Efsen UV Seminar Optimizing UV and Maintenance

Transcription

1 Efsen UV Seminar Optimizing UV and Maintenance Warsaw Efsen Engineering A/S Denmark

2 Optimizing and Maintenance Understanding UV equipment and how to troubleshoot, will enable you to have: Better cure Better product finish Less spareparts Less cost Longer lifetime of equipment Less cost and downtime Optimal use of UV lampe Less energy consumption 15 November 2016 Page 2

3 Key Elements of UV Curing Equipment Dose J/cm 2 (Energy) total energy arriving at the coating surface inversely proportional to speed UV Irradiance W/cm 2 (Intensity) power of the light at the coating surface characteristic of the lamp & geometry of the reflector independent of speed Spectral output of the bulb Wavelength distribution Gallium or Mercury 15 November 2016 Page 3

4 Comparing to turning out a fire. P 300 mw/cm2 250 mj/cm2 needed to turn off the fire 250 mj/cm2 250 mj/cm2 P 150 mw/cm2 250 mj/cm2 250 mj/cm2 P 300 mw/cm2 150 mj/cm2 150 mj/cm2 0 m 100 m 200 m 300 m 15 November 2016 Page 4

5 Optimizing and Maintenance Maintenance: Bulbs Reflectors Cooling system Electrical cabinet Optimizing: UV output Uniformity Life time Giving new life to old UV systems: Upgrading lamp house to WoodCure Upgrading casettes in Hymmen Hackemack systems Exchanging arc systems with microwave systems 15 November 2016 Page 5

6 UV-lamps are fragile be careful Made with attention to detail: Quartz tube diameter electrodes seals - sockets connection leads spectra doping - quartz types Make sure: NO FINGERS on bulbs fat from fingers burn to UV lamps and decrease lifetime - use cotton-gloves or paper, when mounting bulbs. Clean with IPA 99% and cotton cloth NO FINGERS Be carefull when mounting into lampsystem Make sure UV bulbs can move, when mounted. Lamps get warm and expand 15 November 2016 Page 6

7 Banana bulbs Banana bulbs happen when no expansion of bulb is possible or with bad cooling No expansion possible 15 November 2016 Page 7

8 Dirty and dusty lamp & reflector 75% of light from bulb is reflected So NO dirty reflectors Use quality reflectors Clean reflectors with cotton and IPA 75% 15 November 2016 Page 8

9 Dirty and dusty lamp & reflectors Dirty and dusty reflectors is like driving with 1 or 2 tires it is slow and you consume a lot of tires 15 November 2016 Page 9

10 Melted or bumped reflectors Like dirty reflectors the light does not get to the product where we need it it is wasted! 15 November 2016 Page 10

11 Cooling is critical-check it! Air always travels the shortest way with the least pressure So this leaves no cooling for lamp!!! 15 November 2016 Page 11

12 Electrical connections This is W. This should be maintained properly! NOT like this. Clean the cabinets and make sure cooling of transformers and power supplies is good. The investment is worth it. 15 November 2016 Page 12

13 Optimizing and Maintenance Maintenance: Bulbs Reflectors Cooling system Electrical cabinet Optimizing: UV output Uniformity Life time Giving new life to old UV systems: Upgrading lamp house to WoodCure Upgrading casettes in Hymmen Hackemack systems Exchanging arc systems with microwave systems 15 November 2016 Page 13

14 Optimizing UV output First understand what is good and not good. For this, UV measurement is essential, as you cannot see UV light.. Efsen recommends a 4 step approach. This is cheapest and most effective Step 1: Cleaning Step 2: Changing bulbs and reflector Step 3: Changing lamp house Step 4: Changing power supply/electrical cabinet 15 November 2016 Page 14

15 Good vs Bad lamp quality First understand bulb behaviour Then understand what is good and not good We need to start HIGH Good quality bulb clean reflector aligned reflector good power supply 2500 Good quality lamp Bad quality lamp Minimum Ga intensity 500mW/cm2 EIT-UVV Minimum Hg Intensity 300mW/cm2 EIT-UVA hours 1200 hours November 2016 Page 15

16 Step 1: Optimizing UV - Cleaning Use Isopropyl Alcohol IPA and cotton cloth NOT acetone, water, vodka, NOT paper, microfiber etc. 15 November 2016 Page 16

17 Step 2: Optimizing UV Bulb and Reflector change 15 November 2016 Page 17

18 Step 2: Old and New Gallium lamp UVV UVV UVA UVA OLD NEW 15 November 2016 Page 18

19 Step 2: Easy maintenance systems 15 November 2016 Page 19

20 Step 3: Cooling Air Control PULL system (single wall) PUSH/PULL system (single wall) 15 November 2016 Page 20

21 Step 3: Reflector Unit Fixed position 15 November 2016 Page 21

22 Step 3: WoodCure Lamp Module High peak intensity Lower energy consumption less heat More uniform cooling better gloss control Longer life time on bulbs Easy maintenance More production time 15 November 2016 Page 22

23 Step 3: Retrofitted solutions 15 November 2016 Page 23

24 Step 4: Optimizing UV new Power Supply - Cabinet Step 3: 1 x WoodCure lamphouse on Giardina Transformer Step 4: 1 x WoodCure lamphouse on Efsen EPS Transformer STEP 2: 2 x Giardina 15 November 2016 Page 24

25 Step 4: Optimizing UV new Power Supply - Cabinet 15 November 2016 Page 25

26 Step 4: Complete WoodCure System 15 November 2016 Page 26

27 Optimizing Uniformity As good as it gets Measured in focus 15 November 2016 Page 27

28 Compensation Uniformity 1400mm w. 2 extra lamps in the sides Extra lamps Extra length 1650mm to cover 1400mm 15 November 2016 Page 28

29 0,5 4 7, , , , , , , , , , , , , , , , , , ,5 W-LED Uniformity and internal calibration 2 1,9 1,8 1,7 1,6 1,5 1,4 1,3 1,2 1,1 1 Calibrated W-LED-8 (60mm - 100% - 4heads 1200mm) 15 November 2016 Page 29