3-Dimensional Image Processing for Gob Measurement & Weight … · 2006. 10. 18. · = Automatic...
Transcript of 3-Dimensional Image Processing for Gob Measurement & Weight … · 2006. 10. 18. · = Automatic...
30th ASEAN Glass Conference Manila, Philippines Sept. 21, 2006
G M WG M W3-Dimensional Image Processing for3-Dimensional Image Processing forGGob ob MMeasurement & easurement & WWeight Controleight Control
Glass Forming Technology TeamMitsuo Ueda
(presented by Melvin Si, Glass Forming Technology Team)September 21, 2006
30th ASEAN Glass Conference Manila, Philippines Sept. 21, 2006
Development ConceptDevelopment Concept
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Melting Process
DeliveryProcess
FormingProcess
Repeatable SwabbingFilm Function
Repeatable SwabbingFilm Function
Improvement in MachineSetting Accuracy
Improvement in MachineSetting Accuracy
Stable Gob LoadingStable Gob Loading
Repeatable & StableGob Weight・Shape
Repeatable & StableGob Weight・Shape
GlassComposition
GlassComposition
3 Dimensional Image Processing forGob Measurement & Weight Control
High Quality Bottle Production
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Importance of Gob Weight & Shape
Gob Weight VariationDuring Production
Gob Weight VariationDuring Production
Variations and Changesin Filling Level
Variations and Changesin Filling Level
Changes inGob Shape, Fall Angle,
Gob Loading, HeatCapacity, etc
Changes inGob Shape, Fall Angle,
Gob Loading, HeatCapacity, etc
Can Cause1. Glass Defects
(laps, uneven thickness,gauge, finish defects, etc) 2. Machine Downtime
Can Cause1. Glass Defects
(laps, uneven thickness,gauge, finish defects, etc) 2. Machine Downtime
Adjustment of:Gob & Mould Temperature,
Forming Timing and Pressure, etc
Adjustment of:Gob & Mould Temperature,
Forming Timing and Pressure, etc
Results in Breakdown ofForming Conditions andNon-repeatable Quality
Results in Breakdown ofForming Conditions andNon-repeatable Quality
Non-repeatable Gob ShapeDuring Job Change
Non-repeatable Gob ShapeDuring Job Change
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Gob Measurement PrincipleGob Measurement Principle
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3 Dimensional Measurement Principle
Wire Frame Image
Camera 1
Camera 2
Camera 3
GobCalibration Post
Coordinates(0,0,0)
Image
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3 Dimensional Gob Wire Frame Image
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3 Dimensional Gob Wire Frame Image (Zoom)
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Numerical Representation of Gob
1. Continuous volume calculation from gob image
2. Automatic volume(calculated) control = Automatic Weight control
3. Measurement of each cavity. Average value use for control logic. Feeder tube height control.
4. From the 3 dimensional coordinates: Gob length, fall angle, drop consistency are numerically calculated.
1. Continuous volume calculation from gob image
2. Automatic volume(calculated) control = Automatic Weight control
3. Measurement of each cavity. Average value use for control logic. Feeder tube height control.
4. From the 3 dimensional coordinates: Gob length, fall angle, drop consistency are numerically calculated.
Feeder TubeH-1, H-2 measurementH-1, H-2 average data used for Tube height control
Feeder Plunger
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Volume Measurement Accuracy
Image Processing of Water, Oil, Shear Spray Particles on Gob Edge
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Volume Measurement Accuracy
167000
167500
168000
168500
169000
169500
170000
384 385 386 387 388 389 390
実測重量(g)
計測体積(mm3)
R2 = 0.9711R2 = 0.9711
Actual Gob Weight (g)
Mea
sure
d V
olum
e (m
m3 )
Relationship between Measured Volume and Actual Gob Weight
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System StructureSystem Structure
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GMW System Patent Pending
Processing Speed: 1.5 sec/gob (Trigger Signal - Measurement - Calculation - Output - Signal Standby)Automatic Control for all process: BB, PB, NNPB
Camera1Camera2
Display
Keyboard
3-D Measurement Display, Control PC
H1
H2
Camera: Water Jacket, Lens: Air Purge System
Gob Cut Signal
Camera3
Gob Volume, Gob Length, FallAngle, Drop Consistency, TubeHeight Signal trend graph display
Feeder Tube
Gob
Feeder Plunger
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System Features & PerformanceSystem Features & Performance
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GMW Features & Performance
Automatic Gob Weight ControlAutomatic Gob Weight Control
•Fully Automatic System (no need for periodic weight sampling for calibration)
•Weight Variation R of below 1% of control weight
Gob Shape Recording・Retrieval・ComparisonGob Shape Recording・Retrieval・Comparison
•Gob Volume•Gob Length•Gob Fall Angle
Gob Measurement Trend Data ・Recording ・RetrievalGob Measurement Trend Data ・Recording ・Retrieval
•Feeder Tube Height Adjustment•Drop Consistency
Alarm FunctionsAlarm Functions
•Trend Graph Data•Camera Water Jacket Temperature•Camera Lens Air Purge Pressure
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Automatic Control Performance
0.00.20.40.60.81.01.21.41.61.82.02.22.42.62.83.03.23.43.6
0 50 100 150 200 250 300 350 400 450 500 550 600 650Gob Weight (g)
Wei
ght V
aria
tions
R (%
)
GMWManualPlunger BaseSystem
Target below 1%
Gob Volume & Trend Graph
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StandardWeight
ProductionWeightProduct AProduct
Scale Adjustment
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Tool Bar Function
Gob Shape Alarm HistoricalFall AngleGlass Volume
TriggerDetail Job Change CloseDensity ControlWeightProduct
GMW Tool Bar
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Gob Shape Window
CloseGob CaptureGob UploadSave
Product Name: Product AProduction Date: October 12, 2000 10:05:12
(H-1)Volume : 185.20cm3Drop Angle : 2.5° GobLength : 145.2cm3
(H-2)Volume : 181.50cm3Drop Angle : 3.2° GobLength : 150.2cm3
Product Name: Product BProduction Date: October 15, 2000 13:10:14
(H-1)Volume : 170.30cm3Drop Angle : 2.5°Gob Length : 142.1cm3
(H-2) Volume : 168.10cm3Drop Angle : 2.7°Gob Length : 147.6cm3
Gob Comparison
Gob CaptureGob UploadSave
Gob volume, Fall angle, Gob length
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Gob Fall Angle
Front View
Left Side View
Furnace Lehr
Fall Angle
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Alarm Setting Window
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Historical Trend DataProduct AProduct Production Weight
Scale Adjustment1,8,16,24 Hours
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Job Change Data
Job Change Data
CloseNew Job Upload
Product C
Glass Density
ProductionWeight
StandardWeight
Product
Product Data
206.0
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Job Change Database
StandardWeight
ProductionWeight
GlassDensity
CloseUploadDeleteModify
Database
Product List
Product AProduct BProduct CProduct DProduct EProduct FProduct GProduct HProduct IProduct JProduct KProduct LProduct M
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SummarySummary
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3D WireFrame Image
Trend Graph
Compact Housing Unit Control Panel
GMW System
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Summary
1. The GMW system helps contribute to stable production and improve quality.
•Fully Automatic System No need for periodic weight sampling for calibration. This means more time for defects correction
•Stable gob weight control Applicable for BB, PB, NNPB process
Weight variation R of below 1% of control weight
•Job change repeatability Gob images and other numerical parameters helps facilitates job change setup
•Better gob loading & delivery Continuous monitoring of gob length, fall angle & drop consistency for early identification of loading & delivery problems
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Summary
2. Repeatable gob shape & weight, stable gob weight are important factors in achieving light weighting and non-swabbing technology.3. By linking the gob image data with servo-driven mechanism, automatic gob forming is possible.