Technology Transfer>BLOWN_FILM

INFRAGAUGE SYSTEM FOR BLOWN FILM PLANT IRGB-01

DESCRIPTION

packaging film gage monitoring during manufacture is emerging as a necessary element to meet quality demands of end-users including single roll certification. Plastic film manufacturing processes are of two major categories: blown film and flat film extrusion lines. Infragauge sensor technology developed for the first time in India at Central Electronics Engineering Research Institute, Chennai with funding support from Department of Science & Technology, Govt. of India.


The technology of on-line non contact film thickness measurement of systems will meet the long felt need of Indian plastic industry. A fully working prototype of Infragauge system for blown film plant has been fabricated, installed in a typical multilayer blown film plant successfully conducted user industry trials.

This is a novel on-line thickness gauging system consisting of non contact infragauge sensor and an industrial computer based electronic unit with a high resolution graphic terminal. The system measures double lay flat thickness of the film and it indicates average thickness of the film at any point and any instant. In case of multi layer co-extrusion film plants with either oscillating platform or rotating take off, bubble wide thickness profile along with spot and average values are displayed.

The system was demonstrated live to a few interested user industries and equipment manufacturing companies during a technology  exposition held in November 1999 at the blow film plant. 


     sensor on layflat film    Bubble wide thickness profile

FEATURES:

Non- contact ,non-destructive measurement
Fast measurements for mean thickness and profile control
Archive of product set-ups and roll data
Provision for stored calibrations of many different products
 Digital display of spot thickness, mean, STD etc.,.
Profile variations mapped with reference to die zones
Graphic plots to show long term trend, MD profile & statistical analysis of data
Can be tailor-made and retrofitted to any Industry with little downtime
User friendly software developed in Visual C++
calibration facility for user with password protection

SPECIFICATIONS

Sensor

Infrared absorption based Transmission type suitable for monitoring total thickness of a single layer or multi layer Co-extrusion films.

Range

20 to 200 microns (Depends on the type & blend of film)

Accuracy

±1 micron or within 2 % whichever is higher

Sampling Area

10mm Dia. typical

Calibrations

Built in calibration & validation facility for user with password protection

Display

  1. Deviation profile/spot thickness and average thickness page display
  2. Historic scan profile (3 dimensional display of upto10 successive profiles)
  3. SPC data display (statistical analysis) std, mean, X, R charts etc...

Output

4-20 ma isolated current signals, profile data, roll data to printer

Sensor Enclosures

Built to meet IP 55 Industry Standard

19" system computer

  • Intel Pentium based industrial Computer
  • 14" SVGA Colour monitor
  • *4.3 GB HDD, 1.44 MB FDD
  • *Add on multifunction I/O card with 12 bit
  •   ADC & digital I/O
  • *Signal interface cards
  • *± 15 V Power Supply Modul
  • *Optional air cooling unit for the 19" rack keep the electronic assemblies cool.

Software

Windows application software developed in VC++

Archive & Reports

Storage & retrieval of production data in MS Access data base

Alarm

High & Low alarm limits, Visual colour displays

Benefits to blown film manufacturers

Savings in raw materials, energy & less recycling
Less wastage & faster product startups
Consistently better quality product with uniform profile
Rapid return on investment through fast start-up & product change over
Better yield for end user

Potential users :


Monolayer and multilayer blown film manufacturers