History

In 1992 Technology & Services, Inc. pioneered the use of laser-based systems in mass-production environments by developing and deploying a center-face thickness gaging system for a major picture tube manufacturer. This gage would determine the thickness of each picture tube at the center point as it entered the final inspection area, marking those found to be too thin for downstream disposal.

By the year 2000, this technology had matured to the point where T&S could successfully bring it into the float glass production market. We currently have laser-based systems qualifying automotive glass for shipment. These systems are scanning at rates in excess of 10 inches per second, and publishing a thickness datum of 0.0002” accuracy for each 1” of the glass ribbon.

In 2004, T&S successfully introduced the Ribbon-Scan-Pro™ product line to the float glass thickness applications. This integration has allowed us to triple the speed at five times the data density, representing a speed increase of over 10X. This, with an increase of accuracy to +/- 0.0001”.

NIST Accuracy

The accuracy of these systems is customer selected. Ribbon-Scan-Pro™ can provide better accuracy than using hand micrometers. While the gage is able to accurately measure into the microns, customers usually find an accuracy of 0.0001” @ 1 Sigma (NIST traceable) to be useful in the allocation process. The selection of accuracy is more about a particular site’s ability to react to the data and make production decisions on the basis thereof.

The gage maintains NIST traceability from glass samples taken from the line and forming secondary standards from same. These standards are then used to both calibrate and verify the finished gage.

Range

The confocal sensors used trade field of view for resolution. A typical range set would be from 2mm to 8mm, 6mm to 20mm, etc. T&S has methods of configuring sensors that provide views of glass in virtually any range.

Data and Deployment

Consumption and utility of the gage’s data is really a key point of installing the Ribbon-Scan-Pro™. What may not be apparent are the uses that the gage data can be put to. Other T&S gages are actively participating in the customer’s LAN, and with proper authorization, one can view live data from the gage in graphical format anywhere in the plant (or world, for that matter). This data is also linked to the in-house control systems, and is used as the primary qualification for packing glass. With immediate feedback on the changes at the tank, glass is now packing on thickness change as soon as any part of the flock is in thickness tolerance.

Because the gages operate 24/7, with greater than 99% availability, they have become a primary source of thickness data for the process, linking to SQL databases for process history and analysis.

Benefits to End Users

Cost Centers Affected

First, the Ribbon-Scan-Pro™ makes it possible to coordinate the scanned data with packing systems to ensure that glass packs from any part of the ribbon that is in thickness, as soon as it is in thickness. This eliminates the need for hand measurement.

With a T&S Ribbon-Scan-Pro™ on the job, thickness profiles are available for each minute of production. These profiles can be widely distributed, allowing the glass packing operation to proceed with a higher degree of certainty that the glass they are packing is in spec. for the customer, and will not be returned. This with less QC Personnel per shift of operation.

The gage also creates a “data-mine”. There have been several instances now where data collected and stored by the Ribbon-Scan-Pro™ has allowed tank or wareroom engineers to track and correct problems with either end of the process. Without the data accumulated by the gages, this data-mining would be impossible.

Material Usage

Due to the non-destructive nature of the gage, less time and product is wasted to produce a reported thickness.

Real-time data allows the hot end operators to see how close they are running to base tolerance of the product. This allows less tonnage by producing at bottom limit required for the glass.

Constant, automatic thickness reporting benefits product change by allowing glass to be packed for shipment as soon as it is within customers’ specifications.

Quick ROI

Depending on amount of glass produced, our prediction on customers’ return on investment will be less than a year.

Ease of Installation

T&S Ribbon-Scan-Pro™ for float glass applications are easy to install, with a small footprint and low consumption of utilities. Most applications require less than 20 Amps @ 120 VAC. These utility feeds, along with any requested LAN (Ethernet) Connections, are typical for an installed system.

To date, we have been able to ship these gages almost fully assembled, allowing the customer to install by simply lowering the gage into it’s final installed position across the ribbon. To date, there has been no down-time associated with the installation of one of our gages.

The operators need no special certification. Included in our quotations are provisions to take some time with operators on site to train all involved safely and effectively.

Maintenance

Because of the robust nature of our equipment design, maintenance is practically a non issue. Customers are currently experiencing 99.7%+ availability of their gaging systems.

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Marketing Director
Richmond Parks

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