coco-cola maintaince and training(asebi)

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


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


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

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 = 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

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

coco-cola maintaince and training(asebi)

Technology