empty bottle inspection machine

ACEACE TechnologiesTechnologies

Coca-Coca-ColaCola

TrainingTraining

FiltecOmnivision Training

ASEBIASEBIAll Surface Empty Bottle InspectionAll Surface Empty Bottle Inspection

ASEBI is having the following detection points

1. Base Detection2. ISW Detection3. IR Residual Detection4. RF Residual Detection5. Finish Detection6. Thread Detection7. Aux Reject8. Plugged Detection9. Large Object Detection10. OSW Detection11. Scuff Detect

OBJECTIVEOBJECTIVE

Identify Parts of machineKnow how to use software

Using touchpad Bottle changeover Test Bottle

Cleaning procedures Daily Monthly

At the end of this Training you should be able identify following:

Parts of MachineParts of Machine& Utilities& Utilities

Machine ScreenMachine Screen

UtilitiesVoltage: 220VAC +/- 10% 50/60Hz,7KVA - Computer gradeAir: Dry compressed - 8.5CFM @65psig (4.01pm@448Kpa)Water: 5.5gph @ 40psig (20lph @ 276 Kpa)

Light Source (Strobe Lamp)Light Source (Strobe Lamp)

SemitransparentSemitransparentMirrorsMirrors

Protection Protection windowswindows

IRIRBaseBase

(Caméra)(Caméra)ISWISW

(Caméra)(Caméra)

FinishFinish(Caméra)(Caméra)

ThreadThread(Caméra)(Caméra)

Rotating glassRotating glass

Diffuser glass Diffuser glass (Brightfield Option)(Brightfield Option)

OptionOption

IR RLD IR RLD detectiondetection

LED Strobe LampLED Strobe Lamp

IR DetectionIR Detection

Light sourceLight source

IRIR

Rotating glassRotating glass

Principle of functionPrinciple of function

Infra Red photocellInfra Red photocell

Lens system to adjust brightness and zoomLens system to adjust brightness and zoom

Residual liquid inside bottleResidual liquid inside bottle

BT#3BT#3

Principal of function for BasePrincipal of function for Base

Light source Light source

SemitransparentSemitransparentmirrorsmirrors

Protection Protection window and window and lenslens

BaseBase(Caméra)(Caméra)

Rotating glassRotating glass

Diffuser lens Diffuser lens and polarization and polarization filtersfilters

55 33

BaseBase

00M

iddl

e R

imM

iddl

e R

im

Cen

ter

Cen

terO

uter

Rim

Out

er R

im

003355

CenterCenterMiddle RimMiddle Rim

Outer RimOuter Rim

Camera Camera ImageImage

Principle of functionPrinciple of function

Semitransparent Semitransparent mirrorsmirrors

Protection Protection window and window and lenslens

Rotating glassRotating glass

Diffuser lens Diffuser lens and polarization and polarization filtersfilters

ISWISW(Caméra)(Caméra)

Normal Normal mirrormirror

55 33 00M

iddl

eM

iddl

e

Bot

tom

Bot

tom

Upp

erU

pper

003355

MiddleMiddle

UpperUpper

BottomBottom

ISWISW

Principle of functionPrinciple of function

FinishFinish(Caméra)(Caméra)

Light sourceLight source

Parabolic Parabolic mirrorsmirrors

OSWOSWOMNI OMNI

IIII

Sensor positionSensor position

Bottle with no causticBottle with no caustic

Transmitter Transmitter RFRF

ReceiverReceiverRFRF

Bottle with causticBottle with caustic

BT#4BT#4

10MHZ Transmitter10MHZ TransmitterPWM TechniquePWM Technique

Transmitter Transmitter RFRF

ReceiverReceiverRFRF

Caustic Detection (RF-RLD)Caustic Detection (RF-RLD)

““OSW”OSW”

Principle of OSWPrinciple of OSWOSW OSW (Caméra) (Caméra)

Light SourceLight Source

MirrorMirror

Principel of rotation OSWPrincipel of rotation OSW

Lower Lower GuidesGuidesNeck Neck

GuidesGuides

Lower guidesLower guides

Neck guidesNeck guides

P1P1

AA BB CC

Defect is detected in window 2Defect is detected in window 2

#4#4

#3#3

#2#2

#1#1

P2P2 P3P3 P4P4 P5P5

Hard Disk

CPU Card

Alacron Board forBase, ISW, Finish & Thread

InspectionAlacron Board forOSW Inspection

Finish and ThreadCamera

Inner SidewallCamera

Base Camera

IR-RLD Sensor

IR-RLD Board

ServoController

KeyboardController Card

(KCC)Camera Breakout

Board

Servo Motorfor Zoom and

Brightness

Reject Verifier

Finish Strobe (LED) Power +48V Supply

Cooling System

Computer Cage Power

Camera Service Notice SVCN 0232 Inspection HeadInspection Head

Opalglas

TestbottleSensor

Body Belt

Neck Belt

Bottom Blow-OffValve

Rotating GlassRotating Glass

Lenses under inspection headLenses under inspection head

IR-RLDBaseISWLens

Test Bottle Sensor

FinishLen

Reject VerifierReject Verifier

Reject Verifier

StarwheelStarwheel

Dead plateDead plate

Guide rails (wear strips)Guide rails (wear strips)

Air knifeAir knife

E-StopsE-Stops

E-stop

Press in – FreewheelPull out – Hard Break

PowerPowerPower Switch

-When powering down the UPS will keep the unit up for about 1 minute.

Machine Supply.• 230 V AC (single Phase Supply)

Drawer PowerTransformer

StarwheelSystem

Air Filter

StarwheelVacuum

Filter

StarwheelReject Pressure

Regulator

Bottom/DiffuserBlow-OffPressureRegulator

MachinePressureRegulator

Base-cabinetBase-cabinet BackBack doordoor

AirAir pressure Manometer and pressure Manometer and RegulatorRegulator

Mirror

DigitalOSW

Camera

ElevatorMotor

ServoController

Servo Motors

Fuse for ElevatorMotor

Servo / Camera Power Supplies

Resistor

Outer Sidewall Camera BoxOuter Sidewall Camera Box

Camera SideCamera SideProtective CoverProtective Cover

Removable Protective Lens

External Brake

Run Out

Encoder

Fuse

RejectThroughput

(PIN)

Reject Inhibit

(not recommended)

Jam

Upstream Down Bottle

Downstream Down Bottle

Spare

PLC Outputs Inputs 38997

Brake Out (System Ready)

Downstream Gap

LCM CardLCM Card

DC Power Connector

FBIComm Buss

(green)

E-Stop Relay

LCM Card 42189

LCM Card Schematic 42190

OSWComm Buss

(Red)

Optional RF-RLDOptional RF-RLD

RF-RLD Sensor 42007-0

Sonic 1 to detectMissing Bottle

Sonic 2 to closegaps in front of

the Outersidewall

OverheightBottle and

Down BottleSensor

Infeed SonicsInfeed Sonics

Infeed SonicsInfeed SonicsClose upClose up

Door Switch

Door SwitchDoor Switch

Alarm

Warning

Ready

Testbottle request

Systempower is on

Beacon LightBeacon Light

Interface (LCD Touchpad)Interface (LCD Touchpad)

Mouse Pad

Interface (Touchpad)Interface (Touchpad)MousePad

Status OverviewStatus OverviewSign on ScreenSign on Screen

Sign on Screen Status OverviewSign on Screen Status Overview

User Tabs

Reject Icon Identifier

Camera Selection

Freeze all imagesFreeze Detects

Icon Identification• IR Residual Detection• RF Residual Detection• Aux Reject• Finish Detection• Thread Detection• Base Detection• Plugged Detection• ISW Detection• Large Object Detection• OSW Detection• Scuff Detect

User Screens• Status

– Overview– System

• Current Period• Previous Period

– Base– ISW– Finish– OSW– Test Bottle– Reject History– CCRP History

• Control– System– Base– ISW– RLD– Auxiliary– Test Bottle– Reject

History– Bottle

Selection

User Login

Status TabsStatus Tabs

Control TabsControl Tabs

User TabsUser Tabs

Bottle Changeover

Go to “Control” “Bottle Selection”.

Select desired bottle.

Follow on screen instructions.

Bottle Changeover ScreenBottle Changeover ScreenAll parts associated with the changeover are color coded to aid in this All parts associated with the changeover are color coded to aid in this changeover process.changeover process.

Changeover stepsChangeover steps

Changeover stepsChangeover steps

Changeover stepsChangeover steps

Changeover stepsChangeover steps

Changeover cautions

When seating starwheel verify valve plate is clean.Verify starwheel is seated correctly.Tighten the starwheel locking handle Gently tight.

Control TabsControl Tabs

Change User ID here

You must press Change for new ID to take effect

User Logon ScreenUser Logon Screen

Security Settings ScreenSecurity Settings Screen

Test Bottle ProgramTest Bottle Program

Test is running

Time to complete test and bottles to go

Next Auto Start

Time to start after auto start

Running Test Bottle ProgramRunning Test Bottle Program

Security Levels ScreenSecurity Levels Screen

Test Bottle ProgramTest Bottle Program

Results from test bottleResults from test bottle

Base setup

Base setupBase setup

Between

3200 to 3600

Base setupBase setup

Base setupBase setup

Inner Sidewall

Camera/Display – Camera/Display – ScreenScreen

Between 2800 to 3200

Zone Setup – Zone Setup – ScreenScreen

IR-RLDIR-RLDSetupSetup

IR – Liquid Detection Base must be setup

before IR – RLD can be setup.

RF – Caustic Detection

Setup IR-RLDSetup IR-RLDBase Zoom - 10

Setup RF-RLDSetup RF-RLD

Parameter has no effect - Gain is fixed at the RF receiver.

Finish setup

Width = 6Light = 120

Width = 6Light = 120

Width = 6Light = 120

Width = 5Light = 160

Width = 4Light = 120

Width = 8Light = 200

Width = 5Light = 70

Width = 5 Light = 120

Finder Track Width = 5Minimum Track Threshold = 80

Locator

Positions

Finish Locator DiagramFinish Locator Diagram

a

Cb

A Sector

FinishFinish

Outer sidewall

Line Control – ScreenLine Control – Screen

Motor/Brake

OnDelay

StepUp

OffDelay

Step Down

Sensor

Daily maintenance Check list

1. Clean the machine with wet cloth.2. Clean the Lens of camera by tissue paper or soft cloth.3. Clean Diffuser glass by soft cloth. 4. Clean the base strobe lamp cover which is below the DEAD plate.5. Clean the vacuum pump filter. (one is in the machine and other is at the vacuum pump)

Check Points

1. Select proper starwheel and infeed ,outfeed guides. 2. Check after every pack change, all infeed and outfeed guides are properly

fitted . for OSW and EBI 3. Check sucker cups are not missing from starwheel. Check starwheel seal

ring is good and clean. 4. Check the starwheel registration plate is tight. Check starwheel is properly

placed and tightened from upper side.( without Tools )5. Check the inspection head height is right which is mentioned in the

Machine screen (check Menu-control / bottle selection.) 6. Check inspection head locking is done properly. 7. Lock it as per the given direction on the machine Check neck and body

belt are not removed from it placed. (Green and orange belt) 8. Check Bottle changeover is done properly in the machine screen. 9. Check starwheel sucker cups. ( if found damage replace it)

Check Points

11.Select proper starwheel and infeed ,outfeed guides.12.Check Bottle changeover is done properly in the machine screen.13.Check starwheel sucker cups. ( if found damage replace it)14.Check the Height bottle sensor is adjusted as per the bottle profile.15.Check Oil level in vacuum pump.16.Check transmitter and receiver, of Color and RF sensor boxes are in front of

each other. 17.Check Vacuum and Air pressure is ok. (Air pressure required is 6Bar/80 psi) 18.Check Reject pressure is ok. (60 psi) 19. Check water is "ON" for Diffuser Glass 20.Check the Safety cover for the OSW.

Maintaining Record

Daily check list Monthly maintenance list Monthly spare parts list.

Thank youThank youLooking forward for futureLooking forward for future