2. 2
• What is it?
– A system that allows the printer to optimize the printing
process, prevent (recurring) web breaks and claim web breaks
caused by paper related issues, in order to improve overall
productivity and reduce printing costs
• ContiVision automatically determines for every web break:
– The exact time
– The exact break location
– The process circumstances at the moment of the web break
– The variations in paper quality (holes, cracks, …)
– The most probable cause of the web break
ContiVisionContiVision –– Web break analysis systemWeb break analysis system
3. 3
ContiVisionContiVision –– Web break analysis systemWeb break analysis system
Data logger
Data analysis software
HMI
Camera system / recorder
Camera movies Statistical information Analysis information Web break cause list
Sensors/measurementsCameras
4. 4
System overview (1)System overview (1)
• Central industrial PC with 24“ monitor with analysis software
– System is connected with Contiweb through VPN for remote
diagnostics
– System is part of PARS (Pro Active Remote Service):
statistical web break data is reported through PARS
• Connection with Contiweb splicer
– Splicer is equipped with “webdata” (reel management
software including barcode scanner)
• Connection with Contiweb dryer with integrated chill rollers
– Including dryer and chill web tension measurement
5. 5
System overview (2)System overview (2)
• Connection to web severer
• Connection to web catcher
• Web break sensors press (existing and additional)
• Web tension measurement folder (existing)
6. 6
System overview (3)System overview (3)
• Camera system
– In the splicer cameras with automatic fault detection till 18 m/s
– Camera before the dryer
– Cameras in folder
– Expandable with additional cameras
• In total about 80 signals are used to analyze the web break
7. 7
Software for analysis (1)Software for analysis (1)
• Web break is detected by the loss of the web tension, measured in
the chill roller section
• The web break position and process circumstances are
determined by the analysis of all 80 signals of measurement data
• Web break cause is researched from several hundred theoretically
possible causes with following inputs:
– Break position, process circumstances and measurements
– Paper information
– (A minimum of) responses from the operator
8. 8
Software for analysis (2)Software for analysis (2)
• Break time, location, process, relevant process data and possible
causes (with probability calculation) are shown for every web break
11. 11
Camera System (1)Camera System (1)
• Registration of paper defects in the paper roll, as close as possible
after unwinding
• Automatic creation of web break analysis report including photos,
video and production data
• Allows discussion with paper supplier about paper related web
breaks and any possible claims
12. 12
Camera System (2)Camera System (2)
• Area scan cameras, gigabit Ethernet connection
• LED lighting
• State of the art hardware
14. 14
Web break analysis report (1)Web break analysis report (1)
• Report contains:
– Exact web break time
– Exact web break location
– Basic paper data (reel number, paper type, …)
– Unwound length
– Photo evidence of paper defect
– Video evidence is available as attachment (.avi)
– Extended report: additional process information, e.g.
• Process state (printing, washing, …) including history
• Web tension and fanout signals
• Web speed
• Temperatures
– Remarks from printer
16. 16
ContiVisionContiVision -- SummarySummary
• Automatic analysis of all web breaks
– Time, location, process, cause
– Allows process improvements in the printing press
– Allows prevention of recurring web break (causes)
• Automatic paper fault detection
– Allows claims for paper related web breaks, but only if paper was
the proven root cause of the web break
• Separate system with own measurement signals and connections to
existing equipment for presses with a Contiweb splicer and dryer with
integrated chill
