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CLASSROOMCLASSROOM
TODAY’S LESSON:
SPEEDBOOST
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Faster Start-upFaster Start-up
Direct Control of Heater Surfaces and Product Temperature Reduces Adjustments Required
8 hr
1 hr
Conventional Conventional ControlControl
IR ControlIR Control
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Reduced ScrapReduced Scrap
Less Product is Scrapped for Adjustments
$1000 per set-up
Conventional Conventional ControlControl
IR ControlIR Control$100 per
set-up
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Increasing Speeds via Non-Invasive IR-Monitored Heat
Balance
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FrontiersFrontiersPrinciples of the Heat Balance in Time
and SpaceThe Speed Boost EquationBalanced Heat Input via IR ControlApplications
– Laminating, Drying, Printing, Heat Sealing, Color Copying
High Speed Event Detection
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Principles of the IRt/c:Principles of the IRt/c: With Heat Balance With Heat Balance
+-
TT TS TCJTC
+-
TT TS TCJTC
Automatically Computes Heat Balance, Using Material Properties Alone
Can be Configured for Unpowered or Powered Configurations
mVout = c((TC - TS)(1/k) + TS -TS) + (TS - TCJ) = (TC - TCJ) when c = (k)
= Seebeck coefficient
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Non-Invasive Fluid Non-Invasive Fluid Temperature in Tubing via Temperature in Tubing via
IRt/c Heat BalanceIRt/c Heat BalanceTaTsTf
Rf Rt Ro
Tw
Radiation +ConvectionHeat Transfer
q
TR R R
RT T Tf
f t o
os a a
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Thermal Energy Thermal Energy Balance in Space Balance in Space
and Time:and Time:The The TimeTime Domain Domain
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Jean Baptiste Joseph Jean Baptiste Joseph FourierFourier1768-18301768-1830
Fourier’s Equation of Heat Conduction
Unsteady State Heat Conduction for Moving Materials
q
Ak
T
xx
2
21T
x
T
t
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Pierre Simon Marquis de Pierre Simon Marquis de LaPlaceLaPlace1749 -18271749 -1827Laplace Transform Method of Solution
Converts Partial Differential Equation to Ordinary Differential Equation
T x s e T x t dtst( , ) ( , )
0
d T
dx
sT
To2
2
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Francesco PompeiFrancesco Pompei1948 -1948 -
New Method of Solution Leads to a General Equation for Non-Contact Temperature Monitoring of Internal Temperatures of Moving Materials
Th
k
aT T T
aT Tc s s s
sinh cosh 1 0
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Which simplifies to
T K T T T K T Tc s s s o 1 2( ) ( )
where
, KKa
ha
ka a1 2
1 1 11)
sinh (cosh
1 1 2
aFo
ha
kBi /
, and
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Deriving The Speed Boost Deriving The Speed Boost EquationEquation
Set the surface temperature equal to the center temperature, then the equation reduces to
Since K2/K1 is a function only of material properties and speed:
T K T T T K T Tc s s s o 1 2( ) ( )
T T
T T
T T
K
K
c s
s
s o
( )
( )2
1
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The Speed Boost EquationThe Speed Boost Equation
V
V
T
TT
T T
T Tnew
old
new
old
s
s o
, where
• General Equation for Non-Contact IR Temperature General Equation for Non-Contact IR Temperature Monitoring of Monitoring of InternalInternal Temperatures of Moving Temperatures of Moving Materials is Combined with Surface TemperatureMaterials is Combined with Surface Temperature
• Leads to Uniform Material Temperature When Leads to Uniform Material Temperature When Controlled via the Controlled via the Speed Boost EquationSpeed Boost Equation
• Which Forces the Control System to Apply Heat at an Which Forces the Control System to Apply Heat at an Optimally Optimally BalancedBalanced Rate Rate
The ratio can be formed, which then becomes:The ratio can be formed, which then becomes:
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Applying Applying The Speed Boost EquationThe Speed Boost Equation
ToTsT
Thermal Input (oven,dryer, rolls, etc.)
Speed V
V
V
T
TT
T T
T Tnew
old
new
old
s
s o
, where
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Speed Boost Equation is Speed Boost Equation is Generally Linear for Most Generally Linear for Most
ApplicationsApplications
Speed % IncreaseSpeed % Increase
TT T
T Ts
s o
% Increase% Increase
2525 5050
2525
5050
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Implementing Speed Boost to Implementing Speed Boost to Include Non-LinearitiesInclude Non-Linearities
Speed % Increase
TT T
T Ts
s o
% Increase
25 50
25
50
Apply step-wise speed increases in accordance with speed boost equation, and renormalize at new operating condition to account for property changes.
For variable speed systems, program to follow the characteristic curve.
Speed Changes Followed by
Renormalization
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Existing Set-up:Too = 105 C
Ts = 85 C
To = 25C New Set-up:
Too = 120 C
Ts = 85 C
To = 25C Potential Speed
Increase*: 25%
Example Speed Boost: Example Speed Boost: LaminatingLaminating
TT T
T Ts
s o
*Assuming all other factors are permitting
TToooo TTooTTss
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• Existing Set-up:Existing Set-up:TToo oo = 260 C= 260 C
TTss = 85 C = 85 C
TToo = 25 C = 25 C
• New Set-up:New Set-up:TToo oo = 260 C= 260 C
TTss = 85 C = 85 C
TToo = 40 C (with preheat) = 40 C (with preheat)
• Potential Speed Potential Speed Increase*:Increase*: 33%33%
Example Speed Boost: DryingExample Speed Boost: Drying
TT T
T Ts
s o
*Assuming all other factors are permitting
TToo
TTooooTTss
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Precision Drying Control for Precision Drying Control for Maximum Production SpeedMaximum Production Speed
Relative Temperatures Relative Temperatures
at IRt/c Locationsat IRt/c Locations
Dry-Out Point (Phase Change)Dry-Out Point (Phase Change)
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Example Speed Boost: Heat Example Speed Boost: Heat SealingSealing
Existing Set-up:Too = 150 C
Ts = 120 C
To = 25 C New Set-up:
Too = 150 C
Ts = 120 C
To = 45 C (with preheat added)
Potential Speed Increase: 27%
TToo
TToooo
TTss
TT T
T Ts
s o
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Example: High Speed Color Example: High Speed Color Copy ProcessCopy Process
Paper Flow
Energy Flow
TT T
T Ts
s o
TToo
TTooooTTss
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Overcoming Thermal Delays Overcoming Thermal Delays due to Mass of Rollersdue to Mass of Rollers
)TT(PIDT)TT(K
VT
TT
TT
TTKV
intsetpossosw
os
os
sw
becomes algorithm control then
constant, are and if
Tw
Ts
IRt/c. SVTo
Ts
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Speed Boost EquationSpeed Boost Equation
Above Can Be a Simplified Control Algorithm
Keep Equation Balanced to Within a Few % to Avoid Non-Uniformity in Material Temperature
T T T T Ts o1
Heat Source Temperature
Control Loop Gain
Product Surface - setpoint
Product Input
V
V
T
TT
T T
T Tnew
old
new
old
s
s o
, where
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Existing Set-up:Too = 105 C
Ts = 85 C
To = 25C New Set-up:
Too = 120 C
Ts = 85 C
To = 25C Potential Speed
Increase*: 25%
Example Speed Boost: Example Speed Boost: LaminatingLaminating
os
s
TT
TTT
*Assuming all other factors are permitting
TToooo TTooTTss
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• Existing Set-up:Existing Set-up:TToo oo = 260 C= 260 C
TTss = 85 C = 85 C
TToo = 25 C = 25 C
• New Set-up:New Set-up:TToo oo = 260 C= 260 C
TTss = 85 C = 85 C
TToo = 40 C (with preheat) = 40 C (with preheat)
• Potential Speed Potential Speed Increase*:Increase*: 33%33%
Example Speed Boost: DryingExample Speed Boost: Drying
os
s
TT
TTT
*Assuming all other factors are permitting
TToo
TTooooTTss
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Example Speed Boost: Heat Example Speed Boost: Heat SealingSealing
Existing Set-up:Too = 150 C
Ts = 120 C
To = 25 C New Set-up:
Too = 150 C
Ts = 120 C
To = 45 C (with preheat added)
Potential Speed Increase: 27%
TToo
TToooo
TTss
TT T
T Ts
s o
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You Cannot Know For Sure You Cannot Know For Sure That the Product is Right That the Product is Right
Unless You Look...Unless You Look...
WithWith
EXERGENEXERGENIRIRSensorsSensors