compact scanner, advanced measurement and … · continuous investment in tissue solutions ......
TRANSCRIPT
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
Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.
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
Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.
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)
© 2019 by Honeywell International Inc. All rights reserved.
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
Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.
Upstream
Air Blast
top and
bottom
7
24x7 Runnability in Tissue Environment
Air Knife
(Option)
Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.
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
Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.
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
Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.
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
Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.
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
© 2019 by Honeywell International Inc. All rights reserved.
12
Crepe – Basis of Quality Tissue
© 2019 by Honeywell International Inc. All rights reserved.
13
Crepe Impact on the Sheet
Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.
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
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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
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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
Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.
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
Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.
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
Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.
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
© 2019 by Honeywell International Inc. All rights reserved.
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
© 2019 by Honeywell International Inc. All rights reserved.
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
© 2019 by Honeywell International Inc. All rights reserved.
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
Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.
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
ADDITIONAL COMPACT SCANNER DETAILS
24
Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.
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
Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.
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
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27
Easy Serviceability
Swinging doors
with provision
to removeFull access to
electronics
© 2019 by Honeywell International Inc. All rights reserved.
28
Comparison Q6088 Scanner with Q4000 Head
Q4000 Head
Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.
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’
© 2019 by Honeywell International Inc. All rights reserved.
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