Roland Double Sheet Detector R1000, I20-4-O-S, I20-2-O-S-FP, I20-4-O-S-FP, Double Sheet Detector I20 Series Series Manual
...
DOUBLE SHEET CONTROL R1000 SERIES I20
Pos: 1 /Doppelblech/Geräte/I20/Deckblatt/Dec kblatt @ 1\mod_12018721 79421_501.doc @ 5733
Double Sheet Detector I20
R1000 series
Inductive principles –
microcontroller based
Double sided non contact double sheet control of ferrous and non ferrous material
4 exchangeable linearized pairs of sensors for double sheet control of 0.15 – 10 mm
(.004 - .255 inch) sheet thickness
4-channel version allows connection of up to four pairs of sensors
► Suitable for magnetic feeder systems
► Programmable for 255 different sheet thicknesses and materials
► Calibration by Teach-In procedure
► Digital display of sheet thickness and operational parameters
► Monitoring of over-gauge and under-gauge limit
► Monitoring of operating voltage sensor gap
► Galvanically isolated 10-bit input interface and 5-bit output interface
Copyright
2015 ROLAND ELECTRONIC GmbH
©
Otto-Maurer-Str. 17
DE 75210 Keltern
All rights on this document are at Roland Electronic GmbH.
Reproduction (also partly), electronical coverage, translation, transmission to third parties,
only with our prior permission.
===== Ende der Stückliste =====
Subject to change without further notice.
Manual
Double Sheet Detector R1000 Series I20
B0069991 / Rev. 1.7
Table of contents
Declaration of conformity according to EC directives ..................................................................................... 5
1 Safety advices ........................................................................................................................................ 6
1.1 Safety instructions and warnings for user .......................................................................................... 6
1.2 Declaration of icons ............................................................................................................................ 7
1.3 Intended use ....................................................................................................................................... 7
2 Technical data ........................................................................................................................................ 9
2.1 Technical data control unit I20 ............................................................................................................ 9
2.2 Versions of the control unit I20 ......................................................................................................... 10
2.3 Sensors ............................................................................................................................................. 10
2.4 Dimensions of the sensors ............................................................................................................... 14
2.5 Sensor cables ................................................................................................................................... 15
2.6 Scope of delivery (accessories) ........................................................................................................ 16
3 System description .............................................................................................................................. 17
3.1 Measurement principle ..................................................................................................................... 17
3.2 System type ...................................................................................................................................... 17
3.3 General hints for process reliability .................................................................................................. 19
3.4 Control unit ....................................................................................................................................... 20
3.5 Parameters of the control unit .......................................................................................................... 20
3.6 Application examples ........................................................................................................................ 27
3.7 Tailor Welded Blanks ........................................................................................................................ 33
3.8 Design information regarding transporting velocity .......................................................................... 33
3.9 Secondary magnetic flux .................................................................................................................. 35
4 Mounting ............................................................................................................................................... 37
4.1 General mounting instructions .......................................................................................................... 37
4.2 Dimensions of the system ................................................................................................................ 38
4.3 Mounting of sensors ......................................................................................................................... 40
4.4 Sensor mounting in magnetic conveyors ......................................................................................... 44
5 Electrical installation ........................................................................................................................... 47
5.1 General instructions .......................................................................................................................... 47
5.2 Configuration of connectors .............................................................................................................. 47
5.3 Connecting diagram - examples ....................................................................................................... 50
6 Communication with the PLC ............................................................................................................. 55
6.1 PLC inputs ........................................................................................................................................ 55
6.2 PLC output signals ........................................................................................................................... 55
6.3 Timing diagrams ............................................................................................................................... 57
6.4 Internal control (Demo mode) ........................................................................................................... 68
7 Start-up .................................................................................................................................................. 69
7.1 Initially applying power to the system ............................................................................................... 69
7.2 Start screen ...................................................................................................................................... 69
7.3 Operation .......................................................................................................................................... 70
7.4 Configuration menu .......................................................................................................................... 71
7.5 General information regarding the configuration .............................................................................. 76
7.6 Changing, setting-up or checking the configuration ......................................................................... 76
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
3
Manual
Double Sheet Detector R1000 Series I20
Table of contents
B0069991 / Rev. 1.7
7.7 Program parameters ........................................................................................................................ 78
7.8 Adjustment parameters .................................................................................................................... 87
7.9 System parameters .......................................................................................................................... 89
7.10 Data backup ..................................................................................................................................... 96
7.11 Firmware update .............................................................................................................................. 96
8 Operation ...............................................................................................................................................99
8.1 Abbreviated operating instructions .................................................................................................. 99
8.2 Entering a measurement program ................................................................................................. 100
8.3 Zero adjust (after sensor exchange) .............................................................................................. 101
8.4 Teach-In ......................................................................................................................................... 101
9 Fault messages, causes and remedies ........................................................................................... 103
9.1 Faults concerning memory ............................................................................................................ 104
9.2 Faults concerning USB data transmission (virtual RS232) ............................................................ 105
9.3 Faults concerning system operation .............................................................................................. 105
9.4 Faults concerning keyboard ........................................................................................................... 105
9.5 Faults concerning parallel interface ............................................................................................... 105
9.6 Faults concerning sensor test ........................................................................................................ 106
9.7 Faults concerning Teach-In / Zero adjust ...................................................................................... 106
9.8 Faults concerning sensors / sensor cables.................................................................................... 106
9.9 Faults concerning Hardware .......................................................................................................... 107
9.10 Faults concerning supply voltage .................................................................................................. 107
9.11 Other faults .................................................................................................................................... 107
10 Maintenance ....................................................................................................................................... 109
10.1 Replacement of sensors ................................................................................................................ 109
10.2 Exchange of control unit ................................................................................................................ 109
10.3 Replacement of fuses .................................................................................................................... 110
10.4 Data backup via USB interface ...................................................................................................... 110
10.5 Firmware update via USB interface ............................................................................................... 111
10.6 Spare parts .................................................................................................................................... 111
11 Technical records .............................................................................................................................. 113
11.1 Exchange of equipment ................................................................................................................. 113
12 Order data .......................................................................................................................................... 114
12.1 Versions of control unit I20 ............................................................................................................ 115
12.2 Sensors .......................................................................................................................................... 115
12.3 Cables ............................................................................................................................................ 115
12.4 Cable plugs and cable sockets ...................................................................................................... 116
12.5 Other accessories (within scope of delivery) ................................................................................. 116
13 Appendix ............................................................................................................................................ 117
13.1 System configuration form ............................................................................................................. 117
4
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
Manual
Double Sheet Detector-series I20
B0069991 / Rev. 1.7
Declaration of conformity according to EC directives
Manufacturer: Roland Electronic GmbH
Otto-Maurer-Str. 17
DE 75210 Keltern
Product name:
Product type:
Roland Electronic GmbH declares that the product listed above complies with the requirements of
the EMC directives listed below.
Applied Directives:
2006/95/EG Low Voltage Directive
EN61010-1: 2010
I20
Double Sheet Detector-series I20
Safety advices
2004/108/EG: EMC Directive
EN61000-6-2: 2005-08 EN61000-6-4: 2007-01
Date of mark’s apposition: 12.03.2015
Keltern, 12.03.2015
Place, Date Signature Function of the signer
Managing Director
The declaration confirms the compliance with the cited directives. However, it is not any implied warranty of fitness for a
particular purpose especially as it may relate to product liability.
The safety instructions and warnings must be observed.
ISO 9001 : 2008
Reg.-no. 5152 QM08
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
5
Manual
Double Sheet Detector-series I20
Safety advices B0069991 / Rev. 1.7
Blank page
1 Safety advices
1.1 Safety instructions and warnings for user
This handbook contains all information required for the correct operation of the Roland equipment.
It has been written for technically qualified personnel. Unauthorized tampering with the unit,
especially ignoring the warnings in this handbook, can cause malfunction and damage to the unit.
6
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
Manual
Double Sheet Detector-series I20
B0069991 / Rev. 1.7
Only authorized personnel should be allowed to make changes to the unit and perform cable
connections especially the power supply.
Should it be necessary, e.g. in case of service or repair, to make measurements within the unit,
then all customary accidents prevention procedures should be observed. Only professional
electrical tools should be used.
Note The factory pre-settings – especially the upper / lower limit values – have
been chosen such that an optimal machine protection is ensured.
Diverging settings can impair the machine protection.
Safety advice for persons with cardiac pacemakers!
Persons with cardiac pacemakers are to stay away from the sensors!
The strong magnetic / electromagnetic fields of the sensors can cause malfunction
of cardiac pacemakers and other such apparatus!
1.2 Declaration of icons
Warning - general dangers!
Reference to imminent hazards, which can result in severe bodily harm or death.
Warning - dangers by high voltage!
Reference to imminent hazards due to electricity, which can result in severe bodily
harm or death.
Attention - Damage of construction units!
Reference to a potential imminent situation, which can result in damage to the
product or environs.
Note
Useful reference to an application or deepening information.
Safety advices
1.3 Intended use
Flexible Manufacturing Systems in the sheet processing industry require reliable Double Sheet
Control systems in order to protect presses and other sheet processing machines against damage
caused by feeding multiple sheets.
The Double Sheet Detector R1000 I20 was specifically developed for this technical environment.
Depending on the application (type of material, thickness, sensor gap) the I20 can be used with up
to four pairs of sensors. The reliable function of the Double Sheet Detector depends therefore most
importantly on the selection of the correct sensors and the mounting of the sensors.
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
7
Manual
Double Sheet Detector-series I20
Technical data B0069991 / Rev. 1.7
Blank page
8
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
Manual
Double Sheet Detector-series I20
B0069991 / Rev. 1.7
2 Technical data
2.1 Technical data control unit I20
Technical data control unit I20
Operating voltage: 24 VDC, +6 V / -4 V
Power consumption: 15 W
Switch on current: 10 A for 1 ms
External fuse: 1 A medium time lag
Ambient temperature: 0 - 50 °C (30 - 122° F)
Wall mount enclosure I20-2-O-S I20-4-O-S
Protection category: IP65
Dimensions, approx.. (W x H x D) mm 225 x 206 x 112 225 x 206 x 112
Dimensions, approx.. (W x H x D) inch 8.9 x 8.1 x 4.4 8.9 x 8.1 x 4.4
Weight, approx 4.0 kg (8.81 lbs)
Valid from SN-No. 104358 delivery date 09/03/2009
Front panel enclosure I20-2-O-S-FP I20-4-O-S-FP
Protection category: IP40 (inside), IP65 (front cover)
Dimensions, approx.. (W x H x D) mm 240 x 240 x 120 240 x 240 x 170
Dimensions, approx.. (W x H x D) inch 9.45 x 9.45 x 4.7 9.45 x 9.45 x 6.7
Weight, approx 2.2 kg (4.85 lbs)
Additional characteristics:
255 parameter sets memory
Programming via front panel keys
10 galvanically isolated
optocoupler inputs 24 VDC with
common external supply
5 potential free outputs
with positive external supply
Virtual RS232 interface (via USB) for data backup
USB interface for Firmware update
Attention In order to protect the outputs from damage by inductive spikes, the
Specification:
- min. switching voltage HIGH: 13 VDC
- max. switching voltage HIGH: 30 VDC
- min. switching voltage LOW: 0 VDC
- max. switching voltage LOW: 8 VDC
Specification:
- switching output: unwired Emitter and Collector
- max. switching voltage: 30 VDC
- max. switching current: 500 mA
outputs need to be protected by amply dimensioned flyback diodes.
Technical data
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
9
Manual
Double Sheet Detector-series I20
Technical data B0069991 / Rev. 1.7
2.2 Versions of the control unit I20
The control unit article key ist coded as follows:
Control unit I20 with optocoupler interface
I20-2-O-S-FP
A B C D E
Based on the product key shown above, the following versions are available:
I20-2-O-S
I20-4-O-S Control unit for wall mounting, connection of up to 4 sensors,
I20-2-O-S-FP Control unit for front panel mounting, connection of up to 2 sensors,
I20-4-O-S-FP Control unit for front panel mounting, connection of up to 4 sensors,
Data backup
via serial USB
interface
Control unit for wall mounting, connection of up to 2 sensors,
IN/OUT interface
IN/OUT interface
IN/OUT interface
IN/OUT interface
A Type of unit I20
B Number of sensors
C Outputs O Optocouplers
D Connection S pluggable
E Enclosure FP Front panel mounting
2 4 up to 2 sensors
up to 4 sensors
2.3 Sensors
The sensor description has the following code:
IS20-30GS
2.3.1 Sensor pair IS20-30GS / IE20-30GS
A B C D E
Technical data
Application: Double sheet detection
Sheet thickness:
0.05 – 4 mm for steel
0.05 – 10 mm for Aluminum (LW 20 – 30 MS/m):
0.2 – 10 mm for austenitic Stainless steel
Sensor distance: see sensor diagrams
Measurement principle: Eddy current
Protection class: IP54
Weight: ca. 0.25 kg (0.55 lbs)
Material of enclosure: Stainless steel / Brass, Nickel plated
Sensor cable: Quick disconnect
A: Inductive sensor
B: S = transmitter, E = receiver
C: Diameter of sensor head
D: Thread
E: Quick disconnect
at nom. sensor distance (min. / max.)
20 (10 – 40) mm
20 (10 – 40) mm
20 (10 – 40) mm
10
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
Manual
Double Sheet Detector-series I20
B0069991 / Rev. 1.7
2.3.2 Sensor pair IS42-30GS / IE42-30GS*
Technical data
Application: Double sheet detection
Sheet thickness:
0.15 – 8 mm for steel
0.1 – 10 mm for Aluminum (LW 20 – 30 MS/m):
0.4 – 10 mm for austenitic Stainless steel
Sensor distance: see sensor diagrams
Measurement principle: Eddy current
Protection class: IP54
Weight: ca. 0.45 kg (1 lbs)
Material of enclosure: Stainless steel / Brass, Nickel plated
Sensor cable: Quick disconnect
* Transmitter ISQ42. and receiver IE42-30.. may be also used as a sensor pair. Please refer to
chapter 4.3.1 for an example.
2.3.3 Sensor pair ISQ42S / IEQ42S*
Sensor pair ISQ42FS / IEQ42FS*
Technical data
Application: Double sheet detection
Sheet thickness:
0.15 – 8 mm for steel
0.1 – 10 mm for Aluminum (LW 20 – 30 MS/m):
0.4 – 10 mm for austenitic Stainless steel
Sensor distance: see sensor diagrams
Measurement principle: Eddy current
Protection class: IP54
Weight: ca. 0.50 kg (1.1 lbs)
Material of enclosure: Plastic
Sensor cable: ISQ / IEQ42S: Quick disconnect
ISQ / IEQ42FS: 0,2 m, cable firmly connected, with cable plug
* Transmitter ISQ42S and receiver IE42-30S, respectively transmitter IS42-30S and receiver
IEQ42S may be also used as a sensor pair. Please refer to chapter 4.3.1 for an example.
Technical data
at nom. sensor distance (min. / max.)
40 (20 – 80) mm
40 (20 – 80) mm
40 (20 – 80) mm
at nom. sensor distance (min. / max.)
40 (20 – 80) mm
40 (20 – 80) mm
40 (20 – 80) mm
2.3.4 Sensor pair ISQ160S / IEQ160S
Technical data
Application:
Sheet thickness: Depending on the application
Sensor distance: 20 – 80 mm (depending on the application)
Measurement principle: Eddy current
Protection class: IP54
Weight: ca. 0.50 kg (1.1 lbs)
Material of enclosure: Plastic
Sensor cable: Quick disconnect
Part inspection, Material inspection, Hardness inspection
Note The stated measurement ranges are only valid for systems in „Standard“
setting. For details refer to chapter 3.2.
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
11
Manual
A
t
Ax /
A
A
A
Double Sheet Detector-series I20
Technical data B0069991 / Rev. 1.7
2.3.5 Sensor diagrams
Sensor diagrams are available for determining the admissible measuring range depending on the
gap between transmitter and receiver (Ax) and the material. Ax is specified as follows:
x
Fig. 1: Transmitter-receiver gap Ax
The marked areas represent the working ranges of the sensors. For all combinations of sheet
thickness and sensor distance Ax within the range a double sheet condition will be reliably
detected, if the switching thresholds are set “tight”.
The working ranges of the sensors depend very much on the material properties, they can deviate
from the sensor diagrams shown below.
Note The stated measurement ranges are only valid for units of type
„Standard“. For details refer to chapter 3.2.
Blech
Shee
Ax diagrams for sensors IS / IE20-30GS
mm
Ax (2 n)
Ax (n)
x (½ n)
Ax (2 n)
Ax (n)
x (½ n)
Ax (2 n)
Ax (n)
30
20
10
0
Ax / mm
40
30
20
10
0
0,05
Ax / mm
40
30
20
0,05
STEEL
1
234
Sheet thickness / mm
AL UMINUM
1
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
STAINLESS STEEL (Austenitic)
Ax(n) = nominal sensor gap
Sheet thickness / mm
x (½ n)
10
0
0,2
1
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Sheet thickness / mm
Fig. 2: Sensor diagrams for sensors IS / IE20-30GS
12
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
Manual
A
)
A
)
A
)
m
m
Double Sheet Detector-series I20
B0069991 / Rev. 1.7
Ax diagrams for sensors IS / IE42-30GS and ISQ / IEQ42S
Ax (2 n)
Ax ( n)
x (½ n
Ax (2 n)
Ax ( n)
x (½ n
Note The stated measurement ranges are only valid for systems in „Standard“
Ax / mm
80
60
40
20
0
Ax / mm
80
70
60
50
40
30
20
STEEL
20,15 46 8
135 7
Technical data
setting. For details refer to chapter 3.2.
Ax(n) = nominal sensor gap
She et th ickn ess / mm
ALU MINU M
0
0,1
1
Ax ( 2 n)
Ax ( n)
x (½ n
Ax / mm
80
70
60
50
40
30
20
0
0,4
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
STAINL ESS ST EEL (Aus te n itic)
1
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Sheet thickness / m
Sheet thickness / m
Fig. 3: Sensor diagrams for sensors IS / IE42-30GS / ISQ / IEQ42S
Ax diagrams for sensors ISQ / IEQ160S
The sensors are specifically designed for Monitoring Parts for Hardened / Tempered Properties
and Materials Mix up. The sensor gap can range from 20 to 80 mm depending on the geometry of
the parts to be tested.
Note If more than 1 pair of sensors is connected to the system, the sensor
gaps may not deviate from each other more than ±10%. Otherwise the
zero adjustment can be faulty.
Example: S1: 40 mm S2: 42 mm S3: 39 mm S4: 43 mm
All values are within ±10%.
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
13
Manual
Double Sheet Detector-series I20
Technical data B0069991 / Rev. 1.7
2.4 Dimensions of the sensors
14
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
Manual
Double Sheet Detector-series I20
B0069991 / Rev. 1.7
Technical data
Fig. 4: Dimensions of IS/IE sensors bis SE75.wmf
2.5 Sensor cables
Cable marking:
The cables have quick disconnects at both ends. The plug at the control unit side is always
straight.
SCI20S-GG with straight cable socket at the sensor
SCI20S-GW with right angle cable socket at the sensor
SCI20S-GG-TE extension cable for sensor cable (also use as quick disconnect)
Applicable to all cables:
Note The sensor cable is an active component of the sensor technology.
Bending radius: 50 mm at fixed installation
100 mm at flexible installation
Cable diameter: 7.1 mm
Suitable for drag chains, oil-proof, PUR jacket
Superflex Tronic(C)PUR TP 4 x 2 x 0.25 mm²
The technical data of the sensors is valid only if the cable specification is
met. A shielded cable must be used.
The cable length can be to up to 50 m. Following the rule "the shorter the
better" generally leads to better measuring results.
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
15
Manual
Double Sheet Detector-series I20
System description B0069991 / Rev. 1.7
Cable extension SCI20S-GG-TE
The cable extension SCI20S-GG-TE is inserted between the control unit and the existing regular
sensor cable SCI20S-GG, SCI20S-GW.
Note: This cable must be used if the sensors ISQ/IEQ42FS (with firmly
connected cable) are taken.
2.5.1 Allocation of sensor cables SCI20S-GG, SCI20S-GW and SCI20S-GG-TE
Fig. 5: Allocation of sensor cables SCI20S-GG, SCI20S-GW and SCI20S-GG-TE
2.6 Scope of delivery (accessories)
Within the scope of delivery there are accessorial parts, which are separately packaged and put
into the shipment box.
Fig. 6: Accessories, packaged
The volume of accessories depends on
the version of the control unit.
It is shown in Chapter 5.2
“Configuration of connectors“.
16
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
Manual
Double Sheet Detector-series I20
B0069991 / Rev. 1.7
3 System description
Flexible production systems in the sheet processing industry require automated, reliable double
sheet detection in order to protect presses and other processing machinery from damage by
multiple sheets. The I20 was specifically developed for this technical environment. The I20 is based
on the product platform R1000 and consists in the standard version of three components:
• a control unit
• one pair of sensors (transmitter and receiver)
3.1 Measurement principle
3.2 System type
• one pair of sensor cables
The function of the sensor system is based on the measurement of eddy currents. The sensor
system consists of a transmitter and a receiver.
The transmitter generates an electromagnetic field, which generates eddy currents in the target.
The eddy current loss in the sheet dampens the electromagnetic field. These losses are measured
in the receiver and are a measure of the sheet thickness (see also section ”Sensor diagrams“).
With the system parameter “System type“ the function of the I20 can be fundamentally changed.
Possible choices are:
a) Standard
b) FE + AL 0.5 - 3 mm
c) FE + AL 0.1 - 0,8 mm
d) FE + Austenite 0.1 - 1 mm
f) FE + Austenite 0.5 - 3 mm
g) Frequency
h) Damping mode
With the selections b) – f) the following applications are conceivable:
• Only 2 programs are used, one program for ferrous and the other one for nonferrous
material. With each change of material the program for the corresponding material is
switched and the first sheet is used for Teach-In.
• All programs are used. The Teach-In can be performed with running sheet, without stating
nominal thickness and conductivity.
The selections b) - f) are intended as substitution for the mode “Dimension %“ known from the
I10K.
System description
Here mm or inch can be selected as dimension.
The nominal sheet thickness as well as the material must be entered.
For NF (nonferrous) material the electrical conductivity must be entered,
or the conductivity must be determined at sheet standstill. Only then a
dynamic Teach-In can be performed.
The materials which can be measured depend on the restrictions of the
sensor pair used.
Restricted measurement range !
Here only % can be selected as dimension.
The nominal sheet thickness does not need to (/cannot) be entered.
Only FE (ferrous) and NF (nonferrous) material are available for
selection.
A dynamic Teach-In can be directly performed.
Depending on the selection (b - f) only those materials and thicknesses
can be measured! (restricted measurement range!)
Monitoring Parts for Hardened / Tempered Properties and Materials Mix
up. The input of nominal dimensions is not necessary. The measurement
frequency is adjusted according to the task under consideration (review
the following explanations)
Within the system parameter „System type - Standard“ there will be no
error-free dynamic Teach-In execution in a sophisticated constellation of
work environment. The error message 151 "Sheet too thick" is reported.
This problem occurs especially when using magnetic conveyors. For this
case you must choose the system type “Damping mode“.
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
17
Manual
Double Sheet Detector-series I20
System description B0069991 / Rev. 1.7
3.2.1 Explanation for System type “Frequency”
This adjustment of the I20 is used for applications to identify non-hardened or defective parts. The
parts are passed through a sensor C-frame in which they are exposed to an eddy current field.
Non-hardened or defective parts have a different field attenuation from good parts and can
therefore be separated.
Roland Electronic supports the use with no charge application tests in order to ensure the feasibility
of the project and obtain the optimum control unit adjustments.
Differences of the Adjustments of the I20 in Comparison to the Standard Use.
Teach-In
• Instead of the single sheet (1-sheet) part A is used for a teach in of 100%
• Instead of two sheets (2 sheets) part B is used for a teach in of 200%
Sensors
• The pair of sensors ISQ160S/IEQS160S is primarily used for the system type "Frequency".
• Depending of the results of the application tests, the transmitter and the receiver are
mounted in line either vertically (0°) or horizontally (90°).
Illustration with 0° and with 90°
18
Fig. 7: Illustration with 0° and 90°
Sensor Gap and Measuring Position
• The sensor gap must remain constant during the operating mode "Frequency".
The sensor bracket must be correspondingly designed for this purpose.
• The measurement position of the part to be tested must be identical during Teach-In and
measurement.
• For this application glass turntables are very well suited, magnetic transportation systems are
not recommended.
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
Manual
Double Sheet Detector-series I20
B0069991 / Rev. 1.7
System description
Fig. 8: Glass turntable
Operation
• Instead of the nominal thickness the test frequency is selected for the adjustment of the
program parameters. The type of material adjustment is not necessary. The optimum test
frequency is determined at no charge in the application lab.
• The Teach in of 1 sheet and 2 sheet is substituted by the Teach-In of part A and part B
respectively. Preferably a good part is being used being used for the Teach-In.
3.3 General hints for process reliability
The process security of the system is influenced by the following factors:
• the stability of the measuring values
• the setting of under-gauge threshold and over-gauge threshold
• the evaluation of the status signals
Stable measuring conditions will result in stable measuring results. Varying measuring results are
undesirable, because in such cases the user is inclined to decrease the under-gauge threshold and
to increase the over-gauge threshold. On doing so, the user puts up with the drastically increasing
risk of not detecting a double sheet.
The following external factors decisively influence the stability of measuring results and need to be
considered for operation of a double sheet detector:
• the magnetic characteristics of the material
• the tolerance in material thickness
• the geometric conditions at the place of measurement and at the sheet
• the pre-magnetization of FE material in case of magnetic transport systems.
• the smooth run of the material, with low vibrations
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
19
Manual
Double Sheet Detector-series I20
System description B0069991 / Rev. 1.7
From this, some simple rules can be derived, to enable a high process security when abided by:
• Every different sheet (Thickness, material and contour) is measured with separate
measuring program. For exceptions see chapter 3.6.
• The Teach-In has to be done with the same sheets (Thickness, material and contour)
used when measuring.
• Adjust the switching thresholds as tight as possible!
• Keep the sensor gap constant!
• Ensure for sufficient covering of the measuring target!
• Keep the pre-magnetization of FE material as low as possible (suitable mounting of the
transport magnets)!
• Pass the material guided through the sensor!
Furthermore it is necessary that the machine controls checks all status signals of the I20, also the
0-sheet signal. While measuring, only the 1-sheet signal may occur. If 0-sheet or 2-sheet occurs,
the measured sheet may not be transported on. In such cases, the sheet will usually be removed.
• The machine controls needs to evaluate all status signals !
Checking-up through the 0-sheet signal is to assure that a sheet really is between the sensors
during measuring. If 0-sheet occurs while measuring, the measurement is not correct. For example,
a defective sensor holder might change the sensor gap. Monitoring the sheet thickness would then
only be performed apparently.
In case of double sheet severe consequences could then result.
3.4 Control unit
The I20 is based on the product platform R1000.
Major features of the control unit:
• Programmable for 255 different sheet thicknesses / types of sheets
• Calibration by a Teach-In procedure
• Digital display of sheet thickness and operating parameters
• Monitoring of over gauge and under gauge limits
• Monitoring of operating voltage and sensor gap
• Opto coupler for direct I/O control via the PLC for fast measurement operations
• Software firmware update
• Data backup via USB interface
3.5 Parameters of the control unit
The I20 provides for extensive configuration. So, different customer requirements can be served.
Configuration is performed by setting system parameters and program parameters.
System parameters are set only once during commissioning, and will then remain unchanged.
Program parameters contain items which are material and job depending, and enable individual
adaptation to the measuring task.
20
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
Manual
Double Sheet Detector-series I20
B0069991 / Rev. 1.7
3.5.1 Adjustment parameters
Adjustment parameters are assigned to the individual system. They apply only for this system and
should not be transferred to another unit (control unit exchange).
“Zero adjust“
Before commissioning a new system, after having exchanged a sensor or a sensor cable or a
control unit, a zero adjust must be performed. This zero adjust eliminates the variation of the
sensors. The sensors will be zero adjusted “all in one stroke“.
• The zero adjustment is valid for all programs and should be performed only once !
“Test sensor distance”
Checks the sensor distances.
“Deviation of distance”
Indicates the deviation from the set sensor distances.
“Sensors distance”
Indicates the determined sensor distances in mm / inch.
“Control sensors”
Test of wiring / allocation of the sensors.
System description
3.5.2 System parameters
“Language“
System languages available for operating the unit via display and keyboard:
German / English / Spanish / Italian / French.
“System type“
Fundamental setting of the system function.
In „Standard“ setting the nominal thickness, the material and the electrical conductivity must be
specified. In the other settings (see chapter 3.2 system type b – f) this specification is not required,
therefore only FE and NF material within the stated thickness range can be measured.
For details refer to chapter 3.2.
The “Frequency” is specially designed for the Monitoring Parts for Hardened / Tempered Properties
and Materials Mix up.
“Damping mode” is a special application. For details refer to chapter 3.2.
“Display value in…“
Switches the indication of the thickness values on the display between mm inch.
“Display time”
Specifies the holding time for the screen display.
Value range 0.0…2 seconds.
“CLR parameter (Clear Program Parameter)“
Deletes all program parameters. For doing so, the parameter needs to be set to “yes“. Executing
the command requires several minutes, because the program memory will completely cleared. All
program parameters will be reset to the default values and existing Teach-In data will be deleted.
Using this function only makes sense if a unit is to be newly used for another machine.
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
21
Manual
Double Sheet Detector-series I20
System description B0069991 / Rev. 1.7
“Password active“
Switches the password request on/off. If the password request is set “on“, the system / program
parameters can only be changed after the password has been entered.
“Password”
Without password the system data are unprotected against unwanted change. Therefore a
password should be set as soon as the installation is completed and regular operation has
commenced. The factory preset password is “0000”, it can be set to a value between 0000 and
9999.
“Pairs of sensors“
Defines the number of connected sensors. Those sensors are then available for measuring. To a 2channel system I20-2 max. 2 sensors can be connected, at a 4-channel system I20-4 max. 4
sensors can be connected.
“Sensor type“
Currently the sensors IS/IE20-30S or IS/IE42-30S and ISQ/IEQ42FS or ISQ / IEQ160S are
available. For those sensors characteristic curves for linearization purposes exists.
“Default settling time”
Defines the default time which the system requires to achieve stable measurement results, if the
program parameter “settling time” is not available. For details refer to chapter 3.7.2.
“Measurement mode“
Sets how the measuring is to be triggered. The following modes are available:
• Ext. Single (default setting)
Here a single measuring is performed. For doing so, the signal “Measuring start“ must be
externally applied. Another measuring requires a new flank of the “Measuring start“ signal.
• Demo
The demo mode is only intended for test and demonstration purposes. In this mode
measuring is performed until the demo mode is switched off again. For doing so, another
mode must be selected. The repetition time of the measuring is 4 ms.
• Ext. Permanently
Here the measuring is maintained as long as the signal “Measuring start“ is applied.
The repetition time of the measuring is 4 ms.
• Ext. Special
As Ext. Permanently, but: the highest value measured during a measurement cycle is
displayed and maintained until a new measurement cycle is started. This also applies for
the 0-1-2-Warning outputs.
“Hold if 2-sheet“
Selection: “yes” or “no“.
• Yes: The outputs (0-sheet, 1-sheet and 2-sheet) are activated according to the number of
sheets between the sensors. If the equipment detects 2-sheet, the output 2-sheet is
activated and the equipment is blocked until the 2-sheet condition is cleared, see
Section “Mode of operation 2-sheet hold“.
• No: The outputs (0-sheet, 1-sheet and 2-sheet) are activated according to the number of
sheets between the sensors. The equipment does not block the operation if double
sheet is encountered.
22
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
Manual
Double Sheet Detector-series I20
B0069991 / Rev. 1.7
„Output level 0-1-2-warning“
Sets the output logic (0-sheet, 1-sheet, 2-sheet, warning) to 0V or +24V.
“Automat. prog. select”
Selects the method of program selection. If the program is switched frequently, “no” should be
selected, otherwise the memory would be loaded with frequent writing cycles and its lifetime would
decrease (1.000.000 writing cycles).
“IN / OUT PLC voltage”
Monitores the external PLC voltage. If “monitoring” is set and the PLC voltage is not connected, an
error condition would be detected.
“External Adjust“
Determines whether an external Teach-In / zero adjust is to be possible. If “yes“ is set, the PLC can
trigger the procedure via the inputs “Teach-In 0-, 1-sheet“. Default setting is “no“.
• The external adjust may only be performed under supervision of an operator.
“Internal analog zero”
Only for service personnel.
“Internal analog gain”
Only for service personnel.
“Diagnostic“
Diagnostics of the factors determined during the Teach-In. No default setting.
“Compensation factor”
Projected function.
“System info”
Displays the versions of Software and Hardware as well as the bus information.
Identification of the control unit. These information needs to be at hand for telephone support.
System description
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
23
Manual
b
Double Sheet Detector-series I20
System description B0069991 / Rev. 1.7
3.5.3 Program parameters
3.5.3.1 Program parameters for the Double sheet detection
This menu structure is valid for the system types a – f (for details refer to chapter 3.2)
For measuring an eddy current method is used – called “Transmission” measurement. For
linearization purposes there are compensation curves, applicable to various conductivities and
thicknesses. Magnetical materials have their own compensation curves.
To determine the compensation curves a calibration (later merely called “Teach-In“) must be
performed.
In order to avoid frequent Teach-In procedures for different materials and thicknesses, the unit
provides for 255 program memories. Every such memory consists of a data set with the relevant
parameters.
“Program number”
Selects the number of the data set (1…255) which is to be applied for measurement.
“Sensor number“
Input of the selected sensor (/sensor sequence) for multi-channel systems (e.g. I20-4-…).
“Nominal thickness“
Specifies the nominal thickness of the sheets to be measured.
Value range 0.000…15.00 mm (0.000…0.590 in) Default setting 0.00mm / 0.000 inch.
“Material”
Specifies the material to be measured.
Choices: ferromagnetic material, non-magnetic material and non-magnetic material with unknown
conductivity.
“Lower limit TL“ and “upper limit TU“
Changes the limit values for the lower and upper switching threshold. The values can be entered
either in % or in mm/inch. On these thresholds depend the status signals.
In a window comparator the three signals will be generated from the measuring signal. The signal
“0-sheet“ is generated when the measuring signal falls short of the lower switching threshold TL.
The lower switching threshold TL can be set from 1...99%. The signal “2-sheet“ is generated when
the upper switching threshold is exceeded. The upper switching threshold TU can be set from
100...180%. If the measuring value is within both limits, the signal “1-sheet“ is generated.
Obere Schaltschwelle
Upper switching threshold
Signal
Untere Schaltschwelle
Lower switching threshold
2
1
0
Fig. 9: Visualization of switching thresholds
24
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
c
a
Signal range for 0-sheet
Signal range for 1-sheet
Signal range for 2-sheet
Upper switching threshold
Lower switching threshold
a
b
c
TU
TL
Manual
Double Sheet Detector-series I20
B0069991 / Rev. 1.7
The preset values (TU=120% resp. TL=80%) should only be changed under the following aspects:
1. the 1-sheet range is permanently restricted, since the measuring values are very stable. Thus
the process security increases. The restriction can be done by decreasing the TU value, by
increasing the TL value, or both.
2. the 1-sheet range is temporarily extended. Thus the process security decreases. Such an action
should only be performed in exceptional cases, the user has to decide about that. Extending the
1-sheet range is commonly considered due to mechanical problems (fluttering sheets). This
measure prevents the machine from stoppages, until the mechanical problem is solved.
“Nom./curr. settling time”
Defines the time which the system requires to reach stable measurement results.
For details refer to chapter 3.7.2.
“Teach-In 1-sheet“
The Teach-In calibration has to be executed with the material to be processed.
The calibration applies only to the selected program.
“Teach-In 2-sheet“
Because of the linearization of the sensor it is possible to measure with factory calibration in many
applications, as long as thickness, conductivity and material type are known
For a more precise indication, the system can additionally be calibrated to a 2-sheet condition.
The calibration applies only to the selected program.
System description
3.5.3.2 Program parameters for the Monitoring Parts for Hardened / Tempered Properties and
Materials Mix up
This menu structure is valid for the system types g (for details refer to chapter 3.2) For measuring
an eddy current method is used – called “Transmission” measurement. Compensation curves are
being used for linearization. In order to avoid frequent Teach-In procedures for different materials
and thicknesses, the unit provides for 255 program memories. Every such memory consists of a
data set with the relevant parameters.
“Program number”
Selects the number of the data set (1…255) which is to be applied for measurement.
“Sensor number“
Input of the selected sensor (/sensor sequence) for multi-channel systems (e.g. I20-4-…).
“Frequency”
Adjustment of the measurement frequency for this measurement program.
“Lower limit TL“ and “upper limit TU“
Changes the limit values for the lower and upper switching threshold. The values can be entered
in %. On these thresholds depend the status signals.
In a window comparator the three signals will be generated from the measuring signal. The signal
“0-sheet“ is generated when the measuring signal falls short of the lower switching threshold TL.
The lower switching threshold TL can be set from 1...99%. The signal “2-sheet“ is generated when
the upper switching threshold is exceeded. The upper switching threshold TU can be set from
100...180%. If the measuring value is within both limits, the signal “1-sheet“ is generated.
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
25
Manual
b
Double Sheet Detector-series I20
System description B0069991 / Rev. 1.7
Obere Schaltschwelle
Upper switching threshold
Signal
Untere Schaltschwelle
Lower switching threshold
Fig. 10: Visualization of switching thresholds
2
1
0
c
a
Signal range for 0-sheet
Signal range for 1-sheet
Signal range for 2-sheet
Upper switching threshold
Lower switching threshold
a
b
c
TU
TL
The switching thresholds should be adjusted corresponding to the application.
“Nom./curr. settling time”
Defines the time within the system must achieve a stable measurement result.
For details refer to chapter 3.7.2.
“Teach-In Part A“
The unit calibrates part A to 100%.
The calibration applies only to the currently selected program.
“Teach-In Part B“
The unit calibrates part B to 200%.
The calibration applies only to the currently selected program.
26
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
Manual
Double Sheet Detector-series I20
B0069991 / Rev. 1.7
3.6 Application examples
The following are two typical application examples for the use of the I20.
12
Kabel SCI20S
Cable SCI20S
Kabelstecker 2277018
Cable plug 2277018
Kabel SCI20S
Cable SCI20S
System description
21
Kabel SCI20S-GG-TE
Cable SCI20S-GG-TE
Kabel SCI20S-GG-TE
Cable SCI20S-GG-TE
Kabeldose 2276032
Cable socket 2276032
Kabelstecker 2277018
Cable plug 2277018
IS... IE...
Sender
IS...GS
Tran smi tter
ISQ...S
Kabel SCI20S-GG-TE (Verlängerung / Trennstelle)
zwischen Gerät und Sensorkabel
Cable SCI20S-GG-TE (extension / quick disconnect)
between control unit and sensor cable
Empfänger
Receiver
IE...GS
IEQ...S
Kabeldose 2276032
Cable socket 2276032
Kabeldose 2276034
Cable socket 2276034
0,2 Meter
0.2 meters
ISQ...FS
Sender
Transmitter
0,2 Meter
0.2 meters
IEQ...FS
Empfänger
Receiver
For details on the extension cable SCI20S-GG-TE refer to 2.5.1
To the I20-2 up to 2 pairs of sensors of the same type can be directly connected, To the I20-4 up to
4 pairs of sensors.
The system is capable to measure:
a) sequentially by program switching in case of different sheet thickness,
b) simultaneously in case of identical sheet thickness and if the thickness does not exceed a
ratio factor of 2:1 (sequencer).
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
27
Manual
Double Sheet Detector-series I20
System description B0069991 / Rev. 1.7
Explanation of summary output 0-sheet, 1-sheet and 2-sheet:
If the unit is used in simultaneous mode (more than 1 sensor in a program e.g. 1+3+4), the
measurement result is formed as summary output (via I/O and via the Fieldbus Byte 8-11). The
priorities are:
2-sheet is issued if at least one sensor detects 2-sheet.
1-sheet is issued if all sensors detect 1-sheet.
0-sheet is issued if no 2-sheet is detected but at least one sensor detects 0-sheet.
Truth table for summary output
Sensor 1 Sensor 2 Sensor 3 Sensor 4
2-sheet is issued if:
2-sheet any condition
any condition 2-sheet any condition
any condition 2-sheet any condition
1-sheet is issued if:
0-sheet is issued if:
1-sheet 1-sheet 1-sheet 1-sheet
0-sheet 0-sheet / 1-sheet
0-sheet / 1-sheet 0-sheet 0-sheet / 1-sheet
0-sheet / 1-sheet 0-sheet 0-sheet / 1-sheet
any condition 2-sheet
0-sheet / 1-sheet 0-sheet
28
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
Manual
Double Sheet Detector-series I20
B0069991 / Rev. 1.7
Method a) sequentially by program switching
Meaningful, if the sheets to be monitored by the various sensors have different sheet thicknesses.
Also suitable if the nominal thickness changes from cycle to cycle.
For this procedure the respective parameter set (program) must contain nominal thickness and
sensor number. The selection of the program is then performed by the PLC.
The following is a typical application example
System description
Program Thickness Sensor
1 1,5 mm 1
2 0,7 mm 2
3 0,5 mm 3
4 0,8 mm 4
PLC
1. select Prog.1
2. measure Pr.1
3. evaluate result Pr.1
4. select Prog.2
5. measure Pr.2
6. evaluate result Pr.2
7. select Prog.3
8. measure Pr.3
9. evaluate result Pr.3
10. select Prog.4
11. measure Pr.4
12. evaluate result Pr.4
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
29
Manual
Double Sheet Detector-series I20
System description B0069991 / Rev. 1.7
Method b) simultaneously (sequencer)
Advantageous when measuring the same sheet thickness with each sensor. Here the addressing
of each sensor is done automatically by the I20. The inquiry of the sensors is predetermined in the
program.
Note Advantage: Very fast measurements are possible, smaller software
effort on the PLC side.
Only one output is generated for connected sensors. The summary output is formed with the
following priorities: 2-sheet before 0-sheet, 0-sheet before 1-sheet.
The following is a typical application example
Program Thickness Sensor
1 1,5 mm 1, 2, 3, 4
Start
PLC
1. measure Pr.1
2. evaluate result Pr.1
Note
The simultaneous measurement (sequencer) is also applicable for the
simultaneous measurement of sheets with different thickness, with the
following restrictions:
- the sheet thickness ratio must be less than 2:1
- each sheet thickness is controlled by a sensor pair
- the largest nominal sheet thickness is to be set. This will
issued as measurement at each sensor pair as measured value
- for Teach-In it must be used at each sensor pair a sheet which later
corresponds to the sheet thickness to be measured.
30
ROLAND ELECTRONIC GmbH · Otto-Maurer-Str. 17 · DE 75210 Keltern · Phone +49 (0)7236-9392-0 · Fax +49 (0)7236-9392-33
Loading...