sensor technologie · (engineer mech./project manager) hossbach sensor technologie albert-rupp-str....

SENSOR

TECHNOLOGIE

Contents 1 Basic Information……………………………………………………………………………………….……………………… 4

2 Capacitive measuring sensors……………………………………………….......................................... 5

2.1 Sensor Systems…………………………………………………………………………….......................................... 6

2.1.1 Intermittend measurement (Interval)………………………………………………………………....................... 7 2.1.2 Permanent measurement (continuous)…………………………………….…………………………………….….…. 19

2.3 Stand-Alone Sensors………………………………………………………………………………………………….……... 25

3 Inductive measuring sensors……………………………………………………………………...................... 27

3.1 Metal detector…………………………………………………………………………………………….……….…………..… 27

3.2 Blister Count…………………………………………………………………………………………….………………..……….. 28

4 Summary…………………………………………………………………………………………………………………………….... 29

5 Appendix…………………………………………………………………………………………………………………………..….. 30

6 Cost-saving calculation tool (PowerPoint version only)…..................................... 31

HOSSBACH Sensor

Technologie

Dieter Hossbach (Dipl. Phys.; CEO)

HOSSBACH Sensor Technologie Albert-Rupp-Str. 2 D-91052 Erlangen Germany Phone: (49) 9131 – 908 668 5 Fax: (49) 9131 – 908 668 3 E-mail: [email protected] www.hst-hossbach.de

Adrian Hossbach (Engineer mech./project manager) HOSSBACH Sensor Technologie Albert-Rupp-Str. 2 D-91052 Erlangen Germany Phone: (49) 9131 – 908 668 2 Fax: (49) 9131 – 908 668 3 E-mail: [email protected] www.hst-hossbach.de

• Located in Erlangen (near Nuremberg, south Germany)

• 35 years experience (Dipl. Phys. Dieter Hossbach)

• Focus on: High-sensitive Capacititve and Inductive Sensors

• Concentration on DIFFICULT measurement applications

• Customized sensor solutions for incl. electronic data processing

• Major Industries: Pharmaceutical Industry, Hygienic Industry,

Food Industry, Textile Industry

1 Basic information

4

How do HOSSBACH SENSORS work?

All capacitive Sensors generate an electric field, which is manupulated by objects nearby. Proportional to the mass and volume of this object, the sensor outputs a) an analogue voltage or b) a digital switching signal. With >1000 measurements per second, a „scan“ of the product body is done. In dependance of sensor size and product weight, mass variations down to miligrams could be detected. NOTE: All HOSSBACH SENSORS also measures covered or enclosed products CONTACT-FREE. They work independent from lighting conditions!

0V output (analogue)

up to 10V output (analogue)

0V output (digital)

+24V output (digital)

a)

b)

2 Capacitive measuring sensors

5

Object to detect (label, adhesive tape, splice…)

2.1 Sensor Systems

How do the SENSOR SYSTEMS work? ANALYSER + FLOW CONTROLLER

The analogue signal from the sensor, which is proportional to the mass of the product section inside the sensing area is guided to the Control Unit (Flow Controller and/or Analyser) The Control Unit evaluates the Sensor Signal and computes the total weight and the weight distribution. On the computer screen you can see statistical data generated out of each single product and a product curve, which illustrates the weight distribution inside the product.

6

2.1 Sensor Systems 2.1.1 Intermittend measurement How do the SENSOR SYSTEMS work?

ANALYSER + FLOW CONTROLLER

weight distribution of

actual product (red)

Product speed up to 40pps or 10m/s

weight distribution of

recent products (grey)

Average product weight (select number)

Single product weight (product histogram)

Statistical data (current weight, average weight, standard deviation)

Computer interface with Analyser software

HOSSBACH SENSOR (QMS70-O-740,

adult diaper)

Product is scanned with up to 100 weight

measurements!

7

See appendix p.30 for impressive picture of the accuracy of the Analyser!

Product: - diaper / napkin - tubular bag - any guided product

2.1 Sensor Systems 2.1.1 Intermittend measurement How do the SENSOR SYSTEMS work?

ANALYSER + FLOW CONTROLLER

Total weight (g)

Required weight distribution

Weight distribution

All product samples have the same total weight, but they have an irregular weight distribution. With the Sensor Systems HST Analyser and HST Flow Controller these failures will be detected at full machine speed. Also foreign bodies will cause violation of the required weight distribution curve. Additionally to the described observation possibilities and the statistic data, the Flow Controller gives a real-time signal to the machine, when the required curve of weight distribution is violated.

OK product NOK product (folded)

NOK product (irregular core)

8

Measured by HST Flow Controller or HST Analyser

NOK product (displacement)

x

g(x)

WEIGHT DISTRIBUTION

t

TOTAL WEIGHT

(g)

AVERAGE WEIGHT

MIN WEIGHT ALARM

MIN WEIGHT REJECT

MAX WEIGHT ALARM 1

MAX WEIGHT ALARM 2

With the Flow Controller it is possible to REJECT ONE single product – rather than increasing the average weigth for all products. It is recommended to use the Flow Controller parallelly to the Analyser to benefit from both powerful tools

2.1 Sensor Systems 2.1.1 Intermittend measurement

9

TOTAL WEIGHT

(g)

20 g

MIN ACCEPTABLE WEIGHT

MAJOR COST SAVING POTENTIAL!

AVERAGE WEIGHT

MIN ACCEPTABLE WEIGHT

20,8 g

AVERAGE WEIGHT 20,8 g

INCREASED AVERAGE WEIGHT

INCREASED AVERAGE WEIGHT

3σ 3σ 3σ 3σ

20 g


10

Trace from Analyser software to defectives in diaper / sanitary napkin production line

3σ 3σ

AVERAGE WEIGHT

WEIGHT VARIATIONS BEFORE OPTIMISATION

WEIGHT VARIATIONS BEFORE OPTIMISATION

WEIGHT VARIATIONS AFTER OPTIMISATION

WEIGHT VARIATIONS AFTER OPTIMISATION

3σ 3σ


TOTAL WEIGHT

SINGLE PRODUCT

(g)

STANDART DEVIATION

(g)

Less weight deviations in single product and in whole production

High process stability due to bad product ejection

Higher level of product quality

Save money

11

Significant underweight every 6th diaper

Blocked pocket

2.1 Sensor Systems 2.1.1 Intermittend measurement Trace from Analyser software to defectives in diaper / sanitary napkin

production line

1)

Product Histogram Analyser Software see p. 7

12


2)

1 minute

DRUM FILTER RECYCLING

13




3)

14


SAP-hopper refilling

6 minutes 6 minutes 6 minutes



4)

15

Poor core forming vacuum • Blocked filter media • Air leakages • Blocked Core forming pockets • .........


Typical Analyser and Flow Controller implementation (Combination of devices)

16

Analyzing

Controlling


17


IT IS WORTH TO OPTIMISE

THE CORE FORMING

PROCESS TO REDUCE THE

WEIGHT VARIATIONS OF THE

PRODUCTS

18

2.1 Sensor Systems 2.1.1 Intermittend measurement Special Sensors and Sensor Systems for intermittend measurement

A special HST-Sensor for granulate or any bulk material, the QMS 70-SAP-T-Sensor is used. It is a O-shaped tunnel sensor, which measures pulsed material flow. Accelerated for example by compressed air, the material pulse can reach a speed of up to 30m/s and still is measured precisely. In combination with one of the HST-Sensor Systems (Flow Controller / Analyser), the same possibilities for evaluation could be performed (total weight, weight distribution), comparable with guided band materials (s. page 7ff.)

T (in s)

Qu

anti

ty

T=0,01s

QM

S 70

-SA

P-T

1. P

rod

uct

0,01

Product profile (weight distribution)

T=0,02s

QM

S 70

-SA

P-T

0,02

1. P

rod

uct

T=0,03s

QM

S 70

-SA

P-T

0,03 1. P

rod

uct

2.

Pr

Feeding pipe

0 Sensor field

19

2.1.2 Permanent measurement (continuous)

With HOSSBACH SENSOR SYSTMS also continuous products could be controlled as illustrated above. On top of the intermittend measuring Sensor Systems, which are also mostly suitable for continuous measuring, we designed for this application special Sensors and Sensor Systems. Also the special Sensors are suitable for intermittend measurement.

Sensors Sensor Systems for continuous/endless products

QMS70 SAP: Sensor for all bulk materials, as granulate, pills and powder

QMS70-O-725: Sensor for endless web material

HST Ranger: Sensor System for continuous material flow

Combine with any HST Sensor System (Flow

Controller/Analyser/Ranger)

Combine with any analogue HST Sensor

Special Sensors and Sensor Systems for continuous material measurement

20


HOSSBACH SENSOR

Material Flow OK 100% (±tolerance)

Material Flow to small,

eg. thickness (<100%)

Material Flow to high,

eg. thickness (>100%)

Material Flow to small,

eg. density (<100%)

Upper bar graph on RANGER shows actual material quantity; Values for tolerance (lower bar graphs) could be set on RANGER device; When material quantity drops/exceeds tolerance, a switching signal to machine is given

Have a real-time control over material flow, intervene into production to prevent quality costs

PRODUCT

Optimize material flow to reduce raw-(bulk) material consumption and save money!

T = 0s

T = 0,1s

T = 0,2s

T = 0,3s

[v] = x m/s

How do the SENSOR SYSTEMS work? HST RANGER Sensor System for continuous material flow

HOSSBACH SENSOR

HOSSBACH SENSOR

HOSSBACH SENSOR

21


• Special sensor to detect and monitor bulk-material throughput (1 signal per milli-second = 1000 signals per second)

• Analog output signal which is

proportional to the bulk-material mass-flow

Applications: • Optimize and control the material

infeed process (Ongoing material savings)

• Detect failures in the constant material-

feeding, detect blockages • Allow a precise blending of different

raw materials etc.

HST QMS70-SAP for bulk material flow in combination with Sensor System

22


• Special sensor to detect and monitor the PULP-throughput (1 signal per milli-second = 1000 signals per second)

• Analogue output signal which is proportional to the PULP mass-flow

Applications: • Optimize and control the material infeed process (Ongoing material savings)

• Detect failures in the constant material-feeding

• Compare material quality from different suppliers, provide data based feedback

HST QMS70-O-725 for endless material flow of Fluff / Pulp / Non-wovens in combination with Sensor System

23


The HST Cotton Wool Weighing System is one of the most powerful Sensor Systems of Hossbach Sensor Technologie. As the first HST-Sensor System, it now is advanced to a highly sophisticated and autonomic operating device.

HST Cotton Wool Weighing System 1004

• evaluation of material quantities of continuous non-woven products like cotton wool webs

• dosing of weight equal material cords on-line before getting packaged • weight evaluation independent of web thickness and width • speed independent measurement, procedure selectable • weight re-adjustments by remote control (manually) or by external

balance • activation of the tearing device, when package weight is achieved • synchronisation of teasel and packaging speed due to the sag regulation • control of duration and tearing moment of the tearing procedure • visualisation of weight, set weight value and dosing and control status

E-shaped Sensor Control unit

24


How do the Cotton Wool Weighing System work?

Sensor at t=0

Cotton Wool

average density

higher density

average density

lower density

x

dM(x) (Sensor signal)

dx1 dx2 dx3 dx4 dx5 dx6 dx7 dx8

Example:

The Sensor Control Unit also considers the tearing/cutting duration and the sag regulation. The machine timing is fully controlled by the Sensor System and makes it to a

powerful, autonomical, economical, precise tool.

Save money, time and equipment and bring quality to an even higher level at the same time!

[v]=m/s

100%

Sensing field

0% 0%

Pre-set weight of cotton wool has been reached, product is ready to be cut

Product weight corresponds to sum of dx [dM(x1) + dM(x2) +…+ dM(xn)]

25

2.3 Stand-Alone Sensors

How do the STAND-ALONE SENSORS work? Capacitive and inductive (QMS + MDS) Sensors

[v] = x m/s

Object to be detected, appearing

- by distance x or time t (Product components)

- Randomly (overlap, splice, foreign body)

No Signal at T = 0,2s

Signal at T = 0,3s

(+24V ADC)

PRODUCT (Carrier)

[v] = m/s

ProductNOK

ProductNOK

ProductOK

Machine does not await Signal after T=0,16 s (distance: 1,6 x)

Machine do await Signal after T=0,2 s (distance: 2 x)

All HST Sensors work after the same

principle (here QMS70), no matter if they

are one-sided, U-, O- or E-shaped.

They detect reliable even thinnest objects

(as foils, adhesive tapes, glue, etc.) on the

product carrier and gives a digital

switching signal to the machine control

unit, to reject or trace the faulty product.

Signal

at T = 0s +24V ADC

ProductOK

HO

SSB

AC

H S

ENSO

R

x (t)

Signal at T = 0,1s

(+24V ADC)

ProductOK

HO

SSB

AC

H S

ENSO

R

2x (t) 3x (t)

Signal at T = 0,16s (+24V ADC)

HO

SSB

AC

H S

ENSO

R

HO

SSB

AC

H S

ENSO

R

HO

SSB

AC

H S

ENSO

R

26

2.3 Stand-Alone Sensors

A typical analogue sensor for stand-alone application is the QMS 70-100R. It is used to measure and control the filling procedure in any non-metallic container and gives an analogue signal, which is proportional to the quantity of liquid, directly to machine control

Fluid and vial-filling measurement

specified value, e.g. 20ml

analogue output: 4V (ok)

analogue output: 3,7V (nok)

analogue output: 4,3V (nok)

20m

l

19

ml

21

ml

1. After-filling measurement:

2. Simultanious measurement:

QMS 70-100R

Filling machine

In both applications, the specified value for the filling quantity is for example 20ml, which corresponds with a 4V sensor signal. First application: Containers are measured after filling , sorted out afterwards, if they do not meet the specifications Second application : Container is controlled simultanously with filling. When the expected sensor signal is reached, the filling is could be stopped

QMS 70-100R QMS 70-100R QMS 70-100R QMS 70-100R

Product (container/vial)

27

3 Inductive measuring sensors 3.1 Metal detector

Inductive Sensor MDS-O-640

For sensitive products with high quality and safety demands, the metal-detector MDS-O-640 is obligatory

for production supervision.

It detects smallest metallic particles, even metallized foils, in the production at full speed.

Its usage is comparable with the capacitive sensors, but as it only detects metallic objects, it is unsensitive

towards product mass variations . This makes the MDS-O-640 Sensor to a reliable saftey device.

Connect sensor to your machine control unit and be aware of:

- Sharp metal chips from knives or combs RISK OF INJURIES AND LEGAL CONSEQUENCES

- Metallized foils for marking and splicing

- Any machine parts

Powerful tool to prevent costly compensations and bring quality to an even higher level

28

3 Inductive measuring sensors 3.2 Blister Count

How does the Blister Count work? Inductive MDS-Sensors (Blister Count)

10

For packing industry, where Blisters are packed in boxes or get wrapped (e.g. medics, chewing gum), the BlisterCount is a powerful tool, which is easy to install to the packaging line. It measures (counts) the amount of stacked blister layers (0-10pcs) also in closed boxes during production.

Enclosed Blister

Closed box

to machine and Computer (USB)

BO

X 1

BO

X 2

BO

X 3

Production line (BOX n)

Sen

sor

sign

al/

blis

ter

cou

nts

1

2

3

0

Sensor gives signal to machine: „too many blisters“

Sensor gives signal to machine: „too few blisters“

BOX 1 BOX 2 BOX 3

Always pack the correct amount of blisters to safe time and money without weighing afterwards!

Tran

smit

ter

Rec

eive

r

4

Magnetic field

29

4 Summary

Potential and benefits from HOSSBACH SENSOR Products

• Full Automatic, REALTIME Quality Control for Production Lines

• Every product or product section is precisely checked – exclusion of “human error”

• Generate statistical data (average weight, standard deviation etc.) automatically from each single product

• SIGNIFICANT SAVINGS for Raw Materials (cost savings up to 15% from granulate and non-wovens have been achived)

• See drifts and fluctuations of raw material quality or product components, e.g. non-wovens, fillings • Process Optimization, better product quality in general • Rejection or tracing of products which are out of specification (“underweight ” / components missing) • Allow to develop, produce and to control better and more complex Product CORE FORMULA’s • Indirect Cost Savings / additional functions: - Less consumer complains, better consumer satisfaction - More stable production process in general (combining, packaging) - Automatic metal detection, “flipped core” detection (HST Analyser and Flow Controller)

Powerful tools to exceed stand of technology in Quality Management and Economic Production

30

5 Appendix

We received this measurements from a customer in the diaper industry, who agreed in using this data for illustration purposes. What you see is the comparison between the weight measurements of 300 single products weighted extensively by a high-precision scale (purple line) after being weighted „in-line“ with our Analyser (blue line) during full speed production. The accuracy is impressively shown in the almost perfectly fitting curves.

Comparision of accuracy: High precision scale vs. HST Analyser

NOTICE: While it took an employee about 3 hours to measure the products on the scale, store and evaluate it, the Analyser was capable to measure the weight in incredible 30 seconds (at 600ppm), AUTOMATICALLY AT FULL MACHINE SPEED! AND: Not only the product weight was measured by the Analyser, a complete evaluation of weight distribution inside EACH SINGLE product was done! (see. P 7)

31

6 Cost-Saving Calculation Tool

Line speed (pads per minute) 600

SAP per product (gram) 12

Fluff per pad (gramm) 15

Cost for SAP (US$ / ton) 2200

Cost for fluff (US$ / ton) 900

Line Efficiency 75%

SAP cost per minute (US$) 11,88

Fluff cost per minute (US$) 6,08

SAP cost per hour (US$) 712,80

Fluff cost per hour (US$) 364,50

SAP cost per day (US$) 17.107,20

Fluff cost per day (US$) 8.748,00

SAP cost per month (25 days) 427.680,00

Fluff cost per month (25 days) 218.700,00

SAP cost per year (US$) 5.132.160,00

Fluff cost per year (US$) 2.624.400,00

TOTAL SAP and Fluff cost per year (US $) 7.756.560,00

TYPICAL EXAMPLE:

5% cost saving per line per year:387.828,00

Cost savings potential to reduce the SAP and Fluff

content per product:

SAVINGS for reduction of SAP INFEED: 0,4 g per pad

SAVINGS for reduction of Fluff INFEED: 0,4 g per pad

TOTAL Cost savings per year (US $): 241.056,00

Insert your production data and your raw-material costs, and be surprised about the money saving potential in your production!

Thank you for your time!

SENSOR TECHNOLOGIE

sensor technologie · (engineer mech./project manager) hossbach sensor technologie albert-rupp-str....

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