RJG压力传感器.ppt

eDART Workshop with Graph InterpretationRev.4.01RJG Insight SystemeDARTMachine sensorsMold sensors2BenefitsPart Containment Quality assurance in the processCavity Pressure Control Consistency in the ProcessReal Time Data-Instantaneous viewing of the processHistorical Data-Ability to review processCan you tell which are the good parts?With RJG Insight System,you can.3Monitoring PointsCavity PressureInjection PressureStroke Position/VelocityTemperature4Insight System Layout5eDART ComponentsEssentially a ComputerData Storage/MemoryKeyboard/Mouse portsVideo outputEthernet/ModemInsight Software6eDART ConnectionsPower:24VDC Power Adapter (G)Lynx Ports:Sensors and Machine Interface Modules(B)Serial(COM)Port:Remote Access,Touch Screens (A)Video Connection(C)Ethernet(NIC):Network(F)Mouse and Keyboard PS2 Ports(D&E)7Interfacing the eDART with Your Machine8Interface Modules 35mm DIN rail mountable modulesModuleFunctionID7-D-SEQSeven sequence digital input module(universal voltages).Gets machine state.IA1-D-VI0-10V or 4-20mA isolated analog input module for signals from machine.OA1-D-V0-10V isolated analog output,feeds signals to machine controller for transfer.OR2-DDual relay output,Contact rating 2A at 24V for control,valve gate application,sorting,or lights.9Sequence ModuleID7-D-SEQMachine signals connect to terminal 1 through 7,Common to 8Signals must be 24VDC10Sequence ModuleID7-D-SEQ(24VDC)Terminal-ImportanceComes OnGoes OffPurpose1.INJ Forward Injection StartsEnd of holdSearch for peaks,hold pressure.(Required for control)2.1st Stage Inj.StartsInj.goes to holdCreates internal Inj.Forward,Pack,&in 2-Stage“Fill”3.Screw Run Screw motor StartsStopsStroke direction,Zero,Material variation information(Required for control)4.Mold Clamped Mold clamped to pressureMold cracksAccurate cycle time,integration limit,Reset Piezo Adapter&UMPI5.Mold Opening Mold openingMold fully openPinched part detection,Resets Piezo Adapter&UMPI6.ManualMachine in manualIn Full/Semi Automatic modePrevents parts counts and data storage while in this mode7.Shuttle Position Start of cyclePosition 2Start of cyclePosition 1Detects mold position in 2-position shuttle molding8.Input CommonMold Closing Mold begins to closeMold clamps upCycle time with mold opening(Resets Piezo Adapter and UMPI)Mold Open Mold fully openMold begins to closeCycle time and integration limit(Resets Piezo Adapter and UMPI)Second Stage Start of holdEnd of holdCreates internal injection forward and packFill Inj.Moves forward after decompress pointInj.speed changes from fast fill(V1)to slow pack(V2).Measuring of material viscosity(Rare machine signal)11Analog InputIA1-D-VI(0-10v)ConnectionFunctionWire ColorTerminal 1N/A-Terminal 2N/A-Terminal 3Jumper 1-Terminal 4Jumper 1-Terminal 5Jumper 2-Terminal 6Jumper 2-Terminal 70VBlackTerminal 80-10VRedJ1,J2 Communications-Accepts 0-10V/4-20mA signal from machine,thermocouples,etc.12Wiring Dual Relay Output Module OR2-D(Relay Module with Dry Contacts)Cavity Psi TransferWire contacts as normally“Open”or “Closed”Good ControlNote:Serial number and side of module that is wired to transfer the press13Machine Sensors and Equipment14Rotary EncoderLE-R-XXMonitors Stroke/Position,Volume/VelocityAvailable in 30,50,and 100 in.15Rotary Encoder16Volume vs.StrokeThe eDART uses the stroke distance and the screw diameter to calculate a volume measurement.Volume allows the mold data to be machine independent The Screw Diameter must be input into the eDART17Lynx Hydraulic Sensor LS-H-1/4NPT-XXXX”Quick Connect Fitting3,000,5,000 or 10,000 psi Full Scale18Hydraulic PressureThe eDART uses the intensification Ratio(Ri)of the machine and a direct hydraulic measurement to display the Injection Pressure in actual plastic pressure at the nozzle.This allows the mold data to be machine independent.The intensification ratio must be input in the eDART.19Junction BoxJ-LX5-CE,J-LX9-CEAllows Lynx devices to be interfaced with eDART 20Data Needed for Job EntryMold/Plant/Cell/Machine?Screw DiameterIntensification Ratio(Ri)for Hydraulic MachinesLocation of Mold Pressure SensorsPin size for Indirect sensorsLocation and purpose of all output modulesFull scale Injection PSI for electric Machines21Lab 1 ObjectivesGo to the pressIdentify all sensors and modules on machineIdentify the purpose of each module Hook up all sensors to systemGet data for job entryIntensification RatioScrew DiameterPin sizesSensor LocationsModule Locations22Mold Pressure Sensors23Cavity Sensor TypesSensor ApplicationsEjector PinStrain gauge(LS-B)Analog(T-4xx,92xx)Piezoelectric(LP-B)Piezo Flush MountLynx(LP-F)Analog(61xx)Types of SensorStrain GaugePiezoelectric24Behind the Ejector Pin SensorsButton Style(Strain Gauge and Piezoelectric)Installed behind an ejector pinPin transfers force to sensorSensor transfers pressure readings to eDART 25Common Installation26Choosing the Correct ModelKey elements expected pressure vs.pin areaPin size references the surface that contacts plastic partHow to select a sensor:1.Estimated pressure in cavity 10,000 psi:i.e.10,000 psi on a 6.0mm pin generates 438#s of force.Use a 2000#sensor.2.Use more than 10%of the usable range for an individual sensor:i.e.Expected plastic psi should generate more than 50#for a 500#sensor.Note:RJG also has a selection of flush mount sensors for applicationswhere an under-the-pin sensor is not practical.Refer to chart on next page2728Installation IssuesUpside downShallow pocket(Pre-Load)Narrow pocket Uneven pocket bottomRounded corners in pocketPinched cablesCorrect Button Sensor InstallationIncorrect Button Sensor Installation29Indirect Mold PressureSensors that sit behind a pin read pressure indirectly.To get the correct cavity pressure the force exerted on the pin is divided by the area of the pinThe pin size must be input in the eDARTPressure=Force/Area30Flush Mount SensorsLynx and Analog Piezoelectric31Flush Mount SensorDirect Mold PressureSensor becomes part of cavityPlastic applies pressure to sensorThe sensor transfers the pressure readings to eDARTAll RJG flush Direct sensors 30K PSI Maximum Rating32Choosing the Correct ModelFlush Mount Sensor Installation ConsiderationHow large a witness mark allowedGood to 30,000 psi in cavitySensorSensor DiameterLengthLP-F-25-30K2.5mm(0.0984”).2m,.4m,.6m,.8mLP-F-40-30K4.0mm(0.1574”).2m,.4m,.6m,.8m6157,61592.5 mm/4.0 mm(cables sold separately)33Installation IssuesFlush Mount Sensor InstallationDont over-tighten nutEnsure bores are centeredAvoid pinching cablesKeep connectors clean34Sensor Placement StrategyRunnerless system 1a.jpgRun short shots to determine placement of sensors35Process Control“Reduce normal variation”Mold Pressure SensorsWhats the use?2 Primary StrategiesProcess Monitoring“Detect abnormal variation”36Area of InfluenceIncorrectCorrectControl sensors should be located in the“Area of Influence”.Correct37Conventional Runner Multi-Cavity MoldControl:Locate NEAR gate in first cavity to fillMonitor:Locate END of Fill in last cavity to fillAssumption:This works if the first(highest psi)and last cavity(lower psi)to fill are good parts.38Hot Runner/Hot Drop Multi-Cavity MoldControl:Choose a location near the gate in the cavity that best correlates to the average pressure of all cavitiesMonitor:Choose a location at the end of fill in every cavity due to“Multi-Process Disease”39Sensor Selection PracticeWhat model of sensors should be used for this part?3/8”Pin3/16”Pin40Starting Up the eDART 41Setting up eDART Attach Mold Sensors and Machine Interface Modules via Lynx PortsApply Power to eDART 42Job Setup Screen First Screen to AppearTop of the window indicates sensors were foundCreate New Mold Number(Material and Cavities are Optional)Create New Plant,Cell and Machine nameChoose Accept when finished43Sensor LocationsAssigning sensors to taskSerial#:SignalUnique serial number and output numberSenor Type:Kind of sensorSensor Location:Where it goesIdentifier:Uniquely IdentifiesSetupAnalog input/output,sensor adapterNo Duplicate EntriesClick Accept when finished(Until all changes are accepted)44Sensor LocationsSensors by TypeID7-D-Seq(Sequence Module Inputs):Connect up to 7 machine signalsWatch under the Value column for green lights to come on45Sensor LocationsSensors by TypeIA1-D-V1 (Analog Input)Sensor Location ValueAnalog Input Scaling,all modules46Sensor LocationsSensors by TypeOR2-D:Two sets of dry contacts per unitEach set can be setup for different functions47Verify Sensor LocationsFrom the main menu on the task bar bring up the Sensor Location ScreenOpen the tool and extend the ejectorsPress on pinsDo not hit pins Watch for numbers in Value column to changeConfirm Correct Cavity IdentifierPush on the pins and watch these numbersThey will move when the sensor sees pressureStep 1Step 248Setup Software for Shot ContainmentSet the OR2-D Module Side that is wired to the containment device as Sorting Output/Good ControlThis tells the eDART which output to turn on for a good partStep 1Step 249Individual Cavity ContainmentFor Individual Cavity Containment Set all outputs to Sorting Output/Good ControlAdd Cavity IdentifiersAdd Identifiers that match Cavity IdentifiersStep 1Step 2Step 350Failsafe SortingGood Part ControlNormally Open ContactGood ControlEnergizes the contact for a Good partIf anything fails the part will be sent to the Reject binIf your robot will only see a reject signal change the wiring on the OR2-D module to the normally closed contactThis is nearly to failsafe 51Ejector Pin SizesChoose/Enter Ejector Pin(s)SizeClick Match Pins(if all pin sizes are equal)Choose Accept when finished52Machine SizeEnter Screw Diameter and Intensification Ratio(Cylinder Diameter will be calculated)orEnter Screw and Cylinder Diameters(Intensification Ratio will be calculated)Choose Accept when finished5354Zero Injection PressureClick“Zero Now”to zero injection pressure manuallyClick“Zero On Signal”for it to be done by the machine55Viewing Your Process“Standard”View ScreensCycle GraphSummary GraphCycle ValuesStatistics56Cycle GraphInjection PressureShot VolumeCavity PressureCurvesSequence Inputs,Control Outputs,Machine statesShows Real Time Cycle Data57Adding CurvesCycle GraphTo add curve choose“Graph Controls”then“Add a Curve”Choose the Type and LocationChoose“Apply”to add more curves or“Apply and Close”to close window58Zoom/UnzoomCycle GraphChoose“Graph Controls”;“Zoom”Choose a Portion of the Cycle Graph to Zoom in onWill also change times on Cycle Graph59Auto scale Cycle GraphScales curves to Injection Pressure(Highest value)Adjusts curves to fit on Cycle Graph window60Overlays Cycle GraphCompare curves with previous shot(s)Show/Hide overlay61Viscosity and Fill Time AlarmsViscosity is calculated using Fill Integral for Injection PressureViscosity calculation requires an accurate fill volumeAlways set the fill volume on new jobs before you create a template or Alarms62Set Fill VolumePut Cursor at TransferChoose Set Fill Volume at Cursor from Graph Control MenuVolume at 98%full part should show hereStep 1Step 2Step 3Step 4For more information on Setting fill volume see Arts Tip of the day 53 at Press the Yes button63Template ControlsCycle GraphMatching Template equals the same plastic partSelect Template to apply existing templateSave TemplateTo create a template from the current processManage TemplateTo move,copy,delete existing template64Set Screw BottomEnabling cushion monitoringDrive the screw all the way to the bottom and click the Bottom the screw button 65Cycle ValuesShows Values of the CycleReal time valuePeaks,IntegralsSequence TimesComparative Template Values66Adding/Removing ValuesCycle ValuesSelect“Add a Value”Choose Value Types and LocationsChoose“Apply”or“Apply and Close”To Remove:Select the value to be removed and click“Remove Value(s)”67Summary GraphShows Data Over TimeCollects historical data of a processDisplays variations over timeAdd Alarm/Warning limitsAlarm Limits68Documentation of Process ChangesHold PressureFill SpeedScrew RPMMaterial ChangePut cursor overthe note to viewAdding NotesSummary Graph69Adding AlarmClick on the header for the measurement to be monitored and choose Add New AlarmChoose Add New AlarmStep 1Step 270Adding AlarmsAlarms Can also be added directly from the Alarm Settings PageChoose Add AlarmSelect Type and LocationStep 1Step 271AlarmsA High and Low alarm will be added automatically for the variableThe level will be set to 4.5 sigma defaultChange level to appropriate numberBefore the eDART will add an alarm it will look for stable shots.If there has not been 4 stable shots the eDART will wait to add the alarm.72StatisticsAverageMaximumMinimumStd.DeviationExpected VariationCPKPPK,etc.Gives Statistics of Process73Adding/Removing a ValueStatisticsTo addChoose“Add A Value”Select Type of statsChoose Type and LocationsTo RemoveHighlight thevalue(s)Choose Remove Value(s)74Lab 2Create new Mold and Machine on eDARTSet up all Modules and Sensors in Sensor Locations PageInput Ejector Pin Sizes for all Indirect SensorsSet up all Machine Size PageZero Injection PressureSet screw BottomCheck TriggersCycle GraphAdd CurveZoom in on part of cycleAuto sale and Individually scale curvesAdd overlaySet Fill VolumeCreate TemplateDisplay Actual Value and Template Difference on cursor75Lab 2Cycle ValuesAdd remove valuesAdd Peak Value for all Cavity sensorsAdd Cycle Integral for all cavity sensorsAdd Fill TimeAdd Cycle timeShow as%difference from templateSummary GraphAdd CurvePeak Pressure for all Cavity Pressure SensorsCycle Integral for all cavity sensorsZoom in on selected part of dataAdd note at cursorStart data at CursorChange Curve ColorRescale individual curveAdd Alarm to Peak cavity pressureAdd Alarm to Cycle Integral for Cavity Sensor76Lab 2StatisticsAdd Maximum&Minimum for peak pressure sensorAdd Cpk for cycle integral for cavity pressureChange Data Range to Shots Back and look at the last 50 shotsChange Data Range to Summary View then zoom into an area on the Summary Graph and observe data.77Additional ToolsTools from the Main Menu78ViewArranging Your ToolsArrange how tools are displayed on the monitorViews can be stored or deleted79Stop JobAlways stop job when mold is removedAlways stop job and restart if Sensor Location page is accessed multiple times Go to“Main Menu”-“Stop Job”.Yes to stop80Sequence LightsShows the actual hard wired sequence signals Shows the sequence signals as calculated by eDART81Architect Add other tools to monitor for each jobCurrentAdding tools to current Mold or MachineSystemConfiguration for the whole systemMenu Main settingOptionsSave Changes82System ShutdownPowering Off SystemClick on“QNX”menu and choose“Shutdown System”At warning screen,confirm shutdownMessage appears saying you may power down systemPull power cord or fuse 83Troubleshooting84Raw Data ViewerOne stop diagnostic toolView status of ports and sensorsDiagnose when failures occur85Raw Data Viewer Raw Data Viewer,Data DetailsCheck details on sensor calibration and internal firmware se