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Table of Contents
10 System configuration 10 – 1
10.1 System configuration menu .......................................................................... 10 – 2
10.2 TCE Installation and Configuration .............................................................. 10 – 3
10 – 3
Imprint
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zations.
The issue date (month/year) can be found in the footer. Issue date
Postal address:
Brückner Maschinenbau GmbH
Postfach 11 61
83309 SIEGSDORF
GERMANY
Internet:
http://www.brueckner.com
Service:
Tel: +49 8662 63-379
Fax: +49 8662 63-370
E-mail: servtec@brueckner.com
Sales:
Tel: +49 8662 63-510
Fax: +49 8662 63-101
E-mail: sales@brueckner.com
Documentation:
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Fax: +49 8662 4965-402
E-mail: doku@brueckner.com
1 TCE overview
1.1 Introduction
There are two different locations where thickness measurement may take Thickness
place: measurement
variants
• End film thickness measurement
The thickness gauge is integrated in the line's pull-roll module. Film
thickness is controlled via measurements made just before the winder
on the stretched material
Lines either use end film thickness measurement, cast film thickness
measurement or a combination of both.
See the illustration on the next page.
The subject of this manual is end film thickness measurement with the
additional option of cast film thickness measurement.
Lines that are only equipped with cast film thickness measurement are
not treated in this manual.
1 2
The following conventions are used in this manual to describe the control Conventions
software user interface:
Symbol Graphic symbol for the particu- Click on the <Print> sym-
lar function; click with the left bol
mouse key
Button Clicking the button with the left Click on the <Display>
mouse key activates the func- button
tion
Menu item Selecting the menu item with Select the <Clear Actual
the left mouse key activates Roll> menu item
the function
Radio button Selection and activation of one Enable the "Auto“ radio
function button
Menu name Names of user interface win- Open the "Average Con-
dows trol Parameters“ menu
by …
Status and alarm Texts issued by the control The message "In off-
messages software that appear on the sheet position“ appears
user interface in the status display.
The user interface of the TCE control software for the thickness gauge is
called up from the PVSS visualization software.
1 2
3 4
5 6
7 8
9 Function bar
• Pane (4):
“Production rates“ on page 5–1
• Pane (9):
Further information on the function bar is provided below
The following standard buttons are provided in a function bar at the bot- Function bar
tom of the screen:
1 2 3 4 5 6 7 8 9
9 <Sys.Config.>
• <Castfilm> (4)
Optional second thickness measurement on cast film. For additional
information, see “Cast film (option)“ on page 3–13
• <MD-Trend> (5)
Recording of a fixed position trend (thickness profile in machine direc-
tion) in the event of film quality problems. For additional information,
see “Fixed position scan“ on page 8–1
• <Sys.Config.> (9)
Calls up the "System Configuration“ menu for installing and configur-
ing the thickness gauge system. See also “System configuration“ on
page 10–1
The TCE control software for the thickness gauge system is installed
and configured by Brückner Service when the system is first put into
operation. Some settings may be changed only under special circum-
stances and by authorized and trained personnel.
Depending on the line configuration, additional buttons may be available Optional buttons
for certain options, e. g.:
• <Roll Conformity>
Display of the "Roll Conformity“ option for monitoring and correcting
the overall roll profile on the winder. For additional information, see
“Roll conformity (option)“ on page 8–15
• <Edgetrim>
Display of roll data in the roll edge area when the thickness gauge sys-
tem is positioned in front of the edge trim. For additional information,
see “Edge trim (option)“ on page 7–9
Operation of the TCE control software is intuitive and simple. All buttons
are activated by simply “clicking“ with the left mouse key.
For this reason, step-by-step operating instructions are generally not
used in this manual.
Various buttons are used to control the standard functions. These are Standard buttons
briefly explained in the following table.
Button Significance
Button Significance
Certain functions such as carrying out a reset or deleting data are only
possible after the respective query in answered with <Yes> in a confirma-
tion window.
왘 Click on <Yes> to carry out the desired action (e. g. delete data, save
changes, etc.)
왘 Click on <No> if you do not want to carry out the actions or save the
changes
왘 Click on the button with the two arrows next to the data input field
The numerical input window opens
The windows are preset for each individual parameter. For example,
parameters that must be entered to two decimal places (2) appear with
the decimal point in the appropriate position. As well, the maximum
parameter size is limited by the preset number of places (e. g. 2-digit (1), or max.
5-digit (3).
1 2 3
왘 Click on the button with the check mark to transfer the values to the
data field of the screen mask
왘 Click on the <Exit> button to close the numerical input window and
save the entered parameters
왘 Click on this button to transfer the values to the data field in the screen
mask, close the numerical input window and save the entered param-
eter
The Y-scales of the various displays (roll profiles, trend displays) can be Three methods
adjusted by three different methods:
• Central settings in the "Product Data“ menu
• Presetting of the scale ranges
• Individual scale settings
The Y-scale and fixed tolerance ranges appear in the respective displays Display
as follows if the checkboxes are enabled:
If the scaling of the Y-scale is not set using the tolerance settings in the
"Product Data“ menu, i.e. if the checkboxes in the <Thickness+Toler-
ance> tab are disabled, the settings can be made individually in every
profile and trend display:
<Scale> button
The Y-scale can be adjusted for each display in predefined steps by click-
ing on the buttons with the up and down arrows:
There are six predefined steps of ±4%, ±6,5%, ±10%, ±15%, ±25% and
±50%.
The button with the down arrow reduces the graphic size, i.e. the scale
range is increased by a maximum of ± 50% of the average value.
The button with the up arrow enlarges the graphic in a vertical direction,
i.e. the scale range is decreased by a maximum of ± 4% of the average
value.
Clicking on the <Scale> button opens the menu for setting individual Individual scale
scale parameters. See the next section“Individual scale settings“ on page settings
1–15.
Manual changes to the scale can only be made by users with the
appropriate access rights.
• Auto-scale Parameter
If the "Auto-Scale“ checkbox is enabled, the graphic is automatically description
scaled so it is centered in the display and scaled to the display size.
The default setting is "enabled“.
• Scale Range
Scale range in percent of average value. 10% signifies +5% and -5%.
Only appears if the "Auto-Scale“ checkbox is disabled.
• Scale Center
Thickness value at the center of the scale. This field does not appear if
the rated thickness is used as the average value in the "Product Data“
menu.
• Auto-Label
If the "Auto-Label“ button is enabled, the system calculates the correct
spacing between the scale marks.
The default setting is "enabled“.
The PVSS/TCE visualization software lets you view the history of individ-
ual parameters over time in a trend diagram. This section describes how
trend histories are structured and how to operate them.
The menu displays the trend history of a specific parameter over time.
These trend history data can be viewed, printed and saved.
11
10
2
9
2
8
7
3
6
Button Significance
Button Significance
왘 Click on the <Diskette>symbol to save the trend history data of the Saving data
selected time period in a separate file
A window appears in which the file name can be entered:
• Archive
Display of archive into which the trend history data are saved.
The parameters are subdivided into five archive classes. The data
point displayed in the example has been assigned to archive class 5.
• Trigger
Smoothing factor for writing the parameter data. The parameter is only
recorded if the change in the value is larger than the trigger factor
entered here.
Example: Trigger factor "0.2“ means that values will only be written to
the trend history if the actual value changes by more than "0.2“.
The trigger factor is preset to a default setting. In certain cases it may
be useful to observe a certain parameter with a small trigger factor. In
this case it is possible to add the selected trend to the configurable
trend ("add to the configurable trend“). In this way, a maximum of 10
configurable trends can be added to a selection list and can then be
displayed in the PVSS/TCE visualization software with a separate trig-
ger factor. See section“Configurable trends selection list“ on page 1–
24.
왘 Click on one of the two rows for date/time (dark blue fields) Setting the start and
A window with the input options opens: end time
왘 Enter the desired date and time for the start of the trend history
왘 Enter the desired trend history duration
왘 Click on the <Add to configurable trend> button to add this trend to the Adding a trend to
selection list and change its trigger factor the list
The button changes to the <Remove from configurable trend> function
and the "Trigger“ field turns dark blue
왘 Click on the dark blue "Trigger“ field with the left mouse key Changing the trigger
The numerical input window opens factor
왘 Click on the <Remove from configurable trend> button to remove this Removing a trend
trend from the "Configurable Trends" selection list from the list
The "Configurable Trends" selection list can be called up using the follow- Calling up the
ing button in the menu bar of the PVSS visualization software. selection list
The user interface of the TCE control software is closed when you
change to the PVSS main menu (line overview).
2 Thickness measurement
Located at the top of the TCE main menu are the unfiltered raw data of a
scan as received from the connected thickness gauge and the status of
the thickness gauge used for end film thickness measurement. From here
you can access special thickness gauge functions and parameter set-
tings.
The selection of parameters depends on the thickness gauge type and
manufacturer.
The thickness measurement panel contains the following displays and Displays and control
functions: elements
1 2 3 2 4 5 6
10 9 9 8 7
2.2.1 Displays
The <Display> button opens a menu that contains details on the profile Calling up detailed
data received and in which the Y-scale can be set manually. information
왘 Click on the <Display> button
The menu containing the detailed information is opened
The basic configuration of the thickness gauge system is displayed in the Details on
two fields at the top: measurement
system
• The left field indicates whether the scan is an "Endfilm“ or "Castfilm“
thickness measurement
• The right field identifies the thickness sensor used to generate the
data, "Sensor 1“ in this example
The <Details> tab displays detailed information on the thickness meas- Additional data
urement:
The data fields in the <Details> tab provide the following information:
• Time of Scan
Time at which the scan started
• Scan Counter
Number of profiles received since the thickness gauge driver program
was started
• Left Edge
Left edge of film
• Right Edge
Right edge of film
• Scan Width
Scanned film width
• Scan Speed
The speed at which the film is scanned Since the scan quality gener-
ally depends on the scan speed, this value is stored together with the
profile data
• Scan Mode
Some thickness gauges offer a number of different scan modes such
as changing the speed during a scan or scanning in one direction only.
If the thickness gauge supports several modes, the mode currently
active is indicated here
• Maximum/Average/Minimum
Indicates the maximum, average and minimum film thickness during a
scan
• "Auto-Scale" checkbox
By default, this checkbox is always checked.
The received thickness profile is scaled automatically. This means that
the profile is always visible in the center of the display and the Y-scale
is set accordingly. This has the advantage that the actual thickness is
always visible, regardless of the target thickness settings and scale
settings for the product currently being produced
Manual changes to the scaling can only be made by users with the
appropriate access rights.
The panel at the top right of the TCE main menu contains buttons for Thickness
operating end film thickness measurement and the status displays. measurement
operation and status
2 3
A blue "P“ symbol indicates that the scan head is located in the offsheet Thickness gauge in
position beyond the film. Also, the status line displays the message "In offsheet position
offsheet position“:
The shutter is the opening of the scan head through which radiological Shutter open
source passes.
The green square with a yellow circle signifies "Shutter open", indicating
that the thickness gauge is in the process of scanning. Also, the status
line displays the message "Scanning“:
A red alarm symbol appears if there is an alarm, a warning or a fault in Alarm status
the thickness gauge. Also, an alarm message is displayed in the status
line, e. g. "No connection to gauge“.
The red alarm symbol can be clicked to call up details on the alarm and
the current status of the thickness gauge.
Clicking on the alarm symbol opens the "Thickness gauge status“ menu. Details on alarm and
This menu displays general information that applies to any type of thick- status displays
ness gauge:
For detailed information on the alarm conditions, see section “Status dis-
plays“ on page 9–12 and the manuals supplied by the thickness gauge
supplier.
2.3 Configuration
The TCE control software supports various types of thickness gauge sys-
tems that provide a communications connection on the basis of Ethernet
TCP/IP.
The following thickness gauge systems are supported at this time:
• Radiometric thickness gauges
Radiometrie M190 (Thermo Radiometrie)
Betacontrol
After the <Gauge Setup> button is clicked, the configuration menu opens.
It differs for each type of thickness gauge.
There are thickness gauge systems for which the TCE control software
does not provide a thickness gauge configuration. These thickness
gauge systems are equipped with their own monitor and configuration
and maintenance displays.
As an example, the following screen shows the configuration menu for Example of
radiometric thickness gauge systems:" radiometric
thickness
measurement
3 Profile control
The profile control ensures that the film profile is smooth across the entire
film width with as few so-called "thick" and "thin" areas as possible.
The film profile is adjusted by controlling the die bolt temperatures. The
die bolts are physically connected to die lips and are individually heated
to the configured set temperatures. The heat expansion of each individ-
ual die bolt causes the die lips to change position, thus ensuring that the
film thickness across the entire film width (profile in scanning direction) is
within the specified tolerance. The primary task of the profile control is to
control the die bolts on the die so that they are mapped on precisely the
right location of the film in the thickness gauge. This assignment scheme
is referred to as a "bolt map“.
The actual film thickness is controlled by the average control. See chap-
ter “Average control“ on page 4–1
The TCE main menu panels shown below are involved in profile control:
The profile control is operated in the "Profile Control“ (2) menu in the third
panel from the top of the TCE main menu:
왘 Enter the profile control parameters. To set the parameters, see sec-
tion “Profile control parameters“ on page 3–4
왘 Click on the <Start/Stop> button
The <Start/Stop> button appears in green while the profile control is
active. The progress of the control procedure is displayed in the status
display below the button (3 phases)
A control step is subdivided into three phases: "Set“ –> "Transport“ –> Status display
"Measure“. The horizontal status bar indicates the progress in each
phase:
• Set
After the output of new diebolt temperature setpoints the controller
waits a minimum period of time for the diebolts to settle down (see
"Measure“). Then all diebolts are monitored for the actual temperature
to reach the new setpoint (see section “Die bolts“ on page 3–11). After
a limited period of time all diebolt temperatures have to be within the
tolerance band (see "Measure“)
• Transport
After the previous "Set" phase is completed, the control waits until the
film is transported from the die to the thickness gauge. This delay
period is calculated from the length of the production line (defined dur-
ing installation) and the line speed.
• Measure
After the previous "Transport“ phase has completed, the control waits
for the next scan from the thickness gauge. The first received scan will
not be used because it was started during the "Transport“ phase. The
next scans are averaged to calculate the actual profile deviation. The
number of scans averaged depends on the actual 2-sigma value (see
section “System parameters“ on page 3–9).
The <Castfilm>, < AutoBoltmap> and <Roll Conformity> tabs are only
visible if the system is equipped with the corresponding options.
The parameters for aligning the die bolts are entered in the <Alignment>
menu:
These four parameters define the bolt map. The first two are defined by
the stretching process. Normally, the only parameter that needs to be
adjusted if the TD stretch ratio is changed (TD = transverse direction) is
the total film width.
The total width of the "left“ and "right“ die bolts are two parameters that
are influenced not only by the process but by many other factors as well,
including neck in, air knife setting, stretching temperature, etc.
After changes are made to the production process, the correct value for Checking the total
the total width of the "left“ and "right“ edge bolts must be checked using width of the edge
the following procedure: bolts
왘 Measure the width of the cast film beyond the chill roll and enter the
value in the "Castfilm Width“ input field
The system calculates the edge trim position on the cast film. This is
the position on the cast film where the last lateral die bolt ends and the
first fully stretched die bolt on the cast film begins
왘 Mark this position on the film with a felt-tip pen and measure the dis-
tance between the marking and the untrimmed edge of the film
beyond the heater
왘 Repeat this procedure for the other side and enter the results in the
left“ and "right“ input fields of the Total Width of Edge Bolts
The "Thermal Shrink Factor“ parameter is a value based on experience. It Thermal shrink
compensates for the heat shrinkage of the cast film before and after the factor
chill roll. It should only be changed if the procedure described above reg-
ularly leads in alignment errors. The expansion brought about by the ther-
mal shrink factor shifts the marking between the side die bolts and
stretched die bolts toward the film edge, i. e. the bolt map is stretched.
In the <System> tab, parameters for several functions can be defined that
extend beyond the scope of normal operation:
• Limits for Calculating Statistics from Profile Data, "Left" and "Right“
All calculated and displayed average, minimum, maximum and 2-
sigma values are calculated from the profile data between these posi-
tions. These two parameters are used to "cut off" high or unstable
edges. The calculation limits are indicated in the profile displays by
two vertical gray lines. See section “Display of averaged profile data“
on page 3–17
• Quick-Start
This option affects the first control step. If this box is checked, the con-
trol will immediately calculate and output the new die bolt setpoints
after the <Start/Stop> button is clicked, provided the thickness gauge
was previously in operation.
If this box is not checked (default setting), the first control step starts
with the die bolt setting, transport delay, measurement (3 phases), and
then calculates the first new setpoints. Enabling this option is disad-
vantageous if manual changes were made for the die, die bolts and
extrusion output, and the delay and equilibration time have not yet
elapsed. On the other hand, if it is clear that the process has been run-
ning stably, the first control step is performed much more quickly if this
option is enabled
The parameters for the die bolt limits are entered in the <Die bolts> tab:
• Minimum Permissible
The smallest setpoint temperature transmitted to the die bolt control temperature range
system. This condition is displayed as a warning in the die bolt temper-
ature display
• Average
Whether or not profile control is active, the TCE control software will
always maintain this average temperature for all controlled die bolts.
Also, manual changes to individual die bolts will bring about tempera-
ture changes in the remaining die bolts to keep the average tempera-
ture constant. This means that the aperture of the mechanically
adjusted slit of the die lip gap will not change on average, as deter-
mined by temperature settings
• Maximum
The highest temperature setpoint that can be transmitted to the die
bolt control system. The high temperature alarm in the die bolt control
system, which is able to shut down the entire die bolt heating system,
should be set to a higher value by approx. 5% to allow for a little over-
shoot when this maximum temperature is output. This condition is dis-
played as a warning in the die bolt temperature display
• Bending
"Bending“ is another limiting factor that can be used to protect the die
lip from excessive mechanical strain. It operates much like the Differ-
ence parameter described above, except that it limits the difference
between two adjacent differences:
2 +20 °C
1 3 –20 °C
• Maximum
Time after which all die bolts must be within the temperature tolerance
band. If one or more die bolt temperatures are outside of tolerance, a
warning is displayed but profile control continues running
If the line is equipped with the "Cast film“ option, the function bar of the Cast film thickness
TCE main menu contains an additional button called <Castfilm> that calls measurement
up the cast film thickness measurement. display
왘 Click on the <Castfilm> button on the function bar of the TCE main
menu.
The view of the cast film profile data shown below is displayed on the
screen. The display arrangement is fixed. It is only possible to adjust
the scaling of the displays.
• The upper pane of the display shows the thickness profile of the cast
film
This area also contains buttons for operating and configuring the cast
film thickness gauge. These buttons have the same purpose as those
in the TCE main menu for end film thickness measurement.
See also section“Thickness measurement display panel“ on page 2–1
• The center pane shows the profile of the cast film averaged over two
scans
• The bottom pane shows the trend history of the cast film thickness
profile (averaged profile (2 scans)) against time
Two additional optional tabs may appear in the "Profile Control Parame-
ters“ menu depending on the line configuration:
• AutoBoltmap
This option is described in chapter “Special functions“ in section “Auto-
BoltMap alignment (option)“ on page 8–8
• Roll Conformity
This option is described in chapter “Special functions“ in section “Roll
conformity (option)“ on page 8–15
The second pane from the top of the TCE main menu shows the actual
averaged profile data. The TCE control software is configured by default
to display the 4-scan average profile in the TCE main menu.
The scaling of the profile display can be adjusted in the vertical direction Scaling the
(Y-scale) as required. See “Scaling profiles and trends“ on page 1–13. Y-axis
1 2 1 3 4
8 7 6 5
• 2-sigma (7)
2-sigma of the thickness deviation of the displayed profile between the
calculation limits. The absolute value is divided by the average thick-
ness and the result is displayed in percent
The third pane of the TCE main menu shows the actual settings of the die
bolt temperatures.
1 2 3
The TCE control software does not control the die bolt temperatures. It
calculates the setpoints of the die bolt temperature, which are then
transferred to the line control system.
Various PLC systems are used to control the die bolt temperature. As a Automatic die bolt
result, the window opened using the <Diebolts> button depends on the setting
particular installation. This button links to the die bolt system, which is
usually accessed by the PVSS visualization software of the machine (die/
die bolts). See also the PVSS operating manual.
The die bolt temperatures can also be set manually, regardless of Manual die bolt
whether or not the profile control system is currently running. However, it setting
is always beneficial for the profile control to be switched off before the die
bolt temperatures are changed.
The <Diebolts> button calls up the menu for setting/resetting the die bolt
temperatures.
왘 Use the up and down arrow buttons or enter the die bolt number on
the keyboard to select a specific die bolt
The selected die bolt is indicated by a vertical gray line in the tempera-
ture display. The temperature values for the setpoint (dark blue) and
the actual value (light blue) are displayed for the selected die bolt
All die bolt temperature setpoints can be reset at once to the average
temperature defined by the "Diebolt/Average" profile control parameter.
왘 Enable the checkbox of the group of die bolts to be reset:
Manual
Die bolts on each side of the film that are always located outside of the
profile control area
Uncontrolled
Number of die bolts at the edge between the manual die bolts and the
first controlled die bolt
Controlled
All controlled die bolts
• Setpoint
Set temperature value
• Actual
Actual temperature
• Deviation
Deviation of actual temperature from setpoint
If the green box to the left turns yellow, the actual temperature of the
die bolt did not reached the setpoint temperature within the time spec-
ified in the profile control parameter "Diebolt/Maximum Delay after
Temperature Change“. This is only a warning and the profile control
continues controlling this die bolt
• Minimum/Maximum/Difference/Bending
These values apply to the profile control parameters "Diebolt/Mini-
mum“, "Maximum“, "Difference“ and "Bending“. If one of the boxes to
the left turns red, this limit has been reached and the profile control will
freeze the temperature setpoint of this die bolt
• Position on Endfilm
Position of the selected die bolt on the finished film as per the bolt map
• Minimum Change
This is the minimum temperature change made by the profile control.
If the green box to the left turns yellow, the temperature calculated
after the last control step was smaller than this value and is therefore
ignored. This keeps the die bolt temperatures from gradually
approaching the limits in small steps. See the profile control parame-
ters Gain/Minimum Temperature Change. The profile control will still
continue controlling this die bolt
• Individual Gain-Factor
This is an individual gain factor for this particular die bolt. The profile
control system multiplies this factor by the profile control parameter
"Gain/Gain Controller“. The value of the "Actual“ individual gain factor
must lie between the "Minimum“ and "Maximum“ limits.
These three values are for future use. At present, the individual gain
factor is fixed at 1.0
Since the die bolt heaters are monitored and controlled by the line control
system, the corresponding image can be called up in the PVSS visualiza-
tion software from the TCE control software.
왘 Click on the <Heating> button in the "Diebolts“ panel of the TCE main
menu
The window that displays the die bolt heating in the PVSS visualiza-
tion software opens:
For a description of the displays and symbols in this window, see the
"PVSS Visualization Software“ operating manual.
1
2
If one of the warning bits that leads to "freezing“ of the corresponding die
bolt is set, the actual temperature display appears red instead of green.
If there are any die bolt warnings, they can be acknowledged here: Reset of warnings
4 Average control
The absolute film thickness is controlled by the average control using line
speed or extruder output. It is linked to the profile control system. This
means that the average control system can only be used in addition to
the profile control system. The reason for this is that changes in chill roll
speed are synchronized with the settings of the die bolt temperatures to
ensure that the two controllers to not impede each other.
The average control is displayed at the bottom of the TCE main menu.
1 2
The average control can only be switched on if the profile control is run-
ning. See section “Starting profile control and status displays“ on page
3–2.
The following parameters are displayed in the "Average Control“ menu: Description of
displays
• Actual Thickness
Display of the actual value of the profile thickness (average value)
• Target
Entry of the target value for the profile thickness average. The setpoint
can be changed by clicking on the arrow buttons next to the data field.
To enter numerical values, see “Entering numerical values“ on page
1–10
• Status display
Display of the average control status (e. g. "OFF“)
The mode that the average control is to run in is specified at the top of the Take-off control
menu: mode
• Extrusion in Independent Mode
The radio buttons let you specify if, in the independent mode, the film
thickness is to be controlled via the chill roll/line speed or the main
extruder output.
The control parameters are entered in the bottom section of the menu: Control parameters
• Controller Gain
The gain factor ranges from 0 to 1.0. If it is set to 1.0, for example, a
thickness deviation of 1 % will be countered by a change in line speed
or output of 1 %. Since the average control is designed for gradual
changes in the average roll profile thickness, a gain factor of 0.2 to 0.5
is recommended for the average control.
These buttons can be used to display the respective trend histories: Trend history
왘 Click on the <Trend history> symbol next to the enabled radio button
for the average control mode
The corresponding "Trend History" menu opens. The following screen
shows an example of a trend history:
For information on the trend history, see section “Displaying the trend his-
tory of individual parameters“ on page 1–17.
The bottom pane of the TCE main menu shows the averaged profile data
as a trend against time. The TCE control software is configured by default
to display the trend of the 4-scan average profile in the TCE main menu.
The scaling of the trend display can be adjusted in the vertical direction Scaling of the Y-axis
(Y-scale) as required. See section “Scaling profiles and trends“ on page
1–13.
1 2 1
6 5 4 3
Every newly calculated 4-scan average profile is added as an element to Description of trend
the right side of the display as follows: display
1 2
5 Production rates
The menu to the right of the roll profile panel in the second section of the "Thickness and Net
TCE main menu displays the current production rates: Output" menu
The function bar of the TCE main menu contains two buttons for display- Roll data
ing roll data during production.
1 2
The actual production rates are displayed in the "Thickness and Net Out- "Thickness and Net
put" menu: Output" menu
• Thickness
Average film thickness of the current single scan
• Film width
Cut width of roll
• Speed
Actual line speed
• Net output
Actual line output in kg/hour
A prerequisite for the profile control and average control is that the mes- Status display
sage "Good film on winder“ must always appear in the status display. If
this status message does not appear, profile control and average control
cannot run start.
Trend histories can be displayed for all parameters displayed in the Trend histories
"Thickness and Net Output" menu (except for the film width):
• <Thickness>
Clicking on the <Thickness> button opens a pull-down menu with
three thickness trends to choose from: <Average>, <2-Sigma, Total>
and <2-Sigma, Percent>
• <Speed>
• <Net output>
The corresponding trend histories can be called up using these buttons: Recording trend
history
왘 Click on the button of the desired parameter or select the desired
parameter from the pull-down menu under <Thickness>
The "Trend history“ menu of the selected parameter opens (example:
line speed):
For information on the trend history, see section “Displaying the trend his-
tory of individual parameters“ on page 1–17.
The TCE control software provides profile displays of two different rolls:
• the roll that is currently being wound
• the roll that was last produced
For the profiles of the current roll to be stored, the control unit must issue
the status "Good film on winder“. This status message appears in the
"Thickness and Net Output“ menu. This information is issued by the line
controller (winder) via a communication connection.
3 1 2
왘 Click on the <Roll Actual> button (1) in the function bar of the TCE
main menu to display the profile data of the roll currently being wound
왘 Click on the <Roll Last> button (2) in the function bar of the TCE main
menu to display the profile data of the roll last wound
왘 Click on the <Overview> button (3) in the function bar to return to the Returning to TCE
TCE main menu main menu
The following figure shows the profile data display for the current roll: Roll profile data,
current roll
6
5
The display of the roll profile data for the last roll is identical to that of the Roll profile data,
current roll, except that the <Protocol> (6) button and the protocol status last roll
display (5) do not exist.
The top pane of the roll profile display shows roll data stored in the data-
set for the particular roll.
General data are displayed in the left section of the roll data display: General data
• Product
The product name entered in the product data. If any type of product
data memory is installed, the product name can also be read from an
external variable
• Roll number
The roll number of the current roll is increased by "1" every time the
roll is changed. The current number can be overwritten directly in the
roll data display or in the product data
• Roll ID
An automatically generated sequence of digits
• Time started
Time of the first profile measured on the roll
• Last scan
Time of the last scan or of the roll change
• Scans
The number of scanned profiles on the roll
• Average
The average thickness of the displayed roll profile within the calcula-
tion limits
• Minimum
The minimum thickness of the displayed roll profile within the calcula-
tion limits
• Maximum
The maximum thickness of the displayed roll profile within the calcula-
tion limits
• 2-Sigma
2-sigma of the thickness variation within the calculation limits, dis-
played both as a percent of the average thickness and as an absolute
value
• Width
The width of the displayed roll profile. This value may deviate slightly
from the width received from the thickness gauge because it is
rounded to the next profile width slice
• Weight
The roll weight is calculated as the width * length * average thickness *
specific density. The value for the specific density is taken from the
product data
• Diameter
The roll diameter is received from the line control unit
• Density
The roll density is received from the line control unit
In the right section of the roll data display you can define up to 16 freely Sixteen freely
configurable data fields to display specific parameters (in this example: configurable data
film handling data and winder data). fields
These data are either received from the line control unit or they can be
entered manually in the product data.
The following figure shows an example of roll data that displays winder Example of data
data and roll handling (corona) data: fields
There are two methods of configuring the parameters, which may be up Parameter configu-
to 16 in number: ration
• <Config Protocol Data> menu item in the "Protocol" menu.
See section “Roll protocol“ on page 5–8
The roll protocol is either running or stopped, as indicated in the status Roll protocol
message "Good film on winder": running/stopped
Profiles are only added to the running roll if the roll protocol is active
("Running“).
The following roll protocol operating and configuration options are availa- Functions and
ble in the "Protocol“ selection menu: configuration
• Clear Actual Roll
• Finish Actual Roll
• Config. Protocol Data
• Config. Roll Profile Split
• Number Copies Printed
• Quit
The <Clear Actual Roll> menu item can be used to start a new roll proto- Starting a new roll
col even if the roll is not yet finished. This is useful if defective material
was produced for some time due to a malfunction or while setting up the
equipment.
After the <Clear Actual Roll> menu time is selected, a confirmation win-
dow appears:
The function is activated by confirming with <Yes>. The roll data stored in
the protocol up to this point are cleared.
The <Finish Actual Roll> menu item can be used to end a roll and its roll Ending the current
protocol. The roll data are transferred to the "Last Roll“ memory. roll
To confirm this function, the same confirmation window appears as in the
above menu item, <Clear Actual Roll>.
The following two sections describe how to configure the roll protocol and Configuring the roll
the roll split. See sections “Configuring the roll protocol“ on page 5–11 protocol and the roll
and “Configuring the roll split“ on page 5–13. split
The desired number of protocol printouts can be entered in the <Number Number of copies
Copies> menu item. The setting for the number of copies is saved.
The <Quit> menu item can be used to cancel editing of the protocol and Quit
close the "Protocol“ selection menu.
In the right section of the roll data display you can define up to 16 freely Sixteen freely
configurable data fields for roll data. configurable data
See also section “Roll data“ on page 5–6. fields
The following figure shows an example of roll data that displays winder Example of data
data and roll handling (corona) data: fields
The roll data are generally configured by Brückner Service when the
line is put into operation. If the operator would like to make changes
later on, this should only be done after first consulting with Brückner.
The configuration may only be changed by authorized and trained line operator
personnel. A certain authorization level is required to make changes.
Changes to the protocol data only take effect after the system is
restarted.
왘 Select the <Config. Protocol Data> menu item in the "Protocol“ selec- Calling up the
tion menu configuration menu
The menu for configuring the protocol data opens (in this example, the
data fields are already filled):
Enter the data in the 16 rows of the table as follows: Data entry
왘 In the left column, enter the name of the data point (variable name) to
be displayed. Data fields in the table that are filled are highlighted in
green
왘 In the second column, enter the data field label to appear on the
screen page
왘 In the third column, enter the format and unit of measure of the dis-
played data point
왘 Check the box in the corresponding row if you want the roll data value
to be refreshed continuously
The roll profile can be subdivided into several sections. These sections
are separated on the screen by vertical blue lines and are marked on the
printout. For each of these sections, the profile values of "Average“, "2-
Sigma (total/percent)“, "Minimum“, "Maximum“ and "Range (max-min)“
are calculated after a new measurement is taken for the current roll.
These values can be entered into the freely configurable roll data fields
(max. 16 data fields), since the standard profile and trend displays can
only display one value per measurement each.
See also section“Configuring the roll protocol“ on page 5–11.
The "Roll Split“ function is useful if the roll is to be split into sections later Application
on, such as to deliver sections of the roll to different customers. By split-
ting the roll data, each partial roll can be accompanied by its own specific
roll data (printouts, protocols).
To be able to configure these freely configurable roll data, you must know Variable names
the variable names of the data points. The following variables are for the
first (far left) roll section (…001):
Average TceRolSpl001.Avg
Minimum TceRolSpl001.Min
Maximum TceRolSpl001.Max
The variable names of the roll sections to the right are consecutively
numbered with three-digit numbers: …002…, …003…, etc.
The variables must be entered in the protocol data. See section“Configur-
ing the roll protocol“ on page 5–11.
왘 Select the <Config. Roll Profile Split> menu item in the "Protocol“ Calling up the
selection menu configuration menu
The menu for configuring the roll profile split opens:
9
10
1
9
2
8
3
7 4
6 5
7 <New> button – Set up new 8 Set point: Split point position (X-
split point scale)
This description has been arranged in the order in which the menu is best Description of
operated: displays and
functions
• <New> button (7)
Clicking on the <New> button creates a new split point. With the first
click, "1/2“ appears on the display (10). However, this does not yet rep-
resent a roll split since two split points are necessary to define the
outer edges of the band. Clicking the button again splits the roll (the
display indicates "1/3“ for two split rolls, for example). Every further
click adds another split point
In the roll profile display, the split points are indicated by vertical blue
lines (middle pane in the screen).
왘 Enter the desired parameters for the roll split as described above Configuring the roll
split
The roll profile is displayed in the middle pane of the roll profile data. The
roll profile is the average of all profiles measured during the production of
this one roll.
1 2 3 4 5 6 7 8
12 11 10 9
Each profile width slice is represented by a bar such as the following: Display
1 2
• 2-Sigma (2 ,3)
2-sigma of the thickness deviation of the displayed profile between the
calculation limits. The absolute value is divided by the average thick-
ness (see above) and the result is displayed in percent
The roll trend is displayed in the bottom pane of the roll profile data. The
roll trend is exactly the same as the profile trend already described, with
the exception that the roll trend is deleted every time the roll is changed.
For a description of the profile trend, see section “Trend displays“ on
page 4–6.
The trend of the produced roll contains precisely the number of profiles
that were measured during production of this roll.
A trend history can be displayed for the following parameters that appear
in the roll data display in the top pane:
• Average thickness
• 2-sigma, percent
• 2-sigma, total
• Roll length
• Roll weight
• Roll diameter
• Roll density
왘 Click on the desired data field with the left mouse key to open the Calling up the trend
"Trend History“ menu for this parameter history
The corresponding "Trend History" menu opens
The following figure shows an example of the trend history for the
average film thickness on the roll.
The function bar of the TCE main menu contains two buttons for calling
up special views of the roll data. There are two general types of views:
• Three views that are preconfigured in the TCE control software and
cannot be changed:
"Single Scans“
"Filtered Scans“
"Profiles+Diebolts“
These preconfigured views are briefly described in this section. How
to place buttons for these views in the function bar is described in sec-
tion “Assigning buttons“ on page 6–7
The following description assumes that the views have already been
assigned to the two buttons. The following figure shows an example of
the <Single Scan> (2) and <Profiles+Diebolts> (3) buttons.
1 2 3
왘 Click on the desired button in the function bar of the TCE main menu Calling up the views
to display the desired view
The view associated with the button is displayed on the screen
왘 Select the desired view from the top section (1) of the menu Selecting precon-
The selected view appears on the screen and replaces the button that figured views
previously appeared in this position. Views for which buttons already
appear in the function bar are grayed out in the pop-up menu.
For a description, see the following sections:
“Single scan“ on page 6–3, “Filtered scans“ on page 6–4 and “Profiles
and die bolts“ on page 6–6
왘 Select the desired view from the middle section (2) of the menu Selecting user-
The selected view appears on the screen. Views for which buttons defined views
already appear in the function bar are grayed out in the pop-up menu
The section between the two lines will be empty if user-defined views
have yet to be configured.
왘 Click on the <Overview> button (1) in the function bar to return to the Returning to TCE
TCE main menu main menu
The meaning of these displays is identical to that of the profile data dis-
plays for thickness measurement and the trend display in the TCE main
menu. See sections “Display of averaged profile data“ on page 3–17 and
“Trend displays“ on page 4–6.
The advantage of this view with its three displays compared to the TCE
main menu is the larger screen display, which is wider because there
are no menu and display panes on the right. This view also permits a
larger scale printout of the profiles.
왘 Click on the <Print> button (4) in the function bar to print out the "Sin- Printing the display
gle Scan" view
The meaning of these displays is identical to that of the profile data dis-
plays and the trend display in the TCE main menu. See sections “Display
of averaged profile data“ on page 3–17 and “Trend displays“ on page 4–6.
The middle display, "Filtered profile (factor 0.05)“ (2), represents a sum-
mation of the scans, where the newest (latest) scan is evaluated with a
factor 0.05 and scans that have already been summed are evaluated with
0.95. Thus, this display takes into account the entire roll history, unlike the
"Average Profile“ display, which only includes the last 4 scans.
The advantage of this view with its three displays compared to the TCE
main menu is the larger screen display, which is wider because there
are no menu and display panes on the right. This view also permits a
larger scale printout of the profiles.
왘 Click on the <Print> button (4) in the function bar to print out the "Fil- Printing the display
tered Scans" view
3
4
The meaning of the displays is identical to that of the profile data displays
for thickness measurement, the trend display and the die bolt tempera-
tures in the TCE main menu. See sections “Display of averaged profile
data“ on page 3–17, “Trend displays“ on page 4–6 and “Display pane“ on
page 3–19.
The advantage of this view with its three displays compared to the TCE
main menu is the larger screen display, which is wider because there
are no menu and display panes on the right. This view also permits a
larger scale printout of the profiles.
왘 Click on the <Print> button (4) in the function bar to print out the "Pro- Printing the display
files+Diebolts" view
The second and third buttons in the function bar of the TCE main menu
can be assigned and configured by the user.
2 3
왘 Click on the second or third button with the left mouse key User-defined
The roll data view associated with this button appears on the screen assignment of
buttons
왘 Click on the second or third button with the right mouse key
A pop-up menu appears with the following items:
2
3
4
1 Three views that are precon- 2 Views that can be freely config-
figured in the TCE control ured by the user (an example is
software. For a description, shown). The section between the
see section“Calling up special two lines will be empty if user-
views“ on page 6–1. defined views have yet to be con-
figured.
왘 To create new user-defined views, select the <Create/Edit Display> (3) Creating new views
menu item in the bottom section of the pop-up menu
The menu for configuring the views opens. See section “Creating
views“ on page 6–10
왘 To change user-defined views, select the <Create/Edit Display> (3) Changing views
menu item in the bottom section of the menu
The menu for configuring the views opens. See section “Changing
views“ on page 6–12
왘 To delete user-defined views, select the <Create/Edit Display> (3) Deleting views
menu item in the bottom section of the menu
The menu for configuring the views opens. See section “Deleting
views“ on page 6–13
1
2
3 11
11
7 8 9 10
• <New> Buttons
For creating new views. Opens the configuration menu without entries,
i.e. the fields are empty
• <Delete>
Deletes the user-defined view selected in the selection field (1). You
will not be asked to confirm that you would like to delete the view
• <Save>
Saves the entries
• <Close>
Closes the configuration menu without saving the changes
6
1
2
왘 Enter the desired name for the view in the "Description“ (2) field
This name is displayed in the pop-up menu of the button in the func-
tion bar and appears in the selection list for all user-defined views (6)
왘 Enter the desired name for the button in the "Button Text“ (1) field
The additional "Description“ input field disappears from the menu
왘 Enable the "1“ radio button if not yet selected. This defines the top
pane of the three-part view
왘 Below the radio buttons, open the selection list (5) for the parameter
group and select the desired group
왘 Below it, open the selection list (4) for the parameters (data points) of
this program group and select the desired parameter
The display field at the bottom of the menu (3) shows the data point
name (variable name) of the selected parameter
왘 Make the desired settings for the middle pane (radio button "2“) and
bottom pane (radio button "3“) of the view
왘 Click on the <Save> button
The new user-defined view is saved
7 Product data
The product dataset contains product-related data that are not used for
profile and average control. Some of the data are added to the roll data,
causing them to appear in the report/protocol of the produced roll. The
thickness and tolerance settings are used for display and scaling pur-
poses.
왘 Click on the <Product Data> button in the function bar of the TCE main
menu to display or edit the product data
The "Product Data" menu appears on the screen:
The product name entered in the first field appears on the protocol print-
outs of the produced roll. It can also be read from an external product
data storage medium; however, this capability depends on the particular
installation.
왘 Click on the <Overview> button in the function bar to return to the TCE Returning to the
main menu TCE main menu
The setpoints for thickness and tolerance are specified in the <Thickness
+ Tolerance> tab. In addition, the Y-scales can be configured here.
• Tolerance TD
The profile tolerance in a transverse direction (TD). These tolerance
limits are based on the nominal thickness and are indicated in the pro-
file displays as red lines. If the checkbox on the right is checked, the Y-
scale range of the profile display is automatically set to double the tol-
erance range.
• Tolerance MD
The tolerance in the machine direction (MD). These tolerance limits
are based on the nominal thickness and are indicated in the fixed posi-
tion trend displays as red lines. If the checkbox on the right is checked,
the Y-scale range is automatically set to double the tolerance range.
• Tolerance Roll
The TD tolerance of the produced roll. These tolerance limits are
based on the nominal thickness and are indicated in the roll profile dis-
plays as red lines. If the checkbox on the right is checked, the Y-scale
range of the roll profile display is automatically set to double the toler-
ance range.
If the respective "Scale …“ checkboxes are checked, the buttons for indi- Y-scale setting
vidually scaling the graphic are locked and all displays are scaled in
accordance with the tolerance settings.
See also section “Scaling profiles and trends“ on page 1–13.
Some of the data in this menu are included in the protocol of the pro-
duced roll and some are only added to the roll dataset. This will let you
select produced rolls from the roll history according to certain criteria
later on.
The TCE control software itself does not provide archive management of
the roll history. However, you can install a separate production database
called "Roll Data History (RDH)“. You will then be able to select historical
roll data according to the material code and roll ID.
For additional information on the RDH product database, see the "Roll
Data History RDH“ operating manual.
• Specific Gravity
This parameter is used to calculate the output on the winder and the
roll weight. It is not transferred to the thickness gauge and has no
effect on thickness measurement. If the product density changes, the
thickness gauge must always be recalibrated to the new product
• Roll Number
Roll number of roll on winder. After a roll change, this number is auto-
matically incremented by one. The roll number can be manually
changed at any time
• Roll ID
A string of characters that is added to the roll dataset. This ID is a
unique identifier for the particular roll. Depending on the installation,
an external system may generate this value and make it available
automatically
• Remark
A string of characters of your choice that is added to the roll dataset
The treatment data are added to the roll dataset. These values can either
be entered manually or the system can be configured for these data to be
received from an external PLC.
The parameters displayed on this tab are identical to the 16 freely config-
urable parameters displayed in the roll data display. See “Roll data“ on
page 5–6.
How to enter the 16 freely configurable parameters in the roll data is Roll data configu-
described in section “Roll data“ on page 5–6. ration
This tab only appears if thickness measurement takes place prior to the
edge trim. It is not required in lines where the thickness gauge is installed
beyond the edge trim.
The parameters for the edge trim of the roll (side edges) are defined in
the <Edge Trim> tab. This is necessary because the film is not stretched
at the edges and therefore yield much higher thickness values there. For
the process technician, the display presented here provides valuable
information on the transition from the thin film to the thicker edge.
• <Apply
Clicking on the <Apply> button accepts the values
If the line is equipped with the "Edge trim“ option, the function bar of the Edge trim thickness
TCE main menu contains an additional button called <Edgetrim> that measurement
activates a special display of the thickness measurement values in the display
region of the left and right film edge.
왘 Click on the <Edgetrim> button in the function bar of the TCE main
menu
The profile data view shown on the next page appears on the screen.
The arrangement of the display is fixed. The only aspect that can be
changed is the scaling of the displays
• The bottom pane of the display shows a magnified view of the two
edges. The buttons can be used to change the scaling of these views
The <Save Scale> button saves the scaling setting. The "Reset Scale“
button returns the scaling at the edges to the default value
8 Special functions
The fixed position scan is used to create and analyze a thickness trend in Application
the machine direction if there are problems with the film quality. Based on
the fixed point trend, conclusions can be drawn on vibrations in the
motors, rollers and rolls, or on other factors that may be the cause of
thickness fluctuations.
왘 Click on the <MD-Trend> button in the function bar of the TCE main
menu
The "Fixed Position Scan" menu appears:
The "Fixed position scan“ menu is structured as follows: Fixed position scan
menu
8.1.2 Configuration
When configuring the fixed position scan, several key parameters must
be specified to achieve best results.
The input fields are located in the top pane of the "Fixed Position Scan“
menu.
1 2 3 2 4 5 6 7
12 11 10 8 9 8
3 Value of the actual scan head 4 Setpoint of the scan head posi-
position tion for the fixed position scan
왘 Enter the desired parameters for the fixed position scan as described Configuring the
above fixed position scan
After finishing with the configuration, perform a fixed position scan as fol-
lows:
왘 You can change the position of the scan head during the fixed position
scan. To do so, click on the "Left arrow" or "Right arrow" button (2)
depending on the desired direction
The scan head moves to the desired position
왘 To end the fixed position scan, click on the <Go Offsheet> button
The scan head moves to its offsheet park position
왘 Click on the <Overview> button in the function bar to return to the TCE Returning to the
main menu TCE main menu
8.1.4 MD-Trend
The middle pane of the "Fixed Position Scan“ menu displays the aver-
aged trend values of the fixed position scan. Every newly calculated trend
value is added as an element to the right side of this display.
The meaning of the displays in this pane is the same as that of the nor-
mal trend display for transverse scans. See section“Trend displays“ on
page 4–6.
The scaling of the Y-scale can be adjusted as required. See section“Scal- Scaling of the
ing profiles and trends“ on page 1–13. Y-axis
The duration and procedure for calculation and analysis depend on the
fixed position scan configuration. One important factor is the FFT buffer
size. Display field (2) counts the number of measurement values during
measurement. When the predefined number of measurement values in
the FFT buffer is reached, the frequency is calculated and the counter is
reset to 0 for the next measurement.
See also section“Configuration“ on page 8–3.
After each calculation, the "FFT Output“ pane at the bottom of the "Fixed
Position Scan“ menu is refreshed. Also, the measurement trend is dis-
played in the middle pane.
1 2
4 3
The scaling of the Y-scale can be adjusted as required. See section“Scal- Scaling of the
ing profiles and trends“ on page 1–13. Y-axis
The fixed position scan is a fault analysis tool for experienced line-opera- Interpretation of
tor process technicians. To correctly interpret the frequencies, the techni- measurement
cian requires specific knowledge and extensive experience with the line. results
Imparting this knowledge is beyond the scope of this operating manual.
In the optional "AutoBoltMap“ menu of the profile control, the die bolts
can be precisely aligned to the end film. A three-phase alignment proce-
dure (Stimulation -> Calculation -> Activation) is used to determine which
bolts are responsible for which end film areas in the profile control. This
alignment can be set to "automatic“. In this case, the procedure is per-
formed automatically at specific intervals. If set to "manual“, the die bolt
alignment only takes place when started by the process technician.
The alignment changes the "linear“ assignment of the die bolts to the end
film into an "optimized“ nonlinear assignment.
In the <AutoBoltMap> tab, the parameters for precisely aligning the die
bolt positions on the end film are defined on the X-axis and the die bolts
are aligned.
The die bolts are aligned on the end film in three steps: Alignment
procedure
• Stimulation
• Calculation
• Activation
왘 Select the desired die bolt using the arrow keys or enter the desired
die bolt number in the input field
왘 In the field beneath the arrows, enter the temperature stimulation
value for this bolt (e. g. increase by +2.0 °C)
왘 Enter the temperature stimulation for further die bolts in the same
manner
왘 Click on the <Start/Stop> button to start the temperature stimulation of
the selected die bolt
The number of stimulations for this die bolt is counted in the yellow dis-
play field next to "Stimulation“
왘 By clicking on the <Reset> button you can reset all temperature value Resetting the die
for the die bolt stimulation to the die bolt temperature setpoints bolt stimulation
A confirmation window appears that you must confirm with <Yes> to
reset the stimulation to 0 °C
In the second step, a correlation analysis is performed to determine how Calculating the
the die bolt alignment can be optimized (the linear alignment to the end alignment
film is converted to an optimized nonlinear alignment). This alignment
can be performed manually or automatically.
Both procedures are described below.
To align the die bolts manually, they must already have been successfully
stimulated. See section “Die bolt stimulation“ on page 8–10.
왘 Activate the "Man" radio button to perform a manual die bolt alignment
왘 Click on the <Calculate> button to start the alignment calculation. The
correlation analysis program calculates the optimum die bolt alignment
The quality factor of the correlation analysis appears in the green dis-
play field next to "Calculation“
After the calculation is completed, a window appears that contains dia- Calculation results
grams of the calculation results. The trace and the data permit an evalua-
tion of the correlation analysis and provide a variety of information,
including which bolts deviate from the linear alignment on account of the
optimization.
The diagrams and traces in the calculation results window are a tool for
calculation analysis and are designed for experienced line-operator
process technicians. To correctly interpret the results, the technician
requires specific knowledge and extensive experience with the line.These pre-
requisites cannot be imparted in this manual.Please consult Brückner Service if
you have any questions.
The display fields at the top right of the screen show the calculation data:
• The "Samples“ field (examples) indicates the number of stimulations
for this calculation
• If for purposes of analyzing the calculation results you would like to
remove some of the stimulations from the calculation and subsequent
activation, for example because they are outlier values, you can do so
using the <Cut Data> button
왘 You can determine the range for which you would like a calculation to Starting a recalcu-
be made by entering values in the "Begin“ and "End“ fields lation
Example: The calculation was made for stimulations from "1“ (Begin)
to "68“ (End) . If you would now like to recalculate the value leaving out
the first and last stimulations, you can enter "10" in the "Begin“ field
and "50" into the "End“ field
왘 Click on the <Cut Data> button to leave the selected stimulations out
of the calculation and subsequent activation
왘 Click on the <Calculate> button to manually start the recalculation
왘 Close this window by clicking on the <Exit> button
When aligning the die bolts manually, the calculated die bolt alignment Activating the
must be started in the third step. manual alignment
왘 Activate the "Opt" radio button to select the optimized die bolt align-
ment
왘 Click on the <Accept> button to have the profile control apply the cal-
culated die bolt alignment
A confirmation window appears. Confirm it with <Yes>.
The calculated optimized "Boltmap“ will now be used by the profile con-
trol.
The green display field next to "Activation“ identifies the selected bolt
map ("Lin“ or "Opt“).
A display field also shows the date and time at which the die bolt map
was activated.
To align the die bolts automatically, they must already have been suc-
cessfully stimulated. See section “Die bolt stimulation“ on page 8–10.
Perform the automatic die bolt alignment as follows:
왘 Click on the arrow keys to enter the number of control steps with which
the alignment is to be calculated and automatically activated
왘 Activate the "Auto" radio button in the "Activation" pane to perform an
automatic die bolt alignment
왘 In the field beneath the radio buttons, enter a quality factor for the cal-
culation
The activation step does not need to be performed since this third step is
automatic when using automatic boltmap alignment. A display field
shows the date and time of the last die bolt alignment.
The current quality factor of the correlation analysis appears in the green
display field next to "Activation“. The automatic alignment is only acti-
vated if the quality is better than the value specified in the "Activation“
field (e. g. < 100).
A finished roll may contain so-called "thick" and "thin" areas that arise
when there is an increased occurrence of excess thickness and insuffi-
cient thickness in one area of the roll width. The thickness profile of the
finished roll on the winder is created by adding up the thickness devia-
tions. The "thick and thin areas“ can lead to problems when the roll is
processed further (e. g. during metallization).
The control algorithm used here is depicted at the end of this section in a
process diagram to provide experienced process technicians with more
detailed information on this subject. See section “Control algorithm for roll
conformity control“ on page 8–27.
In the optional <Roll Conformity> tab, you can define the parameters for a
profile control that takes into account the entire roll profile. If "thick areas“
are detected, the die bolts in this area are controlled for a certain period
of time to produce a thinner film. In principle, the roll conformity control
feature works by "inverting" the determined roll profile on the die bolts. A
further option also permits the correction of "thin areas".
Roll conformity control can be performed by two different methods: Two methods
• Roll conformity using the roll profile of the entire roll on the winder (all
scans)
• Roll conformity using the average control of a defined number of previ-
ous scans
• "OnProfileControl“ checkbox
If the "OnProfileControl“ checkbox is checked, the roll profile is cor-
rected with each profile control step (e. g. all four scans as set in the
profile control). The roll conformity correction encompasses the profile
of the entire roll on the winder and uses the settings in the "Dev. Min.“
and "Dev. Max.“ fields
• "OnAvgProfile“ checkbox
If the "OnAvgProfile“ checkbox is checked, the roll profile is corrected
using the average values of the film thickness for a specific number of
previous scans. The number of scans can be entered in the "Stack“
field
To set roll conformity control to use the roll profile of the entire roll, pro- Setting and starting
ceed as follows: roll conformity
control
왘 Click on the "ON“ roll conformity checkbox
왘 Check the "OnProfileControl" checkbox
A field in the "Actual Profile“ pane displays "Roll-Profile“, indicating
that roll conformity is being corrected using the roll profile of the entire
roll. An additional field shows the resolution used for the profile control
왘 If you would like to correct "thin areas" in addition to "thick areas", ena-
ble the "add Minima“ checkbox as well
왘 Enter the desired parameters for the roll conformity control as
described in the following parameter description
• Gain 1 and 2
These two gain factors specify how the profile control is to handle the
calculated thickness deviations of the total roll profile. The gain factor
can range from "0“ to "2.0“.
It is possible to specify the gain as a function of the film length on the
winder. See the parameters "Meter counters 1 to 3“
• Metercounter act
Display of the film length currently on the winder in m
The following diagram shows the relationship between the gain factor and
the meter counter.
2
G2
G2
1
G1 G1
G1 G1
0
RS Mco1 Mco2 Mco3 RE RL [m]
No correction is to be made for the first 1,000 m after the beginning of the Example of gain
roll. The roll conformity control is deactivated by entering "0.0" for "Gain factors
1“. From a film length of 5,000 m to 15,000 m, roll conformity control is to
be active with a gain setting of "1.0“ for "Gain 2“. Between film length
1,000 and 5,000 m, gain increases according to a linear interpolation. To
be able start the next roll with the normal profile control, there is to be no
correction from a film length of 15,000 m up to the end of the roll.
• Interpol.
This selection field can be used to activate filtering or smoothing of the
profile correction. If "Crossfilter“ is selected, the calculated target pro-
file is smoothed using the smoothing factor specified under "Factor".
If "None“ is selected, profile correction will take place without filtering/
smoothing
• Factor
The newly calculated profile is cross-filtered with this factor and
thereby smoothed. This prevents abrupt edges in the target profile
To set roll conformity control to use the average control over a defined Setting and starting
number of previous scans, proceed as follows: roll conformity
control
왘 Click on the "ON“ roll conformity checkbox
왘 Check the "OnAvgProfile" checkbox
A field in the "Actual Profile“ pane displays "Avg-Profile“, indicating
that roll conformity is being controlled using the average values of the
film thickness in the previous scans. The additional field shows the
resolution used for the profile control
왘 In the "Stack“ input field, enter the number of scans to be used for roll
conformity control, e. g. 4
왘 If you would like to correct "thin areas" in addition to "thick areas",
check the "add Minima“ checkbox as well
왘 Enter the desired parameters for the roll conformity control as
described in the following parameter description
• Gain 1
This gain factor specifies how the profile control is to handle the calcu-
lated thickness deviations of the average profiles of the last scans. The
gain factor can range from "0“ to "2.0“
The roll conformity control using the average values of the film thick-
ness always uses the same gain factor regardless of the wound film
length. Therefore, unlike in the roll conformity control using the roll pro-
file of the entire roll, meter counters are not used here.
• Interpol.
This selection field can be used to activate filtering or smoothing of the
profile correction. If "Crossfilter“ is selected, the calculated target pro-
file is smoothed using the smoothing value specified under "Factor".
If "None“ is selected, profile correction will take place without filtering/
smoothing
• Factor
The newly calculated profile is cross-filtered with this factor and
thereby smoothed. This prevents abrupt edges in the target profile
If the line is equipped with the "Roll conformity“ option, the function bar of
the TCE main menu contains an additional button called <Roll Conform-
ity> that calls up the current roll profile data.
왘 Click on the <Roll Conformity> button in the function bar of the TCE
main menu
The view of the roll conformity profile data shown below is displayed
on the screen. The arrangement of the display is fixed. The only
aspect of the display that can be changed is the scaling
• The bottom pane (3) displays the current total roll profile on the winder
as calculated by the "roll conformity" function (summation of all scans).
왘 Click on the <Print> button (4) in the function bar to print out the "Roll Printing the display
Conformity" display
The control algorithm used to calculate and control the roll conformity is
illustrated in the following figure. This scheme may assist experienced
technicians in understanding the processes that take place during roll
conformity control. However, this will require a solid knowledge of auto-
matic control engineering.
9 Configuring thickness
gauges
9.1 Introduction
Both of these thickness gauge systems are in widespread use and are
currently not being delivered with their own display monitors.
All menus for the configuration, calibration and diagnosis of the thickness
gauge are provided by the Brückner TCE control software. These menus
can be accessed using the <Gauge Setup> button in the TCE main
menu.
The parameters for the scan mode are entered in the <Scan Mode> tab:
• Scan Speed
The constant speed setpoint for scan program 1 and the speed in the
middle of the film for scan program 2
• Edge Detection
The "ON“ and "OFF“ radio buttons switch between automatic edge
detection and scanning between fixed positions. The activation of a
radio button is transmitted to the thickness gauge. The current edge
detection mode is returned in status word bit "05“
The zero profile is an average profile measured in air and then saved
in the thickness gauge. This zero profile is subtracted from the current
profile if the zero profile compensation is switched to "ON“. To meas-
ure and save the zero profile, use the zero profile compensation
<Start> button. The current zero profile compensation is returned in
status word bits "06“ and "18“
• Actual
The current position of the scan head
"Standardization" refers to when the thickness gauge adjusts itself to zero Definitions
thickness while measuring the air in the gap. Standardization compen-
sates changes in the ambient air and dust.
Standardization should be performed regularly and is usually activated
automatically after a specific time period or after a roll change.
"Calibration" refers to the adjustment of the thickness value for the sam-
ple material to a specified thickness that is precisely determined in the
laboratory. Calibration compensates fluctuations in the specific material
density that are caused by varying additives. A calibration is always
required when the material characteristics change.
The parameters for calibrating the thickness gauge are entered in the Standardization and
<Stdz./Cal.> tab: calibration
• "Auto-Standardize"
The "Roll Change" and "Time Interval" checkboxes define whether
automatic standardization should take place after every roll change
and/or after a specified time interval.
The time interval can be entered in the "Time interval" input field. The
timer for the time interval is reset after an automatic standardization
following a roll change or after a manual standardization.
Both checkboxes are enabled by default and the time interval is set to
240 minutes (equals 4 hours). This means that during production, the
thickness gauge is automatically standardized only after a roll change.
After an extended period in the offsheet position, the scan head is
standardized when the time interval elapses.
The input field for the standardization position functions in the same
manner as the corresponding field in the <Positions> tab. Usually this
value does not need to be changed
The scan head moves to the specified calibration position. Ensure that it
is located on the film if the calibration is performed during running pro-
duction. The input field for the calibration position is the same as the field
described in the <Positions> tab. The sensor averages the sample thick-
ness for 10 seconds.
After the calibration is successfully completed, the thickness gauge
returns its internal calibration factor and the date and time are updated in
the "Last Calibration" field.
Instead of performing these steps, the calibration factor can also be
determined manually and entered directly in the "Calibration Factor“ field.
The <Start Scan> and <Go Offsheet> buttons at the bottom of this menu Operating the
have the same function as the corresponding buttons in the thickness thickness gauge
gauge pane of the TCE main menu. See also section“Thickness meas-
urement display panel“ on page 2–1.
9.2.3 Reference
The radiological half-life of the X-ray source in the scan head must be
checked at regular intervals using a reference measurement. In this pro-
cedure, the thickness value measured by the scan head is compared with
the thickness of a known reference.
There are two types of reference thickness:
• Internal reference (integrated in scan head)
• Sample holder for holding a film from the laboratory (sample reference
with a known thickness)
The parameters for the reference measurement are entered in the <Ref- Parameter
erence> tab: description
In addition, the reference measurement lets you check whether the refer-
ence factor determined by this method is identical with the calibration fac-
tor determined during calibration. See section “Standardization and cali-
bration“ on page 9–5.
The <Start Scan> and <Go Offsheet> buttons at the bottom of this menu Operating the
have the same function as the corresponding buttons in the thickness thickness gauge
gauge pane of the TCE main menu. See also section“Thickness meas-
urement display panel“ on page 2–1.
The parameters for the scan mode are entered in the <Positions> tab: Thickness gauge
positions
• Offsheet/Standardize Parameter
The position on the drive side of the frame in which the scan head is description
parked after clicking on <Go Offsheet> or <Go Offsheet and Standard-
ize>. This value is predetermined by the frame dimensions and gener-
ally does not need to be changed after assembly.
• Sample Calibration
The position to which the scan head is moved after the <Start Calibra-
tion Measurement> command. This is usually a position on or near the
center line if running production is being used as a reference thickness
for calibration. It can also be the position where an optional sample
holder is mounted
• Actual Position
Display of the actual position of the scan head. This value is updated
once per second
The <Start Scan> and <Go Offsheet> buttons at the bottom of this menu Operating the
have the same function as the corresponding buttons in the thickness thickness gauge
gauge pane of the TCE main menu. See also section“Thickness meas-
urement display panel“ on page 2–1.
The <Faults> tab displays the connection status and any faults that
occurred in the thickness gauge:
• Last Fault
The blue display fields shows the fault that last occurred with its fault
number, message text, and date and time of occurrence
• Fault list
The table contains a history of all faults that occurred. You can move
through the table using the scroll bars.
Whenever the internal status changes, the thickness gauge sends a 32-
bit status word. This tab is useful for gaining an initial diagnosis in case of
a malfunction and for testing the basic functions of the thickness gauge.
The <Status> tab displays the status of the thickness gauge parameters:
For test purposes the scan head shutter can be manually opened and <Close Shutter>
closed using the <Close Shutter> button. If the shutter is open, the actual button
thickness reading is displayed in the data field beneath the button.
The following functions are available for testing the scan head drive and Basic manual
the positioning: operation
1 2 3
7 6 5
5 Move the scan head to the 6 Stop the scan head drive
right
9.2.7 Installation
Caution
The thickness gauge installation and the parameter settings
described here have a considerable effect on die bolt
alignment and thus on the quality of the profile.
Inexact work may result in an incorrect profile or die bolt
alignment.
씰 Do not make any manual changes to these values
• Reference Position
This value shifts the physical location of the position 0 (zero) so it is
positioned directly on the center line. The center line is defined as the
middle of the untrimmed film, which must also be the middle of the roll.
The correct setting of this parameter is checked by attaching a piece
of thread along the center line and the zero position of the scan head
• <Search> button
The <Search> button is used to move the scan head to the reference
position
The center of the sensor must be aligned with this thread. The value is
important for aligning the die bolts and must be determined to an accu-
racy of ±10 mm.
• Resolution
The width of the profile slice (sometimes referred to as block or zone
width). This is the width of the measured film that is represented by a
single thickness value. This value is set to 25 mm by default, which is
greater than the resolution in a transverse direction of the sensors that
are in common use. The sensor scans the film at a certain speed, gen-
erally at 10 to 20 milliseconds. All profile values located within one pro-
file slice are averaged to a single profile slice value
• Slices
The thickness gauge assumes that a certain number of profile slices
will be received for a certain line width. The thickness gauge drive pro-
gram divides the line width by the profile slice width and sends this
number to the thickness gauge. This value cannot be changed directly,
but only by changing the slice width or the line width
The buttons described below are only available for a specific user
authorization group.
Default
User
Clicking on the buttons with the left mouse key opens a pop-up menu
that offers both options
If you have made changes, save them as follows: Saving the changes
왘 Click on the <Save> button
왘 In the pop-up menu, select whether the data should be saved as
<User> or as <Default>
If you have made changes you do not wish to use, or if you would like to Restoring data
access the default data, you can retrieve them from the storage location:
왘 Click on the <Reset> button
왘 In the pop-up menu, select whether you would like to restore <User>
data or <Default> data
9.2.8 Simulation
The <Simulation> tab displays the parameters for the thickness simula- Thickness
tion. simulation
• Sensor 1 / 2 Description of
The specification of the simulated thickness value for sensor 1 and, if displays and
installed, sensor 2. The thickness measurement in air is increased by functions
this value (addition to zero profile).
The parameters for the scan mode, the fixed position measurement and
the thickness gauge configuration are entered in the <Scan Mode> tab:
Thickness gauges with infrared technology use a scanning program. The Scan mode
scan head moves back and forth at a specified speed between the scan-
ner limits defined by the two stops.
• Scan Speedpoint
The constant speed setpoint
In this panel (MD Mode), the parameters for the fixed position scan are Fixed position scan
set and the scan is started.
• Set
The "Set“ input field is used to specify the set position of the scan
head for the fixed position scan
• Actual
The "Actual“ field displays the actual scan head position
• Factor
The first correction factor for calibrating the thickness gauge.
For calibration, two films of differing thickness are measured with the
thickness gauge and compared to the exact values determined in the
laboratory (e. g. 10 and 30 µm). The factor is determined from the
deviation between the thickness value measured by the thickness
gauge and the exact sample thickness determined in the laboratory.
The correction factor corrects the slope of the curve
• Constant
The second correction factor for calibrating the thickness gauge.
The correction factor "Constant“ defines an offset for the thickness
measurement that is used if the deviation of the two thickness meas-
urements has the same absolute value.
Example: If the thickness gauge measures 12 and 32 µm for labora-
tory values of 10 undo 30 µm, the offset is 2 µm
The <Start Scan> and <Go Offsheet> buttons at the bottom of this menu Operating the
have the same function as the corresponding buttons in the thickness thickness gauge
gauge pane of the TCE main menu. See also section“Thickness meas-
urement display panel“ on page 2–1.
Whenever the internal status changes, the thickness gauge sends a 32-
bit status word. This tab is useful for gaining an initial diagnosis in case of
a malfunction and for testing the basic functions of the thickness gauge.
The <Status> tab displays the status of the thickness gauge parameters:
• Away Switch
The position of startup switch 2, reversal position of the scan head.
Together with the position of the "Startup Switch“, it defines the largest
possible range that the scan head can move
• Profile Resolution
The resolution of profile thickness measurement. The thickness gauge
delivers averaged thickness values to the TCE control software every
12.5 mm
The following functions are available for testing the scan head drive and Basic manual
the positioning: operation
5 4 3
9.3.3 Faults
The <Events> tab displays the connection status and any faults that may
have occurred in the thickness gauge:
• Last Fault
The blue display fields shows the fault that last occurred with its fault
number, message text, and date and time of occurrence
• Fault list
The table contains a history of all faults that occurred. You can move
through the table using the scroll bars
10 System configuration
Attention
Installation and configuration is performed by Brückner
Service when the line is put into operation.
Changes to the configuration of the TCE control software
may only be made under exceptional circumstances by
authorized and trained line-operator personnel.
씰 It is recommend that changes only be made after
consultation with Brückner Service.
Clicking on the <Sys.Config.> button in the function bar of the TCE main
menu opens the "TCE Installation and Configuration“ menu.
The "TCE Installation and Configuration“ menu has the following tabs in Tabs
which the TCE control software is installed and configured:
• Installation
• Config.
• Diebolts
• Chillr./Extr.
• Misc. Bits
• Misc. Data
• Rolls
• User Data
• To PLC
Index Configuration
fixed position scan 8-3
infrared thickness gauge 9-22
profile control 3-4
radiometric thickness gauge 9-2
roll data 5-9
roll protocol 5-11
Numerics
roll split 5-13
2-sigma value roll profile 5-17 TCE 10-3
A thickness gauge 2-11, 9-1
Actual production rates 5-2 Confirmation window 1-10
Alarm status, thickness gauge 2-9 Control elements
AutoBoltMap thickness measurement 2-1
automatic die bolt alignment 8-14 D
calculation results 8-11 Delay after temperature change 3-13
calling up menu 8-8 Die bolt heating 3-24
die bolt stimulation 8-10
Die bolt temperature
manual die bolt alignment 8-11
changing the setpoint 3-20
resetting the die bolt stimulation
manual setting 3-20
8-10
Die bolt temperatures 3-19
AutoBoltMap alignment 8-8
alarms 3-25
Automatic die bolt alignment 8-14
warning reset 3-25
Average control
Die bolts
display pane 4-1
details 3-22
parameters 4-3
parameters 3-5
starting 4-2
Die bolts, setting up 3-5
stopping 4-2
trend history 4-5 Die lip protection 3-12
Average control system Display
control parameters 4-4 edge trim thickness measure-
ment 7-11
Averaged profile data 3-17
roll conformity 8-25
B Display area
Button functions 1-7 production rates 5-1
Buttons Display pane
changing the assignment 6-2 average control 4-1
die bolts 3-19
C
profile control 3-1
Calculation limits 3-10 thickness measurement 2-1
Calibration of thickness gauge 9-5
Cast film 7-8 E
parameters 3-14 Edge bolts 3-6
thickness measurement 3-15 Edge trim 7-9
Cast film thickness measurement 1-1 Edge trim thickness measurement
Configurable trends 1-24 7-11
Configurable trends, calling up 1-26 End film thickness measurement 1-1