Line Control for Beverage Line

Transcription

Advanced Container
Flow Simulation
for Beverage Lines
Srinivas Kesari
OEM Project Manager
16th June 2011
Copyright © 2009 Rockwell Automation, Inc. All rights reserved.
Agenda Topics
1. Introduction to Beverage Lines
2. Key Packaging Machines
3. Beverage Line Operation and Control
4. Case Study : Line Balancing Simulation
2
Agenda Topics
2. Key Focus Areas
3
Typical Operations in Beverage Packaging
Liquid product
from upstream
process plant
Filling of the
container then
sealing it with a
lid or cap
Palletisation
ready for
transport
Washing of the
container
Pallets of Empty
Cans or Bottles
to be Filled
New or Used or
direct feed from
Blow molder
Conveying
System to
control buffer
stocks
Packaging into
Cases, 6pack,
24 pack etc.
Labeling of the
container
Heating the
product to kill
off unwanted
organisms
Challenges
 Line Performance & Integration
 Reduced Downtime & Waste
 Governmental Regulations
 Extensive material tracking
 Effective usage of Labor in Shop floor
4
Typical Beverage Packaging Line Layouts
Returnable Bottle line
Depalletizer
Uncaser
Soaker
Bottle
Inspector
Filler
Crowner
Fill
control
Pasteurizer
Videojet
Labeller
Caser
Palletizer
Storage
Filler
Crowner
Fill
control
Pasteurizer
Videojet
Labeller
Caser
Palletizer
Storage
Filler
Seamer
Fill
control
Pasteurizer
Caser
Palletizer
Storage
Filler
Crowner
Fill
control
Pasteurizer
Videojet
Labeller
Caser
Palletizer
Storage
Filler
Capper
Fill
control
Pasteurizer
Videojet
Labeller
Caser
Palletizer
Storage
Non returnable line
Depalletizer
Uncaser
Rinser
Can Line
Depalletizer
Riunser
Videojet
Returnable PET Line
Depalletizer
Uncaser
Soaker
Decapper
Sniffer
Blowmolder
Rotary
Rinser
PET Line
Preparation
Filling
Labeling
Packing
5
Typical Beverage Packaging Line Layouts
Example High Capacity Returnable Bottle Line with Buffer Zones
To avoid over dimensioning of equipment, buffer zones are introduced between units to assure filler efficiency and product quality
New Glass
Depall
Decapper
Buffer
Uncaser
Buffer
Soaker
Buffer
Filler
Crowner
Buffer
Fill
control
Buffer
Buffer
ffer
Bu
Bottle
Inspector
Pallet
storage and
inspection
Empty case
washer
Buffer
Depalletizer
Buffer
Bu
ffer
Bottle
Inspector
Empty case
inspection
Full case
control
Buffer
Caser
Buffer
Videojet
Buffer
Pasteurizer
fer
Buffer
B uf
Palletizer
Buffer
Buffer
Buffer
r
ffe
Bu
Stretch/
shrink wrap;
Buffer
Labeller
Labeller
Storage
6
Categorization of Equipment
Equipment at Pre-Filling
Filling Station
Equipment at Post-Filling
End of Line Packaging
7
Agenda Topics
2. Key Packaging Machines
8
Impact of Automation in Beverage
Machine
Key Automation Products
Application
Filler
Synch. Drives / Intelligent IO
Solution / Wireless
Synchronous Position
Gearing
400-600 / min indigenous
Conveyors
Networked Drives – On
Machine
Buffers and Accumulation
Control
600 / min indigenous
Shrink wrappers
Servo Motors – High Speed
IO
Advanced CAM Design
40-50 / min
emerging
Labelers / Sleevers
High End Motion
Dead time Compensation
Stretch-Molding
Temperature Control / High
Speed IO / Wireless
High Speed IO Control
Case Packers / Un-Casers
Motion ( Variant
Sophistication )
Synchronized Path planning
vs Container Size
8 – 12 Cases / min
Palletizers / De-palletizers
Motion
Carton orientation and
Positioning
10 – 12 Cases / min
Comments
9
Automation in Filling Technology
Electronic Valve Control
using Device Logix
decentralized IO control
Wireless IO Communication
(all rotary machines)
Prototype operating
AC-Drive to AC-Drive
Gearing
Established Technology
Wireless reducing Cost of Slip Rings /
Replacing Proprietary Electronics with off-the-shelf components
10
Automation for Sleever Technology
• Performance improvement 50%100% on the same or similar
mechanical solutions
High Speed
Registration Sensor
Label Index
– Achieved through improved Cam
Design and automatic time
compensation mechanisms
– Allows dynamic speed adaptation on
an intermittent system
Cutter
Shooter Motor
Bottle Sensor
Side Belt
Conveyor
• Results are
– Higher reliability – due to fewer stops,
lower accelerations,
– Higher Flexibility – due to more bottle
shapes and sizes in the same
machine
– Smaller Layout – due to better
dynamic speed adaptation
Automation for OPP Labeler Technology
• Minimizing mechanical linkages by
replacing Soft cams thru Servo
Operation
– Achieved through improved Cam
Design and automatic time
compensation mechanisms
– Allows dynamic speed adaptation on
an intermittent system
• Results are
Feeder roll
shear roll
– Higher reliability – due to fewer stops,
lower accelerations,
– Higher Flexibility – due to more bottle
shapes and sizes in the same
machine
– Smaller Layout – due to better
dynamic speed adaptation
Glue gun
Bottle rotator
12
Shrink wrapper Technology Ready made template
Motor A
Continuous
5
6
Sto
p
3
Sto
p
1
Star
t
Star
t
4
Automatic Machine Resynchronization eliminates deadly downtime
Full Recipe Management rather than Black box system
2
13
Agenda Topics
2. Key Packaging Machine
4. Case Study : Line Control Simulation
14
Principles of Beverage Line Operation
• Line should be “Balanced” around the Filler
125
120
115
110
105
er
Tr
uc
k
Fo
rk
Pa
lle
tis
Ca
se
r
La
be
lle
r
lle
r
Pa
st
eu
ris
er
Fi
So
ak
er
Un
Ca
se
r
De
pa
lle
t is
er
100
Tr
uc
k
– To prevent container damage
– Bi-Directional accumulation
tables up and downstream of
Filler to keep line running
130
% of Filler Capacity
• Conveying System Design Critical
135
Fo
rk
– Push empty containers “in”
– Pull full containers “out”
– Filler should run constant at
100% of its rated capacity
Machine Type
• Prerequisite factors for Good Line Design
– Conveyor Section Length
– Variable speed control for conveyors
– Adequate buffer space for accumulation
Proper calculation of buffer zones and control programming is critical
for optimal line layout and operation
15
General Perception of Beverage Line
Performance and Control
• Classic setup of a line will try to set every machine at the maximum rated
speed possible
– Resulting in frequent start/stop
– Resulting in higher maintenance and frequent faults of the equipment
• Modern considerations look at more efficient ways to configure the
equipment
– Adjusting equipment for optimal performance against the manufactured product
– Adjusting conveyors for optimal capacity against the variant machine behaviors
• Goals are
– Continuous production
– Maximum uptime until an upstream or downstream fault causes a filler stop
– Minimum time until the line balances after any equipment stop
Copyright © 2009 Rockwell Automation,
16
Inc. All rights reserved.
16
Traditional Principle of Conveyor Control
• Low End Lines:
Machine
– Most of low end beverage lines do not have any line control, they just rely on couple
bottle sensors to detect bottle starved or bottle blocked, depends on these situations
to start/stop the machines.
– Conveyors will run at a fixed speed and can not be adjusted.
– Operators are also exhausted by monitoring the line status all the day.
Start ConditionBottle detected from Infeed and bottle empty from outfeed
Stop ConditionBottle starved from infeed or bottle blocked from outfeed
17
Traditional Principle of Conveyor Control
• High End Lines:
Machine
– Normally increase 1 or 2 sensors on the infeed conveyor to adjust machine running
speed to Low/Mid/High speed.
– Conveyor will be controlled.
• Break down the line to several conveyor sections and handled by monitoring the status of each
section.
• The concept for this solution is actually filling up every section, make each section as full as possible.
If gap been detected, the upstream section will try to moving faster to fill up the gap, ensure each
machine can running continuously.
Speed will increase to fill up next
18
Steps to accomplish Quality flow control
• Stable, robust and efficient machine control
– Allowing a machine to adapt to different line conditions
– Defining a standard and simple interface to a machine
• Understanding equipment capability and behavior
– Frequency of stops
– Sensitivity to pressure
– Capability to accelerate and decelerate
• Designing appropriate accumulation and transport sections
– Transport conveyors are primarily used for machines to measure volumes and
adapt their behavior
– Accumulation conveyors are used to allow for typical machine downtimes
• Developing appropriate line simulation and control algorithms
Copyright © 2009 Rockwell Automation,
19
Inc. All rights reserved.
19
Analyzing the Line Layout
 To solve the issues from the conventional solution, the best way is doing bottle flow control.
 Flow control is actually bottle volume management
 We also divide entire line to a couple of zones, and calculate the capacity of how many bottles
can be load by each zone.
 Based on this capacity, we can easily understand whether the zone is currently full or not.
Shrink Wrapper
Filler
Pasteurizer
Combiner
Sleever 1
Buffer
Oven 1
Spliter
Accumulator
Pressureless table
Sleever 2
Oven 2
20
Concepts – Line Buffer
 Modeling Line Components
 Critical aspect of any form of Line Flow Control is estimating its fill volume as the fill
volume in combination with the own, preceding and subsequent unit’s material
speeds is the base of a decision to increase, decrease speed or even generate a
stop.
 Our approach will be to program a geometrical buffer model for each Line Element
that effectively passes counts of product (bottles) through the entire Line. For
machines (Fillers, Labelers, Sleevers, wrappers) the physical production rate is easy
to establish, while for bulk product conveyors this mechanism requires rate-relative
estimates using
─ Length
─ Width
─ Physical Speed
─ Calculating Fill Volumes of the system
─ Understanding speeds and volumes of systems before and after
21
Line Balancing Technology
 An AOI is used to handle the flow control for each conveyor section, you input the parameters of
conveyors including length/width/maximum volume/line speed etc. The instruction will calculate
the actual volume of product (bottles) within each section, also adjusting the speed based on how
many bottles are being delivered to the next section.
 We can link up each instruction, just like a soft line layout, and the programmer can easily identify
the status of each section and aid in trouble shooting.
22
Modeling process
Packaging Line Speed : 500 bpm
Filler
2.5m
Filler Outfeed
Conveyor
Speed (meter
Enter the
per minutes
machine speed
6m
Buffer Zone
1m
Dosing Zone
6m
3m
Pressureless
Combiner
Enter the
Conveyor
Parameter
Sleever Infeed
Sleever
23
Agenda Topics
2. Key Packaging Machine
24
Line Simulation Model with HMI
End
Labeler
Line
Line
of Production
Running
Start-Up
Reload Material
-Linemachines
-All
-Conveyors
-Reduce
PLC
conveyor
receive
and
conveyors
operating
speed
end
production
to atare
line
ready
to produce bottle
speed
accumulate
- Stop conveyor
- Stop
when
Conveyor
Conveyors
utilization
conveyor
will
havebe
turn on
different
upon
reach
reaching
zero
once
utilization
or the
low
High
proceeding
set
Utilization%
low
value
limit – Buffer,
machine/conveyor
Infeed,
Outfeed,
-Maximize
-Stop
machine
Filler
after
has output
Dosing,
etcbottle
Run time
infeed
conveyor has
rate
- Adjust conveyor
stop
- Progressive
speed
base onLine
- Progressive Line
Start
utilization
set value
Stopping
-Creating buffer
space on conveyor
DR07 reduce speed for
product accumulation
Infeed Conveyor
Buffer Conveyor
DR08 Stop when Utilization
reach set value
25
Typical Machine interface to Line Controller
• 4-8 Input Signals to the PLC that can be
individually configured
–
–
–
–
–
–
–
–
Do Nothing (default)
Machine Low Production Speed
Machine Run IN / Run OUT Speed
Machine High Production Speed
Machine Surge Speed
Open Infeed
Machine Start permissible
Run by External Reference Speed
• 4-8 Output Signals by the PLC that can
be individually configured
–
–
–
–
–
–
–
–
–
–
–
Do nothing (default)
Static High Signal
Machine Faulted
Machine Producing - Infeed Screw is
running
Pulse per 10 products
Machine Running
Automatic Speed Active
Discharge Saturation
Product Starvation
Minimum Packaging Material
Maintenance required
Line Interface
Line Controller
Sleever
26
Line Control for Beverage Line
Module
Status
Module
Status
Network
Status
Adapter
Status
NODE
Module
Status
Network
Status
NODE
Module
Status
Network
Status
NODE
Module
Status
Network
Status
NODE
Module
Status
Network
Status
NODE
Network
Status
NODE
DeviceNet
Status
PointBus
Status
24VDC
Sink
Input
24VDC
Sink
Input
24VDC
Sink
Input
24VDC
Sink
Input
24VDC
Sink
Input
24VDC
Sink
Input
1
1
1
1
1
1
2
2
2
2
2
2
3
3
3
3
3
3
4
4
4
4
4
4
1734-ADN
System
Pow er
Field
Power
1734
IB4
1734
IB4
1734
IB4
1734
IB4
1734
IB4
1734
IB4
27
Summary
• RA domain expertise consultancy includes….
– Line Layout Modeling
– Technical guidance to Optimize the size of Conveyors,
interconnections between the various Equipments
– Guiding the OEMs on how to use global programming standards such
as Pack_ML
– Provide tools and technologies in the form of templates and function
blocks to help OEMs build higher speed and more flexible
equipments; and assisting Integrators and Users in how to optimize
Line layouts & Plant operations
28
Any questions ?
Thank You
29

Line Control for Beverage Line

Transcription

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