Camera Systems: ECS/Carotek event capturing systems
 
Technology proven to help reduce breaks & improve uptime!
Paper Trade Associates (PTA) represent ECS/Carotek Camera Systems       August, 2009
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Carotek ECS Software
Upgrading from Analog to Digital The Critical Details
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Greetings!

Paper Trade Associates have been working with Event Capturing Systems for over 10 years. We are proud to be offering the finest most cost effective state of the art system available today from ECS/Carotek! Whether you are new to this technology or looking to upgade your existing system you need to take a look at ECS/Carotek! 

In the paper industry, machine uptime is paramount for you to stay competitive in today's worldwide market. ECS's "Uptime by Design" Event Capturing System has successfully reduced breaks in paper mills for over 10 years. Our success is due to our ability to monitor, diagnose and prevent breaks using our real-time analysis and video capturing tools. This has resulted in significant cost reductions for hundreds of papermakers.

ECS Software
database 
 
Software

ECS's Event Capturing Software is written by in-house Software Engineers. ECS's user-friendly software is developed with add-on modules that allow us the flexibility to satisfy individual customer needs.

Record/Review

Windows XP Based application
� Real-Time monitoring of all camera positions
� Simultaneous 9-Camera Review with Individual Playback controls
� Image Processing Histogram Display (per camera)
� Automatic Synchronization with Auto Defect pinpointing
� Hands-Free Event Reviewing
� Time-Based Event Triggers
� Defect Highlighting
� Video Enhancement Controls
� Break Database Provides User Interface for Classification, Historic and Graphical Analysis, and Charting of Events

Defect Detection

Individual and Multiple Camera Mapping
� Defect Logging per Camera
� Cameras configured independently for Region of Interest and Calibration
� External Triggering capabilities
� Defect Classification

Upgrading from Analog to Digital The Critical Details
Benefits of going to digital based system

Digital Architecture

  • Powerful 1 Camera to 1 Computer Architecture for Highest Processing Capability and Reliability
  • All Capture Processors are configured to input Analog or Digital Cameras
  •  System can mix legacy Analog and the latest High Speed Digital Cameras
  • Access ECS from Anywhere in the Mill using ECS RA™ Server
  • OPC Connectivity for monitoring process data points
  • No expensive Proprietary Hardware required

Digital Image Processing/Event Historian

  • 100% Real-Time Image Analysis Performed on Every Frame
  • Dedicated Hole and Tear Detection Modules
  • Trim Squirt, Draw Angle, Formation, and Edge Analysis
  • Web Inspection Module Classifies and Displays Defects for Statistical Analysis
  • Break Database Provides User Interface for Classification, Historic and Graphical Analysis, and Charting of Events


Key Questions Carotek cabinet

  • Can I reuse my existing paper machine hardware?
  • What is a typical upgrade path?
  • What are the costs associated with upgrading?
  • Key Words and Features

    • Analog cameras with signal sent via coaxial cable
    • Digital Ethernet backbone with GigE cameras
    • ECS-Duo
    • TM Technology
    • Frame grabbers and other specialized processing hardware
    • Total Cost of Ownership
    • Console/Capture computer architecture vs. Server Farm
    • Single Point of Failure
    • Maintenance, upgrade
    • Summary

      Cameras installed along the paper machine to record web breaks for later review to help determine break cause have been used since the mid 90's and are now commonplace in every grade of paper manufacture. As these systems are computer based the mill has to evaluate when the technology should be replaced by newer and more advanced components. This paper reviews the concepts of upgrading an analog system in three major categories (1) interface cabinet, (2) paper machine components, (3) signal backbone.

      Analog Based Systems

      The majority of camera systems installed today use analog cameras with coaxial cable transmission to a central location (computer room) where the signal is digitized and buffered on a hard drive or RAM. This analog standard (NTSC - National Television System Committee - http://en.wikipedia.org/wiki/NTSC) was developed in the 1950's and the low cost and high availability of components have made this the choice for camera based security and monitoring systems. As compared to newer technologies these systems have the following limitations:

      � Resolution

        • At 60 images per second NTSC cameras are limited to 240 lines of resolution (by 640 lines wide). This is considered half VGA resolution.

          � Requires specialized hardware - limited to no repair and upgrade path

        • The camera information must be digitized by frame grabber hardware before buffering. Repairing or upgrading specialized hardware in dated computers is either not possible or cost prohibitive.

          � Single Point of Failure - Capture and Console Architecture

        • Most analog based systems have computers that digitize the information (capture computers) and one computer per system that runs the user interface and other global system features (console computer). If this console computer fails - the entire system goes down.

          � Multiple cameras per computer

        • Losing one capture computer removes one to four cameras in the system.

          � Signal loss on coax cable

        • The analog camera signal degrades over distance and will pick-up EMI (electromagnetic interference) from the paper mill environment. Coaxial cable shielding also supports unwanted ground looping from camera location to interface cabinet. Line filters can be used but causes resolution loss due to increased signal attenuation.

          � Frame rate

        • Most analog based systems are limited to 60 pictures per second. 120 frames per second is also available but the resulting video quality from these analog cameras can be poor.

       

      � Total Cost of Ownership

        • Over system life the downtime of analog systems generally increases (more parts fail) and the repair/diagnostic becomes more time consuming and expensive. Camera system downtime may result in further production losses on the paper machine.

          � Multiple spare parts required

        • In many cases utilizing different cameras (higher frame rate, color vs. black and white) requires a different frame grabber. If different cameras are used, the mill must allocate spare parts for different capture units and also for the console computer.

          � Limitation of software features

        • Camera systems used in break analysis today are no longer limited to the reactive approach of simply viewing break video 'after the fact'. Newer systems that process higher resolution images with more powerful processors can provide not only better break images but also several advanced features outlined below.

      Digital Based Systems

      Recently a new camera transmission standard has emerged that does not have many of the limitations of NTSC (analog) and other digital standards (Camera Link, Firewire) - it's called GigE. (http://en.wikipedia.org/wiki/Gigabit_Ethernet and http://www.machinevisiononline.org/public/articles/index.cfm?cat=167). The technology sends the camera information as an Ethernet digital signal from camera to processing computers. In this case the camera is GigE compliant with an RJ45 port. Coaxial cable is replaced by UTP (unshielded twisted pair - see www.belden.com or http://en.wikipedia.org/wiki/Twisted_Pair) or fiber optic. Systems that use this architecture have the following advantages:

    • Higher resolution

    • Camera enclosure cleanliness, shutter speed, depth of field, contrast and light quality are all important concepts for any system (analog or digital). However, there is no limitation of the resolution (lines and width of video signal) that the GigE camera can provide. Currently standard GigE camera used in pulp and paper output VGA resolution (twice that of analog) to XVGA (5 times greater camera resolution than analog). Mega pixel cameras (including HDTV) are available but the current frame rate (as low as 10 pictures per second), sensitivity and cost remove them as alternatives. These will be viable alternatives in the future.

    • No specialized hardware

    • The camera information is presented as a digital signal. No frame grabbers are required. As a result - the computers contain to specialized hardware. The computer components are limited to standard readily available parts - motherboard, processor, hard drive, chassis, power supply and fan. All of the processing of the camera signal is done via software. Upgrading to the next camera platform (higher resolution) only requires the retrofit of standard computer hardware - motherboard and processor.

    • No single point of failure

    • The system is designed as a 'server farm'. There is no console and no capture design. In the digital architecture - all computers are the same. Each computer is its own independent unit and can run a standalone (capture and review) version of the software. If one unit should fail any other unit can take the processing load of the failed computer.

    • One spare part

    • Since all of the computers are the same - only one spare computer is needed for the entire system.

    • One computer per camera

    • Each camera is connected to one computer. Computer downtime only affects the camera it is connected to.

    • Cost effective upgrade path

        • From above 'The computer components are limited to standard readily available parts - motherboard, processor, hard drive, chassis, power supply and fan. All of the processing of the camera signal is done via software. Upgrading to the next camera platform (higher resolution) only requires the retrofit of standard computer hardware - motherboard and processor.'

          � Lossless camera signal transmission

        • The Ethernet signal is lossless between points. Many cable manufactures (Belden - www.belden.com) manufacture special CAT 6 and other UTP cabling that is designed for noisy industrial environments.

          � Pre-molded cables

        • The cable ends exposed on the camera enclosure (power and signal) all use pre-molded cables sets to a junction box. Conduit is used from the junction box to the interface cabinet. No field terminations are used at exposed points - this protects the digital backbone and ensures reliability over time.

      Extended warrantee on hard drives

        • A ghosting procedure allows for easy replacement of hard drives with hard drive warrantees at five (5) years.
        • Low cost of repair
        • No specialized hardware - repairs and parts are not required to match key hardware components. Any Windows compatible hardware can be used for repair or upgrade.
        • Wireless technology can be used for any camera
        • System uses ECS-Duo
    • TM Technology. Computer has both analog (BNC) and GigE inputs

      � Advanced Software features - a general overview includes:

        • Hands free viewing - system opens all cameras to synchronized break point
        • Extended video buffer - 24 hours
        • Improved operator interface with intuitive controls - see ECSTM white paper 'Ease of Use - The Critical Details'
        • Terminal Services -the system can be controlled by any computer on the mill network
        • Interface with PI and other OPC compliant servers. The system can have an OPC server on specific playback computers for unlimited conductivity to other mill systems
        • Advanced grayscale and image processing
        • Multiple beam web inspection with classification and roll map
        • Seamless integration to existing web inspection systems
        • 100% image processing on all images (every frame) include edge defect detection with VGA or higher native signal resolution
        • Integration of event capture to web inspection in single window interface (storyboard display)
        • SQL Library Database
        • Excel export from Library with customized Macros - http://office.microsoft.com/en-us/excel/CH101001571033.aspx (unlimited auto-reporting schemes)
        • Upgrade Path

          An upgrade has three main components:

          1. Cabinet upgrade

          The cabinet can be upgraded with the ECS-Duo

          TM Technology. All of the existing paper machine components can be used (including cameras and lights) with the coaxial cable backbone. Since the computers have both GigE ports and analog ports - upgrading to GigE cameras (with UTP or fiber backbone) requires no change to the computer interface cabinet. Existing analog live view monitors can be reused or new digital flat screen monitors can be used. Typically the existing cabinet is replaced with a new cabinet. Any required parts from the existing cabinet are built into the new cabinet onsite. Properly planned, the cabinet exchange should not exceed one day.

          2. Backbone upgrade

          In many cases the coax can be pulled out of the conduit and UTP (or fiber) can be re-pulled in the same path. UTP lengths over 330 feet require a repeater to extend the signal to 60 feet. Longer distances require fiber optic. See white paper on ECS

          TM backbone options and case studies. This new backbone is required to use GigE compliant cameras. Not all cameras need to be upgraded - any existing position can remain analog. The ECS-DuoTM Technology can read and process either signal.

          3. Paper machine hardware

          Analog cameras can be replaced with GigE compliant cameras. In many cases the same camera enclosure can be reused with minor changes. High frequency focusable lights should be used as well as NEW TECHNOLOGY LED Lighting.
          . See data sheet on ECS

          TM paper machine hardware.

          Costs

          If the existing air, power and cable support infrastructure (trays and conduit) can be reused - the cost to upgrade can be minimized. In addition - the cost for GigE cameras is now near equal to the analog format. Entirely new digital GigE systems will have a minor price point (5 to 10%) above a new analog based system.

Paper Trade Associates (PTA) are manufacturers representatives who have many years experience servicing the Pulp and Paper Industry.  If you would like more information or a product presentation on the above ECS line of products just call your PTA Sales/Service Representative.
 
Sincerely,
 
Tom Morganstern cell 207-232-0685  [email protected]
 
Chris Kellner  cell 413-478-0560                                   [email protected]

Dick Ahn cell  484-431-1318                                       [email protected]
 
PTA office phone 800-290-9944