ContiVision - Web Break Analysis System


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ContiVision - Web Break Analysis System

  1. 1. ContiVisionContiVision™™ GossGoss ContiwebContiweb™™ Web Break Analysis SystemWeb Break Analysis System September 2013
  2. 2. 2 • What is it? – A system that allows the printer to optimize the printing process, prevent (recurring) web breaks and claim web breaks caused by paper related issues, in order to improve overall productivity and reduce printing costs • ContiVision automatically determines for every web break: – The exact time – The exact break location – The process circumstances at the moment of the web break – The variations in paper quality (holes, cracks, …) – The most probable cause of the web break ContiVisionContiVision –– Web break analysis systemWeb break analysis system
  3. 3. 3 ContiVisionContiVision –– Web break analysis systemWeb break analysis system Data logger Data analysis software HMI Camera system / recorder Camera movies Statistical information Analysis information Web break cause list Sensors/measurementsCameras
  4. 4. 4 System overview (1)System overview (1) • Central industrial PC with 24“ monitor with analysis software – System is connected with Contiweb through VPN for remote diagnostics – System is part of PARS (Pro Active Remote Service): statistical web break data is reported through PARS • Connection with Contiweb splicer – Splicer is equipped with “webdata” (reel management software including barcode scanner) • Connection with Contiweb dryer with integrated chill rollers – Including dryer and chill web tension measurement
  5. 5. 5 System overview (2)System overview (2) • Connection to web severer • Connection to web catcher • Web break sensors press (existing and additional) • Web tension measurement folder (existing)
  6. 6. 6 System overview (3)System overview (3) • Camera system – In the splicer cameras with automatic fault detection till 18 m/s – Camera before the dryer – Cameras in folder – Expandable with additional cameras • In total about 80 signals are used to analyze the web break
  7. 7. 7 Software for analysis (1)Software for analysis (1) • Web break is detected by the loss of the web tension, measured in the chill roller section • The web break position and process circumstances are determined by the analysis of all 80 signals of measurement data • Web break cause is researched from several hundred theoretically possible causes with following inputs: – Break position, process circumstances and measurements – Paper information – (A minimum of) responses from the operator
  8. 8. 8 Software for analysis (2)Software for analysis (2) • Break time, location, process, relevant process data and possible causes (with probability calculation) are shown for every web break
  9. 9. 9 Software for analysis (3)Software for analysis (3)
  10. 10. 10 Software for analysis (4)Software for analysis (4)
  11. 11. 11 Camera System (1)Camera System (1) • Registration of paper defects in the paper roll, as close as possible after unwinding • Automatic creation of web break analysis report including photos, video and production data • Allows discussion with paper supplier about paper related web breaks and any possible claims
  12. 12. 12 Camera System (2)Camera System (2) • Area scan cameras, gigabit Ethernet connection • LED lighting • State of the art hardware
  13. 13. 13 Camera System (3)Camera System (3)
  14. 14. 14 Web break analysis report (1)Web break analysis report (1) • Report contains: – Exact web break time – Exact web break location – Basic paper data (reel number, paper type, …) – Unwound length – Photo evidence of paper defect – Video evidence is available as attachment (.avi) – Extended report: additional process information, e.g. • Process state (printing, washing, …) including history • Web tension and fanout signals • Web speed • Temperatures – Remarks from printer
  15. 15. 15 Web break analysis report (2)Web break analysis report (2)
  16. 16. 16 ContiVisionContiVision -- SummarySummary • Automatic analysis of all web breaks – Time, location, process, cause – Allows process improvements in the printing press – Allows prevention of recurring web break (causes) • Automatic paper fault detection – Allows claims for paper related web breaks, but only if paper was the proven root cause of the web break • Separate system with own measurement signals and connections to existing equipment for presses with a Contiweb splicer and dryer with integrated chill