I/O SEALING SCREENS


I/O SEALING SCREENS

1. I/O SEALING SCREEN

You can set up and configure dispenser I/O from the I/O Sealing screen.

Table 1.  Dispenser Inputs

ITEM DESCRIPTION

Dispenser ready

Digital input

This signal indicates that the dispenser is functioning properly with no faults that prevent a normal dispense cycle (for example, the signal might indicate that all mechanical and physical devices are active and ready to dispense). This signal requires the dispenser to be in the automatic mode and at the proper temperature if applicable.

In-process

Digital input

This signal indicates that the dispense system has received a valid style in the dispensing process. This is the period of time between the “style strobe“ and “dispense complete“ signals from the robot. During this time, all dispense monitoring functions will be able to operate.

Volume OK

Digital input

This signal indicates that the volume dispensed for the given style was completed within the predefined limits. When valid, this signal is sent within 50 ms of receiving the "dispense complete" signal from the robot. This signal can be asserted in conjunction with a minor fault. If this signal is asserted, the part and job will be released.

Major fault

Digital input

This signal indicates that an error has occurred within the dispensing equipment. This error will halt robot motion and require manual intervention. At the dispenser user interface panel, determination of a major and minor fault will be programmable. This signal will be sent within 50 ms of a fault occurrence. The "major fault" signal will be monitored continuously by the robot.

Minor fault

Digital input

This signal indicates that an error has occurred. These errors cause an alert, but they do not stop the processing of the current or next job. At the dispenser user interface panel, determination of a major and minor fault will be programmable. Minor faults will be tracked by the dispenser, and they might result in a major fault after a specified number of occurrences. This signal will be sent within 50 ms of a fault occurrence. The robot will check only minor faults after the "dispense complete" signal has been asserted.

Automatic mode

Digital input

This signal indicates that the dispenser is in the automatic mode. This mode is set manually at the dispenser.

Manual mode

Digital input

This signal indicates that the dispenser is in the manual mode. This mode is set manually at the dispenser.

Depressurized

Digital input

This signal indicates that the dispense equipment has achieved a de-pressurized state as determined by a pressure-sensing device. As the pressure exceeds the de-pressurized value, this signal will drop low.

Drum empty

Digital input

This signal indicates that one or both material supply drums are empty. In a single material supply pump system, a "drum empty" signal is followed by a "major fault" signal. In a dual material supply pump system with cross over, a "drum empty" signal alone is used if only one drum is empty. However, if both drums are empty, a "drum empty" signal is followed by a "major fault" signal.

Flow meas. bypas

Digital input

This signal indicates that the dispense controller is operating without flow measurement capability. If this input is ON, the states of input signals Dispenser Ready, Major Fault, and Volume OK are ignored.

Vol. Dispensed

Group input

This signal shows 12 bits of data representing the total volume dispensed for the style that is processed.

Dispense fault data

Group input

This signal shows 8 bits of data representing the fault status of the dispensing system.

Rmt strt in proc

Digital input

(for option Remote Start)

This signal indicates that the remote start has been initiated by the dispense controller. This signal will remain asserted until the dispense equipment is capable of dispensing. The remote start process will include achieving the proper temperature set point, if applicable.

Bubble detected

Digital input

(for option Bubble Detect)

This signal indicates that the dispense controller has detected a bubble (material gap) in the bead while dispensing.

Meter full

Digital input

(for type Shot Meter)

This signal indicates that the shotmeter is full. The signal drops low as the shotmeter piston clears the sensor.

Meter empty

Digital input

(for type Shot Meter)

This signal indicates that the shotmeter is empty or nearly empty as identified by a sensor. (The positioning of the sensor for this signal is adjustable.) This signal can be used in systems that perform multiple styles within a single refill or a single style that requires a greater volume than available from a single shot. This signal will remain asserted until the piston's sensor is above the previously set position.

Meter near empty

Digital input

(for Shot Meter)

This signal indicates that the shotmeter is nearly empty as identified by a sensor. This signal will remain asserted until the piston's sensor is above the previously set position.

Mtr pressurized

Digital input

(for type Shot Meter)

This signal indicates that the shotmeter is at the specified pressure. The pressure is specified by using the "pre-pressurize shotmeter" signal and an analog input voltage that is proportional to the desired pressure. This signal drops when the dispensing is initiated by the robot.

Prim. chk passed

Digital input

(for type Urethane Glass System)

This signal indicates that the primer check passed.

Prim. Chk failed

Digital input

(for type Urethane Glass System)

This signal indicates that the primer check failed.

Felt advanced

Digital input

(for type Clear and Black)

This signal indicates that the indexing of the felt is complete.

Change brush

Digital input

(for type Clear and Black)

This signal indicates that the robot has been initiated to change the primer brush.

Purge request

Digital input

(for option Auto Purge)

This signal is from the dispenser and requests a purge due to dispense inactivity (based on a user-definable time). If the robot is not at the purge position, the robot will request the move from the PLC using the appropriate style and option bits. The purge and home positions can be the same.

Purge in process

Digital input

(for option Auto Purge)

This signal is from the dispenser and indicates that the purge operation is in process. This signal will reset after the purge operation is complete. The "purge in process" signal should be sent within 50 msec of the "OK to purge" signal.

Table 2.  Dispenser Outputs

ITEM DESCRIPTION

Open gun

Digital output

This signal, when asserted, tells the dispenser to turn on guns one through five. Any combination of the guns can be "on" at any given time.

Flow command

Analog output

This analog signal, 0 to 10 V, is comprised of 12 bits that controls the dispense flow rate.

Bead shaping cmd

Analog output *

(for option Atom Air)

This analog signal, 0 to 10 V, is comprised of 12 bits that controls the bead shaping of the dispensed material.

Style Bits

Group output

This is a 7-bit group (binary number) output signal that is used to relay the style information to the dispenser. This corresponds to a maximum Part ID value of 64 in the JOB program header DETAIL.

Style strobe

Digital output

This signal indicates that the style bits are set, per body style, in order for the dispenser to read them. This output remains ON until volume and fault information is read at the end of the dispense cycle.

Fault reset

This output signal goes to the dispenser to reset the fault at the dispenser. Fault reset output is automatically asserted just before sending the style strobe is sent to the dispenser, or just before resuming a paused program.

Dispenser Fault

This output signal is always updated to reflect the status of "Major fault" input from the dispenser. This signal can be used by the PLC to monitor the status of the dispenser.

Dispenser Alert

This output signal is always updated to reflect the status of "Minor fault" input from the dispenser. This signal can be used by the PLC to monitor the status of the dispenser.

Dispense complete

Digital output

This signal is asserted when the dispense cycle is complete. This signal will initiate the dispenser to perform the volume calculations for the current job. Based on the volume dispensed, the "volume OK" signal with or without a minor fault can be asserted. Moreover, a major fault will be asserted based upon the volume dispensed. The "dispense complete" signal shall be pulsed for 50 ms. This signal will be sent from the robot to the dispenser regardless of the result of the previous cycle. The "dispense complete" signal will also be sent as a precautionary measure from the robot to the dispenser when the robot is first turned on.

Remote start

Digital output

(for option Remote Start)

This signal restarts the dispense system from a de-pressurized state. After the de-pressurization, the dispenser will be restored to its previous mode. However, this mode restoration will be possible only if no other manual functions have been selected to change the mode.

Prepressurize Mtr

Digital output

(for type Shot Meter)

This signal is used to pre-set the pressure of a shotmeter after a refill. This signal will be preceded by the analog "material flow command" signal. Both signals will drop low when the "meter pressurized" signal is received from the dispenser.

Reload meter

Digital output

(for type Shot Meter)

This signal is used to prompt a shotmeter to reload or refill. The shotmeter will only refill while the signal is high in order to allow partial refills. This signal will drop low after a preset time following a partial refill or when the "meter full" signal is received from the dispenser. The dispense controller will de-assert the "dispense ready" signal while the reload operation is in progress. If the reload operation is not done properly or a fault occurs during the operation, the dispenser will assert the "major fault" signal.

Depressurize

Digital output

(for type Shot Meter)

This signal is used to relieve pressure from the shotmeter. This signal can be used in conjunction with the analog "material flow command" signal to reduce the pressure to a specific value. Without an analog signal, the pressure will be reduced to a user-predefined value. This signal will remain low until the "de-pressuriz ed" signal is set by the dispense equipment.

Wait Primer Data

Digital output

(for type Urethane Glass System)

This signal informs the dispense controller and PLC that the robot is waiting for a primer check passed of failed input signals before processing with the Urethane operation.

Clear complete:

Digital output

(for type Urethane Glass System)

This signal indicates that the robot has complete the clear primer application.

Black complete:

Digital output

(for type Urethane Glass System)

This signal indicates that the robot has completed the black primer application.

Urethane complete:

Digital output

(for type Urethane Glass System)

This signal indicates that the robot has completed the urethane application.

Advance felt

Digital output

(for type Clear and Black)

This signal informs the dispense controller and PLC to perform an index of the felt.

Brush change complete

Digital output

(for type Clear and Black)

This signal indicates that the brush change has been successfully completed.

OK to purge

Digital output

(for option Auto Purge)

This signal indicates to the dispenser that it is OK to purge. This signal can be received from either the robot or a mechanical device that indicates the robot is at the purge position. The dispenser will drop the "dispense ready" signal during the purge process.

Channel 2 analog **

This is an output signal that provides secondary TCPP-controlled analog output.

* Displayed if beadshaping is used.

** Displayed if Channel 2 Analog is enabled.

2. I/O SEALING DETAIL SCREEN

You can set up and configure dispenser I/O from the I/O Sealing DETAIL screen.

Table 3.  I/O Sealing DETAIL Screen Items

ITEM DESCRIPTION

Digital Inputs/Outputs

This item indicates the range of digital inputs and outputs.

Rack Number

This item is the physical location on which the I/O board or module is mounted. To change the rack number value,
  1. Move the cursor to the Rack Number field.

  2. Type the new value.

  3. Press ENTER.

Slot Number

This item is the space on the rack where the I/O module is connected. To change the slot number value,
  1. Move the cursor to the Slot Number field.

  2. Type the new value.

  3. Press ENTER.

Starting Point

This item is the port number within the sequence of ports on the board or module.

Comment

This item is a text field into which you can type a descriptive comment. To type a comment,
  1. Move your cursor to the appropriate line.

  2. Press ENTER.

  3. Type the comment.

  4. Press ENTER.

Polarity

This item is indicates whether signals are of NORMAL or INVERSE polarity. To set the polarity,
  1. Move the cursor to the Polarity field.

  2. Press F4, INVERSE, or F5, NORMAL.

Complementary

This item indicates whether signals are controlled as complementary pairs. To set complementary pairs,
  1. Move the cursor to the Complementary field.

  2. Press F4, TRUE, or F5, FALSE.