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SM-VIDMON1i(e) Glue Detection Systems for the Corrugated Box Industry. 7950 CASTLEWAY DR. INDIANAPOLIS, IN 46250 317-577-3000 www.frakesengineering.com Contact Dan Turner x 245 or Jim Frakes x 224. EXCLUSIVE U.S. AGENTS FOR. Smofad Control Systems (Aust) Pty Ltd
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SM-VIDMON1i(e) Glue Detection Systems for the Corrugated Box Industry 7950 CASTLEWAY DR. INDIANAPOLIS, IN 46250 317-577-3000 www.frakesengineering.com Contact Dan Turner x 245 or Jim Frakes x 224 EXCLUSIVEU.S. AGENTSFOR • Smofad Control Systems (Aust) Pty Ltd • Phone: Murray 0417384680 or John 0409421175 • e-mail: mdicker@smofad.com.au • e-mail: jwain@smofad.com.au • Copyright 1996-2002 • Australian and International Patents Pending
Recommending a strategy A monitoring system that gives you total quality assurance. 100% inspection of all outgoing production. “State of the Art” video and micro processor technology ensuring reliability and long term life. 1
Vision statement • Our vision is to provide our customer with a high quality inspection system that gives them a competitive edge. • To offer a service and support network that compares to none. • “Sensing your solutions” is not just a catch phrase it is a promise. 2
Goal and objectives • To achieve zero defect on all outgoing products. • To satisfy our customers and to assist in their Total Quality Assurance, with top quality products and services. • To provide historical logging, allowing efficient diagnosis of reoccurring faults in the manufacturing process. • Flexibility with configurations & software to meet customer needs. 3
Today’s environment • Today, market leaders require total quality management solutions. • It’s a cut throat market, businesses are looking for a competitive edge. • Smofad Glue Monitoring Systems are one way of achieving that goal. 4
How did we get here? • Smofad Control Systems was formed in July 1997 by Murray Dicker and John Wain. • Smofad has proven over the years that all of their products are reliable and innovative. • Smofad products are second to none. • Smofads systems Actually WORK ! 5
Available options on Glue Monitoring Systems • Dual cameras can be fitted for internal and external gluing applications. • Spray system can be fitted to identify individual reject product. • Remote monitoring of PLC programs and camera images. • Backup service and support. 6
Special Features • Automatic box recognition • History and error logging • Diagnostics, password protected • Active alarm monitoring • Configurable customer preset • Detection of skewed cartons • Start and stop positions of glue lines • Thickness of glue lines • Tab detection 7
The Process • The box is fed through by the operator. 8
The Process • The Automatic Box Recognition system or (ABR) scans the box. To acquire first box data. 9
The Process • The ABR displays the box layout and all relevant dimensions. 10
The Process • The operator now ACCEPTS or REJECTS the job. 11
Customer Glue Line Positioning Specification A. The glue MUST START 10mm after the START of the glue flap. B. The glue MUST FINISH 10mm before the END of the glue flap. C. The OUTSIDE glue line MUST be 10mm from the edge of the box. 12
Production history and error logging Current production run data is displayed, discriminating to sub levels of rejection. 13
Failed Internal Camera Images, showing defective products.Initiating Alarms and Feeder stops. 14
Internal Camera Image 1 Example of Cardboard Slot stuck in glue headThe following images are actual and were taken at high speed Inspection Result = Fail 15
Internal Camera Image 2 Failure of glue width at high speed Inspection Result = Fail 16
Internal Camera Image 3 Glue blobs at head causing glue lines to continue on afterglue solenoid had turned off Inspection Result = Fail 17
Internal Camera Image 4 Skewing of box Inspection Result = Fail 18
Internal Camera Image 5 No Glue Inspection Result = Fail It can be seen in the adjacent image, that NO Glue has been applied to the box. The graph below indicates that the camera has reported this condition back to the PLC which in this case, (consec rejects set to 3) initiated a feeder stop and alarm. 19
External Camera Images. Showing quality acceptable products. 20
External Camera Image 1 The following image shows correct placement of glue lines in relation to the leading edge. All gluing parameters passed. Inspection Result = Pass 21
External Camera Image 2 The following image shows correct placement of glue lines in relation to the trailing edge. All gluing parameters passed. Inspection Result = Pass 22
Configurable customer presets Customer specs can be accessed and changed at any time. 23
Diagnostics with password protection Setup, customer parameters, and diagnostics are available via a security coded password. 24
Active alarm visual display Active alarms are displayed automatically, identifying the alarm for the operator, this is accompanied by a audible siren. 25
Onsite Communications The latest visit has introduced remote communications with the Internal Gluing Inspection Camera. Interim software has been loaded onto key personnel’s PC’s which allow them to access LIVE images over the Amcor network via Ethernet communications. This function has been very well received, and shows the flexibility and connectivity of the system. Presently, only one person can view images at a time, but this will change shortly to allow multiple people to access images simultaneously. If required a database could be created to store all images as a quality assurance record keeping tool. 28
Onsite Communications • The operator can view live images at their station via a PC monitor accessed from the network. • Customer Key Personal can access live images from anywhere on the customers network. 29
Remote Communications • SMOFAD has successfully accessed live images via remote communications between Melbourne, Australia and Auckland, New Zealand. • Now includes global access. • This provides low cost backup service and support. • Allows quick and effective diagnosis of problems and upgrades. 30
Conclusions This state of the art technology has certainly proved its worth, and will evolve further in time. It is a credit to Amcor in its commitment to improve their processes and quality with the use of innovative and technologically advanced systems. The benefits of such are already being realised, with the potential to increase and deliver quality products to its customers. Murray Dicker & John Wain Smofad Control Systems Copyright 1996-2003 Australian and International Patents Pending 31
Murray Dicker74 - 76 Charles RoadLilydale, VictoriaAustralia, 3140 Ph. 0417384680 Ph (61) 417384680 www.smofad.com.au mdicker@smofad.com.au John Wain34 Wimmera Crescent Keilor Downs, Victoria Australia, 3038 Ph. 0409421175 Ph. (61) 409421175 www.smofad.com.au jwain@smofad.com.au Proudly Australian Copyright 1996-2004 Australian and International Patents Pending 7950 CASTLEWAY DR. INDIANAPOLIS, IN 46250 317-577-3000 www.frakesengineering.com Contact Dan Turner x 245 or Jim Frakes x 224 EXCLUSIVE U.S. AGENTS 32