managing the glass manufacturing process · hardware • 1800 gb ram • 40,2 tb hard disk • 2...
TRANSCRIPT
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Fabio Galliano – Technical Director
Managing the glass manufacturing process
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Outline
• The Digital Era and Industry 4.0
• Bottero strategic vision
• Pillars from the last decade
• Process view close-loop controls
• Evolutionary roadmap
• Summary and conclusions
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The Digital Era and Industry 4.0
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Bottero strategic vision
• Ultimate goal: full, labor-free automation of the glass manufacturing process
• Industry 4.0 identifies a powerful and integrated view, but…
…a fully stable process operation is the key to achieve the goal
• Bottero has a deep and consolidated process knowledge to pursue this objective
• BoX is the first and unique system on the market, conceived and developed to support this vision
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FROM
EQUIPMENT
SUPPLIERS...
...TO PROCESS
ORIENTED
PARTNERS
Bottero Strategic Vision
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Bottero Strategic Vision
Move from equipment supplier to solution
provider partnering with the Customers
• Enhance Bottero offer portfolio with new added value products and novel solutions
• Enrich the value proposition including more and more professional services
• Move from an ecosystem of automation products to a fully integrated automation
platform
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Strategic pillars for the last decade
2.Expertise and competence on the forming process
1.Modelling and Simulation tools and techniques
3.Full control of the production chain through Industrial Automation
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Strategic pillars for the last decade
2.Expertise and competence on the forming process
1.Modelling and Simulation tools and techniques
3.Full control of the production chain through Industrial Automation
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• 496 CPU fully dedicated
HARDWARE
• 1800 GB RAM
• 40,2 TB Hard Disk
• 2 high-duty quadri-processor servers, with 16-core CPUs
• 5,2 teraFLOPS (computer performance indicator)
• Abaqus • Radioss • Motion Solve • Optistruct • Star CCM+ • Mode Frontier
SOFTWARE
A team from aerospace and automotive industry
HUMANWARE
• 22 calculation servers, in parallel configuration
Modelling and Simulation
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Glass viscosity vs. temperature
Forming Simulations
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Simulated Forming Process Steps
Step 1
Blank Side
Parison Forming
Step 2
Invert Mechanism
Reheating
Step 3
Blow Side
Stretching
Step 4
Blow Side
Bottle Forming
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Step 1 – Parison Forming
Bottero strategic view
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Step 2 – Reheating
Bottero strategic view
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Step 3 – Stretching
Bottero strategic view
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Step 4 – Final blow
Bottero strategic view
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Strategic pillars for the last decade
2.Expertise and competence on the forming process
1.Modelling and Simulation tools and techniques
3.Full control of the production chain through Industrial Automation
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“We believe in glass…” The forming engineering FE department has over ten years experience in granting process support in the different areas of the glass production lines. The team combines both engineers and production experts that cooperate to support our Customer in reaching the agreed production target.
Forming Engineering
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“From conceptual design through training to production…”
Service portfolio
•Cooling design •Parison and Mold Design •Support in transition from DG to TG •Support in transition from B&B to NNPB •New container design •Mold Design training •Production training •Production support •Production Support Agreement (PSA)
Forming Engineering
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Strategic pillars for the last decade
2.Expertise and competence on the forming process
1.Modelling and Simulation tools and techniques
3.Full control of the production chain through Industrial Automation
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• Full standardization of HW components, SW modules and communication interfaces
• Tier 1 close-loop controls (DFS, GWC for BB, Servo Plunger, Prop. Valves 2.0, MWM)
Wide configuration capability of special cycles
• Unique, integrated development platform putting together:
• Process view close-loop controls (BoX)
Benefits of Bottero Automation Platform
Supervisory platform with open interface toward external Plant Automation Systems
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Tier 1 close-loop controls
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Vertical &
Horizontal Plunger
Adjustment
Tube Height Control
Magnetic Position
Sensors
Weighing Station
• For both BB and NNPB productions
• Integrated THD (Tube Height Device) and PAC (Plunger Adjustment Control)
• Full stroke plunger motion tracking in NNPB • Integrated Weighing Station for BB
Dynamic Forming System (DFS)
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Servo Plunger integrated with DFS
Fully integrated with DFS to implement gob weight control functionalities without the need of position sensors
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DFS: Plunger Motion Control
Proportional valve for plunger up Plunger up motion Pressing Time
Pressing Time Set-point
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Bottero Proportional Valves 2.0
Output pressure sensors
• Complete mechanic retrofit with existing bases
• Same operator interface with control electronic
Close loop on the output pressure based on a dedicated sensor.
Response repeatability and precision of the output pressure
Response homogeneity among different valves
Better precision of the control at low pressure
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• Tool to support setup and control of productions with multiple weight articles: in principle each section may produce a different weight
• Optional plug-in of Bottero servo feeder (700 series)
• The variable gob weight is achieved regulating the plunger parameters of the servo feeder
• Capability to compensate glass accumulation phenomenon due to the return trajectory of the needles
• Commercial weight scales (e.g. Sartorius)
can be optionally integrated for automatic weight acquisition
Multi-Weight Manager
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BOX :The first and unique tool aiming to control the forming process
PROCESS VIEW CLOSE-LOOP CONTROLS
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Process View close-loop control
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Process View close-loop control
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• Automatic control and optimization of ware spacing
• Automatic control and optimization of vertical glass distribution (VGD)
BOX overview
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The BoX controls and maintains the vertical glass distribution under continuously changing operational conditions (due to the environment and to the production process):
• Feeder temperature & pull changes
• Glass conditions changes
• Temperature changes
• Blank heat transfer changes (new Blank)
• Blank swabbing
• Section stop/start
Goals of BoX VGD Control
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Evolution of the BoX concept 4.0 Technology strategies
BoX
framework
Sensors and measurements
Modelling and Simulation tools and techniques
Process knowledge
Industrial Automation
Global control of the
production process
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The roadmap
5. Machine Learning: correlate input-output of the production process and define a “predictive” e2e model to put under automatic control
4. Big Data Analysis: analyze the data to learn the optimal process behavior
1. Sensors: integrate sensors to measure critical sub-processes
2. Close-loops: control each critical sub-process to minimize drift and variations (furnace, feeder, gob forming, gob loading, parison, final blow, transport, annealing lehr, …)
3. Big data storage: connect all systems on a network and store information in a common database (Furnace, Feeder, IS-machine, Hot End sensors, Cold End inspection equipment,..)
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Measurements on containers at CE
Temperature measurements on molds, plungers, glass, neck rings
Glass temperature and gob weight measures
at feeder level
Measurements on gob loading performance
IR-D measures at HE
IoT (cloud) &
Machine Learning
Predictive Model of the
Production Process
Big Data Analysis
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Machine Learning
Training
Data
Pre-processing
•Normalization
•Scaling dimensions
•Image processing
•etc.
Learning
•Supervised
•Unsupervised
•Minimization
•etc.
Error Analysis
•Precision/recall
•Overfitting
•Test/data validation
•etc.
Model
Phase 1. Learning
Phase 2. Prediction
New
Data
Model
Prediction
Predicted
Data
Corrective
actions
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Summary & Conclusions
Bottero strategic view has been presented…
• Ultimate goal: full, labor-free automation of the glass manufacturing process
• Industry 4.0 identifies a powerful and integrated view, but…
…a fully stable process operation is the key to achieve the goal
• Bottero has a deep and consolidated process knowledge to pursue this objective
• BoX is the first and unique system on the market, conceived and developed to support this vision
• Starting from the BoX experience, Bottero has defined an evolutionary roadmap aiming at the full process automation
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Thank you
This presentation has been prepared for information purposes only and all descriptions, examples and calculations are included in this presentation for illustration purposes only.
The Company does not undertake any obligation to update or revise any statements contained in this presentation, whether as a result of new information, future events or otherwise.
Bottero © 2013. All right reserved. www.bottero.com v1.00 Eng