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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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

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Tighter process control …

Tighter process parameters demand better gauge capability

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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!