Martin Lehmkster 7.1 7632 Agenda 1. Introduction to ISRA 2. - - PowerPoint PPT Presentation

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Martin Lehmkster 7.1 7632 Agenda 1. Introduction to ISRA 2. - - PowerPoint PPT Presentation

Jan 04, 2024 147 likes •656 views

Place for, company logo from speaker Reduction of Downtime, Quality Improvement and Customer Satisfaction with High Speed Web Inspection Systems Martin Lehmkster 7.1 7632 Agenda 1. Introduction to ISRA 2. Reduce costs, increase

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Place for, company logo from speaker

Reduction of Downtime, Quality Improvement and Customer Satisfaction with High Speed Web Inspection Systems

Martin Lehmköster 7.1 7632

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7.1. 7632 Martin Lehmköster 2

Agenda

  • 1. Introduction to ISRA
  • 2. Reduce costs, increase productivity
  • 3. Basics of web inspection

cameras – light – GUI

  • 4. Classification – higher ROI
  • 5. DataMining – make money out of your data
  • 6. Rewind Manager to reduce costs
  • 7. Validation
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7.1. 7632 Martin Lehmköster 3

Agenda

  • 1. Introduction to ISRA
  • 2. Reduce costs, increase productivity
  • 3. Basics of web inspection

cameras – light – GUI

  • 4. Classification – higher ROI
  • 5. DataMining – make money out of your data
  • 6. Rewind Manager to reduce costs
  • 7. Validation
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7.1. 7632 Martin Lehmköster 4

ATLANTA SHANGHAI TAOYUAN

ISRA worldwide

LANSING DARMSTADT ISRA AG

  • world leader in web inspection

world leader in web inspection

  • more than 3500 systems installed

more than 3500 systems installed

  • 280 employees

280 employees

HERTEN (Germany)

  • web inspection center
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7.1. 7632 Martin Lehmköster 5

Agenda

  • 1. Introduction to ISRA
  • 2. Reduce costs, increase productivity
  • examples
  • 3. Basics of web inspection

cameras – light – GUI

  • 4. Classification – higher ROI
  • 5. DataMining – make money out of your data
  • 6. Rewind Manager to reduce costs
  • 7. Validation
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7.1. 7632 Martin Lehmköster 6

Situation

We are facing the fact of increasing We are facing the fact of increasing production costs due to: production costs due to: Increasing Raw Material Costs Increasing Energy Costs

  • More critical Customers

At lower market prices for the products on global markets! At lower market prices for the products on global markets!

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7.1. 7632 Martin Lehmköster 7

Avoid costs of machine downtime

caused machine stop in the print machine detected defect in paper (hole and contamination)

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7.1. 7632 Martin Lehmköster 8

Web Inspection

Finds your defects as early as possible to document and classify the defects to take corrective action to avoid more defects to avoid processing scrap and low quality to avoid customers complaints

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7.1. 7632 Martin Lehmköster 9

Reduce costs of quality change in raw material

Blown film, transparent, tubular film, transmission Width: 400mm, v = 80m/min Change of pellet at 9800m

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7.1. 7632 Martin Lehmköster 10

Reduce costs of quality change in raw material

Blown film, transparent, tubular film, transmission Width: 400mm, v = 80m/min Change of pellet at 9800m

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7.1. 7632 Martin Lehmköster 11

Uncritical defects

PVC, calender, transparent, transmission, v=50m/min

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7.1. 7632 Martin Lehmköster 12

Critical defects

PVC, calender, transparent, transmission, v=50m/min

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7.1. 7632 Martin Lehmköster 13

Agenda

  • 1. Introduction to ISRA
  • 2. Reduce costs, increase productivity
  • 3. Basics of web inspection

cameras – light – GUI

  • 4. Classification – higher ROI
  • 5. DataMining – make money out of your data
  • 6. Rewind Manager to reduce costs
  • 7. Validation
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7.1. 7632 Martin Lehmköster 14

System-Architecture

  • Cabin
  • Data base
  • Operating unit

Illumination Position Encoder Cameras

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7.1. 7632 Martin Lehmköster 15

System overview

  • Display of

inspection data

  • Alarm signals
  • Reports
  • Statistic
  • Interface to

networks

Data base

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7.1. 7632 Martin Lehmköster 16

System for diaper film/ nonwovens

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7.1. 7632 Martin Lehmköster 17

System for paper

  • Cameras:

8 (2.048 pixel)

  • Machine:

PM#25

  • Width:

5.000 mm

  • Speed:

1200 m/min

  • Illumination:

LED white

  • Resolution:

MD: 0.71 mm CD: 0.38 mm

  • Rewind-Manager
  • Marker:

Ryeco 6 color

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7.1. 7632 Martin Lehmköster 18

Light sources

fluorescent light

  • cheap
  • simple maintenance

LED

  • free of maintenance

Special development ???

Transmission Transmission Reflection Reflection

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7.1. 7632 Martin Lehmköster 19

Ultrabright LED Light Line

… … lifespan: 10 years! lifespan: 10 years!

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Many pixels – for the right decision

Web inspection can handle

320 Megapixel / sec per camera

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Resolution and Speed

resolution

Speed of the camera is the key for high quality images!

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Large Images on Demand

Dielines in transparent film of 250µ

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Advantages

  • More pixel better resolution
  • More pixel better pictures
  • More pixel better defect

detection

  • More pixel

better defect classification

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7.1. 7632 Martin Lehmköster 24

Identify Defect Cause & Take Corrective Action to Eliminate Defect

User verification

High Resolution Images = Accurate Classification

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7.1. 7632 Martin Lehmköster 25

Agenda

  • 1. Introduction to ISRA
  • 2. Reduce costs, increase productivity
  • 3. Basics of web inspection
  • 4. Classification – higher ROI
  • 5. DataMining – make money out of your data
  • 6. Rewind Manager to reduce costs
  • 7. Validation
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7.1. 7632 Martin Lehmköster 26

Criteria for a simple/ single classification?

Criteria:

  • bright / dark
  • area
  • lenght / width

Box - Classifier

equal ?

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7.1. 7632 Martin Lehmköster 27

Learning System for Classification

letter letter letter letter

= = A A

A A

A A

A A

A A

A A A A A A

= = B B

B B

B B

B B

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7.1. 7632 Martin Lehmköster 28

Classification with Quick Teach

… … this this is is the the letter letter A A Reliable Reliable classification classification ... ... even even with with noisy noisy background background! !

S S Z Z V V S S () () @ @ = = W W P P Ü Ü E E I I D D B B

B B

B B B B

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7.1. 7632 Martin Lehmköster 29

Requirements for classification

High accuracy Simple operation –with images Display of „human classifier“

  • high amount of criteria

Easy modification/ high flexibility Real time ability/ immediately response Intuitive operation

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7.1. 7632 Martin Lehmköster 30

Box-classifier

Only for simple criteria:

  • area, length, width…

Simple manual definition Unqualified for complex tasks Danger of „forgotten“! Pseudo defects!

  • Very good and stable solution for simple task

– should be included in every system as a plain classifier.

  • Division of defects
  • according to simple

criteria

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Today: „Next neighbour“-classification

Self-learning classifier „Mathematics is hidden“ Easy modification Little basic information (Images) necessary No „over-teaching“ possible Anytime extendible Avoiding pseudo-defects

A fast learning classifier gives a higher ROI

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Fast learning classifier!

?

results time

Get your production run at once with a classifier

  • do not waste time with teaching a classifier
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User-friendly learning

The user selects a defect out of the continuous production Saving of information back to data base of system Description Easy to understand, easy to operate Guarantee for quick implementation

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Learning

  • Requirements …

– Classifier needs image gallery – For every defect class images must be available – Images will be collected during production automatically

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Agenda

  • 1. Introduction to ISRA
  • 2. Reduce costs, increase productivity
  • 3. Basics of web inspection
  • 4. Classification – higher ROI
  • 5. DataMining – make money out of your data
  • 6. Rewind Manager to reduce costs
  • 7. Validation
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Data Preparation – reducing data to a reasonable extent

Individual report Defect- database e-mail list Time table

+

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7.1. 7632 Martin Lehmköster 37

Example: Single lane report to rate quality

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7.1. 7632 Martin Lehmköster 38

central data mining STEP III global network

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7.1. 7632 Martin Lehmköster 39

Agenda

  • 1. Introduction to ISRA
  • 2. Reduce costs, increase productivity
  • 3. Basics of web inspection
  • 4. Classification – higher ROI
  • 5. DataMining – make money out of your data
  • 6. Rewind Manager to reduce costs
  • 7. Validation
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Marking defects

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Winder Interface & Control

Main Inspection System Configuration Data Defect Data Rewind Manager

PLC

Rewind Controls

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Defect Marking and Web Position Synchronization

Start 1 1 1 1 1 ½”

Defect Mark (Bottom Side) Web Sync Marks (Top Side)

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Rewind Manager – total system solution

PLC Decode Barcode PLC Break Control Rewind Manager Sending “slow down” pulse 2000 ft before defect

  • Defect marked at defect location on

top surface

  • Codes marked on bottom surface
  • Mark Reader controls reel map

display to show image and location of next defect to stop on

  • Operator override to skip defect

Rewind Manager to automatically stop re-reeler for defect removal

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Rewind Manager Screen - Map

Current Position Next defect

  • n the web

Defect filter

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Rewind Manager - Defect Selection

Stop on Defects in Red Click on a defect image to toggle stop status

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Agenda

  • 1. Introduction to ISRA
  • 2. Reduce costs, increase productivity
  • 3. Basics of web inspection
  • 4. Classification – higher ROI
  • 5. DataMining – make money out of your data
  • 6. Rewind Manager to reduce costs
  • 7. Validation
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Validation by artificial defects

Image of an artificial defect

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Validation by „real“ defects

Electronic masking of real defect images

Signal Signal

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Advantages of high-end web inspection

Reduction of

  • customer complaints
  • of waste
  • of downtime
  • of costs

Deliver proven quality High return on investment

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Thank you for your attention!

Thank you for your attention! Questions?

Martin Lehmköster ISRA Surface Vision GmbH Albert-Einstein-Allee 36 -40 45699 Herten
  • Tel. +49 2366 9300-0
info.surface@isravision.com