Checkbox Compact

Checkbox Compact
Checkbox Compact
Manual
Checkbox Compact
Type CHB-C-C
Type CHB-C-P
Manual
533 412
en 0211a
[663 484]
Festo Checkbox ®
is a registered trademark of Festo AG&Co,
D-73726 Esslingen, Deutschland
Contents and general instructions
Author . . . . . . . . . . . . . . . . . . . . . . . . . . G. Neumann-Rasaei
Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M. Holder
Original . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . de
Translation . . . . . . . . . . . . . . . . . . . . . transline Deutschland
Layout . . . . . . . . . . . . . . . . . . . Festo AG & Co., Dept. KG-GD
Layout . . . . . . . . . . . . . . . . . . . Festo AG & Co., Dept. KI-DT
Edition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . en 0211a
Designation . . . . . . . . . . . . . . . . . . . . . . . P.BE-CB-COMP-EN
Order no. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533 412
E (Festo AG & Co., D-73726 Esslingen, Federal Republic of
Germany, 2002)
Internet: http://www.festo.com
e-mail: service_international@festo.com
The copying, distribution and utilization of this document as
well as the communication of its contents to others without
expressed authorization is prohibited. Offenders will be held
liable for the payment of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design registrations.
Festo P.BE-CB-COMP-EN en 0211a
I
Contents and general instructions
II
Festo P.BE-CB-COMP-EN en 0211a
Contents and general instructions
Festo P.BE-CB-COMP-EN en 0211a
III
Contents and general instructions
Contents
Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Important user instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes on the use of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Documentation on the Checkbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product-specific terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VII
VIII
VIII
VIII
VIII
VIII
IX
XII
XII
XIII
1.
System summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1.1
1.2
1.3
1.4
1.5
The Festo Checkbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software packages for the Checkbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scope of functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Method of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Buffer zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3
1-4
1-5
1-6
1-9
2.
Fitting and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3
2.4
2.5
Fitting the Checkbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting the power unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the operating voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power supply for external components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3
2-8
2-9
2-11
2-12
2-13
2-14
2-19
IV
Festo P.BE-CB-COMP-EN en 0211a
Contents and general instructions
3.
The I/O module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1
3.2
3.3
3.4
Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
BUFFER/FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
DIAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
4.
I/O module extensions of the Checkbox PLC . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4.1
4.2
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENCODER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start/stop mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting the parts type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counter function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Buffer zone sensors/small parts conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control panel lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3
4-4
4-6
4-8
4-10
4-11
4-13
4-14
4-17
4-18
5.
Teaching parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5.1
5.2
5.2.1
5.2.2
5.2.3
Preparing the teach procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The teach procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Positioning sample parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Observe the scatter of characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scanning further orientations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3
5-5
5-7
5-8
5-9
6.
Testing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6.1
6.2
6.3
6.4
6.4.1
6.4.2
6.4.3
The test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Influence of the tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assessing the test results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3
6-3
6-6
6-8
6-8
6-8
6-9
Festo P.BE-CB-COMP-EN en 0211a
3-1
V
Contents and general instructions
7.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7.1
7.2
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3
7-4
A.
Technical appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-1
A.1
A.1.1
A.1.2
A.2
A.3
A.3.1
A.3.2
A.3.3
A.4
A.5
A.6
Malfunctioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General cause of faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault messages and warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Status displays on the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Examples for ascertaining the features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bandwidth and tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scatter of characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test part deviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-3
A-3
A-4
A-9
A-12
A-12
A-14
A-15
A-17
A-22
A-25
B.
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-1
VI
Festo P.BE-CB-COMP-EN en 0211a
Contents and general instructions
Designated use
The Festo Checkbox has been designed for use under normal
operating conditions in enclosed work rooms in industrial
applications.
The Checkbox Compact described in this manual is intended
exclusively for use as follows:
For contactless checking of the position and quality of small
conveyed parts such as e.g. screws, springs, bolts.
Use the Festo Checkbox only as follows:
–
in accordance with designated use
–
in faultless technical condition.
–
without any modifications by the user.
No guarantee claims can be accepted if the device is opened.
Laser radiation
The Checkbox Compact is a device of laser class 2 as per
EN 60825-1:1997 (class II as per CFR 21 §1040.10, USA).
S Do not open the device.
S Do not dismantle any parts (e.g. prism supports).
S Do not look directly into the laser beam.
Only in this way is the observance of laser class 2 guaranteed and you can avoid damage to the eyes and skin.
The specified limits for pressure, temperature, electrical connections etc. must be observed.
Please observe the standards specified in the relevant
chapters and comply with technical regulations, as well as
with national and local regulations.
Festo P.BE-CB-COMP-EN en 0211a
VII
Contents and general instructions
Operating requirements
–
The features of the conveyed part which determine the
orientation or quality must be recognizable and distinguishable for the Festo Checkbox.
–
It must be possible to integrate the Festo Checkbox in the
material flow.
Target group
This manual is intended exclusively for technicians trained in
control and automation technology, who have experience in
installing and commissioning electronic systems.
Service
Please consult your local Festo repair service if you have any
technical problems.
Scope of delivery
Checkbox Compact
Module with control panel, I/O interface, laser light source
and camera
Documentation
Description of the Checkbox Compact
Accessories
For Checkbox type CHB-C-P: 24-pin connecting cable for the
PLC connection.
Accessories
A summary with accessories available can be found in
chapter A.6.
VIII
Festo P.BE-CB-COMP-EN en 0211a
Contents and general instructions
Important user instructions
Danger categories
This manual contains instructions on the possible dangers
which can occur if the product is not used correctly. These
instructions are marked with a signal word (warning, caution,
etc), printed on a shaded background andmarked additionally with a pictogram. A distinction is made between the following danger warnings:
Warning
This means that failure to observe this instruction may
result in serious personal injury or damage to property.
Caution
This means that failure to observe this instruction may
result in personal injury or damage to property.
Please note
This means that failure to observe this instruction may
result in damage to property.
The following pictograms also mark passages in the text
which warn about the incorrect handling of certain components.
Electrostatically sensitive components These may be damaged if they are not handled correctly.
Danger of injury caused by laser radiation
Do not look into the laser beam. Incorrect handling can
lead to damage to the eyes or skin.
Festo P.BE-CB-COMP-EN en 0211a
IX
Contents and general instructions
Marking special information
The following pictograms mark passages in the text containing special information.
Pictograms
Information
Recommendations, tips and references to other sources of
information.
Accessories
Information about suitable accessories.
Environment
Sections dealing with environmetal aspects.
Text markings
S
The bullet indicates activities which may be carried out in
any order.
1. Figures indicate activities which must be carried out in the
sequence shown from top to bottom.
–
X
Hyphens indicate general activities.
Festo P.BE-CB-COMP-EN en 0211a
Contents and general instructions
Conventions
Festo P.BE-CB-COMP-EN en 0211a
–
The names of operating, display and connecting elements
are represented in the text with upper-case letters e.g.
START, TEACH.
–
Inputs and outputs of the plug connectors are specified
with the pin number as follows:
Input pin 1
I/1
Output pin 2
O/2
–
Plug connectors are shown viewed towards the connections on the device. This view shows the (cable) connections to be wired.
XI
Contents and general instructions
Notes on the use of this manual
This manual refers to the standard designs of the Checkbox
Compact Classic (type CHB-C-C) and Compact PLC (type
CHB-C-P) with operating system version 3.x.
When the Checkbox is switched on, the version number of the
operating system will be displayed briefly (see chapter 2.4).
The options and parameters available depend on the operating system, the type of Checkbox connected and the pre-settings made at the factory. Special customer-specific designs
may differ in technical data, parameter settings and functionality.
The pre-setting of the Checkbox can be modified if required
with the software packages CheckKon (function “Modify system”) or CheckOpti (see chapter 1.2).
Documentation on the Checkbox
Information on using the Checkbox can be found in the following manuals:
Manual
Contents
Documentation on the Checkbox:
– Identbox, Countbox, Sortbox:
type P.BE-Checkbox-..
– Checkbox Compact Classic, PLC
type P.BE-CB-COMP-..
Description of the function, commissioning,
operation and maintenance of the relevant
Checkbox type.
Manuals on software packages
– Checkbox Configurator:
type P.SW-CB-KON-..
– Checkbox Optimizer:
type P.SW-CB-OPTI-..
XII
Operating the Checkbox Configurator
Operating the Checkbox Configurator
Festo P.BE-CB-COMP-EN en 0211a
Contents and general instructions
Product-specific terms and abbreviations
Term/abbreviation
Meaning
Deviation
The Checkbox assesses the feature of a test part which differs most
from the teach data. The smaller the value of the test part deviation,
the more exactly the test part corresponds to the sample parts.
AUTO mode
Operating mode of the Checkbox for automatic parts test (preset
when the Checkbox is started).
Checkbox
A device of type CHB-C...(Checkbox Compact) in the design Classic or PLC
CBC Classic
A device of type CHB-C-C (Checkbox Compact Classic) for identifying
conveyed parts.
Checkbox PLC
A device of type CHB-C-P (Checkbox Compact PLC) for identifying
conveyed parts. Additional connections for a higher-order controller
and encoder.
C-value
The C-value indicates the extent of the scatter of the features
of the sample parts.
Good part
A test part on which all features lie within the tolerances.
Laser class
Identifying the laser radiation as per DIN EN 60825-1:1997
Laser devices are classified according to increasing degree of danger
in the classes 1, 2, 3A, 3B and 4.
Class 2
The eye is not damaged after a brief random influence (up to 0.25 s).
Long-term influences may cause damage. Laser devices of class 2 may
be used without further protective measures, providing it can be assured that for the application neither intentional long viewing (longer
than 0.25 s) nor repeated viewing of the laser beam or mirror reflected
laser beam is necessary.
Class 3a
Comparable danger as with laser devices of class 2. When used with
convex optic instruments (magnifying glasses, telephoto lenses, telescopes), damage comparable to that caused by class 3B can however
occur (damage to eyes and skin).
Teach procedure
During the teach procedure, sample parts on the conveyor belt are
shown to the Checkbox and the features are scanned. This is also
referred to as “Teaching parts.”
Festo P.BE-CB-COMP-EN en 0211a
XIII
Contents and general instructions
Term/abbreviation
Meaning
Features
Characteristic features are ascertained from the contour data of the
sample and test parts. These are, e.g. length, height etc., as well as a
feature for each configuration tool (CheckOpti).
Scatter of characteristics
The value range of a feature ascertained from several parts.
Sample parts
Good parts selected for the teach procedure which show all features
necessary for identifying the parts type.
Orientation
The parts to be checked by the Checkbox may lie in different alignments on the conveyor belt. During the teach procedure, you can
define the orientations by showing the different alignments.
Orientation 1 is the preferred orientation (nominal orientation).
(System) parameter
Checkbox settings (in some cases settings can only be made with
configuration software)
Test data
The test data are the data used for the test. These correspond to the
teach data plus the specified tolerances.
Test parts
All parts shown during the test process.
Test procedure
During the test procedure, test parts on the conveyor belt are shown
to the Checkbox and classified according to their features with regard
to orientation and observance of tolerances. This is also referred to as
“Testing parts.”
Bad part
A test part on which at least one feature lies outside the tolerances.
Teach data
All features ascertained during teaching, in each case with min./max.
limits and average value.
TEACH mode
Operating mode of the Checkbox in which the teach procedure is
carried out.
Parts type
Conveyed part defined by the teach data of the sample parts.
Tolerance
Factor in percent related to the average values and which has an effect
on the min./max. limits of all the features.
XIV
Festo P.BE-CB-COMP-EN en 0211a
System summary
Chapter 1
Festo P.BE-CB-COMP-EN en 0211a
1-1
1. System summary
Contents
1.
System summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1.1
1.2
1.3
1.4
1.5
The Festo Checkbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software packages for the Checkbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scope of functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Method of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Buffer zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3
1-4
1-5
1-6
1-9
1-2
Festo P.BE-CB-COMP-EN en 0211a
1. System summary
1.1
The Festo Checkbox
The Festo Checkbox can be used for visual positioning (without contact) and for the quality check of conveyed parts. Different variants of the Checkbox are available for this purpose,
depending on requirements. The Checkbox Compact is available in the designs Classic and PLC:
Checkbox Compact – device variants
Checkbox Classic
Compact device (without transport device).
Separate sorting out of good parts, incorrectly orientated parts and bad parts
Checkbox PLC
Functions as with Checkbox Classic
plus:
– Extended I/O function
(PLC connection)
– Encoder input 1)
– with CheckKon: Counting of good
parts with preselectable nominal
amount:
Identifying max. 4 parts types, 1 or 2
buffer zone sensors
1) Encoder input: Operating system version ...E must be used for evaluating the encoder signals (see chapter 4.2 ).
Information on further Checkbox variants available can be
obtained from:
Festo P.BE-CB-COMP-EN en 0211a
–
a Festo technical advisor
–
or in Internet under the adress http://www.festo.com
1-3
1. System summary
1.2
Software packages for the Checkbox
Various software packages are available for user-friendly
commissioning, optimizing and monitoring of the products in
the Checkbox family. These software packages have been
developed specially for the products in the Checkbox family
and can be used with all the devices in the Checkbox family.
Software package
Functions
CheckKon
Checkbox Configurator
– Display and evaluation of the last registered test part.
– Display and protocolling the parts
contour as well as the features derived
from the contour.
– Display of the light intensity registered
by the camera.
– Display and print out of the system
configuration.
– Display and modification of the system
parameters.
– Loading a new operating system into
the Checkbox
CheckOpti
Checkbox Optimizer
– User-friendly learning of the sample
parts.
– Monitored checking of parts, display of
the registered features.
– Grading of the parts test with regard to
reliability (evaluation).
– Graphical representation of the test
sequence.
– Optimization of the parts test by manual adaption of the min./max. values of
the teach data or by configuration tools.
– Support in project planning, administration and documentation.
The software package CheckKon, operating system updates
and current product information on the Checkbox Compact
can be found in Internet under the address www.festo.com
(Business Area Pneumatic, Checkbox).
1-4
Festo P.BE-CB-COMP-EN en 0211a
1. System summary
1.3
Scope of functions
Functions of the Checkbox Compact
Festo P.BE-CB-COMP-EN en 0211a
Classic
PLC
Quality check
– Checking the quality, e.g. with rotary and
milling parts
– Machine sorting of faulty and foreign parts
?
?
Position check (nominal orientation)
– Position-orientated supply of good parts to
the following machine
– Return of incorrectly orientated good parts
to the small parts conveyor
?
?
Buffer zone check
– Return of good parts when buffer zone is
full If conveyed parts block the buffer zone
for a long period, the small parts conveyor
will be switched off.
– A check of the position and of the buffer
zone can be made at the same time.
?
?
Buffer zone hysteresis
Monitoring the buffer zone with two sensors
for the delayed switching of the small-parts
conveyor (hysteresis).
-
?
Good parts counting with preselected
number of items
A continuous counter ascertains the sum of all
the good parts
– Transport of defined amounts of components by specifying a nominal number of
good parts
– Nominal number freely selectable for each
parts type
-
?
1-5
1. System summary
1.4
Method of operation
6
5
4
3
2
1
1 Small-parts conveyor e.g. vibrator conveyor, centrifugal machine, stepper
conveyor
2 Transport device e.g. conveyor belt, linear axis
3 Actuators e.g. blow-down valves
4 Passing good parts on to a buffer zone or to the following machine
5 Sorting out bad parts (faulty parts, foreign parts)
6 Returning incorrectly orientated good parts to the small parts conveyor
Fig. 1/1: Incorporating the Checkbox in a conveyor device: Example with conveyor belt
and two actuators
1-6
Festo P.BE-CB-COMP-EN en 0211a
1. System summary
The method of operation of the Checkbox is based on:
Recognition
–
the contactless recognition of small parts
–
the teaching of new parts without programming
–
an integrated quality check.
A small parts conveyor separates the conveyed parts and
passes them onto the conveyor device. The conveyor device
(e.g. conveyor belt, linear axis) can be equipped with maximum 3 actuators for returning or sorting out the conveyed
parts.
The Checkbox registers each conveyed part in contour
images. From the contours the system ascertains part-specific features such as the length, height and surface area. On
the basis of the features, the Checkbox recognizes:
Learning
–
the parts type
–
the orientation
–
the observance of dimensions
–
the quality.
The nominal contour of a conveyed part type is ascertained
by a simple procedure.
1. You “show” the Checkbox several samples of this conveyed part type (scanning) in the nominal orientation one
after the other.
2. If necessary, you can also scan the sample parts in further
orientations.
3. You can save the features of the parts type as teach data.
4. You can test the teach data in the test mode.
Festo P.BE-CB-COMP-EN en 0211a
1-7
1. System summary
Testing
1-8
Each conveyed part registered is compared with the saved
teach data and separated according to the different types.
The test parts are sorted basically into three types:
–
Good parts are passed on e.g. to an assembly plant.
–
Incorrectly orientated parts are returned to the small
parts conveyor.
–
Faulty or foreign parts (bad parts) are rejected.
Festo P.BE-CB-COMP-EN en 0211a
1. System summary
1.5
Buffer zone
The buffer zone serves as a parts buffer for the following
machine e.g. assembly plant.
The Checkbox can monitor the highest and lowest filling
status of the attached buffer zones with one or two sensors
(only Checkbox PLC) and if there is a long blockage, it can
switch the small-parts conveyor on or off as required. When
connecting the buffer zone sensors, please observe the instructions in chapters 3.3 and 4.3.5.
Signal delay
The buffer zone inputs are processed by the Checkbox with a
debounce time. The sensor signal is only evaluated if it is
present for at least 1 second. This delay prevents each conveyed part from triggering the signal “Buffer zone full” when
it passes the sensor.
The delay time of 1 second between the registering of a conveyed part by the sensor and the interpretation of the signal
by the Checkbox must be taken into account when the buffer
zone sections are planned.
Planning the size of the buffer zone
The buffer zone sections (see Fig. 1/2) must be large enough
to enable the machine to operate, if possible, without interruption. Instructions on planning the size of the buffer zone
can be found in the following table.
Festo P.BE-CB-COMP-EN en 0211a
1-9
1. System summary
1 Transport device
1
2 Buffer zone with
one sensor and
the sections A, B
2
3 Sensor 1
3
4 Buffer zone with
two sensors and
the sections A,
AB, B
A
5 Sensor 2
B
4
5
3
A
AB
B
Fig. 1/2: Buffer zone sections
1-10
Festo P.BE-CB-COMP-EN en 0211a
1. System summary
Planning the size of the buffer zone
sections
Buffer zone section A
Section between conveyor device and sensor
Section A must accept all conveyed parts which
lie between the Checkbox and the sensor when
a conveyed part has been registered by the
sensor. The length depends on:
– the geometry of the conveyed parts
– the maximum transport rate of the small
parts conveyor
– the length of the transport device
Buffer zone section AB
Section between sensors 1 and 2 (only buffer
zones with 2 sensors)
Section AB determines the switching delay
(hysteresis) of the small parts conveyor for
regulating the supply of parts. The longer the
section, the less the switching frequency.
Buffer zone section B
Section between sensor and following machine
When the small parts conveyor is switched on
again, operation of the assembly plant without
interruption must be guaranteed before the first
new conveyed parts arrive.
Section B must be designed so that a sufficient
number of conveyed parts are available. The
length depends on:
– the geometry of the conveyed parts
– the maximum time delay between the small
parts conveyor being switched on again and
the availability of the new conveyed parts.
– the length and speed of the transport device
– the average number of good parts conveyed
in the nominal orientation
Festo P.BE-CB-COMP-EN en 0211a
CBC
Classic
CBC
PLC
x
x
-
x
x
x
1-11
1. System summary
1-12
Festo P.BE-CB-COMP-EN en 0211a
Fitting and commissioning
Chapter 2
Festo P.BE-CB-COMP-EN en 0211a
2-1
2. Fitting and commissioning
Contents
2.
Fitting and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3
2.4
2.5
Fitting the Checkbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting the power unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the operating voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power supply for external components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3
2-8
2-9
2-11
2-12
2-13
2-14
2-19
2-2
Festo P.BE-CB-COMP-EN en 0211a
2. Fitting and commissioning
2.1
Fitting the Checkbox
Warning
Sudden unexpected movement of the connected actuators
and uncontrolled movements of loose tubing can cause
injury to human beings or damage to property.
Before carrying out installation and maintenance work,
switch off the following:
– the compressed air supply
– the operating and load voltage supplies.
Laser radiation
S Fit the Checkbox only in its original condition with enclosed intact housing. The prism supports must not be
removed. Only in this way can conformity with laser
class 2 be guaranteed.
S Fit the Checkbox only when it is switched off.
S Fit the Checkbox so that it is not possible to look directly
into the laser beam.
You will then avoid damage to your eyes due to laser radiation.
Fig. 2/1: Laser warning notice on the Checkbox
(see also Fig. 2/2)
Festo P.BE-CB-COMP-EN en 0211a
2-3
2. Fitting and commissioning
1 Warning notice
2 Prism support
1
3 Exit opening
2
2
3
Fig. 2/2: Laser radiation
Transport
Always transport the Checkbox in the original packing;
further transport safety measures are not required.
Place of installation
Please note especially the following ambient requirements:
–
The Checkbox must be placed in a location free of vibration.
–
The fastening must be mechanically stable.
–
The ambient air must be clean: free of oil, no varnish
spray, no grinding dust.
–
The checkbox must be screened from external light and
extreme magnetic fields (caused by e.g. induction furnaces).
In this way you will achieve optimum test results and guarantee a long service life of the device.
Conveyor device
In order that a reliable and reproducible test result can be
obtained, the conveyor device used must fulfil the following
requirements:
S
2-4
Use a high-quality transport system which transports the
parts at a constant speed.
Festo P.BE-CB-COMP-EN en 0211a
2. Fitting and commissioning
S
Ensure that the parts lie in a stable position, e.g. by
means of mechanical devices.
S
Ensure also that the parts are transferred from the conveyor device to the buffer zone of the subsequent machine (e.g. drop pipe, slide, shaker) by means of mechanical devices.
Space required
Please observe the space required for mounting the Checkbox. The dimensions of the Checkbox and weight specifications can be found in chapter A5.
Fastening
There is a fitting profile with a dovetail guide (Fig. 2/4) on the
side of the Checkbox. An appropriate connecting kit (type
HMSV-12, order no. 177 658) is available from Festo as an
accessory.
1
2
1 Fitting profile
2 Dovetail elements
Fig. 2/3: Connecting kit HMSV-12
Festo P.BE-CB-COMP-EN en 0211a
2-5
2. Fitting and commissioning
Fasten the Checkbox over the conveyor device so that:
–
the Checkbox and the conveyor device are fastened
securely to each other
–
the lens coverage of the camera is not obstructed
–
the optical channel is not covered by the conveyor device
–
the warning notice on the Checkbox is visible.
1 Fitting profile
2 Optical channel
of the camera
3 Exit openings of
the laser beam
1
2
2
3
Fig. 2/4: Positioning the Checkbox over a conveyor device
2-6
Festo P.BE-CB-COMP-EN en 0211a
2. Fitting and commissioning
Please note
In order that a reliable test result can be obtained, the
glass surfaces on the prism supports must not be
scratched or dirty.
S Mount the Checkbox so that the parts on the moving belt
do not touch the glass surfaces.
S Use e.g. mechanical devices to ensure that the parts are
correctly positioned.
S If necessary, clean the glass surfaces as described in
Chapter 7.2.
The prism supports must not be removed. Only in this way
will you comply with laser class 2.
S Please consult Festo Service if the glass surfaces are
damaged.
Festo P.BE-CB-COMP-EN en 0211a
2-7
2. Fitting and commissioning
2.2
Connections
1
FE
2
ACTUATORS
3
BUFFER/FEEDER
4
DIAG
5
24 V DC
6
ENCODER
7
PLC
1
2
3
4
5
6
7
Fig. 2/5: Connections on the Checkbox
Function
Chapter
1
– Connecting the functional earth
2.3
2
– Connecting maximum 3 actuators for sorting out the checked parts
3.2
3
– Connecting 1 buffer zone sensor for controlling the transfer of the parts to the
following machine
– 24 V power outputs for controlling the supply system (small parts conveyor) and
the transport system (conveyor device)
3.3
4
– Connecting a diagnostic PC for diagnosing the system, visualizing and optimizing
the test preocedure
3.4
5
– Connecting the 24 V DC power supply
2.3
Connections 6 and 7 only exist on the Checkbox PLC.
6
– Connecting a rotary-pulse generator for ascertaining the speed of the conveyor
system when increased demands are placed on the accuracy of the length.
4.2
7
– Connecting 2 buffer zone sensors for controlling the transfer of the parts to the
following machine
– 24 V power output for controlling the supply system (small parts conveyor) and
the transport system (conveyor device)
– I/O signals for monitoring the process and higher-order controller or for controlling a subsequent machine
4.3
2-8
Festo P.BE-CB-COMP-EN en 0211a
2. Fitting and commissioning
2.3
Electrical connection
Warning
Sudden unexpected movements of the connected actuators can cause injury to human beings or damage to property.
Before carrying out installation and maintenance work,
switch off the operating and load voltage supplies.
Please note
Check within the framework of your EMERGENCY STOP
circuit to ascertain the measures necessary for putting
your machine/system into a safe state in the event of an
EMERGENCY STOP (e.g. switching off the operating voltage, switching off the compressed air).
Caution
Connect the earth connection FE with low impedance to the
earth potential. If possible, use a short cable with sufficient cross-sectional area. In this way you will avoid faults
caused by electromagnetic interference.
Preparing the plugs and cables
Use plugs and sockets from the Festo range corresponding to
the outer diameter of the cables used.
Festo P.BE-CB-COMP-EN en 0211a
Cable outer diameter
Plugs/sockets
4.0...6.0 mm
PG7
6.0...8.0 mm
PG9
10.0...12.0 mm
PG13.5
2-9
2. Fitting and commissioning
Connection
Plugs/sockets
Power supply socket
PG9 or PG13.5
Sensors, actuators
PG7
In order that the completely fitted Checkbox complies with
the IP protection class:
S
Tighten the union nuts of the plugs by hand.
S
Seal the unused sockets with the protective caps supplied.
Caution
Long I/O signal cables reduce the immunity to interference. Do not, therefore, exceed the maximum permitted
I/O signal cable length of 30 m.
2-10
Festo P.BE-CB-COMP-EN en 0211a
2. Fitting and commissioning
2.3.1 Selecting the power unit
The power supply for the Checkbox must fulfil the following
requirements:
–
Voltage range: 24 V ± 15 %
–
Output: 18 W with non-loaded outputs
In order to comply with the EMC limits, the Checkbox is
equipped with a filter for the operating voltage. Use a separate power unit for the Checkbox. Only in this way can the
fitted filter function optimally.
Warning
Use only power units which guarantee reliable isolation of
the operating voltages as per IEC 742/EN 60742/VDE 0551
with at least 4 kV isolation resistance (Protected Extra Low
Voltage PELV). Switch power packs are permitted, providing they guarantee reliable isolation in accordance with
EN 60950/VDE 0805.
By the use of PELV power units, protection against electric
shock (protection against direct and indirect contact) is guaranteed with the Checkbox in accordance with EN 60204-1/
IEC 204. Safety transformers with the adjacent symbol must
be used for supplying PELV networks. The Checkbox must be
earthed to ensure that it functions correctly (e.g. EMC).
Festo P.BE-CB-COMP-EN en 0211a
2-11
2. Fitting and commissioning
2.3.2 Connecting the operating voltage
S
Use a cable with sufficient cross-sectional area for the
operating voltage.
S
Avoid long distances between the power unit and the
Checkbox. Long power cables reduce the voltage supplied
by the power unit.
S
Protect the supply line with a 5 A safety fuse, semi timelag.
Connect the Checkbox to the operating voltage as follows:
Pin
24 V DC connecting plug
1
Do not connect
2
+ 24 V DC, ± 15 %
Protect with a 5 A fuse, semi
time-lag
3
GND
4
Do not connect
Use only a 4-pin M18 socket for the power supply and
connect this only to the connection for the power supply.
1. Insert the plug into the 24 V DC connection on the
Checkbox.
2. Tighten the union nuts of the plug by hand.
2-12
Festo P.BE-CB-COMP-EN en 0211a
2. Fitting and commissioning
2.3.3 Power supply for external components
Please note the following if you connect the Checkbox to
other devices (e.g. PLC, conveyor device) via the connections
PLC, ACTUATOR or BUFFER/FEEDER:
Please note
In order to comply with the EMC limits, the Checkbox is
equipped with a filter for the operating voltage.
A connection between the 24 V potential and GND on the
24 V DC plug with other plugs on the Checkbox or with
other devices will in some cases overbridge the fitted filter.
Asymmetries in the currents in the outward and return
lines reduce the effectiveness of the filter.
S
Use a separate power unit for the Checkbox. Provide a
separate power supply for connected devices.
S
Do not connect the 24 V potential or GND on the 24 V DC
connection of the Checkbox with other plugs on the
Checkbox or with other devices.
S
Make sure that the currents of the inputs and outputs
flow via the Checkbox and that they do not reach the
power unit directly.
Checkbox PLC
Current-consuming devices can also be supplied with power
via the PLC plug. Please refer here to the information in
chapter 4.3.
Festo P.BE-CB-COMP-EN en 0211a
2-13
2. Fitting and commissioning
2.4
Commissioning
Warning
Ascertain the measures which are necessary for putting
your machine/system into a safe state when it is switched
on or off. Please note that sudden unexpected movements
of the connected actuators can cause injury to human
beings or damage to property, e.g.
– when the conveyor device is moved into the basic position after the power supply has been switched off
– when the conveyor device starts automatically after the
Checkbox has been booted, if it is controlled via the
Checkbox.
In order to prevent an automatic start:
S switch off the parameter “Automatic start after switching
on the power supply” in CheckKon.
Before switching on the Checkbox the first time, make sure
you have carried out the following steps:
1. the conveyor device must be fitted
2. the Checkbox must be fitted to the conveyor device
3. the operating voltage must be connected at the 24 V DC
connection.
The following optional steps can be taken for test operation:
S
S
2-14
Connect external components:
–
connect the actuators (chapter 3.2)
–
connect buffer zone sensors and small parts conveyor
(chapter 3.3).
Connect additional components (only Checkbox PLC):
–
connect an encoder (chapter 4.2)
–
connect a higher-order controller (chapter 4.3).
Festo P.BE-CB-COMP-EN en 0211a
2. Fitting and commissioning
1 Illuminated button
START/STOP
2 Illuminated button
STATUS/TEACH
3 Display
1
2
3
Fig. 2/6: Display and operating elements
Function
Festo P.BE-CB-COMP-EN en 0211a
1
–
–
–
–
Starting and stopping the Checkbox
Display switch function Start (green) / Stop (red)
Quitting faults
Saving the teach data
2
–
–
–
–
Switch between AUTO and TEACH mode
Selecting the orientation in TEACH mode
Display scan procedure
Accessing system information (e.g. belt speed when
operated with encoder)
3
– System information and operating displays
2-15
2. Fitting and commissioning
Switching on
Switching on the operating voltage of the Checkbox via the
power unit:
–
The buttons on the Checkbox light up briefly and indicate
readiness to operate.
–
The display shows the following items of system information one after the other:
Display when the Checkbox is switched on
IC 30
Ident. code and version status of the operating system
04 E
Number of memory locations and also the letter E for an
operating system with encoder evaluation.
2048
System setting of the camera resolution in pixels
STOP
Operating status stop
Checkbox PLC
If this is shown in the display “Lock,” the buttons START/
STOP and STATUS/TEACH are blocked (see chapter 4.3.7).
AUTO mode
The operating mode AUTO is preset when the Checkbox is
started. The test procedure runs automatically in operating
mode AUTO.
Start the Checkbox in auto mode as follows:
S
Press the START/STOP button.
Operating status: AUTO
The START/STOP button shows a red light permanently
1 5
2-16
Display: Parts type 1; tolerance 5 %
Festo P.BE-CB-COMP-EN en 0211a
2. Fitting and commissioning
When the Checkbox starts, it triggers the actuator for sorting
out the bad parts. This is to ensure that there are no (unchecked) parts on the conveyor device. The duration of this
procedure depends on the following parameters which can be
set with CheckKon:
–
the distance between the start of the transport system
and the camera
–
the distance between the “Bad part” actuator and the
camera
–
the transport speed.
If the supply of parts is interrupted for a long period, the
Checkbox will show the fault message E 05 or the warning
F 05 (see chapter A.1.2).
TEACH mode
In the TEACH mode, the Checkbox learns all the features for
the parts check when it scans sample parts.
You can switch from AUTO to TEACH mode as follows:
1. Press the START/STOP button.
Operating status: STOP
The START/STOP button shows a green light
permanently
STOP
Display: Stop status
2. Press the STATUS/TEACH button.
CheckKon
If “Fix” is shown in the display, the START/TEACH button is
blocked via CheckKon. A switch to the teach mode is not
possible (see chapter A.2).
Festo P.BE-CB-COMP-EN en 0211a
2-17
2. Fitting and commissioning
Operating status: TEACH
The START/STOP button shows a red light permanently
1 o1
Display: Parts type 1; orientation 1
You can switch from TEACH mode back to AUTO mode as follows:
S
Press the START/STOP button.
Operating status: AUTO
The START/STOP button shows a red light permanently
1 5
Switching off
Display: Parts type 1; tolerance 5%
The Checkbox is switched off in AUTO mode.
1. Press the START/STOP button.
Operating status: STOP
The START/STOP button shows a green light
permanently
STOP
Display: Stop status
2. Switching off the operating voltage.
2-18
Festo P.BE-CB-COMP-EN en 0211a
2. Fitting and commissioning
2.5
Fault diagnosis
If the diagnostic system of the Checkbox detects an operating
fault, the display will show fault code E... or the warning code
F... . Both illuminated buttons flash.
A detailed list of the codes, customer-specific settings and
instructions on eliminating faults can be found in Appendix
A.1.
Types of faults (overview)
Code E... Type
Explanation
01..19
Ambient fault
Fault in the power supply, the
parts supply; dirty lens etc.
20..21
Recognition fault
Orientations or sample parts
cannot be distinguished
40..43
Data fault
Teach data, configuration data
or system parameters are not
compatible or do not exist
>=60
Hardware fault
Internal fault (can only be rectified
by after-sales service)
Button
Status
Meaning
START/
STOP
Flashes red
STATUS
/TEACH
Flashes yellow
Fault message/warning
Checkbox PLC
The Checkbox PLC indicates faults additionally via A/17 (fault)
and A/23 (warning) at the PLC connection (see chapter 4.3.6).
Festo P.BE-CB-COMP-EN en 0211a
2-19
2. Fitting and commissioning
If a fault occurs, the Checkbox will switch automatically to the
STOP status. The user must then intervene.
When the cause of the fault has been eliminated, the fault
messages/warnings must be quitted before the Checkbox
can start again.
1. Eliminating the cause of the fault
2. Quit fault message: Press the START/STOP button
3. Start the Checkbox: Press the START/STOP button
2-20
Festo P.BE-CB-COMP-EN en 0211a
The I/O module
Chapter 3
Festo P.BE-CB-COMP-EN en 0211a
3-1
3. The I/O module
Contents
3.
The I/O module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3.1
3.2
3.3
3.4
Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
BUFFER/FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
DIAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-2
Festo P.BE-CB-COMP-EN en 0211a
3. The I/O module
3.1
Interfaces
1 ACTUATORS
1
2
3
2 BUFFER/FEEDER
3 DIAG
Fig. 3/1: The I/O module of the Checkbox
Function
1
– Connection of maximum 3 actuators for sorting out the
checked parts
2
– Connection of 1 buffer zone sensor for controlling the
transfer of the parts to the following machine
– 24 V power outputs for controlling the supply system (small
parts conveyor) and the transport system (conveyor device)
3
– Connecting a diagnostic PC for diagnosing the system,
visualizing and optimizing the test procedure
Power supply
Please note the instructions on the power supply for external
components in chapter 2.3.3 and in chapter 4.3.
Internal circuitry
of the Checkbox PLC
The following I/O signals are wired internally with the PLC
connection (see chapter 4.3.4...5):
Festo P.BE-CB-COMP-EN en 0211a
–
ACTUATORS
–
BUFFER/FEEDER
3-3
3. The I/O module
I/O signals
Electrical characteristics
3-4
Outputs
– Maximum current loading per channel:
700 mA
– Maximum sum current of all outputs:
ACTUATORS
2.1 A
BUFFER
1.4 A
– PNP-switching
Inputs
– Input current:
– Logical “1:” VON
– Logical “0:” VON
< 30 mA
> 15 V
<5V
Festo P.BE-CB-COMP-EN en 0211a
3. The I/O module
3.2
ACTUATORS
Please note
If there is a failure in the power supply to the Checkbox or
to the actuators whilst the transport device is running, this
can lead to the following:
– Parts may pass the actuator positions without being
checked.
– The actuators cannot sort out checked parts.
Ascertain the measures which are necessary on your machine/system to prevent incorrectly orientated parts or
bad parts from reaching the subsequent machine/system
during such malfunctioning.
Checkbox PLC:
For monitoring the pneumatic supply of the actuators, input
I/19 “Ext-Fault” is provided on the plug PLC. In the event of a
fault, this input will switch the Checkbox PLC to fault status
E 01 by means of a pressure switch.
The Checkbox can control up to 3 actuators for sorting out
good parts, incorrectly orientated parts and bad parts. Possible actuators are e.g. separating filters, reversing stations or
blow-down nozzles which sort out the parts at certain positions on the transport device depending on the result of the
test. The number and assignment of the actuator positions
can vary depending on the application. The assignment of the
actuator positions can be adapted with the CheckKon software.
Connector socket ACTUATORS
Festo P.BE-CB-COMP-EN en 0211a
O/1
Actuator 3
O/2
Actuator 2
3
GND
O/4
Actuator 1
5
Do not connect
3
4
2
1
5
3-5
3. The I/O module
Example of configuration: Transport device with 2 blowdown nozzles
The compressed air valves of the reject positions must be
connected directly to the outputs actuators 1...2. These outputs will be set to + 24 V DC if the parts test delivers the following result:
–
incorrectly orientated or superfluous (good) part
–
bad or foreign part.
If the Checkbox recognizes a test part as a good part, the
signal actuator 3 will be set from rest potential 0 V to
+ 24 V DC and the good part will be delivered at the end of
the transport device.
Output
Signal level (example of configuration)
Actuator 1
The + 24 V DC signal is present when the test part
passes the actuator position for incorrectly orientated
or superfluous good parts. 1)
Actuator 2
The + 24 V DC signal is present when the test part
passes the actuator position for bad or foreign parts. 1)
Actuator 3
The + 24 V DC signal is present when the test part
passes the actuator position for good parts (here the
end of the transport device).
1)
3-6
The duration of the signal corresponds to the time the part
requires to pass the blow-down nozzle.
Festo P.BE-CB-COMP-EN en 0211a
3. The I/O module
3.3
BUFFER/FEEDER
Connector socket BUFFER/FEEDER
O/1
24 V DC / Box ready
– Reference voltage for sensors
(switched off in the stop status)
– Ready to operate
– Control for transport device
O/2
Feeder
Controlling the supply system
(small parts conveyor)
3
GND
Reference voltage for sensors
I/4
Buffer
Buffer zone sensor 1
5
Do not connect
3
4
2
1
5
As an option, direct connection with a Festo Duo cable is also
possible. (see chapter A.6 Accessories).
Identifier duo cable
Signal x
Buffer zone sensor 1
Signal x + 1
Small parts conveyor (feeder)
Small parts conveyor (feeder)
If an external enable signal (24 V DC) can be connected to the
small parts conveyor, you should connect this via pin O/2 on
the plug BUFFER/FEEDER.
Festo P.BE-CB-COMP-EN en 0211a
3-7
3. The I/O module
Buffer zone sensor (buffer)
The Checkbox is set at the factory for use with a buffer zone
sensor. The output of this sensor has 0 V potential in the rest
state. (24 V DC active high = normally-open function).
CheckKon
With CheckKon you can modify the following parameters of
the buffer zone:
–
Switching logic
Buffer zone sensor type = normally open/closed
–
Connecting 1 or 2 buffer zone sensors
(only Checkbox PLC, see chapter 4.3.5.)
–
Signal delay
Minimum sensor signal duration for “Buffer zone empty”
or “Buffer zone full.”
Please note
You can optimize the operating reliability of your supply
system as follows:
– Use sensors which have a sensor output with a potential
of 24 V DC (24 V DC active low = normally-closed function) in the rest state.
– Adapt the setting of the sensor type with CheckKon.
In this way, you can prevent the system from becoming
blocked up in the event of e.g. a cable fracture.
3-8
Festo P.BE-CB-COMP-EN en 0211a
3. The I/O module
Sensor type
Function
B ff zone with
Buffer
ith one sensor
Normallyopen
contact 1)
Normallyclosed
contact 2)
Sensor 1
LOW
Sensor 1
HIGH
The sensor does not register any
conveyed part. The small parts
conveyor is/remains switched on.
Sensor 1
HIGH
Sensor 1
LOW
The buffer zone is full. The display
switches to “Full.” Good parts are
blown down. After the preset
time, e.g. 30 s, the small parts
conveyor will be switched off; the
conveyor device continues to run.
1) Factory presetting
2) To be set with CheckKon (recommendation)
Please note
Leave non-used sensor inputs open. Only in this way is the
Checkbox ready to operate. Otherwise the display shows
the status “Full” during operation, although the buffer
zone is empty. All good parts will be returned. The small
parts conveyor will be switched off after 30 s (standard
setting).
Festo P.BE-CB-COMP-EN en 0211a
3-9
3. The I/O module
3.4
DIAG
Use cable KDI-SB202-BU9 for connecting the diagnostic PC.
(see chapter A.6 Accessories). Connect the diagnostic cable
to the following connections:
–
the diagnostic interface DIAG on the Checkbox
–
a serial interface COM1 or COM2 on the diagnostic PC.
Connector plug DIAG
I/1
Receive data of the Checkbox
O/2
Send data of the Checkbox
3
Data GND
4
Screening/shield
4
3
1
2
CheckKon
With CheckKon you can switch the Checkbox from the operating mode to the diagnostc mode. In the diagnostic mode the
Checkbox transmits additional information via the diagnostic
interface. No parts will be checked during the transmission
period.
Therefore use the connection DIAG only for commissioning
and service:
3-10
S
Do not therefore operate the Checkbox at the full parts
rate in the diagnostic mode. In this way, you can prevent
parts passing the actuator positions without being
checked.
S
Conclude CheckKon or CheckOpti when the settings have
been made.
S
Disconnect the diagnostic cable in continuous operation
and seal the socket on the Checkbox with the protective
cap supplied.
Festo P.BE-CB-COMP-EN en 0211a
3. The I/O module
Further information on commissioning, optimizing and monitoring the Checkbox via the diagnostic interface can be found
in the documentation for the software packages CheckOpti
and CheckKon.
Festo P.BE-CB-COMP-EN en 0211a
3-11
3. The I/O module
3-12
Festo P.BE-CB-COMP-EN en 0211a
I/O module extensions of the Checkbox PLC
Chapter 4
Festo P.BE-CB-COMP-EN en 0211a
4-1
4. I/O module extensions of the Checkbox PLC
Contents
4.
I/O module extensions of the Checkbox PLC . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4.1
4.2
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENCODER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start/stop mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting the parts type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Counter function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Buffer zone sensors/small parts conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control panel lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3
4-4
4-6
4-8
4-10
4-11
4-13
4-14
4-17
4-18
4-2
Festo P.BE-CB-COMP-EN en 0211a
4. I/O module extensions of the Checkbox PLC
4.1
Interfaces
1 ENCODER
2 PLC
1
2
Fig. 4/1: I/O module extensions of the Checkbox PLC
Function
Power supply
Festo P.BE-CB-COMP-EN en 0211a
1
– Connecting a rotary-pulse generator for ascertaining the
speed of the conveyor system when increased demands are
placed on the accuracy of the length.
2
– Connecting two buffer zone sensors for controlling the
transfer of the parts to the following machine
– 24 V power output for controlling the supply system (small
parts conveyor) and the transport system (conveyor device)
– I/O signals for process monitoring and higher-order controller or for controlling a subsequent machine
Please note the instructions on the power supply for external
components in chapter 2.3.3 and in chapter 4.3.
4-3
4. I/O module extensions of the Checkbox PLC
4.2
ENCODER
When higher demands are placed on the accuracy of the
length of the test part, you can connect a rotary-pulse generator to the connection marked ENCODER for ascertaining the
speed of the conveyor system (see chapter A.6 Accessories).
Operating system version ...E (operating system with encoder
evaluation) must be used for evaluating the encoder signals.
Check therefore the operating system version when you
switch on your Checkbox PLC (see chapter 2.4, Commissioning: switching on). Operating system ...E can be found in Internet under the address www.festo.com (Business Area
Pneumatic, Checkbox). For modifications to the operating
system, please refer to your Festo Service.
Pin
ENCODER connector socket
Interface for rotary pulse generator as per RS485 specification
1
A+
2
n.c.
3
B+
4
A-
5
B-
6
5 V supply 1)
7
GND
8
n.c.
1)
2
4
1
6
5
8
3
7
Maximum loading capacity 180 mA
Note the following when connecting a rotary pulse generator:
–
4-4
Do not make any connection between the potentials of
the ENCODER connection and other potentials.
Festo P.BE-CB-COMP-EN en 0211a
4. I/O module extensions of the Checkbox PLC
–
Connect only suitable rotary-pulse generators (Encoder
from the Festo range).
–
Use operating system version ...E.
In order to display the conveyor belt speed, press the button
STATUS/TEACH in AUTO mode. The display will then show the
belt speed of the conveyor unit in [mm/s].
Festo P.BE-CB-COMP-EN en 0211a
4-5
4. I/O module extensions of the Checkbox PLC
4.3
PLC
Please note the following when connecting a higher-order
controller:
S
Use the PLC cable with 24-pin Binder plug supplied
(connection Checkbox PLC).
S
Wire the connections of the PLC according to the cable
assignments in Appendix A.4.
S
Make sure that the maximum sum current of 1 A is not
exceeded.
The reference voltage is provided at pin 4 (GND) and pin 7
(+ 24 V).
Under the following conditions, current-consuming devices
can be supplied with power via pin 4 (GND) and pin 7
(+ 24 V).
–
Connect only current-consuming devices which return the
complete current to the Checkbox. In this way you can
prevent asymmetries in the currents in the outward and
return lines from reducing the effect of the filter.
–
Load the output PLC_Power with maximum 700 mA.
Connector socket PLC
Electrical characteristics of the I/O signals
Inputs
Outputs
4-6
– Input current:
– Logical “1:” VON
– Logical “0:” VON
< 30 mA
> 15 V
<5V
– Maximum current loading per channel:
700 mA
– Maximum sum current of all outputs: 1 A
– PNP-switching
12
13
4
21
3
22
1
24
7
17
8
16
Festo P.BE-CB-COMP-EN en 0211a
4. I/O module extensions of the Checkbox PLC
Functions of the PLC
Pin
Remark
Reference voltage
Fuses: 700 mA, self-resetting switched off in
th st
the
stop st
status
t s
4
PLC_GND
e.g. as reference potential for the PLC
O/7
PLC_Power
+ 24 V DC e.g. as power supply for optoisolated PLC I/O module
Start/stop mode
I/6
Remote start
Selecting the parts type
I/20
Parts type bit 0
I/5
Parts type bit 1
I/18
Start new counting cycle
O/22
Target number reached
– Good parts
O/1
Actuator 1
– Incorrectly orientated parts / incorrect
parts type
O/2
Actuator 2
– Bad / foreign parts
O/3
Actuator 3
Monitoring the buffer zone and controlling
th ssupply
the
l off parts
ts
I/12
Buffer zone sensor 1
I/13
Buffer zone sensor 2
O/8
Small parts conveyor (feeder)
O/21
Checkbox PLC ready to operate (ready)
conveyor device (conveyor)
O/23
Fault status 0: Warning 2)
O/17
Fault status 1: Fault
I/11
Button lock for START/STOP and STATUS/
TEACH button
Counter function and counter status check 1)
Controlling the transfer position:
Fault messages
Control panel lock
Festo P.BE-CB-COMP-EN en 0211a
4-7
4. I/O module extensions of the Checkbox PLC
Functions of the PLC
Pin
Remark
External sensor 1)
I/10
E.g. metal detector or colour sensor for an
additional check of the material properties
which cannot be checked via the contour
registering.
Camera trigger
I/9
Externally controlled switching on and off of
the picture display under especially difficult
conditions.
External faults
I/19
E.g. for monitoring the pneumatic supply of
the actuators. If there is a fault, the Checkbox PLC will be switched to fault status E01
by means of a pressure switch.
Special functions 2)
1)
2)
Counter function and special function “External sensor” cannot be used at the same time.
De-activated at the factory Function can be activated and adapted with CheckKon.
4.3.1 Start/stop mode
The remote control of the Checkbox PLC assumes as a
prerequisite that:
–
power is applied to the Checkbox PLC
–
the boot procedure is concluded (O/7 = HIGH)
–
the signal types Select 0 and Select 1 are stable.
The Checkbox is started with a sequence of signals (pulse) at
pin I/6 LOW>HIGH>LOW and stopped again with the sequence of signals LOW>HIGH>LOW (recommended pulse
duration 500 ms).
4-8
Pin
Signal sequence
Meaning
I/6
LOW>HIGH>LOW
Starts the Checkbox
LOW>HIGH>LOW
Stops the Checkbox
Festo P.BE-CB-COMP-EN en 0211a
4. I/O module extensions of the Checkbox PLC
With manual operation or control via the I/O module, pressing the START/STOP button corresponds to the change of
signal LOW>HIGH>LOW.
Modification to the operating status with start or stop is sent
to the controller via O/21 (Checkbox ready).
Pulse-time diagram
Timing requirement to the higher-order controller
24 V
Power supply
1
0
1
Pin O/7
PLC_Power
Pin I/20 20
Type select
Pin I/5
21
0
1
Type 2
Type 3
0
Start
Pin I/6
Remote start
1
Pin O/8
Feeder
1
0
Stop
t ts
t rs
t rs
0
td
Pin O/21
Box ready
1
0
0.2 s < t rs < 1 s
t ts = min 0.1 s
t d = duration of the switch-on delay
Festo P.BE-CB-COMP-EN en 0211a
rs = remote start
ts = type select
d = delay
4-9
4. I/O module extensions of the Checkbox PLC
4.3.2 Selecting the parts type
A high-order controller can change automatically between
four different parts types.
The change of types takes place in the stop status. The signals at the inputs are then set according to the binary coding
of the desired parts type (see following table). The signals
must be applied continuously before the Checkbox PLC can
start again.
Binary coding
I/20 (2 0)
I/5 (2 1)
Parts type 1
LOW
LOW
Parts type 2
HIGH
LOW
Parts type 3
LOW
HIGH
Parts type 4
HIGH
HIGH
Pulse-time diagram
Parts type change 1 > 4
Type 1
Pin I/20
Type select 0
Pin I/5
Type select 1
Pin I/6
Remote start
Type 4
1
0
1
0
1
0
min 0.1 s
4-10
Festo P.BE-CB-COMP-EN en 0211a
4. I/O module extensions of the Checkbox PLC
4.3.3 Counter function
With CheckKon a counter function can be activated for the
Checkbox PLC and a target number can be specified for each
parts type. Depending on the setting in CheckKon, only good
parts in the nominal orientation or good parts in all learnt
orientations will be counted. The counter function can only be
activated if the special function “External sensor” is not used
(see chapter 4.3 table “Special functions”).
Counter status
The counting process will be interrupted when the Checkbox
stops. The current counter states remain saved. When the
Checkbox is started again, the counting processes are continued with the saved counter states.
Please note
The counting process will be discontinued if the Checkbox
is switched off (operating voltage off ). The current counter
states will be deleted. When the Checkbox is switched on,
it will start a new counting cycle.
Remove, therefore, all good parts from the parts delivery
position when you switch off the Checkbox. In this way,
you will avoid incorrect parts counting when the Checkbox
is switched on again.
Counting process (standard Checkbox design)
If the set target number of a parts type is reached, all further
good parts of that parts type will be blown down at the delivery position for superfluous good parts until the small parts
conveyor is switched off. Bad parts will be further rejected at
the appropriate delivery position.
cFul
Festo P.BE-CB-COMP-EN en 0211a
When the last good part in a counting process reaches the
delivery position for good parts, output O/22 will be set from
LOW>HIGH via the connection “Controller” (“Target number
reached”). The current counting process is concluded. The
Checkbox PLC indicates “cFul.”
4-11
4. I/O module extensions of the Checkbox PLC
All subsequent good parts are returned to the small parts
conveyor. After a time preset with CheckKon, the small parts
conveyor will be switched off.
In order to start a new counting process, the Checkbox PLC
requires the signal “Start new counting cycle” from the
higher-order controller. In order to start the counting cycle,
the signal LOW>HIGH >LOW must be present at input I/18.
Pin
Signal level
Meaning
I/18
LOW>HIGH>LOW
Starts the new counting cycle
O/22
HIGH
Preselected counter status
reached
O/22
LOW
Preselected counter status not
yet reached
Pulse-time diagram
Counter status check
Pin I/18
Start new counting cycle
t sc > 15 ms
1
Pin O/22
Preselected counter
status reached
1
0
Start
t sc
0
10 ms
tr
sc = start counting cycle
r = reset
During the pulse duration tsc good parts are still returned.
The new counting cycle starts with the falling edge at I/18.
4-12
Festo P.BE-CB-COMP-EN en 0211a
4. I/O module extensions of the Checkbox PLC
4.3.4 Actuators
Internal circuitry
The inputs “Actuators 1...3” on the connection “PLC” are
wired internally with the connection “ACTUATORS.”
Actuators
PLC
Function
3
4
GND
O/4
O/1
Actuator 1
O/2
O/2
Actuator 2
O/1
O/3
Actuator 3
Monitoring
For monitoring the pneumatic supply of the actuators, input
I/19 “Ext-Fault” is provided on the plug PLC. In the event of a
fault, this input will switch the Checkbox PLC to fault status
E01 by means of a pressure switch.
Time reaction
Note the following when evaluating the output signals “Actuator...” by means of a higher-order controller:
If the test parts are passed through at a high rate, some parts
may be returned although previously tested parts have not
yet been blown down at the delivery position. This delay arises due to the (long) distance between the actuator positions.
Further information on connecting the actuators can be found
in chapter 3.2.
Festo P.BE-CB-COMP-EN en 0211a
4-13
4. I/O module extensions of the Checkbox PLC
4.3.5 Buffer zone sensors/small parts conveyor
Internal circuitry
The I/O signals for the buffer zone sensors and small parts
conveyor on the connection “PLC” are wired internally with
the connection “BUFFER/FEEDER.”
BUFFER
FEEDER
PLC
O/1
O/21
O/2
O/8
O/3
O/4
0 V reference voltage
Buffer zone sensors
I/4
I/12
Buffer zone sensor 1
------
I/13
Buffer zone sensor 2
Function
– 24 V reference voltage for
buffer zone sensors
– Ready to operate
– Controlling the conveyor device
24 V power output for controlling
a small parts conveyor (feeder)
Small parts conveyor
Time reaction
When the Checkbox PLC is started, it triggers the actuator
which sorts out bad parts. This is to ensure that there are no
(unchecked) parts on the conveyor device.
A delay of a few seconds then occurs between the external
start command (Remote start) and the signal for switching on
the small parts conveyor (feeder). The duration of this delay
depends on ambient parameters, such as transport speed
and geometrical variables.
4-14
Festo P.BE-CB-COMP-EN en 0211a
4. I/O module extensions of the Checkbox PLC
Pulse-time diagram
Switch-on delay of the small parts conveyor
Start
Pin I/6
Remote
start
Stop
1
0
1
Pin O/8
Feeder
0
td
Pin O/21
Box
Ready
1
0
td = duration of the switch-on delay
d = delay
Buffer zone sensors
Sensor configuration
With CheckKon, the Checkbox PLC can be configured for operation with either one or two buffer zone sensors (see Fig.
4/2).
Please note
Leave non-used sensor inputs open. Only in this way is the
Checkbox ready to operate. Otherwise the display shows
the status “Full” during operation, although the buffer
zone is empty. All good parts will be returned. The small
parts conveyor will be switched off after 30 s (standard
setting).
Festo P.BE-CB-COMP-EN en 0211a
4-15
4. I/O module extensions of the Checkbox PLC
Sensor type
Function
Normallyopen
contact 1)
Normallyclosed
contact 2)
Sensor 1
LOW
Sensor 1
HIGH
The sensor does not register any
conveyed part. The small parts
conveyor is/remains switched on.
Sensor ... 3)
HIGH
Sensor ... 3)
LOW
The buffer zone is full. The display
switches to “Full.” Good parts are
returned. After the preset time,
the small parts conveyor will be
switched off; the conveyor device
continues to run.
1)
2)
Factory presetting
To be set with CheckKon
3)
With buffer zone monitoring
– with one sensor: Sensor 1
– with two sensors: Sensor 2
Further information on the buffer zone can be found in
chapter 1.5; on connecting the buffer zone sensors in
chapter 3.3.
1 Buffer zone
2 Conveyor device
3 Sensor 2
4 Sensor 1
2
1
3
4
Fig. 4/2: Buffer zone monitoring with two buffer zone sensors
4-16
Festo P.BE-CB-COMP-EN en 0211a
4. I/O module extensions of the Checkbox PLC
4.3.6 Fault messages
The Checkbox signalizes faults at pins O/17 and O/23. Evaluation of the output signals is accomplished e.g with a machine light:
Machine Meaning
light
O/17
O/23
Red
There is a fault
‹ E60
Ambient, recognition or memory
fault
≥ E60
Hardware fault
HIGH
LOW
Yellow
There is a warning
LOW
HIGH
Green
Faultless operation
LOW
LOW
By means of factory configuration or subsequent conversion
with CheckKon, fault E05 can be defined as warning F05.
Fault
Code
O/17
O/23
Material jam or small parts
conveyor is empty.
Fault
E05
HIGH
LOW
Warning
F05
LOW
HIGH
Deleting the fault:
Festo P.BE-CB-COMP-EN en 0211a
Pin
Signal sequence
Meaning
I/6
LOW>HIGH>LOW
LOW>HIGH>LOW
Deleting the fault
4-17
4. I/O module extensions of the Checkbox PLC
4.3.7 Control panel lock
Via input I/11 (IN24_Key_Inhibit), the two buttons START/
STOP and STATUS/TEACH on the Checkbox PLC can be locked
to prevent unauthorised use. The Checkbox PLC can then be
started or stopped only via I/6 (Remote start). A change to
the TEACH mode is not possible.
Pin
Signal level
Meaning
I/11
HIGH
Button lock
LOW
Button enable
Display with control panel lock
Lock
– Continuous display in the stop status
– Display (duration 1.5 s) when the START/STOP
button is pressed.
CheckKon
The STATUS/TEACH button can also be locked with CheckKon.
Only the START/STOP button can then be enabled with the
HIGH signal at I/11. The STATUS/TEACH button remains
locked. A change to the teach mode is not possible. If the
STATUS/TEACH button is actuated, the display “Fix” will be
shown for 1.5 ms; the Checkbox PLC will then switch to the
AUTO mode again.
4-18
Festo P.BE-CB-COMP-EN en 0211a
Teaching parts
Chapter 5
Festo P.BE-CB-COMP-EN en 0211a
5-1
5. Teaching parts
Contents
5.
Teaching parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5.1
5.2
5.2.1
5.2.2
5.2.3
Preparing the teach procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The teach procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Positioning sample parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Observe the scatter of characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scanning further orientations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3
5-5
5-7
5-8
5-9
5-2
Festo P.BE-CB-COMP-EN en 0211a
5. Teaching parts
5.1
Preparing the teach procedure
The Checkbox registers conveyed parts as two-dimensional,
black-white profile pictures (parts contour). Features for distinguishing different good parts are derived from the parts
contour. Discolouring and surface faults do not influence the
test result during this recognition process.
Features and characteristics of the conveyed parts
–
The Checkbox must be able to recognize those features of
the conveyed part which determine orientation and quality and which are important for the distinguishing process.
–
Small rotationally symmetric parts are particularly suitable. Non-rotationally symmetric parts can however also
be checked if a pre-orientation of the conveyed parts is
made with the small parts conveyor.
–
The conveyed part must be positioned reliably on the
conveyor belt.
–
Festo P.BE-CB-COMP-EN en 0211a
–
The length, diameter and height of a conveyed part
must be suitable for the Checkbox.
–
The conveyed part must be positioned in a stable
orientation on the conveyor belt (it must not roll away
or vibrate).
The conveyed part must be sorted out reliably by the
actuators. Check during a test run to see if the actuators
used (e.g. blow nozzles) can sort out especially large conveyed parts made of material with streamline form.
5-3
5. Teaching parts
Sample parts
Provide suitable sample parts for every parts type in accordance with the following specifications:
–
The sample parts should show all the characteristics
which a part classified as “Good” possesses.
–
Use different sample parts with a usual scatter of features. With the scatter of sample parts, you can determine
the extent to which test parts classified as “Good” may
deviate from each other.
If you are using the CheckKon/CheckOpti software packages,
please note the instructions in the software manuals on how
to prepare the teach procedure.
5-4
Festo P.BE-CB-COMP-EN en 0211a
5. Teaching parts
5.2
The teach procedure
As the Checkbox PLC can save up to 4 different parts types,
the signals to the PLC inputs must be set according to the
binary coding of the desired parts type (see chapter 4.3.2,
table “Binary coding”). The signals must be present permanently.
tool
If, when the parts type is selected in the display, the information “tool” is shown, the memory address is assigned with
additional software tools. The teach procedure can nevertheless be carried out. Further information can be found in the
CheckOpti manual.
S
Switch the Checkbox to the stop status.
S
Start the conveyor device.
Operating status: STOP
The START/STOP button shows a green light permanently
STOP
The display shows STOP
Carry out the teach procedure of parts type 1 at first for the
nominal orientation (orientation 1):
1. Press the button STATUS/TEACH.
Fix
Festo P.BE-CB-COMP-EN en 0211a
If “Fix” is displayed when the STATUS/TEACH button is
pressed for 1.5 s, the STATUS/TEACH key is blocked by
CheckKon. The Checkbox can be started or stopped manually,
but a switch to the TEACH mode is not possible. The Checkbox remains in auto mode. Switch off the button lock in
CheckKon with the parameter “System/operating mode lock
of the TEACH
button = ...”.
5-5
5. Teaching parts
Operating status: TEACH
The START/STOP button shows a red light permanently
1 o1
Display: Parts type 1; orientation 1
The STATUS/TEACH button lights up briefly when the
sample part is registered.
2. Scan the sample parts in orientation 1 (nominal orientation).
3. Pay attention to the positioning of the sample parts
(see chapter 5.2.1).
4. Observe the displayed scatter of characteristics during
scanning (see chapter 5.2.2).
5. Scan the sample parts of the parts type one after the
other in all intended orientations (see chapter 5.2.3).
6. Press the START/STOP button in order to save the teach
data. The Checkbox switches to AUTO mode. This concludes the teach procedure.
Operating status: AUTO
The START/STOP button shows a red light permanently
15
Display: Parts type 1; tolerance 5 %
After saving the data, carry out one of the following steps:
5-6
S
Check the completed teach procedure in test mode
with regard to orientation and quality as described in
chapter 6.
S
Keep a record of your work.
Festo P.BE-CB-COMP-EN en 0211a
5. Teaching parts
Checkbox PLC – parts type 2...4
Register the next parts type in a further teach procedure.
Switch the Checkbox to the STOP status. Address the next
parts type via the PLC inputs and repeat all the steps as from
point 1.
5.2.1 Positioning sample parts
Make sure that the sample parts are positioned in accordance
with the orientation shown.
Festo P.BE-CB-COMP-EN en 0211a
S
Show at least six parts of the current type per orientation.
If possible use different parts, but if necessary the same
part can be shown several times.
S
Carry out the teach procedure as realistically as possible.
Use e.g. the conveyor device and supply device intended
for later operation.
S
Place the sample parts on the conveyor band one after
the other. They should be positioned exactly like the parts
to be tested later. You need not be too careful at first. As
standard during the teach procedure, the parts are sorted
out at the first actuator position. This is to ensure that no
sample parts are unintentionally transported further to
the next machine.
S
In cases where particularly different variations of the ascertained parts contour (view) are permitted or are possible in an orientation, you should show the “extreme”
variations or as many different variations as possible
when teaching.
5-7
5. Teaching parts
5.2.2 Observe the scatter of characteristics
C...
Observe the display when scanning the sample parts. The
display shows briefly for each part the maximum value of the
scatter of characteristics for the feature which currently deviates the most (C value).
C-value
Meaning
< 10
Sample parts are very similar in all features
> 30
Large scatter of at least one feature
–
Low values indicate narrow manufacturing tolerances and
a uniform supply of parts.
–
Very high values indicate that the taught sample parts
differ greatly in their characteristics from each other. If the
(Good) parts are allowed to differ greatly from each other,
the teach procedure can be continued.
The following factors influence the scatter of characteristics:
–
parts geometry
–
different contours of the part, depending on the angle of
rotation around the longitudinal axis (e.g. with springs,
screws)
–
different positioning on the conveyor belt.
A detailed description of the computational algorithm of the
scatter of characteristics can be found in Appendix A.3.2.
It is optimum if the curve of the values changes greatly at first
and then remains increasingly constant. If the value only
changes slightly, a sufficient scatter is then usually achieved
in the current orientation.
If the C-value shown changes considerably, this indicates that
the conveyed part has probably been positioned incorrectly.
5-8
Festo P.BE-CB-COMP-EN en 0211a
5. Teaching parts
If a part has been positioned incorrectly:
1. Press the START/STOP button to conclude the teach procedure.
2. Repeat the complete teach procedure for the parts type.
5.2.3 Scanning further orientations
A parts type is not registered completely until the Checkbox
has recorded all the intended orientations.
1. Press the STATUS/TEACH button in the TEACH mode in
order to set the next orientation.
Operating status: TEACH
The START/STOP button shows a red light permanently
1 o2
Display: Parts type 1; orientation 2
The STATUS/TEACH button lights up briefly when the
sample part is registered
2. Scanning the sample parts in the new orientation.
For the test to be reliable, the features ascertained from the
individual orientations must be clearly distinguishable from
each other.
S
Check whether there is at least one feature by which the
various orientations differ.
S
Make sure in particular that orientation 1 (nominal
orientation) differs clearly in at least one feature from all
the other orientations.
Save the teach data when the sample parts of a parts type
have been learnt in all intended orientations.
Festo P.BE-CB-COMP-EN en 0211a
5-9
5. Teaching parts
E20
If fault E20 is shown, the nominal orientation cannot be distinguished from other orientations.
Possible causes:
–
The nominal orientation was taught several times by
mistake.
S
–
The nominal orientation is too similar to other orientations.
S
5-10
Repeat the teach procedure. Make sure that the
sample parts are positioned in accordance with the
orientation shown.
Optimize the teach data with CheckOpti. With the
CheckOpti software even minimum differences can be
recognized. Please consult your technical advisor in
this respect.
Festo P.BE-CB-COMP-EN en 0211a
Testing parts
Chapter 6
Festo P.BE-CB-COMP-EN en 0211a
6-1
6. Testing parts
Contents
6.
Testing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6.1
6.2
6.3
6.4
6.4.1
6.4.2
6.4.3
The test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Influence of the tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assessing the test results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3
6-3
6-6
6-8
6-8
6-8
6-9
6-2
Festo P.BE-CB-COMP-EN en 0211a
6. Testing parts
6.1
The test procedure
With the parts test, a reliable grading is to be achieved of the
parts to be checked in respect of orientation and quality (e.g.
whether dimensions of the parts have been observed).
Assess the reliability of the teach data in test mode before
beginning with the automatic parts test.
Checkbox PLC
For selecting the parts type the appropriate bit sample must
be present at connection PLC. (compare chapter 4.3.2,
“Selecting the parts type”)
6.2
Test mode
S
Switch the Checkbox to the AUTO mode.
Operating status: AUTO
The START/STOP button shows a red light permanently
1 5
Festo P.BE-CB-COMP-EN en 0211a
Display: e.g. parts type 1; tolerance 5 %
S
Use good, bad and incorrectly orientated test parts from
the parts assortment.
S
Avoid special care in positioning.
The test parts should be positioned (at random) as in
normal operation. If possible, use the conveyor device
intended for this purpose.
S
You must check a sufficient number of parts in order to
obtain a reproducible result. Show e.g. 6 good parts as
well as 6 bad parts per orientation.
S
Observe the Checkbox displays during the test procedure.
When a conveyed part is registered, the status display
will light up briefly. The display will show in each case for
1.5 seconds:
6-3
6. Testing parts
Display: During the test procedure
A...
Assessment of the test part deviation
#...
Assessment of the test part orientation (if more than one
orientation has been learnt)
The following methods or criteria will assist you in assessing
the teach data and the test results:
–
Influence of the tolerance
chapter 6.3
–
Visual check
chapter 6.4.1
–
Checking the features
chapter 6.4.2
–
Checking the orientation
chapter 6.4.3
CheckOpti
If the quality check and the position recognition for the parts
assortment is not sastisfactory, you can use aditional operating parameters and tools with CheckOpti, in order to optimize
the test results. Please consult your technical advisor in this
respect.
If too many good parts are rejected as bad parts:
6-4
S
Increase the tolerance.
S
Repeat the teach procedure:
–
with more sample parts
–
using the conveyor device intended for use
in automatic mode.
Festo P.BE-CB-COMP-EN en 0211a
6. Testing parts
If the checked parts are graded reliably according to orientation and quality, conclude the test mode:
S
Press the START/STOP button.
Operating status: STOP
The START/STOP button shows a green light permanently
STOP
S
Festo P.BE-CB-COMP-EN en 0211a
The display shows STOP
Protect the teach data against undesired modifications:
–
with the CheckKon software, see software manual:
Parameter “System/operating mode/block of teach
button = ...”
–
with the Checkbox PLC as described in chapter 4.3.7
“Locking the control panel.”
6-5
6. Testing parts
6.3
Influence of the tolerance
Bandwidth
When a new parts type is taught, the features of all scanned
parts are recorded. The values of the registered features
differ individually from each other. For each feature there is a
value range (bandwidth) in which test parts are graded as
“Good.” By means of the tolerance setting, you can extend
this bandwidth. Test parts, the features of which lie within the
band width of the sample part or in the tolerance range bordering onto this, will still be accepted as good parts.
With 0 % tolerance, parts will only be accepted as good parts
if their features of which lie exactly within the band width of
the scanned sample parts. Set at least 1 % tolerance. You can
then be sure that good parts are correctly classified despite
minimum position deviations.
Setting the tolerance
The setting must be made in the stop status.
1. Press the START/STOP button: Stop status.
2. Press and hold down the START/STOP button.
3. Increase the tolerance with the TEACH/STATUS button:
setting range
0...20 %
standard setting
5%
recommendation
at least 1 %.
4. Release the START/STOP button.
The value selected will automatically be added to the data of
the parts type and saved.
Optimization
Ascertain in test mode the optimum setting of the tolerance,
especially with critical parts. Use one of the following
methods:
S
6-6
Empirical setting:
Vary the tolerance so that the test of a large number of
parts produces correctly recognized good and bad parts.
Festo P.BE-CB-COMP-EN en 0211a
6. Testing parts
S
Festo P.BE-CB-COMP-EN en 0211a
Setting according to test part deviation:
S
Select sample parts which are suitable as reference
for good or bad parts. The recognition-specific features should lie where possible in the border range
good/bad.
S
Vary the tolerance so that the following test part deviation is shown when the borderline sample parts are
scanned.
‹ 100
Borderline sample part “Good”
› 100
Borderline sample part “Bad”
6-7
6. Testing parts
6.4
Assessing the test results
6.4.1 Visual check
Check the test results e.g. according to the following aspects:
–
Have the orientations been recognized correctly?
–
Is the grading of the parts recognized as good/bad
correct?
Use the sample parts to check the test parts with regard
to their grading. If you have also checked faulty parts,
check whether these have actually been recognized as
bad.
–
Use as many test parts as possible to make sure that they
are correctly output at the delivery positions for good,
bad or incorrectly orientated parts.
Observe the explanations on the test procedure in the next
chapter. If necessary, optimize the test result via the influence
of the tolerance (chapter 6.3).
6.4.2 Checking the features
The individual features of the test parts differ from the average values of the sample part features. The Checkbox ascertains for each test part the feature which deviates the most
(maximum deviation).
A...
6-8
During the test procedure the test part deviation will be displayed for 1.5 seconds. Detailed instructions on the test part
deviation (computational algorithm) can be found in chapter
A.3.3.
Festo P.BE-CB-COMP-EN en 0211a
6. Testing parts
Value
Assessment
Remark
≤ 100
Good part
The smaller the value, the more
exactly the test part corresponds
to the sample parts.
> 100
Bad part
The greater the value, the less the
test part corresponds to the
sample parts.
Display range: 0 to 999
6.4.3 Checking the orientation
During the test procedure, the Checkbox ascertains whether
the orientation of the test part just scanned can be classified
with the orientations of the sample part.
#...
The uncertainty of the orientation recognition is shown for
1.5 seconds after the display of the test part deviation.
Value
Assessment
Meaning
< 100
Test part orientation can
be assigned
The smaller the value, the
more reliably the test part
orientation can be recognized.
> 100
Test part orientation
cannot be assigned clearly
The greater the value, the
less reliably the test part
orientation can be recognized.
Display range: 0 to 999
Festo P.BE-CB-COMP-EN en 0211a
6-9
6. Testing parts
6-10
Festo P.BE-CB-COMP-EN en 0211a
Maintenance
Chapter 7
Festo P.BE-CB-COMP-EN en 0211a
7-1
7. Maintenance
Contents
7.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7.1
7.2
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3
7-4
7-2
Festo P.BE-CB-COMP-EN en 0211a
7. Maintenance
7.1
General information
The Checkbox has been designed for rough industrial environments and is distinguished by high reliability, robust
structure and long service life. Special maintenance is not
required.
Warning
Switch off the following power supplies before cleaning or
undertaking maintenance work:
– the compressed air supply
– the voltage supplies.
Laser radiation
The Checkbox is a device of laser class 2 and contains a
laser of class 3a.
S Do not open the device.
S Do not dismantle any parts (e.g. prism supports).
S Do not look directly into the laser beam.
Only in this way is the observance of laser class 2 guaranteed and you can avoid damage to the eyes and skin.
Festo P.BE-CB-COMP-EN en 0211a
7-3
7. Maintenance
7.2
Cleaning
Remove dirt on the housing, operating elements and conveyor belt with a soft moist cloth.
Please note
When cleaning plastic parts, do not use any solvent or
abrasive cleaning agent which might damage the surface.
Use only non-abrasive, solvent-free cleaning agents.
Fixed cleaning intervals are not stipulated. The frequency of
cleaning depends on the conditions of use at the site.
Faultless functioning of the Checkbox optics can only be guaranteed if the glass surfaces are kept clean and not scratched.
Clean the glass surfaces on the prism supports if they are
dirty:
–
with clean, non-lubricated compressed air,
–
with a soft moist cloth and a non-abrasive cleaning agent.
Please note
S The prism supports must not be removed. Only in this
way will you comply with laser class 2.
S Make sure that the glass surfaces are not scratched; do
not use abrasive cleaning agents. You will then avoid
damage which could lead to malfunctioning of the
Checkbox.
S Please consult Festo Service if the glass surfaces are
damaged.
7-4
Festo P.BE-CB-COMP-EN en 0211a
Technical appendix
Appendix A
Festo P.BE-CB-COMP-EN en 0211a
A-1
A. Technical appendix
Contents
A.
Technical appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-1
A.1
A.1.1
A.1.2
A.2
A.3
A.3.1
A.3.2
A.3.3
A.4
A.5
A.6
Malfunctioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General cause of faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault messages and warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Status displays on the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Examples for ascertaining the features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bandwidth and tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scatter of characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test part deviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-3
A-3
A-4
A-9
A-12
A-12
A-14
A-15
A-17
A-22
A-25
A-2
Festo P.BE-CB-COMP-EN en 0211a
A. Technical appendix
A.1
Malfunctioning
A.1.1 General cause of faults
Problem
Cause
Remedy
Device does not function, both
illuminous buttons flash.
Ambient, setting,
data or hardware fault
1. Identify fault coding in
chapter A.1.2
2. Eliminate fault
3. Quit with START/STOP button
Good test parts are sorted out
as bad parts
– Tolerance set too low
– Increase tolerance and
repeat teach procedure with
more sample parts
– Incorrect parts type selected
via external type preselection
at connection PLC
– Select (correct) parts type
via external type preselection
Bad test parts are accepted by
the device as good parts
– Tolerance set too high
– Deviations for the Checkbox
not recognized
– Reduce tolerance
– With CheckOpti: Optimize the
teach data
– Display cFul
– Good parts in all orientations
are blown back into the small
parts conveyor
The preselected counter status
is reached and is not reset by
the external controller
– Check connection to
controller
– Check PLC program in the
controller
– Response timing point/
duration of the Checkbox
is not correct
– Test part deviation is
displayed for an unusually
long time
Checkbox runs in diagnostic
mode (setting via CheckKon or
CheckOpti)
– With CheckKon/CheckOpti:
Switch from diagnostic mode
to operating mode
Festo P.BE-CB-COMP-EN en 0211a
A-3
A. Technical appendix
A.1.2 Fault messages and warnings
If a fault occurs, the Checkbox will stop automatically. When
the cause of the fault has been eliminated, the fault messages/warnings must be quitted before the Checkbox can
start again.
1. Eliminating the cause of the fault
2. Quit fault message: Press the START/STOP button
3. Start the Checkbox: Press the START/STOP button
Depending on the customer-specific design of the Checkbox
or the configuration with CheckKon, the following faults will
not be displayed:
A-4
–
The fault messages E01, E02, E04, E06, E08, E12 and E14
can be deactivated.
–
Fault E05 is redefined as warning F05 or deactivated.
–
The faults E08 and E14 are only displayed in encoder
operation.
–
Fault E06 is only displayed if the CheckKon function
“Forced abort of analysis” is switched on.
Festo P.BE-CB-COMP-EN en 0211a
A. Technical appendix
Code Cause
Remedy
The fault messages marked in grey can be activated/deactivated with CheckKon.
Ambient fault
E01
External fault
– Signal at connection PLC, check input “External fault:”
HIGH = operation
LOW = fault
E02
Optical fault:
– Glass surfaces on the prism
supports dirty or defective
– Blockage in front of the
optical channel
– Remove dirt with a soft cloth and non-abrasive cleaning
agent or blow down from the glass surfaces with nonlubricated compressed air.
Please consult Festo Service if the glass surfaces are
damaged.
– Glass surface is misty due to
large difference in temperature between the Checkbox
and the environment
– Avoid large differences in temperature.
– Camera registers lower
range of conveyor device.
– Max. parts length exceeded
– With CheckKon:
Correct the setting of the picture limits.
Increase exposure time or ratio encoder frequency/
line frequency
E04
System recognizes too many
incorrect conveyed parts:
> 75 % of the last 20 parts were
graded as bad parts.
– Check the selection of the sample part type
– Increase tolerance
E05
Material blockage (fault):
The Checkbox has not received
a conveyed part for at least
30 seconds 1).
– With manual supply of parts: Quit fault, supply further
test parts or stop the Checkbox.
– With automatic supply of parts: Fill up small-parts
conveyor, check supply line for material blockage, quit
fault.
1) Duration variable, can be set with
CheckKon
Festo P.BE-CB-COMP-EN en 0211a
A-5
A. Technical appendix
Code
Cause
Remedy
F05
Only Checkbox PLC:
Material blockage (warning)
Signal at plug PLC O/23 = HIGH
The Checkbox has not received
a conveyed part for at least 30
seconds 1).
– With manual supply of parts: Quit fault, supply further
test parts or stop the Checkbox.
– With automatic supply of parts: fill up small-parts conveyor, check supply line for material blockage.
Quit warning.
1) Duration variable, can be set with
CheckKon
E06
Maximum permitted parts
length exceeded
Fault E06 is only displayed if
the CheckKon function “Forced
abort of analysis” is switched
on.
– With CheckKon: parameter “Set parameter max. parts
length” correct.
– Set the device so that the parts follow each other at a
recognizable distance.
E07
Optical fault:
reduced brightness
Clean the glass surfaces on the prism supports.
E08
Only in operation with encoder:
Conveyor device blocked or
encoder does not turn.
Checkbox has no control over the conveyor device
– Check fitting and installation of the encoder.
E09
E10
Internal I/O module overloaded
1. Stop the Checkbox
2. Check whether external outputs are loaded with a
current which is too high.
3. Start the Checkbox
or contact the Festo after-sales service.
E12
Overtemperature
– Check the ambient temperature
– Avoid heating from outside, e.g. from sun radiation.
E14
Only in operation with encoder:
Belt speed for the set ratio encoder frequency/line frequency
of the camera (F EZ value) too
high
– Reduce the belt speed
– With CheckKon: Adapt F EZ value
A-6
Festo P.BE-CB-COMP-EN en 0211a
A. Technical appendix
Code
Cause
Remedy
Recognition fault
E20
The nominal orientation cannot
be distinguished from other
orientations, because e.g:
– Parts orientations were
swapped during the teach
process by mistake
or
– The nominal orientation is
too similar to other orientations.
S Repeat the teach procedure. Make sure that the
sample parts are positioned in accordance with the
orientation shown.
S Optimize the teach data with the CheckOpti software.
Code Data fault
Remedy
E40
Teach data are not clear.
When the device is switched on
again, the saved TEACH data
are no longer OK.
– Repeat the teach procedure.
– Check environment for non-CE-conform devices.
– Check that all electrical connections are wired correctly.
E41
Controller has lost system
parameters
– With CheckKon: Load system parameters again.
– Contact the Festo after-sales service.
E42
Controller has lost configuration part of the teach data
– With CheckKon: Load the teach data again.
– Contact the Festo after-sales service.
E43
Teach data are not compatible.
Teach data are not organised
compatibly with the Checkbox
used.
– Use compatible teach data format.
– Repeat the teach procedure.
If a hardware fault message ≥ E60 occurs, please contact
Festo after-sales service.
Festo P.BE-CB-COMP-EN en 0211a
A-7
A. Technical appendix
Fault situation
Cause
Remedy
...Full although the buffer zone
is not full.
Good parts in all orientations
are blown back into the smallparts conveyor.
– Control cable defective or incorrect pin assignment at
connection BUFFER/FEEDER.
– Incorrect sensor type set
– Check correct wiring at
connection BUFFER/FEEDER.
...E02, although length of conveyed part is shorter than max.
permitted length.
– Conveyed part has lots of
holes or is semi-transparent
Conveyed part
– Speed of conveyor belt has
been modified
With CheckKon:
– Increase conveyor belt speed
– Increase exposure time,
dividing factor
– Vary grey value threshold
– Limit camera lens coverage
– Activate filter function
...E02 occurs in the morning,
although the Checkbox worked
perfectly the day before.
– High fluctuations in temperature for example between
day and night
– Conveyor device has been
replaced
With CheckKon:
Setting the picture limits
...E04, although only a few bad
parts pass through the test
procedure.
Moving particles of dirt on the
conveyor device
– Clean the conveyor device
with compressed air
– Install a reject device in front
of the conveyor device
A-8
– With CheckKon: Switch
polarity
Festo P.BE-CB-COMP-EN en 0211a
A. Technical appendix
A.2
Status displays on the control panel
Illuminous button
Button
Status
Meaning
START/
STOP
Continuous
red light
Checkbox is switched on and
is in:
– AUTO mode
(display e.g.: 1 5) or
– TEACH mode
(display e.g. = 1 o1)
START/
STOP
Continuous
green light
Controller is switched off
STATUS/
TEACH
Flashes
New part passes the camera.
START/
STOP
and
STATUS/
TEACH
Flashes red
Fault
Display fault code E... or
warning F..., see Appendix
A.1.2.
Flashes yellow
Operating displays of the Checkbox
Checkbox with encoder
In order to display the conveyor belt speed [mm/s], press the
TEACH/STATUS button whilst the device is operating.
Festo P.BE-CB-COMP-EN en 0211a
A-9
A. Technical appendix
Operating displays
Table fields with a grey background indicate continuous displays;
the remaining displays are shown only for a brief period due to an
event or operating status.
Display when the Checkbox is switched on
IC30
Identification code and version status of the operating
system
4..E
Number of memory groups or parts types and also the
letter E with system setting “with encoder.”
Example: 4 memory locations, encoder
2048
System setting of the camera resolution.
Example: 2048 pixels
Stop
The Checkbox is in the stop status.
Display with control panel lock
Lock
Display in the stop status or for 1.5 s when the START/
STOP button is pressed.
Blocking the keys START/STOP and STATUS/TEACH via
PLC programming A change of operating mode is controlled exclusively by the PLC (see chapter 4.3.1).
Fix
Display for 1.5 s when the STATUS/TEACH button lock of
the STATUS/TEACH key is pressed via the CheckKon configuration software (parameter “System/operating mode
locking of the Teach button = ...”). The Checkbox can be
started or stopped manually. A change to the teach mode
is not possible. The Checkbox remains in auto mode.
Fault message
Details in chapter A.1.2.
A-10
E...
Fault code for system fault
01...99
F...
Warning
05
Festo P.BE-CB-COMP-EN en 0211a
A. Technical appendix
Operating displays
Display during the teach procedure
Value
1 o...
Memory group of the parts type and
number of the sample part orientation
during the teach procedure
1...8
? ...
Selection of the memory group of the
parts type
Checkbox PLC:
1...4
C...
Scatter of characteristics (C-value)
<10:
Sample parts are very similar in
all features.
>30:
Large scatter of at least one
feature
0...999
tool
Memory address assigned with measuring tool or
optimized teach data (CheckOpti)
Display during test procedure
Value
1 5
1. Number:
Checkbox
Classic: 1
Checkbox PLC:
1...4
Tolerance value for the current parts type
1. Number: Number of the parts type
2. Number: Tolerance in %
2. Number:
0...20
A...
Test part deviation: The smaller
the value, the more exact the test part
corresponds to saved sample parts.
≤100: Good part
>100: Bad part
0...999
#...
The smaller the value, the more reliably
the test part orientation can be recognized.
0...999
<100:
>100:
Festo P.BE-CB-COMP-EN en 0211a
Test part orientation can be
assigned
Test part orientation cannot be
assigned clearly
Full
Status of buffer zone (signal from buffer zone sensor)
cFul
Preselected counter reading reached
A-11
A. Technical appendix
A.3
Examples for ascertaining the features
A.3.1 Bandwidth and tolerance
Bandwidth B specifies the extent to which the value of the
feature may vary upwards or downwards.
Tolerance T specifies the per cent increase in the bandwidth
of each feature, related to the average value of the feature.
Cmax tol = Cmax+A × T
100
Cmin tol = Cmin−A × T
100
B = Cmax tol−Cmin tol
= C max − Cmin + 2 × T × A
100
→T=
A
B
Cmax
Cmax tol
Cmin
Cmin tol
T
A-12
B−(C max − Cmin)
× 100
2×A
Average value of the feature
Bandwidth
Feature – maximum
Upper limit of bandwidth incl. tolerance
Feature – minimum
Lower limit of bandwidth incl. tolerance
Tolerance
Festo P.BE-CB-COMP-EN en 0211a
A. Technical appendix
Example
Ascertaining the bandwidth for the feature “Length” of a conveyed part with a set tolerance of 5 % (display on the LCD
TOLERANCE).
Conveyed part lengths [mm] for 5 sample parts ascertained
during the teach procedure: 60 60 61 65 60
Therefore:
A
Cmax
Cmin
T
=
=
=
=
61.2 mm
65 mm
60 mm
5%
Average value of the length
Length – maximum
Length – minimum
Tolerance
B = Cmax − C min + 2 × T × A
100
B = (65−60) + 2 × 5 × 61.2
100
B = 11.12
B
Cmax tol
68.06
Cmax
65.00
A
Cmin
61.20
60.00
Cmin tol
56.94
1
2
1 Bandwidth of conveyed part length
2 Bandwidth with 5 % tolerance
Result: All conveyed parts with a length of 57...68 mm are
classified as good parts. The Checkbox ascertains appropriate value ranges for each feature.
Festo P.BE-CB-COMP-EN en 0211a
A-13
A. Technical appendix
A.3.2 Scatter of characteristics
S=
A
Cmax
Cmin
S
Example
Cmax−C min
× 100 %
A
Average value of the feature
Feature – maximum
Feature – minimum
Scatter of characteristics
Ascertaining the scatter of characteristics for the feature
“Length” of a conveyed part.
The following values are taken from the example
“Bandwidth”
A
= 61.2
Cmax = 65
Cmin = 60
Average value of the length
Length – maximum
Length – minimum
S = 65−60 × 100 %
61.2
S = 8.2 %
A-14
Festo P.BE-CB-COMP-EN en 0211a
A. Technical appendix
A.3.3 Test part deviation
Ascertaining deviation D for C xxx A
D=
A
Cactual
Cmin tol
D
Example
Cactual−A
× 100 %
Cmin tol−A
Average value of the feature
Current feature measurement
Lower limit of bandwidth incl. tolerance
Feature deviation
Ascertaining the deviation for the current feature “Length” of
a conveyed part Cactual = 61 (C xxx A).
The following values are taken from the example
“Bandwidth”
A
Cmin tol
= 61.2
= 56.94
Average value of the length
Length – lower value
Cactual
= 61
Length – current value
D = 61−61.2 × 100 %
56.94−61.2
D = 4.7 %
Festo P.BE-CB-COMP-EN en 0211a
A-15
A. Technical appendix
Ascertaining deviation D for C xxx A
D=
C actual−A
× 100 %
Cmax tol−A
A
Cactual
Cmax tol
D
Example
Average value of the feature
Current feature measurement
Upper limit of bandwidth incl. tolerance
Feature deviation
Ascertaining the deviation for the current feature “Length” of
a conveyed part Cactual = 64 (C xxx A).
The following values are taken from the example
“Bandwidth”
A
= 61.2
Cmax tol = 68.06
Average value of the length
Length – upper value
Cactual
Length – current value
= 64
D = 64−61.2 × 100 %
68.06−61.2
D = 40.8 %
A-16
Festo P.BE-CB-COMP-EN en 0211a
A. Technical appendix
A.4
Connections
Pin
24 V DC connector plug
1
Do not connect
2
+ 24 V DC, +/-15 %; protect with a
5 A fuse, medium time-lag
3
GND
4
Do not connect
Pin
BUFFER/FEEDER connector socket
O/1
24 V DC / Box ready
– Reference voltage for sensors,
switched off in the stop status
– Ready to operate
– Control for transport device
3
Feeder
Controlling the supply system
(small parts conveyor)
2
O/2
3
GND
Reference voltage for sensors
I/4
Buffer zone sensor 1
5
Do not connect
4
1
5
As an option, direct connection with a Festo Duo cable is also
possible. (see chapter A.6 Accessories).
Identifying the DUO cable
Festo P.BE-CB-COMP-EN en 0211a
Signal x
Buffer zone sensor 1
Signal x + 1
Small parts conveyor (feeder)
A-17
A. Technical appendix
Pin
Connector socket ACTUATORS
O/1
Actuator 3
O/2
Actuator 2
3
GND
O/4
Actuator 1
5
Do not connect
3
4
2
1
5
Connector plug DIAG
I/1
Receive data of the Checkbox
O/2
Send data of the Checkbox
3
Data GND
4
Screening/shield
4
3
1
2
Interface for diagnostic PC: Cable type KDI-SB202-BU9
Pin
Checkbox PLC: ENCODER connector socket
Interface for rotary pulse generator as per RS485
specification
1
A+
2
n.c.
3
B+
4
A-
5
B-
6
5 V supply 1)
7
GND
8
n.c.
1)
A-18
2
4
1
6
8
5
3
7
Maximum loading capacity 180 mA
Festo P.BE-CB-COMP-EN en 0211a
A. Technical appendix
Checkbox PLC: Connector socket PLC
– All outputs are electronically limited to
max. 700 mA.
– Maximum sum current 1 A
12
13
4
21
3
22
1
24
7
17
8
16
Pin assignment of connector socket PLC see following table.
Festo P.BE-CB-COMP-EN en 0211a
A-19
A. Technical appendix
Pin
Cable colour Signal
Checkbox PLC: Connector socket PLC
O/1
white
OUT24_Act1
Actuator 1
O/2
brown
OUT24_Act2
Actuator 2
O/3
green
OUT24_Act3
Actuator 3
4
yellow
GND_NT
0 V / reference voltage for buffer zone sensors
I/5
grey
IN24_TypeSel1
External type selection bit 1
I/6
pink
IN24_Ext_Start
Remote start
O/7
blue
OUT24_PLC_Power
Reference voltage + 24 V DC
(Signal level after boot procedure = HIGH)
O/8
red
OUT24_Feeder
Small parts conveyor
I/9
black
IN24_Cam_Enable
External camera trigger
I/10
violet
IN24_ExtSensor
External sensor
I/11
grey/pink
IN24_Key_Inhibit
Button lock
I/12
red/blue
IN24_Jam1
Buffer zone sensor 1
I/13
white/green
IN24_Jam2
Buffer zone sensor 2
O/14
brown/green
OUT_PWM
Do not connect
15
white/yellow
n.c.
Do not connect
O/16
yellow/brown
OUT24_Res2
Not assigned
O/17
white/grey
OUT24_Error
Fault status 1: Status message “Faults”
I/18
grey/brown
IN24_Counter-Rst
Start new counting cycle
I/19
white/pink
IN24_Ext-Fault
Externer fault E01
I/20
pink/brown
IN24_TypeSel0
External type selection bit 0
O/21
white/blue
OUT24_Power
24 V DC reference voltage of buffer zone sensor/
Ready to operate/Control conveyor device
O/22
brown/blue
OUT24_Counter-fin
Target number reached
O/23
white/red
OUT24_Warning
Fault status 0: Status message “Warning”
O/24
brown/red
OUT24_Res1
Not assigned
A-20
Festo P.BE-CB-COMP-EN en 0211a
A. Technical appendix
Internal wiring of the connections ACTUATORS and PLC
PLC
Function
3
4
GND
O/4
O/1
Actuator 1
O/2
O/2
Actuator 2
O/1
O/3
Actuator 3
ACTUATORS
Internal wiring of the connections BUFFER/FEEDER and PLC
Festo P.BE-CB-COMP-EN en 0211a
Funktion
BUFFER
FEEDER
PLC
O/1
O/21
O/2
O/8
O/3
O/4
0 V reference voltage of buffer
zone sensor
I/4
I/12
Buffer zone sensor 1
------
I/13
Buffer zone sensor 2
– 24 V reference voltage of
buffer zone sensor
– Ready to operate
– Control conveyor device
24 V power output for controlling
the small parts conveyor (feeder)
A-21
A. Technical appendix
A.5
Technical specifications
General
Temperature range
– Operation
– Storage/transport
- 5 ... + 50 °C
- 20 ... + 70 °C
Relative humidity
95 %, non-condensing
Protection against electric shock
(protection against direct and indirect contact
as per EN 60204-1/IEC 204)
By means of PELV power units
(Protected Extra-Low Voltage)
Electromagnetic compatibility
– Interference emitted
– Resistance to interference
Tested as per
– EN 55011 Kl A, EN 50081-2
– EN 61000-6-2 1)
Vibration and shock
– Vibration
Tested as per DIN/IEC 68/EN60068 part 2-6
– 1 g acceleration at 9...27 Hz
– 5 g acceleration at 60...150 Hz
– Shock
Tested as per DIN/IEC 68/EN60068 part 2-27
– 30 g at 11 ms duration
Protection class as per EN 60529 (plug connector inserted or provided with protective cap)
IP64
Electric components
– Power supply
– Power consumption
– Current consumption
Interfaces
– Digital I/O as per EN 61131-2
– Encoder connection
– Diagnostic interface
1)
24 V ± 15%; protect with a 5 A fuse, medium
time-lag
With non-loaded outputs typ. 18 W
With non-loaded outputs typ. 750 mA
All outputs electronically limited to max. 700 mA;
maximum sum current 1 A (at PLC connection)
As per RS485
As per RS232 (115 kBaud)
The maximum permitted I/O signal cable length is 30 m.
A-22
Festo P.BE-CB-COMP-EN en 0211a
A. Technical appendix
Electrical characteristics of the I/O signals
Outputs
– Maximum current loading per channel:
700 mA
– Maximum sum current of all outputs:
PLC
1A
ACTUATORS
2.1 A
BUFFER
1.4 A
– PNP-switching
Inputs
– Input current:
– Logical “1:” VIN
– Logical “0:” VIN
< 30 mA
> 15 V
<5V
Camera and lighting
Camera resolution
6/100 mm
Exposure time
128...1000 ìs
Laser class
Class 2 as per EN 60825-1
Class II as per CFR 21 §1040.10 (USA)
Conveyed parts
Conveyed parts
Rotation-symmetrical parts as well as preorientated parts of any geometry
Length
Depending on conveyor belt speed and requested
resolution
Diameter
0.5...25 mm
Light passage of the optical channel
60 mm
Headroom of the optical channel
40 mm
Festo P.BE-CB-COMP-EN en 0211a
A-23
A. Technical appendix
Conveyor and test output
Conveyor rate (examples for belt speed 300 mm/s)
M3 x 25 screws in correct position for mounting
4...5 items/s
Axes @ 18x25 mm for quality check
8 items/s
Bolts @ 5x50 mm tested and in correct position
2 items/s
The conveyor rate depends on the size of the component, the number of orientations and the belt
speed.
Dimensions and weight
Height (without plug)
241 mm
Width
164 mm
Depth
60 mm
Weight
2.3 kg
A-24
Festo P.BE-CB-COMP-EN en 0211a
A. Technical appendix
A.6
Accessories
Accessories
Type
Order
no.
Support bracket for sensors,
quadratic construction form
SOEZ-HW-Q30
165335
Support bracket for sensors, quadratic construction form
Reflex light barrier
Can be connected directly
to Duo cable
SOEG-RSP-Q30-PS-S-2L
165331
– Diameter 20 mm
SOEZ-RFS-20
165363
– Diameter 40 mm
SOEZ-RFS-40
165364
Sender
(24 V power supply required)
SOEG-S-Q30-K-L
165352
Receiver
Can be connected directly
to Duo cable
SOEG-R-Q30-S-2L
165323
Optical waveguide device
Cable connection, separate
clamping space necessary
SOEG-L-Q30-P-A-K-2L
165326
– Light push button function
SOEZ-LLK-RT-2,0-M6
165358
– Light barrier function
SOEZ-LLK-SE-2,0-M4
165360
– Light push button function
SOEZ-LLG-RT-0.5-M6
165356
– Light barrier function
SOEZ-LLG-SE-0.5-M4
165357
Reflectors, round:
One-way light barrier
Optical waveguide – PMMA
fibre PE coating
Optical waveguide – glass
fibre, brass coating
Festo P.BE-CB-COMP-EN en 0211a
A-25
A. Technical appendix
Accessories
Type
Order
no.
Opto-electronic sensors, cylindrical construction form
Reflex light push button
Cable connection, separate
clamping space required
– M12
SOEG-RT-M12-PS-K-L
165338
– M18
SOEG-RT-M18-PS-K-L
165342
Inductive sensors, cylindrical construction form
with standard switching distance, can be connected directly to
Duo cable
Fitting diameter
– 4 mm
SIEN-4B-PO-S-L
150367
– 6.5 mm
SIEN-4B-PO-S-L
150383
Connections BUFFER/FEEDER and ACTUATORS
Adapter cable (Duo cable)
Extension cable 2.5 m
Extension cable 5 m
18685
18684
18686
Sensor plug M12
– 4-pin
– 4-pin
SAE-4GS-7-2,5
SEA-GS7
18666
192008
Duo plug M12, 2 cables
– 4-pin
SEA-GS-11-DUO
18779
CHB-C-P
665967
Connection PLC
Binder plug
– 24-pin with 5 m cable
length
A-26
Festo P.BE-CB-COMP-EN en 0211a
A. Technical appendix
Accessories
Type
Order
no.
KDI-SB202-BU9
150268
TU
656029
NTSD-GD-9
NTSD-GD-13,5
NTSD-WD
18493
18526
18527
HMSV-12
177658
P.SW-CB-Kon-DE
P.SW-CB-Kon-EN
P.SW-CB-Kon-ES
P.SW-CB-Kon-FR
P.SW-CB-Kon-IT
194496
194497
526711
526712
526713
P.SW-CB-Opti-DE
P.SW-CB-Opti-EN
192144
192145
Connection DIAG
Diagnostic cable
Encoder
Encoder with plug
(2 m cable length)
Mains connection
Mains power socket
– straight PG9
– straight PG13.5
– angled PG9
Connecting kit
Dovetail profile
Software
CheckKon
– CheckKon DE
– CheckKon EN
– CheckKon ES
– CheckKon FR
– CheckKon IT
CheckOpti
– CheckOpti DE
– CheckOpti EN
Further sensors, technical specifications, other connections
(plug/cable), cable lengths, etc. can be found in the main
Festo catalogue.
Festo P.BE-CB-COMP-EN en 0211a
A-27
A. Technical appendix
A-28
Festo P.BE-CB-COMP-EN en 0211a
Index
Appendix B
Festo P.BE-CB-COMP-EN en 0211a
B-1
B. Index
Contents
B.
B-2
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-3
Festo P.BE-CB-COMP-EN en 0211a
B. Index
B.1
Index
A
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-25 , A-27
ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 , A-26
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 , 4-13
Assess
Teach data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Assessing the test part . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
AUTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII , 2-16
B
Bad part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIV
Bandwidth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 , A-12
Belt speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Buffer zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Hysteresis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 , 1-11
Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 , 4-14
BUFFER/FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 , A-26
Button
START/STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
STATUS/TEACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Festo P.BE-CB-COMP-EN en 0211a
B-3
B. Index
C
C-value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII , 5-8 , A-11
Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-23
Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
cFul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 , A-11
Checkbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII , 1-3
Classic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII , 1-3
PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII , 1-3
Checkbox Compact
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 , 1-6
CheckKon . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 , 4-11 , A-27
CheckOpti . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 , 6-4 , A-27
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-17
Fitting the electric components . . . . . . . . . . . . . . . . . . . 2-9
Internal wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-21
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 , 4-18
Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Conveyed parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-23
Conveyor and test output . . . . . . . . . . . . . . . . . . . . . . . . A-24
Conveyor parts
Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Counter function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Counter status check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
B-4
Festo P.BE-CB-COMP-EN en 0211a
B. Index
D
Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
Deviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII
DIAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 , A-27
Diagnostic interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XII
Duo cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-17 , A-26
E
Eliminating
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 , 2-13 , A-22
Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 , A-27
F
Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Eliminating faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Feature . . . . . . . . . . . . . . . . . . . . . . . . . . XIV , 5-3 , 6-8 , A-12
Fix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 , A-10
Full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11
G
Good part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII
Festo P.BE-CB-COMP-EN en 0211a
B-5
B. Index
I
I/O module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 , 4-4 , 4-6
I/O signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 , 4-6
Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-17
ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
BUFFER/FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
DIAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
ENCODER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
L
Laser radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
Exit opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Laser class . . . . . . . . . . . . . . . . . . . . . . . . . . . VII , XIII , 7-3
Warning notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Laser radiation , Warning notice . . . . . . . . . . . . . . . . . . . . . 7-3
Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 , A-10
M
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
O
Operating displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Operating mode
AUTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
TEACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . XII , 4-4
Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Operating voltage . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 , A-27
B-6
Festo P.BE-CB-COMP-EN en 0211a
B. Index
P
Parts type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIV
Binary coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 , A-20 , A-26
Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Special functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 , 2-13
Power unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Protecting the teach data . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Pulse-time diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Change of parts types . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Counter status check . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Switch-on delay of the small parts conveyor . . . . . . . 4-15
R
Rectifying, Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
S
Sample parts . . . . . . . . . . . . . . . . . . . . . . . . . . . XIV , 5-4 , 5-7
Scatter of characteristics . . . . . . . . . . . . . . . . XIV , 5-8 , A-14
Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII
Selecting the parts type . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Sensor
External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-25
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII
Small parts conveyor . . . . . . . . . . . . . . . . . . . . . . . . 3-7 , 4-14
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 , A-27
Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
START/STOP . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 , 2-19 , A-9
Start/stop mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Festo P.BE-CB-COMP-EN en 0211a
B-7
B. Index
STATUS/TEACH . . . . . . . . . . . . . . . . . . . . . . . . 2-15 , 2-19 , A-9
STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 , 2-17
Switch-on delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 , 4-15
Switching, The operating mode . . . . . . . . . . . . . . . . . . . 2-17
Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
T
Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII
TEACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIV , 2-17
Teach data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIV
Teach procedure . . . . . . . . . . . . . . . . . . . . . . . . XIII , 1-7 , 5-5
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Test mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Test part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIV
Deviation . . . . . . . . . . . . . . . . . . . . . . 6-4 , 6-8 , A-11 , A-15
Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 , 6-9 , A-11
Test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . XIV , 1-8 , 6-3
Time reaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIV , 6-6 , A-12
tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 , A-11
Type of fault
Ambient fault . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware fault . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recognition fault . . . . . . . . . . . . . . . . . . . . . . . . .
2-19 , A-5
2-19 , A-7
2-19 , A-7
2-19 , A-7
W
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 , A-4
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24
B-8
Festo P.BE-CB-COMP-EN en 0211a
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