From Machine Operator to Bottle Maker

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Shana Randall
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1 From Machine Operator to Bottle Maker Automation for productivity, safety and flexibility May Glassman Lyon

2 Risk Reduction as Stated in the Machine Directive: May Glassman Lyon 2

3 Risk assessment According to EN (Feeder gob) and EN (IS machines), operators manual interaction with the machines and human errors are a source for accidents Feeder standard, more than 70 % of the hazards described are related to interaction with the Feeder IS standard, more than 60 % of the hazards described are related to manual interaction with the IS machine May Glassman Lyon 3

70 % of the hazards described are related to interaction with the Feeder IS standard, more than 60 %

4 Residual Risks by Technical Means (1/4) Lifting device Designed to help the operator avoid heavy lifts LED lamps Designed to increase visibility for the machine operator Machine section without LED Machine section with LED May Glassman Lyon 4

Designed to increase visibility for the machine operator

5 Residual Risks by Technical Means (2/4) Conveyor Ladder Improves access to blow side for the operator Flexconveyor integrated ladder Retrofitted conveyor ladder May Glassman Lyon 5

6 Residual Risks by Technical Means (3/4) Safety flaps Alerts the blank side operator of the risk of overriding blow side mechanisms, making sure the operator is certain no one is in the working area on the blow side Blow head & Blow mold interlock Allows the operator on the blow side of the machine to control the blow head and blow molds May Glassman Lyon 6

the working area on the blow side Blow head & Blow mold interlock Allows the operator on

7 Residual Risks by Technical Means (4/4) GOB distributor guard Alerts of dangerous movement of Gob distributor and prevent access Blank side Barrier Barrier block access to blank side of section during Normal Operation. Prevents unintended access to the blank side May Glassman Lyon 7

Barrier Barrier block access to blank side of section during Normal

8 Residual Risks by Information and Training (1/3) Knowledge transfer more than a manual May Glassman Lyon 8

9 Residual Risks by Information and Training (2/3) Documentation becomes interactive and intuitive to facilitate the knowledge transfer to the end user, and incorporates every support required for the best operation of your system. 3-D renderings in video form explains processes Knowledge transfer more than a manual Instructional videos are embedded in the operators manual Interactive machine set up guide May Glassman Lyon 3-D renderings in video form provides operating instructions for the compleate machinery 9

3-D renderings in video form explains processes Knowledge transfer more than a manual Instructional videos are embedded in the

10 Residual Risks by Information and Training (3/3) First Class Training Centers for Forming Equipment in Europe and Asia Equipment Training Training on Bucher Emhart Glass forming equipment Advanced Application Training Training on Bucher Emhart Glass forming process 10

Equipment Training Training on Bucher Emhart Glass forming

11 Looking for the Future We see each of our products as a package of parts and service including: Standard Operating Procedures Visual tools for better understanding Setup tools Training expertise Parts selection on webshop May Glassman Lyon 11

Procedures Visual tools for better understanding Setup tools

12 Standard Operating Procedures As machine manufacturer, we provide you with the basis of the operating procedures on our equipement throughout the operating instruction notice. SOP available from instruction notice (PDF version) SOP structure May Glassman Lyon 12

throughout the operating instruction notice.

13 Visual Tools These interactive supports make easy to understand technical products. 3D PDF BIS Baffle Module Multimedia Animated Video FlexStacker presentation Plunger Up Control presentation May Glassman Lyon 13

14 Setup Tools Available tools for system configuration can be accessed from the pdf version of the instruction notice. FlexStacker May Glassman Lyon 14

15 Training Center Mechanical training course BIS Machine training Course Length: 5 days NIS, BIS, IS and AIS machines Theoretical and practical training Basic operational training on FlexIS Assembly/dissassembly of mechanisms Feeder/Shear/Tube included May Glassman Lyon 15

practical training Basic operational training on FlexIS

16 Training Center Sundsvall, Sweden Electronic training course Control system FlexIS Training Course Course Length: 5 days Theoretical and practical training System overview Hardware Set up and operation FlexIS troubleshooting Line server May Glassman Lyon 16

Theoretical and practical training System overview Hardware Set

17 Training Center Sundsvall, Sweden Process control equipment Course Length: 3 days PPC Plunger Process Control Process errors and product defects (PPC) TCS Temperature Control System Calibration procedure (TCS) FlexIS Closed loop Control Settings & parameters (closed loop) May Glassman Lyon 17

(PPC) TCS Temperature Control System Calibration procedure (TCS) FlexIS

18 Training Center Sundsvall, Sweden Detailed information of training program content can be found on May Glassman Lyon 18

19 Background May Glassman Lyon 19

20 Background Technical development 2000 BC May Glassman Lyon 2000 time 20

21 Risk Reduction as Stated in the Machine Directive: May Glassman Lyon 21

22 Automation for Health & Safety Our message is: Bucher Emhart Glass is the leader in automating the hollow glass production process Technical development and automation is the key driver for Health, Safety and Profitability May Glassman Lyon 22

23 Bucher Emhart Glass Automation Strategy consists of: Controls Servo technology Sensors Feedback loops May Glassman Lyon 23

24 Development of Controls User interface which clearly visualizes the operation setup Safe stop fullfilling performance level d for servos Safety PLC separating blank and blow side operations Safety PLC providing two hand operation for servo movements Safety PLC providing safe movement of SEI Summary: Bucher Emhart Glass controls ensures fast and reliable operation of the machines May Glassman Lyon 24

25 Development of Servo Technology Eliminates the need of manual interaction for monitoring Eliminates the need of manual interaction for correction Providing systems which are stable over time. The same motion profile is achived, no disturbances from ambient conditions Providing systems which are repetitive. Previous operation setup can be reused Summary: Bucher Emhart Glass servo technology provides repetitive operation of the machines May Glassman Lyon 25

26 Development of Sensor Systems Plunger Process Control (PPC), is a plunger full stroke sensor system Temperature Control System (TCS) measures mold temperature on the blank side BlankRadar is a temperature and image sensor system for mold temperature measurement and gob loading position FlexRadar is an image sensor system for container spacing and wall thichness Summary: Bucher Emhart Glass sensor systems remotly monitors the process parameters May Glassman Lyon 26

27 Development of Feedback Systems Gob weight control: PPC full stroke sensor information is used by the gob weight control algorithm, to adjust the feeder tube height and needle height (NNPB and PB). Gobs are cut toexactly the right weight (volume) to fill the molds. Reduced risk for operator: Manual interference for controlling the gob weight is minimized. Decreased variation createshigher quality and less production disturbances. May Glassman Lyon 27

28 Gob weight control Stability of gob weight variation 28

29 Development of Feedback Systems Constant plunger dwell time: PPC full stroke sensor information is used by the constant plunger dwell time algorithm to control the FPS valve. The controlled plunger motion will ensure good finish Reduced risk for operator: The risk of plunger sticking in the glass is reduced. Sticking plunger will create glass jam. To clean the section from a glass jam manual interaction from the operator is required Too short dwell time increases the risk of section stop, due to unfilled finish which will create glass jam at the section outfeed. Operator manual interaction is needed to clean section from glass May Glassman Lyon 29

30 Constant Plunger Dwell Time: Before activating plunger dwell time algorithm After activating plunger dwell time algorithm 30

31 Development of Feedback Systems Blank mold temperatures: The TCS sensor information is used by the blank cooling algorithm to control the blank bracket On/Off valves. Molds will keep an even temperature over time Reduced risk for operator: Constant mold temperature is essential to ensure stable glass distribution, providing stable mold temperature, reducing the risk of glass jam and need of manual interaction. May Glassman Lyon 31

32 Blank Mold Temperature: Before activating blank cooling algorithm After activating blank cooling algorithm 32

33 Development of Feedback Systems Equal ware spacing: The FlexRadarinformation is used by the bottle spacing control algorithm to control the FlexPusheroutfeed. An even distance between containers on the conveyor is essential for the ware handling. Reduced risk for operator: Bad ware spacing (ware handling) creates problems at the ware transfer (bottles do not properly get into the pockets of the ware transfer). This creates a jam, bottles fall off the conveyor, manual interaction is needed May Glassman Lyon 33

34 Automation => Process Control - Close Loop Vision: Machine Operators => Bottle Maker Automation drives Health, Safety and Profitability Automation Process Control Portfolio PPC TCS BlankRadar FlexRadar Gob weight control Blank Cooling Control Equal ware spacing Constant plunger dwell time control May Glassman Lyon 34

35 Bucher Emhart Glass Vision and Mission Our vision is a world with glass as a dominant and preferred ecological material, enabled by Bucher Emhart Glass as the leading technology provider. Our mission is to support our customers in their quest for sustainable profitability, quality and increased market share in the packaging industry through our automation solutions. May Glassman Lyon 35

36 Thank you Inge Friberg, Compliance Engineer May 5 6, 2015, Glassman Lyon info@bucheremhartglass.com 36

PECS The Control System for Extrusion Blow Molding

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