Maintenance Training This training is intended for Maintenance personnel
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
MaintenanceTraining
This training is intended for Maintenance personnel
Parts of Machine
Computer CabinetInspection Head
Base Strobe Assembly
Circuit Breaker Panel
Diffuser Glass Motor
UPSGearbox
Starwheel Motor Power
Supply
Base Cabinet Front Door
PLC Interface
Vacuum Venturi
with Tank
UPS Batteries
Starwheel Motor Vacuum Venturi Pump
RejectValve
Base Cabinet Front DoorVacuum
Surge Tank
Power Supply Drawer
Controller forReject Conveyor
Motor
Reject Conveyor Motor ControllerStarwheel Motor Power Supply
UPS
Base Cabinet Drawer
Main PowerTransformer
Base StrobeAir Filter
StarwheelSystem
Air Filter
StarwheelVacuum
Filter
StarwheelReject Pressure
Regulator
Bottom/DiffuserBlow-OffPressureRegulator
MachinePressureRegulator
Base Cabinet Back Door
Cabinet Drawer
Maintenance panel
Main Regulator Air
Regulator Base blow off
Regulator Reject Pressure
Machine Input Pressure min. 80PSIBottom blow off press.
Starwheel cleaning pressureReject pressure
Airfilter Panel
! ! !
Cabinet Transformer 115VAC
UPS Card and Batteries
Motors for Diffuser and Brush Drive
Diffuser or Rotating Glass
Test BottleSensor
Body Belt
Neck Belt
Airknife
Rotating Glass Drive
Water Drip Valve
Base Strobe Lamp
Input voltages LED 1000V and 280V
Reject Valve
Vacuum Buffer Tank
Circuit Breakers and Voltage monitor
PLC interface
Computer compartment
Hard Disk
CPU Card
Alacron Board forBase, ISW, Finish & Thread
Inspection Alacron 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
Inspection Head
Reject Verifier
Finish Strobe (LED) Power +48V Supply
Cooling System
Computer Cage Power
Finish interface card
Camera Breakout board
Computer Card cage
Reject verifier Sensorlocated underneath computer card cage
Hard Drivelocated on side of computer card cage
Lenses under inspection head
IR-RLDBaseISWLens
Test Bottle Sensor
Neck Belt
Finish lens
Reject Verifier
Reject Verifier
Touchpad – LCD Display
Starwheel
Starwheel Area
SealringValve plate
Valve Plate
Purge 5-7 psi
Vacuum
Reject PortVacuum/Pressure
Vacuum
Atmosphere
Guide rails (wearstrips)
Upper Starwheel Position
About 1-2mm distance between Bottle and Starwheel plate. To be adjusted with spacer underneath starwheel plate
Position of Infeed PulleyPulley to push with belt slightly against bottle.
Deadplate
Base Blow off Air Knife
Air knife
Adjustment of Base Blow off Valve
Loosen bolts and move valve
Adjust airflow
Conveyor encoder
Drive sprocket of encoder
Sonic 1 to detectMissing Bottle
Sonic 2 to closegaps in front of
the Outersidewall
OverheightBottle and
Down BottleSensor
Infeed Sonics
Infeed SonicsClose up
Sonic Transmitter and Receiver
RF-RLD Sensor
RF-RLD Sensor
Position of RF sensors to bottle
2-3mm space
Adjustment of RF sensor blocks
Adjust the RF Guides, so the bottles don‘t hit against guide plates
Adjustment of RF sensor blocks
Mirror
DigitalOSW
Camera
ElevatorMotor
ServoController
Servo Motors
Fuse for ElevatorMotor
Outer Sidewall Camera Box
Freznel Lens
Servo / Camera Power Supplies
Heater
Light Panel
Cooling Fan
Outer Sidewall Light Panel Box
Intake Air Filter
OSW camera elevation system
Drive motor for elevation system
OSW digital camera
OSW servo controller
OSW infeed guide rails
OSW rotator guides
OSW rotator guides
Rotation OV2 OSW
PowerPower Switch-When powering down the UPS will keep the unit up for about 1 minute.
E-Stops
E-stopPress in – FreewheelPull out – Hard Break
Door Switch
Door Switch
Alarm
Warning
Ready
Test Bottle Request
System Power is On
Beacon Light Tower
This same color scheme is used on all OMNI Screens in lower bottom right corner.
24 VDC Power supply for Computer. On backside of UPS card bracket
115VAC Input
24VDC output
DC-DC converter card
LED‘S DC-DC converter card
PS 4
PS 1
Line Control Module(LCM)
XFMR 2
PD 2
PS 3
PS 5
XFMR 1
Base Cabinet Drawer
HV Rectifier
Sensor connection blocks
Sensor blocks: SB1 and SB3 outside base cabinet. SB2 inside base cabinet
Brake Out (System Ready)
External Brake
Run Out
PLC Interface
Encoder
Fuse
Downstream Gap
Reject Throughput (PIN)
Reject Inhibit
(not recommended)
Jam
Upstream Down Bottle
Downstream Down Bottle
Spare
PLC Outputs Inputs38997
UPS card and batteries
Theory/Functionality:
The OV-II UPS is not a typical AC UPS.The OV-II UPS is a DC UPS whose sole purpose is to switch 24VDC from the power supply in the Base
Cabinet (which is killed when the main power switch is thrown) to the 24VDC battery for a period of one minute to allow Windows to have time to properly
shut down.
The Lead-Acid 24VDC UPS battery is charged with the 30VDC power supply that is mounted in the
Base Cabinet. CB-11, the breaker for this supply, is connected directly to the in-coming 220VAC line to allow charging to take place regardless of the state of the main power switch. The power for this circuit
is not subordinate to the main Power Switch.
UPS Battery
LCM on cabinet drawer
LCM
LCM download screen
1
EncoderMotor
Starwheel
Reference position « 1 »From « Pin 1 Offset »
Vacuum Tubes
Reject conveyor
Light Source (Strobe Lamp)
SemitransparentMirrors
Protection windows
IRBase
(Caméra)ISW
(Caméra)
Finish(Caméra)
Thread(Caméra)
Rotating glass
Diffuser glass (Brightfield Option)
Option
IR RLD detection
LED Strobe Lamp
IR Detection
Light source
IR
Rotating glass
Principle of function
Infra Red photocell
Lens system to adjust brightness and zoom
Residual liquid inside bottle
BT#3
Principal of function for Base
Light source
Semitransparentmirrors
Protection window and lens
Base(Caméra)
Rotating glass
Diffuser lens and polarization filters
5 3
Base
0M
iddl
e R
im
Cen
terO
uter
Rim
035
CenterMiddle Rim
Outer Rim
Camera Image
Desciption of Inspection zones
Principle of function
Semitransparent mirrors
Protection window and lens
Rotating glass
Diffuser lens and polarization filters
ISW(Caméra)
Normal mirror
5 3 0M
iddl
e
Bot
tom
Upp
er
035
Middle
Upper
Bottom
ISW
Principle of function
Finish(Caméra)
Light source
Parabolic mirrors
Caustic Detection (RF-RLD)OSW
OMNI II
Sensor position
Bottle with no caustic
Transmitter RF
ReceiverRF
Bottle with caustic
BT#4
“OSW”
Principle of OSWOSW (Caméra)
Light Source
Caméra
Mirror
Principel of rotation OSW
Lower GuidesNeck
Guides
Principel of OSW inspection
Lower Guides
Neck Guides
A B C
Defect on bottle « A »
P1 P2 P3 P4 P5
Lower guides
Neck guides
P1
A B C
Defect is detected in window 2
#4
#3
#2
#1
P2 P3 P4 P5
Lower Guides
Neck Guides
A B C
#4
#3
#2
#1
P1 P2 P3 P4 P5
Lower Guides
Neck Guides
A B C
#4
#3
#2
#1
P1 P2 P3 P4 P5
Other defect in new bottle on zone 4
Base Camera/Display
3000 - 3500
Base Zone Setup
Base Algorithms
Calibration Procedures
Base Inspection Setup
Zone Setup – Screen
Algorithm – Screen
Masks
Inner Sidewall
• ISW Calibration procedures• Base-Inner sidewall parameter description
s
Finish Inspection
aCb
A Sector
Finish
Finish Locator DiagramWidth = 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
Tracking WindowWidth
Locator Positions
Tracking Centering – Screen
Lane AWill not allow Sector Average Size light level to drop below this value
Increasing this value makes it easier to detect object. DO NOT EXCEED 50!!
Lane BWill not allow Sector Average Size light level to drop below this value
Decreasing this value makes it easier to detect object.
Finish Setup procedures
• Finish Setup
Camera/Display
Horizontal Registration
Vertical Registration
Masks
Window Setup
Algorithm
OSW setup
• OSW setup
Setup IR & RF RLD
Base Zoom - 10
Line Control – Screen
Test Bottle Program
Test Bottles are run from this
Screen
Start Test Here
Test is running
Time to complete test and bottles to go
Next Auto Start
Time to start after auto start
Running Test Bottle Program
Results from test bottle
Test bottleBottle Insertion
To change either selection below requires maintenance level password access.
• In order– Bottles must be run in order
• This is the recommended method.• Random Order
– Bottles can be run in any order. The machine will automatically resort the order and show results.
Bottle Changeover Screen
Changeover steps
Changeover cautions
• When seating starwheel verify valve plate is clean.
• Verify starwheel is seated correctly.• Tighten the starwheel locking handle is
extremely tight.
Bottle Changeover
All parts associated with the changeover are color coded to aid in this changeover process.
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
Related Documents
