Overview

Basic Specification (typical)

Thickness range	6-35mm (0.2-1.4”)
Width range	500-1300 mm (20-60”)
Types of defects detected	All known defects like scratches, periodic defects, orange peel, grooves, depressions, finger cookling, paper tension, paper splices, colour spots

Operating Principle

A powerful LED light source, installed beside the conveyor, illuminates the gypsum boards.Two high speed grayscale cameras pick up the light intensity/contrast changes from the light reflected from board surface. “Peaks” and “valleys” on the surface will give different light reflections. Advanced image processing techniques evaluate and classify the defects and all images are readily displayed on the system computer.

Functions

Protected installation

The system is designed to give trouble free operation in the harsh environment below the wet belt. Powerful blower system is supplied that constantly provides the camera enclosures with pressurized filtered air. The air exits from the camera apertures preventing the cameras from contamination from falling dust. Additional protection is provided by means of a mechanical shutter that will automatically close to prevent falling debris contaminating the cameras during production start up and stops. The system computer is safely installed in a full size floor mounted PC cabinet.

Software

Real time view of scanned images, including the last ten, either all images or only the ones exceeding a selectable defect level. Statistical graphs display showing percentage for each quality level. Trend graphs show defects levels, periodic and long defects distribution over time. Recipe handling with up to 8 quality levels, each displayed with an unique color for easy board quality update to operators. Each image also gives corresponding digital quality output signals. Images are stored in compressed format in the system database. The database can later be searched for images with criterias such as date/time/defect levels/number of defects/comments etc. Network TCP/IP is provided to factory line and remote diagnostics.

Periodic and long defects

Periodic defects, caused by dirt on conveyor rollers, and also scratches, which can be very thin, have in common that the defect area of the boards is very small, but continuing over longer periods of time they are totally unaccceptable. Special mathematical evaluation is used to find these periodic defects, which wouldn’t otherwise be found. These defects are also given extra evaluation in the software users interface.

Paper roll quality evaluation

The complete data for each paper roll is evaluated and stored as a paper quality index in the system database. This information can be very useful in contacts with the paper supplier.

Auto calibration

The system will automatically adapt to changing ambient light conditions and variations in the paper color nuances. However basic calibrations for product changes with different paper colors should be made. These are easily done.

Benefits

In-line quality control

Installed under the roller conveyors before the knife the system will give an early warning when there are defects. With the boards turned face down there can be no manual surface inspection. Not finding the defects until the final board inspection after the dryer will result in a loss of production for about an hour. If the end customer gets defect boards the costs will be even higher.

High resolution, high-speed imaging

The defects can be smaller than an operator can see, down to the fiber structure of the paper.

Ease of use

The system is uncomplicated to use, with easy to understand user interface and system setup. No complicated computer commands like in older vision systems. Stored board images can be “re-run” for fine-tuning of quality levels.

Well-proven design

LIMAB has supplied the FalconEye system for 10 years to many of the market-leading wallboard producers worldwide.

Complete package

With the complete system assembled at LIMAB, we provide a complete turn-key solution, where we as the only contractor take full responsibility. The FalconEye includes all the hardware and software needed for any factory installation. LIMAB provides commissioning, training, and on-going product support and service worldwide.

Specifications

Board width (maximum)	1.500 mm (60″)
Board length	Unlimited
Production line type	Continuous or cut boards
Line speed (maximum)	275 m/min (900 ft/min)
Board thickness	No limit
Defect size sensitivity	1 x 1 mm at 60 m/min (0.003 x 0.003” at 200 feet/min)
	1 x 3 mm at 180 m/min (0.003 x 0.1” at 590 feet/min)
Power supply	230 VAC/115 VAC, 50/60 Hz
Ambient temperature	0-40° C (32-104°F)
Cameras	Dual high speed line scan cameras 2000 Hz
Protection Class	IP64 (NEMA 4X)
Lighting	LED 600 lumen
Blower capacity	690 m3/hour (0.55 kW)