Light Based Measurement for Light Weight Cans
The Future is Lighterweight of a 12 oz. can will reduce to about 9g in 2020!
Lightweighting means…(also called downgauging)
• Reduced costs
• Reduced energy use and emissions (CO2)
• Lightest metal containers possible while meeting the performance requirements of customers and consumers.
Lower Weights Need
• Tighter specifications / tolerances
• Improved process capability (Cpk)
• Better measurement (Gauge R&R)
• More attributes controlled
Gauge Capability • Measured using statistical methods as
Reproducibility and Repeatability and known as Gauge R&R
• “Gauge R&R … measures the amount of variation in the measurement system arising from the measurement device and the people taking the measurement.”
Any gauging system is subject to variability due to limitations of the gauge (repeatability) and operator influence (reproducibility)
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Arbitrary scale
Gauge Capability
Gauge capability is expressed as a percentage (%R&R) of the process variation
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%R&R
As process parameters get tighter, keeping the same gauge capability means higher (worse) %R&R
Arbitrary scale
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Tighter process control …
Tighter process parameters demand better gauge capability
Arbitrary scale
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… demands better gauging
Human Error
Observer Effect
observing a situation or phenomenon necessarily changes that phenomenon.
Non Contact Inspection Techniques
General advantages of Non Contact Tech
Less maintenance
Lower lifetime costs
Improved
Gauge
Capability
Reduces drift and
deterioration
No risk of product
distortion
Proven Reliability
• Optical Ends gauges – June 2001
• over 50 installations over the world
World leader in coatings measurement
Over 25 years experience
Continual improvement
Capacitive option still
offered
• 3 year R&D partnership with a leading UK university
• Custom optical metrology technique specially designed for measuring coatings on cans
Optical Gauge
Infrared interferometry
including black inkalso matte
and practical method for tactile lacquers
Internal & External Coatings
• Over-varnish on colored inks • Matt• Tactile
More complex
Less complex
Sencon Shell Gauge
a step-change in performance
Fast measurement savespress downtime
• High speed laser scanning delivers a step change in measurement speed.
• Measurements taken at 2 points to 64 points
• Example: 16 point results delivered in around a 1/3 of the time of competing systems
Contact measurement
Non-Contact measurement
Each laser pass = 2 data point sets
2 passes gives 4 radial data sets
24 shell batch in <9 minutes
1 2
Laser scan
Measurement Station
Thickness
setting piece
Upper
Surface
laser
No time lost for changeover
Back End Gauge
The Sencon Solution
The Sencon Solution
VisualizationsNeck area graph with 150 curves
Dome reform data
3D model generated from
neck measurement data
Feature Sencon non-contact
Contact gauges
Plug diameter (A) P P
Flange width (B) P P
Open can height (C) P P
Minimum stand diameter (D) P O
Dome depth (E) P P
Reform diameter (G) P P
Reform Height (H) P O
Reform eccentricity & concentricity P O
Seaming Clearance (J) “J dimension” P O
Measures what’s needed
Future Sencon capability
Feature Sencon non-contact
Contact gauges
Body diameter (F) P O
Flange angle (I) P O
Shoulder height (K) P O
Neck angle (L) P O
Flange radius (M) P O
… using the existing measurement data set
The right technology for the task
End Progression Gauge micro-focussed laser
illuminated probe
Dome Reform Gauge laser
Back End Gauge micro-focussed laser
illuminated probe
Optical Coatings Gauge infra-red
interferometry
Optical Shell Gauge laser
Thanks!