Voith Quality Control System (QCS) OnQuality
Voith’s Quality Control System (QCS) OnQuality is a smart and integrated concept to enable producers to gain control over production processes and product quality. It offers the opportunity to stabilize and optimize the product quality and the production process while increasing productivity and decreasing operation and maintenance costs.
Thanks to the Voith QCS system, we can better monitor our manufacturing process and intervene in time if necessary. This allows us to optimize our product quality and increase efficiency.
Due to the very compact and flexible design, only Voith was able to fulfill a challenging installation position with a necessary 90° pivoting of the scanner. Now we can determine exact measured values even in this difficult location.
We decided to replace our existing QCS with Voith OnQuality because of the short rebuild and commissioning time of only 12 hours, as well as the seamless and individual integration into our existing process control system.
In addition, curl can be reduced and the runnability of the machine and the grade change process improved. The cost savings achieved with this range up to several million euros per year for a modern packaging paper machine.
Our QCS solutions meet highest technology standards. We are happy to support Paraibuna in operating their new machine as efficient as possible and with optimum production quality.
The solutions that Voith presented matched perfectly to our requirements in the field of QCS, we are confident that with the new system installed we are future proof.
We are happy to partner with UPM to improve the mill’s overall efficiency and to renew our close and longstanding collaboration.
OnQuality 4.0
OnQuality 4.0 is the next level of quality control systems for papermakers on the path to digitization. The system consists of all the important elements required for a future-proof and effortless quality handling of the paper production:
- Secure cloud solution with various analysis tools, reports and dashboards
- Virtual sensors for online measurement of parameters that can otherwise only be measured in the laboratory
- Location- and time-independent technology consulting to optimize quality controls and grade change processes.
The OnQuality 4.0 system can be upgraded modularly for all Voith OnQuality systems already installed within short time.
OnQuality.Scanners
The robust measuring frames are designed in such a way that they can be integrated into all paper machines even when space is limited and ambient temperature is high. The OnQuality.Scanners are integrated either as an integral part of the OnQuality quality control system or as a stand-alone system with direct OPC connection to other process control systems. The reliability of this innovative measuring technology has proven itself in new world-class paper machines as well as in the replacement of older quality control systems.
Product range
- Standard O-frame for most applications
- Flexible width up 11.855 mm (38’ 11‘‘)
- Single side frame for narrow installation
- Flexible width up to 9.705 mm (31‘ 10‘‘)
- Highest reliability in the industry
- Flexible application for all size paper machines
- SEB mounted directly to frame to reduce wiring (option)
- Garage function to keep sensors clean (option)
OnQuality.Sensors
OnQuality.Sensors are compact, robust and include state-of-the-art technology. They incorporate a smart sensor and comprehensive diagnostic functions and ensure easy access for maintenance and system extension. Interfaces are easy to use. All sensors include the new processor board with powerful signal processing capacity and standardized communications. Measuring plates and heads are largely standardized components and thus guarantee a plug-and-play configuration of the sensors.
Product range
- OnQ Ash Sensor Fe 55
Contactless measurement of mineral content in a paper web using gamma ray absorption. - OnQ Ash Sensor Fe 55 XRF
Contactless measurement of mineral content in a paper web using gamma ray absorption and additional XRF. - OnQ Basis Weight Sensor Krypton 85
Contactless measurement of basis weight, designed for basis weight range up to 1200 g/m². - OnQ Caliper Sensor Dual Air Bearing
Contactless measurement for accurate measurement of paper thickness, based on the measurement of the magnetic resistance between the measuring plates. - OnQ Optical Caliper Sensor
Non-marking online measurement of paper thickness based on optical and magnetic measurements. - OnQ Caliper Sensor Light Touch
Contacting sensor for accurate, on line measurement of paper thickness based on magnetic reluctance through the sheet. - OnQ Coat Weight Sensor IR Reflection
Contactless measurement of coat weight by the absorption of the reflected infrared light of a defined wavelength spectrum. - OnQ Color Sensor 45°c:0°
First industrial, full spectral, online sensor which measures color, whiteness, brightness and opacity. - OnQ Fiber Orientation Sensor
Measures the surface fiber orientation profile, using high-resolution macro photography and digital image processing. - OnQ Gloss Sensor 75°
Contactless measurement of gloss for machine-finished and calendered board and paper, according to the ISO 8254-1 Tappi 480 method. - OnQ Moisture Sensor IR Reflection
Measures moisture content single sided and contactless, based on the proven "same spot" technology. - OnQ Moisture Sensor IR Transmission
Contactless measurement of moisture content by the absorption of infrared light at four wavelengths. - OnQ Moisture Sensor Microwave DS20
Measures moisture content via microwave technology. - OnQ Tissue Sensor TecoSens
Measures moisture and fibre weight of tissue paper grades without the need for radiometric sensors.
To overcome the boundaries of physical sensoric Voith offers several virtual sensor applications.
SpecialSensors
OnQ FormingSens
OnQ FormingSens measures the water weight in the former using high-frequency, ultra-precise microwave technology, without sources of radioactivity. Since the process influences in the former are constantly changing, the water weight should be continuously determined. Voith Paper has developed the OnQuality.FormingSens sensor, which measures the water weight in real time and defines an optimal water weight on a sustained basis for lasting process improvement.
With multi-ply wire sections, couching is optimized by unambiguously defining the water weight for the individual plies. Radioactive sources, which are used in most handheld measurement devices, are also omitted thanks to the harmless microwave sensor system.
OnQ FormingSens can be used with almost all former types and grammages. The installation positions within the former can be arbitrarily chosen as long as the expected water weight is within the measurement limits.
OnQ.FormingSens forms the for the advanced process control OnEfficiency.Dewatering.
With multi-ply wire sections, couching is optimized by unambiguously defining the water weight for the individual plies. Radioactive sources, which are used in most handheld measurement devices, are also omitted thanks to the harmless microwave sensor system.
OnQ FormingSens can be used with almost all former types and grammages. The installation positions within the former can be arbitrarily chosen as long as the expected water weight is within the measurement limits.
OnQ.FormingSens forms the for the advanced process control OnEfficiency.Dewatering.
OnV FeltView
OnV FeltView is a system for continuous online measurement of felt moisture and permeability for the clothing in the press, enabling optimized felt conditioning.
The measuring head is equipped with two sensors. A moisture sensor based on microwave technology determines the felt moisture on the basis of the change in the dielectric constant. This change is brought about by the quantity of water present in the felt. A permeability sensor measures the pressure difference between a water jet penetrating the felt and a reference pressure, thereby determining the permeability. The machine speed has no influence on the measurement process. With OnV FeltView, felt conditioning is optimized, energy is saved, and felt wear is reduced.
OnV FeltView is used in the press section, and it was recently optimized for the special requirements of hygienic paper production.
The measuring head is equipped with two sensors. A moisture sensor based on microwave technology determines the felt moisture on the basis of the change in the dielectric constant. This change is brought about by the quantity of water present in the felt. A permeability sensor measures the pressure difference between a water jet penetrating the felt and a reference pressure, thereby determining the permeability. The machine speed has no influence on the measurement process. With OnV FeltView, felt conditioning is optimized, energy is saved, and felt wear is reduced.
OnV FeltView is used in the press section, and it was recently optimized for the special requirements of hygienic paper production.
OnC WebDetect nx / LA
OnC WebDetect is a novel web break detector that detects web breaks by means of reflected visible and infrared light, thereby preventing unnecessary downtimes due to faulty activations.
The measuring principle is based on a spectroscopic procedure that takes into consideration the special optical characteristics of the paper web as well as the dryer fabric or dryer cylinder. This results in no impairments in break detection, either in changing paper characteristics (moisture and basis weight fluctuations) or due to the aging and discoloring of clothing. The measurements are processed with OnC WebDetect in a microchip, which compensates for outside light influences. The measurement signal is filtered, and trigger thresholds are precisely calculated and continuously adjusted.
OnC WebDetect is used in pre-dryer and after-dryer sections on fabrics, dryer cylinder or in open draw, as well as with coaters and speedsizers in the dryer section.
The measuring principle is based on a spectroscopic procedure that takes into consideration the special optical characteristics of the paper web as well as the dryer fabric or dryer cylinder. This results in no impairments in break detection, either in changing paper characteristics (moisture and basis weight fluctuations) or due to the aging and discoloring of clothing. The measurements are processed with OnC WebDetect in a microchip, which compensates for outside light influences. The measurement signal is filtered, and trigger thresholds are precisely calculated and continuously adjusted.
OnC WebDetect is used in pre-dryer and after-dryer sections on fabrics, dryer cylinder or in open draw, as well as with coaters and speedsizers in the dryer section.
OnQuality.Actuators
In paper manufacturing, the quality of the paper produced is highly dependent on the cross directional (CD) profile of the product. As in many other producing industries, the more uniform the product the better. To obtain uniform CD profiling, and thus achieve good profile accuracy, Voith developed the actuators of the OnQuality product family. They are impressively accurate, even under the most challenging conditions, and also feature highly precise positioning.
OnQ ModuleSteam
The OnQ ModuleSteam controls the moisture cross profile in the press. It brings about high dry content, good moisture cross profiles and improved threading in the dryer section.
High runability and clear production increases are the outstanding advantages of the OnQ ModuleSteam steam box. With especially easy maintenance, it offers an extraordinary potential to increase dry content and profiling due to its vaporization zones. By vaporizing the paper web and lowering the water’s effective viscosity in the stock, the OnQ ModuleSteam steam box increases the effectiveness of the press nip.
High runability and clear production increases are the outstanding advantages of the OnQ ModuleSteam steam box. With especially easy maintenance, it offers an extraordinary potential to increase dry content and profiling due to its vaporization zones. By vaporizing the paper web and lowering the water’s effective viscosity in the stock, the OnQ ModuleSteam steam box increases the effectiveness of the press nip.
Due to its small space requirement, it can be easily retrofitted into an existing press section. The design principle of the OnQ ModuleSteam steam box allows the smallest widths of the profiling zones.
OnQ ModulePro
With its innovative nozzle and valve technology, the OnQ ModulePro nozzle moisturizer delivers an optimal moisture cross profile over the entire paper web, ensuring smooth processing to the reel.
OnQ ModulePro with Profilmatic MP moisture cross profile control delivers optimal moisture results, even for simultaneous treatment of moisture cross profile, total moisture and curling. An optimal spray angle and ultra-fine drops of water produced by a finely atomizing dual-substance nozzle provide for uniform water absorption over the entire web. Higher quality paper at the reel or before the calender or coating unit improves winding at the reel, reduces breaks and allows a lower dry content at the reel or higher web speeds.
Depending on the installation location, OnQ ModulePro is used for moisture cross profiling, curl reduction or remoistening.
OnQ ModulePro with Profilmatic MP moisture cross profile control delivers optimal moisture results, even for simultaneous treatment of moisture cross profile, total moisture and curling. An optimal spray angle and ultra-fine drops of water produced by a finely atomizing dual-substance nozzle provide for uniform water absorption over the entire web. Higher quality paper at the reel or before the calender or coating unit improves winding at the reel, reduces breaks and allows a lower dry content at the reel or higher web speeds.
Depending on the installation location, OnQ ModulePro is used for moisture cross profiling, curl reduction or remoistening.
V30 upgrade nozzles
Poor moisture profile and unwanted marks in the paper are often the results of defective nozzle moisturizers. Since the replacement of the complete system is associated with high investment costs, this occurs only rarely. To counteract this problem Voith developed the V30 upgrade nozzles: Here you just have to replace the air-atomizing nozzles instead of completely replacing the nozzle moisturizer. This will give you a much finer spray pattern over a larger volume range compared to competitors’ nozzles, as well as a better paper quality due to a finer mark-free spray application.
Nozzle replacement is easily done by screwing out the old mouthpiece of the nozzle and screwing in the new V30 upgrade nozzle from Voith. Both the spray beam itself and the control remain untouched. Replacement of the nozzle requires a detailed technical check in advance.
Nozzle replacement is easily done by screwing out the old mouthpiece of the nozzle and screwing in the new V30 upgrade nozzle from Voith. Both the spray beam itself and the control remain untouched. Replacement of the nozzle requires a detailed technical check in advance.
OnQ ModuleJet
The OnQ ModuleJet is an automatic control system that consistently ensures the highest quality of the basis weight cross profile in headboxes with dilution water technology.
Control of the basis weight cross profile with OnQ ModuleJet is done by adjustment of the dilution water valves that are arranged over the machine width through the actuator system. The inflow of dilution water is exactly dosed by means of precise linear movement. In combination with the Profilmatic control software, the OnQ ModuleJet actuator system guarantees uniform basis weight cross profiles and provides for short engagement times after malfunctions. The optimal valve position is calculated by Profilmatic with the aid of various algorithms and adjusted by the actuator system.
Control of the basis weight cross profile with OnQ ModuleJet is done by adjustment of the dilution water valves that are arranged over the machine width through the actuator system. The inflow of dilution water is exactly dosed by means of precise linear movement. In combination with the Profilmatic control software, the OnQ ModuleJet actuator system guarantees uniform basis weight cross profiles and provides for short engagement times after malfunctions. The optimal valve position is calculated by Profilmatic with the aid of various algorithms and adjusted by the actuator system.
The OnQ ModuleJet actuator system is used in headboxes with dilution water technology for cross profiling.
OnQ ModuleTap
Installing OnQ ModuleTap actuators ensures the highest consistent quality of the basis weight cross profile in headboxes with dilution valves (ball valves).
With OnQ ModuleTap, a consistently high basis weight profile quality is guaranteed by means of a rotary motion (0-90°) on the basis of the profiles measured. The combination of Profilmatic control software and the OnQ ModuleTap actuator system provides good and stable basis weight cross profiles and short engagement times until reaching the guaranteed quality values after downtimes, grade changes or breaks.
With OnQ ModuleTap, a consistently high basis weight profile quality is guaranteed by means of a rotary motion (0-90°) on the basis of the profiles measured. The combination of Profilmatic control software and the OnQ ModuleTap actuator system provides good and stable basis weight cross profiles and short engagement times until reaching the guaranteed quality values after downtimes, grade changes or breaks.
OnQ ModuleTap is used in headboxes where dilution water dosing is carried out via ball valves. The automatic control system is especially suitable for retrofitting headboxes from various manufacturers that have no dilution water system.
OnQ ModuleStep
The OnQ ModuleStep actuator controls the cross profile of the grammage. Simultaneous adjustment of all actuators ensures good control dynamics and clearly improved profile quality.
Control of the cross profile with the OnQ ModuleStep is done through mechanical profiling by zones of the headbox aperture, using stepper motors. The resulting contoured headbox outlet corrects the cross profile in the desired manner. The adjusting unit - consisting of stepper motor, gears, micrometer and hand wheel - was specially designed for the harsh environmental conditions in the paper and board industry. Adjusting increments of 0.6 micron ensure good control quality. Each actuator includes an integrated status and diagnostic display. The actuator adjustment is precisely measured by means of position, protectingthe aperture of the headbox from damage.
Control of the cross profile with the OnQ ModuleStep is done through mechanical profiling by zones of the headbox aperture, using stepper motors. The resulting contoured headbox outlet corrects the cross profile in the desired manner. The adjusting unit - consisting of stepper motor, gears, micrometer and hand wheel - was specially designed for the harsh environmental conditions in the paper and board industry. Adjusting increments of 0.6 micron ensure good control quality. Each actuator includes an integrated status and diagnostic display. The actuator adjustment is precisely measured by means of position, protectingthe aperture of the headbox from damage.
OnQ ModuleStep actuators can be installed on all headbox types. They are especially suitable for retrofitting older headboxes.
OnQ ModuleCoat / OnQ ModuleSpeed
OnQ ModuleCoat is used for coat weight cross profile control on blade coating units and OnQ ModuleSpeed for coat weight cross profile control on film coating units. Both systems ensures uniform distribution of the coating color in machine cross direction.
Cross direction control with OnQ ModuleCoat / OnQ ModuleSpeed takes place via adjustment by zones of the profiling device. For this, the actuator is equipped with an incremental and absolute encoder. The additional position feedback provides absolute reliability for protection of the profile rail. The auto-mapping function of the Profilmatic control automatically checks the correlation between actuator position and measurement position in the paper web. This allows uniform distribution of the coating color. The "mapping model" adjusts to the measured change.
Cross direction control with OnQ ModuleCoat / OnQ ModuleSpeed takes place via adjustment by zones of the profiling device. For this, the actuator is equipped with an incremental and absolute encoder. The additional position feedback provides absolute reliability for protection of the profile rail. The auto-mapping function of the Profilmatic control automatically checks the correlation between actuator position and measurement position in the paper web. This allows uniform distribution of the coating color. The "mapping model" adjusts to the measured change.
OnQ ModuleTherm
OnQ ModuleTherm is suitable for the control of the thickness profile on the calender for all calender types and all paper and board grades. With OnQ ModuleTherm, profiling is carried out by tempered air.
OnQuality.Controls
OnQ GradeControl
OnQ GradeControl is a system for multi-variable control of basis weight, moisture, coat weight and ash content. It ensures the stability of the quality parameters in machine direction. With the controls' help the drying performance of the dryer section, and thus the moisture of the paper, is perfectly adjusted. Cylinder dryers, infrared dryers or air dryers of all machine types can be flexibly controlled. The basis weight is controlled by means of the thick stock flow rate into the “short cycle.” In the same way, the chromaticity coordinate of the finished paper is kept constant during production.
OnQ GradeManager
OnQ GradeManager provides comprehensive and easily operable grade management through chosen control methods to enable quick and stable grade changes. The multi-user interface allows the execution of grade changes and the administration of grades at the same time without interference.
Your Benefits
- Optimized moisture during grade change through model based steam control
- Minimized breaks and enhanced runability due to better moisture control during grade change
- Fast weight and ash grade change through control of stock- and filler flow
OnQ Profilmatic
OnQuality.Profilmatic is a progressive cross profile control software program characterized by high reaction speed and delivering very flat cross profiles.
OnQuality.Profilmatic determines the shape of the profiles using quick and precise unfiltered, high-resolution profile measurements. Its ability to determine the portion of random noise in the measurements and the genuine cross profile variation makes the traditional filtering method for processing measurements obsolete.Continuous, dynamic profile mapping allows exact local mapping of the actuator control zones to the profile measurements.
OnQuality.Profilmatic determines the shape of the profiles using quick and precise unfiltered, high-resolution profile measurements. Its ability to determine the portion of random noise in the measurements and the genuine cross profile variation makes the traditional filtering method for processing measurements obsolete.Continuous, dynamic profile mapping allows exact local mapping of the actuator control zones to the profile measurements.
OnQ WetEndControl
OnQ WetEndControl controls and optimizes chemical addition in the approach flow system. This prevents negative effects due to overdosed chemicals and reduces chemical costs.
OnQ WetEndControl is available for application in retention, gas and charge. To stabilize retention, OnQ WetEndControl measures the white water consistency and controls it by dosing the retention agent. OnE WetEndControl for gas controls the addition of deaeration chemicals on the basis of the dissolved or free gas content. The added amount is reduced to what is absolutely required, which in turn minimizes the effect on other chemicals. OnQ WetEndControl for charge controls the dosing of the fixing agent based on the cationic demand by measuring the amount of anionic material in the stock.
OnQ WetEndControl is used in the approach flow system to control chemicals, thereby improving their efficiency.
OnQ WetEndControl is available for application in retention, gas and charge. To stabilize retention, OnQ WetEndControl measures the white water consistency and controls it by dosing the retention agent. OnE WetEndControl for gas controls the addition of deaeration chemicals on the basis of the dissolved or free gas content. The added amount is reduced to what is absolutely required, which in turn minimizes the effect on other chemicals. OnQ WetEndControl for charge controls the dosing of the fixing agent based on the cationic demand by measuring the amount of anionic material in the stock.
OnQ WetEndControl is used in the approach flow system to control chemicals, thereby improving their efficiency.
ComCore
The Voith Quality Control System (QCS) based on the modular automation platform ComCore. The modularity allows easy to integrate of your QCS into existing automation systems and provides clear information to the paper manufacturer. The easy-to-use user interfaces allow direct access and optimization of the quality parameter profiles.
To lay the foundation for the digitization of your mill integrate your QCS into dataPARC cloud – the Voith cloud solution.
Success Story
Decor paper specialist Ahlstrom-Munksjö modernizes its quality control system with ComCore
Due to the technical performance spectrum, the Unterkochen team decided to modernize the quality control technology with the ComCore QCS system by Voith Digital Solutions. ComCore is an automation platform developed specifically for the paper industry. It comprises digital assistance, measurement and control systems that can also be expanded with the OnEfficiency and OnCare product families.
The start-up processes have accelerated considerably, and the changeover times have been shortened.
Service
With our On-site Services and service locations we are your reliable partner in maintaining and continuously improving your QCS.
With the OnPerformance.Lab we offer expert remote consulting, audits and troubleshooting to improve your papermaking processes based on your QCS data.
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