Contamination on the surface of a soft calender roll can result in hot spots that may permanently damage the polymer coating of the roll surface.
The SS100 System is an automated inspection system for detecting, measuring, and classifying thermal features and defects occurring on soft roll calenders used in paper-making.
Synchronised with roll rotation, SS100 System uses one or more Raytek MP50 Process Imagers to scan the entire roll surface and provides temperature data independent of roll rotation rate to automatically detect hot spots. When it detects a hot spot, the system automatically generates an alarm allowing an operator to take prompt corrective action to prevent costly damage to the calender roll surface.
When an alarm is generated, information is automatically saved indicating the time, date and the duration of the condition as well as the corresponding thermal image.
Operating principle
A roll rotating at 720 RPM (12 Hz) with a line-scanner operating at 48 Hz results in measuring only four temperature lines per roll rotation - too few to construct a thermal image of the entire roll surface. Without synchronising the imaging process to roll rotation, measured temperature lines are recorded randomly, are not displayed in the correct order and hot spots appear streaked and undefined. Furthermore, the thermal image will vary with roll rotation rate. Precisely synchronising the imaging process overcomes these limitations.
The SS100 System operates synchronously with roll rotation. The scanner starts recording the first line of data at the '0'-position. At the beginning of the second rotation, the scanner starts recording at the '0'-position plus precise offset determined by the system's synchronisation electronics.
After several rotations, the entire surface of the roll is scanned. DataTemp SS100 Software then arranges the scanned lines in the correct order to construct an accurate 2-dimensional thermal image or 'snapshot' of the roll. The image is continually analysed to identify and locate temperature features and anomalies and to raise appropriate alarms.
Benefits of using continuous thermal roll monitoring include:
* Prevent costly downtime and roll resurfacing.
* Automatic hot spot detection.
* Automate quality monitoring and documentation.
* Software supports multiple MP50 Process Imagers.
* Configure custom sectors for each calender roll.
* Define specific configurations and data files.
* Analyse sector temperatures automatically.
* Automatic fail-safe alarm logging.
* Optional analog and digital outputs for each sector.
* Multiple language support includes English, German, French, Italian, Swedish, and Finnish.
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