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
• Continuous web offset printing with a high speed rotary die.
• Actual carton jam at press speed.
Jam Video
Background
• Continuous 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 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
Problems with current method of jam detection
• Not truly speed sensitive.
• Photo-eyes operate in parallel to one common input.
Passive Jam Detection (PJD)
Photo-Eyes
Problems with current method of jam detection
• Not 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 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
• Continuous 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 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
“Real-World” Simulation
XiLinx Integration
Carton Line RepresentationSwitchboard
Test Stand
“Real-World” Simulation
Encoder Carton Simulator
Variable Frequency Motor Controller
Carton Line Representation
Photo Eye Motor
“Real-World” Simulation
XiLinx Integration
5 & 12 Volt Power Supplies
XiLinx Micro-Controller
Terminal Strip
Power LED
“Real-World” Simulation
Switchboard
“Real-World” Simulation
• 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
?
?
? ??
??
Top Related