Multiplexed NIR spectrometer technology
NIR identification in sorting processes
Multiplexed NIR spectrometer are widly used for the identification of plastic material in recycling plants. Waste collections from e.g. household waste are identified and analysed by an optical spectrometer and can therefore be sorted out.
KUSTA1.9MPL-24V - Multiplexed NIR spectrometer for recycling
Material identification in sorting plants
Multiplexed NIR spectrometer KUSTA1.9MPL-24V (formerly KUSTA1.9MPL) is a fast scanning near-infrared sensor, which is used for the identification of bulk solids in sorting plants. On a conveyor belt the singulated material is passed by under the illumination unit and the reflected radiation is transferred to the optical multiplexer via fiber cables. The multiplexed spectrometer scans the 64 measuring tracks at frequencies of up to 70 Hz and sends the identification results to the process control via an ethernet protocol.
KUSTA1.9MPL-24V is mainly used in plastic- and waste paper recycling. Depending on the application certain standard identification routines are included, which enable to reject several material types referring to freely selectable criteria.
In the version “-24V”, which is available from January 2016, the optical multiplexer, the spectrometer and the RGB sensor come in a separate housing of protection degree IP65, which can be mounted directly at the probe. Due to the high scan rate, materials on even 2 to 3 m wide conveyor belts can be identified at speeds of up to 3 m/s. For the detection of smaller particles (< 30 mm in diameter) hyperspectral imaging cameras KUSTAx.xMSI are recommended.
Additional equipment is described below.
Suitable software for LLA NIR technology is described here.
Schematic illustration of a sorting plant based on KUSTA1.9MPL-24V
Technical specification KUSTA1.9MPL-24V
| KUSTA1.9MPL-24V | ||
| Method | Non-contact and non-destructive testing (NDT) method based on NIR spectroscopy; Detection of absolute remission as a function of the wavelength |
|
| Wavelength range | 1.36 µm - 1.94 µm | |
| Spectral resolution | < 8 nm | |
| Dispersion per pixel | 4 nm | |
| Scan rate | 30 Hz - 70 Hz | |
| Number of measurement tracks | Max. 64 | |
| 16bit RGB sensor | Integrated | |
| Operating voltage optical unit | 24V DC, max. 3,6A (without industrial PC and control cabinet heating) | |
| Operating voltage industrial PC | 24V DC, max. 4,8 A | |
| Operating voltage control cabinet heating | 24V DC, 7A, 150W | |
| Voltage 24V power supply |
90…265 V AC, 50-60 Hz, fuse 20 A (T) Input: 100 V ... 240 V AC; Output: 24V DC / 20A |
|
| Environmental operating temperature | +5 °C to +55 °C | |
| Environmental operating humidity | In process: 5 % - 95 % 20 % - 95 % rel. |
|
| Weight | 31 kg | |
| Dimensions (LxWxH) | 500 mm x 500 mm x 300 mm | |
| Base device | Optic module containing the spectrometer, optical multiplexer and control electronics in a housing of protection class IP65, external: industrial PC, 24V power adapter | |
| PC configuration | Operating system Windows® 7 Embedded, 1,7 GHz, 8 GByte RAM, Solid State Disk 80 GByte, conectivity: DVI, COM, USB, Ethernet | |
| Software | Control software KustaMPL, customer specific analysis routines Optional: spectrometric development environment KustaSpec |
|
| Operation | Process mode: the process unit interacts via Ethernet interface with the industrial PC, which evaluates the spectra. Controling the system with a TFT display, mouse and keyboard for service purposes is possible but is not included in the scope of delivery. | |
| Probe lines | PMAmpl (Remission) or PMT (Transmission) | |
| Scope of delivery | Multiplexed NIR spectrometer KUSTAx.xMPL-24V, industrial-PC, 24V power supply | |
Product picture
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uniSPEC1.9MPL-24V - Multiplexed NIR spectrometer for science
NIR technology for quality control
Multiplexed NIR spectrometer uniSPEC1.9MPL-24V (former uniSPEC1.9MPL) was developed for analytical evaluation of material in the production process. Due to the high spectral resolution, these NIR spectrometers are ideal tools for scientific applications. Additionally, a high luminous intensity and a large sensitivity of the spectrometers are perfect properties for the use in quantitative- and rapid analysis applications of material streams.
The spectrometer are widely used as online analytics in food industries, plastics- and paper industry, for thickness measurement in control of coatings, the quality control in mineral industry and many more. Depending on the application, uniSPEC1.9MPL-24V is utilised. LLA advises the best fitting device for the customised application.
For each application, customised analysis modules are developed. Additional control software for the NIR spectrometer is custom-built and scope of delivery. The user interface can be designed and customised. The software can be used to store measured information for a future analysis or to change parameters in working processes.
The multiplexed NIR spectrometer can be connected to probe lines (64 measurement tracks) via fiber cables. Thereby a spatially resolved recording of material streams is generated.
In real time, analytical results will be automatically forwarded to a subsequent control system (e.g. nozzle control system) by a standardised interface (e.g. Profibus, Ethernet). This ensures a reliable identification and ejection of defective material (impurities, rejects, extraneous material).
Additional equipment is described below.
Suitable software for LLA NIR technology is described here.
► Qualitative and quantitative analysis in the plastic industry
► Analytical evaluation of industrial minerals
► Evaluation of layers in the printing industry
► Analytical evaluation in the food industry
Technical specification uniSPEC1.9MPL-24V
| uniSPEC1.9MPL-24V | ||
| Measurement method | Contactless and destruction free measurement based on NIR spectroscopy; measurement of absolute remission depending on the wave length | |
| Wavelength range | 1.36 µm – 1.94 µm | |
| Spectral resolution | < 8 nm | |
| Dispersion per pixel | 4 nm | |
| Scan rate | 30 Hz – 70 Hz | |
| Number of measurement positions | Max. 64 | |
| 12bit RGB sensor | Integrated | |
| Operating voltage optical unit |
24V DC, max. 3.6A (without industrial PC and control cabinet heating) | |
| Operating voltage industrial PC |
24V DC, max. 4.8 A | |
| Operating voltage control cabinet heating |
24V DC, 7A, 150W | |
| Voltage 24V power supply | 90…265 V AC, 50-60 Hz, fuse 20 A (T) Input: 100 V ... 240 V AC; Output: 24V DC / 20A |
|
| Environmental operating temperature | +5 °C to +55 °C | |
| Environmental operating humidity | 20 % – 95 % rel. | |
| Weight | 31 kg | |
| Dimensions (WxHxD) | 500 mm x 500 mm x 300 mm | |
| Base device | Optics module consisting of spectrograph, optical multiplexer and control electronics in cabinet, protection class IP65, external: industrial PC, 24V power supply | |
| PC configuration | Operating system Windows® 7 Embedded, 1,7 GHz, 8 GByte RAM Solid state disk 80 GByte, Interfaces: DVI, COM, USB, Ethernet |
|
| Software | Control software MPL, analysis software KustaAna customer specific analysis evaluation and monitoring software Optional: spectrometric development environment KustaSpec |
|
| Operation | Process mode: process unit interact with the industrial PC via an Ethernet interface which evaluates the spectra. A TFT display control system, mouse and keyboard is available for service purposes but is not extent of delivery. | |
| Probe lines | PMAmpl or customised single probes upon request | |
| Scope of delivery | Multiplexed NIR spectrometer uniSPEC1.9MPL-24V, industrial-PC, 24V power supply | |
Optional Equipment
Optional equipment for KUSTA1.9MPL-24V and uniSPEC1.9MPL-24V
The multiplexed NIR spectrometer KUSTA1.9MPL-24V and uniSPEC1.9MPL-24V can be delivered optionally with:
■ Process probes,
■ Calibration CUa and CLm,
■ Valve control for pneumatic ejection unit.
All information regarding these accessories are listed below.
Process probes
Compact probe lines and single probes
The process probes collect the light reflected from or transmitted through the samples. The light is transferred to the spectrometer via fibre cables. The designed probe lines are connected to the multiplexed NIR spectrometer KUSTA1.9MPL-24V or uniSPEC1.9MPL-24V. Depending on the application, single probes or probe lines are offered.
Probe lines and components
The probe line PMAmpl consists of two parallel illumination units (LU) and a line with the integrated coupling optics (OL). All three items are affixed to each other by plates. The double-sided illumination unit reduces shadow formation on the input material stream, leading to an enhanced identification rate.
Mounting brackets allow installation of the probe line above the conveyor belt. Rubber buffers are added for vibration absorption. Heat-resistant glass protects the optic line (OL) in the probe lines to prevent staining and damage. Active cooling covers and automatic calibration equipment are available accessories.
The probe line PMT consists of an optic line below a shute and an illumination unit installed above the shute. The probe line PMT is designed for the evaluation of transparent material e.g. plastic foils.
Customised design of probe lines
The customisation of the probe lines is based on the following customer specific requirements:
■ Number of desired measurement tracks
■ Speed of the material stream
■ Measurement width for the material stream (conveyor belt width)
■ Height of the the material stream
■ 120 V version available
The probe lines are designed for measurement widths of 500 mm (PMAmpl500) to 2800 mm (PMAmpl2800). The measurement pitch is application specific and may be chosen between 20 mm to 50 mm. The coupling optics of the fibre cables realise a minimum track width of 25 mm. Two different probe line versions are offered for different material size: Vertical clearance ca. 300 mm (LR30) or ca. 500 mm (LR50).
| PMAmpl | PMT | |
|---|---|---|
| Measurement method | Remission | Transmission |
| Probe line configuration | Compact unit with measurement optics (OL) and double sided illumination unit (LU) | Measurement optics and illumination unit separated |
| Measurement distance | 240 – 300 mm (Version LR30) 420 – 500 mm (Version LR50) |
Distance between measurement optics and illumination unit 300 mm |
| NIR sources | Linear halogen light bulbs, 230 V or 120 V version available | |
| Standard lengths | 1000 mm, 1600 mm, 2000 mm, 2800 mm* | ----- |
*Customised lengths between 500 mm - 2000 mm in a 200 mm scheme on request
Calibration CUa and CLm
Exceptional results require exact measurements. A periodical calibration of the measurement system is necessary to maintain high quality results. The calibration can be done manually utilizing the calibration line CLm. The CLm consists of an aluminium frame which holds the calibration material. Handle bars are integrated for easier handling. The probe line PMAmpl can be equipped with the automatic calibration unit CUa for the automation of the calibration. The calibration unit CUa includes two support arms, the calibration line CLa, a motor and the electronic control unit. The motor-driven support arms move the calibration line into the calibration plane. This process takes only a few moments. The CLa is moved back into the protected parking position after calibration.
Dependent on the brightness of the sample material, three different calibration materials are available:
■ Version Bright - suitable for standard applications in paper and plastic recycling, and bright (white) materials in general
■ Version Medium - suitable for darker materials such as gray rock
■ Version Dark - suitable for dark to black materials
Valve control for pneumatic ejection unit
The NIR process spectrometer KUSTA1.9MPL-24V can be optionally equipped with a valve control for pneumatic ejection unit in sorting machine systems. In addition to the standardised device control software, a complete solution for machine builders is available to realise sorting processes much easier.
The valve control unit consists of an ethernet fieldbus coupler, digital output modules of each 16 single channels are mounted side by side. Depending on the required configuration level, up to 1024 fast-switching compressed-air-valves can be controlled. Fieldbus coupler is directly connected to an control-PC of the process spectrometer via ethernet interface.
According to device control software KustaMPL, all functions to communicate with the valve control unit is already given. An individual material identification method can be loaded and sorts to be eject can be chosen in the sort table. The device control software transmits corresponding signals while sorting process to the valve control unit in real-time. The software evaluates important parameter for valve control such as e.g. time delay between identification and ejection (delay) as well as the adjustment of the close-open times of the valves.
Technical specification
Ethernet fieldbus coupler
| Connection | 2 x RJ-45 |
| Transfer rate | 10/100 Mbits/s |
| Voltage supply | 24 V DC (-25 % ... +30 %) |
| Input current max. | 280 mA at 24 V DC |
| Max. number bus modules | 64 |
| Protection level | IP 20 |
16-channel digital output module
| Number of outputs | 16 |
| Voltage via power jumper contacts | 24 V DC |
| Output current per channel max. | 0.5 A |
| Cable cross-section | Unifilar: 0.08…1.5 mm² Finely stranded: 0.25…1.5 mm² |