FleXinspect - T

PartnerIng for perfect packagIng solutIons

 – Main Focus
M

• Major Planned Developments

– Next generation Mechanical Machine with
Vision inspections (Flex T)
– Next generation Vision Machine (Flex BC)
– New Vision Platform for use in new &
existing products – SMAN
– New technologies e.g. Chromatic wall
thickness
– New Modular Rotator
– New UI

29 June 2018 2
 – Machine Concept
T

 Offer all of the inspections currently available in the Veritas iM at a ALL

NEW MACHINE with the ability to add new vision inspections, with a
fantastic nice looking aspect
 Features:
 6 / 9 / 12 / 18 / 24 / 30 / 48 pocket Star wheels
 Speeds up to 420BPM
 Up to thirteen inspection (nine rotate) stations
 Vision & Modulated Check Inspections
 Vision Dip, Plug, & Ring Inspections
 Chromatic Wall thickness
 (with VMA as an option)
 Vision Base Code Reading
 Active cooling of main electronics

29 June 2018 3
 – Machine Concept
T

4
The Frame:
• Is comprised of a
few large weldments
that are bolted
together. This will
facilitate assembly.
• Is crafted to facilitate
machine cleaning
• Acts as part of the
jacket set.

29 June 2018 6
 – Door Movements
T

7
Man / Machine Interface Panel:

• Display is higher
up
• Display sweeps
around front of
the machine
• Display may be
rotated to be
viewed at the
ware reject area.
• Display may be
rotated to
facilitate
inspection set-
up.

29 June 2018 8
 – Control Panel Movements
T

9
 – Electrical Packaging
T

 Totally enclosed electronic

components
 Air Conditioner is Standard
 Simplified Wiring
 Jetter Controls
 All components in one Enclosure

29 June 2018 10
Machine Concept

29 June 2018 11
 – Twin Screw In-feed
T

Provides container stability on entry for containers that are tall and narrow.

29 June 2018 12
Changeable Drive Assemblies
• Drive assemblies can be built and installed as modules

29 June 2018 13
The Inspection Mounts: Detail of Inspection
Mount Bracket

• Facilitate quick
positioning of
sensors.
• Support sensor
mounting in
both horizontal
and vertical
orientations.

Lower Inspection
Mount Ring (Upper
ring and mounts
will be similar).

29 June 2018 14
 – Star Wheel Configurations
T

24 Pocket Star Wheel

(Ability to run competitive tooling)

# of Pockets Maximum Rotate Inspection Maximum

Bottle Stations Stations Speed
Diameter

48 32mm 9 22 400 BPM

24 65mm 9 13 400 BPM

18 83mm 7 10 350 BPM

12 115mm 5 6 250 BPM

9 130mm 3 5 180 BPM

6 170mm 2 3 150 BPM

29 June 2018 15
Machine Options - requirements
• We want to maintain our infeed and outfeed positions at 120°.
– This means the number of pockets on our starwheel needs to be evenly
divisible by 3.
– Odd numbers cause difficulties when we need to decrease the pocket
number for larger containers. It also prevents inspection possibilities
looking through the entire starwheel.
• We use 24 pocket starwheels currently, so the next logical
choices for more pockets are 30 and 36 pockets.
• We need to run containers up to 65mm in high speed mode to
match the NIS machine capabilities.

29 June 2018 16
Machine Versions Studied
24 Pocket 24 Pocket 24 Pocket Jumbo 30 Pocket 36 Pocket

Standard Starwheel Sidewall Starwheel Sidewall Starwheel Sidewall Starwheel Sidewall Starwheel

(in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm)
Max Pockets 24 24 24 30 36
Machine Diameter 26.50 673.10 26.50 673.10 29.75 755.65 33.07 840.00 38.98 990.00

Inspection Space per pocket 6.86 174.21 6.86 174.21 7.70 195.58 6.88 174.65 6.77 171.91

Inspection pockets available 13 13 13 16 19

• 24 Pocket Standard is the standard starwheel made of solid nylon that was installed at
Glasstec and is of the style supplied with Veritas.
• 24 Pocket Sidewall Starwheel is the post and finger type starwheel, suitable for sidewall
inspection.
• 24 Pocket Jumbo is a post and finger style with the diameter increased to the maximum
size that Drive 2 is capable to turn. This allows more inspection area, without more
pockets.
• 30 Pocket Sidewall starwheel is post and finger style minimally sized to run a 65mm
container using 30 pockets.
• 36 Pocket Sidewall starwheel is post and finger style minimally sized to run a 65mm
container using 36 pockets.

29 June 2018 17
Drives Studied Drive 1 Current Jetter
Amplifier - Jetter JM215

• After determining the starwheel Motor - Jetter JL4-0750-44

Gearbox - Alpha TP+ 025 MA
geometry, solid model designs
were created in ProEngineer.
From these, mass moment of
Inertia (I) was calculated. This Drive 2 - 30 pocket capacity
information was then used to Amplifier - Jetter JM215

calculate gearbox sizing and Motor - Jetter JH5-2730-87

Gearbox - Alpha TP+ 110 MF
then motor requirements.
• I narrowed down to 3 different
drives that could run the desired
starwheels at speeds of 400 Drive 3 - 36 pocket capacity

BPM. Amplifier - Jetter JM640

Motor - Jetter JL8-6800-162
• To the right are the 3 drives with Gearbox - Alpha TP+ 110 MA
the components listed.

29 June 2018 18
Three Drives

29 June 2018 19
Expected performance
• Drive 1 was sized to 440
operate a 24 pocket 420
starwheel at 400 400
BPM. It achieves this 380
but will only operate 360

the sidewall capable 340 Drive 1

BPM
starwheel at 350. 320
Drive 2
Drive 3
• Drive 2 can operate 300

the 24 Jumbo and 30 280

pocket at 400 BPM. 260

If used on a 36 240

pocket, it will achieve 220

200
370 BPM. 24 pocket starwheel 24 pocket sidewall 24 pocket jumbo 30 pocket sidewall 36 pocket sidewall
starwheel starwheel starwheel
• Drive 3 will run all
starwheel versions at
410 BPM or higher.

29 June 2018 20
Flex XL 24 Pocket

• This version has does not meet maximum speed criteria in sidewall
mode.
• Significant design work complete.

29 June 2018 21
Flex XL 30 Pocket

• This version uses the same amplifier as the current design.

• Hoops not shown to proper size.
• Redesign required
– Hoops, dead plate, drive, drive mounting, infeed guide rail, infeed screw mounting.
29 June 2018 22
Tooling
• Replace Post and Finger at job
change

• If we choose to not include

uprights and mounts (just nylon
fingers and rollers)

29 June 2018 23
30 Pocket – (ø840mm) Tooling Breaks
• To cover our diameter range, we need to produce down to 9 pocket
starwheels.
• 18 pocket starwheels will handle everything made on a triple gob NIS machine
(90mm MAX) at 320 BPM. This includes the popular 750ml wine bottles that
fall in the 78-83mm range.
• We may need to produce 24 pocket tooling to allow higher speed for
containers Up to 78mm.
• I recommend we produce 30, 18 and 9 pocket tooling. Speed requirements
may require us to produce the intermediate 24 pocket tooling as well.

Available Tooling Container Diameter Breaks

Pockets Bottle Diameter Est. Speed

mm inch BPM

30 66 2.60 400

24 78 3.07 370

18 107 4.21 320

12 152 5.98 270

9 190 7.48 200

29 June 2018 24
Changeable Drive Assemblies
• Drive assemblies can be built and installed as modules

29 June 2018 25
Recommendations
• Complete the 24
pocket machine that
is being assembled,
in April, as the first
priority
• Design the 30
POCKET machine as
the next priority
• Redesign the
inspection optics to
combine and reduce
their size
• Provide the option at
build time to use the
26.5” or 33” wheel
29 June 2018 26
 – Assurance inspection
T

•Use setup fixture for

repeatable finger placement
•Track inspection results per
pocket
•Monitor Pass/Fail
percentages
•Monitor finish
movements
•Monitor pockets with
camera
•Inspections are less
affected by container
movement

29 June 2018 27
 – Modulated Check
T

• No focusing
• High sensitivity
• Lights do not interfere with one another
• Lights are programmable (brightness &
frequency)
• Different light intensities
• Self-diagnostic
• Long lifetime
• Sensors not sensitive to ambient light
• High signal to noise ratio

29 June 2018 28
 – Body Check
T

• Standard focus is: 60 mm / 2.4 inch

• Standard lenght: 100mm / 4.0 inch

29 June 2018 29
 – Crocodile Wall Thickness
T

•Chromatic Glass Thickness system

•Emhart will have exclusive rights to head

29 June 2018 30
Chromatic vs VMA

7000
Corners Flats

6000

5000

Distance 1
4000 Distance 2
Thickness
Intensity 1
3000 Intensity 2

2000

1000

0
1 14 27 40 53 66 79 92 105 118 131 144 157 170 183 196 209 222 235 248 261 274 287 300 313 326 339 352
degrees

29 June 2018 31
Chromatic vs VMA
7000
Corners Flats
6000

5000

Distance 1
4000 Distance 2
Thickness
Intensity 1
Intensity 2
3000
VMA Thickness μM

2000 VMA Thickness

1000 CHRoc Thickness

0
1 15 29 43 57 71 85 99 113 127 141 155 169 183 197 211 225 239 253 267 281 295 309 323 337 351
degrees

29 June 2018 32
 – Vision Plug Inspection
T

• Image acquisition using

– Super bright LED light source
– High speed area matrix pixel camera

• Non contact inspection for

– Min Bore
– Max Bore
– Oval Finish
– Birdswings

29 June 2018 33
 – Vision Dip Inspection
T

• Image acquisition using

– Super bright LED light source
– High speed area matrix pixel camera
– Acquire multiple images as the bottle rotates

• Non contact inspection for

– Dip
– Height
– Lean
– Saddle

29 June 2018 34
 – Vision Ring Inspection
T

• Image acquisition using

– Super bright LED light source
– High speed area matrix pixel camera
– Acquire multiple images as the bottle
rotates
• Non contact inspection for
– T – Thread diameter
– E – Thread root diameter
– F – Finish top diameter
– D – Locking ring height
– H – Neck

29 June 2018 35
 Flex T
Vision Plug Ring and Dip

PartnerIng for perfect packagIng solutIons

Vision Plug Gauge

29 June 2018 37
Vision Ring Gauge

29 June 2018 38
Vision Dip

29 June 2018 39
Vision Plug

29 June 2018 40
Vision Plug Ring

29 June 2018 41
Vision Plug Ring Dip

29 June 2018 42
Vision Plug Ring Dip

29 June 2018 43
Show with Vision Sidewall Starwheel

29 June 2018 44
Side View of Inspection

29 June 2018 45
Inspection Front View

29 June 2018 46
 – Base MNR
T

•Reads bottom dot, peanut, and alphanumeric codes

•Optics provide an enlarged & sharp image of the mold code

•Use custom algorithms to decode mold number

•Exceptional reliability on round and non-round containers

29 June 2018 47
 – Line Scan Sidewall
T

Use linescan cameras to view the sidewall of the

container while it is in the rotational station.
• Multiple cameras
• 360° view of bottle
• Defects viewed with no distortion
• No blind spots
• Works with embossing
• High intensity light sources
• Detects: Stones, Seeds, Bird
Swings, Blisters, Oil Marks, &
Folds
Ware Handler
• Sidewall Inspection
Starwheel.
(Lower cyclic rates with
sidewall inspection
capability.)

• Adaptor for standard

starwheel mount post.
(Higher cyclic rates with
reduced sidewall
inspection capability.)

29 June 2018 49
Bottle Image (Birdswing)

“Unwrapped”
Red indicators image of detection
highlight bottle withofbirdswing
birdswing
visible behind
at attachment points the
andembossing
along the swung
glass
Bottle Image (Paint Dots)
This image shows a wine
bottle with painted-on dots A B C D E
of various sizes. Dots from
both the front and back of
the bottle are shown.

This image illustrates

detection for the following
dot sizes:
A 0.38mm - 1/64”
B 0.79mm - 1/32”
C 1.57mm - 1/16”
D 2.36mm - 3/32” Even has the ability to detect
defects that occur on inspection
E 3.17mm - 1/8”
zone boundaries.
 – Post Style Starwheel
T

Provides the best

access for Light
Source
Projected Flex T
speed is 350
BPM.

29 June 2018 52
 Line scan camera imaging
• Testing with tele-centric lens and 1024 pixel for Sidewall

Non enhanced blister logo area

Enhanced blister under logo area

29 June 2018 53
Line Scan Sidewall on Non-Round

• Jack Daniel Bottle

– Narrow light causes dark
areas at the corners
– Wide light allows 360º
inspection

29 June 2018 54
 – Ring Damage Detection
T

• Detecting flange finish, knockout

& wire edge
– Use high resolution view of the finish
– Mounted on-axis light to Veritas iM
– Take multiple images as bottle rotates

29 June 2018 55
FleXinspect T linescan finish amber beer
without defects

A = back inside surface

B = Front outside surface
C = Bead outside surface
D = under the bead

29 June 2018 56
FleXinspect T linescan finish A/B amber with
vertical split

29 June 2018 57
FleXinspect T linescan finish A/B amber with
blister under the surface

29 June 2018 58
 – Defect Classification

29 June 2018 59
 – Training Set

29 June 2018 60
Laser Coded Reader
• Laser coding of glass bottles
improves traceability June 21,2008, 14:22
• Laser etching is currently being
done by some customers
• Development of an on-line laser
code reader could eliminate the
use of machine codes (dots or
seven segment)
• Reader algorithm running in SMAN
platform on Emhart vision
processor

29 June 2018 61
 – New User Interface

– This project brings together the best of the existing Veritas and Super
systems to create a new robust generic vision platform that can be used for
future developments.
– Focus on easy setup and use
– Emhart/Inex will have full control of user interface and use of vision
processing algorithms.

29 June 2018 62
 – New User Interface

29 June 2018 63
 – New User Interface

29 June 2018 64
 – New User Interface

29 June 2018 65