Sensor for Production and Quality Control

Transcription

1 Sensor for Production and Quality Control VisioCount C Operation Manual Blister induced current Visio- Machine Count C magn. field switching output / input USB Interface Software Control Machine Ejector Computer

2 Delivery Extent VisioCount C including : - receiver - transmitter VisioCount Software Flow Controller USB Interface Cable HOSSBACH Sensor Technologie Veilchenweg 40 D Erlangen Germany Tel. xx / Fax. xx / info@hst-hossbach.de URL : 2

3 Features : blister counter for many kinds of cartoners control of exactly blister filled packages detection of missing and supernumerary blister(s) sensitive also for perforated blisters detection rate > 600 packages per minute easy adjustment due to teach in-features PC software for adjustment and operation control +24V +/- 10% operation voltage switching, opto-coupler output +24 V / 20mA small and robust housings including all the electronics Description : The VisioCount C ensures user, that only correctly blister filled boxes will leave the packaging machine. The VisioCount C is a smart control system, which is, due to its ingenious concept, very easily integrated in blister packaging machines, cartoners and directly accessed by external logic controls. The VisioCount C outputs a +24V signal for each box, that is filled with the accurate number of blisters. Missing or supernumerary blister will let blink the referring LED indicators. The number of blisters and the kinds of blisters, e.g. small, large, perforated or not may vary in a very wide range. Instead of troublesome adjustments, the VisioCount C is adjusted for the just packaged blister box either by applying a 24V signal to its teach-in input or by help of a computer program. Using the VisioCount C software operation and adjustments are controlled and visualised. Building Blocks : Blister Sensor Machine Machine VisioCount C equipment induced current magn. field switching output / input USB Interface Control Ejector machine line device Software Computer Operation Elements : distance ok rear side of the Receiver 3

4 Operation Elements 6 5 distance ok pin male connector for - power supply +24VDC, stabilised - teach-in input, teach-in procedure is initialised by a +24V signal - switching output, activated for each correctly filled blister box green OK LED blinks, when a correctly filled blister box is detected red +1 LED blinks, when the box contains supernumerary blister(s) yellow +1 LED blinks, when blister(s) is/are missing The bi-colour LED gets off, when the distance between receiver and transmitter is either teached-in by help of the computer program or adjusted mechanically by finding the referring distance. No blister in the measuring field! for mechanical distance correction : if red Distance LED shines : the distance is too low if yellow Distance LED shines : the distance is too high 6 USB connector for interconnection to and communication with an external computer 4

5 Measurement Principle USB interface cable to machine control and power supply voltage transducers serial interface logic control, parameters signal processing circuit measuring field to signal coverter Receiver evaluating the amount of attenuation of the magnetic field by the aluminium sealed blisters. Receiver will only and everytimes output a switching signal, when boxes contain the correct number of blisters. box with a missing blister --> less field attenuation attenuated measuring field (= less field lines) box containing correct number of blisters --> correct field attenuation box containing a supernumerous blister --> higher field attenuation transport direction field lines of the measuring field before being absorbed by the alumium foils of the blister. measuring field generator amount of absorption depending on the number and kind of blisters being in the sensor field. voltage transducer transmitter to power supply 5

6 Machine Control Cable USB Cable Receiver Machine Programmable Logic Control Personal Computer for adjustments and validations Transmitter Power Supply 24VDC System Overview : Power Supply Cable Dimension : [mm] Transmitter 30 M distance ok Receiver M

7 Screen Elements : Operation Screen (8) (1) (2b) (2) (2a) (2c) (3) (1a) (1b) (1c) (2d) (2e) (2f) (2g) (4) (5) (7) (1) (1a) (1b) (1c) (2) (2a) (2b) (2c) (2d) (2e) (2f) (2g) (3) (4) (5) (6) (7) (8) Fig. 1 (6) Profile Panel : each down going curve represents measurements of one blister box (see also chapter for Machine Interferences ). Display actual reading : This number shows measurement values without synchronisation (see also chapter for Machine Interferences ). The measurement range indicates, when the VisioCount C gets out of range. This bar graph indicator visualises the actual reading in a graphical way. Evaluation Panel contains or refers to : The blister box evaluation values corresponding to the lowest profile values of the profiles (1). Upper tolerance values. Evaluation values exceeding these values indicate boxes with missing blisters Lower tolerance values. Evaluation values falling lower than these values indicate boxes with supernumerary blisters. The number last value indicates the evaluation value of the last blister box. This value refers to a green point of (2) and a minimum of a profile curve of (1). The counter count ok is increased by 1, each time the evaluated blister box value lies between the referring upper and lower tolerance value. The counter defects is increased by 1, each time the evaluated blister box value either exceeds the referring upper tolerance value or falls under the referring lower tolerance value. The counters OK and defects are reset, when pushing this icon. The indicator line status messages shows actual messages or statuses. Pushing the button start teach-in initialises the teach in-procedure. The panel Measurement contains buttons to control the operation of the measuring sensor, including menus to set the configuration parameters. The panel Communication contains elements to adjust the communication port of the PC and to see PC operation status. This panel contains the buttons for terminating the program and to see the software version. This area shows the system date and time. 7

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9 Installation 9

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11 Installation Mounting : top ca. 120 mm *) 10 mm, minimal, variable distance mm, constant distance receiver blister filledbox machine / transport tunnel wall transmitter machine / transport tunnel wall bottom 11

12 Installation Mounting : reference installation drawing - Chose a location in the machine, where the blister boxes pass the transmitter and the receiver in a constant distance. - This location should be free of moving metallic parts, that could interfer the measuring field, and therefor operation performance - Mount receiver and transmitter of the VisioCount C as indicated in the Mouting drawing. - Receiver and transmitter must be mounted in the middle of the box feeding tunnel. - The receiver and transmitter must be mounted with distances as indicated in the Mounting drawing. - The white plastics heads of receiver and transmitter must not covered by metallic parts, especially mounting parts. 12

13 Installation Electrical Interconntions : USB InterfacConnector and Plug Connections drawing - Receiver and transmitter of the VicioCount C are connected to stabilised +24VDC +- 10% to power up operation. The power supply cable should not carry along spikes or potential differences. - The PNP switching output is connected to the machine PLC. This output signalises incorrectly filled blister boxes. - The PNP switching input is connected to the machine PLC. Activating this input will initialise the teach-in procedure for the just packed box size, i.e. number of packed blisters. ( if the PLC output has not the same ground, 0V level as the power supply the 0V pin of the receiver must conneted to the referring 0V/ground of the PLC. - For adjustments, analysis and validation purposes the receiver of the VisioCount C is connected by the USB cable to the external PC. USB Interface Connector : communication VisioCount C <-> PC distance USB ok Plug Connections : power supply and switching output Receiver sensor version switching ouput 4 pin female connector cable pin 1 power supply +24V brown pin 2 teach in +24V white pin 3 power supply 0V/GND blue pin 4 switching output "0V/24V" black Receiver taring / white +24VDC / brown output / black 0V / blue PNP Transmitter : switching output, PNP 4 pin female connector cable sensor version switching ouput pin 1 power supply +24V brown pin 3 power supply 0V/GND blue Transmitter VDC / brown 0V / blue

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15 Start - Up 15

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17 Start - Up Without Computer : - Mount the receiver and transmitter according the mounting drawing. - Power on receiver and transmitter. - Adjust the distance receiver to the fixed transmitter the way that the distance LED gets off. For that adjustment no blister box must in the between receiver and transmitter... and no other metallic part. - Then let pass the correctly filled blister boxes. - Switch the teach-in input to +24V for at least 2 or 3 boxes. - After releasing the teach-in in put from +24V or switching to 0V the teach-in procedure is finished. - Correctly filled boxes will activate the switching output for a signal pulse. The green OK led will blink each time. - Incorrectly filled boxes will leave the switching output inactive. For boxes with missing blisters the red -1 led will blink. For boxes with supernumerary blisters the yellow +1 led will blink. The advantage of the start-up without external computer is : - Fast start up. The dis-dvantage of the start-up without external computer are : - The standard default parameters will be used. These must not be ideal for the control of the current blister boxes. - The adjusted distance between receiver and transmitter may be in-acceptable. - The thresholds for incorrectly filled boxes may not be ideal. 17

18 With Computer : Start - Up Communication Setup with the Computer : - Mount the receiver and transmitter according the mounting drawing. - Connect the receiver to the external PC by the original USB Cable. - Start the VisioCount C program. - Power on receiver and transmitter. - Test the communication between PC and VisioCount C by selecting the used USB communication port in the Communication panel. - Press button test - If the message window No VisioCount C found appears, select another com port. Mostly the highest com port is the correct one. - If the message window VisioCount C found appears, the communication is set up and the further operation adjustments can be performed. Not correct communication port Correct communication port 18

19 With Computer : Start - Up Receiver-Transmitter Distance Adjustment : - The optimal adjustment referring the distance between receiver and the transmitter -including machine specific adaptions- is automatically adjusted using the following procedure. - Push the sensor calibration button of the Measurement panel. The Sensor Calibration window opens. - Push the download button to get the parameters from the receiver. - Push the auto detection button. Now the distance adjustment procedure is performed and the referring parameters are evaluated. - Push the upload button to transfer the new parameters to the VisioCount C. - Leave the Sensor calibration window menu by pushing the ready button. Sensor Calibration Window VisioCount C parameters are downloaded to the computer. The distance parameters are evaluated. The new parameters are uploaded to the VisioCount C 19

20 With Computer : Start - Up teach - in : - The teach-in procedure must be started, if - for the first time - a new kind of blister box should be checked - the VisioCount C is powered on again - the mounting, especially the distance between receiver and transmitter was modified ( Here the automatic detection must be re-started as well as other sensor settings. See chapter Sensor Calibration Window ) - Start measurement pushing the start button. - Pushing the start teach-in button initiates the teach-procedure. - The teach-in procedure is performed during scanning a single blister box. - The teach-in procedure should be performed, when the blister boxes pass the VisioCount C continuously. - The VisioCount C may work satisfactory after the teach-in procedure with the pre-set internal parameter sets. For control, optimising and test purposes the start-up steps of the following pages should be followed.. teach-in procedure started by pushing the teach-in button 20

21 With Computer : Start - Up First Run : - The machine runs - the boxes pass the VisioCount C - Start operation pushing the start button - The Evaluation Panel (2) show the blister box values as green dots. -The green blister box values are between the upper and lower tolerance values, blue lines. - If the blister boxes are filled correctly can be checked measuring boxes with a missing or a supernumerary blister, (next step). - The Profile Panel (1) shows the profile of several blister boxes. The profiles have almost the same course. operation screen 21

22 With Computer : Start - Up incorrectly filled blister boxes : - The upper screen shot - visualising the Profile Panel (1) and the Evaluation Panel (2) - shows the every 8th blister box has a missing blister. - The lower screen shot - visualising the Profile Panel (1) and the Evaluation Panel (2) - shows the every 8th blister box has a supernumerary blister. adjustment hint : - The lower tolerance curve (lower blue line) could be adjusted closer to the green point, representing the correctly filled boxes. (next step) - Each adjustment must uploaded into the VisioCount C receiver --> settings menu. here every 8th box has a missing blister here every 8th box has a supernumerary blister 22

23 With Computer : Start - Up Sensor Calibration Window : - The adjuster upper limit sets the distance of the upper limit points to a dynamically evaluated average value of several good measurement value, i.e. correctly filled boxes. See adjuster number of averaged values. Normally 20 digits is a good parameter for detecting missing blisters. - The adjuster lower limit sets the distance of the lower limit points to a dynamically evaluated average value of several good measurement value, i.e. correctly filled boxes. See adjuster number of averaged values. Normally 20 digits is a good parameter for detecting supernumerary blisters. - The parameter hysteresis fixes the distance measured from the bottom of one blister profile to the beginning of the falling of the profile of the next blister. This prevents the VisioCount C to detect two or more blisters, only because of little ups and downs within the same blister profile curve. Normally 20 digits is a good parameter. - The parameter signal width sets the duration of the switching output signal. - The parameter number of products for teach-in is presently fixed to 1. This shortens the teach-in procedure. Only one correctly filled blister box has to be scanned. - The parameter number of averaged values is presently fixed to 1. This shortens the teach-in procedure. Only one correctly filled blister box has to be scanned. - The parameter number of averaged values determines how many measuring values of correctly filled blister boxes are averaged to give a reference to the upper limit and lower limit. - The parameter amplification is automatically evaluated by pushing the automatic detection button. The automatic detection procedure adjusts the internal amplification due to the installation condition of the receiver and the transmitter. The amplification parameter should be between 5 and 110! Adjustment Window 23

24 With Computer : Start - Up Sensor Calibration Window : - To see and to change the parameter settings, they must be loaded from the Visiocount C by pushing the download button. - Changed parameters must be uploaded to the VisioCount C by pushing the upload button. - Pushing the ready button exits the Sensor Calibration Window. - Buttons save settings and load setting are not active. The referring features are realised by the High Performance Software Package. adjustment hints : - Do not forget to upload changed parameters to the VisioCount C - The procedure automatic detection should deliver values between 5 and 110. If not, the distance between receiver and transmitter has to be changed! - The parameter number of averaged values should not set too low, preventing an unstable upper and lower limit curve. 10 may be a good parameter value. Adjustment Window 24

25 With Computer : Start - Up Software Settings Window : - Software updates can be uploaded after pressing the update main processor button. - The language can be shoosen using the language scroll menu. - Pressing the button show version indicates the present software version - Pushing the ready button exits the Software Settings Window. - Buttons upload and download are not active. The referring features are realised by the High Performance Software Package. Adjustment Window 25

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27 Trouble - Shooting 27

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29 With Computer : Trouble Shooting - The VisioCount C may also measures interference signals arising from moving machine parts as well as from crosstalk to the connection cables. - These interferences can be made visible at the operation screen. - Perform tests without blister boxes and with empty blister boxes during running and stopped machine. - If interferences occur, they are now made visible by zooming also the lowest ones. - Interferences are only of importance, if they are high relative to the distance tolerance curve to measuring value curve. operation screen showing interference signals - no blister in the measuring field - 29

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