Navigation System Manual [PDF]

Zitiervorschau

NAVIGATION SYSTEM

BEGAPT TECH SOLUTIONS A-79, DDA Shed, Okhla Industrial Area, Ph-2, New Delhi-110020, Telephone: +91-11-40817580 E-mail:[email protected]

BEGAPT@2012:PRIVACY POLICY

BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual

IMPORTANT INFORMATION Notes on Copyright© Under the copyright laws, this publication may not be reproduced or transmitted in any form, electronic or mechanical, including photocopying, recording, storing in an information retrieval system, or translating, in whole or in part, without the prior written consent of Begapt Tech. Solutions Pvt. Ltd. LabVIEW National Instruments, NI, ni.com are trademarks of National Instruments. Microsoft, Windows7 and microsoft.com are trademarks of Microsoft Corporation Inc. U.S.A

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Navigation System Manual

CONTENTS:  Chapter 1 - Company Overview  Chapter 2 - Introduction to Navigation System  Chapter 3 - Setup and Configuration - Begapt Software  Chapter 4 - Reinstallation of software  Chapter 5 - Connection Overview  Chapter 6 - Troubleshooting Steps  Chapter 7 - Do’s & Don’t’s

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Navigation System Manual

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Company Overview Begapt Tech Solutions Begapt Tech Solutions Pvt. Ltd is a leader in automation and Control technologies that enable utility and industry customers to improve their performance while lowering environmental impact. Begapt Solutions is a complete solution provider in the field of Control and automation, Human Machine Interaction, Electromechanical systems, Mechatronics, Artificial Intelligence and Machine vision to meet specific need of its customers.

We work with automotive R&D departments and OEMs to specify, prototype, implement and test systems to bring reliable, feature rich, high quality products and services with least development lead-time. We facilitate the development, design, testing and trouble-shooting of various controllers along with the consultancy

services

for

impartial

technology

assessment

and

technical

endorsement. BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual

Our Equipments carry a warranty of one year against any manufacturing defects. Our customers have rarely used this in the past.

All

our equipments

have been

working without any undue problems and require very little attention as far as maintenance in concerned. Just in case your equipment needs attention, we are just a phone call away in New Delhi. We have a well trained team of installation and maintenance engineers on call round the clock.

Technology Technology plays a key role for Begapt Solutions. We have activities throughout India working to develop unique technologies that make our customers more competitive, while minimizing environmental impact.

Sustainability Sustainability is integral to all aspects of our business. We strive to balance economic, environmental and social objectives and integrate the min to our daily business decision.

Our expertise is in availability. Our strength is in delivering the right solution for you. We've worked with hundreds of small, medium and large companies, including Fortune 500 companies - and they've all needed something unique to their environment. We've combined over a decade of experience to offer you arrange of availability solutions. Below you'll find a snapshot of our capabilities. Can't find exactly what you're looking for? Call us anyway. Chances are we've done it before.

Development Services We have extensive experience working with large OEM's to help them define, develop and bring to market system management and availability solutions that

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Navigation System Manual

meet the needs of their customers. We also work with large companies, such as Motherson Group, Delphi & many more, to customize high availability applications to their environment.

Education Services Begapt's education and training solutions range from the design, development and delivery of an entire curriculum to public course offerings. We offer on-site private workshops and courses that are customized to only the elements that you need to know.

Contact us at: Begapt Tech Solutions Pvt. Ltd #A-79, DDA Shed, Okhla industrial Area, Phase-2, New Delhi (India)-110020 Phone no- +91-11-40817580, +91-987188063

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Introduction to Navigation System Navigation system is such an important machine used in wiring harness industry. It has a wide scope of application. It is also called process guiding machine. It guides the process in making sub assembly of wiring harness. It also indicates the position for pickup the wires and insertion point of the wire and checking the TBO. While doing insertion of various wires it also checks the continuity of the both end

of wire. It has

a wide range of features such as;  LED Indication for wire insertion  LED Indication for wire pickup  Sensor feedback for wire pickup  Continuity testing  TBO testing  Automatic Pneumatic Locking  Diagnosis  Report This System includes 1 Minicomputer along with 1 Monitor, 1 Keyboard, 1 Mouse. It consists of wiring plate designed for specific operation.

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Navigation System Manual

Why Navigation System needed? In wiring harness industry there is a major quality concern about the wrong fitting, wrong wire insertion and TBO defects. This is the very effective system to resolve this type of quality concern. It guides the operator for wire insertion by indicating the position of insertion on the monitor screen as well as there is an indication through optical medium. There is a system to check the TBO of the holder. This system is user friendly.

Application and Specification Navigation system is used as a process guided system. This particular system is used to detect the process as well as pull checking and continuity of the sub assembly of harness. So, that it may check that the insertion of wire as well as correct colour of wire is inserted in a correct place or not. The specifications are as following: 1.

PC based system.

2.

Highly customized software.

3.

User may decide that which points should be used in a connector or not.

4.

User may decide that system is running with or without sensor.

5.

User may decide the direction of process.

6.

User may move the system from one place to another place easily.

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Setup & Configuration This section describes each subsection of the Navigation System hardware as well as how they interact with each other to perform the tests.

Computer System The computer system has following configuration (system configuration may depend from system to system as per requirement): Intel(R) Pentium(R) Gold G5400 CPU@ 3.70GHz 4GB Installed Memory RAM 500GB Hard Drive Windows 7/ Windows 10 Professional Operating System 19” Monitor 64-bit operating system, x64-based processor

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Navigation System Manual

Begapt Software This section describes the system software.

Login Window

This is the login window screen. User has to login to perform the desired operations. Here, user has to enter his/her User name and Password. Main window can only be opened by correct entry of login User name and Password.

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Navigation System Manual

Main Window

This is the Main Window screen of the Navigation System. After successful login by the user the Main Window screen will be appeared.

Model Window

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Navigation System Manual

This is the Model Window screen and its icon is available in the main window screen. When the user has to Add, Edit, Delete and Copy the model, it has to select the specific tab in the model window in order to perform the desired task. For example, suppose user wants to add a model they may go into the “Add Model” option.

Suppose user wants to delete a model first of all they may select a model and then goes into the “Delete Model” option.

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Navigation System Manual

In similar way, suppose an user wants to edit name/part no./barcode of a model first of all they may select the model first. After that they may clicks on to the “Edit Model” option. After that the above screen will come. According to the requirement of user they may change their name/part no./barcode and then click on to the “ok” button. In similar way, suppose an user wants to copy a model first of all they may select a model and then clicks on to the “Copy-Model” option.

Connection Settings Window When user clicks on to the “Connection Settings” the following window will appear.

In this window user may check his/her Input/output connections.

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Navigation System Manual

When user opens the connections they may see the above window as shown. Now user can check his all connections. If user wants to check his/her Holder LED connections user may open the holder led connections as well other also. If user wants to add any new connection then they add by clicking the add button. If user needs to delete the save data they can delete also by clicking the delete as well as they can edit that also. The above figure shows that the connection of holder led connections.

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Navigation System Manual

Teach Window Teaching is the important part of the machine software. In this part you will teach those point which you are using in your hardware part. When you click on the teach button a window will open as shown in figure. When user clicks on to the teach window following screen will appear. This window is having two kinds of options.  Production  Connector/Wire



Production

For that the user wants to clicks on to the production.

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Navigation System Manual

Now user needs to select a model.

Now you see five buttons to use. Add button is used to add that point which we need. If you add any wrong string then you can delete that string by clicking the delete button. First select the string which you want to delete and then click the delete button.

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If you need to edit any string you can edit it by clicking the edit button and then you see a window is open as shown in figure.

So, this is all about the “production”.

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 Connector/Wire

 In this section first of all user goes into the “select connector” section.  After that he/she may goes into the “select file to load” section and then clicks on to the “save connector image” option.  After that clicks on to the “select holder pins to teach” option. Here the list of pins which are teaching is come here.  After that click on to the “select wire” option and select the name of wire whatever you are written in “pickup led” section.  If wire is having single colour then you select 1 in “No. of colours” section and according to that colour option is come and you have to select the wire colour according to your requirement. If number of colours is increasing according to that you have to select the numbers in “No. of colours” section and also colours of wire.

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Navigation System Manual

 After that goes into the “Teach point size”. In that section you may select the size by scrolling the button and after selecting size you may select the pin

number of holder/connector where you wants to insert that colour combination of wire.

 After that a popup screen will come. If you want to save these settings then you click on to the “OK” option otherwise clicks on “cancel”. BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual

ou clicks on to the “Save” button.  After that when all steps are done then y you

 After clicking on to the save button then you may proceed all of these steps for another holder/connector pins.  If user wants to add wire code and circuit no. then they may goes into the “edit wire details” option. Then select select the wire and click on to the edit option.  When user done his/her editing in the “edit wire details” then they clicks on to the quit button and leave that window.

Production Window

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Navigation System Manual

The above figure shows the “production” window of Navigation machine.  When user enters in that screen first of all they scan the barcode of that model, if barcode is available, otherwise user may select model by manually clicking on to the

select model option.  Then user clicks on to the “start test manua manual” l” option. After that operation will be started.  When production is running in “production” window “Wire” shows that which wire user have to insert in the connector.  According to that “Circuit no.” and “Wire code” is also display here.  "Operator name” indicates that which operator/user is now working on that system.  “Production Count” indicates that “Total no.” of production of that model. Apart from that it also shows that in “Total no.” of production how many productions

are “OK” and “NG”. un the production at same time “cycle time” will also run. It may  When user run

indicate that at what time it will takes to complete a production.  Cycle time history shows that how much time the previous production may take. It is basically a record of previous production production time in seconds.  When user completing one operation successfully the “Pass” message is displaying in the system and “Green light” of tower light is also glowing.

 If operation is not successfully done or user/operator may leave the production screen without out completing the operation, it may counts the production of “NG” and also the “Red light” of tower light is also glowing with buzzer.  The below figure shows that the running production screen.

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Navigation System Manual

 This screen shows that where the user/operator has to insert the wire and what’s the wire name or colour.

 The above screen will appear when production is done successfully and at the same time “green light” of tower light will also glow.

 The above screen will appear when production is not done successfully or the production is NG. At same time “red light” of tower light will also glow with buzzer. This screen will only appear when system is login with operator ID and the same is BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual

not happen when the system is login with administrator ID. n window without completing/damage in  In that case when user leaves the productio production the production, this screen will appear and at a same time harness is also gets

locked.  To leave this screen user may enters the administrator ID and password.

Admin Window

The above ove figure shows the “admin” window of Navigation machine.

User Info Settings

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Navigation System Manual

The above figure shows the “User Info Settings” window of Navigation machine. In this window there is an option of “Add User” and “Delete User”. In “Add user” administrator may makes the login id and password for the different user. In that section there is an option where administrator may decide that which window is enable for the different user. Apart from that there is an option of “Delete user” due to that administrator may delete the user.

When user clicks on to the setting option, then above window will appear. According to requirement user may make changes in the system setting. For example, if user does not want to display the “cycle time display”, they may click on it and off the display. After that user may clicks on to the “Quit/Save” button. Then a pop-up window will appear. If user wants to save those settings, then user may clicks on to the “OK” otherwise click on “Cancel”. The below figure represent this.

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Navigation System Manual

In user info/settings there is an option of “Reset Production Count”.

If user wants to reset the production at any time, they may use this feature. When user clicks on “Reset production count” the above window will appear.

If user clicks on to the “Reset Counts”, then the above window will appear. If user clicks on to the “OK” then all counts may get reset and production count may start from zero otherwise not. If user clicks on “OK”, then below window will appear. After that user may click on to the “Back” button, so that user may leave that window.

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Navigation System Manual

 System

This window shows about the “System Information”.

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Navigation System Manual

Report Window

This window will appear when user clicks on the report button. User can see the report time-wise along with date, type of worker, user type, part no., result. Figure below shows that the “Production Report”.

User can also see the “Harness Report” by selecting the report and then click on to the “view” button. Figure below shows that the “Harness Report”.

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Navigation System Manual

Diagnosis Window Figure below shows that the “Diagnosis Window”. When user clicks on to the diagnosis this window will appear.

Figure below shows that the “Diagnosis Window”. When user clicks on to the diagnosis this window will appear. By using this window user may see that the all pickup led, holder led and TBO is working fine or not. There is also a timer and the range of that time is between 100-1500 ms (mille seconds). User may check that all led’s are working fine or not by selecting one by one method by clicks on to the “Run” button. Otherwise they may also check that all led’s working fine or not at a time by clicks on to the “Run All” option. BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual

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Re-Installation of System Components This section will describe how re-installation of all the system components in future can be done.

Warning  Qualified personnel must complete all work.  Do not apply power to the Navigation System until an Engineer is present and has instructed you to do so.

 Window re Installation Procedure  Insert the Window CD into DVD/CD writer.  Setting up your Computer & BIOS changes (If required). Now reboot your computer after popping in the all new Windows 7/10 DVD you just created into the DVD Drive. In most cases if you do this you'll automatically boot into the Windows 7/10 Installation DVD. But in some cases if the Boot device order is changed in the BIOS it may boot into your older OS, instead of our DVD. In that case you'll need to change the BIOS settings to get it done (More details in a different tutorial).

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Booting Up and First Installation Steps Steps from here are pretty straight forward. Read the descriptions in each pages before ore clicking the Next button to avoid any disasters. IF there is an options to choose in these steps you may find them with each image.

Figure a

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Navigation System Manual

You may choose your Language options by selecting the dropdowns 'Language to install', 'Time and Currency format' and 'Keyboard or input method' here. I decided to leave everything to 'US' but it would be better. For selecting the correct settings here for non-English users.

Figure d

Figure e

This screen is where the installation wizard begins. The install now options will leads to the advanced install options. For repairing a corrupt installation the 'Repair your computer' button located at the bottom-left can be used. For fresh installs just click the Install now button.

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Navigation System Manual

Figure e

Tick the 'I accept the license terms 'check box and click 'Next' to proceed.

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Navigation System Manual

Which type of installation do you want? This screen provides two options, Upgrade and Custom (advanced). The upgrade option is for those who wish to upgrade an existing installation of older version of Windows to Windows 7/10. It is confirmed that Windows Vista can be upgraded to Windows 7/10 without any issues, but Windows XP is still a problem. We will opt for the second option here, the Custom install.

Where do you want to install Windows?

Clicking on the 'Custom' button brings the install location selection screen. In the test machine we have an un-partitioned empty disk. But in the case of a normal installation all your hard drive partitions (e.g. C:\D:\etc.) will be listed here. Choose the drive as you like (a 15GB size is re-commended). Make sure the drive doesn’t have any important data or the Windows 7/10 installation will wipe-out the contents of that partition. You can back-up the data to another partition (e.g. for installing in D:\drive move important files from there to say E:\ drive or to an external USB drive) for safe keeping.

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Partitioning/Creating or Modifying Partitions Click the Drive options (advanced) for advanced partition management options like 'Delete', 'Format', 'New' and 'Extend'. To create a new partition clicks the new button. But if you have list of partitions in the previous screen, choose the one where you are planning to install windows 7/10 and click Format. Then click 'Next' to proceed.

The 'New' option provides a text box to enter the size of the partition you wish to create in MBs. A 15GB (15*1024=15360MB) is recommended. In this case I opted for the full size of my virtual drive, i.e. 9216 MB. Click the Apply button to continue. You may be greeted with a message to ensure that all Windows features work correctly; windows might create additional partitions for system files. This is a new feature in Windows 7/10 to have a small boot partition for system files. Click Ok to continue. So here we are, a new primary partition of 8.8 GB is created along with a System type partition of 200 MB. Select the partition you just created and click Next to continue.

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Navigation System Manual

All right, we are all set. The Windows 7/10 installation begins. Time to grab a cup of coffee for and wait for 15-30minutes for the all new OS!

 Navigation system software re-installation procedure  LabView run-time Engine re-installation Procedure

Installation Steps: Step 1 - Initialization At first the installer initializes. It is recommended that the user exit all programs before continuing the Setup. It also states that if virus scanning utilities are disabled the installation speed may be improved. The LabView RTE has a License Agreement which must be accepted to install the program. The License Agreement is displayed in the fifth step. If the standard LabView RTE is the only program being installed there is no activation required for the License Agreement. When the initialization is complete you are able to proceed to the next step.

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Navigation System Manual

Step 2 – Destination directory You are then given the option to select the primary installation directory. It

is

recommended that you allow the installer to use the default directory.

Step 3 - Features Then you are allowed to select the features to install. By default all options are installed. If you desire to deselect a feature click on the icon to the left of the feature and choose from the options in the left-click menu. When a feature is selected the disk space required by that feature is displayed. If all features shown here are installed the total disk space required is around 375 MB. If a computer already has National Instrument software the icons may appear differently indicating that they are already installed. If a custom installer has more software than the RTE more items may appear here.

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Step 4 - Product Notifications The next step allows you to choose to allow the installer to contact National Instruments to search for the latest notifications on the products you are installing. By leaving the box checked (default) you acknowledge that your IP address will be sent and collected in accordance with the National Instruments Privacy Policy. You are able to review National Instruments Privacy Policy. If you are not connected to the Internet you should deselect this box.

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Navigation System Manual

After the installer has contacted National Instruments any notifications will be displayed. If there are notifications please review them before continuing

the

installation. If there are no notifications the following window will be displayed.

Step 5 - License Agreement(s) Next, the License Agreement is displayed for review. By default the I do not accept the License Agreement radio button is selected and the installation cannot proceed. This is so the user may review the agreement and choose to accept it once it is reviewed. If there are other License Agreements for a custom installation they will be accessible for review through tabs at the top of the Agreement section. Upon acceptance the installation may proceed. The full license agreement is not displayed in this image.

Step 6 - Installation Summary The final step before installation is the installation summary. The summary may be saved to a file if desired. If the summary is not accurate you may click the Back button to change the installation settings. If it is correct click the Next button to begin the installation. BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual

Step 7 - Installation If the installation includes only the features shown above with no previous National Instrument software there are 28 parts to the installation. The installation time will vary depending on the computer speed and number of applications running.

Once the installation is complete you may select the Finish button to close the application. You must restart your computer to complete the installation. You will be prompted to Restart, Shut Down or Restart Later. If the installation included other drivers not shown in the walk-through you may need to install hardware. If this is the case shut down the computer and installs the hardware before running the software.

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Navigation System Manual

NI Visa run-time re-installation Procedure Installation Steps: Step 1 - Initialization At first the installer initializes. It is recommended that the user exit all programs before continuing the Setup. It also states that if virus scanning utilities are disabled the installation speed may be improved. The NI Visa run-time has a License Agreement which must be accepted to install the program. The License Agreement is displayed in the fifth step. If the standard NI Visa run-time is the only program being installed there is no activation required for the License Agreement. When the initialization is complete you are able to proceed to the next step.

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Step 2 – Destination directory You are then given the option to select the primary installation directory. It

is

recommended that you allow the installer to use the default directory.

Step 3 - Features Then you are allowed to select the features to install. By default all options are installed. If you desire to deselect a feature click on the icon to the left of the feature and choose from the options in the left-click menu. When a feature is selected the disk space required by that feature is displayed. If all features shown here are installed the total disk space required is around 375 MB. If a computer already has National Instrument software the icons may appear differently indicating that they are already installed. If a custom installer has more software than the RTE more items may appear here.

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Navigation System Manual

Step 4 - Product Notifications The next step allows you to choose to allow the installer to contact National Instruments to search for the latest notifications on the products you are installing. By leaving the box checked (default) you acknowledge that your IP address will be sent and collected in accordance with the National Instruments Privacy Policy. You are able to review National Instruments Privacy Policy. If you are not connected to the Internet you should deselect this box.

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Navigation System Manual

After the installer has contacted National Instruments any notifications will be displayed. If there are notifications please review them before continuing

the

installation. If there are no notifications the following window will be displayed.

Step 5 - License Agreement(s) Next, the License Agreement is displayed for review. By default the I do not accept the License Agreement radio button is selected and the installation cannot proceed. This is so the user may review the agreement and choose to accept it once it is reviewed. If there are other License Agreements for a custom installation they will be accessible for review through tabs at the top of the Agreement section. Upon acceptance the installation may proceed. The full license agreement is not displayed in this image.

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Step 6 - Installation Summary The final step before installation is the installation summary. The summary may be saved to a file if desired. If the summary is not accurate you may click the Back button to change the installation settings. If it is correct click the Next button to begin the installation.

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Step 7 - Installation If the installation includes only the features shown above with no previous National Instrument software there are 28 parts to the installation. The installation time will vary depending on the computer speed and number of applications running.

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Once the installation is complete you may select the Finish button to close the application. You must restart your computer to complete the installation. You will be prompted to Restart, Shut Down or Restart Later. If the installation included other drivers not shown in the walk-through you may need to install hardware. If this is the case shut down the computer and installs the hardware before running the software.

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Connection Overview This section describes all the wiring connection made in the sheet resistance measurement setup.

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BS-29

BS-26

BS-29

BS-26

BS-30 BS-27

BS-26

BS-29

BS-05

BS-06

Fig.: Demonstrative View of Wiring Plate

CONNECTION OF RELAY:

The internal connection of a relay is shown in the figure above. V1 and V2 are the voltages applied on the terminals (+ & -) of the relay. Terminal Normally Closed (NC) is normally connected to the Common terminal and when the coil is energized, the common terminal switches to Normally Open (NO) terminal. BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual

Connection of Relay Module: Circuit diagrams are self explainable. Here 24v is supplied into the panel.

2

4 24V 1 3 GND J1

6 O1 5 C1

8 P1 7 O2 J2

10 P2 9 O3

12 C2 11 P3

14 C3 13 P4

J3

16 O4 15 C4 J4

18 O5 17 C5

20 P5 19 O6 J5

22 P6 21 O7

24 C6 23 P7 J6

26 C7 25 -

28 27 J7

30 D1 29 D3

32 D2 31 D4 J8

34 D5 33 D7

36 D6 35 J9

Fig: Relay Card (BS-06)

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Connection details of pins with BS-06 with other boards or circuit: CONNECT FROM

CONNECT TO

BS-06 O1

NOT CONNECTED

C1

PC CONNECTOR

P1

PC CONNECTOR

O2

NOT CONNECTED

C2

24V SOLENOID

P2

24V MAIN

O3

GND TOWER LIGHT

C3

NOT CONNECTED

P3

GND MAIN

O4

GND TOWER LIGHT

C4

NOT CONNECTED

P4

GND MAIN

O5

GND TOWER LIGHT

C5

NOT CONNECTED

P5

GND MAIN

O6 C6 P6 O7 C7 P7 D1

PIN 7 BS-30

D2

PIN 8 BS-30

D3

PIN 9 BS-30

D4

PIN 10 BS-30

D5

PIN 11 BS-30

D6

PIN 12 BS-30

D7

PIN 13 BS-30

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BS-05: It is a Begapt board BS-05 which has 20 relay connections. In the BS-05 board these terminals are connected to the green connector and the terminals are assigned as: V1= 24V and GND (assigned as required) V2= D NO=0 NC=C COMMON= P These relays are operated with 24V dc at one of the voltage terminal (D) and other terminal be grounded. Relays are operated with NPN type sensors. J1 2

4 24 VOLT

1

3 GND

J2

J3

J4

6

8

10

12

D1

D11

O11

P11

5

7

9

11

13

D2

D12

C11

O1

O12

J12 46

14

16

P1

J6

J7

J8

18

20

22

24

26

28

P12

P2

D3

D13

O13

P13

15

17

19

21

23

25

27

C12

O2

C2

D4

D14

C13

O3

C1

J13

48

J5

J14

J15

J16

50

52

54

56

58

60

62

64

P17

P7

C7

30

J11

34

36

38

40

42

44

C3

P14

P4

D5

D15

O15

P15

29

31

33

35

37

39

41

43

O14

C14

O4

C4

D6

D16

C15

O5

P3

J18

J19

68

70

72

P18

P8

D9

D19 O19

P5

C5

P16

P6

D7

D17

O17

29

31

33

35

5

7

9

11 13

15

17

19

5

O16

C16

O6

C6

D8

D18

C17

O7 O18

C18

O8

C8

D10

BEGAPT TECH. SOLUTIONS PVT. LTD.

J10

32

J17 66

J9

74

J20

76

78

80

J21 82

84

P19 P9

C9

P20

P10

9

11 13

15

17

19

D20 C19

O9 O20

C20

O10

C10

7

Navigation System Manual

Connection from each NO & Common of 1 Relay connected to the each channel of the I/P Card as specified in the programming.

CONNECT

CONNECT TO

FROM

BS-05 D1

O/P OF NPN SENSOR 1

D2

O/P OF NPN SENSOR 2

D3

O/P OF NPN SENSOR 3

D4

O/P OF NPN SENSOR 4

D5

O/P OF NPN SENSOR 5

D6

O/P OF NPN SENSOR 6

D7

O/P OF NPN SENSOR 7

D8

O/P OF NPN SENSOR 8

D9

O/P OF NPN SENSOR 9

D10

O/P OF NPN SENSOR 10

D11

O/P OF NPN SENSOR 11

D12

O/P OF NPN SENSOR 12

D13

O/P OF NPN SENSOR 13

D14

O/P OF NPN SENSOR 14

D15

O/P OF NPN SENSOR 15

D16

O/P OF NPN SENSOR 16

D17

O/P OF NPN SENSOR 17

D18

O/P OF NPN SENSOR 18

D19

O/P OF NPN SENSOR 19

D20

O/P OF NPN SENSOR 20

BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual

Fig: Sensor Card (BS-05)

Fig: BS-30 (CONTROLLER CARD) BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual

Fig: BS-27 (COMMUNICATION/EXPANSION CARD)

Fig: BS-26 (INPUT CARD)

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Navigation System Manual

Fig: BS-26 (MUX CARD)

Fig: BS-26 (OUTPUT CARD) BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual

Fig: BS-29 (CONNECTOR BLOCK)

DESCRIPTION OF VARIOUS CARDS: BS-30: This is Begapt Board which is used to communicate with PC by serial communication. It has 5 inputs and 7 outputs and one communicating IC. The output connections are connected to BS-06 relay board and are used to operate various outputs such as locking mechanism, tower lights etc.

BS-27: This is Begapt Board which is used as communication/expander board connecting to various cards for performing desired operations. It has 5 ports named PORT 0, PORT 1,

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Navigation System Manual

PORT2, PORT3, and PORT4. The connections are described below:

CONNECTOR NAME 10 PIN WHITE CONNECTOR

FROM PORT 0 (BS-27)

TO TOP SELECT BS-26 (INPUT CARD)

10 PIN WHITE CONNECTOR

PORT 1 (BS-27)

TOP SELECT BS-26 (OUTPUT CARD)

10 PIN WHITE CONNECTOR

PORT 2 (BS-27)

TOP SELECT BS-26 (MUX CARD)

10 PIN WHITE CONNECTOR

PORT 3 (BS-27)

TOP SELECT BS-26 (BOTTOM CARD)

BS-26: This is Begapt Board which is used as Input, Output and MUX board. Each board has 48 points which is connected to the TBO & Sensor connections, Tray LEDs and Holder LEDs respectively. It is connected through BS-29 board.

BS-29: This is Begapt Board which is used as interfacing of each Input, Output and MUX board to the TBO & Sensor connections, Tray LEDs and Holder LEDs respectively. It acts like interfacing units. This board is connected to BS-26 board by Ribbon Cable.

Holder Pins and Holder LED Connections: Each pin is directly connected to the each channel of the BS-29 board (MUX) as specified in the programming. The LEDs representing the pin is connected parallel to the wire connecting the pin. The positive pin of the LED is connected parallel to the wire and the negative pin of the LED is shorted together and connected to the GND terminal of the BS-29 board.

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Navigation System Manual

Tray LED Connections:

Each LED has 2 pins positive and negative (5v and GND) connected directly to the BS29 board (OUTPUT) through a 2 core wire at the specified channels in the programming.

Selector Switch Connections:

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Navigation System Manual

The above image shows that the selector switch. This switch is having two points. One is having input point and another is having output point. In input side there is a connection of 24v and ground, which is coming from the supply end. In output side there is a connection of 24v and ground and that is directly connected to BS-30 board. This switch is used for providing power supply to the machine.

Push button Connections:

The above image shows that the Push Button. This is used for starting the PC as well as starting the production. If the PC is in off condition then first off all user may press on this button to on the system. After that user may go into the production window and after selecting the model, they may press this button to start the production. These button having a connection of 5v and input connection, which is connecting to the BS-30 board. Apart from that these button is having a connection of “PC ON” which is connecting to the BS-06 board. In that case one point is connected to the Pi1 point i.e. common point of the relay and second point is connected to the C1 point i.e. normally closed point of the relay.

Common point Connections: The below image shows that the common point of the system. This is used for providing continuity to the wire which is used in the ECU/Connector. This point is having a 2 pin connection. One is positive and second is negative i.e. 5v and ground respectively, which is directly connected to the BS-29 board.

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Navigation System Manual

Sensor Connections:

Each sensor has 3 wires. In which one is goes on to the 24v, second is goes on to the ground and third is goes on to the point D of the BS-05 board i.e. output of NPN sensor is connected to point D of BS-05 board.

Tower Light Connections: The below image shows that the tower light. It may indicate that the production is completing in a good way or not. When “OK” product is making by user according to

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Navigation System Manual

the method in that case “green” light will glow. But if user makes “NG” or not good product as per method in that case “red” light with “buzzer” will glow. It contains 4 connection, in which

one is connected to the 24v (positive) and rest of the three

connection of respective colour of light is directly connected to “N.O.” point i.e. normally closed point of BS-06 board.

LED Display Board: The below image shows that the LED display board. This display board is used to display document which is necessary to the system and production concern.

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Navigation System Manual

Holder LED & Solenoid Wiring Connection:

The above image shows that the connection or wiring diagram of “holder led and solenoid”. Solenoid consists of two wiring point one is “24V” and another is “ground (GND)”. 24V wire point is directly connected to “P2” point of “7 Relay Board” and ground wire point is directly connected to the Solenoid ground (Solenoid GND) terminal. Holder having one switch pin which is shown in the above diagram. Switch pin consists of two wires above and below position of the white ring. One wire point is directly connected to the “GND” terminal and second wire point is connected to the “Solenoid GND” terminal.

BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual

Holder has one micro or limit switch. Limit switch consists of two wire point, one is connected to the “common point (P)” and another is connected to the “normally open (N.O.)” point of limit switch and another end of both wire is directly connected to the “connector block of Input or TBO card”. Holder also consists led’s and pins. Led’s has two connection point, one is 5V and another is ground. Ground of all led’s getting common and directly connected to the “J1 point of MUX connector block”. 5V wire point of led’s and pin are joint and common wire point of respective led’s and pins are directly connected to the J2, J3 etc. point of “MUX connector block” respectively.

Filter Circuit:

The above image shows the “filter circuit” which is use for the protection of “controller (BS-30) card”. Blue terminal of filter circuit having two points, one is 24V and another is GND which is connected to the respective terminal of supply. Green terminal of filter circuit having two point, one is 24V and another is GND which is directly connected to the 24V and GND points of “controller (BS-30) card”.

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Navigation System Manual

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Troubleshooting Steps 1. There is no proper power supply.  Check the power cable is whether connected or not to main power supply.  Check the proper AC voltage i.e. 220V.  Check whether extension board in the panel is properly working. 2. There is no proper 24V power in the panel.  Check whether power adaptor(24v) or SMPS(24v) is properly working (check the led indicator present in adaptor or SMPS for indication of power).  Ensure to turn ON the selector switch for 24V power in the panel.  Ensure whether there is no any short circuit between the 24V, 9V, 5V and GND respectively (ensure there is no any power in the panel while checking the short circuit) with the help of multimeter.  If selector switch is ON and adaptor or SMPS is working, then check the voltage at terminal of 24V and GND with the help of multimeter.

3. There is an error while opening the navigation application which is shown below, this is due to that there is no proper communication.  Check whether 24V power is proper or not.  Check the serial cable i.e. DB9 connector is properly connected to RS232 port of CPU.

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Navigation System Manual

 Check the controller cable i.e. USB cable is properly connected to CPU.

4. Functionality of navigation system.  Kindly ensure to diagnose all the parameters of diagnosis window at least once a day.  Diagnosis of Holder LED, Tray LED, TBO and Sensors that these are properly working.

 If Holder LED is not working proper.  Check the 10 pin connector is properly connected from Port 2 and Port 3 of BS27 card to Top Select and Bottom Select respectively of BS-26 (MUX Card) Card as shown in figure below.  Check the 2 pin connector is properly connected to J21 or J22 connector of BS26 (MUX Card) Card as shown in figure below.

BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual

 If Tray LED is not working proper.  Check the 10 pin connector is properly connected from Port 1 of BS-27 card to Top Select of BS-26 (Output Card) Card as shown in figure below.  Check the 2 pin connector is properly connected to J21 or J22 connector of BS26 (Output Card) Card as shown in figure below.

BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual

 If TBO or Sensor is not working proper.  Check the 10 pin connector is properly connected from Port 0 of BS-27 card to Top Select of BS-26 (Output Card) Card as shown in figure below.  Check the 2 pin connector is properly connected to J21 or J22 connector of BS26 (Output Card) Card as shown in figure below.

BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual

 If Sensor is not working proper.  Check that 24v is proper in the BS-05 Card or not.  Ensure the particular sensor output is connected to the corresponding D terminal of each BS-05 Card.  Yellow box shown in the figure indicates the 24v terminal of the BS-05 Card and Black box indicates the D (1-20) terminal of the BS-05 Card.

BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual

 If Solenoid or any of the tower light is not working.  Check that 24v and GND is proper in the BS-06 Card or not.  Ensure the 8 pin connector connected from the BS-30 Card to the corresponding D terminal of each BS-06 Card as shown below.  Ensure the corresponding NO and P connections of BS-06 Card.

BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual

 Ensure

some connections in the BS-30 Card which is indicated in the figure for

suitable and proper working.

BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual

Fig: Navigation System

BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual

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Do’s and Dont’s The following items should be followed during use of this machine.

 Keep the machine away from flammable liquids, gases, and aerosols. A fire or an electric shock might occur.

 Unplug the power cord from the wall outlet before you move the machine.  While moving the machine, you should take care that the power cord will not be damaged under the machine.  Do not turn off the power while the machine is in operation. Doing so may damage the machine components.  Before unplugging ging the power cord or turning off the main power switch, make sure remaining machine components are off.  Do not touch areas on or around the probe unit.  When you use this machine for a long time in a confined space without good ventilation, you may detect an odd smell. To keep the workplace comfortable, we recommend that you keep it well ventilated.  If the machine is moved from a cold to a warm place, c condensation may form inside it.

BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual

 After moving the machine, do not use it for at least an hour. The machine requires this time to adapt to its new environment.  Do not open the covers of the machine when it is in operation.  Do not move or tilt the machine when the machine is in operation.  Do not allow small objects such as paperclips to fall into or become stuck inside the machine.  Do not knock the machine and place other thing on the fixture while it is operating. Doing so may hamper the production or you will get error.  Be sure to make a note of the registered machine settings in case they are lost due to accident or malfunction.  The supplier shall not be liable for any loss or damage resulting from a failure of the machine, loss of settings, or use of the machine.

BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual

FAQ Q1. Power not coming in panel? Sol. Check the adaptor (power supply). Q2. PC not getting ON? Sol. a) Check power cable and measure the voltage and other end. b) Check VGA cable. c) Check monitor power supply. Q3. Start test button, tower light not working? Sol. Check connector cable at both the end. Q4. Sensor not working? Sol. a) Check power. b) Check connecting cable at both end. Q5. Continuity error? Sol. a) Check pin. b) Check connection at pin as well as in board side. c) Check method. Q6. Locking not working? Sol. a) Check air pressure. b) Check connecting cable at switch pin as well as in terminal side. Q7. Holder LED and Pick-up LED not working? Sol. a) Check connecting cable. b) Check power supply.

BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual

BEGAPT TECH. SOLUTIONS PVT. LTD.

Navigation System Manual