From Machine Operator

to Bottle Maker

Automation for productivity, safety and flexibility

May 2015 - Glassman Lyon

Risk Reduction as Stated in the Machine Directive:

May 2015 - Glassman Lyon 2

Risk assessment

According to EN 13042-1 (Feeder gob) and EN 13042-3 (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 2015 - Glassman Lyon 3

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 Machine section

without LED with LED
May 2015 - Glassman Lyon 4
Residual Risks by Technical Means (2/4)
Conveyor Ladder
Improves access to blow side for the operator

Flexconveyor integrated ladder Retrofitted conveyor ladder

May 2015 - Glassman Lyon 5
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 2015 - Glassman Lyon 6

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 2015 - Glassman Lyon 7

Residual Risks by Information and Training (1/3)

Knowledge transfer more than a manual

May 2015 - Glassman Lyon 8

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.

Instructional videos are

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

3-D renderings in video form

provides operating instructions
for the compleate machinery
Interactive machine set up
guide
May 2015 - Glassman Lyon 9
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

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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 2015 - Glassman Lyon 11

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 2015 - Glassman Lyon 12

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 2015 - Glassman Lyon 13

Setup Tools

Available tools for system configuration can be accessed from

the pdf version of the instruction notice.

FlexStacker

May 2015 - Glassman Lyon 14

Training Center

BIS
Mechanical training course

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 2015 - Glassman Lyon 15

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 2015 - Glassman Lyon 16

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 2015 - Glassman Lyon 17

Training Center Sundsvall, Sweden

Detailed information of training program content can be found on

http://www.emhartglass.com/

May 2015 - Glassman Lyon 18

Background

May 2015 - Glassman Lyon 19

Background

Technical
development

2000 BC 2000 time

May 2015 - Glassman Lyon 20

Risk Reduction as Stated in the Machine Directive:

May 2015 - Glassman Lyon 21

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 2015 - Glassman Lyon 22

Bucher Emhart Glass Automation Strategy
consists of:

Controls
Servo technology
Sensors
Feedback loops

May 2015 - Glassman Lyon 23

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 2015 - Glassman Lyon 24

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 2015 - Glassman Lyon 25

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 2015 - Glassman Lyon 26

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 to exactly the right weight
(volume) to fill the molds.

Reduced risk for operator:

Manual interference for controlling the gob weight is minimized.
Decreased variation creates higher quality and less production
disturbances.

May 2015 - Glassman Lyon 27

Gob weight control

Stability of gob weight variation

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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 out-
feed. Operator manual interaction is needed to clean section
from glass

May 2015 - Glassman Lyon 29

Constant Plunger Dwell Time:

Before activating plunger After activating plunger

dwell time algorithm dwell time algorithm

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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 2015 - Glassman Lyon 31

Blank Mold Temperature:

Before activating blank After activating blank

cooling algorithm cooling algorithm

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Development of Feedback Systems

Equal ware spacing:

The FlexRadar information is used by the bottle spacing control
algorithm to control the FlexPusher outfeed. 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 2015 - Glassman Lyon 33

 Automation => Process Control - Close Loop
Vision: Machine Operators => Bottle Maker

Automation drives Health, Safety and Profitability

Automation
Process Control Portfolio

PPC FlexRadar
TCS
BlankRadar

Gob weight control Blank Cooling Control Equal ware spacing

Constant plunger dwell

time control

May 2015 - Glassman Lyon 34

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 2015 - Glassman Lyon 35

Thank you

Inge Friberg, Compliance Engineer

May 5 6, 2015, Glassman Lyon www.bucheremhartglass.com
info@bucheremhartglass.com

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