Geometry & fault detection system for glass | Load Validator - Glassquality
LiteSentry Load Validator Geometry + Fault Detection System

LOAD VALIDATOR™

GEOMETRY + FAULT DETECTION SYSTEM FOR GLASS

The Load Validator™ provides an accurate, repeatable, consistent measurement of glass size, load size, and critical fault conditions likely to cause glass breakage and line interruptions.

Load Validator technology is available as a stand-alone system or included with the Owl 5.

Load Validator

Load Validator™ Geometry + Fault Detection System

» Key Application: Coating Line, Tempering Furnaces

» For use on critical continuous processes such as a high vacuum coating system or washer preceding tempering.

» Detect fault conditions in the glass or load geometry.

» Alarm the conveyor system to stop the glass load before the load enters the continuous process.

Owl 5 Furnace Optimization System

» Key Application: Tempering Furnaces

» Discern most colored glass, as well as various coating & colored glass combinations

» Automated measurement of Thickness,

»Size, Coating (LowE 1, 2, 3, i89, Non-coated), Locations of parts

»Detect faulty loads

»Real-time feedback to the furnace

»Stop conveyor in event of a fault

»Systematic and repeatable adjustments made to furnace with no operator interruption

Ensures correct load geometry and detects faults before glass enters critical processes

The Load Validator™ is installed on the production line prior to critical continuous processes, such as high vacuum coating systems or washer stations preceding tempering. Real-time, 100% inspection collects, analyzes, and reports out data on every glass sheet. Detection of non-conforming loads or defective glass triggers alarms that stop the conveyor system, preventing the defective material from furthering processing.

Load Validator HMI

#CONDITIONTOLERANCE
0NO ERRORN/A
1WIDE LOAD+/- 3mm
2PART OVERLAP6mm
3BROKEN GLASSANY SEPARATION
4SHORT PART+/- 12mm*
5MINIMUM DISTANCE BETWEEN PARTS
TRAVEL DIRECTION (5a)
CROSS CONVEYOR (5b)


+/- 12mm
+/- 3mm
6CORNER OFF (6a)
NON-RECTANGULAR (6b)
6mm
>120mm
7LONG LOAD+/-12mm*
* DEPENDING ON CONVEYOR ACCURACY 

ROI of LiteSentry Load Validator technology

Load Validator technology pays for itself by preventing as few as 4 to 5 shutdowns based on:

  • 5 to 20 hours per shutdown
  • Minimum of $2,000 per hour of non-production NOT including lost revenue
  • $20,000 average financial impact of coater interruption 
  • Improves optical quality by optimizing heat-time or heat-profile and preventing overheating of small loads
  • Eliminates lost production due to recipe changes
  • Eliminates operator errors due to incorrect inputs
  • Detects 7 fault conditions including wide load, part overlap or stacking, broken glass, short part, minimum distance between parts, corner off, and long load.
  • Ability to stop a faulty load from moving into the furnace.

  • Improves optical quality by optimizing heat-time or heat-profile and preventing overheating of small loads
  • Eliminates lost production due to recipe changes
  • Eliminates operator errors due to incorrect inputs
  • Non-contact, real-time measurement of glass size, thickness and low-E coating
  • Detects 7 fault conditions including wide load, part overlap or stacking, broken glass, short part, minimum distance between parts, corner off, and long load.
  • Ability to stop a faulty load from moving into the furnace.

Typical Load Validator screen

Good load
Bad load Short lite Corner off Non-rectangular
Bad load – Corner off Part spacing/overlap Bad load Corner off Part spacing/overlap
Bad load – Excessive long load

ROI of a LiteSentry Owl

What is the value of 10 seconds In a 24-hour period?

240 second cycle time = 360 load vs @ 230 second cycle time = 376 loads

16 loads additional throughput per day

Load Validator technology pays for itself by preventing as few as 4 to 5 shutdowns based on:

  • 5 to 20 hours per shutdown
  • Minimum of $2,000 per hour of non-production NOT including lost revenue
  • $20,000 average financial impact of coater interruption 

Learn how the new Load Validator™ can increase
your bottom line.