1. www.exergen.com1 CLASSROOM TODAY’S LESSON: SPEEDBOOST

2. www.exergen.com2 Faster Start-up Direct Control of Heater Surfaces and Product Temperature Reduces Adjustments Required 8 hr 1 hr Conventional Control IR Control

3. www.exergen.com3 Reduced Scrap Less Product is Scrapped for Adjustments $1000 per set-up Conventional Control IR Control $100 per set-up

4. www.exergen.com4 Increasing Speeds via Non- Invasive IR-Monitored Heat Balance

5. www.exergen.com5 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

6. www.exergen.com6 Principles of the IRt/c: With Heat Balance Automatically Computes Heat Balance, Using Material Properties Alone Can be Configured for Unpowered or Powered Configurations

7. www.exergen.com7 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   

8. www.exergen.com8 Thermal Energy Balance in Space and Time: The Time Domain Thermal Energy Balance in Space and Time: The Time Domain

9. www.exergen.com9 Jean Baptiste Joseph Fourier 1768-1830 Fourier’s Equation of Heat Conduction Unsteady State Heat Conduction for Moving Materials

10. www.exergen.com10 Pierre Simon Marquis de LaPlace 1749 -1827 Laplace Transform Method of Solution Converts Partial Differential Equation to Ordinary Differential Equation

11. www.exergen.com11 Francesco Pompei 1948 - New Method of Solution Leads to a General Equation for Non-Contact Temperature Monitoring of Internal Temperatures of Moving Materials

12. www.exergen.com12 Which simplifies to

13. www.exergen.com13 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:

14. www.exergen.com14 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:

15. www.exergen.com15 Applying The Speed Boost Equation

16. www.exergen.com16 Speed Boost Equation is Generally Linear for Most Applications Speed % Increase % Increase 2550 25 50

17. www.exergen.com17 Implementing Speed Boost to Include Non-Linearities Speed % Increase % Increase 2550 25 50 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

18. www.exergen.com18 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

19. www.exergen.com19 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

20. www.exergen.com20 Precision Drying Control for Maximum Production Speed Relative Temperatures at IRt/c Locations Dry-Out Point (Phase Change)

21. www.exergen.com21 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

22. www.exergen.com22 Example: High Speed Color Copy Process Paper Flow Energy Flow ToToToTo T oo TsTsTsTs

23. www.exergen.com23 Overcoming Thermal Delays due to Mass of Rollers Tw Ts IRt/c. SV To Ts

24. www.exergen.com24 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

25. www.exergen.com25 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

26. www.exergen.com26 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

27. www.exergen.com27 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

28. www.exergen.com28 You Cannot Know For Sure That the Product is Right Unless You Look... With EXERGENIR Sensors