Closing Loops and Enabling Efficiencies
We have a keen interest in obtaining the best possible line data for its control systems to use in closed loop applications. That is why we utilize the best technologies for measurement of gauge, opacity, width, temperature, diameter, wall thickness and any other measurable property of your manufactured product.
Applied Measurement Technologies
ON-CAL 3 Calender Gauging
The FACTS ON-CAL 3 is a precision gauge for the measurement of nonmetallic calendered materials, such as rubber, vinyl and other plastic materials. It is a non-nuclear, contact measurement gauge that incorporates automatic zero calibration to maintain high accuracy. No electronics are used on the calender on this simple, robust design. Being so close to the calender nip, ON-CAL gauges reduce transport lag, thus providing a fast response.
Nuclear Transmission & Backscatter
Utilizing the transmission of alpha and other particles (radiation) through the production material under test, a received and measured number of particles can be used to calculate the basis weight (g/m^2) of the material. Radioactive sources such as strontium 90 and krypton 85 are utilized under strict government regulation as sources of radiation. Nucleonics remain one of the most highly used sensing schemes in the plastic and rubber sheet and film industry. When coupled with thickness measurement technology, density values can be determined. FACTS retrofits existing nucleonic sensing systems , and also provides brand new systems as well. As with all of our offerings, FACTS provides unmatched 24/7 service.
Infrared Line Scanning
An infrared line scanner can capture an array (cross axis) of temperature data across a target material many times a second. These temperature arrays are very useful in calculating the temperature profile of a sheet moving under the range of the scanner, or the linear temperature array of a blown-film bubble. FACTS is uniquely positioned to offer a control system that can read and accept these data arrays, and act out control strategies according to the read data.
Laser Diameter Gauging
A scanning laser is shot across one axis of the target profile or tube. The profile blocks the beam and creates a shadow area. This shadow area rests on an optical sensor which in turn reads the starting and ending point of the shadow. 1, 2, or 3 axis profile systems can be implemented. Utilizing more than one axis provides the ability to measure ovality and eccentricity of a tubular profile. FACTS often works with existing laser gauges, or recommends sensor-only systems (skip the fancy vendor HMI) to our clients looking to complete their line control needs. Multiple gauge systems spread over the length of a processing line can provide “hot” and “cold” gauge readings, and tie inputs of one diameter to new targets for diameters upstream.
Ultrasonic Wall Thickness
Submerged underwater, an ultrasonic (1-10MHz) source blasts sound waves at a target tube or wire. The receiving end of the transducer receives the returned bounce signals and deciphers Inner Diameter (ID) measurements of single-lumen, unreinforced tubing. In control systems involving wire, the measured ID is used to adjust the setpoint of extruder speeds. In tubing, puller, takeoff speeds, vacuum or air support systems setpoints are adjusted.
Capacitive Sensing
Tuned systems, such as in blown-film lines, can utilize capacitive sensing technologies for thickness measurements in line. This single-sided technology is useful with non-ferrous metals with single side access.
Spectral Coherence Interferometry
Utilizing a spread spectrum light source and watching the specific returned reflection pattern, FACTS StraDex sensor systems are able to determine film thickness for single-layer film and layer thickness for multi-layer film. Utilizing this technology, FACTS line control systems can control extruder speeds on multi-layer, multi-extruder lines to yield proper product layer ratios and total thicknesses.
Machine Vision
FACTS control systems integrate with a number of available vision systems. From tire cord count and alignment to reinforced tube thread detection, FACTS line control systems can seek and record all data for continuous processes, issue alarms, and provide outputs for marking bad products.
Laser Triangulation Gauging
A laser triangulation gauge uses a laser light source and PSD or CCD linear sensor and utilizes the basic law of reflection (although diffused) where the angle of index matches the angle of reflection. Laser triangulation gauging is used to measure distance (thickness) to the material (production material) and the sensor/laser pair. Laser gauging is often used in conjunction with nucleonics to help complete density of material ==> nucleonics give us basis weight, and lasers give us thickness. Utlizinng these two values, density can be calculated (and also controlled).
Air Calipers
Often used when laser triangulation and eddie current/proximity sensors can not be used, a pair of aIr calipers ride material (typically one on top, and a stationary plate on the bottom) just as a puck rides on an air hockey table. The distance between the materials is the resultant thickness of the ridden material.
| Retrofit Exisiting Web Profile Scanner |
.jpg) | ApplicationPlasatic sheet and film (cast & blown)Calendering (rubber & plastics)Coating linesAsphalt shingle roofing lines Retrofirs & UpgradesCost effective solution when the existing scaaner mechanical frame is in good condition and the source has sufficient remaining useful life.Complete new frame system, offering an array of measurement technologies, are also available.FACTS retrofit solutoins retain the existing scanner frame and mechanical components, along with the source and detector.All electronics are replaced. A new frame controller and new console system is provide. The only electronics that are normally retained is the detector preamp in the detector head.Full Auto profile control, APC, is an available option |
| Non-Nuclear Scanner |
.jpg){kind=spacer} | The FACTS PMC Series O- Frame Scanner provides a rugged, high speed scanning platform and is designed for precise and repeatable performance with an extended life of operation, even in harsh environments. FeaturesHigh speed scanning up to 10 inches per secondNon-proprietary, off-the-shelf componentsUp to four sensors per frameAccomodates any pass line angle with our unique trunion moutingvailable in web widths up to 240 inches Benefits & PaybackLong-term reliability and opertionNon-proprietary componentsEase of sericeabilityLow cost of lifetime maintence |
.jpg) | Features Complete system includes sensor assembly, console, frame controller, and single side scanning frame.True Thickness MeasurementScanning Profile MeasurementUp to four sensors per frameProfile measurement for machine direction, cross direction, and overall thickness control.Available in web widths up to 120 inchesAppicationsSuitable for any application where the product to be measures is non-conductive and is flexible enough to make a 45 wrap around the reference roll such as:Foam sheetMuti-layer sheet and filmMaterials with variable amounts of filler or heavily pigmented Measurement Range : 2mils to 500 mils (.002″ to .500″) ProvidingControl/monitoring of: Feed rates Speeds Pressures Positions Dimensions Weight Color Temperatures – Cold Start ProtectionHeater & Drive Enclosures Information Management: Data collection & Logging Data Analysis Inventory Tracking Production Reporting Visualization |
| Extrusion |
.jpg) | Machine direction and cross direction measurement and control for sheet and film processes. Control functions:Machine direction thickness or weightCross direction Auto Profile ControlAuto Die Bolt mapping Sample Appications:Plastic sheet and film (cast & blown)Calendering (rubber & plastics)carpet linesCoating linesAsphalt shingle roofing linesSaturators |
