Agp GML246 Process Report 1 - CBG Evergem

ATTENTION CONFIDENTIAL - PROPRIETARY INFORMATION © 2024 AGP Group.
The information shared in this communication is confidential and proprietary of AGP, it´s disclosed only for This material may be used only for the purpose of business communications with companies of the AGP
conducting the business relationship between the Parties, it’s disclosed under a non-disclosure agreement and Group. In case you need to copy or distribute any part of this material to any other person, please contact AGP
it’s being subject to the limitations and restrictions described therein. to request written authorization.
GM L246 ROOF
08/04/2024 | EVERGEM
Esteban Amezcua PREPROCESS
MAKING THE WORLD CLEANER, SAFER AND MORE ENJOYABLE

Copyright 2024- AGP Worldwide Operation GmbH - Proprietary. Confidential only for internal use - disclosed under NDA.
CBG 1
2
INTRODUCTION
GM DEVELOPMENT EVOLUTION
DEVELOPMENT 3
4
TRIALS BACKGROUND
STABILIZATION OF THE PROCESS
5 CALIBRATION AND VALIDATION OF MACHINE
6 CUTTING
7 BREAKOUT
8 GRINDING
Copyright 2024- AGP Worldwide Operation GmbH - Proprietary. Confidential only for internal use - disclosed under NDA. 3
1.- INTRODUCTION
SHAPE ANALYSIS
IRREGULAR SHAPE WITH NOTCH

The complexity of the shape of the glass is high for the cutting process. There are not best
practices available in AGP group for this specific new development.
What are the characteristics of this glass?

• Notch deep: 181 mm
• Notch width: 279 mm
• Notch radios: 90
• Glass thickness: 3,1 mm
• Glass length: 1690 mm
• Glass width: 1218 mm
• Color: Clear
• No coating applied before preprocess.
2.-DEVELOPMENT EVOLUTION
TRACKING
GM L246
• The development of GM L246 started 4 months
ago.
• In the graphic, we can see the yield and production
evolution (all PP).
• Back in December 2023, we had a good first
campaign. 992 pieces, yield of 78%.
• After that, from January to March 2024 we
struggled in the process to get the same results,
even by trying to simulate same conditions that
worked at the beginning. This leaded to start a
battery of tests and research to stabilize the April 2024
process.
• Several cutting programs were made, and different
improvements were performed for 3 months.
• In March, a new CBG program was developed and
tested successfully for this project. This new
program gave us stability in the last 2 campaigns. Dec 2023
• 1st campaign : 12 of March, we got 80 % yield.
Total produced: 217 pcs. (Only CBG)
• 2nd campaign: 02 to 04 April, we got 92 % yield.
Total produced: 4300 pcs. (Only CBG)
Fig.1 Production and yield evolution
3.- TRIALS BACKGROUND
PROGRAMS
GM L246 BATTERY OF TESTS

1.- The first program made in December 2023 had a
fake notch. It gave us an acceptable result (78 % yield,
992 pcs) in the first campaign, but we couldn’t get the
same stability in the next trials. We invested time to 1 2 3
simulate the same conditions, but it didn’t work. 1 1 1
2.- In the next trials, the fake notch was split in 2 parts
trying to remove them one by one.
3.- Subsequently, the notch was split in more parts, to
reduce the glass area to be break at each time.
4.- The cutting relief was changed to different
directions and positions.
5.- Different cut lines inside the notch, combined with 4 5 6
cutting reliefs. 1 1 1
6.- The deep and shape of the fake notch was also
changed.
This programs had a low yield and lack of stability.
The common variable is the position of the press,
always in the middle of the area of the notch or the Fig.2 Examples of trials made with a fake notch
small pieces.
PROGRAMS
GM L246 BATTERY OF TESTS

• In parallel, programs with single notch were tested.
The variables involved are:
➢ the position of the satellite
➢ the amount and position of press
➢ pneumatic pressures. 7 8 Satellite 9
Satellite
7.- Satellite is placed under the glass shape, to hold Satellite
the cut line and create the lever effect. 1 1 Press
1 Press
8.- The satellite is moved further, towards the middle Press
of the glass shape.
9.- Press was moved close to the cut line, satellite is
placed in the same position than trial #7.
• During the breakout sequence, the press was
configured to have a delay time down between 0,3
– 1,0 seconds.
A
• The press was also configured to pull out the glass,
making a short movement towards the operator
side.
Fig.3 Examples of trials made with single notch
PROGRAMS
BEST PRACTICE KNOWN TO PERFORM THE BREAKOUT

• The best practice known to make the breaking for any
regular shape (straight cut lines or small radios) is to press
press beside the cut line, while the satellite in the glass
other side of the cut line under the glass makes a
support. The location of the satellite is always away
from the press location to get a lever movement. This
movement will open the cut line.
• If the position of the satellite and the press is well
defined, and the pressure used is correct no chips belt
should appear. This theory didn't work for the notch in
the GM L246. satellite
• When we press in the middle of the notch, the lever
effect is not consistent, it doesn’t repeat. Is well
known that the cut must be good enough to facilitate
the breaking. Even tough, when the cut is well done if
the press is made in the center of the notch the lever
effect create chips in the radios or corners due an Suction cups
unbalance of the glass opening. The weakest radio will
be opened first and the ones that resists to open will Satellite position
break consequently of the high pressure used or the
delay time of the press waiting down.
Lever effect Lever effect
• Sometimes the glass won’t have chips, but they will 20-25 cm
appear with the minimum variation in the process.
That’s the reason why this breaking method is not
stable for this glass shape. Press
Fig.4 Lever effect on the notch Fig.5 The suction cups in the breakout table
4.- STABILIZATION OF THE PROCESS
NEW DEVELOPMENT
NEW PROGRAM DEVELOPMENT
• Now days, the process has been stabilized.

A new way to cut and break the glass shape has been
press
developed for Bando machine.
• The difference with the old best practice and the new
one in use is eliminating the lever effect when we Opening glass
open the glass notch, the breaking sequence and the
combination of different pressures for the press and
main cutter.
• As it showed in the image #6, no lever effect is
performed to open the glass. The press will push right satellite
in the middle of the cut line, in parallel the satellite
belt
will hold the glass from the bottom.
Fig 6 The press is located exactly in the middle of the cut line, the satellite follos the same position under the glass.
• By making sure that our cut is well performed, the

press in the breakout table will open the glass
smoothly, avoiding having chips. Press high pressure
is used around the notch, to be able to manage the
force needed. Middle pressure is used in the rest of
the press around the glass to avoid having chips due
mixing same pressures.
• A total of 10 press around the notch are used.
Fig 7 Position of the press around the notch
5.- CALIBRATION AND VALIDATION OF MACHINE
CENTERING
TV – 50 TV – 50
BA – 48 BA – 47.5
CALIBRATION CENTERING SYSTEM AA – 50.5 AA – 50.5
Rear Side
To ensure the position of the glass, before is
transferred to the cutting table a dedicated program
was created to perform the validation and calibration TV – 50
of the centering system. BA – 50 TV – 50
AA – No need to adjust BA – 50
o The max position deviation accepted is 1.0 mm. AA – No need to adjust
For Main Cutter

Glass FLow
Glass Dimension
1224x1371
TV – 50
BA – 50 TV – 50
AA – No need to adjust BA – 50
AA – No need to adjust
Front Side
TV – 50 TV – 50 TV – Target Value
BA – 52.5 BA – 53 BA – Before Adjustment
AA – 49.5 AA – 49.5 AA – After Adjustment
Fig 8 Calibration centering of the glass
CUTTING
VALIDATION OF THE CUTTING TOOL CENTERING

To validate the position of the cutting tool, we used a
dedicated program in the CBG.
o The deviation found for eccentric direction was
0,03 mm.
o The deviation found for the duplicated was 0.0 mm
Fig 9 Calibration centering of the glass
CUTTING
VALIDATION OF THE CUT LOAD

To validate the cut load applied over the glass, and
compare with the setup parameters in both CBG’s we
used the instrument U-Force 30354-0066 Flat Bottom
Force Gauge 10 x.
We elaborated a table to convert the Mpa to Kg and
Newton.
o A difference of cut load was found between CBG
left and Right side, when we use the same pressure
set up.
o 19 % less pressure was delivered in the CBG left
side, for high pressure.
o 17% less pressure was delivered in the CBG left
side, for middle pressure.
o The difference of pressure was compensated in the
machine to get the same conditions in both of
them.
Fig 10 Compressed air pressure validation
BREAKOUT
VALIDATION OF THE BREAKOUT

To validate the tension of the belt, we performed
some measurements.
Belt
o Checked the sag (must be 8mm or less) measured
gap is 8mm.
Satellite heads (Front and Rear)
o checked and adjusted the level against the small
and large table
o before 0.5mm difference
o after 0.0mm
o Cleaned the bearing rails greased the linear
bearings of the front and rear satellite disks
Fig 11. validation of the breakout elements
6.- PROCESS IMPROVEMENTS
CUTTING, BREAKING AND GRINDING
Adjustments and calibration

1.- The cutting pressure works as follows: Centering Cutting Breakout Grinding
The cutting program was made to work only with 1 pressure, this means the straight lines
and radios including the notch are being cut with the same cutting load. Fig.1 The shaping of the glass is made in 4 steps in the Bando machine
For Evergem Bando machine, 0,26 +/- 0,01 Mpa are used.
It was discovered when we increase the cutting load pressure, the cut is not efficient and
is hard to remove the notch.
2.- For the breakout, we used 2 different press loads:
- High for the notch of 0,30 +/- 0,02 Mpa
- -Middle for the rest of the press: 0,25 +/- 0,01 Mpa
The cutting table must be clean and free of any contamination.
3.- For the grinding, its important to align correctly the level of the wheel against the glass
and the dressing stone to avoid microchips. The FANUC speed is 30% giving us a cycle
time of 42 sec.
Entry point
Fig.12 Wings cut line Fig.13 Cutting path
LET’S CREATE
THE FUTURE OF
MOBILITY, TOGETHER
ATTENTION CONFIDENTIAL - PROPRIETARY INFORMATION © 2024 AGP Group.
The information shared in this communication is confidential and proprietary of AGP, it´s disclosed only for This material may be used only for the purpose of business communications with companies of the AGP
conducting the business relationship between the Parties, it’s disclosed under a non-disclosure agreement and Group. In case you need to copy or distribute any part of this material to any other person, please contact AGP
it’s being subject to the limitations and restrictions described therein. to request written authorization.

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ATTENTION CONFIDENTIAL - PROPRIETARY INFORMATION © 2024 AGP Group.

MAKING THE WORLD CLEANER, SAFER AND MORE ENJOYABLE

STABILIZATION OF THE PROCESS

5 CALIBRATION AND VALIDATION OF MACHINE

IRREGULAR SHAPE WITH NOTCH

What are the characteristics of this glass?

Fig.1 Production and yield evolution

GM L246 BATTERY OF TESTS

GM L246 BATTERY OF TESTS

Fig.3 Examples of trials made with single notch

BEST PRACTICE KNOWN TO PERFORM THE BREAKOUT

NEW PROGRAM DEVELOPMENT

• Now days, the process has been stabilized.

• By making sure that our cut is well performed, the

Fig 7 Position of the press around the notch

For Main Cutter

VALIDATION OF THE CUTTING TOOL CENTERING

Fig 9 Calibration centering of the glass

VALIDATION OF THE CUT LOAD

Fig 10 Compressed air pressure validation

VALIDATION OF THE BREAKOUT

Fig 11. validation of the breakout elements

Adjustments and calibration

Fig.12 Wings cut line Fig.13 Cutting path

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