Insight Software for Oven Tracker

Key features:

Profiling and Analysis

• Key Analysis Functions include Datapaq Value, max/min temperature, time at temperature, slope calculation, rise and fall calculation, & peak difference.
• Wizards - set up your process easily with Wizards
• Operator mode permits the software operation to be simplified to a Wizard based command and response level.
• Statistical Process Control - view and analyse historical data variations
• BakeChart - new and improved function
• Analysis Alarms - QA as simple as checking for a green 'pass' light
  
• Cure Prediction - remove trial and error from process optimization with the Datapaq Value
  
• Multiple Paqfile Viewing - tab quickly from file to file and make detailed comparisons
  
• Context Sensitive Help - when and where you need it
  
• Improved Graphical Interface - 3D Graphing
• Virtual Probe – create a virtual profile trace from collected data
• Area Under Curve Calculation – quantify total cure and accurately highlight over cure problems
• Import from Clipboard – import profile data easily from a spreadsheet directly into Insight
• NEW Mimics – View data against a picture of your oven and its key operational components

Analysis Functions

For each thermocouple the following can be calculated:

• Max/Min shows the maximum, mean, and minimum temperatures at the precise time they were reached. The standard deviation and the deviation from set temperature are also shown.
• Time at Temperature shows the time spent above predetermined temperature thresholds.
• Datapaq Value Calculate the Index of Cure against coating supplier cure specifications using all temperature data from the profile graph that contributes to the cure process.
• Rise / Fall: This analysis mode calculates the rates of heating and cooling for each probe over user-defined temperature ranges, and the time the temperature is within each range.
• Slope calculates the maximum rate of heating and cooling for each probe, the times at which these occurred, and the average rate of change of temperature for each probe.
• Peak Difference identifies the two probes that recorded temperatures with the biggest difference within the profile. It can therefore be used to identify where the worst imbalances of heating are occurring on the product.
• View Data shows the raw temperature and time data for each thermocouple throughout the run.
  
  
  
  
  

Wizards

Simply select the wizard for the task you want to perform. Wizards make the software intuitive to use, even for infrequent operators.

Wizards are designed to guide you step by step through a particular process, while at each step giving you the opportunity to 'back up' to the previous step if you realize you have made a mistake. Wizards also cut down on training requirements.

The Wizard menu shown pops up as soon as you start the software. Wizards are available to help you to: open a file, set up a process file, set up your oven, product or recipe, create a tolerance curve, reset or download the data logger. There is also a Wizard to guide you through setting up the new Download Plus feature.

Operator Mode

In the NEW release of Oven Insight software, Operator Mode permits the software operation to be simplified to a Wizard based command and response level. The non skilled operator is lead step by step through the process of performing a profile run, which culminates with him being told whether the QA criteria of the run are achieved or not. This is all performed without him necessarily having to view the profile, do any analysis or interpret data himself. Despite the simplicity of operation, no compromise in profile analysis is experienced, since all high level analysis, alarms and reporting options can be configured in the process file used. The operator, having no access to the process file, is prevented from using incorrect or changing analysis parameters accidentally. Configured by the technician who has complete access rights to the Insight software, a list of operators can be created each with his own security password, allowing comprehensive tracking of profile analysis activities and by whom.

Statistical Process Control

Prevent oven process problems before they occur with Insight's new integrated Statistical Process Control (SPC) function. View and analyse historical data variations in key analysis parameters such as Datapaq Value, Time at Temperature and Peak Temperature without the need even to export data.

BakeChart

A new and improved BakeChart function assists with quantifying cure directly against the paint suppliers 'BakeChart' (or Graphical Cure Window). Create and store a digital version of the paint suppliers cure window and automatically compare against collected Time at Temperature data to determine whether the profile satisfies the cure specification. Use the new, unique, ISO cure feature to derive Datapaq Value parameters. Use this information to define the BakeChart area in terms of Datapaq Value (index of cure values). Identify the Datapaq Value tolerance range for your process allowing accurate day-to-day QA.

Analysis Alarms

With Insight it is now possible to set alarms to highlight when a process has gone out of tolerance. For example, if the temperature of a product should not exceed 404°F (207°C) during the curing process, it is now possible to set an alarm to activate if this temperature is exceeded.

When an alarm has been triggered there is a tab at the bottom of the page that will show you exactly which conditions triggered the alarm.

The alarm status light changes from green to red as the temperature is exceeded.

Cure Prediction

Using the Datapaq Value 'index of cure' value against paint suppliers' recommended cure parameters, it is now possible to manually manipulate the shape of the profile graph to see what effect it has on the cure performance. Create the ideal profile for your process on your computer, predict oven settings, and then use as a target template profile.

Using a wizard to guide you step by step through the process, you can create a Tolerance Curve either free hand or by using a previously obtained Paqfile (Datapaq file) as the reference profile template. The tolerance band can either be a single band or a double band (inner band = preferred/ outer band = acceptable).

For each band the theoretical Datapaq value is then calculated against paint cure schedule data. Using these values it is possible to create theoretical tolerance bands which can be used effectively for commissioning and new process optimization studies.

Without tedious repetitive testing it is then possible using the tolerance curve to change the shape of the profile graph template and see what effect it has on the Datapaq value and so the total cure. Applying this technique it is possible to estimate the effect of parameter modification on the profile performance.

By making the tolerance band offsets 0°C the tolerance wizard can be used to create theoretical ideal curves, which can be overlaid. Below are two images of a profile graph. The first is an experimentally obtained tolerance graph from a customer's application showing a Datapaq value of 74. The second image is the same profile manually altered by the operator simply by repositioning the data points to give a theoretical profile shape equivalent to a Datapaq value of 100. This ideal profile trace can then be used as a target profile during optimization studies to create the desired cure. The tolerance curve can be overlaid on top of experimental data to see the match in profile shape.

Multiple Paqfile Viewing

Tab quickly from file to file and make detailed comparisons. This new facility of Insight Software makes comparison of different files easier than ever before. Your QA manager can now have all the day's profile files, collected from different production shifts, open and then compare them easily simply by switching backwards and forwards.

Context Sensitive Help

Insight software is now supplied with context sensitive help. This means that on most dialogues there now appears a help button. Pressing this button takes you directly to the area of help specific to the function being viewed.

To help you out with routine operation, Insight Software introduces Dr Thermocouple. Whenever you may need to be prompted, Dr Thermocouple is at hand to give advice.

Improved 3D Graphing

Insight software comes with improved 3D graphing capability. Controlled by the mouse it is now possible to easily orient the 'view graph' view to see graphically hot and cold spots in the oven. As shown above this facility is very useful for flat bed mesh belt oven processes like IBO ovens. From a plan view the thermograph information shows exactly where in oven (Zone and belt location) the cold spot is located. From the thermograph key it is possible to match the graph colors to accurate temperatures recorded.

Virtual Probe

Mean
The mean virtual probe allows the operator to display the mean temperature profile trace for a user selectable list of probes. The virtual probe trace would be calculated as the mean of probes 1 to 6. On the profile graph below you will see that the 6 measurement channels have now been complimented by channel 7 labelled Mean.

Please click on the graph above to see larger image.

First Derivative
A function which gives the slope of a curve; that is, the slope of the line tangent to a function.

In this example we have two curves displayed. The left curve (blue) represents the math function
f(x) = x³ . The right hand curve represents the first derivative of the blue curve. The calculated math function of this curve is f(x) = 3x².

As you can see from the red first derivative trace the highest values are generated where the slope / gradient of the blue trace is greatest. In the example all slope are positive, but in practice, it is very possible that the first derivative value may be negative if the slope is negative (Profile Cool Cycle).

Where this becomes important in profiling is where you are looking for phase transitions in a profile trace which affect the gradient of that trace. Often the first derivative identifies such transitions easier.

Area Under Curve Calculation

For many years customers have requested the ability to measure area under the curve. In most situations this was required to help quantitatively verify total cure. In practise most requests were satisfied by the use of the Datapaq Value calculation.

A new benefit function, Area Under the Curve, has been highlighted in the automotive industry relating to quantifying the possible level of over cure. Although peak maximum temperature gives some indication of possible over cure, it provides no indication of the time period of which over cure is taking place. Calculating the area under curve above the working maximum threshold temperature gives a more accurate measure of the level of possible over cure damage due to both temperature and time.

Both graphs below illustrate the same peak maximum for thermocouple 2. Despite this, using the Area Under Curve calculation above 200°C / 392°F, it is easy to see that the graph on the right shows far more potential for over cure problems than the graph of the left.

Please click on the graphs above to see larger images.

Import from Clipboard

Read non Datapaq profile data directly into Insight software from a spreadsheet application, easily and efficiently. Following the step-by-step Wizard, simply copy the raw temperature readings of interest from the spreadsheet. Add appropriate profile parameters (sample interval; start date and time; probe locations) to complement the raw data and allow interpretation of the profile.

NEW Mimics

Show the location of key oven features such as burners, fans and control thermocouples directly against the profile trace. Attribute profile characteristics to the actual oven operation enabling a better understanding of the process necessary for control and optimisation. Find process faults quickly and efficiently even down to the offending faulty re-circulating fan or badly adjusted baffle.

Simply drag and drop the appropriate symbol of the oven component and locate at the appropriate distance/zone into the oven with a choice of displaying it on top or left/right of the oven. For involved processes with many features, employ the mimic rules function to help describe your oven with ease and efficiency but with the detail that makes data interpretation accurate. Create the oven configuration once, store in the process file, making it instantly available at download.