industry 4.0 application in gfm textile machines...company headquarters czech republic kastanova...
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INDUSTRY 4.0 APPLICATION IN GFM TEXTILE MACHINES Product traceability during coating process in production of car interior foils
Company Headquarters CZECH REPUBLIC KASTANOVA 141d 617 00 BRNO Tel. : +420 530 555 100 Fax : +420 530 555 155 www.gfm.cz
Brno
R&D AND PRODUCTION OF CUSTOMIZED
MACHINES AND LINES
Technical yarn and fabric processing machines and lines
Customized production lines for automotive and medical
industry
GF Machinery s.r.o
» Asia Wuhan Onlyway New Material Co.
Mr. Tony Li
Wuhan, P.R. China
Email:[email protected]
» North America Bynamics Corp.
Mr. Ivan Filippov
Delta, CANADA
Email: [email protected]
» India Mr. Trilok Singh Panesar
New Delhi, INDIA
Email: [email protected]
» Brazil Rivitex Com.Imp. e Exp. Ltda
Mr.Thomas Schwarzbach
Sao Paulo, BRAZIL
Email: [email protected]
OUR DEALERSHIP NETWORK
» Russia Mireks zao
Mr. Aleksey Kaljan
Moscow, RUSSIA
Email: [email protected]
» Technical fiber (glass and/or basalt fiber) and fabric processing machines and lines » Online/Offline Choppers » Assembled Roving lines (Winders, Braking tension systems, Creels, Transport, Curing) » Finishing equipment: Creels, Printing lines, Winding, Unwinding Units » Laminating lines » Lines for chemical treatment (yarn, fabric) » Formatting lines » Customized production lines and equipment for automotive industry » Headliners production lines » Coating lines (coating of interior foils by hot melt method) » Press Units 10-200kN
» Customized fabric processing production lines and equipment for medical/ hygienic industry » Laminating lines, Converting lines » Services » Customized production lines design, machinery, processing equipment and devices including control system (Solidworks 3D modeling and design) » Prototyping and testing » Upgrading and refurbishing of existing production lines, machinery, processing equipment and devices
OUR PRODUCTS AND SERVICES
a) TECHNICAL FIBER AND FABRICS
PROCESSING MACHINES AND LINES
» ASSEMBLED ROVING PRODUCTION SYSTEM
» PRINTING LINE FOR GLASS MESH
» CHOPPERS
SPECIAL FINISHING LINES
b) MACHINES AND LINES FOR
AUTOMOTIVE INDUSTRY
» Coating lines (interior car foils), Headliners production Lines
» Laminating, Converting Lines
c) CUSTOMIZED MACHINES FOR
MEDICAL/HYGIENIC INDUSTRY
INDUSTRY 4.0 APPLICATION IN GFM TEXTILE MACHINES AND LINES Product traceability during coating process in production of car interior foils
Production of Car Interior Foils
Car interior foils coating (by “hotmelt” method)
Using PUR or PONR glue type (exact amount of glue: 80-120g/m2)
To prepare interior foil to next process (thermocovering machine)
GFM delivered more than 21 Coating Lines within last 5 years to
Faurecia company branches, located all over the world (USA, Mexico,
China, India, France, UK, Poland, Brazil…) for projects e.g.:
Ford
Tesla
Volvo
VW
Production of Car Interior Foils
COATING LINE GF-CL 1200
Unwinding Unit
Loading of foil by pneumatic operated arms
Sensor for roll diameter checking
Guide edges control
Optical sensor for loading of foil by correct side
Unwinding Unit
Guide Edges sensor
Optical sensor (to define
correct side of foil)
Roll diameter sensor
Capacity depends on
processing speed about 20-40m
For connecting of foils in
continual process
Inlet Accumulator
Coating width depends on customer request (300-1100mm)
Coating width adjustable by 1mm
Motorized change of coating width
Connecting to main PLC via E-thernet
Melters per customer request (20kg slugs, Drum 200l,…)
Slot Die + Melter (PUR/PONR glue coating)
Continual or Stop & Go Coating process
Outlet Accumulator
Tension control (by torque moment of accumulator motor) Meters measurement (from motor revolutions-for detecting two foils connection) Trolley with Dock Station Connecting to next process (Thermocovering machines)
Winding Unit
General definition: the capability to trace “something”
In context of manufacturing practice we usually mean the ability to verify/recall the products “manufacturing history” / machine history
This can include (but isn’t limited to):
Input material / subcomponents used (supply chain tracing)
Parameters of the manufacturing process used
Results of all the verification steps performed on the product (sensor data & human inspection results)
Traceability/Generally
We use multi-purpose industrial wireless barcode scanner for several tasks:
The operator reads out the barcode from the roll of foil when he inserts it into a machine – this results in automatic selection of the corresponding product in the HMI/PLC – prevents operator error (Poka/Yoke)
A common variant of our machine has two hot-melt nozzles and two corresponding melters (PUR or PONR glue type) – each using different type of glue. To unlock the melter, the operator needs to read a correct barcode from the glue – preventing an unintentional mix-up (Poka/Yoke)
Traceability-Automatic product setting/Poka Yoke
Input foil Glue type
Traceability-Automatic product setting/Poka Yoke
The machine automatically applies a new parameter setup once the new foil reaches the coating area.
We log the time when each roll coating was started
On the machine output a label for each roll is printed, including the type of material used (foil & glue type) and some process parameters
Traceability/Automatic product setting
Another important source of traceability data might be the quality control (automated) systems that are collecting data from various sensors or process control loops
Analyzing this data from quality control systems and using them in the manufacturing process minimizes scrap material production.
Traceability/Quality control
Traceability/ Machine Integration between Supplier & Plant
Often the data from the individual measuring parts located in the
manufacturing lines are logged centrally in plant data collection
systems for further quality control analysis and resulting quality
reports
Many companies now implement central data collection on plant
(or even on the corporation) level
Statistical analysis of the data can allow significant cost savings
in the manufacturing process
The company using a plant level data collection system is able to optimize glass fibre manufacturing process
Machines from GFM can be connected to the data collection system at several levels/types of production
Traceability/ Next Example-Fiberglass Chopping process
By collecting the process parameters, their comparison an statistical analysis the company is able to minimize the time between rebuilds
Data is also used by maintenance departments for maintenance planning and minimizing gaps in production
Traceability/ Next Example-Fiberglass Chopping process
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