YM:NDC TDI

Template:Infobox bms

ACHTUNG_MOM

2 Basic Commissioning

The (basic) commissioning is mostly done by the NDC engineer.

The latest version of the commissioning protocol is always found on your server in

_engineering\private\documents\protocols\templates\Protocol_NDC_TDI.doc.

Follow the instructions in the protocol how to handle the backup!

2.1 Preparation

• Complete the safety commissioning at the corresponding location
• Adjust the pneumatic filters (→ Commissioning of Festo_MS..LFM)
• If NDC is still packed, open it, that the NDC Guy is able to work
• Remote PC should be free for him (at second day he needs)
• 230V connection with grounding check, Power Switch is in the +SI11, don't switch on, only messureing that there is no shortcut

2.2 Assistance / Checking

• Provision of electric supply (230V)
• Adjustment of pneumatic pressure (~ 0.8bar)
• Check of I/O signals:
  • park position (status at S7/PVSS)
  • film/sheet break (Force EnaOup)
  • emergency stop (hit a safety bumper or m-stop button nearby)
  • Scanning
  • Sensore Stopped
  • Offsheet
  • Gauge Alarm
  • Scanner Stall
  • Edge Detection
  • Drive Manual (If Switch on the NDC Panel is switched to manual)
  • Sample Check
  • Scanner initialized
  • Scanner Hold

• Center Line should be mark on NDC
• Drive to fix positions with "MD Mode" and check if the real Position is according to the value which you have set and also the yellow mark in the visualisation is correct. 3 points of each side as seen from the middle line and for each point you drive from the lef side and right side to this point.
• Check together with NDC guy that the different algorithm, different products (clear film, white film, pearlized film) have different algorithm, are correctly sent from BMS to NDC system
• Check NDC commissioning protocol
  • Sigma values are in the range
  • X, Y, Z values are in the range (You get a Excel file, where the NDC guy messures every 200 to 500 mm this values. One file with plate closed, one with plate open)
• You get also an Commissioning file from the NDC guy, where he put in the screenshots from PVSS.
  • Check that the film thickness is correct with the shown values at the NDC Programms
  • The real film thickness should be recognized in maximum 3 steps. (When the scanner drives in the film and out of film)

2.3 Finalization

• Take a picture of all items (CDs, USB flash drive, documentation, ...) and attach it to the handover protocol

3 PVSS Gauge Setup

3.1 Scan Mode

Scan Speed: Set this parameter to get approx. one scan per minute.

Left / Right Stop: Scanner moves between this positions.

MD Mode: Set the position to which the scanner should move when you want to start a MD scan.

3.2 Gauge Settings

Factor, Constant: Refer to chapter Calibration.

3.3 Status

On this page some status bits are displayed as well as the positions of startup and away switches.

With the button "Archive" you select wether you want to record the actual position of the scanner in the status archive.

If you don't experience any trouble with the positioning behaviour, it is recommended to leave that function "OFF" in order to save archive space.

3.4 Events

The eventlist contains normal status events (like "scan started") and also errors.

3.5 Offset

For scanning without film during commissioning you will need a offset in order to see actual values.

The offset is just added to the actual thickness. It is reset by clicking the "Reset to Zero" button or simply by going offsheet.

3.6 Definition of algorithms

Different algorithms or applications are used for different film types.

Which algorithms can be used is listed in the "cover sheet" that comes with every NDC sensor.

This sheet is delivered together with the sensor on site - also at BMS it must be available prior to commissioning.

File:NDC Algo CoverSheet.png

In WinCC > TCE > GaugeSetup a pulldown menu can be configured to show and switch between the different applications:

File:NDC Algo GaugeSetup.png

To edit or enter more appications use the configuration button.

File:NDC Algo GaugeSetupConfig.png

When adding a new line, simply click on the field description to enter a new proper name according to the coversheet. And click on the field number to enter the application number as listed in the cover sheet.

File:NDC Algo GagSetup Edit.png

In above example, we have chosen App Number 5, which then should get a description like "special voided".

4 Calibration of a NDC thickness gauge

Factor and Constant

In difference to a beta gauge uses an IR-gauge a factor and a constant for calibration.

Both values together describe a linear equation: y=f*x+c.

Only if both values are ok the actual thickness value is correct.

4.1 Calculation of factor f and constant c using Excel

1 have at least 2 different samples

2 Measure samples in laboratory and enter values below

3 Set Factor =1.0

4 Set Constant to 0.0

5 Measure samples in thickness gauge and enter raw values below

6 The calculation is done automatically

7 get the values from the diagram and enter the values into PVSSII

Use the excel file in the Infobox for this calculation.

4.2 Simplified Calibration

If there is only one sample with one thickness value available (e.g. from the actual production), then the linear equation can’t be solved.

Hence the simplified calculation should be used.

a. Measure the thickness of the sample in the laboratory

b. Measure sample in thickness gauge (or use the average thickness value)

c. Adjust the constant to have the same values from laboratory and thickness gauge. The calculation is a simple subtraction.

d. Don't change the factor, leave it as it was.

e. Never do the adjustment by changing the factor only! Why?

If you change the factor, then the slope of the equation will change.

If the thickness changes then this will give disproportionate values.

With high thickness changes you will see this immediately, but during normal production this would result in a wrong two-sigma value (variance, width of the distribution).

5 NDC RemoteView

Install the NDC RemoteView software as local root at RMT and CAE:

• Delete the default host (10.0.14.161)
• Add the new hosts according to the NDC engineer (see example table below)
• Check all added hosts

Device	Host address
Cast Scanner	10.xx.yy.105
Cast Scanner Transmitter	10.xx.yy.109
Cast Scanner Receiver	10.xx.yy.110
PullRoll Scanner	10.xx.yy.106
PullRoll Scanner Transmitter	10.xx.yy.111
PullRoll Scanner Receiver	10.xx.yy.112

• Deleting default host
  Deleting default host
• Adding new hosts
  Adding new hosts
• Checking hosts
  Checking hosts

6 NDC Backup Java

Install the NDC Backup Java software as local root at RMT and CAE:

• System type: 8000
• Connection type: Ethernet
• Hostname and port: 10.xx.yy.zzz and 20000 (see table above)
• Filename: e.g. Cast-Scanner_10.16.82.105_2013-05-13
• Click the Save button

After the backup procedure has finished, the message Save Completed Succesfully is shown.

• Backup log
  Backup log

7 Troubleshooting

After an E-Stop you cannot start the scanner again to scan. Only Button which is working is "Go Offsheet". This is because with an E-stop NDC switch off the Power for his Moduls and they need to initialisize again!

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winder output value changes to 0 every hour:
File:Win out zero.jpg

When the winder output changes to 0, you can see the event "FIND ORIG" in the history at the same time
File:Thickness win out.jpg

To fix this problem, open the Software "NDC RemoteView" File:NDC sc.png and connect File:NDC connect.png according to your KOM number

The Option "FIND ORIG" should always be "OFF" !!!
File:NDC remote.png