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QCS Integration Overview

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Integration Overview

The Dilution Control System integrates with Quality Control Systems (QCS) to receive real-time basis weight profile data. This data is essential for the closed-loop control of dilution valves.

QCS Scanner
Measures profile
Profile Data →
Interface
Modbus / OPC / Direct
Processed Data →
Dilution Control
Profile processing

Supported QCS Systems

The Dilution Control System supports integration with all major QCS manufacturers:

ABB

DIU (Digital Interface Unit), Accuray AC6/AC6000

View Guide →

Honeywell

Experion QCS, Measurex

View Guide →

Valmet / Metso

Valmet IQ, Metso IQ, DNA

View Guide →

Yokogawa

CENTUM VP/CS, ProSafe-RS

View Guide →

JASCH

Indian QCS systems, custom integration

View Guide →

Generic / Other

Any Modbus-compatible QCS system

View Guide →

Data Requirements

The Dilution Control System requires the following data from the QCS:

Required Data

Data Item Description Typical Format
Basis Weight Profile Array of measurements across the web width Float array (100-300 points)
Profile Valid Flag Indicates if profile data is current and valid Boolean
Scanner Status Scanner operating state (scanning, parked, error) Integer / Enum

Optional Data

Data Item Description Usage
Profile Timestamp Time of last profile update Detect stale data
Profile Average Mean basis weight value Reference for target setting
Profile Sigma Standard deviation (2-sigma) Profile quality indicator
Edge Positions Left/right edge databox indices Automatic edge detection
Scan Direction Current traverse direction Profile synchronization

Interface Options

Multiple interface options are available depending on your QCS system:

Modbus TCP

Most Common

  • Standard industrial protocol
  • Supported by most QCS systems
  • Easy configuration
  • Reliable performance
Port: 502 Speed: Fast

OPC DA

Legacy Systems

  • Windows-based interface
  • Automatic tag discovery
  • Requires OPC server installation
  • Good for complex tag structures
DCOM-based Speed: Medium

Direct Memory

ABB DIU Specific

  • Direct memory access
  • Highest performance
  • ABB-specific protocol
  • Requires DIU configuration
Custom protocol Speed: Fastest

Common Configuration

Regardless of QCS vendor, the following configuration steps are common:

  1. Network Setup

    Ensure the control PC can communicate with the QCS interface:

    • Verify IP connectivity (ping test)
    • Configure firewall rules for required ports
    • Use static IP addresses

  2. Profile Parameters

    Configure profile settings in the Dilution Control System:

    • Number of Databoxes: Match the QCS configuration (e.g., 200)
    • Profile Register/Tag: Address where profile data starts
    • Data Type: Float (4 bytes) or Integer (2 bytes)
    • Byte Order: Big-endian or little-endian

  3. Zone Mapping

    Map scanner databoxes to actuator zones:

    • Set front-side and back-side offsets
    • Configure mapping direction
    • Verify using profile visualization

  4. Signal Scaling

    Configure any required scaling:

    • Raw value to engineering units conversion
    • Typically: 1:1 for g/m² values
Start with Generic

If you're unsure about your QCS interface, start with the Generic / Modbus guide. Most QCS systems support Modbus TCP as a standard interface.