Patent Application
20080134724
The present invention relates to manufacturing and associated control systems. More specifically, the present invention relates to controller-implemented systems for managing and operating automated equipment for the manufacturer of glass containers.
For the purpose of promoting an understanding of the principles of the present invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will, nevertheless, be understood that no limitation of the scope of the invention is thereby intended; any alterations and further modifications of the described or illustrated embodiments, and any further applications of the principles of the invention as illustrated therein, are contemplated as would normally occur to one skilled in the art to which the invention relates.
Generally, one form of the present invention is a software and hardware system that controls manufacturing equipment to produce bottles made of glass on two container forming machines connected together, such that production settings on one of the container forming machines can be changed without interrupting production on the other container forming machine. In another embodiment, the control system leverages off-the-shelf PLC components to precisely schedule output images based on calculated output image times, distributing those output image update times via a fiber optic data network. In other embodiments, the manufacturing equipment produces other products as will occur to those skilled in the art.
As shown in
Control room terminal 102 resides in a control room of the manufacturing facility and is used for creating, modifying, copying, and deleting job data. The job data is stored on the hard disk of control room terminal 102 in data tables they database, such as a MICROSOFT ACCESS database, and it includes the function timing for all production sections in terms of “degrees” (as will be discussed further herein) for “ON” and “OFF” states. The job data also includes information regarding the configuration of the system and other parameters specific to the particular job. The job data is accessed via the “Eclipse Job Editor,” which is described further herein, and which in this embodiment is developed using VISUAL BASIC for WINDOWS.
Operator interface computer 104 is typically located on the plant floor near the production machine. It communicates with the control room terminal 102 and the PLC's (programmable logic controllers) in the system via network hardware 106. In one embodiment, the PLC's are Allen-Bradley PLC's, and network hardware 106 comprises an Ethernet LAN. The operator interface computer 104 executes an operator interface program, which is a combination of RSVIEW software by Rockwell and custom programming in Visual Basic. RSVIEW is a development package that communicates with Allen-Bradley PLC's and provides tools for developing reference-based screens for interacting with the PLC's. The operator interface computer provides the following functionality:
In this illustrated embodiment, an Ethernet network 106 enables communication between the control room terminal 102 and the operator interface computer 104. Network 106 also provides a high-speed communications path between all of the PLC processors located in the controller racks 112, 114, 116, and 118 via the Allen-Bradley E-NET modules 142 in each rack 114, 116, 118 (and, in some embodiments, rack 112 as well). The operator interface computer 104 also communicates to these processors by using network 106 for downloading and production data changes.
High speed connection network 108 is preferably a SYNCHLINK network, which provides a very high-speed fiber-optic communications path between all of the PLC processors located in the controller racks 112, 116, and 118 via Allen-Bradley SYNCHLINK modules 144 located in each rack. The SYNCHLINK module 146 in main controller rack 112 is the time master, coordinating the system clock for each processor, thereby ensuring that each processor is synchronized on a standard time base. In the present embodiment, the synchronization achieves one picosecond accuracy. Time master 146 also continuously sends buffered data (including the next 8 output image execution times, based upon the current production rate) to each processor through its respective SYNCHLINK module 144.
DeviceNET network 110 provides a high-speed communications path between all of the operator panels 125 and the DeviceNET module 148 located in the main controller rack 112. Each operator panel 125 in the system 100 has a DeviceNET Interface Board (not shown) connected to the Push Buttons, Switches, Indicator Lights and a +24 VDC Source Voltage. It is through this board that DeviceNET 110 detects the operation of the buttons and switches, and lights the indicator lights on each operator panel 125 when commanded to do so.
Controller racks 112, 114, 116, and 118 are each built upon an Allen-Bradley CONTROLLOGIX chassis, which provides slots and a backplane for interconnecting various modules. In the present embodiment, as illustrated in
The main controller rack 112 in the illustrated embodiment includes three CONTROLLOGIX 5561 processors programmed to act as a main processor, array processor, and HEWR (Hot End Ware Reject) processor, respectively. The main processor performs synchronization and timing calculations. It also calculates the output image execution times that are broadcast to the section controllers via the high speed communications network 108. The array processor receives job data from operator interface computer 104 and converts it from “ON” and “OFF” degree timing into a binary image for each of the outputs for each section of the system 100. These binary images are then sent to the appropriate section controller processors. The HEWR processor monitors the requests for rejecting bottles (to be blown off by a solenoid) from the section's reject switches, monitors the position of each section's bottle(s), and controls the sequencing of the reject process.
Main controller rack 112 also houses two CONTROLLOGIX E-net Ethernet modules. One is used for processor to processor communications, and the other communicate with the operator interface computer 104. A CONTROLLOGIX SYNCHLINK module is used for the master clock and transmitting buffered data to the other processors. A CONTROLLOGIX DeviceNET module interfaces with the push buttons and indicator lights located on each section's operator panel 125. CONTROLLOGIX input modules are used to detect the HEWR Photo-Eye (see below) and synchronization pulses from the drive system 135. CONTROLLOGIX output modules are used to energize the HEWR blow-off solenoid, and provide synchronization pulses to the drive system 135. Some of the outputs in this rack are also sent to the drive system 135 to indicate production counts for production data acquisition.
Each of the section controller racks 114, 116, and 118 controls four of the I.S. machine's sections' outputs for operating the container-forming mechanisms. A 20-section Eclipse E-Timing control system would contain five of these section racks. In this illustrated embodiment, each section controller rack 114, 116, or 118 includes a CONTROLLOGIX 5561 processor, known as the Section Processor. The processor is programmed to allow it to perform its section timing functions. The program is common across all of the section controllers, but each instance does identify itself through these discrete inputs, which are energized in a specific pattern for rack number identification.
The section processor performs synchronization and timing calculations. It also schedules the output image execution times that are received from the processor on the Main Controller rack 112 via the SYNCHLINK modules 144. In addition to scheduling the output execution times, this processor also manages the incrementing of a pointer to a row in an array Binary Output Images. This element of the array becomes the output image that is sent to the output modules for execution at the scheduled times.
Each Section Processor continually receives status information from the Main Processor so that it can stop one or more production section(s) if a fault is detected. In addition, these processors send their status to the Main Processor so that it can react accordingly if a fault is detected in the Section Controller Rack.
The Main Processor also reacts to Push Button status data from the operator panels 125 through the DeviceNET module 148 located in the Main Controller rack 112. As Push Buttons are activated/deactivated, the status of each is stored in the DeviceNET module 148. The Main Processor continuously scans this data and broadcasts it to the Section Processors so that the appropriate section can respond to Push Buttons and Switch activity that is pertinent to it (e.g., “Section Start,” “Program Stop,” “Auxiliary Cycles,” and “Container Reject Requests”).
A CONTROLLOGIX E-Net Ethernet module communicates with the main controller's processor. A CONTROLLOGIX SYNCHLINK module receives master clock data and buffered data from the Main Processor. A CONTROLLOGIX's input module detects the condition of the “maintenance stop” hardwired circuit and uniquely identifies the section rack.
Each section rack in this embodiment also includes 12 CONTROLLOGIX output modules, which energize the solenoid valves on the machine and standalone controllers such as pusher systems 140 and gob distributors. Each section uses three of these 16-point output modules, providing a total of 48 outputs per section. These modules have the ability to schedule output images to occur at a specific time. The Eclipse E-Timing Control System takes advantage of this capability to provide accurate function timing. The control system 100 takes advantage of this capability to provide accurate function timing.
Each section has a solenoid valve 20 with a valve block cover that connects the outputs of a controller rack's output modules to the solenoids on the production machine.
Each section on the machine has two operator panels 125 that contain the pushbuttons and lights necessary for control of the section. One of these panels is on the front side of the machine, with the other located on the back side of the machine. Each operator panel 125 has a DeviceNET Interface Board connected to the Push Buttons, Switches, Indicator Lights and a +24 VDC Source Voltage. It is through this board that the DeviceNET 110 detects the operation of the buttons and switches, and lights the indicator lights when commanded to do so.
The HEWR system 130 is a combination of a photo-eye, which detects the presence of bottles at a blow-off solenoid, the blow-off solenoid, and the Reject switches on the operator panels 125. The system 100 calculates the position of each section's bottles as they travel down the conveyor to insure that the correct bottles are blown off when a reject request is received.
The drive system 135 and the E-Timing system should be precisely synchronized. The E-Timing control system also sends timed Interceptor signals to the drive system 135 so that the glass can be distributed to the appropriate sections at the proper time.
The pusher system 140 reacts to “pushout” timing signals from the E-Timing control system so that the containers can be pushed out onto the Main conveyor at the appropriate time.
Glass Container Forming with E-Timing Systems
E-Timing Systems control the movement of mechanisms and cooling functions used to form glass containers. The mechanisms are typically actuated by means of an electronic solenoid valve, which in turn provides pilot air to a larger cylinder that physically moves the mechanism. Other mechanisms are based upon servomotors and have their own separate control systems. The E-Timing System provides “trigger pulses” to these servo systems at the appropriate time for the servomechanism to execute its pre-programmed motion profile.
Glass container forming machines are referred to as I.S. (Individual Section) Machines. An I.S. Machine contains between 8 and 20 duplicate stations, referred to as Sections. Each Section has its own set of moulds and forming equipment for producing between 1 and 4 containers during each cycle.
The sequence in which the mechanisms actuate, and the amount of time that they remain actuated, are determined by the forming process for that particular container type. Each section's sequence begins with the delivery of molten glass cylinders, referred to as “Gobs,” to the back side of the section and into the Blank Moulds. Other mechanisms on the “Blank” side are actuated to assist in the forming of a preliminary container called a parison. When the Blank side forming steps are completed, the parisons are transferred to the front side of the machine where they are positioned inside the final moulds. Here again other mechanisms on the “Mould” side are actuated to assist in the forming of the finished container. The containers are then mechanically taken out of the moulds and positioned onto a cooling plate. Then they are pushed out in a rotary motion onto a common conveyor. Immediately after the parisons are transferred to the mould side of the machine, a new set of gobs is delivered to the blank side, continuously repeating the sequence until commanded to stop. In alternative embodiments, other methods of material handling are implemented will occur to those skilled in the art.
In some embodiments, the system that delivers the glass gobs to the sections can only deliver to one section at a time. The time that it takes for a gob distributor to deliver gobs to all of its associated sections is the same amount of time that each section takes to complete a forming cycle. The synchronization between the gob distributor and the I.S. machine is controlled by the interaction of signals between the Gob Distributor Drive Control System 135 and the E-Timing System. The Gob Distributor is capable of delivering the glass to the sections in a patterned sequence called the “Firing Order.”
The Firing Order is determined by a few process requirements and parameters. One is the desired distance between the bottles on the main conveyor.
The spacing of the containers on the conveyor, referred to as the “Ware Spacing,” is often important in the glass forming process. As illustrated in
The space between the containers on the main conveyor is achieved by the combination of belt speed, pusher finger spacing and the timing of when they are pushed onto the conveyor. As shown in
Turning to
The feeder mechanism 330 creates the gobs 335 by extruding the glass into cylinders that are then cut by a set of shears 332. The shears 332 are typically actuated by a cam 334 on the feeder mechanism 330. Each time the mechanism 330 feeder extrudes a new set of gobs, a notch in the cam is detected by a proximity switch 336. The digital pulses created by the feeder proximity switch 336 are referred to as feeder prox pulses. For example, on a 10-section machine, a machine cycle consists of 10 Feeder Prox Pulses and one Gob Pulse.
The machine cycle is always 360 degrees. In a 10-section machine there are 36 degrees between sections.
The section base angles (the number of degrees between the gob pulse and the starting point of a particular section) determine the firing order. For example, for a firing order of 1-3-5-7-6-2-4-8-9-10, the Section Base Angles for sections 1-10 would be 0-180-36-216-72-144-108-252-288-324, respectively. Each section starts its cycle when its base angle occurs in the machine cycle. Since the machine cycle and section cycle are equal in time, when the section cycle completes (360°) it is time to start again.
Each section has up to 48 functions (mechanisms and cooling). The function timing is set by entering its ON degrees and OFF degrees. Once a section has its functions properly timed, the timing can be copied to the remaining sections.
Since we are timing off of the Feeder Prox. Pulse (or a precise synthetic pulse generated by some drive systems), which is at regular intervals, and the gob takes longer to travel to the outer sections' blank molds after delivery, each section has a “Base Angle Offset” parameter, which is added to the section angle. This allows the setup personnel to work with section angles in even 36-degree increments and to maintain consistent function timing for each section.
The control of the speed of these 48 functions per section is accomplished by utilizing a virtual timing drum. The “ON” time and “OFF” time of each function is entered in degrees (0-360). This allows the production rate to vary for a production run without having to retime the sections functions. As the production rate increases the time represented by a degree decreases, but the timing in degrees remains the same.
Refer to
The overall flow of a machine section is shown in the flowchart in
The “Job Editor” program typically resides on control room computer 102 (see
As illustrated in
One may press the “TAB” key until the focus is positioned on the “Command Button” that you want, and then press the “ENTER” key to execute the associated action. In
Using a Mouse
In addition to using the keys as described above, the present embodiment allows any object to be selected/executed by positioning the mouse cursor on the object, then clicking the left mouse button.
Command Buttons
The Main Menu, as illustrated in
The “copy job” option allows copying an existing job to a new job file. It can create the copy to be used on either the same or the other half of the tandem machine. With this, four different copy options are available:
When one edits an existing job, the settings and/or program of the job are modified using the user interface as described below, and changes may be saved in the job file. In some embodiments, the “edit existing job” command button yields an interface with an option to save the modified file under a new job name, while in others the user must copy a job file to a new name, then edit it in order to achieve the same result.
The “print job” command button prints the job summary data and event timing for a selected job. The “delete job” command button permanently deletes all data associated with the selected job.
When any of the Command Buttons are activated, the first step is to select the primary Job for the selected operation. This is accomplished by selecting the desired Job Name from the “Select Job Name” dialog box as shown in
The dialog box defaults to listing Job Names for “A” Machine Jobs. This can be changed to display only “B” Machine Jobs, or “All” Jobs by clicking the appropriate “Jobs” option button from the group. If there are more Job Names than can be displayed in the available list, a vertical scroll bar will appear that allows scrolling down through the list. The user can click on the desired Job Name then click the “Accept” button to continue, or click the “Cancel” button to cancel the operation.
In response to selection of the “edit existing job” command button in the main menu (
The “edit job configuration” screen illustrated in
The job name field displays the job name previously assigned to the job. Similarly, the shop configuration field displays the shop configuration identifier previously assigned to the job. These entries cannot be modified here.
The event configuration field displays the event configuration code previously assigned to the job. This entry can be modified here by selecting another event configuration from the drop-down list presented. If the event configuration selection is changed, the present embodiment does not update the remaining values on the screen, though in other embodiments the screen will be automatically updated. In the former type of embodiment, after changing the event configuration file, the user should accept the change to leave this screen, then return to it using the “editing system job” command button on the main menu. This will refresh the event list for the synchronization events to reflect the new event configuration.
In this embodiment, if the Event Configuration is changed, the following files associated with a job will need to be modified: Auxiliary Cycles Configuration, Event Groups, Run Timing, Auxiliary Cycle Timing, and Start Cycle Timing. The reason is that all of these files reference events by the event number, which may not relate to the same mechanism after changing to a different Event Configuration File.
The auxiliary cycles configuration field displays the auxiliary configuration previously assigned to the job. This entry can be modified here by selecting another auxiliary configuration from the drop-down list. As with the event configuration selection, if the auxiliary configuration is changed, the following files associated with the job will need to be modified: Auxiliary Cycles Configuration, Auxiliary Cycle Timing, and Start Cycle Timing.
The machine field displays the tandem machine half (A or B) previously assigned to the job.
The machine base angle offset field displays the machine base angle offset in degrees for the tandem machine half previously assigned to the job. This entry can be changed here by entering a value between 0-359.5 degrees. Typically, “A” machine jobs will have a base angle offset of zero degrees.
The ware spacing field displays the ware spacing in inches between the two sections' wares. In this embodiment, this entry can be changed here by entering a value between 0-21 inches.
The number of sections field displays the total number of sections used for the job. For example, on a 16-section machine running reduced sections (by dropping two sections), the “number of sections” field might be set to 14. In this embodiment, this entry can be changed here on the “edit job configuration” screen by entering a value between 1-20 sections.
The lead section field displays the lowest numbered section used for the job. For example, on a 16-section machine running with reduced sections (by dropping two sections), the program might drop section #1 on the “A” machine, so the “lead section” field would be set to 2. If the drop section is section #9 on the “B” machine, the lead section setting would be 10. This entry can be changed here by entering a new value between 1-20.
The number of gobs field displays the number of gobs delivered to each section in this job. This entry can be changed here by entering a value between 1-4 gobs.
The “number of phantoms” field displays the number of phantom pockets created on the conveyor for this job. This entry in this embodiment can be changed here by entering a value between 0-4 phantom pockets.
The “synchronization events” group allows the user to select the “trigger” events for starting and concluding auxiliary cycles and HEWR. Selecting from the event name drop-down list automatically fills in the associated event number. The user can then select whether the “ON” or “OFF” degree of this event is to be used as the trigger.
The “run start event” selection and On/Off degree selection establish which event is used to determine the starting point of a normal run cycle. Typically, this synchronization event is set to the “TakeOut-OUT” and “ON” degree.
The “run stop event” and On/Off degree selection establish which event should be used to determine the stopping point of a normal run cycle. Typically this Synchronization Event is set to the “Invert” and “OFF” degree.
The HEWR event selection and On/Off degree selection establish which event should be used to determine the starting point of a “hot end ware reject” cycle. Typically this Synchronization Event is set to the “Gob Interceptor” and “ON” degree.
The “separate cold mold/blank cycles” entry determines whether the blue buttons on the mold side and blank side operator panels 125 (see
The “gob-dependent clear cycles” field displays the total number of cycles that should elapse before canceling the dependent events. The purpose of this field is to allow gob-dependent events to continue until all gobs have cycled out of the blanks and molds before ignoring them. This entry can be changed here by entering a value between 1-2 cycles.
The “gob reject clear cycles” field displays the total number of cycles to should elapse before canceling hot end ware reject for a section after gob delivery has been cancelled. This entry can be changed here by entering a value between 1-12 cycles.
The “number of single rejects” field displays the number of cycles for a specific container to be blown off when a “single reject” switch has been activated. This entry can be changed here by entering a value between 1-9999 containers.
The “mold side reject delay” field determines the number of cycles to delay before rejecting ware after a “mold side reject” switch has been activated. This entry can be changed here by entering a value between 1-12 cycles.
The “blank-side reject delay” determines the number of cycles to delay before rejecting ware after a blank side reject switch has been activated. This entry can be changed here by entering a value between 1-12 cycles.
The “nominal container width” field displays the standard average width in inches of the container running on this half of the tandem machine. This parameter is used in conjunction with the hot end ware reject parameter, and can be changed here by entering a value between 0.5-21 inches.
The “maximum container width” displays the maximum width in inches of the container running on this half of the tandem machine before it is considered to be a “down or stuck” container. Any container wider than this will be blown off. This entry can be changed here by entering a value between 0.5-21 inches.
The “minimum container width” field displays the minimum width in inches of the container running on this half of the tandem machine before it can be considered to be a broken container (glass shard). Any container narrower than this will be blown off. This entry can be changed here by entering a value between 0.5-21 inches.
The “minimum container gap” field displays the minimum gap in inches between containers running on this half of the tandem machine before they should be considered to be “stuck” containers. Any gap narrower than this will result in a blown-off. This entry can be changed here by entering a value between 0.001-21 inches.
The “maximum allowable degree change” displays a maximum number of degrees that an event's timing can be changed in one cycle. This entry can be changed here by entering a value between 0.5-50 degrees.
Selecting the cancel button will discard any changes that have been made on the screen. The accept button will retain any changes made on this screen; however, the job still must be saved on the “edit existing job” screen for the changed data to be retained for future use.
The “auxiliary program configuration” screen illustrated in
The “process name” field displays the process name (i.e. PB, NNPB, etc.) previously assigned to the configuration. This entry cannot be modified here.
The “auxiliary program name” down-down selection box allows a user to select the auxiliary program to be modified. The “name” field allows the user to name or rename the auxiliary program name.
The “cycle counts” field allows the user to specify the number of cycles that this auxiliary program executes after the appropriate push-button on the blank or mold-side operator panel 125 is pressed.
The “trailing rejects” field allows a user to specify the number of cycles that this auxiliary program continues to reject ware after it has completed.
The “available events” list displays all of the event names that are available for including in this auxiliary program. The “selected events” list displays all of the event names that have been selected for including in this auxiliary program.
The buttons located between the “available events” and “selected events” lists are used to add or remove event names from the selected events list. The “>” button adds the currently highlighted event name from the “available” list to the “selected” list. The “>>” button adds all event names from the available list to the selected list. Likewise, the “<” button removes the currently highlighted event name from the selected list, while the “<<” button removes all event names from the selected list.
The save button saves the current auxiliary program configuration changes to be applied when the job data is saved on the “edit existing job” screen. Note again that if that save operation is not completed, then changes to the auxiliary programming configuration screen will not be retained. The “exit” button immediately discards the current auxiliary program configuration changes.
As illustrated in
The “event group” scroll bar allows a user to select which group number is to be edited. The “group name” field allows one to enter a memorable name for this group.
Each group can have up to 12 events assigned to it. The events for the selected group may be selected by using the 12 drop-down lists of event names.
Each selected event can have either its “On” degree, “Off” degree, or both jogged when the event group is being manipulated on the operator interface computer 104. The user can use the “group events configuration” screen to select which degrees are jogged by placing a check mark in the check boxes “Use On Degree” and/or “Use Off Degree” for the associated Event.
As illustrated in
The “base angle” (fire order) determines the firing order for job delivery to each of the sections. Typically, sections 1 and 9 are at 0 degrees in the firing order. The “section angle” (gob drop offset angle) determines the offset for each section due to the difference in gob drop travel time among sections. The “HEWR zone adjust” field stores the HEWR zone adjustment in inches for each section.
As illustrated in
The “On” and “Off” degree fields allow the user to enter timing for the associated event. The “fill events (F8)” option displays a dialog box for selecting the sections in which events should be filled. After selecting the sections, another dialog box is displayed, which allows the user to select which events will be copied to the selected sections. The “exit (F10)” option returns the user to the “edit job configuration” screen.
Selecting the “save job data” command button on the “edit job configuration” screen saves all changes and modifications made on the individual configuration screens to the job database.
Selecting the “exit” command button on the “edit existing job” screen discards all changes and modifications made on the individual screens, leaving the job database unaffected.
A software program in a memory associated with operator interface computer 104 in this illustrated embodiment provides a control interface for users on the production floor to monitor and manage the control system 100. The top-level interface menu is illustrated in
A green rectangular border around a button indicates the currently selected command button. Any user interface object with this border is referred to as having the “focus.” This green focus rectangle is used throughout the Eclipse Operator Terminal application and indicates an object that could cause an action if the “ENTER” key were to be pressed.
A user can use the “UP ARROW” or “DOWN ARROW” keys to move the focus until the focus is positioned on the desired command button and then press the “ENTER” key to execute the associated action.
In
As shown in
The currently selected Event Timing (ON or OFF) is indicated by the green rectangular border around the degree value. As with the menu in
Interacting with Event Timing Screens
Navigation Keys
To move between degree values within the timing screens, use the following keyboard keys:
Special Keys
Menu Keys
The Menu Bar displays the keyboard Function Keys (F1-F10) and their assigned function. In this example embodiment:
The On/Off degree values on the Event Timing Screens can be changed by “Jogging” the value Up 1 degree by pressing “F5,” or Down 1 degree by pressing “F6.” To change a value by directly entering a numeric value, press the “ENTER” key while the value has the focus. The Degree Change Screen (see
The user can type a new degree value (0-359.5) using the keyboard's numeric keys. To accept the change, use the “Tab” key to move the focus to the “Accept” button and press the “Enter” key. To cancel the change and revert to the previous value, us the “Tab” key to move the focus to the “Cancel” button and press the “Enter” key.
Pressing Function Key “F2” while on an E-timing Screen displays the “Select Section” screen. The “Select Section” screen (see
Pressing Function Key “F7” while on an E-timing Screen displays a “Section Selection” screen as shown in
Use the “Tab” key to move the focus forward to the next object, and a combination of the “Shift” and “Tab” keys to move the focus backwards to the previous object. When the focus is positioned on a Section Number “Check Box,” using the “Space Bar” toggles between selecting and deselecting that section from the selection set. When the focus is positioned on a command button, use the “ENTER” key to execute the associated action.
The command buttons on the Section Selection Screen perform the following actions:
On this screen and other dialog screens certain letters and numbers have an underline beneath them. This underline indicates a “Quick Key” for the associated object. By holding down the “ALT” key and depressing the “Quick Key,” the associated command button is activated, or the operation is performed.
Pressing Function Key “F4” while positioned on a “Run Cycle” E-timing Screen, displays a “Select Event Group” screen as illustrated in
Event Groups (see
Each Event defined in the Group can have its ON Degree, OFF Degree, or Both ON & OFF Degrees defined as being associated with the Group. These are indicated on the Event Group Screen display by a Black background and Yellow numbers. A Blue background and White numbers indicate non-associated degree values.
When one of the Jog +/− buttons is pressed, all of the associated degree values increment or decrement by 1 degree. Note, however, that the new values are not sent to the Eclipse Timing system until the “F8” “Send Changes” key is pressed. Pressing the “F8” key also returns you to the previous E-Timing screen. To leave this screen without accepting any pending changes, press the “F10” key.
Pressing Function Key “F3” while positioned on an E-timing Screen displays a “Select Cycle” screen as illustrated in
Auxiliary Cycles are special cycles that allow different timing (for the Events that are included in the Auxiliary Cycle's definition) to be realized upon activating the cycle. Auxiliary Cycles are activated by pressing their associated Push Button(s) on the Blank and/or Mold side operator panels 125.
As with the “Run Cycle” Timing Screen, the auxiliary cycle management screen illustrated in
This description of Angles relates to a system that includes a tandem machine with the APPLIED MOTIONS Drive System. Each Section has 3 angle offsets that can affect when events occur in relation to the Master Pulse, a continuous train of synthetic pulses generated by the APPLIED MOTIONS drive system.
The Machine Differential Angle allows offsetting each half of the tandem machine from the Master Pulse. Generally, the A-Machine's “Machine Differential Angle” is left at 0-degrees, while B-Machine's is adjusted to increase or decrease the separation between each machine's containers on the flight conveyor.
The Base Angle (Fire Order Degrees) determines the section firing order within the machine. Similarly, the Section Angle (Drop Offset) compensates for the variation in Gob Drop travel time down the various lengths of trough. This Angle affects events configured as “Section Angle” dependent. Although most events are configured as “Section Angle” type events, some events such as “Gob Loading,” “Air Ride,” “Pusher Start” and “Pocket Air” are not. They are configured as “Base Angle” dependent and are only affected by the Machine Differential and Base Angle offsets.
To change the “Machine Differential” Angle, the user presses “TAB” or “UP/DOWN ARROW” keys to move the Focus to the numeric entry box for “Machine—B Differential” (see
As illustrated in
To change the “Section” Angle, the user presses the “TAB” or “UP/DOWN ARROW” keys to move the Focus through the Angles screen in
The Section Angle (Drop Offset) is usually used to bring a Section to the Drop. If all sections on a machine need to move closer to or further from the drop, then use the APPLIED MOTIONS Drive System's “Feeder Phase” offset entry (for the appropriate machine A or B) to bring the Drop to the sections instead. See the “Drive System Synchronization” section of this disclosure for more information on synchronizing with the Drive system.
As shown in
The Job Data is stored in a MICROSOFT ACCESS database on the Control Room Terminal 102. This data is read from the Database and sent to the Eclipse Controller on a Job Load. In order to perform a Job Load, all sections on that particular machine must be in a Maintenance Stop state. Each machine has “Section Status” indicators that show if the sections are running, stopped or in a Maintenance Stop state. When all of the sections for a machine are in Maintenance Stop, a button appears on the Job Load/Save Screen with the title “Load ‘A’ Mach. Job” or “Load ‘B’ Mach. Job.” If any sections are not in Maintenance Stop state, a red message “NOT IN MAINTENANCE STOP” appears in the button's place.
Once all of the sections are in Maint. Stop, one can use the “TAB” key to move the focus to the appropriate “Load” button on the Job Load/Save Screen and press “ENTER.” This displays a “Select Job” dialog box screen as shown in
This will start the Job Load procedure. While loading a job, there will be a “Job Load Status” screen displayed that indicates the progress of the job load, as will be understood by those skilled in the art. Once all of the Job Data has been sent to the Eclipse controller and read back into the Operator Interface (verified), the progress message will indicate that it is “Done Downloading to Eclipse,” and a button appears to remove the progress display.
At any time a user can save the job running on either “A” or “B” machine without interrupting the machine. To save a job, press “F2” and the “Job Save” dialog box will be displayed as illustrated in
Accessing Diagnostics from Main Menu
The main menu provides access to the various diagnostic screens as indicated in
The Section Output Status Screen, an example of which is shown in
When a short circuit is detected as indicated by the “Fuse” column LED being red, the physical output module in the Eclipse Controller trips an electronic fuse. This electronic fuse will remain tripped until cleared by either pressing the “Reset Section's Fuses” command button on this screen, or by cycling the Maintenance Stop circuit for the given section.
The fifth column is an Override button for each output. These overrides are only available in a “Stopped” condition, and then only after the “Enable Section's Overrides” button has been activated on this screen. Use the “UP ARROW” or “DOWN ARROW” keys until the focus is positioned on the Override command button that you want, and then press the “ENTER” key to activated (energize) the associated output. The override button will turn red, indicating that it has been activated, and the On/Off status LED will turn green. To cancel the override, simply press the “ENTER” key again.
As shown in
To test the operation of the buttons, place the section in Maintenance Stop then activate the DeviceNET inputs by pressing the desired buttons. While the button is depressed the indicators on this screen will turn Green to verify their operation. When the Eclipse system energizes one of the lamps, the associated DeviceNET output can be verified on this screen. If this screen indicates that the lamp is on or flashing, but the actual lamp does not light, the LED and/or LED module located on the Mold/Blank side operator panel may need to be replaced.
The Section Remote Control Screen, illustrated in
In the event that a DeviceNET board or a pushbutton on the operator panel fails, this screen allows all Blank Side Operator Panel capability to be exercised at the Eclipse Operator Terminal 102. The ARROW keys are used to position the focus on the section that is to be controlled, then the user presses “ENTER.” He or she verifies that the desired Section Number is displayed below the image of the panel, then by using the ARROW or TAB keys, positions the Focus on the desired switch, then presses “ENTER” to activate or deactivate that function depending on whether it was previously inactive or active. The Remote Control Screen indicates inactive functions (i.e. CMC, START, STOP, HEWR, etc.) by a gray switch/push button symbol. Active functions are indicated by the switch or push button being the color of the actual lamp used at the operator panel on the Blank Side of the machine.
As shown in
The Shop Status Screen displays the run status of all sections, as shown in
Also below the machine graphic is a table of “Cycle Counts.” These counts represent the number of machine cycles that each section has Run, Run with Gob Delivery, and Run executing an Auxiliary Cycle (Cold Mold, Cold Blank, and Swab). It also has a counter that displays the total number of bottles blown off for each section, either through HEWR or Auxiliary Cycles. To reset the Cycle Counters, a user can go to the “Run Statistics Screen” by using the “TAB” key to move the focus to the Cycle Counts Table and press “ENTER.”
As illustrated in
As illustrated in
Conveyor Data
There are four values displayed in inches on this screen that are used to track the bottles' movement down the conveyor. They are “tandem distance” (the distance between the centerlines of the two inside sections of a tandem machine), “ware spacing” (the distance between the lead containers of two neighboring sets of ware on the conveyor), “downstream photo eye” (the distance from the centerline of the last section to the HEWR downstream photo eye), and “downstream solenoid” (the distance between the photo eye and the reject air nozzle). Tandem distance and ware spacing can only be changed in this embodiment by editing the relevant job in the “job editor” and then re-downloading the job data. The downstream photo eye and downstream solenoid values can be modified by the user with the interface on the screen.
Container Data
There are eight container data values displayed in inches on this screen that can be modified independently for each machine. They are the “normal width” (diameter) of the containers, “maximum width”; or the largest container diameter allowed before a container is considered too wide (e.g., a bottle that is down or stuck to another) and rejected; “minimum gap”; or the smallest gap between two containers that is allowed before they are considered too close to each other (e.g., stuck) and rejected; “minimum width,” or the smallest container diameter allowed before a container is considered too narrow (e.g., a broken bottle) and rejected; “blow duration %” or the percentage (50-100%) of the container's diameter that the reject nozzle should blow; “blank reject delay,” or the number of cycles after a blank-side HEWR switch is activated to wait before the desired ware is in the pusher mechanism; “mold reject delay,” or the number of cycles after a mold-side HEWR switch is activated to wait before the desired ware is in the pusher mechanism; and “single rejects,” or the number of cycles of ware to reject when a “single reject” HEWR switch has been activated.
As illustrated in
The Real Time Trend is a graphical strip chart that plots various data points on a scrolling chart. The newest data appears on the right of the trend and scrolls to the left.
The Reject Flag Pulses are present when the container at the photo eye is to be rejected, either by operator action (HEWR switches, Auxiliary Cycle switches, etc.), or due to a Down & Stuck condition.
The Photo Eye Pulses are present when a container is at the photo eye.
The Section Zone Windows pulses represent where in time the Eclipse controller calculates a sections' containers to be. The Photo Eye pulses for a given section's containers should align within the zone window associated with that section. The zone windows for each section are color-coded and can be toggled On or Off to make it easier to see a specific zone or zones.
The Trend Control Buttons allow the real-time trend to be paused and the time span to be scrolled backward and forward.
The Trend Time Span Buttons allow the amount of time displayed in the real-time trend to be changed (2-120 seconds).
Numeric entries (−21 to +21 inches) in the Zone Adjust Numeric Entry fields allow the associated zone window to be adjusted forward or backward to line up with the appropriate container set's Photo-Eye pulses. These values should typically be as close to zero (0) as possible. A large value typically indicates that the “Pusher Start” Event's ON time has been adjusted to accommodate a variation in the Pusher mechanisms' fingers, home position or speed.
The Menu Bar allows toggling the sections' Zone Windows on and off by pressing “F1”-“F8.” Pressing “F9” displays the same screen for the other half of a tandem machine. To return to the “Main Menu,” users press “F10.”
HEWR Setup Guidelines
The following guidelines are intended to assist the Job Setup personnel with setting up the Ware Reject system for optimum performance. In order to have good reject characteristics one should first have good ware handling.
The first step is to make sure that the Eclipse Job Data and Drive system data are both set for the proper ware spacing (e.g., 10.5″) and number of phantom spaces (pockets). Ensure that the Photo-Eye lens is clean and is properly aligned at the bottom of the containers.
Pusher Setup is the most critical step to achieving good ware handling.
Ware Placement on the conveyer is the second most critical step to achieving good ware handling.
Phantom Space(s) on the Conveyor
The use of phantom spaces must first be configured in the Eclipse Job File that was downloaded, and on the Drive system that controls the machine conveyor (flight conveyor). Use the “Machine-B Differential” angle to spread the ware groupings apart or to bring them closer together.
If adjusting the “Machine-B Differential” angle creates the proper phantom spacing, but also causes collision on the other end of the ware groups, the groups on each machine have to be made smaller by adjusting the Pushout Event timing, in order to create the required space on the conveyor.
Adjusting the HEWR
These steps use the “HEWR Parameters” and “HEWR Zone Adjust” screens to achieve proper reject characteristics.
Cavity Windows
Each zone window is divided into 2 cavity windows for double gob in the PLC program (see
When tuning zone windows, the most critical aspect is to center the 2 bottle pulses in the zone window as best you can (see
Zone Windows
With the Zone Windows, it is preferable to have as little or no overlap if possible. However if the Zone windows do overlap as in
Where there could be a problem with overlapping Zone Windows is when an entire bottle pulse falls within the overlapping area (see
As shown in
The “Status at Section Controllers” panel on the left side of this screen displays various monitored conditions for each of the section controllers (4 sections per controller) in a column.
The indicator is green when the Section Controller is properly communicating with the Main Controller. It turns red when an error occurs.
The Chassis ID Error indicator is green when the Section Controller (chassis) is properly addressed with +24 VDC Inputs on the Input Module: Section Controller #1 (Sections 1-4)=Input #1, Section Controller #2=Input #2, Section Controller #3=Input #3, Section Controller #4=Input #4. It will turn Red if the PLC program detects a different Section Controller number than the hardwired DC Input indicates.
Chassis IP Error
This indicator is Green when the Section Controller's Ethernet Module is properly addressed. The IP addresses for each chassis in this example embodiment are:
If an Ethernet module is improperly addressed for its location, the indicator will turn Red. The processor recognizes the mismatch and will automatically re-address the Ethernet module for the appropriate address. This is helpful if an Ethernet module fails and requires a replacement, it will automatically define its address.
The Ethernet Heartbeat Error indicator is Green when the Section Controller's Ethernet Module is properly receiving “Heartbeat” pulses from the Main Controller. If not, this indicator will turn Red.
The SYNCHLINK module in each chassis provides a high-speed fiber optic communications channel to the Main Controller. This communication channel is used to synchronize the clocks of each chassis and to provide the Output execution times for the next eight (8) half degree indexes of event timing (Internal Timing Drum). The SYNCHLINK Error Indicator is Green when the Section Controller's SYNCHLINK Module is communicating properly. If not, this indicator will turn Red.
The Master Index and New Index values display the current Master Index value as read from each chassis. The display of these values is not real-time, and as such will be close together in value but not exact. If these values are changing, then everything is OK. If these values stop changing, then the Section Controller is no longer updating its internal Timing Drum. These values are in units of ½ degree and, therefore, are in the range of 0-720.
The “Status at Main Controller” panel on the right side of the System Status Screen displays various monitored conditions for each of the section controllers or racks (4 sections per controller) in a column.
The Section Processor Fault indicator is Green when the Main Controller is properly communicating with the Section Controller. It turns Red when an Error occurs in that communication.
The Ethernet Communication Fault Indicator is Green when the Main Controller's Ethernet Module is properly communicating with the Section Controller's Ethernet Module. The indicator turns red if an Error occurs in that communication link.
The System Synchronous Indicator is Green when the Main Controller detects that all conditions are stable for properly starting and delivering glass to all sections. If a condition is not met, this indicator will turn Red.
The Feeder Synchronous Indicator is Green when the Main Controller detects that the incoming Feeder pulse is stable and present. If an “out of tolerance” change is detected in the frequency of the incoming Feeder Pulses, or if it is missing entirely, this indicator will turn Red.
The Main Menu illustrated in
This screen has two (2) options available through command buttons. The “No—Cancel” closes the dialog box and allows the operator terminal program to continue running.
The “Yes—Quit” button terminates the operator terminal program.
In various alternative embodiments, the PLC's used in various capacities are replaced by other models, by general purpose microprocessors, or by application-specific integrated circuits (ASIC's). In any of these variations, one or more memory units are associated with each processor or controller to store data and program information as will occur to those skilled in the art. Such memory devices may comprise one or more distinct units of memory, which include one or more types, such as solid-state electronic memory, magnetic memory, or optical memory, just to name a few.
By way of non-limiting example, the memory can include solid-state electronic Random Access Memory (RAM), Sequentially Accessible Memory (SAM) (such as the First-In, First-Out (FIFO) variety or the Last-In First-Out (LIFO) variety), Programmable Read-Only Memory (PROM), Electrically Programmable Read-Only Memory (EPROM), or Electrically Erasable Programmable Read-Only Memory (EEPROM); an optical disc memory (such as a recordable, rewritable, or read-only DVD or CD-ROM); a magnetically encoded hard drive, floppy disk, tape, or cartridge media; or a combination of these memory types. Also, the memory is volatile, nonvolatile, or a hybrid combination of volatile and nonvolatile varieties.
All publications, prior applications, and other documents cited herein are hereby incorporated by reference in their entirety as if each had been individually incorporated by reference and fully set forth. While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.
While the invention has been illustrated and described in detail in any drawings and the foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only one or more preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.
This application claims priority to U.S. Provisional Patent Application 60/864,889, “Glass Container Forming Controller,” filed Nov. 8, 2006, which is hereby incorporated by reference as if fully set forth herein.
| Number | Date | Country | |
|---|---|---|---|
| 60864889 | Nov 2006 | US |
