gob image analyser | brochure

S E E I N G I S K N O W I N G

G O B I M A G E A N A L Y S E R

The complexity within glass container forming and the competitionfrom alternative packaging materials leads to a growing demand forimproved product quality and high efficiency. Gedevelop’s leadingmarket position and innovative development is facing the increasingrequirements with products that contribute to accuracy and a returnon investment.

GIA ConceptInformation on gob shape and temperature as well as automatic weightcontrol has become essential for today’s glass container operations tominimise costs and maximise quality.

The GIA concept makes it possible for operating staff to take imme-diate actions to improve gob properties and to prevent future problems.It is equipped with state-of-the-art software and hardware to enhanceaccuracy and quality as well as to increase flexibility and cost efficiency.Up to four gobs can be analysed and controlled simultaneously withas many cameras – supported by one central unit.

Increased flexibility allows the user to configure the system to hisown needs. It can either be two cameras on a single IS-machine, ontwo IS-machines, or two cameras each on two different IS-machines– one central unit is sufficient.

• GIA is a “closed loop” system and includes gob image analysis, gobweight control, gob temperature measurement and storage of reference gob profiles

• GIA is a non-intrusive, optical measurement system, thus a non-contact concept

• GIA starts analysing at the initial stage of gob forming, i.e. advancedlook ahead feature

• GIA can co-operate with other gob process control systems

• GIA can be applied in all different production processes

G O B I M A G E A N A L Y S E R

CameraThe GIA camera is equipped with a pneumaticvortex cooler, providing cooling of the cameraas well as heating of the lens system to preventcondensation. Overpressure in the casing keepsdust and oil away.

As an option, the camera can be installed ate.g. blank load position, which means that thegob image comparison can be made betweenshearing and delivery position.

To make installation simple, the dimensionsof the camera have been adapted to suit theavailable space.

Central UnitOne central unit can support up to four cameras,allowing a variety of different applications withmultiple camera configuration for DG, TG andQG operations.

The Central Unit (CU) consists of a simplecompact enclosure housing disk drives andelectronics assembled on a mounting panel.Optionally, the unit can be installed in an existingcabinet at a remote position. Information on thegobs is displayed on a high-resolution colourscreen.

Gedevelop AB, Florettgatan 27B, SE-254 67 Helsingborg, Sweden. Phone: +46 42 38 66 70. Fax: +46 42 20 16 86. [email protected]. www.gedevelop.com

The principle of the Gob Image Analysing functionis based on a line scanning technique, whichallows even very long gobs as well as velocity tobe measured. All gathered data – shape, weight,temperature, drop consistency, swing pattern,length, diameter, reference profile and reject –from up to four gobs can be processed througha single central unit and displayed on a centralscreen.

Non-contact measurement is an advantage inthe environment where the GIA system is ope-rating. The system can be installed without inter-fering with production. It requires virtually nomaintenance and eliminates mechanical wear onthe IS-machine equipment like moulds andplungers. It is also independent of the glass-forming process technique.

The operating staff are able to follow thebehaviour of the gob throughout the entireforming process. The machine operator can makeadjustments on the operator’s panel withoutbeing exposed to heat and noise. Productionproblems can be analysed at a very early stagefor immediate action, allowing operators moretime for quality control, etc.

Higher resolution, better image accuracyBy using a 1024 pixel scan line array a high reso-lution is obtained. The higher sensitivity of thearray is also essential when measuring e.g. smallflint gobs.

Full 256 grey-scale analysisThe possibility of mapping grey-scales to custom-ized colours gives the operator better insightinto the gob properties.

Anomalies as well as intermittent discrepanciesin the gobbing process can be identified. Forrepeat production runs, the image also facilitatesthe setting up of the same conditions as theprevious operations.

Gob Image Analysing

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Gob Image Analyser


Gob Weight Control

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Gob Image Analyser

The Gob Weight Control function of the GIAsystem is based on an advanced PLC, whichkeeps the gob weight stable. The gob weight andthe GWC function adjust the tube height or theplunger position to keep a constant gob weight.

Reduction of weight and timeControl of the gob is essential and will allow anoverall reduction of the glass container weightat an average of 1.5%.

Reduction of tolerances implies better condi-tions in the forehearth and allows glassmakersto stay close to the set point, thus enabling themto reduce overall weight and consequently cutproduction costs.

Whether it is a B&B, P&B or NNP&B process,to reach the correct weight of the product assoon as possible should be seen as a logical target.

By using the automatic gob weight control ofthe GIA system, run-in time is considerablyreduced.

Easy dynamic setting of parametersThe gob weight controlling is done by the GWCsoftware, which also controls the input and outputsuch as digital up/down output for the tube drive(s).Up to four instances can be run in one CPU.

The GWC supports easy dynamic setting ofparameters for the simplified control unit Para-meters such as inner and outer working range(two levels of control-response), backlash com-pensation and pulse-length can be set. The setpointweight can also be set dynamically, which is com-pared to the weight fed by the GIA. The differencein weight causes the GWC to react and issuesproper output for the tube drive.

An operator‘s panel (OP) is connected to thegob weight control for supervision and routineoperation. For each GWC one OP is required,which can be independently assigned to a GIA.

GWC specifications

SoftwareSoft PLC for weight control and I/O

Hardware5.7 inch 320 x 240 graphic touch screen Profibus I/O system

Relay output terminals230 V AC, 2A for tube actuation.Digital output 24 V DC for pilot lights,swing limits and/or hot ware rejection

Power input100-240 V/, 50-60 Hz, 6A


Gob Temperature Measurement

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Gob Image Analyser

The GIA camera has a built in GTM for measuringthe temperature along the length of the gob. Foreach scan (slice), a temperature measurement ismade on about an 8 mm wide spot in the centreof the scan. All the temperature measurementscan be shown superimposed on the image dividedinto up to 12 zones. An average gob temperatureis also computed and presented.

Two-colour pyrometerA two-colour pyrometer highlights the tempe-rature profile throughout the gob. It has a numberof advantages over one-wavelength pyrometers.It features the insensitivity to variations in theglass’ emissivity and minimises the influence ofsignal attenuation caused by dust and smoke,closely associated with the gob forming process.

GIA pyrometer principleThe GIA pyrometer works in a wavelength spect-rum where most types of glass materials aresemitransparent. This means that the radiationoriginates from the volume of the gob ratherthan from the surface, as is the case with ordinaryglass pyrometers detecting radiation from a nar-row band of around 5 microns.

GTM Specifications

Measuring range 900-1300°C / 1650-2375°F

View angle 2,5° at 1100 mm distance / 43"

Target diameter 8 mm / 1/3"

Spectral range 0.8-1.1 microns

Response time <2 msec

Accuracy ±3° C / 4° F

Repeatability ±1.5° C / 2° F

Operatingtemperature 20°-40° C / 85-100° F


Gob Reference Storage

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Gob Image Analyser

Significant reduction of run-in time can be achievedby the saving and retrieval of gob images for postprocessing by the Gob Image Analyser. All jobsetup files and reference gobs stored on the CUhard disc can be accessed through the standardfile system.

Shortens run-in timeIncreasingly shorter production runs mean it isimperative to reduce the time from start of thejob change to a minimum. The sooner the targetedpack rate is reached, the higher the total produc-tion output, thus allowing for better benefits.

For the repeatability function, the image alsoeases the labour of setting up the same conditionsas for a previous run job.

Quicker reaching of the correct gob charact-eristics – gob weight, shape, drop and temperature– influences the run-in time. After a change oforifice the gob will be formed and a first gobsample is taken for the calibration of the camera.After that, the GIA system will be set in an auto-matic mode and the operator is free to assistwith the job-change while the gob is automaticallycontrolled to the set profile. The run-in time losscan be reduced as the gob weight is the correct

one from when the first gob is loaded into theblank mould.

Stabilising the processThe automatic gob weight control will stabilisethe process as only small corrections are madeand the weight can be reduced as the tolerancesare tighter and the human factor is eliminated.A saving of 1.5-2 gram per container is a fact ina plant with an average container weight ofapproximately 300 grams.


Communication and Interaction

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Gob Image Analyser

The Gob Image Analyser has enhanced provisionfor communication and connection to externalsystems.

The GIA system is based on a client/servertechnology using DCOM interface to providemeans for necessary data exchange and remotecontrol. This enables any Windows based appli-cation e.g. Microsoft Excel and other third partySPC and SCADA programs to take advantageof the GIA real-time output capabilities.

GIA clients can be connected to the GIAserver over the LAN (Local Area Network) andin addition over the Internet.

Gob viewers can be connected to optionalCUs for easy real-time comparison between dif-ferent production lines as well as at differentplant locations.

Remote on-line help will also be possibletogether with software updates.

Third party “plug-ins” can be attached to theGIA software through standardized softwareinterface components.

GIA Server withViewer (client)

GIA Server 2 withViewer (client)

GIA Server 1 withViewer (client)

GIA Viewer

GIA Viewer

GIA Viewer

SPCMS Excel

LAN 1

LAN 2

Internetcommunication

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GGob Image Analyser

GIA Media Broker Server – GMBS – Information exchange software for Gedevelop’s gob image analyser

Information Exchange SoftwareThe GMBS acts as an information exchange soft-ware, a bridge, between the analyser system and other software systems such as Statistical, Math, Quality Assurance, SCADA, Visual Basic and Excel.

The media broker pulls real-time data of the gob image analyser and transfers it using different con-nectivity servers.

Servers are available for Windows Socket connec-tion (WinSock), Dynamic Data Exchange (DDE) or Ole for Process Control (OPC). Custom-made connectivity servers can be made on request.

Try before you buyThe GIA media broker server is purchased and li-censed utilizing a “Try before you buy” procedure.

GIA Media Broker Server – OPC

• Acts as an OPC Server

• Supports local and remote connections

• Camera and GWC tags for data access requests

• Any third party OPC compliant client can be connected

GIA Media Broker Server – DDE

• Acts as a DDE Server

• Supports local and remote connections

• A sample of an Excel document explaining how to connect and how to format data is included

• Easily integrates with any third party NetDDE enabled software such as Microsoft Excel and Microsoft Access

Gedevelop AB, Florettgatan 27A, SE-254 67 Helsingborg, Sweden. Phone +46 42 38 66 70. Fax +46 42 20 16 86. [email protected]. www.gedevelop.com

Gob Image Analyser

GIA Media Broker Server – WinSock

• Acts as a Windows Socket Server

• Uses TCP/IP as network protocol

• Data is transmitted as an eXtensible Markup Language (XML) document (sample included)

• The data layout is defined by the XML document

• Data is validated by an XML Schema Definition (XSD) document (sample included)

• Uses unlicensed WinSock client for storing data in CSV format (Microsoft Excel)

• An unlimited number of clients can be connected

• Simple example of WinSock client in Visual Basic source code is included

Gedevelop ABEstablished in 1986, is today a world leadingpartner for the major manufacturers of glassfibre and glass containers. With a dedicatedteam, Gedevelop is innovative and com-mitted to state-of-the-art solutions andtechnology. With close access to productionprocesses, Gedevelop is engaged in thecontinuous development, manufacture andsupply of reliable process measurement andcontrol equipment.

Gedevelop ABFlorettgatan 27B,SE-254 67 Helsingborg, SwedenPhone: +46 42 38 66 70Fax: +46 42 20 16 [email protected]

www.gedevelop.com

mailto:[email protected]

www.gedevelop.com

gob image analyser | brochure

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