10/9/2024 GreCon Training

Ahmed Fathy
Measurement principle
For the measurement operation, there is a radiation source below the measurement job and a
measurement chamber above the measurement job. The measurement radiation emitted by the
radiation source penetrates the measurement job. Depending on the material quantity and the
specific weight of the measurement job, a part of the radiation is absorbed. The radiation
component that is not absorbed is converted into electrical signals in the measurement chamber.
The electrical signals are converted into measurement values and compared using evaluation electronics
with a pre-set desired value. Deviations from the desired value are marked in color in the measurement
value graphic on the screen.
Radiator holder
The radiator holder houses the radiation source (X-ray tubes), which transmits the necessary radiation for
determining the measurement values. The radiation source is secured through a shutter arm, which securely
closes the radiation outlet. The position of the shutter is queried through an initiator

Heating-up time of the X-ray tubes

The X-ray tube needs a heating-up time of approx. 60 minutes. Measurement values can be recorded during
this heating-up phase. These values can, however, be subject to slight variations till the required operating
temperature of the tubes is reached.

High voltage generator

The generator cabinet houses the high-voltage generator module. The functional state of the generator is
indicated by means of an operational state lamp.
Local electronics
In the on-board electronics, the signals from the measurement chamber are converted into measurement
values and control signals are generated for the measurement operation. All the operating elements for
operation of the measurement system are integrated on the front side of the on-board electronics.
Signal - Multi-color lamps
The signal multi-color lamps indicate the operational state of the measurement system. The status display of
the radiation source is current-monitored and if there is a defect, it switches off the generator.
High-voltage supply

The high-voltage supply must be switched on for operating the X-ray source.

Releasing the safety circuit:

After booting the touch Panel, the red operating light "System malfunctioning" lights up on the local
electronics.

The safety circuit of the BWQ must be activated using the Acknowledge button on the local electronics.

It is only possible to activate the safety circuit when both Quick Stop buttons are unlocked.

After the safety circuit is activated, the green operating light "System in operation" lights up on the local
electronics.
Activating the Measurement System

After a system fault by the Quick Stop button, the green signal lamp on the local electronics goes out. The
red signal lamp "System malfunctioning" lights up.

• Unlock the Quick Stop button with a key.

• Check whether there are people in the danger zone of the system.

• Press the Acknowledge button on the local electronics.

• The red signal lamp "System malfunctioning" goes out.

• The green signal lamp "System in normal operation" lights up.

Activating the measurement system

After a system fault by the Quick Stop button, the green signal lamp on the local electronics goes
out. The red signal lamp "System malfunctioning" lights up.
• Unlock the Quick Stop button with a key.
• Check whether there are people in the danger zone of the system.
• Press the Acknowledge button on the local electronics.
• The red signal lamp "System malfunctioning" goes out.
• The green signal lamp "System in normal operation" lights up.
Calibration
The continuous action of ambient influences on the measurement system can falsify the measurement result
after some time. To counteract this, the system needs a reference value. The system gets this reference
value from a calibration normal that can be swiveled in. Here, during the calibration process in the radiator
holder, a calibration normal is mechanically swiveled over the radiation outlet. This recorded measurement
value is used as the reference value.
Operation of the Touch Panel
From the Touch Panel, control commands can be interactively passed directly to the measurement system.
On the various menu pages, it is possible to view information about the current measurement operation as
well as status information about the plant operation.

Measurement value display:

By default, the TouchPanel is pre-set to the following menu.

Manual control:
Control commands can be given interactively to the system from the menu Manual control. To open this
menu, in the main menu, touch the button Manual Control.
Values Table
Apart from the graphical depictions, information on the current production type can be viewed
4.1 Pre-settings
The menu option Pre-settings serves for inputting all the parameters and recipe data that
are required for recording the measurement value.

4.1.1 Calibration

The default values for the calibration are stored in the program option Calibrate. The
Tolerance Calibration Value checks the calibration normal for excessive fouling. If there
are excessive dirt deposits on the calibration normal, the tolerance calibration value is
exceeded. No measurements can be carried out. A manual calibration can be triggered
from this menu.

Description of the positions:

Displays the currently measured calibration value.

Displays the previous calibration value.

Displays the set value of the calibration.

Displays the permissible deviation from the given calibration value.

Specifies after how many traversings a calibration is carried out.

Carries out a manual calibration.

 Saves the new settings of the calibration values.

4.1.2 Calibration Table

In the Calibration Table menu, the recorded calibration values can be viewed, selected
according to a certain date.

Description of the positions:

Input field for which date the calibration values are to be displayed.

Starts the search.

Display window of the selected calibration values. Status 1: The calibration value was
accepted into the system. Status 2: The calibration was faulty and the value was not
accepted into the system.

4.1.3 Offset the offset, a general correction factor can be set for the measurement

value recording. The offset value is set off against the measurement value
 and influences the graphically depicted measurement result. As a pointer to
an activated offset, the offset value appears as a large display in the
graphics.

Note:
An offset value should only be activated if there are compelling reasons to do
so. An activated offset value influences the Weight per unit area values
shown.

Description of the positions:

Shows whether the offset value is calculated positively or negatively with respect to the
measured value.

Inputting the offset value.

Saves the offset value that has been set.

4.1.4 Nominalpresets

In the set value defaults, the recipe (production type) for the next measurement
operation is selected and activated. The recipe parameters are only displayed and cannot
be edited.
 Description of the positions:
Selection of the production type.

[optional]
With the order evaluation activated, the order designation can be selected in addition to the
production type.

Displays the desired weight per unit area from the recipe specifications.

Displays the recipe factor that has been set.

Determination of the tolerance threshold.

The period between the end and start of a traversing.

Example:
With a measurement delay of 10 seconds, the measurement head waits for 10 seconds at
the edge before it crosses the goods being measured in the opposite direction.
Determination of the speed with which the measurement is run.

Activates the selected recipe.

[optional]
Activates the selected recipe.

4.1.5 Recipe
In the Recipes menu, new production types are created or existing ones edited or deleted.
Changes to a production type do not have any influence on the ongoing measurement and
the currently activated production type. A newly generated production type can only be
activated in the Presettings menu.

Description of the positions:

Creation of a new production type:
When creating a new production type, the new name is input here. Then, after a
confirmatory query, the new parameters can be specified.
Changing a production type:
If changes need to be made to pre-set recipe parameters, with the arrow button, the
corresponding production type is selected and after the changes, the Save button is used
to save it.
Deleting a production type:
To delete production types, the corresponding production type is selected with the arrow
key and with the function Delete, deleted from the database.

Specification of the desired Weight per unit area in Kg/m² and the production width.
 Recipe Factor:
All the recorded measurement values reference themselves to a stored absorption curve,
which covers the spectrum from a full incident radiation up to the maximum Weight per unit
area .

Production-dependent influences that vary recipe-specifically must be equalised with a

recipe factor.

When creating a new recipe, a reference Weight per unit area (laboratory section) must be
incorporated as a desired value for the currently measured Weight per unit area to the
BWQ.
The recipe factor must be adjusted in such a way that the measurement value tallies with
the reference value.

Mathematically, the recipe factor is obtained as follows:

surface weight value of BWQ - measured
Recipe faktor K =
reference surface weight value (laboratory section)

Note:
In case of a weight comparison between the current weighed values and the
laboratory values, contemporaneous values must be compared.
Hence, values from the history have to be retrieved and used.

Menu for calculating the recipe factor:

From this menu, by inputting the two Weight per unit area s, the recipe factor is calculated
automatically. Upon confirmation with the button "Accept “, the recipe factor is stored in the
recipe parameters.
Deletes the production type. A confirmatory query is displayed, which must be answered
with "Yes “or "No“.
Resets changes that have been made to a recipe.

Saves the displayed recipe.

4.1.6 Operating mode

In order to be able to control the quality of the scatter accuracy of mechanical scatter or
wind scatter in the ongoing process, one or more zones along the direction of production
can be specially evaluated by using the operating modes stationary or stepping operations.
In stationary operation, measurements are taken at a fixed point (stationary position). In
stepping operation, one zone each is evaluated across several points (up to max. 8 points)
over a given path (step length).
 Description of the positions:
Determining the position of the measurement head during stationary operation. The
dimension provides the distance from the material border on the side of the calibration
position.
Determining at how many positions measurements are to be taken in stepping operation.
With the selection, the corresponding input fields are displayed.

Over which route every step should be measured is determined here.

Determining the positions in which the measurement head carries out the measurements
during stepping operation. The dimension provides the distance from the material border of
the side of the calibration position.
Deletes the production type. A confirmatory query is displayed, which must be answered
with "Yes“ or "No“.

Resets changes that have been made to a recipe.

Saves the displayed recipe.

.
 Description of the positions
The green bar graphically shows the position between the minimum and maximum setting
of the individual dispersion flaps.

Nomenclature of the respective dispersion flap.

Displays the percent values between the minimum and maximum setting of the individual
dispersion flap.
Controls all the dispersion flaps in parallel, depending on whether the selector switch is
open or closed.

Closes the selected dispersion flap upon activating the button.

Opens the selected dispersion flap upon activating the button.

Measurement
The measurement value recording is started from the menu Control. With the X-ray tube switched
on, the measurement is launched with the Start button. The measurement trolley moves into its
calibration position and picks up its reference dimension. Next, the measurement trolley moves into
the materials area for measurement value recording.

Description of the positions:

Displays the status of the measurement process.

Starts the measurement process.

Stops the measurement process.

Operating mode
 Description of the positions:
The operating mode can be selected here. If data regarding the stepping operation is stored
in the recipe, this operating mode can also be selected.

4.1.7 X-ray

The status of the X-ray tubes can be viewed in this menu. The tubes can be switched off with the
function Off.

Description of the positions:

Status display of X-ray tubes is switched on or off.

Button for switching off the X-ray tubes.

History of Evaluation
The button History can be used to view any desired measurement from the database with the
relevant parameters. In the History Selection bar, through the specification of a date and a time, a
table with the measurements that have taken place in that period is loaded. Through a selection with
the left mouse button in the table, each of the measurements can be displayed graphically and
numerically.
 Description of the positions:
Input fields for the starting and ending time of the period from which the measurement
values are to be displayed. The measurement values are selected with the button
"Search“.

All the measurement values recorded in the selected period are displayed in this list.

Alarms
Currently queued alarms are displayed in a dynamic scroll bar below the main menu. The degree
of seriousness of the alarms is marked by a difference in the coloring.

Occurring errors: Red messages

Warnings: Yellow messages
Notes: Blue messages

Additionally, critical errors are shown in flashing text.

Upon clicking the scrollbar, a PopUp window is displayed, which shows additional information on
the current alarms.
 Description of the positions:
Dynamic scrollbar with plain text message of the currently queued alarms.

PopUp window with detailed information on the current alarms. In case of several alarm
messages, it is possible to switch to the other alarms in the window.
Blow Detection System
UPU 6000
2.1 Component description
The following components are generally installed at a measurement system.

Upper cross beam:

The sound recording tubes with the receiver units are located at the top cross beam.
Lower cross beam:
The transmitter units with the transmission stages and the ultrasonic transmitters are lo-
cated at the lower cross beam. Depending on the system configuration, up to four ultra-
sonic transmitters can be supplied by one transmission stage.
Upper measurement channel [receiver]:
The upper measurement channel absorbs the unabsorbed sound waves through a sound
absorbing tube and forwards them on to the evaluation electronics.
Lower measurement channel [transmitter]:
 The lower measurement channel directs a defined sound energy from its ultrasonic
transmitter to the underside of the measurement material.
Control electronics:
The control electronics with their electronic components for controlling the measurement
sensor technology are located at the pedestal. In the computer module, the output signals
of the measurement channels are converted into measurement values.
Control cabinet transmission stages
The transmission stages for controlling the sound energy are located in the control cabi-
net.
Pneumatic system:
The pneumatic maintenance unit controls the supply pressure and filters the supplied air
for cleaning the transmission stages and receivers.
Encoder
The encoder generates pulses from the rotation of the wheel, which are used for length
measurement of the measurement material.
Measurement material detection
The measurement material detection detects incoming measurement material.
Adjustable feet:
The adjustable feet are secured at the base. The entire system structure can be aligned
with adjusting screws according to the production height.
Edge spray marking [optional]:
Blows of Type 2 can be marked directly on the material border with a coloured marking.

2.1 Functional description

GreCon – Ultrasonic measurement systems determine unglued zones, weak points in the material
and hidden blows in board-shaped measurement materials. The measuring principle is based on
irradiation of the measurement materials with ultrasound. The measurement range is covered across
the entire production width with several measurement channels arranged horizontally nextto one
another. Each channel can be viewed independently. Depending on the system configuration, either
only the two outermost channels, or, if process optimization is activated, all the channels, can be
individually switched on or off.

The ultrasonic transmitter transmits sound waves onto the measurement material. The non- reflecting
component of the sound waves penetrates into the measurement material and is ab- sorbed and
evaluated by the ultrasonic receiver. A weakening of the absorbed sound energy is registered as a
setpoint deviation and signalled as a possible weak point in the material.

To protect the sound quality from external interferences like reflections, the useful signal is secured
by protective curtains.
3.1 Calibration / Adjustment
Channels which, in the framework of the calibration, showed a deviation from the reference value
must be set back to the default value by means of an adjustment.

The channels of the UPU should be adjusted (calibrated) at regular intervals to compensate for slight
pollution or dirtying of the sensor system and differences between the individual channels of the
system.

System

Calibrate

A new calibration of the channels is started upon activation of the "Adjustment" button. Upon end-
ing the adjustment, the new values are displayed in a result list and can be accepted or discarded.

The list shows the last completed adjustments sorted according to date. The last adjustment is
displayed in the list as position 1.

The percentage display shows the status of a channel. From a status of 5% upwards, the receiver
of the channel should be replaced. Depending on the status, the color of the field also changes. [25%
= yellow, 5% = red]

The checkmarks display whether the channel shows a deviation from the reference value in the
framework of an adjustment.

Discarded adjustments can be hidden in the display.

After the adjustment, a reference pollution test is automatically carried out to determine a comparison
value for the upcoming pollution tests.
3.2 Pollution test
With process optimization activated, a pollution test can be carried out. When doing so, the individual
measurement channels are checked cyclically for pollution. To that end, the deviation of the
measurement values is considered with respect to the reference value. Polluted measurement
channels and channels with too much of a shortfall of output are switched off automatically if the
shortfall is 30%. A corresponding message is displayed on the screen. A reference pollution test and
pollution test can also be carried out manually.

NOTICE

Depending on the system configuration, a pollution test is automatically carried out

every 200 boards during a gap between boards.

The list shows the last completed pollution tests sorted according to date. The last pollution test is
displayed in the list as position 1.

The color displays the calculated degree of pollution of the channel. Green

= no pollution
Yellow = slight pollution, cleaning is recommended

Red = intense pollution, channel is switched off

Cancelled pollution tests can be hidden in the display.

The test is started manually by touching the "Pollution test" button.

A reference pollution test is carried out manually by touching the "Reference test" button.
3.3 System Start / Stop
The measurement value recording is started and ended from the menu "System Start / Stop".

System

Start / Stop

3.4 Configuration Settings

For carrying out the measurement operation, parameters according to which the measurement
operation is carried out must be specified for the system. The following chapters describe the
programmed items in which the required parameters are specified.

Configuration

Settings

By selecting the various menu tabs, the corresponding dialogue boxes for adapting the default set-
tings data are displayed.

Changes are saved to the customer settings using the "Accept" button. The menu is closed using
the "Cancel" button. Changes in the customer settings are not saved
DMR 6000
2.1 Component description
The following components are generally installed at a measurement system.
Measuring frame:
All the measuring sensors are located in the measuring frame. The disconnection of
measuring frame and support feet prevents a transfer of the external influences to the
measuring sensors.
Upper measuring head:
The upper measuring head comprises a movable measuring shaft and a digital incremen-
tal encoder, which records the position change. A moving infeed guard absorbs forces
from inflowing measurement material.
Lower measuring head:
The lower measuring head is identical to the upper measuring head except for the moving
infeed guard. A deflector protects the measuring shaft against inflowing measurement
material.
Control electronics:
The electronic components for activating the measuring sensors are located in the control
electronics. In the computer module, the output signals of the measuring heads are con-
verted into measured values. The operating elements for controlling the measurement
system are on the front side.
Measurement material detection:

Two sensors detect whether there is measurement material in the sensor technology ar-
ea. The sensor at the upper measuring track detects inflowing measurement material.
The current production speed is determined from the signal of the lower sensor.
Encoder:
The encoder is activated by the transported measurement material and transfers the
pulses to the control electronics.
Pneumatic system:
The pneumatic maintenance unit regulates the supply pressure and filters the infeed air
for distribution to the control valves.
Infeed guard:
A moving infeed guard absorbs forces from inflowing measurement material.
Adjustable feet:
The adjustable feet are secured at the base. The entire system structure can be aligned
with adjusting screws according to the production height.
Control cabinet cooler:
For protection from overheating of the electrical components, the control electronics is
fitted with a control cabinet cooling device if the ambient temperatures are critical.
2.2 Functional description
GreCon thickness gauges determine the thickness of board-shaped or endless measurement
materials directly in the production line.

The thickness of the measurement material is determined by incremental distance

measurement. The position X1 is considered a reference value, which is recorded for closed
measuring rollers without measurement material. If measurement material is guided between
the measuring rollers, the position of the incremental encoder changes. The modified value X2
is forwarded to the controlelectronics for the generation of the measured value.

Horizontal forces acting on the measuring sensors are absorbed by a moving infeed guard. The
inflowing measurement material is fed to the measuring sensors by an inflow ramp.

2.2.1 Set value position

With a set value position the measuring rollers are prepositioned to the recipe-specific target
thick- ness. The travel paths of the measuring rollers are reduced to a minimum. With the
reduced movements the net measuring surface is maximized and board edges are approached
more gently.