TroublePad Dual High-Speed Camera – Dual High-Speed Camera System for Production Lines

• Context :
  Clairefontaine papermaking factories and the Hamelin group manufacture paper for a variety of applications. The paper can be used to make notebooks, reams, folders, etc. Their sites have special machinery for manufacturing, cutting and assembling sheets. Manufacturing operations are carried out at high speed.
• Challenge :
  The sheets are handled by high-speed machines. Occasionally, jams or other problems can occur while operating the equipment. It is therefore essential to be able to identify the cause of these malfunctions.
• Goals :
  To avoid machine stoppages due to paper jams when making reams of paper, envelopes, notebooks, etc. for example.
• Keywords :
  Paper, jamming, guillotine, paper trimmer, sheets, binding, high speed, high speed video, high speed camera, high speed, high speed video

First, a special machine lays out and cuts large sheets that are stacked in batches of 500. The reams of paper are then wrapped. These layout and finishing operations require the machinery to be perfectly adjusted and all components to be in good condition.

The Trouble Pad camera displays the stacking and cutting sequences. Maintenance technicians can access slow-motion images of the machinery in operation. They can accurately identify the fault and act quickly to adjust settings or replace components as required. The slow-motion feature is a real boon when searching for phenomena that are impossible to see with the naked eye !

Conclusion : Thanks to the Trouble Pad system, the Clairefontaine papermaking factories and the Hamelin group have access to information that would be impossible to detect with the naked eye. Slow-motion images simplify machinery tuning and maintenance operations. The Clairefontaine paper mills and the Hamelin group have been using Trouble Pad at their production sites since 2018.

• Context :
  Many pharmaceutical laboratories are using increasingly complex production lines, with high production rates and safety requirements. The production of vaccines, drugs, injectable vials, insulin for diabetic patients, etc. is carried out on special machinery that can cope with the high production rates. However, high-speed production rates mean it is not always possible to have a clear idea of the mechanical phenomena that can occur during the manufacturing process.
• Challenge :
  Vials, blister packs, graduated syringes or medical pens are made up of many sub-components (embossed aluminium strips, seals, glassware, tubing, etc.). Several operations are required to ensure that all these parts, once assembled, comply with the customer’s specifications and that the machinery does not become out of sync. In addition, machinery may exhibit random behaviour during different operations. The manufacturers use high-speed Trouble Pad cameras to catch phenomena that are impossible to see with the naked eye! The slow-motion images provide new information.
• Goals :
  To ensure that the machine settings are suited to risk-free high-speed production, that productivity is optimal and that the machinery does not get out of sync. To enable maintenance staff to understand production incidents, using.
• Keywords :
  Caps, capsules, liquid, medical, pharmaceutical, high speed, high-speed video, high-speed camera, high speed, high-speed videos

Conclusion :
The manufacturers use high-speed Trouble Pad cameras to catch phenomena that are impossible to see with the naked eye ! High-definition slow-motion replays of the phenomena provide new information, enabling technicians to quickly reset their machinery.
Pharmaceutical companies such as Pfizer, Aptar, Novo Nordisk, Lilly, Sanofi, GSK, and others have been using Trouble Pad for several months at their manufacturing premises.

• Context :
  Gebo Cermex, SIDEL and ZALKIN specialise in the engineering and manufacture of packaging lines for a wide range of market sectors: from food and beverages to pharmaceutical products, as well as cleaning and hygiene products.
• Challenge :
  Machines require fine-tuning and adjustment prior to shipment and installation at the end customer’s premises.
• Goals :
  To understand malfunctions to be able to adjust machines quickly during production.
• Keywords :
  Machine tuning, packaging line, special high-speed machinery, high-speed video, high-speed camera, beverages, hygiene…

Many adjustments are required in order to ensure the packaging machines function correctly during assembly/manufacture. Operators are faced with high-speed sequences that cannot be broken down by the naked eye.

The Trouble Pad camera makes it possible to break those sequences down. Technicians can then identify precisely the improvements that need to be made thanks to the slow-motion images.

The machines are quickly adjusted, and promptly shipped and installed on site.

In addition, field technicians can take the camera kit on site to save time on certain delicate adjustments. The slow-motion footage saves valuable time on their callouts.

Conclusion : Thanks to the Trouble Pad high-speed camera, setup and adjustment times are improved.
Gebo Cermex has been using Trouble Pad since 2018 at its Lisieux production site. Sidel and Zalkin have several portable camera kits that enable technicians to use slow-motion images on site, or on lines that are being installed worldwide. The Trouble Pad slow-motion feature is a precious asset in every manufacturing process!

• Context :
  The Hager and Schneider Electric groups are major players in the electricity industry, and both have many production sites in France and abroad.
  The sites manufacture electrical components (circuit breaker components, etc.) and have state-of-the-art manufacturing lines.
• Challenge :
  To carry out component assembly operations and ensure stability of finished products (spring units, small metal components, etc.).
• Goals :
  To adjust machine positioning, improve machine settings, stabilise sequences, avoid assembly defects, tune machinery on the assembly chains.
• Keywords :
  Malfunctions, defects, electrical components, circuit breakers, high speed, high-speed video, high-speed camera

To guarantee production quality, technicians must ensure that the line is not disrupted by sudden movements. These movements sometimes occur at random. In addition, there are many different items, requiring fine machinery adjustments for each new production run..

The high-speed Trouble Pad camera detects the disruptive movements, which are invisible to the naked eye. Maintenance technicians can view slow-motion images of the mechanical parts as they move. They can precisely identify the defect and act on the appropriate parts of the machine.

The slow-motion images are easily accessible, as the installation of the Trouble Pad high-speed camera only takes a few minutes !

Conclusion : Thanks to the Trouble Pad high-speed camera, motion detection enables technicians to quickly correct defects, with minimal shutdown times.
HAGER and Schneider Electric use several Trouble Pad systems at their different production sites.

• Context :
  ROXANE St LEGER (Perenchy site in Northern France), Eaux Cristaline / EVIAN Savoie / BADOIT Saint Galmier / VOLVIC / MONT ROUCOUS / NIAGARA WATER  / NESTLE WATERS/ Aqua Sant’Anna /  REFRESCO EAUX have different production sites in France and abroad with many high-speed bottling lines, each of which has a TROUBLE PAD high-speed video kit.
• Challenge :
  Random phenomena can cause synchronisation issues and defects on high-speed bottling and labelling lines.
• Goals :
  To fix machine malfunctions, improve machine tuning, reduce production outages, using slow-motion images to help maintenance or production technicians.
• Keywords :
  Malfunctions, defects, bottling, high speed, high-speed video, high-speed camera

The machines must be perfectly tuned to maintain production rates (50-70,000 bottles /hour). There are many parameters involved: new capsule design, empty bottle weight, size variations. Random desynchronisation events can occur in the machine cycle and shut down production.

The high-speed Trouble Pad camera detects these slippages, which are invisible to the naked eye. Maintenance technicians can view slow-motion images of the mechanical parts as they move. They can identify the specific defect thanks to the high-speed Trouble Pad camera. In addition, there may also be a security issue for personnel given the speed of these machines.

The machine can then be recalibrated, quickly and safely. The High-speed Trouble Pad camera is a precious asset and the slow-motion images are accessible in just a few minutes !

Conclusion : Trouble Pad reduces production shutdown times and improves line productivity.

• Context :
  Moët and Chandon Veuve Clicquot (Epernay/Reims 51), LVMH Group, has several production sites in the Marne and many high-speed bottling lines.
• Challenge :
  Putting muselets (braided wire) and aluminium caps on champagne bottles.
• Goals :
  To fix machine malfunctions, improve machine tuning, and reduce production outages.
• Keywords :
  Malfunctions, defects, bottling, high speed, high-speed video, high-speed camera

The machines must be perfectly tuned to maintain production rates. There are many parameters: the type and thickness of the capsule, surface condition and size variations. Random desynchronisation can occur in the machine cycle and shut down production.

The high-speed Trouble Pad camera detects these slippages, which are invisible to the naked eye. Maintenance technicians can access slow motion images of the mechanical parts as they move. They can identify the specific defect thanks to the slow motion.

The machine can then be recalibrated quickly.

Conclusion : Production downtime has been reduced thanks to Trouble Pad and the slow-amotion images,
MOET AND CHANDON and Veuve Cliquot have been using the Trouble Pad high-speed camera at their production sites for several years.

• Context :
  Ontex manufactures hygiene products (incontinence briefs), KIMBERLY Clark and ESSITY make paper tissues. ONTEX, KIMBERLY-Clark and ESSITY have several production sites in Europe. Many different manufacturing operations are carried out at high speed: folding, assembly, cutting.
• Challenge :
  Assembling absorbent paper sheets that make up the incontinence brief. Rolls of tissue paper, cutting, assembly, packaging of tissues or absorbent paper.
• Goals :
  To ensure that the sheets stay flat before assembling the finished product. To ensure that piles of tissues remain in position during the packaging process.
• Keywords :
  Hygiene, medical, sheets, Folding, cylinders, rotation, high speed, high-speed video, high-speed camera

During the production process a machine is used to cut precise lengths of sheets of absorbent paper. Technicians must ensure that rotating cylinders are perfectly adjusted so as not to break the flow of these cut sheets.

With the tablet that is connected to the Trouble Pad high-speed camera, the operator can see the sheet as it is passes over a spinning roller. The ultra-fast rotation of successive rollers can cause the sheet to fold over on itself. This crease usually causes quality defects on the finished product. Similarly, when making absorbent or tissue papers, the machines operate at very high speed and require incredibly precise settings.

The machinery’s movements are invisible to the naked eye. Maintenance technicians can see the mechanical parts moving in slow-motion using the Trouble Pad’s high-speed video footage. They can install the TroublePad camera in parts of the machinery that humans cannot access, to identify the defect that they would otherwise be unable to see. Setting up the camera only takes a few minutes!

The source of the disruptions can then be identified, and quality improved.

Conclusion :

Motion detection enables technicians to view the position of the roll of paper. As a result, defect (creasing) detection occurs earlier in the process and avoids quality defects on the finished product.

ONTEX has been using Trouble Pad since 2018 at its production sites in France and Spain.

Essity Gien, Kunheim and Mannheim use it … as does Kimberly-Clark in Rouen.