compact scanner, advanced measurement and … · continuous investment in tissue solutions ......

EMEA HUG

COMPACT SCANNER, ADVANCED MEASUREMENT

AND CONTROL FOR TISSUEHarri Oksanen

September 25, 2019

Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.

Integrated, Real-Time Business and Manufacturing Management Order - Invoice

1

Solution from Corporate Office to Finished Goods Shipments

Order

Management

Planning and

Scheduling

Cost and Profit

Optimization

Stock Prep

Control

Pulping

Control

Recycled Fiber

ControlInvoicing

Logistics

Management

Finished

Goods &

Warehouse

Management

Quality

Management

Reel & Roll

Production

Management

Raw Materials

and Energy

Control

Paper

Machine

Control

Converting

Production

Management


Purpose-built sensors, scanners, controls, and business apps for tissue manufacturing

2

Continuous Investment In Tissue Solutions

• Business Management (Covered in OptiVision MES Session)

– Introducing OptiVision R600 – extensive tissue manufacturing solution from orders to shipments

▪ Tissue Winding, WIP and Finished Goods Inventory/Replenishment, Converting Plant, Finished Goods Product Management

• Tissue Machine Measurement and Control

– Introducing Experion® MX Q6088 Compact Scanner

– Experion MX R702

– MXIR Fiber Weight and Moisture sensor retrofit for DaVinci scanner

• Lifecycle Service and Support

– QCS 4.0 cloud-based solution for QCS system health and control/process performance

– Introducing QCS Platform Migration Package providing cyber security, peer-to-peer QCS-DCS flexible integration, Extended Historian, CD and MD Multivariable Control, Virtualization, and One-Click Upgrades

EXPERION MX Q6088 COMPACT SCANNER


Q6088 Compact Scanner Overview

4

Description Value

Maximum Beam Width 320.00 inches [8000mm]

Maximum Sheet Width

(Comply with EN349)256 inches [6400mm]

Minimum Scan Speed 50 mm/s [2 in/s]

Maximum Scan Speed Up to 355 mm/s [13.97 in/s]

Minimum Ambient Temperature ⁰C [5 ⁰F]

Maximum Ambient Temperature 65 ⁰C [ 4 ⁰F]

Web temperature (⁰C) 8 ⁰C [ 76 ⁰F]

Sensor Gap 10.2 mm [0.4 in]

Dusty Environment Protection

• Purging and sealing of end bells

and beams

• Sealed heads

• Head gap air purge

Power 115/230 VAC, 50/60 Hz

Scanner Weight173 LB + 2LB/IN

[91 KG] + [0.4 KG/CM]

Certifications CSA / UL / CE

MD Head Width 343 mm [13.5 in]

• Sealed, Temperature Controlled Head

• Non-nuclear basis weight and moisture

• All new scanner frame with tissue

environment protection

• Sensors and signal processing with

EDAQ technology

• Improved serviceability with all

electronics in one end

• Remote operator panel

• Online crepe & tissue caliper sensor

© 2019 by Honeywell International Inc. All rights reserved.

5

Q6088 Compact Scanner

• Proven scanner technology, environmentally sealed, “hardened” for use on paper, tissue, and other harsh environment production lines

• Latest EDAQ-Based Sensor Technology

– Non Nuclear MXIR Sensors

▪ Fiber Weight & Moisture

▪ Moisture

▪ Single-Sided Coat Weight

– Tissue Crepe

– Nuclear Basis Weight

(Partial list - most common sensors)


6

Compact Scanner Features and Benefits

• Low TCO, Simple to serve

• Restricted space mounting

• 25% smaller machine direction versus

Q4022-34, Q4000-80 scanners

• Optimal positioning in production process

Dual Sensor HeadStandard Single Head

• Full sheet measurement over edge

• Environmentally sealed, temperature controlled

• Beam seals and air purge prevent dust ingress

• EDAQ Technology

• QCS 4.0 Cloud-based monitoring

Simple Beam Design


Upstream

Air Blast

top and

bottom

7

24x7 Runnability in Tissue Environment

Air Knife

(Option)


Comprehensive solutions for Tissue

8

QCS Measurement Sensors: Extensive & Growing Portfolio

• Basis weight

– Infra-Red (Tissue)

– Isotope choices: 147Pm 85Kr 90Sr

– Ash insensitivity options

• Moisture

– Infrared

▪ Single Sided or Transmission

– Microwave

– ExPress Moisture (MD & CD)

• Caliper

– Contacting or Non-contacting Optical

• Ash

– Mixture insensitivity options

• Crepe (Tissue)

• Color

• Gloss

• Opacity

• Porosity

• Surface Topography

– Smoothness, Roughness

• Formation

• Fiber Orientation, Anisotropy

• Strength (ESS)

• Coat Weight

• Multi-layers/Polymers

• Sheet Temperature, X, Y & Z


Ideal non-nuclear solution for most tissue applications

9

Infrared Moisture & Fiber Weight Measurement

Advantages of MXIR technology

• Non-nuclear, single sensor solution

• Same spot measurement

– Measurement from all detectors simultaneously at 4Khz

– High frequency 200Hz process analysis

– High resolution 10mm streaks

• Multi-pass measurement

– Higher sensitivity to cellulose & moisture, less sensitive to passline variation

▪ Head alignment, X, Y & Z position

▪ Air gap temperature

▪ Scattering channel compensates dust and carbon

• Easy calibration for most tissue grades

• Continuous correction for background IR changes

Ethernet

Diffusing Reflective Surface

Dif/Ref Surface

Light Chopper

Measurement & Diagnostic

Processor

Measurement & Diagnostic Processor

Beam Splitt

er

Water Detector

Fiber

Detector

Scatter

Channel


Ideal non-nuclear solution for most tissue applications

10

Infrared Moisture & Fiber Weight Measurement

Advantages of MXIR technology

• Simplified Maintenance

• Automatic gain adjustment for all channels

• Enhanced Diagnostics

– Control lamp power monitoring by filament resistance

– Current/voltage to filament monitored

– Chopper frequency / sync signal health monitored

• Improved Reliability & Stability

– Extended InGaAs (Indium Gallium Arsenide) detectors

▪ Long life and high stability single crystal detectors

▪ Insensitive to changes in temperature


Nuclear (147Pm) BW vs. TRIR BW

0 100 200 300 400 500 600

14.5

15

15.5

16

16.5

17

scans

ave

ra

ge

BW

[gsm

]

nuclear BW

TRIR BW

Green lines = reel changes

Red lines = grade changes

Black lines = STDZ


12

Crepe – Basis of Quality Tissue


13

Crepe Impact on the Sheet


Enhanced Visibility on Tissue Process

14

Crepe Structure Measurement

• Revolutionary Honeywell sensor for tissue and towel makers

• Characterize crepe structure of sheet numerically and visually online

• Non-contacting, imaging-based measurement

• Prorietary algorithms for realtime image analysis, integral compensation ensures

– Repeatable measurement in varying conditions

– Robust performance in highly challenging environment

– Maintenance free operationMathematical algorithms:

•Topography Analysis

•Texture Analysis

Image enhancement,

e.g. dynamic dirt

correction

Visual surface

image for operator

Tissue Crepe measurements

•Crepe Micro

•Crepe Macro

•Folds per inch

•Impurity


Crepe Structure Measurement

15

• Measured Variables:

- Crepe Folds per length unit (centimeter or inch)

- Crepe Micro

- Crepe Macro

- Crepe Impurity

- Caliper*

- Stretch* (MD scan average only)

• Images captured at 10Hz rate, numeric values reported as profile and scan average

• operator can observe images from up to 4 freely selectable CD positions during each

scan

• Passline and grayscale measured as auxiliary and diagnostic measurement


Crepe Micro/Macro – Blade Change Impact

Crepe coarsiness increases as a blade wears

16

= blade change

• Rapid initial decay in micro

crepe during blade settling

• Crepe micro decreases as the

blade wears

➢ Surface softness and

silkyness decreases

• Crepe Macro increases as the

blade wears

➢ ”Energy” (=amplitude

and/or frequency) of crepe

waves increase

= blade change


Crepe Folds per Inch – Blade Change Impact

Folds/length shows good repeatability

17

= blade change

• Rapid initial decay in measurement

during first 5-15min due to blade

settling followed by more linear decay

similar to crepe micro

• As the blade wears

➢ Wave length of creping increases

➢ Bulkiness and surface area

decreases

0 1 2 3 4 5 6 7 8 970

80

90

100

110

120

130

140Grade 125

Blade Life [h]

Fold

s /

inch

1

2

3

4

5

6

7


Unique Tool Unlocks Higher Quality and Efficiency

18

Benefits of Crepe Structure Measurement

• Realtime feedback from creping

• Unprecetended tool to:

– Improve crepe quality and uniformity

– Gain crepe target faster after any upset like doctor blade change, sheet break or grade change

– Optimize complex creping process for better runnability and economy

– Enhance paper machine performance for improved converting and total efficiency

– Accelarate trial run and trouble-shooting processes

– Monitor production and equipment conditions with continuously delivered image snapshots on selectable locations across the sheet


High performance with low cost of ownership

19

Tissue Quality Control Summary

• Honeywell’s tissue quality control solution is based on proprietary MPC technology specifically engineered for challenging paper and tissue processes

• Simple traditional tuning concept has been applied to new Alpha MPC MD control

• Fully automated IntelliMap tool ensures easy maintenance and highest performance of CD optimization

• Advanced optimization features reduce energy and material costs, sustain high levels of tissue machine efficiency, increase return on investment

• Native Honeywell QCS 4.0 support solution leverages data and knowledge, pushing process performance and efficiency beyond the limits


20

Typical Quality Optimization Concept for Tissue Process

• Quality optimization architecture (CD&MD) utilize unique proprietary model predictive multivariable controllers

– Scalable

– Improved control performance

– Simplified configuration and tuning

• Native QCS 4.0 integration

Alpha MPC

MD Optimizer

Stock Flow

Control

MPC CD

Optimizer

Retention

flow

OptimizationJet/Wire

Control

Hood

Temperature

Optimization

Crepe Ratio

Control

Dilution or

SlicelipSteam

Shower

Hood

Dampers

TAD/Yeankee

Steam

Optimization

Machine

Speed

Control

Experion MX

Measurements

- Weight

- Moisture

- Crepe Structure

- Color*

Dryer Shutdown

Setpoints

Optimization Targets

Constraints

Disturbance Variables


Experion MX : All-in-One Integrated Solution for Tissue21

Moisture CD Control

- Crepe profile control

- Magibox steam generator

Reel Scanner:- Q6088 Scanner

Sensors:- IR weight / moisture

Sensor

- Kr85 & Pm147 (recycle)

- Crepe

Quality & Process Control:

- MD & CD Weight Control

- MD & CD Moisture Control

- Coordinated Yankee /

Hood Energy Control

- Grade Change Control

Web Defect Monitoring

- 2 or sets of high-speed camera

Weight

CD Control

MegaFire Yankee Hood

Burners

Crepe Quality On-line

Web Inspection

Express CD scanner

- Moisture measurement

• EPKS full integration

• Control Builder & Consoles

➢ FTE / DSA / CEE

• SIL2 & SOE

• ISASecure L2

• Ethernet/IP

• OPC UA/

• Modbus TCP

• ProfiNet

• Universal I/O

• Ring I/O network

• Simulation / SIM-UOC

Process & Safety Control

with Control Edge™

86% is fiber,

energy, &

chemicals

QCS

-Single Point

Moisture measurement

Hood Damper

CD Moisture Control


22

Case Example - Energy Optimization

• Objective to minimize total drying energy cost on a TAD machine based on the electricity and natural gas cost while keeping controlled variables within quality limits

• Two scenarios tested against traditional control application

– Minimizing natural gas consumption: 1.2% total cost reduction achieved

– Minimizing electricity consumpition: 0.6% total cost reduction achieved

– No reduction in control performance or in recovery times

AlphaMPCController


ExperionMX User

Engineering Station

Experion MX – World’s first IIoT QCS

Mill Water

Supply

Blower, Filter

MD /CDDamper Control

BW, Moi, Crepe, Coord. Speed,

FTE

OPC-DA

Inbound

traffic ONLY

4G

Routerport

Outbound

traffic ONLY

AMQP – Advanced

Message Queuing Protocol

Sentience

Cloud

Secured Data

Edge Device

Embedded PC

https://qcs.demo.dev.connectedplant.honeywell.com

http://www.google.com/url?url=http://www.photoshopdaily.co.uk/featured/new-dell-precision-workstations/attachment/dell-precision-t3600-left/&rct=j&frm=1&q=&esrc=s&sa=U&ei=jGO1VPOePMSE7gbX0IDwCA&ved=0CBgQ9QEwAQ&usg=AFQjCNHfNepweJHBM0Jn74Ctl6A4EgKW6A

https://qcs.demo.dev.connectedplant.honeywell.com/

ADDITIONAL COMPACT SCANNER DETAILS

24


Improves Safety and reduces installation time

25

Utility connection and Cable Termination at the same end

• Pre drilled holes with fittings

• Marked for identification

Utility Connection Cable Termination

• Pre drilled holes with fittings

• Marked for identification


Easy to Maintain and troubleshoot

26

All Electronics in Sealed Cable End Bell

Frame

Controller

Motor

Controller

Power

Supply

Motor

EDAQ

board

Ethernet

Switch

MSS PC

with Fan

Frame

Controller

Motor

Controller

Power

Supply

Motor

Termination

board

EDAQ

board


27

Easy Serviceability

Swinging doors

with provision

to removeFull access to

electronics


28

Comparison Q6088 Scanner with Q4000 Head

Q4000 Head


Q6088 : IIoT Scanner based on EDAQ Technology

29

• EDAQ = truly intelligent scanner

• All scanner & sensor measurements and

diagnostics available online anywhere

24x7

• Built in smart fault-models and alerting

system

• Built in PM maintenance routines

• QCS4. ready ‘out of the box’


Scanner Comparison

30

Q6088 Q4022 Q4000

Application Paper machines with basic

measurement needs

Paper machines with moderate

measurement needs

Premium scanning platform for

all paper making applications

Beam Material Extruded Aluminum Steel Extruded Aluminum

Beam Shape U-Beam I-Beam Box Beam

Max Sheet Width 6 m [236 in] 6 m [236 in] 10 m [396 in]

MD Head Width 343 mm [13.5 in] 467 mm [18.3 in]460 mm [18.1 in]

645 mm [25.4 in]

Internal Sensors 1 or 2 4 4 or 6

External Sensors 0 1 2 or 4

Max Scan Speed 355 mm/s [14 in/s] 406 mm/s [16 in/s] 1200 mm/s [48 in/s]

EDAQ / Ethernet Yes Only MXIR Yes

MSS Location Cooled Endbell Remote PMP Cooled Endbell

Advanced Diagnostics Yes No Yes

Maintenance Software Yes No Yes

Final Specifications TBD

compact scanner, advanced measurement and … · continuous investment in tissue solutions ......

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