MeasureIT DLP Training

Smart Platform
Sensors

Ramesh Satini
23-Jan-2006
3BUS 004 729 R0101 -1
 MeasureIT Scanning Platforms
The Strongest, Most
Reliable Scanner in
SP1200 the Industry
„ Papermaker’s acceptance
worldwide with over 2000
installed
„ Proven reliable and
SP700 rugged in harsh
environments
„ Ease of maintenance with
end column access
„ Edge-to-edge scanning
with accuracy
3BUS 004 729 R0101 -2

Reflection
SP
 MeasureIT Measurements for All Applications

Basis Weight Moisture

Krypton HemiPlus
Strontium Reflection Plus
Promethium Microwave

Ash
2-Component
3-Component

Color
Scanning
Caliper GT
Single-Point
3BUS 004 729 R0101 -3
 MeasureIT Measurements for All Applications

Coat Weight Fiber Orientation

Direct IR
Weight Difference
Ash Difference Arc Laser Source
Detector

OptiPak
Formation Gloss
Opacity
Brightness
3BUS 004 729 R0101 -4
 MeasureIT Basis Weight
Measurement
3BUS 004 729 R0101 -5
 Principle of Measurement

Smart Sensor Measurement

Interface Processor
68332 68030

Auto- 16-Bit Linear- Time g/m2 + lb/Ream

Calibrate A/D ization Stamp

SP
I/I o Msmt Host Service
Output System Work-
station
BW BW
IT
Measure
Basis Wt
Sensor

1000 Msmts Data Box Time-Based Diagnostic

Per Second Averages Msmts Information
3BUS 004 729 R0101 -6
 Principle of Measurement

„ The source module emits a radiation beam that is attenuated by process and
sensed by the detector module.
„ STLK-11 Source is a sealed capsule of beta emitting Radio isotope Krypton 85
gas,(85Kr) with a half-life of 10.76 years.
„ The detected signal exhibits an approximate negative exponential response
3BUS 004 729 R0101 -7

versus basis weight.

„ The sensor microcontroller converts radiation transmission into weight per unit
area.
 Principle of measurement
„ T=I/Io
„ T = Fractional Transmission (0.9=90%)
„ Io = Signal level detected off-sheet
without process in the gap.
„ I = Signal detected with process in the
gap.
„ As the process weight increases the
fractional transmission (T) decreases,
T is expressed in PPT (Parts Per
Thousand)

„ Where
e=natural logarithm base(2.718)
u=the attenuation coefficient
BW=basis weight
„ Source intensity decreases to half after
10.7 years for kr 85, 2.6 yrs for Pm
147. Smart processing electronics has
sufficient resolution so that
3BUS 004 729 R0101 -8

replacement of decayed source

shouldn’t be required for 2 to 4 half
lives.
 One Millisecond Sensor Response Time
Up to 12 Times Faster to See all the Fine Details
„ High-speed detector
„ Custom-designed
ionization chamber
„ Direct-coupled electronics
„ No remote analog cables
„ Proprietary detector
tuning
„ Optimized process
sensitivity
„ Minimized composition,
3BUS 004 729 R0101 -9

pass angle and deflection

sensitivity
 0.1mm Streak Detection — Industry's Best in Single Scan
„ Streak-optimized geometry
10 mm streak „ Conical beams for maximum
signal-to-noise levels
„ Small measurement area for
ABB MeasureIT
Basis Weight precise streak and edge detection
„ 32-bit on-board processing power
Conventional „ 1000 measurements per second
„ 16-bit A/D conversions
„ Fully integrated signals
10 mm
„ Advanced signal processing
„ Time-based measurement
„ 1200 data point profile resolution
„ Precise mapping
3BUS 004 729 R0101 -10

„ Advanced MD and CD control

 2 Hour Standardize Frequency

„ All-point Standardization
accounts for dirt, drift and
pressure changes

„ Permanent factory
calibration is linear over
the entire process range

„ Internal check sample

routinely verifies sensor
performance
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 Air Superiority
ABB’s Patented Air Superiority Provides
You with the Best Accuracy

Minimize The Air Control The Air Measure The Air

Smart Basis Weight Conventional

Based on Ideal Gas Law PV = mrT

Detector Detector
MassAir = PV
Detector rT
P = Air column barometric pressure
d
V = Air column volume (A6 d)
Air Air
Column Process Gap Air Process T = Air column temperature
Process Column r = Air constant
Source

Source
36 g/m2 Air Column Source

70 g/m 2 Air Column

Basis Weight = Mass Total
— Mass Air — Mass Dirt

Air Superiority!
3BUS 004 729 R0101 -12
 Modular Compact Design
„ Vertical, plug-in sensor
modules
„ Fast, easy installation and
maintenance
„ Minimum MD space required
„ Greater operator access and
room to expand
„ Robust, reliable components
„ Low parts count
„ Self-calibrating and testing
electronics
3BUS 004 729 R0101 -13

„ Advanced diagnostics port

 PC-Based Set-up and Troubleshooting Tools
„ Set-up parameters
„ Calibration constants
„ Tuning constants
„ Standardize limits
„ Heater status
„ Diagnostic parameters
„ Sensor status
„ Temperature controls
„ Heaters
„ Electronics
„ Sensor inputs/outputs
„ Check/calibrate samples
„ Internal check sample
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„ Standardize
„ Alarms
3BUS 004 729 R0101 -15

Source Hardware
3BUS 004 729 R0101 -16

Detector Module
 Air Column measurement

„ Coil inductance,
which varies as
the gap is varied,
sets the
frequency of an
oscillator which is
converted into
voltage.
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 Smart BW Hardware & Software Functional setup
3BUS 004 729 R0101 -18
 Sensor calibration- setup
„ BW sensor head constants consists of 6 constants K0
to K3, GapWCC & Air Mass are used convert
millimeters from Air Column measurement into g/m2 air
mass.
3BUS 004 729 R0101 -19
 BW standardization limits
3BUS 004 729 R0101 -20
 Sensor verification/Calibration
„ External Check samples
„ The sample check verification procedure establishes a base line for
standardize (AIS) and sample check on air (PPT), and uses a series of
sample checks to verify the accuracy and repeatability of sensor.
„ Sensor Correlation
„ Single point verification
„ BW=(BWM-DIRT) XPCnSLP + PCnOFF
„ PCnSLP = Slope correction; PCnOFF = Product Code Offset.

New slope=old slope*Lab BW/QCS BW

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 Single Point Calibration
3BUS 004 729 R0101 -22
3BUS 004 729 R0101 -23

SEI Board
 SEI Board

„ DS1 will be ON if
the power is
applied to open the
Shutter.
„ When power
applied to Heater
DS3 LED should
be flashing.
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 Diagnostic card & Print Book

Acrobat Document
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3BUS 004 729 R0101 -26

STLK-11 Hardware
 Real-Time Health Reporting
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 Preventive Maintenance

„ Periodical Checks includes

„ Windows inspection & cleaning.
„ Checking electrometer test function, and Record electrometer
in Log file.
„ Checking sensor air purge flow.
„ Checking the heater condition and recording output duty cycle
„ External sample checks & calibration.
„ Online correlation
3BUS 004 729 R0101 -28
3BUS 004 729 R0101 -29

Troubleshooting
 TLS-1 Source Hardware

„ Source module. The

Radio isotope used is
Strontium 90, with Half
Life of 29.1 years.
„ Detector consists Ion
Chamber, electrometer
and High Voltage
supply to ion chamber.
3BUS 004 729 R0101 -30
 TLS-1 Detector Hardware
3BUS 004 729 R0101 -31
 TLS-1 Hardware circuit
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 TLS-1 Air Shutter Parts
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 MeasureIT Moisture
Measurement
MO4226
3BUS 004 729 R0101 -34
 MeasureIT Moisture Measurement MO4226
Detector Head Measurement
Output

Specular
Reflecting
Hemisphere
Detector

Specular
Reflecting
Hemisphere

Monochromator
Reflector
Cavity High Wattage
Source Lamp
3BUS 004 729 R0101 -35

(field replaceable)
Source Head
 Moisture Measurements Comparisons
Available On-Line Moisture
Measurement Technologies
Infrared Microwave Radio Frequency
• Transmission • Differential Dielectric • Conductivity
• Reflection • Absorption
PROS
Better accuracy Higher weight ranges
Better sensitivity High carbon black at low moisture
Better spatial resolution High iron oxide

CONS
Limited weight range
Effected by high carbon black
3BUS 004 729 R0101 -36
Can not measure bound water Contacting measurement
Less sensitive @ low moisture Non-selective measurement
ie. less accurate

Not applicable to opaque materials Low spatial resolution Inaccurate

Low reliability
Obsolete
 ABB Optimized Moisture Measurements
MeasureIT Application Optimized Sensors
Measurement Range

Sensor Application Moisture (%) Basis Weight (g/m2)

Moisture Measurement Tissue, Fine Writing, 0-30% 10 - 340 Std.

MO4226 Newsprint, Board, 50 - 500 Ext.
(Transmission I.R.)
Packaging

Moisture Measurement Tissue, Fine Writing, Newsprint, 0 - 45% Std.

MO4227 Board, Packaging, Pulp 15 - 70% Ext. 8 - Unlimited
(Reflection I.R.)

Moisture Measurement
DS20
(Non-Contacting Board 3 - 70% > 100
Microwave) 3 - 500 GSM H2O

Moisture Measurement
DS30
3BUS 004 729 R0101 -37

(Non-Contacting Board, Pulp 3 - 70% > 700

Microwave) 500 - 1500 GSM H2O
 MeasureIT Moisture Measurement MO4226

Detector Head Measurement

Output
Specular
Reflecting
Hemisphere
Detector

Over 2500 in Operation!

Specular
Reflecting
Hemisphere

Monochromator
Reflector
Cavity High Wattage
Source Lamp
3BUS 004 729 R0101 -38

(field replaceable)
Source Head
 Principles of Measurement
„ Infrared energy from a high-
Detector Head Measurement intensity quartz halogen lamp is
Output
Specular
focused through band pass filters
Reflecting into a patented polished optical
Hemisphere
Detector cavity
„ The cavity acts to reflect this
energy through the sheet many
times
Specular „ Multiple wavelengths are
Reflecting
Hemisphere measured by a single detector and
proprietary signal processing, to
Reflector Monochromator directly calculate percent moisture
Cavity High Wattage
Source Lamp (without basis weight input)
(field replaceable)
Source Head
3BUS 004 729 R0101 -39
 Basics of IR Measurements – Transmission type
3BUS 004 729 R0101 -40
 Infrared Spectrum

„ The pattern of
absorption versus
wavelengths called
the absorption
spectrum.
„ R = Ir/Ia,
where R = is the ratio,
Ir = intensity of
refence signal,
Ia = intensity of
absorption signal.
„ X=IR1/IR2
IR1= water weight
IR2= fiber weight
3BUS 004 729 R0101 -41

„ %M=f (X)
 Multi-Pass Design – High Optical Efficiencies

„ Captures all scatter

including
„ High angle scatter
„ Insensitive to sheet scatter
power!

„ Low signal loss

„ High S/N at all weights!

„ Overlaping focus at the

center of the cavity
„ No flutter sensitivity!
3BUS 004 729 R0101 -42
 Multi-Pass Signal
Low Basis Weight High Basis Weight

Patented optical cavity design provides multiple passes through a focal point
(98% at same spot):
„ Increases the measurement sensitivity
„ Decreases sensitivity to changes in scattering
3BUS 004 729 R0101 -43

„ Decreases the sensitivity to varying basis weight

„ Eliminates single pass measurements
(example: pinhole effects in tissue)
 How Do We Compensate for Scattering Variations?

„ ABB "Hemi" IR sensors reflect the IR energy repeatedly

through the same spot on the web. The higher the
scattering of the sheet, the fewer times, on the average,
the IR passes through before reaching the detector. This
"Hemi" feature greatly reduces path length variation
resulting from scattering variations.

„ The use of a Reference wavelength, spectrally close to

the absorption wavelength, means that both the
numerator and the denominator of the measurement ratio
experience almost the same scattering-induced variations
3BUS 004 729 R0101 -44

so that this "common mode error" cancels out.

 Signal Strength
Moisture Measurement MO4226 Infrand Optics Receiver

Diffusing Reflective
Surface

Diffusing Reflective
Surface

Infrand Plus
Light Source

Only MeasureIT Moisture Measurement

MO4226 provides true insensitivity to
scattering power and basis weight without
loss of signal strength.
3BUS 004 729 R0101 -45
 No Basis Weight Input Required

„ Determines PERCENT MOISTURE directly

„ Uses multiple IR wavelengths and spectral analysis
„ No need for a Basis Weight measurement from a nucleonic
sensor
„ Result
„ Effects produced by optical scattering are again removed by
means of "common mode" measurements.
3BUS 004 729 R0101 -46
 Absorption Spectrum for Water & Cellulose

Infrared Selectivity - To separate various components, we must

select wavelengths that are uniquely absorbed by each of them.
3BUS 004 729 R0101 -47
 IR Absorption vs Temperature

„ A near IR absorption
spectrum of water at several
different temperatures.

„ Note: The 1.9 micron

combination band narrows,
increases in magnitude, and
shifts to the short wavelength
as temperature increases.
Goldstein, R., The near IR absorption of liquid water at temperatures
between 27 and 209°C, California Institute of Technology, Technical
Report No. 43, October, 1963.
3BUS 004 729 R0101 -48
 Moisture Measurement MO4226 Sensor Design
„ ABB's approach is through sensor
design (not compensation!)
„ Careful selection of band pass
filters
„ Proprietary technique for fine
tuning the center frequency

„ Results
„ Measurement frequency
Goldstein, R., The near IR absorption of liquid water at temperatures
between 27 and 209°C, California Institute of Technology, Technical positioned as marked
Report No. 43, October, 1963.
„ Providing the desirable effect of
making the measurement
insensitive to sheet temperature
3BUS 004 729 R0101 -49
 MeasureIT Moisture Measurement MO4226
„ Direct measurement of percent
Measurement
Detector Head
Output moisture
Specular
Reflecting „ Optical cavity for best sensitivity
Hemisphere
Detector
„ Insensitive to optical scattering
changes.
„ Single detector for stability and
Specular reliability
Reflecting
Hemisphere
„ Insensitive to sheet temperature
Reflector Monochromator changes
Cavity High Wattage
Source Lamp „ Single - permanent calibration
(field replaceable)
Source Head for all grades
3BUS 004 729 R0101 -50
3BUS 004 729 R0101 -51

HemiPlus Hardware
 MeasureIT Moisture
Measurement
DS20 & DS30
3BUS 004 729 R0101 -52
 Moisture Measurement DS20/DS30

„ The ABB sensor is based on a dual frequency design utilizing the

dielectric effect. One frequency is used as a reference signal, the other is
selected as a measurement signal.

„ The ratio of the reference frequency to the measurement frequency is

calibrated to water weight

„ The ratio technique greatly reduces sensitivity to thermal, mechanical,

and electrical variations in the sensor and its environment.

„ Microwave sensor requires compensation from sheet temperature and

the Basis weight sensor to compute percentage moisture.
3BUS 004 729 R0101 -53

„ DS20 can measure H2O 2-70% up to 600 GSM , while DS 30 measure

2-70% moisture up to 1500 GSM.
 Principles of Measurement
„ The DS20 & DS30 use two Top Cavity Half
microwave frequencies, as shown
in this schematic. Reference
frequency is
„ One frequency couples to the unaffected by water

moisture in the web, the other is

unaffected by moisture.
„ The difference between the two
frequencies is a function of the Paper
amount of moisture present.
„ Cavity deflections, due to frame or
temperature variations, effect both
frequencies and cancel out. Measurement
frequency is tightly
coupled to water
3BUS 004 729 R0101 -54

Bottom Cavity Half

 Principles of Measurement
„ The DS20 & DS30 utilize a tuned resonant cavity. The electric field is minimum at the web
location for the reference frequency and is maximum at the web location for the measurement
frequency. Water has a high dielectric constant compared to cellulose or other additives. This
high dielectric constant, interacting with the electric field, influences the resonant frequency of
the measurement frequency but not the reference frequency.

Reference Measurement Resonance at Measurement Resonance at

Low Moist. High Moist.

Measurement

Shift
3BUS 004 729 R0101 -55

∆f1
∆f 2
Frequency shift = f(moisture)
 Principles of Measurement
„ Water is the only component of paper that causes a significant shift to the
measurement frequency. The change in the difference between the reference and
measurement frequencies allows an excellent measurement of moisture. Things that
influence signal amplitude does not effect the moisture measurement.

Constant Frequency Shift

Variable Amplitude
AMPLITUDE

Due to:
Sheet additives
(dyes, pigments,
coating fillers,
carbon black)
Detector Temperature
Oscillator Amplitude
Detector sensitivity
3BUS 004 729 R0101 -56

REF MEASURE

FREQUENCY
 Moisture Measurement DS20 & DS30
„ Use microwave measurement for applications where basis weight is greater
than 100 g/m2, water weight is less than or equal to 1500 g/m2 and moisture
is greater than 3%.
„ ABB includes an Infrared pyrometer to measures sheet temperature (not air gap
temperature). This is to compensate for the shift in dielectric constant of water
versus temperature.
„ The ABB dielectric constant measurement is less sensitive to sheet temperature
than the microwave absorption method.
„ On-board intelligence and 32-bit microprocessor use a scientifically rigorous
real-time algorithm, instead of lookup tables and setpoints used by others.
„ The MeasureIT Moisture Measurement DS20 or DS30 does not need
temperature correction for detector temperature.
„ The MeasureIT Moisture Measurement DS20 or DS30 is not sensitive to frame or
temperature induced deflections.
„ Two models cover the range, DS20 up to 500 g/m² water weight, DS30 up to
3BUS 004 729 R0101 -57

1500 g/m² of water weight.

 Microwave Sensor Block Diagram

ASPC
E
C
Analog output S Carriage
P2 Pins 1,12 from Processor Board
Serial data from sensor
5 volt amplitude with
SA150 5 ms pulses width

P1Pins E,F
Program Jumpers P1Pins E,F
P1Pins G,H P1Pins G,H
- 28 Volts From Processor Program Jumpers
- 28 Volts - 28 Volts
Microwave Sensor

120 VAC

ASPC and Carriage board pin assignments per

functional drawing for either -003 or
-004 backplane

Use Function Key F5 to animate.

3BUS 004 729 R0101 -58

Press Escape to quit .

 Measuring Head type DS-20
3BUS 004 729 R0101 -59
 Measuring Head type DS 30
3BUS 004 729 R0101 -60
 Windows Service Workstation Health Page
3BUS 004 729 R0101 -61
 MeasureIT Caliper GT
Sensor
Technical
Presentation
3BUS 004 729 R0101 -62
 Principles of Measurement
3BUS 004 729 R0101 -63
 Gliding Technology for Enhanced Security

1 cm

Sleek wedge shape

Displaces wrinkles

Self-cleaning, reduces
3BUS 004 729 R0101 -64

build-up
 Principles of Measurement

Strong, Composite Construction Ceramic Layers

Ferrite Layer
Web Travel Paper

Ceramic

Sensing Ferrite C-Core

Coil
Coil Side Sensing
Plane

1 cm

V-Shaped Highly
Facets Polished
Strong, Woven Entry Area for Gliding
3BUS 004 729 R0101 -65

Polyester Self Cleaning Surfaces

Lead-in Arms
 Magnetic Circuit & Coil Inductance

„ Magnetic circuit
„ Ferrite C-core with a coil and a
Magnetic Ferrite Target
Flux Path
Thickness ferrite target
“t”
„ Varying thickness “t” changes
Web magnetic flux path & magnetic
reluctance of the circuit
C-core
“L”
Ferrite „ Resulting coil inductance “L” is a
Coil
“C” function of the thickness “t”
„ Inductance measured by means
L-C f of an L-C oscillator
Oscillator
„ Output frequency (f) is related to
the inductance
3BUS 004 729 R0101 -66
 The Phase Locked Loop (PLL)

„ Patented Phase Locked Loop (PLL) converts this frequency to a

voltage with an unprecedented speed
„ Dedicated 32-bit microprocessor with 16-bit A/D conversion at 1kHz
rate completes the caliper signal processing
To Data
Box
Building

HDLC
Communication
Link
Phase Locked Loop (PLL)
f Feedback v´ 1kHz v´ 16-bit 32-bit
L-C Phase Loop A/D
Micro
Oscillator Comparator Low Pass Converter
Control Filter 1kHz Controller

Anti-Aliasing
Voltage
Controlled
Oscillator
Dedicated Sensor
3BUS 004 729 R0101 -67

High Speed Measurement Circuit Micro Controller

 The Phase Locked Loop (PLL)
continued

„ PLL technique performs comparison

between two frequency sources, one
Phase Locked Loop (PLL) external & one internally generated
„ PLL automatically tunes internal frequency
L-C f Phase Feedback
Loop
v´ via a Voltage Controlled Oscillator (VCO)
Oscillator Comparator
Control
„ Perfectly tracks external frequency
„ Tuning changes by VCO indicative to any
changes in external frequency source
Voltage „ Benefits
Controlled
Oscillator „ High speed signal output proportional
(VCO)
to external frequency
„ Much faster responding than
High Speed Measurement Circuit conventional counting techniques
3BUS 004 729 R0101 -68
 Benefits of the Phase Locked Loop (PLL)

„ The PLL circuit forms corner

stone for many modern digital
Phase Locked Loop (PLL)
instrumentation and
Phase
Feedback communication systems
Loop
Comparator
Control „ Digitally tuned broadcast
technology
Voltage
Controlled „ Cellular phone
Oscillator
communications
„ Automatically tuned radio
receivers
„ Auto-tracking CD players
3BUS 004 729 R0101 -69
 Performance Specifications

„ Accuracy – +/-0.5 micron (0.02 mil) or 0.5% of process

„ Response Time – 1 ms
„ Range – 20-2000 microns (0.8 - 80 mils)
„ Measurement Area (CD) – 1 cm (0.39 in)
„ Temperature Compensation – None Required
„ Defect Isolation and Correction* – Unique to ABB
„ Intelligent Standardize* – Unique to ABB
3BUS 004 729 R0101 -70

* Scanning Platforms SP1200 & SP700 Only

 Consistent Measurement Performance

„ Self-testing electronics
„ Smart diagnostics
„ Intelligent standardization
techniques
3BUS 004 729 R0101 -71

„ Temperature insensitive
3BUS 004 729 R0101 -72

Hardware Overview
3BUS 004 729 R0101 -73

Signals Overview
3BUS 004 729 R0101 -74

Active Coil (Bottom)

 Retraction pneumatic system
3BUS 004 729 R0101 -75
 Schematic of Sensing planes Retraction
3BUS 004 729 R0101 -76
 Sensing Planes

„ Active coil
„ Passive Target
„ Sensing planes
3BUS 004 729 R0101 -77
3BUS 004 729 R0101 -78

Sensor setup
 Standardization variables
3BUS 004 729 R0101 -79
 MeasureIT Color
Measurement
CL4250
3BUS 004 729 R0101 -80
 Electromagnetic Spectrum
3BUS 004 729 R0101 -81
 Hunter L a b System
„ “L” indicates
lightness on a
scale from
0(black) to
100(white).
„ “a” represents the
colors red &
green, +ve
represents RED, -
ve represent
GREEN.
„ “b” represents
blue & yellow. ,
3BUS 004 729 R0101 -82

+ve represents
YELLOW, -ve
represent BLUE.
 Optical Brightening Agents

„ OBAs are type of colorant used in paper industry, have the special
ability to absorb light in the ultraviolet (UV) region, which is outside
the visible portion of the spectrum, and re-emit that light energy in
the visible region, normally blue wavelengths. This way, OBAs are
able to give paper a brightness boost by utilizing light energy in the
non-visible range.
„ The AccuRay color sensor uses a xenon gas discharge lamp as a
source, which is rich in UV emission, thus no supplementary UV
source is required.
„ Sensor has a UV filter which can be put on or off-line at any time,
thus allowing the user to monitor OBA levels in the product, and
make adjustments accordingly.
3BUS 004 729 R0101 -83
 Color Measurement Options - Scanning Platforms

Mill Network (TCP/IP)

Advant

Control Network

MP

Scanning Platform
Scanning Platform
3BUS 004 729 R0101 -84

AccuRay 1180/SP Direct ABB Quality Control System

 Industry's Leading On-Line Color Measurement
Laboratory-Quality Accuracy On-Line
„ Co-designed with GretagMacbeth
„ Multiple indices
„ Leading edge technology

High Performance Design

„ Compact, plug-in modules
„ Integral processing power
„ Patented, sealed optics
„ Dynamic AutoFocus*
„ Smart diagnostics
3BUS 004 729 R0101 -85

Proven result: Fast, accurate measurement and control

* Patented
 Measures Multiple Appearance Indices
„ Color coordinate „ Brightness
„ XYZ „ TAPPI
„ Hunter Lab „ ISO
L * a * b * Color Space
„ L*a*b (CIE Lab) L*
„ CIE LCH Lightness „ CIE Whiteness
white
„ Y, dominant
wavelength, b* „ Fluorescence
excitation purity yellow „ Delta UV
brightness
„ Color difference „ Opacity
-a* a*
„ Delta E green red „ TAPPI
„ CMC (1:1 or 2:1) „ Printers
„ FMC-2 -b*
blue „ Metamerism index
„ Reflectance (%)
black
3BUS 004 729 R0101 -86
 Full Spectral Color Calculation
% Reflection Standard
of Sample
* Observer
* Illuminant

%R Sen. Energy

Z Y X

360 nm 750 nm 360 nm 750 nm 360 nm 750 nm

„ User-selectable illuminants
„ A, C, D65, CWF, DLF
„ 2° or 10° observer
„ Primary and secondary illuminants
„ Excessive metamerism alarming
3BUS 004 729 R0101 -87

„ Inter-instrument agreement allows enterprise standards

 Industry's Highest Spectral Resolution
Improves Color Measurement Accuracy

Green Sample
%R

35

30

25

20

15

10

360 750

L * a* b*
3BUS 004 729 R0101 -88

5 nm: 51.12 -34.45 18.45

20 nm: 51.06 -33.52 17.91
Delta E = 1.08
 Single, High Intensity Xenon Source
Spectral Power, „ Superior signal-to-noise ratio
Watts/10 nm
„ 14 kilowatt flash
„ Absolute, no averaging or optical
100 filtering
ABB Xenon Source „ Accurate even on dark shades
10 „ Ambient light insensitive
„ Dual Beam Geometry
1
„ Ratios out lamp variations
„ Real-time
0.1
„ Ultraviolet rich
Tungsten Source
Daylight Filtered „ Includes fluorescent sample
0.01
„ UV normalization
„ Long, useful lamp life
3BUS 004 729 R0101 -89

300 400 500 600 700 800

Wavelength - NM „ > 2 million flashes
„ No calibration shift
 On-Line CIE Whiteness --
New ISO Standard for White Papers

„ Single index corresponds to visual

assessment
„ Based on color coordinates
„ Covers entire visible spectrum
„ Only xenon with normalized UV
qualifies
„ Requires D65 source balanced
down to 300 nm

“It is not hard for you to define a common set of product

benefits: runnability and printability. Add whiteness to
the demands from the art directors of publishers and
advertising agencies, and you have the major properties
asked for in a printing
paper.”
Hans Hildorsson, IKEA PPI Magazine, Viewpoint
3BUS 004 729 R0101 -90
 High Performance Backing Module
„ Black and white backing for
"infinite" thickness measurement
Black Standardize
Cavity „ Shade dependent
„ Per wavelength correction
„ Black and white standardization
Black AutoFocus
Backing „ Ensure long term accuracy
Tile
Tile
„ Up to 2 hour intervals
White „ In the measurement plane
Backing White
Tile Standardize „ Blue check sample certifies
Tile
measurement performance
„ AutoFocus tile verifies on-line
focal plane measurement
Check Sample Tile
3BUS 004 729 R0101 -91
 “Infinite” Thickness* Measurement Results

White Newsprint „ Tightens dynamic correlation

74% Opacity
%R with the laboratory
90 Conventional
„ Simulates lab measurements
Target
80

70
Color
CL4250
„ Strengthens operators
60
confidence in on-line
50
standards
40 „ Vehicle for faster start-ups
30
and shade Changes
„ Similar standards across
360 750 basis weight range
Conventional ABB
Target (White-Backed) Color „ Improves control performance
L* 82.43 86.10 81.94
a* -0.11 -0.70 -0.22
b* 6.61 7.99 6.37 „ Simulates dye sample
3BUS 004 729 R0101 -92

∆E 3.97 0.55
calibration method
* Patented
 Performs Day After Day in Harsh Environments
„ Sealed optics keeps dust out
„ Proven controlled air plenum (CAP)
„ Controls sensor temperature
„ Keeps window and tiles clean
„ Bernoulli hold down
„ Controls passline without contact
„ Eliminates flutter/edge curl
influences
„ AutoFocus Module* continually
accounts for focal plane variations
„ Compact, plug-in modules ease
maintenance
„ Quick-connect utilities
3BUS 004 729 R0101 -93

„ Automatic tile cleaning routine

• Patented
 Color Control Overview
3BUS 004 729 R0101 -94
 Challenges of Coloring Process
Very long delay and slow wet-end (circulation) dynamics
Large color variations from furnish and colored broke
Color uncertainty of base-loading dye addition
Complex dye characteristics
Interacts with grade change weight and moisture variations
Red Blue Yellow OBA/FWA

Target
Base load dyes L Automatic
Broke Mixing a Color
Furnish
Tank b Control
Wet-End Colorant ∆uv System
Blend Mach. Addition OBA/FWA
Chest Chest
Fan
Pump Weight/Moisture
3BUS 004 729 R0101 -95

Headbox

Refiners On-line
Color
Wet-end dynamics Measurement
Transport delay
3BUS 004 729 R0101 -96

Hardware
 Hardware Overview
„ SCMM Hardware
„ Optics subassembly , contains
spectrophotometer
„ Color Power Board
„ PTC Heater module
„ CAP
„ SBTM Major components
„ TSC Board
„ SMI daughter board
„ Stepper motor
„ Carousel assembly.
„ Auto Focus sensing coil
3BUS 004 729 R0101 -97

„ PTC heater module.

3BUS 004 729 R0101 -98

Carousel and Tiles

 Smart Color Electrical overview
3BUS 004 729 R0101 -99
 Configuration Parameters
3BUS 004 729 R0101 -100
 Diagnostic Command & Color measurement Data
3BUS 004 729 R0101 -101
 Calibration

„ Primary Calibration, calibrates the instrument against

the Primary standard. This procedure should not be
necessary during normal startup as the sensor is
calibrated before shipment. This requires
„ White calibration
„ Black Calibration
„ UV Calibrate procedure
„ This can be used to make the on-line color & UV brightness
agree with lab instruments. This procedure determines the “UV
scale” necessary for UCC & UV operation.
3BUS 004 729 R0101 -102
 Troubleshooting

„ SCMM should flash 7 times during normal standardize sequence.

„ White stdz tile UV included (filter out)
„ White stdz tile UV excluded (filter in)
„ Hole UV included
„ Hole UV excluded
„ AutoFocus tile UV included
„ White backing tile UV included
„ Check sample tile UV included
„ To reset ECC board,
$$uc_reset 0x27 {ENTER}
„ To Display SCMM Status array
I>:long
3BUS 004 729 R0101 -103

I>ucColor01->cmmStatusArray {ENTER}
„ Tiles cleaning & lamp check.
3BUS 004 729 R0101 -104

SCMM status array

 MeasureIT Optical Properties
Measurement
OP4255
3BUS 004 729 R0101 -105
 Optical Properties Measurement OP4255

3 Measurements in a Single Sensor Module

„ Formation

„ Opacity

„ Brightness
3BUS 004 729 R0101 -106
 Upper Module

To Frame Sense
Terminals

Power

Source
Brightness
Signal

Measurement
Processor
PCB Light
Collimator

Brightness
Photo Detector Brightness
Blue Filter
3BUS 004 729 R0101 -107

Brightness
Optics
 Upper Head Assembly, Brightness Measurement
3BUS 004 729 R0101 -108
 Lower Module
Opal Glass Window Contacting
Wear Plate
Formation Fiber
Optics Line

Air Supply
Regulator
Frame -
Air Line Filter
Opacity & Formation
To Frame Measurement
Terminals Electronics

Light
Collector

Green Customer
Filter Air

Opacity
Photo Detector
3BUS 004 729 R0101 -109
 Lower Head Assembly, Formation & Opacity
3BUS 004 729 R0101 -110
 Formation

„ Simultaneously measures optical transmission of

concentric 1mm and 30mm diameter regions of the
sheet
„ Electronic filtering removes unwanted (slow) influences
below 10HZ (dirt, frame vibration, electronic drift)
„ RMS — DC converter averages 50 msec of relative
optical density inputs to provide statistically significant
formation voltage
„ Single, universal head constant converts DC voltage to
formation index (RODS)
3BUS 004 729 R0101 -111
 Formation Measurement Features

„ High Speed
„ Simulates “look through” test
„ Machine & process analysis tool
„ Single number for operator display and control
„ Unaffected by dirt
„ Machine speed independent
„ Statistically significant sample per measurement cycle
3BUS 004 729 R0101 -112
 Opacity Measurement

„ TAPPI Standard (T425 om-91) response

„ Human eye spectral sensitivity
„ TAPPI defined source (color temp 2854° ±200°K)
„ High sensitivity in 75-98 point range
„ Calibration independent of grade-dependent R
(reflectivity)
3BUS 004 729 R0101 -113
 Brightness Measurement

„ TAPPI Standard (T425 om-91) response

„ Opacity compensated for true infinite stack reflectance
„ 3000°K color temperature light source
„ Calibration standards link traceability to laboratory
„ Air purge design for dusty environments
3BUS 004 729 R0101 -114
 MeasureIT X-ray Ash
Measurement
3BUS 004 729 R0101 -115
 Ash Measurement Without Compromise
„ ABB offers the only sensor
that measures as many as 3
components of ash from a
Detector
single sensor – you don’t have
High-Speed Detector
to choose between buying
2 x-ray sensors or measuring
only 2 components Diagnostic
Port
Dynamic Air Mass Control
„ Fast & confident accuracy –
1,000 measurements per
second for optimum filler Small
formulations Aerodynamic
Gap Diagnostic
Port

„ X-ray tube source – high X-ray Source

signal-to-noise ratios
3BUS 004 729 R0101 -116

„ Reliability through easy Source

installation & maintenance
 X-ray Ash Measurement Family

ABB offers a family of Application-Optimized

Measurements to meet your particular needs
Measurement Range
Measurement Application Ash Basis Wt. (g/m2)

3-Component Newsprint, 0-35%

(Clay/CaCO3 /TiO2) Fine Writing, Coated 0-75 GSM 20-250

2-Component Fine Writing, 0-35%

(Clay/CaCO3) Coated, Board 0-80 GSM 20-500

2-Component Fine Writing, 0-35%

(Clay/TiO2) Coated, Board 0-105 GSM 20-550

2-Component Fine Writing, 0-35%

3BUS 004 729 R0101 -117

(CaCO3 /TiO2) Coated, Board 0-90 GSM 20-500

 Principle of Measurement

Ionization Chamber
& Electrometer (I)

Process X-ray Beam

Filter (I0)

Filament Leads

Cathode
Target
Anode Electron Beam
HV Cable
3BUS 004 729 R0101 -118

„ Process absorbs part of incident radiation (IO)

„ Ash weight is derived from the transmitted radiation (I)
„ I = IOe-µρt = IOe-µ(Ash)
 „ X-ray energy is
created when by
impacting
monoenergetic
electrons on a high
atomic number target (
tungsten).
„ T = I/Io.,
PPT=T*1000

A=mass of Ash
3BUS 004 729 R0101 -119

F=mass of Fiber
W=mass of Water
Ua,uf,uw=attenuation
 Smart Processing Center
3BUS 004 729 R0101 -120
 Theory of X-ray Ash Measurement

„ Photo-electric absorption: an individual X-ray at a

known energy is absorbed by giving all its energy to
an electron. The X-ray then ceases to exist.
„ As the atomic number 'Z' of an element increases, the
number of electrons orbiting the nucleus increases
and the probability of an X-ray being absorbed
increases by Z4!
„ This sensitivity to heavier elements is the physical
principle used to measure minerals in paper.
„ Minerals have higher average Z compared to paper
3BUS 004 729 R0101 -121

and water!
3BUS 004 729 R0101 -122

Sensor Types
 X-ray Cross Sections and Source Spectrum

530
X-ray Tube Spectrum
480
430

380

330 TiO2
280

230

180

130
80 CLAY
30
3BUS 004 729 R0101 -123

0
3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8
 2 Component Measurement Principles
...So that the spectrum contains
equal area underneath each
Move the spectrum...
component’s curve
Stopping 570
Stopping 570
Power
(Attenuation Power
510
Coefficient) (Attenuation 510
450
Coefficient)
450
390
390
330
330
270 270
210 Chalk 210 Chalk
150
150
90
Clay 90 Clay
30 30

0 0
3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8
Photon Evergy ( KeV) Photon Evergy ( KeV)
3BUS 004 729 R0101 -124

Before After
 3 Component Measurement Challenge

No matter where you move the ...It is impossible to get equal

spectrum... areas
within the spectrum
Stopping 570 Stopping 570
Power Power
(Attenuation 510 (Attenuation 510
Coefficient)
Coefficient)
450 450

390 390

330 330
Titanium Titanium
270 270

210 Chalk 210 Chalk

150 150

90 90 Clay
Clay
30 30

0 0
3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8

Photon Evergy ( KeV) Photon Evergy ( KeV)

3BUS 004 729 R0101 -125

Attempt #1 Attempt #2
 Solution: Change the Shape of the Spectrum!

Now you can move the spectrum... ...In a way to get equal areas
within the spectrum!
Stopping 570 Stopping 570
Power
Power
(Attenuation 510
Coefficient) (Attenuation 510
Coefficient)
450 450
390 390
330 330
Titanium Titanium
270 270

210 Chalk 210 Chalk

150 150

90 90 Clay
Clay
30 30

0 0
3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8

Photon Evergy ( KeV) Photon Evergy ( KeV)

3BUS 004 729 R0101 -126

Attempt #1 Attempt #2
 One Sensor Measures All 3 Components
„ ABB is the only company that can
measure all Titanium Dioxide, Calcium
Shaped X-ray Source Carbonate and Clay with a single
Spectrum sensor.
Stopping
Power
570
„ 3 component capability through
(Attenuation 510
Coefficient)
450
proprietary X-ray shaping
390 „ Provides composition insensitivity
330
Titanium
270 „ Unaffected by broke and recycled
210 Chalk variability
150

90 Clay „ Total ash measurement

30
„ No “assumed” ash ratios or product code
0 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8
kitchen factor inputs.
Photon Evergy ( KeV)

„ Dynamic basis weight, air mass and

moisture inputs.
3BUS 004 729 R0101 -127

„ Even responds to changing product

mixtures.
 Fast and Confident Accuracy

„ ABB offers you the most confidence in x-ray ash

measurement which results in a better return
„ 1,000 measurements per second
„ Dedicated 32-bit processor
„ Millisecond response time
„ Accuracy of ±0.2 g/m2 ash or 0.25% ash.
„ 2 hour intervals between standardization
3BUS 004 729 R0101 -128
 Easy Installation and Maintenance

„ Vertical, plug-in module

„ Robust, reliable
components
„ Low parts count
„ Self-calibrating and testing
electronics
„ Advanced diagnostics port
„ Most advanced PC-based
troubleshooting tools
3BUS 004 729 R0101 -129
 Service Workstation X-ray Ash Health Page
3BUS 004 729 R0101 -130
 Source Module description
3BUS 004 729 R0101 -131
 Detector Module Overview
3BUS 004 729 R0101 -132
 Source & Detector module SEI Diagnostic Ovw
3BUS 004 729 R0101 -133
3BUS 004 729 R0101 -134

Check Sample
 Ash Sensor Standardization Limits
3BUS 004 729 R0101 -135
3BUS 004 729 R0101 -136