Abstract:

• Machines for manufacturing glass containers (e.g. beverage bottles)
• Large number of servo drives – up to 140 drives are coordinated
• High throughput (up to 800 bottles per minute)
• Maximum availability – 24 hours a day, 365 days a year
• Integrated network technology using Ethernet TCP/IP
• Synchronization of the servo drives by means of Ethernet-based JetSync technology
• Synchronization of the drives in the µs range
• Repeatability of all outputs within 1 ms
• Remote maintenance

Criteria in Favor of Jetter AG:

The universal control technology with integrated drive systems and end-to-end Ethernet is used in a wide range of plant and machine engineering sectors. As a result the system grows to accommodate the requirements of the respective applications and is not only focused on one application. This was a major consideration for the company, which decided to switch over completely to Jetter control systems. From a technical viewpoint the integrated drive systems and universal networking with Ethernet-TCP/IP using internet and IT technologies are a main reason for collaboration. The customer is now able to use one single system to accomplish what was only possible with a large number of different systems with a varied assortment of software. The Jetter JetWeb permits programming of the entire control and drive system with one single program.

The customer and Jetter AG work together in close partnership. The customer, for example, runs the dedicated application and development resources of Jetter AG under its own management.

Technical Description of the Production Plant:

The production of glass bottles is much more complex than the final product would suggest. It includes the following plant sections:

• Gob forming
• Gob distribution
• Pre-forming of the containers
• Transfer
• final forming of the containers
• Transport of the bottles to the lehr for annealing
• Container inspection

Previous solutions made use of three different and very specific systems to implement the time control for the different processes and the valve blocks, servo-axes and transport. Frequently, these solutions came from different manufacturers and encountered great problems concerning incompatibility, limited communication and restricted options regarding data management, alarm handling, diagnostics and remote access.

In contrast, the new system integrates timing, the entire servo controller, the machine control, transport and several additional small control units into one system. Any problems due to interfering interfaces between inconsistent systems can thus be avoided. Ethernet-TCP/IP is used as end-to-end network technology. This provides consistency from the control center, remote access via internet, the online database, the visualization and operation units through to shipping.

• One software for all configurations
• One control cabinet design for all configurations
• Fully modular layout. Each segment can be operated and maintained completely independently of the rest of the machine
• On unit replacement: Automatic download of the IP-address, the operating system, all parameters and tasks with automatic restart

Components used:

Control Systems:

• JetControl 647

Motion systems:

• JetMove 203
• JetMove 215
• JetMove D203-JC241
• Drives of the JL and JH series

Operation and visualization:

• JI-PC302