FUTEC MAXEYE.P

The high-end defect detection system by FUTEC, called the MaxEye.P, uses five state-of-the-art image processing steps. They include:

• Specialized line-scan camera technology
• Image capture system
• A detection engine
• Defect classification
• Auto-control stabilization

These defect detection processing steps provide the highest quality performance ever from a FUTEC control system. On top of the high quality image process system, the MaxEye.P was designed with various functions based on customer feedback received over the past 25 years. Today the MayxEye.P is one of the most powerful and easiest to use defect detection systems on the market. MaxEye.P has various technologies that support the detector itself as well as achieving powerful, flexible, high-quality control.

Defect Classification
Conventional systems have a problem; when detecting minute flaws with little contrast, they would detect background noise and harmless flaws. Also, parameter choices including only "signal level, "width" and "length", can not provide the sufficient control some customers need. On the other hand, MaxEye.P's real-time defect categorization achieves perfect detection that is not effected by background noise or muddied by harmless defects. MaxEye.P does this by taking such factors as area ratio, aspect ratio, circularity and other specific factors into account. Besides, it accurately determines the cause of such defects as foreign matters, contaminations or insects and achieves quality improvement efficiently.

MaxEye.P: Applicable Lines: Film Lines, Paper Mills, Metal Finishing Lines, Slitter Machines , Coating Lines, Coil lines and others.

MaxEye.P Defect types: Foreign Matters, Pinholes, Streaks, Contaminations, Dimples and Dents, and many other defects.

MaxEye.P Features & Benefits:

• Fastest camera on the market
• 100% web inspection 100% of the time; no operator input needed
• Automatically detects contamination and surface imperfections using high speed cameras
• Flaw video system - records defect images and stores them for later analysis
• Sorts defects into categories and displays a histogram enabling quick analysis and correction of the most common defects
• Networking - All MAXEYE.P systems can be connected via standard LAN (local area networks) to the customer’s PC network. This enables all flaw information to be extracted for analysis away from the process
• Stable sensitivity even at high process speeds
• Store system settings by job number making set-up fast and easy
• Defect is clearly shown on screen with x-y coordinates to allow easy location; multiple defects can be displayed at a single time
• Optional Labeler applies a tag to the web’s edge so the defect can be easily found in the finished roll
• Zoning - can divide inspection width up to 32 zones (lanes)
• Hardcopy - print-out shows distribution defects at a glance.

• Continuous, pro-active inspection - 100% of the web, 100% of the time
• Consistent quality of inspection guaranteed, regardless of operator experience or shift changes
• Increases productivity by optimizing press speed and quality levels
• Provides early warning of impending faults
• Improves company image and competitive advantage
• Identifies random and continuous flaws and can even show that apparently random flaws are repeated
• Displays flaws on screen for rapid identification of nature and source of the fault
• Can be used towards ISO 9000 accreditation
• Reduces contractual penalties
• Maximizes production yield from expensive materials and reduces need for production over-runs
• Minimizes waste of expensive materials, processing costs and embarrassing and expensive customer returns
• Makes short production runs easy and more cost effective
• Can help to maximize utilization of existing machinery
• Frees up operators for other tasks

System Configuration for MaxEye.P:

There are two lighting methods used for detection of defects: Reflection or Transmission. The standard lighting system, diffuse reflection, works with all opaque materials such as papers, carton laminates and foils. The transmission lighting system, placed under the web, works with translucent materials such as films. A combination of both can be used.

• Signal processing unit
• Camera
• Lighting unit with ballast box
• Rotary encoder
• Beacon light with horn
• Cables, PC & Printer
• Color flaw video system

• Labeler
• Light control switch
• Transmission light box
• Separate flaw monitor
• Remote LED

Camera Unit		Monochrome	Monochrome Digital
	Clock Speed	Max 40 MHz	40 MHz
	No. of Pixels	1024, 2048, 2500, 4096	2048, 4096
	No. of Cameras	Max 64
Lighting Unit		Fluorescent, Halogen, Metal Hallide Tubes
Signal Processing Unit (SPU)	Detection Algorithm	Contrast, Width, Length, Area, Circularity, Aspect Ratio, and Area Ratio
	Classification	100 types
	Special Analzyer	Repeating, Cluster, Edge Crack, Defect Cancellation
Operator Console	OS	Windows 2000®
	Monitor	17 inch
	UPS	Included as standard
	Media Storage	DVD-Ram
	Printer	Color Ink Jet
Auxiliary	Rotary Encoder	1,000 ppr, 2,500 ppr, 5,000 ppr
	Warning Unit	Beacon Light with Horn
I/O	Inputs	Lot Change (Change Spools & Coils), Out of Materials
	Outputs	Real-Time Defect x 2, Delayed Defect (for Marker or Labeler) x 2

MaxEye.P Operation
When materials need to be run at a high rate, delivered on time with zero flaws MaxEye.P is the system that keeps you running with confidence. MaxEye.P is designed so everyone can use it as their virtual tool from the first day of installation. Its ergonomic design enhances easy operation and lightens job related stress.

Flexible Inspection Lanes
Operators can divide the web into up to 32 lanes of arbitrary width. Operators can also pin-point the location in cross-web direction. The lane number corresponds to that used in the Flaw Map screen, in which the number of defects is shown. Operators can identify defect distribution in corresponding slit rolls by looking at this screen.

Mask-out a certain lane
Operators can mask-out individual lanes from inspection. If too many defects are detected in a certain lane(s) and the operator has no choice but to discard that lane(s) as scrap, operators can blank-out that particular lane(s) from inspection.

Overlapping Lanes
If defects are located close to the boundary of a lane division, chances are that the defect may traverse the adjacent lanes. By defining a buffer zone near the lane boundary, defects within the set buffer zone may be recorded in both lanes.

Product Code Registration
Up to 2000 product codes can be registered. Each product code identifies a set of sensitivity and other parameters. Operators can rapidly select any product code to suit the next job.

Validate Roll/Batch Number
An external knife-cut signal may be used to increment the roll number. However, if the web footage (meterage) count is less than the set length, the system can disregard the knife-cut signal and keep the current roll/batch number. In this way the system counts only satisfactory rolls in terms of length.

Multiple (External) Outputs
Various combinations of outputs are possible. For example, Alarm(Horn), Beacon Light, Marker, Defect Image & generic defect detection outputs.

Password
Password protection can be assigned to any screen to prohibit access by unauthorized personnel.

Self-Diagnosis
Self-Diagnosis generates internally-made defect signals to check that the system identifies them as expected. This tests various system processes to ensure they are functioning correctly.

Display Camera Signal
By displaying camera signals on the PC monitor, operators can set the right threshold level (sensitivity) visually without using the oscilloscope. This also helps judge whether the cameras are in normal state or not.

System Monitoring for MaxEye.P:

Flaw map The flaw map screen shows the defect distribution over the web in cross-web and down-web direction, so that operators can visually recognize the quality of the product now under production at a glance. This also helps identify the causes of these defects without losing time.

Collective Images Screen (Flaw Map plus) Existing flaw maps only showed defects as "points", which might be only good for evaluating products in a wide range. However, for the area where these defects ('point") are gathered together, it could be insufficient. MaxEye.P has a collective image system to solve this problem. Collective Images Screen attaches the images of any defect-concentrated-point (10 square centimeters), enabling easy evaluation. The defect evaluation of the whole defect-concentrated area can be done visually.

Trend Graph The graph shows defects in bar chart format by lane and/or by the rank and/or by the group of defects. This helps control the quality of slit rolls in terms or quantity or types of defects included.

Multiple Defect Images By displaying 20 defect images simultaneously, all defects of the same group can be checked efficiently. Operators can specify the causes of defects by observing the development or reduction of serious or sequential defects. Furthermore, in order to check and review the production performance efficiently, this system can playback these images.