SUPERSCAN for continuous and consistent quality control and product grading
Due to ever increasing production speeds and new press technologies, the demands on inspections of the panel surface are also increasing. More and more is expected of people as “control instruments”.
Inspectors can be easily distracted from their task for brief moments. In this case, panels can reach downstream production processes and the customer without being inspected. This situation can lead to unsatisfied customers and product return claims.
The old manual method required a sharp Mark 1 Eyeball.
Manual inspection is replaced by the SUPERSCAN system. This ensures a continuous and constant quality control; the parameters used to make a decision remain constant.
Depending on the end product, different measures that are necessary for the further processing of the panels can be taken.
SUPERSCAN objective surface inspection of panels. The objective surface inspection of decor master panels and sorts out defective panel segments after the saw.
SUPERSCAN inspects the surface pattern of each panel Inline to ensure consistent sorting. Detailed conclusions for upstream production process adjustments are possible through fault and statistics reports. Thus, not only the sorting but also the entire production process can be optimized.
GreCon SUPERSCAN is self-learning. Thus, the learning of new decors by the operation staff is possible within a minute. Two successive panels are scanned during the production process and their data compared. If the deviations between the panel scans are smaller than the preset tolerance limits, the data is used as a master. All the following panels will be compared with this master.
SUPERSCAN’s panel marking system marks the defective areas by spraying fluorescent ink on the press size panel. After cutting, only the marked individual planks that are recognized as defective are sorted out. It is also possible to classify the panels according to the type, position and number of defects. Then the system transfers the information to the production PLC, which will carry out panel sorting.
SUPPERSCAN inspecting panel surface and sorting out defects.
SUPERSCAN SPM & SPL — inspect furniture panels & laminate flooring
All panels will be compared with the master. New patterns like coated sheets, wood pattern, and tile structure can be learned within a very short time. As an option to the SUPERSCAN system, GreCon offers a panel marking system, which marks the defective areas by spraying fluorescent ink on the press size panel. After cutting, only the marked individual planks that are recognized as defective are sorted out. The inspection results are transferred to the PLC of the production machine, which will carry out the sorting of the panels into the correct stack.
Decorative Surface Quality Control System — SUPERSCAN
Furniture panels and laminate flooring.
SUPERSCAN SPR — for two-sided inspection of raw panels
The automatic image processing system guarantees 100 % inspection and allows for consistent sorting by detection of surface faults and defects of raw panels. The SUPERSCAN SPR system inspects the surface of each panel in the production line to ensure consistent sorting. Detailed conclusions for upstream production process adjustments are possible through fault and statistics reports. Each panel is inspected by a camera system on the top and bottom surfaces. Defective areas are detected where the surface differs from the normal (faultless) surface. Any detected area is classified in types of faults and defects. The parameterization of quality allocation and sorting rules is adjustable. The data of surface faults or defects of each panel is shown on the monitor. The inspection results are transferred to the PLC of the production machine, which will carry out the sorting of the panels.
Raw Panel Surface Quality Control System — SUPERSCAN
Raw panel inspection after the sander.
FIBERVIEW — for one-sided inspection of fiber sizes
Inspects the fiber quality and identifies the number and size of shives, thus ensuring a continuous, consistent spread fibers in MDF panel production. Monitoring of tolerance limits, reports and statistics allow for detailed conclusions of the upstream production process. The fiber mat is inspected by a camera system after the pre-press across a width of about 400 mm. The shives are automatically detected and classified by three image processing steps. The energy consumption of the refiner can be optimized depending on the required fiber quality. For example, the process can be directly influenced by changing the distance of the refiner discs, thus reducing energy needed to produce optimal sized shives. The goal is to analyze the surface of the product for the occurrence of shives (big fibers). Use of refiner energy can be optimized and also reduce the number of rejects.
Inline Fiber Quality Control — FIBERVIEW
Inspection of fiber sizes.
Surface Inspection Principle
Through the use of completely new technology in image processing systems, it is very easy to monitor many different patterns with the GreCon Surface Inspection System Super scan. The system exploits the fact that pressure cylinders print the patterns and the pattern is repeated according to the cylinder’s circumference.
The strength of the system is based on its ability to differentiate between minor graduations of shades in the pattern, such as knots, and actual defects that do not belong to the pattern.
Patches, insects, dirt, paper displacement, paper folds, overlay faults, thermal reams
Dents, press plate faults, overlay faults, panel abrasion, synchronized grain check
Surface inspection system SPL 5000 Modules
Surface Inspection Applications
Can you find the defects in these panels? Click to enlarge.
Wood Based Panel Industry:
the SUPERSCAN is used in furniture and flooring productions after the coating presses (short-cycle or continuous) and inspection of goods received for further processing.
Decorative surface panels (one or two sides)
Lacquered panels (single-color or pattern)
Furniture panels (single-color or pattern)
MDF sanded / un-sanded
Other: PVC, print, lamination, etc.