Get Thermoforming out of the Black Box.

Transcription

1 Get Thermoforming out of the Black Box

2 Horst R. Dänzer Dipl.-Kfm., Ing. (grad.) Consultant MANAGEMENT & TECHN. SERVICE Thermoforming is till now like a Black Box v Thermoforming is an open process v Machine, Tool, Plug, Sheet and Marketprice! causes particular settings they are depentend! v for proper setting a TF-System, you need good Informations, Knowledges and a good Intuition to get good and exact the same products as last time v A lot of disturbances may have an effect on thermoforming v Wrong settings occur due to Disturbances or due to insufficient notations or Intuition v You will find the varying result in the cardboard box v And You have to control the output very careful 2

3 Horst R. Dänzer Dipl.-Kfm., Ing. (grad.) Consultant MANAGEMENT & TECHN. SERVICE So far v the insufficient recording of process data is (was) one of the the great disadvantages of thermoforming. v The product quality was adjusted by the production department, dependent on the process parameters, which mostly are based on the technician s intuition and experience and disturbances leads to varying product Quality 3

4 Horst R. Dänzer Dipl.-Kfm., Ing. (grad.) Consultant MANAGEMENT & TECHN. SERVICE Conclusion v It is a really Sisiphus-Work to control millions of products v Better you try to control the process as the injectionmoulder do since a long time! v It is also a Sisiphus-Work to capture the process data and analyse the dependent relationships v First of all you need a tool to monitor and record the data (process and product data) which will able you to look into the running process 4

5 Horst R. Dänzer Dipl.-Kfm., Ing. (grad.) Consultant MANAGEMENT & TECHN. SERVICE Which Tool will help you get Thermoforming out of the Black Box v As a grey Thermoformer and Consultant, now I will give you an idea how you can look into the Black Box by using Tool Vision, can understand and control the TF-process. v The new system Tool Vision enables the production department to visualize the status of the production process at any stage, to document it and to control it real time. v You will find the better results in the cardboard box v Because you control the process, you can reduce controlling the output and increase your profit! 5

6 v An Innovative built-in data logging system for your thermoforming tools v v For Real time Recording, Analyzing and Controlling of process data during Thermoforming Suitable for any thermoforming machinery - Thin and Heavy Gage - 6

7 vnow you have to make a decision: v Make v or Outsource You should compare your development-time and - cost with the price for the readymade and customizable high sophisticated system Tool Vision! which documents the data and makes sure that you don`t lose data when power is shut down 7

8 Capturing Integration Visualization The process data are recorded by specially designed sensors close to the process within the tool Air pressure, forming air, clamp air und vacuum Plug position, Clamp position Tool strain gauge Tool temperatures In the machine: Infrared measurement of the sheet temperature, if you want: Sheet thickness 8

9 Capturing Integration Visualization Suitable for any thermoforming machinery Recording, Analyzing Controlling Quality assurance Visiualization A specifically adjusted sensor package will be installed in each Tool (Thin Gage) or in the Machine (Heavy Gage). LAN TCP/IP Network Integration retrofittable for new and existing Tools Tool Vision Box Actual data will be recorded online and evaluated in real time It will enable a visualization of all essential parameters and show meaningful the running thermoform process in total. and they will be documented, 9

10 Process Visualization v A simple and clear arranged graphic shows all important or selected data at one sight 10

11 Monitoring process v Detail windows can be used easily to compare the actual process graph with previously established target areas 2- dim. target areas called high quality windows or (hot spot) v Leaving the set tolerances can lead immediately to an adequate reaction, i.e. starting from sending out an alarm till rejecting the effected items. 11

12 Process Graphs Appreciation for the thermoforming process Strain gage Process normal Forming air vacuum 12

13 Process Graphs Appreciation for the thermoforming process Process Inline caused by linkage extruder and thermoformer: from time to time are steps required to adjust the feed or the cycletime 13

14 Quality assurance Example graphs Process vacuum control Previously established target area (Hot spot) vacuum normal 14

15 Quality assurance Example graphs Process vacuum control vacuum collapses because of a puncture in the product à reject! 15

16 Quality assurance Example graphs Strain gage Strain gage normal 16

17 Quality assurance Example graphs Strain gage with target area and control Strain gage increases because of double product 17

18 Advantages for production v Increase of the production efficiency v Reduction of scrap up to 50 % v All important process data available v More product steadiness through reference data v Appreciation for the forming process v Protection of machines and tools by threshold monitoring 18

19 Advantages for Quality assurance v Visualization of the productions process and continuous process control. v Separation of defect items v Documentation of the process v Documentation of production run 19

20 Causal Research example Graphs Fast anasysis thanks to expressive graphs ---- plug ---- forming air Forming air is activated at the same time as the the plug starts Forming air collapsed while moulding Preset Forming pressure is not reached 20

21 Advantages for Process Developement v Analysis of the actual situation v Basic knowledge about the forming process v Creating of basic data for tools and products v Identifying of problems v Problems give you the initial point for Developing new tools without weak points 21

22 Advantages for Maintenance v Creating of basic data for tools and products v Track the condition and maintenance history of a tool and a machine v This allows you to plan the maintenance interrupts for minimum costs and makes sure, that the thermoforming-system is proper working during the other time 22

23 What was the speakers mission last days? Save Energy, save Material, have better products By Invest in a System like Tool Vision, you will get this and in addition the understanding of your TF processes no waste in the cardboard boxes and automatically the documentation of the Production Datas, which will keep your customer with you. Tool Vision leads to an thermoforming evolution you save money - and you can even use it for BDE-purposes (Production Data capturing ) 23

24 Final Word v The mechanical drillings needed for the installation/fixing of the sensors should be allocated when you purchase a new tools. v The new thermoforming machine you will buy in the future, should have Tool Vision as Standard Feature v otherwise an electronic standard interface, similar to EUROMAP 12 technical Recommendation for Electrical interface between molding machine and handling device (2009) to increase the advantage of systems like Tool Vision for Process-Controlling 24

25 Contact to Tool Vision Peter Schöberl Schöberl Messtechnik Adelmannstr. 17 D Zusmarshausen Germany Tel.: +49 (0) 8291 / Fax: +49 (0) 8291 / info@toolvision.de 25

26 Horst R. Dänzer Dipl.-Kfm., Ing. (grad.) Consultant MANAGEMENT & TECHN. SERVICE Get Thermoforming out of the Black Box enough illustrated? Are you convinced of the technique and the benefit of Tool Vision? Questions? Peter later is waiting for you at his exhibition table 26

27 Thank you for your Attention Horst R. Dänzer 27