www.exergen.com 1

CLASSROOMCLASSROOM

TODAY’S LESSON:

SPEEDBOOST

www.exergen.com 2

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

www.exergen.com 3

Reduced ScrapReduced Scrap

Less Product is Scrapped for Adjustments

$1000 per set-up

Conventional Conventional ControlControl

IR ControlIR Control$100 per

set-up

www.exergen.com 4

Increasing Speeds via Non-Invasive IR-Monitored Heat

Balance

www.exergen.com 5

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

www.exergen.com 6

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

www.exergen.com 7

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

www.exergen.com 8

Thermal Energy Thermal Energy Balance in Space Balance in Space

and Time:and Time:The The TimeTime Domain Domain

www.exergen.com 9

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

www.exergen.com 10

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

www.exergen.com 11

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

www.exergen.com 12

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

www.exergen.com 13

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

www.exergen.com 14

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:

www.exergen.com 15

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

www.exergen.com 16

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

www.exergen.com 17

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

www.exergen.com 18

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

www.exergen.com 19

• 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

www.exergen.com 20

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)

www.exergen.com 21

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

www.exergen.com 22

Example: High Speed Color Example: High Speed Color Copy ProcessCopy Process

Paper Flow

Energy Flow

TT T

T Ts

s o

TToo

TTooooTTss

www.exergen.com 23

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

www.exergen.com 24

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

www.exergen.com 25

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

www.exergen.com 26

• 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

www.exergen.com 27

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

www.exergen.com 28

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