Procemex Twin

Integrated Web Monitoring & Web Inspection System

”Procemex TWIN is a breakthrough result of utilizing our joint competences in web break monitoring and web inspection, and combining this with a real requirement from customers for a more simple, flexible and, above all, more performance containing solutions”
Mika Valkonen, CEO of Procemex

PROCEMEX TWIN - designed for operators

The start point of the Procemex TWIN system are machine operators. The system assists operators in handling all production quality, and production efficiency items with the aid of a set of computer supported analysis tools.
Under normal running conditions the left hand monitor is used for displaying live images and a machine efficiency time chart. The right hand display continuously updates a defect map that identifies different defects with respective symbols.


Should a machine disturbance occur e.g. web break or paper defect, the monitors change modus and form a unified user interface that displays a complete story of the event with its original root cause


For the operator, analysis is easy as the system classifies paper defects and displays its evolution through the process. It is wholly beneficial for the operator, that defects and web breaks are analysed and displayed in such a clear way.

Intuitive Dual Screen user interface for fast and easy root cause analysis for web breaks and paper defects.

One system – one image processing hardware for different camera types

Procemex TWIN is constructed with the idea of using different types of cameras within the same system, as with different machine parts requirements for visualization differ. The same image processing hardware understands different camera types. One server supports up to 64 cameras and several servers can be configured together within the same system. The cameras can be web monitoring cameras i.e. positioned alongside the process or web inspection cameras built into a camera beam across the paper web.

  • The Procemex Server can process up to 64 cameras
  • Preventative image analysis file
  • Web break file
  • Defect file
  • Process disturbance file
  • Preventative image analysis file

Procemex 4 channel- DSP-image processing board with SuperCircle memory

Leading edge image processing technology

”No moving/wearing parts” The goal of data processing. Images and videos are stored in RAM-memory located on each image processing board. The amount of RAM memory is a factor in recording time length requirement.
High performance DSP processors handle image raw processing, analysing and event classification. The videos are stored in RAM memory by using the SuperCircle-Memory concept. This means that videos are stored continuously in RAM-memory, while simultaneously important data, e.g. paper defects or reel change events, are copied into a permanent event bank.


The SuperCircle feature is a must, e.g. in the case of a paper defect, it is necessary to make a defect image and also a short video from each camera located upstream of the disturbance position. Naturally, there is a real need to process several subsequent defect events completely, and independently of each other, through the entire processing line.
While the actual hard image processing work is achieved on DSP processor boards, the server computer manages files, performs SQL-database handling, user interface visualization and data distribution to other clients. The permanent data is is stored on a RAID secured break & defect bank.

Image processing technology for analog and digital cameras

Procemex image processing is designed to operate smoothly with analog and digital cameras:

  • PAL/NTSC black & white camera (half image)
  • PAL/NTSC color camera (half image)
  • Progressive Scan camera (full image)
  • Line-to-Matrix camera (patented)
  • Line Scan camera
  • Infra Red camera
  • Procemex-Flex 1.3 million pixel camera

Resolution comparison of different matrix cameras.

Intelligent digital 1.3 million pixel camera technology – the backbone of high definition web break monitoring and defect detection


Procemex started developing totally new digital imaging technology in 2005, for web monitoring and web inspection. This technology is named Procemex Flex, and it is derived from flexible, software-configurable, intelligent camera technology. This camera opens new doors in visualising process problems and, especially, for providing high resolution images of paper defects.


The resolution with 1.3 million pixels is over 6 times higher than the standard PAL black & white camera and almost 9 times higher than NTSC color resolution. Such high resolution, the extended amount of greyscales, coupled with up to 500 frames per second, offer premium performance for papermakers and printers.

Intelligent digital 1.3 million pixel camera technology – features

  • In-house developed intelligent camera technology
  • leading edge resolution with 1.3 million pixels
  • entire images or partial scanning
  • DSP-based image processing & analysing inside the camera
  • SuperCircle-RAM-memory inside the camera
  • on-line defect classification inside the camera
  • visualization in greyscale or in colour
  • up to 500 images per second
  • image frequency can be synchronized with line speed (e.g. with rotating process parts creating a stroboscope effect)

Web Inspection

There has existed, from the first paper machine, a need to identify and understand visual sheet defects, which must be detected and identified in real-time and presented to the papermaker in an easily understandable way.


To achieve detection of relevant defects a number of digital Procemex Flex cameras are installed to a camera beam or multiple beams, when detection is required at multiple locations or on both sides of the sheet. This specially constructed beam absorbs machine vibration, and is sturdy enough for  the  widest machines in the world. Sheet widths well in excess of 12 meters can easily be reached.


The ProcemexTwin system can be reconfigured to match evolving detection and quality requirements that modern paper manufacturers face. Cameras can be added/removed and new beams can be configured whenever required.

Investing in ProcemexTwin technology provides the quality edge for today and the future.

High tech paper illumination
For sharp defect images the fast  paper movement needs to be frozen. This requires high camera shutter speeds that can only be achieved with sufficient illumination.


Light beams are typically located on the opposite side to the camera beam, so called transmission illumination. The light beam can also be located on the same side  using  reflection illumination method.


Both camera and light beam have been designed so, that they require only 20cm of space in MD. This ensures installation in narrow positions without expensive machine modifications. The light beam features an automatic retraction solution ensuring trouble-free tail threading.



The cameras can be used for high definition defect detection across the paper web in camera beam or along the process


Procemex TWIN benefits for papermakers

  • Easy to operate as defects and web breaks are analysed the same way.
  • The combination of defect detection cameras and upstream located web monitoring cameras provide a powerful tool for paper defect root cause analysis.
  • The most advanced, intelligent camera technology results in higher resolution i.e. better definition and understanding of web breaks and defects.
  • Compact system architecture and unified components reduce the amount of parts and require less maintenance.
  • Real-time event detection, event analysis and classification
  • Flexibility – system configurations are software-based and can be easily reconfigured
  • Expandability – web monitoring cameras along the process and web inspection cameras inside the detection frame can be added afterwards
  • Superior data distribution within your mill network.
  • Enables on-line collaboration between papermakers and printers

Camera cooling & cleaning in hostile environments

Procemex has a set of cooling and cleaning solutions for different parts of the process. On the wire and press section of paper machines, it is common to use pinhole cameras for the most difficult positions. With a pinhole camera the cooling air is blown out through a specially formed 5 mm hole. The air forms a strong flow and the pinhole camera films the target through the hole.

Pinhole camera installed under the pick-up position on a coated fine paper machine.


After 2 weeks in use the above piece of stock accumulation was removed from the camera housing. As the 5 mm hole was clear the camera  continuously maintained 100% visibility.


A solution for easier camera positions is a single or  double air knife cleaning. A 3-chamber air flow is formed in front of the protection window of the camera housing to keep it clean.

Procemex 3-chamber air knife cleaning

Water cleaning is also available for cameras. The protection lens of the camera housing is automatically cleaned with a pre-defined washing length and interval. Camera cooling is maintained by temperature insulation inside the camera housing and by using instrument air. In some positions > 60 C / 140 F it is necessary to use a Vortex cooler to guarantee a suitable ambient temperature for the camera.

Web monitoring lights in various parts of machines feature also water cleaning and air cooling if needed.


The web inspection cameras and illumination modules are cooled by blowing air through the camera and light beam.
Integrated Web Monitoring & Web Inspection System

 

Procemex Twin Brochure
 

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