System Overview

1. System Overview Model 2060 Infrared Flaw Detector Technology Bruce T. Dobbie

2. Mission Statement R.K.B. OPTO-ELECTRONICS, INC. is a designer and manufacturer of high-speed machine vision web inspection technologies and related products. We are committed to web based material manufacturers, converters, customers and our industry that depend on us to guarantee that product superiority is maintained at the highest possible level. We are dedicated to increasing customer satisfaction, continuously improving our products and services, and providing opportunities for our employees to achieve their maximum potential.

3. Product: Infrared Flaw Detector; Model 2060 http://www.rkbopto.com/rkbproducts/2060.html or http://www.webinspection.us/rkb_products/literature/m2060.html FOR MORE INFO...

4. Technology

5. Overview of Technology Our Infrared Flaw Detection Technology offers quality inspection of web based materials for holes and various visual defects  (i.e., bugs, oil, dirt and scale). our infrared defect detection technology has all of the system electronics contained in one single NEMA rated free standing console.  Generally located near the tender control stations, this integrated control unit facilitates both installation (by eliminating the need for several time consuming connections) and operation (by improving accessibility and maintenance through the consolidation of all components into one location).  Lamp driver circuitry, sensing and noise reduction circuitry, power supplies, sensitivity controls, output processing systems and audio/visual alarm and system software displays are located inside the enclosure.

6. Overview of Technology Operation:  Using an array of phototransistors located very close to the web material surface at 1 inch (25mm) intervals (cross direction), the photo cells monitor the intensities of infrared light.  The phototransistors are mounted on interchangeable PCB modules in an air purged inspection enclosure.  Each inspection module consists of 6 transistors that cover 6 inches (15.24cm) of cross direction web.  Each module is a quick connect with various test points for easy and complete system check and maintenance.

7. Overview of Technology A Narrow inspection aperture, typically 1/32" (0.8mm) wide in the machine direction limits the "field of view" of each phototransistor.  This FOV reduction technique reducing formation noise normally created by unblemished material to assure a high "signal to noise" ratio.  The inspection aperture also acts as an ambient light prohibitor.

8. Overview of Technology A Narrow inspection aperture, typically 1/32" (0.8mm) wide in the machine direction limits the "field of view" of each phototransistor.  This FOV reduction technique reducing formation noise normally created by unblemished material to assure a high "signal to noise" ratio.  The inspection aperture also acts as an ambient light prohibitor.

9. Overview of Technology Distinguish between sizes of defects:    Defect size classification are standard in all technologies and allow for the removal of larger defects considered rejectable from salable product.  Additionally, the detection and monitoring of the smallest possible defects allow production the ability to monitor process machine performance, schedule proper preventative maintenance of defect causing areas and allow for production grading of material should a threshold of small defects per roll exceed a present quality limit.  All defects are classified, channelized and separated into individual reporting algorithms with location in both the cross machine and machine direction, time the event took place and size of the event.

10. Overview of Technology Add Analysis and Reporting:  Our Quality Assurance Management System (QAMS) software ToolPack also is included with each system and provides detailed information on overall production of the machine.  Repeating defect detection capabilities are included with each Flaw Detection System.  This feature enables operators to quickly located the source of the repeating defect such as wire holes, damaged fabrics and roll decomposition.  Every repeating defect will be displayed on the monitor and will indicate location in both machine and cross machine direction. 

11. Overview of Technology Unique Sensitivity Aperture ensures 100% uniform inspection of the web.

12. Overview of Technology Installation areas in most cases are prior to the take up reel (commonly referred as the jumbo roll) at the end of web material processing. Most installations should be after the basis weight gauging unit as picking can occur from gauge guides.

13. Infrared Flaw DetectorFeatures Independent lamp power supplies dedicated to power the infrared lamps used to transmit light through the web material towards the specialized inspection modules mounted above the web opposite the lamp assembly

14. Infrared Flaw DetectorFeatures Specialized Infrared quartz lamps and proprietary infrared lamp modules used depending on the application.

15. Infrared Flaw DetectorFeatures Specialized Inspection Modules utilizing phototransistor cells and proprietary processing circuitry.

16. Infrared Flaw DetectorFeatures Integrated control enclosures and operational control centers. NEMA rated, these enclosures contain all the operational CPU systems, electronic signal processing circuitry and related components. Both enclosures contain closed loop self contained air condition systems which maintain the operational environment at consistent temperature. The display enclosure is formatted as a stand alone unit with touchscreen functions with optional remote station integration capabilities.

17. Infrared Flaw DetectorFeatures Individual power on/off switches to enable or disable inspection modules for easy serviceability and maintenance procedures.

18. Infrared Flaw DetectorFeatures Precision machined hardware ensuring perfect inspection alignment

19. Infrared Flaw DetectorFeatures Environmental Sound Inspection Assembly

20. Infrared Flaw DetectorFeatures Premium DC Voltage Supplies

21. Infrared Flaw DetectorFeatures Durable and specialized Audio/Visual Alarm Systems

22. Infrared Flaw DetectorFeatures Integrated Signal Processing Systems housing the engineering workstation where all analog/digital processing is performed. As part of the serviceability of RKB systems, each system comes complete with a dual channel oscilloscope and various testing points to ensure reliable operational and serviceability is maintained.

23. Infrared Flaw DetectorFeatures • Military type connections ensure solid electrical specifications are maintained and environmental protection is achieved.

24. Infrared Flaw DetectorFeatures • Meets quality initiative and ISO requirements. • Detection 24/7 without the need for operational intervention. • Eliminate the need for manual inspections.

25. Infrared Flaw Detector Applications • Sheeters • Paper Machines • Roto • Laminators • Slitters • Coaters • Non-wovens

26. Infrared Flaw Detector Detection Results • The result is the detection of any autonomous defect like holes, dirt, bugs, scale, light spots, gels and coating voids.

27. Typical Installation

28. Typical Installation

29. Installations at Major Manufacturers

30. References • For reliability; large, medium and small companies turn to RKB for their defect fault inspection requirements.

31. Related Websites • http://www.rkbopto.com • Syracuse, New York, United States • http://rkb.chinapaper.net • Suzhou, Jiangsu, China • http://www. fioproin.it • Milan, Italy • http://www.swallowmachinery.com/ • Meltham, Holmfirth, United Kingdom • http://www.quality2process.com • Delden, Netherlands • http://www.splicedetector.net / www.hole-detection.com / www.webinspection.us / www.splicedetector.com • Syracuse, New York, United States