CAP30 Flex

Introduction to Positioning Device

September 2009
 Introduction to Positioning Device

CAP30 flex is equipped with a positioning system.

Its purpose is to improve the cap position accuracy by
moving every cap to match the Pre-Laminated-Hole
position.
Positioning device by using a camera detects the Pre-
Laminated-Hole onto the packages and adapt the cap
position in reference to it.
 Introduction to Positioning Device

Applicator Unit (Y Trigger

Adjustment)

X
Vision
Adjustment
System
 Introduction to Positioning Device
Hole positioning capturing

TRIGGER CAMERA IMAGE

ANALYSIS
X
PLH
centre X Deviation

0 Y

Camera
Y Deviation centre
0
Command the vision system,
without using the machine PLC, Capture the hole image. PLH position
to provide a fast signal. deviation.
 Introduction to Positioning Device

X adjustment

The servomotor (2), move the cams group (3). One of that cams act on the cap
holder roller (4) moving the cap in X direction.
Introduction to Positioning Device

Y adjustment

Y = ±3 [mm]

Changing the Phase of the Applicator Unit servomotor (1), it is possible

change the Y position of the cap holder.
 Introduction to Positioning Device

Importance of positioning device

During production the package forming change (PLH is moving)
and the PS correct the Cap Position

Xbar-S Chart of Y
1 1 1
2.0 1 1 1 1111 11 111 11
1
1
1 11 1111 11
1
1 111 11 1 1 11111111 1 1 1
11 1 1
1 1 1 1 1 1 1
1 1 1 1 1 111 1 111
U C L=1.646
Sample M ean

1.5
_
_
X=1.267

1.0
LC L=0.888
1 1 1 1 1 1 11
1 1 1 11 11 11
11 1 11
1111 1 1111 11111111 1 11 1
111 11 1
1 1 1 1
1 1
0.5 1111 1
1 54 107 160 213 266 319 372 425 478 531
Sample

0.8 1
1
1
U C L=0.6855
Sample StDev

0.6

_
0.4 S =0.4084

0.2
LC L=0.1312
1 54 107 160 213 266 319 372 425 478 531
Sample

So, if the PS is switched Off the Cap should still be placed on

PLH, but with lower accuracy
 Positioning system settings
See CAP30 MM, Chapter 12.1.10 (General Offset) & 1
12.1.11 (Setting machine using vision system) & 12.1.12
(Cap offset)

The setting flowchart

2
“Normal settings”
• Positioning system Off
• Cap Applicator have to be set as a standard machine
• Package with the PLH according template (1)
• Package Positioner set to have Cap placed correctly (2)

Position System Settings 3

4
• Positioning System ON
• All offset set to 0
• Package with the PLH according template (1)
• Set General Offset (3)
• Set Single Cap Holder Offset (4)
 Positioning system settings
The Trace page gives the
indication about performance

When the packages are

fed to package line the
±3Y ±2X 0 camera is triggered.
If the PLH is detected
the light is green.
If not, is red

This is the main input for

the troubleshooting;
If the hole is detected out during the production, it
of this range the blue
alarm appear
should be checked
periodically
 Positioning device troubleshooting

This led should become red for an

The illuminator when active emit instant at every virtual axis
a red light, it is on only in revolution (at 288°). When the led
production or when the specific become red the camera has
function on the HMI is selected. received the trigger
Picture below shows the effect
of the dirtiness on the
illuminator: the light is not Removing the cover the lens
constant because of obscurity. protection is accessible, it should
be checked for dirtiness. Picture
Troubleshooting for technician below shows an example of
dirtiness on the camera protection
Troubleshooting
If machine stop for too many waste packages or start
ejecting packages from the waste device

In case the ejected packages are without caps applied check:

 The machine for cleaning (glue residues may create caps lost)
 The cap holders are working properly (cap holder springs)
In case the ejected packages are with caps applied check:
 The positioning device trend: the led is always green, the trend
works always across to zero and the correction is always less
than +/-3mm in Y and less than +/-2mm in X direction.
 The waste device setting (see MM. 11.1.1-2)
If Machine shows positioning device alarms

In case of Yellow alarms check:

 The positioning device trend: the led is always green
If the led is red the analysis failed, in this case check:
 The illuminator is working and the light is constant (see next slide)
 The camera lens cover is clean (see next slide)
 The camera receive the trigger for every package (see next slide) and in
case of problems see MM 12.1.6.

 Connect the laptop and make an offline analysis (MM 12.1.8)

In case of blue alarms check:
 The trend works always across to zero and the correction is always
less than +/-3mm in Y and less than +/-2mm in X direction.