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The “Blistbuster” Software

The “Blistbuster” software is an Aeroel exclusive data processing algorithm, installed in the dual axis sensors, that can be very useful to check the diameter smoothness of a continuous product (for instance magnet wire) and to detect a very special type of recurrent flaws, commonly called “Blisters”.

What is a “Blister”?

In some manufacturing processes, as i.e. the enameling of copper wire, it’s possible, under given conditions, that on the wire surface a special kind of flaws are produced: these are very similar to small bubbles or holes and they turn into very local diameter changes. In addition, when they appear, they persist on quite long wire sections, until the cause has been removed. Measuring the simple average diameter or even the max and min diameter is not enough to detect and “measure” that type of flaws.

blister 01

How to detect “Blisters” ?

The “Blistbuster” software has been designed to detect and to “measure” such type of flaws, using new and dedicated numerical parameters. Considering the speed of product, the very small dimensions of each flaw, the gauge scanning frequency and the flaw location along the wire circumference, it is absolutely impossible to guarantee that any single flaw is seen and detected.

Nevertheless, by storing into the processor memory a rather high number of single-scan measurements and processing them using a special statistical algorithm, it is possible to determine that some of these has been taken just over a local flaw, as the result of such a scan is very different form the average wire diameter and much higher than the single scan repeatability of the gauge itself. So the diameter deviation of such scans has really to be imputed to the product non-uniformity.

In example, the sketch below shows the “distribution” of the measurements taken on a moving wire, having small and recurrent flaws: in addition to the main Gaussian distribution (which is typical of the gauge) an additional “spurious” distribution can be seen, that is due to the blisters.

blister 02

The Output Data

The Blistbuster software processes K x N scans (or single measurements, couples of X & Y values) and computes 3 new parameters:

  • PDF = Percentage of “faulty” scans over the total number  K x N
  • ADF = Average flaw height, expressed as Diameter Change and always in MICRONS INTEGERS, no matter of the pre-set measuring resolution and units.
  • IDF = Flaw Index, overall parameter given by the product  20 x ADF x PDF / DFSCAL

The parameters to adjust

In addition to the overall sampling time, set by K and N factors, the user can set:

  • the DFSCAL code or the system sensitivity, to attenuate the IDF value dividing it by 1 or 10 or 100, in order to reduce its variation range;
  • the DFSENS code or the flaw detection threshold, , to be always programmed much higher than the gauge single scan repeatability. That is expressed as Diameter Change and always in Millimeters, no matter of the pre-set measuring resolution and units.

Important comments

Please notice that :

  • The Blistbuster function is active ONLY when the product K x N is greater or equal than 200, to have a reasonably high number of data to process.
  • It is strongly recommended to use high scan frequency sensors, to improve the measuring repeatability.
  • The Blistbuster function is based on statistical assumptions: a quite long section of wire must be checked, including a rather high number of flaws.
  • It is absolutely impossible to detect any single scan or to measure its real dimensions.
  • As it is impossible to know and measure the true geometry and dimensions of the flaws, the computed parameters are not directly related to the true dimensions and to the quantity of flaws, but they can be used as “process indicators” related to the wire quality and they can be very helpful to monitor the process and to prevent from manufacturing defective product.

Logo UeLogo MinisteroFriuli venezia GiluliaFonfo SviluppoProgetto cofinanziato con il Fondo Europeo di Sviluppo Regionale del Programma Operativo Regionale del Friuli Venezia Giulia Obiettivo "Competitività Regionale e Occupazione" programmazione 2007/2013