UPU 5000
Inline Delamination Detection and Process Trending with the Ultrasonic Measuring System
With the UPU 5000 all production reserves can be exhausted. The production process is more effective, the availability of the systems and the profitability increases.
The GreCon Ultrasonic Measuring System UPU 5000 is an optimum measuring system, for presenting unused power reserve, reducing costs and eliminating disagreeable blows at the beginning of the process and to minimize the associated re-manufacturing.
Your Benefit
Reduces (eliminates) complaints
Reduces the rate of rejected material to < 1 %
Shows irregularities in the production process and the panel homogeneity, process trending
= quick rectification
= saving of production costs
Warns before blisters occur
Optimisation of pressing times
Cutout of defective panel sections
Combination with ct-frame possible
Quick production change-over
Revaluation of existing production lines
Quick amortisation
Revelation of reserve capacities and hidden costs
Blow Detection and Process Optimisation
The heart of the system, the ultrasonic receiver is influenced by changes in important process parameters, such as press factors, density or material moisture. These process parameters directly influence the quality of a panel. The degree of glue cure is a measure of ultrasound absorption.
The higher the degree of glue cure, the lower the absorption of the ultrasound by the panel. Using the trend calculation from the measured values, the plant operator is able to prevent the production of blister panels. This way, the production of rejects can be avoided.
Also, production processes can follow and record during a longer period on the basis on the measured values. If these values are consolidated with other production values a further optimisation potential will occur. Besides the parameters to optimise the production process, the UPU 5000 presents an integrated blow detection for final quality control and sorting of the measured panels. If blows occur, their size and location is clearly represented. The defective panels are marked, and a signal is given to allow them to be identified for rejection. Different blow definitions allow a graded quality sorting.
Automatic Calibration and Adjustment
Basically, the quality of the measuring results depends on constant conditions during measurement. Because this cannot be permanently ensured under tight industrial conditions, the GreCon Ultrasonic Measuring System is equipped with a patented automatic calibration and dirt accumulation control.
To a reference value, the system is automatically checked for accumulated dirt at pre-determined intervals. If an inspection channel strongly deviates from the adjusted reference value due to this dirt accumulation, a warning is output for the operator. If signal degradation reaches the limited value, the next maintenance interval is indicated.
ct-Frame
In additional, the UPU 5000 can be equipped with a ct-frame. The system can be calibrated and adjusted at any time by moving the ct-frames sideways out of the production line. Maintenance, diagnostics and repairs can be carried out during the running production.
Furthermore, the mobile construction of the system allows an escape run in case of big blisters and thus prevents the measuring system from being damaged. Altogether, a nearly continuous system availability can be achieved.
Operational Reliability
Thanks to the external automatic calibration, an integrated self-diagnostic system and the construction of the system with a ct-frame, a high availability and operational reliability and, above all, a constant measuring quality is ensured. The automatic external adjustment and the integrated dirt accumulation control ensure a measurement that is independent of surroundings.
Only an external adjustment of each inspection channel ensures a permanently reliable measurement. This ensures that the represented information is a reliable basis to regulate and optimise production processes. Only like this is it possible to go beyond a simple yes/no statement and to optimise the process by means of the intelligent, newly developed parameters.
Construction of the System
Up to 22 inspection channels can be mounted on a frame, which is made out of patented aluminium profiles. The cable and compressed air ducts integrated in the profile and thus protected against surroundings.
Optimised Measurement Transducers
Ceramic transmitters, which are installed below the material to be measured, create the necessary ultrasonic energy. The emitted ultrasonic pulse is directed to the receivers through the panel. The receivers, installed above the material, can tilt backwards or forwards. Thanks to this hinged mechanism, the receivers are protected against damage by big blisters and mechanical misadjustment.
Combination with Other Measuring Systems
The UPU 5000 is a modular system that can be adapted to changing requirements at any time. It can be combined with the GreCon Thickness Gauge DMR 5000 and the GreCon Board Scale GS 5000 or Continuous Board Scale CS 5000 to a quality assurance station.
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Infomaterial
