Krones HS Contiroll Training Manual Page 1 of 55

Transcription

Krones HS Contiroll Training Manual
Page 1 of 55
Course Agenda
Introduction to Krones HS Contiroll
Safety
Describe warning indictors
Overview of parts
Starting Up the Krones HS Contiroll
Operating Krones Contiroll
Touch screen
Demonstrate creating a label with the Contiroll
Create a quality label
Define short term production interruptions
Changing over
Cutting labels
Cleaning
Page 2 of 55
Page 3 of 55
Safety
Safety Labels
 When operating the Krones HS Contiroll Labeler it is important to follow the safety
guidelines.
 Make sure to follow all the warning and labeled guidelines for solvents and chemicals.
 Pay attention to the following warning labels on the machine.
Burn Hazard
Pinch Point – Moving Parts
Electrical Shock Hazard
Page 4 of 55
Safety Devices
Human Machine interface
Emergency Stop
Emergency Stop Switch
Emergency Stop
Switch
Describe a situation in which you might have to use the emergency safety stops.
Page 5 of 55
Machine Doors
Safety Switch on
Main Door.
Cutting Unit Guard Door
Do not reach into the cutting guard doors while the machine is being jogged.
Safety Switch on
the Cutting Guard
Door.
Notes
Page 6 of 55
Control Cabinet Doors
If there is a malfunction call an electrician. Do not proceed to turn on the machine.
The control cabinet doors and
machine guards must all be closed.
Hot Melt Unit
Be sure to wear protective gloves and glasses when working on hot parts.
The guards must be installed
on the hot melt unit before
production.
Notes
Page 7 of 55
Starting Up the Krones HS Contiroll Labeler
Starting up
a. Set the main switch to the ON position
b. The data screen is displayed after 2 minutes
c. The heaters take 20 minutes to reach the desired temperature.
Turn the main
switch to the ON
Position.
Checking the Air Pressure
Verify the main air
pressure is within
range (approx. 6
bar).
Notes
Page 8 of 55
Logging onto the Machine
Be sure to log off to the machine after you are done.
Use the green
transponder to log
onto the machine.
Machine Mode
Turn the key horizontally
to enter the set-up
mode.
Type Selection
Make sure the type in
dark blue is correct.
Notes
Lamp Test
Page 9 of 55
Ver. 6.20 - MMA, Functions,
Aux. Functions, Lamp Test
Ver. 6.22 – Krones,
Functions, General, Lamp
Test
Handling Parts
Pay attention to the marks and refer to the Krones handling parts overview
Machine Head
Ver. 6.22 - Krones, Functions,
General, Lamp Test
Check the supporting column
to make sure the machine
head is at the correct height.
Checking Mechanical settings
a. Make sure you use the correct
graphics
as well as UPC codes.
Ver.labels.
6.22 -Verify
Krones,
Functions,
b. Clean the cutter drum, vacuum-assisted ripper cylinder, sensors and reflectors. These
General, Lamp Test
parts should be cleaned regularly.
Explore the labeler on the plant floor, walk through the various mechanical settings and preform
a lamp test. Describe the results of the lamp test, and list any questions from the walk through
below.
Page 10 of 55
Rotary cutter
Check the compressed air pressure of the cutter clamping bars once per shift (when
applicable.
Connect the compressed air
gun to the valve and inflate
the pressure pad. (Min. of 5
bars required)
Do not release the compressed air gun General,
valve unless
you
have removed the gun from the valve.
Lamp
Test
Notes
Page 11 of 55
Guidance of Label Film
Check if the deflection rollers run smoothly and the label film has been threaded correctly using
numbers and the threading diagram.
Safety
a. Make sure all the guard doors are closed and there is no one in the danger zone
b. Make sure the emergency stop switch is activated.
Label Position
Check the height of the reel
holders and the ultrasonic sensor
Register Mark Sensor
Setting the Cut- off Position
Check the supporting column
to make sure the machine
head is at the correct height.
General, Lamp Test
Page 12 of 55
Check the container passage
a. Pay special attention to the transfer points between infeed worm, infeed, starwheel,
carrousel, and discharge starwheel.
b. Check the cutting of the label, the transfer points, and the gluing of the leading/trailing
edge of the labels.
Release the container stop
and jog a few containers into
the machine.
General, Lamp Test
Make sure the container stop
locked.
Press JOG and hold it.
Switching to Automatic Mode
a. Close the guard doors
b. Reset the malfunction warnings
General, Lamp Test
General, Lamp Test
Use the key switch to set the
machine to automatic mode
(vertical key position).
Select AUTO mode.
General, Lamp Test
Ver. 6.22 - Krones,
Functions,
General, Lamp Test
Page 13 of 55
During Production


Pay attention to any warnings on the touch screen .
To navigate to the alarms go to Krones – Messages – Active Alarms
Touch Screen Warning Indicators
Notes from
the touch
screen

Warning
Malfunction
warnings
STOP the
machine
immediately.
If there are several alarms you might have to call up the list or refer to the help menu
(top right of the touch screen)
Gluing Unit
Regularly check the quantity of
glue in the reservoir and refill to
recommended level when
needed.

Do not refill the glue too much at once, or otherwise the temperature will drop.
Containers
 Check the conveyors for container
s which
haveTest
been fallen over.
General,
Lamp
 Make sure the containers enter the machine smoothly.
Page 14 of 55
Quality of Labeling
Regularly check the quality of labeling. Pay special attention to:





The correct label position.
Gluing and glue pattern on the label.
Dimension tolerance of the containers.
Clean and dry containers.
Cut-off point deviation and cut quality.
Machine Assemblies
1. Infeed
2. Reel holder and
splicing unit
3. Labeling station with cutting
unit and
vacuum-grip cylinder
4. Gluing unit
5. Machine head and carrousel
6. Machine table with base
7. Screen
Name each of the components above
1
2
3
4
5
6
7
Label Passage Overview
Container passage / back-up switches (infeed / discharge)
Page 15 of 55
Page 16 of 55
Back-up switches at the infeed (E1, E2, E3) and discharge (A1, A2, A3) of the machine detect
the flow of containers. They regulate the machine speed and stop the infeed worm if necessary.
There is also a so-called speed control system where a central computer controls the speed of
the complete line.
The "infeed monitoring" sensor checks the container flow at the infeed of the machine. It
monitors whether the containers enter the machine in an upright position or whether they
have fallen over.
Notes
Notes
Page 17 of 55
Page 18 of 55
Labeling
Quality of the label
 Regularly check the quality of labeling. To do so, remove containers from the discharge
conveyor. Make sure to pay attention to:
 Correct label position
 Amount of glue and glue pattern on the label
 Dimension tolerance of the containers
 Clean and dry containers
 Cut-of point deviation and cut quality
Container passage / labeling station
The cut and glued label is transferred to the container passing by.
The label transfer accuracy is essential for quality.
The container plates must rotate to ensure that the container picks up the label
correctly from the vacuum-grip cylinder.
The container plates are turned by a servomotor using a toothed belt.
Page 19 of 55
Describe the purpose of each machine part listed below
Servomotor
Label film guider
Gluing unit
Vacuum-grip cylinder
Feed roller
Cutting unit
Label carrier film
buffer
Reel holder
Splicing unit
Page 20 of 55
Page 21 of 55
Label passage / reel holder
The label film is unwound using a servomotor. The machine controller determines how much
label film is required.
Sensors have been installed for
detecting the reel diameter
and the end of the reel.
Label passage / splicing unit
The splicing unit is used for the exact transfer of the new label reel to the empty reel.
The leading end of the label film is threaded manually in the device, held with vacuum and
taped down with double-sided adhesive tape.
Page 22 of 55
Label passage / reel change-over
The machine continues operation while the reel is being changed. The splicing unit cuts off the
label film of the used reel and bonds it automatically to the new reel.
Notes
Page 23 of 55
Change-Over and Set Up
This chapter describes the type change-over for types that has already been set up and tested
successfully. The change-over of the container type and label is described here. It is important
that a specified sequence be followed:
1. Preparation
2. Type change-over on the touch screen
3. Changing over and setting the main machine (MMA)
4. Changing over and setting the labeling stations (LS1/LS2)
5. Testing the container passage
Preparation
 Read your production documents thoroughly so that you know for certain which type
you wish to produce.
 Obtain the correct labels and prepare some containers in the infeed.
 Obtain all the handling parts that are required for the new type and place parts on the
machine. Check this identification to ensure that you are using the correct parts.
Change-over on the Touch-screen
 On the touch screen, navigate to Krones – Type Management – Type Parameters (some
parameters may require a higher level access).
Select “Type
Management” from the
drop down menu.
Ver. 6.22 - Krones,
Functions,
General, Lamp Test
Accept the type
Ver. 6.22 - Krones,
Functions,
General, Lamp Test
Page 24 of 55
Confirm the type change.
Setting the machine
 When changing over and setting the machine it is important to lock out/tab out to
prevent it from being turned on unintentionally.
Machine Mode
Ver. 6.22 - Krones,
Functions,
General, Lamp Test
Use the key to switch the
machine to the set-up mode
(horizontal key position).
Height Adjustment System, Machine Head
 On the touch screen, navigate
to -MMA-Functions-General
height adjustment. The
Ver. 6.22
Krones, Functions,
machine head needs to be at the topmost position.
General, Lamp Test
Page 25 of 55
Bottle Present Sensor
Loosen the clamping lever and
swing the bottle present sensor
to the side prior to the changeover.

Guide Rails
Change the infeed and discharge
guide rails. Pay attention to the
Ver.numbers
6.22 - Krones,
item
when Functions,
changing
the parts.
General, Lamp Test
Notes
General, Lamp Test
Page 26 of 55
Changing the Stop Starwheel
Lift off the knob of the
supporting bolt and pull down
the knob of the vacuum cylinder,
then remove the stop starwheel.
Infeed Worm
AfterLamp
you remove
General,
Test the clamping lever
you can pull the worm out of the drive
shaft.
Open the clamp and swing out the
housing.
Infeed Worm Lubrication
 Infeed worms can easily jam; make sure that they are in a horizontal position during
assembly and disassembly.
Before fitting the drive shaft, lubricate
it sufficiently.
Page 27 of 55
Adjusting the Infeed Guide on the Infeed Worm
Turn the rotatable stop adjustment
system below the infeed worm to the
required position.
Then turn
the star
gripTest
at the front side
General,
Lamp
until the required position is reached
(the bolt head is used as a stop).
General, Lamp Test
Guide Flap
Pull out the bolt and remove the
flap. Make sure the bolt is not
jammed, the flap is guided by a
bolt head.
Infeed/Discharge Starwheels
General, Lamp Test
Swing the sensor back to the
stop (to production position) and
retighten the clamping lever.
Page 28 of 55
How to Use the Bottle Present Sensor
Swing the sensor back to the
stop (to production position) and
retighten the clamping lever.
Container Plates
 Make sure the container plates are properly
engaged.
General,
Lamp Test
To change the container plate,
press the lever of the clip and
then lift off the plate.
Centering Bells
General,
Lamp
Test
 Lubricate the centering bolt before
fitting
the bell.
Press the lever on the clip, pull
down and then remove the bell.
General, Lamp Test
Page 29 of 55
Rolling-on Unit
Change the parts of the rollingon unit using an open-end
wrench.
Height Adjustment system and Machine Head
General, Lamp Test
Move the machine head
to the correct height on
this supporting column.
Ver. 6.22 - Krones,
Functions,
General, Lamp Test
The exact height of the
machine head is reached
if the clearance is
between 8 - 12 mm.
Ver. 6.22 - Krones,
Use a containerFunctions,
to check
the exact height.
General, Lamp Test
Page 30 of 55
Changing-over and adjusting the LSx Labeling Station
Setting the labeling station
Retract the labeling station using
the hand wheel.
Changing the Vacuum-assisted Gripper Cylinder
Ver.
6.22
- Krones,
Functions,
 The vacuum-assisted gripper cylinder
must
rest
properly
on the vacuum disk.
General, Lamp Test
Lift the vacuum assisted gripper cylinder
off the polygon shaft. Pay attention to
the zero reference point mark when
setting down the vacuum-assisted gripper
cylinder.
Mechanical Adjustments
The mechanical adjustments have been
stored as a “note” in the touch screen.
The control system does not use these
Ver.
6.22i.- e.
Krones,
Functions,
values,
they only
serve as a
information for the operator and must
General, Lamp Test
be adjusted manually on the machine.
General, Lamp Test
Page 31 of 55


Release the clamping lever and set
the sensor to the specified scale
value.
Retighten the clamping lever.
Inclination, Labeling Station
Set both registers (value A) to the
specified value using an open-end
wrench.
Loosen the lock screws on both sides of
the labeling station.
Height Adjustment System, Labeling Station
The labeling station can be raised or
lowered using the push buttons.
Set the register (value B) to the specified
value.
Label Web Guide
Loosen the lock screw, set the ultrasonic
sensor to the specified scale value (value
C), and retighten the lock screw.
Page 32 of 55
Labeling station, forward/backward
Actuate the register (value D)
using the hand wheel and adjust
the labeling station to the
specified value.
Reel Holder
Release the clamping lever;
reelFunctions,
holders to the
Ver.adjust
6.22 -both
Krones,
specified value. Retighten the
General, Lamp Test
clamping lever.
Vacuum-assisted gripper cylinder
 If the pressure on the vacuum-assisted gripper cylinder is too low follow the instructions
below.
General, Lamp Test
Check the value on the vacuum
pressure gauge.
General,
Lampadjust
Test the specified
If necessary,
value using the lever of the
valve.
Page 33 of 55
Pressure in the Cutter Drum too Low
Check the value on the vacuum
pressure gauge (this value is
always lower than that on the
vacuum-assisted gripper cylinder
for label transfer). If necessary
adjust the specified value using
the lever of the valve.
Blowing Pressure on the Cutter Drum
Adjust the pneumatic valve to
the specified value using the
scale.
Adjusting the Label Height
 Check the correct label position on the vacuum-assisted gripper cylinder
The label must protrude
approximately 2 mm beyond the
vacuum bar.
Notes
Page 34 of 55
Manual Feed
 Switch the machine to the set-up mode using the key switch
Switch the feed roller to manual
operation and feed some labels
in the jog mode.
The arrow indicates the current
position of the sensor light on
the label. Jog the small back
arrow in the LS1/LS2 graph to
the position shown.
Checking the Label Cut
 Feed and cut some labels in the set-up mode and remove them manually.
 The cutting position will move closer to the required position each time a label is cut.
Testing the Container Passage
 To test the container passages first navigate to LS1/LS2 – Functions – Main Functions.
Set the feed roller on the touch
screen to AUTO.
Page 35 of 55
Changing the Label Reels
Touch Screen Message
A message on the touch screen
will appear alerting you to
change the label film reel.
Reel Holder
General, Lamp Test
Replace the empty label film roll
(release air from holder)
Install new roll (pressurize again).
Vacuum Selector
General, Lamp Test
Use this button to unwind
sufficient label film.
Set the vacuum selector switch Ver. 6.22 - Krones, Functions,
for splicing to the label film reel.
General, Lamp Test
General, Lamp Test
Page 36 of 55
Preparing Label for Splicing Unit
Align label in clamp to ensure it
is cut in the center.
General, Lamp Test
Align label in clamp to ensure it
is cut in the center.
General, Lamp Test
Applying Adhesive Tape
Splicing tape is applied to print
side on right hand label roll (1),
and back side of left hand label
roll (2).
(Tape is applied in the center of
the label and approx. 4mm from
end)
Page 37 of 55
Setting Up the Splicing Unit
Switch vacuum to hold
label on the side that is
needed.
Position label so that is
the recommended
height and position.
Close the Splicing Unit
 Make sure that the label has not shifted
Close the splicing unit
using the flap stops.
Reactivate the Pneumatic Brake
 The brake is released automatically when the reel is changed.
Brake Release
0 = Brake blocked
1 = Brake released
Page 38 of 55
Short-Term Production Interruptions
During the course of a workday it might be necessary to turn off the labeler. Follow the
instructions for turning off the equipment for a short-term production interruption.
Lock the infeed stop and make sure the machine is emptied.
Press here to close the
infeed stop.
Turn the Machine OFF, but the heater remains ON
Press here to turn off the
machine.
After the interruptions are complete, turn the machine back on.
Press here to turn on the
machine.
Observe the first containers that run through and check their quality.
Adjust the container
stop to AUTO
Page 39 of 55
End of Production and Machine Shutdown
In order to empty the machine, adjust the infeed stop to manually open (1). After the gap
detector has responded press the RESET button on the gap detector and hole it. Then empty
machine of all container stop (2).
1
2
Container Stop
Infeed Stop


Turn the machine and conveyors OFF
Lock Out/Tag Out the machine to prevent it from being turned ON.
Turn the machine
and conveyors OFF.
Notes
Page 40 of 55
Label passage / label carrier film buffer
The label film is threaded through the rollers according to the marks (numbers and arrows).
The buffer continuously tensions the label film to prevent it from falling down.
It also ensures a sufficient supply of label film during splicing.
A sensor on the bottom side
monitors the current position.
Page 41 of 55
Label passage / label film guider
A label film guider has been provided to maintain the label carrier film in the required
horizontal position.
A sensor monitors the required
label height.
Label passage / register mark sensor
 The register mark sensor records the register marks provided.
 These signals are processed by the controller and the label length is readjusted.
Page 42 of 55
Label passage / feed roller
The calculated label length is achieved by means of a servomotor on the feed roller.
The pinch roller presses the label film against the feed roller.
Notes
Page 43 of 55
Label passage / cutting unit
 The label film is cut to the required length by the cutting unit.
 It comprises a vacuum-assisted cutter drum and a cutting rotor with separate
servomotor. An encoder for determining the exact position is provided both on the
rotor and the roller.


Notes
The label is cut when the cutter meets the cutting strip.
Labels can be cut to different lengths.
o L min. = 170 mm
o L max. = 600 mm
Page 44 of 55
Label passage / gluing unit
 The gluing unit comprises a glue bowl, a glue roller and two glue scrapers.
 A label wiper is also installed.



Notes
Hot glue is pumped from the bowl to the roller.
A glue film is provided through the gap set between the glue scrapers and the roller.
Heating elements and temperature sensors have been installed in the gluing unit.
Page 45 of 55
Label passage / vacuum-grip cylinder



Vacuum bars on the vacuum-grip cylinder take the labels from the cutter drum.
Through the contact with the glue roller, a strip of glue is applied to the leading and
trailing edge of the label.
Afterwards, the label is transferred to the container.
Sensor 2: Label must be provided
Sensor 3: Label must not be provided
Notes
Page 46 of 55
Page 47 of 55
Control elements / touch-screen
Cleaning


Clean the labeler at regular intervals to avoid problems
Use short term production interruptions for learning (e.g. lack of containers at infeed),
especially in the area of the cutting unit, glue scraper, vacuum-assisted gripper cylinder,
and on the deflection rollers
Cleaning Tools




Do NOT use any sharp edged tools,
especially in the area of the cutting
unit and the vacuum-assisted gripper
cylinder.
Do NOT use a higher pressure washer
Use only lint-free industrial cloths, a
brush, or a sponge for cleaning.
Refer to the operating manual for cleaning intervals and instructions.
Page 48 of 55
Main Machine
 To start cleaning you first want to remove all labels and other production residues that
have been left in the machine.
Sensors
Regularly clean container
present sensor and
reflector.
Regularly clean sensors 2 & 3.
Monitoring 2 = Label MUST be
provided. Monitoring 3 = Label MUST
NOT be provided.
Feed Roller
Remove debris from the
feed roller as well as the
pinch roller.
Page 49 of 55
Gluing Unit
 Remove labels that have accumulated in the gluing unit and on the glue scraper.
Vacuum-assisted gripper cylinder
 Be careful of the plastic parts
 JOG the vacuum-assisted gripper cylinder one complete revolution to ensure all have
been cleaned.
Remove debris from the
vacuum bars and the
vacuum holes.
Cutting Unit
 Dirt on the surface and in the vacuum holes impairs the cutting behavior (formation of
chips, label tears).
Regularly clean the cutter
drum and the anvils.
Notes
Page 50 of 55
Clean all vacuum holes on
the cutter drum using a drill
bit (1.5mm). Turn the drill
bit while pulling it out to
remove contaminations.
Brushing-on Unit/rolling on Unit
 Remove debris between the brushes and on the sponge roller.
If the contamination is
severe remove the parts for
cleaning.
Deflection Rollers
Remove contaminations on
the deflection rollers, on
the splicing unit, the buffer
system, and on the label
web guider.
Page 51 of 55
Cleaning Agents
 Several machine components can be seriously damaged if aggressive solvents are used.
Component
Vacuum bars, vacuum
assisted gripper
cylinder, and splicing
unit
Plant approved
solvent
Cutting Unit
Glue reservoir
Plant approved
solvent
Component
Medium
Sensors
Damp cloth
Rolling-on unit
Plant approved
solvent
Component
Medium
Door panels
Warm water, Soap
suds, Window
cleaner, Cleaning
alcohol (max. 25%)
Touch screen
Damp cloth
Cleanfix cleaning oil,
Hot clean, UV
(depending on the
glue type)
Rolling-on unit
Warm water, Cleanfix
EV 60, Cleanfix
Standard
Table area
Warm water
Medium
Identify what cleaning chemicals you have on hand at your plant, write the answers below.
Page 52 of 55
Maintenance and Possible Malfunctions
Problem: Label film Torn
If the label tears in the labeling station, this will be signaled by the sensor in the buffer system
and the machine will be stopped automatically.
What to do
After the label film has torn, the label
film must be rethreaded.
Arrows are provided on the deflection
rollers showing the precise route of
the label film.
Refer to threading diagram.
Causes of Rethread
Look for possible causes for the label film tear (label material, sluggish deflection rollers, sharp
edges, foreign bodies, etc.) and eliminate them.
Resume Production
Once you have re-threaded the label film, proceed to start the machine.
Problem: Label Lengths Outside Tolerances
If the actual label length is continuously cut larger or smaller than the permissible tolerance
(+0.5% of the required label length) the reason may be a faulty print of the label (distance
between register marks). This fault can also occur in an individual label reel.
What to do
Check the quality of the labels:



Is the register mark printed clearly?
Are they electrostatically charged?
Do they always have the same lengths?
Use a new label reel from the store and watch to see whether the fault continues to occur.
Page 53 of 55
Resume Production
Once you have checked the quality of the labels, proceed to start the machine.
Problem: Register Mark
It is possible that the machine controller loses the register mark. If 5 subsequent register marks
(standard value) are not detected, the machine will be stopped automatically…
What to do
 Check where the register mark is positioned on the label.
 Check whether the label length is outside the tolerance.
 Check whether the mark color or width changes.
 Check whether the register mark clearly stands out from the rest of the label.
Problem: Label Transfer from the Cutter Drum to the Vacuum-assisted Gripper Cylinder
Machine Mode
Use the key to switch the
machine to the set-up
mode.
Cleaning
Clean the cutter drum or the vacuum assisted gripper cylinder.
The Pressure in the Cutter Drum is too Low
Adjust the correct vacuum
in the cutter drum.
Page 54 of 55
Blowing Pressure on the Cutter Drum
Adjust the correct blowing
air pressure on the cutter
drum.
Label Pick up by the Vacuum-assisted Gripper Cylinder
Check whether the clearance
between the cutter drum and all
vacuum bars on the vacuum-assisted
gripper cylinder is 0.6mm.
Rotate the vacuum cylinder manually
to the position shown.
The rear edge of the trailing edge
vacuum bar must be shifted by 2mm
to the center of the anvil bar (label
overlap).
Call a Mechanic
If you have are still having problems with the label or the vacuum-assisted gripper cylinder call
a mechanic.
Problem: Label Transfer from the Vacuum-assisted Gripper Cylinder to the Container
Pressure Between Leading-edge Vacuum Bar and Container
Check the pressure between the leading-edge vacuum bar and the container (dimension 12mm depending on the container/product).
Call a Mechanic
Call a mechanic is you are still having problems with the vacuum assisted gripper cylinder or the
container.
Label Transfer to the Container
Jog a container into the cut-of point between the center of the polygon shaft (vacuum-assisted
gripper cylinder) and the center of the carrousel.
Page 55 of 55
The three centers (vacuum-assisted gripper cylinder – container – carrousel) must be in
alignment with each other.
To ensure a correct label transfer, the center of the leading-edge vacuum bar (flat
surface/glued label surface) must meet the center of the container.
Call a Mechanic
If you are still having problems with the label transfer to the container call a mechanic.

Krones HS Contiroll Training Manual Page 1 of 55

Transcription

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