7.5 KiB
New Layout:
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New Inverters:
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SEW Motor for the Bottle Turner:
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Line (Black) motors on the line:
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Bottle turner logic:
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Speed follow up linked to the Lowerator Encoder: !
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This must be calibrated with the Labeler speed. Adjusting the "DB BT Logic M130".RCP.ProductionVel to the maximun speed that corresponds to the 68.42 m/min of the encoder.
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This can be done for each format on the BT Setup Page: !
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The Minimal speed it is used to limit the minimal speed that the machine can run with low friction. Normaly this is 30 bottles/min in mm/sec ( 100 mm/sec aprox)
Logic:
The BT runs the endless screws with the M130 SEW motor using belts. The screws are mounted over linear bearing to admit jams in case of bottle entered on the wrong side o turned. The two screws are pushed together with a pneumatic piston. The piston works with 2 different pressures. The high pressure when the screws are ramping up and the normal pressure when the screws are in normal production speed. On test the high pressure was set to 6 bar and the run pressure to 2,5 bar. The piston has a sensor to indicate a jam, if the sensor not read the machine must stop. Also there is a Torque control on the inverter to also stop if the torque is more than a HMI value.
The BT operates endless screws using the M130 SEW motor and belts. These screws, situated over a linear bearing, can sense jams if a bottle is incorrectly positioned or turned. A pneumatic piston pushes the two screws together, functioning at two pressure levels: high pressure during ramp-up, and normal pressure during regular production. During testing, high pressure was set at 6 bar and run pressure at 2.5 bar.
The piston has a sensor to detect jams. If the sensor fails to read the piston at the back, the machine must stop. Additionally, a Torque control on the inverter halts the operation if the torque exceeds a certain HMI value. Normally on the test the torque range from 1 to 2 but on the startup can reach 2,6. So all the test was set to 3. Normally the machine stops before for the torque control that the sensor on the piston.
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On the PLC the protocol FC Mot Manage Movigear ADV_DPRDAT (FC528) was added to run the Movigear inverter for M130. To add this protocol we need to make small changes on the UDT Motor.
On the FC380 is call the logic (FB BT Logic FB227) for the BT on net 20. The FB needs:
- Minimun accumulation to allow the BT to run
- Maximun accumulation to stop
- Safety_Driver : Sensor to detect jams
- Door1 / Door2.
- Pilz ok: To set the alarm if the safety is not reset.
- Start / Stop / Reset : Buttons to handle Automatic logic.
- The Motor used to run the BT. From the motor it gets the speed and torque.
The FB BT Logic handles the recipe data and the Automatic state of the machine. Also output the lights states for the buttons, and the enable for the M130:
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The timers TON / TOFF for the minimal / max accumulation are handled inside the FB. This times can be changed on the HMI.
On the FB logic the ramp check to activate the High pressure are calculated like this:
// Finish pulse when the motor reachs the velocity and is not more in ramp
#TON_HighPressure.S := ( ( #Motor.OUT_VFD_REQ_Speed_Hz - #Motor.STATUS_VFD_ACT_Speed_Hz ) / 1000.0) < 0.1;
#Status."High Pressure Step" := NOT #TON_HighPressure.Q;
#TON_HighPressure.TW := 40; // 4sec
So 0.1 means 10% of change in the speed.
To enable the M130 to run:
#Status."Drive Enable" := #Status.Auto AND #Status.Enable_MinAccum AND #Status.Enable_Outfeed OR
#Status.Manual AND #Status.Enable_Outfeed;
EMD: Created 2 new zones as described on the electrical diagram
To manage the 12 zones, was needed to add a new EMD page because the maximun of zones are 10 for each page/ DB. Created new DB 224.
Added 2 alarms.
New Alarms:
| Alarm | Description | IO involved |
| 371/02/4 TableTop - M130 - ThermoMagnetic Swich Tripped | Current protection shitch turn off | E2.0 |
| 371/50/0 TableTop - M99 - ThermoMagnetic Swich Tripped | Current protection shitch turn off | |
| 371/50/1 TableTop - M99 - Trip VFD | Inverter stopped and in alarm | |
| 371/50/2 TableTop - M99 - DP Alarm | Fieldbus conecction error | |
| 371/50/3 TableTop - M99 - Disconnector Switch Open | Motor shitch disconected | |
| 371/50/4 TableTop - M99 - Manual Mode | Motor in manual mode | |
| 371/50/5 TableTop - M99 - Power OFF | Motor in stop mode | |
| 371/51/0 TableTop - M100 - ThermoMagnetic Swich Tripped | Current protection shitch turn off | |
| 371/51/1 TableTop - M100 - Trip VFD | Inverter stopped and in alarm | |
| 371/51/2 TableTop - M100 - DP Alarm | Fieldbus conecction error | |
| 371/51/3 TableTop - M100 - Disconnector Switch Open | Motor shitch disconected | |
| 371/51/4 TableTop - M100 - Manual Mode | Motor in manual mode | |
| 371/51/5 TableTop - M100 - Power OFF | Motor in stop mode | |
| 371/52/0 TableTop - M101 - ThermoMagnetic Swich Tripped | Current protection shitch turn off | |
| 371/52/1 TableTop - M101 - Trip VFD | Inverter stopped and in alarm | |
| 371/52/2 TableTop - M101 - DP Alarm | Fieldbus conecction error | |
| 371/52/3 TableTop - M101 - Disconnector Switch Open | Motor shitch disconected | |
| 371/52/4 TableTop - M101 - Manual Mode | Motor in manual mode | |
| 371/52/5 TableTop - M101 - Power OFF | Motor in stop mode | |
| 371/53/0 TableTop - M102 - ThermoMagnetic Swich Tripped | Current protection shitch turn off | |
| 371/53/1 TableTop - M102 - Trip VFD | Inverter stopped and in alarm | |
| 371/53/2 TableTop - M102 - DP Alarm | Fieldbus conecction error | |
| 371/53/3 TableTop - M102 - Disconnector Switch Open | Motor shitch disconected | |
| 371/53/4 TableTop - M102 - Manual Mode | Motor in manual mode | |
| 371/53/5 TableTop - M102 - Power OFF | Motor in stop mode | |
| 371/54/0 TableTop - M130 - ThermoMagnetic Swich Tripped | Current protection shitch turn off | |
| 371/54/1 TableTop - M130 - Trip VFD | Inverter stopped and in alarm | |
| 371/54/2 TableTop - M130 - DP Alarm | Fieldbus conecction error | |
| 371/54/3 TableTop - M130 - Disconnector Switch Open | Motor shitch disconected | |
| 371/54/4 TableTop - M130 - Manual Mode | Motor in manual mode | |
| 371/54/5 TableTop - M130 - Power OFF | Motor in stop mode | |
| 371/14/0 TableTop - Bottle Turner - Jam | Bottle turner safety sensor open. This sensor detects that the screws were opened. May indicate jam inside the bottle turner. | E103.0 - S3-M130 |
| 371/14/1 TableTop - Bottle Turner - Door 1 | Door 1 open | E3.5 |
| 371/14/2 TableTop - Bottle Turner - Door 2 | Door 2 open | E3.6 |
| 371/14/3 TableTop - Bottle Turner - No min. Accumulation | There is not minimun accumulation to start the bottle turner. | E103.2 - B3-M130 |
| 371/14/4 TableTop - Bottle Turner - Outfeed Full | The outfeed photocell indicates the conveyor are full | E103.3 - B3 -M130 |
| 371/14/5 TableTop - Bottle Turner - Pilz Not Ready | The safety pilz is in alarm | e2.7 |
| 371/14/6 TableTop - Bottle Turner - Not started | Bottle turner need to be started | |
| 371/14/7 TableTop - Bottle Turner - Max Torque reached | Bottle turner reached the maximun torque allowed on the HMI | |
| 371/18/0 TableTop - Bassa Pressione P1-M93 | Pressure low to run the EMD | E5.2 |
| 371/18/1 TableTop - Bassa Pressione P1-M102 | Pressure low to run the EMD | E5.3 |