BundleChek User Manual

BundleChek User Manual
Bundlechek
User Manual
ClearVision Technical Writing Dept.
Last Updated: January 17, 2013
Document #: MC093
Revision #: 005

Declaration of Conformity
(According to EN 45014)
Manufacturer:
Valco Melton
A division of Valco Cincinnati, Incorporated
411 Circle Freeway Drive
Cincinnati, OH 45246
USA
Authorized Representatives in Europe:
Valco Cincinnati, Ltd.
Unit 7-8
Hortonwood 32
Telford TF1 7YN
England
Designed by:
ClearVision Technologies
5A - 1225 E. Keith Rd
North Vancouver, BC V7J 1J3
Canada
Melton S.L.U.
Pol. Industrial
Agustinos
calle G, n. 34
31160 Orcoyen
Navarra, Spain
declares that the product:
Product Name:
ClearVision BundleChek
complies with the following Council Directives:
Low Voltage Equipment:
EMC:
2006/95/EC
2004/108/EC
and conforms to the following standards:
Conducted & Radiated Emissions:
EN61326-1, Class B, 2006
Power-line Harmonics & Flicker:
EN 61000-3-3, 2008
Immunity:
EN61326-1, Class B, 2006
Safety:
EN60950-1, 2006
Place and Date:
Cincinnati, Ohio USA
CE Mark first fixed 2012
Signature:
Graham T. Manders
VP Engineering ClearVision
This Declaration of Conformity has been generated electronically and is legally binding without signature.
Contents
Contents
1) Introduction................................................................................................................ 1
2) Overview......................................................................................................................2
3) System Components.................................................................................................3
4) Working with the BundleChek System.............................................................. 8
5) Safety.......................................................................................................................... 11
6) Software User Interface........................................................................................ 12
7) Troubleshooting..................................................................................................... 13
8) Maintenance............................................................................................................ 16
9) Support...................................................................................................................... 17
BundleChek Specifications.......................................................................................18
BundleChek Quick Troubleshooting..................................................................... 19
Important Confidentiality Notice: This information has been produced for the exclusive use of
the ClearVision customer _______________________________________________________.
No reproduction, alteration, or disclosure of the contents, outside of the intended user, to any third
party, is allowed without prior written consent from ClearVision Technologies Inc.
Disclaimer: ClearVision Technologies Inc. reserves the right to make changes with or without
notice. Your product may not be exactly as shown.
© 2013 ClearVision
i
1) Introduction
1) Introduction
This is the user manual for the ClearVision BundleChek system. It contains information on how the
system works, how it is used, and how it should be maintained. It also contains safety guidelines
and troubleshooting tips. If there are any questions beyond what is covered in this manual, please
call ClearVision Technical Support. Contact information can be found in the Support section of this
document (p.17).
© 2013 ClearVision
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2) Overview
2) Overview
BundleChek is designed to integrate into your existing bundle conveyor; it works with the ClearVision
GlueChek and FoldChek systems to eject bundles containing defective boxes. The main BundleChek
system components include an Ejection Unit, a Control Cabinet, a Camera & LED unit, and a UV
marking system. When a defective box is detected, an invisible UV mark is sprayed on the bottom of
the bundle containing this defective box as the bundle leaves the counter ejector. The camera and
lighting system, located just before the ejection unit, scans the incoming bundles for the UV mark.
If one is detected, the bundle is diverted to a secondary conveyor (supplied by the plant), known as
the Reject Conveyor. The machine operator can then sort the defective bundles when time permits.
Indicator Light
Ejection Unit
Undermount
Photoeyes
Encoder
Reject
Photoeye
Camera &
LED Unit
© 2013 ClearVision
BundleChek
Cabinet
E-Stop
2
3) System Components
3) System Components
The main components of the BundleChek system are as follows.
3.1) BundleChek Cabinet
The BundleChek Cabinet controls all BundleChek
operations. It also works with the main Cabinet
that controls GlueChek / FoldChek operations.
Most of the main BundleChek components
(including the Ejection Unit, the Camera & LED
Unit, the E-Stop Enclosure, the indicator stack
light, and the encoder) are connected to the
BundleChek Cabinet.
3.2) Counter Ejector Junction Box
The junction box contains electrical connections
near the counter ejector.
It acts as a connecting point between the
BundleChek Cabinet and the main system
Cabinet, as well as other components such
as the UV Spray System, the counter ejector
trombone, and the counter ejector tray.
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3) System Components
3.3) UV Spray System (Air Treatment and Spray Nozzle)
The UV Spray System consists of a pneumatic air treatment component, a UV dye container,
and a spray nozzle. This system permits the marking of bundles using a UV dye at the counter
ejector.
Air to Spray Nozzle
Air to Reservoir
Air Inlet
Dye to Spray
Nozzle
Dye Tank
3.4) Undermount Photoeyes
These photoeyes detect the positions of bundles on the main conveyor, allowing correct triggering
of the Camera & LED Unit.
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3) System Components
3.5) Camera & LED Unit
The Camera & LED Unit images the bottom of box bundles in search of the dye mark left by the
UV Spray System.
3.6) Ejection Unit
The Ejection Unit moves bundles determined to contain defective boxes off the primary conveyor
and onto the Reject Conveyor.
3.7) Reject Conveyor
The Reject Conveyor is the secondary conveyor that defective bundles are ejected onto. This is
provided by the plant.
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3) System Components
3.8) Reject Conveyor Photoeye
The Reject Conveyor Photoeye detects whether the Reject Conveyor has become full. When the
Reject Conveyor is full, an alert dialog first pops up on the main Cabinet screen; if the dialog is
not acknowledged for some time, the buzzer on top of the main Cabinet sounds.
3.9) Encoder
The encoder determines the speed of the conveyor and tracks the position of the belts used in
performing speed calculations, which in turn helps to determine when a bundle has reached the
Ejection Unit.
3.10) E-Stop Enclosure
The E-Stop pushbutton disables all outputs for BundleChek. The
green light is illuminated when the system is active.
To reset the E-Stop after it has been pressed, pull out the red
E-Stop button and press the green reset button.
Green light / Reset button
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3) System Components
3.11) Indicator Stack Light
The indicator stack light shows the status of the system. It will
operate in a few different ways depending on the system status,
the most common of which are as follows:
Green: System is active and ready to eject bundles.
Red: System is disabled or in a fault condition (see Troubleshooting section for possible causes and fixes).
Green light on, with Red light flashing: System is active;
a bundle has just been sprayed and an ejection is
therefore expected soon.
At least the red light or the green light should be on at any given
time.
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4) Working with the BundleChek System
4) Working with the BundleChek System
BundleChek works by tracking boxes that are rejected by a ClearVision inspection system (i.e.
GlueChek or FoldChek). When defect boxes are put into a bundle by the counter ejector, the bundle
is automatically marked on the bottom with UV-fluorescent dye. The BundleChek camera looks
for bundles with this mark, and diverts any bundle with a failure mark onto a dead-end Reject
Conveyor.
After a bundle has been rejected, an operator should do the following to sort out the defects:
1) Remove the strapping from the rejected bundle.
2) Find and remove the rejected box (or boxes) from the bundle. These boxes can be identified by UV-fluorescent dye sprayed on one edge. This dye glows under UV light, but in most cases this dye will still be wet and can be seen even with the naked eye.
3) Add one or more good boxes to the bundle so that the total number of boxes is correct again.
4) Shuffle the bottom box up into the bundle. If this is not done, the same dye mark on the bottom of the bundle will be found and the bundle will be rejected again.
5) Put the bundle back onto the conveyor before the strapper. The bundle will now be strapped and
inspected like any other bundle.
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4) Working with the BundleChek System
4.1) Refilling the UV Dye Tank
Refill UV dye tank when you can begin to see the bottom dome of the tank.
Warning: It is important to follow the instructions below very carefully, as any unscrewing
of caps prior to the release of air pressure will result in the spraying of dye. The dye is a
skin-irritant and could cause damage to eye tissues if it is accidentally sprayed in the eye
and not promptly flushed out.
Air to Spray Nozzle
Air to Reservoir
Air Inlet
Dye to Spray
Nozzle
Dye Tank
Pressure Release Valve
To refill the dye tank:
1
Turn off the upstream air supply via the air supply valve (i.e. the valve that controls the air
supply to the air inlet).
2Pull up the pressure release valve to release any remaining air pressure.
It is now safe to remove the UV tank lid and refill the dye.
3
Place cap back onto the dye bottle, ensuring that it is screwed back on properly.
4
Turn upstream air supply back on.
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4) Working with the BundleChek System
Regularly check to ensure that there is at least enough dye to cover the bottom of the dye tank.
Note that this is not the same UV dye that is used in the GlueChek spray system; please contact
ClearVision to order more dye when necessary.
4.2) Using the E-Stop Button
Push the red E-Stop button near the Ejection Unit
if the BundleChek system needs to be stopped at
any time. At all other times, make sure the green
light is on under the red button. If it is not on, pull
out the E-Stop button and press the green reset
button. The green light should now be on.
4.3) Photoeyes
Ensure that the view of each photoeye is not obstructed by anything.
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5) Safety
5) Safety
•• Do not place hands near the Ejection Unit;
bundles may eject at any time.
•• Use the E-Stop button if a jam occurs, or if the
machine operation has become unsafe.
•• Before refilling the UV dye container, ensure that pressure from the air line is turned off
(via the air supply valve) and vented to prevent the remaining dye from spattering out of
the container. To release the air pressure, pull the pin at the top of the pressure release
valve up.
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6) Software User Interface
6) Software User Interface
This is the Settings screen in the system software accessible from the main Cabinet. See table
below for a description of each BundleChek-related button.
In addition to the buttons listed below, all other buttons on the Settings screen (i.e. the GlueChek
/ FoldChek buttons) also work in concordance with BundleChek. For example, pressing Tag Next
Box results in the marked box being ejected by the Ejection Unit.
Button Name
Description
Disable BundleChek
Stop the system from analyzing or ejecting bundles. This also causes the
red light on the indicator stack light to turn on.
Eject Next Bundle
Ejects the next bundle that the main Cabinet analyzes.
Spray for BundleChek
Activates the spray nozzle at the counter ejector every 10 seconds.
Primarily used for visually testing the functionality of the spray system.
BundleChek Spray Prime
Use if the spray system has run dry and needs to be primed.
Indicator Lights
Shows status of the air pressure at the Ejection Unit and the E-stop. If
either one is disabling the system, the indicator light will be red.
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7) Troubleshooting
7) Troubleshooting
The list below provides an overview of the most frequently asked questions, and is meant as an
introductory guide to common troubleshooting scenarios. Should you require any additional
assistance or have any questions, please do not hesitate to contact ClearVision Technical Support
(see the Support section for contact information). Most problems can be resolved in less than 30
minutes with the assistance of remote support.
Issue 1: Red indicator light is on
Primary Cause:
Connection with Camera & LED Unit has failed.
Fix:
Wait 30 seconds, and see if green light comes on.
If the green light does not come on after 30 seconds, check for the following possible causes:
Cause 2:
The E-Stop button has been pressed.
Fix:
Pull out the E-Stop button, and then
press the green reset button. The
green button should now light up.
Cause 3:
Camera & LED Unit is (physically) disconnected.
Fix:
Check that the cables are properly connected.
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7) Troubleshooting
Cause 4:
The Disable BundleChek button on the Settings page at the Control
Cabinet has been pressed.
Fix:
Press Enable BundleChek in the Settings page at the Control Cabinet.
Cause 5:
There is no air pressure being applied to the Ejection Unit.
Fix:
Check the pressure regulator dial to ensure that there is pressure being
applied to the Ejection Unit; it should be between 50 and 100 psi. Adjust
the regulator pressure to 80 psi, as well as the upstream air pressure if
necessary.
Issue 2: Neither red nor green indicator light is on
Cause:
There is no power to the BundleChek Cabinet.
Fix:
Ensure all power cables are plugged in, and that all breakers / switches are
turned on.
Issue 3: Bundles not being ejected
Cause 1:
There is no / not enough pressure provided to the spraying system.
Check that there is the following amount of pressure provided:
• 40 psi to the air line
• 25 psi to the dye tank
Fix:
Dye Tank
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7) Troubleshooting
Cause 2:
The UV spray is not functioning properly.
Fix:
Ensure that the UV dye tank contains enough dye to cover the bottom dome
of the tank. Click the Spray for BundleChek button on the Settings screen
in the main Cabinet to test. If there is no spray then there may be air in line,
in which case press BundleChek Spray Prime button until spray is seen
coming out of spray nozzle.
Cause 3:
The spray is not ready to be used.
Fix:
Prime the spraying system by pressing BundleChek Spray Prime in the
Cabinet software Settings screen.
Cause 4:
The piston located under the Ejection Unit is not attached properly.
Ensure that the end of the piston is properly seated in the hook as shown.
Fix:
Issue 4: Constant pop-ups on screen / buzzing of alarm
Cause:
Reject Conveyor is full.
Fix:
Pull the rejected boxes from the conveyor, and re-strap the bundles.
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8) Maintenance
8) Maintenance
8.1) Regular Maintenance
•
Regularly blow dust off the Camera & LED Unit housing with compressed air. If the lens
becomes dirty, use a damp cloth to clean it.
•
Regularly clear scrap from the Ejection Unit, also with compressed air.
•
Check the level of UV dye in the dye container at least once per month, and refill as needed.
The supplier information of the dye is provided below, but please feel free to contact
ClearVision to order more dye.
8.2) Machine Lockout and Maintenance
Before any electrical or mechanical maintenance can be performed on the BundleChek system,
the following energy sources must be disconnected and locked out according to company safety
procedures.
• 120 VAC power cord to BundleChek
Cabinet
• Pressurized air to the Ejection Unit
(mounted under conveyor)
• Pressurized air to the spray nozzle
air preparatory system (mounted on
the counter ejector)
Note: For electrical toubleshooting,
electrical schematics are provided
inside the BundleChek Cabinet.
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9) Support
9) Support
ClearVision systems are equipped with remote access software which allows ClearVision staff
access to systems at anytime. Please do not hesitate to contact ClearVision if there are any issues
with your ClearVision system.
You can contact ClearVision support either by phone at 1-866-528-0212 ext. 4 or by email at
support@clearvisionboxes.com.
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9) Support
BundleChek Specifications
INDICATOR
EJECTION UNIT
UNDERMOUNT
PHOTOEYES
ENCODER
REJECT
PHOTOEYE
CAMERA
MODULE
CONTROL
CABINET
Specifications
Description
The ClearVision BundleChek system is designed to
integrate into your existing bundle conveyor either before or
after the strapper.
The system consists of a set of five lifting arms, a control
cabinet, a camera module, and a marking system. When a
defective box is detected, an invisible UV mark is sprayed
on the bottom of the bundle which contains this defective
box as it leaves the counter ejector.
A camera and lighting system just before the lifting arms
scans the incoming bundles for the UV mark. If one is
detected, the bundle is diverted to the secondary conveyor
(supplied by plant). The machine operator can then sort the
defective bundles when time permits.
Max. Bundle Dimensions:
55” x 50” (1,400 mm x 1,270 mm)
Max. Bundle Weight:
100 lbs (45 kg)
Max. Conveyor Speed:
100 ft/min (30 m/min)
Max. Boxes / hr:
26,000 boxes / hr @ 25 boxes / bundle
Max. Bundle Speed:
1,200 bundles / hr
Min. Bundle-to-Bundle Gap:
1.5 seconds gap between bundles
Installation Prerequisites
Main Components
Marking Module
EMERGENCY
STOP
Marks the bundle with a defective box
using a UV dye as the bundle leaves the
counter ejector.
Camera Module
Detects the invisible UV mark on the
bundle with the defective box.
Ejection Unit
Diverts the bundle containing the
defective box off the primary conveyor.
Control Cabinet
Houses PLC and electrical components.
Supported Conveyors:
Steel roller with rollers above frame
Conveyor Width:
28-46” (610-1,168 mm)
Conveyor Height:
Min. 24” (610 mm)
Conveyor Length:
Min. 60” (1,500 mm) straight section
Power:
110-220 VAC @ 3A
Air Supply:
Min. 80 psi
Customer-Supplied
Secondary Conveyor:
Angled free-wheeling conveyor
Design specifications subject to change without notice.
18
ClearVision | 5A - 1225 E. Keith Rd. | N. Vancouver, BC | Canada | 604.998.4012
www.clearvisionboxes.com
9) Support
BundleChek Quick Troubleshooting
Check the following two items if BundleChek is not behaving as expected:
Indicator Stack Light:
Is the red light on?
If the red light is on:
•• Check that the E-stop button is pulled out and the
green button is pressed.
•• Check that the ejection unit has air pressure (80
psi).
•• Check that Disable BundleChek is not pressed in
the Cabinet software Settings.
•• If the green light does not come on after 30 seconds,
press Disable BundleChek in the Cabinet software
Settings, and press again to re-enable.
BundleChek Reject Conveyor:
Are bundles not being ejected?
If bundles are not ejecting:
•• Check that there is pressure to the spraying system.
There should be:
- 40 psi to the air line
- 25 psi to the dye tank
•• Ensure that the spraying system tank has dye in it,
by doing the following:
a) Use the shut-off valve to turn off the pressure.
b)Pull on the pressure relief valve to vent the
system.
c)Open the tank and look inside.
•• Prime the spraying system by pressing Prime
BundleChek in the Cabinet software Settings.
•• Check that the piston has not fallen out of the groove
at the ejector unit.
© 2013 ClearVision
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19
© 2011 ClearVision
If BundleChek is still not behaving as expected, please call ClearVision at 1.866.528.0212, option 4.
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