo TsTsTsTs

Example Speed Boost: Heat Sealing Existing Set-up: T oo = 150 C T s = 120 C T o = 25 C New Set-up: T oo = 150 C T s = 120 C T o = 45 C (with preheat added) Potential Speed Increase:  27% ToToToTo T oo TsTsTsTs

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