Ircon ® ScanIR ® 3 Linescanner How to deal with sectors/zones? Rev. A 07/2013

Never out of range – the positioning of sectors/zones Always the best results – an overview to the sector/zone modes The unique one – using the Automatic Sector Sectors/Zones – Agenda

Sector vs. Zone Sector for continuous processes 1-dimensional portion of a line Calculation with each new line Sector Result Zone for discrete/discontinuous processes 2-dimensional grid Calculation with each snapshot Zone Result

Sector/Zone: Properties Set of properties: Name Size and position (fixed) Mode for a unique result Alarm threshold Output interface for the result (digital/analog hardware output module, DDE interface, etc.) Can overlap partially or completely Number of sectors/zones supported by the software is practically unlimited (Number of sectors/zones supported by the scanner itself is limited!)

Sector: Positioning Fixed position for a sector during the runtime software Sector position defined via left and right edge

Zone: Positioning Fixed position for a zone during the runtime software Zone position defined via 4 edges Concave rectangleConvex rectangleRight-angled rectangle

Zone: Positioning Comfortable positioning of zones under the Configurator’s graphical editor 1.Record a snapshot 2.Load the snapshot into the graphical editor 3.Overlay the zone grid like desired

Never out of range – the positioning of sectors/zones Always the best results – an overview to the sector/zone modes The unique one – using the Automatic Sector Sectors/Zones – Agenda

Sector/Zone: Modes The sector/zone mode provides one unique result – in most cases, a temperature value Does one really need this many modes?

Sector/Zone: Modes Maximum, Average, Minimum Sector Maximum:90°C (194ºF) Average:80°C (176ºF) Minimum:70°C (158ºF) Maximum  detecting of hot spots Average  controlling of process devices Minimum  detecting of temperature holes Maximum  detecting of hot spots Average  controlling of process devices Minimum  detecting of temperature holes

Sector/Zone: Modes Case Study Customer runs in the averaging mode to control the process Temperature changes due to seasonal fluctuations How can one eliminate ambient temperature changes?

Sector/Zone: Modes Maximum – Average, Average – Minimum The given modes provide relative temperature differences compensating absolute temperature changes! Temperature differences represent the sector only – no need for readjustments! Sector Maximum – Average = 90°C – 80°C = 10°C Process = 80°C Sector Maximum – Average = 80°C – 70°C = 10°C -10°C Process = 70°C

Sector/Zone: Modes Greater Value: (Max – Avg) or (Avg – Min) Sector Maximum – Average = 90°C – 80°C = 10°C The mode provides relative temperature differences independent from the direction of deviation! Average – Minimum = 80°C – 75°C = 5°C Greater Value (10°C) or (5°C) = 10°C

Sector/Zone: Modes Case Study Monitoring of glue tracks on a supporting material finally used for nappies Temperatures close to ambient  quite noisy signals Glue tracks

Sector/Zone: Modes Maximum – Minimum Sector Maximum – Minimum = 30°C – 24°C = 6°C Maximum – Minimum maximizes the sector result, especially for noisy measurements!

Sector/Zone: Modes … an aspect in regard to averaging 2 units Does the archer hit the target in the average?

4°C Standard Deviation = 4°C 2°C Standard Deviation = 2°C Sector/Zone: Modes Standard Deviation Sector The standard variation shows how much variation exists from the average! Average 30°C Sector Average 30°C

Sector/Zone: Modes Case Study Monitoring the operator’s loading efficiency in a tempering oven Bad loading Better loading Loading area

Threshold: 80°C Sector/Zone: Modes Covered Area The Covered Area counts the pixel above a threshold and relates it to the total number of pixels! … configure a zone completely, covering the whole snapshot Covered Area: 45%

Sector/Zone: Modes Case Study Monitoring of polymer rollers refining paper surfaces A too steep temperature increase indicates a wrong alignment of the roller © Metso Paper Machine

Sector/Zone: Modes Gradient, positive gradient, negative gradient Gradient:detection of rising or falling slopes Positive gradient:detection of rising slopes only Negative gradient:detection of falling slopes only Gradient:detection of rising or falling slopes Positive gradient:detection of rising slopes only Negative gradient:detection of falling slopes only … represents the steepness and the direction of a slope Sector ∆ Temp Length ∆ Temp !

Sector/Zone: Modes Case Study Hot spot detection for glass wool processing (continuous process) © Saint-Gobain Isover G+H AG Uncritical Critical! A simple sector running in Maximum mode cannot do the job because it calculates the result for each line separately!

Sector Line 2 Line Line Sector/Zone: Modes Max of Area Max of area monitors for hot spots over multiple lines in continuous running applications! Area building: adjacent pixel defined by a threshold Pixel counting: alarm threshold via number of adjacent pixels Area threshold: 80°C Alarm threshold = 5 pixel No alarm! (4 pixel) Alarm! (6 pixel)

Sector/Zone: Modes Snapshot Counter Zone result is increased by 1 with each new snapshot Zone result is a number and not a temperature value any longer Mode can be used as life indicator (“heart beat”) for the remote control system

Never out of range – the positioning of sectors/zones Always the best results – an overview to the sector/zone modes The unique one – using the Automatic Sector Sectors/Zones – Agenda

Automatic Sector Case Study Manufacturing of bonded multi-layer materials Uniform coating of a polymer layer onto the paper board: a) detecting of gaps/holes over the process width b) detecting of too fast running edges © Tetra Pak GmbH © SIG Combibloc GmbH, Germany Significant running edge requires alarming

Automatic Sector Position Temperature Top Bottom Valid area Temperature gap! Waving edge Left edge Right edge

Automatic Sector Automatic Sector is dynamically positioned via: a) Gradient (similar to the generic sector) b) Temperature threshold

Automatic Sector Automatic Sector detects: a) running/waving edges (velocity for the edge position) b) temperature gaps (threshold related to the sector average)

Automatic Sector For standard sector modes, use subsectors Automatic Sector width not constant  give the subsector width as a percentage Subsectors represent separated rollers Automatic Sector Subsector1Subsector2 20%40%60%80% © Tetra Pak