Worn or incorrect roll and chuck profiles can lead to bad double seams, machinery breakdowns, product holds and customer complaints. Putting incorrect or worn Rolls or Chucks in the seamer without inspection can produce bad seams – which can stop production (or worse).
Using a non-contact, laser based profiloscope – the inROLL is able to scan profiles of seaming Rolls and Chucks (or other tooling – including carbide and ceramic tools) automatically, easily and quickly. The system can be used for acceptance testing for new seaming rolls or chucks, for quality assurance purposes for used tooling and for stress analysis.
inROLL is the first dedicated computerized automatic, non-contact seaming Roll and Chuck gauging system. By scanning the profile, it is capable of detecting defects in the profile, analyze angles, radius, measuring distances and automatically measuring the differences between a roll’s specification and the roll’s actual profile. This system replaces optical comparators, projectors and other techniques for manually (and subjectively) comparing contour profiles for rolls, chucks and other tooling.
Using a micrometric table, the operator can position practically any tooling into view. Once positioned correctly, the operator captures the image and the software automatically analyzes it against a given standard graph, which can be either a previously scanned image (the same tooling when it was brand new) or even a CAD drawing!
The operator can:
Zoom in and out of the profile
Find any radius, angle or distance on the profile
Export the profile to CAD or compare it with a CAD drawing
Import a reference profile from a CAD drawing(including regions of interest)
View automatic measurements (compare it to the spec)
Each standard can have “regions of interest”, which allows the operator to automatically measure radii and angles anywhere on the profile. The measurements can be integrated into reports and inspected for variations over time, both between different rolls and for the same roll at different measurement positions.
For rolls, the system will automatically detect roll depth, height and length. For chucks, the system automatically measures the chuck width, angles and more. Both first and second operation rolls can be inspected easily. The system can also be used to inspect can necks, flanges and other characteristics. The system can print out graphs which can be compared with the original drawings.
Customers using the inROLL system are able to quickly return their investment by evaluating rolls and chucks already in storage. When companies have problems with a particular head, they often choose to replace the roll or chuck (or not replace it because it hasn’t reached it’s can count). Often, these “suspicious” rolls and chucks are placed in a storage with other rolls and chucks that may still be good.
No one is truly sure if these are good or bad, and because of their high costs they are typically not thrown out. Customers who used the inROLL system on such rolls found that between 70% and 80% of their rolls were still in good shape, and were able to reuse them. Other rolls were thrown away or returned to the manufacturer in situations where they did not match the original requirements. As rolls are quite expensive, this is a great way to quickly recover the cost of the system almost instantly!
Manufacturing often produces different results from the original design. The inROLL allows you to import your diagrams directly from Auto CADTM or other CAD software. Regions of interest are extracted automatically based on the design and the actual profile can be accurately compared with the original drawings!
Some manufacturers may have identical roll designs with different catalog numbers. Reduce inventory by combining all rolls with identical profiles into one part number!
Resolution: 0.0002″ (0.005 mm) or better (0.25″ (6.3 mm) range)
Calibration resolution: 0.0001″ (0.002 mm) or better
Roll & chuck Diameter: 1.75″ to 7″ (44.5- 178 mm) (custom diameters upon request)
Distance from roll bottom to groove: Up to 2″ (50 mm)
Angles: Up to 89.4 degrees
Radius Higher accuracy: .25″ or less
Radius Lower accuracy: above .25″
Acceptance testing for new rolls and chucks – prevent bad seams!
Monitor tooling wear to replace rolls and chucks only when they need to be replaced
Isolate bad profile designs to work with your supplier and correct them
Locate duplicate roll & chuck designs – reduce inventory!
Compare design with manufacturing specs (New: full import of CAD drawings, including radius and angle regions of interest!)
Reverse engineer tooling design
Compare designs from different manufacturers
Non-contact scan will not be skewed by anvil radius or other mechanical tolerances
Print to scale (50:1 ratio by default)
Export and import from CAD (DXF, point list and image support)
Automatic extraction of Regions of Interest from CAD files
Automatic and manual correlation between standard and actual profile
Automatic length, depth and height measurements
One unit works with all tooling as well as can flanges, necks, etc
Automatic radius and angle finder
Allows the operator to measure any angle, distance and/or radius
Windows OS Application
High resolution system
Return on investment
Reduce your inventory by finding bad rolls, rejecting them or placing them back in the seamer