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Challenge / Problem
Kama PPM needed to replace a foreign paper web monitoring system and acquire a tool for analyzing the causes of breaks.
The production line operates at speeds over 600 m/min, and a single break means downtime, losses, and added workload for staff. The client required a system that not only detects incidents but also stores videos prior to the break for further review.
Solution
We developed a hardware-software complex for paper web monitoring to control over 40 sections of the line.
The solution combines industrial cameras, synchronized lighting, monitoring server, and specialized infrastructure for video stream transfer and storage.
The system keeps the last 60 seconds before a break and helps identify the root causes of incidents.
Key Features:
- Control of over 40 production line sections
- High-speed recording up to 150 frames/s
- Resolution up to 4K for detailed analysis
- Handling video streams up to 40 Gbit/s
- Server platform with 1 TB RAM and NVIDIA A5000 GPU
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Results
- Reduced breaks through earlier identification of causes
- Increased output due to shorter downtimes
- Lowered workload on maintenance staff
- Archive of the last 60 seconds before incidents for in-depth analysis
- Created a database for statistics and predictive analytics on breaks
Technical Details:
- The system includes 40 industrial cameras and mobile cameras for flexible deployment in various BDМ zones.
- Cameras operate in the wet section, drying, bonding, coating, soft calender, and longitudinal slitting areas.
- Special protective housings and air cooling system were developed for use in high temperature and humidity.
- Data transfer is implemented via fiber optic network.
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