Operation of Machine
Introduction
Job Number
16007
Client
Tata Consumer Products LTD
Company
Bector Automation RML India Pvt. Ltd.
Plot No. G/9/2/3. Phase No.-3, Nighoje, Tal. - Khed,
Dist. - Pune 410 501, Maharashtra, India
Date
21-02-2024
1. Machine Description
Top load bottle case packers revolutionize industrial packaging, ensuring swift and precise handling of bottles. With unmatched versatility, they effortlessly accommodate diverse bottle types, optimizing efficiency and throughput. Seamlessly integrated into automated lines, these machines streamline production, minimizing labor costs and downtime. Moreover, they champion sustainability by reducing material wastage and energy consumption. In the dynamic landscape of manufacturing, top load bottle case packers stand as indispensable allies, empowering industries to meet evolving demands with unparalleled speed and precision
2. Major Sub-Assemblies list
Note: Click on the Assemblies for the Detail Introduction of sub-Assemblies
3. Warranty
1. Machine Guarantee
BAR India Pvt. Ltd. guarantees this machine to be free from defects in material or workmanship under normal operation, as defined in the contract, for a period of 12 months following Take-over.
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BAR India Pvt Ltd agrees under this warranty to repair or replace at our discretion any original part which fails. This includes all costs of labour on site provided by BAR India Pvt Ltd or our authorised agent for 6 months following Take-over.
This warranty will not cover any section of the machine that has been modified by any party other BAR India Pvt Ltd. Issues caused by improper operation or maintenance will not be covered.
2. Software Guarantee
All software and software engineering are guaranteed for a period of 90 days following Take-over.
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3. Request for Warranty Assistance
In the event of a warranty fault it is imperative that the customer gathers as much information as possible about the fault including a part number identification from section 7 of this manual and contact BAR without delay
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4. Exclusions
The warranty excludes normal consumable items such as vacuum cups. Also excluded is normal wear and tear to items such as bearings and conveyor belting.
Our contact details:
Bector Automation RML India Pvt. Ltd. Plot No. G/9/2/3. Phase No.-3, Nighoje, Tal. - Khed, Dist. - Pune 410 501, Maharashtra, India
P +91 7506506099
Safety Assessment
Introduction to General Safety:
Where appropriate, it is intended that this equipment complies by the guidelines presented in
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AS4024 - Safety of Machinery [1]
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BS EN415-7:2006 - Safety of Packaging Machinery [2]
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ISO 13849:2006 Safety-Related Parts [3]
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and/or IEC 62061 Safety of Machinery [4]
The equipment supplied is fully automatic. With the exception of conveyors, operation and maintenance staff are only required to be exposed to moving or hazardous parts when the machine has been de-energized. For this reason, from a guarding and safety perspective, the Gantry Pick and Place System will be treated as a single safety cell. The proposed guarding is illustrated in below figure
1. Electrical and Control Systems
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The risk assessment conducted by Bector Automation RML India Pvt Ltd for the proposed machinery demonstrates a commitment to ensuring a safe working environment. The implementation of Lockout and Tagout (LOTO) procedures, along with a systematic evaluation of potential hazards, underscores the company's dedication to minimizing risks associated with the machinery.
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The decision to designate the machinery as a single safety cell, based on the highest scoring hazard, reflects a pragmatic approach to safety management. By focusing on the most severe risk identified through hazard rating numbers, Bector Automation RML India Pvt Ltd prioritizes addressing potential dangers that could have significant consequences.
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Furthermore, the determination of required performance levels (PL) for safety functions of safety-related components at PL(d) emphasizes the importance of reliability and effectiveness in the safety measures. PL(d) signifies a high level of risk reduction, indicating that the safety cell is designed to mitigate potential hazards with a robust and dependable safety system.
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This comprehensive risk assessment and safety approach not only align with industry best practices but also demonstrate Bector Automation RML India Pvt Ltd's commitment to ensuring the well-being of workers and the overall safety of the manufacturing environment. It sets a standard for responsible machinery design and operation, promoting a culture of safety within the organization.
2. General requirements
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As mentioned previously, with the exception of conveyors, operation and maintenance staff are separated from the moving and hazardous parts of the machine by the guard structure when the machine is energized. Access to the internal parts of the machine can only be possible when the machine has been de-energized, and the machine is deemed to be in a “Safe state”. For this reason, the safety system shall be designed and implemented to serve the sole function of de-energizing all moving or hazardous equipment when a non "Safe State" is detected.
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With reference to Figure.2, and the required levels of protection (SIL 2 and PL(d)), the components required to make the safety control system will be a safety controller, safety contactors, emergency stops, door switches, photoelectric sensors and a safety air service unit. The devices within the safety control system are expected to respond, and the safety system switch, to a safe state within 0.8 seconds of any potential fault detection or safety function demand. Maximum fault detection time (i.e., determining the difference between device fault or safety function actuation) should be no more than 3 seconds. These values are determined from experience with similar machinery.
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Considerations during the design phase in respect to the operating environment of the machinery were made.
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The machinery due to its function and operating environment will not be subject to shocks or vibrations.
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Electromagnetic compatibility is adhered to by installation of electrical components undertaken by qualified personnel.
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The machine is designed for a non-wash down food packing environment.
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Material selection and professional design solutions have been implemented to ensure mechanical durability.
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It is expected the machine will be operating in ambient room temperature.
Correct maintenance of machinery componentry, both mechanical and electrical is outlined in the machinery manual that is supplied with the Robot Pick and place System.
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Above and beyond the manufacture certifications of the devices used, correct installation and implementation of devices must be adhered too. Fault detection should cover but is not limited too.
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Cross circuits
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Short circuits
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Open circuits
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Cross terminals
2.1 HAZOP
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HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document
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2.2 PLC (NX1P2-1140DT1)
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Sysmac NX1P CPU with 24 Digital Transistor I/O (PNP), 1.5 MB memory, EtherCAT (0 servo axes, 4 PTP axes, 16 EtherCAT nodes), Ethernet/IP and 1 serial option port
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Note: Click on the Image for the Component Manual
2.4 Emergency Stops
Emergency stops are located in the most practical places around the machine. Practical places are often driven by such factors as
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At control points (i.e., below the Operator panel)
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In areas to ensure that no matter where an operation staff may be located, they can easily get to an emergency stop position
Direct guidelines are also used to place emergency stops such as that specified in BS EN 415 [2]. For example, these are relating to distances from conveyor guard tunnel openings and distances between emergency stops. The safety function of the emergency stop is to divert the safety system to an unsafe state when activated and in turn completely de-energise all machinery. Below are the part details and a reliability block diagram of the emergency stops to demonstrate the required architecture.
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Note: Click on the Image for the Component Manual
Table.5: Emergency stops part data
Description
Part No.
Quantity
Sick E-Stop
ES21-SA10F1
3
2.5 Door Switches
Doors are designed to restrict access into all areas where there is potential for contact with moving machinery. Access to these areas should only be allowed when the motion has stopped. All equipment is energized via the safety circuit; therefore, the safety function of the door switches is to identify access to these areas is possible by turning the safety system to a non-safe state which in turn de-energizes all machinery. Below are the part details and a reliability block diagram of the door switches to demonstrate the required architecture.
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Note: Click on the Image for the Component Manual
Table.6: Door Switch
Description
Part No.
Quantity
Safety Door Switch
RE13-SAC & SK
4
2.6 Safety Monitored Air Service Unit
A number of the moving parts within the machinery supplied are pneumatically operated. Actuation of these pneumatic devices are electrical, however the energy associated with the mechanical movements is pneumatic. As mentioned previously, to ensure complete de-energizing of the equipment, all pneumatic devices must have their energy removed. A safety monitored dump valve is expected to achieve this if signaled to do so by the safety controller. Below are the part details and a reliability block diagram of the safety dump valve to demonstrate the required architecture.
Figure.9: Air service unit RBD
Table.6: Safety Relay part data
Description
Part No.
Quantity
Air System Unit
MS6-EM1-1/2
MS6-LFR-1/2-D6-C-R-M-AS
MS6-FRM-1/2
MS6-5V-1/2-E-10V24-AG
1
3.PERSONAL SAFETY
As part of the commissioning programme, an “on machine” training course is carried out by BAR India Pvt. Ltd. Training is split into 2 categories:
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Operator and Maintenance Training - for personnel who will operate or maintain the machine. Only authorized and fully trained personnel are to operate or maintain this machine. Certificate attached records the operators and maintenance personnel who have completed this training.
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Technical Support Training - for personnel who will provide technical support for the machine. Only authorized and fully trained personnel are to give technical support for this machine. Certificate attached records the technical personnel who have completed this training.
It is the client’s responsibility to perform all operator, maintenance and technical support training after the takeover certificate has been issued.
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Please refer the below Training Certificate.
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Electrical
1. PLC Program
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The program is supplied on a USB drive.
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This USB is made available in the event of the machine program becoming corrupt and the program needs to be reloaded.
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Any program changes made by personnel other than BRML programmers should be documented, and a copy sent to Brml to keep the master records up to date.
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Program changes may also be able to be made via the modem (if fitted)
2. Electrical Certificate of Compliance
All electrical component and modules manual will be provided on hand.
3. Electrical Drawing
Introduction - Enclosures
1. Panel Dimensions
2. Gear plate Layout
Terminals
Utility Socket
3. Maintenance
Important Precautions: -
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READ this manual before operating or servicing this equipment.
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ALWAYS remove power and wait at least 30 seconds before connecting / disconnecting any internal harnesses. Failure to observe these precautions may result in damage to, or destruction of the equipment.
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ALWAYS take proper precautions when handling static sensitive devices.
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SAVE this manual for future reference.
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DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
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DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
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4. Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
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Please refer the below attachment for HAZOP Document.
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Introduction - Chassis and Guards
1. Introduction - Chassis
1.1 3D Model
1.2 Chassis Operation
Chassis provides support to the different sub-assemblies.
1.3 Maintenance
Important Precautions: -
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READ this manual before operating or servicing this equipment.
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ALWAYS remove power and wait at least 30 seconds before connecting / disconnecting any internal harnesses. Failure to observe these precautions may result in damage to, or destruction of the equipment.
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ALWAYS take proper precautions when handling static sensitive devices.
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SAVE this manual for future reference.
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DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
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DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Refer click the below Maintenance Schedule for Chassis.
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2. Introduction - Guards
2.1. 3D Model
Door Material - Polycarb
Door Switches - i10-E0354 Lock (Sick Make)
2.2 Guards Operation
Guards cover equipment and provide safety protection for operation of the equipment.
3. Spare Parts
Introduction - Infeed Conveyor
1. 3D Model
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Product Contact Parts - SS 306
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2. Infeed Conveyor operation
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Infeed Conveyor receives the Bootle and Transfer to Collation Unit
3. Maintenance
Important Precautions: -
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READ this manual before operating or servicing this equipment.
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ALWAYS remove power and wait at least 30 seconds before connecting / disconnecting any internal harnesses. Failure to observe these precautions may result in damage to, or destruction of the equipment.
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ALWAYS take proper precautions when handling static sensitive devices.
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SAVE this manual for future reference.
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DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
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DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Refer click the below Maintenance Schedule for Infeed Assembly.
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3. Spare Parts
4. Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
Please refer the below attachment for HAZOP Document
5. Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
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The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
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Refer the below about the Troubleshooting.
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Introduction - Collation Unit
1. Collation Conveyor
1.1. 3D Model
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Product Contact Parts - SS304
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Product Non-Contact Parts - SS304
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1.2. Collation Unit Assembly operation
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Collation Conveyor receives product from infeed conveyor to form matrix. As per the requirements.
1.3. Maintenance
Important Precautions: -
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READ this manual before operating or servicing this equipment.
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ALWAYS remove power and wait at least 30 seconds before connecting / disconnecting any internal harnesses. Failure to observe these precautions may result in damage to, or destruction of the equipment.
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ALWAYS take proper precautions when handling static sensitive devices.
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SAVE this manual for future reference.
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DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
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DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Refer click the below Maintenance Schedule for Main Drive Assembly.
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3. Spare Parts
Note: Click on the Image for details about Spare parts
4. Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
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Please refer the below attachment for HAZOP Document.
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5 Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
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The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
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Refer the below about the Troubleshooting.
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Introduction - Case Conveyor
1. Case Conveyor Assembly
1.1. 3D Model
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Product Contact Parts - SS304
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Product Non-Contact Parts - SS304
1.2. Case Coneveyor Assembly operation
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Case Conveyor Transfer the Case into Gantry Filling Station.
1.3. Maintenance
Important Precautions: -
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READ this manual before operating or servicing this equipment.
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ALWAYS remove power and wait at least 30 seconds before connecting / disconnecting any internal harnesses. Failure to observe these precautions may result in damage to, or destruction of the equipment.
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ALWAYS take proper precautions when handling static sensitive devices.
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SAVE this manual for future reference.
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DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
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DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Refer click the below Maintenance Schedule for Case Conveyor Assembly.
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3. Spare Parts
Note: Click on the Description for details about Spare parts
4. Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
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Please refer the below attachment for HAZOP Document.
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5 Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
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The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
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Refer the below about the Troubleshooting.
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Introduction - Gantry
1. Gantry Assembly
1.1. 3D Model
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Product Contact Parts - SS304
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Product Non-Contact Parts - MS Powder Coated
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1.2. Gantry Assembly operation
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Gantry Pick the bottle matrix and Place into the case which is located in filling Station
1.3. Maintenance
Important Precautions: -
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READ this manual before operating or servicing this equipment.
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ALWAYS remove power and wait at least 30 seconds before connecting / disconnecting any internal harnesses. Failure to observe these precautions may result in damage to, or destruction of the equipment.
-
ALWAYS take proper precautions when handling static sensitive devices.
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SAVE this manual for future reference.
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DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
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DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
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3. Spare Parts
Note: Click on the Description for details about Spare parts
4. Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
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Please refer the below attachment for HAZOP Document.
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5 Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
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The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
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Refer the below about the Troubleshooting.
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Introduction - Exit Conveyor
1.Exit Conveyor Assembly
1.1. 3D Model
1.2. Exit Conveyor Assembly operation
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Magazine will be loaded manually.
1.3. Maintenance
Important Precautions: -
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READ this manual before operating or servicing this equipment.
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ALWAYS remove power and wait at least 30 seconds before connecting / disconnecting any internal harnesses. Failure to observe these precautions may result in damage to, or destruction of the equipment.
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ALWAYS take proper precautions when handling static sensitive devices.
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SAVE this manual for future reference.
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DO NOT allow untrained personnel to operate, clean, inspect, maintain, service or tamper with this equipment.
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DO NOT connect or disconnect any digital or analogue components to the equipment with power connected or damage may result.
Refer click the below Maintenance Schedule for Exit Conveyor Assembly.
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3. Spare Parts
Note: Click on the Description for details about Spare parts
4. Risk Assessment
Risk Assessment or HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards in a work process. In this approach, the process is broken down into steps, and every variation in work parameters is considered for each step, to see what could go wrong.
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Please refer the below attachment for HAZOP Document.
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5 Troubleshooting
Troubleshooting is the process of identifying, diagnosing, and resolving problems or issues that arise in various systems, equipment, or processes. it involves a systematic approach to problem-solving, using a combination of analytical, technical, and problem-solving skills.
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The first step in troubleshooting is to identify the problem. This can involve gathering information about the issue, including when it started, what systems or equipment are affected, and any error messages or symptoms that are observed. Once the problem is identified, the next step is to diagnose the root cause. This involves analyzing the information collected and using technical knowledge to determine what is causing the issue. After the root cause is identified, the next step is to develop a plan for resolving the issue.
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Refer the below about the Troubleshooting.
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Guards Spare
Image of Guards Switches
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Refer the below PDF for the Installation manual of Safety switch.
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MCB Spare
Image of MCB
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Refer the below PDF for the Datasheet.
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Spares
Sr.No.
Spare Location and Identification on the Machine
Remarks
Part No.
1.
MZT8-Sick
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MZT8-Sick
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Refer the below Datasheet
2.
DOL-0804-G10MC
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DOL-0804-G10MC
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Refer the below data Sheet
3.
Sick-GTB6-P4231
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Sick-GTB6-P4231
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Refer the below Datasheet
4.
ADN-S-50-10-A-P-A
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ADN-S-50-10-A-P-A
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Refer the below Datasheet
5.
DFM-32-160-P-A-GF
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DFM-32-160-P-A-GF
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Refer the below Datasheet
6.
DFM-12-80-B
-P-A-KF
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DFM-12-80-B-P-A-KF
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Refer the below Datasheet
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Sr.No.
Spare Location and Identification on the Machine
Remarks
Part No.
7.
DFM-32-20-B-PP-A
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DFM-32-20-B-PP-A
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Refer the below Datasheet
8.
CPE14-M1BH-5J-1/8
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CPE14-M1BH-5J-1/8
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Refer the below Datasheet
9.
VUVS-LK20-M52-AD-G18-1C1-S
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VUVS-LK20-M52-AD-G18-1C1-S
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Refer the below Datasheet
10.
DFM-20-100-P-A-GF
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DFM-20-100-P-A-GF
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Refer the below DataSheet
11.
Bottle Stopper BKT 16007-1890
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Bottle Stopper BKT 16007-1890