STC Win-SPS SYSTEM 155 Winding Machine for Fiber Sensors ...lphe.epfl.ch/scifimats/matprod/winding/MANUAL--Winding_Machine... · Win-SPS SYSTEM 155 Winding Machine for Fiber Sensors

STC

Win-SPS SYSTEM 155

Winding Machine for Fiber Sensors

Win-SPS.155-6

Manual

Version 1.05

STC ELEKTRONIK GMBHKrellenhäuser 3D-07973 Greiz-Moschwitz

Tel.: 03661/6618Fax: 03661/687830e-mail: [email protected]

Contents

Contents

1 General Remarks and Basics 31.3 Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.4 Declaration of Conformity and Manufacturer’s Declaration, Resp. . . . . . . . 31.5 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.6 Basic Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.7 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Safety 62.1 General Safety Remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.2 Designation of Remaining Risks and Hazardous Areas . . . . . . . . . . . . . . 62.3 Safety-Conscious Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.4 Safety Instructions for the End User . . . . . . . . . . . . . . . . . . . . . . . . . 72.5 Safety Instructions for the Operator . . . . . . . . . . . . . . . . . . . . . . . . . 72.6 Indication of Specific Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.7 Interdiction of Unauthorized Modifications or Alterations . . . . . . . . . . . . 82.8 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 Connection Requirements and Assembly 103.1 Connection Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.5 Start-up of the Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113.6 Specific Features of the Winding Axle . . . . . . . . . . . . . . . . . . . . . . . . 123.7 Specific Features of the Positioning Axle . . . . . . . . . . . . . . . . . . . . . . . 123.8 Documents and Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4 Operation and Monitoring 134.1 Operation and Monitoring Controls . . . . . . . . . . . . . . . . . . . . . . . . . 134.2 Preparatory Steps Before Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . 134.3 Description of the Production Process . . . . . . . . . . . . . . . . . . . . . . . . 144.4 Menu Structure and Branching . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154.5 Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164.6 Messages on the Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5 Creating and Editing of Technology Databases 225.1 Creating a New Technology File . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225.2 Association of the Technology File with the Production . . . . . . . . . . . . . . 235.3 Data Storage and Network Interconnection . . . . . . . . . . . . . . . . . . . . . 23

6 Data Archiving and Data Display 246.1 Opening of Archived Data Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246.2 Data Storage and Network Interconnection . . . . . . . . . . . . . . . . . . . . . 24

STC Elektronic GmbH Greiz Win-SPS.155-6–Sensorwickelmaschine 1

Contents

7 Service Menu and Unlocking the System 257.1 Access Key Approval and Service Locking . . . . . . . . . . . . . . . . . . . . . . 257.2 The Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267.3 Notes for Remote Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

8 Service and Maintenance 288.1 Cabinet and Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288.2 MSR – Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288.3 Regular Technical Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288.4 Spare and Wear Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

9 Documentation of the Control Cabinet 29

10 Contact 30


General Remarks and Basics

1 General Remarks and Basics

1.3 ManufacturerSTC Elektronik GmbHHard- und Software AutomatisierungstechnikKrellenhäuser 3D - 07973 Greiz

1.4 Declaration of Conformity and Manufacturer’s Declaration,Resp.

EC - Declaration of ConformityIn terms of the EC Machinery Safety Directive 98/37/EC Annex II A

ManufacturerSTC Elektronik GmbHHard- und Software AutomatisierungstechnikKrellenhäuser 3, D - 07973 Greiz

We hereby declare that the control system hereafter satisfies all of the requirements of theEG-Machinery Directive 98/37/ECDesignation of the control ormachine

Win-SPS.155-6 winding machine for fiber sensors

Product number and year Win-SPS.155-6 03/2015Applied harmonized Standards,in particular:EN 292–1 11/91 Safety directives for machinery, basic terminologyEN 292–2 06/95 Safety directives for machinery, technical principlesEN 294 08/92 Safety directives for machinery, safety distances

EN 418 10/92Safety directives for machinery, emergency stopequipment

EN 614–1 04/95 Ergonomic design principlesEN 983 09/96 Electrical equipment of machinesEN 61800–3 Electrical interference – EMI

Greiz, the place and dateIdentification of the signatory Mr. Stiebert, Reinhard is the CEO of STC Elektronik GmbH

The winding machine WM6 is put on the market as an unfinished machine, since the precau-tions for the external safety device for laboratory operation will be designed and provided bythe end-user.

1.5 Intended Use

The winder control unit serves as an operation and monitoring control of a special machinefor winding fiber sensor coils on a coil former according to the specification.



The following items should be verified and approved by the responsible user:

Mains voltage 3 x 400 V, tolerance ±10 % CEE–connector 16A–50Hz.

In the mains input there must be no earth leakage circuit breaker of 30 mA becauseinternal frequency converter have earth leakage currents.

The mains voltage should be protected against overvoltage spikes on the current-carrying and neutral wires.

Protection against mechanical load, dust and aggressive media.

The operation must be carried out by trained personnel.

The technological and procedural parameters should have sufficient distance from themaximum permissible values of the products.

The application conditions must not exceed the limiting parameters of the controlsystem.

Modifications of the safety control units and the emergency stop circuit are prohibited.

In case of faulty operation of the control system, the system must be switched off.

The electromagnetic compatibility is designed for industrial environments.

The user is also responsible for ensuring the compliance with the general operation andstaff safety regulations and for the approval of the production release.

The controller is not verified and approved for public, security relevant, military, andmedical purposes where special provisions apply.

The operator training in the risks of special machines as well as the prevention of hazardsis incumbent on the user. The manufacturer of the control unit is irresponsible for anypossible damage.

1.6 Basic Construction

The winding machine is built into a rigid frame made from special section tubes and consistsof the main components: fiber unwinder, fiber guidance, hub and control system.

The frame has adjustable machine feet to adjust the machine horizontally.The mounting of the components of the machine is accomplished with aluminum profileswhich are connected to the frame.

The fiber processing consists of a motor-controlled seat for Kuraray coils, a fiber guidancewith dancer control, and a measuring device for length and force.The dancer control controls the motor drive of the fiber unwinder spool in two directions andthus keeps the tension approximately constant. The setting of the tension occurs with thecounterweight of the dancer. The length measurement is accomplished with a measuringwheel and the power measurement with a bending beam sensor.

The fiber winding on the hub is realized with a positioning wheel, which is moved by a linearguide. The winding process starts from a programmable starting position and proceedsprogram-controlled with a pitch of 275µm.

The user supplied winding hub is mounted on a threaded stub and is driven by a servo driveand positioned in angle. The drive of the hub is connected to the control unit in such a way,



that the winding on the hub is carried out in the form of a thread.

The control cabinet is installed in the frame. It includes the interface components and thedrive level control. The control console is attached to the frame on a pivoting support.The control of the winder is realized with SoftSPS, which is located in the control consoleand is connected to the components in the control cabinet via a bus system. The controlsystem is described in detail in the following chapters.

1.7 Technical Specifications

Space requirement

Sufficient space as well as good accessibility on all side of the machine have to be providedfor.In case of transporation activities an additional mechanical protection bar could be helpful.

Machine dimensions L x W x H : 2500 x 800 x 2000 mmWeight ca. 500 kg

Electric connection

The electric connection of the cabinet is made by a power cable with a 5-pin CEE 16A three-phase plug. The length of the cable is about 5 m. Power, neutral and ground wires must befed from a noisefree supply.

Mains voltage 3× 400 V, tolerance ±10 %, CEE–connector 16A–50Hz

In the mains input there must be no earth leakage circuit breaker of 30 mA becauseinternal frequency converter have earth leakage currents.

For potential compensation the machine can be connected to the potential compensationof the building with an additional protective conductor (e.g. 16 mm2).

Environmental influences

The environment should meet the following requirements:

Temperature in the engine range +10 to +40 °CRelative humidity up to 60 %

Other boundary conditions according to chapter 1.5 "Intended use".


Safety

2 Safety

2.1 General Safety Remarks

The controller is compliant with the state of the art technology and is operationally safe.

In the present case it is part of a system and thus has to be integrated into the overall conceptwith respect to connection and procedural technology. Concerning the safety technologythis coordination has to be realized by the user, who also has to pay attention to the specificconditions and hazards of the application during installation.However, danger can emanate from controls and machines, if they are not operated correctlyor as intended by trained or at least properly instructed personnel, or if they are usedimproperly or for not intended purposes.Reaching into the machine area is always dangerous. The switch-off of the machine due tosafety issues is realized by an emergency stop.

In the current case the possibility of a design of a system, that is used in a laboratory only, isto be taken into account, which allows for an operation without protective doors.The details and features of the conditions to comply with the safety regulations and releasefor production is up to the operator.

In case of malfunction in the control system, the system must be switched off and our serviceinformed.The supplier will not be liable for any damages of the product or consequential damages.

2.2 Designation of Remaining Risks and Hazardous Areas

At the winding machine there exists a risk through rotating and linear moving parts. In thecontrol cabinets and in the devices of the electrical installation there are dangerous voltagesup to 600 V. A contact should absolutely be prevented. In the dangerous areas warninglabels are attached.

If there are remaining risks for personnel or equipment despite the constructively safe oper-ation the end-user should indicate these risks by signs and codes of conduct or respectivelytake appropriate measures to avert the danger.

A known risk is touching the moving parts of the machine when the control is in the startready state or in operation.

The moving parts of the motors and the linear unit are dangerous.

2.3 Safety-Conscious Operation

The information in the respective operation instructions and safety regulations have tobe observed before doing any work concerning the planning, installation, commission-ing, adjustment, operation, changes in the conditions of use and operation, maintenance,inspection and repair.


Safety

2.4 Safety Instructions for the End User

Supervisors should become familiar with chapter "2" and the necessary operation knowledgeof the system.The responsibility for the organizational and safety relevant measures to ensure and complywith the legal regulations is incumbent on the operator of the installation. This includes alsoadditional measures to achieve the operational and occupational safety as well as the safetytraining of the operating personnel regarding the behavior of automatically operating plant.

You must make sure that the Chapter 2 "Safety" and the description of appropriate handlingis read, understood, and respected by the operating personnel.

The controller must only be operated in perfect condition. Basically, for operating theinstallation the national accident prevention provisions and the valid industrial safetydirections must be adhered to.

Only original replacement parts that are approved by the manufacturer are to be used. Theprocurement occurs exclusively through the manufacturer, since some parts need to becalibrated or adjusted.We draw attention to the fact that non-original parts and/or accessories, that are not suppliedby us, are not automatically released and in case of damages the liability is excluded.

2.5 Safety Instructions for the Operator

The controller may be used only after instruction by qualified staff, each operation must beavoided, which impairs the operational or occupational safety.

Before putting the unit into operation the facility should always be checked for signs ofdamage or defects by the operating and supervisory staff.During operation, changes in normal operation (eg error messages) have to be observedand evaluated.Safety or production relevant conditions should be reported to the person responsible andprecautions be taken to avert damages.Safety devices may not be removed or blocked.

Operators must be familiar with and respect chapter 2 "Safety" and chapter 4 "Operationand Monitoring".

The machine setter personnel should in addition also be familiar with and respect chapters5 "Technology Database" and 6 "Data Archiving and Data Display".Chapter 3 "Installation and Commissioning" is important for service and installation per-sonnel. In case of doubt the manufacturer should be consulted.

2.6 Indication of Specific Hazards

Machine control systems are electrical equipment which must be maintained and operatedexclusively by authorized personnel in compliance with the regulations in VDE100 et seq.and accident prevention VGB4.


Safety

Work on the system must only be carried out in the off state and measurements performedwith caution to prevent hazards. Electrical cabinets must not remain open or be operated inthe on state.The operation and the operational ready mode must not occur in unattended state. Afterfinishing the production the main switch is turned off.

1.) Mains voltage is located in the following areas:

Main switch, mains fuses, terminals, power supplies, frequency converters and sockets

Control, winding engine and unwind motor

Attention, an external voltage exists in the controller area through the integratedUPS if mains are switched off.

2.) Manipulation of the control system

Manipulations, wrong connections and other interventions on the controller can causedangers.The following interventions are especially dangerous:

changing the wiring or provisional changes

pulling of plugs during operation

blocking areas in the winding and laying regions where movements take place

misalignments of the end-position

changes in the software and file system

high-priority network access with computer overload when multitasking

3.) Risk of bruises on rotating parts

The winding machine is designed without protection doors for laboratory use according tothe specifications. Hazards may arise from unintentional intervention in rotating parts. Anappropriate assessment of the risks and protection measures has to be carried out by theend user.

A residual risk is caused by malfunction of the control system or mechanical jamming inthe winding and laying areas.

2.7 Interdiction of Unauthorized Modifications or Alterations

The machine controls must not be modified neither constructively nor concerning safetyaspects without our consent. Any unauthorized modification excludes the liability.

2.8 Transport

The transport is carried out on pallets/boxes or by special transports with appropriatefastening and lashing of the machine body.


Safety

Humidity and shocks should not act on the machine and the control system. Thereforeit has to be fastened to the transportation vehicle in a protected environment and, whereappropriate, with shock absorbers. All external environmental influences should be keptaway. No other goods may be put on top or wrapped over the machine cargo.

The fastening and lashing should take place only at the frame beams using a protective film.During transport with forklifts or trucks it is important to provide protection from tippingover.


Connection Requirements and Assembly

3 Connection Requirements and Assembly

3.1 Connection Requirements

Mains voltage 3× 400 V 50 Hz with neutral conductor N and protec-tive conductor PE with a 5-pole standard socket CEE16A. Standard fuse 16A (optional adjustment possible).In the mains input there must be no earth leakagecircuit breaker of 30 mA.

EMC No steep transient or other glitches are allowed to besuperimposed on the mains, N and PE lines. Thereshould be a separate protected supply from the controlvoltage network.

Potential compensation The optional cable for potential compensation can beaccomplished with a separate copper wire of 16 mm2

diameter.Space requirements The installation site of the machine should be located

in a traffic-calmed area without direct sunlight on themonitor screen.Enough space in front of the control cabinet should beavailable for the operator.Advantageous would be a direct eye contact with theworkspace.

3.2 Assembly

The assembly, installation and commissioning is usually done by the manufacturer or addi-tionally trained staff in coordination with the end user.

The additional enclosures or bulkheads of the working area for "Laboratory operation" areprovided by the end user.

3.3 Installation

Installation and commissioning is usually done by the manufacturer or additionally trainedstaff in coordination with the operator.

Additional optional door switches or the like may be integrated optionally by the end user incoordination with the manufacturer.

3.4 Commissioning

Commissioning is usually done by the manufacturer or additionally trained staff in coordi-nation with the operator. During commissioning special caution and attention is required.All safety measures must be adhered to.



The following sequence is recommended as a minimum directive:

Optical control of all devices and cables for integrity and professional mounting andinstallation

Completeness check of the potential compensation and electrical measurement of thePE and N terminal (grounding monitoring of all equipment and cable trays)

Power control and commissioning of the mains fuse and the power supplies

Control of the earth leakage circuit breaker and emergency stop button

Boot the control computer and set up, where appropriate

Enter service menu after entering the password

Switch on the motors briefly and check their operation

Switch on signal lamps briefly and check their function

Check dancer control, fiber tension and length measurement

Close service menu and lock password level

Set up technology for trial operation

Without fiber start test production with switching on the unwinder control and start thetrial operation with the start button(The system should be kept under constant observation and in case of irregularities beturned off.)

If all checks are successful the fiber can be inserted and the production be started.Hereby the parametrization and the settings in the technology file have to be taken intoaccount. Only low speeds should be set in the technology file and with the potentiome-ter.

3.5 Start-up of the Control System

The setting of the control loops is accomplished with the parameters of the configuration filesin the path C:\WIN-SPS.155\CONFIG. Changes should only be made by the manufactureror in cooperation with the manufacturer.

The controller settings are pre-parameterized and may only be changed by qualified person-nel under their own responsibility.For this purpose, an editor is to be used, which does not change the specified data format.Appropriate is the integrated editor.The parameter change is done at the beginning of the line without changing delimiter,number of lines and format. Format errors result in messages and faults of the system. Theincorrect entry of control parameters is not monitored and may cause global error responsesof the system.

The optimization of the control parameters occurs by trial operation with a technology filethat executes all cases.



3.6 Specific Features of the Winding Axle

The winding axle is speed-controlled in angular position via a frequency converter. Theangular resolution is 0.1 deg and indexes a speed array with 3599 speed markers. The fre-quency control has a range of 0−50 Hz, which corresponds to a speed of about 0−30 U/min.The control of the inverter is carried out by the IPC with a scaled standard signal of 0−10 V.The initialization of the zero position of the winding axle is accomplished by a cam on thewinding wheel and a proximity sensor at the winder. The starting positions of the windingoperations are dependent on this zero position which is stored in the technology files.

With the winding process switched on the direction and speed of the hub can be changedwith the potentiometer on the control panel.The maximum value depends on the data in the technology file. Around the zero pointand the end position plateau have been programmed to facilitate the ergonomic operation.The speed of the glue curing can also be controlled by this potentiometer. The maximumrotation speed of the hub for the curing of the glue is stored as a fixed parameter.

3.7 Specific Features of the Positioning Axle

The positioning axle controls the position of the positioning wheel directly on the windinghub and thus the fiber position. The position of the positioning wheel is controlled by thecontrol system and follows the thread of the hub. In addition, the starting position for thewinding process in the technology file and the manual offset in the service are taken intoaccount and determine the position absolutely. Through the angular position of windingwheel and the resulting linear angle after several revolutions the relative position of thepositioning wheel is unambiguously defined over the entire range of the threaded region.

The positioning axle is initialized before each start. The zero mark is located at the rear inthe initialized state. The status of the initialization is monitored. In case of malfunctions theaxle may stop or winding errors may occur.

3.8 Documents and Drawings

The controller manual, the E-drawings for the control cabinet, and the connection planof the machine are provided in three copies at delivery. The equipment documents of oursubcontractors are issued in a single copy.

Additional documentation is available on request.

The documentation of the operating system and a backup copy of the controller programare provided on data media in a single copy.


Operation and Monitoring

4 Operation and Monitoring

4.1 Operation and Monitoring Controls

Cabinet – Controls and Messages

Main switch Mains connection and safety shutdown.Emergency stop Button for manual emergency stop.

All processes are stopped and must be re-initialized.The status of the processes must be checked.

Power ON button Button to switch on the safety relay.—The buttonlamp is lit (this switching is only possible with closedsafety circuit of the door and the emergency stop).The green tower lamp signals the operational readi-ness.

Potentiometer The rotation direction and speed of the hub can beset with the potentiometer.

Operation The winder of the fiber supply spool is controlledby the switch with the following functions: Manual,Switched off, Automatic. The switch is located abovethe spool.

Button start Start of the initialization of the machine and the pro-duction dependant on what is in process. The yellowpart of the tower lamp is lit.

Button stop Stop of the initialization of the machine and the pro-duction dependant on what is in process.

Button acknowledgment The red light indicates malfunctions and a buzzer isactivated. The button resets the buzzer.

IPC keyboard and mouse Data entry and navigation in the menu and controllergraphic interface.

IPC monitor Display of data, messages and visualization of controlprocesses and production data.

Cabinet – Monitoring Devices

LED indicator Voltage monitoring of the control voltages.Display of digital inputs and outputs.

Fault current breaker Ground leakage control and protection against accidentalcontact.

Watchdog Monitoring of the control functions.Power down system Controls the start and the shut-down of the controller

4.2 Preparatory Steps Before Start-up

The controller may only be put into operation by trained and authorized personnel. Safetydevices may not be dismantled or blocked.



Before each start the winding system should be checked for signs of damage or defects bythe operating and supervisory staff.

4.3 Description of the Production Process

The system is switched on at the main switch of the control cabinet.After booting of the control computer the system is henceforth operational.The emergency stop button and safety switches must be in the non-actuated state. Thebutton "Power" is actuated. The green tower lamp is lit. Upon the occurrence of messageson the screen the corresponding reactions should be initiated.

In the selection window for the technology the desired technology file with the associatedproduction data is selected.

Before start up of the system the whole work area must be checked for any source of dangerand all persons must maintain the relevant safety margins.

Before the start of production, the fiber is thread over the pulleys and fixed. Withincreased attention the selector switch can be set to "manual" for a slow unwindingspeed in order to provide the necessary fiber length. After completion of the preparationof the fiber the selector switch is set to "automatic". Here the fiber is tensioned and thetension controlled.

If a fiber error data file exists it can now be loaded into the service window. If the startingpoint of the fiber length is not equal to zero, the starting point on the unwinding wheelcan be set with the slider.

To start the initialization the "START" button is pressed.

The yellow tower lamp lights and the winding and laying axle are initialized.

After the completion of the initialization the fiber is fastened at the hub. Before the startof production the potentiometer is set to zero.

To start the production the "START" button is pressed.

The yellow tower lamp lights and the winding process begins. Since the potentiometer isstill set to zero the winding hub does not yet move. By slightly varying the potentiometerin the desired direction the exact positioning of the fiber can be controlled. If the exactposition is confirmed the speed according to the technology data can be set with thepotentiometer by turning it into the end position. If a slower rotation speed for theprocess is desired it can be set with the potentiometer.

To end the winding process the "STOP" button is pressed or by waiting for the automaticstop at the end of the layer.

During the production the production parameters can be tracked on the screen.

BEFORE ANY SETTING TO WORK AND CONNECTION OF THE WINDING MACHINE THEOPERATOR HAS TO CONVINCE HIMSELF THAT THE ENTIRE SYSTEM IS FREE FROMANY DANGER.



4.4 Menu Structure and Branching

From the window menu the various submenus are called.

Branching of the menu level

Left side of the window:

Main window of the production process

Reset the status of the initialization and restart the next winding layer

Archive window showing the production data of previous windings

Exit—Exit the controller program and enter Microsoft windows surface

Password approval

Technology mask for selecting and entering the winding technology

Service window for machine control and for special functions

Right side of the window:

Parameter cursor for increasing the parameter in small steps

Parameter cursor for increasing the parameter in coarser steps

Parameter cursor for decreasing the parameter in coarser steps

Parameter cursor for decreasing the parameter in small steps

Call the Maintenance window

"START" button to start the winding or the initialization

"STOP" button to stop the winding and the initialization



4.5 Main Screen

On the main window the process parameter of the production are shown in text format. Themain window appears automatically at the start of the controller program and from otherwindows by pressing the "Main Window Process" button.

The following assignments are stored:

FIBER ERROR

– Display of the next fiber error record(closest point of failure in m, thickness in µm and comment)

DATA MANAGEMENT

– Display of the currently selected technology file

– Display of the currently generated archive file

WINDING DATA

– Indication of the fiber diameter and the desired fiber tensionThe desired fiber tension is adjusted manually by shifting the dancers weight. Thetension is controlled on the screen.

– Display of fixed pitch and the starting angle of the thread (0−30 deg)

– Display of the beginning and the end of winding in mm.Reference point for these positions is the zero position M0P of the machine.

– Display of the starting angle for placing the fiber and of the maximum speed of thewinding hub in U/min.

PRODUCTION DATA

– Display of the current angle of the hub

– Display of the current thread number of winding

– Display of the current position of the thread of the winding start on the hub (mm)

– Display of the current fiber speed (m/s)

– Display of the current fiber tension (cN)

– Display of the current potentiometer setting for manual speed adjustment (±%)



STATUS

– Display of current status of the machine

? Display of readiness for starting the initialization of the functions and the produc-tion

? Display of current initialization steps

– Display of the current fiber length and the next fiber error

– Display of the current action of the linear axle

– Display of the current action of the hub

– Display of the current action of fiber tension control

MESSAGES

– Display of current messages with message number and description text

– Acknowledgement button to confirm the acknowledgment of the messages and to resetthe buzzer

Listing of messages:Winding machine shut off M001Winding machine started M002Winding machine running M003Winding machine finished M004Winding machine not within the set-point range M005Winding machine within the set-point range M006Fiber unwinder shut off - no winding operation M007Fiber unwinder in operation M008Winding speed manually changed M009!! Automatic glue curing in operation !! M010Fiber tension - GW tripping - machine stop M011Fiber error thick section - machine stop M012No fiber errors data file/no blob file is loaded M013

Winding drive FU1 not ready M035Unwinding drive FU2 not ready M036Linear axle not ready M037

Error message from interface or communication M195Error reading RunMode file M196Brief Ethernet bus interruption M197Hardware blokage - Interface not available! M198Acknowledgment key pressed M201Network not available M202Error in technology file M204Automatic shutdown M205Power off or UPS power failure M206Emergency Stop - system stop M207IPC-periphery watchdog 24VDC shutdown M208System error M210



Grafic Display

– Graph of the last 360 ° rotation – Display of the number of revolutions

– Graph of the last 360 ° rotation – Display of the fiber speed

– Graph of the last 360 ° rotation – Display of the fiber tension

For real time reasons the graphic display can be switched off during production.



4.6 Messages on the Main Screen

Main screen during initialization

Main screen before turning on the production



Main screen during production

Main Screen at stop by fiber error



Main screen during the processing of the fiber error and display of the manual processing ofthe fiber error. Thereafter display of the next fiber error.

Main screen on the control panel


Creating and Editing of Technology Databases

5 Creating and Editing of Technology Databases

5.1 Creating a New Technology File

The branching to the technology window is done from the window menu

The creation of new technology files should be done with the machine switched off!

– With the slider "Technology file" the required technology is selected.

– With the sliders the parameters are set to the required values. The selected sliders mayalso be modified using the arrow keys on the right side.

The parameters of the pitch should not be changed, because they are permanently integratedand optimized in the system. Important is the exact adjustment of the beginning and theend of the winding range. For each layer a separate technology file is created to account forthe offset in the gaps between the fibers.

With the lower slider the maximum winding speed is set through the specification of thenumber of revolution. In special cases the variable speed control on the right side of thescreen may be used.

A reset button resets the system to standard settings. The parameter specifications forthe standard settings are stored in a parameter set permanently and can be modified inconsultation with the manufacturer.

After each modification of parameters the button "Save" is displayed. With it the modifica-tions are permanently stored in the technology file.


Creating and Editing of Technology Databases

5.2 Association of the Technology File with the Production

The production can be executed by operation under technology control. For this purposethe data of a selected technology files are assigned to the production.

This is done by clicking the "Select technology file for processing".

During the winding process the technology file should not be changed. With unchangedtechnology file a modification of the parameters can still be made during the production inorder to vary the winding process.

5.3 Data Storage and Network Interconnection

The technology data storage is done under reserved paths and for each technology in anseparate file.In this way it is possible without restriction to archive the data on external computers and totransport technology files by copying.

The storage of the technology files takes place in the pathC:\WIN-SPS.155\TECHNOLO\Technology files are automatically readable files and must not be changed in their dataformat.


Data Archiving and Data Display

6 Data Archiving and Data Display

6.1 Opening of Archived Data Files

With the window menu "Archive Graphics Window" the archive data are displayed.

The selection of the desired file is done in the archive data file selection window. Aftermarking the file with the button "Select File" the data are displayed.Use the radio button "Velocity profile", "Fiber speed" and "Fiber tension" to select thegraphic. The slider "Winding No." indexes the desired turn.The slider "Angle .. 70 °" indexes the display of the stored values for rotation speed, speedand tension.

On the upper right side of the screen the current message history is displayed. With a buttonthis history may be cleared e.g. at the start of a winding process.

6.2 Data Storage and Network Interconnection

The data storage of the archive files is done in reserved paths and for each winding processand winding layer in a separate file.Archive files are created as formatted text in fixed format.The storage of the archive files is done in the pathC:\WIN-SPS.155\ARCHIVE\The data storage of service files is done in reserved paths and for each day in a separate file.A permanent archiving of all messages and important machine actions is integrated.The storage of the service files is done in the pathC:\WIN-SPS.155\SERVICE\


Service Menu and Unlocking the System

7 Service Menu and Unlocking the System

7.1 Access Key Approval and Service Locking

Password entry is prompted from the window menu password approval. In an input windowthe user is prompted to enter user identification and the password number. Confirmation isdone with OK. Behind the user the status "active" is displayed.

On correct entry the technology, service or maintenance functions are unlocked. For labora-tory operation the technology and service functions are unlocked beforehand. Switching tothe operating language English is currently not implemented.

With the button "Enable OFF" the access to the services will be blocked.



7.2 The Service Menu

With the window menu "Service Window" the service interface is displayed.

Service functions:

– The first slider is used to adjust correctly the load cell of the fiber tension measurement.In unloaded load cell the display is adjusted to zero.

– The second slider is used to enter the limit tension of the fiber for switching off themachine.

– The third slider is used to enter the offset of the linear unit for the fiber positioning. Thisoffset can be modified anytime and the positioning of the fiber follows immediately.The setting is permanently stored.

In the central region of the window the editing of the fiber error file and of the actual lengthis done.

– When changing the supply spool the current length counter is reset.

– In the selection window the associated error file is selected and loaded. The error filemust first be copied in the directory C:\WIN-SPS.155\FiberFehler\.

– As an option the initial value of the length counter may be set to a value greater than 0,if an already used supply spool is used. The management of the remaining length ofpartly used supply spools must be done manually.

The display of internal values of the machine occurs in the central region of the window.



7.3 Notes for Remote Maintenance

Extensive remote maintenance options are available in Win-SPS systems.

The coupling of the service computer with the machine is accomplished via the internetusing TeamViewer.

Access to all monitoring functions in the main, service and maintenance windows is possible.Updates can be transferred and installed.

The acquisition of an additional license is necessary to use the TeamViewer.


Service and Maintenance

8 Service and Maintenance

8.1 Cabinet and Electrical System

The electrical system requires very little maintenance in clean environments.

The electrical equipment must be cleaned periodically, bearing in mind, that dirt or cleaningagent penetrating the device and buttons influence the function.

The cleaning must be carried out without solvent and mechanical stresses on the screen andthe keyboard must be avoided.

The review of the functioning of the protective measures and the repair work are performedby authorized technicians in accordance with accepted engineering standards in regularintervals.

The safety notes of chapter 2 and the electrical requirements of chapter 3 should be observed.

8.2 MSR – Equipment

The measuring instruments, such as load cell, dancer potentiometer, initiators and linearunit must be checked for integrity and in function.

The fiber rollers should be checked daily for smooth running, since they are operated withoutlubricant. If necessary the bearings should be cleaned.

8.3 Regular Technical Checks

The interval of safety and machine checks is in the responsibility of the end-user.

We provide non-binding recommendations as a guide.

Integrity, damage or defects daily by the operating personnelPollution monthly by operatorsSafety devices semi-annual (BG partly Monthly)Fault current breaker andpotential compensation

semi-annual (BG partly Monthly)

8.4 Spare and Wear Parts

A complete list of the equipment used is found in the documentation for the electric part.For any questions contact the manufacturer.


Documentation of the Control Cabinet

9 Documentation of the Control Cabinet

At delivery the current documentation of the control system is handed over as Annex 1consisting of circuit, and/or connection and wiring diagrams and lists of the equipment andsuppliers.


Contact

10 Contact

STC ELEKTRONIK GMBHKrellenhäuser 3D-07973 Greiz-Moschwitz

Tel.: 03661/6618Fax: 03661/687830e-mail: [email protected]
