Download - Active Jam Detector (AJD) Travis Bailey Mike Pyne Dave Willis Advisor: Dr. Bradley Bazuin Sponsor: Ron Kelley GPC.

Active Jam Detector (AJD)

Travis Bailey

Mike Pyne

Dave Willis

Advisor: Dr. Bradley Bazuin

Sponsor: Ron Kelley GPC

Active Jam Detector (AJD)Presentation Outline

• Introduction

…………………………….Mike Pyne

• Decision Logic of the Active Jam Detector

…………………………….Dave Willis

• Active Jam Detector Testing

…………………………….Travis Bailey

• Results and Conclusions

…………………………….Mike Pyne

Opening

• The 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

Background

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

Graphic Packaging Video

Background


• Actual carton jam at press speed.

Jam Video

Background



• Current method of Jam Detection.


Problems with current method of jam detection

• Not truly speed sensitive.

Speed ranges on Passive Jam Detection

• Jog/Phase run 3.70 seconds

• Slow run 1.50 seconds

• Normal run (<180 m/min) 1.20 seconds

• Normal run (>180m/min) 0.13 seconds



• Photo-eyes operate in parallel to one common input.

Passive Jam Detection (PJD)

Photo-Eyes



• 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 Packaging

Cost 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 system

• Device 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.

Background



• Current method of jam detection.

• Solution to the PJD problem.

Active Jam Detection is the solution to the problem

• Actively 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 AJD

Dave WillisYES

OR

NO

NO

STOP

YES

GO

How the AJD Works…

1. Calculate 2 consecutive carton lengths and store the values.

2. Multiply the current carton length by 25% and store the value.

3. Take the absolute value of the difference between carton lengths.

4. Examine if the difference is less than 25% of current length.

YES = OK NO = JAM

Basic Overview Flow ChartCURRENTCARTONLENGTH

"A"SUBTRACTOR |(A - B)|

1 0 1 0 1 1 1 0 1 1 0 1

1 0 1 0 1 1 1 0 0 1 0 0

0 0 0 0 0 0 0 0 1 0 0 1PREVIOUSCARTONLENGTH

"B"

101011100100

1 0

0 1

SUBTRACTIONRESULT

"C"

IS "C" "D"

25% OFCURRENTCARTONLENGTH

"D"

NO

STOPPRESS

YES

CONTINUECHECKING

101011101101

X 25%

001010111011

COMPARE C & D

Complete AJD Representation

With the logic

formulated, we can now

examine each of the

different subsystems

Subsection #1- Counter

PHOTO_EYE

ENCODER

1 0 1 0 1 1 0 1 1 1 0 1

IS MSB = "0"?

YES

COUNTER

FAST STOP SIGNAL

CURRENT PULSE COUNT

TO SECTION#2

RESET

NO

PHOTOEYE SIGNAL

Subsection #2 – Data Control

TOREGISTER

"A" ANDSECTION #3

TOREGISTER

"B"

FROMSETCTION #1

101110

1

01111

101101

101111

101100

101110 101101

PHOTOEYECONTROLLED

SWITCH

PH

OT

OE

YE

SIG

NA

L

CU

RR

EN

T P

ULS

E C

OU

NT

Subsection #3 - Shift Register

TOSECTION

#6

FROMSECTION

#2

101011101101

0 0 1 0 1 0 1 1 1 0 1 1

00

10

1111

01

0

01

011

00

10

SHIFTEDBY 2 BITVALUES

CURRENT PULSE COUNT

SHIFT RIGHT BY 2 BITS

0 0

D

Subsection #4 - Registers

10

10

111

011

01

1 0

1 0

1 1

1 0

1 1

1 0

RE

GIS

TE

R "

B"

1 0

1 0

1 1

1 0

1 1

1 0

NEXTVALUE TO

BEREGISTERE

D IN "B"

CURRENTVALUE IN

"B"REGISTER

TOSECTION

#5

10

10

111

011

01

1 0

1 0

1 1

1 0

1 1

1 0

RE

GIS

TE

R "

A"

1 0

1 0

1 1

1 0

1 1

1 0

NEXTVALUE TO

BEREGISTERE

D IN "A"

CURRENTVALUE IN

"A"REGISTER

TOSECTION

#5

FROMSECTION

#2

FROMSECTION

#2

Subsection #5 - ABS(A-B)

TOSECTION

#6

FROMSECTION

#2

101011101101

CURRENT "A"REGISTER

VALUE

SUBTRACTOR (A - B)

1 0 1 0 1 1 1 0 1 1 0 1

1010111001001 0 1 0 1 1 1 0 0 1 0 0

0 0 0 0 0 0 0 0 1 0 0 1

1 0

0 1

A - B

FROMSECTION

#2

C

CURRENT "B"REGISTER

VALUE

Subsection #6 - Compare

FROMSECTION #2

COMPARE (C & D)

1 0 0 1

FROMSECTION #3

IS THE "C" VALUELESS THAN THE "D"

VALUE?

C

D

CONTINUETO CHECK

10

1 0

0 1

JAMDETECTED.

SEND SIGNALTO FAST

STOP.

YES

NO

AJD Testing

Travis Bailey

• Phase One– XiLinx Simulation

• Phase Two– Bench Testing

• Phase Three– “Real-World” Simulation

Testing Process

XiLinx Simulation

XiLinx Foundation Series Software

XiLinx Simulation

XiLinx Simulation

• Limitations– XiLinx Testing Only

– Lack Of “Real-World” Influences

• Benefits– Graphical View of Software Flow

– Timing Simulation Capabilities

– Convenience

Bench Testing

• Location– 3038 Kohrman Hall

• Equipment Used– Digital Multi-meter

– 5 Volt Power Supply

– Function Generator

– Logic Analyzer

– Oscilloscope

Multi-meter

Power Supply

Function GeneratorLogic Analyzer

Test Circuit

Oscilloscope

Bench Testing

• Benefits– Available Equipment

– Convenience

– Circuit Testing Beyond XiLinx Simulations

Bench Testing

• Limitations– Generated Input Signals

– Testing of “Perfect” Conditions

“Real-World” Simulation

• Location

– Graphic Packaging Company, Kalamazoo,MI

• Components

– Carton Line Representation

– XiLinx Integration

– Switchboard


XiLinx Integration

Carton Line RepresentationSwitchboard

Test Stand


Encoder Carton Simulator

Variable Frequency Motor Controller

Carton Line Representation

Photo Eye Motor


XiLinx Integration

5 & 12 Volt Power Supplies

XiLinx Micro-Controller

Terminal Strip

Power LED


Switchboard


• Benefits– Similarity to Actual Carton Press

– Photo Eyes, Encoder, Switches

– Effects of Outside Influences

• Limitations– Difficult to Modify Design

Results and Conclusion to the Active Jam Detector Project

Mike Pyne

Results and Conclusion to the Active Jam Detector Project

•Device 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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