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GLASS MANUFACTURER MAIN PRODUCT
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GLASS MANUFACTURER MAIN PRODUCT
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Quality and Control Systems (QCS) -Architecture
Scantech quality and control systems (QCS) are manufactured with open architecture and modular equipments or devices that communicate through an Ethernet TCP / IP network.
“Open” means that Scantech equipments are designed to freely communicate with customer computers and systems.
Scantech concept of modularity is based on the following three (3) main characteristics:
1. The equipment must be independent and self-sufficient. This means that it completely fulfills the task for which it’s been designed to perform.
2. The equipment modules can flexibly be assembled in the order that achieves the best configuration that suits the customer’s application.
3. The equipment itself is designed in a modular fashion.
2. The equipment modules can flexibly be assembled in the order that achieves the best configuration that suits the customer’s application.
3. The equipment itself is designed in a modular fashion.
Independence and self-sufficiency:
This is a very stringent requirement because it sets a specific task to each device. This implies that each device is equipped with its own intelligence (computer). It also minimizes external wiring, that is to say, there are only power and network connections. Examples:
The scanner’s function is to measure. It must therefore produce accurate measurements by itself, with the correct physical units, useable by other QCS equipments, or by the customer.
The control system function is to compute set-points and to apply them.
The function of an operator interface is to drive a QCS system. It must therefore display measurement data, accept commands, display status and reports. But in no case, be involved in the manufacturing process or in the measurement computations.
The control system function is to compute set-points and to apply them.
The function of an operator interface is to drive a QCS system. It must therefore display measurement data, accept commands, display status and reports. But in no case, be involved in the manufacturing process or in the measurement computations.
Assembly of the modules:
The Scanners, Control Systems, and User Interfaces must be able to be assembled in any quantity for different network topologies.
Equipment Modularity:
The equipments themselves must be designed as an assembly of sub-modules in order to achieve a high level of standardization.
Openness:
Each device must be equipped with configurable communication ports and also be able to support major market standards for the data exchange such as OPC.
These aforementioned qualities provide Scantech customers with very important benefits:
Reliability: Is the result of the high level of standardization.
Ease of maintenance: In addition to component standardization, it is a direct result of the segmentation and distribution of tasks.
Reduction of spare parts stock.
Scalability: Our approach allows easily the addition of new equipment to any initial configuration.
Long term sustainability: Is also a direct consequence of the modularity of the equipment.
Ease of maintenance: In addition to component standardization, it is a direct result of the segmentation and distribution of tasks.
Reduction of spare parts stock.
Scalability: Our approach allows easily the addition of new equipment to any initial configuration.
Long term sustainability: Is also a direct consequence of the modularity of the equipment.
Scantech offers three main types of equipment:
1. Scanners, whose task is to provide the necessary measurement data needed to control the manufacturing process and to determine the quality of produced materials.
2. Control Systems, whose function is to drive the manufacturing line so that the production parameters measured are within the customer defined tolerances of quality.
3. User Interfaces (such as operators, production supervisor, maintenance staff or quality manager… ) drive the scanners and control systems (commands, parameters, status…) and display quality parameters in real time. They also provide statistical processing, reporting, and archiving amongst a lot of other functions.
2. Control Systems, whose function is to drive the manufacturing line so that the production parameters measured are within the customer defined tolerances of quality.
3. User Interfaces (such as operators, production supervisor, maintenance staff or quality manager… ) drive the scanners and control systems (commands, parameters, status…) and display quality parameters in real time. They also provide statistical processing, reporting, and archiving amongst a lot of other functions.
A scanner or a gauge is a measurement system typically located on a production line. Its function is to characterize the main parameters of flat materials during their manufacturing process which consequently allows to control the line.
There are three possible modes of operation:
1. Manual Control: It is performed by the operator.
2. Automatic Customer Control: The scanner transmits data to the customer’s control system.
3. Automatic Scantech Control: The manufacturing process is controlled by Scantech’s equipments.
2. Automatic Customer Control: The scanner transmits data to the customer’s control system.
3. Automatic Scantech Control: The manufacturing process is controlled by Scantech’s equipments.
The scanners consist of three main modules combined to meet the requirements of the customer’s application:
1. The Mechanical frames: They are adapted to the width of the material to be measured, to the constraints of space, to the environmental conditions and to the type of measurement needed.
2. The Control System which defines the internal electronic, network and software architecture of the scanners. It includes also the necessary electrical equipment.
3. The Sensors which are selected in order to provide the best measurement solution for each application. From a network and software point of view, scanners can handle any number of sensors, but available space constraints on the production line along with actual customer requirements normally limit the quantity to three or possibly four.
2. The Control System which defines the internal electronic, network and software architecture of the scanners. It includes also the necessary electrical equipment.
3. The Sensors which are selected in order to provide the best measurement solution for each application. From a network and software point of view, scanners can handle any number of sensors, but available space constraints on the production line along with actual customer requirements normally limit the quantity to three or possibly four.
The scanners operate in scanning mode or in fixed point position.
In scanning mode, the material is measured along its full width (including edges) in a constant back and forth pattern. The measured path, taking into account the material movement, is shown in the figure on the left.
In almost all cases, the corresponding statistical sampling is more than enough to correctly characterize the measured quality parameters.
In “fixed point” mode, the sensor(s) is placed at a specific point across the width of the material to be measured. It only provides measurements in the production direction (machine direction).
This mode is best used when the cross profile is not very important and mainly when the process control response time in the machine direction needs to be very fast.
Mechanical frames are selected according to the material width, the type of measurement to be performed and the environmental constraints.
O-Shape Frames
“O” shaped frames are used to guide and move sensors, whose heads are located under and above the material to be measured, in a continuous back and forth pattern.
O Frames have two advantages:
Their transverse space is reduced to the line width and does not overstep too much on the side lines.
They can be manufactured in very wide widths (ten meters and even more).
They can be manufactured in very wide widths (ten meters and even more).
But, they also have a drawback: since the sensors consist of two independent parts, typically a transmitting head and a receiving head, both moved synchronously and hence subject to variations of their alignment that may impact the measurement if the sensors design has not been thoroughly thought off.
Scantech offers four model ranges of O-shape Frames:
1. The LO1 range consists of lightweight and economic frames for measuring materials up to 4000 mm wide with all types of sensors.
2. The MO1range covers intermediate widths from 4500 to 7000 mm.
3. The HO1range is extremely robust and designed for very wide materials, for clean room environments or inversely for very harsh environments.
4. The HLO1 range is used for materials with vertical paths. 
2. The MO1range covers intermediate widths from 4500 to 7000 mm.
3. The HO1range is extremely robust and designed for very wide materials, for clean room environments or inversely for very harsh environments.
4. The HLO1 range is used for materials with vertical paths.
C-Shape Frames
“C” shaped Frames have a perfect geometry since transmitters and receivers have a fixed relative position. The sensors are mounted in the arms of the “C” – shaped Frame and the complete frame is continuously moved back and forth transversally across the measured material. The disadvantages are that the maximum product width that can be measured is 2.5 / 3 meters, and that sufficient space (one frame length) must be available on one side of the production line for frame travel.
“C” shaped Frames have a perfect geometry since transmitters and receivers have a fixed relative position. The sensors are mounted in the arms of the “C” – shaped Frame and the complete frame is continuously moved back and forth transversally across the measured material. The disadvantages are that the maximum product width that can be measured is 2.5 / 3 meters, and that sufficient space (one frame length) must be available on one side of the production line for frame travel.
C Frames are commonly used for optical sensors applications in order to optimize the measurement precision and they are also a suitable solution for applications where there is little space in the machine or vertical directions.
C Frames are essential if the application requires the complete removal of the scanner from the production line.
C Frames are essential if the application requires the complete removal of the scanner from the production line.
Scantech offers four “C” Frame model ranges:
1. The LCI1 range with sensors embedded in the C Frame arms can be used for applications with air gaps (distance between the arms) up to 700 mm. They can be installed in spaces as narrow as 200mm in the machine direction.
2. The MCI1 range with sensors embedded in the C Frame arms can be used for applications with air gaps up to 700 mm too. But the lower arm cross section is larger (250x300mm).
3. The HCI1 range with has also sensors embedded in the C Frame arms. HCI1 frames have an extremely strong structure suitable for hot or even very hot environment. The arm cross section is 400mm and the air gap can reach 4000mm.
4. The LCO1 range has external sensors fixed on the arms and not located inside the arms. The air gap is limited up to 200mm.
2. The MCI1 range with sensors embedded in the C Frame arms can be used for applications with air gaps up to 700 mm too. But the lower arm cross section is larger (250x300mm).
3. The HCI1 range with has also sensors embedded in the C Frame arms. HCI1 frames have an extremely strong structure suitable for hot or even very hot environment. The arm cross section is 400mm and the air gap can reach 4000mm.
4. The LCO1 range has external sensors fixed on the arms and not located inside the arms. The air gap is limited up to 200mm.
In the majority of the cases, SCANTECH standard models meet customer application requirements. However, sometimes, requirements such as space constraints or other special installation criteria do not match with our standards.
Please do not hesitate to indicate to us your needs. Scantech applications design office will quickly study and respond to your requirements with a proposed mechanical solution, specifically tailored to meet your application’s needs.
LO1 Gauge Frame for materials up to 4150 mm in width
A precise design for an attractive price
The LO1 series closed frames are designed for lines where the measured product width does not exceed 4150mm in width.
Eight frame sizes are available. The following table depicts the measurable width for each model and type of sensor:
The gap, which is the distance between the two sensor heads, can be adjusted from 10 to 180 mm. The adjustment depends on the type of sensor, application,thickness of the material to be measured, and safety considerations.
This frame is suitable for measured product whose pass angle with the horizontal is between 0° and 45°.
This frame is suitable for measured product whose pass angle with the horizontal is between 0° and 45°.
The standard product pass line (distance from the floor at which the product passes) is between 700 and 720mm, and can be reduced to 620 mm if required. For higher pass line levels the scanner is mounted on adapted legs.
Frame
The frame is manufactured with 6 mm thick steel tubes of 150 x 150 mm rectangular cross section for the horizontal beams (150x50mm for the frame uprights). Compared to other steel profiles, the tubular structure is by far the strongest both in bending and torsion. This design provides the frame an excellent mechanical stability while optimizing space.
During final assembly, the complete guiding system is attached to surfaces directly machined on the already fully welded and assembled frame. This manufacturing method ensures that head alignment is perfect in all axes and no adjusting or leveling system is necessary. An alignment deviation of less than 0,2mm is achieved in all motion axes throughout the frame. This solution avoids the on-site difficult and extremely time consuming alignment maintenance operations.
The operator side of the scanner is no wider than the frame upright (150x50mm). This small side profile minimizes obstructions for the line operators and hence facilitates easy and safe threading of the product through the scanner.
Measurement Sensor Head Guiding
The measurement head guiding system consists of two carriages equipped with linear ball bearings running on hardened chrome rails (HRC 62). The assembly, statically over determined, is extremely stable. The sensor heads are mounted on these carriages.
The carriages are pulled by timing polyurethane belts reinforced with steel cables. The belt tensioning system can be easily disassembled from the carriages.
The belts are supported throughout the frame. Therefore, the belt tension can be adjusted optimally, avoiding vibration and premature wear, thereby increases the equipment reliability.
The upper and lower belts are coupled directly via a single shaft which transmits the motion. This assembly is extremely simple and is very reliable.
The belt fastening system on the carriages can easily be disassembled. It allows decoupling the heads easily and quickly for maintenance operations (for example to clean the sensor heads or to replace the sensor windows). Re-coupling the head is very simple. No alignment operation is necessary since a mechanical device automatically determines the relative sensor positions.
Covering / Protection of the guiding and the drive systems
Except for the area of passage of the sensor supports, the scanner is completely closed by covers hence protecting the guiding system from dust and fibers. The covers are designed to be easily and very quickly removed. Optionally they can be made of aluminum in order to reduce their weight and facilitate handling.
For very harsh environments, the area of passage of the sensor supports can be completely closed and the scanner can be operated with a higher internal positive pressure to further reduce internal contamination risks.
Maintenance
Reliability and ease of maintenance were closely studied in order to minimize machine down time. All maintenance operations are designed to be very easy and fast.
Examples:
Lubrication of linear bearings: It’s done with a standard grease gun with no need to remove the covers.
Measurement head uncoupling: Again there is no need to remove covers for this operation. A hatch gives the access to the coupling system.
Head re-coupling: A mechanical system quickly resets the optimal head alignments without any type of specialized time consuming procedure.
Lubrication of pulleys: It can be done easily by removing only one cover fastened without screws.
Access to the motor and drive shaft: Again there is only one cover to remove (fastened without screws).
Measurement head uncoupling: Again there is no need to remove covers for this operation. A hatch gives the access to the coupling system.
Head re-coupling: A mechanical system quickly resets the optimal head alignments without any type of specialized time consuming procedure.
Lubrication of pulleys: It can be done easily by removing only one cover fastened without screws.
Access to the motor and drive shaft: Again there is only one cover to remove (fastened without screws).
Electrical cabinet
All electrical components of the scanner are assembled in a cabinet mounted to the drive side of the frame. Scantech scanners are complete stand-alone machines that can be installed and set up much faster than conventional gauge systems with remote electrical cabinets that require additional wiring, testing, and interconnections troubleshooting.
MO1 Gauge Frame for materials Frame from 4500 to 6650mm in width
A precise design for an attractive price
The MO1 series closed frames are designed for lines where the measured product width ranges from 4500 to 6650mm.
Five frame sizes are available. The following table depicts the measurable width for each model and type of sensor:
The gap, which is the distance between the two sensor heads, can be adjusted from 10 to 180 mm. The adjustment depends on the type of sensor, application, thickness of the material to be measured, and safety considerations.
This frame is suitable for measured product whose pass angle with the horizontal is between 0° and 45°.
This frame is suitable for measured product whose pass angle with the horizontal is between 0° and 45°.
The standard product pass line (distance from the floor at which the product passes) is between 980 and 1000mm, and can be reduced to 900 mm if required. For higher pass line levels the scanner is mounted on adapted legs.
Frame
The frame is manufactured with 6 mm thick steel tubes of 250 x 150 mm rectangular cross section for the horizontal beams. The frame uprights are made with 150x40mm thick steel sheet. Compared to other steel profiles, the tubular structure is by far the strongest both in bending and torsion. This design provides the frame an excellent mechanical stability while optimizing space.
During final assembly, the complete guiding system is attached to surfaces directly machined on the already fully welded and assembled frame. This manufacturing method ensures that head alignment is perfect in all axes and no adjusting or leveling system is necessary. An alignment deviation of less than 0,2mm is achieved in all motion axes throughout the frame.
This solution avoids the on-site difficult and extremely time consuming alignment maintenance operations.
The operator side of the scanner is no wider than the frame upright (150x40mm). This small side profile minimizes obstructions for the line operators and hence facilitates easy and safe threading of the product through the scanner.
The pass line level includes mounting plates which are fixed on the operator side and mobile on the electrical cabinet side. On the mobile side, the mounting plate consists of two steel plates, one attached to the line structure and the other attached to the frame; they are linked together by roll bearings. The frame is then free to thermally expand or contract, thereby preventing possible mechanical deformations.
Anti vibration plates are also installed between the frame fixing plates and the mounting plates.
Measurement Sensor Head Guidance
The measurement head guiding system consists of two carriages equipped with linear ball bearings running on hardened chrome rails (HRC 62). The assembly, statically over determined, is extremely stable. The sensor heads are mounted on these carriages.
The carriages are pulled by timing polyurethane belts reinforced with steel cables. The belt tensioning system can be easily disassembled from the carriages.
The belts are supported throughout the frame. Therefore, the belt tension can be adjusted optimally, avoiding vibration and premature wear, thereby increases the equipment reliability.
The upper and lower belts are coupled directly via a single shaft which transmits the motion. This assembly is extremely simple and is very reliable.
The belt fastening system on the carriages can easily be disassembled. It allows decoupling the heads easily and quickly for maintenance operations (for example to clean the sensor heads or to replace the sensor windows). Re-coupling the head is very simple. No alignment operation is necessary since a mechanical device automatically determines the relative sensor positions.
Covering / Protection of the guiding and the drive systems
Except for the area of passage of the sensor supports, the scanner is completely closed by covers hence protecting the guiding system from dust and fibers. The covers are designed to be easily and very quickly removed. Optionally they can be made of aluminum in order to reduce their weight and facilitate handling.
For very harsh environments, the area of passage of the sensor supports can be completely closed and the scanner can be operated with a higher internal positive pressure to further reduce internal contamination risks.
Maintenance
Reliability and ease of maintenance were closely studied in order to minimize machine down time. All maintenance operations are designed to be very easy and fast.
Examples:
Lubrication of linear bearings: It’s done with a standard grease gun with no need to remove the covers.
Measurement head uncoupling: Again there is no need to remove covers for this operation. A hatch gives the access to the coupling system.
Head re-coupling: A mechanical system quickly resets the optimal head alignments without any type of specialized time consuming procedure.
Lubrication of pulleys: It can be done easily by removing only one cover fastened without screws.
Access to the motor and drive shaft: Again there is only one cover to remove (fastened without screws).
Measurement head uncoupling: Again there is no need to remove covers for this operation. A hatch gives the access to the coupling system.
Head re-coupling: A mechanical system quickly resets the optimal head alignments without any type of specialized time consuming procedure.
Lubrication of pulleys: It can be done easily by removing only one cover fastened without screws.
Access to the motor and drive shaft: Again there is only one cover to remove (fastened without screws).
Electrical cabinet
All electrical components of the scanner are assembled in a cabinet mounted to the drive side of the frame. Scantech scanners are complete stand-alone machines that can be installed and set up much faster than conventional gauge systems with remote electrical cabinets that require additional wiring, testing, and interconnections troubleshooting.
HO1 Gauge frames for harsh environments, clean rooms, and large width applications
The most stable and robust frame on the market
The series HO1 Frames are extremely robust and the beams are closed above and under the material to be measured.
The highly rigid frame allows the measurement of materials up to 12 meters wide and also makes it the ideal frame for delicate measurements where a high degree of accuracy is necessary.
The absence of opening over and under the material makes it the best choice for severe environments (dust, fibers, moisture, solvents, etc.) and also for very clean applications where dust, which might be generated by the scanner guiding system, cannot be tolerated on the material.
There are twenty frame sizes in this range, with a 500 mm width difference between models. The following table depicts the measurable material width for each model and type of sensor:
The gap, which is the distance between the two sensor heads, can be adjusted from 10 to 80 mm. The adjustment depends on the type of sensor, application, thickness of the material to be measured, and safety considerations.
The standard product pass line (distance from the floor at which the product passes) is between 810 and 830mm, and can be reduced to 770 mm if required. For higher pass line levels the scanner is mounted on adapted legs.
Frame
The frame is formed by a structure consisting of horizontal beams that have a cross section of 400 x 350 mm which has an extremely high Young’s modulus (stiffness). For example, the deflection at the center of a 10 meter wide machine is less than xxxx. The resistance to torsion is also impressive. On the scanner’s drive side, electrical components are installed in a thick welded enclosure that forms a very rigid upright. On the operator side, the frame is manufactured from 40 mm thick steel plate. This frame assembly has an exceptional strength and stability.
During final assembly, the complete guiding system is attached to surfaces directly machined on the already fully welded and assembled frame. This manufacturing method ensures that head alignment is perfect in all axes and no adjusting or leveling system is necessary. An alignment deviation of less than 0,2mm is achieved in all motion axes throughout the frame. This solution avoids the on-site difficult and extremely time consuming alignment maintenance operations.
The frame beams have side openings to allow passage of the carriages. This configuration is very practical for clean room environments because there is no risk that dust from the upper beam will fall on the material.
Another design benefit of the side opening is that dust, fiber, water or other matter from the measured material cannot fall onto the lower beam. This machine is therefore ideal for harsh environments such as non-woven material applications, float-knells, and coating or paper mill lines.
The operator side of the scanner is no wider than the frame upright (150x40mm). This small side profile minimizes obstructions for the line operators and hence facilitates easy and safe threading of the product through the scanner.
Optionally, the frames of series HO1 gauges can be opened on the operator side. In this case the upper beam is attached to the line frame and the operator side upright is then removed.
The pass line level includes mounting plates which are fixed on the operator side and mobile on the electrical cabinet side. On the mobile side, the mounting plate consists of two steel plates, one attached to the line structure and the other attached to the frame; they are linked together by roll bearings. The frame is then free to thermally expand or contract, thereby preventing possible mechanical deformations.
Anti vibration plates are also installed between the frame fixing plates and the mounting plates.
Air Circulation
Temperatures variations between the upper beam and lower beam can happen as the material being produced acts as a thermal shield between the two beams. In this case the two beams may not thermally expand/contract by the same amount. This results in frame deformation that cannot be compensated by the mobile mounting plate.
Even though these deformations are compensated by the sensors which are measuring the distance between the two heads constantly, Scantech philosophy is to completely avoid or limit active compensations. Thus, the HO1 frames are designed to allow a high rate air flow to circulate between and through the lower and upper beams.
This design homogenizes the temperature of the frame and avoids any mechanical deformation. The series HO1 Frames are the only ones on the market equipped with this feature.
This design homogenizes the temperature of the frame and avoids any mechanical deformation. The series HO1 Frames are the only ones on the market equipped with this feature.
Air circulation is an extremely effective method to ensure dimensional stability of the frame. Scantech supplies this frame on all machines where the measurements are highly sensitive. It’s the case for example, when the measured material is very thin, such as plastic bi-axially oriented film applications.
For most of the applications frame air circulation is not necessary. Nevertheless, Scantech uses it in harsh environments by blowing air directly into the guiding volume. This generates a slight over pressure so that dust and fibers cannot enter inside the beams. For example, it’s a very useful feature for non-woven material applications.
Measurement Sensor Head Guidance
The measurement head guiding system consists of two carriages equipped with linear ball bearings running on hardened chrome rails (HRC 62). The assembly, statically over determined, is extremely stable. The sensor heads are mounted on these carriages.
The carriages are pulled by timing polyurethane belts reinforced with steel cables. The belt tensioning system can be easily disassembled from the carriages.
The belts are supported throughout the frame. Therefore, the belt tension can be adjusted optimally, avoiding vibration and premature wear, thereby increases the equipment reliability.
The upper and lower belts are coupled directly via a single shaft which transmits the motion. This assembly is extremely simple and is very reliable.
The belt fastening system on the carriages can easily be disassembled. It allows decoupling the heads easily and quickly for maintenance operations (for example to clean the sensor heads or to replace the sensor windows). Re-coupling the head is very simple. No alignment operation is necessary since a mechanical device automatically determines the relative sensor positions.
Covering / Protection of the guiding and the drive systems
Except for the area of passage of the sensor supports, the scanner is completely closed by covers hence protecting the guiding system from dust and fibers. The covers are designed to be easily and very quickly removed. Optionally they can be made of aluminum in order to reduce their weight and facilitate handling.
For very harsh environments, the scanner can be operated with higher internal positive pressure to further reduce internal contamination risks as explained above.
Maintenance
Reliability and ease of maintenance were closely studied in order to minimize machine down time. All maintenance operations are designed to be very easy and fast.
Examples:
Lubrication of linear bearings: It’s done with a standard grease gun with through access doors that are located at both ends of the scanner.
Measurement head uncoupling: Doors at both ends of the scanner provide direct access to the coupling system.
Head re-coupling: A mechanical system quickly resets the optimal head alignments without any type of specialized time consuming procedure.
Lubrication of pulleys: It can be done easily by removing only one cover fastened without screws.
Access to the motor and drive shaft: Again there is only one cover to remove (fastened without screws).
Measurement head uncoupling: Doors at both ends of the scanner provide direct access to the coupling system.
Head re-coupling: A mechanical system quickly resets the optimal head alignments without any type of specialized time consuming procedure.
Lubrication of pulleys: It can be done easily by removing only one cover fastened without screws.
Access to the motor and drive shaft: Again there is only one cover to remove (fastened without screws).
Electrical cabinet
All electrical components of the scanner are assembled in a cabinet mounted to the drive side of the frame. Scantech scanners are complete stand-alone machines that can be installed and set up much faster than conventional gauge systems with remote electrical cabinets that require additional wiring, testing, and interconnections troubleshooting.
System
The System is the scanner’s electronic architecture, network, and software.
Scantech offers two different types of systems:
1. SSA1: This system is suitable for simple configurations where the scanner has a limited number of inputs and outputs. A single sensor can be supported. The internal network has a fixed configuration and operates at a speed of 1Mbits/sec.
2. SSA2: This system is dedicated to more complex applications. It is built around a chain of microprocessors communicating through a deterministic high-speed bus (100Mbits/sec). This topology allows various configurations of input and output capacities and supports multiple sensors, their number being limited by mechanical or space consideration and constraints.
2. SSA2: This system is dedicated to more complex applications. It is built around a chain of microprocessors communicating through a deterministic high-speed bus (100Mbits/sec). This topology allows various configurations of input and output capacities and supports multiple sensors, their number being limited by mechanical or space consideration and constraints.
Both systems allow the scanner to communicate with any number of other equipment (other scanners, control systems and user interfaces).
Both systems, and especially SSA2, are extremely advanced and have no equivalent on the market. For example, the sensors are systematically equipped with their own intelligence. Scantech has been developing and offering this concept for twenty years and has become the most experienced supplier in the field.
Scantech SSA1 Control System
Although dedicated to simple applications, the SSA1 system has no other equivalent system today. Apart of the SSA2, it is the most powerful, the fastest and the most integrated system on the market.
It is built around six core functions:
1. The CPU
Entirely developed by Scantech, it is a powerful onboard computer (400MHz), with high memory capacity and many communication options. Running under a Linux based real time kernel operating system, it is located inside the Scanner electrical cabinet on the drive side.
It performs the following tasks:
Manages the internal scanner bus.
Configurable communication with the drive controller.
The inputs and outputs.
Finalizes the measurement processing, especially when data from both heads is necessary to determine the correct physical quantity.
Manages the communications with the external world through a 100Mbits Ethernet network, three serial links ports, one being specially dedicated to customer communication, and one USB port for maintenance. The scanner can be connected in parallel with any number of other machines, scanners, control systems and user interfaces. This architecture has the unique advantage of providing real redundancy at the user interface level, and also eliminating any processing or computation related to the manufacturing process and measurement calculations. In other words, with the operator interface off the measurement and control system will continue to pilot the manufacturing line.
Communicates through standard protocols such as Modbus, Modbus TCP/IP and OPC.
Configurable communication with the drive controller.
The inputs and outputs.
Finalizes the measurement processing, especially when data from both heads is necessary to determine the correct physical quantity.
Manages the communications with the external world through a 100Mbits Ethernet network, three serial links ports, one being specially dedicated to customer communication, and one USB port for maintenance. The scanner can be connected in parallel with any number of other machines, scanners, control systems and user interfaces. This architecture has the unique advantage of providing real redundancy at the user interface level, and also eliminating any processing or computation related to the manufacturing process and measurement calculations. In other words, with the operator interface off the measurement and control system will continue to pilot the manufacturing line.
Communicates through standard protocols such as Modbus, Modbus TCP/IP and OPC.
Optionally, manages a local operator interface installed on the drive side of the scanner.
2. Internal Communication Bus
2. Internal Communication Bus
This bus has a fixed configuration and works at 1Mbits/sec. It links the master CPU to the intelligent electronic boards of the sensor heads.
3. Standard interface for all sensor kinds
The communication interface is the same for all emitting or receiving sensor heads. It includes a programmable logic device which channels (voltages, currents, temperatures …). This allows the main operating parameter to be all digitized (Voltages, current, temperatures…) at the same rate as the measurement channels. Therefore the operating parameters can be displayed as profiles similar to the measurements. This integrated oscilloscope is a unique tool, extremely powerful and useful, for the maintenance, particularly in case of remote intervention.
4. Drive System
Scantech equips it’s scanners with a brushless servo-drive with an integrated resolver. This technology combines flexibility, technical performance, and remarkable reliability.
Flexibility, since the drive controller has its own central processing unit which allows it to be easily programmed for specific functions. For example, the measurement heads can be easily programmed for a specific sequence in case of material break. Moreover, the unit constantly checks the internal drive parameters (temperature, currents, torque, etc. …).
The high performance is ensured by Brushless servo drives designed for 24 hour/ 7 day operation for robotic applications requiring quick dynamic reaction times.
Flexibility, since the drive controller has its own central processing unit which allows it to be easily programmed for specific functions. For example, the measurement heads can be easily programmed for a specific sequence in case of material break. Moreover, the unit constantly checks the internal drive parameters (temperature, currents, torque, etc. …).
The high performance is ensured by Brushless servo drives designed for 24 hour/ 7 day operation for robotic applications requiring quick dynamic reaction times.
5. Input and Output (I/O)
This system includes a standard set of inputs and outputs (speed acquisition, material length, some analogic and some logic I/O).
6. Local Operator interface
Optionally, SSA1 supports a local graphical operator interface. The operator can enter commands, check the scanner status, view alarms and even view the profiles measured material. The local interface is extremely useful when scanner(s) are located away from the line control rooms.
Scantech SSA2 Control System
It has been developed for managing very complex configurations. It is designed for multi-sensor applications and for configurable and flexible topology. It is by far the most advanced, powerful, fastest, integrated QCS control system available in the market.
Entirely developed by Scantech, the SSA2 system is built around a microprocessor chain, whose number may be variable, which communicate through an internal deterministic high-speed bus (100Mbits/sec). The IID Microprocessors (IID = Intelligent Interface Device) interface the specific electronic modules of the measurement system and control. A master computer manages the processors network communications with the external world; that is to say with other Scantech equipment or customer computers.
The SSA2 system has been designed around three core functions:
1. The master computer
It is a powerful onboard computer (400MHz), with a large memory capacity and many communication options, and is running under the real time Linux kernel operating system. It is located inside the Scanner electrical cabinet on the drive side.
It performs the following functions:
Manages the internal scanner bus.
Finalizes the measurement processing, especially when data from both heads is necessary to determine the correct physical quantity or when data from an other scanner or equipment is needed.
Manages the communications with the external world through a 100Mbits Ethernet network, three serial links ports, one being specially dedicated to customer communication, and one USB port for maintenance. The scanner can be connected in parallel with any number of other machines, scanners, control systems and user interfaces. This architecture has the unique advantage of providing real redundancy at the user interface level, and also of eliminating any processing or computation related to the manufacturing process and measurement calculations. In other words, with the operator interface off the measurement and control system will continue to pilot the manufacturing line.
Communicates through standard protocols such as Modbus, Modbus Ethernet and OPC.
Manages a configurable local operator interface mounted on the drive side of the scanner.
Finalizes the measurement processing, especially when data from both heads is necessary to determine the correct physical quantity or when data from an other scanner or equipment is needed.
Manages the communications with the external world through a 100Mbits Ethernet network, three serial links ports, one being specially dedicated to customer communication, and one USB port for maintenance. The scanner can be connected in parallel with any number of other machines, scanners, control systems and user interfaces. This architecture has the unique advantage of providing real redundancy at the user interface level, and also of eliminating any processing or computation related to the manufacturing process and measurement calculations. In other words, with the operator interface off the measurement and control system will continue to pilot the manufacturing line.
Communicates through standard protocols such as Modbus, Modbus Ethernet and OPC.
Manages a configurable local operator interface mounted on the drive side of the scanner.
2. The Interface microprocessors (IID)
Equipped with a powerful onboard computer (400MHz), and having a large memory capacity too.They are plugged on all the scanner and control system electronic modules.
For example:
For example:
Numerical acquisition boards for detectors.
X-ray sources control boards.
Video acquisition for laser sensors.
Input and output boards.
X-ray sources control boards.
Video acquisition for laser sensors.
Input and output boards.
They have the following tasks:
They fully manage the electronic modules operation, handle the measurement channel acquisitions, computations and local inputs and outputs.
They manage the communication with the internal high speed bus.
They manage the communication with the internal high speed bus.
Similar to the SSA1 system, each electronic module provides 16 analog channels. This allows the main operating parameter to be digitized (Voltages, currents, temperatures…).
They are all sampled at the same frequency as the measurement channels. Therefore the operating parameters can be displayed as profiles the same way as measurements. This integrated oscilloscope is a unique tool, extremely powerful and useful for the maintenance, particularly in case of remote intervention.
3. Internal Communication Bus
It is a high speed (100 Mbits / sec) deterministic bus. Deterministic means that the frame period is fixed and well defined. The timing of each single task is therefore ensured. This bus can support any number of IID interface processors as thus any number of sensors.
The SSA2 architecture allows variable topologies and is very flexible. As for the number of sensors, the number of I/O boards is not limited too. The figure shows an example of a possible configuration. The I/O flexibility makes it very easy to build simple control loops such as line speed control, control of the rate of flow of raw material or coating knife control from any Scantech equipment.
The overall computation power is really impressive as each IID embeds a 400MHz microprocessor 
The overall computation power is really impressive as each IID embeds a 400MHz microprocessor
Drive System
Scantech SSA2 is equipped with a brushless servo-drive with an integrated resolver. This technology combines flexibility, technical performances, and remarkable reliability.
Flexibility, since the drive controller has its own central processing unit which allows it to be easily programmed for specific functions. For example, the measurement heads can be easily programmed for a specific sequence in case of material break. Moreover, the unit constantly checks the internal drive parameters (temperature, currents, torque, etc. …).
The high performance is ensured by Brushless servo drives designed for 24 hour/ 7 day operation for robotic applications requiring quick dynamic reaction times.
Flexibility, since the drive controller has its own central processing unit which allows it to be easily programmed for specific functions. For example, the measurement heads can be easily programmed for a specific sequence in case of material break. Moreover, the unit constantly checks the internal drive parameters (temperature, currents, torque, etc. …).
The high performance is ensured by Brushless servo drives designed for 24 hour/ 7 day operation for robotic applications requiring quick dynamic reaction times.
Local Operator interface
SSA2 also supports a local graphical operator interface. The operator can enter commands, check the scanner status, view alarms and even view the profiles measured material. The local interface is extremely useful when scanner(s) are located away from the line control rooms.
Sensors
There are many types of sensors for online measurement and they can be classified into two (2) families:
1. Sensors that contact the measured material
2. Non-contact sensors
2. Non-contact sensors
Scantech offers only the latter category: non-contact sensors. These sensors satisfy the vast majority of applications by means of the following four (4) technologies:
1. X-ray Sensors: Scantech is the leader in this technology and was the first to introduce in 1992 an x-ray sensor for the thickness measurement of plastic films and in 1993 for the weight of non-woven materials.
X-ray sensors are used, almost exclusively, for the measurement of the thickness of metal sheet.
2. Infrared Sensors: Scantech systematically uses these type of sensors to measure the thickness of barrier layers of multi-layer films, and often use them for the measurement of coating weights and humidity.
3. Beta Radiation Sensors: It is a technology that Scantech offers as a last resort when it is the best compromise for the measurement of thickness or weight. Beta sensors use a radioactive source which causes more and more difficulties for customers regarding legal compliances.
4. Laser Triangulation Sensors: Scantech has developed its own proprietary design. This sensor is used for measuring the thickness of inhomogeneous materials (i.e. variable density, layers of very different nature, foam…). Theses sensors can also quantify the material surface such as roughness.
X-ray sensors are used, almost exclusively, for the measurement of the thickness of metal sheet.
2. Infrared Sensors: Scantech systematically uses these type of sensors to measure the thickness of barrier layers of multi-layer films, and often use them for the measurement of coating weights and humidity.
3. Beta Radiation Sensors: It is a technology that Scantech offers as a last resort when it is the best compromise for the measurement of thickness or weight. Beta sensors use a radioactive source which causes more and more difficulties for customers regarding legal compliances.
4. Laser Triangulation Sensors: Scantech has developed its own proprietary design. This sensor is used for measuring the thickness of inhomogeneous materials (i.e. variable density, layers of very different nature, foam…). Theses sensors can also quantify the material surface such as roughness.
Different types of sensors can be coupled on the same scanner in order to achieve other measurements. For example, an X-ray sensor coupled with a Laser triangulation sensor can measure the density of a material.
All Scantech sensors are interfaced through the internal scanner bus and possess a local intelligence allowing the direct digitization of the sensor signals and the pre-processing of measurements.
Low energy X-ray transmission sensor
The best choice when the cross profile must be finely controlled
Principle
This sensor is designed for the measurement of basis weight or thickness (when the density is constant) of relatively light or very light materials It is based on the transmission principle.
An X-ray tube located in the emitting head (source) produces a beam of X-rays which is detected and whose total energy (I0) is measured by the receiving head. When a material is placed in the space between the two heads (air-gap), part of the beam is absorbed, and only the transmitted fraction (I) is detected (fig. 1).
The transmitted beam is more or less attenuated according to the quantity of matter present in the gap. Figure 2 shows the relation between the thickness (constant density) and the remaining transmitted signal. The signal value is 100% when there is no material between the heads.
Knowing precisely this relation, and measuring, for a given material, the percentage of transmitted signal, one can determine the basis weight or thickness of homogeneous materials.
X-ray tube
An X-ray tube is an electric device which generates X-rays.
A filament (in red on figure 3) is heated by a current. It emits electrons around its surface. The target (in blue), is set to a positive voltage (accelerating voltage). The electrons are therefore accelerated and hit the target. The collisions cause the emission of X-rays. Obviously X-rays are emitted over 4π but are stopped by the tube wall except for those emitted through the window (in light blue).
The window material is selected to minimize X-ray absorption and an almost cylindrical beam of X-rays is formed (with a low taper angle of emission).
A filament (in red on figure 3) is heated by a current. It emits electrons around its surface. The target (in blue), is set to a positive voltage (accelerating voltage). The electrons are therefore accelerated and hit the target. The collisions cause the emission of X-rays. Obviously X-rays are emitted over 4π but are stopped by the tube wall except for those emitted through the window (in light blue).
The window material is selected to minimize X-ray absorption and an almost cylindrical beam of X-rays is formed (with a low taper angle of emission).
There are two principal advantages for using such a tube:
No emissions when the supply voltage is off. It is therefore very safe for maintenance interventions.
Selection of the beam energy which allows the measuring range to be optimized by adjustment of the accelerating voltage.
Selection of the beam energy which allows the measuring range to be optimized by adjustment of the accelerating voltage.
Detectors
Scantech develops and manufactures its own detectors. The detector of course is very important and to a large extent, it defines the performance level of the sensor. The control of detection technologies is one of the reasons for the high level of performance reached by Scantech X-ray sensors.
For proprietary reasons, Scantech does not disclose technical details about its detector technologies.
Characteristics
Scantech sensors have remarkable properties. It is the best solution for applications where a fast measurement and a precise profile are necessary, as in the case of controlling a die (e.g. cast and oriented films). They outperform by far infra-red or beta technologies.
Indeed, it is the only sensor to combine the following properties:
Astonishing range of measurement: For example with an energy level of less than 5kev (accelerating voltage lower than 5kVolts), polypropylene film from 2µm up to 2000µm can be precisely measured! This sensor reproduces very well the film edge shape of biaxially-oriented films (fig. 4 depicts a left edge).
With a slightly higher energy level, the range of measurement is significantly extended. With 7kVolts one can reach 6 to 7kg/m2.
With a slightly higher energy level, the range of measurement is significantly extended. With 7kVolts one can reach 6 to 7kg/m2.
Excellent precision: At low energy levels, the X-ray absorption interaction with the measured matter is binary. An X-ray is either completely stopped, or it passes through the matter without any energy loss and with no deviation from its trajectory (as if there were no matter). Because of these only two possibilities one obtains the best possible statistics (binominal) and therefore the best accuracy. Figure 5 depicts the typical level of accuracy that can be obtained on a finished film with the measuring system controlling the die. It is a 6.6µm thin BOPP film (capacitor film). The finished film (5.5m wide) has a 0.026µm thickness standard deviation.
Very short response time: The scanner’s excellent accuracy allows response times lower than 10 msec. Even at high scanning speeds, which are necessary to reduce the influence of the thickness variations in the machine direction, the profile is read correctly by the first scan. Thickness variations are seen with their real amplitude and are not smoothed at all. This is extremely important in order to have fast and effective die control.
The best streak resolution: The streak resolution is the best amongst all available technologies. For certain applications, Scantech has achieved resolutions of less than 0.2mm in the cross direction! The very straight X-ray beam, without any diffusion, makes such good streak resolution possible. The following figure depicts a profile zoom from a mesh application measurement, where the material pitch is 3mm. In order to obtain such a level of details the pencil beam width in the cross direction is collimated to 0.2mm!
Very easy to use: The sensor is very easy to use and no calibration is necessary for:
Any change in thickness or basis weight across the complete range.
Color changes.
Additive changes.
Re-calibration can be performed in minutes when there is a change in filler proportion and then the new calibration coefficients are stored in a recipe.
Safe maintenance. There is no emission of X-rays when the sensor is not powered. Therefore there is no safety risk when performing maintenance.
In most cases, no administrative authorization is required. For a large majority of applications a voltage of less than 5kVolts is sufficient. In this case, there is no emission around the heads of the sensor. No prior approval, authorization, or regular annual control is required in whatever countries. 
Very short response time: The scanner’s excellent accuracy allows response times lower than 10 msec. Even at high scanning speeds, which are necessary to reduce the influence of the thickness variations in the machine direction, the profile is read correctly by the first scan. Thickness variations are seen with their real amplitude and are not smoothed at all. This is extremely important in order to have fast and effective die control.
The best streak resolution: The streak resolution is the best amongst all available technologies. For certain applications, Scantech has achieved resolutions of less than 0.2mm in the cross direction! The very straight X-ray beam, without any diffusion, makes such good streak resolution possible. The following figure depicts a profile zoom from a mesh application measurement, where the material pitch is 3mm. In order to obtain such a level of details the pencil beam width in the cross direction is collimated to 0.2mm!
Very easy to use: The sensor is very easy to use and no calibration is necessary for:
Any change in thickness or basis weight across the complete range.
Color changes.
Additive changes.
Re-calibration can be performed in minutes when there is a change in filler proportion and then the new calibration coefficients are stored in a recipe.
Safe maintenance. There is no emission of X-rays when the sensor is not powered. Therefore there is no safety risk when performing maintenance.
In most cases, no administrative authorization is required. For a large majority of applications a voltage of less than 5kVolts is sufficient. In this case, there is no emission around the heads of the sensor. No prior approval, authorization, or regular annual control is required in whatever countries.
Design
Although this Scantech sensor is extremely simple to use, it is very difficult to design and requires a high level of expertise.
Scantech was the first company to introduce the x-ray technology into the market for the measurement of light materials (plastic, non-woven, etc.) even though the technology has been used with much higher energies for 40 years in metallurgical applications.
Scantech owns patents for the low energy technology sensors (less than 5keV) in principal countries, although the technology has been largely copied in recent years..
Nevertheless, Scantech is 15 years ahead in terms of technological developments in this field, and its sensors have reached an unequaled level of maturity:
There is no drift with time no matter what the variations