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Fabio Galliano Technical Director Managing the glass manufacturing process

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Page 1: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Fabio Galliano – Technical Director

Managing the glass manufacturing process

Page 2: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Outline

• The Digital Era and Industry 4.0

• Bottero strategic vision

• Pillars from the last decade

• Process view close-loop controls

• Evolutionary roadmap

• Summary and conclusions

Page 3: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

The Digital Era and Industry 4.0

Page 4: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Bottero strategic vision

• Ultimate goal: full, labor-free automation of the glass manufacturing process

• Industry 4.0 identifies a powerful and integrated view, but…

…a fully stable process operation is the key to achieve the goal

• Bottero has a deep and consolidated process knowledge to pursue this objective

• BoX is the first and unique system on the market, conceived and developed to support this vision

Page 5: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

FROM

EQUIPMENT

SUPPLIERS...

...TO PROCESS

ORIENTED

PARTNERS

Bottero Strategic Vision

Page 6: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Bottero Strategic Vision

Move from equipment supplier to solution

provider partnering with the Customers

• Enhance Bottero offer portfolio with new added value products and novel solutions

• Enrich the value proposition including more and more professional services

• Move from an ecosystem of automation products to a fully integrated automation

platform

Page 7: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Strategic pillars for the last decade

2.Expertise and competence on the forming process

1.Modelling and Simulation tools and techniques

3.Full control of the production chain through Industrial Automation

Page 8: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Strategic pillars for the last decade

2.Expertise and competence on the forming process

1.Modelling and Simulation tools and techniques

3.Full control of the production chain through Industrial Automation

Page 9: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

• 496 CPU fully dedicated

HARDWARE

• 1800 GB RAM

• 40,2 TB Hard Disk

• 2 high-duty quadri-processor servers, with 16-core CPUs

• 5,2 teraFLOPS (computer performance indicator)

• Abaqus • Radioss • Motion Solve • Optistruct • Star CCM+ • Mode Frontier

SOFTWARE

A team from aerospace and automotive industry

HUMANWARE

• 22 calculation servers, in parallel configuration

Modelling and Simulation

Page 10: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Glass viscosity vs. temperature

Forming Simulations

Page 11: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Simulated Forming Process Steps

Step 1

Blank Side

Parison Forming

Step 2

Invert Mechanism

Reheating

Step 3

Blow Side

Stretching

Step 4

Blow Side

Bottle Forming

Page 12: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Step 1 – Parison Forming

Bottero strategic view

Page 13: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Step 2 – Reheating

Bottero strategic view

Page 14: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Step 3 – Stretching

Bottero strategic view

Page 15: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Step 4 – Final blow

Bottero strategic view

Page 16: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Strategic pillars for the last decade

2.Expertise and competence on the forming process

1.Modelling and Simulation tools and techniques

3.Full control of the production chain through Industrial Automation

Page 17: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

“We believe in glass…” The forming engineering FE department has over ten years experience in granting process support in the different areas of the glass production lines. The team combines both engineers and production experts that cooperate to support our Customer in reaching the agreed production target.

Forming Engineering

Page 18: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

“From conceptual design through training to production…”

Service portfolio

•Cooling design •Parison and Mold Design •Support in transition from DG to TG •Support in transition from B&B to NNPB •New container design •Mold Design training •Production training •Production support •Production Support Agreement (PSA)

Forming Engineering

Page 19: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Strategic pillars for the last decade

2.Expertise and competence on the forming process

1.Modelling and Simulation tools and techniques

3.Full control of the production chain through Industrial Automation

Page 20: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

• Full standardization of HW components, SW modules and communication interfaces

• Tier 1 close-loop controls (DFS, GWC for BB, Servo Plunger, Prop. Valves 2.0, MWM)

Wide configuration capability of special cycles

• Unique, integrated development platform putting together:

• Process view close-loop controls (BoX)

Benefits of Bottero Automation Platform

Supervisory platform with open interface toward external Plant Automation Systems

Page 21: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Tier 1 close-loop controls

Page 22: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Vertical &

Horizontal Plunger

Adjustment

Tube Height Control

Magnetic Position

Sensors

Weighing Station

• For both BB and NNPB productions

• Integrated THD (Tube Height Device) and PAC (Plunger Adjustment Control)

• Full stroke plunger motion tracking in NNPB • Integrated Weighing Station for BB

Dynamic Forming System (DFS)

Page 23: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Servo Plunger integrated with DFS

Fully integrated with DFS to implement gob weight control functionalities without the need of position sensors

Page 24: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

DFS: Plunger Motion Control

Proportional valve for plunger up Plunger up motion Pressing Time

Pressing Time Set-point

Page 25: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Bottero Proportional Valves 2.0

Output pressure sensors

• Complete mechanic retrofit with existing bases

• Same operator interface with control electronic

Close loop on the output pressure based on a dedicated sensor.

Response repeatability and precision of the output pressure

Response homogeneity among different valves

Better precision of the control at low pressure

Page 26: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

• Tool to support setup and control of productions with multiple weight articles: in principle each section may produce a different weight

• Optional plug-in of Bottero servo feeder (700 series)

• The variable gob weight is achieved regulating the plunger parameters of the servo feeder

• Capability to compensate glass accumulation phenomenon due to the return trajectory of the needles

• Commercial weight scales (e.g. Sartorius)

can be optionally integrated for automatic weight acquisition

Multi-Weight Manager

Page 27: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

BOX :The first and unique tool aiming to control the forming process

PROCESS VIEW CLOSE-LOOP CONTROLS

Page 28: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Process View close-loop control

Page 29: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Process View close-loop control

Page 30: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

• Automatic control and optimization of ware spacing

• Automatic control and optimization of vertical glass distribution (VGD)

BOX overview

Page 31: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

The BoX controls and maintains the vertical glass distribution under continuously changing operational conditions (due to the environment and to the production process):

• Feeder temperature & pull changes

• Glass conditions changes

• Temperature changes

• Blank heat transfer changes (new Blank)

• Blank swabbing

• Section stop/start

Goals of BoX VGD Control

Page 32: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Evolution of the BoX concept 4.0 Technology strategies

BoX

framework

Sensors and measurements

Modelling and Simulation tools and techniques

Process knowledge

Industrial Automation

Global control of the

production process

Page 33: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

The roadmap

5. Machine Learning: correlate input-output of the production process and define a “predictive” e2e model to put under automatic control

4. Big Data Analysis: analyze the data to learn the optimal process behavior

1. Sensors: integrate sensors to measure critical sub-processes

2. Close-loops: control each critical sub-process to minimize drift and variations (furnace, feeder, gob forming, gob loading, parison, final blow, transport, annealing lehr, …)

3. Big data storage: connect all systems on a network and store information in a common database (Furnace, Feeder, IS-machine, Hot End sensors, Cold End inspection equipment,..)

Page 34: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Measurements on containers at CE

Temperature measurements on molds, plungers, glass, neck rings

Glass temperature and gob weight measures

at feeder level

Measurements on gob loading performance

IR-D measures at HE

IoT (cloud) &

Machine Learning

Predictive Model of the

Production Process

Big Data Analysis

Page 35: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Machine Learning

Training

Data

Pre-processing

•Normalization

•Scaling dimensions

•Image processing

•etc.

Learning

•Supervised

•Unsupervised

•Minimization

•etc.

Error Analysis

•Precision/recall

•Overfitting

•Test/data validation

•etc.

Model

Phase 1. Learning

Phase 2. Prediction

New

Data

Model

Prediction

Predicted

Data

Corrective

actions

Page 36: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Summary & Conclusions

Bottero strategic view has been presented…

• Ultimate goal: full, labor-free automation of the glass manufacturing process

• Industry 4.0 identifies a powerful and integrated view, but…

…a fully stable process operation is the key to achieve the goal

• Bottero has a deep and consolidated process knowledge to pursue this objective

• BoX is the first and unique system on the market, conceived and developed to support this vision

• Starting from the BoX experience, Bottero has defined an evolutionary roadmap aiming at the full process automation

Page 37: Managing the glass manufacturing process · HARDWARE • 1800 GB RAM • 40,2 TB Hard Disk • 2 high-duty quadri-processor servers, with 16-core CPUs • 5,2 teraFLOPS (computer

Thank you

This presentation has been prepared for information purposes only and all descriptions, examples and calculations are included in this presentation for illustration purposes only.

The Company does not undertake any obligation to update or revise any statements contained in this presentation, whether as a result of new information, future events or otherwise.

Bottero © 2013. All right reserved. www.bottero.com v1.00 Eng