Non contact measurement & inspection
is our patent. I was surprised no one else had thought of it. We’ve also patented specific outputs from the technology, such as predicting sheet breaks and runnability issues.”
THE FLIR SOLUTION
Depending on the application, IVS uses either FLIR A50/A500 or A70/A700 FLIR IR thermal cameras. “With their higher resolution, we tend use FLIR A70/A700 models for papermaking machinery applications,” reveals Frackowiak. “However, ThermoVision can also benefit machines that produce corrugated paper for packaging. We use FLIR A50/A500 series cameras for corrugators as these applications do not require the same level of resolution, helping to minimise costs for customers.”
Rugged, IP66-rated FLIR A50/A500 and A70/A700 series cameras offer multiple field-of-view options, image streaming, and simple integration with the specific needs of customers. By providing quick access to thermal characteristics, users of these cost-effective cameras can maximise asset uptime and minimise maintenance costs.
“In my opinion, FLIR IR cameras are competitively priced considering the capabilities they offer. During my initial research, I came across other thermal cameras of similar
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specification, but they cost more. We’re incredibly happy with FLIR IR cameras and now standardise on these models.”
SEEING IS BELIEVING
There are essentially two ways of adopting ThermoVision on a papermaking machine. First, as an add-on to existing sheet break systems. FLIR IR cameras see ‘invisible’ defects that visual spectrum cameras cannot. The system also detects wet streaks in real time, helping to prevent costly sheet breaks that can lead to hours of downtime. Second, the system can involve sending the sheet-wide thermal profile to a quality control system (QCS) scanner. A QCS scanner moves back and forth across the sheet, a process that takes anything from seconds to minutes. However, using data captured by FLIR IR cameras, it is possible to feed the QCS in real time. While the control system will not likely work in real time, capturing images with FLIR IR cameras at 30 frames per second, for example, means the system can provide an average profile every second, supporting ultra-fast control system decisions. “A big issue with a QCS scanner is its location at the end of a papermaking machine,” explains Frackowiak. “From placing pulp on the wire, ready for manufacturing into paper, to running through the entire machine and reaching the
QCS scanner, no quality measurement checks take place. However, by positioning a FLIR IR camera at the beginning of the process, perhaps in the press section, we can immediately detect defects like wet streaks or incorrect moisture profiles. This is important because some start-up processes can take hours, with papermaking plants unable to thread the web due to problematic sheet breaks. We now have a way of letting them know why, saving significant time.” Several papermaking facilities are already taking advantage of the technology. Following the award of its patents, IVS now has two papermaking systems running with ThermoVision in the USA, as well as a corrugator. Multiple quotations have been sent to further potential customers, with some planning to include ThermoVision in their next capital expenditure budget.
With the right innovation and technology, even a mature process like papermaking can see step changes in key metrics - such as quality, efficiency, uptime, and control. Thanks to the ingenuity of proprietary IVS systems and the capabilities of FLIR IR thermal vision cameras, papermaking is set to reach a whole new level.
Teledyne FLIR
www.teledyneflir.com March 2025 Instrumentation Monthly
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