Active Jam Detector (AJD) Travis Bailey Mike Pyne Dave Willis Advisor: Dr. Bradley Bazuin Sponsor:...

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Transcript of Active Jam Detector (AJD) Travis Bailey Mike Pyne Dave Willis Advisor: Dr. Bradley Bazuin Sponsor:...

  • Active Jam Detector (AJD)Travis BaileyMike PyneDave Willis Advisor: Dr. Bradley BazuinSponsor: Ron Kelley GPC

  • Active Jam Detector (AJD)Presentation OutlineIntroduction.Mike PyneDecision Logic of the Active Jam Detector.Dave WillisActive Jam Detector Testing.Travis BaileyResults and Conclusions.Mike Pyne

  • OpeningThe purpose of the AJD is to reduce cost to graphic packaging corporation due to die damage and down time. With current production speeds of up to 45 cartons per second, fast reliable jam detection is necessary. Mike Pyne

  • BackgroundContinuous web offset printing with a high speed rotary die.

  • Graphic Packaging Video

  • BackgroundContinuous web offset printing with a high speed rotary die.Actual carton jam at press speed.

  • Jam Video

  • BackgroundContinuous web offset printing with a high speed rotary die.Continuous web offset printing with a high speed rotary die.

    Current method of Jam Detection.

    Actual carton jam at press speed.

  • Problems with current method of jam detectionNot truly speed sensitive.

  • Speed ranges on Passive Jam DetectionJog/Phase run3.70 secondsSlow run1.50 secondsNormal run (180m/min)0.13 seconds

  • Problems with current method of jam detectionNot truly speed sensitive.Photo-eyes operate in parallel to one common input.

  • Passive Jam Detection (PJD)Photo-Eyes

  • Problems with current method of jam detectionNot truly speed sensitive.Photo-eyes operate in parallel to one common input.Not enough photo-eyes for all jobs.

  • Why Jam Detection Is Necessary

  • Actual Cost To Graphic PackagingCost at Graphic Packaging Corporation Kalamazoo Michigan, are estimated at $250,000 This includes damage to the die and lost production due to down time.

  • Goals of a new systemDevice must be able to process different flow speeds.Device must be able to select carton size.Device must be able to interface with current equipment.Device must have override switch for start-up and maintenance.Device should be able to operate at 150% current speeds.Device should have user-friendly Human Machine Interface.Device design should cost less than $2000.00.Device should have alarm history/parts counter.

  • BackgroundContinuous web offset printing with a high speed rotary die.Actual carton jam at press speed.Current method of jam detection.Solution to the PJD problem.

  • Active Jam Detection is the solution to the problemActively looking for each carton as it is produced is the only way to ensure all cartons are accounted for.At high productions speeds keeping track of each carton is quite a challenge.Xilinx Microcontroller. 95108-7

  • Decision Logic of the AJDDave WillisNOSTOPYESGO

  • How the AJD WorksCalculate 2 consecutive carton lengths and store the values.Multiply the current carton length by 25% and store the value.Take the absolute value of the difference between carton lengths.Examine if the difference is less than 25% of current length.

  • Basic Overview Flow Chart

  • Complete AJD RepresentationWith the logic formulated, we can now examine each of the different subsystems

  • Subsection #1- Counter

  • Subsection #2 Data Control

  • Subsection #3 - Shift Register

  • Subsection #4 - Registers

  • Subsection #5 - ABS(A-B)

  • Subsection #6 - Compare

  • AJD TestingTravis Bailey

  • Testing ProcessPhase OneXiLinx SimulationPhase TwoBench TestingPhase ThreeReal-World Simulation

  • XiLinx SimulationXiLinx Foundation Series Software

  • XiLinx Simulation

  • XiLinx SimulationLimitationsXiLinx Testing OnlyLack Of Real-World InfluencesBenefitsGraphical View of Software FlowTiming Simulation CapabilitiesConvenience

  • Bench TestingLocation3038 Kohrman HallEquipment UsedDigital Multi-meter5 Volt Power SupplyFunction GeneratorLogic AnalyzerOscilloscope

  • Multi-meterPower SupplyFunction GeneratorLogic AnalyzerTest CircuitOscilloscopeBench Testing

  • BenefitsAvailable EquipmentConvenienceCircuit Testing Beyond XiLinx SimulationsBench TestingLimitationsGenerated Input SignalsTesting of Perfect Conditions

  • Real-World SimulationLocationGraphic Packaging Company, Kalamazoo,MIComponentsCarton Line RepresentationXiLinx IntegrationSwitchboard

  • Real-World SimulationXiLinx IntegrationCarton Line RepresentationSwitchboardTest Stand

  • Real-World SimulationEncoderCarton SimulatorVariable Frequency Motor ControllerCarton Line RepresentationPhoto EyeMotor

  • Real-World SimulationXiLinx Integration5 & 12 Volt Power SuppliesXiLinx Micro-ControllerTerminal StripPower LED

  • Real-World SimulationSwitchboard

  • Real-World SimulationBenefitsSimilarity to Actual Carton PressPhoto Eyes, Encoder, SwitchesEffects of Outside InfluencesLimitationsDifficult to Modify Design

  • Results and Conclusion to the Active Jam Detector ProjectMike Pyne

  • Results and Conclusion to the Active Jam Detector ProjectDevice must be able to process different flow speeds.Device must be able to select carton size.Device must be able to interface with current equipment.Device must have override switch for start-up and maintenance.Device should be able to operate at 150% current speeds.Device should have user-friendly Human Machine Interface.Device design should cost less than $2000.00.Device should have alarm history/parts counter.

  • Results:Device is able to process different flow speeds.Carton size does not effect AJD system.Device is able to interface with current equipment.Device has an override switch for start-up and maintenance.Device can operate at 150% current speeds.AJD proof of concept design did cost less than $2000.00.Total cost of AJD project .$2370.58 Actual Spent ..$213.79

  • Results:Device is able to process different flow speeds.Carton size does not effect AJD system.Device is able to interface with current equipment.Device has an override switch for start-up and maintenance.Device can operate at 150% current speeds.AJD proof of concept design did cost less than $2000.00.Device should have user-friendly Human Machine Interface.Device should have alarm history/parts counter.

  • Wonder-Ware Touch ScreenHuman Machine Interface.

  • Conclusion

  • Questions???????

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