Check Weighing Solutions by Hardy How They Fulfill Customer Needs

Application Note Check weighing Solutions by Hardy How they fulfill customer needs

Who is this application WHAT IS CERAMIC SENSOR (in-motion) parts, products and packages. note for? TECHNOLOGY? Simple platform scales are used for static Process Control Engineers, Automation check weighing. Load points (load cells Engineers, Systems Integrators, OEM’s or Ceramic sensor technology measures and mounting hardware) or platform anyone who intends to design, install, scales are incorporated with conveyors to commission, support, purchase or offer mechanical deflection caused by a process weighing solutions for the product being placed on, or traveling provide in-motion check weighing. purpose of manufacturing or processing over the lead cell by measuring the product. change in “reactance” (combination In-motion check weighing is made easier with Hardy’s WAVERSAVER® technology, What is discussed? of capacitance and inductance). The advantages of using this technology which ignores plant and process Traditionally, cost effective stain gauge are: reaction times 3 to 5 times faster mechanical vibrations such as those technology (analog) has been used than strain gauge load cells, 3 times created by the conveyor belts. in applications below about 100 ppm (Pack per Minute). Above this pack rate the overload capability, better stability OEM’s, Systems Integrators, and their using two stage signal filtering (one Using Hardy’s EDGE® technology the customers have had to turn to more stage in the load cell the 2nd in Check Weigher can be configured to advanced measurement sensors such as oil damped stain gauge load cells (faster the controller) and package edge help sequence items on and off the settling time), the much more costly detection, to name a few of the key scale, divert out-of-tolerance material, or magnetic force restoration load cells separate classified product. (more speed, faster settling time and advantages. higher accuracy), and the like.

This application note discusses all five CHECK WEIGHING CHECK WEIGHING APPLICATIONS application types, customer needs and a APPLICATIONS BY HARDY newer sensor and controller technology 1. Verify package contents - ceramic sensor technology. Check weighing can be used for a 2. Check product tolerance wide variety of applications including verifying package contents, 3. Classify product checking product tolerances, 4. Identify parts identifying parts, classifying product and checking for overload safety. 5. Overload safety check

Hardy Check Weighing Equipment

Hardy check weighing controllers with Under/Accept/Over lights can be used to analog (strain gauge technology) or notify the operator of the weight status. digital (ceramic sensor technology) are used to check weigh static or dynamic

Hardy Process Solutions • 9440 Carroll Park Dr., Ste. 150 • San Diego, CA 92121 Tel 858.278.2900 • Fax 858.278.6700 • www.hardysolutions.com • [email protected] Material Feed Management by Rate Increased Productivity Application Note

and the correct numbers of cartons are on a pallet. Controls For example, the beverage industry weighs kegs and Check weighing system controls range from manual canisters to make sure they are empty prior to filling and to fully automatic. A manual (static) check weighing full within tolerance after filling. operation requires an operator, or a mechanically automated piece of equipment, to place the item on 2. Check Product Tolerance the scale and observe Under/Accept/Over lights. A fully automated system is where the item is automatically Checking a manufactured product’s weight verifies if it is weighed in-motion. The check weight controller then within design tolerances. For example, an directs downstream diverter gates to route product injection molding company can detect improperly based on weight. Automated control is done by a host produced product by using a Hardy weight controller computer or a PLC program communicating with a and load point(s)/platform scale to check weigh each Hardy front-end. part as it falls out of the mold. In a coating process, the quality and thickness of the coating can be verified by Data Collection the additional weight.

In addition to verifying the weight and directing product 3. Classify Product flow, a check weighing system can also provide valuable statistical information. This information can be used A mix of different items can be sorted by weight and for SPC (Statistical Process Control) to support the diverted to the proper packaging station for requirement for quality records. classifying or grading purposes. For example, variable weight products such as fruit and vegetables can be Usually the check weighing station is an inspection classified or graded by their weight class using a Hardy station after the manufacturing or packaging process. weight controller and load point(s)/ platform scale. If the By analyzing and feeding back the results of the check check weighing process is in-motion, relays from a Hardy weighing operation, the source process can be adjusted weight controller can be set to divert the product to the to optimize quality and lower costs. Automatic or proper station. manual feedback, or information is downloaded to a printer, computer or PLC for control, SPC calculation or 4. Identify Parts data storage. Items with different weights can be identified TYPICAL USE OF CHECK WEIGHING automatically by a check weighing system. For example, APPLICATIONS assembly processes use Hardy Process Solutions weight controllers and load point(s)/platform scales to verify the 1. Verify Package Contents correct parts have been delivered.

Hardy Process Solutions check weight controllers 5. Overload Safety Check and load point(s)/platform scales are used to weigh packages to confirm that they have been filled to the Items are often weighed to ensure they don’t violate proper level or that they contain the correct number of safety limits. For example, a train car is weighed with a parts. A wide variety of products ranging from boxed Hardy weight controller and load point(s)/platform scale food, bagged grain and glass bottles to gas cylinders can to make sure it doesn’t exceed the weight tolerance of be weighed to verify the contents. Check weighing can an upcoming bridge. determine whether or not the correct numbers of items are in a box, the right numbers of boxes are in a carton, Hardy Process Solutions • 9440 Carroll Park Dr., Ste. 150 • San Diego, CA 92121 Tel 858.278.2900 • Fax 858.278.6700 • www.hardysolutions.com • [email protected] Material Feed Management by Rate Increased Productivity Application Note

CUSTOMER NEEDS custom networks, custom HMIs, and proprietary embedded programming that in-house engineering Due to the advances in PLC and SENSOR technology, an groups or technicians have no access to. opportunity to use process control and process weighing tools for more demanding checkweighing applications Troubleshooting is very difficult, parts are long lead time exists. or unavailable, OEM support is slow, and not familiar with the system due to the custom nature of the application. The table below illustrates (from most demanding Other systems on the market have similar designs, to least) the typical range of current end user with custom hardware, proprietary programs, and no checkweighing requirements by capacity; accuracy and guarantee of long term support or availability. speed (these numbers are intended to be illustrative only and therefore may vary in unique situations in the field). WHAT DO MANUFACTURERS WANT? The areas of opportunity the Hardy 4050CW challenges, and displaces the proprietary check weigher solutions Check Weighers that are developed using standard, in that currently use Magnetic Force Restoration (MFR) off-the-shelf technology. technology, is highlighted below in YELLOW. Solutions that use known and readily Weight +- Accuracy Read Weight Proprietary Proprietary (kg) (% of piece Speed Sensor Yesterday Today available technology: For example - PLC’s, weight) (ppm) Method (pre 2012) HMI’s and weight measuring components such as load cells and indicators. <0.6

Easy to modify & fix: WHAT DO MANUFACTURERS HAVE TODAY? • A system that the Electrical & Instrumentation (E&I) technicians can monitor, access the programming, Custom Hardware & Software that is proprietary, easily pinpoint a failure and replace the appropriate obsolete or unreliable. The current hardware being component within minutes vs hours or days. used by manufacturers is mostly custom system • A system that increases MTBF and decreases MTTR. comprising of obsolete or proprietary circuit boards,

In house Engineers, Technicians or contracted Systems controller, a digital load cell interface card and a high Integrators are trained and are very capable at using PLC speed Digital Sensor Point (DSP) capable of 0.5 gram Software. resolution. The bundle is perfect for building new systems for both static and dynamic check weighing WHAT ARE THE BENEFITS? or retrofitting the weight measurement electronics of older, less reliable systems. Reliability and lower life cycle costs. Accelerated ROI. The Hardy DSP (LOAD CELL) is designed for industrial • Off the shelf components that are readily available applications requiring a fast, accurate and repeatable and supported ongoing. response to change in weight conditions. With • Familiar components/technology that are well known. no moving parts and laser welded assembly, the • Component cost is considerably less than the current hermetically sealed DSP is rated to IP69k will provide hardware components. a robust and long lasting solution to the most • Less dependence on vendor resources for upgrades, challenging environments. modifications, and troubleshooting. • Components are robust and not subject to failure due • Lower Total Cost of Ownership - It’s not a black box, to handling. it is an off-the-shelf solution. It integrates to Rockwell • Limited set of cost effective spares can be kept on-site and other PLC’s. • Easier swap out of hardware • Up to 250 packs per minute - It breaks the traditional • Easier upload of software, configuration and analog strain gauge “speed barrier”, without the cost of calibration parameters dramatically reduces MTTR MFR (Magnetic Force Restoration or Other similar high (mean time to repair) in the event of a failure. speed/resolution technologies) • Inter component communication via industry • Smart Features - It offers advanced EDGE DETECTION standard fieldbus protocols such as EthernetIP (weight on & weight off) and operator indication of • One HMI can display the production data for multiple DATA QUALITY rows • The open platform allows for unlimited data collection PROOF OF CONCEPT WITH CUSTOMER and transfer to our MES system. • Future loop control for weight control, and other Research, Validation & Testing controls enhancements are easily added. • Depending on application: ROI can be reduced from This concept of using known, and readily available years to months or months to weeks. technology: For example - PLC’s, HMI’s and weight measuring components such as load cells and WHAT’S THE SOLUTION THAT PUSHES HARDY UP indicators was researched and validated with a large TO 250PPM? US based Consumer Packaged Goods manufacturer. The Hardy 4050CW solution was retrofitted into The Hardy high speed HI 4050CW CHECK WEIGHING existing equipment. It required minimal modification Bundle can process up to 250 high resolution weight to the production lines/lanes within which the check measurements per minute per lane. The 4050CW weighing was required. The customer was able to use bundle consists of a special version of the HI 4050 their existing enclosures and HMI locations. The Hardy weight controller, a digital load cell interface card and 4050CW Check weighing case study (this document can a high speed Digital Sensor Point (DSP) capable of 0.5 be found at www.hardysolutions.com) illustrates the gram resolution. The bundle is perfect for building new success story and value delivered. systems for both static and dynamic check weighing or retrofitting the weight measurement electronics of older,

Hardy Process Solutions • 9440 Carroll Park Dr., Ste. 150 • San Diego, CA 92121 Tel 858.278.2900 • Fax 858.278.6700 • www.hardysolutions.com • [email protected]