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Current user manual for the AVBIS 3000 series

1. OV dc Run Fig 8 Safety controller configuration summary GS02 Gate Switch Complementary Contact switch Manual reset logic Terminals S8 S9 S10 Mapped to 3O1 Simultaneous Closed open debounce time 6 ms Open closed debounce time 50 ms Startup test disabled GS03 Gate Switch Complementary Contact switch Manual reset logic Terminals S5 S6 S7 Mapped to SO1 Simultaneous Closed open debounce time 6 ms Open closed debounce time 50 ms Startup test disabled Q5 Out Reset SO 1 reset needed 24V dc Reset needed Configuration Summary Configuration CFG1 By S Sama Date 02 20 2010 File name 3 Door csc 7 Internal Calibration and Checks de Remove the chassis top cover by removing the 4 topmost screws on the side rails 2 on each side Then pull the cover to the rear about Y inch and then up and away Refer to figures 3 and 4 for the layout and identification of the internal system controller components Power up the controller in the normal run mode as per section 3 Adjust the DC output voltage of power supply PS4 to 46 0 volts down from the nominal 48 0 volts Activate Lamp On Off relay K4 Adjust the DC output voltage of power supply PS3 to 11 0 volts down from the nominal 12 0 volts Adjust the DC output voltage of power supply PS2 to 24 0 volts Confirm that all 4 LEDs are illuminated on the relay board Check for 24 0 5 volts DC at JSC24V on t
2. t n PHS compliant pqupoooopogoo kees m R k ralla k gt Door 1 Coor2 Coors Ground Wiring O 60 TET BE TET eye GED MN eo E KEES S ES 2p z He oir our Falsa AC Input LED 18 AWG Low Voltage Fig 6c Low voltage wiring ae el Y SI el Ei Ele el Y oL I EE E E ERN FE D DESEN HERES O ER PA BL E ea 6 ca GA 6 0 LE TIA FS NC K RCG RC Pour compliant 109 i p Umi xli A Lad E sl Fan El o HE PER A A LI T Ad AC Input LED Door Door2 Door3 E Stop USB Lamp Lamp vO 22 AWG Signal amp External Power Fig 6d Signal control and external power output wiring 2 23 J00Q SLUBU 9 IJ 0L10c 0c c0 S1EQ ewes c g 19409 uoneanDijuoo weeg BuutAA sindul eW jejes pue uoj s 329 ima edo dos Ausbau JO 1deoxe uonueAuoo eubis 34s dois y Buisn umous ale sjoqui s LOS de sajinoo ey AJddng amo g Wajs g En EN a a E JP AO 9p Ave Za ta Oy D Op 25 Asano H UV VH Ajddns Jamog E 9p APZ de Ve de Ve deal e 010 60 80 ZO 90 GO PO O cO LO CV CV IV IV Os COS LOS CCS WES OZS 615 815 ZIS 913 SLS PLS ELS O O O A 95 SS PS tS POI POO OOO e ar TOT CURT APC E ve X S 2 S S N di ei Fig 7 Safety controller simplified schematic System Settings Normal power up mode Mute o
3. Correct S Incorrect S End Offset too small Sample Points Allows operator to gather several values for S if the rotational position of S is unknown approximate or changes due to poor mold consistency The system will gather a number of sample points number selected by the operator are the degrees surrounding the end of thread and then select the smallest of these samples as the S value AVID DOES NOT ADVISE USING MORE THAN 1 SAMPLE POINT UNLESS ABSOLUTELY NECESSARY AVID RECOMMENDS ADJUSTING THE ANGLE OF THE END OFFSET IN ORDER TO FIND THE SMALLEST S Scan Speed Generally Set Between 20 50 The scan speed adjusts the speed of the rotary table during the Thread Start Search Slower speeds may be desired if the search is for a gap in a snap top or other feature The slower the scan speed the AVBIS can measure S with higher repeatability at the cost of time Very slow speeds have been known to create errors during the measurement routine particularly on bottles with very long thread lead ins End Offset gt 20 Very high scan speeds have been known to create errors on bottles where the difference between T and E is very small S Type Several Different methods can be employed to measure the S dimension depending upon the shape of the thread and E wall above the S The S Offset value is used differently for each S Type S Type 0 Two points on the top of the thread and two points above the thread on the E wall are me
4. Excel Excel spreadsheets may be used for data collection and analysis The system will automatically insert data into the spreadsheet The worksheet must be selected and will be identified with the particular bottle so multiple worksheets may be used for different bottles Data will automatically be indexed by row or column depending upon the worksheet layout each time a bottle is measured and the data is sent to the worksheet The First on sheet box permits the entry of the first cell Row or Column for bottle 1 The Data Cell assignments are entered in Data Setup menu under the Excel Setup tab Data File Allows the operator IT to select a remote file to export bottle data information into The Data Delimiter allows the operator to select how the data is organized for compatibility with various SPC programs Note This option should ONLY be accessed by trained operators or IT Inspection System Values Rotary Center Permits recentering along the AVBIS X stage axis This should not be adjusted unless instructed by an AVID technician Rotary Home Offset if equipped Permits operate to enter a degree offset from the rotary stage s home position Vertical Home Offset Permits adjustment of the Y Axis Home Offset position This should only be adjusted by a trained operator as aroubleshooting tool The touch screen may be aligned when this symbol is selected A new screen will be displayed which prompts the user to tou
5. Lower removable hard drive Upper removable hard drive bay Drive 1 in the RAID 1 bay Drive 0 in the RAID 1 array array YY ritemaster Kee SE USB connectors DVD ROM or R W drive 7 Parts List Mfr Part Computer oJ o o IE Powersupply ss FSP550 60PLG_ Sparkle Power Inc t Yes Data Sheet Motherboard PABBF me 1f Yes Data Sheet Harddrive ST380815AS_ Seagate Yes Data Sheet DVD RAM drive SH 223L_ Samsung 1 Yes UserGuide Serial O Board 4 port POL QUATTRO PCI Lava Yes Data Sheet Ethernet board 10 100 PCI F5D5000 Belkin 1 Yes User Manual Graphics board 512P3 1213 LR__ Evea i Yes Data Sheet Fan 12VDC 120 X 120X25mm DF121225BM Dynatron 1 Yes Data Sheet UPS A E A A UPS SMX500RTIU Tripp Lite 1 Yes Data Sheet Motors O E E LLL Servo Motor 1 stack 2000 count SM2315D Animatics 9 Yes Catalog
6. Metric Converts AVBIS 3000 to be setup and measure in metric System restart required Scale Allows the AVBIS 3000 to recognize the weight scale and associated controls Concentricity Allows the AVBIS 3000 to recognize the concentricity add on and associated controls Thickness Allows the AVBIS 3000 to recognize the thickness add on and associated controls no longer offered or supported Push Up Allows the AVBIS 3000 to recognize the push up tester and associated controls Bore Gauge Allows the AVBIS 3000 to recognize the bore gauge devices and associated controls Auto Level Allows the AVBIS 3000 to automatically adjust for light conditions Auto Feeder Allows the AVBIS 3000 to recognize the pick and place devices and associated controls AVBIS 3000P Windows File Dialogs Allows the AVBIS to recognize Windows menu and font size settings Y Stage Up Allows the AVBIS to be configured with the Y Stage oriented above the AVBIS 3000 Rotary Limit Allows the AVBIS 3000 to recognize the limit switch on the rotary table Barcode Allows the AVBIS 3000 to recognize the barcode reader device and associated controls AutoFeeder Allows the AVBIS 3000 to be configured as an AVBIS 3000P Auto Home Vertical Automatically Homes Vertical Y Stage after a feeder RUN cycle 52 Graphics Enable Enables the view of the Thread Start Search during RUN Slows down the search routine Password Allows the Da
7. Go To Rotary Home Probe Select Raise Set Center Probe Find Wm Set Open Retract Go Calibrate Bore Size mm WEN Open Measure A 0 4292 Probe I INCH Start ES e Wi fe amp AVID Vision System AVID Wall Thickness Sys amp AVID IR Thickness Gauge laan Wision Image Monitor SP untitled Paint aam 12 54 PM c Ifthe tips are straight no ball bulb or point press the Select button and manually position the contact point d Press SAVE e Enter the Calibration Ring standard s height and ID into the appropriate displays Place the Calibration Ring onto the rotary stage centered on the index hole f Press the Calibrate button The system will move the tips to the camera field of view and close the gripper The vision system will measure the distance between probe rods and then the bottom position of the support block The probe will then be automatically moved to the center of the calibration ring The system will use the probe to scan through the nominal center of the calibration ring to calculate a measurement offset and the center of the rotary table Do not jar the system during this procedure 91 pe AMID VWininn mo Monitor Go To Rotary Home Retract Probe Raise Probe Close Probe Bore Gauge Camera Probe Length Find Standard Bore Stage Height 0 9000 Go Set Down Set Open Select
8. 43 orr ss00 744 OFF 45 OFF 46 OFF EA asooo T T T o J o A amp nn 17 When complete press the Setup button Press the Data tab Uncheck the boxes for Show Unused Heights and Show Unused Angles All unused cells will disappear 90 135 180 215 270 315 Min Max Avg T Enbl ON ON ON ON ON ON ON ON ON 10 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 Es ON 9 5000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 61 ON 9 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 Ez ON 8 5000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 81 ON 8 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 7 ON 7 5000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 101 111 Min Max ON 7 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 ON 6 6000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 18 If sending thickness data to a pre created Excel worksheet press the Worksheet File button Locate the worksheet file desired and Open it Due to the different data export methodologies of the AVBIS and ABT
9. AVBIS 3000 Operation Manual 3000M 3000C 3000P VERSION 9 AND HIGHER AVID Corporation 222 International Drive Suite 105 Portsmouth NH 03801 Copyright O 2010 Table of Contents 3 Neck Finish Diagram 51 Bottle Measurements Guide 4 Quick Reference Program Setup 79 Calibration Guide 5 Quick Reference Motion Setup 87 Common Error Messages 7 Control Screen 89 Troubleshooting 8 System Controls 95 Software Conflicts 9 Part Buttons 96 Returning Equipment for Repair or 10 Stage Controls Replacement 11 Data Setup Data DisplayTab Appendix A In Depth Bottle Programming Guide 12 Data Setup Data Setup Tab Appendix B Bottle Wall Thickness Module 13 Data Setup Measurement Setup Tab 15 S Types 23 Data Setup Allowed Data Types Tab 24 Data Setup Excel Setup Tab 25 CAD Setup 27 Basic Setup Wall Tab 28 Basic Setup Bore Gauge Tab 31 Basic Setup Measure Tab 32 Basic Setup Camera Tab 33 Basic Setup System Tab 34 Basic Setup Autofeed Tab 35 Basic Setup Conveyor Tab 36 Basic Setup Misc Tab 37 Basic Setup Concentricity Tab 43 Basic Setup Advanced Options 47 Feeder Controls 49 Using Bladder Restrictor Collar 50 Dimensional Measurement Requisites Neck Finish Dimensions D dE i C I Quick Reference Programming a New Bottle Preform For Measurement PROGRAMMING SHOULD ONLY BE CONDUCTE
10. Action a Press the Basic Setup button Press the Measure tab Place a standard vertical block at the center of the rotary table wide side facing the camera b Enter the height of the standard in the Nominal box Press the Home Vertical button The system homes itself around the standard height After homing the system will prompt to set the offset Press Yes Press SAVE c Check height using several Y Blocks Enter the correct nominal height for each block and press the Height button under Auto Measure STEP 6 Width Calibration Tools Required X Blocks available through AVID Explanation Ensures that width and two measurement field measurements are being properly measured Note measurements made utilizing a two measurement fields will be less repeatable than those made in a single field due to the nature of motor and stage errors Action a Place the X blocks provided by AVID on the rotary stage One must be on top of the other b Move the Y Stage until the top block is visible in the center of the video field c Press the Measure Tab Enter in the nominal value for the top block Press the Width button under the AutoMeasure heading d Reverse the blocks Enter the proper nominal and measure the width Width variances greater than 0 0015 of nominal indicate a potential step size problem Call AVID for support STEP 7 Rotary Table Level Adjustment Tools Required Ball leveling tool 2x 1 2500 steel balls available
11. Boston Round Rotary and Boston Round Vertical Limitations Due to the type of sensor filters used the ABTIS WTS systems are designed to measure the wall thickness of PET bottles only The wall thickness of other materials cannot be measured The ABTIS WTS cannot measure wall thickness lower than the push up height of the bottle Heel and or foot thickness measurements are not possible Thick OK Cannot Measure Push Up The ABTIS WTS cannot measure the wall thickness of opaque bottles If the light emitted from the light tube cannot pass through the PET with enough intensity to be detected by the sensor thickness cannot be ascertained Due to the differences in the absorption of light by different PET resins different multipliers may be needed to measure wall thickness accurately for different bottles 111 Control Screen The control screen displayed at system start up is divided into three regions E s ym Wall tech System Ver AWA D 02 S N 105 000 0111 Ele Edt View Test Help Thickness Poll Was o Test Thickness Current part number is Test Lamp Bottle Count oO Wall Tube System Controls top right Permits access to setup and data screens and controls for frequently used functions Data Readout top left Displays height and angle settings and the thickness data gathered from the last bottle
12. Check the speed settings of the load arm in the Basic Setup Conveyor Tab e Some bottles may be too light to be moved over the surface of the conveyor belt or experience friction and topple Not all bottle neck finishes appear in the CAD setup screen Image Monitor e fthe bottle neck is very long certain neck finishes may not appear in the field e In Data Setup decrease the nominal value for height and SAVE This system will assume the bottle is shorter and bring the Y stage up bringing the neck finishes into view e Note that the height data collected will be flagged by the AVBIS as out of specification due to the lower height nominal that was entered into Data Setup Increasing the tolerance will prevent flagging e If difficulties persist call for AVID technical support A bottle sample may be requested by AVID technicians for testing e Note that the height data collected will be flagged by the AVBIS as out of specification due to the lower height nominal Saving taking a long time e Check hard drive space in Windows Explorer If hard drive becoming full contact AVID for recommended course of action e Checkthat antivirus suite or protection software is not scanning hard drive during system saving Code files are large data files that do no need be scanned by an antivirus software program Probes sticking or opening unevenly jerking when ID measurements are taken e Ensure that bearing rails are clean see picture Use a cott
13. T dimension MUST be turned ON at the ZERO angle End Offset Value in Measurement Setup explanation below Scan Speed Value typically between 8 and 12 gt Thread Start Search can be tested in CAD Setup if S is ENABLED and turned ON at ZERO Otherwise it will only function in the RUN mode gt Bear in mind that bottles formed by 2 stage production preform to bottle typically do NOT have a consistent datum point relative to the body i e the thread start moves around in relation to the body NOTE The S dimension usually BUT NOT ALWAYS found at the thread start is NOT RELEVANT to the thread start search However measuring the S is often useful for determining the End Offset explanation to follow How Thread Start Search Works 1 The bottle is rotated clockwise at the Scan Speed until the thread T projection on the LEFT side of the neck finish drops below 1 2 of the T nominal value The rotation stops 2 The bottle is rotated counter clockwise at 1 2 the Scan Speed until Y of the thread T is visible projecting from the sidewall E on the left side of the neck finish The rotation stops 3 The bottle is rotated counter clockwise in degrees equal to the End Offset value End Offset is therefore is equal to the of degrees of neck rotation from L of the thread start lead in to the position of interest usually the position where S can be measured 4 After rotating the End Offset the rotational position i
14. 12 000 Measured Height Limits Maximim Kibb Method C Vertical Save Part 13 Go to the Data Tab Check the boxes for Show Unused Heights and Show Unused Angles Typically Pass Fail by Rows and Pass Fail by Columns are left unchecked unless nominal and tolerance data is desirable Measurement Setup Excel Multipliers Enable for Data Input Wall Tube By C Height Angle f Show Unused Heights Display Metric i Show Unused Angles Pass higher than nominal data Exit First Row Col Pass Fail by Rows i Show Data Settings EN EN T Pass Fail by Columns Data File Worksheet File Data Delimiter comma M Data File 14 Press the Save Part button Save the changes to the correct filename the filename will already exist as it was created earlier Save Part 15 Press the Exit button on the tab Exit 16 ROTARY If conducting a rotary thickness scan turn ON the heights to conduct the scans at If only certain angles are of interest turn ON the angles of interest only If all angles are of interest turn ON all angles OR VERTICAL If conducting a vertical profile thickness scan turn ON all the heights that vertical scan should measure Turn ON the angles the profile scan should take place at MICELI CA AE EA AAN AA E 65 Enbl OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF ON 10 0000 0 0000 ET cnn OFF 9 9500 NMBMBNENNENNUDDVVMNMSSSVJUIP
15. After homing Hide from the Feeder window select the proper bottle file and continue as normal 11 n Select Select EMERGENCY STOP SWITCH Emergency situations ONLY In the event of an emergency press in the EMERGENCY STOP switch on front of the machine This will immediately cut all power to the stages and motion devices When you have cleared out the problem pull the emergency stop out and press the Blue RUN button on the front of the computer box if applicable Click on the Reset button and allow the stages to reset and home Return to regular routine 12 Standard Operating Procedures SOP AVBIS 3000 Picker Vision Measurement System 1 Click the part button associated with the bottle or part you will be measuring This will load the program System Controls GM amp Data Setup CAD Setup Manual Reset Ww E Clear Data View Data d es 33 mm Templet 04 419T 1 950 ml Mayo Seaforth 38 mm Templet MIO S OR scm 2 The system may query you to load parts a certain way onto the system and or verify that the correct bottle or part is has been selected loaded and or load a particular fixture onto the system Confirm that you have read and will follow the instructions by clicking on the OK button FAILURE TO FOLLOW THE INSTRUCTIONS MAY RESULT IN IMPROPER MEASUREMENT OF PARTS OR DAMAGE TO THE SYSTEM AVID Bottle Inspection Is this the most recent
16. C Data Setup Entry Nominal Value Tolerance Value Y Offset Value from the top of bottle optional SHO A H i CAD Setup Entry r Select Up Down E Select Point Nominal Position D oe Upper Search Limit _ Adjust Upper and Lower Limit Hommel be Lower Search Limit Measured Minimum diameter detected within search window the i i B Y offset down from top of finish E E Multiple B Dimensions may be utilized to search for B Morminal minimum finish diameters B 1 5404 o Upper search tint E a Serevent ro ot T X Lower search limit D Left D Right aka Pilfer Height Tamper Evident Height Measurement Height of Tamper Evident Bead Measured from the top of finish to a gauge point under the bead Can be used to measure the height from the top of finish to a gauge point under ANY bead specified as A Data Setup Entry Nominal Value Tolerance Value A Dimension enabled and turned ON at SAME angles X Offset from the Max projection of the Bead Gauge Point optional CAD Setup Entry Select A dimension and setup position and limits before selecting D Select Left Right Set Gauge Line Under the left side of Bead A at desired point Measured D Nominal J m D X Offset First point detected which is X distance from the Bead Max projection The Y coordinate of this point is subtracted fro
17. Conveyor mue on Get Preform 1 Return Preform 1 Regression Graph Measure Rotate Laser Graph Allows the Concentricity Sensor to be Setup and Tested Test Get Preform 1 Picks a preform from slot 1 and moves it to the concentricity position ENSURE THAT THE POSITION IS SET IN THE AUTOFEED TAB BEFORE USING Return Preform 1 Returns the preform from the concentricity position to slot 1 ENSURE THAT THE POSITION IS SET IN THE AUTOFEED TAB BEFORE USING Regression Graph Maximizes the concentricity regression graph Measure Measures a preform loaded in the concentricity position Rotate Rotates a preform loaded in the concentricity position Laser Graph Maximizes the Laser Sensor signal graph Useful for testing or setting the distance of the laser sensor Setup Max Height Allows the user to set the Maximum distance the pickup will drop at the Concentricity position Useful for preventing damage to the pickup arm or laser 46 Understanding Concentricity Below is a diagram of the laser concentricity module on both AVBIS 3000P and APTIS 1000 systems MEINT AG USTITIETIT Distance Adjustment Arm Laser BE Sensor Drive Drive Motor Ben Gear Distance Adjustment Arm Allows the laser sensor to be moved closer to further from the preform sidewall Should only be altered with preforms of very different body diameters Height Adjustment Arm Allows the laser se
18. Data Delimiter E Data File The Data Tab allows user to establish data output settings and data display settings Note All settings in the Data Tab are file specific Excel Excel spreadsheets may be used for data collection and analysis Thickness data MUST be sent to a DIFFERENT worksheet file than the data collected by the AVBIS bottle software i e the AVBIS and ABTIS cannot share the same worksheet file The system will automatically insert data into the spreadsheet The worksheet must be selected and will be identified with the particular bottle so multiple worksheets may be used for different bottles Thickness data from individual bottles will automatically sent to the worksheet file as a block each time a bottle is measured organized by height or angle headings and separated by two lines in the Excel file Enable for Data Input Displays if bottle thickness file is linked to an Excel file By Height Angle Toggles output headings by height or angle First Row Column Allows the user to identify the initial cell the data block will be placed Worksheet File Allows the user to select an individual worksheet file for data collection Multipliers Wall Tube Displays the multiplier factor being used for the particular bottle PET resin Most PET resins utilize a multiplier of approximately 0 02850 Show Unused Heights If checked displays all unused heights in the data readout screen
19. Go Pressing this button will advance the next bottle until it reaches the electric eye then to the load position Load Unload Arm Allows the operator to setup the loading unloading and ejecting arms Load Pos Set Go Allows the operator to set the loading position of the loading arm i e pushes the bottle from the load point on the input conveyor until it is centered over the center of the rotary table UnLoad Pos Set Go Allows the operator to set the unloading position of the loading arm e pushes the bottle from the center of the rotary table to the scale output conveyor Eject Pos Set Go Allows the operator to set the ejecting position of the loading or ejecting arm i e pushes the bottle from the scale to the output conveyor or collection bin nd loading arms Rotary Stage Positions Allows the operator to adjust the load unload and reflector levels for the rotary table ROTARY STAGE POSITIONS SHOULD NOT BE CHANGED UNLESS INSTRUCTED TO DO SO BY AN AVID TECHNICIAN OR AN OPERATOR TRAINED BY AVID Rotary Load Set Go Allows the operator to set and place the rotary table into the load position to accept bottles from the input conveyor Rotary Unload Set Go Allows the operator to set and place the rotary table into the unload position to eject bottles onto the scale and or output conveyor Limit Height Set Go Allows the operator to set the height of the reflector switch
20. It can be disabled later if it unnecessary to report 108 Also ensure that the zero 0 angle is setup in the first row as this will be the first set of measurements Step 4 VR the red arrow buttons at the bottom of the screen scroll to the MEASUREMENT SETUP tab Step 5 If the bottle finish fits within the field of view of the camera T dimension is 2 300 turn ON Neck in Single Field Turn the Thread Start Search ON Set the End Offset at 15 This will likely be changed in CAD Setup Set Sample Points to 1 Set the S Type and S Offset values appropriate to the finish profile see the manual for descriptions of S Types and S Offsets Set the Scan Speed between 10 and 40 10 is slower but very repeatable 40 is faster but isn t as repeatable Set S as Datum ON Estimate the S Datum Offset o To estimate look at the finish from overhead Locate the S Now mentally calculate the number of degrees from the position of S to the parting line you wish to label 0 If you calculated counter clockwise from S i e the parting line BEFORE the S your S Datum Offset is NEGATIVE If you calculated clockwise from S i e the parting line AFTER the S your S Datum Offset is POSITIVE See drawing below for help There is a shortcut to this that we will discuss later On single step bottles and preforms the Panel Offset value is equal to the S Datum Offset value we S Datum Offset Pd SE S S Datum Offset S
21. Measured Distance from Top of Finish to point on the right or left finish tangent to the T projection Multiple H measurements may be made at different offsets from the first T Note all multiple H positions are relative to T 1 uge point H Left nominal T tangent SN H X offset K T 1 7232 HT setup incorrectly Gauge point must be ABOVE actual position 65 HZ Left HZ Right SPI H aka H Husky Method Measurement Clearance Height for Closure on the Left or Right Side of the Neck finish down to the top of the NSR 2 Data Setup Entry Nominal Value Tolerance Value Ensure that H is ENABLED and turned ON at desired angles Z dimension is ENABLED and turned ON at SAME angles OPTIONAL X Offset from the Z max projection The X offset may be used to shift the measurement point left or right from the measured Z position CAD Setup Entry Z dimension setup correctly prior to setting up HZ HZ is setup very similar to X except the gauge line measures to the TOP of the NSR not underneath Optional Position gauge point to desired X offset location from the left Z projection Measured Distance from Top of Finish to point on the NSR left or right finish offset from maximum Z projection HZ gauge line HZ 0 4893 66 Height Left Height Right Measurement Overall Height of the container
22. SSL LX3044GD Lumex H o yY Resistor 4 75K 1 4W 1 m flm MFR 25FBF 4K75 YAGEO as p CC Capacitor tuf 50V ceramic SRI55ET04MAR AVX e po 7 Header 2 pin dual row PBCO1DFAN Suis e AA Eo OA O ECE Connector USB panel nout PX0842 B Bugn fh DataSheet Connector M8 3 pole F______4R3PO0A27C300___ Brad Harrison DataSheet Connector M8 3 pole M______ 4R3PO6A27C300____ Brad Harrison_ t_ DataSheet Connector M8 4 pole F 4R4POOA27C300 prad Hamion b DataSheet Connector M12 4 pole F dualkey 7R4A00A19A120_ prad Hamion DataSheet Connector M12 4 pole F one key BR4A00A18A120 prad Hamion DataSheet Connector 7 8 5 pole F one key 1R5004A20A120 Brad Harrison 1 DataSheet Cable USB 2 1 ft A male B male useana StarTech LL AVID Eo p deeem 4 40 Some Connector PC D sub 9 pin female MD9F3S600X 929 2 Positronics Connector PC D sub mixed female CBD7W2F35S600X Postone P ago Terminal block 2 pin 1714955 Phoenix hi DataSheet Power Entry module 4303 0001 gSchwter Jh DataSheet Fusedrawer 4303 2401 Schute pata Sheet Fuse 5A 250V 5X20mm fast act 217005H LittleFuse 2 Data Sheet System Components Configuration Guide This manual contains Information on the major System Components as well as connection and identification information Revision 1 0 Augus
23. Under the Calibration heading press the Light button The light tube will extend and drop down to the sensor height and the ABTIS WTS will calibrate the raw dark level The light will turn on and the raw light level will be calibrated The probe will pull up and retract 5 Under the Thickness Gauge heading press the Probe Down button The rotary stage will shift over to the thickness inspection position The light tube will again extend and drop to the sensor height 6 Goto the Stage Control Menu and press the Y Stage button Move the stage down until there is enough space so you can put the bottle under the tip 7 With the tip now in the bottle move the Y Stage up until the square of light is at the center of the circle you drew on the bottle Make sure the bottle is correctly lined up so the light beam is striking the plastic straight on not angled 8 Under the Calibration heading click on the Standard Thickness value Enter in the thickness you measured with the micrometer on the pop up keypad 9 Under the Calibration heading press the Sensor button The ABTIS WTS will now calculate the multiplier required to acquire the thickness you measured The measured thickness will appear under Measurement 10 Press HIDE The light tube will retract and the rotary stage will return to the center position Auto Feed Conveyor we Thickness Gauge Setup Calibration gt Thickness Gauge GO Set Rota
24. d A E lt SAVE your selections to the created bottle file Press HIDE The bottle preform will be positioned at the correct height in front of the camera assuming you entered the correct height in HhghtL HghtR Press the CAD SETUP button in the System Controls menu Press HghtL Setup HghtL to your preference Skip S for the moment and check T and E and ensure they are measuring in the correct places Adjust the search limits for T and E if required Press S Press EITHER of the Find S buttons on the right side of the screen This will begin the Thread Start Search The bottle is rotated clockwise at the Scan Speed until the thread T projection on the LEFT side of the neck finish drops below Ya of the T nominal value The rotation stops The bottle is rotated counter clockwise at the Scan Speed until 1 of the thread T is visible projecting from the sidewall E on the left side of the neck finish The rotation stops The bottle is rotated counter clockwise in degrees equal to the End Offset value End Offset is therefore is equal to the of degrees of neck rotation from Le of the thread start lead in to the position of S Press S again Set up the limits if required for the S Type you have selected Press S again if you changed any of the limits Record the value measured Change the End Offset value greater OR less than 15 by clicking on the End Offset value in CAD Setup see illustration below 109 Align Cu
25. it is NOT multitasking capable Allow the AVBIS to go through the motion routines required before clicking on the next button IV Excel Open Error Message Excel Open Error This message is seen when opening a bottle file CiProgram FileslAVIDiBottlelExceliRR XLS could not be found Check or pressing a bottle part button It is caused when the spelling of the file name and verify that the file location is correct the Excel file the bottle file was linked to has been dee ce or de If the SECH bs Is If you are trying to open the file from your list of most recently used files ed Oe te Ue on the File menu make sure that the file has not been renamed moved drive check to make sure the drive and file is accessible to the AVBIS or deleted V Path Error Message Part file not found This message is sometimes seen when selecting a part l button It is caused by selecting a Saved Bottle from File C Program Files AVID Bottle Setup DefaultFiles MZ one folder location and then pressing a part button that test IN links to a bottle file in another folder location In other words the AVBIS links to the folder the last bottle file was run from Go to the Saved Bottle button and select OK the file you wish to run The AVBIS will then link to that folder location 7 VI Setup Error T E Error Message This message is seen in both CAD Setup and the RUN T is not enabled for the EI measurement Ple
26. 48 volt DC power is supplied to the system servo motors on the 2 large pins This power is removed during safety shutdowns Three small pins are jumped to the COM 1 connector to provide bidirectional serial RS232 communications to the motors as well The COM 1 female 9 pin D Sub connector is in turn cabled to the Com 1 port of the system computer An optional second bank of motors may be implemented with another Motor Fanout Panel and using the similar PWR 2 and COM 2 connectors 4 3 Computer This is a female B type USB connector used with a standard USB 2 0 compatible cable to connect the internal safety controller module to the system computer Support software on the computer can be used to configure the safety controller module and to monitor it s operating state 4 4 EPO This female 4 pin M12 connector connects the external emergency stop switch to the internal safety controller module The switch must have 2 poles of normally closed contact pairs 4 5 Door 1 Door 2 Door 3 These female 4 pin M8 connectors attach to the system guard door switches Magnetically coded switches are used each with a normally closed and a normally open pair of coordinated reed switch contacts 4 6 I O Power This female 5 pin 7 8 inch connector provides 24 volt DC power at up to 60 watts to attached general purpose input output hardware An intelligent I O block with compatible connector is normally used which communicates with the syste
27. Be sure to press SAVE after correcting S Excel Setup A Fee a EI S 9 9 The Data Display Sheet can also be viewed by pressing View Data in the System Control menu however changes to nominals and tolerances cannot be saved from View Data 20 Data Setup Data Setup Tab p File Edit Options HghtLeft HghtRight S T E XLeft XRight z ID Width Note the data settings window will only display options for dimensions ENABLED in the Allowed Data Types tab 7 3400 7 3400 0 0610 1 2570 1 1650 0 5700 0 5700 1 3770 1 0150 0 0000 Tolerance 0 0600 0 0600 0 0120 0 0120 0 0100 0 0150 0 0150 0 0100 0 0150 0 0000 Nominal Values X Pos 0 0981 00981 00000 00000 0 0000 00203 00203 00000 0 0000 0 0000 The nominal value is normally the value of the Y Pos 0 0329 0 0329 0 0000 0 0424 0 0787 0 0000 0 0000 0 5187 0 1250 0 4970 dimension the target dimension which may be obtained from a bottle drawing or spec sheet Click the value and enter a new one using the number pad that appears Note that entries made on Left dimensions will automatically be transferred to the Right for that same dimension if ENABLED vo ON ON ON ON ON OFF OFF OFF ON ON ON ON OFF ON ON ON ON ON OFF OFF o ON ON OFF ON ON ON ON ON ON ON o OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF 0 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF Tolerance Values o OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF The total toler
28. Data Setup Entry Y Offset Nominal Value Tolerance Value Height Left must be turned ON at ALL angles there is a finish dimension to be made X offset Distance in from edge to measure height cannot be a negative number Y offset Distance down from top edge to establish edge for X offset cannot be a negative number CAD Setup Entry Optional Set gauge point X Y offset manually Set light i blue crosshair just BELOW the point you wish to capture height Height Measured Height of bottle is measured X offset from the left or right top edge Height gauge point 67 Discussion Height Measurement Understanding the search method employed to measure height is critical to establishing a starting point for finish dimensions 1 The system first searches down to find the top of the bottle at point 1 2 From point 1 the system moves down Y offset to locate point 2 3 From point 2 the system looks left to find the side wall at point 3 The Y offset entered to establish 2 is important The offset should establish point 2 where a repeatable side wall point 3 can be located In this case below the top radius The Y offset cannot be negative because this would cause the system to try and locate the starting point above the top of the bottle 4 Once the side wall is located the system moves in from point 3 the X offset to locate point 4 5 From point 4 the
29. E E es d ok Y ag A d D A 24 VDC 60 W O 12 VDC 30W lamp Lamp On Off Relay board power supply PS2 power supply PS3 relay K4 Fig 3 Internal Components Safety relay K1 Safety relay K2 24 VDC power LED2 po eRe AD 24 unc JACL amp B Hs Camera LED 24 VDC 40 W Safety controller Fan current limiter R5 power supply PS1 regulator U1 Fig 4 Relay Board 6 Circuit Function Description Figures 5a 5b 5c and 5d show the complete system controller circuitry The Banner Engineering model SC22 3 safety controller labeled as SC1 in Fig 5c has outputs SO1A and SO1B wired to JCoil that drive force guide safety relay coils K1 and K2 respectively on the relay board shown in Fig 5a K1 and K2 each have 2 poles in a DPST configuration These contacts are wired in tandem from the AC line input at JACin to the JACmotors connector line output to power supply PS4 and to the JACIO connector line output to power supply PS2 Servo motor power from power supply PS4 and I O power from power supply PS2 will therefore only be enabled when both of K1 and K2 are activated Normally closed contacts from K1 and K2 are wired to SC1 pins S20 and S21 through JFault These contacts are monitored by SC1 to determine whether the K1 and K2 relays are functioning properly with undamaged contacts If not then SC1 will remove power from both the K1 and K2 coils SC1 will then light the front panel Reset button with an output from pin O6 Pressing the Re
30. Home Extend Probe Lower Probe Open Probe Set Down Set Open Set Center Bore Size Bore Tip Calibration Probe Tip Offset Stage Center INCH 0 0000 Measure The bore gauge tab sets up and calibrates the bore gauge Go to Rotary Extends and lowers the bore gauge tips to the center of the rotary platform but does not open the tips Home Returns the Bore Gauge to the home position Extend Probe Extends the Bore Gauge over the rotary stage Lower Probe Lowers the Bore Gauge tips towards the rotary stage Open Probe Opens the Probe Tips to their maximum open position Standard If supplied with a ring standard this tool allows for standard measurement setup Height Pressing the height display allows permits entry of the height of the calibration gauge from the base to the top of the ring ID Pressing the ID display allows the user to enter in the inner diameter of a standard on the pop up keypad Probe Length Probes of different length and shapes may be used with the bore gauge The length of the probe from the bottom of the support block to the probe contact point must be entered prior to measurement or calibration Find System automatically locates the contact point and measures the length of the probe to that point Select Allows the operator to manually locate the probe contact points Bore Stage Controls Allows the user to set
31. ITO Coupler Installed Correctly note position on stage shaft D ig R ES ub t Coupler Installed Incorrectly Coupler Too High On Stage Shaft 103 I need to remove the ID probe housing to gain access to the Deltron Slide e D probe crashes can result in damage to the Deltron slide In order to access the Deltron slide the ID probe rod and probe box must be removed wi d 1 Remove these 8 bolts Unplug limit switch Remove 4 bolts 104 Removing Light Source for Return to AVID Tools Required Metric hex wrenches Robotunit frames OR small Flat Head Screwdriver Maytec frames Light Duty Wire cutters snips 1 Shutdown the AVBIS software by exiting to the Windows desktop Shut Windows down by clicking on Start gt Turn Off Computer gt Turn Off When the monitor goes black turn the power off to the system at the uninterrupted power source Tripp Lite or APC power supply The AVBIS should remain powered off until the light source is reinstalled 2 Remove the panel behind the light source if gt applicable If the AVBIS frame is a Robotunit A design you will need a metric hex wrench to Thumb 5 remove the panel clips If the AVBIS frame is a 7 Screw Maytec design you will need a small flathead f e wrench to pop off the panel clips p x Zu bv 3 P able Ties pf 3 Loosen the thumbscrew at the rear of the bl
32. Lug Search S Offset Lug Offset S Type Thread End Projection Scan Speed Finish Thread Start as Datum Thread Datum Offset Lean Lean Data 1 T Panel Setup Lean Data 2 Width 1 Single Field Max Width Search Min Width Search Thickness Min Width Search 90 Panel As Placed Panel as Placed Panel Offset Panel Thread Offset Panel Step Measurement Fields HE Measurement Setup A Allowed Data Types A Excel Setup A Feeder Setup a e Je jojo ojo Sae lt TD se O Return to the bottle main screen by pressing HIDE and press the Thickness button In the thickness main screen press the Setup button Go to the Bottle Tab Enter in the nominal height of the bottle by clicking on the display and entering the appropriate height on the on screen keypad Enter the Maximum height limit the highest height that thickness will be measured by the ABTIS WTS from the dropdown menu Enter the Minimum height limit Ideally the minimum would be zero However because the bottle push up and mirror offset prevent this enter in a minimum height limit that will prevent the light tube from contacting the push up 12 Check the box for the Method of thickness scan to be used Rotary scans will measure thicknesses around the circumference of the bottle at selected heights Vertical scans a k a wall profiles will measure thicknesses vertically of all selected heights at selected angles Measurement Setup Exit i Bottle Height
33. Usually disabled after initial setup Show Unused Angles If checked displays all unused heights in the data readout screen Usually disabled after initial setup Pass Fail by Rows If checked displays the Enable Tolerance rows in the data readout screen and allows the highlighting of failing cells Usually disabled Pass Fail by Columns If checked displays the Enable Tolerance columns in the data readout screen and allows the highlighting of failing cells Usually disabled Display Metric If checked converts variables to metric Pass higher than nominal data If checked passes those thickness readings greater than the nominal setting Thicknesses less than the nominal are highlighted Show Data Settings If checked displays all data settings set by the user Usually enabled but can be disabled for a data only presentation Data File Data Delimiter Allows the user to choose the delimiter to the data output stream Data File Allows the user to select a destination file for thickness data usually for use by SPC software Usually linked to a dat or txt file Exit Closes the Setup Tab window Save Part Saves changes Operator must select correct file to associate changes to 115 Setup Bottle Tab Measurement Setup Bottle Height 0 000 Measured Height Limits Method 5 x Exit i Minimum soen gt Rotary Vertical The Bottle Tab allows the
34. be seen repeatably in profile Therefore a different methodology must be employed Threaded preforms bottles have typically one or two thread leads and therefore have one or two positions for the measurement of S for the moment let us ignore finishes with 3 or more leads On a properly made set of molds this position s of the S is constant to the parting line of the preform bottle The AVBIS is capable of locating this these S positions through use of the thread start search Since the AVBIS can locate the S then locating the parting line is simply a matter of offsetting from the position where the AVBIS measures S Step 1 Press the NEW BOTTLE button Press the CREATE button Save the new bottle profile as a new file with a name that will identify the bottle Assign your new profile to a Part Button The assigned button will highlight green Place the bottle or preform in a fixture at the center of the rotary stage Step 2 Press the DATA SETUP button Using the red arrow buttons at the bottom of the screen scroll to or click on the ALLOWED DATA TYPES tab Enable those dimensions to be measured If multiple measurements of the same dimension are needed e g width dimensions at different heights or HT at different shoulder locations press the green up arrow button to enable those extra measurements Note that certain dimensions require that another dimension is enabled and being measured see the requisites section of the manual
35. below the Ai operator placed search limit for a change slope greater than the S Offset value Typically an offset of 4 is used on most bottles Use Bottles with a straight sidewall that remains mostly straight until the thread slope intersect S Type 4 is also the ONLY S Type that can be used on rounded thread profiles S offset 4 3 0 1254 Note the rounded thread non constant slope of the thread profile to E the right S Types 0 1 2 and 3 would not work on this bottle finish Also note that the USL has been set on a straight spot on the sidewall 28 S As Datum If S as Datum is turned ON the Thread Start Search will run as normal However after turning the End Offset value and measuring S if enabled and turned ON at 0 the bottle will then turn from this position a value equal to the S Datum value Both negative and positive values can be used Positive values will turn the bottle counter clockwise negative values will turn the bottle clockwise This offset position from the thread start will be set as ZERO for all NECK FINISH measurements The offset position will NOT be set as zero for Panel Width measurements Typically S As Datum is used to rotate from S to one parting line or the other the one before the thread start or after See drawing below we S Datum Offset A a Ss S Datum Offset N d x N 4 Panel Setup S to Panel Offset S to Panel Offset applies to the body p
36. could be entered reducing the number of pixels to step out Theoretically S Type 1 could also be used for this finish S Type 3 S Offset 1 S Type 3 is essentially the same as S Type 0 except that all points between an upper and lower search limit set by operator are used to calculate a line intersect All points on the top of the thread between 25 and 75 of nominal thread projection and all points on the E wall between search limits are measured to provide points from which best fit lines are constructed The intersection of the lines is the S position The S offset number in pixels provides an accept band The intersect point will be shifted to the first point within the accept band where the lines could intersect to avoid an intersection within the thread E wall radius Use Bottles with straight and clean sidewall and thread surfaces mainly PET products or clean injection molded finishes Upper Limit Lower Limit Intersect P aint LIEST ek Uoper search limit Lower seal cie wenn Note in both of the CAD Setup screens to the right the sidewall above the thread is very straight And long allowing many points to Be gathered between the USL and LSL S Offset 1 Also note the constant slope of the thread profiles Ss 01027 Upper search limit Lower search Wm S Type 4 S Offset 4 7 Upper Search Limit S Type 4 is the reverse of S Type 1 S Type 4 scans the sidewall
37. eege SSES d 1 Yes 6 Power Supplies Power supply 12 VDC 2 5 A 30W _ PS5R SC12_ DEC f es DataSheet Power supply 24 VDC 2 5 A 60W PS5R SD24____ DEC f Yes DataSheet power supply 4EVDO 10A Frau mge 1 Yes fe PO OO E MES MERO CN Safety Controller O O EE MESS MER Front panel contros Switch head short lever 2 pos L21KA03_ BACO Controls lt Yes Catalog Switch 3 position clip 833 BACO Controls 1 es Catalog Switch contact block SPST NO _ 83E10 BACO Controls Yes Catalog Switch contact block SPST NO B3E10 BACO Controls lt es Catalog Switch 3 position clip B33E____________ BACOControls es Catalog Switch contact block SPST NO Bop BACOControls lt Yes Catalog Switch contact block SPST NO B3E10 BACO Controls lt Yes Catalog Switch 3 position clip B33E____________k BACOControls es Catalog Switch contact block SPST NO B3E10 BACO Controls lt Yes Catalog Switch LED block red B3EARL___________ BBACOControls lt es Catalog Switch 3 position clip B33E___________ BACOControls 1 es Catalog Switch contact block SPST NO B3E10 BACO Controls 1 Yes Catalog Switch LED block bue B3EABL_ BACO Controls lt es Catalog Indicator LED 13mm green 3SBLG24ST 13GNF E3 Controls 8 Yes DataSheet steator LED temm amber Jeeaesr mr Groo rr az EL LL mg ll ooo oo oo o Wire duct slotted PVC t Xi lb y y y O Scre
38. for data output by selecting the appropriate part button Press the Basic Setup button in the System Controls menu Select the System Tab Press the Worksheet File button Select the spreadsheet file you loaded or wish to use 3 If the spreadsheet is organized by rows most common select the By Rows option in the setup If it is organized by column select the By Column option Determine the starting row or column number for data entry and put that number in First On Sheet Note make sure that in Excel the columns and rows are labeled by number and not by letters If there are letters go to Tools Options click the General tab and check the R1C1 Reference Style box Save the Excel file with this change 4 On the System Tab press SAVE Save it to the bottle profile Now everytime the bottle pa rt button is selected it will automatically open the Excel spreadsheet as well Be sure to go into Excel and Save As a different filename otherwise the AVBIS will overwrite your template with data 5 With the desired bottle button highlighted Press the Data Setup button in the System Controls menu Using the red arrow buttons scroll over to Excel Setup Select the appropriate cells for the data and angle combination that corresponds with the correct cell number on the spreadsheet Once entered press SAVE All data collected during measurement will go into the appropriate cells on the spreadsheet when the Send Data button is pressed in System Controls Data
39. in the plastic packaging industry End Offset is the number of degrees between 1 2 full thread position and the position of S The End Offset will vary with the taper of the end of the thread This offset can be found in the bottle s mold drawing or by approximation trial and error How Is End Offset Determined Recommended S Method gt Since the End Offset is typically NOT noted on bottle drawings and is not consistent between different bottles finishes it must be determined through experimentation and or trial and error The easiest way to determine the End Offset is to first make an educated 23 approximation of the angle from 1 2 of the thread start to the point where the thread reaches its zenith usually between 8 and 20 degrees the sharper the lead in the smaller the angle Enter this approximation into the End Offset in Measurement Setup gt Next go to CAD Setup Measure the S dimension and run the Find S procedure Find S is actually the Thread Start Search When the thread start search is complete measure S again making sure the S Type and S Offset are appropriate for the profile you are measuring Now change the End Offset in CAD by clicking on the End Offset number Repeat the Find S procedure Remeasure S gt Repeat this process of adjusting the End Offset performing the thread start search and measuring S until End Offset yields a number where the S is smallest Incorrect S End Offset too big
40. is E Multiple E dimensions will reference the matching T dimension eg T1 E1 T2 E2 lt E 1 5405 lt E 1 5396 E Search Limit Thread E Search Limit Thread 63 F aka Flank Measurement Neck Diameter Can be used to be measure ANY point to point diameter Data Setup Entry Nominal Value Tolerance Value Optional Y Offset from the Top of Finish CAD Setup Entry Move F offset limit to desired location Measured Minimum point detected Y offset below Top of Finish on the left and right side of the bottle Distance between X coordinates is FE Multiple F dimensions may be performed to measure finish diameters at a fixed distance from the top of finish 64 HT Left HT Right SPI H aka H SPI Standard H ISBT Standard Closure Height Measurement Clearance Height for Closure on the Left or Right Side of the Neck finish Data Setup Entry Nominal Value Tolerance Value Ensure that H is ENABLED and turned ON at desired angles T dimension is ENABLED and turned ON at SAME angles E dimension is ENABLED and turned ON at SAME angles X Offset from the T max projection The X offset may be used to shift the measurement point left or right from the measured T position CAD Setup Entry Optional Position gauge point to desired X offset location from the left T projection
41. is sent automatically when using the Feeder option Data cells that do not need to be sent to Excel should be set at 0 Therefore it is possible to ignore data that the AVBIS needs for measurements but are not necessary to officially report 33 SOK K da bid CAD Setup Jum s 7 e eem jJ xen xv ore Sch wem Left Z 1 0685 A uci A an E A E Eet W A a A N Left Right hind Align Cursor mmm NEN NEM CAD Setup permits the operator to select setup tools and then apply them by clicking on the image The top row of buttons displays the measurements that have been enabled and turned on in Data Setup When a measurement button is selected the system will perform the measurement display the measurement points and values and display the offsets relevant to the measurement Dimensions that are extrapolated and not actually measured will NOT be displayed if selected lean flash weight etc The side column of controls permits modification of the offsets and measurement positions Only those buttons that are relevant to the selected measurement will be active Min Max Buttons The min or max button will cause the system to search for a min or max point within the upper and lower search limit positions The min max buttons will become enabled during the set up of body panels ONLY Upper Lower Limit The upper and lower limit buttons permit the operator to define the area in which
42. it is positioned on the weight scale Press the Unload Pos SET button Press YES to associate this setting to the bottle file Press the Eject Pos GO button a Load Arm Only System The load arm will push the bottle from the weight scale off the system In the Stages menu press the Load Arm button and move the bottle until it is off the weight scale Press the Eject Pos SET button Press YES to associate this setting to the bottle file Press SAVE Save the changes to the appropriate bottle file Press HIDE b System With Eject Arm The eject arm will slide out and push the bottle off the weight scale onto the output conveyor or receptacle In the Stages menu press the Eject Arm button and move the bottle until it is off the weight scale Press the Eject Pos SET button Press YES to associate this setting to the bottle file Also enter in an Eject Distance for the output conveyor if equipped to move after the bottle has been placed there Press SAVE Save the changes to the appropriate bottle file Press HIDE Place several bottles on the input conveyor Press the FEEDER button in the System Controls menu Select the number of bottles on the input conveyor by left clicking pressing the appropriate number THEN right clicking the appropriate number Press the CLEAR DATA button Press YES when prompted Press RUN Observe the loading and unloading procedures When complete make any necessary changes in the Basic Setup Conveyor tab SAVE any
43. m System Controls top right Permits access to setup and data screens and controls for frequently used functions Video Image top left The image display shows both live and stored images of the bottle as well as graphic displays of points measured on the bottle Part Buttons bottom The Part Buttons section allows quick selection of commonly measured bottles and displays the bottle file currently active 16 System Controls Note Version 8 software has removed the Saved Bottle and Reset buttons Finish Measurement System Ver AY9 00 01 S N 101 000 0134 Bottle Manual Test Help New Part The new part button is used when a new bottle or preform is System Controls to be programmed By pressing this button the operator can either create an entirely new bottle or preform profile modify a pre existing bottle or perform template and save the new values into a new bottle or preform profile or call up a saved bottle or preform profile for use Data Setup CAD Setup Manual Data Setup OO Displays the menus for dimension selection dimension nominal and tolerance entry measurement setup Excel al s setup and Feeder Setup CAD Setup Displays an interactive menu and video screen which permits the operator to view and adjust measurement points and i dimensions selected in Data Setup EF Manual LA Displ his manual in Microsoft Wordvi o EE Send Data Clear Data View Data Basic Setup Displays a ne
44. measured Tube Lamp Status bottom Displays the status of the wall tube and lamp Also displays the number of bottles run 112 Control Screen System Controls ZA Send Data Clear Data Refresh Thickness Poll 0 BUD Test Thickness Setup Button Pressing this button opens the Setup Window to change bottle or data handling settings Send Data Button Pressing this button sends data to Excel if in a Manual Mode Usually disabled grayed out unless testing for data handling Clear Data Pressing this data erases data collected in the data readout screen and resets the bottle count to zero 0 Note when a new bottle part file is selected in the AVBIS bottle software this action is taken automatically to prevent data mishandling Pressing this button does not clear data from the Exel worksheet Exit Pressing this button returns the user to the AVBIS bottle program Pressing this button does not shut down the wall thickness software Refresh Resets and refreshes the light tube and light levels Thickness Read Presents the thickness of the PET material between the light tube and the sensor Not typically used by the operator Poll Presents a live thickness reading of the PET material between the light tube and the sensor Not typically used by the operator Program Display Displays the bottle thickness file currently being utilized by the ABTIS WTS and the AVBIS 113 Con
45. necessary Press the Clear Data button when complete 20 EXIT back to the bottle program Test the program by running the bottle program Make any changes as necessary Calibrating For Resin The ABTIS WTS is set to use a multiplier factor of 0 02850 as a default AVID Corporation has found that most PET resins used in bottles have a refractive index the ratio of the speed of light through air versus the speed of light through the material that is compatible with or extremely close to this multiplier However there are some PET resins that require the multiplier to be changed From a chemical standpoint these resins may be no different than other resins using the normal multiplier however light transfers differently through these materials While manual changes to multiplier are possible the time required for trial and error in order to acquire the correct multiplier is often not available The AVBIS ABTIS features an automatic calibration feature to determine this multiplier 1 Draw a small circle 1 8 diameter on a relatively flat portion of the bottle sidewall with a permanent marker 2 Using either a ball micrometer or CALIBRATED Hall Effect pen Magna Mike measure the thickness of the plastic at the center of this circle Record this number 3 Inthe AVBIS software access the file you wish alter the multiplier for by pressing the part button 4 Goto the Basic Setup Wall Tab Remove any bottle from the rotary stage
46. of points to be averaged is determined by the period display at the bottom of the window In the above pictured window each point along the green line is an average of 8 actual measurements around the preform If the operator adjusted the period lower more spiking would appear as less averaging would take place The black line displays the average linear regression of the points The average of the regression points is set by the order display at the bottom of the window In the above pictured window each point along the black line is an average of 8 averages around the preform If the operator adjusted the order lower the line would appear flatter as fewer averages were being calculated lt 3 Data Regression Display inl x In the graph to the right we see a preform with potential concentricity problems The points actually form a curve themselves Trend Max f 0 1330 Data Max T 0 1421 Avg Max 0 1420 Order f 8 E Higt Trend Min EXE Data Min EXUN Avg Min 0140 Period EA e Low 51 Basic Setup Advanced Options System Options Tab System Setup Yalues System Options 1 System Options 2 Change Password EN RETOS AREA These settings should remain unchanged unless instructed to make adjustments by AVID Setup Options Conveyor Allows the AVBIS 3000 to recognize the conveyor devices and associated controls Auto Feeder must be checked AVBIS 30006
47. position at all times The switch keys should be kept in the sole possession of the responsible Safety Officer 2 6 Power Switch Powers the system controller On and Off When rotated to Off all power outputs are shut down 3 Operation 3 1 Normal System Startup 1 To turn on the system the operator should first check that all guard doors are closed and that the emergency stop button is not actuated 2 Then rotate the Power switch to the On position 3 Wait for the blue Run button to light No other indicator should be lit Observe all warnings cited in section 2 4 Press the Run button momentarily 5 The blue Run button light should extinguish and power will be applied to the motors and l O hardware 6 Toturn off the system controller rotate the Power switch to the Off position at any time 3 2 Commissioning Periodic and Daily Safety System Check 1 Turn on the system as described in section 3 1 above 2 Activate the system E Stop switch Verify that the front panel E Stop indicator lamp is lit Verify that motor power is removed by checking that both LED s on each system servo motor are extinguished Verify that UO power is removed by checking that all LED s on the system I O block are extinguished 3 Deactivate the system E Stop switch Verify that the front panel E Stop indicator lamp is extinguished The blue Run button should light Press the Run button momentarily The blue Run button light should extinguish and verify th
48. position for the maximum width at the specified search height 4 Search Height Height you wish to search for the min or max Measure Panel as Placed Min Max Width Searches The Panel as Placed feature in Measurement Setup returns the bottle to its original position on the rotary stage i e how the operator placed the bottle on the stage and sets this position as ZERO for width measurements 30 Note the system ASSUMES that when Panel as Placed has been selected the bottle is being loaded with the parting line facing the camera i e along the axis of the camera Measure Panel As Placed Enabling this feature will return the bottle to its ORIGINAL placement position for the measurement of widths ie how the bottle was placed on the rotary stage by the operator conveyor arm or autofeeder Panel Offset Adjusts the arc length the AVBIS will search through for the min or max width search Options Preform Disables the search feature of the ID measurement USE ONLY WITH PREFORMS IN A FIXTURE HOLDER Image Store Stores bottle images from the monitor during RUN Images are saved to C ProgramFiles AVID Bottle lmages in omp format Lug Search Searches for a bottle lug to provide a reference point on snap cap style pharmaceutical bottles Lug Offset The degree offset from the leading edge of the lug to the center of the lug Using LUG SEARCH 1 Program the Bottle as normal 2 Add Z an
49. precisely place limit and nominal points Also useful for determining if the system has a focus problem by examining the gray level haze around a bottle 35 Basic Setup Wall Tab Basic Setup Values Camera system Autoreed Conveyor we Concentricity gy Calibration GO to Rotary Center en 0 0000 Light Show Thickness Be Ao coe Beas Set 0 0000 Standard Thickness Measure GO to Min Y Stage Hght set 0 0000 og Measurement 0 0000 Mirror Offset Rotary Speed Thickness Gauge Allows the user to make position changes for the stages used by the thickness program Also allows calibration of the thickness sensor Thickness Gauge GO to Each button sends stages to their set positions for the corresponding system position Set Rotary Center Sets the position of X Stage such that the center of the rotary plate is centered under the center of the light tube Set Probe Extension Sets the position of the Bore X Stage such that the light tube is centered over the center of the rotary plate Set Probe Height Sets the position of the Bore Y Stage such that the light beam is centered on the center of the thickness sensor Changing this position requires checking the alignment of optics in the thickness software Set Min Stage Height Sets the position of the Y Stage such that the light tube will not collide with surface of the rotary plate dur
50. pushbutton Resets the safety controller module This will only light in the event of a serious internal malfunction such as welded or stuck safety relay contacts or failure of the safety controller module itself A soft error may correct itself by actuating the button If the red Reset button light stays on the system must not be used and the Power Switch should be rotated to the Off position Alert the Safety Officer of the situation 2 4 Run Button Blue colored illuminated pushbutton When lit indicates that the system controller is ready to be activated Then pressing the button will enable the motor and l O hardware power outputs WARNING When performing the system run operation it is the user s responsibility to make sure that all potential hazards are clear and free of people and unwanted materials such as tools that could be exposed to the hazard Failure to do so could result in serious bodily injury or death 2 5 Bypass Key Switch Key operated bypass switch that allows unrestricted guard door operation for testing and maintenance purposes by Qualified Service Personnel only for up to a maximum of 30 minutes Doors may be opened without loss of power to the motors and I O hardware The emergency stop button remains fully operational After 30 minutes if any guard door has been previously opened power to the motors and l O hardware will be removed Normal full safety monitoring is enabled The switch should normally be in the Off
51. rotary stage and or verify that the correct bottle or part is has been selected loaded and or load a particular fixture onto the system Confirm that you have read and will follow the instructions by clicking on the OK button FAILURE TO FOLLOW THE INSTRUCTIONS MAY RESULT IN IMPROPER MEASUREMENT OF PARTS OR DAMAGE TO THE SYSTEM AVID Bottle Inspection Is this the most recent part to use for this 150ml Milk Collection Bottle Part 811 7009 A2 3 Press the Run With Feeder button Manual Feed Manual Feed Hide Bottles Pause JE 8 E Pause System Status Enter the number of total parts you will be measuring Enter the pause time in seconds for the system to wait between the switching of parts generally 4 10 seconds Place the first part on the rotary table Click the Run button The part will be run When the part is finished the system will prompt the operator to remove the part Remove the part The system will now prompt the operator to place a new part onto the rotary stage When a new bottle is detected the timer pause time will begin Once it reaches 0 the system will begin measuring the next part Faults STOP BUTTON Non emergency situations If for any reason the STOP button is clicked while the system is running the system will produce a fault and stop moving at the next available halt position Check that nothing is jammed and click RESET Stages will reset and home After homing Hide f
52. system measures up to the top of the bottle to locate point 5 Offsets can be manually entered in the Data Setup menu Typical offset numbers X offset 0 04 Y offset 0 02 68 K aka S1 55 Measurement Height from Top of Finish to Point under start of first thread Data Setup Entry Nominal Value Tolerance Value T Dimension ENABLED and turned ON at SAME angles E Dimension ENABLED and turned ON at SAME angles X Offset from T CAD Setup Entry Optional set X Offset manually Measured First point detected which is X offset distance from the Thread Max projection T The Y coordinate of this point is subtracted from the Top of finish Value to give K K is only measured once on the left side during first scan K is only measured after S which is used to determine the start of the thread K gauge line K 0 2708 K Nominal K X Offset 69 L Left L Right Measurement Height from Top of Finish to Top of Bead Data Setup Entry Nominal Value Tolerance Value X offset to Create gauge point from Max projection of bead CAD Setup Entry Establish upper and lower search limits for bead below L Establish a gauge line X offset from the edge of bead Measured Distance from Top of Finish to Top of the bead Sometimes used in lieu of H when measuring down to the top of the tamper bead or NSR L gauge
53. the measurement will be performed The upper and lower limits may be adjusted independently in relation to the inspection point The search limits are relative to the measurement point so they will move when the measurement point is moved The position of the limits may be adjusted with the arrow buttons or by clicking the desired location on the video screen Left Right Up Down The left right up down buttons adjust the offset position of the measurement If the measurement point has an upper and lower search limit the search limits will move with the measurement point The position of the measurement point may be adjusted with the arrow buttons or by clicking the desired location on the video screen 34 gt I IS Rotary The left or right rotary buttons will index the rotary table to the next rotary position The panel dimensions must be set up independently at each rotary position Note If the S measurement is selected i e green in the upper horizontal menu these buttons will change to Find S Find S When the S dimension is selected in CAD setup the Rotary Buttons switch to Find S buttons Pressing either Find S button will start the Find Thread Start search if enabled Panel Left Right The left right panel buttons will move the vertical and horizontal stages to bring the panel measurement point 1 8 into the field of view The measurement point min max and search windows will be displayed Mea
54. the tips to the camera field of view and close the gripper The vision system will measure the distance between probe rods and then the bottom position of the support block The probe will then be automatically moved to the center of the calibration ring The system will use the probe to scan through the nominal center of the calibration ring to calculate a measurement offset and the center of the rotary table 6 The calculated value of the probe tip diameter is displayed as probe tip offset Press SAVE PIN PROBE LENGTH CONTACT POINT TIP 39 Basic Setup Measure Tab Basic Setup Values M H Measure Width Manual Pin 0 0000 Ball Width Height Pixels 0 000 0 000 MM 0 000 0 000 INCH 0 000 0 000 Standard Width ELM A Camera 1 Field Resolution At Center Nominal Auto Measure Weight 1 Read Show Hide Minimize Weight Width Height Home Vertical Measured 0 0000 The Measure Tab allows the operator to calibrate the AVBIS 3000 Note only an operator trained in system calibration should access and make changes to this tab as improper calibration will result in incorrect measurements Measure Width Permits the measurement of objects within the field of view Manual Pressing this button will cause a full field image to appear The operator may use the cursor to select a poin
55. to indicate gray levels in a 3 X 3 matrix covering the video image The gray level values of each point will be displayed Adjusting the light source if background correction is not utilized may eliminate heavy shading Image Clear Image Clears the present image of any graphics that have been super imposed If a stored image is displayed it will remain displayed Auto Exposure Auto exposure resets the camera exposure to zero and then gradually increases the exposure until an acceptable gray level or brightness is detected This may take about 20 seconds to complete This feature should be utilized if the image is too dark Back Ground Correction When the system starts up it stores an image of the shading in the real image for this reason a bottle must not be in the image during startup or when the background correct button is pressed When background correction is executed the shading is removed from the image causing the background to appear white This correction permits the system to be used over a wide range of illumination conditions 41 Basic Setup System Tab Basic Setup Yalues geg E System Inspection System Values Miscellaneous Rotary Center MEZEN Format OEE Rotary Home Offset D Password Reset Rows Vertical Home Offset EE First on Sheet Ka Data File Touch Screen wm 1 mn O The system tab controls basic configuration settings
56. to add or change an angle to measure at press the cell in the Angle column and enter in the angle on the pop up keypad Note HghtLEFT and HghtRight MUST be ON on ALL rows in which any other cell is turned ON Example if F is ON at angle 65 HghtLeft and HghtRight must be ON at angle 65 Also note that if you wish to use the thread start search T and E must be enabled at zero 0 see Requisites section of the manual Also ensure that a zero 0 angle is setup in the first row as this will be the first set of measurements 10 Using the red arrow buttons at the bottom of the screen scroll to the MEASUREMENT SETUP tab Enable necessary searches fields offsets and S Type by pressing the corresponding on off cells or entering the value If the bottle is a wide mouth ID is greater than 2 variety 2 measurement fields will be necessary SAVE your selections Press HIDE see the Measurement Setup section for further information kb 11 Press the CAD SETUP button in the System Controls menu Press the first dimension along the top of the screen to check limits and field for correct positioning and measurement Adjust limits and fields if necessary see CAD SETUP section for further definitions When you are satisfied with setup press HIDE SAVE your changes when prompted if no changes were made in CAD Setup the AVBIS will not prompt to SAVE kb 12 With the bottle on the rotary stage press RUN Observe the crosshairs on the vi
57. 3000C The system will only enabling that number of bottles Also allows operator to select a measure the number of bottles selected If the system is enclosed the specific bottle in order to view data after the bottles have been run system will check if a door has been opened and reset and home the stages if necessary RESET Button Clears all bottle data saved in the individual Feeder Grid cells and HIDE Button resets the bottle count to 1 Closes the Feeder Window 56 AVBIS 3000P Feeder Operation Get 1 Inspect 1 Return 1 Run Disable Data Hide Grid Husky168 Feeder Grid Allows operator to view how many bottles to be measured Operator can select more or less bottles by first left clicking on the number turning the cursor into a crosshair then right clicking on the number enabling that number of bottles Also allows operator to select a specific bottle in order to view data after the bottles have been run or to load it and inspect it specifically Get Button Loads the preform bottle selected in the feeder grid from the tray to the rotary stage Inspect Button Inspects bottle currently on the rotary stage used after pressing the Get button Return Button Unloads bottle currently on rotary stage back to the appropriate location on the tray Run Button Performs loading procedure measurement routine and unloading procedure for bottle selected in the Feeder Grid only Clear Data Butto
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59. BR 2 Computer Connections T DB9 serial cable connection to auxiliary hardware A DB9 serial cable connection to the SC106 system controller COM 1 S DB9 serial cable connection to the weight scale VGA DB15 cable connection to the touchscreen monitor Customer RJ45 ethernet cable connection for the network MEE DT WEE gt a a a i sae P 3 gt 415700002 www SuperLogics com AO IEC 320 C13 AC line input cord to a UPS battery backup outlet USB connectors M DB9 serial cable connection to the touchscreen monitor PS2 type keyboard and mouse connectors U DB9 serial cable connection to the UPS W RJ45 ethernet cable connection to the I O Block 3 SC106 System Controller Connections IEC 320 C13 AC line input cord to a UPS non battery backup outlet 3 pin female M8 cable connection to the camera illumination LED 7 pin female mixed Dsub cable connection to the motor fanout panel PWR input connector DB9 female serial cable connection to the computer A DB9 connector USB B cable connection to any computer USB port System PWR 2 COM 2 Computer Es Three female 4 pin M8 cable connections to the system guard door switches 3 pin male M8 cable co
60. D BY A SYSTEM PROGRAMMER 1 Press the NEW BOTTLE button Press the CREATE button Save the new bottle profile as a new file with a name that will identify the bottle 2 Assign your new profile to a Part Button The assigned button will highlight green 3 Place the bottle or preform in a fixture at the center of the rotary stage 4 Press the DATA SETUP button 5 Using the red arrow buttons at the bottom of the screen scroll to or click on the ALLOWED DATA TYPES tab 6 Enable those dimensions to be measured If multiple measurements of the same dimension are needed e g width dimensions at different heights or H at different shoulder locations press the green up arrow button to enable extra measurements Note that certain dimensions require that another dimension is enabled and being measured see Requisites section of the manual SAVE your selections to the created bottle file 7 Using the red arrow buttons at the bottom of the screen scroll to the DATA SETUP tab 8 Enter Nominal and Tolerance values for each dimension by pressing on the individual cell you wish to change and enter the new value on the pop up keypad values for Left dimensions will automatically be copied to the Right of that dimension If you need to enter a Y Position for example ID depth or width heights enter a Y Position value accordingly 9 Turn the dimensions ON or OFF at the angles you do or do not wish the AVBIS to measure at If you wish
61. E MUST BE TAKEN IN REMOVING HANDLING PACKAGING AND SHIPPING COMPONENTS OF AVID SYSTEMS FAILURE TO COMPLY WITH INSTRUCTIONS WILL RESULT IN DELAY AND OR CHARGE FOR REPAIR REPLACEMENT REGARDLESS OF WARRANTY STATUS ELECTRONICS COMPUTERS MONITORS STAGES MOTORS SCALES ETC gt WRAP COMPONENT COMPLETELY IN BUBBLE WRAP PACK IN AN APPROPRIATE BOX WITH PACKING MATERIALS STYROFOAM PEANUTS CRUMPLED NEWSPAPER ETC SO COMPONENT CANNOT SLIDE IN BOX UP TO 3000 00 CHARGE FOR IMPROPERLY PACKED ELECTRONICS CAMERAS PLACE PACKING TAPE OVER OPEN END OF CAMERA SEALING DUST AWAY FROM OPTICS WRAP IN BUBBLE WRAP PACK TIGHTLY IN SMALL BOX WITH PACKING MATERIALS UP TO 5000 00 CHARGE FOR IMPROPERLY PACKED CAMERAS LENSES OPTICS LIGHTING SOURCES gt WRAP COMPONENT CAREFULLY IN BUBBLE WRAP PACK IN AN APPROPRIATE BOX WITH PACKING MATERIALS SHIPPING ADDRESS AVID CORPORATION ATTN REPAIRS 222 INTERNATIONAL DRIVE SUITE 105 PORTSMOUTH NH 03801 PLEASE CALL AVID CORPORATION FOR MORE INFORMATION REGARDING RETURNING SYSTEM COMPONENTS 107 Appendix A An In Depth Guide to Programming a New Part on the AVBIS This guide will teach you how to program preforms or single step bottles Preforms or bottles made by the following processes single step injection extrusion blow single step stretch blow all have a single parting line spanning vertically from the top of the neck finish down to the base bisecting the part i
62. HZ Right HF Left HF Right L Left L Right A X Left X Right CLEAR Enabled Enabled Enabled Enabled Disabled Enabled Enabled Enabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled D Left D Right W Left W Right Z SU D1 A Radius Nck Left Nck Right UI Left Ul Right Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled UI Width LI Left LI Right LI Width Lean Lean2 Flash ID Width PHght L PHght R Thick Conc Push Up Weight Cavity Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled gt Data Display A Data Setup A Measurement Setup A Allowed Data Types A Excel Setup A Feeder Setup 4 rl O10 o 9 oo swe de ole Click on any cell labeled Enabled or Disabled to determine whether an associated data type should ever be available for measurement or displayed These settings override any other enable settings on the Data Setup tab Each Data type is available as up to 25 multiple measurements e g Z1 Z25 by pressing the green up down arrow However certain data types cannot be measured beyond the first level despite being listed e g S SU K Weight Cavity Lean1 Lean2 E T etc The same Data Types
63. ID Set Center Ox E i Stage Control X Motion Axis Fast Move Stage X Stage Y Stage Rotary NA Bore Y stage Bore Xstage EA Ce A li Controls Go To Start Set Park Home Selected Home All m e SES 2 0 Conveyor Bore Tip Calibration Probe Tip Offset Meas Point Calibrate Bore Size Leen RECH Stage Center GES d Start Es e Wi B gt BAvID Wision System AVID Wall Thickness sys amp AVID IR Thickness Gauge E3JAvID Vision Image Monitor d untitled Paint aame 12 55 PM The calculated value of the probe tip diameter is displayed as probe tip offset This number may be adjusted by selecting the text box to fine tune the probe tip diameter g Press SAVE when calibration is complete ID probes will pull out of ring and the stages will return to their parked positions 92 STEP 4B ID MISALIGNMENT The following instructions are to realign the ID probes and stages in the event of a crash Only AVID trained operators should attempt to realign the ID probes or stages Only perform the alignment if the probes are misaligned Tools Required Hex Wrenches Action a Press Basic Setup in the System Control menu Press the Bore Gauge tab Press the Extend Probe button Allow the Bore X stage to slide out so the probes are up over the rotary table Press the Y Stage button Lower the Y Stage to 8 0000 so there is no possibility of a cras
64. IS WTS the two systems cannot share the same Excel Worksheet files Each system must be linked to a unique Excel Worksheet Choose the appropriate starting Row and Column number Press the Save Part button and save to the correct file when done Press the Exit button on the Measurement Setup window Get an Excel File 21x E gv e amp tckE D027 0 0385 0 0223 0120 0 0339 0 0265 pO30 0 0345 0 0160 pOD7 0 0249 0 0153 Desktop bo7s 0 0273 0 0195 Cal 0028 0 0365 0 0201 0073 0 0331 0 0212 My Computer 0019 0 0268 0 0141 ms My Network P File name BottleProfile xls Files of type Excel Files PAS Cancel Thickness _ _ _ _ Poll Test Thickness Measurement Setup Excel Multipliers m IT Enable for Data Input Wall Tube J 002850 By C Height Angle Show Unused Heights M Display Metric T Show Unused Angles M Pass higher than nominal data T Pass Fail by Rows iv Show Data Settings F Pass Fail by Columns Data File Worksheet File Data Delimiter ESP Data File mera e 19 To test if data is being sent to the Excel worksheet file correctly press the word Test on the top of the Data Readout screen and select the Random Data option The selected cells will fill with random data the bottle count will index to 1 and the data will be sent to Excel in the selected format Check the worksheet for problems and correct as
65. JUSTED ENTIRE SYSTEM MUST BE RECALIBRATED 90 STEP 4A ID Probe Calibration Tool s Required 1 0000 Ring Gauge hex wrenches if changing tips or realigning Explanation Ensures that ID is measured properly Action a ID Probe should only be calibrated after Steps 1 3 have been completed The bore gauge tips are changeable to accommodate different style bottles When tips are changed or adjusted the system MUST be re calibrated to measure the diameter and position of the tips b Press Basic Setup in the System Control menu Press the Bore Gauge tab If the tips have a ball bulb or point type contact the tip length will have to be established Press the Extend Probe button then the lower probe button Press the Find button under the Probe Length heading The system will determine the measurement contact point If the point is not satisfactory the contact point can be manually positioned by pressing the Select button and clicking on the correct position If the probe tips are too long to be measured automatically measure the distance manually using calipers AVID Vision Image Monitor Pla Es e Stage Control ES Motion Axis Move Stage deve Y stage Bore Ystage Controls Go To Start Set Park Home Selected Home All Standard Probe Length Bore Stage Bore Tip Calibration Probe Tip Offset Stage Center E 0 8956 Set Down Ger KEZE Meas Point
66. N at the ZERO angle Scan Speed above 0 End Offset Set usually between 8 and 15 degrees Lug Search Z and B ENABLED and turned ON at the ZERO angle Lug Offset is nearly always a NEGATIVE value Scan speed should be set to 10 Width Y Position set at the height from the base where width should be measured Press AutoPanel in CAD after checking Width 1 Adjust as necessary ID YPosition set at the depth from the sealing surface where ID should be measured 59 Bottle Measurements Descriptions of Standard System Measurements A aka Pilfer Band Tamper Evident Bead Y rset Definition of Measurement Max Diameter of Tamper Evident Bead Can be used to measure ANY bead diameter or maximum diameter Data Setup Entry Upper Search Llimit Nominal Value Tolerance Value Y Offset Value from the top of bottle optional Nominal Lower Search Limit CAD Setup Entry Select Up Down Select Point Nominal Position Adjust Upper and Lower Limit A Nomina Measured Maximum diameter detected within search window the A Y offset down from top of finish Multiple A dimensions may be used to search for maximum bead diameters A 1 7225 TE A ou 4 y Mida af S f qn Fo ES be TAE At cde r L ere g gt d 4 x 60 Measurement Min Diameter of Tamper Evident Recess J Can be used to measure ANY minimum diameter
67. Radius of the tamper evident bead underhang Data Setup Entry Nominal Value Tolerance Value A dimension is ENABLED and turned ON at SAME angles CAD Setup Entry Position gauge line for A Radius manually under the bead Measured Radius of A underhang ch limit ch limit Radius gauge line R 0 0239 78 ID Measurement Inner Diameter of Neck Data Setup Entry Nominal Value Tolerance Value Y offset Y Pos from top of finish to nominal position THIS HEIGHT CANNOT BE GREATER THAN THE LENGTH OF THE PROBE ENTERING A VALUE LARGER THAN THE PROBE LENGTH CAN SEVERELY DAMAGE THE SYSTEM CAD Setup Entry None Pressing the ID button in CAD will run the ID measurement routine After measuring ID and retracting the probes from the bottle neck the system will pause Wait until the monitor displays a live image of the bottle neck finish before continuing Measured Max Inner Diameter Multiple ID measurements can be taken at multiple Y positions and at different angles Y Offset ID 79 HF Left HF Right Measurement Clearance Height for closure NOT based upon T Data Setup Entry Nominal Value Tolerance Value Fis ENABLED and turned ON at SAME angles X Offset from the F projection The X offset may be used to shift the measurement point left or right from the measured F position CAD Setup Entry Position the gauge line for HF using the same method f
68. Row Column Buttons Moves the pickup tool to the next or previous column or row on the grid array Note 1 On Tray position must be setup before using these controls to prevent crash Air Test Time Delay time of air pressure Pressure Amount of air pressure used to inflate the bladder or pickup tool Heavier bottles or bottles filled with water should use more pressure MAX 30psi Open Close Gripper Opens Closes pickup bladder tool Open Close Clamp Opens closes concentricity clamp 43 Basic Setup Conveyor Tab AVBIS 3000C ONLY Basic Setup Yalues Load Pos e ELE se co UnLoad Pos ae RS Eject Pos xm EZA 00 Move Conveyor Load Unload Arm _ Rotary Stage Positions Other Settings Load Speed NN Load Rotary UnLoad EH So y El Height Eject Speed Exit Distance The conveyor tab allows the operator to control the bottle conveyors a Move Conveyor Allows the operator to setup the bottle loading point for the input conveyor Next Bottle Pressing this button will advance the next bottle until it reaches the electric eye laser Pressing this button will also call up the stage control window and automatically highlight the input conveyor The operator can then advance the bottle to the proper loading position Set Pressing this button sets the amount of movement required to move the bottle from the electric eye to the load arm
69. S INSTRUCTED TO DO SO BY AVID Misc Settings Bore Open Sets open speed for bore gauge 54 Basic Setup Advanced Options Misc Tab System Setup Values x System Options 1 System Options 2 Stage Settings Camera Settings Camera Size HPixels MINE Clock HPixels ME V Pixels MEE Rate VPixels ME Exposure Gain Program Messages Cycles Test These settings should remain unchanged unless instructed to make adjustments by AVID Align H Pixels Length of horizontal crosshair in pixels V Pixels Length of vertical crosshair in pixels Camera Settings Clock Clock speed for the camera Rate Image grab rate for the camera Exposure Exposure rate for the camera Gain Gain setting for the camera Cycles Number of cycles camera will run during an autoexposure test 55 Feeder Controls AVBIS 3000M Manual Feed Manual Feed Hide Bottles Pause Disable Data Output JE JE System Status The AVBIS 3000M does not have an automated feeder in the traditional sense However using the feeder mode of the 3000M allows the operator to simply load and unload the bottles without having to press Send Data after each bottle The system will wait after the bottle is removed from the stage for the next part Once placed the AVBIS will perform a countdown and then begin measuring the next part The data is exported if enabled auto
70. S will perform a vertical profile scan between the maximum and minimum search limits setup in the bottle tab at the angles turned ON in the data readout screen Exit Closes the Setup Tab window Save Part Saves changes Operator must select correct file to associate changes to 116 Advanced Setup Controls General Tab r Setup Rotary Axis taht Gear Ratio ELE 4 Lamp Timeout ERN minutes Vertical Axis Align Optics Gear Ratio Misc Error Text Main Screw Pitch Clock Divisor Allows modifications to be made to stage and light settings used for thickness calculations Changes should only be made by AVID technicians operators trained by AVID or under instructions from AVID Rotary Axis Gear Ratio Displays the gear ratio used on the rotary stage usually 5 1 Vertical Axis Gear Ratio Displays the gear ratio used on the Y stage usually 10 1 Screw Pitch Displays the screw pitch of the lead screw of the Y Stage Clock Divisor Displays the clock divisor of the Y Stage and thickness sensor Lighting Lamp Timeout Displays the timeout setting for the halogen lamp The lamp will automatically turn off if not used within the timeout period The lamp will automatically turn on when in use Align Optics Pressing this button opens the thickness sensor window displaying raw data values to allow for alignment of the light source to the sensor Should not be changed unless instructed do so by an AVID t
71. SAVE your selections to the created bottle file To properly setup the Thread Start Search so you can then offset to the parting line ensure that you have enabled HghtL amp HghtR S T and E Step 3 Using the red arrow buttons at the bottom of the screen scroll to the DATA SETUP tab Enter Nominal and Tolerance values for each dimension by pressing on the individual cell you wish to change and enter the new value on the pop up keypad values for Left dimensions will automatically be copied to the Right of that dimension lf you need to enter a Y Position for example ID depth or width heights enter a Y Position value accordingly Turn the dimensions ON or OFF at the angles you do or do not wish the AVBIS to measure at Most preforms and single step bottles can be setup with the following angles 0 the parting line 1 O or 15 10 15 off the parting line to avoid potential flash and 90 90 from t he parting line If you wish to add or change an angle to measure at press the cell in the Angle column and enter in the angle on the pop up keypad Note HghtLEFT and HghtRight MUST be ON in ALL rows in which any other cell is turned ON Example if F is ON at angle 65 HghtLeft and HghtRight must be ON at angle 65 If you wish to use the thread start search S T and E must be enabled at zero 0 see the Requisites section of the manual You will also need to enable S at zero to setup the thread start search properly
72. abled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled UI Width LI Left LI Right LI Width Lean Lean2 Flash ID Width Thick Overflow Fillheight Push Up Weight Cavity Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Enabled Disabled Disabled Disabled Disabled Disabled B y Dats Display A Data Setup A Measurement Setup A Allowed Data Types A Excel setup A Feedersetup 7 alolalololol save m 5 Goto the Data Setup Data Setup tab and turn Thick ON at zero 0 Do not enter any nominal or tolerance data for Thick Eile Edi Options Angle Hght Left Hght Right T E Thick 9 2500 9 2500 1 0480 0 9700 0 0000 Tolerance 0 0300 0 0300 0 0080 0 0080 0 0000 0 1234 0 1234 0 0000 0 0000 0 0000 YPos 0024 0 0294 00424 O0545 0 0000 o ON ON ON ON ON sw ON ON ON ON OFF 0 OFF OFF OFF OFF OFF 0 OFF OFF OFF OFF OFF 0 OFF OFF OFF OFF OFF o OFF OFF OFF OFF OFF 0 OFF OFF OFF OFF OFF o OFF OFF OFF OFF OFF o OFF OFF OFF OFF OFF 0 OFF OFF OFF OFF OFF os Data Display A Data Setup A Measurement Setup A Allowed Data Types A Excel Setup A Feeder Setup IK e e e e o o en ojo Press Save Upon saving the following AVID Wall Thickness System message will appear Thickness E Gauge File occum Creating a Thickness Gauge File not found Creating a New File for this B
73. ack light source tube This will allow you to pull the entire backing plate off the light tube 4 The backing plate has a yellow cable supplying power to the LED Follow the cable back to the computer cutting it away from the frame by snipping the cable ties holding it in place At the computer unscrew the cable end at the connection 5 Carefully pack the entire assembly you removed into a box with bubble wrap Ship to AVID 105 SOFTWARE CONFLICTS e AVID CORPORATION ONLY PROVIDES AND SUPPORTS SOFTWARE FOR THE AVBIS 3000 AND PERIPHERALS INCLUDED WITH THE SYSTEM e PERFORMANCE ISSUES CAUSED BY NON AVID SOFTWARE INSTALLED BY THE CUSTOMER FOLLOWING SYSTEM DELIVERY ARE THE RESPONSIBILITY OF THE CUSTOMER REGARDLESS OF WARRANTY STATUS AND OR SOFTWARE ORIGIN e USE OF 3 PARTY SOFTWARE THAT PREVENTS AVID CORPORATION FROM SUPPORTING SERVICING THE AVBIS 3000 MAY RESULT IN SUPPORT CONTRACT TERMINATION e AVID CANNOT PROVIDE UPDATES TO ACCOMMODATE 3 PARTY SOFTWARE ON THE AVBIS 3000 e AVID DOES NOT RECOMMEND THE FOLLOWING SOFTWARE HARDWARE BE INSTALLED ON THE AVBIS 3000 ACTIVE SCANNING ANTIVIRUS SOFTWARE EMAIL CLIENTS AUTOMATICALLY UPDATING PROGRAMS ANALYSIS SOFTWARE GAMES PRINTERS AND PRINTER DRIVERS USB DEVICES DRIVERS SERIAL DEVICES AUDIO CLIENTS PASSWORD PROTECTED SCREENSAVERS oooooooooOo 106 RETURNING AVBIS EQUIPMENT FOR REPAIR OR REPLACEMENT DUE TO THE FRAGILE NATURE OF AVID EQUIPMENT EXTREME CAR
74. age out of view of the camera 3 Press the Test Light icon a If OK is seen press the Background Correction button to continue b If Light Level too High or Light Level too Low appears press the AutoExposure icon A taskbar will appear and the light level will reset If problems persist or this does not correct the message contact AVID for assistance STEP 1 Measurement Calibration E avin Vision Image Monitor l U UUU EES File Camera Detect Region Edit Logic Measure Stage View Help Tool Required 1 000 Gauge Pin Explanation Ensures that measurements within the field T E H S A Z F etc are accurate Action a Place the 1 00 diameter Gauge Pin into the index hole at the center of the rotary stage b Press the Basic Setup button in the System Control menu Raise the Y Stage until the Gauge Pin is roughly centered in the Video Image screen c Click on the Measure Tab Enter 1 0000 under the words Standard Width d Press the Calibrate button gt lt CALIBRATE BUTTON e Press SAVE Step 2 Rotary Center Calibration AutoCenter Alignment a ee Tool Required 1 000 Gauge Pin Explanation S Ensures that the center of the rotary stage is lined up with the Camera L Auto Center center of the camera field Also ensures rotary stage center will line up with ID probes a Perform the Measurement Calibration in Step 1 Keep the 1 00 diameter Gauge Pin on the rot
75. al Component Layout134 6 GIFCUILF UNC HOM Desc LEE 136 7 Internal Calibration and Check 147 8 Parts List 148 1 Overview The model SC106 System Controller controls power distribution to the system servo motors on all motorized stages to the attached l O block device used to operate hardware such as solenoid valves and sensors and to the halogen lamp in infrared measurement equipped systems Internal power supplies provide 48 volts DC for the motors 24 volts DC for the I O hardware and 12 volts DC to the halogen lamp An additional 24 volt DC power supply is dedicated to the internal safety control circuits and is also used for powering an illumination LED on imaging equipped systems Additionally the System Controller incorporates a Banner Engineering SC22 3 safety controller module to monitor an emergency stop button and one to three safety door switches A full description of the SC22 3 module and all relevant safety warnings and safety standard compliance declarations are available in the Banner Engineering Safety Controller Models SC22 3 and SC22 3E Instruction Manual Most any machine state or fault that might be unsafe is neutralized by removing power from the system motors and any attached I O hardware Lamp and camera power are not disabled as part of a safety shutdown WARNING All servicing of the System Controller is to be performed by Qualified Service Personnel only No user operator adjustments i
76. ammed This message can appear at any time the load arm on an AVBIS 3000C is attempting to move If the message is seen press the emergency stop and move the arm slowly back to the start position Pull the emergency stop out and restart the AVBIS If this message is seen frequently it may be indicative of a problem with the load arm or load arm motor Contact AVID for instructions XI Incorrect T E Value IN Incorrect T E value This message appears while saving in Data Setup if the T and E values are not possible T must ALWAYS be larger than E System Interrupt Error Doors Were Opened Check Doors and Blue Run This message appears when a RUN is attempted but the doors have been opened or the Button XII Doors Opened System Interrupt Error emergency stop has been pressed and or the system has not been reset XIII Stages Resetting This message will appear if the reset button is pressed and will remain up until Wait Message stages motors have relinked XIV Clear Fault Stages Resetting Message appears if emergency stop has been pressed during RUN Address system problem f Select X Clear Fault and Press Reset ALL STAGES WILL HOME AUTOMATICALLY Trouble Shooting If your plant is enrolled in a support program with AVID Corporation or Pressco Technologies please feel free to contact AVID or Pressco for assistance Contact your supervisor to find out which company is providing support
77. ance band value of the nominal dimension Click the value and enter a new one using the number pad that appears Note that entries made on Left dimensions will automatically be transferred to the Right for o OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF that same dimension if ENABLED S Daa Dispisy A Data Setup WessUremenSSUr A Miawed Date Types A Ecel Soup A Feeder Sep GI Angles KE ole oli NN o j Click an angle cell to enter a rotary stage angle for bottle measurement up to 10 angles of measurement are currently possible on the AVBIS Note most programs REQUIRE measurements at O It is generally a good idea to program angles in sequential order as this allows the AVBIS to measure more efficiently and makes programs easier to troubleshoot in the event of a problem o OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF o OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF o OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF o P 9 a P o T m S S p par e eo On Off Click on any cell that says ON or OFF to toggle the enabled state for measurement of a particular data type at a particular rotation angle Xpos Ypos The X and Y offsets for data types ex D X K may be entered manually Most users will use the CAD set up for rough positioning then enter the offsets values from drawings after the bottle has been set up Note The X axis is left and right the Y axis is up and down ID Y Pos will place the ID tips the Y Pos depth f
78. anel offset from the S rotational position Panel Offset is useful for determining a specific rotational position for the first width measurement the zero angle for width S to panel Offset is one of two ways to set up specific orientation of the bottle for measuring bottle body widths Width in Single Field When body dimensions are less than 51mm 2 the panels may be measured in a single field of view speeding measurement and simplifying min searches Width in Single Field is turned ON and then may be selected for individual panels in the CAD setup Panel Searches The system may be configured to search for the panel to ensure that it is parallel to the axis of the camera when measuring Bottles that are not parallel with the camera may yield incorrect panel measurements Min Max Searches should be used if the panel s degree of offset Panel Offset from the thread start position is unknown or if the offset is too difficult to determine or if the offset varies due to the manufacturing process 2 stage preform to bottle production 20 Max Search TT Oval bottles should utilize a maximum panel search if the thread start search lug search cannot yield a constant datum point During a max search the bottle will be rotated 90 degrees from the starting position to search for the approximate maximum width within an arc defined by the panel steps at a height determined by width search height Min Search EN Rectangular bottles s
79. ar lens collars there is one set screw in each collar c Ifthe number was negative slowly turn the Postive Adjustment Screw If the number is positive slowly turn the Negative Adjustment Screw Press Camera L frequently while turning the Adjustment Screws to check progress Only very small adjustments with the Adjustment Screws are required to adjust perpendicularity Once zeroed perpendicular tighten the Front Lens Collar set screw with a hex wrench d Press Camera L The tightening of the lens collar set screws tends to shift the camera slightly If the camera lost perpendicularity remember the value of error Loosen the Front Lens Collar set screw Compensate for that error value by turning the Negative or Positive Adjustment Screws accordingly Tighten Front Lens Collar set screw Tighten Rear Lens Collar set screw Press Camera L If camera lost perpendicularity remember the value of error Loosen both Front and Rear Lens Collar set screws Compensate for that error value by turning the Negative or Positive Adjustment Screws accordingly Tighten Front and Rear Lens Collar set screws Press Camera L Exposure Front Camera Collar Telecentric Lens Camera F Stop Adjustment Collar Pos Neg Adjustment Knobs Rear Camera Collar Note Very small adjustments lt 001 can be made with the Positive and Negative Adjustment Screws while the Lens Collar set screws are tightened IF PERPINDICULARITY IS AD
80. ary stage b Press the Camera Tab Press the Auto Center button The stage will move slightly and the Pin will move to the center of the Video Image screen A pop up window will ask if you wish to set the current position as the rotary center Press the Yes Button Press SAVE Remove the Gauge Pin from the rotary stage Ball Measure 89 Step 3 Perpendicularity Adjustment Tool s Required Machinist square hex wrenches Explanation Ensures that the surface of the rotary stage and the apparent AVID Vision Image Monitor Fie Camera Detect Reg E Motion Axis X Stage Rotary Move Stage E Slow angle of the camera are wm perpendicular ee Bore Ystage june Action 0 1399 a Place the precision square on the EE rotary table The right angle should T mem be at the center of the table and should appear as an L shape on Se HA the image monitor b Press Basic Setup Lower the rotary table Y Stage so that only the square appears Press the Camera Tab Press Camera L If the number is greater than 0 0080 the camera may need to be adjusted a Ensure that the camera is secured tightly to the telecentric lens by Measure Auto Center Camera Back Light Test Test Patterns Show turning camera clockwise b Loosen but do not remove the Sal Monture I set screws securing the lens in the 0 000 D be front and re
81. ase check the bottle Data routine It is caused by improper setup of the T and E Setup dimensions in reference to S and or the Thread Start Search In order to measure S or run the Thread Start Search T and E must be enables and turned on at zero and at any other angles S is to be measured at VII Bad Parameter Call Message Typically seen in CAD Setup or during the RUN routine of a bottle this error is caused by an improperly setup S measurement Make sure the correct S nominal has been entered in Data Setup and that the correct S Type and S Offset are set Vill Data Error Message This message appears in the dialogue box of the Feeder window or in the video image box if run in Manual Mode The error is caused if the AVBIS detects a Height T or E dimension that is far from the nominal tolerance The AVBIS assumes that the incorrect bottle type has been placed on the rotary stage The error will stop the bottle measurement routine and if in Feeder Mode return the bottle to the tray or push the bottle from the rotary stage Check to make sure that correct bottle is being run on the AVBIS If so check to make sure there is no excess flash dirt or hairs on the neck finish that the AVBIS may be detecting IX Bad Parameter Cell This message appears in CAD and during RUN if S is setup incorrectly Click on OK until the message disappears and review the setup for S nominal T E S Type S Offset and setup in CAD X Load Arm J
82. asured to provide points from which lines are constructed The intersection of the lines is the S position The S offset 4 number in pixels provides a dead band The intersect point will be shifted to the first point within the dead band where the lines could Intersect intersect to avoid an intersection within the thread E wall radius 2 Use Bottles with straight and clean sidewall and thread surfaces and sharp non rounded intersects such as glass and specific PET finishes AVID DOES NOT RECOMMEND THE USE OF S TYPE 0 FOR MOST PLASTIC BOTTLES 24 S Type 1 S Offset 5 The slope created by two points on the top of the thread is calculated the slope is calculated in pixels The top is then examined towards the E wall until the change in the slope is Intersect greater then the pixel value of S offset Use Bottles with straight and clean thread surfaces with a relatively constant slope to the sidewall such as HDPE and S offset specific PET finishes Note striker cuts that create a step close to the intersect point may cause problems in measuring S with S Type 1 S offset 5 S offset 5 Note the above CAD Setup screens above The sidewall above the intersect slants slightly and is short therefore S Types 0 2 3 are not ideal for the finish Also note the lack of a sharp intersect S will be measured inside a radius and measurements MAY range 25 5 Offset in Pixels S Type 2 S Off
83. at power is applied to the motors and l O hardware 4 Repeat steps 2 and 3 using in turn each guard door switch and corresponding front panel door indicator instead of and identically to the E Stop switch and E Stop front panel indicator Commissioning Checkout A Qualified Person must perform the safety system commissioning procedure above before the safeguarded machine application is placed into service and after the internal Safety Controller module configuration is created or modified Periodic Semi Annual Checkout A Qualified Person must also perform a safety system re commissioning semiannually every 6 months or at periodic intervals based on the appropriate local or national regulations Daily Operational Checks A Designated Person must also check the effectiveness of the protective devices each day that the safeguarded machine is in service WARNING The commissioning periodic and daily safety system checks must be performed by appropriate personnel at the appropriate times as described above in order to ensure that the safety system is operating as intended Failure to perform these checks may create a potentially dangerous situation which could lead to serious injury or death WARNING If all of these checks cannot be verified do not attempt to use the safety system that includes the System Controller and the guarded machine until the defect or problem has been corrected Attempts to use the guarded machine under such c
84. ch several points for alignment Miscellaneous Format Allows the operator change how many decimal point positions are displayed in all text boxes Note adjustments will NOT effect measurement data accuracy Password Reset Relocks system to prevent access to Data Setup and Basic setup screens 42 Basic Setup Auto Feed Tab AVBIS 3000P ONLY Basic Setup Yalues Bore Gauge Positions 1st On Tray Pick Height Bottle Spacing X 28600 Prev Row Prev Col v REC Next Row Next Col Conveyor Lift Height Conc Center G Rotary Center Conc Height set s Drop Height Step Through Scale Center Scale Height Pick offset MTS Air Test Time 500 msec Open Gripper Pressure EZE psi Open Clamp The auto feed tab controls the positions of the autofeeder picker Positions Allows the operator to set or go to the following pickup arm positions 1 On Tray Position of the pickup head bladder so the bottle preform is over the first bottle preform in the tray Pick Height Height of the pickup head bladder over the bottle preform to pick it from the tray Lift Height Height of the pickup head bladder for transporting bottles preforms to and from the rotary table Note the lift height should be set high enough for the bottom of the bottle preform to clear the rotary table Rotary Center Position of the pickup head bladder so t
85. changes Programming A Preform or Bottle for Pickup Arm Loading and Unloading AVBIS 3000P PROGRAMMING SHOULD ONLY BE CONDUCTED BY A SYSTEM PROGRAMMER 1 2 Follow instructions for Programming a New Bottle for Measurement Load the preform template into the tray and load the preforms into the grid slots starting with slot 1 If measuring bottles load the bottle centering grid into the tray and load the bottles into the grid starting in the top left slot a dn order to program correctly a preform MUST be placed in the top left slot This is the first on tray position regardless of number written on the slot Ensuring that the correct bottle part button desired is highlighted press the BASIC SETUP button in the System Controls menu Press the AUTOFEEDER tab Lining up with the Rotary Stage Press the 1 ON TRAY button In the Stage Control menu press the BOTTLE TRAY button Advance the tray until the first preform bottle is in line with the center of the rotary table Press the TRANSPORT ARM button Move the Transport Arm until the pickup tool is directly over the preform bottle Press the PICKUP ARM button Lower the pickup arm until the pickup tool is just inside just over the first preform bottle on the tray Adjust the tray position or transport arm if necessary by retracting the pickup arm slightly and moving the tray or transport arm When the first preform bottle is lined up press the SET button Sett
86. d B to the Allowed Data Types Z is the bead diameter dimension B is the neck diameter beneath Z Determine the approximate Z and B nominal values use calipers if necessary lf these measurements are not critical set large tolerances so they are not flagged as out of tolerance by the system Turn ON Lug Search Determine the negative lug offset value this typically requires trial and error Set the SCAN SPEED at 8 or less In CAD Setup set the Z search area on the bead Set the B search area beneath the Z in the area that the LUG will appear SAVE wo BIO During RUN the bottle lug should face in the general direction of the camera The system will search for the lug first When AVBIS detects a remarkable change in the difference between the Z and B ie the camera sees the edge of the lug the rotary table will stop The rotary table will then turn the negative offset value to the center of the lug AVBIS now sets this rotary position as 0 All measurements will be taken at angles FROM the center of the lug Thread End Projection USUALLY SET AT 0 50 Effects how the AVBIS finds the thread start in Thread Start Search Changing the value adjusts the equation used by the AVBIS to find locate the Thread Start See Appendix for further explanation 31 Data Setup Allowed Data Types Tab Allowed Data Types for Default Start File Edit Options Hght Left ght Right S T Tmax E HT Left HT Right HZ Left
87. d N 23593 JJ dJ Y e J8 r0o44u0j3 Ajajes ER ON 22 A UAY J9S9Y S d4 H 222S 108 18 3 2 pay L E TA abueug 1100C 83 lt d MY 22 83tUM n e 9MU 22 De i ro e Q n MY 22 eug E LK p To E P di Abedsc aa a Si T gMy 22 9e37UM t ssedhg S dy 2 una S dy L mo a usdd T Ab2ISC ay a dund eL 31IneJC 83 IC itry schemat Fig 5c Safety circu 1 JO ebeg O Oae ewes e O T e3 pueog UTOC 4o430 34eusg uot3e4oduoj IAY J 2v uanga IMA Zb Fig 5d Motor Power COM board schematic 8 7 a e E Stop RN N e Qe e Qe og JB d Sl a ee g Fan Power Gel Ie g e uu O Do Ed ca ge ee oo 00 NC NM ACS RC AVID Corp AYSCFB FL Brit camp Lant 3 a d S E S C MENA E x E Li ebben opeooopoodQgQeue Pra O Dee t NN men nu e A LIT EE n o I O mmm CS CS E z EH 1 ECH E AC Input LED Dori Door2 Dor E Stop USB Lamp Lamp vO Cn Off Power Power 18 AWG AC Wiring Fig 6a AC wiring I d e e d Za E a aa 18 ZAN S e d SS IN el Za S N Z MTS e D di tg TEN IN HF DE RC X SP 500 4 Ne ROG k 3 NC f lla Fig 6b Ground wiring 2 e eo 00 eo qo0 BID Corp OMGCRB RLG
88. d of view and circular NOT OVAL Aperture ca F e Align the light with the adjustment screws at the rear of the light source to center the light in the camera field of view 96 Common Error Messages Smarth otor inittalize error E I Smartmotor Initialize Error Message This message is sometimes seen during system startup or when homing stages Check to Cannot establish a link to Matars make sure the emergency stop button is not pressed in and that all motors cables are plugged in to the motors and into the back of the driver box illumination Error Il Illumination Error Message Do T d Object in image This message is sometimes seen during bottle program startup It is caused by an obstruction between the light source and camera Check to make sure that a bottle camera cap or an artifact is not obstructing the path of light from the light source to the camera Retry Cancel Component Request Pending Il Component Request Pending Message An action cannot be completed because a component AVID Vision System is not responding Choose Switch Ta to activate the component and correct the problem Retry Game This message is seen at various times during the operation of the AVBIS It is caused by trying to open too many applications within the AVBIS bottle program at one time or performing actions in too rapid succession Remember that while the AVBIS bottle program resembles a Windows program
89. deo display as measurements are made When complete make any necessary changes in CAD Setup or Data Setup SAVE any changes The Bottle Profile is now complete Note For bottles with similar characteristics e g bottles with the same neck finish dimensions but different heights program one bottle completely as instructed above For the next bottle press NEW BOTTLE in System Control but press MODIFY when prompted The system will then ask if you wish to use an existing profile as a template Select the existing profile and OPEN The system will then prompt you to Save As another filename The new file will contain the same setup including loading unloading and data export links Change the appropriate values in DATA SETUP CAD SETUP Obviously different bottles will have different setups An HDPE snap cap pill bottle will have a different method of measurement than a PET salad dressing bottle The same AVBIS is capable of measuring both bottles however there is no golden standard of how to program them Practice and experimentation as well as some trial and error will yield bottle programs that measure the desired dimensions in the desired locations regardless of operator This reference guide is NOT a substitute for formal training at AVID and coverage by the AVID support contract Programming A New Bottle for Conveyor Loading and Unloading AVBIS 3000C PROGRAMMING SHOULD ONLY BE CONDUCTED BY A SYSTEM PROGRAMMER Foll
90. e just below the support blocks and is displayed as Yellow crosses after the measurement CONTACT POINT gt TIP Stage Center The distance from the bore gauge s home position to the center of the rotary stage Calibrate Button Pressing this button calibrates the bore gauge against a ring standard 37 PROBE LENGTH Bore Gauge Probe Diagram Draw Rod Collar 7 Draw Rod Stop Draw Rod Probe Housing gt Vertical Slide 2 Vertical Slide Plate 2 38 SWITCHING PROBE TIPS The bore gauge tips are changeable to accommodate different style bottles When tips are changed the system must be re calibrated to measure the diameter and position of the tips 1 Remove the tips from the ID probe by loosening the screws holding the pins into the blocks 2 Insert the new probes into the blocks and gently retighten the screws 3 Place the Calibration Ring onto the rotary stage centered on the index hole 4 Press Basic Setup in the System Control menu Press the Bore Gauge tab Press the Find button to determine the probes length If the system incorrectly locates the tips press the Select button to manual locate the probe tips by pressing the left mouse button Press the Right mouse button to exit Enter the Calibration Ring standard s height measure with calipers and ID written on ring gauge into the appropriate displays Press SAVE 5 Press the Calibrate button The system will move
91. echnician Misc Error Text Displays the error message that will inserted into cells if a thickness problem is encountered usually a point where thickness cannot be measured NOTE ALL OTHER ADVANCED CONTROL TABS SHOULD NOT BE ACCESSED Programming 1 Inthe AVBIS bottle program create a bottle file as normal Do not Enable Thick When completed run the bottle program to ensure that the AVBIS is measuring the bottle as desired 2 Program the conveyor load position picker rotary center position such that the loading results in the bottle and neck finish PRECISELY centered on the rotary stage Use the hole at the center of the rotary stage as a guide for centering if necessary 3 Ensure that T and E have been enabled and the correct values have been entered Similar to the AVBIS ID centerline search the AVBIS uses these setting to conduct a thickness centerline search in order to drop the tube inside the neck of the finish Data Setup for part numbe Hght Left ght Right S T Tmax E HT Left HT Right HF Left HF Right L Left L Right A X Left 700mL Enabled Enabled Disabled Enabled Disabled Enabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Nck Left Nek Right UI Left UI Right Return to Data Setup Allowed Data Types tab and ENABLE Thick Disabled Disabled Disabled Disabled Disabled Disabled Disabled Disabled Dis
92. es perpendicular from the parting line Meeting this requirement can be achieved by altering the angles of measurement For example let us assume a bottle with an S dimension located 90 degrees from the parting line Typical bottle setups will provide a measurement at 0 degrees the rotary position of the S and at 90 degrees from the S the parting line However if this bottle has flash at the parting lines those measurements at 90 degrees will include any flash projections Thread Start S W Parting Line In this scenario go to Data Setup and change the 90 degree angle of measurement Depending on the amount of flash up to 25 degrees of change may be needed to provide good measurements Typically Non PET bottles require 15 degrees or more of offset 88 Calibration Guide These instructions are for BASIC calibration and auditing purposes ONL Y Major system calibrations should be performed only by AVID technicians under the direction of AVID technicians or AVID trained technicians Improper calibration can result in improper measurements or damage to the system Follow instructions carefully Note steps 1 4 use tools provided with the AVBIS 3000 the 1 0000 Gauge Pin the 1 0000 Ring Gauge and the machinist square Prior to Calibration a light check should be performed 1 Press the Basic Setup button in the System Control menu Access the Camera tab 2 Ensure that there is nothing in view of the camera Lower the Y St
93. exist for all AVBIS systems however not all can be run on every AVBIS system For example an AVBIS not equipped with a weight scale cannot measure weight although it appears on the Allowed Data Types screen For an explanation of each dimension see the Dimensions section of this manual CLEAR Pressing this button will DISABLE ALL dimensions This may be useful when attempting to undo changes made without operator knowledge Data Setup Excel Setup Tab Data Setup for part numberDefault Start File Edit Options on o 6 0 0 0 0 0 0 0 0 OO O o o o o o O Oo O O O o o o o O o O o o oc o o o Oo Data Setup A Measurement Setup A Allowed Data Types p A FeederSetup 4 EST en nn S gt Extended analysis graphing and storage of the data can be handled by external SPC programs or standard programs such as Excel Data is stored in a text file that is imported into the data analysis program The user may modify the analysis program to provide customized data analysis When the Excel button is selected the Excel spreadsheet program will run on systems that have it installed The data file created during bottle measurement will be imported into Excel automatically 1 Create or load a spreadsheet file for use as a template with the bottle profile you desire Load it onto the AVBIS or onto the local network into a location of your choice that will not be changed 2 Select bottle profile you wish to enable
94. f the thread S position e Check the position of T and E in CAD setup e Check the End Offset value in Measurement Setup in Data Setup The End Offset value is typically between 7 15 degrees e fthe bottle has interrupted threads orient the bottle so S is facing the rear of the machine ID measurement is incorrect measured at wrong position tips are not centered in the bottle neck e Check Y Position of ID in Data Setup e Recalibrate ID gauge with ring standard SAVE e Check if bore gauge is centered by going to the Bore Gauge tab in Basic Setup Extend and lower the probe Go to the System Tab and press the image of the blue crosshair The vertical line of the crosshair should lie between the pins of probe on the image monitor Call AVID tech support if it is out of alignment e Checkstage centering by placing a one inch gauge pin in the rotary stage and pressing Basic Setup then Camera Tab and press Auto Center Recalibrate ID gauge with ring standard SAVE Data Entry Error e Data entry error messages are usually encountered when entering values in Data Setup with the number pad window The most common error is the entry of two decimal points when modifying an existing value Check the value cells carefully for unintended values Width Measurements at Wrong Position e Check the Rotary positions that are enabled e Check the Stage positions for each Rotary position Stages Axis not moving e Check if motor switch is turned o
95. far to the left of center Turn the distance adjustment arm until the peaks are centered in the graph Inform your operators or create a message that informs users that the distance must be adjusted to run this particular preform o A i P I lt Received Light Waveform 4 Laser Sensor Too Far From Preform If the laser sensor is too far from the preform sidewall preform diameter is small the two peaks will not be centered in the graph they will be far to the right of center Turn the distance adjustment arm until the peaks are centered in the graph Inform your operators or create a message that informs users that the distance must be adjusted to run this particular preform hw LA x gt a ai c Ia Ki G o fa X o If the peaks always appear unusual on all preforms this may be an indication of an alignment problem Contact AVID to schedule a service S Concentricity Understanding the Regression Graphs After a preform is measured at the concentricity station a regression graph will appear This graph illustrates the thicknesses the sensor measured as the preform was turned in front of it oO Data Regression Display IBI x D 161 Trend Max Trend Min Data Max 01613 Avg Max 01613 Order e m High 717 Data Min EXE Avg Min 01608 Period 8 E Low 31 The points along the green line are average thickness points around the preform The number
96. for the autofeeder Note the reflector MUST be raised every time the input conveyor advances a bottle to the loading arm Settings Load Speed Adjusts the speed of the load unload arm 1 being the slowest Eject Speed Adjusts the speed of the eject arm if equipped Exit Distance Adjusts the distance the output conveyor moves after the bottle is placed on it by the eject arm if equipped 44 Basic Setup Miscellaneous Tab Basic Setup Yalues x Exit Custom Message Settings Fixture Height Home Settings Custom Message Allows the creation of a custom message that will pop up whenever the program is selected Creating a Message Enter the message you wish to pop up in the space Then press Create Message Press Save Part and select the program Deleting Message Clear the Message by clicking on Create Message then Create Message Press Save Part and select the program Fixture Height If a fixture is necessary to measure a particular bottle preform the fixture height should be entered The AVBIS will then subtract this offset amount from height measurements Note Fixture height should ONLY be used if the height measurement Hght Left Right is a CRITICAL measurement If not add the fixture height value to the height nominal value in Data Setup 45 Basic Setup Concentricity Tab AVBIS 3000P ONLY Basic Setup Values vas neren Wes comera system fotoo
97. from Top of Finish to operator defined intersect point on neck finish Operator Entry Nominal Value In CAD operator positions a right angle tool that opens onto the two planes and the intersect point as shown below The system plots the points along each plane until they reach an intersect point Note Ll is useful for calculating non standardized dimensions LI 0 2442 AEN LI Width Lower Intersect Width Measurement Width from the LI position on the left side of the bottle to the LI position on the right side Operator Entry Nominal Value Note Ll must be enabled and turned on to calculate LI Width Similar to Width LI Width values will not be displayed in CAD 83 Width Measurement Width of bottle from body panel to opposite body panel Data Setup Entry Nominal Value because there is no depth measurement the width nominal should equal the largest width or depth dimension Tolerance Value however because the AVBIS does not distinguish between cylindrical and oblong bottles the system will not flag out of tolerance measurements Y Position height from bottle base to location where width measurement should take place CAD Setup Entry Press the Width 1 button After it completes the search press the AutoPanel button The system will automatically go to each of the selected Y positions for each width measurements and determine the width search areas The AVBIS will measure the MAX width
98. h b Press the Lower Probe button The probes should appear in the vision monitor Press the Camera Tab Press the blue crosshair icon C The vertical line of the crosshair should be between and parallel to the probe tips and shown below DS AVID Vision Image Monitor Lamst L etecl meoor d DS AVID Vision Image Monitor File Camera Detect Region e Loosen but do not remove the four bolts securing the ID unit to the top of the frame See image below 93 n RA f While observing the image on the screen move the entire ID assembly backwards or forwards until the probes are centered on the vertical blue crosshair Retighten the four bolts Retightening may change position of ID probes If so loosen bolts and continue to adjust until crosshair lines up g Ifthe probes appear as below the tip assembly needs to be aligned AVID Vision Image Monitor Eie Camera Detect Region Edi Loge Measure Stage View Help h Slightly loosen one of the hex bolts behind the probe blocks Grasp the horizontal rail and twist the probes until they are parallel with the blue crosshair on the image monitor Retighten the bolt After aligning perform the ID calibration procedure Step 4A 94 STEP 5 Vertical Home Offset Calibration Tools Required Y Blocks 2 0000 4 0000 and or 6 0000 are ideal Explanation Ensures that proper height measurements are being made
99. he relay board With JP12V jumpered and JP24V open on the relay board check for 12 0 5 volts DC at JFan Move the jumper to JP24V if the fan is 24 volt Momentarily jump either pin of JFault on the relay board to R5 on the end closest to JCoil LED3 and LED4 should extinguish Relays K1 and K2 should deactivate The power LEDs on PS2 and PS4 should also extinguish The red Reset pushbutton on the front panel should light and stay lit Press the Reset button and its lamp should extinguish Repeat the previous with the other pin of JFault jumped to R5 8 Parts List Description MtrPartk ll O Chas AO Cabinet rack mount A SLCASERAU Buproges h Panel back Kette Back Rad avo h Panel base adapter Controller Base Adapter RifpdaviO kl Panebase Contrller Base R2fod Jawa h A DIN rail 85mm IMlng AS Fan 12VDC 120 X 120 X 25mm Feazeenu Beste Screw lat head MX 6mm SS Screw flat head M4 X 6mm 8 Screw flat head M4 X 20mm SS Screw tiat head 6 32 5 16 88 OoOO Screw socket 1 4 20 58 1888 O O OOOO Screw socket 8 32 1 4 oxide Screw socket 8 92 ER oxide EE 88 Screw pri 6 22 9 8 Ek O B EECHER Screw phi 8 82 aw ss E ELE Bracket UE steel YO ELE Standoff 8 32 EES 98 hex dT dT Washer DD oxide TB ooo o o Washer 410 88 O EE aser M4 88 O o oo Washenspilok MASS fd TCU Nut ex M4 88 Pd CU o Nut hex 46 tooth washer ss OOO O e oo
100. he bottle preform is over the center of the rotary table Drop Height Height of pickup head bladder over the rotary table to drop the bottle preform onto its center Push Up Center if equipped Position of the pickup head bladder over the push up sensor Push Up Height if equipped Height of the pickup head bladder on the push up sensor Note the push up height should be set so the bottle is pressed firmly against the push up sensor Scale Center if equipped Position of the the pickup head bladder so the bottle preform is centered over the scale Scale Height if equipped Height of the pickup head bladder so the bottle preform is on the scale Set Sets the current position of the axes after being moved in the Stage Control menu to the highlighted position button Go Goes to the selected position Step Through Steps through all autofeeder positions and heights and queries the operator following each position for corrections Note this button is best used as a setup tool to test the pickup arm with a new bottle preform profile Pick Offset Bottle Spacing unenclosed systems only The space between the bottles or preforms placed on the tray The operator must enter these values for the autofeeder to function X Horizontal spacing from the center to center between preforms bottles placed in the tray Y Vertical spacing from the center to center between preforms bottles placed in the tray Prev Next
101. hould utilize a minimum panel search if the thread start search lug search cannot yield a constant datum point The bottle will be rotated in steps within an arc defined by the panel steps at a height determined by width search height This will be set as the 0 or start rotational position for the panel measurements NE Bottle Parallel With Camera Bottle Mot Parallel with Camera Max Search Bottle Parallel vith Camera Bottle Mot Parallel With Camera 8 It is crucial to understand that the AVBIS does NOT distinguish between widths and depths This is because the AVBIS cannot be programmed to understand the difference between a bottle that is cylindrical and one that is oblong Therefore widths and depths are simply widths taken at different angles from 1 the thread start or 2 each other Using Min and Max Width Searches 1 Turn Panel as Placed ON 2 Turn either Max Width Search OR Min Width Search ON 3 Enter the Panel Offset you desire a MIN From the placed position the bottle will offset counterclockwise this number of degrees then search from this position clockwise to the same number of degrees BEYOND the placed position for the minimum width at the specified search height b MAX From the placed position the bottle will rotate 90 counterclockwise then offset counterclo ckwise this number of degrees then search from this position clockwise to the same number of degrees BEYOND the placed
102. iew Data Allows data gathered from last bottle or selected bottle in Picker Feeder to be viewed Exit to Windows Exit will move the stages to home close the program properly and then shut down the bottle program To completely turn off power shut down the Windows operating system Press the power button on the uninterrupted power supply UPS after the system shuts down Run Feeder Displays the auto picker conveyor control menu and associated feeder command buttons Bottle Current number of bottles that have been measured Test 1 The Test 1 button will execute the measurement program for the bottle highlighted in the part buttons area Note the bottle MUST be present on the rotary stage before pressing this button If the system is enclosed the system will check if a door has been opened and reset and home the stages if necessary 17 Part Buttons Part Buttons Y 1 SS SS Y 1 LLL LLL LLL EE _ __ JI Eh LLL The Part Buttons area of the Control Screen permits the selection of different bottle inspection routines with the press of a single button This simplifies system operation when it is used by plant operators who might be unfamiliar with system setup When a button is selected it will turn green and the associated bottle part template file and setup parameters including conveyor or autofeeder setups will be automatically loaded The Y stage will also move to accommodate the bottle puts the neck fi
103. in neck support ring Z as shown below Nck Left and Neck Right will reference this bead A 1 5529 PARA Setup the X Dimension gauge point underneath the support bead Z Neck straightness will be calculated from this point vertically Setup the Nck Straight Dimension gauge point on the left shoulder offset from the A dimension setup earlier See below Neck gauge point M Meck straight 0 1541 87 Discussion Avoiding Bottle Flash AVID Vision Image Monitor AVID Vision Image Monitor lel ES File Camera Detect Ragion Edit Loo Measure Stage View Help File Camera E eo Regu Mn Edit Logit Measure lage NEW Help NEN M O Bottle Thread Start Bottle Parting Line note flash Due to the molding process bottles typically have excess material located on the parting line While trimmers and cutters limit this material even trace amounts of flash can be detected by the AVBIS Because the AVBIS views this material as part of the bottle it can cause faulty horizontal and vertical measurements if not taken into account during bottle programming Non PET bottle manufacturers typically cannot avoid producing flash and must therefore ignore it during measurement The easiest way to ignore bottle flash is measure at a location offset of the parting line However customer and tooling specifications often request a measurement at or near the parting line and 90 degre
104. ing measurements However this will NOT prevent the light tube from contacting the bottle push up if a program is improperly setup in the thickness software Position Values Stage position value for each of the corresponding positions Mirror Offset Value Distance between the bottom of the light tube and the center of the mirror directing light to the thickness sensor Mirror Mirror Offset l l Thickness Probe Tip Rotary Speed Speed setting for the rotary during thickness measurements Calibration Light Determines the raw level of light being emitted from the light tube at the sensor Sensor Determines the multiplier factor of a PET resin based on a measured thickness of a given sample see Calibrating for Resin Standard Thickness Value Thickness of a sample point measured with a secondary calibrated device such as a ball micrometer or Magna Mike Used to determine the multiplier factor see Calibrating for Resin Measurement Value Measured thickness of a PET sample based on the value entered in Standard Thickness Value Thickness Gauge Show Thickness Displays current thickness reading Probe Down Lowers the light tube to the probe height Measure Measures the wall thickness of the object currently in front of the probe 36 Basic Setup Bore Gauge Tab Basic Setup Values Standard Height 0 9000 Go ID 1 0000 Probe Length Bore Stage Go To Rotary
105. ing the Pick Up Height Press the PICK HEIGHT button Press the PICKUP ARM button in the Stage Control menu Lower the Pickup Arm the tool is to an appropriate depth in the preform bottle Press the SET button Setting the Lift Transport Height Press OPEN GRIPPER button Adjust the air pressure if necessary by clicking on the air pressure display and raising or lowering the pressure Press the LIFT HEIGHT button Press the PICKUP ARM button in the Stage Control menu Raise the pickup arm until the bottom of the preform bottle is higher than the rotary stage or fixture on the rotary stage and above the other preforms bottles in the tray Press the SET button If in doubt raise the pickup to its highest point and click set Setting the Rotary Center Press the ROTARY CENTER button Press the TRANSPORT ARM button in the System Control menu Move the transport arm until the preform bottle is centered over the rotary table preform holder bottle fixture Press the Pickup Arm button Lower the preform bottle until it is in the holder fixture or until the bottle rests on the center of the rotary table if the preform bottle was not centered correctly raise the arm slightly press the TRANSPORT ARM button and center the preform bottle over the holder fixture rotary stage center Press the SET button Setting the Drop Height Press the DROP HEIGHT button Press the PICKUP ARM button Lower the preform bottle until it is just seated in the holde
106. line L 7 0 7931 L Measurement VW Measurement L X Offset evident 70 W Left W Right see L Drawing on Preceding Page Measurement Height Width of Bead Data Setup Entry Nominal Value Tolerance Value Ensure that L dimension is ENABLED and turned ON at SAME angles CAD Setup None Measured Height of Bead The W is always measured when the L dimension is enabled but the data is displayed only when W is enabled The W dimension is performed at the the same X offset as the L L gauge line L 7 0 7931 71 Lean 1 Measurement Offset of the centerline of One finish diameter Measurement from the Centerline of another diameter measurement Data Setup Entry Nominal Value Tolerance Value In Measurement Setup select the diameters lean will be determined by for example Width 1 and E Ensure that those diameters are ENABLED and turned ON at the SAME angles CAD Setup Entry None Because Lean is an extrapolation from data collected during the RUN routine it cannot be measured in CAD Measured System calculates the offset in system units English or Metric between the two centerlines The Polarity or of the offset indicates the direction of lean The lean data is displayed as linear offset inches millimeters not in degrees width 1 22 Lean 2 AKA Loreal Lean Measurement Offset of left edge a
107. m computer over an Ethernet link using the Modbus TCP protocol This module is then attached to various product specific control components as needed such as air or water solenoid valves relays sensors etc This power is removed during safety shutdowns 4 7 Lamp Power This female 4 pin M12 connector connects to an external halogen lamp in infrared measurement equipped systems 12 volt DC power at up to 30 watts is provided on two separate wire pairs 4 8 Lamp On Off This male 3 pin M8 connector is normally attached to an IR controller in infrared measurement equipped systems Only 2 of the 3 pins are used to apply a 3 to 32 volt DC control signal to a solid state relay in the system controller that connects and disconnects power to the Lamp Power connector 4 9 Camera LED This female 3 pin M8 connector is normally attached to an illumination LED on imaging equipped systems Only 2 of the 3 pins are used to apply 24 volt DC power to the LED through an included 1K ohm current limiting resistor 5 Internal Component Layout Refer to figures 3 and 4 for the layout and identification of the major system controller components Back panel Terminal SC22 3 safety 48 volt servo motor Front panel connectors block TB1 controller module SC1 power supply PS4 controls wn ei M au A i x p A M I A ii O4 i a bh i a E em DH t S es f m 4 18 PO ok im E 1 E z 2 d t H y TM E 3 Bu W i 4 i 4 I
108. m the Top of finish Value to give D D gauge line 0 6686 L MET e e JU ciini Nominal position for A 1 E Lower Search limit A Ve AAA Se 62 E aka Thread Sidewall Diameter Measurement Min Diameter above or below thread Data Setup Entry Nominal Value Tolerance Value T Dimension ENABLED and turned ON at SAME angles Optional Y Offset from the T max thread projection The Y offset may be positive or negative Y offset 0 When the Y offset is set to 0 the system will locate the first thread then search under the thread for the minimum diameter The search will end if another thread is detected Y offset gt 0 When the Y offset is set greater then 0 the system will search from the maximum thread projection T below the first thread the distance specified as Y offset The system will report the minimum diameter detected in this search area Y offset lt 0 When the Y offset is set less then 0 the system will search from the maximum thread projection T above the first thread the distance specified as Y offset The system will report the minimum diameter detected in this search area CAD Setup Entry Optional Move search limit above or below first thread Measured E Nominal E Offset D E Offset gt 0 lt p Minimum point detected above or below the first thread on the left and right side of the bottle Distance between X coordinates
109. mage of the entire neck region and making measurements based on that image Therefore neck measurements are limited to the field of view of the camera The neck dimensions of bottles or preforms with a T dimension greater than 2 inches 51mm will generally not be measured effectively by the AVBIS if the measurements are taken within a single field of view due to distortion towards the edges of the lens and or the neck simply does not fit in the field of view of the camera If a bottle neck finish is too large and does not completely fit in the video display Neck in Single Field should be turned OFF When measurements are taken the bottle will offset from the centerline a value EQUAL to the T dimension of the bottle to the left and then right allowing the AVBIS to see both sides of the neck finish and then calculating the distance Note if Neck In Single Field is turned OFF the program MUST have a T and E dimension enabled and ON at Zero Only the left side of the neck finish will be viewable in CAD setup and horizontal measurements will not be displayed In order to ensure that setup is correct RUN the bottle and pay attention to where the measurements are taking place indicated by the red Xs Adjust as necessary Find Thread Start Thread Start Search Understanding Thread Start as a Datum Point gt When measuring bottles a datum zero rotational position is needed If the bottle were simply placed on the stage and no searches lug or th
110. matically to Excel or to the SPC software Bottles Arrows System Status Display Increases Decreases the number of bottles to be run of the specific Displays current status of machine as measuring failed passed bottle type faulted or reset Pause Arrows RUN Button Increases Decreases the pause time between bottle loading and Starts automated mode of AVBIS 3000M measurement start allowing the operator greater or lesser time to remove a measured bottle and load a new bottle Pause Button Pauses measurement routine When paused no other buttons may Disable Data Output be pressed Prevents the AVBIS from sending data to Excel or to the network Useful when testing a set of preforms for movement and data is not Part is required Displays the current bottle program being run Hide Button Closes Manual Feeder Window AVBIS 3000C Conveyor Feeder EX Run Conveyor Hide Bottles OOOO OOOO O00 OOO OOOOODOCO0O OOOOGOOOOOOOOOOOOOOOOOOOOO Number of Bottles EJ System Status PREFORMS SHOULD NEVER BE MEASURED FROM THE FEEDER CONTROL SCREEN ON THE AVBIS 3000C SERIOUS SYSTEM DAMAGE CAN OCCUR Part is Feeder Grid Displays the current bottle program being run Allows operator to view how many bottles to be measured Operator can select more or less bottles by first left clicking on the number RUN Button turning the cursor into a crosshair then right clicking on the number Starts the automated mode of the AVBIS
111. n Clears all bottle data saved in the individual Feeder Grid cells and resets the start grid to 1 Disable Data Output Prevents the AVBIS from sending data to Excel or to the network Useful when testing a set of preforms for movement and data is not required Ready Measuring Display Displays the current status of the AVBIS 3000P Part is Displays the current bottle program being run Grid Displays the current grid type being used by the AVBIS 3000P RUN Button Starts the automated mode of the AVBIS 3000P The system will only measure the number of bottles selected in Feeder Setup in the Data Setup screen If the system is enclosed the system will check if a door has been opened and reset and home the stages if necessary HIDE Button Closes the Feeder Window Cells Pattern Tabs Allows setup of Cells and Patterns based on the grid format the 3000P is equipped with 57 Using Bladder Restrictor Collar Option for AVBIS 3000P using bladder pick up tools Certain choked neck preforms are simply too narrow for the smallest available bladder to enter fully particularly The use of the restrictor collar allows the preform to be picked up squarely by the bladder 1 Loosen thumbscrew on bladder so collar slides over rubber bladder onto grooved metal surface of bladder fixture Tighten thumbscrew 2 When programming the feeder set the Pick Height such that the base of the restrictor collar just touches or is sligh
112. n and illuminated on the front of the computer box If emergency stop button was depressed it must be pulled out again Emergency stop cuts power to all motion devices After pulling out the emergency stop button the AVBIS must be rebooted e Check that all motors have a green light on them If not contact AVID for support The AVBIS 3000 s weight scale is providing inaccurate measurements due to factory vibrations drafts AVBIS w scale option e While the AVBIS 3000 is not designed for use in locations of high vibrations air movement the weight scale can be adjusted to compensate for unstable conditions 1 Press and hold the SAMPLE button on the scale itself until bASFnc appears 2 Press the PRINT button once Cond will appear with a blinking digit 3 Press the RE ZERO button until the digit becomes a 2 4 Press the PRINT button once ENd will appear followed by CL AdJ 5 Press the CAL button scale will return to the standard gram readout with the the Response and Slow illuminated Now the weight value will have a slower response time thus ignoring the fast changes in weight values 6 Press and hold the SAMPLE button until LASFnc appears 7 Press PRINT button once Cond will appear with a blinking digit 8 Press SAMPLE button once St b will appear with a blinking digit 99 9 Press the RE ZERO button until the digit becomes a 2 10 Press the PRINT button once ENd will appear followed by CL AdJ 11 Press
113. n power up disabled Monitored system reset Safety Input Devices E501 Emergency Stop Dual channel Contact switch Manual reset logic Terminals 1 S2 3 4 Mapped ta SO1 Simultaneous Closed open debounce time 6 ms Open closed debounce time 50 ms EDMO1 External Device Monitoring Dual channel Contact switch Terminals S20 21 Mapped to SO1 Closed open debounce time 50 ms Open closed debounce time 50 ms Non Safety Input Devices MRO1 Manual Reset Single channel Contact switch Terminals S22 Mapped to SO1 Closed open debounce time 6 ms Open closed debounce time 50 ms Monitored reset Safety Outputs 01 No delay Response times SO1 ESO1 10ms GS01 10ms GS02 10ms GS03 10ms Status Outputs Q1 E Stop Track ESO1 OV dc Run Q2 Door 1 Track GSO1 OV dc Run O6 Sys Reset System reset needed 24V dc Reset needed 03 Door 2 Track GS02 OV de Run GS01 Gate Switch Complementary Contact switch Manual reset logic Terminals 11 12 13 Mapped to SO1 Simultaneous Closed open debounce time 6 ms Open closed debounce time 50 ms Startup test disabled BP01 Bypass Switch Dual channel Contact switch Terminals 514 15 516 17 Mapped to GS01 GS02 GS03 Simultaneous Closed open debounce time 6 ms Open closed debounce time 50 ms Bypass time limit 30 minutes O24 Door 3 Track GS03
114. nish of the bottle in view of the camera To clear a button of its assigned bottle profile right click on it and erase the part number To overwrite a button assign a new bottle profile to the desired button Overwriting the button does not overwrite the bottle profile it is linked to Therefore it is possible to have many more bottle profiles than buttons Stage Control The Stage Control window allows the operator to control all motion devices from one central menu location Note only those motion axis included on the system will be displayed Motion Axis Pressing a motion axis button allows the operator to select the desired motion device LED Indicators If the stage is powered it will indicated with a green LED If the stage is unpowered due to an open door or fault the stage will be indicated red Move Stage Allows the positioning of the selected motion device within it travel limit Pressing the speed button in the center adjusts the speed the device will move Reset All Resets the motor if a door was opened or the Emergency Stop button was pressed If this button is pressed the Home All button should also be pressed after power to the stages is restored LEDs turn green Controls Go to Start Sends the selected motion device to its start position Set Park Stage Control Motion Axis X Stage Rotary Bore X Stage Bore Y Stage e Load Arm Q AI I Input Conveyo
115. nnection to the IR Controller Lamp On Off 4 pin dual key female M12 cable connection to the IR system halogen lamp 4 5 pin female single key M12 cable connection to the E Stop switch 5 pin female 7 8 mini cable connection to the I O block 24 VDC power input 4 Motor Fanout Panel Connections 7 pin male mixed Dsub cable Unused connection to the SC106 COM System Controller at PWR 1 connector Nine 7 pin female mixed Dsub cable connections to the servo motors 7 pin male mixed Dsub cable connection to one of nine motor fanout panel connectors 5 VO Block Connections 7 8 mini male cable power input connection to the System Controller power output at I O Power Eight 4 pin female M12 cable connections for 8 input and 8 output 24 VDC general purpose I O ports Two 4 pin female M12 ethernet cable connectors connect either one to the computer W RJ45 ethernet port 6 Computer Front Panel The two RAID 1 configured hard drives should only be removed with the computer powered off To remove a hard drive rotate the barrel key lock counter clockwise 1 4 turn on the drive drawer Then lift up on the drawer handle and pull the drive out To insert the drive push it in until it begins to engage and then lower the handle to complete the entry Only gentle force is required Then rotate the barrel key clockwise Lo turn on the drive drawer and remove the key
116. nside the System Controller are necessary or recommended by the manufacturer Modification of the System Controller can result in a loss of safety monitoring and serious hazards to operator personnel WARNING Always disconnect power from the System Controller and the guarded machine before making any connections or replacing any system component Use extreme caution to avoid electrical shock at all times Serious bodily injury or death could result WARNING The commissioning periodic and daily safety system checks see section 3 2 must be performed by appropriate personnel at the appropriate times in order to ensure that the safety system is operating as intended Failure to perform these checks may create a potentially dangerous situation which could lead to serious injury or death WARNING Verify that the guarded area is clear of personnel and unwanted materials such as tools before applying power to the guarded machine Failure to do so could result in serious bodily injury or death 2 Operator Controls Systemi reni b UD Fig 1 Front Panel Controls 2 1 E Stop Lamp Amber colored and when illuminated indicates that the emergency stop button has been activated Power to the motors and I O hardware is removed 2 2 Door 1 Door 2 Door 3 Lamps Green colored and when illuminated indicate that a corresponding guard door 1 2 or 3 is open Power to the motors and I O hardware is removed 2 3 Reset Button Red colored illuminated
117. nsor to be moved to different heights Should not require changing by operator Laser Sensor Ruby red laser sensor for measuring preform sidewall thickness Drive Belt Transfers power from the drive motor dear to the drive rollers Drive Rollers Drive the preform around when clamped Clamping Rollers Hold the preform against the drive rollers when measuring concentricity Clamping rollers should spin freely when not pressed against a preform Inflow Adjustment Adjusts the speed of closure of the clamping rollers Does NOT adjust force pressure exerted against the preform Closing Air In Air supply to close the clamp Opening Air In Air supply to open the clamp 4 Concentricity Setting Up 1 Setup preform for all other measurements vision etc Preform CANNOT be setup for concentricity only Some vision tests must be made prior to moving to the concentricity test station 2 Apply a strip of semi transparent tape to the preform near the transition to the cap as photographed below Without the tape it will be difficult to see the laser dot striking the preform 3 Setup preform for feeding into all other positions except CONCEN CENTER and CONCEN HEIGHT 4 Click on Concen Center Move the transport arm and the pickup until the preform side wall just touches the drive rollers The correct position of the preform before clamping is just touching the two rollers near the laser emiiter receiver The preform should no
118. nto two halves This parting line is formed by the two halves of the mold coming together When measuring a standard dimension on a bottle or preform quality technicians typically make the initial measurement at or just off the parting line This measurement is said to be made AT ZERO or AT PARTING LINE Any diameter measured at this position is also known as PARTING LINE TO PARTING LINE or SEAM TO SEAM Following the initial measurement 0 quality technicians make a second measurement of the same dimension 90 from the parting line This measurement is said to be made at 90 or 90 to PL The goal for taking measurements at the parting line and then at 90 to the parting line is to 1 Detect dimensional ovality in the case of diameters 2 Inthe event of dimensional problems the measurements provide the plant tooling department with measurements that can be understoon tooling departments generally work in 2 directions Performing these measurements by hand with calipers is relatively intuitive because you can see parting line and position the calipers properly based on its location The trick is to have the AVBIS 3000 measure the bottles preforms in this same fashion However the AVBIS 3000 is unable locate the parting line through visual detection as the vision system is examining the profile not the surface of the bottle preform The parting line does nat project from the finish and cannot
119. o use for this 150ml Milk Collection Bottle Part 2811 7009 A2 3 FOR PREFORMS If measuring preforms the system CANNOT be run using the Feeder Each preform must be loaded and unloaded by hand into a fixture on the rotary stage Be sure to setup the fixture properly before running the preform FOR BOTTLES Load the bottles in order of cavity number from left to right onto the conveyor Make sure that the first bottle left most is not blocking the laser beam 4 PREFORMS Load the first preform into the fixture on the rotary stage Press the Test 1 Rotary button The preform will be run automatically At the end of the measurement routine the system will return to the main screen If the measurements all passed specifications set in the AVBIS DATA PASSED will be displayed DATA FAILED will be displayed if any measurements were out of tolerance Press the SEND DATA button to send the measured data to Excel Repeat step 4a until all preforms are measured BOTTLES Press the Run with Feeder button This will open the Feeder window Conveyor Feeder Run Conveyor pu RE ER Part is811 7009 Medela System Status Count the total number of bottles loaded onto the conveyor and enter this number in the Number of Bottles box by touching the box and entering the total number on the pop up keyboard and pressing the Enter button on the keypad A number of yellow balls will appear in the feeder wind
120. om slot 1 and move it to the concentricity position to be clamped 2 Once clamped click on laser graph A window will open in the top right of the screen showing the returns from the laser striking the two walls outer and inner of the preform The peak on the left is the outer wall while the oeak on the right is the inner wall AGOOD signal will appear similar to the right In this case a good signal tall yellow and blue peaks is seen for both the inner and outer walls and the two peaks are roughly in the center of the graph Problem Signals 1 Weak Signal From Inner Wall Problems can appear if the graph if the preform is too heavily tinted to allow the signal to return from the inner wall as seen below This could also be caused by a transition band in the detection area of the laser Try moving the preform down so the laser hits an area higher from the transition point to the cap 2 No Return From Inner Wall If the preform is near opaque or green no laser signal will be received from the inner wall of the preform Preforms that return no inner wall signal cannot be measured with the concentricity module lt 3 Rece ived Light Waveform ES ERR ERR ES SES O Lea T 49 lt Received Light Waveform 3 Laser Sensor Too Close to Preform If the laser sensor is too close to the preform sidewall preform diameter is large the two peaks will not be centered in the graph they will be
121. on of support ring towards the E wall Z dimension is Required ENABLED and turned ON at SAME angles CAD Setup Entry Manually position gauge line for X under the left bead z en Measured Distance from Top of Finish to the bottom of the support ring in X offset from the edge X gauge line et ee ee X 0 8662 75 Z aka Neck Support Ring NSR Measurement Diameter of support ring Can be used to measure ANY maximum diameter similar to A but NOT above the T dimension Data Setup Entry Nominal Value Tolerance Value Y offset from top of finish to nominal position of support ring CAD Setup Entry Position Upper and Lower search limits above and below support ring Measured Max Diameter of Support ring Multiple Z measurements may be used to measure max diameters Z 1 8522 PARA IMD Nominal position for Z 1 Lower search limit 76 SU aka S1 55 Measurement Height from Top of Finish to Intersect Point of Base of Thread Start and sidewall Data Setup Entry Nominal Value Tolerance Value T dimension is ENABLED and turned ON at SAME angles E dimension is ENABLED and turned ON at SAME angles CAD Setup Entry Upper and Lower Search limits under the first T projection SU offset 5 SU 0 2838 Uppies nr cop A pl A eer eee TI A Radius aka Tamper Radius Measurement
122. on swab and alcohol brake cleaner acetone to clean slide grooves Do not use oil or lubricants as these attract dust and can worsen sticking e Contact AVID for further assistance Horizontal Bearing Rail Grooves 100 I need to install a new motor gear reducer coupler e Seethe below diagrams for stage parts and assembly 4 Hex Bolts Washers if installed 4 Hex Bolts Coupler Housing Cover Limit Switch Track Motor Gear Reducer Coupler Stage Stage t ibi 23 11010 salu nss6ZO0vOQO In MIMI GT IHOVCITWAV f4 2G Cvo 4 By cago Coupler Installed On Gear Reducer Shaft 101 E iG APEX DYNAMICS INC ODEL A B F 04 2 G82 P2Z IN 1D00407955D 3 AYIO 01031 O AN ACKLASH 5 ARCMIN MD Bud MJ M WN WAYNA SP PEM fw N Wad 000 6 N MM WORA Ty d Wd OPOS N em yond OR AN EL O d J Vue UON LINN O ur N L 0 1 OA 8 WON A EI dWY SZ vel HI E 1497169 4 MIA vy 5w12 MOLLY WSN 1030 sc DOARE QO31vH Or t NOISHSA Md 2007 61 80 34 wO SAN OSI EZMWS PALSAS OAUJIS LL VYOLLNI VSN M 30V NOL VHOdHOD SOLL VWINV Gear Reducer w Coupler Installed Onto Stage Shaft Motor Attached w kd WaN 00 SN P a RA Ne WdHOFOS N A ing c ed bite PU di m E Guess v4 A g Fee SSW TO MOLLY EEN 3090 amp AP Dive ION EIA At AA PO Mvo Daw Hex Bolts Installed 102 bims E aims ll LITITI
123. onditions could result in serious bodily injury or death WARNING Verify that the guarded area is clear of personnel and unwanted materials such as tools before applying power the guarded machine Failure to do so could result in serious bodily injury or death 1 Designated Person 2 Qualified Person A person or persons identified and designated in writing by the employer as being appropriately trained and qualified to perform a specified checkout procedure A person who by possession of a recognized degree or certificate of professional training or who by extensive knowledge training and experience has successfully demonstrated the ability to solve problems relating to the subject matter and work 4 Connections System Controller Model SC 106 S N 100 240 VAC AVID Incorporate Fig 2 Back Panel Connectors 4 1 AC Input Unlabelled and located to the extreme lower left on the back panel as shown in Fig 2 Mains power is applied to the male IEC320 C13 connector portion of this combination AC input module with a compatible power cord A removable fuse drawer is just above the connector containing two 5 amp 250 volt 5 X 20 mm fast acting fuses Littlefuse 217005H or equivalent The power source must be 100 240 VAC single phase at 50 or 60 Hz with ground pin 4 2 PWR 1 COM 1 PWR 2 COM 2 PWR 1 is a female 7 pin combination D Dub connector that is connected to the PWR connector on the Motor Fanout Panel
124. operator to modify the height height limit settings and scanning method for the bottle file Bottle Height Displays the nominal height of the bottle Clicking on the number allows the height to be changed This value MUST be correct Measured Height Limits Maximum Displays the maximum height along the bottle sidewall that thickness data will be gathered at Thickness points ABOVE this limit will not be measured Minimum Displays the minimum height along the bottle sidewall that thickness data will be gathered at Thickness points BELOW this limit will not be measured IMPORTANT NOTE Because the tip of the light tube cannot drop below the pushup height of the bottle and because the light emitter is not actually at the bottom of the tube the user should set the Minimum Height Limit slightly higher than the actual pushup height to allow for clearance and prevent damage to the system For example if a bottle has a pushup of 1 25 the minimum height limit should be set at approximately 1 35 to allow the light tube to clear the pushup Experimentation may be necessary to gain the greatest search area without colliding with the push up Contact with the push up could cause measurement problems or damage even with the built in fail safes Method Rotary If selected the ABTIS WTS will perform a 360 ro tational scan of thickness at the heights turned ON in the data readout screen Vertical If selected the ABTIS WT
125. or H Measured Distance from Top of Finish to point on finish tangent to the F position auge point IEE BEEN ee F 1 7218 eeina e o R wem 2d HF 0 7981 en e eR AAA 80 Tmax Measurement Max Diameter of thread profile Data Setup Entry Nominal Value Tolerance Value CAD Setup Entry Position search window upper and lower search limits over thread area Measured Max Diameter of the threads within search area Multiple T may be measured The system will start at the last T and search down for the next T T MAA Tmax 1 7240 Nominal position for Tmax 1 te veu HM Mine iili 8l Ul Upper Intersect Measurement Height from Top of Finish to operator defined intersect point on neck finish Operator Entry Nominal Value In CAD operator positions a right angle tool that opens onto the two planes and the intersect point as shown below The system plots the points along each plane until they reach an intersect point Note Ul is useful for calculating non standardized dimensions a Ul 01967 Ul Width Upper Intersect Width Measurement Width from the Ul position on the left side of the bottle to the Ul position on the right side Operator Entry Nominal Value Note Ul must be enabled and turned on to calculate Ul Width Similar to Width Ul Width values will not be displayed in CAD 82 Ll Lower Intersect Measurement Height
126. ottle New File for this Bottle File must be Flle must be edited before using edited before using This message is to indicate that because no thickness file yet exists for the bottle a new thickness file with the same filename as the bottle is being created in the C Program Files AVID ABTIS Codes directory with default settings These settings will need to be changed before it can be used Go to the Data Setup Measurement Setup Tab In the lower right are settings for Thickness If you wish the ABTIS WTS system to set zero at the same zero reference position as the AVBIS turn Panel As Placed OFF and set the Panel Offset for 90 The AVBIS will use the found Datum position and rotate counter clockwise by 90 so the angles displa yed in the ABTIS WTS software correspond to the angles displayed by the AVBIS OR If you wish the ABTIS WTS system to set zero at the same position the bottle was placed in turn Panel As Placed ON and set the Panel Offset for 90 The AVBIS will use the bottle s placed position as the Datum and rotate counter clockwise 90 so the angles displayed in the ABTIS WTS software correspond to the bottle s placed position This method is typically used in situations where Panel as Placed is turned ON in Panel Setup Data Setup for part number Test Thickness File Edit Options S Methods Options Find Thread Start Preform Neck Insert End Offset Image Store Sample Points
127. ow equal to the number of bottles you selected 10 Run Conveyor Hide Bottles ws Reset c E Part i811 7009 Medela System Status Press the RUN button in the feeder window The system will home all stages before commencing measurement Wait Message 1 Homing All Stages After homing the system will measure the bottles After measurement each bottle will be weighed and then ejected off the system Data from each bottle will be automatically sent to the Excel file after it is ejected from the system Bottles that are within programmed tolerances will be marked with a green ball Bottles outside of programmed tolerances will be marked with a red ball Run Conveyor Bottles Number of Bottles EJ When the system has finished measuring and the STOP button switches to RUN press the Hide button in the feeder window to return to the main screen 13 If sending data to Excel open the Excel Worksheet in the Windows Taskbar bottom of screen Click on File gt Save As Save the file to the appropriate network location with an appropriate file name Close Excel by clicking File gt Exit Faults STOP BUTTON Non emergency situations If for any reason the STOP button is clicked while the system is running the system will produce a fault and stop moving at the next available halt position Check that nothing is jammed and click RESET Stages will reset and home
128. ow instructions for Programming a New Bottle for Measurement Ensuring that the bottle part button desired is highlighted press the BASIC SETUP button in the System Controls menu Place the matching bottle on the conveyor close to but not at the load position Press the CONVEYOR tab Press the NEXT BOTTLE button The rotary stage will lower so the laser reflector is in the correct position The conveyor will move the bottle until it cuts the laser beam In the Stages menu press the INPUT CONVEYOR button and advance the bottle using the on screen arrow buttons until the bottle is positioned correctly in front of the loading jaw Press the SET button under the Next Bottle button Press YES to associate this setting to the bottle file Press the Load Pos GO button The load arm will move the bottle to a default position on the rotary stage If the bottle moves too quickly or too slowly increase or decrease the LOAD SPEED setting In the Stages menu press the LOAD ARM button and move the bottle until it is centered on the rotary stage You will have to hold the bottle against the arm when moving the arm backwards Once centered press the Load Pos SET button Press YES to associate this setting to the bottle file Press the Unload Pos GO button The rotary stage will move to the exit position and the load arm will push the bottle from the rotary stage onto the weight scale In the Stages menu press the LOAD ARM button and move the bottle until
129. part to use for this 150ml Milk Collection Bottle Part 2811 7009 A2 3 Run with Feeder button This will open the Feeder window Count the total number of parts loaded onto the tray and enter this number onto the display grid by first left clicking on the grid then right clicking on the total number Individual tray cells can be turned off individually by right clicking on them 13 Feeder Operation Get 1 Inspect 1 Return 1 Run Disable Data Press the RUN button in the feeder window The system will home all stages before commencing measurement Wait Message Homing All Stages After homing the system will measure the parts Data from each part will be automatically sent to the Excel file after it is ejected from the system Parts that are within programmed tolerances will be marked with a green square Parts outside of programmed tolerances will be marked with a red square When the system has finished measuring and the STOP button switches to RUN press the Hide button in the feeder window to return to the main screen 13 If sending data to Excel open the Excel Worksheet in the Windows Taskbar bottom of screen Click on File gt Save As Save the file to the appropriate network location with an appropriate file name Close Excel by clicking File gt Exit Faults STOP BUTTON Non emergency situations If for any reason the STOP button is clicked while the system is running the system will
130. produce a fault and stop moving at the next available halt position Check that nothing is jammed and click RESET Stages will reset and home After homing Hide from the Feeder window select the proper bottle file and continue as normal LE CR E Clear Fault and Press Reset ALL STAGES WILL HOME AUTOMATICALL Y 14 Homing Stages Please Wait EMERGENCY STOP SWITCH Emergency situations ONLY In the event of an emergency press in the EMERGENCY STOP switch on front of the machine This will immediately cut all power to the stages and motion devices When you have cleared out the problem pull the emergency stop out and press the Blue RUN button on the front of the computer box if applicable Click on the Reset button and allow the stages to reset and home Return to regular routine 15 Control Screen The control screen displayed at system start up is divided into three regions AVID Vision Image Monitor Ma EI Finish Measurement System Ver A 9 00 01 S N 101 000 0134 E File Camera Detect Redio n Edit Logie Measure Stage View Help Bottle Manual Test Help Data Setup System Controls CAD Setup Manual qu RO ee LI e a E View Data Ho Send Data Clear Data Bottle Part Buttons 28mm PCO 1810 8oz Bottle Master Spice Test 1 0000 Plug 200zVCT 120z Master Cylinder ll IN MAMA LLL LLL ii iul
131. r O Move Stage CAS Slow m Y Stage Reset All Go To Start Set Park Home Selected Home All Sets the current position of the selected motion device as the park position Home Selected Homes the selected motion device Home All Homes all motion devices Should be pressed when system is RESET or when a fault occurs NOTE MOVING STAGES MANUALLY IN STAGE CONTROL DISABLES MOST FAILSAFES PAY ATTENTION TO STAGE POSITIONS WHEN MOVING STAGES 19 Data Setup Data Display Tab B TE Hght Right S T E X Left X Right Z ID Width The data from the last bottle measured is displayed cado cowo oomo oomo oom oo oo 00m oo om for each angle measured along with the nominal and a e tolerance values entered during bottle setup 7 3421 7 3488 1 2572 1 1649 0 5649 0 5749 1 3771 1 0269 jeune esi nec ii A a uu uem eue EET mur ee E EE Data that is out of tolerance will be highlighted in red O O _ __ __1 i l E ee Ee et el however width and weight measurements are never highlighted Press the green up down buttons to view extended layered data multiple widths IDs etc Only the data types ENABLED and turned ON in Data Setup will be displayed Incorrectly entered nominal or tolerance values may be corrected by clicking on the appropriate cell and entering the new value on the pop up keypad
132. r fixture or until the bottle is placed on the rotary stage Press the SET button If your system is equipped with a weight scale or concentricity option follow the above steps to set appropriate positions for each Setting Grid Spacing Calculate or measure the center to center distance between preforms bottles in the tray Enter the horizontal distance between preforms bottles in X and the vertical distance in Y Systems with enclosures do not have this option Testing Press the STEP THROUGH button The system will now walk through all the loading and unloading positions of the autofeeder At each point the system will query the operator to OK the position If the position is incorrect and the operator presses the NO button the system will stop the walk through at that position so the operator may correct the location When complete press SAVE Standard Operating Procedures SOP AVBIS 3000 Manual Vision Measurement System 1 Click the part button associated with the bottle or part you will be measuring This will load the program Ep Finish Measurement System Yer A 9 01 02 S N 101 001 0157 x Bottle Manual Test Help Data Setup CAD Setup System Controls E v Clear Data View Data Bottle 04 419T 1 950 ml Mayo Seaforth 38 mm Templet 33 mm Templet MTRO S oO Xa 5 28 Pm 2 The system may query you to load parts or fixtures a certain way onto the
133. r the system fan at JFan One of JP24V or JP12V are shorted to select 24 VDC or 12 VDC respectively for power to the fan Camera LED power is output at JCam line power input for the halogen lamp power supply PS3 is at JACLamp and front panel control 24 VDC power is at JFP24V Relay K4 switches line power to PS3 on and off by means of a 3 32 volt DC control signal from the rear panel Lamp On Off connector Relay board LEDs LED3 and LED4 show the on off state of K1 and K2 respectively LED 1 is lit when AC line power is at JACin and LED2 monitors onboard 24 VDC power from power supply PS1 Figures 6a through 6d show a pictorial representation of all internal point to point wiring according to subsets of function and wire gauge Figure 7 was generated from the Banner Engineering Safety Controller PC Interface program which is installed on the system computer lt shows a simplified schematic of the system controller connections to the SC22 3 safety module Different labels are used in that diagram for some of the controls and outputs Use the SC22 3 pin number names as a correspondence guide Figure 8 provides a summary of the detailed functionality that has been programmed into the SC22 3 safety module This was also generated from the Banner Engineering Safety Controller PC Interface program Symbol names are matched to those in figure 7 130140684 9999 ae O pueog he ey 4ep 043u05 weashs pe3e4oduoou qI U Q T 21
134. r to the motors Power Switch Powers on off the safety controller motors and safety devices System will not function in power off state Intentional bypassing or modifying the safety controllers is done so at the customers risk AVID is not liable for injuries or damage caused by modified systems SC106 System Controller Technical Guide This manual contains Complete information on using the SC106 System Controller as well as safety maintenance and troubleshooting information Revision 1 0 August 2010 Table of Contents 1 Overview 127 2 Operator Controls 128 2 1 E Stop Lamp 128 2 2 DOOF 1 Deet DOORS AIMS e 128 2 3 Reset Button 128 2 4 Run Button 129 2 5 Bypass Key Switch 129 2 6 Power Switch 129 3 Operation 130 3 1 Normal System Startup130 3 2 Commissioning Periodic and Daily Safety System Check e ecceeeee eec ceeeeee rennen 130 4 Connections 132 4 1 AC Input 132 42 PWR ER COCOM GPWR2 COM e M M er ee 132 4 3 Computer 132 4 4 EPO nuc Cines 132 4 5 Door 1 Door 2 Door 3132 4 6 lI O Power 133 4 7 Lamp Power 133 4 8 Lamp On Off 133 4 9 Camera LED 133 5 Intern
135. read start search were enabled the position it was placed in would be called zero by the system and angles of measurement would be from the angle of original placement 22 gt While this approach may be necessary for certain bottle types and or finishes manual placement tends to lack repeatability and accuracy bottle code that relies heavily on the operator to place the bottle correctly is likely to produce poor measurements unless care is taken gt Therefore searches are used to locate a known point on the bottle will ALWAYS appear IN PROFILE on the bottle At this time the AVBIS can use either the thread start or the lug tab as a point of reference gt Because the AVBIS was designed to measure bottles with a known thread start the thread start search is the most reliable and common way to find datum point to measure from gt Thread Start search is used to find and provide a consistent rotational datum point from which other measurement positions can be determined These other measurement positions are defined as angles in Data Setup i e angles defined in Data Setup are angles FROM the thread start unless Data Offset is entered To operate the thread start search the following are required E dimension must be ENABLED E dimension nominal value MUST BE CORRECT E dimension MUST be turned ON at the ZERO angle T dimension must be ENABLED T dimension nominal value MUST BE CORRECT
136. rom the Feeder window select the proper bottle file and continue as normal LE HEN E Clear Fault and Press Reset ALL STAGES WILL HOME AUTOMATICALL Y Homing Stages Please Wait EMERGENCY STOP SWITCH Emergency situations ONLY In the event of an emergency press in the EMERGENCY STOP switch on front of the machine This will immediately cut all power to the stages and motion devices When you have cleared out the problem pull the emergency stop out and press the Blue RUN button on the front of the computer box if applicable Click on the Reset button and allow the stages to reset and home Return to regular routine Standard Operating Procedures SOP AVBIS 3000 Conveyor Vision Measurement System 1 Click the part button associated with the bottle or part you will be measuring This will load the program a Reset Zw Clear Data View Data d es 33 mm Templet Data Setup CAD Setup 04 419T 1 950 ml Mayo Seaforth 38 mm Templet MIO LO scm 2 The system may query you to load parts a certain way onto the conveyor and or verify that the correct bottle or part is has been selected loaded and or load a particular fixture onto the system Confirm that you have read and will follow the instructions by clicking on the OK button FAILURE TO FOLLOW THE INSTRUCTIONS MAY RESULT IN IMPROPER MEASUREMENT OF PARTS OR DAMAGE TO THE SYSTEM Is this the most recent part t
137. rom the bottle sealing surface Width Y Pos will place the width nominal position the Y Pos from the bottle foot Users of older AVID affiliated vision systems will recognize the Xpos Ypos as X Y Offsets Save Click to be prompted to save all settings to a bottle part file template Sheet Buttons Use the Red arrow buttons to move among the different setup sheets Use the Blue arrow buttons to move within the displayed sheet Use the Green arrow buttons to view additional data types ex T1 T25 on the same sheet 21 Data Setup Measurement Setup Tab L Measurement Setup for Sport Wales E File Edt Options S Methods Options Neck in Single Field ON Find Thread Start ON Preform OFF dh Flat Thread OFF Neck Insert OFF End Offset 13 Image Store OFF Sample Points 1 Lug Search FE S Type 3 Lug Offset 10 S Offset 1 Thread End Projection 0 50 Scan Speed 20 Finish S as Datum OFF S Datum Offset 0 Lean Panel Setup S to Panel Offset O Lean Data 1 Width in Single Field OFF Lean Data 2 Width 1 Panel as Placed OFF Max Width Search OFF Min Width Search OFF Thickness Panel As Placed OFF Panel Offset 90 Thickness First OFF Panel Step 10 Width Search Height 0 98 Data Gispla Data Setup Measurement Setup ele elo ojo Click any method value cell to begin changing it Save B Hide lt gt n gt Neck in Single Field The AVBIS 3000 was designed to quickly measure the neck dimensions of bottles by capturing an i
138. rsor AntoPanel Press Find S again When finished press S again Did the value get larger or smaller If smaller you are going in the correct direction when you changed the End Offset Continue in that direction until the S gets larger again When you have reached a value of End Offset that yields the smallest S you can continue and setup other dimensions in CAD Setup Incorrect S End Offset too big Correct S Incorrect S End Offset too small Adjust limits and fields if necessary see CAD SETUP section for further definitions When you are satisfied with setup press HIDE SAVE your changes when prompted Step 6 Before setting up the autofeeder if equipped place the bottle on the rotary stage and press RUN Observe carefully The Thread Start Search will run and locate the S dimension Then BEFORE any other values are measured the bottle preform will turn the value you set in S Datum Offset in Measurement Setup Step 4 This SHOULD have put the parting lines perfectly by eye perpendicular to the camera The AVBIS will measure here 0 is Scan 1 then turn 10 and measure again 10 is Scan 2 then turn an additional 80 and measure ag ain 90 is Scan 3 If the parting lines did NOT line up at 12 and 6 o clock at Scan 1 then you will need to adjust the S Datum Offset in Measurement Setup Adjust the S Datum Offset and RUN again Adjust until the S Datum Offset yields a Scan 1 where the parting lines are perpendic
139. ry Center IERT Mirror Offset Liaht E d HE 0 2200 g Show Thickness Save Mi co Set Probe Extension 10 8185 Sensor Probe Down Standard Thickness GO Set Probe Height 9 3799 Rotary Speed CU KUN Measure co Set Min Stage Height 0 9499 Measurement KEEN 11 Press the Thickness button in the System Controls menu 12 Press the Setup button and click on the Data tab 13 The new calculated multiplier will appear Press the Save Part button and save to the correct filename The new multiplier is now saved to the bottle thickness file Appendix C CE and Systems with Doors Systems ordered after January 1 2010 are equipped with CE compliant safety controllers and doors These safety controllers prevent access to the system by removing power and communication with the motors and motion devices while the system is powered on hted Bottle Thickness Inspection System E Stop Light Indicates that the emergency stop button has been pressed in Door 1 2 3 Lights Indicate that doors 1 3 are open Reset Button Resets the safety controller Run Button Indicates the status of the controller If lit indicates that connection from the controller to the motors has been interrupted ByPass Key Switch Key protected bypass switch allows safety controller to be bypassed for 30 minutes Doors may be opened without loss of power or communication After 30 minutes controller will shutdown powe
140. s SET as zero unless a Thread Datum Offset is entered see below All measurement angles will be referenced from this position END OFFSET IS GENERALLY NOT NOTED ON BOTTLE DRAWINGS THEREFORE EXPERIMENTATION OR APPROXIMATION WILL BE NEEDED TO FIND THE PROPER END OFFSET FOR EACH BOTTLE The Y value of T stated in Step 2 can be changed by adjusting the Thread End Projection value in Measurement Setup For example if the thread end projection were set at 0 75 the bottle would rotate until Y of the thread disappeared The bottle would then be rotated counter clockwise until 3 4 of the thread was visible projecting from the sidewall The End Offset value therefore would be less than if the Thread End Projection were set to 0 5 Assume that all bottles are different despite similar neck finishes Therefore there is no golden standard or template that all bottles will adhere to Just as the molds and processes that produce each bottle are unique each bottle program should be unique to the bottle Flat Thread Thread profiles that are flattened i e the thread T does not form a point or radius at its tip will not measure effectively with the Thread Start Search as there is no maximum T for the AVBIS to track on Turning Flat Thread ON allows the AVBIS to handle these unusual thread finishes The Flat Thread option was designed for 63mm PET blow stretch finishes after the moil is removed End Offset For most AVBIS users
141. set varies l MEI is i a ee Upper Search Limit Measures the S by locating a point on the E sidewall above the thread via an upper search limit line and then calculating the first point on the thread that is S offset out from the E wall Use Bottles with flat top threads little or no slope such as a 28mm CSD finish artifacts on sidewall striker steps Such as rough cut HDPE and other problematic finishes Note S Type 2 requires that the operator set an upper search limit USL for the S measurement in CAD setup The USL will be the position along the sidewall that S offset steps away from S offset 8 On the finish to the right the USL has been set S to intersect the sidewall above the thread An 0 0676 offset of 8 has been entered therefore the AVBIS will step out 8 pixels from the intersect of the USL and the sidewall and measure down to the thread Note that the thread profile is flat at the intersect Therefore S Types 0 1 3 and 4 would not work since they rely on the slope of the thread for calculation S offset 11 On the finish to the right the USL has been set to intersect the sidewall above the cutter step above the thread An offset of 11 has been entered therefore the AVBIS will step out 11 pixels from the intersect of the USL and the sidewall and measure down to the thread If the measurement down to the cutter step were desirable and smaller S offset
142. set button will then activate SC1 pin SR and SC1 will recheck to see if the malfunction has been cleared SC1 also monitors up to three system guard door switches at pins S5 through 13 that are connected directly to the back panel door switch connectors These are 3 wire connections to allow for a normally closed and normally open contact in each switch to be monitored In a similar way pins S1 to S4 monitor the system DPST normally closed contacts of the E Stop switch by direct wiring to the back panel E Stop connector Activating any of these switches causes K1 and K2 to deactivate and outputs at SC1 pins O1 through O4 will light the appropriate status indicator lamp on the front panel When all safety switches have been subsequently deactivated SC1 will light the front panel Run pushbutton with the output pin O5 Pressing the Run button will signal SC1 at pin S22 to reactivate K1 and K2 The front panel DPST normally open contacts of Bypass keyswitch are connected to SC1 pins S14 to S17 to monitor the selected bypass state SC1 is powered by 24 VDC power supply PS1 on the relay board with a connection to JSC24V Additional normally open contacts on K1 and K2 are wired in series between the RC and RCG shutdown pins of motor power supply PS4 by means of JRC of the relay board Contact opening disables motor power with a much faster decay than the sole removal of line input power by K1 and K2 U1 of the relay board provides optional 12 VDC power fo
143. surement points are unique to each rotary position If the image is clicked the point selected will be moved to the center of the video image Clicking the image is a rapid way to jog the system to the desired measurement location Set All Pressing this button after establishing upper lower and nominal limits for one side of a width measurement in CAD Setup will copy those limit locations to the opposite side of the bottle and to all other angles associated with that width location Center Moves the center of the rotary stage to the center of the video field Align Cursor Runs cursor alignment program Note cursor alignment in CAD should be done with the mouse Align mouse cross hairs with the on screen cross hairs Display Numbers Top Left and Right Show the Position of the Cursor on the CAD grid Align Cursor Display Number Bottom above the AutoPanel button Shows the current End Offset Value Clicking on the value allows the operator to change the number useful during initial setup AutoPanel Auto Panel Pressing this button assigns all enabled width and thickness measurements to operator designated Y Position in Data Setup locations along the height of the bottle The operator can then fine tune these locations by selecting the individual widths along the top bar Zoom Pressing this button overlays a separate video window onto the screen that allows the operator to zoom in on points of interest or to
144. t 2010 Table of Contents 1 System Block DiagramError Bookmark not 2 Computer Connections 154 3 SC106 System Controller Connections 155 4 Motor Fanout Panel Connections 156 5 1 0 Block CGonnechons 157 6 Computer Front Panel 158 7 Parts Ust mme 159 1 System Block Diagram Motors Guard Door 1 Switch Guard Door 2 Switch Guard Door 3 Switch E Stop Switch Halogen Lamp IR Controller Lamp On Off Camera LED Solenoid valves Sensors etc Camera Network Auxiliary Gauge Weight Scale IR Controller Keyboard Mouse AC Line Power Rack Safety Switch 1 PWR RS232 PWR 1 48 VDC COM 1 4 RS232 9 Motor Fanout Panel Door 1 Door 2 Fr Door 3 EPO Line In 12 VDC Be Lamp Power Lamp On Off 20 ma Camera LED ee NDE I O Power Computer I O Block PWR me 8 24 V Outputs rm Computer 8 24 V Inputs Link m E Ec WAT USB Lem Ethernet Ww USB USB B Ethernet m RJ45 RS232 T RS232 ied 5 S USB USB Touchscreen VGA mdse VGA y 1 RS232 Line In Serial UO M PS2 Line In m PS2 UPS Battery Battery Backed Out Backed Out Line In Serial I O EPO Bypassed Out
145. t be tilted due to pressure against the rollers but remain vertical SET the CONCEN CENTER to this position See illustration below left Drive Roller 4 With the pickup arm adjust the height of the preform such that the laser dot hits just above the transition point to the cap It should be placed such that the laser gathers thickness measurements near the transition between the cap of the preform blue and the body yellow See illustration above right If satisfied SET the CONCEN HEIGHT to this position Be sure to SAVE your positions Discard the preform with the tape on it adhesive residue can influence measurement 5 In the illustration below the drop height has been setup incorrectly The laser dot has been placed on the preform cap Because the laser beam is hitting the preform on a curve it is reflecting at an angle to deep to be detected by the emitter receiver No information peaks will be received by the concentricity module This would also be the case if there is a transition band along the inner wall of the preform at the position of measurement Concentricity measurement with the laser concentricity sensor is not possible in these bands 48 Concentricity Understanding the Laser Graphs 1 After setting the positions you think appropriate for concentricity measurement load a preform into slot 1 click to the Concentricity tab and click Get Preform 1 The system will automatically select the preform fr
146. t to be measured The system will perform a horizontal and vertical measurement within the field and display the values in Pixels Inches and Millimeters At Center Pressing this button measures the width of the part in the field from the rotary stage center Nominal The number displayed is the nominal dimension of the part or standard to be measured Pixels MM Inch Displays the values for the measured object in the field Auto Measure The Automeasure permits the measurement of objects larger then the field of view 1 Place the object at the center of the rotary table 2 Select the Nominal box and enter the object dimensions height or width 3 Press the Width or Height button The system will automatically measure the height or width and display the measurement Home Vertical If for any reason the vertical offset needs to be changed radical change in environment temperature unusual height readings etc the Home Vertical button can be used to reset the Vertical Home Offset Place a vertical gauge block at the center of the rotary stage enter the height nominal of the block and press Home Vertical The system will measure the block and recalculate the vertical home offset The system will prompt the operator to save following homing Weight Allows the user to interact with the scale readout Read Displays the current weight reading on the weight display Show Opens the weight scale window to permit
147. t top of bottle from bottom left Data Setup Entry Nominal Value Tolerance Value In Measurement Setup select Width and top finish dimension Ensure that these dimensions are ENABLED and turned ON at the SAME angles CAD Setup Entry None Because Lean is an extrapolation from data collected during the RUN routine it cannot be measured in CAD Measured System calculates the offset in system units English or Metric between the two left edges The Polarity or of the offset indicates the direction of lean Lean 2 73 T aka Thread Diameter Measurement Diameter of thread Data Setup Entry Nominal Value Tolerance Value E dimension is ENABLED and turned ON at SAME angles CAD Setup Entry Upper search limit for the T Dimension MUST BE ABOVE THE FIRST FULL THREAD Measured Max Diameter of the first thread Multiple T may be measured The system will start at the last T and search down for the next T i i T L T E Ua orgullo a TE xod h x qM CMM D d LI Cen ER 2 S oU Biber VC em SU MD m OE SSH E TE A y b kb TN p Ce x ar pp o 1 4 74 X Left X Right aka Finish Height Measurement Height from Top of Finish to bottom of support ring Can be used to measure ANY vertical height to the underside of the Z bead x Dimension Data Setup Entry Nominal Value Tolerance Value X offset from greatest projecti
148. ta Setup CAD Setup and Basic Setup buttons to be password protected Contact AVID for master password Only ONE password can be set Check for Height Error Will prevent ID from running if bottle height is significantly out of spec to prevent damage Single Data Out Allows the AVBIS to send data in a single string that will be overwritten after every bottle is measured If not selected strings will be added not replacing Brake Motor Allows the AVBIS to utilize a brake motor on the Bore Y Stage no longer offered or supported Change Password Allows the Password to be changed Note AVID Corporation is NOT responsible for lost or forgotten passwords Restrict Scan Restricts the view of the Thread Start Search during RUN allowing the search to run faster Database Server Allows data to be exported into database server setup by AVID Data Status Allows the AVBIS 3000 to display Data Passed or Data Failed after measurements Run ID Allows bottle programs to be identified to Gainseeker SPC program Block Data Allows data to be sent as a block in lieu of a string Show Servers Hides or displays the AVID Vision System and other modules in the Windows taskbar Show Tool Tips Shows or hides tooltips Excel Protection Enables Excel Protection on ALL programs The AVBIS will send a command to Excel after every bottle data send to engage sheet protection This prevents accidental or intentional changing of da
149. ta in the worksheet by operators PASSWORDS If a password has been set the system will request that a password be entered when the following buttons are pressed Data Setup CAD Setup Basic Setup Advanced Basic Setup Once unlocked the system will remain without protection until 1 Another bottle program is selected re engages the password 2 Password Reset is pressed in Basic Setup System Tab 53 Basic Setup Advanced Options Stage Settings Tab System Setup alues x Exit System Options 1 System Options 2 Stage Settings Assignment Motor Speed Polarity Misc Settings BoreX D Bore Open 8000 GE Ba Min Bore X 5 0000 Conc EJ Transport PickUp Tray In Conveyor Out Conveyor Load Arm UnLoad Arm O GO On oak OQ rn Thickness These settings should remain unchanged unless instructed to make adjustments by AVID Assignment Assigns motor numbers to particular motion devices AVBIS 3000P Settings Transport 7 PickUp 8 Tray 6 AVBIS 3000C Settings In Conveyor 7 Out Conveyor 0 unless specified Load Arm 6 Unload Arm 0 unless specified Thickness 0 unless specified Bore Gauge Settings BoreX 4 Bore Y 5 Motor Speed 1 10 Sets motor speed DO NOT ADJUST UNLESS INSTRUCTED TO DO SO BY AVID Polarity Sets polarity of motor DO NOT ADJUST UNLES
150. the ABTIS WTS add on modules as an option to AVBIS 3000 series systems due to difficulties experienced with training programming flexibility and speed This appendix is for those customers whose systems still have the WTS option AVID encourages customers still using the WTS option to consider trading in their WTS module for a discount on a standalone ABTIS 1000 bottle wall thickness system Preface PLEASE READ The ABTIS WTS add on systems are designed as slave systems to the AVBIS 3000 series systems Therefore the ABTIS WTS system and thickness software must be regarded as a separate entity from the AVBIS 3000 and bottle software Each bottle program will have a thickness program attached to it if Thick is ENABLED with the EXACT same filename Only ONE thickness program can be linked to a particular bottle program You cannot associate a different thickness file to the bottle file For example if you create a bottle file called Boston Round and enable thick it will create a thickness file called Boston Round Every time the Boston Round file is called up in the AVBIS software the Boston Round thickness file will also be called up Therefore if you want a bottle program with a vertical thickness program AND a rotary thickness program you will need to create TWO bottle programs with different filenames one with a vertical thickness program and one with a rotary thickness program for example
151. the CAL button scale will return to the standard gram readout with the the Response and Slow illuminated Now the scale will ignore slight fluctuations in the weight value Bottles tip or fall over while being loaded onto or off the rotary stage AVBIS 3000C e If the rotary table is not level with the load unload positions the resulting ridge or gap between the rotary stage and the conveyor adapter plate can cause bottles to tip over while being moved e Check the Rotary Load and Unload Positions and feel for any ridge or gap with your fingers or by pushing a bottle across by hand Adjust the positions if required Load Position Problem e Press the Basic Setup button in the System Control menu Press the Conveyor tab Press the Stages button in the System Control menu Press the Y Stage or X Stage button and SLOWLY move it until it is level with the conveyor adapter plate Press Rotary Load Set Press SAVE Unload Position Problem e Press the Basic Setup button in the System Control menu Press the Conveyor tab Press the Stages button in the System Control menu Press the Y Stage or X Stage button and SLOWLY move it until it is level with the conveyor adapter plate Press Rotary Unload Set Press SAVE Bottles tip or fall over while being moved by the load arm AVBIS 3000C e Check that the load arm is set at the appropriate height for the bottle being moved It can be moved by sliding it up and down on it mount e
152. the default positions of the bore gauge Set Down Sets the current Y up down position of the bore gauge as the down position The bore gauge should be moved down until the probes begin to open Select Set Down to set the down position Set Open Sets the current bore gauge tip position as the open position The bore gauge should be moved down until the probes are fully open Select Set Open to set the open position Set Center Sets the current position of the bore gauge as the center of the rotary stage position The bore gauge should be moved right or left until it is directly over the center of the rotary table Select Set Center The present probe position will be set as the bore gauge center of the rotary table BORE STAGE CONTROLS SET DOWN SET OPEN SET CENTER SHOULD NOT BE CHANGED UNLESS INSTRUCTED TO DO SO BY AN AVID TECHNICIAN OR AN AVID TRAINED OPERATOR Bore Tip Calibration Allows the user to calibrate bore gauge tips Probe Tip Offset Allows the user to enter in tip offset values Tip offset is the width of both of the contact tips from the outside edge of the pin to the contact point Meas Point The point along the outside edges of the bore gauge pins that the AVBIS uses to calculate ID The probe measurement point is displayed in pixels This is the vertical position on the probes where the system will measure the distance between the probes The Meas Point should be adjusted to b
153. through AVID Corporation Explanation Ensures that the rotary table is parallel to the camera axis and ensures an accurate measurement across the top of the bottle Action a Place the stage alignment tool on the rotary table at a slight angle to the camera b Raise the table until the balls are visible using the Y Stage controls in Stage Controls c Select the Ball Measure button in the Camera Tab The difference in height between the two balls will be displayed below the button The difference should be less than 0 005 0 1mm If the height difference between the balls is greater than 0 007 the stage should be leveled as this indicates that physical crash or accident may have occurred Contact AVID for instructions 95 STEP 8 Light Source Alignment ONLY PERFORM IF SUGGESTED BY AVID Tools Required Hex Wrenches Explanation The light source must be concentric and parallel to the camera lens assembly Action a Darken the room the AVBIS is in Place a piece of white paper in front of the camera lens The light shining on the paper should be centered over the lens b Move the Light until the projected light is centered over the lens Paper Paper See O Aligned Mot Aligned C Tighten the light mounting screws d Close the Aperture F Stop at the back of the lens This will cause the aperture to appear as a spot of light in the image The aperture should be at the center of the fiel
154. tly above the sealing surface of the preform to be picked up When the air pressure air test is turned on the restrictor forces only the bottom third of the bladder to inflate inside the neck finish of the preform The restrictor also prevents the preform from cocking during inflation and pick up as the preform sealing surface will contact the flat of the restrictor base 58 Dimensional Measurement Requisites Certain dimensions require the measurement of another bottle feature in order to be measured Be aware that although a specification sheet or bottle drawing does not require a certain measurement the AVBIS may require that measurement for proper dimensioning Requirement HghtL 8 Required at ALL angles of interest HghtR T E at same angles EA E menge S X _TandEatsameanges H Zatsameangles HE jFatsameanges gt Nck A at same angles Straight Z at same angles Left Right X Left AND Right at same angles D JjAatsameanges SU TandEatsameanges gt K X TandEatsameanges Z 4 Z2 HTRight HghtRight at the same angle is required for ANY right side XRight measurement DRight etc Process Requirements Certain processes will only work or will work more efficiently when certain other dimensions or elements are enabled or included Process Requires Thread Start Search T and E turned O
155. to your system Background Calibration Bottle Image is Red Gray Not Black e Background calibration will be incorrect if a bottle or sample is left on the rotary table during startup To set a new background remove the bottle select Basic Setup from the System Controls area the Camera tab and press Background Correction e If this fails remove bottle or sample from rotary table select Basic Setup select the Camera Tab and press Auto Adjust The system will cycle through the light settings until it has found an OK light setting When complete press Background Correction and then SAVE T not found e Check the Height Y offset The thread is recognized as a projection from the top of the bottle If the top edge of the bottle is located in a position that is far from the real E wall the calculated projection may be incorrect Typically an offset of 0 5mm is acceptable unless a large radius is present T is measured at incorrect position incorrect distance in CAD Setup e Check the nominal values for T and E in Data Setup T should ALWAYS be larger than E e Check the upper search limit for T in CAD Setup S being measured at incorrect position on thread profile e Checkthe S Type being used to make sure the correct method is being used and that it is setup correctly in CAD Setup S being measured at incorrect rotational position e Checkthe nominal values for T and E in Data Setup T should ALWAYS be larger than E T and E are used to find the end o
156. trol Screen Data Readout jEnbl Height 0 5 10 15 20 25 30 3 40 Ia 600 65 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF I The data readout displays the thickness settings for the current bottle thickness file and the thickness data collected from the last bottle measured Enbl Row Displays those angles at which the ABTIS WTS is collecting data Angles can be enabled or disabled by clicking on the ON OFF toggle Enbl Column Displays those heights at which the ABTIS WTS is collecting data Heights can be enabled or disabled by clicking on the ON OFF toggle Height Column Displays those heights selected for measurement By clicking on a height number it can be changed to value close to the original 0 05 Angle Column Displays those angles selected for measurement Only angles at 5 increments may be toggled ON or OFF Data Grid Displays the thickness data collected Data falling outside tolerance ranges is highlighted in red 114 Setup Data Tab Measurement Setup Of x Excel Multipliers iv Enable for Data Input Wall Tube J 002850 By C Height Angle r Show Unused Heights M Display Metric T Show Unused Angles M Pass higher than nominal data First Row Col iv Show Data Settings Iv Pass Fail by Rows Iv Pass Fail by Columns Worksheet File Data File
157. ular to the camera However there IS a shortcut to this Position the preform or bottle on the rotary stage such that the parting lines are perfectly at the 12 and 6 o clock positions facing the back and front of the machine and the S dimension or one of the S dimensions is somewhere between 6 and 12 Go to CAD Click on S and press Find S The Thread Start Search will run as normal After completing a value will appear to the left of the Set Zero button If everything was done properly this value generally negative is equal to the number of degrees between the S dimension and the parting line that WAS at 12 You can now use this value to properly setup the S Datum Offset Example if the value is 82 that means that there are 82 between the S and the parting line AFTER the S If you wish to set the parting line AFTER the S as 0 then the S Datum Offset and generally Panel Offset should be set to 82 If you wish to set the parting line BEFORE the S as 0 then the S Datum Offset should be 98 180 82 After all this is finished the preform or bottle should be RUN again to ensure all the measurements look good and there are no problems with the data that can be attributed to incorrect programming If you are satisfied with the program the bottle preform can then be programmed with the autofeeder and setup for data output to Excel or the network 110 Appendix B Wall Thickness Module AVID Corporation no longer offers
158. ured by the AVBIS FLASH is a calculation After measuring the other neck finishes the bottle preform will turn 1 0 degrees off of the angle of the parting line determined from a drawing or approximation The rotary stage will turn an additional 20 degrees in 1 degree increments or steps The AVBIS will measure the T dimension at each of these incremements The smallest T measured T Min is subtracted fro the largest T measured T Max Measured Absolute Value of T Max T Min je Monitor Aegion Edit Logic Measure Stage View Help Ai PRA n h I 1 AL dl LR HB 2 MU WANI i ut A hn ANN Flash Measurement Scan As It Appears in RUN mode m NOTE FLASH IS A MEASUREMENT OF THE VARIANCE IN T OVER A 20 DEGREE ARC AROUND THE PARTING LINE BECAUSE THE AVBIS IS MEASURING T THE AVBIS CANNOT DETERMINE ON WHICH SIDE S OF THE NECK FINISH THE FLASH IS PRESENT ON FURTHER INSPECTION WILL BE NECESSARY 86 Neck Straightness Nck Left Nck Right Measurement Vertical measurement from bead area under main neck support ring Z to shoulder Data Setup Entry X Left AND X Right dimensions ENABLED and turned ON at same angles as Nck Left and Nck Right A dimension ENABLED and turned ON at same angles as Nck Left and Nck Right Nominal Value Tolerance Value CAD Setup Entry Place A dimension upper and lower search limits ONLY around the bulge below the ma
159. w clamp block 6mm yellow M46 Entree bh Screw clamp block 6mm Deck M46 Entree bh End section gray EMS Eneee bh y Endsop pav Enee RB y Cable USB 2 0 3ft JUSB2HABB J Startech pf A ll ae Relays O O O y o Relay SSM SPST 10A 200VAG_BS1SSA210 00 1 wees 1 ves parasheet MA oq 1 E T qd 4 Relay Board o y y Relay Board PC board JAVSCRBRev 10 Win bh Relay 4PST 6A 24VDC coil G7SA 3A1B DC24 en PB Data Sheet Socket relay PCB mount PzgSA P En P Data Sheet Power supply 24 VDC 40N RAC40 24SA Recom H Weg DataSheet Terminalblock 2 pn 1840366 1 Phoenix 7 _ DataSheet Terminalheader 2 pn 1844210 Phoenix P DataSheet Terminal block 3 pn 757022 Phoenix HM DataSheet Terminal header 3 pin 1757255 1 1 Phoenix M DataSheet Resistor carbon film 1K 5 2W ON1025E Ohmite H Resistor carb film 100K 5 1W OM1045E Onmte ff j Regulator 12V 1 A SIP R 78B12 1 0 Recom DataSheet Capacitor 10uf 20V tantalum TAPi06K020SCS Wun bh o Z Capacitor 47uf 35V tantalum TAP476K035CCS Wun bh Diode 600V 14A tN4005E354 Men RB o o Y LED red short lens diffused SSL LX3044ID Lumex H poo LED amber short lens diffused SSL LX3044AD Lumex p LI LED green short lens diffused
160. w menu at bottom of screen with controls to system hardware Basic Setup Bottle Stages Pressing the Stages button will bring up a stage control window allowing control of each individual motion device Pressing this button also allows the operator to return all or selected motion devices to their individual home limit switches move a single axis or place a device at its start position Reset Re links and homes all stages Thickness Concentricity if equipped Switches screen to the wall thickness no longer available as an option to the AVBIS 3000 or concentricity program if equipped Send Data The send data button is automatically activated after a bottle is measured Data from the current bottle is stored in the measurement file and may be viewed with the View Data button but is not stored to permanent data files until the Send Data button is pressed This permits the operator to re measure a bottle if required prior to saving the data After sending data bottle data may be updated by changing the bottle count and re measuring the appropriate bottle Data cells in the Excel file will be overwritten with the new data Other data storage files will be appended with the bottle number and new data Clear Data The clear data button will reset the bottle count to 0 and clear the stored data file that is used by external data analysis software such as Excel or other statistical program V
161. weight scale tuning Hide Hides the weight scale window Minimize Minimizes the weight scale window into the Windows taskbar 40 Basic Setup Camera Tab 7 t Basic Setup Yalues E4 Wall Bore Gauge Measure Camera System Auto Feed Conveyor Misc Concentricity Alignment Back Light Test Image Test Pattems Camera L Auto Center E EJ WS lear Rarkagrnuned Show EN EN EM Image Correci n OK Show Real A Ball Measure qo t 0 000 PA Auto Exposure LIGAT Exposu a The Camera tab is used to check and adjust the video camera Note only an operator trained in camera calibration should access this tab as improper calibration will result in incorrect measurements Alignment Camera L Measures a square to perform camera vertical alignment 0 0080 is generally acceptable Auto Center Automatically centers a vertical pin and sets the centerline of the Rotary table The pin should utilize a 375 dowel pin to ensure accuracy Once centered the operator should SAVE Ball Measure Utilizes two steel balls to adjust the perpendicularity of the rotary table 0 005 is generally acceptable Back Light Test The brightness of areas within the video image may be measured to determine the shading within the illumination system This is of concern if background shading correction is not used When the test button is pressed the system will acquire a new image and measure nine points
162. within a 1 8 inch search area above and below the specified Y position This search area can be changed by clicking the desired width button and moving the upper and lower search limits The search can be changed to a MIN search by clicking the desired width button and pressing the MIN button Upper search limit Measure Left Width 1 Ith 2 1817 Measure at Max Point Lower search limit 84 PHght L PHght R Measurement Vertical Measurement from base of bottle to the position of the Width measurement Data Setup Entry Allowed Data Types Select the PHght L R that corresponds the Width you are interested in For example if you are interested in the height where Width 3 is measured Enable PHght L 3 and PHght R 3 Nominal Value O because there is no depth measurement the width nominal is irrelevant Tolerance Value 0 see above CAD Setup Entry Set up the Widths properly PHght will not measure in CAD but data will appear during the Run 85 FLASH Measurement Value of T at the Parting Line Data Setup Entry T Dimension ENABLED and turned ON at 0 E Dimension ENABLED and turned ON at 0 Nominal Value 0 Tolerance Value max allowable flash ANGLE of Parting Line from thread start as determined from a drawing or approximation CAD Setup Entry Setup T and E as normal Flash cannot be measured in CAD Process Unlike most other dimensions meas

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