The Third Dimension
KHS strikes new paths with 3D line design, complete with powerwall and 3D laser scanning
Peter Hoffmann*
KHS has made the jump from the second to the third dimension with 3D line design, thereby generating still more benefits for companies in the beverage, food and nonfood industries. At the same time, advances in powerwall and 3D laser scanning make virtual system site inspections possible, allowing even more accurate insights into the world of systems and at the same time more individual and precise operation during line design.
From 2D to 3D line design
Until now, 2D line design has been the standard procedure. Companies in the beverage, food, and nonfood industries were basically provided with a project drawing showing a view of the required line. As the name suggests, 3D line design now has the advantage of the third dimension. Whichever scale the system is represented in, the machines, conveyors, and all other system components contained in the system are depicted in correct proportion to one another with reference to the length, width, and height of the required interfaces.
A system that learns
In a 3D representation, for example, it is easy to see the exact inclines and declines on conveyors, or how high the bottle washer is in comparison to other machines, and much more. This makes it possible to easily adapt line conditions to existing building conditions. 3D planning also makes it possible to create an expert system piece by piece and integrate it into planning processes. This makes the 3D system an intelligent system that is capable of learning. For example, for a planned new line the information as to which containers of which size are to be processed in which capacity is entered.
* Line Design Manager, KHS AG, Dortmund, Tel.: +49 (231) 569-1521
Here, the system immediately recognizes which maximum inclines and declines are plausible on the conveyor systems to be integrated. This both shortens the planning phase and eliminates possible sources of error right from the start.
KHS powerwall allows large-scale 3D viewing
It goes without saying that a newly planned system can be better represented and displayed in 3D than in 2D. Large-scale presentation of this 3D system is now possible using the new KHS powerwall. The powerwall is based on the following technical setup: using special software, four PCs split a stipulated 3D line project into two different overlapping images that are then projected onto a screen.
Visible from both above and below: 3D panorama viewing
Standing before the powerwall, customers can experience their future line in the third dimension unlike anywhere else. Just like at a 3D movie, 'theater-goers' are presented with special glasses that enable them to see in 3D. With the help of what is known as a fly stick, viewers can enter and navigate through the line as they require by pressing the function buttons and simultaneously moving the fly stick in the right direction. They can take a virtual tour of the system, during which the machines can be viewed from the floor or seen from above, for example. They can also control the speed at which they observe their future system, taking it fast or slow, just as they wish. The software also features panorama viewing, where the perspective is changed simply by turning the head.
Changes are allowed!
3D imaging on the powerwall is particularly useful when companies in the beverage, food, and nonfood sectors wish to make a virtual assessment of the line they have ordered and planned before it is manufactured. The advantage here is that should one or other component prove less convincing than in the initial planning when seen virtually, this can be recognized in good time and appropriate countermeasures taken. New ideas can be swiftly integrated into the 3D design and then again viewed in 3D. Maximum safety of investment is a given.
Exact representation of individual machines
The powerwall display integrates both a view of the overall line and of the individual machines as required. For this purpose, a link must be made to a 3D presentation of the respective machine. The list of possibilities is endless, with both a virtual tour through the pasteurizer or a detailed inspection of all washing stages in the bottle washer both feasible, for example.
Visualization of upstream and downstream systems
The system can also visualize any stages in the process connected upstream or downstream of the line equipment, such as the syrup room or the conveying and storage logistics. This allows interfaces to be recognized well in advance, assessed and, if necessary, altered – an important prerequisite for holistic planning.
Machine placement also requires planning
Looking at the powerwall, customers can also plan how individual machines can be best brought into the plant. For example, where can large machine parts be most easily maneuvered into the designated production shop? Where exactly are the critical points in the building regarding the conveying of individual parts to their intended point of assembly? All this can be visualized on the powerwall, enabling precise preparation when positioning a new line within the plant. This favors the exceptionally quick setup of the new line machinery and shortens the commissioning phase.
Perfect preparation for expected new developments
A mutual virtual site inspection of a new line using the powerwall is the perfect way to familiarize the entire technical staff of a company with new KHS line equipment. A portable powerwall solution makes this possible. Future system operators can thus discuss the new line concept in detail with decision-makers at the respective beverage, food, or nonfood company. Questions from individuals on the new engineering system can be clarified in advance. This procedure motivates employees and keeps them in pleasant anticipation of 'their' system. The next logical step in the proceedings would be to train employees in advance on the powerwall – something that is also feasible here.
3D laser scanning for maximum precision measurement
Necessary data on the building in which the new system technology is to be installed can be determined in a number of ways for 3D animation on the powerwall. One possibility would be to glean data exclusively from specific architectural plans. However, if the building where the line is to be installed has a number of critical points (such as varying heights and levels or recesses in the production shop area), it is advisable that customers recheck their data using 3D laser scanning (allowing 360° imaging). This is the only way of guaranteeing accuracy right down to the last detail – regardless of whether the shop is empty or full of line machinery. The advance measurement of shop floors filled with line machinery prior to line design is particularly important if certain machines within the line are to be replaced – when integrating a new filler, for example.
Before the production shop is measured using the 3D laser scanner, all measurement processes are precisely planned and measuring positions determined based on the shop floor plan. Ten to thirty scanning processes are required to exactly record the current status. Each measuring process takes 30 seconds to 3 minutes. During this period, up to 21 million points are recorded. Because of the huge number of points, this is called a scatter plot. After all of the measurements have been taken, the individual scans are merged thereby generating an extremely accurate shop image in 3D, into which the line designed for the respective plant can now be perfectly integrated.
It's good to know that KHS cordons off a six-meter radius during laser scanning. This means that operating personnel present in the shop during scanning processes are not exposed to any risk.
Performing a 3D laser scan once the new line machinery has been integrated into the plant also has the great advantage of being able to present the company with an as-built documentation at the end of the scanning process, depicting all aspects of the new engineering system in 3D. If conversions are planned in the future, or if certain machines are to be replaced, the 3D design is helpful, allowing new ideas to be rapidly integrated into the 3D animation and shown on the powerwall.
Complete planning of new enterprises made easy
Using 3D line design, the powerwall and 3D laser scanning, KHS is also now perfectly equipped to produce complete plans for new enterprises. Buildings, logistics, and technical systems can all be visualized in detail, with all interfaces precisely defined.
Heralding a new era of 3D line design
All told, with 3D line design and innovative tool highlights, such as the powerwall and 3D laser scanning, KHS is heralding a new era of line engineering that has many advantages versus previous setups. Innovative 3D line design emphasizes KHS' competence at providing complete solutions in accordance with the KHS motto of "Quality right down the line".
