Web Quality Monitoring

Web Quality Monitoring
SmartView WQM Adds New Value to SmartView Systems.

SmartView Web Quality Monitoring (WQM) is a powerful tool for automatically measuring the web quality and formation characteristics of any nonwoven material. This revolutionary technology uses previously recorded sample images of different web quality levels to determine the quality of the material as it is being produced. Actual quality values in the same terms as the mill uses for quality assessment are reported during on-line inspection in real time.

Web Quality Monitoring Benefits
For the first time you can have a real-time evaluation of nonwoven web formation. This enables operators to make process changes that impact quality before large amounts of off-spec material are produced. In every nonwovens process, there are one or more web quality properties that can vary from time to time. These processes have many variables that affect the web appearance in different ways. Each process variable ultimately affects the price and the cost of the end product. These web properties can be anything from web formation, flock uniformity, or surface texture to brightness, embossing. or print pattern uniformity. The SmartView WQM package allows the operators to know the overall web quality for the entire web in real time. It can even predict the post-processing properties of the product as it is being produced. These revolutionary web quality monitoring capabilities enable web producers to minimize cost and maximize price.

  • Quality values or labels based on product-specific standards
  • Accurate real-time web quality measurement
  • Easy system setup and training using visual tool set
  • Easy data access through simple user interface, OPC or ODBC

SmartView WQM Thinks Like You Do!
When asked about good quality web formation, most operators say, “I know it when I see it”. Until now, web-formation analysis has been a difficult property to evaluate consistently. Traditionally formula-based calculations and statistical measurements have been used to calculate a representative value that may or may not correlate with what is obvious to the eye.

SmartView WQM looks at the surface in much the same way humans do. It looks at an area of the web and compares that area to what the web is supposed to look like or what it has looked like in the past. It then determines the quality of the currently produced material. SmartView sees it, knows what it sees, and reports it in terms you can understand and use.

SmartView WQM Speaks Your Language.

The SmartView user interface has always been available in a number of languages around the world. It has always provided information in terms that can be understood and used by operators and process-control professionals.

SmartView Web Quality Monitoring continues this advantage by providing web quality and formation results that are immediate and reported in terms that are currently used to describe the web quality on your line. For instance, if the material is characterized by the web formation and you label them Poor, Usable, Good, Better, and Outstanding that is what SmartView WQM will report instantly as you are producing the material. Or if the same property is measured using any numerical scale (for example from 1 to 10), that’s the scale SmartView WQM will report. However you refer to the quality of your material, SmartView WQM can be trained to report the results in these same terms. And all this information is available in real time as the material is being produced - not after a roll, shift, or day's-worth of material has been produced.

Automated Image-Recognition Technology

Even though the use of SmartView WQM looks, and actually is, very simple, hat is going on behind the scenes is far from simple. SmartView WQM automatically analyzes and groups the sample images of the material. It uses advanced image-processing technology to automatically sort images into groups where like images are in the same group and unlike images are separated into different groups. This way the system learns and memorizes what the material of different quality looks like. These groups are then simply assigned labels or numeric values according to mill quality standards. This way the system learns what the user, not a theoretical formula, calls different quality levels. Through these two learning steps the system knows what an image of Poor, Usable, Good, Better, and Excellent or quality 1 – 10 material looks like. All this knowledge is stored into the real-time engine that analyzes the material on-line. The on-line system will then use the same advanced image-processing technology to recognize the images its sees. Thus it can automatically report Good (material) when it sees Good material or report quality value of 5 when it sees material having a quality value of 5.

Evaluate Almost Any Web Property

SmartView WQM can evaluate almost any visual web property using overall image analysis. Formation, surface texture, brightness, embossing, pigmentation, or even pattern uniformity are easily evaluated and reported in real time. This enables the operator to make process changes that impact quality before large amounts of off-spec material are made.

If you can see it, SmartView WQM can objectively evaluate it!

Upgrading Existing SmartView Systems With WQM Is Easy.

Existing SmartView systems can easily be upgraded to include WQM capability.

In most cases, all that is required is additional software, which can be installed and set up in less than a day. The system can then be trained as it first sees material with various web qualities.