WB-92-01 Tba-22 [PDF]

Zitiervorschau

TBA/22 Training Document This Training Document is intended for Training purpose only, and must not be used for any other purpose. The Training Document is not replacing any instructions or procedures (e.g. OM, MM, TeM, IM, SPC) intended for specific equipment, and must not be used as such. Note! For safe and proper procedures, refer to the equipment specific documentation.

Name:

Course introduction

1

TBA/22 introduction

2

TPMS service system

3

Packaging material/package integrity 4 Supply systems

5

Tube forming

6

Sterile system components

7

Sterile system

8

Drive and jaw system

9

................................................................................................................

................................................................................................................

Design control system

10

Final folder

11

ASU 2 R

12

Sealing

13

Filling system

14

Electrical system

15

Electrical equipment

16

GE_Fanuc______________________17

Technical Training Centre Lund, Sweden WB-92-01 Issue 9909

Special machine functions

18

Cleaning systems

19 20

1 Course Introduction

Technical Training Centre

Information regarding Safety Regulations at the Technical Training Centre in Modena This list summarizes a number of items which may concern you, as a participant in this training course. Read the list, and if anything remains less than clear, or if you have any questions, feel free to contact your instructor. 1. Study and follow the sections on Safety in the course literature, for instance the OM, MM and EM. 2. You are entitled to ask persons who have no business to be near the machine, to stay at distance, for safety reasons. 3. Never touch any other machines than those used in your own training course. 4. There may be cables which are still electrically live, although they have been disconnected from their terminals. 5. In some machines, safety switches may be bridged or disconnected, for training reasons. 6. Find out exactly where the emergency stop switches for the machine as well as the conveyor are located. 7. When starting a machine, the person doing the starting must make absolutely sure that this does not expose anyone else to danger. 8. Certain chemicals, used in your training course, may be hazardous to your health and constitute a danger of fire or explosion. Make sure you know how such chemicals are marked and how to handle them. 9. It is strictly prohibited to wear rings, watch, or necktie when working with the machine. This prohibition also applies to loose-fitting clothes or anything else that might get caught in the machinery. 10. A first aid kit and stretcher are kept in the machine hall. 11. Study the information on what to do in case of fire and which escape routes to follow. A diagram of escape and evacuation routes is posted in every classroom. 12. If you observe or discover anything that might jeopardize safety, immediately tell your instructor.

Technical Training Centre 1/9701

- Modena Via Emilia Ovest

11 10

Tetra Pak Italiana

Test Hall Switchboard

9

Via Delfini

Reception1

3 2

Warehouse

5 4 6

New Building

78

1 Reception2

Production Technical Training Shool Guard Main Entrance

Canteen

Goods Entrance

Tel. +39 059 898222

Fax. +39 059 898134

e-mail: [email protected]

Meeting Rooms 1 2 3 4 5 6 7 8 9 10 11

Volta - video conference (ground floor New Building) Archimede (first floor New Building, between New Building and Test Hall) Michelangelo (first floor New Building, between New Building and Test Hall) The Globe (second floor New Building) Product Room (second floor New Building) Video Conference (second floor New Building) TPI 1st Floor (above Switchboard on the first floor of Tetra Pak Italiana) TPI 2nd Floor (above Switchboard on the second floor of Tetra Pak Italiana) Raffaello (above Production) Galileo (near Reception 1) Leonardo (near Reception 1)

Information to Course Participants at the Technical Training Centre in Modena Welcome to Technical Training Centre! Here is some information which might be helpful to you as a course participant. If you need additional information or help, feel free to ask your instructor. Start of course Normally, the first day of your course begins at 09.00. Your instructor will meet and welcome you in the coffee room.

Daily time schedule Classes

08.30 - 10.00

Coffee-brake 10.00 - 10.20 Classes

10.20 - 12.00

Lunch

12.00 - 13.00

Classes

13.00 - 16.30

Your instructor will tell you if there are any changes in the schedule.

Lunch Lunch is served in the canteen. You can choose among several dishes; menus are posted at the canteen entrance. If you are a not from BUTB in Modena, your instructor will give you lunch-coupons.

Coffee room You are invited to use the coffee room and the vending machine during all breaks in classes. Instructor will provide you with “coffee key”.

Smoking Smoking is allowed in some places marked with a sign.

Telephones Ask your instructor for assistance.

Computers

ID card

Safety regulations At the start of the course, your instructor will go through the Safety Regulations . These regulations must be strictly observed. In case you are uncertain about anything in the regulations, you must clarify it with your instructor.

Course evaluation You are requested to write down your comments on the course on the Course Evaluation form. At the end of the course your instructor will collect all the forms.

Working clothes It is necessary to wear safety shoes in the Technical Training Centre, while working at the machines . For your use during the course, you may borrow a set of coveralls. Each participant is given a locker in the changing-room. The instructor will hand you the locker key. You may then select a set of coveralls from the coveralls cabinet in the changing-room. Your instructor will help you if needed. You may exchange your coveralls for clean ones every Monday morning. Ask your instructor if you need to change at any other time. Used and soiled coveralls are to be placed in the laundry basket in the changing-room. At the end of the course you have to empty and lock your locker and return the key to the instructor. If you wish to retain your locker for a subsequent training course, tell your instructor.

Valuables You are responsible for your own valuables.

Money exchange To change currency or cash traveller’s cheques, please go to the Rollo-Bank which is close to Tetra Pak entrance. It is open 09.00 - 16.00.

Hotels If you want to change hotel during the course period, please contact the course co-ordinator at Technical Training Centre.

Transport

Travel arrangements Go to the Travel agency for reservations, reservation changes, or confirmation of reservations. The travel agency is located close to Reception 2 and open 07.30 - 17.30 (fridays - 17.00).

Visa Make sure that you have Italian Visa (if needed) valid during you staying in the country.

Medical care Ask your instructor for assistance.

Safety precautions

Machine safety devices Emergency stop buttons Learn the position of the Emergency stop buttons in order to stop the equipment immediately in case of danger to people or damage to the equipment. The Emergency stop buttons do not switch off the power at the mains power switch. Pushing the Emergency stop buttons will reset the equipment program to Zero position and deactivate all pneumatic cylinders.

0-Series

2.282302014sp.fm

LH side

RH side

Tetra Pak

Doc No. MM-82302-0104

17

2 TBA/22 introduction

Technical Training Centre

Technical Training Centre Lund, Sweden

Electrical carbinet

Strip applicator (ASU RH side) Superstructure

Machine type

Service unit

TBA/22 1/9905

Issue

OH 828 Automatic splicing unit

Drive

Main groups

Jaw system Machine body

Final folder

TBA/22 High speed for added value

TBA/22 High speed packaging system

High speed that adds value The TBA/22 creates an entirely new standard of capacity in the aseptic packaging of liquid food. It provides a highly competitive solution for achieving lower operating costs, higher productivity and greater space efficiency. The capacity is a remarkable 20,000 packages per hour for the TBA 250 B and TBA 200 B with straw openings and secondary packaging solutions. The system offers a high speed straw applicator and a high speed cardboard packer. The beauty of the system is that it is fast and simple. The higher capacity has been achieved by increasing the speed of the filling machine and designing innovative solutions such as the new jaw unit and the new final folder.

Cost-effective, productive and space-efficient The TBA/22 has been designed with the specific purpose of reducing the costs and raising the productivity of producers. Cost-effective Savings on packaging operating costs are achieved through lower capital costs, lower utility consumption, lower operator costs, improved space utilisation and less waste on a per package basis. High productivity and space efficiency The unparalleled capacity of 20,000 packages per hour is achieved with a very compact footprint. Producers can expand capacity in the space they already have available, without having to invest in major extensions or new plants. User-friendly Significant steps have been made to increase user-friendliness for operators and service technicians. The TBA/22 provides: • Easy access; • Efficient handling of consumables such as packaging material and the LS strip; • An interactive operator interface.

TBA/22 machine functions 8

3

2 7 6

10 11 1 4

12

5 9

1. Packaging material supply Two reels of packaging material are placed in an integrated section of the machine. The reels are spliced automatically by means of induction heat. The two-reel concept enables the next reel to be spliced before the one currently in use is finished – an ideal feature for contract packing and short production runs of the same product with different designs. 2. Longitudinal sealing Induction heat is used for sealing the longitudinal seam of the packages. Preheating is not needed, as the inductor applies the strip immediately.

3. Aseptic system Sterilisation of the packaging material is achieved by letting the packaging material pass through a deep bath of heated hydrogen peroxide. Rollers remove the hydrogen peroxide from the packaging material and remaining residues of H2O2 are evaporated by hot sterile air. The temperature in the aseptic chamber is monitored so that it will not exceed 100°C. Problems caused by polyethylene sticking during short stops are thus avoided. The aseptic chamber has been designed with a minimum of slots and screws, and the surfaces are angled to enable efficient cleaning. The TBA/22 has a self-balanced sterile air overpressure that is automatically monitored and which makes for very reliable operation.

4. Jaw unit The jaw unit consists of 2 chains opposite each other driven at constant speed by a servo-motor. Each chain is made of 10 links and the links move against fixed cams. To minimise lubrication, solid oil bearings have been used as much as possible. No hydraulics are needed. 5. Single final folder The final folder consists of a single chain driven at constant speed by a servo-motor. There are no hydraulics. Use of lubrication grease is minimal in order to avoid the risk of leakages on the packages. Individual temperature-regulated air nozzles for the flap sealing improves the sealing.

6. Product filling system The product filling system has a level probe that senses the liquid level very precisely and controls it with an electronic system and a regulating valve.

11. Service unit The service unit for the closed cooling system and foam cleaning is located at the front of the machine. Easy connection of all utilities simplifies installation.

7. Platforms The spacious platforms and stairway make the machine very accessible and provide a safe working environment. The design complies with the directives for CE-marking.

12. Interactive operator’s panel The TBA/22 has an interactive operator’s panel at floor level with a touch sensitive display. It contains very extensive alarm functions and it is also possible to switch between different languages very quickly. The operator guidance supports the operator with detailed instructions, such as what actions to take to reset the machine into the production position. This feature helps save labour and reduce downtime. The operator can easily adjust the most important sealing parameters, centering of the longitudinal seal, package volume etc.

8. Air cooling of the electrical cabinet The electrical cabinet has a compressorcontrolled air cooler so that the temperature will not exceed 40°C, even if the maximum number of options are built in. 9. Waste conveyor Rejected packages are discharged at the front of the machine, which improves waste handling and does not affect the operator’s working area. 10. Integrated closed water cooling system The TBA/22 has an integrated closed water cooling system which acts as a cooling medium for the transversal seal, final folder and longitudinal sealing. About 10% of the water is continously purified through an ion exchange filter which means that lime deposits are eliminated in the cooling system.

Peroxide container system The TBA/22 has a closed water system for heating the hydrogen peroxide. The tank is insulated. To avoid overfilling, the maximum level in the tank is supervised by a level probe.

Packaging line monitoring system (PLMS) Automatic recording of line efficiency is made possible by the PLMS. The system records data about stoppages: duration, frequency and waste. The data can be analysed off- line by transferring it to a PC via a modem or diskette. Foam cleaning Alkali foam cleaning is standard for external cleaning (cleaning of jaw system, final folder and aseptic chamber). Foam is dynamic and penetrates into unseen surfaces to give a very hygenic environment. CIP cleaning The cleaning-in-place function (cleaning of product valves and product piping) is automatically switched between production and the cleaning configuration by a group of valves. This feature also records the CIP parameters, i.e. the concentration, temperature and flow of the cleaning media, which are presented on a chart diagram.

Longitudinal seal strip application The longitudinal seal strip applicator is located at floor level to allow easy access. Sealing is done by induction heat. Two jumbo reels are spliced automatically and last for about 1 hour, with one jumbo reel for TBA 250B packages.

TBA/22 packaging line Filling machine

Ink jet date printer

Filling machine The TBA/22 creates an entirely new standard of capacity in the aseptic packaging of liquid food.

Straw applicator The Tetra Straw Applicator 22 HS applies a drinking straw to the package. Package sizes: TBA 200B and TBA 250B. Straw types: S-, T- and U-straws.

Straw applicator Tray shrink Distributor Pallet system

Cardboard packer

Cardboard packer The Cardboard Packer 71 is designed for the high speed system and makes distribution units of 3x8 and 3x9 standard trays. Package sizes: TBA 200B and TBA 250B.

What is high speed? On the 16th of June 1999,

A high-performance system solution

Maurice Greene shaved 0.05 of a second off the world record for the men’s 100 metres. He ran the distance in 9.79

The TBA/22, the Tetra Straw Applicator 22 HS and Tetra Cardboard Packer 71 together make a complete solution that ensures high levels of performance. The Domino A300 ink jet printing unit is used for date-printing. High-speed multipack packaging equipment will be available in the near future.

seconds to become the fastest short-distance sprinter in the world. An athlete will spend years priming his body, his breathing, his running style, the movement of his limbs, in preparation for that one big day when he, hopefully, will truly hit

Domino A300 The Domino A300 offers highly flexible print capability that can meet the ever changing demands of the customer. The fully automated start-up and shutdown functions, simple user interface and advanced fluid supply systems combine to make the A300 truly operator friendly. New software developments, specifically designed for Tetra Brik packaging lines, will enable “jaw” identification numbers to be printed onto the packages.

his peak. If he is a worldclass athlete, he might succeed in breaking the record by a tenth or two of a second. The chances are he will not do it again. It is a once-in-a-lifetime achievement.

Tetra Straw Applicator 22 HS The applicator is small and compact, making it easy to integrate the machine with the packaging lines. The applicator works with the flow principle. To ensure a precise application of the straw, the packages are lifted up from the conveyor chain to a transport belt when passing through the application area.

Speed is, of course, relative. The TBA/22 has not merely “shaved” the record for the fastest packaging machine in the

The applicator head, containing the ladder band, is mechanically connected and driven by a servo-motor. The straw is applied with the help of pressure pads that move with the packages.

world. At 20,000 packages an hour, it has almost doubled the capacity of its nearest rival. Nor is it a once-in-a-lifetime achievement. The TBA/22 does it every hour, every day–reliably, efficiently, convincingly.

Tetra Cardboard Packer 71 The Tetra Cardboard Packer 71 packs Tetra Brik packages into cardboard trays in the 3x8 and 3x9 packing patterns. The machine is easy to adjust from one packing pattern to another. The packages are fed through a distributor that separates the flow of packages into three parallel lines. The packages are then fed into the packer and grouped in the required packing pattern.

Technical Data: Tetra Brik Aseptic filling machine TBA/22 Water supply (cold)

Capacity filling machine Packages per hour:

Connection pressure, kPa (bar): 300-450 (3-4.5) Temperature, °C (°F): Max. 20 (68) Consumption, production: Sterile air compressor, l/min: 8 Sterile air compressor plus cooling system compressor, l/min: 14-16

20000 TBA 250B TBA 200B

Filled product type Non viscous product only

Water supply (hot)

Product supply Connection pressure, kPa (bar):

Connection pressure, kPa (bar): Temperature, °C (°F): Consumption production: External cleaning, l/cycle:

160±40 (1.6±0.4)

Steam Connection pressure, kPa (bar): Temperature, °C (°F): Consumption, kg/h:

170±30 (1.7±0.3) 130 (266) 2.4

300-450 (3-4.5) 55-60 (130-140) 0 250

Compressed air Connection presssure, kPa (bar): 550–600 (5.5 –6) Consumption, production, Nl/min: 420

Electricity Connection: Voltage, V: Frequency, Hz: Recommended main fuse, A (To obtain selectivity): Consumption: Pre-heating, kW: Sterilisation, spraying, kW: Sterilisation, drying, kW: Production, kW: Cleaning, kW:

400/230±10% 50/60±2%

Detergent (external cleaning) Alkali, l/cycle: 1.2 (1.8*) * Only applicable for optional upgraded external cleaning.

125

Cleaning in place (CIP)

31 27.5 20 32 10

Connection pressure, kPa (bar): Flow, l/h: Noise level

Hydrogen peroxide, (H2O2)

Sound pressure level, Lp dB(A): ≈4

Consumption, l/h:

Max. 350 (3.5) Min. 8000

77

Installation drawing No. 648571-3. TBA 21 MACHINE PULL TAB IKOS MODENA 5/98 FRIZIO

3906

598

50 85

21

70

18

00

11

84

Measurements in mm

Business Unit Tetra Brik

We reserve the right to introduce design modifications without prior notice. Tetra Pak and Tetra Brik Aseptic are trademarks belonging to the Tetra Pak Group.

Tetra Pak Marketing Services. Promotional Material Code 8201 en. 12.99

2340

5079

7

Technical Data: Tetra Brik Aseptic filling machine TBA/22 Capacity filling machine Packages per hour:

TBA 250B TBA 200B

20000

Filled product type Non viscous product only Product Supply Connection pressure, kPa (bar):

160±40(1.6±0.4)

Steam Connection pressure, kPa (bar): Temperature, C° (°F): Consumption, kg/h:

170±30(1.7±03) 130(266) 2.4

Electricity Connection: Voltage, V: Frequency, Hz: Recommended main fuse, A (To obtain selectivity): Consumption: Pre-heating, kW: Sterilization, spraying, kW: Sterilization, drying, kW: Production, kW: Cleaning, kW:

400/230±10% 50/60±2% 125 31 27.5 20 32 10

Hydrogen peroxide, (H202) Consumption, I/h: Water supply (cold) Connection pressure, kPa (bar): Temperature, 00 (°F): Consumption, production: Sterile air compressor, L/min: Sterile air compressor plus cooling system compressor, l/min: Water supply (hot) Connection pressure, kPa (bar): Temperature, C°(0F):

≈4 300-450 (3-4.5) Max. 20(68) 8 14-16

300-450 (3-4.5) 55-60 (130-140)

Consumption production: External cleaning, I/cycle:

0 250

Compressed air Connection presssure, kPa (bar): Consumption, production, NI/mm:

550—600(5.5 —6) 420

Detergent (external cleaning) Alkali, I/cycle: 1.2 (1.8*) * Only applicable for optional upgraded external cleaning. Cleaning in place (CIP) Connection pressure, kPa (bar): Flow, I/h:

Max. 350 (3.5) Min. 8000

Noise level Sound pressure level, Lp dB(A): Installation drawing No.

77 648571-3.

2.2B3023B00en.fm

2 Machine body

Tetra Pak

Doc No. MM-82302-0103

149

2.2B3023F00en.fm

6 Service unit

Tetra Pak

Doc No. MM-82247-0103

293

2.2B3023A00en.fm

Tetra Pak

Doc No. MM-82302-0103

39

3 Drive

3-1 Drive - description SPC reference

648523-0400

3.6

3.5

3.2

3.3

2.2B3023C00en.fm

3.1

3.5 3.4

3.1 3.2 3.3 3.4 3.5 3.6

176

Doc No. MM-82302-0103

Drive, jaw unit Drive, design correction Volume adjustment Drive, final folder Plates Photocell unit

Tetra Pak

3 TPMS service system

Technical Training Centre

Tetra Pak Maintenance System Broschyr 9934 en

4 Packaging material/ package integrity

Technical Training Centre

TETRA PAK

Packaging material

Technical Training Centre Lund, Sweden

TBA/3 −8 −9

Machine type

3/9003

Issue

OH 135:5

1 Outer coating (polyethylene) 2 Paper board (Bleached) 3 Alifoil 4 Internal coating 1

5 Paper board (unbleached) 6 Printing 7 Lamination (polyethylene) 8 Internal coating 2 (polyethylene)

Packaging material, TBA/m and TBA/j Moisture or water

Product

Light

Micro organism

Oxygen Flavour

Odours

Internal coating 2

Alifoil

Paper board

Printing

Internal coating 1

Lamination

Paper board

Outer coating

Technical Training Centre Lund, Sweden

Machine type

Issue

Tetra Brik Aseptic

1/9501

OH 526

Creases

Alt. 2

Lightbrown

1 Top fin crease 2 Top crease 3 Longitudinal crease 4 Bottom crease 5 Bottom fin crease

TETRA PAK

Technical Training Centre Lund, Sweden

Machine type

TBA/3 −8 −9

6 Double crease 7 Top flap crease 8 Bottom flap crease 9 Spout crease 10 Perforation

Issue

3/9003

OH 135:4

2 Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

1

Paper board Cooling water

Inner coating

Principle of ridge inductor sealing

Product

Machine type

2/9402

Issue

OH 225

Longitudinal seal (LS)

Paper board Internal coating LS strip

Technical Training Centre Lund, Sweden

Machine type

Issue

1/9501

OH 527

Longitudinal seal (LS) strips Technical Training Centre Lund, Sweden Machine type

LDPE

HDPE

1/9411

Issue

LDPE

LDPE

LDPE

LDPE

Primer

Primer

Primer

PET

EVOH

PET

Primer

Primer

Primer

LDPE

LDPE

LDPE

OH 512

LHL−STRIPS 7,5/0,1

PPP−STRIPS 7,5/0,075

LSE−STRIPS 7,5/0,075

62125

409813

115382

144536

code number

code number

code number

code number

Normally used for UHT milk and water

Used for most filling products

Used for products sensitive to exposure of oxygen

WINE−STRIPS

7,5/0,075

Must be used when filling wine

Tetra Brik Aseptic Transversal Sealing Evaluation

5 Supply systems

Technical Training Centre

Superstructure

T4220 T4210

Machine type

Y5501

TBA/22

ASU

Y6205 Y7303

1/9905

Issue

Y7315 Y7407 Y7408

Y1401

Y1302

Y1223

Y1311

Y1112

Valve panels

T1502 T1231

Y1111

T4200 Y1316

Y1107

Y1220

Y1325

Y1108

Y1221

Y1114:2 Y1114:4

Y5306 Y6203

Y1301

T3109

Y4230

Y3112

Y5504

Y1324

Y3111

T4230

Y1502 T1501

Y3110

T5306

Y1303

Y3103

Y2104

Y1501

Y3109

Technical Training Centre Lund, Sweden

T4301

Y4220

Service Unit

Y4210 Y4200

Machine Body B2201

Y2201

T2201

A2201

P2

Y7410

OH 829

Y7411 Y7412 Y7413

P1

U2201

Z2201 Y7425

Air Supply Unit

Pneumatic panel

Y 3112 Y 3111 Y 3110 T 3109

Y 3103

U 3109

Y 3109

Y 2201 B 2201

5 A 2201 T 2201 U 2201 Z 2201

1

Connection block Air 2

Ice water, inlet Cold water Ice water, outlet

3 4

Supply HI−HL

1 2 3 4

Air inlet Air jet gun Pilot air ASU, pull tab, superstructure and mascine body 5 Service unit

Technical Training Centre Lund, Sweden

Machine type

Central refilling of hydrogen peroxide Hot water Issue

TBA/22

1/9905

OH 830

Technical Training Centre Lund, Sweden

Pneumatic system Overview Valve panel ASU

Machine type

TBA/22

Valve panel Superstructur

Valve panel Machine body

Valve panel Service unit

P2

1/9905

Issue

Air supply unit P1

OH 831:1

Flow line P1 Flow line P2 Control flow line Return flow line Air jet gun

Pneumatic system

F1231

Technical Training Centre Lund, Sweden

Superstructure

U1231

Spraying

U1502

T1231

Colum ball / lid cleaning

U1501

T1502

T1501

D−valve F−valve product sterile air

C31162

C1114

F1325

TBA/22

Y1114:4

Y1114:2 Y1325

B−valve C31161

Y3116

F13112

Cleaning sleeve

F13111

Machine type

Preheating Step 2

Y1311

F1302

Y1302

A−valve F1301

Y1301

Squee−gee Pendulum roller roller C1502

Y1502

C1501

Y1501

1/9905

Issue

Heat exchanger valve Step 2 Step 1 C1108

C1107

Preheating Step 1

Reference Point

C1111

C1112

Top filling Movable lower E−valve H2O2 bath forming ring CIP in F1223

C1401

C−valve

F1324

F1303

OH 831:2

S1303 Y1108

Regulating valve

Y1304

P2

P1

F1304

Y1107

Y1111

Y1112

Y1223

Y1401

Y1324

Y1303

Technical Training Centre Lund, Sweden

Pneumatic system Machine body

Tube altitude Z43012

Filling H2 O2 −tank U1210

Z43011

Machine type

U4200

TBA/22

T4200

Flap heating top Right Left

Flap heating bottom Right Left

U4210

T4210

U4220

T4220

Package Draining Filling bath blowing peroxide bath F1221

U4230

T4230

Waste box

F1220

C5501

U5306

Y1210

U4301

T5306

T1210

Z1210

T4301

Outfeed of waete in front C5504

Flushing F.F.

Tube flusher

S21041

S21042

1/9905

Issue Y4200

Y4210

Y4220

Y4230

Y5306

Y1221

Y1220

Y5501

Y5504

Y2104

OH 831:3

P1 Superstructure

P1

P2

P1 ASU

P2 Superstructure

Technical Training Centre Lund, Sweden

Pneumatic system Service unit Foaming

Flushing Aseptic chamber Jaw system Final folder cleaning cleaning cleaning

Machine type

TBA/22 3/9904

Issue

P1

Flow line Control flow line Return flow line

OH 831:4

Pneumatic system Technical Training Centre Lund, Sweden

ASU Heating device

Photocell

Cooling

Material lock 1

Material lock 2

Web tension

Pressure rail

Cutting

Material holder

Machine type

Inductor Heating device

TBA/22 1/9905

Issue

OH 831:5 P1

Flow line Control flow line Return flow line

Side feeder Side feeder pos 1−2 pos 2−1

Ventilating valve

Pneumatics Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Air conditioning units

Machine type

1/9411

Issue

OH 511:1

Seat and slide valves Non–actuated

Actuated

Seat Valve head Housing Return spring

Housing Slide

Pneumatically operated slide valve

Pneumatics Direction of movement

Force

Speed

Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Machine type

Issue

1/9411

OH 511:12

Pneumatics Control signal

4

2

14 5

Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

1

Machine type

3

Issue

1/9411

OH 511:3

Pneumatics Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

5/2 monostable directional valve

Machine type

1/9411

Issue

14 3 1 5 14 3 1 5

2 4 2 4

OH 511:4

Pneumatics Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Valve with separate air supply to pilot valve

Machine type

1/9411

Issue

14 3 1 5 14 3 1 5

2 4 2 4

OH 511:5

Pneumatics Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

5/2 bistable directional valve

Machine type

1/9411

Issue

14 3 5 1 12 14 3 5 1 12

2 4 2 4

OH 511:6

Pneumatics 3−position directional valve

4

2

4 12

5

1

3

2 14

12

14

5 1 3

Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Machine type

Issue

1/9411

OH 511:7

Pneumatics 2

Soft−start valve

1

12 3

2

1

3 12

1

2

3 12

1

2

3 12

Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Machine type

Issue

1/9411

OH 511:8

Pneumatics Vacuum ejector, controlled by solenoid

3 1

2

Vacuum ejector, controlled by compressed air

1

3

2

Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Machine type

Issue

1/9411

OH 511:10

Pneumatics Single−action cylinder

Double−action cylinder

Rod−less cylinder

Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Machine type

Issue

1/9411

OH 511:11

Dampening

Piston position

Undamped

To hard damped Correctly damped Time

Pneumatics Throttle valve

Throttle check valve

Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Machine type

Issue

1/9411

OH 511:9

Pneumatics Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Magnetic piston sensor

Machine type

1/9411

Issue

OH 511:14

Pneumatics Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Main air supply line

Machine type

Air user

Pressure gauge Shut−off valve

Air user

1/9411

Issue

Air user

Condensate water

OH 511:15

Air user

Pneumatics Function principle Valve cabinet Y08 1

3 2

U05

Suction cups

B06 Hot melt pump T05 U04

C4 Z04 Valve panel

T04 U03

Y03 C3

T03

5

4

24

3 1

2

22

Y02 C2

Y01 C1 YO00

Pressure A1 supply

Z1

T1 U1 Z2

Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Machine type

Issue

1/9411

OH 511:16

Technical Training Centre Lund, Sweden

Pneumatic system TBA/3 C14

Superstructure Product valve

Machine type

3

36

39

TBA/3 87

L18

32

2

2

1 3

C12

1 3

LS- and SAhot air element

C7

C9

Paper brake

Drop chute

C2

C13

C8

L34

1

4 3

L19 L16

4

L41

51 3

37

42

41

33 2

2

5 1

3

L20

38

4

2

5 1

3

L4

35

8

9 4

2

51

3

S1

M8 1

3

T7 Guard

1

M7

15

D2

2

RT1

9606

Issue

A2 M3

L12

3

1

L11

2

3 1

L9

2

OH 581

-

-

C4 Cut left

3 1

L10

3 1

2

2

2

13

12

11

C3 Cut right

3 1

L7

C6 Left

C5

Valve panel

1

A1 T5:2

T5:1 M5:2 14

T5:3 M5:1

M5:3 7

27

Element FS top left

Element FS bottom

Element FS top right

Right Design correction

Jaw system

24

2

2

T3

Air jet pistol

Air jet drop shute

Sterile air valve

Steam barrier valve

2

Jet diverter valve

Separator heat exchanger C15

C16

Machine body

Final folder

L5

Pneumatic system TBA/8 AIR INLET VALVE

HEAT EXCHANGER VALVE

RIGHT

C21:2

C21:3

54

C23

C44:1

C44:2

VACUUM ASEPTIC CHAMBER

ELEMENT MOVEMENT SA

LS

C24:2

C24:1

SHORT STOP ELEMENTS MOVEMENT SA

PEROXIDE BATH TOP FILLING

LS − COUNTER ROLLER SHORT STOP

LS

AIR COMPENSATION VALVE

F18

C26 C20:1

12

Y70 C86

C20:2

2

EJECTOR

LEFT

C21:1

UPPER SUCTION VALVE

3 1

SQUEE−GEE ROLLER

LOWER SUCTION VALVE

C44:3

C71:1 PREHEATING VALVE 211

210

540

JAW SYSTEM

240

241

861

860

200

201

260

261

2

3 1 5

3 1 5

3 1 5

3 1 5

3 1 5

3 1 5

3 1 5

Y102

781

B2

3 1 5

3 1 5

131

C7

2

C9

3 1 5

M3

70 4

Y7

2

MACHINE BODY

2

4

Y13

3 1 5

3 1 5

STERILE AIR VALVE B

C8 80 4

Y8

2

RT1

2

4

Y78

3 1 5

3 1 5

1/9501

Issue

A7 1

T68

PT10

M84 2

2

2

Y1

M1

51

1

171

451

471

21

12

F6

12

F5

2

Y38 3 1

1

2

1

2

271

270

280

C47

C45

C46:1

C46:2

CLEANING TRAY DRAINING

C27 DROP CHUTE

AIR NOZZLE

M 2

PHOTO CELLS

PEROXIDE BATH FILLING DRAINING

PEROXIDE BATH DRAINING

MACHINE BODY

CENTRAL LUBRICATION PUMP

AIR JET PISTOL

REFILLING PEROXIDE

11

550

C2

M38 T38

M55

461

1

12

OH 487

61

T55

2

AIR

841

1

2

4

2

4

2

4

2

4

2

4

2

4

2

4

2

4

2

4

2

4

Port 14

3 1 5

Y28

3 1 5

Y27

3 1 5

Y2

3 1 5

Y46

3 1 5

Y45

3 1 5

Y47

3 1 5

Y17

3 1 5

Y5

3 1 5

3 1 5

Y6

M68

T1

1

T84

1

3 1

2

PRODUCT VALVE A 4

3 1 5

1021

C13

2

STEAM BARRIER VALVE C

Y9

F102

1020

LEFT AUTO CORRECTION

Y34 12

2

VALVE PANEL

2

4

R

4

TBA/8 100V

Y12

SPRAY TANK AIR

41

90

T4

GUARD Port 14

681 C D

3 1

2

4

Y14

121

A B

Y18 M4

141

R

181

4

2

4

Y26

2

Y20

4

2

4

Y86

2

Y24

4

2

4

Y44

2

4

T21

R

Y23

3 1 5

C D

1

2

A B

Y54

4

3 1 5

R

441

12

2

2

4

Machine type

RIGHT

440

Y35

M21 Y21

C14

230

231

711

3 1 5

212

710 2

Y71

4

Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

SUPERSTRUCTURE AIR KNIFE

SPLICER PRESSURE JAW

DRIVE UNIT PRESSURE ROLL

DATING UNIT STOP

AUTOMATIC SPLICING UNIT

SPLICER BRAKE

FINAL FOLDER UNIT

FLAP SEALING AIR

FINAL FOLDER LOWER PART

General The technology of using compressed air to create movement is termed Pneumatics. In the Tetra Pak packaging machines and distribution equipment, compressed air is used to:make components move, operated by pneumatic cylinders • make components move, operated by pneumatic cylinders • control and operate valves • create vacuum and supply air nozzles with air The pneumatic system consists of two parts. One part is located external to the machine; in it, the required pressure is generated. The external pneumatics include compressor, air conditioning unit, main air supply line, etc. The other part is inside the machine and includes regulators, valves, cylinders, etc. The air used in the pneumatic components must be clean and dry; pressure and flow rate must also be as required. The recommended values are specified in the installation manual (IM) for the machine concerned. In some systems, the components are factory prelubricated once and for all, requiring no further oil or grease; air for these components must be as free from oil as possible. However, if such a component is once mist lubricated, it must always be mist lubricated from then on. The pneumatic system of each machine is documented in the form of a diagram. In order to simplify its construction and make the diagram easier to read, the various components are shown as symbols.

Pressure source

Shut–off valve

Pressure regulator with gauge

Valve

Cylinder

As there are many models and versions of machines, and some of them have been rebuilt or modified to differ from their original design, it is very important that the correct, up–dated, and currently valid pneumatic diagram is used when working with a particular machine.

Technical Training Centre 1/9411

Training Document. For training purpose only.

3

Components Air conditioning units The first unit the air passes through on its way to the machine is the air conditioning unit. It consists of a separator, pressure regulator with pressure gauge, and, on some machines, lubricator. Normally, a shut–off valve is built into the conditioning unit.

Pressure regulator Shut–off valve Air conditioning unit symbol

Pressure gauge

Separator Lubricator

The purpose of the separator is to remove water and other pollutants that might be present in the compressed air. The separator consists of a filter element and a reservoir with a drain valve. The filter element may be made of sintered bronze. The input air is made to rotate, so that water drops and the larger solid particles are flung outwards against the inner surface of the reservoir. Condensated liquid runs down to to bottom of the reservoir, where it is removed through the drain valve when the input air is turned off.

Separator

The purpose of the pressure regulator is to provide air at a constant pressure, independent of the load on the system. It is a form of pressure reduction valve, and its function will be explained under the heading of Valves.

Pressure regulator

The pressure gauge indicates the pressure setting.

Pressure gauge

The lubricator (mist lubricator) provides the compressed air with oil. The injected amount of oil is proportional to the flow rate of the air and can be preset. In systems whose components are factory prelubricated, no oil must be added to the compressed air, as oil would wash out the grease in the prelubricated components.

Lubricator

4

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Valves The purpose of valves is to regulate the flow rate and pressure of the compressed air and control its flow direction. The valves are controlled and operated either manually, by means of electrical signals from the PLC, or pneumatically by other valves. Valves are subdivided into two groups – seat valves and slide valves. These groups differ in their design.

Seat valve

The seat valve controls the flow of air by means of its valve head and seat. The valve head only has to move a short distance to change over but needs considerable change–over force. Non–actuated

Actuated

Seat Valve head Housing Return spring

Slide valve

The slide valve controls the air flow by means of a movable slide. To change over, the slide has to move a relatively long distance, but the force needed for it is small. Non–actuated

Actuated

Housing Slide Return spring

In respect of their purpose, valves are grouped as follows: • directional valves, controlling the flow direction of the compressed air, for instance to operate the reciprocating movement of the piston in a pneumatic cylinder. • flow rate regulating valves, controlling the amount of air per time unit, for instance to control the speed of the piston in a pneumatic cylinder. • pressure regulating valves, controlling the pressure in the pneumatic system. Before proceeding, we shall take a look at the symbols for the valves, and how they are constructed and function.

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Training Document. For training purpose only.

5

The valve symbols denote the function of the valves but not their design. This means that valves that look differently, due to the way they are designed and constructed but function in the same manner, are shown with the same symbol.

Valve symbols

The illustration shows the working principle of a slide valve, which may be in either of two positions. Outlet. Port for output air

Slide

Pilot air

Pilot air

Inlet. Port for input air

Vent. Port for evacuation

Valve housing

Position 1 The valve has received pilot air on the lefthand side. The passage between inlet and outlet is open, and the vent is closed

Position 2 The valve has received pilot air on the righthand side. The inlet is closed, and the passage between outlet and vent is open.

This valve can be shown simplified as a symbol. The symbol consists of a square, with the ducts through which the air is able to pass shown as arrows. To the left and right of the square, the manner in which the valve is controlled is symbolised, for instance with a horizontal line for pneumatic control. The lines above and underneath the square represent the ports connected to the input and output air lines. Outlet

Valve housing Pilot air

Pilot air

Inlet

Vent

Position 1 The valve symbol is shown with open passage between inlet and outlet, and closed vent.

6

Position 2 The valve symbol is shown with open passage between outlet and vent, and closed inlet.

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The function of the valve is illustrated by means of symbols. Each position the slide may be in is shown as a symbol, and the symbols are drawn after one another. The ports are only shown on the symbol in active position in the pneumatic diagram, which is the starting position of the valve. Outlet Active part of symbol Pilot air Inlet Compressed air supply.

Vent

Position 1 The pilot air is received on the lefthand side of the symbol, which means that the lefthand side of the symbol is active. Compressed air passes through the valve and can actuate a cylinder

Position 2 The pilot air is received on the righthand side of the symbol, which means that the righthand side of the symbol is active. The air in the cylinder can be evacuated.

To make it easier to identify them, the ports are numbered: input air port – No 1; output air port – No 2; vent port – No 3. The pneumatic signal ports take their numbers from the ports they provide passage between; for instance, port No 12 connects input and output air. 2 12 1

3

As the valve in the example has three ports and a slide which may be in two positions, it is termed a ”3/2 valve”. Similarly, a five–port valve with a three– position slide becomes a ”5/3 valve”. The valve may be operated in several ways. Other than pneumatically, it can be operated manually, by a spring, or electrically. The different ways are shown as symbols. In the following example, an electrically operated 5/2 valve with spring return operates a double-action pneumatic cylinder.

Cylinder Control signal

Outlet ports

14 Vent port

Return spring Vent port Inlet port

The control signal is received on the lefthand side of the symbol. Compressed air passes through the valve and into the plus compartment of the cylinder, while its minus compartment is vented.

4

2

5

1 3

The control signal is discontinued, and the return spring moves the slide. The compressed air is now directed to the minus compartment of the cylinder, while its plus compartment is vented.

The various forms of valve symbols used in our pneumatic diagrams are explained in greater detail in the section of this text where the function of the valves is described.

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Training Document. For training purpose only.

7

The monostable valve features spring return, i e in idle position, the slide is always in the same position. One advantage of this type of valve is that it is possible to operate a cylinder in both direction with only one control signal output from the PLC. Electrically controlled, monostable valves are used extensively in Tetra Pak machines. The pilot air is controlled by means of an solenoid, powered by 24 or 48 V DC from a PLC output. The pilot air system is an integral part of the directional valve.

Monostable directional valve

Electrically controlled, monostable directional valve.

Cylinder Electrically controlled, monostable valve

4

2 Seal Pilot valve Solenoid

5

1

3

14

From PLC

In those cases where the valve receives air with a reduced pressure, which is lower than the change–over pressure of the valve, the pilot valve can be supplied separately with air from the pneumatic system. On some valves, for instance Mecman Series 581, change–over is effected by turning the seal between the valve proper section and the control section upside down. Then control port No 14 in the connection plate is connected directly to the compressed air system. Electrically controlled, monostable valve with separately supplied solenoid valve 4

Electrically controlled, monostable directional valve with separate air supply to pilot valve.

2 Seal Pilot valve Solenoid

5

Pressure regulator

8

1

3

14

From PLC

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Bistable directinal valve

The valve has no spring return, and thus the slide can be in either of two idle positions, depending on which one of the two solenoids was most recently activated. Consequently, two outputs from the PLC are always required to control a bistable valve.

Electrically controlled, bistable directional valve

4

5

2

1

3

12

14

From PLC

From PLC

Valves of the bistable type are used if, for instance, it is desirable that the cylinder is to remain in the position it moved to as a result of the most recent valve operation, even if the the output signal is discontinued. The same standard principle for numbering the ports applies to this kind of valve. Pilot air at port No 12 connects ports No 1 and No 2, pilot air at port No 14 connects ports No 1 and No 4, in both cases admitting passage of input air.

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9

This valve type is used, for instance when a cylinder is to remain in position at an emergency stop. Below, an electrically controlled 5/3 valve is illustrated. 4

3-positioned directional valve

2

Electrically controlled, 3– positions directional valve with closed middle position. 5

1

3

14

12

No control signal to ports No 12 and No 14 means that the return spring positions the slide in the middle; all ports closed. 4

5

2

1

3

14

12

On port No 14 receiving a control signal, the slide moves to the right in the picture. This means that port No 1 is connected to port No 4, and port No 2 to port No 3. 4 2

5

14

1

3

12

On port No 12 receiving a control signal, the slide moves to the left in the picture. This means that port No 1 is connected to port No 2, and port No 4 to port No 5.

The valve can be in three positions. In addition to the two positions of a 2– position valve, the 3–position valve has a middle position with all ports closed(as exemplified above) or open for venting. Two PLC outputs are required to control the valve. If there is no signal when the system is depressurised, the return spring puts the valve in its middle position.

10

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Soft-start valve

This type of valve is used in order to make pressurisation of the pneumatic system soft and smooth. Variable stop

1

Telescoping slide

2

3 12

Idle position. In idle position, ports No 2 and No 3 have an open connection. The pneumatic system is depressurised.

1

2

3

Pressurisation phase. During the pressurisation phase, the connection between ports No 1 and No 2 is partly open, and pressurisation has begun. The width of the opening is regulated by means of a variable stop (limit screw).

1

2

12

3

Full flow. When the pressure has risen to approximately 75% of the pressure in the compressed air supply line, the connection between ports No 1 and No 2 is opened all the way.

12

The three positions of the telescoping slide are illustrated, somewhat simplified. When the control signal is received, the slide moves up against the variable stop, opening a narrow connection between ports No 1 and No 2 (pressurisation phase). When the pressure has risen to approximately 75% of the pressure in the compressed air supply line, the valve opens all the way. On depressurisation or at an emergency stop, the valve provides full flow directly between ports No 2 and No 3 (depressurisation).

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11

This kind of valve is used to regulate the flow of air, which is restricted equally much in both directions.

1

Throttle valve

2

Throttle valve

Throttle fitted in directional valve

If throttles are incorporated in a directional valve, they are fitted in the outlet ports and consist of brass screws. Normally, such throttles are factory fitted in most of our directional valves. Normally, they provide adequate speed regulation accuracy. This kind of valve is used when the air is to be regulated in one flow direction only.

1

2

When the air flows from port No 1 to port No 2, it must pass through the throttle and can thus be regulated.

1

Throttle check valve

2

If, on the other hand, the air flows from port No 2 to port No 1, it passes through the check valve without being regulated.

In order to achieve better accuracy in speed regulation, throttle check valves can be used, for instance fitted in the end sections of the cylinders. This is done when the cylinder is located remote from the directional valve. If throttle check valves are being used, the throttles integral with the directional valves must be fully open; adjustment must only be made by means of the throttle check valves. This is a manually operated ball valve, used to shut the supply of air to the entire pneumatic system. Normally, it is built into the air conditioning unit.

Shut-off valve

The pressure switch triggers an alarm to the control system, if the pressure drops below a preset value. This value can be adjusted.

Pressure switch

12

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Pressure regulator

Correctly set pressure is a condition of correct speed control and correct force. For this reason, a pressure regulator is a always fitted in the air conditioning unit. To enable the pressure regulator to function well, there must be a pressure difference between input and output air of not less than 0.8 bar. Some machines have an extra pressure regulator within the pneumatic system for the purpose of allowing the reduction of the air pressure to some of the cylinders. Outlet pressure set screw Force spring

Diaphragm Inlet port Outlet port

Seat Valve plate

The valve plate of the seat valve is operated by the diaphragm, which in its turn is actuated by the outlet pressure of the pressure regulator. The force created by this pressure is balanced by the spring force on the other side of the diaphragm. By increasing the spring force by turning the set screw, the seat valve is opened and is kept open until the outlet pressure exceeds the spring force. Thus the diaphragm and the spring force together maintain a constant, preset outlet pressure. If the pressure on the outlet side drops, for instance due to air used in moving a cylinder, the seat valve opens again.

Vacuum ejector with valve

This valve generates underpressure through its ejector effect. It is used, as an example, to supply a vacuum to suction cups. There are two types of vacuum valves. One type which is electrically controlled and generates a release pulse when the direction of flow is reversed. The other type in entirely pneumatic and generates the release pulse by means of a built–in accumulator.

1

3

1

3

2 Electrically controlled vacuum ejector

2 Pneumatically controlled vacuum ejector

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13

Cylinders The purpose of a pneumatic cylinder is to perform a movement, powered by compressed air. In simple terms, the pneumatic cylinder consists of a cylinder housing with two end sections, a piston with piston rod, and two connections to the pneumatic system. Plus compartment

Minus compartment Piston rod

Rear end section

Connection

Piston

Cylinder housing

Connection

Front end section

The piston is provided with seal–rings, separating the two compartments. The front end section has a piston rod guide and seal. When compressed air is admitted into the plus compartment (pressurisation), and the air in the minus compartment is vented, or evacuated (depressurisation), the piston rod extends out of the cylinder – the piston performs a plus stroke. If the flows of air are reversed, the piston rod is withdrawn into the cylinder – the piston performs a minus stroke. Plus stroke

Minus stroke

The cylinder described above is a double–action cylinder with single–side piston rod. This means that both the plus stroke and the minus stroke are performed powered by compressed air, and that there is a piston rod at one end only.

14

Training Document. For training purpose only.

Double-action cylinder

Technical Training Centre 1/9411

Single-action cylinder

In the single–action cylinder, a spring effects the minus stroke. Spring

Piston rod

Rod-less cylinder

Such a cylinder is double–acting, but its piston rod has been replaced by an attachment sliding along the outside of the cylinder shell. The movement may be transferred to the attachment mechanically or by means of magnets. Attachment

Connection End section

Magnetic piston sensor

Piston

Cylinder housing

Connection

End section

A magnetic piston sensor is fitted on the cylinder for the purpose of giving the PLC information on the current piston position. This information is then utilised by the PLC as a precondition of, for instance, the changing over a directional valve etc. Magnetic piston sensor

Fully electronic magnetic piston sensor; when the magnetic field of the piston alters the resistance in a semiconductor element inside the sensor, an output signal is transmitted to the PLC; the sensor has a switch–off delay of 20–30 ms.

Magnetic piston Double–action cylinder with magnetic piston

Technical Training Centre 1/9411

When replacing a cylinder with a magnetic piston, it is important that the replacement cylinder also has a magnetic piston. A cylinder with the correct length of stroke and diameter, but without magnetic piston, will not actuate the magnetic piston sensors.

Training Document. For training purpose only.

15

The direction, force, and speed of movement of the piston rod can be controlled. To ensure that the piston rod stops moving softly and smoothly, there are also end position dampers. The various functions are explained in the following. The direction of movement is controlled by directional valves..

Direction of movement

In order to control the movements of a double–action cylinder, a five–port valve is required. As the valve is actuated by a control signal, its slide changes over, and the compressed air is led to the plus compartment of the cylinder, while the minus compartment is vented. The piston performs a plus stroke. If the control signal is discontinued, the return spring of the valve moves the slide back again, and the flow of air reverses direction; the minus compartment is filled with air, the plus compartment is vented, and the piston makes a minus stroke. The force which the piston rod exerts on the load, is regulated by varying the pressure of the air – reducing the pressure decreases the force. The pressure is controlled by means of a pressure regulator.

Pressure regulator

16

Valve

Force

Cylinder

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Speed

The speed of the piston is regulated by varying the flow of air on the return side in the cylinder. This is done by means of the throttles in the valve, or with throttle check valves fitted in the line between the valve and cylinder.

Throttle check valve

Throttle in valve outlet port

Speed regulation by means of throttles in valve Speed regulation by means of throttle check valves; throttles in valve to be fully open

The reason why throttling is done on the return side of the cylinder is to make the movement smooth. Pressure Correct (vented air throttled)

Wrong (input air throttled)

Time

If the cylinders used are small, or the air lines between cylinder and valve are long, the alternative of employing throttle check valves offers better speed regulation accuracy; the valve throttles must in this case always be fully open.

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The movement of the piston is dampened at both end positions by built–in dampers in the cylinder end sections. The dampening effect is regulated with adjustment screws. The purpose of the dampers is to decelerate, i e slow down and stop, the piston a smoothly. In this way, damage to the cylinders, caused by the piston striking the cylinder end section with some force, is eliminated. Dampening also reduces vibrations in the machine. If, on the other hand, the dampening effect is too great, the piston may bounce back and come to a stop with a jerk. Cylinder end section

Adjustment screw

Dampening

Double-action cylinder with variable end position dampening

Piston

The air on the vent side of the cylinder passes through the large, central opening in the cylinder end section

A protrusion on the piston closes the central opening in the end section, so that the vented air is forced through the narrow duct, in which the adjustment screw enables the flow, and thus dampening effect on the piston, to be regulated.

In order to successfully set both speed and dampening, it is important first to make sure that the pressure in the system is correct. Thereafter, the cylinder speed can be set, and lastly, the dampening effect. Piston position

Undamped

Damped too much Correctly damped Time

18

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Main air supply line

Shut–off valve Pressure gauge Air user

Air user Condensate water

The main air supply line should form a ring main line through the premises; this will allow the users of air to receive it from two directions. There should be a drop of 5–10 mm per metre in the direction of flow. Underneath the lowest point in the ring line, a condensate drain cock is to be fitted. The output connections to the users should be fitted on the top side of the main line piping; this will keep condensate water and dirt from following the air into the user device. There should also be a pressure gauge to make it possible to check that correct air pressure is being maintained. The diameter of the main line piping depends on its length as well as the number of pipe bends and elbows, connections, and valves in the line. The larger the number of such components that the air must pass, the bigger the pipe diameter must be to prevent excessive pressure drop up to the points where the air is used. The pipe–lines should be be installed so that they are easily accessible for checking that they are tight.

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19

Function principle This is an example of a principle diagram of a pneumatic system: Valve cabinet

Y08 1

3 2

Suction cups

U05 B06

Hot melt pump T05 U04

C4 Z04 Valve panel

T04 U03

Y03

C3

T03 Y02 4

24

2

22

3

1

5

C2

Y01 C1 YO00

U1

Pressure supply

Z2 A1

Z1

T1

The input compressed air passes through manual valve A1, water separation filter Z1, and pressure regulator T1; pressure gauge U1 indicate the pressure. If the pressure drops below a preset value, pressure switch B06 indicates a warning by lighting a signal lamp on the control panel. The pressure switch should be connected as the last component in the system in order to sense the pressure drops created by the other components.

20

Training Document. For training purpose only.

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Pressurisation valve YO00 is used to make pressurisation of the system slow in order to allow cylinders in wrong positions to return smoothly to their correct idle positions. The pressurisation time can be adjusted by means of an adjustment screw in this valve. Valve YO00 also has a safety function, for instance if an emergency stop requires the system to be instantly depressurised. Valve Y01 is a 3–position valve with closed middle position. If, for instance, the machine is emergency stopped, the valve moves to the middle position, and cylinder C1 remains in the position it was in at the stop. A B C T U Y YO Z

manual valve cylinder cylinder pressure regulator pressure gauge electrically controlled valve pressurisation valve filter

Pressurisation Control line Depressurisation Vacuum line Valve panel Valve cabinet

Valve Y02 is monostable and electrically controlled. It has throttles in its outlet ports for regulating the speed of cylinder C2. Valve Y03 is also monostable and electrically controlled, but its pilot valve is supplied with air separately from a line, connected before soft–start valve YO00. This means that valve Y03 does not have to wait for the slow build–up of pressure via the soft–start valve but changes over instantly as soon as valve A1 opens. The separate supply of air also allows valve Y03 to be supplied with air at a reduced pressure, for instance to limit the force of cylinder C3. Pressure regulator T04 regulates the pressure to cylinder C4. This cylinder acts as an air spring, and for this reason, an accumulator is connected to the air line. Pressure regulator T05 regulates the pressure to the hot melt pump and thus controls the amount of hot melt adhesive to be extruded. Y08 consists of a vacuum ejector and two valves. When the righthand valve is activated, compressed air flows from port 1 to port 3 and, due to the ejector effect, a vacuum is generated at port 2, to which the suction cups are connected. When the lefthand valve is activated, compressed air is supplied directly to the suction cups, which thus are receive a blast of air, releasing their suction and blowing their ducts clear. Silencer Z2 is common to the whole pneumatic system. The designations in the diagram follow a certain system, usually consisting of a letter and a number. The components which the compressed air comes to first are given the same number, in this case 1, but different letters to denote their functions: A for manual valve, Z for filter, and T for pressure regulator. The number of a valve, for instance Y02, determines the numbers of the following components. The output lines from the valve are given numbers beginning with 2, followed by the number of the outlet port, i e numbers 22 and 24. The cylinder is designated C2. Whenever setting is done in the pneumatic system, it is important to do it i the right order: 1input pressure 2speed (throttle check valves or valve throttles) 3dampening (end position dampers in cylinders)

Technical Training Centre 1/9411

Training Document. For training purpose only.

21

Symbols The following table, which is an excerpt from the Tetra Pak Standards (DS 208.35), lists the symbols that are normally used in our pneumatic diagrams. Symbol

Meaning Single–action cylinder with return stroke by spring.

Double–action cylinder with single–ended piston rod.

Double–action cylinder without piston rod.

Double–action cylinder without piston rod, with variable dampening at both end positions. Double–action cylinder with variable dampening at both end positions.

Double–action cylinder with variable dampening at both end positions and magnetic piston. Torque cylinder.

2/2 directional control valve, controlled by pressure acting against return spring. 3/2 directional control valve, controlled by pressure acting against return spring.

22

Training Document. For training purpose only.

Technical Training Centre 1/9411

3/2 directional control valve, controlled by solenoid with return spring. 3/3 soft–start valve.

5/2 directional control valve, controlled by pressure acting against return spring. 5/2 directional control valve, controlled by solenoid with return spring. 5/2 directional control valve, controlled by solenoid valve with separate air supply. 5/2 directional control valve, controlled by solenoid in both directions. 5/3 directional control valve, closed in middle position, controlled by solenoid and return spring. 5/3 directional control valve, open in middle position, controlled by solenoid and return spring. Variable throttle valve.

Non–return valve with variable throttle check.

Rapid–exhaust avlve.

Technical Training Centre 1/9411

Training Document. For training purpose only.

23

Pressure regulator with relief port, spring controlled. Adjustable spring force.

Shut–off valve with exhaust port.

Silencer

Accumulator

Separator with water trap and automatic drain.

Lubricator.

Air conditioning unit, consisting of filter, pressure regulator, pressure gauge, and lubricator.

Pressure gauge.

Electric pressure switch with change–over contact and variable pressure setting. Magnetic piston sensor.

Ejector.

24

Training Document. For training purpose only.

Technical Training Centre 1/9411

Water panel

Filter 1 Ball valve Pressure gauge

Pressure switch B 2102 Solenoide valve Y 2108

Connection block Air Ice water, inlet

5

4

3

Cold water, inlet

2

Ice water, outlet Supply HI−HL 1 2 3 4 5

Cold water inlet Flushing final folder Superstructure Spray gun Compressor unit

Technical Training Centre Lund, Sweden

Central refilling of hydrogen peroxide Hot water

Machine type

Issue

TBA/21

1/9804

OH 778

Cooling water system 1 2 3 4

29 28 27 26 25 24

5

23

6

22 21

7

20

8

19

9

18 17 16

15 14 13 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Expansion wessel (O 2530) Pressure gauge (U 2501) Temperature sensor (B 2510) Conductivity sensor (B 2520) Ion exchanger (O 2520) Filte (Z2520) Ball valve (A 2530) Non−return valve (J 2530) Heat exchanger (K 2550) Water saving valve (S 2550) Sight glass (U 2560) Filter (O 2560) Heat exchanger (K 2510) Expansion valve (S 2513)

Technical Training Centre Lund, Sweden

11 10 15 16 17 18 19 20 21 22

Regulating valve, capacity (S 2514) High pressure transmitter (B 2540) Low pressure transmitter (B 2541) Cooling compressor (P 2540) Pressure switch (B 2501) Security valve (F 2530) Cooling water pump (P 2501) Flow meter, SA transformer (S 8404) (unused in TBA/21)

Machine type

23 24 25 26 27 28 29

Issue

TBA/21 TBA/22

2/0001

Flow meter, ion exchanger (S 2520) Flow meter, LS transormer (S 2320) Bleeding valve (A 2501) Flow meter, final folder (S 5305) Flow meter, TS transformer left (S 4309) Flow meter, TS transformer right (S 4310) Ball valve (A 2520)

OH 832

Infeed slider Technical Training Centre Lund, Sweden

Peroxide system SA−sealing

LS−sealing

Guide cooling final folder

TS−sealing left

Tube flusher

Sterile system

TS−sealing right

Machine type

Spray gun Cooling water system

Flushing final folder

TBA/22 Cold water

Heat exchanger

OH 833

Heat exchanger

1/9907

Issue

Hot water

Water panel

Compressor unit

Water system

Hygenic cleaning system

Cooling Water System General Tetra Brik filling machines use water to cool different components, like: • inductors in the jaw system • guide rails in the final folder • oil in the hydraulic system • air in the electrical cabinet The cooling water system can either be open or circulating. Circulating cooling water is used when the temperature of the ordinary water supply is too high, over 20 ˚C. In an open system, the water is consumed, while a circulating system uses the same water over and over again. Chilled unit

From cooler

Chilled unit

Cooler

Return to cooler

Drain Open cooling water system

Circulating cooling water system

Many machines have a separate water cooling system. This means that there is some kind of heat exchanger between incoming water and water to be cooled. In an open separate water cooling system, the cooler is part of the machine.

Open separate cooling water system

Cooler

Heat exchanger

Heat exchanger

Chilled cold water

Chilled unit

Heat exchanger

Chilled unit

Cold water

Circulating separate cooling water system

The cooling system of the machine is documented by means of a diagram. To simplify the construction and make it easier to understand, the diagram is made up of symbols for the different components. The design of the cooling water system varies depending on machine type, development step and rebuilds. Thus it is important to use the correct cooling water diagram when working on the machine.

Technical Training Centre 1/9902

TM-00075

Training Document. For training purpose only.

10-1

In order to be able to cool efficiently, the water must be of adequate quality and temperature. Data on water quality to be used for the different machines can be found in the IM, MM or OM.

Cooling water

The kind and quality of the water differs. Below some examples: • Raw water is a surface or ground water. Depending on where it is taken, it contains different ingredients and impurities. • Drinking water is produced from raw water. Drinking water must not contain components that may cause illness. • Deionized water is produced from drinking water. In deionized water you control the amount of hardening ions. • Totally desalinated water is also produced from drinking water. All salt ions, both positively and negatively charged ions, are removed.

Components A cooling water system is built up of many components. The most important and frequent ones, are described below. Manual valves are opened and closed manually.

Manual valve

An electrically controlled valve receives a control signal from the machine control system when to open and close.

Electrically controlled valve

A pressure gauge displays the pressure in the cooling water system.

Pressure gauge

In order to protect the cooling water system, there might be an over-pressure valve included in the system.

Over-pressure valve

Overpressure valve

The overpressure valve opens up if the pressure in the cooling water system exceeds a preset pressure. Water is then released, causing the pressure to decrease in order to avoid damages to the cooling water system. The filter is used to filter off solid particles and other impurities which may clog valves and narrow passages, or in any other way affect functions in the cooling water system.

10-2

TM-00075

Training Document. For training purpose only.

Filter

Technical Training Centre 1/9902

Magnet device

The magnet device prevents forming of lime deposits in the cooling water system. It is built up of a mechanical filter and a magnet device.

3 4

1

2

• Mechanical filter - The filter basket (1) collects any solid impurities in the water. Inserted in the filter basket there is a magnet rod (2), collecting any magnetic impurities like iron chips. The magnet has a plastic cover to prevent corrosion. • Magnet separator - This consists of two permanent magnets (4) forming a gap (3), through which the water flows. The function of the magnet separator can be described like this: Between the magnets (4) there is a heavy magnet field. The magnet field affects the lime in the flowing water so that the lime deposit formed in the cooling water system does not adhere to the cooling water channels. Instead the lime deposit will follow the cooling water out to the return line. The function of the magnet device is temporary. Magnet field 4

4

Untreated water. The crystals gather and stick easily on surfaces.

Water tank

Technical Training Centre 1/9902

Magnetically treated water. The crystals do not gather and do not stick on surfaces.

There is a water tank in some machines, and it works as a reservoir for the water.

TM-00075

Training Document. For training purpose only.

10-3

The accumulator is a vessel containing air. The air can be compressed, to take up any pressure variations caused by temperature variations.

Accumulator

A temperature sensor monitors the temperature and signals the control system if the temperature raises above or falls under the preset values.

Temperature sensor

The thermostat is used to keep a constant temperature by regulating the flow and thus the supply of colling water to a component.

Thermostat

A pressure guard monitors the pressure and signals the control system if the pressure raises above or falls under the preset values.

Pressure guard

Heat exchangers are used in a cooling water system to transfer heat from one circuit to another, without any direct contact between the medias. The two main types used are tube heat exchanger and plate heat exchanger.

Heat exchanger

Cold water Hot water Plate heat exchanger

The water pump circulates cooling water, used to cool various components.

Water pump

Non-return valves are used in the cooling water system to direct the flows.

Non-return valve

A throttle is used to set a desired flow through a component or a part of the cooling water system. The throttle can be fixed or adjustable.

Throttle

The flow meter is a floating body meter used to measure small liquid flows with high accuracy.

Flow meter

10-4

TM-00075

Training Document. For training purpose only.

Technical Training Centre 1/9902

In the valve housing of the flow meter, made of transparent plastic, there is a conical passage with its narrowest part turned downwards. In the passage there is a ball affected by the flow of the water. Low water flow

High water flow

When the flow increases, the ball is lifted. Due to the fact that the passage is conical, the ball will stabilise in a specific position, and the flow can be read on the graduated scale.

Constant flow valve

In order to make the water flow to the water ring compressor independent of the pressure in the water line, there is a constant flow valve fitted just before the compressor. The constant flow valve is designed for a fixed flow.

The acting part of the valve is a soft rubber washer. In the middle of the washer there is a hole, through which the water flows. The size of the hole varies depending on the water pressure, and thus keeps the water flow through the valve constant. Low water flow

High water flow

The shape of the rubber washer at low and high water pressure, respectively in a constant flow valve.

• Low water pressure - The shape of the rubber washer makes the hole in the middle relatively large, i e water with low pressure flows through a large hole. • High water pressure - The rubber washer is deformed so the diameter of the hole is small. This will cause the rubber washer to reduce the water jet, but as the water pressure is high, the same amount of water will flow through the valve as when the pressure is low.

Technical Training Centre 1/9902

TM-00075

Training Document. For training purpose only.

10-5

The conductivity sensor monitors the electrical conductivity in the water, and signals the control system if the conductivity raises above or falls under the preset values.

Conductivity sensor

A softening filter is a container with a bed material, often consisting of small polystyrene balls. When the water gets in contact with the bed material, there is an exchange of ions. Thus the amount of hardening ions in the water is reduced and you get a soft, so called dehardened water.

Softening filter

Function The cooling water is used to cool the inductors, the guides in the final folder, the hydraulic oil and the sterile air. The diagram below describes a system that may be run both open and recirculated. Simplified cooling water system for a TBA/19

Separator

SERVICE UNIT Scrubber

Drain

B4

Z1

A

Compressor M (M7)

VALVE PANEL GUARD B7

Cirk. cold water inlet A4

B

Cold water

A1

Z3

Y32

M5

Z5 LIME SEPARATOR

FINAL FOLDER

C E

Cirk. cold water outlet Sealing unit

JAW SYSTEM

L

FM2

TS− sealing

FM3

(K50)

R

Cooler hydraulic system

D A2

Water connection B shall always be connected and valve A1 open, as there is always a need for consumption water to cool components in the service unit. For circulated cooling water, the water connections A and E shall also be connected, and the valves A2 and A4 be closed. The circulating water enters the system at connection A, is filtered in filter Z1 and flows further on to the jaw system and final folder. The pressure is monitored by the pressure guard B7. The water flow through the inductors in the jaw system can be read on flow meters FM2 and FM3. At point D the circulated cooling water turns back and flows out at outlet E. For an open cooling water system only water connection B shall be connected and the valves A1, A2 and A4 be open. The cooling water enters at connection B, is filtered in filter Z3 and flows through the lime separator Z5.

10-6

TM-00075

Training Document. For training purpose only.

Technical Training Centre 1/9902

At point C the water flow is branched and the consumption water flows on to the service unit. The remaining water flows pass the open valve A4 and into the system. The pressure is indicated on the pressure gauge M5. At branching point D the cooling water is drained through valve A2. The following is a separate closed cooling system with three separate circuits Simplified cooling water diagram for a TBA/21

Inductor Final folder

Jaw unit TS−sealing

Pull Tab

Guide cooling

Z2 B1 Water panel

O2

Q

V

C/A

Cold water

T

B4

B3

P

P P2

Heat exchanger

O1

K2

K1

P

Heat exchanger

T B2

A2 Compressor unit

M M2

Water cooling unit M1 M

U1

B5

F1

P

P1

One circuit is cooling the heat sources on the machine and it is called the water cooling unit. It is a closed circuit. The water used in this circuit must be totally deionized in order to remove all particles that could clog the cooling pipes in the transversal sealing inductors. Approximately 10% of the total flow is circulated through a total deionizing filter C/A. The second circuit is called compressor unit. It is a closed circuit and it is actually the cooler in the machine. In this system, which is identical to a refrigerator, gas is used as media. The third circuit is an open circuit, meaning that the water is drained off after being used to cool the compressor unit. When the water cooling unit is filled with water, valve V is open and the water flows through the deionizing filter, C/A. The temperature of the water in this circuit should be 12 ˚C. This is monitored by sensor B2 after the heat exchanger K2. To maintain that temperature, the compressor unit takes up the heat energy needed from the water cooling unit in the heat exchanger K2 (evaporator) in which the gas will be evaporated. This energy will then be transferred by the gas to another heat exchanger K1 (condenser), where the energy will be transferred to the water in the open circuit. The gas will be condensed after the condenser.

Technical Training Centre 1/9902

TM-00075

Training Document. For training purpose only.

10-7

Symbols The table below contains the symbols that normally are used in Tetra Pak cooling water system diagrams.

Symbol

Meaning

Accumulator

C/A

Deionizing filter

Non-return valve

Electrically controlled valve

Manual valve

Filter

Throttle, adjustable

Constant flow valve

Cooler

Water pump

M

Motor

Water tank

10-8

TM-00075

Training Document. For training purpose only.

Technical Training Centre 1/9902

Symbol

Meaning

Heat exchanger

Cooling coil

Deaerator

Flow meter

Pressure gauge

Q

Conductivity sensor

T

Temperature sensor

P

Pressure guard

Pressure regulator

Technical Training Centre 1/9902

TM-00075

Training Document. For training purpose only.

10-9

10-10

TM-00075

Training Document. For training purpose only.

Technical Training Centre 1/9902

6 Tube forming

Technical Training Centre

Packaging material web

Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/21 HS

1/9905

OH 834

Constant web tension Technical Training Centre Lund, Sweden

Increase motor speed

Decrease motor speed

Machine type

TBA/22 1/9909

Issue

OH 835

PLC

Compressed air

Motor Drive Control Motor, Driven roller

M

PLC

Motor Drive Control

M

7 Sterile system components

Technical Training Centre

Technical Training Centre Lund, Sweden

Aseptic food processing

Machine type

Sterilized packaging material

Sterile surrounding 1/9501

Issue

Commercially sterile food

Aseptic transfer

OH 525

Aseptic packages

High and Low Acid Foods HIGH ACID

LOW ACID

No Growth of Pathogenic No Spore Germination No Public Health Risk Commercial St erility Achieved by Pasteurisation

Growth of Pathogenic Spore Germination Public Health Risk Commercial Sterility Achieved by Sterilsation/UHT treatment

Fruit Juices Yoghurt Tomato Products Sauces Soups Vegetables Milk Meat Egg Products pH 2

3

4 4.6 5

6

7

8

9

97 0830 SL 14.009 Tetra Brik Packaging Systems

Sterile system overview Technical Training Centre Lund, Sweden

Air Peroxide Aseptic chamber

Product

Machine type

Water

TBA/21 TBA/22

Packaging material

1/0001

Issue

Peroxide bath

OH 905

Compressor

Peroxide tank Tight tube Air superheater

Sterile system TBA/22 Technical Training Centre Lund, Sweden

Pause Air Hot air Pre−heated air alt. cooled air Steam Product

TBA/22

Machine type

Water Peroxide Compressed air

3/0003

Issue

OH 812:5

Sterile system

1 Compressor

35 Peroxide pump

2 Water separator

36 Peroxide tank

3 Air superheater

37 Valve − refilling peroxide

4 Heat exchanger

38 Peroxide container

5 Heat exchanger valve

39 Safety cap

6 Spray nozzle

40 Diluting tank

7 Preheating valve

44 Filter − spray tank

14 Sealing water valve

45 Spray tank

15 Constant flow valve 16 Scrubber

47 Pressure switch presterilization

23 Reference point valve

48 Air superheater temp.

24 Sterilization bath

49 Presterilization temp.

25 Valve − top filling peroxide bath

53 Level sensor − water bath

26 Water bath heaters

54 Level sensor − peroxide bath

27 Circulation pump − hot water

55 Water bath temp.

28 Safety valve

56 Peroxide bath temp.

31 Pressure expansion tank

57 Level sensors − peroxide tank

32 Valve − filling peroxide bath

58 Peroxide tank temp.

33 Valve − draining peroxide bath

A Valve peroxide bath cooling

34 Filter Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/21

1/9802

OH 768

Scrubber

Water Air

Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Machine type

Issue

TBA/21

1/9410

OH 503

Principle of constant flow valve Rubber ring

Constant flow rate of water

Water with fluctuating pressure

Water at low pressure

Constant flow rate

Water at high pressure

Technical Training Centre Lund, Sweden

Constant flow rate

Machine type

Issue

1/9904

OH 819

Water separator

Water Air

Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Machine type

Issue

TBA/21

1/9410

OH 504

Heat exchanger valve 0

0

By pass

By pass

0.0

Status cycle 1.0 Min. cooling

Workbook TBA/21 Heat exchange vlve Issue 970604

1

0

Min. cooling

1

1

Max. cooling

1.1 Max. cooling

C A

B

AP−Valve 440630−020V (Aseptic Product Valve)

TETRA PAK

Technical Training Centre Lund, Sweden

Machine type

Issue

1/9208

OH 453:1

Technical Training Centre Lund, Sweden

Regulating valve

TBA/19 TB/19, TBA/21

Machine type

4/9810

Issue

Product Compressed air

OH 497

Non−conductive part of the regulator Conductive layer in the diaphragm Non−conductive layer in the diaphragm Non−conductive coating

Peroxide bath

Peroxide Water

Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/21

1/9802

OH 769

Level relay Peroxide spray quantity Cooling

L 52

A1

L 50 A2

B1 B3 B2 15

16

18 To PLC INPUT L 11 (24 VDC)

RM3 LA1 A1 15

Function 1

Time value s

25

A2 16 18 26 28

500k

R−sector 25 30 35

R−value

(x0.1) (x10)

R U

Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/22

1/9909

OH 882:1

Level relay Peroxide spray quantity Filling tank

L 52

A1

L 50 A2

B1 B3 B2 15

16

18 To PLC INPUT L 11 (24 VDC)

RM3 LA1 A1 15

Function 1

Time value s

25

A2 16 18 26 28

500k

R−sector 25 30 35

R−value

(x0.1) (x10)

R U

Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/22

1/9909

OH 882:2

Level relay Peroxide spray quantity Spraying

L 52

A1

L 50 A2

B1 B3 B2 15

16

18 To PLC INPUT L 11 (24 VDC)

RM3 LA1 A1 15

Function 1

Time value s

25

A2 16 18 26 28

500k

R−sector 25 30 35

R−value

(x0.1) (x10)

R U

Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/22

1/9909

OH 882:3

Tetra Brik TBA/21 Level control in peroxide tank A306

A307

A1

A1

A2

A2

B1

B2

B3 15

16

B1

18

A121.00

B2

A1

A2

B3 15

16

18

L11

A121.02

Level sonds 1 .Maximum level when bath is empty and when service switch is on. 2. Maximum level when bath is filled 3. Start filling when bath is filled 4. Supervising if the level is to high. Stops filling. ALARM

1 Y1210

4 2 3

Tetra Brik TBA/21 Level control in Peroxide tank Issue 980121

18

L11

L11

B2

16

A121.01

A308

B1

B3 15

Peroxide filling station Peroxide Compressed air Vacuum

Technical Training Centre Lund, Sweden

Machine type

Issue

Tetra Brik Aseptic

1/9609

OH 594

8 Sterile system

Technical Training Centre

Ladder diagram TBA/22 TPOP 10:Production. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Design OK. Packages made from material that was in the H2O2 bath before inching started are ejected. After 2 sec of inching A valve opens at filling sector and design control starts. After 10 sec motor start and self holding. After 9.9 sec must H2O2 temp. and level be right. After 3 sec starts peroxide bath filling. After 1 sec synchronization FFU-JUM. Sound alarm for 10 sec.

9:Motor start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right temp on flap sealing element. Right temp in H2O2 tank. All doors closed If no start attempt within 90 sec steps down to 7.

8:Flap heaters on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product at A-valve.

7:Signals to Sterilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All. doors closed. Right temp in H2O2 tank. Drying time ended 15 min. Sterile inching is possible. After 14 min B-valve closes. Sterile air pressure reads on both separator and aseptic chamber. Preheating valve open.

6:Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spraying time ended 90 sec. .................. 88 sec Reference point valve open. Preheating valve closed.

. . . . . . Pause. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 sec Alarm limits: fast -10.5 sec slow-21 sec. After 18 sec B-valve closing.

. . . . . . Spray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 sec Reference point valve closes. After 8 sec: Preheat valve opens, check reg. valve pos. Filling for 9 sec. (50 cc). Checks level after 8.5 sec.

5:Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre.ster.temp 280 °C. All doors chamber closed. Steam temperature. When 280 °C is obtained, spraying starts automatically after 10 sec. Heat exhanger in bypass. Preheating valve in bypass until 280°C is obtained. However temporary opens to keep A.C. temp at 39-40 °C. B-valve and reg. valve opens. Circulation on H2O2. Heat and circulation in water bath. Air superheater at 360 °C. Compressor on, reads on separator pressure switch.

4:Heat sterilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water separator low level. Cleaning pipes disconnect. All doors closed. Inching packaging material for 40 sec.

3:Tube sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling. water pressure and cleanness. All doors closed. Power to motors to help when threading packaging material. Strip applicator on. Possible to slow inch without LS, draining 3 min.

2:Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power. Air pressure. Water pressure. All doors closed.

1:Step 0

Technical Training Centre 1/9610

TM-00106

Training Document. For training purpose only.

1

Ladder diagram TBA/21 TPOP 10:Production. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9:Motor start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8:Flap heaters on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7:Signals to Sterilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6:Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................. 88 sec

. . . . . . Pause. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 sec

. . . . . . Spray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 sec

5:Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4:Heat sterilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3:Tube sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2:Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:Step 0

Technical Training Centre 1/9610

TM-00106

Training Document. For training purpose only.

2

Ladder diagram TBA/21 TPOP

Technical Training Centre 1/9610

14:2

External cleaning

14:1

CIP cleaning

13

Doors, Aseptic chamber

12

Venting Aseptic chamber

11

Production ended

TM-00106

Training Document. For training purpose only.

3

Technical Training Centre Lund, Sweden

Sequence diagram Heat sterilization Pos 4

Machine type

0

3

6

9

12

15

18

21

24

27

30

Pos 5

sec

Pos 6−11

TBA/22

R 1000 Seal water Y 1104 Compressor K 020 (25) Air pressure separator B 1102

Alarm to pos 3

Alarm to pos 1

1/9905

Issue

Air super heater K 028 280 C Temp. mon. Heat. Ster B 1106

OH 836:1

Regulating valve C 1314 B−valve Y 1323

10 sec delay

Sequence diagram Technical Training Centre Lund, Sweden

Spraying 0

10

20

30

40

50

60

70

80

90 sec Drying

R 1006

(88)

Filling spray tank Y 1230

Machine type

Level spray tank B 1230:1

ing Fill

(8.5) E mp tyin g

(21)

(10.5)

TBA/22

Level sensor spray tank A 300:18

Alarm: Drying and jump to pos 1 Alarm: Spray fault

Alarm to pos 3

Level sensor spray tank B 1230:2 (18)

B−valve

Open

Y 1323 > 1.5 sec Alarm to pos 1

Check B−valve pos B 1302 (88)

1/9905

Issue

Preheating valve Y 1114:2

Open

Pause (88)

Preheating valve Y 1114:4

Open

Pause

> 1.5 sec Alarm to pos 1

Check preheating valve pos B 1111

> 1.5 sec Alarm to pos 1

> 1.5 sec Alarm to pos 1

OH 836:2

(68)

Spraying Y 1231 (10) (8.5)

Reference point Y 1112 Check regul. valve pos B 1321 Pendelum roller Y 1501

Closed

Technical Training Centre Lund, Sweden

Sequence diagram Drying

Pos 7

Machine type

Pos 6

0

2

4

6

8

10

12

Pos 8

14 15 Signal exhange

min

TBA/22

Drying timer R 1015

B−valve Y 1323

Drying ready M 813

1/9905

Issue

Regulating valve C 1314

Check reg. valve pos B 1321 (5 sec)

OH 836:3

Aseptic chamber pressure B 1103

Alarm to pos 1 Check temp 60 sec Alarm to pos 7

FFU Heating elements K 033 Max 90 sec

Sequence diagram

1

2

3

4

6

7

st er iliz er he at in M g ot on or st ar t Pr od uc tio n Pr od uc tio n Ve en d nt in g AC do or s op Cl en ea ed ni ng Fl ap

to

5

Si gn al

Dr yin g

Machine position

Pr ep ar at io n Tu be se al in He g at st er iliz Sp at io ra n y

Technical Training Centre Lund, Sweden

Peroxide system

9

8

10

11

12

13

14

Machine type

Circulation cooling water K 22

TBA/22

Water pump (heat perox.) K1 Heating water 1 K 26 Heating water 2 K 27

Filling peroxide tank Y 1210

m in 6

6

m in

Maximum level when bath is filled > 1 min

Tank filled 10 s

20 sec

1/9905

Issue

Peroxide container empty

20 s

Peroxide container empty = Alarm

Alarm: Low level peroxide tank 15 sec

Peroxide pump K2

Stop every time the bath is emptied 10 sec 20 sec

Filling spray tank Y 1230

OH 836:4

5 sec

10 sec

20 sec 9 sec

68 sec

Spraying Y 1231 Check bath level 9.9 sec

Filling peroxide bath Y 1220 Draining peroxide bath Y 1221

< 3.0 sec No level > 9.9 sec Level

Closed 3 sec 11 sec

20 sec

Closed Sterile inching

20 sec

Technical Training Centre Lund, Sweden

Sequence diagram Heat exchanger Heat sterilization Pos 4

Spraying

Drying

Pos 5

Machine type

Pos 6 SP2 = 107 C

Pos 7 SP1 = 95 C

t > 40

Top A.C.

t < 107

B 1109 t > 39

TBA/22

t > 280

Temp. monitor 280 C 0 sec

88 sec Pause

Y 1114:2:4 Preheating valve (inverted)

27 sec

8 sec Open

10 sec

90 sec Regulating position 5 min

Y 1111

14 min

Closed

0

0

1

1

0

1

1

1 0.5 sec Flip heat exchanger

OH 836:5

Y 1107 step 1 Heat exchangers valve Y 1108 step 2

Open

Max Cool

Y 1323

Min Cool

B−valve

Bypas

1/9905

Issue

18 sec

Sterile system TBA/21 HS

49 23 21

20 Aseptic chamber 21 Tunnel 22 Pendulum roller

Technical Training Centre Lund, Sweden

1 Compressor 2 Water separator 3 Air superheater

29 Expansion tank 30 Valve, filling peroxide bath 31 Valve, draining peroxide bath

57

22

TBA/21 HS

Machine type

4 Heat exchanger 5 Heat exchanger valve 6 Spray nozzle 7 Preheating valve 8 Regulating valve 9 Product valve (A) 10 Sterile air valve (B) 11 Steam barrier valve (C) 12 Steam filter 13 CIP valves 14 Steam trap 15 Sealing water valve 16 Constant flow valve 17 Scrubber 18 Filling pipe 19 Product level probe

23 Squee−gee rollers 24 Reference point valve 25 Sterilization bath 26 Water bath heaters 27 Circulation pump, hot water 28 Safety valve

11

43 41

24

12 51 14

40 52

48

39

50

14

20

42

13 25

9

28

10 27

6

26

8 47 7

53 54

29

19 18 45 30

2/9908

Issue

15

16

31

5

32 17

55

56

33

34

2

35

OH 812:1

4

1

44

36

37

38 3 46

32 Filter 33 Peroxide pump 34 Peroxide tank

38 Diluting tank 35 Valve, refilling peroxide 39 Spray valve 36 Peroxide container 37 Safety cap

41 Filter 42 Filter 43 Spray tank

44 Level sensor, water separator 45 Pressure switch

46 Air superheater temp. 47 Presterilization temp. 50 Pressure switch 48 Steam temp. 51 Level sensor, 49 Aseptic chamber temp. water bath

52 Level sensor, 55 Level sensors, peroxide bath peroxide tank 53 Water bath temp. 56 Peroxide tank temp. 54 Peroxide bath temp. 57 Level sensors, spray tank

Sterile system TBA/21 HS Technical Training Centre Lund, Sweden

Drying before tube sealing Air Hot air Pre−heated air alt. cooled air Steam Product

TBA/21 HS

Machine type

Water Peroxide Compressed air

2/9908

Issue

OH 812:2

Sterile system TBA/21 HS Technical Training Centre Lund, Sweden

Heat sterilisation Air Hot air Pre−heated air alt. cooled air Steam Product

TBA/21 HS

Machine type

Water Peroxide Compressed air

2/9908

Issue

OH 812:3

Sterile system TBA/21 HS Technical Training Centre Lund, Sweden

Spraying Air Hot air Pre−heated air alt. cooled air Steam Product

TBA/21 HS

Machine type

Water Peroxide Compressed air

Closes after 18 seconds

2/9908

Issue

OH 812:4

Sterile system TBA/21 HS Technical Training Centre Lund, Sweden

Pause Air Hot air Pre−heated air alt. cooled air Steam Product

TBA/21 HS

Machine type

Water Peroxide Compressed air

2/9908

Issue

OH 812:5

Sterile system TBA/21 HS Technical Training Centre Lund, Sweden

Drying Air Hot air Pre−heated air alt. cooled air Steam Product

TBA/21 HS

Machine type

Water Peroxide Compressed air

Closes after 14 minutes

2/9908

Issue

OH 812:6

Sterile system TBA/21 HS Technical Training Centre Lund, Sweden

Production Air Hot air Pre−heated air alt. cooled air Steam Product

TBA/21 HS

Machine type

Water Peroxide Compressed air

2/9908

Issue

OH 812:7

Sterile system TBA/21 HS Technical Training Centre Lund, Sweden

Stop Air Hot air Pre−heated air alt. cooled air Steam Product

TBA/21 HS

Machine type

Water Peroxide Compressed air

Open (no by− pass) 0−5 min

2/9908

Issue

OH 812:8

Sterile system TBA/21 HS Technical Training Centre Lund, Sweden

Ventilation Air Hot air Pre−heated air alt. cooled air Steam Product

TBA/21 HS

Machine type

Water Peroxide Compressed air

2/9908

Issue

OH 812:9

Sterile system TBA/21 HS Technical Training Centre Lund, Sweden

1 Compressor 2 Water separator 3 Air superheater

TBA/21 HS

Machine type

4 Heat exchanger 5 Heat exchanger valve 6 Spray nozzle 7 Preheating valve 8 Regulating valve 9 Product valve (A) 10 Sterile air valve (B) 11 Steam barrier valve (C) 12 Steam filter 13 CIP valves 14 Steam trap 15 Sealing water valve 16 Constant flow valve 17 Scrubber 18 Filling pipe 19 Product level probe

20 Aseptic chamber 21 Tunnel 22 Pendulum roller

29 Expansion tank 30 Valve, filling peroxide bath 31 Valve, draining peroxide bath

23 Squee−gee rollers 24 Reference point valve 25 Sterilization bath 26 Water bath heaters 27 Circulation pump, hot water 28 Safety valve

2/9908

Issue

OH 812:10 32 Filter 33 Peroxide pump 34 Peroxide tank

38 Diluting tank 35 Valve, refilling peroxide 39 Spray valve 36 Peroxide container 37 Safety cap

41 Filter 42 Filter 43 Spray tank

44 Level sensor, water separator 45 Pressure switch

46 Air superheater temp. 47 Presterilization temp. 50 Pressure switch 48 Steam temp. 51 Level sensor, 49 Aseptic chamber temp. water bath

52 Level sensor, 55 Level sensors, peroxide bath peroxide tank 53 Water bath temp. 56 Peroxide tank temp. 54 Peroxide bath temp. 57 Level sensors, spray tank

Peroxide Water Compressed air Air Hot air

Peroxide system TBA/21 HS Heat sterilisation Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/21 HS

1/9907

OH 860: 1

Peroxide Water Compressed air Air Pre−heated air alt. cooled air

Peroxide system TBA/21 HS Filling spray tank Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/21 HS

1/9907

OH 860: 2

Peroxide Water Compressed air Air Pre−heated air alt. cooled air

Peroxide system TBA/21 HS Spraying

Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/21 HS

1/9907

OH 860: 3

Peroxide Water Compressed air Air Pre−heated air alt. cooled air

Peroxide system TBA/21 HS Alarm spray system Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/21 HS

1/9907

OH 860: 4

Peroxide Water Compressed air Air Pre−heated air alt. cooled air

Peroxide system TBA/21 HS Filling peroxide bath Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/21 HS

1/9907

OH 860: 5

Peroxide Water Compressed air Air Pre−heated air alt. cooled air

Peroxide system TBA/21 HS Draining peroxide bath Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/21 HS

1/9907

OH 860: 6

Peroxide handling TBA/21

040V

Emptying diluting tank

Emptying peroxide tank

Peroxide Water Compressed air Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/21 040V

1/9706

OH 746:1

Peroxide handling TBA/21

040V

Filling new peroxide

Diluting peroxide during compressor run

Peroxide Water Compressed air Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/21 040V

1/9706

OH 746:2

9 Drive and jaw system

Technical Training Centre

TBA/21 HS Jaw system Overview

Technical Training Centre 1/9610

TM-00126

Training Document. For training purpose only.

1

Forming, overview

The packages are formed at the top of the jaw system. The packages are formed by the jaws (grey) and the volume flaps (green).

Technical Training Centre 1/9610

TM-00126

Training Document. For training purpose only.

2

Forming, pressureside

After the forming, the jaws must be closed while the seals cool.

Technical Training Centre 1/9610

TM-00126

Training Document. For training purpose only.

3

Cut

The cut is done by knifes synchronised with the jaw system.

Technical Training Centre 1/9610

TM-00126

Training Document. For training purpose only.

4

Folding flaps, overview

The folding flaps (blue) perform the design correction for the packages.

Technical Training Centre 1/9610

TM-00126

Training Document. For training purpose only.

5

Folding flaps, function

The folding flap stroke is set by a cam (yellow) which is controlled by a servomotor. The servomotor affects the cam via a belt (green) and two eccentric shafts (blue, grey).

Technical Training Centre 1/9610

TM-00126

Training Document. For training purpose only.

6

Sealing pulse

The sealing pulse (red) arrives immediately after the jaws are closed.

Technical Training Centre 1/9610

TM-00126

Training Document. For training purpose only.

7

Jaw pressure

The jaw pressure comes up from two springs (violet) in each pressure jaw.

Technical Training Centre 1/9610

TM-00126

Training Document. For training purpose only.

8

Volume adjustment, overview

The position of a cam (yellow) afftects the volume flaps to close more or less. The cam position set the volume of the packages.

Technical Training Centre 1/9610

TM-00126

Training Document. For training purpose only.

9

Volume adjustment, function

The cam position is controlled by a stepper motor via gears (grey) and and eccentric shafts (violet).

Technical Training Centre 1/9610

TM-00126

Training Document. For training purpose only.

10

K 24

3x400 V AC

Technical Training Centre Lund, Sweden

Emergency stops safety relay

K 25 PLC

Door guards safety relay

Rectifier

Crank guard

Machine type

Hardware enable 570 V DC

Safety relay

TBA/22

(Positioning Greasing) (Start greasing cycle) Motor low speed Motor high speed Software enable

K4

DMC

Resolver

1/9905

Issue

Out ready Position error Home position Motor running Motor retardation

Jaw unit

Motor

Angle encoder

Zero jaw

Angle encoder (bit 7)

OH 837

Synchronize internal clocks

1

To FFU DMC

2

Control of Main motor

Troubleshot DMC DMC Alarm TPOP: DMC Alarm

No

Hardware disabled ? Yes

Check 24V Pin 6*

Yes

No

A603 safetyrelay OK ?***

Yes

Check 24V Pin 36*

No

Yes

Check connection L11**

No Check connection Pin 35 & 36

Reset Safetyrelay A603

Restart

Hardwaware disabled

Restart

No

Yes

Hardware disabled

* There must be 0V DC on pin 7A05 and 7B24

Yes Replace DMC

No

** L11 = 24V DC Production

*** LED "Out" must be ON

Continue to page 2 Restart: Switch fuse F19 Off and On.

1

Troubleshot DMC

Continue from page 1 Internal hardware fault No

Yes

Linesupply L1, L2, L3 OK ?

Yes

Powersupply output 570Vdc OK ?

Yes

No No

F19, K 24, K25, Z3 OK ?

Continue to page 3

Yes

Replace

Replace DMC

NO

Replace defect parts

Restart

Internal hardware fault ?

Yes

Production

Restart: Switch fuse F19 Off and On.

2

Troubleshot DMC Continue from page 2

Position error exceeded

Yes Restart

No

Continue to page 4 No

Position error exceeded ?

Yes

Is it easy to turn mechanical parts ?

Replace mechanical parts

No

Yes Replace n DMC

Restart

No

Position error exceeded?

Yes Replace Servo motor

Production Restart: Switch fuse F19 Off and On.

3

Troubleshot DMC

Continue from page 3 Internal system fault ?

Yes

Yes Restart

Internal system fault ?

Yes

No No

Production

Replace DMC

Continue to page 5 Restart

Production

Restart: Switch fuse F19 Off and On.

4

Troubleshot DMC Continue from page 4

Temperature fault ?

Yes

Motor hot ?

No

Yes

Let the motor cool down and check for mechanical friction

No

Continue to page 6

Bridge PINS 4 & 5 (PTC) in motor and check PTC*

Restart

No

Temperature fault

Yes Bridge pins 4&5 on DMC

Repair or replace cable

PTC No broken. Replace servo motor

Temperature fault

Yes Replace DMC

Production

* The resistance of the PTC should be 84 Ohm in room temperature.

Restart: Switch fuse F19 Off and On.

5

Troubleshot DMC Continue from page 5

Software disabled

Yes

Check 24V Pin 15*

No

No

Check K120/K105 O37.10

Yes

No Check output module

Check connection to DMC

Yes

Function OK ? No

Replace DMC

Production

Continue to page 7

* Use 7A05 or 7B24 (0V DC) Restart: Switch fuse F19 Off and On.

6

Troubleshot DMC Continue from page 6

Yes Torque limit exceeded ?

Mechanical friction * ?

Yes

No No

Replace DMC (or Servo)

Replace mechanical parts

Continue to page 8 Restart

Production

* The torque can be measured by connecting an oscilloscope to the analogue output on the DMC. Set R120=10.

7B21 => 0Vdc 7B22 => Torque(1Volt = 6,85 Nm) 7B23 => Positionserror (1 volt = 102 Steps) Restart: Switch fuse F19 Off and On.

7

Troubleshot DMC Continue from page 7

Cyclical timer interrupt* ? No

Yes

Check Hard- and Software signals.

Restart

Continue to page 9

Production

* As long as the Hard- und Software signals are low the Cyclical timer interrupt alarm will be shown on DMC! Restart: Switch fuse F19 Off and On.

8

Troubleshot DMC Continue from page 8

Volume not exsist.

Pin 31 on DMC 24V & I11.15 ="1" *?

Yes

No

No

Ja

Datatransfer OK? (O40.05,O40.12)**

No

Continue to page 10 Ja Repair wires ****

No

Check PLC program***

Volume value in PLC Register OK ? ***** Yes

Replace DMC

Restart

*Data request from DMC ** Description of datatransfer in Functional Description MM21MC ***Check position of sensor for volumedetection compared to knob on maincam. **** 7A07 (Data), 7A08 (Data clock), 7A10 (Data enable) 7B31 (Data request) ***** Actual volume shown on TPOP.

Restart: Switch fuse F19 Off and On.

9

Troubleshot DMC Continue from page 9

Resolverfault ?

Restart

No

Resolverfault Yes Check connection Motor/DMC*

Continue to page 11

Restart

No

Resolverfault Ja Replace DMC

Restart

No

Resolverfault Ja Replace Servomotor

Production

* Cable and connections

Restart: Switch fuse F19 Off and On.

10

Troubleshot DMC Continue from page 10

Yes Homeposition fault_

No

Homepos. Sensor and cables OK? PLC I16.00

Yes

Continue to page 12

Homeposition fault

No Replace DMC

Restart

Production

Restart: Switch fuse F19 Off and On.

11

Troubleshot DMC Continue from page 11

Yes Shunt (Bleeder) fault *? No

Continue to page 13

Check for friction in gearbox of FFU, maincam or belts.

Shunt (Bleeder) fault *?

Yes

No Replace DMC

Restart

Production

* The LED 2 could flash but not more than 2-3 times during 10 seconds.

Restart: Switch fuse F19 Off and On.

12

Troubleshot DMC Continue from page 12 Nein

Fault FFU Synchron.

Yes

No

Angle encoder OK ?*

No

Yes

Replace angle encoder

End Angle encoder value in PLC OK ?

No

Replace Encoder module

Yes

Datatransfer OK to DMC? ** Yes

No

Check datatransfer**

Restart

Production

* Crank jaw system slowly and make sure that the instrument is showing all values. ** See "Volumedata fault"

Restart: Switch fuse F19 Off and On

13

Electric drive systems

S N

S N

Training Document This Training Document is intended for Training purpose only, and must not be used for other purpose. The Training Document is not replacing any instructions or procedures (e.g. OM, MM, TeM, IM, SPC) intended for specific equipment, and must not be used as such. Note! For safe and proper procedures, refer to the equipment specific documentation.

Technical Training Centre

Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Frequency-controlled asynchronous motor . . . . . . . . . . . . . . . . . . . . . . . . 5 The squirrel-cage asynchronous motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Frequency converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fault-finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Drive systems with DC motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 The DC motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DC Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Fault-finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Stepping motor systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 The stepping motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Fault-finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Servosystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 The servomotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Control unit, drive electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fault-finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Angle encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Temperature (safety) switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Electric drive systems Introduction By electric drive systems we mean various types of electric motors which, together with some form of electronic controls, drive or perform mechanical movements.

Control unit

Motor

Mechanics

One type of electric drive system is a variable speed motor, which drives a main shaft. On this shaft, cams, belt pulleys, gears, sprockets, etc may be fitted, which in their turn provide the motive power for mechanical movements. What, in this case, is considered the electric drive system are the motor and the speed control device.

Speed control

Motor

This textbook describes such electric drive systems as are employed in the Tetra Pak packaging machines and process equipment: • Frequency-controlled asynchronous motor. • DC motor with variable speed control. • Stepping motor systems. • Servomotor systems. All drive systems are described in general terms; in other words, their function as employed in a specific machine is not being explained.

Technical Training Centre 1/9706

Training Document. For training purpose only.

3

Overview In the following, the various drive systems are described briefly and summarily. Later on, each system is presented in detail in separate chapters. Frequency-controlled asynchronous motors are very common and cheap drive devices. The motor is an asynchronous squirrel-cage motor, whose speed is controlled by means of a frequency converter. The rotary speed depends on the frequency. Such drive systems are often used to drive a main shaft which, via cams, gears, etc, drives a number of mechanical movements.

Frequency-controlled asynchronous motor

Drive systems with DC motors can be used for a great variety of tasks, from simple speed control to advanced positioning. For instance, they are often used when the speed has to be varied over a wide range. A further advantage of the DC motor is that its speed is only slightly affected by load variations.

Drive system with DC motor

Stepping motors are mostly used in positioning, with small loads. It can be regarded as a digital motor which converts electric pulses into mechanical motion. Each pulse equals a defined angle of rotation by the motor shaft - one step.

Stepping motor system

Servosystems are capable of converting any mathematical function into a mechanical movement. It may be cam functions (electronic cams), speed functions, torque functions, etc.

Servosystem

General As previously mentioned, electric drive systems consist of a motor and a control unit. The control unit may be anything from a simple speed controller to highly advance control electronics, which may make the motor perform virtually any function. The motors may have either open or feed-back control. An induction motor usually has open control, while a servosystem in itself constitutes a system feed-back control. In an open control system, there is no feed-back between the motor or load and the control unit. This means that if any of the factors determining the function of the system changes, for instance voltage, amperage, or position, the function of the system will also change. There is no automatic correction or compensation; if correction is required, it has to be made manually. Input values

Control unit

Motor

Function

In a feed-back system, the control unit monitors the function of the motor or load. If the motor function deviates from the predetermined function, the control system will automatically correct this condition. Input values

Control unit

Motor

Open control system

Feed-back control system

Function

Feed-back

4

Training Document. For training purpose only.

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Frequency-controlled asynchronous motor Frequency-controlled asychronous (induction) motors are mostly used for simple drive functions, without feed-back from the motor or load to the control unit. Such a drive can in principle be used to regulate the speed from standstill upwards. The motor is a squirrel-cage asynchronous motor, and the control unit a frequency converter.

The squirrel-cage asynchronous motor The squirrel-cage asynchronous motor is the absolutely most commonly used AC motor. There are many reasons for this; here follow the most important: • it is cheap, • it is very reliable, • it is a standard product complying with the IEC standard. IEC motor

P D

N H

M E

C

B

A

Amongst other things, IEC standardization means that the outside dimensions of the motor, its mounting holes, and its shaft dimensions are standardized for each motor power. The diagram shows those dimensions which are subject to standardization. Thanks to this standard, the user is not tied to a certain manufacturer or supplier. A plentiful supply of standard motors of different makes is always available.

Construction

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The rotor in the asynchronous motor has a cagelike winding (hence the term 'squirrel-cage'). It is not wired to any power source, which means that there is no need for sliding contacts or brushes for its power supply. Besides, the rings which short-circuit the conductors are often shaped like fan impeller vanes. Altogether, this makes this type of motor extremely simple and robust: no windings, no sliding contacts, no separate fan in the rotor.

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5

In the stator are the field windings. They are designed to generate a rotating magnetic field when connected to a three-phase alternating voltage. Stator

Rotor

Usually, three-phase motors can be reconnected for two alternative supply voltages. The most common way is to either D-connect (delta connect) or Y-connect (star connect) the three phases of the field winding. If the marker plate on a three-phase motor specifies voltage values for both D and Y-connection, the motor may be run on, for instance, either 3×230V AC or 3×400V AC. The diagram below shows how to place the connection links for 3×230V and 3×400V. In both cases, the potential over the windings will be 230V.

W2 U1

W2

U2 V1

U2

V2 W1

V2

U1

W2

U2 V1

U2

V2 W1

V2

U1

V1

W1

U1

V1

W1

L1

L2

L3

L1

L2

L3

D-connection, 3×230V

6

W2

Y-connection, 3×400V

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Function

When the field windings are connected to a three-phase alternating voltage, a rotating (1) magnetic field (2) is generated through the motor. The magnetic field induces currents in the conductors (3) of the cage winding; in this way, forces (4) are created, which cause the rotor to rotate with the magnetic field.

B

A 3

Slip

S

4

S

N 1

N

2

Current entering plane Current exiting plane

The speed (rpm) of the asynchronous motor is determined by the frequency of the voltage supplied to the motor, calculated in accordance with this formula: 2 × frequency × 60 Speed = -------------------------------------------------------Number of motor poles In principle, the speed can be regulated from stand-still upwards, with certain limitations in the upper and lower sections of the speed range. The speed determined by the frequency, as per the formula above, is called the synchronous speed. The synchronous speed is the rotation speed of the magnetic field, generated in the field windings when supplied with a threephase AC voltage. The table below shows the synchronous speeds at various frequencies for motors with different number of poles. Frequency (Hz)

Number of poles

10

30

50

100

2 4 6 8

600 300 200 150

1800 900 600 450

3000 1500 1000 750

6000 3000 2000 1500

The actual, true, speed of the motor is determined not only by its synchronous speed but also by how great a load the motor is driving. This speed is called the asynchronous speed, and the difference between the synchronous and asynchronous speeds is termed slip. The slip is directly proportional to the output motor shaft power. The illustrated sequences, A and B above, demonstrate how the rotor lags behind the rotating field. In a way, this can be compared to a hydraulic coupling. Diagram A shows the motor in a random field position that may be referred to as F. Diagram B shows the motor when the field has rotated 45 degrees: F + 45 °. In diagram B, it can be seen that the rotor has not turned as far as the field, i e the rotor follows the field with a certain degree of slip. Example: a four-pole 50 Hz motor has a rated speed of 1440 rpm. Thus the slip is 60 rpm at the rated load.

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7

Although, as previously stated, the speed can be regulated from stand-still upwards, this should not be done. At 85-90 Hz, losses in the motor will, for various reasons, be so great that the torque drops to approximately one third of the rated torque. Power consumption, however, remains as high as at the rated speed. A rule-of-thumb is never to regulate the speed beyond 87 Hz. At low frequencies and unchanged load, the fan impellor fitted to the motor shaft will no longer be able to cool the motor adequately. Then the danger is considerable that the motor will overheat. As a counter-measure, a separately driven fan may be installed. Torque, Power

Power

100% Losses

50% Torque

25

50

75

Frequency (Hz)

100

Frequency converter A frequency converter converts the mains power frequency to whatever freqency is required for the motor. Usually, the mains power frequency is either 50 Hz or 60 Hz. A frequency converter consists of four main parts: • The rectifier, which is fed with an AC voltage from the mains grid, produces a DC voltage. • The intermediary circuit, in which the DC voltage is smoothed. • The inverter, which reconverts the DC voltage into an square-waved AC voltage of the frequency required for the motor. • The regulation unit, which controls and monitors the other parts.

Function

Briefly, what happens in a frequency converter can be described as follows: Rectification, smoothing, inversion (reconversion), control.

Regulation unit

Rectifier

8

Intermediary circuit

Inverter

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M

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Pulse width modulation

The predominant type of frequency converter is the PWM converter (Pulse Width Modulated). With this converter, voltage as well as frequency are regulated by controlling both the number of pulses and their energy. The reason for this is to make the virtual value of the voltage conform as closely to a sine curve as possible. Sine-shaped voltage reduces losses in the motor. In the 50 Hz and beyond range, the motor is fed with one pulse per semiperiod, alternatingly positive and negative. The virtual value of such a squared pulse equals the rated voltage of the motor, for instance 400 V.

50 Hz

The virtual value of the voltage is as follows: Input frequency --------------------------------------- × Rated voltage = Output effective value Rated frequency In the example above: 50Hz ------------- × 400V = 400V 50Hz At 25 Hz, the motor is fed with a number of pulses per semi-period, and the virtual voltage value, which drops proportionally to the reducing frequency, will be: 25Hz ------------- × 400V = 200V 50Hz 25 Hz

A PWM frequency converter thus regulates both the voltage and frequency to the motor.

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9

Fault-finding In the following, the most common faults and their causes that may appear in asynchronous motors are described. When fault-finding in electric drive systems, you should use a type TRMS measuring instrument. TRMS measuring instruments give correct values for all types of signals.

TRMS stands for True Root Mean Square.

Fault; The motor hums abnormally loudly while running, or hums without rotating: • Loss of voltage on one phase, possibly due to a blown or tripped fuse. Note that the overcurrent protection of small motors may not always trip when this kind of fault occurs. Fault: The motor does not start, or stops in mid-run: • The overcurrent protection has tripped. Fault: The motor runs hot: • Worn bearings. • One or several field windings have short-circuited. • Excessive load. Fault: The motor vibrates: • Unbalanced load, for instance a pulley, sprocket, or coupling. Fault: The motor will not start: • No voltage to the control unit. • Fuse in or to the control unit blown or tripped. • External starting conditions not met. • No setpoint provided by the regulating unit. • Short-circuited field windings.

10

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Drive systems with DC motors Drive systems with DC motors can be used for everything from simple speed regulation without feed-back to advanced positioning. Such a system can be used to drive and brake the motor in either direction with precisely controlled acceleration and deceleration. In this book, only simple speed-controlled systems are described. The motor used is either a separately or permanently magnetized DC motor, and the control unit a DC converter.

The DC motor For speed control with DC motors, usually a separately magnetized motor is used. Permanently magnetized motors are more suitable for positioning duties. The principal advantage of separately magnetized motors is their speed stability, i e the speed is only slightly affected by load variations. Besides, the speed can be varied within a wide range. These qualities make the separately magnetized motor ideal for speed regulation.

Construction

The component parts of the DC motor are: • The stator, which carries the field windings. • The rotor, which carries the rotor windings. • The commutator with carbon brushes. In permanently magnetized DC motors, permanent magnets have been substituted for the field windings. Stator

Rotor Commutator

Carbon brushes

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11

The principle of the function of the DC motor is illustrated below.

Function

2 3 1

S

N Current entering plane Current exiting plane

A conductor (1) carrying a current, which is positioned in a magnetic field (2), is affected by a force (3). The magnitude of the force is determined by the strength of the field and the amperage in the conductor. The field is generated by the field windings in the stator, and the current in the conductors is governed by the voltage of the power supplied. The speed of a DC motor is determined by the magnetic field strength and the rotor voltage. In order to vary the speed, either the voltage to the field windings or to the rotor windings can be altered. Most common is to control the speed by regulating the rotor voltage. In principle, this can be done within the entire motor speed range while still retaining the same torque. In supplying direct current, constant magnetic and current flows are created through the motor. In order to achieve continuous rotation, the windings must be reconnected (pole reversing) as the rotor revolves. Such reconnection is termed commutation and may be either mechanical or electronic.

Commutation

The diagrams below show how a loop or winding in a DC motor is commutated mechanically in order to make it rotate continuously.

N

S

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N

S Miscellaneous

DC motors should always be connected with cables which are screened and whose conductors (strands) are twisted. The screen is to be grounded at each end. Screening is done in order to prevent electromagnetic interference (noise) to enter or emerge from the system.

DC Converter In order to regulate the voltage, and thus the speed of the DC motor, a DC converter is used. It consists of three main parts: • The rectifier, which turns the supply voltage into direct current. • The power unit, which feeds the motor with direct current. • The regulating unit, which controls and monitors the other parts. Field Power unit

Rectifier

Rotor

Regulating unit

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Fault-finding In the following, the most common faults that may appear in DC motors and their possible causes are described. When fault-finding in electric drive systems, you should use a type TRMS measuring instrument. TRMS measuring instruments give correct values for all types of signals.

TRMS stands for True Root Mean Square.

Fault: The motor runs hot. Note that DC motors normally get fairly hot, 70-80 °C as measured on the motor casing. • Excessive load. • Motor having exceeded maximum speed for a considerable length of time. • High ambient temperature. • Worn bearings. • Short-circuit in field winding. Fault: High idling current. • Worn bearings. • Worn or sticking carbon brushes. Fault: High starting current. • Worn bearings. • Worn or sticking carbon brushes. • Break or short-circuit in field winding. Fault: Fluctuating speed at constant setpoint. • Excessive load variation. • Worn or sticking carbon brushes. Fault: Abnormal brush wear. • Incorrect spring force on carbon brushes. • Dirt and/or uneven commutator. • Short-circuit in rotor winding.

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Stepping motor systems Stepping motors are mainly used for the positioning of small loads. They may be regarded as digital motors, converting electric impulses into mechanical movements. Each pulse corresponds to a defined angle of movement by the motor shaft - one step. Normally, in stepping motors there is no feed-back of load and position.

The stepping motor Construction

A stepping motor consists of two main parts: • A permanently magnetized rotor. • a stator, carrying the windings. The permanently magnetized rotor may have a varying number of poles, or, as they are normally termed, rotor teeth. A common figure is 50. Most stepping motors have two phases, i e two field windings. There are, however, also fivephase motors. The diagram below shows a two-phase motor with six rotor teeth. Rotor Stator N

S

S

N

N

S

Field windings

N S

Rotor tooth

This diagram (below) shows a section through a 200-step motor. It is a twophase motor with 50 rotor teeth. This is a very common type of motor.

Rotor

Stator

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15

The stepping motor converts electric pulses into rotation, and each pulse results in a defined angle of rotation - one step, according to the following formula:

Function

360° One step = -----------------------------------------------Steps per revolution In the following, the function is described: When a current flows through a pair of field windings (fig 1), the stator poles are magnetized and attract rotor teeth with opposite stator teeth polarity. By switching in the next pair of windings, (fig 2), the next stator pair will also become magnetized; the change in magnetic flow will cause the rotor to turn 15 degrees. Then, as the first stator pair is disconnected (fig 3), the rotor will turn another 15 degrees. By connecting and disconneting the flows of current through the field windings according to this pattern, the rotor will revolve in steps of 15 degrees (figs 1 - 6). For a two-phase motor with six rotor teeth, the number of steps per revolution will equal 24: 2 × number of phases × number of rotor teeth = 2 × 2 × 6 = 24 Thus, the motor in the example will move through 24 steps per revolution, and in accordance with the previously given formula, one step is: 360° ----------- = 15° 24 The speed at which the motor rotates depends on how rapidly the field windings are being reconnected. All stepping motors function as described in the above example. The only difference is that a standard motor has more numerous stator poles and rotor teeth. This gives smaller and more numerous steps per revolution.

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1

2 N

N

S

N

N

N

S N

S

S

N

S

S

S

N

N

S

S

3

4 S

N

S

N

N

S

S

N

S

S

S

N

N

N

S

S

N

N

5

6 S

S

N

S

S

S

N S

N

N

S

N

N

N N

S N Training Document. For training purpose only.

S

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17

The design of the stepping motor is such that some of its features may be misinterpreted as defects in the motor, unless the causes are known.

Miscellaneous

Stepping motors often become hotter than motors of other types. The reason is that full motor current always flows through its windings, also at stand-still. This is termed holding torque. The reason for this is that the motor must remain in position, as it usually lacks feed-back. The torque imposed by the load must not shift the motor out of position. Normally, stepping motors have class B winding insulation, which means that the temperature of the windings may rise to 130 °C. An motor casing temperature of 90 °C does not cause any thermal damage to the motor. A stepping motor cannot be operated without a load. It requires a load moment of inertia which is at least equal to its own internal moment of inertia in order to be able to accelerate normally. Unloaded, the motor will race. A stepping motor may jerk, as power is switched on. The reason for this is that it has a number of fixed positions, for instance 200. If the rotor rests between two positions, it will jump to one of these fixed positions. The movement cannot exceed ±0.9 degrees in a 200-step motor. Stepping motors should always be connected with cables which are screened and whose conductors (strands) are twisted. The screen is to be grounded at each end. Screening is done in order to prevent electromagnetic interference (noise) to enter or emerge from the system.

Control unit The control unit generates the electric pulses which drive the motor. The change of angle made by the motor is entirely controlled by the number of pulses generated by the control unit. The control unit consists of: • The rectifier, which converts the supply voltage into direct-current voltage. • The power unit, which generates the pulse train to the motor. • The pulse control logic, which determines how the power unit will generate the pulse train.

Rectifier

Power unit

M

Pulse control logic

External control signals

The pulse train, or rather pulse trains, is generated by the power unit, which is controlled by the pulse control logic. A pulse train must be generated for each motor phase. The pulse trains are fed into the field windings, offset in time. In

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this way, the windings fitted around the stator are receiving power in succession. A revolving magnetic field is thus created, which turns the permanently magnetized rotor with the flow of magnetism. The speed of rotation of the motor is proportional to the frequency of the pulse trains. The position of the motor is based on the fact that it always turns one step per pulse. This, together with the lack of feed-back between the motor and the control unit, is the reason why, if a pulse is being missed, there will be no correction made by the control unit. The most common cause of missed pulses is that the motor is underdimensioned and has not the power to shift the load at the preset acceleration and speed parameters. A further cause of missed pulses is that there may appear resonant oscillations in couplings between motor and load.

Fault-finding In the following, some faults that may appear in stepping motor systems are described. Note In order to be able to carry out fault-finding in a stepping motor system, it is necessary to fully understand in general terms how the entire system and its various components parts function. One should also know how the particular system concerned is supposed to work as well as knowing, or being in a position to find out, the normal or rated values (voltage, amperage, etc) of the control and communication signals. TRMS stands for True Root Mean Square.

When fault-finding in electric drive systems, you should use a type TRMS measuring instrument. TRMS measuring instruments give correct values for all types of signals. Fault: The motor will not start: • No voltage to the control unit. • Fuse in or to the control unit blown or tripped. • External starting conditions not fulfilled. • No setpoint from the pulse control logic. • Motor windings short-circuited. Fault: Motor races: • Load too light or disconnected.

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Servosystems A servosystem is capable of transforming any mathematical function into a mechanical movement. This means that servosystems can replace mechanical elements, such as cams and cam shafts, indexing gears, differentials, etc. A servosystem consists of a servomotor with its control unit. Servosystems can be used for the following kinds of control functions: • Speed control; the motor speed follows a predetermined speed function. • Positioning; the position, linear or angular, follows a predetermined function. • Torque control; the torque of the motor follows a predetermined function. • Hybrid control; the system alternates between different kinds of control functions, for instance motor speed control during one part of the working cycle and positioning during another part. Motors and control units for servosystems cannot be combined in just any way. They comprise integrated systems, and the same supplier should be selected for both motor and control unit.

The servomotor The servomotor, which is a permanently magnetized brushless AC motor, is a relatively new type of motor. It has been specially designed for use in servosystems. Characteristic of this motor is its high performance in every respect, but principally that it provides much higher output power in relation to its size than other types of motors. Servomotors have great overload capacities and can cope with rapid load fluctuations. The overload capability also provides a torque reserve which is needed for quick acceleration and braking of a load. Sine-shaped motor current and electronic commutation give, in addition to a very wide speed range, also silent and smooth running and high efficiency rating. As can be seen, servomotors possess excellent qualities; in addition to what has already been enumerated, they provide high torque and have a low internal moment of inertia. They are, however, expensive. In order to achieve all these good features, it is necessary to use very rare and costly magnetic materials in the permanently magnetized rotor. Samarium, cobalt, and neodymium are examples of typical rotor materials. In principle, a servomotor consists of a permanently magnetized rotor and a stator of iron, which carries the windings.

Construction

Stator Field winding

Rotor Permanent magnet

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In a motor of this design and construction, nearly all motor losses take place in the stator. This means that the transfer of heat to the surrounding becomes short and quick. Electronic commutation and the absence of motor slip also contribute to the generation of less heat, which thus is easier to get rid of than in other motor types. Heat

Function

The windings in the stator generates a rotating (1) magnetic field (2) through the motor. The permanently magnetized rotor (3) is attracted by the poles of the field and will rotate (4) synchronously with it . 2

S

S N

N

1

S N S N

3 4

The rotating field is generated by the electronic commutation of the field windings. If the motor is to be at stand-still, for instance to maintain a torque or a position, the field windings are made to generate a static field.

Electronic commutation

Electronic commutation means that the current to the motor windings is being switched electrically.

Resolver

Beside the rotor and stator, the resolver forms a vital part of the servomotor. The resolver is an angle encoder, which all the time senses the angle position of the motor and feeds this information back to the control unit. The control unit uses the information to commutate the field windings so that the motor performs the required function. As an example, the field windings are to generate a rotating field of a defined strength for the motor to drive a load at a specific speed.

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In principle, a resolver is a rotating circular transformer, supplied with a carrier (AC voltage) of 1 - 20 kHz. The carrier induces one sine and one cosine signal in the fixed windings. The sine and cosine signals are modulated on the carrier. These signals specify the absolut angle position of the rotor. Carrier

Sine

Cosine

The sine and cosine signals are converted into a digital signal, and with this, get the resolver into a certain resolution. A two-pole resolver produces 8 192 pulses per revolution, and a four-pole resolver produces 16 384 pulses per revolution. In addition to the resolver specifying the absolute angle position, the control unit is capable to calculate, with the aid of the pulses: • the direction of rotation, by determining whether the sine or cosine signal comes first. • the position (change of angle), by counting the number of pulses, • the rotational speed (rpm), by counting the number of pulses per second, • the acceleration, by counting the number of pulses per second squared. The servomotor and resolver should always be connected with cables which are screened and whose conductors (strands) are twisted. The screen is to be grounded at each end. Screening is done in order to prevent electromagnetic interference (noise) to enter or emerge from the system.

Miscellaneous

Control unit, drive electronics The control system for a servomotor consists of three main parts: • Program • Regulating unit • Power unit

Program

Regulating unit

Position regulator

Speed regulator

Power unit

Servomotor

Torque regulator

Resolver External control signals

22

3 x 400 VAC

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Program

The regulating unit

The program contains information on the movement cycle of the motor. It can also be said to describe the functions which the motor is meant to perform. Often the program communicates with an external control system, for instance the PLC of a packaging machine. The regulating unit controls the movement cycle of the motor utilizing the information from the program and the resolver, as well as by measuring the current between the power unit and servomotor. The regulating unit usually contains three regulators, or as they may also be termed, regulating loops. The position regulator counts the pulses from the resolver. The total number of pulses provides information on the position of the load, its angle position, and change of angle. The speed regulator regulates the speed by counting the number of pulses per second. The speed regulator also regulates the acceleration. The torque regulator measures the current from the power unit to the motor. The amperage of the current is directly proportional to the torque of the motor.

The power unit

The power unit supplies the motor with electric power (current). It is normally fed by three-phase AC from the mains. The supply voltage is rectified and connected to a transistor bridge with six transistors. By means of the transistor bridge, controlled by the control unit, the motor windings are commutated, so that the motor performs as required. The switching frequency is 3 - 20 kHz, depending on make and system selected. The power unit supplies the motor with three sine-shaped currents, which are offset 120 electrical degrees relative one another. Sine-shaped current contributes towards smooth running and small losses. The power unit also regulates the amperage of the currents. The size of the currents is proportional to the torque of the motor.

Fault-finding In the following, some of the faults that may appear in servosystems are described. Note In order to be able to carry out fault-finding in a servomotor system, it is necessary to fully understand in general terms how the entire system and its various components parts function. One should also know how the particular system concerned is supposed to work as well as knowing, or being in a position to find out, the normal or rated values (voltage, amperage, etc) of the control and communication signals. TRMS stands for True Root Mean Square.

When fault-finding in electric drive systems, you should use a type TRMS measuring instrument. TRMS measuring instruments give correct values for all types of signals. Fault: The motor will not start: • No voltage to the control unit. • Fuse in or to the control unit blown or tripped. • External starting conditions not fulfilled. • No setpoint from the regulating unit. • Motor short-circuited.

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23

Miscellaneous In this section are described certain components which are common in electric drive systems but which are not specific to a particular type of system.

Angle encoders Angle encoders are used in many drive systems to record or monitor the angular and linear positions of the system, its direction of rotation, speed, etc. An absolute encoder converts the angle position of a shaft into an electric signal. The electric signal is a digital code of some kind, for instance a binary code, BCD code, or gray code. The mostly used is gray code and the number of bits in the code determines how precisely the angle encoder can record the angle position. An eight-bit code has a resolution of 256 and can record the angle position within ±0.7 degrees.

Absolute encoder

The key component of the angle encoder is a code disc, fitted to a shaft. On the disc, there is a pattern of tranparent and opaque areas. These areas comprise the actual code. For each angle value, there is a unique combination of areas, which can be transscribed into logic ones and zeroes.

Code disc with gray code

One one side of the code disc, there are light-emitting diodes and on the other side phototransistors. The light-emitting diodes shine their light on the code disc, and the phototransistors sense light or non-light, depending on which position the disc is in. The phototransistors give the position of the disc in the form of a binary signal. As the disc rotates, a signal is continuously being registered, corresponding to the absolute angle position of the shaft on which the code disc is fitted or connected with.

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Phototransistors LEDs

Incremental encoders

0 1 0 1

An incremental encoder converts a defined angle turn into an electric pulse. By counting the number of pulses, the encoder records how big the turn is. The number of pulses per revolution determines how precisely the angle encoder can record a change of angle. An encoder, giving 10 000 pulses per revolution, can record an angular change within ±0.036 degrees. Just as absolute encoders, incremental encoders have a code disc. On the code disc, there is a pattern of bars with the same resolution as the encoder has. The bar pattern is often divided into two channels, offset half a pulse relative one another. By sensing which channel comes first, the direction of rotation can be determined. Often, there is a reference pulse, a so-called zero pulse, which generates one pulse per revolution. Channel 1 Channel 2

Reference pulse

Just as in absolute encoders, the pulses are sensed by light-emitting diodes and phototransistors. As the code disc rotates, a pulse train is created. The number of pulses indicates how big a change of angle the shaft has made.

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Temperature (safety) switches Under certain circumstances, it is suitable to supplement the regular motor protection with temperature safety switches. These switches protect the motors from overheating, caused by overloading, insufficient cooling, too high ambient temperature, high starting frequency, or similar faults. The temperature switches are fitted in or on the windings in the stator and ensure that power to the motor is cut if a preset temperature is being exceeded. There are several types of temperature safety switches; below, three of them are described: • Bimetal types of temperature switches usually work on the principle of the bimetal element tripping and cutting power at a given temperature. Such a switch is wired into the control circuit of the motor, or, in the case of motors of low power, directly into the power circuit of the motor. No separate control unit is required. • Thermistors are temperature-dependent semiconductors. Thermistors of PTC (Positive Temperature Coefficient) type are the most common ones. These offer the advantage of very slight increase of resistance on rising temperature right up till the reference has been reached. Then the resistance increases sharply, up to 1000 times. Thermistors must be connected to a separate control unit, which cuts the power supply to the motor. • Resistor elements are temperature-dependent resistors. Resistor elements, for instance PT 100, are mainly used in large motors, where they are wired into the motor windings. PT 100 signifies that the element is made of platinum and has a resistance of 100 ohm at 0 °C. Resistor elements must also be connected to a separate control unit.

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10 Design control system

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Design control TBA/21 Textbook MT-83018-2

TMCC Design control system

+ 24 VDC DC common TPOP design position

Bit 0

1

TMCC

2

558230

3 FAULT POWER S 1 Reg mark DCS S 2 Design OK S3 S4 S5 S6 S 7 > 192 S 8 < 64

9 10 11 12

Register mark photocell 3 bars Enable TMCC Enable data communication Clock signal Data signal

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01 EF 2

345

89 67 A

15

Register mark photocell 4 bars

Data request

Precorrection out

13 14

Bit 7

27

31

SW 1

BCD

Encoder

25

16

32

17

5

Design OK

Analog output to DMC

18 20

Register mark signal

RS232

22 23 24

Machine type

Issue

TBA/22

1/9907

OH 862:1

TMCC ASU

+ 24 VDC DC common

1

TMCC

2

558230 FAULT POWER S 1 Reg mark ASU S2 S3 S4 S5 S6 S7 S8

27

Design signal ASU

01 EF 2

89 67 A

345

SW 1

BCD

Bar code photocell 4 bars Bar code photocell 3 bars

17 18 RS232

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Machine type

Issue

TBA/22

1/9907

OH 862:2

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Design Control Servo motor positioning

0.7 mm* Mechanical stop, 0.5 mm*

Machine type

TBA/22

Precorrection

1/0004

Issue

Home position sensor

OH 959

Regulation area * Distance to inductor

Home position

Mechanical stop

PHOTOCELL

0V 0.7-2.0V (analog)

0-24V (digital)

screen

OUTPUTS

+24V

POWER

Cable: COLORS & PURPOSE

Photocell Adjustment of sensitivity on photocell

Sensitivity knob Run Program selector switch Memorize Adjustment Indicating lamp (LED)

1 Set

Photocell reading on "White" background

2 Set

Photocell memorize "White"

3 Set

Photocell reading on "Black" background

4 Adjust

LED lights up (Black background)

5 Adjust

LED Out (Black background)

6 Set

"RUN" Position

Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/21

1/9609

OH 599

Textbook

MT-83033-1

7HFKQLFDO7UDLQLQJ&HQWUH /XQG6ZHGHQ

This textbook has been compiled by the Technical Training Centre in Lund. Some of the pictures in the book are also available as OH pictures. For further information on training material, please contact the Technical Training Centre.

Issue 1/0005 © 2000, Technical Training Centre No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means: electronic, electrostatic, magnetic tape, mechanical photocopying, recording or otherwise, without permission in writing from Technical Training Centre.

Training Document This Training Document is intended for Training purpose only, and must not be used for other purpose. The Training Document is not replacing any instructions or procedures (e.g. OM, MM, TeM, IM, SPC) intended for specific equipment, and must not be used as such. 1RWH! )RUVDIHDQGSURSHUSURFHGXUHVUHIHUWR WKHHTXLSPHQWVSHFLILFGRFXPHQWDWLRQ

7HFKQLFDO7UDLQLQJ&HQWUH

Contents General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TMCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Design control offset adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Folding flaps and eccentric shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Reading a register code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

General Most Tetra Brik packaging machines produce packages from FUHDVHG packaging material. The creases are folding impressions to facilitate the forming of the package.

&UHDVHGSDFNDJLQJPDWHULDO The shaded area shows the part of the packaging material used to make RQH package.

7RSFUHDVH

%RWWRPFUHDVH

5HJLVWHUFRGH

On a finished package, the creases coincide with the edges of the package. This means that the package must be made from a particular section of the packaging material web. In order to achieve this, the machine must:

 

synchronise the material web with the jaw system, so that the jaws seal and cut the package in the right places, feed the material one package at a time in order to maintain synchronisation with the jaws.



Synchronise packaging material and jaws

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Training Document. For training purpose only.



Feed one package at a time Jaw

Jaw

Jaw

Jaw

3

It is the GHVLJQFRQWURO which synchronises material and jaws and causes one package at a time to be fed forward. When this is done, the creases of the package are correctly placed as the jaws move against the tube, so that the machine produces packages of the ULJKWVKDSH.

This package is well shapen and folded along the creases; it has been made from the appropriate section of the material web.

On this package, the creases in the web and the edges (folding) of the package do not coincide; it has been made from the wrong section of the web.

However, the jaws do not have to hit the tube at an exact spot for the packages to be correctly formed. The positions of the creases relative the jaws may fluctuate within a VPDOOUDQJH without affecting the shape of the packages. The design control device endeavours to place the creases in the PLGGOH of this range by continually PDNLQJVOLJKWDGMXVWPHQWVRIWKHWXEHIHHG.

4

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Construction This picture shows the components that make up the design control.

TMCC

PLC

DMC

Photocells

TPOP Folding flaps

Folding flap mechanism

Servomotor

Technical Training Centre 1/0005

Angle encoder

Training Document. For training purpose only.

5

The SKRWRFHOOV sense the register code, a mark printed on every package. When the register code moves past the photocells, signals are generated which are decoded by TMCC. The decoded signal is referred to as GHVLJQVLJQDO. The GHVLJQFRQWURORIIVHW, on the TPOP, is used to regulate the crease position manually relative the jaws. The DQJOHHQFRGHU is connected to the drive of the machine and continually reads the machine position in the form of an electric signal. As the jaws are connected with the drive, this signal also defines the position of the jaws. The position of the machine (machine angle) can be read on the display of the angle encoder. The 70&& (Tetra Pak Multi-Purpose Controller) incorporates the program for the design control. It receives the signals from the photocells and the angle encoder. The TMCC then determines, based on these signals, whether to increase or decrease the feed rate of the packaging material web (tube). The 3/& comprises the control system of the machine. For instance, it provides the TMCC with certain data, required for the design control function. The '0& (Digital Motion Controller) converts information received from the TMCC to the required servomotor position. The VHUYRPRWRU is a kind of motor capable of stopping in a defined position with great precision. It is mechanically connected to the folding flaps and thus determine how far they move, i e their stroke. The IROGLQJIODSV regulate the feed rate of the packaging material web. They can assume any one of 256 positions (steps 0 - 255).

• •

6WHSV constitute the regulation range during production. At step 0, feed of packaging material is at a minimum, while step 255 gives the highest feed rate. 3UHFRUUHFWLRQ, a folding flap position utilised during start that affects the feed rate very little.

Photocells

Servomotor

Folding flaps

DMC

Angle encoder

Design control offset

6

TMCC

PLC

Training Document. For training purpose only.

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Function :KDWKDSSHQV"

Through its in-movement, the jaws provides the fixed and major feed of packaging material. The design control then adds a small amount of web feed by means of the folding flaps. If the crease position is high relative the jaws, the design control increases the feed of material, i e the additional feed is greater. If the crease position is low, the design control reduces the feed of material, i e the additional feed is less. The feed rate is regulated by DOWHULQJWKHVWURNHRIWKHIROGLQJIODSV. Folding flap

The folding flap stroke increases when the creases are positioned high (→ step 255).

The folding flap stroke decreases when the creases are positioned low (→ step 0)

The design control device endeavours to regulate the speed (feed rate) of the tube, so that it is as close to the machine speed as possible. )ROGLQJIODS VWURNHV (regulation range) SURYLGHVYLUWXDOO\OLQHDUUHJXODWLRQRIWKH IHHGUDWH. How much the design control device is to add to the feed depends on where the creases are positioned relative the jaws.

Folding flap stroke



 3UHFRUUHFWLRQ

Technical Training Centre 1/0005

Training Document. For training purpose only.

Feed rate

7

To determine whether to increase or decrease the feed rate, the machine must compare the crease position with the jaw position. The design signal is a pulse indicating the crease position, and the angle encoder indicates the jaw position. The design signal is generated by the photocells sensing the register code, which is being decoded into a design signal in the TMCC. The register code is printed on the packaging material in a defined place relative the creases. Consequently, the register code defines the crease position as well. In order for the packages to be well–shapen, and thus acceptable, the signal must be received while the machine is positioned within a certain range. This range is called the SURGXFWLRQVHFWRU, or the range for acceptable packages.

Decoding

1 2

Production sector (1) Production angle (2)

Design signal

TMCC

The production sector is symmetrically located around the SURGXFWLRQ DQJOH*. The production angle is the value of the angle retrieved by the TMCC from the PLC. The design control endeavours to place the design signal at the production angle. Design deviation is a measure of how the creases are located relative the FRUUHFWSRVLWLRQ. Correct position means that the design signal is received precisely at the production angle.

see page 21 (terminology list)

'HVLJQGHYLDWLRQ

The design deviation is expressed as a length, and must during production not exceed ±1,5 mm. If the deviation is kept within ±1,5 mm, the packages are correctly formed, indicating the design signal has come within the production sector. This ±1,5 mm limits the production sector; there are no angle values received from the PLC. The TMCC computes the design deviation value by measuring when, in relationship to the correct position, the design signal is received. 0 mm design deviation means that the design signal comes at the production angle (in the middle of the production sector). Design signal

$

%

Production sector

$

-1,5

-1

-0,5

%

Production angle, Correct position

0

0,5

Machine position Design deviation mm

1

1,5

'HVLJQVLJQDO$ is coming early, relative the production angle. The design deviation is -0.6 mm (low creases), and the folding flaps are to decrease the feed rate in order to raise the crease position. 'HVLJQVLJQDO% is coming late. The design deviation is 1.1 mm (high creases), and the folding flaps are to increase the feed rate in order to lower the crease position.

8

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The orientation and magnitude of the design deviation determines how the stroke of the folding flaps is to be altered. Positive deviation, i e high crease position, increases the folding flap stroke; towards step 255. Negative deviation, i e low crease position, decreases the folding flap stroke; towards step 0. The stroke is altered by the number of steps which corresponds to the current design deviation. The design control endeavours to minimize the design deviation.

([DPSOH

Below, an example is illustrated of how the design is regulated, reaching a stable position; two cases are shown with different initial premises and preconditions (A and B) The upper part of the diagram shows the feed provided by the folding flaps, and the lower part shows the fixed feed provided by the jaws. The jaws provide the major proportion of the total feed.



Feed rate

)HHGE\IROGLQJIODSV

-1,5 mm 

$ +1,5 mm

-1,5 mm 

% +1,5 mm

Time



The graphs for examples A and B show how the folding flap stroke is altered in order to regulate the design. The shaded areas above and below the curves represent the design deviation.

)HHGE\MDZV

In example A, the folding flaps add relatively much to the feed in order to minimize the design deviation. The stroke is being stabilized around step 180.

Technical Training Centre 1/0005

In example B, the folding flaps add relatively little to the feed in order to minimize the design deviation. The stroke is being stabilized around step 80. 1RWH 7KHUHLVQRUHODWLRQVKLSEHWZHHQWKHSDUDPHWHUVJLYLQJWKHGHVLJQGHYLDWLRQ DPLQLPXPDWIROGLQJIODSVWURNHVWHSLHKDOIZD\WKURXJKWKHUHJXODWLRQ UDQJH,QERWKWKHDERYHH[DPSOHVPLQLPXPGHVLJQGHYLDWLRQLVUHDFKHGDW GLIIHUHQWVWHSVZLWKLQWKHUHJXODWLRQUDQJHH[DFWO\ZKHUHGHSHQGVRQSUHYDLO LQJFRQGLWLRQVPDFKLQHPDWHULDOSURGXFWSUHVVXUHHWF,IWKHIROGLQJIODSV KDYHWRFRQWULEXWHPXFKWRWKHIHHGWKHIROGLQJIODSVWURNHHQGVXSLQWKH KLJKHUSDUWRIWKHUHJXODWLRQUDQJHDQGYLFHYHUVD

Training Document. For training purpose only.

9

TMCC TMCC is a programmable control board used for a variety of functions in the Tetra Pak machines. The diagram below shows how TMCC works in the design control device for TBA/22. The front of the board is illustrated overleaf, where there are also explanations of the various LEDs, switches, etc. on the board. Photocells

TMCC Register code decoding

Angle decoding Angle encoder Servomotor

PID regulation

Design control offset Output data to DMC

Terminal (PC)

DMC

Communication with PLC and terminal (PC) PLC Settings

The TMCC program (DCS22) consists of six principal functions:

•

5HJLVWHUFRGHGHFRGLQJ: This part of the program decodes the signals from the photocells, converting them into a design signal.

•

$QJOHGHFRGLQJ: This part decodes the angle values utilized in the design control.

•

3,'UHJXODWLRQ: Here the design deviation is computed and the stroke of the folding flaps determined. The computation consists of a PID algoritm.

•

2XWSXWGDWDWR'0& (servomotor): This part of the program provides data for the DMC on the folding flap stroke.

• •

&RPPXQLFDWLRQZLWK3/&DQGWHUPLQDO (PC).

10

DCS22 Design Control System 22

6HWWLQJV: Here are stored volume-dependent parameters (values) retrieved by the TMCC from the PLC.

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TMCC, front

TMCC LEDs explained: )$8/7 (red) not used in this application. 32:(5(green) indicates that the TMCC is powered with the correct voltage. 6(yellow) flashes when the register code is being decoded. 6 (yellow) lights up when acceptable packages are being produced. (Design OK.) 66(yellow) not used in this application. 6 (yellow) lights up when the design control works in the upper part of the regulation range, 75-100% of the range. 6 (yellow) lights up when the design control works in the lower part of the regulation range, 0-25% of the range.

TMCC FAULT POWER S1 S2 S3 S4 S5 S6 S7 S8

(SW1)

An identical TMCC is used for all package volumes. Volume-dependent data, needed by the TMCC, are collected from the PLC. It is possible to communicate with the TMCC via TIT (terminal, PC). Upon the command 5 (on-line), the following is displayed continuously:

(Terminal)

• • •

Design deviation for the current package Mean deviation for the ten latest packages produced Folding flap stroke, mean position for the ten latest packages produced

Upon the command 6 (status), further information on design control can be obtained, for instance volume-dependent parameters which the TMCC collects from the PLC:

• • • • •

Machine speed, in terms of packages per hour Web cutting pitch, also called Repeat length, volume-dependent parameter collected from the PLC Production angle, volume-dependent parameter collected from the PLC Design control offset setting (±500 scale units, about ±5 mm) Control parameters P, I, and D

The TMCC also has an analogue output 0-10V (terminal), from which it is possible to transmit one of the parameters listed above, for instance to a recorder. With the selector 0 - F (SW1), the parameter to be transmitted from the output is selected. 1RWH that the selector must never be set at 0 during operation. 0 is a programming position which zeroes all the parameters in the TMCC. The TMCC also communicates with the TPOP via the PLC. These are the alarms available:

Technical Training Centre 1/0005

•

0DOIXQFWLRQSKRWRFHOOV: if the photocells fail to sense the register code, this alarm is triggered. The machine runs on with the same folding flap stroke for another five register codes. If the photocells have not resumed sensing the register code, the machine will stop.

•

3ULQWHGGHVLJQRXWRIOLPLW: If the design deviation of six consecutive packages exceed ±1,5 mm, this alarm is triggered and the packages are discarded. If the design deviation continues to exceed ±1,5 mm the machine will stop after 100 such packages. Just five package with a deviation exceeding ±1,5 mm is allowed and led into the final folder.

•

6HUYRV\VWHPIDXOW: in case of a servo system fault, an alarm indicates this fact on the TPOP.

Training Document. For training purpose only.

11

Design control offset adjustment The position of the creases can be adjusted manually by means of the design control offset adjustment (on the TPOP). Everything described in the foregoing (pages 3 - 11) refers to the automatic part of the design control. In order to make it easier to understand the function of the design control offset adjustment, one should deal with this separately from the automatic control.

•

The DXWRPDWLFFRQWURO endeavours to achieve the correct position (design signal at the production angle).

•

0DQXDOUHJXODWLRQ, by means of the design control offset adjustment, determines where this position is.

Together, this makes the packages obtain the correct shape, i e with the creases in the right places. Then, what does a correctly formed package look like? Correctly formed, the package material is folded along the top and bottom creases, as illustrated below.

&RUUHFWVKDSH

The crease is designed to fold in this precise manner. That is why the crease does not have to be in the exactly correct position in order to fold correctly. In order to determine whether the package is correctly formed, one has to look at a ILQLVKHGSDFNDJH, i e one that has come out of the final folder. Such a check is part of the package checking procedure by the machine operator. The automatic control is unable to determine how the creases are actually folded. All it is able to is to sense how the GHVLJQVLJQDO relates to the jaws; thus is it only LQGLUHFWO\¶DZDUH¶RIKRZWKHFUHDVHVDUHEHLQJIROGHG. There are always variations in the packaging material, tolerances in the machine, etc, which cause packages sometimes to be incorrectly formed in spite of the fact that the design signal comes within the production sector. Faults, like the one illustrated above, may occur, for instance if the register code location relative the creases is close to the limit of what the packaging material specification accepts. In the example below, the distance between the register code and the bottom crease is on the long side but still within the tolerance.

12

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Crease position too low on the package

Crease position too high on the package

Register code

Bottom crease, correct position as per specification Tolerance range Bottom crease, actual position

The automatic design control device will endeavour to fold the packaging material at the correct position, as specified, as that is where the TMCC assumes the crease to be. The design correction offset adjustment is now used to shift the correct position so that it coincides with the actual position, i e shift the position towards which the automatic design control aims. &RQFOXVLRQ If the crease position is not correct, in spite of design signal within the production sector, the crease position must be adjusted by means of the design control offset. It is possible to shift the crease position about ±5 mm. Increasing the value raises the crease position on the package, decreasing the value lowers it. 1RWH &KDQJLQJWKHRIIVHWKDVWKHVDPHHIIHFWDVVKLIWLQJWKHSKRWRFHOOVYHUWLFDOO\L HDOWHULQJWKHUHODWLRQVKLSEHWZHHQWKHGHVLJQVLJQDODQGWKHMDZV $OVRQRWHWKDWWKHSDFNDJHVDUHPDGHXSVLGHGRZQLQWKHMDZV\VWHP/RZ FUHDVHSRVLWLRQRQWKHSDFNDJHPXVWQRWEHFRQIXVHGZLWKORZFUHDVHSRVLWLRQ UHODWLYHWKHYROXPHIODSV

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Training Document. For training purpose only.

13

In order to show what happens on changing the offset, we shall go through an example. It presumes that the creases are 1.5 mm too high on the finished packages, in spite of the design signal close to the production angle. The folding flap stroke fluctuates around step 160, and the offset value is set at 0.

([DPSOH

Design signal

Machine position Production angle, Correct position Design deviation -2

-1

0

1

2

3

4

Crease position +3

+2

+1

0

-1

-2

-3

The design deviation is close to 0, but the crease position on the finished packages is offset by +1.5 mm, i e too high crease position on the finished packages. In order to compensate this fault, the offset should be decreased by appr 150 scale units. This will shift the production angle so that a design deviation close to zero will place the creases correctly on the finished packages. The design deviation will now, temporarily, be -1.5 mm, but is quickly being regulated and closes in on zero again (1, 2, 3, and 4 in the diagram below). 1

2

3 4

Machine position Production angle, Correct position Design deviation -3

-2

-1

0

1

2

3

Crease position +3

+2

+1

0

-1

-2

-3

On changing the offset, the folding flap stroke is temporarily decreased in order to raise the crease position. After a while, the folding flap stroke will stabilize around step 160 once again.

14

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The diagrams below illustrate LQSULQFLSOH what happens when the offset is being changed, in accordance with the example on the previous page. 1

2

3

4

Produced packages

1

2

3

4

Produced packages

200 100 2IIVHW

0 -100 -200

1 'HVLJQGHYLDWLRQ

0 -1 -2

-1 &UHDVHSRVLWLRQ

0 +1 +2

180 170 )ROGLQJIODS VWURNH

160 150 140 130 120

Technical Training Centre 1/0005

Training Document. For training purpose only.

15

Start The machine always start and stop with the design in correct position, except at the first start after WLJKWWXEH and when VWHULOHLQFKLQJ has been performed. )LUVWVWDUW After WLJKWWXEH and VWHULOHLQFKLQJ has been performed the folding flaps are in SUHFRUUHFWLRQ. When the machine is started the folding flaps consequently affect the feed very little, and the packaging material web is fed forward slowly relative the machine. The folding flaps will remain in precorrection position until the design signal appears within the precorrection out sector. This will cause the flaps to assume a position within the normal regulating range, step 0-255.

Design signal

Precorrection

Precorrection

Design signal

Precorrection out

Machine position

Precorrection out sector Production sector

The precorrection out sector is made quite wide, corresponding to a design deviation of ±10 mm. When the design signal enters the sector the folding flaps will go to step 0 or step 255, depending on if the sector is entered when +10 mm or -10 mm of design deviation. The design control system will then quickly correct the deviation toward 0 mm. 2WKHUVWDUWV All other starts are performed when the correct design position is maintained from the preceding stop. The folding flaps are kept in a step between 0 and 255. This allow the machine to make correctly formed packages immediately after the start with the design in correct position.

16

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The diagram illustrates an example of the starting sequence. 

Feed rate -1.5 mm



)ROGLQJIODSV

+1.5 mm



Design deviation within ±10 mm

-DZV

3UH FRUU

Time

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Training Document. For training purpose only.

17

Folding flaps and eccentric shafts The stroke of the folding flaps affect the feed rate of the packaging material web; consequently, it is the stroke that controls the design. How great the folding flap stroke becomes, depends on the position of the servomotor.

Folding flaps

Folding flap cam

Stop block

Gearing ratio

Eccentric shafts

Servomotor

The position of the servomotor actuates, via a timing belt reduction gearing, the eccentric shafts, which in its turn shifts the folding flap cam sideways. The sideways, or lateral, position of this cam determines how far the mechanism is to pull the folding flaps and thus the magnitude of the folding flap stroke. In order to further explain how the design control device works, we shall take a closer look at the eccentric shaft. But before that, we shall briefly explain how the servomotor works, as the position of the eccentric shafts is proportional to the servomotor position.

(FFHQWULFVKDIWV

The URWDWLRQRIWKHVHUYRPRWRU is controlled by positions, and to turn it through one full revolution, 16 384 positions are required. Characteristic of the servomotor is that it has extremely exact positions. When the TMCC says that the folding flaps are to go to, for instance, step 0, the following happens: The DMC converts step 0 into the value 25 000 and starts the servomotor. The motor then feeds back continuous information to the DMC in its current position, and when the motor position equals 25 000, it stops. It has now rotated one revolution + 8616 positions. The diagram overleaf describes the different positions of the eccentric shafts.

18

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Step 255, 0.7 mm* Closed position, 0.5 mm* Regulating range

Step 0

Precorrection

Stop block

Home position sensor * Distance to inductor

Home position

Mechanical stop

0HFKDQLFDOVWRS The mechanical stop prevents the eccentric shaft from rotating further in that direction. The stop also functions as calibration position for the servomotor. When the machine is started, the servomotor rotates until the eccentric shaft reaches the mechanical stop. +RPHSRVLWLRQ(reference position) The home position is located 400 positions from the stop. 3UHFRUUHFWLRQ Precorrection, 18875 positions from the stop. 6WHS Step 0, 29000 positions, the position in the regulating range where the feed of material is increased the least. 6WHS Step 255, 41750 positions, the position in the regulating range where the feed of material is increased the most. &ORVHGSRVLWLRQ In this position, the folding flaps reach 0.5 mm from the inductor. This position is used for mechanical settings and is never reached during production.

Technical Training Centre 1/0005

Training Document. For training purpose only.

19

Reading a register code The register code is a printed mark on the packaging material. When it passes the photocells, the cells read the 26 digital information bits in a particular order. These bits are decoded into a pulse, the design signal, in the TMCC. 1RWH 7KHSKRWRFHOOVFRQWLQXRXVO\UHDGWKHSDWWHUQRIWKHSULQWHGGHVLJQRQWKHSDFN DJLQJPDWHULDOEXWWKHUHDGLQJRIWKHUHJLVWHUFRGHELWVLQWKHULJKWRUGHU LVUHTXLUHGWRHQDEOHWKHGHFRGLQJRIDGHVLJQVLJQDO When one of the photocells reads a flank on the register code, both photocells register what they ’see’: blank, white, positive flank, or negative flank. This is translated into a binary code (ones and zeroes) as follows:

%ODFN :KLWH 3RVLWLYHIODQN 1HJDWLYHIODQN

   

:KDWKDSSHQV"

(white to black) (black to white)

The binary code is stored in a shift register as it is read when the register code passes the photocells. The contents of the shift register are compared continuously with the contents of another register with fixed contents. When the lines of ones and zeroes are identical in both registers, the register code has been decoded, and a pulse, the GHVLJQVLJQDO, is generated.

 

Shift register where the binary code from the photocells is stored Register with fixed contents

The design signal is generated when the contents of the two registers are identical.

Below, an example is shown of how the photocells read the register code. Here photocell B reads a negative flank and A reads black  (A, B) is transmitted to the shift register.

Here photocell B reads a positive flank and A reads white  (A, B) is transmitted to the shift register.

$

20

%

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Glossary :HEFXWWLQJSLWFK $XWRPDWLFUHJXODWLRQ &UHDVHSRVLWLRQ 'HVLJQGHYLDWLRQ

'HVLJQVLJQDO

3UHFRUUHFWLRQ &RUUHFWSRVLWLRQ 0DQXDOUHJXODWLRQ 0DFKLQHSRVLWLRQ 1HJDWLYHIODQN 3RVLWLYHIODQN 3URGXFWLRQVHFWRU 3URGXFWLRQDQJOH

5HJLVWHUFRGH 5HJXODWLRQUDQJH )ROGLQJIODSVWURNH

Technical Training Centre 1/0005

The length of the cut-off piece of packaging material required to make one package. Also called Repeat length. The automatic regulation endeavours to reach the correct position, with the design signal within the production sector. The position of the creases on the finished package. Correct crease position results in correctly formed packages. A measure of where the design signal is relative the production angle (correct position); must not exceed ±1.5 mm during production. In other contexts also termed design error. Pulse generated each time the register code passes the photocells. It indicates the crease position indirectly. In other contexts also termed photocell puls, photocell signal or register mark. The folding flap position used during start and inching. No (0) design deviation, design signal exactly at the production angle. Manual regulation (design control offset) is used in order to adjust the crease position ZKHQWKHGHVLJQ VLJQDOLVZLWKLQWKHSURGXFWLRQVHFWRU. The angle position of the main shaft of the machine; indicates through mechanical connection the position of the jaws. When a photocell reads the change from black to white, it registers a negative flank; a negative flank produces a logic zero (0). When a photocell reads the change from white to black, it registers a positive flank; a positive flank produces a logic one (1). Corresponds to an angle sector in which the design deviation lies within ±1.5 mm; also termed range for acceptable packages. The positive flank of the angle value with which the design signal is compared in order to enable the TMCC to compute the design deviation. The production angle is a volume-dependent parameter collected by the TMCC from the PLC. Mark on the packaging material which the photocells read. In other contexts also termed register mark, photocell mark, or bar code. Step 0-255. Used to control the design during production. Folding flap steps 0 - 255; how much the folding flaps affect the feed of packaging material.

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21

Tetra Pak

Description

1. Table of Content 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

TABLE OF CONTENT .............................................................................................................................1 ABBREVIATIONS....................................................................................................................................1 INTRODUCTION .....................................................................................................................................1 DESIGN CONTROL SYSTEM OVERVIEW ...............................................................................................2 TMCC CONNECTIONS...........................................................................................................................3 BASIC PROGRAM FUNCTIONS ..............................................................................................................5 OTHER PROGRAM FUNCTIONS ............................................................................................................6 TMCC FRONT PANEL SWITCH .............................................................................................................7 TMCC FRONT PANEL LEDS .................................................................................................................8 ENCODER FUNCTION AND GRAY CODES .............................................................................................8 OUTPUT SIGNAL ...................................................................................................................................8 DESIGN ADJUSTMENT SIGNAL .............................................................................................................8 TERMINAL (PC) COMMUNICATION ........................................................................................................9 VOLUME PARAMETER TRANSFER ......................................................................................................11 PROGRAM DOWNLOAD.......................................................................................................................12 APPENDICES .......................................................................................................................................13

2. Abbreviations DCS22 DCS21 DCU EEPROM LED PC PID PLC TMCC TPOP Flexbox

Design Control System for TBA/22 filling machines Design Control System for TBA/21 filling machines Design Correction Unit (68 457-010V) Electrically Erasable/Programmable Read-Only Memory Light Emitting Diode Personal Computer Proportional, Integral and Derivative control algorithm Programmable Logic Controller, (like TPMC or GE-Fanuc) Tetra Pak Multi-Purpose Compact Controller (558 230-0300) Tetra Pak Operator Panel Industrial Computer Interfacing the TPOP and logging the machine events

3. Introduction The DCS22 program is intended for the TBA/22 filling machines, and the program runs on the TMCC, Tetra Pak Multi-purpose Compact Controller, hardware. The program reads the register mark photocells at the paper tube and the machine angle encoder. From these parameters the output is calculated via a PID-algorithm. This output value is sent, through the analog output 0, to a servomotor system which moves the folding flaps. The DCS22 program is based on the DCS21 program and it’s intended for TBA/22 filling machines. This Functional Description is intended for users of the DCS22 "function", i.e. electrical designers, test engineers, service engineers and alike. Its purpose is to give a full understanding of the behaviour of the DCS22 program together with the TMCC as a system. (The internal structures of the DCS22 program will not be discussed. For electronic system development purposes a special report covering these areas is available.)

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4. Design Control System Overview The design control system can be illustrated as below, where TMCC is the central part in the system, and all other parts in the system are connected to the TMCC. Inside the TMCC symbol is a simple representation of the functional blocks of the software:

Photocells

TMCC Read Photocells

α

Angle Encoder

Servo Motor Read Angle Encoder

TPOP

Calculation (PID) Servo Driver

Output to Servo Driver

Flexbox

PLC

Terminal, (PC)

Communication with PLC and Terminal

Parameter Settings

The connections and the functions are explained in the following pages. The DCS22 program flow is further explained in the "Basic Program Functions" chapter.

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5. TMCC connections The TMCC is a general purpose hardware and its inputs and outputs are fully controlled by the software, in this case the DCS22 program. The connections below have been chosen for the DCS22 function (a pin connection diagram is available in the appendices):

+24V Ground

1 2

Angle Encoder, bit0

9 10 11 12 13 14 15 16

Angle Encoder, bit7 Register Mark Photocell, (4bar) Register Mark Photocell, (3bar) Design Adjustment Signal

TMCC Power Supply HighOut0-3

AnalogOut0

25 26 27 28

Volume Acknowledge Not used Regulating Mode Signal Not used

5

Analog Output to Servo Driver

31 32

Register Mark Photocell Pulse Design OK

6

Diagnostic Analogue Output

19 21 29 30

Not Used Not Used Not Used Not used

LowIn0-7 HighOut6-7 AnalogOut1

17 18 3

HighIn0-1 AnalogIn0

DCS22 Enabled

20

HighIn3

Not used

7

FastIn0

Volume Enable Volume Clock Volume Data

22 23 24

Not Used Not Used

4 8

HighIn5-7

AnalogIn1 FastIn1

HighIn/LowOut2 HighIn/LowOut4 HighOut4 HighOut5

The functions of these signals are as follows (some functions are further explained in the following chapters): +24V Ground

+24 Volt power supply. From the Electrical Cabinet +24V supply. Ground power supply. From the Electrical Cabinet ground connection.

Angle Encoder, bit0 - bit7 24V inputs from the machine angle encoder that has 8 bits and counts from 0 to 255 (decimal). bit7 is the Most Significant Bit (MSB) and bit0 is the LSB. Register Mark Photocell, (4bars) 24V input from the register mark photocell positioned beside the paper tube above the jaw system. The (4bars) indicates that this photocell reads the 4 bars part of the register mark (also called clock).

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Register Mark Photocell, (3bars) 24V input from the register mark photocell positioned beside the paper tube above the jaw system. The (3bars) indicates that this photocell reads the 3 bars part of the register mark (also called data). DCS22 Enabled 24V input from the PLC. When this signal is: • LOW (0V) - the DCS22 sets the precorrection mode. • HIGH (24V) - the DCS22 runs in the regulating mode. (Refer to next chapters for explanation of the precorrection and regulating modes). Volume Enable Volume Clock Volume Data These 24V input signals are controlled from the PLC. They are used for transmitting the Repeat Length and Production Sector values to the DCS22 program. Refer to the chapter below describing this transmission protocol. Analog Output To Servo Driver Analog (0-10V) output signal connected to the servo driver. The servo driver reads this analog signal and moves the folding flaps in order to actuate the corrections requested by P.I.D. algorithm of the TMCC. For more information related to the relationship between the analog voltage (0…10V) and the mechanical position of the folding flaps, refer to the servomotor application program description or the maintenance manual. Register Mark Photocell Pulse 24V output to the PLC. This is a 40 ms long pulse sent when the DCS22 program has decoded a register mark. Design OK 24V output to the PLC. This signal is HIGH (24V) as long as the design error of a package is less than ±1.5. Diagnostic Analog Output An analogue (0-10V) output that sets one of the following signals after each package: SW1 position Function 8 Design error of current package (∗ ∗ ). 9 Design error of current package (∗ ∗ ). A Filtered design error ("90% old + 10% new"-algorithm). (∗ ∗) B Output signal to the servo driver. C Filtered output signal. D Design Adjustment potentiometer. ∗ 0…10V on this output equals to -5…+5 mm. Refer to the appropriate chapter below for a complete description of this function. Volume Acknowledge This is a 24V output to the PLC. Refer to the chapter below describing the transmission protocol for volume parameters. Regulating Mode Signal This is a 24V output to the PLC. When the DCS22 program is in precorrection mode status this signal is low. This signal goes high only when the DCS22 program enters into regulating mode.

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Design Adjustment Analog Input Analog (0-10V) input which is connected to the PLC analog output. A voltage close to 0V means that the paper tube position (compared with the jaws) will be higher than with a voltage close to 10V (in other words: an increasing voltage on this input will move the paper tube downwards in the jaw system). The total tube adjustment range is ± 5 mm. Not Used These inputs and outputs are not used in the DCS22 program. They should be left unconnected.

6. Basic Program Functions The DCS22 program for the TMCC is written in the C-language and it is not possible to modify this without the proper knowledge and development tools (this must be done in a technical development facility). The parameters that need to be changed (e.g. volume parameters) are controlled from the PLC. Program flow: At start-up or reset (the TMCC may be reset manually by setting the SW1 switch on the front panel in position "0" for a few seconds, then back to its previous position and finally turning off and on the TMCC card) the DCS22 program initiates all its internal variables and reads the volume parameters sent from the PLC. After this first step the program enters an eternal loop, i.e. it repeats the program over and over again. This loop has the following basic functions: • Wait for a valid photocell reading of the register mark. This routine decodes the edges of the register mark (and of the other part of the design as well) and for every edge (black to white, white to black) it stores the photocell values in a shift register. The shift register is a 26-bit single register (compared to the first MultiStep routine that used two separate shift registers with 6 and 7 bits respectively, which in some cases could cause a false decoding). This shift register is compared with a special pattern that corresponds to a correct register mark. If they are equal a register mark has been detected and the program can proceed with its calculations. • When the register mark has been detected the DCS22 program reads the machine angle encoder. To get an acceptable accuracy of the machine angle an interpolation is done by comparing the remaining time of the current angle (i.e. until the angle encoder changes to a new value) with the time for a complete angle. This gives a decimal number (for example, 72.95) telling where the register mark is in relation to the machine jaw system. • When the register mark has been detected the DCS22 program also sends the Register Mark Photocell Pulse signal to the PLC without any delay. • The calculated register mark angle is now compared with the preferred design angle, i.e. the production sector set from the PLC offset by the Design Adjustment value (for example, 74 - 1.25 = 72.75). The comparison gives the angle error and together with the repeat length it is possible to calculate the design error in millimetres for the current package (the example: 72.95 - 72.75 = 0.20; 0,20 * 245(repeat length) / 256(no of sectors per package) = 0.19 mm design error). The design error is positive if the register mark (the design) is too "high" in relation to the jaw system, and vice versa. • The design error is used as an input to the PID control algorithm. The algorithm uses a quadratic Ppart, which means that it has a faster response for larger design errors. Otherwise, it is a standard P.I.D. with integral and output range limitations. The P, I and D factors have been tested on filling machines to give a well working design control in both normal production and start/stop sequences. In order to achieve the better performances of the controlling action, all P.I.D. parameters are scaled differently according to the design error. If the design error is outside the ±5 mm window the regulator

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output drives directly the analog output of the TMCC. In this way the DCS22 is capable to minimize the time needed to reach the design position. When the design error enters into the previous window the regulator output is divided by 8. This means a smother controlling action and a better stability of the design control system. • When the P.I.D. algorithm has calculated a new output value, ranging from 0 (precorrection) to 255 (maximal paper pull), this is converted into an analogue signal 0…10 V to the Servo Driver which relies the folding flaps movement. • From the calculated design error the DCS22 program also decides whether it should accept the package or not. If the package is accepted the DesignOK signal to the PLC is set. The decision is based upon the following rules: Design Error Design error of last package is less than ±1.5 mm Otherwise

Package Accepted YES NO

• The DCS22 program then start again to search for a new register mark. Besides this main program flow the DCS22 program also checks if anything is sent from a terminal through the RS-232 serial interface. If so, it returns the appropriate answers to the terminal, refer to the "Terminal communication" chapter.

7. Other Program Functions Besides the basic program functions described above the DCS22 program performs some other functions and decisions: Precorrection vs. Regulating mode: • The TMCC analog output, which drives the Servo motor driver, works in the range 0…10 Volts. The value displaied by the TMCC, thought the serial port, can therefore be from 0 to 255. • The precorrection mode is used when the paper tube is far out of design, to move it as fast as possible to the correct position. The precorrection position lets the paper tube "move upwards" in relation to the jaws. • A normal production start always begins in the precorrection mode. The DCS22 program continuously calculates the design error, also during precorrection mode. A number of packages are thrown away before the PLC turn on the signal DCS22 enabled. From this moment the DCS22 stays in precorrection mode until the design error becomes less than ±10 mm; when this condition is fulfilled the DCS22 enters in regulating mode and turns on the Regulating mode signal. • When in regulating mode the DCS22 program tries to keep as low design error as possible. When the design error is less than ±1.5 mm then the Design OK signal (and front panel LED) is turned on. The filling machine is "in production". • When the DCS22 program runs in the regulating mode it continues in this mode until: • more that five consecutive packages have a design error greater than ±10 mm, • more than four Register Marks should have passed the photocells, i.e. they are missed, • the PLC resets the DCS22 Enable signal. When one, or more, of these condition is true the DCS22 program switches to precorrection mode (and consequently the Regulating mode signal turns off).

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• When the filling machine is in short stop the design control system remains in regulating mode. When started again the DCS22 program tries to keep the design control as good as possible, just like in normal production mode. Volume Parameters: • Normally the volume parameters are sent from the PLC, refer to the "Volume Parameter Transfer" chapter. In this case the SW2 of the TMCC card must be set to position '0'. • However, for test purposes and in special cases, it is possible to set a default Repeat Length and Production Angle with the SW2 switch on the TMCC side (the TMCC must be pulled out of the rack system). The Repeat Length and production angle may be set to one of: SW2 Pos. 0 1 2 3 4 5 6 7 8 9 A B C D E F

Repeat Length, mm Reserved 140 140 140 140 140 140 140 160 160 160 160 160 160 160 160

Production Angle Reserved 32 34 36 38 40 42 44 68 69 70 71 72 73 74 75

8. TMCC Front Panel Switch The front panel switch SW1 is used for selecting one of the available formats for the diagnostic output. The following table resumes the variable which can be monitored though the diagnostic analog output. SW1 0 1 to 7 8 9 A B C D E F

Function Programming mode: in this position it is possible to download the DCS22 program. Refer to the "Program Download" chapter. Not used. Design error of current package (∗ ∗ ). Design error of current package (∗ ∗ ). Filtered design error ("90% old + 10% new"-algorithm). (∗ ∗) Output signal to the servo driver. Filtered output signal. Design Adjustment signal. Not used. Not used. (∗ ∗ ) 0…10V on this output equals to -5…+5 mm.

NOTE: In normal production mode the SW1 should be set to position 8.

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9. TMCC Front Panel LEDs The TMCC front panel LEDs have the following meaning in normal production mode: LED FAULT POWER S1 S2 S3 S4 S5 S6 S7 S8

Function Not used in this program Should be turned on (Green). Indicates that the power supply to the TMCC is correct. Flashes when a Register Mark is detected, the flash being approx. 40 ms. Turns ON when the design is within ±1.5 mm i.e. "in production". Not used. Not used. Not used. Not used. ON = The analog output signal is set at its upper range ( greater than 192 = 7.5 V). ON = The analog output signal is set at its lower range ( less than 64 = 2.5 V).

10. Encoder Function and Gray Codes The angle encoder is connected to the machine main shaft and outputs 256 degrees (values) for each package. The encoder is a 256 degrees version which means that one package range from 0 to 255 and then back to 0 again. The value sent to the TMCC is Gray-coded, which means that only one of the eight signals (bits) changes for each change in degree (this prevents erroneous angle values on the signal lines.) This also means that the DCS22 program must convert the value into a "normal" representation before it can be used in calculations. A conversion table is given in the appendices.

11. Output Signal The PID algorithm calculates a new output value for every package. The calculated output value ranges from 0 to 255. This value is converted into an analogue signal for the Servo motor driver that moves the folding flaps accordingly. When the machine goes in precorrection the analog output signal is frozen.

12. Design Adjustment Signal The TPOP is used to move (fine-adjust) the design position in relation to the jaw system. The TPOP is connected via Flexbox to an analog output of the PLC. The DCS22 program converts the voltage level into an angle offset that is then added to the constant production angle set by the PLC. The adjustment range ±500 on TPOP corresponds to a movement of ±5 mm on the design position, this range being the same for all volumes. Negative settings will move the design downwards in relation to the jaw system, and vice versa.

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13. Terminal (PC) communication A terminal, or a PC with a terminal program, is not necessary during normal production, but may be used for test and service purposes. Through the serial interface it is possible to see the design error, output values and other DCS22 status values. The communication is a standard RS-232 serial interface. Use a cable suitable for the TMCC and the PC (terminal). Necessary pin connections are: PC 9-pin female 2 3 5

TMCC 9-pin male 3 2 5

If you are using a PC, any terminal program may be used, like "TIT" or other terminals such as Hyperterminal, windows 3.11 terminal etc. . Configure the program for: • • • • •

Baudrate: Parity: Bits: Stopbits: Flow Control:

9600 None 8 1 None

The commands and parameters, if any, to the DCS22 program is entered on the keyboard, and the command is executed when the RETURN key is entered. (The commands and parameters are not echoed on the terminal). The functions described below are available: Annn

Angle nnn. The Production Angle (=machine angle) may be set with this command. nnn is the new angle value, ranging from 0 to 255 decimal degrees. Normally the Production Angle is set from the PLC, but this command overrides the PLC setting. It may be used in test purpose to find the correct nominal Production Angle, which will later be set from the PLC. Note that the Design Adjustment Value set by the potentiometer is added to this value. For example: A72 sets the Production Angle to 72 degrees.

Dddd

D-constant: Sets the D parameter in the PID controller algorithm, in 1/100 units. The original value will be restored after a TMCC reset.

E

Displays the current Encoder value, first the hexadecimal Gray code, then converted to decimal.

Fooo

Force ooo. This command forces the analog output signal to a certain value which is (ooo). F0 resets the forcing: F0 Reset (disable) output force. F1 Force to output = 0. F2 Force to output = 1. ... F255 Force to output = 254.

Iiii

I-constant: Sets the I parameter in the PID controller algorithm, in 1/100 units. The original value will be restored after a TMCC reset.

Pppp

P-constant: Sets the P parameter in the PID controller algorithm, in 1/100 units. The original value will be restored after a TMCC reset.

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Rn

Reporting ON/OFF. This command enables and disables the automatic reporting of the design error and output value for every package. R0 Disable reporting. R1 Enable reporting.

S

Status: This command displays a list of parameters that may be of interest for test and service purposes: ***** DCS22 Status ***** DesignError, mean : 0.00 Output, mean : 0 Machine Speed, p/h: 65535 Repeat Length, mm : 0.00 Prod Angle, const : 0 Pot: 128 Pc: 1.29, Ic: 0.05, Dc:

H

0.10

Displays the available commands as follows: ******************* DCS22 Help Menu ******************* S shows the status of the parameters P changes the P constant in 1/100 units I changes the I constant in 1/100 units D changes the D constant in 1/100 units F forces the analog output. F0 = disable forcing R R1=reporting ON R0=reporting OFF A changes the production angle E shows the encoder position: gray, decimal H shows the available commands

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14. Volume Parameter Transfer The Repeat Length, the Production Angle may be sent from the PLC to the DCS22 program. This sending uses four digital +24V signals and the protocol is as follows: From PLC: VolumeEnable VolumeClock VolumeData From TMCC: VolumeAcknowledge

1. Set VolumeEnable

5. Output last bit

2. Output bit 1

6. Toggle VolumeClock

3. Toggle VolumeClock

7. Reset VolumeEnable

8. Repeat the message until VolumeAcknowledge is set

4. Shift out all data bits

• The bit time must be at least 5 ms. • The output bits are shifted with the least significant bit (LSB) first: Repeat

LengthProduction Angle

• The Repeat Length is in 1/10 of mm, i.e. a repeat length of 245 mm is sent as 2450. • The Production Angle is in integer degrees, i.e. a sector of 123 is sent as 123. Other features: • The signal VolumeAcknowledge in the protocol is useful when, for example, the PLC starts up earlier than the TMCC, or if the TMCC is replaced or reset during power on. In these cases the VolumeAcknowledge is reset to low and the PLC should start to send the message again. • The DCS22 program must receive at least two complete message that are exactly the same before is sets the VolumeAcknowledge signal.

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15. Program Download The DCS22 program should be downloaded to the TMCC during machine production, but it may be necessary to do a new download if the TMCC has been replaced or if a new release of the DCS22 program is available. The download is done from a PC with at least one diskette station and one serial RS-232 interface. Refer to the "Terminal (PC) Communication" chapter for a description of the communication parameters. Download procedure: 1. Connect the cable between the PC and the TMCC front panel connector. 2. Set the SW1 front panel switch to position "0" 3. Insert the program diskette marked "48197 - x01" (x = current revision) into the PC diskette station. 4. Start the download program TMCC11.EXE by entering the command: A:TMCC11 5. When the program menu appears enter the communication port in use, normally "1". 6. Now a directory listing will appear. Select the A: drive by pressing the key. 7. A list of the files on diskette A: will appear. Select the file D48197.x01 (x = current revision) by using the arrow keys. (First use the right arrow to select the file window). 8. When the file is selected press the function key , and the automatic download starts. 9. The progress of the download may be monitored in the lower part of the screen. 10. When the new program is downloaded without errors press the function key to exit the TMCC11.EXE download program. 11. If a label (with the program number and LED functions) is supplied together with the diskette this label should be affixed to the TMCC front panel, aligned with the LEDs. 12. Set the TMCC front panel switch SW1 to production position "8" and the download procedure is finished. 13. Cycle the power OFF/ON by removing the TMCC card from the rack.

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16. Appendices Gray Code Table Gray ---- ------- ---• ---- --•• ---- --•---- -••---- -••• ---- -•-• ---- -•----- ••----- ••-• ---- •••• ---- •••---- •-•---- •-•• ---- •--• ---- •-----• •-----• •--• ---• •-•• ---• •-•---• •••---• •••• ---• ••-• ---• ••----• -•----• -•-• ---• -••• ---• -••---• --•---• --•• ---• ---• ---• -----•• -----•• ---• --•• --•• --•• --•--•• -••--•• -••• --•• -•-• --•• -•---•• ••---•• ••-• --•• •••• --•• •••--•• •-•--•• •-•• --•• •--• --•• •----•- •----•- •--• --•- •-•• --•- •-•--•- •••--•- •••• --•- ••-• --•- ••---•- -•---•- -•-• --•- -••• --•- -••--•- --•--•- --•• --•- ---• --•- ----

Dec 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

Gray -••- ----••- ---• -••- --•• -••- --•-••- -••-••- -••• -••- -•-• -••- -•--••- ••--••- ••-• -••- •••• -••- •••-••- •-•-••- •-•• -••- •--• -••- •---••• •---••• •--• -••• •-•• -••• •-•-••• •••-••• •••• -••• ••-• -••• ••--••• -•--••• -•-• -••• -••• -••• -••-••• --•-••• --•• -••• ---• -••• ----•-• ----•-• ---• -•-• --•• -•-• --•-•-• -••-•-• -••• -•-• -•-• -•-• -•--•-• ••--•-• ••-• -•-• •••• -•-• •••-•-• •-•-•-• •-•• -•-• •--• -•-• •---•-- •---•-- •--• -•-- •-•• -•-- •-•-•-- •••-•-- •••• -•-- ••-• -•-- ••--•-- -•--•-- -•-• -•-- -••• -•-- -••-•-- --•-•-- --•• -•-- ---• -•-- ----

Dec 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127

Gray ------• --•• --•-••-••• -•-• -•-••-••-•

••-••-••-••-••-••-••-••-••-••-••-••-••-••-••-••-••-• ••-• ••-• ••-• ••-• ••-• ••-• ••-• ••-• ••-• ••-• ••-• ••-• ••-• ••-• ••-• •••• •••• •••• •••• •••• •••• •••• •••• •••• •••• •••• •••• •••• •••• •••• •••• ••••••••••••••••••••••••••••••••••••••••••••••••-

•••• ••••-••-•• •--• •--•--•--• •-•• •-•••••••• ••-• ••--•--•-• -••• -••--•--•• ---•

---------• --•• --•-••-••• -•-• -•-••-••-• •••• ••••-••-•• •--• •--•--•--• •-•• •-•••••••• ••-• ••--•--•-• -••• -••--•--•• ---•

----

Dec 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191

Identity

4-58716-0000

Dec 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255

•••• ••••-••-•• •--• •--•--•--• •-•• •-•••••••• ••-• ••--•--•-• -••• -••--•--•• ---•

---------• --•• --•-••-••• -•-• -•-••-••-• •••• ••••-••-•• •--• •--•--•--• •-•• •-•••••••• ••-• ••--•--•-• -••• -••--•--•• ---•

----

Functional Description

Tetra Brik PS S.p.A. Issued by / Date: Fabio Bassissi / 10-Feb-2000

Gray ------• --•• --•-••-••• -•-• -•-••-••-•

•-••-••-••-••-••-••-••-••-••-••-••-••-••-••-••-••-•• •-•• •-•• •-•• •-•• •-•• •-•• •-•• •-•• •-•• •-•• •-•• •-•• •-•• •-•• •-•• •--• •--• •--• •--• •--• •--• •--• •--• •--• •--• •--• •--• •--• •--• •--• •--• •--•--•--•--•--•--•--•--•--•--•--•--•--•--•--•---

Approved by / Date: Fabio Bassissi / 10-Feb-2000

ECN

73343

Document type

Version

Page

DSC

00

13 (14)

Tetra Pak

Description

Connection Diagram

3 4

AnalogIn0 AnalogIn1

LowIn0 LowIn1 LowIn2 LowIn3 LowIn4 LowIn5 LowIn6 LowIn7

9 10 11 12 13 14 15 16

5 6

AnalogOut0 HighIn/LowOut0 AnalogOut1 HighIn/LowOut1 HighIn/LowOut2 FastIn0 HighIn/LowOut3 FastIn1 HighIn/LowOut4 HighIn/LowOut5 HighIn/LowOut6 RS-232/CAN HighIn/LowOut7 Transmit HighOut0 Receive HighOut1 StatusOut HighOut2 StatusIn HighOut3 Ground HighOut4 +10V HighOut5 CANhigh HighOut6 CANlow HighOut7 NoConnect

17 18 19 20 21 22 23 24

1 2

+24V 0V

Design Adjustment Servo Driver Signal DiagnosticOutput

+24V Ground

7 8

FP3 FP2 FP4 FP6 FP5 FP7 FP1 FP9 FP8

TMCC

25 26 27 28 29 30 31 32

AngleEncoder0 (LSB) AngleEncoder1 AngleEncoder2 AngleEncoder3 AngleEncoder4 AngleEncoder5 AngleEncoder6 AngleEncoder7 (MSB) RegisterMarkPhotocell, 4bar (clock) RegisterMarkPhotocell, 3bar (data) DCS22 Enabled VolumeEnable VolumeClock VolumeData VolumeAcknowledge Regulating Mode Signal

Photocell pulse DesignOK

Functional Description

Tetra Brik PS S.p.A. Issued by / Date: Fabio Bassissi / 10-Feb-2000 Identity

4-58716-0000

Approved by / Date: Fabio Bassissi / 10-Feb-2000

ECN

73343

Document type

Version

Page

DSC

00

14 (14)

Description of how to download an application program for TMCC from Windows95/98 From main menu select Start - Programs - Accessories - Hyper Terminal, Double click on Hypertrm Enter a name and choose an icon to be able to continue. Press OK In the square for ”Connect using” choose Com 1 Press OK Set the port setting to the following: Bits per second: 9600 Data bits: 8 Parity: None Stop bits: 1 Flow control: None Press OK From the menu choose File, click on Properties Click on Settings Press ASCII Setup Choose: Send line ends with line feeds Echo typed characters locally Line delay: 100 milliseconds Character delay: 0 milliseconds Wrap lines that exceed terminal width Press OK Press OK Set the multi-switch on the TMCC card to 0 Print: P1 Press: Enter Print: E_FLASH Press: Enter Print: D Press: Enter From the menu choose Transfer - double click on Send Text File Choose: Look in: 3½Floppy (A:) Files of type: All Files (*.*) Double click on D48197.101 (example of a program name)

11 Final folder

Technical Training Centre

Final folder Package

Air for heating Pressure Movement

Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/22

1/9903

OH 806:1

Technical Training Centre Lund, Sweden

Swing frame

Flap sealing

Squeezer

Machine type

Discharge unit

TBA/22

Drive shaft Conveyor

1/9905

Issue

Chain support Station chain

OH 806:2

Final folder Description

Technical Training Centre Lund, Sweden

Machine type

TBA/22

1/9905

Issue

Drive OH 806:3

Final folder

Technical Training Centre Lund, Sweden

Machine type

TBA/22

1/9905

Issue

OH 806:4

Final folder

Synchronisation

Technical Training Centre Lund, Sweden

Machine type

TBA/22

1/9905

Issue

OH 806:5

Final folder

Conveyor

Swing frame Technical Training Centre Lund, Sweden

Final folder

Machine type

TBA/22

1/9905

Issue

OH 806:6

Technical Training Centre Lund, Sweden

Machine type

TBA/22

1/9905

Issue

Infeed

OH 806:7

Final folder

Flap sealing Technical Training Centre Lund, Sweden

Final folder

Machine type

TBA/22

1/9905

Issue

OH 806:8

Final folder

X

Squeezer

X

Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/22

1/9905

OH 806:9

Technical Training Centre Lund, Sweden

Check temperature

Machine type

TBA/22

Home position FFU

1/9905

Issue

Alarms

Package

OH 806:10

Final folder

K 24

3x400 V AC

Technical Training Centre Lund, Sweden

Emergency stops safety relay

K 25 PLC

Door guards safety relay

Rectifier

Machine type

Hardware enable 570 V DC

Safety relay

TBA/22

Find Home position Synchrons drive High speed inching Low speed inching Software enable

K4

DMC

1/9905

Issue

Out ready Position error Home position Motor is running

Resolver

Resolver signal main motor

Motor

Final folder

Home position

Home position

OH 839

Synchronize internal clocks

1

To FFU DMC

2

Control of Final folder motor

12 ASU 2 R

Technical Training Centre

ASU 2R Packaging material web Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/21 HS

1/9905

OH 840:1

B 72234 B 6107

B 7512

B 7501

B 7412

B 72102 B 72112

B 72233

B 7403:1 B 7403:2 B 7401 B 72232

ASU 2R Automatic splicing unit Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/21 HS

1/9905

OH 840:2

PLC

Jog

Jog P

P

MICRO MASTER

MICRO MASTER

ASU 2R Drive motor control Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/21 HS

1/9905

OH 840:3

0

1000

2000

3000

4000

5000

6000

7000

8000

Time (mS)/Stroke (mm)

Technical Training Centre Lund, Sweden

Reel 1 empty/ manual signal splicing B 74011 / S 7402

Reg. code sensor Data B 74031 Clock B 74032

19000 14000 13000 7000 0

Drive roller loop ASU M 7208

1135

6235 Loop full

A

Machine type

DC brake 5035

Web tension

10 0

Y 7407, C 74071, C 74072

TBA/22

5935

Pressure rail

1170

Y 7408, C 7408

Lock cylinders 1

15 0

1170

Y 7303, C 73031, C 73032

24 0

1255

Y 7410, C 7410

1510

Material holders

6235

3835

Side feeder 1 − − − 2

1/9905

Issue

2395

B 7412 B 7512

K 7416

488 0

2035

Y 7412, Y 7413, C 7412

Power switch

100 0

4165

C 7411, B 7411 C 7414, B 7414

3775

5275 ASU SA

4720

OH 841

Sealing

5170

A 7417, L 7417

5035

Lock cylinders 2

15 0

Y 7315, C 73151, C 73152

17500 14000 13000 0

Drive roller magazine ASU M 7217

A = 370 ms at 250 B A = 345 ms at 200 B

1

2 3

4

5

6 7

8

Web magazine full

Splice sequence finished

Sequence diagram ASU

1510

Cutting

Y 7411

10 0

4630

Basic function of the ASU Production Pressure rail cylinders C 7408

Photocell, reading bar code B 7403

Drive roller M 7208

Web tension cylinders C 7407

M Inductor L 7417

Cutting cylinder C 7410

Knife Side feeder cylinder C 7412, C 7413

Loop

Lock cylinders C 7303, C 7315

Photocell, start splice sequence B 7401

Material holder cylinders C 7411, C 7414

Packaging material

Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Machine type

Issue

TBA/21

1/9409

OH 500:1

Basic function of the ASU Splicing, step 1 M 7208 C 7407

M

B 7401

C 7411, C 7414

Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Machine type

Issue

TBA/21

1/9409

OH 500:2

Basic function of the ASU Splicing, step 2 M 7208 C 7408

M

B 7403

C 7303

Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Machine type

Issue

TBA/21

1/9409

OH 500:3

Basic function of the ASU Splicing, step 3

M

C 7410

Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Machine type

Issue

TBA/21

1/9409

OH 500:4

Basic function of the ASU Splicing, step 4

M

C 7410

C 7411, C 7414

Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Machine type

Issue

TBA/21

1/9409

OH 500:5

Basic function of the ASU Splicing, step 5

C 7408

M

Prepared station

C 7412 C 7413

Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Machine type

Prepared station

Issue

TBA/21

1/9409

OH 500:6

Basic function of the ASU Splicing, step 6

M

C 7411, C 7414

Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Machine type

Issue

TBA/21

1/9409

OH 500:7

Basic function of the ASU Splicing, step 7

M

L 7417

C 7408

Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Machine type

Issue

TBA/21

1/9409

OH 500:8

Basic function of the ASU Splicing, step 8

C 7407

M

C 7315

Tetra Pak Processing & Packaging Systems AB Technical Training Centre, Lund, Sweden

Machine type

Issue

TBA/21

1/9409

OH 500:9

13 Sealing

Technical Training Centre

TPIH-2000 Textbook MT-83014-2

Longitudinal sealing Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/22

1/9906

OH 859

Strip applicator

Guide wheel Pressure roller

Adjusting screw

Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/21

1/9806

OH 772

Automatic strip splicing unit Bobin 1

B6208 Strip rotation monitor

B6207 Stripbreak B6201 Indicator strip end bobin 1 B6204 Indicator stop of splicehed

Splicer ASSU

Bobin 2

Cutting wire

B6202

Sealing band

Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/22

1/9907

Air cooled channel Strip holder

OH 861

Textbook

TPIH-2000

MT-83014-2

Technical Training Centre Lund, Sweden

General information on IH TPIH-2000 is a generator, which generates a high–frequency current. This current is utilized to induce heat in the packaging material, for instance in transversal sealing. TPIH stands for Tetra Pak Induction Heating.

Induce = to bring about, to produce IH = induction heating

The TBA machines are equipped with IH generators, and the high–frequency current induces heat in the aluminium foil layer of the packaging material. The heat causes the plastic (PE layers) to melt, and thus the packages can be sealed. The induced heat causes the plastic (PE) to melt, so that the packages can be sealed.

Heat induced in the aluminium layers

PE PE

Paper

PE=Polyethylene

PE

Al

Al PE

Paper

PE

PE

Al=Aluminium

Induction heating is also employed to heat the PE layer at the opening arrangement of the package. The heat changes the structure of the PE layer, making the plastic more brittle. For this reason, the package becomes easier to open. The method of heating a material without a direct source of heat, i e to produce heat in the material, is based on a current of high frequency. One could say that the high–frequency current transfers energy to the material, There are two ways of producing heat by means of high–frequency current: • Induction heating (for instance transversal sealing in TBA machines) • Dielectric heating (for instance in a microwave oven)

Technical Training Centre2/9608

Training Document. For training purpose only.

5

Induction heating is used to heat materials which are electrically conductive (metals). This is the method employed in the TBA machines for transversal sealing, zone heating at the opening arrangement of the package, longitudinal sealing (TBA/21), strip application (TBA/21), and splicing of the packaging material (TBA/21).

Induction heating

The diagram below shows the principle of this method. High–frequency current

Coil Magnetic field

Electric conductor

Induced current

The high–frequency current creates a magnetic field around the coil. This magnetcic field oscillates in time (at the same frequency) with the current, inducing a current in an electric conductor placed in the magnetic field. In its turn, the induced current oscillates in time with the magnetic field and produces the energy that heats the material. In the TBA machines, induction heating works as shown in the diagram below.

IH generator Current path in the aluminium foil Inductor

The IH generator (TPIH-2000) generates a current of high frequency. The inductor functions as a coil and creates a magnetic field. Heat is induced in the packaging material as a result of a current being induced in the aluminium foil. This leads to the melting of the PE layers, so that they can be sealed.

6

Training Document. For training purpose only.

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Dielectric heating

Dielectric heating is used to heat non–conductive materials, such as wood. This method is also employed in microwave ovens. The diagram below shows the principle of this method.

High–frequency current Electric field

Plates

Material, e g wood

The high–frequency current produces an electric field between the plates. The field oscillates in time with the current, and the molecules of the material will in their turn also oscillate in time with the field. The oscillations produce energy, which heats the material. Note In order for this method to work, the material must contain ions or polar molecules, i e molecules which are influenced by electric fields. Water molecules are polar, and as wood always contains a certain amount of moisture, it is perfectly possible to heat wood according to this method.

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7

TPIH-2000 An IH system incorporating a TPIH generator is designed as the diagram below shows.

IH system

Potentiometer

IH generator, TPIH-2000

Current rail

Inductor Transformer

Coaxial cable

The generator converts the mains voltage to a high–frequency voltage. The magnitude of the high–frequency voltage is set by means of the potentiometer as a percentage of the maximum voltage; for instance, 850 translates as 85% of the maximum voltage. In its turn, the high–frequency voltage determines the power in the inductor. This relationship of the voltage is proportional to the square of the power; for instance, if the potentiometer is set at 850, the power in the inductor becomes 0.85 x 0.85 = 0.72, i e 72% of the maximum power. On page 10, more can be found on the relationship between voltage and power. The coaxial cable conducts the high–frequency current to a transformer near the inductor. The transformer has a transformation ratio of 5:1, i e it reduces the voltage and increases the current by a factor of 5. Consequently, the power remains unchanged, but low voltage in the inductor cuts down the danger of spark–over and improves safety. The last part of the passage of the current to the inductor goes through a current rail. In the current rail, power losses occur, and for this reason, the rail is made as short as possible. The inductor functions as a coil and creates a magnetic field which induces current in the packaging material.

8

Training Document. For training purpose only.

Technical Training Centre 2/9608

Usually, a TBA machine is equipped with several IH generators, for instance three, one for each pair of jaws and one for the zone heater.

Generator TPIH-2000

On the front of the generator, there is an alarm panel, connections for control signals and power inputs, and an output for high–frequency current. The light– emitting diodes on the alarm panel indicate faults and errors etc, and can be used to facilitate fault–finding.

Alarm panel

Connections for control signals

Connections for power inputs

Output for HF current HF=high frequency

Technical Training Centre2/9608

Training Document. For training purpose only.

9

Explanation of the light–emitting diodes on the alarm panel: Output Voltage Low (red). If this is the only red light–emitting diode that is on, one of the following faults has occurred: 1) The generator is defective and must be replaced. 2) 10 V DC is not being supplied to the potentiometer. 3) The potentiometer has been set at too low a value. 4) The potentiometer is defective. Mains Voltage Low (red). Power feed to the generator is insufficient. At least one of the phases supplies less than 85% of the nominal power, and the generator cannot in its turn provide the correct power. Check the input power fuses. Temperature High (red). The temperature inside the generator is too high. Most likely, the fan is defective. If this is the case, the complete generator assembly must be replaced. Load Error (red). There is an error in the load, i e the coaxial cable, current rail, transformer, or inductor. Output On (green). Lights up when a pulse is being converted into the correct load, i e when the system functions correctly. Control Voltage On (green). The power feed to the control section functions correctly. The diagram below shows the connections for the control signals and input power. The No at each connection, shows how the cable concerned is marked.

28 24 20 16 12 8

30 26 22 14

30 26 22 18 10 4

10

6

30 28

Power alarm. Common alarm to PLC for: Output Voltage Low, Mains Voltage Low, and Load Error.

26 24

Temperature alarm to PLC.

22 20 16

Power setting from POT. 10 V DC to POT 0V

14 12

24 V DC 0V

8

Sealing pulse from PLC

30 Neutral 26, 230 V AC 50/60 Hz Three–phase 230/400 V AC 50/60 Hz 22 Phase R 18 Phase S 10 Phase T 6 Neutral 4

Ground

Training Document. For training purpose only.

Technical Training Centre 2/9608

Function

The TPIH-2000 generator works in accordance with the block diagram below. It comprises an power section and a control section.

TPIH-2000 Control section Temperature alarm PLC Power alarm PLC Sealing pulse PLC Power setting POT 24 V DC 230 V AC

Power section

Triple pulse rectifier

Voltage regulator

Power step

Filter

Output transformer

The control section is powered by 230 V AC and 24 V DC. It controls, for instance, voltage and frequency, and monitors the unit. It also controls the alarm panel. The power section is powered by 3x400 V AC and incorporates the following functions: Triple pulse rectifier, which converts the alternating voltage (AC) into a direct current (DC) of appr 325 V. Voltage regulator, which stabilises the direct voltage at appr 350 V. Power step, which converts the direct voltage into a high–frequency square pulse of 350 V, 0.5 MHz. Filter, which generates a sinus–shaped high–frequency alternating voltage of 300 V, 0.5 MHz. Transformer, with a ratio of 1:1, which is used to isolate the load from the generator. The load comprises the coaxial cable, transformer, current rail, and inductor.

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11

As previously mentioned, the power in the inductor is determined by the output voltage from the generator. In order to understand how the output voltage is regulated, we have to take a closer look at what happens in the filter section of the generator.

Uin

Filter

Uout

In order to regulate the output voltage, the fact is exploited that the ratio between the output and input voltages (Uout /Uin) in the filter is not constant. This ratio depends on the frequency, as shown in the diagram below. Uout /Uin

Power regulation

At the resonance frequency, the ratio between output and input voltage reaches maximum.

Resonance frequency Maximum power

Minimum power

Regulation range Frequency 0.485

0.550

(MHz)

The 0.485-0.550 MHz frequency range is utilized to regulate the output voltage and thus the output power. Within this frequency range, the ratio between output and input voltage is virtually linear. Thus it is the frequency which is altered in order to regulate the power. The setting of 999 on the potentiometer is equal to a frequency of 0.485 MHz, which gives maximum power (2kW). The setting of 850 corresponds to a frequency which gives the power of 0.852 x maximum power (0.852 x 2=1.4 kW), etc. Note This way of calculating disregards the fact that the phase angle, cosine ϕ, varies with the power. At low power, cosine ϕ is reduced; for instance, at a potentiometer setting of 440, the power may be 0.9 x 0.442 x maximum power.

12

Training Document. For training purpose only.

Technical Training Centre 2/9608

Comparison between TPIH2000 and older IH generators TPIH-2000 has been installed in the following machines from the development step specified. • TBA/8 060V • TBA/9 140V • TBA/10 120V • TBA/21

Much of the loss occurs in the current rail. In the TPIH-2000 system, a major part of the current rail has been replaced by a coaxial cable. But the coaxial cable cannot cope with as high an amperage as a rail, so therefore the current is transformed in a transformer near the inductor instead of in the generator itself.

The significant difference between TPIH-2000 and the older model generator is that TPIH-2000 is a transistor generator, while the older model is an electronic valve generator. A comparison between the two generator types shows the following differences: • The output power of TPIH-2000 is adjustable while the machine is running. This is not possible with the older IH generator. • In TPIH-2000, the output power is not dependent on the mains voltage (within a range of -15 to +10 per cent of the nominal value). In the old model, there is a direct relationship between mains voltage and output power. • TPIH-2000 consumes 1.5 kW while the old model uses up appr 4 kW. Nevertheless, the inductor power is equally high, appr 1 kW, which is due to the losses in the TPIH-2000 system being lower. TPIH-2000

Generator Inductor Coaxial cable

Current rail Transformer

Old model IH generator

Generator Current rail

Inductor

• The voltage across the inductor in the TPIH-2000 system is 40-50 V; in the old IH generator it is appr 90 V. Low voltage is preferable as it reduces the danger of spark–over and improves safety. • The frequency in TPIH-2000 is 0.5 MHz, compared with 1.8 MHz in the old generator. • TPIH-2000 is based on transistor technology, and the old model IH generator on electronic valves. Transistors are very reliable with a long working life, while valves have a limited life. • Inside TPIH-2000, there is no high-tension. Maximum voltage is 400 V, while the high-tension section of the old model generator carries 5000 V.

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13

TPIH test instrument For TPIH-2000, there is a special test instrument (TP 68462-101). It can be used for the measuring of: • HF voltage • HF current • Load phase angle (cosine ϕ) • Pulse time (duration) The test instrument is intended to be connected in series with the coaxial cable from the generator, as shown in the diagram below.

Printer socket Display Selector

To be connected to generator

To be connected to coaxial cable

Note that a user’s manual for the instrument is being supplied.

The measuring results can be used to calculate the power and impedance of the load. P=U x I x cosϕ (Power = Voltage x Amperage x Cosine ϕ) Z=U/I (Impedance = Voltage/Amperage) Impedance is to be roughly 50 Ω. Normal value is 40-65 Ω. Note The pulse time is determined by the machine PLC and does not require adjustment. If the special test instrument for TPIH-2000 is not available, the pulse time can be measured by means of a pulse time meter (TP 102 90243-90) and the HF voltage by means of an HF voltmeter (TP 103 90243-114). In this case, measuring is done at the copper rail by the inductor (secondary transformer side).

14

Training Document. For training purpose only.

Pulse time meter HF voltmeter

Technical Training Centre 2/9608

Instruction manual

Note: The following is copy of the instruction manual enclosed to the TPIH test instrument 68462.

TPIH test instrument 68462 Instructions (rev Sep 91) The TPIH test instrument is used for checking the high frequency part of a TPIH system.

1 Connecting The instrument is connected in series with the coaxial cable between the generator and the IH-transformer, usually closest to the generator. NOTE: Connection and disconnection of the test instrument must be done, when the generator is not pulsing e g with the machine in the short stop position.

2 On and off The instrument is started with a rotary switch. Approximately five minutes after the latest activation of the switch, the instrument is automatically turned off.

3 Measuring Voltage (V), Current (A), Phase angle between voltage and current (degrees) and Pulsetime can all be measured. Disregard any numbers that are displayed prior to the measurements. When the measurement is finished note the values directly. a Pulses The toggle switch to the right is put in position ”pulse”. The instrument measures and stores pulse time after every pulse. The voltage, current and phase angle are measured and stored after half the pulse time. In order for the instruments to make correct measurements, i e in the middle of the pulses, at least 2 pulses are needed. The LED ”pulse” lights up during the pulse and ”sample” lights up when a measurement is taking place. Put the toggle switch in position ”hold” when no more new measurements are needed. b Continuous signals The toggle switch to the right is put in position ”Continuous”. The instrument shows the measurements for voltage, current and phase angle appr. 3 times/second. If, at a certain point, the measurements are to be stored, the toggle switch is put in position ”hold”. c Single pulse The rotary switch is turned to position ”pulse time” and the toggle switch to the right to position ”Continuous”. The toggle switch to the left is used to preset an expected pulse time (N.B.! Pos. values). Change the toggle switch to the right to position ”pulse”. It is now possible to measure a single pulse.

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15

4 Power, energy etc By using the measured values several others can be calculated. Power = Voltage x Current x Cos (phase angle) (W). Pulse energy = Power x Pulse time (mWs). The Impedance’s absolute value = Voltage/Current (ohm). Cos ±5 = 0.996 Cos ±10 = 0.985 Cos 0° = 1 2 Cos X 1 - x : 6700 -40° < x < 40°

5 Trouble shooting for load error If there is a load problem only short pulses are delivered by the generator. The results from the measurements will be approximate but they could make trouble shooting easier. During a pulse with load problem the LED ”sample” is lit up during the entire pulse, while LED ”pulse” is off. Load examples (Test instrument connected closest to the generator)

Phaseangle (Degrees)

Voltage/Current (Ohm)

Optimal load (no load problem)

0

50

Normal load (no load problem)

±15

40 - 65

Short circuit in coax. cable, contacts, primary of IH-transf.

pos (3)

1 - 10 (1)

Open circuit in same as above.

neg (3)

200 - 2000 (2)

Short circuit in inductor, current rail, secondary of IHtransformer.

pos

10 - 20

Open circuit in same as above

neg

2-5

No packaging material on the inductor.

neg

5 - 15

(1) = The greater value, the greater distance between problem and instrument. (2) = The greater value, the shorter distance between problem and instrument. (3) = The greater phase difference, the greater distance between problem and instrument.

6 Connection of chart recorder To record voltage, current and phase as a function of time a chart recorder e g Brush can be connected. 1 Connect the included cable to the recorder. marking ”V” : Voltage 100 mv = 100 V marking ”C” : Current 50 mv = 1 A marking ”P” : Phase 10 mv = 1 ˚ marking ”O” : O 2 Isolate cables that are not used. 3 Connect to the instrument. The toggle switch to the right is put in position ”pulse”.

16

Training Document. For training purpose only.

Technical Training Centre 2/9608

7 Battery The instrument is powered with a standard 9 V battery e g 6LR61. An alcaline battery gives approximately 40 hours operation. When approximately 5 hours operation are left, ”batt” is displayed. The instrument gives correct values until 000 is displayed and it switches off automatically. The battery eliminator is used when you want to measure during long time, e g with a recorder. With the battery eliminator connected and the rotary switch in position ”batt” the display should show 8,5 V - 14 V.

8 Accuracy Accuracy for new instruments used according to 3a and 3b. ± (2 % + 1 V) 100 - 350 V Voltage ± (2 % + 0,03 A) 2-7A Current ± (5 % + 2 ˚) -30° - +30° Phase Pulse time ± (2 % + 2 ms) 10 - 1000 ms To compare two instruments, connect them in series. Then interchange them since the values depend on the distance from the load, especially if the load differs from 50 ohm.

9 General The instrument can operate in temperatures from 0 to 45 ˚C. It should not be used immediately after major temerature change. Store the instrument in a dry place. Temporary storage temperature: -20 to +60 ˚C Do not use the instrument if water has penetrated into it. Do not dismantle the instrument when the coaxial cables are connected. The panel can be opened if the lower screw in the middle is loosened.

Technical Training Centre2/9608

Training Document. For training purpose only.

17

14 Filling system

Technical Training Centre

Technical Training Centre Lund, Sweden

Regulating valve

TBA/19 TB/19, TBA/21

Machine type

4/9810

Issue

Product Compressed air

OH 497

Non−conductive part of the regulator Conductive layer in the diaphragm Non−conductive layer in the diaphragm Non−conductive coating

Principle of filling system

RM3 LA1 A1

A2 16 18 26 28

15

Function

25

R−sector 25 30 35

1

Time value s

500k

Leakage detector

R−value

(x0.1) (x10)

R U

PLC

Level transmitter

U/P Transducer

Product Compressed air

Technical Training Centre Lund, Sweden

Machine type

Issue

TBA/21 HS

1/9905

OH 847

UP−Transducer Technical Training Centre Lund, Sweden

Principle

FM = Magnetic force FR = Feedback force P1 = Supply pressure P2 = Outlet pressure 1 = Exhaust

Machine type

TBA/21

FM

FM

FM

FR FR

1

FR

1/9609

Issue P2

P2

OH 612

P1

FM = FR

P1

FM > FR

P1

FM < FR

Level Transmitter Type PMS (Potentiometric Measuring System) http://www.helios-level.ch/level/pms_e.html

Features • • • •

For Training purpose ONLY!

Linear level signal transmission No calibration in wide product conductivity range Suited for products with conductivity > 1 mkS*cm Mesearing independed of pressure, temperature,dielectric and density

Basic principles The level probe ¬ is immersed in the earthed liquid (product) ¯ and consists of a stainless tube (see picture 1). The ends of the probe are connected via two insolated leads - with an off-eath generator ® . This generates AC voltage with frequency of 5 kilohertz to energise the probe ¬ . High resistance amplifier ® is connected thrue the matching transformer (not shown) to the container wall (filling pipe) and generator terminal. The amplifier converts the milli-volt signal to a 0-20 mA signal.

G

-

¬

¯

°

®

f=5 kHz

¯

To PLC 0-20 mA

±

Picture 1. Please note that resistors ° are just simbolical representation of product resistence . However, during the Level Probe sensitivity settings two real 1.75K resistors are used to simulate the product (see correspondent MM page).

The purpose of usind AC current is:

a) to minimise zero drift; b) to simplify level signal amplification and transmission; c) to utilize "skin effect" when the AC current has a tendency to flow on the conductor surface rather then in its bulk. This increases an effective resistance of foam between the probe and container wall and therefore minimizes its effect on level reading. The foam still can create a false level signal when the product is absent. This situation should be avoided. Does the level signal depend on product resistance? The resistance of product (Rprod) and the immersed part of probe (Ri) together form a Wheatstone bridge (see picture 2), in which the voltage drop (Uprod) in the product is equal to the half of the voltage drop on the immersed part of the probe (Ui).

G

Lp

f=5 kHz

Rni U0

To PLC

L

Ui

Ri

Rprod

Uprod

Picture 2. If U0 is the generator output voltage, Lp is the total length of the probe and L is the product level, then: Ui =U0*L/Lp ; Uprod=Ui/2=U0*L/(2*Lp) Assuming that U0 and Lp are constants then: Uprod=k*L where k is a constant equal to U0/(2*Lp) So, level signal Uprod does not depend on the conductivity of the product but depends linear from the product level. Evgeny Lavrentiev BUTB Modena

15 Electrical system

Technical Training Centre

Pos. in EM

Line/ Voltage

GE Fanuc In/Out

Function

Page N El. diagr.

Part N

Terminal N

B4200 Design signal ASU X1003 127- ,127, 127+ Q0122

I0025

G101

TS sealing pulse

Location on the machine

16 Electrical equipment

Technical Training Centre

Emergency stop module

A1 S13 S24 X2 41 Reset /Test 24VDC In 1 B

In order to make the safety output close, the reset circuit must be closed and then opened.

13

23

33

1

1

1

On In

Type: JSBR4

Out In A

2

2

2

2

A2 S14 S23 X3 42

14

24

34

X2

A1 S13

K2

S14

Protection circuit

Reset and supervision circuit S24 K1

S23

A2

13 K1

23 K1

33

41

K1 K1

K2

14

Technical Training Centre 1/9609.

Tm-00003

K2

24

K2

34

42

Training Document. For training purpose only.

K2

X3

Safety relay A1 S13 S24 X2

41

13

23

33

1

1

1

Reset /Test 24VDC

1

In B

On

JOKAB SAFETY

In

TYPE: JSBR4

Out

2

In A

2

24 VDC

2

2

A2 S14 S23 X3

42

14

24

34

A1 S13 S24 X2

41

13

23

33

1

1

1

Reset /Test 24VDC

Emergency switch 1

In B

On

JOKAB SAFETY

In

TYPE: JSBR4

Out

2

In A

2

2

2

A2 S14 S23 X3

42

14

24

34

A1 S13 S24 X2

41

13

23

33

1

1

1

Reset /Test 24VDC

In B

Alarm reset 1

On

JOKAB SAFETY

In

TYPE: JSBR4

Out In A

A2 S14 S23 X3

2

42

Technical Training Centre Lund, Sweden

2

14

2

24

2

34

Machine type

Issue

1/9908

OH 868

ASU

A 602

TBA/22 Safety Modules

Supply Safety Controlled Output

Y7407 Web tention Y7408 Pressure rail Y7410 Cutting Y7411 Material holder

Safety chain input ASU Door Guard Emerg. Stop Module Door Guards 24VD

A 601

A 600 Supply Safety Controlled Output

Supply Safety Controlled Output

Reset

Reset

Auxil. Reset Contact

A 603 Supply Safety Controlled Output 0.5S Delay

Safety chain input

Safety chain input

Top, Bottom front door

Main Motor, FF motor

Auxil. Reset Contact

Door Guards

B1505 B1506 Bottom covers B1224 B1225

K4 Main Motor K 115 K3 Clean pump K9 Tran. Waste Y3101 Hot W.

Emerg. Stop Buttons

K007 Drive roller

K002 Hydr. Perox. Pump

K6 FFU Motor

K002:1 K004:1 K006:1 K007:1 K008:1 K010:01 K036:1 K034:1 K118

Hydrogen peroxide Pump Main motor Final folder Drive roller Drive loop ASU External conveyer Drive magazine ASU Control voltage/ Time recorder Reset relay

B2810 B2811 B2812 B2813 B2830 B2831 B2832

Door guard 10 Door guard 11 Door guard 12 Door guard 13 Door guard 30 Door guard 31 Door guard 32

S1 S5 S1801 S1802 S2803 S2804 S7813 S900

Control cabinet outside Control cabinet inside Front platform Top platform Right side panel Left side panel ASU bar Control panel

K3 K4 K6 K9 K118

Cleaning pump Main motor FFU motor Transport of waster Reset relay

Safety Relay for: Two Hand Control Emergency Stop Interlocked Gate/Hatch Enabling Device Safety Strips SCALE 1:1

Safety Mats

Approvals:

Foot Switches Area Restriction Machine I/O EMC

Category 4

(NRTL/C=USA & Canada)

SAFETY RELAY UNIVERSAL RELAY JSBR4 is used to: • Comply with safety levels for safety devices • Give safe stops to dangerous machines and processes • Supervise the internal safety of machines • Fulfil regulations MACHINES & PROCESSES Safety relays can be used for a wide range of applications including: Industrial Robots, Presses, Automatic Production Systems, Paper Machines, X-Ray Machines, Bakery Machines, Printing Machines, Automatic Warehouses, Laser Machines, Handling Equipment, Power Shears etc. FUNCTION The JSBR4 has two inputs, both of which have to be closed to keep the safety output contacts closed. A short circuit across the inputs will cause the output contacts to open. The inputs can however be subjected to a continuous short circuit without damaging the safety relay. In order to make the safety outputs close the reset input must be closed and opened. In this way an unintentional reset is prevented in the case of a short circuit in the reset button cable or if the button gets jammed in the actuated position. The reset input can also be used for

test/supervision to ensure that contactors or valves have returned to their initial off "stop" position before a new start can be allowed by the safety relay. When the JSBR4 is used as a Two Hand relay both buttons have to be pressed within 0.5 seconds of each other in order to close the outputs. When the JSBR4 is used for Safety Mats and Safety Strips the ”stop” condition is given following detection of a short circuit between input channels A and B. Neither the safety mat, safety strip or the relay will be damaged by a continuous short circuit. This also gives the advantage that if there is a failure between the inputs in the installation, the safety relay will not be damaged. SAFETY LEVEL The JSBR4 has a twin supervised safety function. Neither component failure, short circuit or external disturbances (power loss etc) will prevent the safe function of the relay. This is valid both for the inputs A and B as well as for the reset input. The JSBR4 operates at the highest safety level for safety relays (category 4). The true two channel safety function has the advantage that the installation demands for safety can be reduced depending on the fact that a short circuit between the input opens the safety outputs directly.

JSBR4 Dual Input Channels 3NO/1NC Outputs Short circuit supervised reset LED Indication of Power on, Inputs and Outputs Available in wide range of voltages DIN-rail Mounting 45 mm in width

REGULATIONS & STANDARDS The JSBR4 is designed and approved in accordance to relevant standards. Examples of relevant standards are EN 2921/2, EN 60 204-1, IEC 204, VDE 0110, VDE 0113, BS 2771… CONNECTION HANDBOOK In our connection handbook are numerous circuit diagrams showing examples of Safety Relay combinations solving safety problems eg: • Time reset of safety devices • Safe time delay of stop function

Simple - Safe - Reliable 980315

Expansion relays provide: More safe outputs Delayed safe outputs Indicating outputs SCALE 1:1

Approvals: *

*

EMC (NTRL/C=USA & Canada)

* Approvals applied for

EXPANSION RELAY MORE OUTPUTS By connecting expansion relays to a safety relay it is easy to increase the number of safe outputs. This means that an unlimited number of dangerous machine operations and functions can be stopped from one safety relay. SAFE SOFT STOP When a gate is opened a program stop is first given to the machine’s PLC/servo which brakes the dangerous operations in a soft and controlled way. The safety outputs then break the power to the motors, that is, when the machine has already stopped. Normally between 0.5 and 1 second is needed to brake a dangerous machine operation softly. Soft stop ensures many advantages: The machine lasts longer. Parts being processed are not damaged. Restart from stopped position is enabled and simplified. A safe soft stop is achieved by means of a safety relay which gives the program stop, and an expansion relay, JSR1T, which gives safe delayed stop signals. See examples in

our Connection Handbook.The drop time delay on a JSR1T can as standard be selected from 0 to 8 seconds. By connecting several JSR1T´s in series even longer times can be achieved. WHEN ARE DELAYED SAFE STOPS USED? Delayed safety stop signals can be used for emergency stops according to EN418 § 4.1.5. Stop category 1, i.e. a controlled stop with power to the actuator(s) available to achieve the stop and then removal of power when stop is achieved. Stop category 1 may also be permitted when it is not possible to gain physical access to the machine before the safe stop is affected eg: Gates, access time is 1 sec. Covers and gates which are locked until dangerous operations and functions have been stopped. Long distances between a safety device and a dangerous machine function. SAFETY LEVEL The JSR1T has twin stop functions,

JSR1T Width: 45 mm Power supply: 24V DC Function indicating 4 NO 1 NC Outputs

that is, two relays with mechanically operated contacts. A monitored stop function is achieved by connecting the test output (terminals X1 and X2) to the test or reset input on the safety relay which is expanded. One condition for a safe delayed stop is that the delay cannot increase in the event of a fault. The JSR1T complies with this requirement. CONNECTION HANDBOOK In our connection handbook are numerous circuit diagrams showing examples of Safety Relay combinations solving safety problems e g: • Time reset of safety devices • Safe time delay of stop function

Simple - Safe - Reliable 980316

Safety relay A1 S13 S24 X2

41

13

23

33

1

1

1

Reset /Test 24VDC

1

In B

On

JOKAB SAFETY

In

TYPE: JSBR4

Out

2

In A

2

24 VDC

2

2

A2 S14 S23 X3

42

14

24

34

A1 S13 S24 X2

41

13

23

33

1

1

1

Reset /Test 24VDC

Emergency switch 1

In B

On

JOKAB SAFETY

In

TYPE: JSBR4

Out

2

In A

2

2

2

A2 S14 S23 X3

42

14

24

34

A1 S13 S24 X2

41

13

23

33

1

1

1

Reset /Test 24VDC

In B

Alarm reset 1

On

JOKAB SAFETY

In

TYPE: JSBR4

Out In A

A2 S14 S23 X3

2

42

Technical Training Centre Lund, Sweden

2

14

2

24

2

34

Machine type

Issue

1/9908

OH 868

A 103 Technical Training Centre Lund, Sweden

RD

03

B1106 05

YD RD

07

B1222 09

YD

TC1− A133 TC1+

0 C 01

0 C

02

TC2− A134 TC2+

Machine type

TBA/22

A 137 01

Air super heater

02/A1 Q0193

PROGRAM 1 insert

2

TABLES edit

STATUS 3 modify 4 search

5

PRINT 10 zoom

6

− ALW ON

03/A2 Q0194

LOOP 6 ( )

P ID IND SV L6

1/9905

Issue

PV L6

CV SP

CV L6

PV

ALW OFF MAN ALW OFF UP

L10

OH 842

ALW ON DN

C:\DAT I\LM90\NEW PT\SIMONET REPLACE

0 FFL INE PRG: SIMONET %S0007 : ALW ON

RUNG 0068 : :

Temperature control overview

PID Function Block Data

Data Item

Description

Output

This is a signed word value representing the output of the function block before the application of the optional inversion. If no output inversion is configured and the output polarity bit in the control word is set to 0, this value will equal the CV output. If inversion is selected and the output polarity bit is set to 1, this value will equal the negative of the CV output.

Diff Term Storage

Used internally for storage of intermediate values. Do not write to this location.

Int Term Storage

Used internally for storage of intermediate values. Do not write to this location.

Slew Term Storage

Used internally for storage of intermediate values. Do not write to this location.

Clock

Used elapsed time storage (time last executed). Do not write to this location.

Lower Range

Lower range for SP, PV for faceplate display.

Upper Range

Upper range for SP, PV for faceplate display.

Reserved

Reserved for GE Fanuc use. Cannot be used for other purposes.

Initialization Values The following table lists typical initialization values for the PID function block.

Register

Purpose

FB Units

Suggested Default

Range

%Ref+0 %Ref+2 %Ref+3 %Ref+4

Loop Number Sample Period Dead Band Selection + Dead Band Selection -

10 msec Counts Counts

1 100 msec (10) 320 320

0 to 10.9 min 0 to 100% of error 0 to -100% of error

%Ref+5 %Ref+6 %Ref+7

Proportional Gain Derivative Integral Rate

0.01%/% 0.01 seconds Repeats per 1000 sec

User Tuned User Tuned User Tuned

0 to 327.67%/% 0 to 327.67 sec 0 to 32.767 repeats/sec

%Ref+8 %Ref+9 %Ref+10 %Ref+11

Bias Upper Output Clamp Lower Output Clamp Minimum Slew Time

Counts Counts Counts Seconds per full travel

50% (16,000) 100% (32,000) 0% (0) 0

-100% to +100% -100% to +100% -100% to +100% 0 to 32. 767

Technical Training Centre 1/9905

TM-00100

Temperature settings TBA/21 HS Technical Training Centre 1/9905

Alarmlimits temp controller are all relative value within [xx] = not used as an alarmlimit Conn ection

Description

C/M

Setvalue

Al high (C)/High lim (M)

Al Low (C)/Low lim (M)

Sample

P

I

D

PWM timebase

Comment

TM-00101

B1106

Heat sterilization

M

280°C

B1222

H2O2-bath

M

68°C

B1208

Water temp H2O2 system

M

B1212

Temp H2O2-tank

C

B1109

Temp top aseptic chamber

M

95°C

B2510

Cooling water

M

12°C

7°C

High limit value will start cooling, low limit value will stop the cooling. Range high and low 2°C-20°C.

B001

Cooling electrical cabinet

M

34°C

28°C

High limit value will start cooling, low limit value will stop the cooling. Range high and low 20°C-24°C.

B5307

Flap heating top left

B5308

Flap heating top right [15°C]

15°C

B5309

Flap heating bottom left

B5310

Flap heating bottom right

B1310

Steam temp

M

B1105

Air super heater

C

360°C

B6001

SA splice head

C

To be tested

C

Not possible to change from TPOP

90°C

72°C

450°C

[2°C]

2°C

500 (5 sec)

19000 (190%/%)

220 (0.22 repeats/s)

3000 (30 s)

10 s

Controls the switching of the heatexchanger. Not possible to change for the operator.

25

2000

3000

2000

500 msec

120°C 15°C

Setvalue range (69°C-76°C)

20°C

Setvaluerange