The ES8000 offers a wide range of functions and capabilities:

Measurement: It performs non-contact dimensional measurements of food and beverage shells and progressions, supporting various end sizes (46mm to 95mm, nominally 113 to 307, plus up to 100mm, which includes 404 with the ES8001X variant). It can measure plain, colored, and black coated ends, and supports both centered and off-center rivets.

Automation & Loading: It features automatic operation with minimal operator supervision during normal use. It has three high-capacity, manually-loaded drawers (up to 50 ends per drawer), allowing operators to load/unload one drawer while the gauge tests from another for high throughput. Each drawer has independent input and output stacks. Software Control: The gauge is controlled via Sencon's proprietary Process Master software, which allows for batch testing, procedure scheduling, and results viewing.

Flexibility & Customization: It comes with pre-set procedures, but new procedures can be created and existing ones edited (with supervisor login). There's no practical limit to the number of procedures, allowing for customization to specific factory lines, presses, or customer specifications. Additional end designs or features can be added via Sencon's Gauge Builder™ software framework.

Results & Reporting: Results are sent as electronic reports to a factory data system or printer. The gauge provides immediate warnings via the operator screen and beacon lights if measurements are outside test specifications. Results can be viewed in various detailed formats (R&R, single end, batch, text, and 2D graphic views).

Advanced Features: Includes "Virtual Sectioning™" for detailed graphical profiles of progression stages and material thickness, eliminating the need for physical sectioning.

The ES8000 improves product quality and ensures accurate measurements through several key features:

Non-Contact Sensors: It utilizes dual laser calipers that simultaneously scan above and below the end, measuring features from both top and bottom surfaces. This non-contact approach requires little maintenance.

Comprehensive Data Visualization: Compiled test results provide a clear, accurate, and comprehensive visualization of measured features.

Immediate Alerts: If specification limits are reached, the gauge gives immediate warning via the operator screen and colored beacon lights (amber for gauge fault/stoppage, red for measurement outside specification).

Programmable Limits: Supervisors can program pass, warning, and fail limits for various measurements.

Traceability: Results can be linked to individual shells and presses, and batch information includes the factory floor press each end came from, allowing for identification of production process issues.

Calibration & Verification: The gauge performs automatic pre-batch thickness verifications, and full servicing and recalibration are recommended annually by Sencon engineers to maintain precision. Users can also view calibration history to identify trends.

Basic operation of the ES8000 for testing batches of ends involves a few steps:

Prepare and Stack Ends: Sample ends must be clean and stacked in the correct order based on progression stage or pocket, not exceeding 110mm height.

Select Procedure: Operators can select commonly used procedures via shortcut buttons on the Mimic screen, or choose from a full list on the Schedule screen.

Check Batch Details: On the Schedule screen, verify or amend details such as the correct press, procedure, drawer number, ends per selection, and total ends.

Load Ends: Open the designated drawer and carefully insert the stack of ends into the in-stack bay, ensuring they fit loosely between the pins.

Schedule Procedure: Once ends are loaded, press the "Schedule" button. If no other procedures are running, it starts immediately; otherwise, it's added to a queue.

Gauge Tests Ends: The gauge automatically locks the drawer, takes ends, scans them, and places them in the out-stack. Operators don't need to supervise continuously, as beacons alert to issues.

Retrieve Tested Ends: Once testing is complete, the drawer unlocks, and tested ends can be removed from the out-stack.

Process Master™ is Sencon’s proprietary gauge control and batch scheduling software that runs on a Windows™ PC integrated within the ES8000 system. It serves as the primary interface for controlling and running the gauge. Its key roles include:

Procedure Management: All testing is based on programmable batch-testing sequences called "procedures". Process Master™ allows operators to select and schedule these, and supervisors to create, edit, and configure them.

Gauge Control:It enables day-to-day operator actions like running batches and viewing results through a touchscreen interface.

Batch Scheduling: It manages the queuing and execution of measurement procedures.

Reporting: It compiles measurements and results into detailed reports, which can be saved to a network drive or sent to a printer.

System Configuration: Supervisor login provides access to advanced settings for system configuration, user accounts, and message mapping.

The ES8000's design, with three independent loading drawers, allows for flexible multiple batch operations:

Scheduling Simultaneously: Operators can load different batches into different drawers and schedule their respective procedures at the same time. The gauge will test them in the scheduled order.

Continuous Operation: While one procedure runs from one drawer, operators can empty, reload, and reschedule another drawer. This allows for continuous gauge operation, maximizing throughput.

Combining Small Batches: For smaller batches (less than 25 ends each), multiple batches can be stacked together in a single drawer, provided the total stack height is within limits. It's crucial to stack them in the correct order (first batch on top, last batch on bottom) to ensure accurate result association.

The ES8000 incorporates several safety features and has specific routine maintenance guidelines:

Safety Features: Includes an emergency stop button (disables all moving parts), interlocked test compartment door (disables movement when open), and air dump valve. Automatic moving parts are enclosed, and warnings about nip and crush hazards are given. Mains-voltage electrical circuits are within a locked compartment, and compressed air components require trained personnel for adjustment. It also incorporates Class 2 lasers, advising against direct eye contact.

Emergency Stop: In an emergency, pressing the button stops all movement. To re-energize, pull the button out and press the reset button.

Routine Checks: Operators should remove excess ends and debris every shift. Monthly checks include cleaning the gauge (without solvents), checking fan filters, removing debris from lower laser lenses and thickness setting piece, and visually inspecting chuck jaws and end transfer grippers for damage. Beacons' operation should also be checked monthly.

Professional Servicing: A full service and recalibration by Sencon are recommended every 12 months, including inspection, adjustment, lubrication, wear part replacement, calibration of precision mechanisms, software updates, and re-verification.

In Process Master, 'Procedures' are key programmable elements. Data structures that define how a batch of ends should be tested. A procedure specifies the end type, the specific measurements to take, and the pass/fail thresholds (limits) for each measurement. Operators select pre-set procedures for testing, but users with supervisor login rights can amend existing procedures or create new ones to tailor the gauge's operation to specific needs.

The ES8000 End Measurement System supports a range of end sizes.

• Ends sizes from 46mm to 95mm (1.81" to 3.74"), which are nominally 113 to 307, with automatic adjustment.
• The special order ES8001X supports ends up to 110mm (4.33") which includes 404
• All circular easy-open beverage and food ends and shells are supported
• The ES8000 measures the widest range of easy-open beverage and food shell diameters without the need for change parts or adjustment
• The system is also capable of accepting interchangeable end sizes for progression measurements
• Typical drawer capacity of 50, 202 ends per drawer, with a maximum stack height of 110 mm

Process Master uses reports to create permanent records of test results, either as a text file saved to a network drive or printed. Reports can display results in various formats (lists, tables). Supervisors can enable report generation within a procedure and select from available report layouts and destinations. They can also create new report definitions or edit existing ones, although fixed format reports used by the ES8000 are based on pre-defined layouts, meaning only destination or name can be changed, not their look or content. It's crucial to back up the Process Master database after any changes to procedures or reports to prevent data loss.