LaserSpeed: Intro to Non-Contact Length & Speed Measurement
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The document discusses non-contact laser measurement technology, particularly the Laserspeed gauge, highlighting its advantages for accurately measuring product length and speed in various manufacturing applications. It emphasizes the challenges of traditional measurement methods, such as inaccuracies and maintenance issues, and showcases case studies demonstrating significant cost savings and operational improvements achieved through the adoption of this technology. The presentation concludes that non-contact laser measurement offers immediate payback and long-term advantages by replacing mechanical encoders.
LaserSpeed: Intro to Non-Contact Length & Speed Measurement
- 1. Only the Accurate Survive: Understanding Non-Contact, Laser- Based Technology for Measuring Product Length and Speed
- 2. Non-Contact Laser Measurement Non-Contact Laser Gauge Today’s Speaker Solutions Development Manager Veteran of high-tech measurement controls industry Mechanical engineer & engineering metrologist Stuart Manser, Beta LaserMike 20 yrs with Beta LaserMike Extensive expertise in non- contact measurement
- 3. Non-Contact Laser Measurement Non-Contact Laser Gauge Presentation Overview Intro: Productivity and quality challenges Non-contact laser measurement technology Application examples ROI of measurement accuracy Conclusion Questions
- 4. Non-Contact Laser Measurement Non-Contact Laser Gauge Introduction Global competition is fierce Manufacturers driven to optimize productivity, improve quality, and remain competitive Problem: length and speed measurement inaccuracies Undesirable results: costly rework, quality issues, material waste, and product returns
- 5. Non-Contact Laser Measurement Non-Contact Laser Gauge Need for Accurate Length and Speed Converting segments and applications where length and speed measurement accuracy is critical. Converting Industry Sector Critical Application Process Requirements Paper Continuous length Plastic Film & Sheet Reel or roll length Foil Cut control Labeling Speed control Packaging Stretch/draw control Printing Product positioning Non-Wovens Quality control Narrow Web Index and positioning Composite (Carbon Fiber) Splice synchronization Building materials Print synchronization Many other sectors……. The list continues…….
- 6. Non-Contact Laser Measurement Non-Contact Laser Gauge Common Measurement Approaches Contact measurement systems: Rotary encoders Wheel tachometers Drive & shaft encoders Problems: Slippage Day-to-day wear Debris build-up Mark/damage product Calibration and service Inaccuracies >1 – 2% or greater
- 7. Non-Contact Laser Measurement Non-Contact Laser Gauge LaserSpeed Non-Contact Technology for accurately measuring length and speed Non-contact encoder Measures product directly Uses Laser Doppler Velocimetry (LDV) technology Highly accurate, repeatable product length and speed measurements Better than .05% accuracy, . 02% repeatability Permanently calibrated
- 8. Non-Contact Laser Measurement Non-Contact Laser Gauge How LaserSpeed Works Non-Contact, Laser Encoder The speed measurement is made where the Laser beams converge. The LaserSpeed detects Laser moving product Beams regardless of shape, Standoff surface, or color Distance -Vel Pass Line +Vel Depth of Field
- 9. Non-Contact Laser Measurement Non-Contact Laser Gauge Laser Doppler Velocimetry (LDV) Theory λ d= 2 sin κ d v= t 1 t= f V = d* f T L = ∫0 vdt Fringe direction
- 10. Non-Contact Laser Measurement Non-Contact Laser Gauge LaserSpeed Measurement Capabilities Measure product speeds to 39,000 ft/min (12,000 m/min) Stand-off distances to 39.4 in (1000 mm) Depth of field to 4.0 in (100 mm) Customizable pulse rates to 5 MHz
- 11. Non-Contact Laser Measurement Non-Contact Laser Gauge Application Examples Profile: Sanitary products manufacturing Problem: Inaccurate length measurement at slitter/rewinder station due to mechanical encoder errors – slippage, debris build-up Solution: LaserSpeed encoder provides near .05% length accuracy Results: Eliminated 2% product give- away Realized $40,000 savings/yr ROI in 3 months
- 12. Non-Contact Laser Measurement Non-Contact Laser Gauge Application Examples Profile: Packaging production Problem: Inaccurate cut control due to tachometer slippage & bounce, resulting in 90 ft of scrap with each change-over (25 per day) Solution: LaserSpeed encoder accurately measures product length & speed; provides precise pulse counts to control cutters Results: No slippage errors Cuts to target length, even during change-over Potential savings of $202K/yr Reduced maintenance costs
- 13. Non-Contact Laser Measurement Non-Contact Laser Gauge Application Examples Profile: Paper manufacturing Problem: Over-supplying and shorting product by 2.5% due to tachometer slippage; also significant flying splice problem Solution: LaserSpeed encoder accurately measures length on take-up roll and controls tension on unwind roll Results: Higher length & speed accuracy Reduced product give-away and scrap Precise control of splicing speeds Decreased downtime
- 14. Non-Contact Laser Measurement Non-Contact Laser Gauge ROI of Measurement Accuracy
- 15. Non-Contact Laser Measurement Non-Contact Laser Gauge Conclusion LaserSpeed: Proven measurement technology Highly accurate length and speed Ideal replacement for mechanical encoders Provides numerous productivity, operational, and quality advantages Delivers immediate payback and long- term savings
- 16. Non-Contact Laser Measurement Non-Contact Laser Gauge Product & Contact Information www.laserspeedgauge.com USA: +1- 937-233-9936 UK: + 44 1628 401510 Germany: +49(0)231 758 93 0 Asia: +86 21 6113 3688 eMail: sales@betalasermike.com
Editor's Notes
- #9: The LaserSpeed has one laser diode source and it splits the light into two beams that exit the gauge aperture at an angle. LaserSpeed projects an Interference pattern on the surface to be measured. The two beams converge and overlap at the standoff distance. The overlap region is called the depth of field. A fringe pattern is generated by the two intersecting laser beams. This creates the measurement region. As the product moves through the measurement region, light is scattered back to the LaserSpeed at a frequency proportional to the speed of the material. The frequency is measured, converted to a speed, and pulses are generated at a rate proportional to the speed. External counters or PLCs count the pulse to determine length.
- #10: The formulas show the mathematics behind the measurement principle: 'd' is the fringe spacing. 'f' is the frequency, which is determined by the scattering of light from the measurement surface. Since 't' (time) is the inverse of frequency, we have the two parameters to calculate velocity, 'v'. Length is determined by integrating velocity over time.
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