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Doc. IS0xxx

Rev.04 | Date: August 25, 2021

MCP-8I Quick Start Guide

How to Eliminate False Triggers

False Triggers

will cause a lot of

issues

with the

Inspection System

and the

Sensor’s Data

that is collected. A

False Trigger

occurs when the ‘

Photo-eye / Scanner’

triggered

scrap

or flying debris

. For the CGS Sensor, it is recommended to have the trigger ‘

after / behind

’ the

sensor to better filter out triggers due to scrap. We can also

filter

out

these triggers

using the

‘

Minimum Product Length

’ setting for each sensor channel.

Here is how to configure the ‘

Minimum Product Length

’ setting:

1. Navigate to the

‘Inspection Window’

by pressing the button labeled ‘

INSPECT

’.

Figure 109: Navigating to the Inspection Window

2. Navigate to the ‘

Inspection Channel’s Settings Menu

’ by pressing the ‘

Wrench

’ button.

Figure 110: Navigating to the Sensor Channel's Settings

Summary of Contents for MCP-8I

Page 1: ... 10 Pattern Index 10 Early and Late Start Tolerances 11 Early and Late End Tolerances 11 Glue Pattern Animation Types 11 Volume Animation 15 Pattern Tolerance Examples and Explanations 16 Glue Line Start Early Late Tolerances 16 Glue Line End Early Late Tolerances 17 Gap Tolerance 18 Glue Pattern Correction Explained 20 What is the Glue Pattern Correction 20 How does Glue Correction Work 20 Use Va...

Page 2: ...s 39 How to Learn an Unglued Sample Learn the Reference 40 How to Learn a Glued Sample 41 How to Clear the Inspection Counters 42 How to Change the Learn Wait Prompt Timeout 43 How to Enable Disable Volume Inspection Analog Sensors Only 44 How to Check the Last Failed Product s Signal Data using the Inspection Diag 46 How to Save the Sensor s Data to Send for Assistance 48 How to Determine the Sen...

Page 3: ...ay Cover by unscrewing the 4 retaining screws holding it in place to the control s base assembly Figure 1 MCP8I Overlay Screw Locations 3 Insert the Sensor Module into the next available empty slot Figure 2 Inserted Sensor Module 4 Replace the MCP 8I s Display Cover using the attached 4 retaining screws Note1 It is advised that the person installing the Sensor Module use a electronic grounding str...

Page 4: ...tings Backup Check here for instructions 2 After performing a System Settings Backup power OFF the control 3 Insert the USB Stick with the Software Update into the Control s USB Port 4 Power ON the control and wait a few minutes for the update process to complete Note The control s screen display will turn on after the update is completed 5 The USB Stick can be removed from the control after the u...

Page 5: ...e that the settings file will be named Typically members of Technical Service and Engineering name them using their initials as part of the name to identify who performed the backup After the desired file name is entered press the button labeled BACKUP to complete Figure 5 Insert Backup Name Save Note When a USB Stick is in the MCP 8I s USB Port the desired directory should be selected before perf...

Page 6: ...2 Confirm the Settings Restore by pressing the button labeled Yes Note All current data on the control will be lost and overwritten and it can not be recovered afterwards Before performing a system restore it would be safer to perform a backup first Figure 7 Settings Restore Overwrite Warning Note When a USB Stick is in the MCP 8I s USB Port the desired directory should be selected before continui...

Page 7: ... Start Guide Jam Window Details Explained Understanding Jam Window Graphics Window Display Conditions The Jam Window will look different based on the following conditions Glue Station Type Figure 8 Glue Station Setup Menu Sensor Modules Installed Using the Inspection Sync Scanner OR External Inspection Learn Input Figure 9 Inspection System Settings Sync External Learn Enable ...

Page 8: ... Jam Setting will be transferred Figure 10 Jam Global Setting Input Box Jam Option Text Descriptions o Valve Channel Jam V Indicates Valve Channel 1 Indicates the Valve Index Scanner 1 Indicates the Scanner Trigger Input Selection Figure 11 Valve Jam Prompt o Sensor Channel Jam S Indicates Sensor Channel 1 Indicates the Sensor Index Int 1 Indicates the Scanner Trigger Input Selection Int 1 Scanner...

Page 9: ...12 Doc IS0xxx Rev 04 Date August 25 2021 MCP 8I Quick Start Guide Configuration Examples Regular MCP8I 074xx101 1 Sensor Sync Scanner Figure 14 Jam Window Regular MCP8I 074xx101 1 Sensor Sync Scanner TipSealer MCP8I JTS0134 1 Sensor External Learn Enabled Figure 15 Jam Window TipSealer MCP8I JTS0134 1 Sensor External Learn ...

Page 10: ...yed pattern graphic contains useful relative to the inspection process and analysis Figure 16 Inspection Window Measured Pattern Length The Measured Pattern Length is displayed in the center of the Glue Inspection Graphic above the Glue Pattern Animation Figure 17 Glue Pattern Graphic Pattern Length Pattern Index The Pattern Index is displayed in the center of the Glue Pattern Animation that is dr...

Page 11: ...or s Early and Late End Tolerances are displayed on the Top Righthand side of the Glue Inspection Tolerance Graphic The Number displayed on the Lefthand side indicates the current setting of the Early End Tolerance The Number displayed on the Righthand side indicates the current setting of the Late End Tolerance Figure 20 Glue Pattern Graphic End Tolerances Glue Pattern Animation Types Centered Pa...

Page 12: ...3 Centered Yellow Red Pattern Animation Started Early Pattern Animation The Pattern Animation is considered to be Started Early when the start of the pattern drawn is to the left of the zero point the vertical line of the tolerance box When the pattern started early and it is still within the 30mm tolerance the start of the pattern is drawn within the grey tolerance box and the color of the glue a...

Page 13: ... is outside the 30mm tolerance the start of the pattern is drawn to the right of the grey tolerance box and the color of the glue animation is red Figure 27 Start Late out of Tolerance Pattern Animation Ended Early Pattern Animation The Pattern Animation is considered to be Ended Early when the end of the pattern drawn is to the left of the zero point the vertical line of the tolerance box When th...

Page 14: ...ght of the zero point the vertical line of the tolerance box When the pattern ends late and it is still within the 30mm tolerance the end of the pattern is drawn within the grey tolerance box and the color of the glue animation is green Figure 30 End Late in Tolerance Pattern Animation When the pattern ends late and it is outside the 30mm tolerance the end of the pattern is drawn to the right of t...

Page 15: ...s area the product s glue volume is good inside the Sensor s Positive and Negative Volume Threshold Tolerances Excess Over Glued Area indicator is represented on the right side Section 3 of the volume bar and is colored red When the black indictor is in this area the product s glue volume is outside over the Sensor s Positive Volume Threshold Tolerance Figure 33 Inspection Window s Volume Animatio...

Page 16: ...distance the pattern is allowed to start late and still be considered Good and within tolerance Anything outside of the Tolerance will trigger a failure As shown in Figure 27 Zone 1 is the Pattern Start location that will cause a failure because the pattern Started Early Outside of the Tolerance window Zone 2 is the Pattern Start location that will cause a pass because the pattern Started Early wi...

Page 17: ... the pattern is allowed to end late and still be considered Good and within tolerance Anything outside of the Tolerance will trigger a failure As shown in Figure 29 Zone 1 is the Pattern End location that will cause a failure because the pattern Ended Early Outside of the Tolerance window Zone 2 is the Pattern End location that will cause a pass because the pattern Ended Early within of the Tolera...

Page 18: ...s can lead the inspection to identify the learned pattern as two smaller patterns A Gap Error will occur if the distance between the end of the first small pattern and the start of the second smaller pattern is larger than the Gap Tolerance Gap Tolerance Example In Figure 31 we can see the Learned Glue Pattern Figure 39 Learned Pattern With No Gaps In Figure 32 we can see that the glue volume drop...

Page 19: ...oc IS0xxx Rev 04 Date August 25 2021 MCP 8I Quick Start Guide In Figure 33 we can see that the glue volume dropped out a bit more causing a gap that is greater than the 50mm tolerance This will cause a Gap Error and or a Extra Pattern Error since there are technically 2 patterns now Figure 41 Pattern with Gap Greater Than 50mm ...

Page 20: ... Sensor s Pattern Correction How does Glue Correction Work Glue correction is useful when the inspection software is not properly identifying the Pattern s Glue Start and the Pattern s Glue Length also referred to as the Pattern s Glue End The Glue Correction Start and End Parameters are meant to be one of the last parameters to be tweaked They should only have to 5mm from their default setting So...

Page 21: ...identified the Glue Pattern Start at 17mm from the edge of the tab The Glue Pattern Length was identified as 163mm long We have verified that the Glue Pattern on the product started at 20mm and was 160mm long To help the Inspection Process identify the correct pattern dimensions we need to Lower the Glue Correction Start from 8mm to 11mm Increasing the Glue Correction Start from 8mm to 5mm would c...

Page 22: ...he CGS 40 Sensor identified the Glue Pattern Start at 20mm from the edge of the tab The Glue Pattern Length was identified as 163mm long Meaning the Inspection Process identified the Glue Pattern End at 183mm We have verified that the Glue Pattern on the product started at 20mm and was 160mm long Meaning the Glue Pattern was supposed to End at 180mm To help the Inspection Process identify the corr...

Page 23: ...product started at 20mm and was 160mm long Meaning the Glue Pattern was supposed to Start at 20mm and End at 180mm To help the Inspection Process identify the correct pattern dimensions we need to do both Lower the Glue Correction Start from 8mm to 11mm Lower the Glue Correction End from 8mm to 11mm Increasing the Glue Correction Start from 8mm to 5mm would cause the Glue Pattern s Start to be ide...

Page 24: ...e 49 Navigating to the Use Valve Parameters Setting Not Linked Off Default After the Learn Button is pressed the Sensor s Data for the next triggered product will be used as the Standard Learned Pattern Data The operator should verify that the learned pattern data displayed on the screen is accurate because this mode could learn the wrong pattern dimensions if there was an issue with the Gluing op...

Page 25: ... Sensor for Auto Learning The Sensor Channel can be setup so that the operator is not required to press the Learn Button for each job For this to work the following conditions must be met The Linked Valve Channel s Mode is Standard Figure 50 Valve Mode Configuration For AutoLearning Volume Inspection must be Disabled Product Length Inspection must be Disabled Figure 51 Inspection Configuration For...

Page 26: ...Auto Learning Figure 52 Inspection Learn Button Hidden What happens when the Sensor is Linked to a Valve in AutoGlue Figure 53 Valve Channel s Mode In AutoGlue Since the Glue Pattern can change based on the Product s Length a Learn MUST be performed for each job After the Learn Button is pressed the Standard Learned Pattern Data is calculated using the measured product length and the Start End Del...

Page 27: ...e still requires the learning of a glued sample More information can be found here For the CGS 40S Gate Sensor 280xx244 The White CGS 40S Gate Sensor should be running in Manual Reference mode unless told otherwise from a member of Engineering This is also going to be the most common mode for the sensor to run in The Manual Reference mode requires learning an unglued sample at the start of each jo...

Page 28: ...3 Alarms Alarm Light Buzzer and Consecutive Fault s Relay have 3 alarm modes that can be configured under the Inspection Setup Window Alarms Setup Figure 55 Inspection Alarm s Setup Window Navigation Timer Mode The Alarm will be active for the set trigger time Next Good Product The Alarm will remain active until the next good product User Reset The Alarm will remain active until the operator clear...

Page 29: ...dow Figure 56 Sensor Channel Alarm Setup Window Sensor Channel Alarm Light Buzzer and Consecutive Fault s Enable Settings Each Alarm has 3 mode settings Off Inspection Faults will not trigger alarm for this channel On Inspection Faults will trigger alarm for this channel ON Vmin Inspection Faults will trigger alarm when the machine speed is above the VMin setting Note The Vmin setting for the chan...

Page 30: ...ion Faults will be Marked or Kicked if the Alarm is Enabled for the Inspection Channel If the Marking Valve is Enabled the Distance to MarkValve Setting will appear This is the Distance from the Sensor to the Marking Valve It must be entered correctly in order for the marking valve to fire at the correct location Note The Distance to the Marking Valve MUST be set for each Sensor Channel Figure 57 ...

Page 31: ...en the sensor connection is disconnected There are 3 output alarm options Red Alarm Light Relay or Both Figure 59 Sensor Channel Disconnect Alarm Sensor Channel Sensor Link Disconnect Alarm If the Sensor Link Disconnect Alarm is Enabled when the corresponding valve channel is on and the Sensor Channel is off the selected alarm output option will trigger There are 3 output alarm options Red Alarm L...

Page 32: ...igation The Marking Valve Setup Window is located under the Inspection Setup Window This is where you will set the Valve Type and other typical Valve Settings Settings Worth Discussing Voltage Correction This setting should remain at 100 unless discussed with members of Engineering It is only used for early versions of the control to compensate the Marking Valve s Voltage Regulator when incoming A...

Page 33: ...until after 20mm Manual Mode will display an option to the user to manually set Mark Valve Delay allowing the operator to change the Spray start location as they see fit Mark Valve Length Mode This setting has two modes Auto and Manual Auto Mode will set the Mark Valve Length based on the settings used for the first gluing channel Meaning if you are gluing for 200mm the Spray for defective product...

Page 34: ...Control s Current Application Version FPGA Is the Control s FPGA Version The number in front of is the Version of FPGA1 and the number after is the Version of FPGA2 Voltage Tab Details Figure 68 Diagnostic s Voltage Tab EXT Is the External Output Voltage V1 Is the Voltage for Valve 1 84v is the Voltage OFF indicates the Valve Channel is Currently Off V2 Is the Voltage for Valve 2 84v is the Voltag...

Page 35: ...Details Figure 70 Diagnostic s Scanner Tab This Tab will display all of the current Valve and Sensor Channel s Trigger Selection Trig Selected Scanner Input Channel State Is the Current State of the Scanner Trigger Input Pulse Last Product s Scanner Trigger Pulse Count TipSealer Tab Details Figure 71 Diagnostic s TipSealer Tab Glue Station Type Selected TipSealer Type TipSealer Status Status of Ti...

Page 36: ... of Control Outputs Relay 1 State of the Consecutive Fault Machine Stop Feed Stop Relay Figure 73 Relay 1 Location Indicator Relay 2 State of the Ejector Reject Relay Figure 74 Relay 2 Location Indicator Beacon Yellow Light State of the Beacon s Output for the Yellow Light Beacon Red Light State of the Beacon s Output for the Red Light Beacon Blue Light State of the Beacon s Output for the Blue Li...

Page 37: ...s How to Update Inspection Tolerances 1 Navigate to the Inspection Window by pressing the button labeled INSPECT Figure 75 Navigating to the Inspection Window 2 Navigate to the Inspection Channel s Settings Menu by pressing the Wrench button Figure 76 Navigating to the Sensor Channel s Settings 3 Enter the Tolerances Sub Menu and Select the desired Tolerance to update Figure 77 Inspection Channel ...

Page 38: ...i OH 45246 USA www valcomelton com TEL 1 513 874 6550 FAX 1 513 874 3612 Doc IS0xxx Rev 04 Date August 25 2021 MCP 8I Quick Start Guide 4 Using the thumbwheel buttons set the desired value and press the button labeled APPLY Figure 78 Updating a Tolerance ...

Page 39: ...ume Indicator is in the green Good Glue area but near the red Low Under Glued Area 5 Manually adjust the Valve s Glue Wheel s glue amount to the Absolute Maximum Glue amount that is acceptable 6 Run a few products and check where the black Current Volume Indicator is on the Volume Bar If the indicator is in the red Excess Over Glued Area increase the Positive Volume Tolerance and then run a few mo...

Page 40: ...igure 79 Navigating to the Inspection Window 2 To Start the Learn Process for an Unglued Sample Press the button labeled REF Figure 80 Learn Unglued Sample Button 3 When the Waiting prompt appears feed product into the machine Once the Learn is completed Confirm the Learn was successful prompt Figure 81 Unglued Sample Learn Prompts Note1 The Glue Valves and or Glue Wheel should be Disabled when le...

Page 41: ...ssing the button labeled INSPECT Figure 82 Navigating to the Inspection Window 2 Press the button labeled LEARN Figure 83 Inspection Learn Button 3 When the Waiting prompt appears feed product into the machine Once the Learn is completed Confirm the Learn was successful prompt Figure 84 Learn Wait Prompt Success Prompt Note1 If the Learn was not successful repeat steps 2 3 Note2 The Learn Wait Tim...

Page 42: ...on Counters 1 Navigate to the Inspection Window by pressing the button labeled INSPECT Figure 85 Navigating to the Inspection Window 2 Navigate to the Statistics Window by pressing the button labeled STAT Figure 86 Navigation to Statistics Menu 3 On the Statistics Window press the button labeled CLEAR and Confirm the verification prompt by pressing the button labeled Yes Figure 87 Clearing the Sta...

Page 43: ... Start Guide How to Change the Learn Wait Prompt Timeout 1 Navigate to the Inspection Window by pressing the button labeled INSPECT Figure 88 Navigating to the Inspection Window 2 Navigate to the Inspection System Settings Menu by pressing the button labeled SETUP Figure 89 System Inspection Settings Window 3 Select the Learn Timeout parameter Figure 90 Learn Timeout Setting ...

Page 44: ...lume Inspection Analog Sensors Only 1 Navigate to the Inspection Window by pressing the button labeled INSPECT Figure 91 Navigating to the Inspection Window 2 Navigate to the Inspection Channel s Settings Menu by pressing the Wrench button Figure 92 Navigating to the Sensor Channel s Settings 3 Enter the Tolerances Sub Menu and Select the desired Tolerance to update Figure 93 Inspection Channel s ...

Page 45: ...eeway Dr Cincinnati OH 45246 USA www valcomelton com TEL 1 513 874 6550 FAX 1 513 874 3612 Doc IS0xxx Rev 04 Date August 25 2021 MCP 8I Quick Start Guide 4 Locate the Volume Switch and set it as desired Figure 94 Volume Inspection Enable ...

Page 46: ...pection Window 2 Navigate to the Inspection Diagnostic s Window by pressing the button labeled DIAGN Figure 96 Navigating to the Inspection Diagnostic Window The Inspection Diagnostic s Window is used to do a Visual Verification of the Sensor s Data In the image above there is a typical signal form a CGS sensor that is not being used in a continuous gluing application Comparing the current product...

Page 47: ...iagnostic Graph View Select 5 Exit the Inspection Diagnostic Window s Settings Menu and return to the Inspection Diagnostic s Window 6 Setting the Alt View Activation Switch to ON will now display the last fail product s signal data Setting the switch to OFF will display the current product s signal data Using the images below as a reference the last failed product s signal data on the right looks...

Page 48: ...istance 1 Insert a USB Stick into the MCP 8I s USB Port 2 Navigate to the Inspection Window by pressing the button labeled INSPECT Figure 100 Navigating to the Inspection Window 3 Navigate to the Inspection Diagnostic s Window by pressing the DIAGN button Figure 101 Navigating to the Inspection Diagnostic Window 4 Press the button labeled SAVE and then Confirm by pressing the button labeled Yes Fi...

Page 49: ... disappears it is now safe to remove the USB Stick Figure 103 Saving Data Wait Prompt 6 On a Windows PC the files will be located in a folder on the USB stick labeled sensordata This folder will have sub folders that include the sensor type the data was stored for and a special date and time code built into the name The files inside the folder will be what is needed to troubleshoot issues Figure 1...

Page 50: ... Figure 105 Navigating to the Inspection Window 2 Navigate to the Inspection Diagnostic s Window by pressing the DIAGN button Figure 106 Navigating to the Inspection Diagnostic Window 3 Jog an Unglued Product up to the sensor and stop with the product underneath the sensor 4 When the belts are stopped the Information Bar s description changes to display the text Current The number next to the text...

Page 51: ...oduct up to the sensor and stop with the product underneath the sensor 6 With the belts stopped as before Record the sensor s Current Value as the High Point Figure 108 Current Sensor Value For Product With Glue These data points can then be given to a member of the Technical Service or Electrical Engineering groups to assess if this sensor will be a good fit for glue inspection on the customers m...

Page 52: ... triggered by scrap or flying debris For the CGS Sensor it is recommended to have the trigger after behind the sensor to better filter out triggers due to scrap We can also filter out these triggers using the Minimum Product Length setting for each sensor channel Here is how to configure the Minimum Product Length setting 1 Navigate to the Inspection Window by pressing the button labeled INSPECT F...

Page 53: ...mbwheel buttons set the desired value and press the button labeled APPLY Figure 111 Setting the Minimum Product Length After setting the Minimum Product Length setting trigger signals less than that duration will be filtered out and ignored Note1 This must be done for each inspection channel that triggers need to be filtered for Note2 For the CGS Sensor Only If the trigger is after the sensor the ...

Page 54: ...Scanner parameter should be set to 0 mm The Sensor Channel s Reference Mode parameter should to be set to Manual The Sensor Channel s Glue Correction Start End parameters should be set to 0 mm Each of these parameters are found under the Inspection Channel s Settings Menu Here are instructions to navigate to the settings menu 1 Navigate to the Inspection Window by pressing the button labeled INSPE...

Page 55: ...lly being activated To get around this the Inspection Alarm Light Buzzer and Consecutive Faults Relay activation parameters has a ON Vmin option This will cause the control to not alarm until the machine speed is above the Sensor Channel s Vmin threshold These parameters can be found under the Inspection Channel s Settings Alarms Menu Here are instructions to configure the settings 1 Navigate to t...

Page 56: ...Then press the button labeled APPLY Figure 117 Setting Alarm On Above Vmin 5 In the same menu Select the Sensor Channel s Vmin setting Using the thumbwheel buttons set the desired machine speed at which the desired alarms can be activated and press the button labeled APPLY Figure 118 Setting the Sensor Channel s Vmin Setting Note1 Products that fail and have the alarm activation suppressed will st...

Page 57: ... Learn Enable to ON 3 Set the Learn Output Optional 4 Set the Learn Input Timeout this is the Time Duration necessary to enter learning mode Note1 This feature is will only work with the Sync Scanner Input This means that when this is being used the Sync Scanner feature cannot be used Note2 The External Learn will trigger a Pattern Learn Volume Learn Inspection Length Learn or Barcode Learn This w...

Page 58: ... OH 45246 USA www valcomelton com TEL 1 513 874 6550 FAX 1 513 874 3612 Doc IS0xxx Rev 04 Date August 25 2021 MCP 8I Quick Start Guide Note4 Use the following Diagram for the wiring of the External Learn Input Figure 121 External Learn Input Wiring Diagram ...

Page 59: ...nication is used to send and receive data to configure the control without user interaction The parent machine is connected to the DB 9 connector on the front of the control 1 Navigate to the System Setup Window and Select COM Interface Mode Figure 122 Navigate to the COM Interface Mode 2 Select Desired Communication Mode and Click Apply Figure 123 COM Interface Communication Mode 3 Power Cycle th...

Page 60: ...v 04 Date August 25 2021 MCP 8I Quick Start Guide Using the MCP 8I Simulator 1 Load the IBS File that contains all of the controls settings by clicking the button at the top of the application labeled Load IBS File Figure 124 Simulator Load IBS File Button 2 Load the file named SavedCurrent ibs Figure 125 Loading the SavedCurrent IBS File ...

Page 61: ...3 Load the Sensor s Data by clicking the button at the top of the application labeled Load Sensor Data then select which channel to load the data to Unless otherwise noted load the data to Sensor Channel 1 Figure 126 MCP8I Simulator Load Sensor Data Button 4 Usually there will be 3 data files to choose from GOODDATA txt BADDATA txt and CurrentData txt Figure 127 Loading Sensor Data Files ...

Page 62: ...1 The Simulator was orginally meant just to show the different control windows and parameters The MCP8I Simulator allows the user to run the simulation code based on the settings that are set That being said you can changes settings and rerun the simulation and get different results Note2 The Simulator has the ability to show the Inspection Alarm States This is only available for the Inspection Si...

Page 63: ...ww valcomelton com TEL 1 513 874 6550 FAX 1 513 874 3612 Doc IS0xxx Rev 04 Date August 25 2021 MCP 8I Quick Start Guide Revision Notes Version 4 0 08 25 2021 Added Jam Window Descriptions Added Marking Valve System Settings Description Added Diagnostics Menu Descriptions ...

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