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USER MANUAL - Visi-Trak

1. 151 13 ALARM CONNECTION ae 159 13 1 CHOOSING AN ALARM OUTPUT WIRE AND 000 159 13 2 SETTING UP POSITION LIMIT SWITCH AND nennen 163 13 3 POSITION TRANSDUCER INSTALLATION AND TESTING nenne nennen 165 13 4 INSTALLING YOUR TRUE TRAK 20 20 SOFTWARE 8 nennen 168 INDEX 1 i Technical Support Technical support is available by Phone 216 524 2363 Fax 216 524 9594 Mail Visi Trak Worldwide LLC 8400 Sweet Valley Drive Suite 406 Valley View OH 44125 4244 When calling for support please have the following information available 1 Model and Serial number of system 2 Version of software being used Click Help About for the version number File Monitor Display Display Functions Production Help SIME Ea ee Help Topics What s New FasTrak2 Help About 3 As comprehensive description of the problem as possible including steps made before the error occurred error messages etc If describing a shot profile it is generally easier to e mail over a backup copy of the suspect profile ii Using Windows95 98 XP Win7 True Trak Version 5 software is designed to run using Windows 95 98 XP Win7 for an operating system This allows a number of programs and or windows to be op
2. EEE 54 4 3 1 SAVING SHOTS SAVE ALL METHOD 255 ne 54 4 3 2 SAVING SHOTS SAVE NONE 54 4 3 3 SAVE SHOTS SHOT SKIP METHOD cd 55 4 3 4 SAVE SHOTS TIME SKIP 55 DFE see M TT 60 PROFILE MAIN SCREEN a ee ta 60 opu CHOOSE RD T 61 5 2 CHOOSE PAR 61 5 3 BACKUP RESTORE amp DELETE Yan ica 62 Ile dir 62 PERFORMING AcBACKUP a uates o 62 5 9 1 2 RESTORING THE BACKUP SET deed teres vob uds a 64 ERINIIIONS 65 5 3 2 BACKING UP THE DATASERVER teh cct ei e xr ecu d Lu 65 NEST e d Cal teen ne 66 5 92 9 TO BACKUP AUTOMATICALLY it Desa 66 TO BACKUP MANUALI Y 66 5 4 RESTORING TO THE DATASERVER en sc ici 67 TK 67 5 5 EXPORT DATA WINDOWS 12 70 5 6 EXPORT ALARM SUMMARY DATA TO THE WINDOWS
3. T1 DISPLAY MACHINE AND COMPUTER LIST 0 011 errans 71 SAVE EN 71 S SET LOTAFSTROKELENSTH ne 72 er uec 72 5 9 CHOOSE LANGUAGE 72 US RASS 73 edi 73 SS uicit 73 SOS 73 s MEL A 73 MONITOR aC aa npn 77 6 A REALTIME MACHINE ii o lo 77 6 2 FAS TRAK BOARD SETUP SCREEN FOR FASTRAK2 9 78 6 2 RAK BOARD MONITOR 2 5446 ee 79 REAL TIMES CREEN E adn 80 6 5 SUREXTRAK CONTROL INTERFACE ta Ruta 83 DIS PLA o 88 TM PROFILE SCREENS VARIOUS TYPES OF ia 88 TOIT EAST 90 SHOTS SCREEN DAN Era bte Pom pne ia
4. HD a turn off the computer click the 2 5 button in the lower left hand corner From the list of options select Shut Down and follow the screen prompts b torun another program click on the required icon 18 1 5 Help Topics The Help screen can be displayed by one of the following ways 1 Select Help from the Menu the main Contents Page will be displayed 2 Press the F1 function key 3 Place the cursor over the label of interest and click the Left mouse button then press the F1 key Moving Around in Help In the descriptions some of the text may be highlighted in Green with an underline or a dashed line These words indicate associated topics when the cursor is over the word it will be displayed as a hand press the left mouse button to display the associated topic Underlined topics indicate a jump when selected a whole new help screen will be displayed to return to the previous screen click the Back button on the menu bar Topics underlined with a dashed line indicate a pop up when selected a secondary window will display to return to the original click the left mouse button with the cursor positioned anywhere on the help screen The Help Contents Button Page The Contents page displays a number of books containing related topics click on a book to display the topics click on a topic to display or click on the book to close it The Index Button In the upper dialog box t
5. 2081 8 1910 8 1561 3 1433 1 1040 9 955 4 520 4 DRE Rod 4 Head 151 93 E 26 83 113 94 26 50 15 96 26 16 37 98 25 83 0 0 V csfs FSV 25 50 Parameter Low Alarm High Alarm Value Units Parameter Low Alarm High Alarm Value Units Biscuit Size 0 6 1 1625 Fill Time 0 0 0 0 64 933 MS Cycle Time 30 0 45 0 59 678 Slow Shot Velocity 14 0 15 0 15 8 IPS Calc Start Fast Shot 15 0 15 5 16 222 IN Avg Fast Shot Velocity 0 0 0 0 89 563 5 Runner Full velocity 140 0 145 0 142 4 IPS User Avg Yel Range One 0 0 0 0 0 0 IPS Avg Fill Velocity 125 0 135 0 100 1 IPS Intens Rise Time 0 0 0 0 849 74 MS 7 1 3 Position Time Based The shot profile is displayed using the layout Position vs Velocity based scaling is used up to the impact event at which the scaling changes to Time based versus Position based allowing the squeeze distance to be determined As above 89 7 1 4 Time Based File Monitor Display Display Functions Production Help Live Shots Parameter Low Alarm High gt value Biscuit Size 0 6 0 9 1 1625 Cycle Time 30 0 45 0 59 678 Calc Start Fast Shot 15 0 15 5 16 222 Runner Full velocity 140 0 145 0 1424 Fill Velocity 125 0 135 0 100 1 e The shot profile is displayed as Velocity vs Time this type of plot will be familiar to those who have worked with real time analog collection devices such as a strip chart recorder e Transducer Plot displays the posi
6. 98 Display 98 Display Functions 102 103 104 Distance UNITS ann 25 40 Downtime 46 65 109 110 111 E Effective Peak Intens 138 End of Shot Velocity 25 26 27 28 40 79 137 138 139 gk BER RASSE 19 93 94 96 Fast Shot Distance 139 Fast Shot Rise Time 137 Fast Shot Time ue tia 137 FasTrak Board 53 54 78 79 80 115 116 123 MUS D US 39 Heads O 35 46 104 19 78 46 Impact Pressure to Peak 138 Intens Rise Time 138 Intens Squeeze Distance 138 Internal Parameter 30 L Last 50 Shots Screen 53 88 Oh TETTE 95 96 Limit Switches u ab zan 32 Live Shots Ann en 90 92 104 M Machine 45 48 WAX c 53 54 55 95 Metal At Gate 28 39 139 Metal Temperature 139 MTM 95 Minimum Stroke Length 25 26 27 28 40 MUK 79 MV OF062 14 2 115 116 117 MV O 062 15 eng 115 116 MVO 0628
7. Program File Recycled 2 isiSetup a 4223 Documents and Setti H O FT2 DRAWINGS Open the C Install7 06 directory and run the etup exe file E newmenus mnu operator Ext partext sc password txt pkzip25 exe profile mnu E profileg mnu profiles mnu E PSENSOR TXT reaini exe RODPITCH TXT semaphor txt setup GID eatin hin Figure 14 ess the Install New TrueTrak System button 168 it2_portable_installation pdf Adobe Reader Sele ee la 2 True Trak 2020 tm 7 06 Installation 1 10 xi This program will install the TrueTrak Software into the following directory The installation screen Change this before continuing if you would like to use a different directory gives you a number of CAVEN options The first section allows you to choose which programs 1f any Start Part Editor at TrueTrak Startup progr y Control are started along w th the Start Monitor Setups at TrueTrak Startup Dist Vel Rod main Plot program Start Board Monitor At TrueTrak Startup 4 te Uri Fic SureTrak Control Installed 21 IRS 2 The Start Part Editor ESA sa MM MPS 2 at TrueTrak Startup will Start SureTrak Control at TrueTrak fartup MM MPS 20 3 U run the Part Setup Automatically Start When the Computer Boots program when you start Install Windows NT D
8. DC MODULE 06 5 10 Pr ar BH I I c HH OUTPUT JRETURN Sx S 52 ar j 1nainn Way j 1naing Wal Te EZ HILLAS mr m LIVE 20 NEUTRAL MYO 06e88 MULTIPLEXER INTERFACE PCB NEUTRAL 7 e 1ZOVAC NEUTRAL MODULE COLOR BLACK AC OUTPUT RANGE 12 140 The PLC module 1 at the top right of the diagram is connected to normally closed contacts CR 7 and CR 1 PLC module 1 in this case expects current flow when no alarm is activated Therefore during a state of NO ALARM relay is de energized current will flow through normally closed contacts CR 7 and CR 1 PLC module 2 is connected to normally open contacts CR 8 and CR 5 This module expects current flow only when an alarm is triggered Therefore during a state of NO ALARM no current will flow through contacts CR 8 and CR 5 When an alarm is triggered 120VAC Live is output at TB1 12 and sent to CR A The relay energizes The Green light goes out and the Red light is lit Simultaneously PLC module 1 has no current flow because contacts CR 7 and CR 1 are now open Contacts CR 8 and CR 5 close and current flows through PLC module 2 156 Section 13 Alarm Connection 158 13 Alarm Connection 13 1 Choosing a
9. module with AC voltage An example of this type is shown below inaug Holas n 4 nd nn xal Lia Lf LIWII Way Iv O D EJ 4 m co L__ O n a Ly n HILIAS inan Lia Lf LIWII Way Iv m aL L__ 15 O ro T HILIMS O B c O I r E LINI Way 17 120V AC LIVE O TD 4 hs INdIND__ 334 093Z La unio SI HILIMS 4 LIWI a _ 5 120V AC NEUTRAL PLC ADD ON DC MODULE PLC ADD ON AC MODULE 5 it is important to install the correct Opto module into the proper location the MVO 06288 Multiplexer Interface Board For the first and third alarm you need to use a black OAC5 AC output module installed in the OPTO 6 and OPTO 8 location on the Multiplexer Interface Board For Alarm 2 place a red ODC5 DC output module in the 7 location Note that a fuse is placed inline with the AC Alarms 150 12 3 The Indirect Method This method is used when you need maximum flexibility from a single alarm output and costs must be kept at minimum Instead of directly connecting alarm lights or PLC s directly to the MVO 06288 Multiplexer Interface Board as in the Direct Method a control relay with multiple conta
10. 0065 3PDT RELAY CR fovoc Note that we again can mix and match components that require different voltage types when we use the Indirect Method Below is an advanced alarm setup For simplicity we use two AC lights green and red When no alarm is activated the green light remains lit However when an alarm is triggered the green light goes out and the red light is lit 153 L X O El L1 LJ L1 7 O O 7 la PAPAS PAP N i2 Ile I mi 5r 5r orc ln 4 4 gt SE 2 S xal I 11 L_ L_IL_IL_I u OPTOS OPTO 5 cA So 12 LIVE gt lez lle 120VAC LIVE 02 32 a gt oz CA i CA c2 isl E ile 120 40 NEUTRAL r7 L m L L MVD 06288 MULTIPLEXER INTERFACE PC B COVAC NEUTRAL 120VAC Live is input at TB1 11 and also at CR 9 In a state of NO ALARM the green light is lit because contacts CR 9 and CR 3 are normally closed and the relay CR has not been energized Current will flow through CR 9 and CR 3 while CR is de energized When an alarm is triggered 120VAC Live is output at TB1 12 thus causing CR to energize This opens contacts CR 9 and CR 3 and the Green light goes out because current will no longer flow through the lamp Concurren
11. TSCS89I COL 891 c 66 FSC 891 891 66 FSC 891 6 FSC 891 CO 126 10 7 Setting up the Ethernet port on the computer The following 1s a description of how to connect a FasTrak2 Portable to a separate computer If you have an integrated monitoring computer then the computer and the FasTrak board are located inside the same cabinate and are normally connected by a cat5 crossover cable that goes directly from the FasTrak2 board to the FasTrak Direct Connection ethernet port on the computer Otherwise the steps shown here the same that are performed by Visi Trak Worldwide personel before an integrated system 1s shipped On the computer open the Network Programs onnections dialog Documents A 3 Control Panel Settings Network Jus ons Printers and Faxes mi Taskbar and Start Menu Search Help and Support _ Log Off Jay Windows Professional Turn Off Computer O og no Network Connections File Edit View Favorites F x E LAN or High Speed Internet Double click on the ethernet port that you are going to connect to Took ou have more than one port and don t know which you are going to use try plugging and unplugging the ethernet cable from the port on e FT2 Portable When you unplug the cable an X will appear 1n the symbol for that port on the computer shown below e f ex
12. 1 POSITION IN TIME MS Parameter Low Limit High Limit Value Parameter Low Limit High Limit Value 0 0 899999 0 0 0 0 99 0099 IPS Cycle Time 0 0 0 0 38 4472 SEC Fill Velocity 0 0 0 0 89 4594 IPS Calc Start Fast Shot 0 0 0 0 15 0499 Intens Pressure 0 0 0 0 0 0 PSI Sleeve Full Velocity 0 0 0 0 98 9445 IPS Fill Time 0 0 0 0 11 1782 5 Pressing the Ok button closes the Choose Shots dialog Note that if you are viewing the Last 50 Shots Screen the Ok button is the small unlabeled button at the bottom of the Choose Shots dialog You can also exit from the dialog by pressing Enter orEsc Once you have selected a shot to view the Live Shots button in the upper left of the screen changes to SE No real time updates will be displayed until you click on this changing it back to Live Shots Pressing the Ok button closes the Choose Shots dialog Mote that if you are viewing the Last 50 Shots Screen the Ok button is the small unlabeled button at the bottom of the Choose Shots dialog You can also exit from the dialog by pressing Enter orEsc 5 1 Choose Shots Used to view previously saved shots for the current part Shot Number Machine Part Shots Date GMtest NEWPART 0 100002 00 14 YISITRAK 1 000003 10 01 1999 08 21 27 uu e us imm 000004 10 01 1999 08 22 08 Method a Click on Choose Shots on the File menu b A list of saved shots is displayed
13. 399899999999 B LEE win ur E lb m M Y gt uw E XT YF gt y v 6 R x r L nidi dili OS J y KJ DS IU F ee a a _ ne m b oS 5 4 i a S Al y T n gt d 6 oie L ad d D ta iF 2 F TERNES ANE a LI e s a gt a E 57 58 59 60 61 62 63 64 65 66 67 68 69 70 gt gt gt gt gt gt gt gt gt gt gt gt gt No Output Click on the module you wish to use or OK Cancel press Tab to use the next module Manual Entry Control Outputs Monitor Outputs E d VF 161 Choose Wire EDM GH OOOO See RC UN Opto Wire Number 1 Click on the module you wish to use or Monitor OK Caneel press Tab to use the next module Manual Entry Control Outputs Click on the module you would like to use for the alarm output this will display were to connect the common connection for the alarm device indicated with an arrow pointing in towards the board and display the output connection for the alarm with an arrow pointing away from the board Click OK then click save changes 162 13 2 Setting up position limit switch and wiring Part Setup Delete This Part to Existing Parts Copy to
14. Min Average Range Std Dew Lowy High LCL UCL Ziel Zucl min Fill Time 4256 1092 114 3 165 42 00 oO oo oo 000 000 Total Shot Time 1040 3 935 4 973 0 104 9 19 9 0 0 0 0 0 0 0 0 0 00 0 00 0 00 Slow Shot Time 884 7 26 5 803 1 858 2 1457 0 0 0 0 0 0 0 0 0 00 0 00 0 00 Fast Shot Time 956 9 128 3 170 0 28 6 195 5 0 0 0 0 0 0 0 0 0 00 0 00 0 00 Fast Shot Rise Time 42270 0 00 25 82 122 70 18 23 0 00 0 00 0 00 0 00 0 00 0 00 0 00 Cycle Time 33 64 29 36 31 06 4 28 1 20 0 00 0 00 0 00 0 00 0 00 0 00 0 00 Time Interval One 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 Time Interval Two 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 User Time Int Three 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 Tem Time m Four 1 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 User Time Int Five 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 y A A gt A statistical summary of the recorded values is available on the Trend Chart The following values are displayed e Max Maximum value in the selected range e Min Minimum value in the selected range e Average Average of all the values the selected range e Range Range between minimum and maximum value recorded e Standard Deviation Standard deviation of all the values in the selected range e Alarm Limits The alarm values set for the parameter by the user these will be used to calculate the Cpk and e
15. click on the shot to display it C Click on the button at the bottom to close window 5 2 Choose Part Used to view previously saved shots for a part which isn t currently being monitored 61 Choose Part x Machine Part Params Shots NEWPART 0 Method a Select Choose Part on the File menu b Select the machine and part required then click OK C From the list of shots select those required 5 3 Backup Restore amp Delete 5 3 1 Backup This procedure is designed to familiarize the user with the Backup and Restore utility of the True Trak Monitoring Program Version 5 xx TrueTrak Backup Restore x Restore Delete 5 3 1 1 Performing a Backup 1 Click File on the Menu Bar Choose Backup and Restore from the drop down menu 2 Choose Backup from the choices in the True Trak Backup Restore window Backup Setups and Data Backup Setups Scrap Downtime Shot Profiles Shot Parameters Alarm Data All Save Last 50 Shots Purge Downtimes Purge Alarm Summaries Machine NEWPART VISITRAK Purge Options for Profiles All and Parameters ext Most Recent 50 Shots Purge Data Number Backup Zip File C Abackup zip Params Shots e g C BACKUP 2ZIP Debug Setup File Backup 62 3 The Backup Setups Data window presents the user with several options a Click the checkboxes in t
16. 10 12 Total Alarms Shots 23 56 79 105 69 5 5 Export Data to Windows Clipboard Recorded parameter data can be copied from the True Trak monitoring program to an external program such as Excel Word etc for presentation and analysis purposes Method 1 Using the Choose Part function ref section 5 2 select the part which you want to copy data pue ee ee UN Select Export Data to Windows Clipboard on the File menu From the window select the shot numbers and parameters to be exported Click the OK button The selected data will be copied to the Windows Clipboard Open the application i e Microsoft Excel Paste the data into the application Depending on the application this is achieved by a number of ways typical functions to look for are Paste From Clipboard Paste Special 7 The selected shot parameter data along with shot numbers and alarm values should be displayed on the application Sheet Window Page Form 01 VISITRAK Worldwide Shot Number Date Time 1 08 15 1997 15 17 08 626 461 2 08 15 1997 15 17 24 626 461 Alarm Min Alarm Max Warn Min Warn Max l Inite Fill Time Total Shot Time 28 9130 28 9130 70 5 6 Export Alarm Summary Data to the Windows Clipboard This function allows you to export the alarm summary data to the windows clipboard The part used is the one currently displayed on the Plot Screen The data is stored as counts per shift of the number of shots with
17. 105 05 97 Visi Trak amp is a registered U S Trademark of Visi Trak Worldwide LLC
18. Option Machine Not Monitored Drop Down List Box Provides a list of hidden choices from which you can select To activate click the down arrow button Clicking an item in the list will select it The selected item is then the only item visible Scrolling List Box Provides a list of choices not all of which can be seen at one time To select an item scroll through the list until the desired choice is visible Clicking an item in the list will select it List Box Provides a list of visible choices from which you can select Clicking an item in the list will select it Option Box Provides choices that are selectable by clicking either a check box or a radio button 11 Text Box Requires a numeric or text input by the user Click the Text Box with mouse and type an entry with keyboard Command Buttons Clicking Command Buttons will perform an action of some kind Command Buttons are labeled as to their function Dialog Tabs Dialog Tabs look similar to folders inside a filing cabinet Clicking a Dialog Tab will activate a page mini window within a Window 12 Section 1 Getting Started Closing Down Help Visi Trak is a Registered U S Trademark of Visi Trak Worldwide LLC 14 1 Getting Started Closing Down r 1 Two ways to start the program 1 Version icon on the Windows screen a Click on the True Trak b Click the MUA button in the low
19. Users who require this feature should contact Visi Trak for more information 12 Biscuit Size MM The measured difference between the final plunger position and the Total Stroke Length If a value of 818 or 20777 mm is being displayed then the Total Stroke Length has been set too short see Determining Total Stroke Length 13 Calculated Start of Fast Shot CSFS The position when the user set Minimum Velocity for CSFS has been equaled or exceeded and the user set Minimum Position for CSFS been exceeded Set in Part Editor Basic Setup It s position can be marked on the trace see Marks On Profiles 14 Intens Pressure PSI BAR The intensified pressure recorded when the user set Time for Intens Pressure has elapsed i e line E on the Profile user entered a time of 100 MS at which a pressure of 2650 PSI was recorded The Time for Intens Pres is set on the Advanced Part Setup screen 15 Intens Rise Time MS Time between the intensification start P3 and the pressure set in Press for Response Time being reached period F on Profile i e took approx 210 MS for the intensifier to reach the predefined pressure of 3000 PSI Useful for determining intensifier delays The Press for Response Time is set on the Advanced Part Setup screen 16 Effective Peak Intens PSI BAR The final pressure recorded during the intensification period Pressure H on Profile Note if the intensifier is dying off during intensification this will not be the ma
20. the reference trace will no longer appear on the screen Note The reference trace is always the last saved saving a new reference trace will override the previous one Overlay and Reference trace only available in Position Time based display The shot pressure is not viewable in Position Time based display 8 2 Overlay Allows a number of shot profiles to be overlaid on top of each other useful to determine consistency of the shot The trace below shows 10 shots overlaid File Monitor Display Display Functions Production Help Live Shots 1907 2 1430 4 953 6 476 8 T Head 147 92 e 26 83 110 94 26 45 73 96 26 06 36 98 25 67 0 0 SV csfs FSV 25 28 Parameter Low Alarm High Alarm Value Units Parameter Low Alarm High Alarm Value Units Biscuit Size 0 6 0 9 0 9625 Fill Time 0 0 0 0 32 661 5 Cycle Time 30 0 45 0 158 48 SEC Slow Shot Velocity 14 0 15 0 15 025 IPS Calc Start Fast Shot 15 0 15 5 16 367 Avg Fast Shot Velocity 0 0 0 0 136 84 IPS Runner Full Velocity 140 0 145 0 199 64 IPS User Avg Vel Range One 0 0 0 0 0 0 IPS Avg Fill velocity 125 0 135 0 199 01 5 Intens Rise Time 0 0 0 0 522 0 5 103 8 2 1 To Start Overlaying 1 Onthe Profile Screen menu click Display Functions 2 Click on Overlay the next and subsequent shots will be drawn on top of the current profile 8 2 2 To Stop Overlaying 1 Onthe Profile Screen menu click Display Functions 2
21. 0 0 0 0 1089 13 PSI Impact Pressure To Peak 0 0 0 0 0 0 0 0 918 192 Intens Squeeze Distance 0 0 0 0 0 0 0 0 0625 Sleeve Full Velocity 0 0 0 0 0 0 0 0 141110 IPS Runner Full Velocity 0 0 0 0 0 0 0 0 Maisie IPS Fill Velocity 0 0 0 0 0 0 0 0 70 5342 IPS User Velocity Pos One 0 0 0 0 0 0 0 0 0 0 IPS User Velocity Pos Two 0 0 0 0 0 0 0 0 0 5 User Velocity Pos Three 0 0 0 0 0 0 0 0 0 0 5 User Velocity Pos Four 0 0 0 0 0 0 0 0 0 0 5 User Vel Range One 0 0 0 0 0 0 0 0 0 IPS User Vel Range Two 0 0 0 0 0 0 0 0 0 0 IPS User Vel Range Three0 0 0 0 0 0 0 0 0 0 IPS For descriptions of each parameter listed refer to section 11 7 3 Trend charts allow for quick analysis of a parameter s repeatability over the monitoring period To display the Trend Chart screen either 1 Pull down the Display menu and select Trend Screen 2 Click the Right mouse button A popup menu will appear Select Trend Chart from this menu File Monitor Display Display Functions Production Help Live Shots on Machine Visi Trak Shot End 3 STEP CLOSED LOOP TEST 4200 0 3632 8 SLOW SHOT TIME 2498 3 1931 1 1100 0 2 CYCLE 0 0 1 5250 1 3375 1 1500 m y m 0 9625 0 7750 1 4 7 10 13 16 19 22 25 28 31 34 3 40 43 Shot Number A trend chart for 3 user selected parameters Slow Shot Time Cycle Time amp Biscuit Size The Live Shots box in the top left h
22. 1400 Pres 0 5y 0 500 PSI None Variable VOLTS v Units ype Test Calculator Die Pres 0 10v 0 20K PSI High Die Pres 0 10v 0 1379 BAR ADS5SSOKF SState Temp sens volts 0 0 110 0 Volts Pres1 54 0 703 07 KG CM 2 Hoo TT 05 0 SState Temp sens VDLTS 1 10 0 VDLTS Pres 0 10 0 10000 PSI Pres 0 10 0 1000 BAR Not Used Note After creating a new analog sensor you MUST RESTART all the True Trak programs to 5 Volts You should NOT do this when you are about to make a shot CMD Volts 10 to 10 Click on the new sensor type to highlight it Click on the Description box to change the name to the new sensor name Select the Variable type and the Units to be displayed in Type in the Hi and low limits of the output of the new sensor Transducer 1 0 Ranges High Low Volts 00 5 0 PSI 00 5000 0 Click on save change Note After creating a new analog sensor you MUST RESTART all the True Trak programs You should NOT do this when you are about to make a shot To verify an analog reading you can measure the voltage coming into the system input that value into the Test calculator and it will display the value that should show up in the parameter screen Test Calculator 3 Volts 332 0 F For 4 20mA output 1 5V The output from the transmitter module is 4 to 20mA which after passing thru a 250 ohm resistors becomes 1 to 5 volts Ama x 250 20ma x 2500hm 5 vo
23. Click on Overlay the next shot will be drawn on its own 8 3 Zoom Used to expand a particular portion of the shot profile Start by using one of two methods selecting zoom from the options profile menu or press the right button on the mouse to bring up the pop up menu 1 Select Display Functions on the profile menu 2 Select Zoom from the sub menu 3 Position cursor line at start point and click the left button on the mouse 4 Move the cursor line to the end position and click the left button on the mouse 5 The zoomed portion of the profile should now be displayed Also the Zoom Window displays the start end and delta difference between start and end values for Position Time Velocity and Head amp Rod side pressures To zoom again repeat 3 amp 4 7 Select Unzoom from the Display Functions menu to return to the normal display 8 3 1 Pop Up Menu 1 Click the right button on the mouse to see the pop up menu Click on Zoom Position cursor line at start point and click the left button on the mouse Move the cursor line to the end position and click the left button on the mouse Qr der The zoomed portion of the profile should now be displayed Also the Zoom Window displays the start end and delta difference between start and end values for Position Time Velocity and Head amp Rod side pressures To zoom again repeat 3 amp 4 7 To view the next recorded shot in zoom mode click the words Sele
24. IN 2 Biscuit Volume 7 42445 IN 3 Opening Force 535 041 TONS Biscuit Weight 671171 LBS Copy P1 and P2 to part setup Runner Weight 828826 LBS Check this to copy P1 and P2 Runner Volume 3 15845 IN 3 Save Changes as measured back from impact back to the setup when you press the Save Changes button The calculator can be used to aid setting up of the die cast machine Enter values in the spaces provided the calculated values will automatically update e Plunger Diameter Diameter of the shot tip Dry Shot Length Also known as the Total Stroke Length This is the distance from the fully retracted position piston position at the start of the shot to the face of the ejector moving half with the die closed This value has to be known as accurately as possible as number of parameters such as biscuit length P1 P2 etc are determined from this value See Determining Total Stroke Length Shot Sleeve Volume Plunger area dry shot length e Casting Weight Weight of the cast parts e Overflow Weight Cumulative weight of all overflow metal e Cavity Weight Casting Weight Overflow Weight e Weight B Weight of the runner and the biscuit e Total Shot Weight Weight of the cast parts overflow runner and biscuit 38 Shot Sleeve Full How full the sleeve is when the metal has been poured but the piston has not begun to move SSF Posn P1 Shot Sleeve Full Position This is the plunger pos
25. Local Area Local rea Connection 127 4 Local Area Connection Properties When you double click on the icon for OK Cancel Local Area Connection Properties er aM if you are connecting directly to the Authentication Advanced Portableuncheck all but the Internet Protocol Click once on the Internet Protocol and press the Properties Client for Microsoft Networks File and Printer Sharing for Microsoft Networks Jmnstall 128 Internet Protocol TCP IP Properties VEU dau way 129 the Use Following Ip radio button er an IP address for the computer first three numbers of this 192 168 254 100 192 168 254 in this 192 168 25499 For the computer the last number can be an number except 99 in the range 1 to 255 I have chosen to use 192 168 254 100 for the address rsor to the Subnet Mask field 192 168 254 100 ormally this will be filled 255 255 255 0 for the subnet mask 130 UNS server address automatically gi 131 Local Area Connection Properties Press the Close button to close the Authentication ocal Area Connection Properties 132 10 8 Getting the Computer to talk to the Fastrak2 board Getting the Program to Talk to the FasTrak2 Board Make sure the ethernet cable connects the computer to the FT bs Start the True Tra
26. Other Mchine Save AllParts Calculator Machine Basic Advanced Parameters Positions Marks Channels Setup E20 Part NEWPART Limit Switch Position Wire Starting Ending Limit Switch 1 23 q Pasition Position Position PN IL imit Switch 2 30 1 0 0 Measure 1 00 00 Positions Limit Switch 4 32 Positions 3 0 0 00 0 0 Limit Switch 5 25 4 00 4 00 0 0 Limit Switche 00 26 Switches Limit Switch 3 31 E 2 0 0 dien E 00 00 np F10 Change Focus This is the Current Part Save Changes Reload Saved Setup Print Click on the Position Tab Click on the Wire Box this will display a picture of the opto 22 I O board for a control system Choose Wire ES um ue 68 69 70 355258525522 ok a3 253234 idas GN Y aper yon u pr von a DOSIVO DSIVO Ds IVO Fast Dat 77 239999393939 xp di ue A A eS 23 2 n 51 d cl Wir r a a v V V V V V V V V V V V V 57 58 59 60 61 62 63 64 65 66 67 dI ib S m Ju J di I NW _ PER 9 T UT a z 4 Fl a amp l No Output OK Cancel press Tab to use the next module Esa Pesca Manual Entry Click on the Monitor output this will display a picture of the MVO 06288 mux adaptor 163 Choose Wire EDM
27. Range 1 2 3 Place the cursor over the first shot in the range required and press the Left mouse button Move the Cursor to the last shot required and press the Left mouse button The zoomed range will now be displayed 7 3 4 To Unzoom a Shot Range either 1 Press F8 to display values for all shots recorded Press the Right mouse button to display the pop up menu select Show All Shots Press the Right mouse button to display the pop up menu select Trend Chart Setups in the Time Period to Display enter a value for the last x shots to display or enter a shot range Printing Trend Charts Ensure that the colors selected for printing the trend chart are set correctly in Display Color Setup ref 7 8 In particular it is recommended that white be used for the Trend Background setting Select Print from the File menu Depending upon the default values set for the printer you may want to changes the settings click the Properties button Normal amp Landscape are recommended settings Click the OK button to save the settings Click OK to print out the chart 93 7 4 Trend Chart Setup Screen Trend Chart Setups a Average Miniter neue P Fil Time 25 30 si Used for X Bar Only Total Shot Time 21 Trend Time Period to Display 1 Last 50 Points Fast Shot Rise Time Cycle Time 10 30 Shot Range from 86 To 117 Time Interva
28. Sample the transition from on off or off on Window Displays the name of the parameter where it can be edited Alarm Limits Enter Warning and Alarm Limits along with any wire outputs Clear Button Resets the alarm limits to zero 31 2 4 Positions Screen Set positions to trigger a limit switch measure a velocity or calculate an average velocity between 2 points Jelete This Part Copy to Existing Parts Copy to Other Machine Save All Parts Calculator Basic Advanced Parameters Positions Marks Channels Shot Control Setup _ ENTRO MET gt Starting Ending T Switch 1 Position Position Position Set Limit Measure 1 11 1 0 0 0 0 Switches 2 20 2 0 0 0 0 ee Positions 3 0 0 inThese 3 00 00 0 0 4 00 00 Monitor This Part save Changes Reload Saved Setup Print SET LIMIT SWITCHES AT THESE POSITIONS A flag position is placed on the trace When this is reached the Digital Output Board MVO 06288 sends out a signal to the diecasting machine or ancillary equipment An example for use would be setting a position for switching off a pump in vacuum diecasting MEASURE VELOCITY AT THESE POSITIONS Enter up to 4 positions at which the velocity is measured and reported under User Velocity Position 1 4 The 4 positions can be indicated on the trace ref 2 5 Profile Marks MEASURE AVERAGE VELOCITY IN THESE RANGES Enter up to 4 pairs of p
29. Status 4 192 168 254 99 Connected E20 WISITRAK Uploading The FasTrak Board Monitor program will appear and should immediately connect with the FasTrak2 Board This 15 indicated here by the word Connected under the Comm Status Monitor Status Upload Complete If this 15 the first time you have connected to this FasTrak board you will see the Monitor Status display Uploading for a second or two and then it will display Upload Complete 134 Section 11 Parameters Visi Trak amp is a Registered U S Trademark of Visi Trak Worldwide LLC 136 11 Parameters The True Trak 20 20 automatically calculates 35 parameters Some parameters require user defined limits ranges etc to be set before they can be calculated these values are entered on the Part Editor Basic Setup Advanced Setup and Position screens The following is a list of all 35 parameters with an explanation of how they are calculated Also the user can connect thermocouples and other analog devices which can be monitored allowing more parameters to be calculated The Parameters are expressed in one of the following units Units MS milliseconds SEC seconds IN inches MM millimeters PSI pounds per square inch BAR bar pressure IPS inches per second FPM feet per minute CMPS centimeters per second MPS meters per second P1 Position at Shot Sleeve Full P2 Position for Metal at Gate P3 Position for Cavity Full the
30. appear in black type on the screen options not available are grayed out 2 Anumber of passwords can be set on the same level 3 When the computer boots up the functions available will be set to the level of the DEFAULT password To Enter a Password 1 Click Passwords on the File menu 2 Enterthe password in the window and Click OK 3 Various menu options will be available disabled depending on the level of the password entered It is recommended that when a high level user leaves the unit he resets the password with a lower level one To Enter a New Password 1 Click Passwords on the File Menu 2 Click the Edit Passwords button This function may not be available if the password level in operation is too low 3 Click the New button the passwords list will drop down 1 row enter the level number and password in the boxes 4 Click the Save Changes button to save Setting the Password Level of a Function The level of a function can be set using the Notepad text editor found on the Start Menu Programs Accessories The File to be edited is PROFILE MNU found in the V5 EXES directory The number at the end of each menu option indicates its password level i e a level 5 function requires a password of Level 5 or greater before being displayed 5 11 Save Shot Y N On the Last 50 shots screen at the top of the parameter bar chart the shots may or may not be marked with a dot A dot indicates that the shot is being sav
31. cylinder forward and back the position will increase to the total stroke length if it appears that the total stroke length is wrong you may need to clean the position sensor or the cable may be bad 123 10 6 Determining the TCP IP address of the FastTrak2 Board Determining the TCP IP Address of the FasTrak2 Board 04 ESS Lond TIMES I 4 MAE NUM I C 66 7 891 261 O TALAJ mL FETE 2 SWS E 2 LOOO t 0010 0 A 6 6 C v u 7155 nner _ LI 8 28 8 B 32 1 2 1 1 Be Be Be Be A 7 7 B a a B B 60000 ah ena Y AN WEW wax Lom Anp m y u a The original ip address address of board when 1s shipped from Visi Trak Worldwide is marked a label the main FasTrak2 board It is shown here with a red oval 124 SWS 5 5 3 E Also shown here are the locations of switch SWS and the two seven segment leds located on this board Pressing SWS causes the ip address to scroll across ne leds 125 66 FST 891
32. displayed on the right hand side if there are more machines than can be displayed in the window Click on the arrow buttons to move through the list MACHINE TYPE Indicates whether the diecasting machine is Hot or Cold chamber ROD PITCH Displays the rod pitch of the position transducer being used on that machine Typically US customers will be using 20P transducers Europe will be using 2mm Toshiba amp UBE machines may also be fitted with 2mm transducers Contact Visi Trak Worldwide if unsure as to type of transducer used Click on the arrow button to view other transducer types SAVE CHANGES BUTTON Click to save changes made 45 3 2 Advanced Machine Setup The Advanced Machine Setup is displayed by selecting View on the Machine Setup screen and clicking the Advanced Machine Setup button Advanced Machine Setup X Number of Impact Points Calculate Parameters Using Head Pressure 10 Position C Pressure 11 Pressure Timeouts Sec Difterential Curve Type Machine Down None 30 Cycle Start NUMBER OF IMPACT POINTS Set up a window pre and post impact straddling the P3 line between which the maximum pressure is found TIMEOUTS SEC Machine Down If the time between making the last shot and the next is greater than the value entered here then the Visi Trak Worldwide computer will consider the machine to be down and will begin recording downtime Ref 9 1 Down
33. end of shot e Display time is the time displayed on the screen at the end of shot Grouped at the bottom of the screen are the controls for setting how frequently the individual shot parameters and profiles are to be saved You may choose a different method for saving parameters than for saving profiles The descriptions that follow describe the methods for saving parameters The methods for profiles are the same Note that no matter which method you choose the parameters and profiles from last fifty shots are always available e Acquire All means that all parameters will be saved until the Max Saved number is reached Thereafter each new shot will be saved and the oldest deleted e Acquire None means that no parameter data will be saved 53 e Time Skip saves the number of shots specified the Acquire Count editbox and then saves no more until the number of seconds specified in the Skip Seconds editbox has elapsed Skip Seconds are entered in the same editbox as the Skip Count When Time Skip is selected the label for this editbox changes e Shot Skip saves the number of shots specified in the Acquire Count editbox and then skips saving for the number of shots specified in the Skip Count editbox e Begin Monitoring Button this is only enabled when the FasTrak Board Monitor program is not running Pressing this button will close the Monitor Setup the current screen and start the FasTrak Board Monitor 4 3 Saving Shots Confi
34. here is exceeded It is recommended that a value slightly less than the maximum Fast Shot velocity is used to ensure that it is reached on every shot If too high a velocity is used then it may not be reached every shot producing erroneous Risetime values TIME FOR INTENS PRESS MS Used to calculate the ntens Pressure parameter The True Trak will report the Intensification pressure measured at the time entered here PRESS FOR RESPONSE TIME Time between the intensification start P3 and the pressure set here being reached Reported as Intens Response Time BISCUIT TIME DELAY 2 3 Parameters Part Setup Screen Configure alarm limits warning limits define wires for sending out alarms and customize parameter descriptions to user preference The window consists of 2 halves the upper details the current settings for the parameters the lower is used to edit the settings for a chosen parameter 2 3 1 Parameters Screen Upper Half Setup Create New Part Delete This Part to Existing Parts Copy to Other Machines Calculator Machine Basic Setup Advanced Setup Parameters Positions Marks Channels SureTrak Control E20 Par Waring limis Limits Parameter Description Units Low Wire High WireLow Wie High wire Time Interval Two User Time Int Three VISITRAK User Time Int Four User Time Int Five Biscuit Size Cale Start Fast Shot Intens Pressure Intens Rise Time Monitor T
35. leads so the transducer slowly descends into the hole 165 Once in contact with the rod rotate the transducer body until the flat portion is perpendicular to the direction of rod motion and facing the set screw holes as shown below In typical cylinder applications the flat edge should face the rod end of the cylinder If the transducer mounting block is mounted such that the flat edge is not facing the rod end of the cylinder the lead and trail wires of the transducer will have to be reversed pins A and D of the MS connector The transducer has two internal sensing heads which generate independent output signals so it is important that the flat edge is properly positioned When the flat edge is correctly positioned and the appropriate gap between the transducer and the rod has been established tighten the set screw s that holds the transducer in place one quarter turn beyond finger tight Do not over tighten or damage will result MS CONNECTOR cy 4 MALE FLAT PORTION Figure 44 SET SCREWS SENSOR FACE aw A 1 DLDEST STYLE 1 PERMANENT KEY gt NYLON TIPPED SETSCREW gt 2 1 RETAINING BLOCK T CURRENT STLYE Sometimes better results are obtained PREVIDUS STYLE when the transducer is allowed to float on the grooved rod This will reduce wear on the transducer and ensure that the transducer remains in contact with the rod To float a transducer simp
36. parameters that exceeded the warning or alarm limits Each parameter type is stored on a separate row For each shift there is a Totals row that has the total number of shots that shift and the total number of warnings and alarms You may select rows using the normal windows listbox selection methods and then either copy the selected rows to the clipboard or delete the rows from the alarm summary file The format for the clipboard data is shown below There are two fields in the first row The machine name and the part name The next row contains the names of the columns Each row following this contains the counts for one parameter for one shift Only parameters that had one or more warnings or alarms are shown There is always a Totals row that contains the total number of shots with warnings the total with alarms and the total number of shots taken that shift both with and without alarms or warnings E20 Worldwide Date Shift Parameter Low High Low High Total Total Total Warning Warning Alarm Alarm Warnings Alarms Shots 07 05 1997 2 Totals 0 12 23 07 05 1997 2 Total Shot Time 0 12 07 05 1997 2 Position P1 0 12 08 31 1997 Totals 2 09 15 1997 2 Totals 11 05 1997 2 Totals Display Machine and Computer List Displays a list of computers on the network Save Shot as CVS File 71 5 7 Set Total Stroke Length You can use this to set the total stroke length for the part setup Set the Total Stroke Len
37. range D on Profile 35 Fast Shot Distance IN MM The distance between Calculated Start of Fast Shot position to the End of Shot Velocity position Distance D on Profile 36 Analog Channels i e Metal Temperature Measurements taken from analog sensors can also be displayed 139 view Options Tools 02 mtddemo1 Shot 43 Wed 09 04 1996 10 22 17 rm zy c 002001112170 A 1 4 Profile A Y 0 ns T 00 5 m aJ c da co rm au et i Profile B 140 Section 12 Alarm Output Wiring 142 12 Alarm Output Wiring Page Z 137 139 140 141 142 143 144 145 146 147 148 149 150 TABLE OF CONTENTS Description Table of Contents Definition of Direct and Indirect Alarm Output wiring Direct Method Connecting a single AC light Direct Method Connecting three AC lights Direct Method Connecting a single DC light Direct Method Connecting three DC lights Direct Method Single Alarm output to PLC Direct Method Triple Alarm output mixed one light two PLC Indirect Method Connecting a Single AC light via Control Relay Indirect Method Connecting to both an AC light and the PLC Indirect Method Connecting to an AC light and the PLC using a DC voltage Control Relay Understanding the Control Relay s contacts Indirect Method advanced Two AC lights One connected to normally closed contacts and the other connected t
38. sub categories for the LADLE could be ELECTRICAL CLEANING etc Any number of Categories and Sub Categories can be entered Note The 4 System Category entries Index 00 are used by the program and should NOT be edited 1 To enter a new Category click in the list where you want to enter it and then click the New button Enter the information in the Level and Description windows In the above example a New Category and Sub Category were required to enter a new downtime cause Die Broken Core Pin The Die was given Category number 5 and Broken Core Pin sub category number 1 and the descriptions were entered accordingly 2 To delete an entry click on it to highlight and click the Remove button 3 Press the Save Changes button when finished 110 9 3 Edit Downtimes This screen displays all of the recorded downtime periods The start of the downtime is indicated by System Category Machine Down The end of the downtime is indicated by System Category Machine Up Displayed alongside the entries are the time of event part being run and operator name 9 4 Edit Shifts Day Shift Actual Day Start Time New Remove 1 Saturday Sunday 2 Sunday 07 30 Actual Day Sunday 3 Sunday 15 30 Monday 1 Sunday 23 30 Sunday Thursday Holen ns ee C Monday Friday onday onday Tuesday 1 Monday 23 30 Tuesday f Saturday Tuesday 2 Tuesday 07 30 Wednesday Tuesday 3 Tuesday 15 30 Wednesday 1 Tuesday 23 30 Wednesday 2 Wednesday 07 30 S
39. the screens as required 7 Press the Save Changes button and Close Down the Window 16 1 3 Getting Started Begin Monitor Method One 1 Click Monitor on the Profile Screen menu Click Monitor Setup on the Tools menu In the large upper window click on the machine you want to monitor 2 3 4 nthe lower window click on 5 the button to view list of available parts Select part Click in the Monitor This Part box a check will appear showing that this part is now being monitored Enter a value for the Post Impact Sample Time Sec if required Select the save method for the shot parameters and profiles part in upper window M Monitor Setup If required click on the Monitor Alarms box to turn on alarm monitoring a tick will appear Click on the Save Changes button the settings should now appear alongside the machine and Post Impact Parameters Profiles Machine Part Sample Display Skip Acquire Max Skip Acquire Max 3010 100 0 Shots 1001 1001 0 Shots 1100 1100 A DCM 5 T2 YN 800 8 0 Shots 5000 5000 0 Shots 5000 5000 DCM3 Stest YN 05 0 Shots 1001 1001 0 Shots 1002 1002 Demo Shot End Dynamic Closed Loop 1 00 0 Shots 5000 5000 0 Shots 5000 5000 20 VISITRAK YN 050 0 Shots 1001 1001 0 Shots 1002 1002 Visi Trak Shot End DYNAMIC CLOSED LOOP TEST Y Y 3 00 Shots 1001 1001 OShots 1002 Y Post Impact Seconds Current Part Name Monitor This Part Sampl
40. vertical line which separates position based to time based monitoring 1 Fill time MS The time taken for the metal to fill the diecavity and the overflow wells Calculated by measuring the time for the plunger to move from the metal at gate position P2 to the cavity full position P3 distance A on Profile 2 Total Shot Time MS The time from the start of the shot until the End Of shot Velocity EOSV is detected Distance B on Profile 3 Slow Shot Time MS The time from the start of shot until the position for Calculated Start of Fast Shot CSFS is detected Distance C on Profile 4 Fast Shot Time MS The time from the Calculated Start of Fast Shot CSFS position to the End of Shot Velocity EOSV position Distance D on Profile 5 Fast Shot Rise Time MS The time interval between the Calculated Start of Fast Shot CSFS to the time when the Peak Fast Shot Velocity was reached Interval G on Profile If a value of 54000 MS is displayed then either the CSFS or the PFSV have been set incorrectly 6 Cycle Time SEC The time interval between subsequent cycle start signals the time for the die cast machine to produce a part 137 7 to 11 User Time Interval One to Five SEC Time interval measured between an device switching on off The outputs are received from a programmable controller for example a pump switching in vacuum diecasting This function is not possible with 20205 2020AT or multiplexed systems
41. whether or not to monitor this machine Choose the part to be Curent Part Name l l Post Impact Seconds monitored on this Monitor This Part Sample Time Display Time machine 01537965 Monitor Alarms Amount of time to sample pp of Time To Parameters pressures and position after Display on the Plot the end of shot E XE 3 Acque cour Acquire All Acquire Count Acquire None Acquire None nn 50 Skip Count 3 30 Skip Count nn Time Skip Time Skip data from individual hots i sho Shot Skip 9999 Max Saved Shot Skip 9999 Max Saved Specify how often to store plots of the individual shots e Current Part Name is a pull down list box that you used to select which part will be monitored on this machine e Monitor This Part a check in the checkbox tells the FasTrak Board Monitor program to monitor this machine If this box is empty then this machine will NOT be monitored even if the FasTrak Board Monitor program is running e Monitor Alarms a check in the checkbox tells the FasTrak Board Monitor program that alarm levels should be used to set and clear the alarm wires on the FasTrak board If this box is blank the wires will NOT be triggered even if parameters that have been mapped to alarm wires exceed their alarm levels e Post Impact Sample Time sets the amount of time the FasTrak board will monitor the analog inputs and position values after the
42. 118 119 120 Shot Sleeve Full 28 39 137 138 139 Shot Sleeve Volume 38 Sleeve Full Velocity 138 Slow Shot oet e 92 137 SoF POSU 39 Standard Deviation 95 97 Standard Screen 89 93 Statistical Summary 92 93 95 96 a ee teste RUE 97 Sure Tak el 24 38 77 T TIME Basada tilda 90 Time for Intens Press 138 TOSHIDA ta biet m t A 45 Total Shot Time 137 Total Shot Weight 38 Total Stroke Length 25 38 40 138 Trend Chart 92 93 94 95 96 U 45 46 98 Er 95 96 UNZOOM 93 104 105 User Avg Vel Range 32 139 User Time Interval 138 User Velocity Positions 138 V Velocity at these Positions 32 138 Velocity for 29 Velocity Units 25 40 MOMO sodes deo ds ELE ductos 120 W Warning Limits 30 94 Weight Be 38 2 Zero Speed 79 Zio VEEE ALOE TE 95 97 A E A ges 95 97 7 93 104
43. 2 AS PROFILE MIARKS e tur De E Ea 33 2 6 CHANNELS PART EDITOR SCREEN 25 35 2 7 ANALOG SENSOR SETUP en 36 2 30 IT ae 38 UA 38 2 10 CREATINGA NEW PART duce sea 40 212 UCM 40 2 12 COPY PART TO OTHER MACHINES 41 2V3 GOPY XISTING PARTS A a ee 41 3 MACHINE SETUP su suo LE ue cuiii gr al Set M a tahoe aed 45 MACHINE EDITOR as e hen ee 45 3 2 ADVANCED MACHINE S E E a 46 3 3 CREATE A NEW MACHINE SINGLE 48 OA DEBE TE AMACHINE 5 lesen es 48 4 MONITOR SETUP SINGLE nnne 51 4 T1 MONITOR SE T R zone ds obo 51 4 T1 UPPER HALF OF SCREEN aman cora dedu etus eade disant ncs 52 4 1 1 MONITOR A DIFFERENT PART 88 8 52 4 2 EOWER HIALF OF THE SEREEN sz 2 2 20 FER EXE uen nS 53 3 SAVING SHOT
44. 20 Monitoring System 51 ay Windows Explorer 7 Suspend Ed Windows Messaging Shut Down men a AA Monitor setup Board Monitor Mouse Pointer Start Menu Start Button Taskbar Application Buttons Minimize Button Maximize Button Close Button ee X File Edit View Help Menu Bar Scroll Bar A 4 1 object s 2 1017 AM Desktop Icons Desktop icons are shortcuts to programs or files Just about anything can be placed on the Desktop for quick access Start Button Clicking the Start button located on the Taskbar opens a pop up menu that contains shortcuts to programs and system settings The True Trak Program can be also started from this menu in the Programs menu Shutting down the computer is accomplished by clicking the Start button and choosing Shut Down from the menu Taskbar Programs windows that are open i e running are shown on the Taskbar as Application Buttons Switching between programs is accomplished by clicking an Application Button Application Buttons See Taskbar above Mouse Pointer A small cursor in the shape of an arrow that provides a reference of mouse movement Minimize Button Hides a window but does not actually close it Clicking the appropriate Application Button on the Taskbar will reactivate the Window Maximize Button A dual function button that either enlarges Maximi
45. 8 32 116 144 145 149 150 151 153 06408 115 118 On Off Input Screen 31 Operator 112 aAa 150 153 OScIIOSCODO ee 121 AA 103 104 Plus 25 28 33 38 39 137 138 139 a 25 28 33 38 39 137 138 139 eo 28 29 33 39 46 137 138 139 Parameters 24 29 30 40 46 52 65 91 94 95 99 137 Passwords nadaa ica 73 Plunger Diameter 28 38 Position Transducer installation zs 165 165 Position Time Based 89 Positions 24 32 33 41 138 139 c 97 Press for Response Time 29 138 E 73 93 96 Profile Marks 24 28 32 33 41 138 139 pulse 165 PUTO 63 65 R Range t E 93 95 96 139 Real Time Machine List 77 Reference aca 103 RESIOre ae 53 62 64 67 ROG ann 35 45 46 48 104 Rod PPAEGTYG nee 45 48 Rod 35 Runner Full Velocity 138 S Save SNOU ehem 55 73 Saving NOS 54 89 Selected Shots 90 Sensor Buffer Board 115
46. GH OOOO See RC UN Opto Wire Number 1 Click on the module you wish to use or Monitor OK Caneel press Tab to use the next module Manual Entry Control Outputs Click on the module you would like to use for the alarm output this will display were to connect the common connection for the alarm device indicated with an arrow pointing in towards the board and display the output connection for the alarm with an arrow pointing away from the board Click OK then click save changes 164 13 3 Position Transducer Installation and Testing General The Visi Trak Bi directional Transducers utilize a patented sensing process in conjunction with a specially modified rod to provide non contact position and velocity detection of linear motion devices The transducer is typically used with a cylinder rod or external tail rod which has been pre grooved and plated through the Visi Trak modification process This combination generates two digital square wave pulse trains 90 out of phase each having an approximate duty cycle of 5096 as the rod is moved These digital outputs are interfaced to electronic assemblies used to monitor or control position velocity or direction Two transducer models are presently available and provide position resolutions of 0 0125 20 Pitch and 0 025 10 Pitch respectively Caution The Visi Trak transducer must be handled with care at all times The transducer incorporates a thin metallic face a
47. NTED THE TREND CHARTS ARE ONLY PRINTED IF THE STATISTICAL SUMMARY IS NOT BEING 2 1 2 1 4414412 1 96 7 6 STATISTICS A BRIEF OVERVIEW aret ri nate xo a uva ra un pe cta nn ae 97 TIA DISPLAY CONFIGURATION IC E UR UIS ae 98 COLOR CONFIGURATION sicario 98 NES EDIT THE COLORS ee De 98 9 CORNER PARAMETER Susi 99 S DISPLAY FUNCTIONS ee ee 102 8 1 REFERENCE TRACE 1 1 6 nenn e 102 8 1 1 TO SAVE A REFERENCE 102 8 1 2 DISPLAY REFERENCE 0 6 6 nennen 103 8 1 3 To STOP DISPLAYING THE REFERENCE 2 0 2 4 103 8 2 OVERLAY 103 8 2 1 TO START OVERLAYING 104 8 2 2 TO STOP 104 AO eee 104 8 3 1 POP UP WIE 104 pA UNZOOM nee 105 9 PRODUCTION STILL IN
48. Post Impact Sample Time Sec 8 Select the save method for the shot parameters and profiles 9 Click on the Save Changes button the settings should now appear alongside the machine and part in the upper window 10 Return to monitoring 11 When the next shot is received the new part should appear on the screen 52 4 2 Lower Half of the Screen The bottom of the screen shown overleaf shows the details on the setup for the machine that has been selected from the list on the top and allows the operator to make changes to the setup Saving parameter data for a shot requires approx 1Kbyte of memory saving a shot profile requires approx 20Kbytes Thus to conserve memory it is recommended that saving of profiles is kept to a minimum If a large number of shot data is to be saved then frequent backup of the data is recommended ref Backup amp Restore The operator can use the Max Saved entry to limit the number of shots that will be saved The program also has a shot pool function where the last 50 shots recorded for a part a saved These can be viewed via the Last 50 Shots Screen ref 7 1 1 under Display on the Profile Screen Menu When the next shot is recorded to first shot in the pool is dumped The bottom of the screen shows the details on the setup for the machine that has been selected from the list on the top and allows the operator to make changes to the setup Choose whether alarms are being used or not Choose
49. RD 115 10 5 3 TESTING USING SOFTWARE DIAGNOSTIC PROGRAMS 000 emeritis 115 10 1 FAS TRAK BOARD 07010 116 10 2 EXTERNAL INTERFACE BOARD acid 117 10 3 SENSOR CONVERTER BOARD 07014 118 10 3 1 SENSOR CONVERTER BOARD WIRING DIAGRAM 0 119 10 4 TESTING THE SIGNALS FROM THE POSITION TRANSDUCER mereri 120 10 4 1 TESTING WITH VOLTMETER ON THE SENSOR CONVERTER BOARD 120 10 5 TESTING WITH AN OSCILLOSCOPE ON THE EXTERNAL INTERFACE 121 10 5 1 TESTING THE SIGNALS WITH THE SOFTWARE DIAGNOSTIC 123 10 6 DETERMINING THE TCP IP ADDRESS OF THE FASTTRAK2 124 10 7 SETTING UP THE ETHERNET PORT ON THE 127 10 8 GETTING THE COMPUTER TO TALK TO THE FASTRAK2 BOARD 0 133 S He 137 12 ALARM OUTPUT WIRING 222220022 aa lie 143 12 1 DEFINITION OF DIRECT AND INDIRECT ALARM OUTPUT 144 12 2 PHE DIREGT METHOD As 145 12 3 IHE INDIRECT METHOD
50. Reload Saved Setup to restore to the last saved settings Click on the Save Changes button to save current settings If no more changes are to be made to the part click on the x button to close the window Otherwise click on the required Part editor sheet 34 2 6 Channels Part Editor Screen The True Trak computer has 16 inputs which can be used to monitor analog signals during the shot Generally the head and rod side pressure transducers are connected to channels 1 amp 2 and other analog devices such as thermocouples are connected to Channels 3 and 4 Part Setup Create New Part Copy to Other Machine Delete This Part Copy to Existing Parts Save All Parts Calculator Machine Basic Advanced Parameters Positions Marks Channels Shot Control Setup Visi Trak Shot End z Channel Analog Sensor Head Rod Channel Names Extended Channels 3STEP CLOSED LOOP TEST 1 Pres 05 0 10000 PSI E 3 STEP OPEN LOOP TEST 2 Pres 0 5 0 10000 PSI Ch 2 Sg erg DYNAMIC CLOSED LOOP TEST Not Used Cx when 4 tna Continuous 5 CMD Volts 10 to 10 Channels is selected on the 6 C ene Display Setup 7 CMD Volts 10 to 10 5 8 Not Used Ch 8 C Analog Sensor Setups F10 Change Focus Monitor This Part Save Changes Reload Saved Setup Print e Channel Identifies the analog channe
51. THE PROCESS BEING 109 See e Co 109 9 2 DOWNTIME SETUP SCREEN comu r Cm en IE cU acia 110 Nm 111 EDIT ee ee MM III EMI LED MM ID 111 9 5 DOWNTIME SUMMARY 111 OPERATOR IENON ee ee en ee ser 112 10 MISCELLANEOUS BOARDS POSITION 115 BOARDS iaa 115 10 1 2 BOARD esse aan en en rasen nee een ato 115 10 1 2 X49 07001 ADAPTER 115 10 1 2 X49 07011 ETHERNET 115 10 2 FAS TRAKZ BOARD anne ea braun Quia deaf 115 10 3 49 07012 DIGITAL SERVO AMP 115 10 4 MVO 07014 BUFFER SENSOR CONVERTER 115 10 4 1 BUFFER SENSOR CONVERTER WIRING emeret 115 POSITION 115 10 5 1 TESTING WITH VOLTMETER ON THE SENSOR BUFFER 115 10 5 2 TESTING WITH AN OSCILLOSCOPE ON THE EXTERNAL INTERFACE BOA
52. TIME Thus the computer determined that the end of shot occurred at 8 plotting the 1st 8 of piston movement ss1 in the position part of the display The remainder of the slow shot ss2 the fast 27 shot fs and the intensification squeeze distance int being displayed in the time based portion of the display Note the pressure curve the pressures corresponding to the different stages of the shot are marked pr1 pressure during slow shot pr2 pressure during fast shot pr3 intensification pressure If you are displaying a profile similar to above then enter a value for the Minimum Stroke Length which resides somewhere in the fast shot 2 2 Advanced Part Setup This screen displays a number of variables which are used to automatically calculate some of the parameters displayed for each shot Part Setup dr x Create Delete This Copy to Existing Parts Copy to Other Machines Calculator Machine Basic Setup Advanced Setup Parameters Positions SureTrak Control 35 Plunger Diameter Velocity for Rise CSFS 8 73 Distance from P1 to 1500 0 Time for Intens Pres Ms Distance from P2 to 2500 0 Pres for Response Time 12 0 Minimum CSFS Position Biscuit Time Delay 5 Minimum CSFS Velocity 22222 Monitor This SaveChanges Reload Saved Setup PLUNGER DIAMETER Diameter of the shot tip sleeve Note if the diameter changes so too will the positi
53. Time Fast Shot Time Position 1 Time Interval One Position P2 Time Interval Two Metal Temperature User Time Int Three Intens Pressure User Time Int Four Cycle Time User Time Int Five Biscuit Size Intens Rise Time Eff Peak Intens Impact Pressure To Peak Intens Squeeze Distance Sleeve Full Velocity OK Runner Full Velocity ww Avg Fill Velocity 1 Profile Screen menu click on Display 2 From the sub menu click on Corner Parameters 3 Choose Corner Parameters window is displayed The left hand box lists the parameters currently being displayed the right hand box lists the remainder 4 To transfer a parameter from one list to the other click on it The parameter will appear in the other list 5 Itis impossible to have more than 8 parameters being displayed a message stating that the LH box is full will appear You will have to remove a value from the LH box before transferring the required parameter 6 When all the changes have been made click on the OK button 7 un required parameter was transferred a quick reset is achieved by x clicking on the button to close the window then reopen the window the previous changes won t be saved 99 Section 8 Display Functions 101 8 Display Functions File Monitor Display Production Help Show Reference Trace Save as Reference Trace Overlay Zoom Unzoom 8 1 Reference Trace When an optimum shot profile has been record
54. Visi Trak SENSE MONITOR CONTROL True DIE rue gt T k20 20 USER MANUAL ersion 2010 Visi Trak is Registered U S Trademark of Visi Trak Worldwide LLC Table of Contents DTECHNICAL SUPPOR 7 Il USING WINDOWS95 98 7 0 8 1 GETTING STARTED CLOSING DOWN 2 12 1 15 1 1 GETTING STARTED NEW MACHINE AND NEW PART 15 1 2 GETTING STARTED CREATE NEW 88 16 1 3 GETTING STARTED BEGIN 8 sese ease seres a senses 17 1 4 GETTING STARTED CLOSING DOWN THE 5 5 8 emere serenus 18 sl HO gt GS L 19 Eom cedi eR 19 Z PART 24 2 BASIC PA RT SEL P vla isse sies et 25 22 IND VANCED RAR Ir OE T P edle 28 2 3 PARAMETERS PART SETUP SCREEN 29 2 3 1 PARAMETERS SCREEN UPPER HALF 29 2 9 2 PARAMETERS SCREEN LOWER HALE EDITOR u a a edge 30 24 POSTON O CREEN st ee deemed o tees bout Rare 3
55. a 9 Click on the board you have 7 WORLD The one above is the older 0659 External Servo Amp board The one on the right is the new Digital servo Amp that plugs directly into the sure Trak2 External Interface Cancel ee Ce COC OC ea Quadrature Divisor 255 save Changes The position Quadrature pulses can be divided down by 255 times The counts from the position transducer are divided by this number Thus if you have say a 200 pitch transducer you can set the quadrature divisor to 10 and use the 20 pitch Rod Pitch setting This is an 8 bit number and so can only have values from 1 which is the default to 255 47 Replace Biscuit Time Delay with Time to Measure Biscuit Replace Biscuit Time Delay with Time to Measure Biscuit If you check this box the last entry of the Advanced Part Setup in the Part Setup program is changed from a Biscuit Time Delay to the amount of time in seconds to wait after impact before measuring the biscuit It is assumed that sampling is set in the Monitor Setup program to sample at least this long The Biscuit size is calculated from the sampled data and the Biscuit Size parameter returned by the FasTrak2 board is ignored This only works for FasTrak2 boards When finished click the Save Changes button and then Close the Window 3 3 Create a New Machine Single Computer 1 Select Monitor from the menu on the Profile Screen 2 Select Machi
56. a of the biscuit runner casting amp overflows Used to calculated the opening force on the die Opening Force Area Cast Overflow Spray Metal Pressure This is expressed in Tons If metric units are use then the tons are metric tons If English units are used the tons are 2000 Ibs each If you wish to use imperial tons you must add an entry in the Config section of the EDITPART INI file ref 5 7 Text Editor If there are other parameters that you would like to include please contact Visi Trak Worldwide LLC 39 2 10 Creating A New Part The program creates a new part by duplicating data from a current default part You then make any changes necessary to the new part and then save it 1 2 From the shot profile menu select Monitor Select Part Setup the Part Editor screen will be shown with values for either a default part or the last part to be edited being displayed Click on the machine number which you want to add a part to Note that the machine has to already exist if it doesn t then you have to Create a New Machine first Click Create New Part button At the prompt enter the new Part Number The Part Number should be 8 characters long Press the OK button to save If the current values do not require changing the press the Save Changes button and Close Down the Window If the current settings require changing then click on each field and enter the required value for each Distance Units Velocity Units Tot
57. acing on the end value and click again as with the zoom function If you have selected the wrong range then either press the F8 key or click the right mouse button and from the popup menu select the Show Shots F8 option Reselect the range The calculated values will now be based on the displayed range 7 5 4 Entering LCL amp UCL Click on the value required Press the Backspace key to delete the current value Type in a new value Press the Tab key to enter value The Cpk will be recalculated using the new value S 7 5 5 Printing the Statistical Summary screen 1 Select Print from the File menu 2 Depending upon the default values set for the printer you may want to changes the settings click the Properties button Black Text Normal Landscape are recommended settings Click the OK button to save the settings 3 Click OK to print out the table Note the trend charts will NOT be printed The trend charts are only printed if the statistical summary is not being displayed 96 7 6 Statistics A Brief Overview In the statistical analysis used we are trying to derive a value for Cpk the capability index Cpk indicates how close a process mean is to the nearest control limit with the distance being a function of the standard deviation for the process Typically a distance of 3 standard deviations are used thus if the nearest control limit is 3 standard deviations away then Cpk will be 1 If a
58. al Stroke Length Minimum Stroke Length End of Shot Velocity To view the advanced settings click the Tab for the window required i e want to set up alarm imi j me Parameters limits click on the Parameters tab i LI NEC Press the Save Changes button and Close Down the Window 2 11 Deleting A Part 1 2 3 4 5 6 Select Monitor from the Profile Screen menu Select Part Setup from the submenu Select the machine and part that is to be deleted Click the Delete This Part A window will appear asking you to confirm the deletion Click the OK button Close the Window NB It is not possible to delete the last part on a machine 40 2 12 Copy Part to Other Machines Used to copy a part setup on one machine to a number other machines i e a die will be used on a number of machines in the plant 1 2 3 4 Select Monitor from the Profile Screen menu Select Part Setup from the submenu On the Part Editor select the machine and part that you want to copy Click the Copy to Other Machines button Will see a list of current machines and a Y next to any that already have the part Click on the machines that you want to copy the part to Hold down the Ctrl button to select more than one machine Click the Begin Copying button Continue in the Part Editor or close the window 2 13 Copy to Existing Parts Used to copy a screen from one part to others If a number of parts have similar s
59. alarms customize parameter descriptions Positions Set positions to trigger a limit switch measure a velocity or calculate an average velocity between 2 points Profile Marks Configure marks to appear on the shot profile indicating positions and ranges where various parameters are being measured Also select whether the position will be marked with a vertical line or a mark the color of the mark and add a labe Channels Set up which analog sensors are on which channels Sure Trak Configure settings for the Sure Trak shot controller May not be visible on sytems not using the Sure Trak controller To view the different windows click the tab for the window required i e want to set up alarm limits Parameters click on the Parameters tab tup E 24 2 1 Basic Part Setup This screen contains the information for the 5 basic parameters which are required to monitor a part To view select Monitor Part Setup Part Setup x Create New Part Delete This Part Copy to Existing Parts Copy to Other Machines Calculator Machine Basic Setup Advanced Setup Parameters Positions Marks SureTrak Control 31 Part Distance Units Inches Millimeters CO Centimeters Velocity Units 3 IPS FPM CMPS MPS Total Stroke Length Es 85 Minimum Stroke Length End of Shot Velocity Monitor This Part Save Changes Reload Saved Setup Print Note that 3 of the 5 settings Distance Units Veloc
60. anced Part Setup 24 28 39 138 139 Alarm EINS 30 31 95 96 Alam 52 53 65 150 Analog Channels 139 Analog NAD UE usce eto e t tea 30 Analog Input Screen 30 Analog Sensor 35 36 Average o onnanannnnennnneenannnn 32 94 95 139 Average Velocity 32 139 Avg Fast Shot Velocity 139 Avg Fill Velocity 138 Avg Slow Shot Velocity 139 B e AA 53 62 63 64 65 66 Basic Part Setup 24 25 BISCU bes D Ec 29 92 138 Board Number 78 79 BOX SOFGeD d de tcs 90 BUSY ML 79 calculator aden 38 Casting 38 Channels det 24 35 41 98 Color Configuration 33 73 98 Corner Parameters s secet 99 CDK m 95 96 97 COPS 28 29 33 137 138 Cycle Start Relay 117 92 137 D Data CONECO ETE 79 JataSer Vel dando ias 65 67 Differential ae seen 46 98 Digital Output 32 Display Configuration
61. and corner indicates that the Trend Chart is being updated as each new shot is recorded Note The Trend Chart will NOT be printed if the Statistical Summary screen is being displayed Press the F5 key to remove the Stat Summary Screen The Trend Chart is a line graph with Shot Number on the bottom x axis and parameter values on the vertical y axis The parameter name forms the chart background Horizontal lines indicating set alarm and warning limit values More than one parameter can be viewed at a time allowing for correlation study as above where 3 parameters are being displayed the only limitation to the of number of parameters that can be displayed is the resolvability by the naked eye 7 3 1 Individual Shot Values Moving the mouse cursor line over the chart displays the shot number date amp time and value s for individual shots 92 7 3 2 Clicking the right mouse button on the trend chart screen pops menu with the following choices c1 Live Trend Chart Show the last 50 shots with real time updates Show All Shots F8 Show all available shots for this part Trend Chart Setups Change what is displayed parameters shot range etc Statistical Summary Display a statistical summary of the data Standard Screen Close the Trend Screen and return to the standard shot profile screen Note If the menu item is not applicable it will not appear 7 3 3 To Zoom in on a Shot
62. and wiring 159 Choose Wire gt Ju _ 4 gt 2 5 10 gt 3 gt 5 2905 gt gt 22 2917777 Varn pen von 2 o g DSIWO OSIVO DSON OSIYO r bf FATE EE A gt e lt gt G 9 S e wi a x X wire hb Connection gt 2 4 Bi LT I O Number gt 5 ie j T 5 ld Opto Wire Number 16 1 0 Number 32 Limit Switch 4 Click on the module you wish to use or Control Outputs Monitor Outputs OK Cancel press Tab to use the next module Manual Entry By clicking on the l O LED light this selects the output you wish to use when the light 15 clicked the display will show a orange line were to connect the wire to the terminal strip 62A it also show the number 32 Note For Control units some l O outputs are already being used by the system make sure the I O you select is not being use for control purposes If the is not being used for control you may have as many alarms set to that I O you need For setting up outputs on a monitor only system click on Monitor Output 160 This will display a picture of the 06288 adaptor Alarm board Choose Wire gt B ad E wu mu FABLE mem
63. ata to the windows clipboard The part used is the one currently displayed on the Plot Screen The data is stored as counts per shift of the number of shots with parameters that exceeded the warning or alarm limits Each parameter type is stored on a separate row For each shift there is a Totals row that has the total number of shots that shift and the total number of warnings and alarms 68 e You may select rows using the normal windows listbox selection methods and then either copy the selected rows to the clipboard or delete the rows from the alarm summary file The format for the clipboard data is shown below e There are two fields in the first row The machine name and the part name The next row contains the names of the columns Each row following this contains the counts for one parameter for one shift Only parameters that had one or more warnings or alarms are shown There is always a Totals row that contains the totalnumber of shots with warnings the total with alarms and the total number of shots taken that shift both with and without alarms or warnings E20VISITRAK Date Shift 07 05 1997 07 05 1997 07 05 1997 08 31 1997 09 15 1997 11 05 1997 11 05 1997 11 05 1997 High Parameter Low Warning Warning 2 Totals 2 Total Shot Time 0 2 Position P1 0 2 Totals 2 Totals 2 Totals 2 Total Shot Time 0 2 Position P1 0 Low Alarm High Alarm Total Total Warnings 0 12 12 12 0 0 0 0 0 12
64. be sure to maintain continuous contact of the transducer face to the rod and to keep the flat side perpendicular to the direction of rod motion If this method results in satisfactory operation of the transducer check the mounting structure arrangement in relation to the transducer to ensure that the transducer is being properly installed and mounted 10 5 Testing with an Oscilloscope on the External Interface Board Prior to applying power to the transducer assembly make sure that all power and signal connections are properly made to the external electronics using a good quality shielded cable This shielded cable will help to reduce noise interference on the output signal lines Although transducer testing is best accomplished with the use of an oscilloscope a standard voltmeter may also be used The most convenient place to test a transducer s signals is at the external electronics terminals rather than at the transducer s connector Use the following table to determine which terminals the transducer s signals are connected to on each type of printed circuit board Part Number Description Lead Input Trail Input DC Ground MVO 07014 Buffer Converter 1 3 TB1 4 TB1 2 X49 07002 External Bd TB2 3 TB2 4 TB2 2 Using an Oscilloscope It is best to inspect the transducer outputs using a two channel oscilloscope so that both digital outputs can be viewed simultaneously 1 Set the scaling on 5 volts per division vertical and approximately 2 milli
65. ble to zip the data after so many shots have been recorded or at 3 specified times during the day During the saving process two files are created MAZ contains the downtimes and part setup files The zipped file name comprises of the machine number part number date and time the data was zipped PAZ contains the shot profiles parameter amp alarm data and the part setup files The zipped file name comprises of the machine number part number first and last shot saved i e part 1234RTHF on machine 9 is to be zipped the first shot in the group is shot number 45 and the last is shot number 287 The zip file will be named 9 1234RTHF 45 287 PAZ the time zipped is also saved The files unless configured otherwise will be saved in the VS5BACKUP folder 5 3 2 3 To Backup Automatically 1 Open the Backup window 2 Choose between backing up after a number of shots have been recorded or at specific times during the day 3 Thelarge window details the machines parts and shot counts for those currently being monitored 4 Click the minimize or exit buttons to close window 5 The files will be automatically backed up at either the prescribed time or when the count has been reached 5 3 2 4 To Backup Manually 1 Click the Zip Now button to begin the zip process all currently stored data will be zipped 2 Close the window when finished 66 5 4 Restoring to the Dataserver A dataserver is used on a networked syst
66. cking on the button or select File from the menu and Exit 7 Ifyou want to edit the Advanced Machine Settings select View from the menu and then Advanced Machine Setup Follow 6 to close down 15 1 2 Getting Started Create New Part The program creates a new part by duplicating data from a current default part Make any changes necessary to the new part and then save it 1 From the shot profile menu select Monitor 2 Select Part Setup the Part Editor screen will be shown with values for either a default part or the last part to be edited being displayed 3 Click on number of the machine that you just created Note that the machine has to already exist if it doesn t then you have to Create a New Machine first 4 Click Create New Part button At the prompt enter the new Part Number The Part Number could be up to 28 characters long Click the OK button to save Part Setup Create Mew Part Part 5 If the current default values do not require changing press the Save Changes button and Close Down the Window ref line 6 in the previous section 6 Ifthe current settings require changing then click on each field and enter the required value for each Distance Units Velocity Units Total Stroke Length Minimum Stroke Length End of Shot Velocity To view the advanced settings click the Tab for the window required i e want to set up alarm P limits click on the Parameters tab 8 Edit
67. cted Shot in the upper left corner of the screen The words will change to Live Shots Select Unzoom from the Display Functions menu to return to the normal display Note that even though the shot is being recorded in zoom mode all of the shot data is still being recorded 104 8 4 Unzoom Used to exit the Zoom function and display the standard shot profile Two methods 1 Select the Options menu and then Unzoom 2 Press the right button on the mouse to display the pop up menu click on Unzoom 105 Section 9 Production Visi Trak amp is a Registered U S Trademark of Visi Trak Worldwide LLC 108 9 Production still in the process of being written File Monitor Display Display Functions Help Down Time Setup Edit Downtimes E dit Shifts Downtime Summary Operator Sign On Alarm Summary Data 9 1 Downtime During continuous monitoring Machine Downtime can be recorded A time the Machine Down Timeout is entered for the machine Under Advanced Machine Setup If the time between making the last shot and the next is greater than this value then the machine will be considered down and the downtime period will be recorded The downtime will be recorded until the next shot is made Thus machine utilization can be determined The Downtime Setup Screen is used to configure the types of downtime the Edit Downtime Screen is used to enter the particular downtime events and the Downtime Summary Screen displays t
68. cts is used The below example shows a common control relay used in conjunction with the Multiplexer Interface Board to activate an AC light when an alarm has been triggered O TD O TU 4 O G2 O D 4 O n O D O gt AA A A 7 2 112 mi x 370 120VAC NEUTRAL 5 11 L JL_JIL_ IL 8 6 cA d db OAC LIVE 22 E BE r 120VAC NEUTRAL gt gt o gt 32 C ISE SEN SE 4 m L m L m L L LIVE 06 88 MODULE BLACK MULTIPLEXER E ERE PE PCE AC OUTPUT RANGE 12 140VAC DACS SPDT RELAY 120 The above diagram shows the Indirect Method in its most basic form Here is how the circuits work 120 AC Live voltage is input at TB 1 11 When an alarm is triggered that voltage is output to TB1 12 and sent to Control Relay at CR A This energizes the relay CR because a 120VAC Neutral is input at CR B thus completing the circuit When the relay energizes it closes the normally open contacts CR 6 and CR 9 This allows current to flow through the lamp completing the circuit The next example of the Indirect Method is only slightly more complicated We will still use the same basic setup except this time we add another circuit to the Control R
69. d File control all t t Meas 1 17 F9 Glabals LYDT 0 96 mmm F10 Control Mods Event Log _OFF View Del Zip MW 17 18 Velocity 86 6000 IPS Position 15 95 IN These are the current velocity and position as reported by the 2 board Position 24 5 Zero The Max Position displays the maximum position that the rod has reached since the screen was displayed You can zero this by pressing the Zero button to the right When in manual mode Event Log OFF View Del Im Zip The event log is a text file that lists Sure Trak2 events such as changes in the digital inputs or outputs warning messages and a sampling of the position velocity and feedback voltages during a shot Once you turn on the log the program saves these events continuously until you turn the log off The log is saved in C ft2 log The events in the log are only saved while this screen is displayed If you want to view the current file press the View button to bring up the notepad program with the ft2 log file loaded Pressing the Del button deletes the current log If the Zip checkbox is checked the file will be zipped into C ft2 zip before it is deleted This is used to send the file to Visi Trak Worldwide to help diagnose a problem You should NOT normally have the Event Log on It should only be on when you need to record the events to help diagnose a problem When the Event L
70. d with DC voltage If so your wiring would be like this 3 60YDC SOURCE 7 UC GROUND 3 06 88 MLIL TIPLEXER INTERFACE A DC voltage is input to TB1 11 When an alarm is triggered that voltage is output to TB1 12 thereby completing the circuit The next page shows how to wire DC alarm lights for all three outputs 147 J 60VDC SOURCE O D O O 72 72 O O 1 O PP ad bd rn mas mare ie ila Dy 320 Il Scil es v DC GROUND 5 60VDC SOURCE lo 11 L ILC dL JL LAMP OPTos 6 5 o d 4 221182118211 Se VDE GROUND 23 72 5 60 0 SOURCE lt S SE LAMP ME L dL d y UC GROUND cf MyYO 06238 MULTIPLEXER INTERFACE PCB UPTO COLOR RED DC OUTPUT RANGE 5 60WDC OUCS a Co 25222 The above diagram shows that a DC voltage is input to TB1 11 1 13 TB1 15 When alarms are triggered the input voltages are output to TB1 12 TB1 14 and TB1 16 ALARM DC VOLTAGE IN DC VOLTAGE OUT Alarm 1 opto 6 TB1 11 TB1 12 Alarm 2 opto 7 TB1 13 TB1 14 Alarm 3 opto 8 TB1 15 TB1 16 148 Another common way of utilizing alarm outputs is to connect them directly to
71. e For the X Bar chart the number of shots included in each average is specified in the Average Every editbox just above the chart types 7 4 4 Time Period to Display This section allows you to select a range of shots to display Your choices are to show the most recent 50 shots or to specify a particular range of shots Note that if you wish to display all the shots you don t need to do it here just press F8 at the main trend chart screen 7 4 5 Alarm and Warning Limits Checking either of these causes that set of limits to be displayed as horizontal dashed lines on the trend chart Moving the cursor over the chart causes a line to be displayed showing the shot number date time recorded and the measured value of the point 94 7 4 6 Select the Parameters 1 With the Trend Chart displayed click the Right Mouse button 2 From the Sub menu select Choose Parameters a list box of all the recorded parameters will be displayed 3 Click on the parameter to select unselect 4 Click the OK button when finished 7 4 7 To Select a shot range Under the Time Period to Display select either 1 Last x Shots the selected number of shots starting with the most recent shot are displayed 2 Shot Range from x to x displays a chart showing the range selected 3 Click the Save Changes button 7 5 Statistical Summary Screen Alarm Limits E N 61 Group Size 1 7 z
72. e Time Display Time DYNAMIC CLOSED LOOP TEST Monitor Alarms 300 00 Parameters Profiles Acquire Acquire Count Acquire All Acquire Count 7 Acquire None 7 Acquire None 1 Skip Count 1 Skip Count C Time Skip Time Skip f Shot Skip 1001 Max Saved Shot Skip 1002 Max Saved Save Changes Begin Monitoring 10 Close the window and return to the shot profile screen 11 When the next shot is received the new part should appear on the screen 17 Method Two 1 Click on Monitor Click on Part Setup 2 3 Click on the part you would like to monitor 4 Click on Monitor this part Part Setup Delete This Part Copy to Exi Machine Basic Advanced Parameters Visi Trak Shot End Part EDUSEUCLUUE TEST 3 STEP OPEN LOOP TEST Distanc DYNAMIC CLOSED LOOP TEST RAMPTEST Velocits WEE ol F10 Change Focus Monitor This Part 1 4 Getting Started Closing Down The System It is not a good idea to pull the plug on the unit to close down the program At best this will cause loss of data and at worse lead to hardware failure It is highly recommended that the computer is closed down in a systematic fashion as detailed below Select File and then select Exit File Monitor Display Display Functions Production Help The program will be closed down and return to the Windows main screen If the intention 1 to
73. e of the lamp thereby completing the circuit 145 True Trak Monitoring system has eight available alarm outputs To install an alarm light for the last three output your wiring would be as such C3 4 120 LIVE 2 lo mi LAMP Sr lloc I3 reo ro os 120VAC NEUTRAL 4241 T9141 S3 118 EE LJL JL JL 6 5 120 LIVE 1T AF e F 1 gt gt gt 5 a ES 120 NEUTRAL Ug 17 CU qp 120VAC LIVE EN 4 L LAMP 120 NEUTRAL 06289 MULTIPLEXER INTERFACE PCB ef m E __ Tu C ppt OCS UPTO MODULE COLOR BLACK AC OUTPUT RANGE 12 140WAC The above diagram shows that 120VAC Live is input to 1 11 1 13 TB1 15 When alarms are triggered the input voltages are output to TB1 12 TB1 14 and TB1 16 As you can see the three available alarm outputs are located between TB1 11 thru TB1 16 The following chart may help you ALARM 1 6 TB1 11 TB1 12 C3 Q3 Alarm 2 opto 7 TB1 13 TB1 14 Alarm 3 opto 8 TB1 15 TB1 16 Remember to use a fuse when wiring with AC voltage to avoid damage to your system 146 possible that your alarm light is powere
74. ed to turn a shot on off click on it 5 12 Print Print the shot profile currently being displayed on the screen Ref 7 8 Color Configuration to set up the colors 5 13 Minimize Removes the current window from the screen but doesn t close it down A couple of screens have to always be active even though they may not be being displayed Board Monitor Event Manager 5 14 Exit Closes the window 73 Section 6 Monitor Visi Trak amp is a Registered U S Trademark of Visi Trak Worldwide LLC 76 6 Monitor File Display Display Functions Production Help Part Setup Machine Setup Monitor Setup Real Time Machine List FasTrak Board Setup FasTrak Board Monitor Here is where the part machine and monitoring setups are made along with analyzing the Fas Trak2 Boards Part Setup Refer to Section 2 0 Machine Setu D Refer to Section 3 0 Monitor Setu D Refer to Section 4 0 6 1 Real Time Machine List Machines to Display Realtime x Machine Display Of use to systems monitoring multiple machines used to choose which machines are to be displayed on the screen May be monitoring a number of machines but have a particular interest in one of them i e setting up a die 1 Click on the machines to turn off on as required X indicates to be plotted 2 button turns all the listed machines 3 The None button turns all the listed machines off 4 Click OK to save settings and then cl
75. ed i e the current setup has the lowest scrap it can be saved and drawn on the screen enabling future shots to be compared with it File Monitor Display Display Functions Production Help Live Shots 1910 8 a 1433 1 955 4 4 4 ines 8 477 7 u Head 199 72 a 27 18 119 79 26 82 79 86 26 46 39 93 26 10 0 0 A 4 SS csfs FSV 25 73 Parameter Low Alarm High Alarm Value Units Parameter Low Alarm High Alarm Value Units Biscuit Size 0 6 0 8125 Fill Time 0 0 0 0 66 293 MS Cycle Time 30 0 45 0 61 206 SEC Slow Shot Velocity 14 0 16 0 16 925 IPS Calc Start Fast Shot 16 0 16 5 15 482 Avg Fast Shot Velocity 0 0 0 0 79 595 IPS Runner Full Velocity 140 0 145 0 113 39 IPS User Vel Range One 0 0 0 0 0 0 IPS Avg Fill velocity 125 0 135 0 98 05 IPS Intens Rise Time 0 0 0 0 591 36 5 8 1 1 Save a Reference Trace 1 Have the required profile displayed on the screen 2 Select Display Functions from the profile menu 3 Select Save As Reference Trace 102 8 1 2 To Display a Reference Trace 1 Select Display Functions from the profile menu 2 Select Show Reference Trace as future shot profiles are displayed so too will the reference trace 8 1 To Stop Displaying the Reference Trace Select Display Functions from the Profile menu on the submenu Reference Trace will be marked with a tick 2 Select Show Reference Trace to deactivate
76. egun to move SHOT COMPLETE The shot has past the Minimum Stroke ILength and slowed below the End of Shot Velocity ZERO SPEED The plunger is not moving Inputs The following is a list of inputs for a control system Opto 22 Terminal Display START SHOT FOLLOW THROUGH RETRACT JOG SHOT AT HOME OK FOR VAC FAST VACUUM ON LOW IMPACT FILL TEST 81 The following is a list of outputs Opto 22 Terminal Display SLOW SHOT OUTPUT ACCUMULATOR LS1 LS2 LS3 LS4 LS5 LS6 Current Step 27 06 Making a SHOT Control State ACTIVE n Control current step 27 Making shot 6 06 displays the flash version of the Fastrak2 board Control State Active 82 6 5 Sure Trak Control Interface Used to view the Sure Trak interface only of concern for those users using the Sure Trak shot control system See Sure Trak Control manual for more information Part Setup 13 x Create New Part Delete This Part Copy to Existing Parts Copy to Other Machine Save All Parts Calculator Machine Basic Advanced Parameters Positions Marks Channels Shot Control Setup 20 M Ending Vacuum Low Low Impact Limit Switches Vac Velocity Loop Gain Accel Velocity Wait Impact From Input Description Pos Wie Switch 3000 NEWPART 1 5 10 Limit Switch 1 29 2 10 5 2 T 3012 Break Settings 3j Limit Switch 3 Lect oe 4
77. elay This time when an alarm is triggered we simultaneously activate an AC light and send a signal to the PLC using only one alarm output 151 4 O m D D Bis 7 m td p A art LB 2 I mi E LAMP r se wu 5 5 120VAC NEUTRAL 3112311231158 87 it In II I Ge A Y A O ll 228 5 PTOS DPTO OPTOS 10 AL I da d e LIVE lt HEE Se exl Ex 1551 Al B 120VAC NEUTRAL gt xz a gt g j T5 fe 4 ll Sx Sx II Sx EE 4516 120vAC LIVE PLC 1 ADD UN DC MODULE MYO 06288 MULTIPLEXER INTERFACE PCE 99 COLOR BLACK OUTPUT RANGE 12 140WAC OACS 3PDT RELAY 120 As you see from the above diagram the overall circuit did not change much from the previous example Here s how it works A 120 AC Live voltage is input at TB1 11 When an alarm is triggered that voltage is output to TB1 12 and sent to Control Relay at CR A This energizes the relay CR because a 120VAC Neutral is input at CR B thus completing the circuit When the relay energizes it closes the normally open contact pairs CR 6 CR 9 and CR 4 CR 7 This allows current to flow through the lamp and also the output of the PLC I O module is returned to the negative terminal thereby completing b
78. em Without the server it is only possible to view current data on the workstation The server can be used to store the data transferred from the local computers 5 4 1 Restoring The restore function is used to unzip previously zipped files allowing the data to be viewed Upon starting the Restore process the program examines the V5backup folder the list of zip files is displayed in the Files to Restore window See above for info on file types and naming structure The restored data can either be merged with the current profiles amp parameters currently being displayed on the server or the current data can be deleted and the restored data being shown 1 Click on the files to be restored More than one can be chosen 2 Choose to merge or delete current data 3 Click the Begin Restore button 4 Select Choose Machine Parts from the File menu to view the shot profiles Export Shot Parameters Export Shot Parameters Shot Number Date Parameters 000001 11 05 1997 14 39 47 Fill Time Total Shot Time Slow Shot Time Fast Shot Time Fast Shot Rise Time Cycle Time Time Interval Time Interval Two User Time Int Three User Time Int Four User Time Int Five All Export to Clipboard Export to CSV File Begin Export This function allows you to export parameter data to the Windows Clipboard e The part used is the one currently displayed on the Plot screen e The individual shots are shown on the left Yo
79. en or active letting the user switch between windows or to view several windows simultaneously Navigating the Windows environment is done with a mouse and a keyboard Other devices such as trackballs can also be used Using the Mouse Visi Trak Worldwide systems are supplied with an industrial panel mounted mouse see image It functions identically to a standard PC mouse except that is stationary To move the mouse pointer on the screen you need to manipulate the round button in the center Pointing ol m button Right mouse Left mouse 24 au dod button B E CLICK or single click Press or tap the left mouse button once 4 D gt E DOUBLE CLICK Press or tap the left mouse button TWICE in quick succession D XXE RIGHT CLICK Press or tap the right mouse button once Note this is typically used to bring up alternate menus etc e c i J Press AND hold the left mouse button while moving the mouse pointer Release the left mouse button when finished Windows Desktop Desktop Icons Windows Desktop My Computer Network Neighborhood Inbox wy 1 Recycle Bin 3 Floppy 4 True Trak Monitoring Wersion 5 WinZip TA Programs 77 Accessories 3 Documents gt 73 StartUp Settings Windows A Find d MS DOS Prompt Help Y TrueTrak 20
80. er Low Alarm High Alarm Value Units Biscuit Size 0 6 1 1625 IN Cycle Time 30 0 45 0 59 678 SEC Calc Start Fast Shot 16 0 16 5 16 222 Runner Full Yelocity 140 0 145 0 142 4 IPS Avg Fill velocity 125 0 135 0 100 1 IPS Fill Time 0 0 0 0 64 933 MS Slow Shot Velocity 14 0 15 0 15 8 IPS Avg Fast Shot Velocity 0 0 0 0 89 563 IPS User Avg Vel Range One 0 0 0 0 0 0 IPS Intens Rise Time 0 0 0 0 849 74 MS 88 True Trak keeps record of the Last 50 Shots recorded when the next shot is recorded it replaces the oldest shot in the shot pool the 1st and last shot numbers in the pool are shown at the top of the trend chart The trend chart is a bar graph a green block indicates that the value was within limit a yellow block indicates in warning and a red block indicates in alarm To view a shot move the cursor bar to the required shot in the trend chart and click The shot is displayed on the screen along with the parameter data and recorded values Unless the shot is being saved then once it has been removed from the shot pool it will be lost To save shots ref 4 7 Saving Shots those shots which are being saved are indicated by a black dot at the top of the trend chart To return to the standard screen click on Display Standard Screen 7 1 2 Standard Screen Switches from the Last 50 Shots screen to the regular display File Monitor Display Display Functions Production Help Live Shots
81. er left hand corner From the list of options select Programs from the list select True Trak 2020 Monitoring System 2 A number of screens will load until the Profile Screen is displayed in the background with the Monitor Configuration Screen overlaid Note the Profile Menu File Monitor Display Display Functions Production Help _ across the top of the screen this is where the majority of functions are chosen whilst running the program Monitor Display Display Functions Production Help Visi Trak Shot End 3 STEP CLOSED LOOP TEST Shot 1 Tue 03 23 2010 10 53 56 1 1 Getting Started New Machine and New Part This section firstly describes how to set up a new machine then setup a part for this machine and then how to monitor this machine and part You must create the machine first and then the part To Create a New Machine 1 ee Mono from the menu on role 2 Select Machine Setup Monitor Display Display Fi Part Setup Machine Setup Monitor Setup Real Time Machine List FasTrak Board Setup FasTrak Board Monitor 3 Select Edit from the upper menu 4 Select Create and at the prompt enter the Machine Number of the new diecasting machine you want to monitor 9 Click on OK You will return to the Machine Editor Select and make changes to the Machine Type and Rod Pitch as required 6 Ifthat s all required press the Save Changes button and then close the screen down by either cli
82. er we must ensure that the correct velocity is being read for example consider a shot where the slow shot is set to a velocity of 10 IPS If we were only trying to capture the end of the fast shot event using the End of Shot Velocity then the computer would have problems It would be well within it s right to use the 26 first 10ips velocity that it encounters To ensure that the correct velocity is detected we incorporate the Minimum Stroke Length parameter It is basically a flag position which the plunger has to pass before the End of Shot Velocity is looked for Ideally it should be put somewhere in the fast shot IP R EE FEE TTT H Head SD t BE 0 LI Sl OP IN 0 Nw 2000 MACHINE 5 ycle Time ntens 3846 14 PSI en rei Fe Shot ae IN inten Ver Range one 14 19 IPS SHOT 315 User Avg Vel Range Tuo 105 08 IPS Thr Apr 1997 19 16 35 From the above profile the part was running with the fast shot commencing when the piston had reached 10 0 On the above profile the Minimum Stroke Length was set to 16 in which lies in the fast shot The shot below was recorded on the same machine as the previous trace but this time the Minimum Stroke Length was incorrectly entered at 8 in PTT TTT TTT TT TT type LL LLL PE HH424 H H4I MEN NNI II C UI GO ITA CI cat FH Sr POSITION
83. ettings only one has to be edited the changes can then be copied to the other parts 1 2 3 4 5 6 7 8 Select Monitor from the Profile Screen menu Select Part Setup from the submenu Select the machine and part that are to be edited Make the changes to the part if any Click the Copy to Existing Parts button The Copy To window is displayed Select the machine and parts that you want to copy to Select what information is to be copied Basic Setup Advanced Setup Parameter Limits User Defined Positions Profile Marks FasTrak Channels Reference Trace Select which parts are to receive the data in the Parts to Copy to area Click the OK button Continue editing parts or close the window 41 Section 3 Machine Setup Visi Trak amp is a Registered U S Trademark of Visi Trak Worldwide LLC 44 3 Machine Setup Eile Display Display Functions Production Help Part Setup Monitor Setup Real Time Machine List FasTrak Board Setup FasTrak Board Monitor SureTrak Control Interface Used to configure the die cast machine setup To view select Monitor Machine Setup 3 1 Machine Editor Machine Editor File Edit View Machine Machine Type Hot Chamber Cold Chamber Number Pitch 20 save Changes MACHINE NUMBER The number of the diecasting machine can be up to 3 characters long To view a different machine click on the required number A scroll bar will be
84. gth Using The Current The current shot has a stroke length of 25 538 Enter the size of the biscuit for this shot The Total Stroke Length is 28 0 IN Press the Save button to save this value to the current part setup If this is the current part in the Part Setup program you MUST RELOAD THE PART in that program in order for it to recognize the change Save Total Stroke Length Cancel 5 8 Text Editor This is a very simple text editor that can be used to make changes to the initialization files such as the VISITRAK INI file that contain settings for the program These files are found in the V5 EXES directory The File menu has three selections e Open Use this to open a file Only one file may be open at a time The default directory for the open command is the V5 EXES directory where the INI and MNU files are located e Save Use this to save changes You may only save to the same file name e Exit Exit from text editor 5 9 Choose Language Change between English and German text 72 5 10 Passwords This facility is provided for situations where the unit is used by a number of operators each with a different level of usage i e Operator A may only be required to obtain shot profiles recorded on the machine to which the unit is hooked he doesn t need to know how to setup parts and configure machines whilst Operator B needs to be able to set up machines parts etc 1 If an option is available it will
85. gure how the shot parameters profiles are to be saved using one of the methods below Click the dot next to the required method 1 Save Save every shot recorded Ref Method 2 Save None Chosen if no data is to be saved Ref Method 3 Time Skip The time period has to elapse before the next shot will be saved Ref Method Acquire Count How many shots are to be saved when the time period has elapsed Skip Seconds How many seconds to wait before the next shot s is are saved Max Saved Maximum number of shots to save Ref Maximum Number Reached 4 Shot Skip Saving of data is based on shot count Ref Method Acquire Count How many shots are to be saved when the skip count has been reached Skip Count How many shots to skip before the next shot s is are saved Max Saved Maximum number of shots to save Ref Maximum Number Reached 3 1 Saving Shots Save All Method Click Monitor on the Profile Screen menu Click Monitor Setup on the Monitor menu Select the machine and part that you want to edit Click the Dot alongside the Save label Enter the maximum number of shots to be saved in the Max Saved window Click the Save Changes button 4 3 2 Saving Shots Save None Method 1 Click Monitor on the Profile Screen menu 2 Click Monitor Setup on the Monitor menu 3 Select the machine and part that you want to edit 4 Click the Dot alongside the Save None label 5 Click on the Sa
86. he Backup section to choose the data that should be backed up An ALL Button is available to users who wish to backup all the options available Note To minimize disk space used choose only the options that you need b Next select the Purge Options that are to be used Ref 5 3 1 3 DEFINITIONS section for further explanation Choose the Machine s and parts that are to be backed up An ALL button is available if you want all Machines and Parts to be included in the backup set d In the editbox under Backup Zip File specify a path name for the backup set Initially this path is C V5 BACKUP ZIP The C V5 specifies the folder that the backup will be saved in BACKUP ZIP is the name of the zip file that will be saved in that folder Note Filenames and folder names can be no longer than 8 characters each not including the ZIP extension This is known as the DOS filename standard For example an acceptable path would be C FOLDER99 12345678 ZIP where FOLDERQ9 is the 8 character folder name 12345678 is the 8 character filename and ZIP is the file extension The folder should already exist Visi Trak Worldwide recommends using a different file name for the backup set each and every time a Backup is performed Using the same name as a previous backup will append the current backup data to the last backup set This could create duplicate backup data especially if you haven t previously PURGED data It may be desirable to use t
87. he date for a backup name such as 061098 zip or Jun10_98 zip Once a file name has been entered press the Begin button The file will be saved into the V5 directory under the name you gave it Network users may have a different path All Setup Files Debug setup files backup This button is located in the bottom right corner of the screen lf you press it all the setup files will be saved to the Backup Zip File The purpose of this is to create a file that can be emailed to Visi Trak Worldwide in order to help solve problems us this only when instructed by VisiTrak technician 63 5 3 1 2 Restoring the Backup Set 1 Click File on the Menu Bar Choose Backup and Restore from the drop down menu 2 Choose Restore from the choices in the True Trak Backup Restore window Hestore Setups and Data x Destination Restore Machine Part Params Shots Machine Setups Scrap Downtime Shot Profiles V Shot Parameters Alarm Data SureTrak Pgm Globals All Load Zip File 3 the Restore Setups and Data window click the Load Zip File button Open Look in avs gl ES File name Files of type Cancel as read only 4 Navigate through the folders or drives A if the file is on floppy disk until you find the backup set you want to Restore Highlight the file and click the Open button 5 When the zip file has been loaded all machines included in the in back
88. he recorded downtimes graphically This function does not work for a multiplexer system as the machine may be being monitored but due to the nature of sampling the m c being down may not be detected 109 9 2 Downtime Setup Screen Down Time Setup E x Category Sub Index Sub Cagegory System Category Program Exit N System Category Program Start a 00 System Category Auto Down 00 System Category 11 Machine Up 01 DieCast Machine 01 Electrical 01 DieCast Machine 02 Mechanical Index Description 01 DieCast Machine 03 Hydraulic System Category 01 DieCast Machine 04 Scheduled Categoy EM System Category 01 DieCast Machine 05 Cleaning O1 DieCast Machine D6 Empty Sub Category 00 Program Exit 02 Misc Downtime 1 Electrical 02 Misc Downtime 02 Union Meetings 03 Heater Failure 01 Fatal 03 Heater Failure 02 Overflow Save Changes 03 Heater Failure 03 Electrical Operator 01 Lunch Break This screen is used to configure the downtime categories used in your particular plant The downtimes are recorded sorted by 2 levels Category and Sub Category The Category is used to gather together related downtimes i e one main category will collect all the problems associated with the DIE another would consist of LADLE problems etc The sub category details individual problems for the main topic i e typical sub categories for the DIE could be BROKEN EJECTOR STUCK CORE POLISHING typical
89. hen a Fas Trak board has acquired the data from a shot this program reads the data from the board saves it and notifies the other programs that there is new shot data available Note If this program is not running then you are not monitoring The Status and Menu screen displays the current status of each Fas Trak board If there is only one Fas Trak board connected to the computer only one column will be of displayed You can also activate the screen by pressing the F6 key on the key board after entering Fastrak Board monitor The status are as follows e Board Board Number e Address Address of board being monitored e Comm Status Displays the status of the board must be connected for it to monitor the machine e Machine The machine number the board is monitoring e Monitoring Status Displays the status the board is in Should be in upload complete or data ready state 79 6 4 Real time Screen The board monitor program also allows you to diagnose problems with the Fas Trak board To do this Click on the Real Time option or press the F8 key on the key board F2 Set Dac Velocity 96 6000 IPS Chan Volts 0 5 r Status Current Step 27 06 Nu mm Making 9 SHOT F4 Valve Test Position 15 95 IN 40 10 Control State ACTIVE FS Test Alarms memm 1 53 FB Status and Menu Max Position 39 75 Zeoj Meas 1 52 Al WOT 5 0 Inputs Dutputs zus Cid 10 0 ATHOME F8 Realtime Uploa
90. hift Start OF Shift Wednesday 3 Wednesday 15 30 Thursday 1 Wednesday 23 30 23 Thursday 2 Thursday 07 30 v Make All Days Like This Day Save Changes 9 5 Downtime Summary 111 9 6 Operator SignOn Operator Signon 3 Machine Operator _ Edit Ellen Wittenberg Wittenberg Fran Napoli Tom Miller John Smith Randy Miller Joe Smith Used to assign operators to machines that they are running their name will appear on downtime sheet To Assign a Name 1 Click on the Machine to be assigned 2 Click on the Operator name 3 Click the OK button To Edit Operator Names 1 You can only add or delete operator names at certain password levels The Edit button is only displayed when operating at the appropriate password 2 Click the Edit Button 3 The screen below will be displayed EE Ini xl First Name Last Name Ellen Wittenberg Clare Wittenberd Fran Napoli Abreviation Tom Miller John Smith Randy Miller Jae Smith Ellie Wittenberd Miller Tom Peter Wilson 22 Johannes Alpher Delete Save Changes Cancel Insert 4 Click the Insert button on the new line enter the operator details 5 delete a name click on the operator name and then click the Delete button 6 Click the Save Changes button when finished 112 Section 10 Miscellaneous Boards Position Transducer 114 10 Miscellaneou
91. his Part Save Changes Reload Saved Setup Print PARAMETER DESCRIPTION amp UNITS The name of the parameter and it s measured units 29 WARNING LIMITS When a recorded value is outside of these values it will appear in yellow on the View Parameters screen Hi amp Low limits can be entered and an alarm wire can be assigned ALARM LIMITS When a recorded value is outside of these values it will appear in red on the View Parameters screen Hi amp Low limits can be entered and an alarm wire can be assigned 2 3 2 Parameters Screen Lower Half Editor The lower screen is used to edit the parameter settings 3 types of parameters are available Internal Parameter One of the 35 standard parameters that are calculated by the Visi Trak Worldwide FasTrak Analog Input A value recorded from a device connected to the analog channels i e metal temp FasTrak On Off Input Reports when an analog device is switched off or on The type of parameter is displayed in the Parameter Type box on the window INTERNAL PARAMETER SCREEN Biscuit Size Parameter Type Internal Parameter Alarm Value Wire Low Warning Internal Name Biscuit Size High Warning o f E High Alarm Internal Name The description given to the parameter by the True Trak Useful if the user has redefined some descriptions we know what the original name was Window Displays the name of the parameter whe
92. ib dead 88 T 21 2 XS TANDARD O CREEN iuo ote ceo eeu om Cad 89 TAS POSITION IME BASE Dias rn staret det ao ee SR om ine 89 TACA TIME BASED dd 90 7 1 5 DISPLAYING LIVE SHOTS OR SELECTED SHOTS 00 440 4 90 TAO BOX SCREEN cen at a ae 90 722 PARAMETERS A 91 TRENDICHART Se ee Re id 92 ELSA INDIVIDUAL SHOT VALUE ee 92 POPUP MENU a a 93 1 3 3 TO ZOOM INONASHOTRANGE estrictas 93 79 9 PRINTING TRENDICHART SE titi 93 7 42 TRENDGHART SETUP SCREEN st ne ici 94 TAA PARAMETERS TO DISPLAY es ee ee ee 94 Ze FED POW IME SH ti Pas 94 4 9 CHART TYPE Son ii ee ici 94 LAA TIME PERIOD TO DISPEAF is 94 T 2 5 ALARM AND WARNING LIMIT S ti a is 94 16 SELECT THE PARAMETERS 2 ete ee lidia 95 VO SELECT ASHOT RANGE nox ERES een nein 95 7 3 STATISTICAFSUMMARY SCREEN se ld ee 95 7 5 1 DISPLAYING sais 96 7 5 2 REMOVING THE STAT SUMMARY 96 7 5 3 TO CHANGE THE 8 96 7 5 4 ENTERING LCL 96 7 5 5 PRINTING THE STATISTICAL SUMMARY 5 2 4 0 96 NOTE THE TREND CHARTS WILL BE PRI
93. ing Minimum Stroke Length amp End of Shot velocity When the piston is moving forward how does the Visi Trak Worldwide True Trak determine whether it s the slow shot fast shot or intensification stage Unfortunately it can t without some human interaction by using the End of Shot Velocity in conjunction with the Minimum Stroke Length parameter it s possible for the Visi Trak to determine the various stages in the shot The End of Shot Velocity is used to detect the deceleration of the plunger as it slows down during the final stages of cavity fill In the early stage of fill the liquid metal flows into the cavity unrestricted Cavity partially filled no backpressure no resistance to fwd travel of piston Metal At Gate However when the cavity is almost filled it then becomes harder for the metal to be injected into the cavity a back pressure develops which slows the piston down Cavity Full Cavity Fills Backpressure Slows piston down Hydraulic Cylinder Cavity P3 By monitoring this deceleration we can determine when the cavity fills and intensification begins This point is coincides with the slowing down of the piston from the high velocity used during cavity fill to the much lower velocity when the intensifier kicks in The low velocity that we are trying to detect is called the End Of Shot Velocity The End of Shot Velocity is typically set at 10IPS 0 25m s and has been found to work well at this value Howev
94. ion TB1 1 5vdc TB1 2 Ground N D LEE S 10 1 1 adaptor baord 50 pin ribbon connector to Multiplexer Interface used for alarms limit switches and other external signals for systems set up as a Monitor For systems setup for Control this would be connected to a board 10 1 2 Ethernet adapter board link between the Fastrak2 Board and Computer 116 10 2 External Interface Board Shown below are the two external interfaces to the FasTrak2 board The one on the left is the older model and was the standard until February of 2006 W wm IM ua MVo o7o02 x49 07002 Rev 1 Power connection 1 1 pos 12vdc 1 4 neg 12vdc 2 1 position cycle start command signal connections 3 Analog Input 4 Digital servo amp connection 49 07002 Rev E only 117 10 3 Sensor Converter Board MVO 07014 Bed Bl S SNA z Es C15 EC les ij gt lt SE za 159 lt e QUE BT fip eee E 3 E meg 4 gt Sas j oo aes pe E 4 o QOS oir fee 24 SN lt a a JE C i Eu The MVO 07014 sensor converter Board provides two sets of buffered single ended lead amp trail signals allowing multiple signals to be drawn from one Visi Trak Worldwide transducer The board als
95. ition where the volume of metal fills the shot sleeve The distance from this point to P3 the impact position is entered in Advanced Part Setup ref section 2 2 Metal At Gate P2 Also known as the Runner Full position The plunger position when the liquid metal front is at the gate The distance from this point to P3 is also entered in Advanced Part Setup ref section 2 2 Note If the Copy P1 and P2 to Part Setup checkbox is checked then when the Save Changes button is pressed the program will calculate the distances from P2 to P3 the end of shot and from P1 to P3 and will transfer the resulting values to the current part setup These are the only values that will be changed in the current part setup Velocity During Fill Gate Velocity Only one of these values has to be entered along with the Gate Area If the required gate velocity is known then enter this and the calculator will determine the required plunger velocity Velocity During Fill for a given gate area This can be used to determine the effect of gate area and speeds Sweep to Fill Cavity Distance the piston travels from when the metal reaches the gate until the cavity is full of metal Filltime The time from when the metal reaches the gate until the cavity is full of metal Hydraulic Cylinder Dia Diameter of the hydraulic piston Metal Pressure Intensification pressure hydraulic cylinder area plunger area Area Cast Overflow Spray Projected Area the plain are
96. ity Units and End of Shot Velocity are usually kept constant thus to perform a basic part setup only requires knowledge of the Total Stroke Length of the machine and the Minimum Stroke Length for the part DISTANCE UNITS Units to measure the position amp distance traveled by the plunger Choose from Inches Millimeters or Centimeters U S customers will typically be using Inches VELOCITY UNITS Units to express the velocity of the plunger during the shot Choose from IPS Inches per Second FPM Feet per Minute CMPS Centimeters per Second MPS Meters per Second U S customers will typically be using IPS TOTAL STROKE LENGTH This is the distance from the fully retracted position piston position at the start of the shot to the face of the ejector moving half with the die closed This value has to be known as accurately as possible as a number of parameters such as biscuit length P1 P2 etc are determined from it Ref Determining Total Stroke Length MINIMUM STROKE LENGTH This is a position after which the FasTrak board begins to look for the End of Shot Velocity It should be set so that it resides within the fast shot portion of the shot END OF SHOT VELOCITY After the minimum stroke length has been exceeded the FasTrak board then looks for a reduction in velocity signifying the end of the fast shot This indicates that the intensification has begun For Imperial a typical value is 10 IPS for metric 0 25 MPS 25 Comments on us
97. k program on the computer B IT ET No Syctem Connect ras TT pagam i ming vll the File menu and choose Exit and STOP Comm Status Machine ans Cernrentc Monitoring to shut the program down You have Ext STOP Monkoring to do this twice Pull down the Monitor menu and choose FasTrak Board Setup Part Setup Machine Setup Monitor Setup Real Time Machine List FasTrak Board Setup FasTrak Board Monitor 133 Hy FasTrak Board Setup Computers This Computer EXA Boards At This Computer an Board Board Mia d New Delete dialog appears check e Address of the FasTrak2 Da umber Beard Address Type Top 20000 Board Number 17 2 3 B C Singe Multiplex 7 FasTrak amp ddess 132 168 254 33 Part 20000 ttom of the Machines At This Computer Board FasTrak Machine Number Channel Machines At This Computer Board FasTrak Mux Machine Number Channe T 2 A A B C C Channel C C C File Monitor Display Display Fur MEN Part Setup TR Machine Setup Monitor Setup Real Time Machine List down the Monitor menu and choose FasTrak Board Monitor MATES Ele View Connect Help Bnard Address Comm Status Machine Part Monitor
98. l e Analog Sensor Displays the type of sensor currently set for the channel If a different type of sensor is required click on the x button A list of the currently configured sensors is displayed Click on the sensor required e Head Pressure Rod Pressure None Used to indicate which channels are being used to monitor head and or rod side pressure If no pressure transducers to be used as either head or rod side then click on the dot next to none 35 2 7 Analog Sensor Setup Analog Sensor Setup Analog Sensor Description Pres 0 0 10000 PSI Pres 0 5 D 10000 PSI Pres 0 5y 0 5000 PSI A Type y 1 5v 32 932 F Variable PSI Type J 1 54 0 500C Pressure PSI Units 1 5 32 1832 1 5v 0 1000 _ Transducer 1 0 Ranges Volts 3 L High Test Calculator Pres 0 5y 0 689 5 Bars midi Pres 0 5v 0 344 75 Bars Volts 0 0 5 0 Volts Raw 4 0 Converter Value Pres 1 5 0 10000 PSI E PSI 0 0 1 0000 PSI Pres 1 5v 0 5000 PSI Pres 1 5v 0 689 5 Bars Pres 1 5v 0 344 75 Bars Note After creating a new analog sensor you MUST RESTART all the True Trak programs K 1 5v 0 1400 F Y ou should NOT do this when you are about to make a shot Pres 0 5 0 500 PSI Die Pres 0 10v 0 20K PSI A number of sensors transducers can be hooked up to the system monitored either continuously or at a specific point d
99. l One 9 900 Time Interval Two Use Limits CS Anis N User Time Int Three Parameters User Time Int Four being charted User Time Int Five No Biscuit Size 3 1 0 Yes 8 Shot Number Alarm Limits Calc Start Fast Shot No Intens Pressure No p Warning Limits Intens Rise Time pu amp Check to display these Da limits on the chart Peak Intens Save Changes TN M an This screen allows you to change what is displayed on the Trend Chart Screen 7 4 1 Parameters To Display Highlighting parameters in the listbox causes them to be plotted on the trend chart page There is no set limit on the number that may be selected but if the plots will not reasonably fit on the screen the program will ask to you to reduce the number 7 4 2 Fixed Plot Limits Also shown in the listbox are fixed limits for each parameter These are not part based One set of limits is used for all parts To change the limits for a parameter click on the parameter in the listbox The max and min values will be loaded into the editboxes on the right You may now change the values and also click on the Use Limits checkbox The limits will not be used unless this checkbox is checked Pressing the Save Changes button saves the changes and returns you to the trend chart screen 7 4 3 Chart Type You can plot individual points or averages by choosing Trend or respectively under Chart Typ
100. lts 37 2 8 Sure Trak This screen is used to configure new shot profiles for those systems using Sure Trak Control ref the Sure Trak Shot Profile Entry Screen section in the Sure Trak Shot Control System Manual for further details On systems without the Sure Trak control the Profile Entry Screen will not be available 2 9 Calculator Monitor Part Setup Calculator x Edit Alloy Distance Units IN MM CM Alloy Edit Velocity fe E 7 CMPS E MPS Aluminium 380 This be TN Currently Weight Units LBS KG Selleced Plunger Diameter Dist to Fill Runner 154362 IN Plunger Area 533956 IN 2 MetalatGate P2 120410 As measured Dry Shot Length 24 IN Velocity During Fil 150 IPS from the start x of shot Shot Sleeve Volume 142 549 IN 3 Gate Area 7 IN 2 Casting Weight LBS Gate Velocity 1 27276 5 Changing Overflow Weight dr E LBS Cavity Volume 63 6061 either of these Cavity Weight 5 75 LBS Sweep to Fill Cavity 10 7088 nu Weight i5 LBS Filltime 71 3826 MS Total Shot Weight 7 25 LBS Intens Press 4004 PSI Density 0904 LB IN 3 Plunger Gate Ratio 8 48503 Volume of Shot 80 1331 IN 3 Hydraulic Cylinder Dia Inde IN AS measured 4 Shot Sleeve Ful 56 2607 Hydraulic Cylinder Ares 19 6349 IN 2 from the start SSF P1 10 4374 IN Metal Pressure 13223 1 PSI Biscuit Length DEE IN Area Cast Ovrflw S pray EVE
101. ly loosen the set screws slightly The magnet in the end of the transducer will keep it in contact with the rod If the transducer was supplied without the connector attached or the transducer can t be installed with the connector attached proceed to the next section 166 For transducer assemblies which have the connector soldered on simply push the extra wire length into the mounting hole until the connector rests flush on the mounting surface Take caution with these wires so that they do not bind or break Use four 4 40 screws to attach the connector to the mounting block The assembly is now ready for use Wiring If the transducer was supplied without a connector or the transducer can t be installed with the connector attached cut the wire leads to allow for about 2 of slack from the connector mounting surface Strip each lead 1 4 and proceed to solder the leads to the connector as shown below If the transducer mounting block is mounted such that the flat edge is not facing the rod end of the cylinder the lead and trail wires of the transducer will have to be reversed pins A and D of the MS connector When soldering make sure that a clean solder joint results and no solder bridges exist 167 13 4 Installing Your True Trak 20 20 Software 2 Desktop E a My Documents amp My Music 48 My Pictures PrintScreen Files B My Computer Local Disk C B 4223 autoback H E fti
102. n alarm output wire and connection Part Setup Create Mew Part Copy to Existing Parts Copy to Other Machine Save All Parts Calculator Machine Basic Advance Parameters Positions Marks Channels Shot Control Setup Visi Trak Shot End v Part Remove Add Warning Limits Alarm Limits is Parameter Description Units Low Wire High Wire Low Wire High Wire 3STEP CLOSED LOOP TEST Fill Time 00 0 i 3 STEP OPEN LOOP TEST Total Shot Time MS 0 0 0 00 0 00 0 00 0 5 Step pen Loop Slow Shot Time MS 000 000 a ddl Fast Shot Time MS 0 0 0 00 0 00 0 00 o C rent Fast Shot Rise Time MS 0 0 0 00 0 00 0 00 0 DYNAMIC CLOSED LOOP TEST Time SEC 00 000 300 25450 25 5 RAMPTEST Time Interval One MS 0 0 0 00 0 00 0 00 0 Time Interval Two MS 0 0 0 DD 0 10 0 10 0 User Time Int Three MS 0 0 0 00 0 00 0 00 0 User Time Int Four MS 0 0 0 00 0 00 0 00 0 User Time Int Five MS 0 0 0 10 0 00 0 00 0 20 Good Shot Wire Number on Good Shot Wire only if there are NO WARNINGS save Changes Reload Saved Setup Print Parameter Number Alarm None Value Wire Low Warning 7 6 11 4 High Warning E ION Low Alarm 4 Low Alarm High Alarm 12 14 High Alarm 30 0 35 0 15 8 16 2 F10 Change Focus Click on the Parameter Tab Click on the Alarm Wire box this will display a picture of the Opto 22 I O board Selecting I O output
103. n t clash with the background color of the profile screen Ref 7 8 Color Configuration for details on changing the screen colors LINE TYPE Select the type of mark by clicking the dot next to that required None No mark Vertical A vertical line across the whole trace Useful for indicating positions P1 and P2 Base A small block mark which appears across the bottom of the position velocity curve LABEL Add a label to the mark up to 5 characters in length OFFSET Positions the label on the screen 0 at the bottom 8 at top 33 ADDING NEW 1 2 5 6 Click on the Add button will see the Marks to Add box listing the marks available Click on the mark required By holding down the shift button and clicking you can select a continuous list of marks by holding the Ctrl button and clicking you can add a number of separate marks Click on the OK button to enter the list To format the mark click on it in the Mark Source Description box Format the settings as detailed below Click on the Save Changes button to save current settings If no more changes are to be made to the part click on the x button to close the window Otherwise click on the tab of the Part Editor sheet required REMOVING MARKS 1 2 3 gt In the Mark Source Description box click on the mark no longer required Click on the Remove button the mark will be deleted from the list If a mark was accidentally deleted click on the
104. n the Part Editor On the profile the average velocity V is being measured between the 2 yellow marks at 3 and 9 inches The positions can be marked on the profile ref Profile Marks 30 Position P1 IN MM Shot Sleeve Full Position This is the plunger position where the volume of metal fills the shot sleeve The Fas Trak board measures back from P3 the Distance from P1 to P3 is entered in Advanced Part Setup Position P1 is shown on the Profile 31 Position P2 IN MM Metal At Gate Position also known as the Runner Full position The plunger position when the liquid metal front is at the gate The Fas Trak board measures back from P3 the Distance from P2 to P3 entered in Advanced Part Setup Position P2 is shown on the Profile 32 Position P3 IN MM Cavity Full Position The plunger position when the die cavity and overflows are full coincides with the position at which the End of Shot Velocity is measured Position P3 on the trace is the vertical line indicating where the monitoring changes from position based for the shot to time based for the intensification period 33 Avg Slow Shot Velocity IPS FPM CMPS MPS The average velocity recorded between the initial movement of the plunger and the Calculated Start of Fast Shot Velocity range C on Profile 34 Avg Fast Shot Velocity IPS FPM CMPS MPS The average velocity recorded between the Calculated Start of Fast Shot position to the End of Shot Velocity position Velocity
105. nd permanent damage can result if this face is scratched dented or abused Also care must be taken when wiring the transducer since improper wiring or short circuits may destroy the device n all cases improper wiring short circuits or physical damage to the transducer does not constitute a warranty failure If transducer failure does occur under normal operating conditions and within the warranty period the defective device must be returned to the factory for inspection prior to warranty replacement or credit Before returning a transducer contact Visi Trak for a Return Authorization number Installation The transducer has already been pre tested at the factory and a small sticker should be located on the face This sticker provides the recommended gapping distance 0 005 between the rod and the transducer If the sticker does not exist proceed to install two layers of Scotch tape on the face 0 0025 nominal thickness and make sure the tape covers the face only Any tape located on the sides of the transducer body may prevent proper insertion of the transducer into the transducer mounting block due to the close tolerances that exist Carefully slide the transducer into the proper hole of the transducer mounting block until it touches the rod The internal magnet will help to pull the transducer to the rod Do not let the transducer bang into the rod but carefully control the speed of the transducer contacting the rod by holding the
106. ne Setup 3 Select Edit from the upper menu 4 Select Create and at the prompt enter the Machine Number of the new diecasting machine you want to monitor 5 Click on OK You will return to the Machine Editor Select and make changes to the Machine Type and Rod Pitch as required 6 If that s all required press the Save Changes button and then close the screen down by either clicking on the button or select File from the menu and Exit 7 Ifyou want to edit the Advanced Machine Settings select View from the menu and then Advanced Machine Setup Follow 6 to close down 3 4 Delete a Machine Deleting a machine will delete all the information for the machine parts setup on the machine and all shot profiles for that machine currently saved on the computer 1 On Profile Screen menu select Monitor 2 Select Machine Setup from the submenu 3 Machine Editor screen click on the machine number you want to delete 4 Select Edit from the menu 5 Select Delete You will see a prompt asking you to confirm the deletion click on the OK button to confirm 48 Section 4 Monitor Setup Visi Trak amp is a Registered U S Trademark of Visi Trak Worldwide LLC 50 4 Monitor Setup Single Machine Monitor Monitor Setup 4 1 Monitor Setup Monitor Setup Parameters Pmfies 00 1000 1000 0 Shots 1000 1000 9 Used to select which machine and to monitor ho
107. o allows the lead amp trail signals to be 1 driven over long distances without loss of signal strength 2 filtered and strengthened 118 10 3 1 Sensor Converter Board Wiring Diagram The sensor converter can be wired in a number of ways depending upon the system 12VDC TRANSDUCER POWER TRANDUCER GROUND LEAD SIGNAL INPUT TRAIL SIGNAL INPUT LEAD SIGNAL OUTPUT LEAD SIGNAL OUTPUT lt gt LEAD SIGNAL 1 OUTPUT LEAD SIGNAL 1 GR UND 81 1 LEAD SIGNAL 2 OUTPUT 1 2 TB1 3 TB1 4 1 5 TBi 6 TB1 7 TBi 8 1 9 T81 10 T81 11 181 12 TB1 13 8 14 781 15 781 16 LEAD SIGNAL 2 GROUND TRAIL SIGNAL OUTPUT TRAIL SIGNAL OUTPUT lt gt TRAIL SIGNAL 1 OUTPUT TRAIL SIGNAL 1 GROUND TRAIL SIGNAL 2 OUTPUT TRAIL SIGNAL 2 GROUND 1 TB3 2 3 4 V DRIVE 5V TD 24 DC GROUND CH A FORWARD PULSES CH B RETRACT PULSES 12VDE POWER DC GROUND TBe 1 1 MOUNTED ON INSIDE WALL OF ENCLOSURE FN 12VDC INPUT DC GROUND INPUT LEAD SIGNAL 1 LEAD SIGNAL 1 GROUND i TRAIL SIGNA amp PRIMARY DUTPUT LEAD SIGNAL 2 OUTPUT LEAD SIGNAL 2 GROUND SECONDARY DUTPUT TRAIL SIGNAL 2 1 LEAD SIGNAL OUTPUT LEAD SIGNAL OUTPUT TRAIL SIGNAL OUTPUT TRAIL SIGNAL DUTPUT 7 THIRD OUTPUT DIFFERENTIAL 119 10 4 Testing the Signals from the Position Transd
108. o normally open contacts Indirect Method advanced Two AC lights two PLC modules using normally open and normally closed contacts 143 12 1 Definition of Direct and Indirect Alarm Output wiring Visi Trak Worldwide defines two methods for alarm output wiring e Direct wiring directly into the MVO 06288 Multiplexer Interface to activate alarm lights e Indirect using a Control Relay in conjunction with the 06288 to activate alarm lights Detailed descriptions and examples are provided on the following pages to help you determine the method that is best for your application 144 12 2 The Direct Method This is perhaps the easiest and most common method used Here is how you will wire a light to come on when a software determined parameter has exceeded your specified limit E JE 79 10 qo I 2 2 EEES oz A 1123111158 H In ls PTOS OPTOZ 6 OPTOS IF IE IP 1 20 LIVE _ m gt 32 32 03 I le 120VAC NEUTRAL Lo JL_ 06288 MULTIPLEXER INTERFACE PCB MODULE COLOR BLACK AC OUTPUT RANGE 12 140 VAC DACS An input voltage of 120 volts AC Live is supplied to the MVO 06288 Multiplexer Interface Board at TB1 11 When an alarm has been triggered that voltage is output to 1B 1 12 which is connected to one sid
109. og is ON the words ES are show in red to alert you Chan Volts 0 1 1 53 mama 2 0 02 These are the current voltages measured on the different analog channels Normal channels range between 0 to 5 volts Cmd 1 53 m Meas 1 52 LVDT 50 10 0 Meas 1 17 80 When the 17 18 checkbox is checked these three lines show Cmd The voltage in the command register This is not a measured value Meas Meas This is the measured voltage that is currently being output from the DAC to the valve LVDT LVDT The measured LVDT feedback voltage When the 17 18 checkbox is not checked these lines are moved up and re labeled and show the current values of channels 6 7 and 8 If you have a digital servo amplifier there will be two sets of these measurments The first set is the shot control the second is for pressure control If you click on this checkbox the display will change and channels 6 7 and 8 will be replaced with the command voltage the measured command voltage and the LVDT Feedback This configuration is shown above This is only useful if you have an control system and channels 17 and 18 are have been connected to the LVDT feedback and measured command volts respectively When this checkbox is clear channels 1 through 8 are displayed Status Following are the status definitions CYCLE START The Cycle Start signal is active high SHOT IN PROGRESS The plunger has b
110. oints between which the Visi Trak will calculate the average velocity of the piston Reported as User Avg Vel Range 1 4 The positions of the 4 pairs can be indicated on the trace ref 2 5 Profile Marks 32 2 5 Profile Marks Here the user can configure marks to appear on the shot profile indicating positions and ranges where various parameters are being measured You can also select whether the position will be marked with a vertical line or a mark the color of the mark and add a label Copy to Existing Parts Calculator Delete This Part Copy to Other Machine Save All Parts Basic Advanced Parameters Positions Marks Channels Shot Control Setup Mark Source Description Color Line Type Label Calc Start Fast Shot None Position P1 Verlical Position P2 Offset Position P3 Add Remove Vel Range 1 Start Pos Vel Range 1 End Pos Vel Range 2 Start Pos Vel Range 2 End Pos The positions of the following can be indicated on the profile e Vacuum On Off Velocity Positions 1 4 Velocity Ranges 1 4 Start and End points Calc Start Fast Shot CSFS Positions P1 P2 P3 Monitor This Part save Changes Reload Saved Setup MARK SOURCE DESCRIPTION The name of the parameter being marked on the profile COLOR The color of the mark choose from Cyan Lt Blue Red Yellow Green Blue Black and White Note that when choosing a color ensure that it wo
111. ons for P1 and P2 for equal shot weights DISTANCE FROM P1 TO P3 The distance from the Shot Sleeve Full Position P1 to the Impact Position P3 The position of P1 can be displayed on the trace ref 2 5 Profile Marks DISTANCE FROM P2 TO P3 The distance from the Metal At Gate Position P2 to the Impact Position P3 The position of P2 can be displayed on the shot trace ref 2 5 Profile Marks CALCULATED START OF FAST SHOT CSFS Minimum CSFS Position and Velocity These 2 values allow the Visi Trak Worldwide True Trak to determine the point at which the Fast Shot 2nd Stage began The operator has to enter a flag position Minimum CSFS Position after which the True Trak will look for an increase in plunger velocity When the Minimum CSFS Velocity has been exceeded the True Trak records this position and reports it as the Calculated Start of Fast Shot CSFS They work in a similar manner as the Minimum Stroke Length and End of Shot Velocity described earlier MINIMUM CSFS POSITION The plunger position after which the Minimum CSFS Velocity is sought 28 MINIMUM CSFS VELOCITY The Minimum Velocity for the Calculated Start of Fast Shot When this has been exceeded then the CSFS is reported Used in combination with Minimum CSFS Position VELOCITY FOR RISE CSFS This value acts as an end flag to determine the Fast Shot Risetime parameter The Fast Shot Risetime is the time from when the CSFS was measured and when the velocity entered
112. or At TrueTrak Startup SureTrak Control Installed Board Monitor programs to be Start SureTrak Control at TrueTrak Startup checked and you will probably ant them to Automatically Automatically Start When the Computer Boots d Start When the Computer Boots as shown to the left v Start Part Editor at TrueTrak Startup Control Setup Start Monitor Setups at TrueTrak Startup Duk Vel Rod If this is a Sure Trak2 control Units Units Pitch system you should check the 2 N IPS 20 SureTrak Control Installed and Sl Be el esaet Demi MPS 2MM then the Start SureTrak Cantrol at TrueTrak Startup MM MPS 20P under Control Setup that most Automatically Start When the Computer Boots matches your die cast machine Computer Monitoring Computer The DE a SE as 1 e 551 Data Archiver remain as they are Press the Continue button to begin the Local Installation on the Data Archiver installation Office Workstation Recreate Machine s and Part s an Existing Restore Point Use Restore Point Browse for Restore Path When the installation 15 complete you will see following icon on your screen Double clicking on this will start the main plot program 170 2 250 ohm resistor unicidad 37 4 4 20MA output 111 37 19 Adv
113. ose the window Note If a machine is being monitored but is not being displayed on the screen the shot data is still being recorded 7 6 2 Fas Trak Board Setup Screen for Fastrak2 systems FasTrak Board Setup Computers This Computer CAVA Boards 4t This Computer Board Board Mhz or New _ Delete Number Board amp ddress Type Port 32 158 254 33 asTrak2 20000 Rue Board Number IF 2 4 70 8 Board Single Multiplex FasTrak2 Address 192 168 254 99 Machines At This Computer Board FasTrak Mux Number Channel 1 tow lt 5 Board Number C C C Channel C C C This is used to define which computer Fas Trak board channel the machine will be monitored Having this screen correctly set is paramount for the system to operate correctly hence it is most likely that this screen will either be pre configured by Visi Trak Worldwide prior to shipping of the system or a Visi Trak Worldwide engineer will set it up during installation The screen consists of 3 parts Computers Boards At This Computer Machines At This Computer The operator shouldn t have to make any changes to the computers screen hence it will not be described Boards At this Computer Board Number Up to 8 Fas Trak boards can be installed per computer Board Address Depending upon the system up to 8 Fas Trak Boards may be installed To enable the comp
114. ot Parameter data to the backup file 5 Alarm Data Saves Alarms data to the backup file Menu Bar Located at the top of the Plot Screen Window Clicking a word on the menu bar with the mouse will activate a drop down menu The user can then select an action to be performed Availability of choices on the Menu Bar and subsequent drop down menus depend on the current Password Level set e Purge Options The following options are located in the Backup Setups and Data screen e Purge Data Checking this option will delete the Shot Data not Setups from the hard drive once the backup is complete This option is recommended for most backups e Save Last 50 Shots Checking this option will keep the last 50 shots on the hard drive if the Purge Data option is checked e Purge Downtimes Check this option to delete downtime information after the backup has completed Zip File A file that has been compressed by a utility such as PKZIP These files are saved with a zip extension The True Trak Backup utility will save your backups as Zip files 5 3 2 Backing Up to the Dataserver A dataserver is used on a networked system Without the server it is only possible to view current data on the workstation The server can be used to store the data transferred from the local computers 65 5 3 2 1 Backing Up The data recorded on the local units can be automatically transferred to the server To maximize the amount of data stored it is possi
115. oth circuits Note that the PLC I O module is DC voltage type Using the relay gives you the flexibility to use different voltages from a single alarm output 152 If you are using DC modules the MVO 06288 Multiplexer Interface Board you would wire as follows 4 El p EN dl AF ry i Ile Il mi LAMP H zal 5 1 0 NEUTRAL OA m Aa D lm 2 Fe ETT perma pring pemg LI 12VDC SOURCE MM d T 22 E2 Sc HS ESIESIESESB H m C2 C2 c2 55 G CR Vi i bii T 213 4516 120 LIVE PLC 140 ADD ON DC MODULE 06 88 MULTIPLEXER INTERFACE PCB Again this looks real similar to the previous example however there are some important differences For this circuit we need to make sure that the proper Opto module and also the correct relay CR is used This time we have a Red ODC5 module installed in the OPTO 6 location and CR is a 12VDC relay The input to TB1 11 is 12VDC When the alarm is triggered that voltage is output to TB1 12 and sent to CR A A DC ground is connected at CR B which energizes the relay Contacts CR 6 and CR 9 close and current flows through the lamp Simultaneously contacts CR 4 and CR 7 close and complete that circuit 09 LIP TL MODULE COL DC OUTPUT RAN
116. process is required to be in control to 5 std deviations then a Cpk of 1 66 is required If the value for Cpk is lower then the process is not in control The Standard Deviation s is the square root of the average variance of the groups If the group size is 1 then this is the same as the standard deviation of all the data Note if the group size is 1 then Cpk becomes Ppk Z The number of standard deviation units from the process average to either the alarm value or the user specified limit In capability assessment Zucl is the distance to the upper control limit Zlcl is the distance to the lower control limit and Zmin is the distance to the nearest specification limit Zucl UCL Mean Sigma LCL Mean Sigma Uses the Absolute Value Zmin smaller of Zucl Zlcl Zmin Cpk 3 stddev Sum of AII Values Average Number of Values 97 7 7 Display Configuration Choose which analog profiles are to be drawn on the screen Which analog sensors are connected to which channels is defined on the Channels window in the Part Editor Display Configuration x Display Curves As Pressures C Continuous Channels Pre Impact Curves Post mpact Curves v Head Pressure M Head Pressure v Rod Pressure Rod Pressure Differential Pressure Differential Pressure a FasTrak Channels Display Curves As Pressures If monitoring pressures only then click Pres
117. proper functioning of the electronics Typically if a transducer becomes defective one output will look as shown and the second will show either a continuous high or low voltage or show a very poor duty cycle Slight rotation of the transducer in the block occasionally improves the duty cycle and quadrature phase shift however continuous high or low outputs indicate a defective device 122 10 5 1 Testing the signals with the software diagnostic programs 1 Testing the inputs to the Fas Trak Board The transducer test for the signals going to the Fas Trak Board is run from the Fas Trak Board Monitor program Pull down the View menu and choose Fas Trak Board Monitor Click Real Time Tab bottom left or press the F8 key File Monitor Display Display Ft mee Part Setup Machine Setup Monitor Setup Real Time Machine List FasTrak Board Setup FasTrak Board Monitor F2 Set Dac Velocity 96 6000 IPS Chan Volts 0 r Status Current Step 27 06 F3 Null Valve M EIE eem F4 Valve Test Position 15 35 IN 40 10 Control State ACTIVE F5 Test Alarms m Cmd 1 53 FB Status and Menu Max Position 39 75 Zero Meas 1 52 m F7 Terminal WOT 50 Inputs Outputs Cmd 10 0 ATHOME F8 Realtime Upload File control Meas 1 17 Globals LYDT 0 96 pum F10 Control Mods Event Log OFF zp 1718 2 You jog the
118. r Limit Switch 4 32 o 10 5 m Limit Switch 5 lt Integral 10 6 Limit Switch 6 57 lt Derivative 0 Follow Warmup Shot Through 100 o Stop Po if wief is Off Save Changes Reload Saved Setup Print 100 0 This is the Current Part F10 Change Focus v 800 ol 60 0 is 400 20 0 0 0 75 0 00 3 00 5 00 3 00 12 00 15 00 18 00 21 00 24 00 27 00 30 00 Position 83 Visi Trak is Registered U S Trademark of Visi Trak Worldwide LLC Section 7 Display 87 T Display File Monitor Display Functions Production Last 50 Shots Screen Standard Screen Box Screen Parameters Trend Screen Position Time Base Position Based Time Based Transducer Plot Display Setup Display Color Setup Corner Parameters 7 1 Profile Screens various types of The shot profile can be presented in a couple of different ways depending on the method chosen in the Display submenu 7 1 1 Last 50 Shots Screen This screen displays the shot profile the 8 corner parameters and a trend chart for the last 50 shots recorded File Monitor Display Display Functions Production Help Live Shots 2081 8 nz 1910 8 1561 3 1433 1 1040 9 955 4 520 4 Rod 477 7 Head 151 93 a 26 83 113 94 26 50 75 96 26 16 37 98 25 83 0 0 V csfs 25 50 Paramet
119. re it can be edited Alarm Limits Enter Warning and Alarm Limits along with any wire outputs Clear Button Resets the alarm limits to zero FASTRAK ANALOG INPUT SCREEN Metal Temp Parameter Type FasTrak Analog Input Alarm Clear Value Low Warning loo aa High Warning loo C C E NotUsed Low Alarm loo High Alarm loo Sample Period Position during shot Sample Point Time 5 during intensification 00 0 5 FasTrak Analog Channel Which channel the analog device is connected to Sample Period Define when the analog sensor will be read Position During Shot is to sample prior in the pre impact Time During Intensification samples after impact Sample Point Input either the position or time at which the analog sensor is to be read 30 Window Displays the name of the parameter where it can be edited Alarm Limits Enter Warning and Alarm Limits along with any wire outputs e Clear Button Resets the alarm limits to zero FAS TRAK ON OFF INPUT SCREEN Alarm FasTrak On Off Input Clear Value Wire Low Warning 0 0 fo High Warning 0 0 0 Low Alarm 0 0 0 High Alarm oo o v acuum Off EE Parameter FasTrak On Off Input No 1 2 A 4 Sample Point C Transition from Off to On Transition from On to Off Fas Trak On Off Input No Which channel the analog device is connected 1 4 Sample Point
120. rivers for the Monitor the TrueTrak software Coxpulsi Start Board Monitor at TrueTrak Monitoring Computer C FasTrakl FasTrak2 Startup will run the C Data Archiver Board Monitor program Local Installation on the Data Archiver the program that Olfice Workstation communicates with the FasTrak2 and records the shot data when you start Recreate and Part s from an Existing Restore Point Ka E DER GEN Use Restore Point Browse for Restore Path The Automatically Start When the Computer Boots opt on w ll run the True Trak software Cancel automat cally when the computer 15 turned on If this is FasTrak2 Portable system you may not want any of these checked In any case you can rerun this setup program and change the startup programs you must choose Update Existing TrueTrak System on the first screen to update 169 Start Part Editor at TrueTrak Startup Control Set mE I Y Te mm T L m LOT ir Per For a dedicated monitoring tart Monitor Setups at rue Startup Dist Vel computer you will probably want Start Board Monitor At TrueTrak Startup Units Units Pick the Part Setup and FasTrak 5 20 SureTrak Control Installed zur MM MPS 2MM start Surelirak Control at T rueTirak Startup 4 2 Units Units Fitch f IN IPS 20P C MM MPS 2MM 5 20 v Start Board Monit
121. s Boards Position Transducer Boards 10 1 Fas Trak2 Board MVO 07000 MONITOR CONTROL BOARD UI APEX PROCESSOR MVO 07010 MONITOR CONTROL BOARD U1 CYCLONE II PROCESSOR 10 1 2 X49 07001 Adapter Board 10 1 2 X49 07011 Ethernet Adapter 10 2 Fas Trak2 Board MVO 07002 EXTERNAL BOARD REV B USED WITH EXTERNAL SERVO AMP BOARD ONLY X49 07002 EXTERNAL BOARD REV E CAN BE USE WITH EXTERNAL OR DIGITAL SERVO AMP BOARD 10 3 X49 07012 Digital Servo Amp Board 10 4 MVO 07014 Buffer Sensor Converter 10 4 1 Buffer Sensor Converter wiring Diagram Position Transducer 10 5 1 Testing with a voltmeter on the Sensor Buffer Board 10 5 2 Testing with an oscilloscope on the External Interface Board 10 5 3 Testing using software diagnostic programs 115 10 1 Fas Trak Board MVO 07010 uw A 4 EEE EEE EN TEE TER E 41 20001 T wvo o7001 CECA i IA 1 adaptorJ1 J2 50 pin ribbon connector to Multiplexer Interface used for alarms limit switches and other external signals for systems set up as a Monitor For systems setup for Control this would be connected to a board SW5 dip switch used to alter the incoming digital signal from the position transducer and Programming the monitor control board Push Buttons Switch To reset the board SW3 or to get IP address of board SW8 LED Display Displays status of board Ethernet adaptor board Power connect
122. seconds per division horizontal The horizontal scale may need adjustment based on the speed of rod motion 2 Connect the channel 1 probe to the lead input terminal the channel 2 probe to the trail input terminal and the ground lead to the DC ground terminal of the external electronics Use caution when connecting or disconnecting the scope probes to ensure that any two terminals are not accidentally shorted together This may result in permanent damage to the transducer 3 Apply power to the transducer assembly and initiate rod motion it is recommended to maintain slow rod speed when monitoring the outputs so that the scope traces may be easily analyzed During rod motion view the scope traces and confirm that they appear as shown below Adjustments of the horizontal sweep and or trigger level on the scope may be necessary to obtain a better trace 121 Phase shift 90 Deg Typ Duty orae 50 The pulses should illustrate a duty cycle of approximately 50 That is the duration of the high level should be approximately the same as the duration of the low level This should be true for both pulse traces Also confirm that a phase shift is evident between the two channels This shift should be approximately 90 degrees or in other words one pulse should rise or fall in the middle of the other pulse s high or low state Although these items do not need to be absolutely perfect they should be reasonably close to obtain
123. sures Then go onto specify which transducers are to be displayed pre impact and post impact Differential pressure is of interest to UBE users only Display Curves As Continuous Channels Displays the 4 Fas Trak channel readings 7 8 Color Configuration Used to configure the colors for displaying the shot profile reference trace alarms and printing 7 8 1 To edit the colors 1 Click on the color box for the parameter you wish to change 2 From the pop up color palette click on the new color and the OK button 3 Click on the Save Changes button Screen Printer Mormal Reference Normal Reference Time Axis Y Position x Position Velocity Head 1 Rod Pressure Analog 2 Differential Analog 3 Analog 4 Background Border Grid Text Trend Background Alarm Color Warning Color No Alarm History Color No Alarm Text Color Save Changes Restore Original Colors 98 7 9 Corner Parameters Along the bottom of the profile screen information for up to 8 parameters is displayed Here the user can choose which parameters will be displayed on the screen Note Even though only 8 parameters are being displayed the remainder are still being calculated To view the list of values recorded for all the parameters see Display Parameters Choose Corner Parameters x Parameters to Display Available Parameters Start Fast Shot Total Shot Time Fill Time Slow Shot Time Fast Shot Rise
124. t 0 050 Pitch Groove The above schematic shows the digital square wave signals produced by a position encoder with an output of 20 pulses per inch 0 050 pitch The lead and trail signals are 90 degrees out of phase thus there are 4 transitions a b c amp d per pitch 1 every 0 0125 Hence with a 20 pitch sensor the displacement of the rod can be determined to 0 0125 120 With no rod motion the meter will typically read either 0 or 12 volts DC depending on the location of the sensing head to the groove profile It might be easier to read the voltmeter if the rod is moved forward slowly or when the rod retracts 4 Check both lead and trail signals to confirm proper readings Although a voltmeter will not show problems typically caused by improper mounting poor duty cycle and quadrature it will allow you to see the continuous high or low levels at the lead or trail signal input terminals displayed by most defective transducers The presence of continuous high or low voltages at the external electronics input terminals doesn t rule out improper mounting or defective cabling as possible problems however If the voltmeter doesn t stabilize it is sometimes better to remove the transducer from the mounting block and manually move it along the modified rod being careful to temporarily remove the position transducer s cable so as not to short the terminals of the MS connector on any metal objects If this procedure is used
125. tc unless different values are entered in the UCL and LCL columns e LCL amp UCL Upper and Lower Control Limits used to calculate Z and Cpk e Zucl amp Zicl Calculated Z for the upper and lower control limit e Zmin The smaller of the two Z values e Process capability index e Percentage of recorded values outside of the calculated Cpk value e Inthe Left corner the Number of shots is displayed along with the group size 95 7 5 1 Displaying With the Trend Screen displayed Display Trend Chart 1 Press the F5 function key the Statistical summary screen will be displayed 2 Press the right mouse button from the popup menu select the Statistical Summary option Note while the Statistical Summary screen is displayed the real time updates of the Trend Chart will not work The Cpk values are initially calculated using the Alarm Limits If different limits are to be applied then these can be entered in the Lower control Limit and the UCL Upper Control Limit columns respectively 7 5 2 Removing the Stat Summary To remove the Statistical Summary screen from the Trend Chart i e to print the Trend Chart 1 Press the F5 function key the Statistical summary screen will be removed 2 Press the right mouse button from the popup menu select the No Statistical Summary option 7 5 3 To Change the Range Place the cursor on the start value and click the left mouse button followed by pl
126. the PLC Many PLC s require an add on module to allow for this Visi Trak Worldwide does not supply these modules so be sure to check your PLC documentation or contact the manufacturer to determine the hardware needed The PLC may also require specific software programming before these modules will work Before attempting to wire directly into your PLC determine what the output voltage will be so that the correct OPTO module can be used For example if your PLC outputs at 24VDC then you Will need to have a red ODC5 DC output module installed on the MVO 06288 Multiplexer board Wiring into the PLC using the direct method is as follows opto TB e lle m 2123 2z 2z a PLC 1 0 ADD ON 3 yy TS SS S9 hc MODULE E lo Im 11 H B LJL JL JL DPTOS 7 6 DPTDS PS A A 7 IM IM 19 52 Sx SI ds L m E m L INTERFACE PCB 5 If the PLC I O module were an output type you would use a fuse before wiring PLC output to TB1 11 149 Sometimes your specific application requires some flexibility For example you decide you want one alarm output when triggered to activate an AC light You want another alarm output sent directly to the PLC which uses a DC voltage And a third alarm to output to the PLC using a different add on
127. time Cycle Start To monitor a shot the Visi Trak Worldwide computer requires that after receiving the Cycle Start Signal the piston must begin moving before the time entered here elapses If the piston doesn t move then the machine is considered to have timed out and the green cycle start box will change to red Timeout The cycle start signal can triggered by pressing the manual cycle start button on the unit or a relay on ladle pour or die lock can be wired to the unit CALCULATE PARAMETERS USING Indicate which pressure transducer you want the various pressure parameters to be calculated from Head Rod or Differential DIFFERENTIAL CURVE TYPE Of interest to UBE diecast machine users if the machine is not an UBE then the value should be NONE UBE users should select from the list the machine that they are using Contact Visi Trak Worldwide LLC if the list doesn t include your machine HMI Control with Binary Valve Hml selected if controlling a Binary control system iw Sure Trak2 Control servo Amplifier Board Type 06596 f Digital Servo Amp Choose Sure Trak2 Control selected if control system using a servo amp board lf you are not sure what boards you have click on choose the click on the picture of the servo amp board you have 46 Choose Your Servo Amplifier Board R53 20 02 C22 p ole 7 77 VISI TRAK MVO Aa ns DIGITAL SERVO AMP 2 Var pea X4 20008 ery
128. tion quadrature pulses at the point the screen is clicked on 7 1 5 Displaying Live Shots or Selected Shots In the top left hand corner a text box is displayed showing whether the displayed shot profile is 26 83 20 12 13 41 6 70 0 0 Value 64 933 15 8 89 563 0 0 849 74 the current shot profile Grey Box labeled Live Shots or previously recorded shots Red labeled Selected Shot 7 1 6 Box Screen Displays summary boxes for each of the diecasting machines Details Machine Number Part Number Last Shot number and time recorded whether the machine is running and if it is in alarm 7 2 Parameters Displays table of the recorded values for the parameters being measured Warning Alarm Parameter Low High Low High Value Fill Time 0 0 0 0 44 6591 Total Shot Time 0 0 0 0 0 0 0 0 2478 97 MS Slow Shot Time 0 0 0 0 0 0 0 0 242354 5 Fast Shot Time 0 0 0 0 0 0 0 0 55 4292 5 Fast Shot Rise Time 0 0 0 0 0 0 0 0 0 0 MS Cycle Time 27 0 28 0 25 0 32 0 27 9742 SEC Time Interval One 0 0 0 0 0 0 0 0 0 0 MS Time Interval Two 0 0 0 0 0 0 0 0 0 0 5 User Time Int Three 0 0 0 0 0 0 0 0 0 0 5 User Time Int Four 0 0 0 0 0 0 0 0 0 0 5 User Time Int Five 0 0 0 0 0 0 0 0 0 0 MS Biscuit Size 0 0 0 0 0 0 0 0 83 483 IN Calc Start Fast Shot 0 0 0 0 0 0 0 0 15 2000 IN Intens Pressure 0 0 0 0 0 0 0 0 1137 3 Intens Rise Time 42 0 47 0 40 0 51 0 45 0 5 Peak Intens 0 0 0 0
129. tly contacts CR 9 and CR 6 close Current flows through the Red lamp indicating an alarm state The level of complexity increases with the next few examples They require an understanding of the Control Relay s internal contacts The following chart may help to simplify the internal workings of the relay Normally Open Contact Pairs Normally Closed Contact Pairs 69 0 1 39 A Normally Open means that the circuit is open or broken and that no current can flow between the two contacts until the relay is energized Normally Closed means that the circuit is closed and that current is allowed to flow between those two contacts when the relay is NOT energized Concurrently when the relay IS energized the Normally Closed contacts open and current can no longer flow 154 RELAY NUI ENERGIZED Ey 27 The above diagram depicts an electrical representation of the relay s contacts when de energized and energized 155 This last example builds the previous one This time we add two PLC modules to further demonstrate the possibilities PLC I D ADD ON DC MODULE 1 120 LIVE 7 4 O CI 7 ir CI i O 7 Oo bo gt OUTPUT 112 lle Il ml JRETURN ow 3 Per RE el 25 1 1 HA lo 12 11 01 5 L7U AII UN
130. u can choose a subset of these if you wish e The parameters that you wish to export are listed on the right Choose one or more Holding down the Ctrl key while selecting a parameter will add it to the list without removing any others e Pressing Ok will copy the selected parameters to the clipboard Each field will be separated by a tab Each record is terminated with a CR LF combination There are two fields in the first row The machine name and the part name The fields in the second row contain the parameter names The parameter data is next one row for each shot Following this are four rows containing the alarm and warning levels for each parameter The last row contains the units for each parameter 67 Example output follows 01 Shot Number 1 2 Alarm Alarm Warn Warn Units Min Max Min Max MS Date 08 15 1997 08 15 1997 0 0 0 0 0 0 0 0 MS Time Fill Time Total Shot Time 15 17 08 28 9130 626 461 15 17 24 28 9130 626 461 0 0 600 0 0 0 0 0 Export Alarm Summary Data to the Windows Clipboard Export Delete Alarm Summary Data Date Warning Counts Alarm Counts Total Total Total Shift Parameter Low High Low High Warnings Alarms Count 11 05 1997 2 Totals Total Shot Time 0 Position P1 0 Delete Selected Range Export to Clipboard File Export Alarm Summary Data to the Windows Clipboard This function allows you to export the alarm summary d
131. ucer 10 4 1 Testing with a Voltmeter on the Sensor Converter Board Prior to applying power to the transducer assembly make sure that all power and signal connections are properly made to the external electronics using a good quality shielded cable This shielded cable will help to reduce noise interference on the output signal lines Although transducer testing 1 best accomplished with the use of an oscilloscope a standard voltmeter may also be used The most convenient place to test a transducer s signals 1s at the external electronics terminals rather than at the transducer s connector Use the following table to determine which terminals the transducer s signals are connected to on each type of printed circuit board Part Number Description Lead Input Trail Input DC Ground MVO 07014 Buffer Converter 1 3 1 4 1 2 49 07002 External Bd TB2 3 TB2 4 TB2 2 Using a Voltmeter To test the transducer s lead and trail signals using a voltmeter 1 Apply power to the transducer assembly 2 Hold the positive probe of the voltmeter on either the lead input terminal or the trail input terminal and the negative probe on the DC ground terminal of the external electronics 3 Next initiate rod motion As the rod is moved the voltmeter reading should stabilize at approximately 5 7 volts DC which is the average of the digital square wave signal Digital Square Wave Signal ds lt 0 0125 Pulse Width 12V OV 12V OV l
132. up set will appear in the Machine window Choose the Machine s and part s to be restored An ALL button is available if you choose to restore the entire backup set 6 If you choose one part to restore you will be given the opportunity to choose the machine number you are restoring to This will default to the same machine the part originally resided on but you may force the part to a different machine Note however that the machine settings will be restored along with the part 7 Select the Restore options left side of window by clicking the appropriate checkboxes An ALL button is available if you choose to restore all the data Note Only the data that was backed up can be restored For example if during the backup process you did not check the Shot Profiles option then this data cannot be restored by checking this option in the Restore Setups and Data window 8 Click the Begin button 64 5 3 1 3 Definitions Backup The process in which saves Machine and Part Data so that it may be archived and restored at a later time This data is saved into a compressed file zip Backup Options The following options are located in the Backup Setups and Data screen 1 Setups Saves Part Setup information to the backup file Should always be checked 2 Scrap Downtime Saves scrap data and downtime data to the backup file 3 Shot Profiles Saves the shot profile or shot trace to the backup file 4 Shot Parameters Saves the Sh
133. uring the shot A number of transducer types have already been defined for the system at Visi Trak Worldwide and are listed lt Please contact Visi Trak Worldwide if there are any problems concerns regarding the following When Setting up a new sensor click on the last Analog Sensor on the list Click on Edit then click on Create Analog Sensor Setup File 3 d _ Create Ins 09 Sensor Description Raw 4 0 Converter Value Y i Pres 1 5v 0 10000 PSI Pres 1 5v 0 5000 PSI Hus El arare ous Te Pres 1 5v 0 583 5 Bars nits Pres 1 5v 0 344 75 Bars 1 5v 0 1400 Transducer 1 0 Ranges Pres 0 0 500 PSI gt Test Calculator 0590 SState Temp sens Pres 0 10 0 10000 PSI Pres 0 10 0 1000 Note After creating a new analog sensor you MUST RESTART all the True Trak programs Not Used O to 5 Volts CMD Volts 10 Die Pres 0 10v 0 20K PSI Low High Die Pres 0 10v 0 1379 Volts Volts 0590 SState Temp sens 1 5 0 703 07 KG CM 2 L VOLTS YOLTS You should NOT do this when you are about to make a shot ES This will create an identical sensor that was highlighted on the list 36 Analog Sensor Setup File Edit Analog Sensor Description Pres 1 5v 0 10000 PSI CMD Volts 10 to 10 Pres 1 5v 0 5000 PSI Pres 1 5 0 689 5 Bars Pres 1 5 0 344 75 Bars 1 5v 0
134. uter to access a particular board each board has it s own IPaddress An Internet Protocol IP address is a numerical label that is assigned to devices participating in a computer network that uses the Internet Protocol for communication between its nodes The address is programed on the Fasttrak2 board If more than one board is installed then they will need to be addressed with different addresses 78 FasTrak2 is selected for new system Machines At This Computer When a new machine is created in Machine Setup the machine number is automatically entered in this window if only one Fas Trak board is being used then the values 1 for Board Number and 1 for Mux channel will be automatically assigned For other systems the operator will have to assign the machine to individual boards With multi board units you will need to be concerned with the board number and address that the machine signals are connected to the MUX channel will be 1 6 3 Fas Trak Board Monitor Used to view the current operation being performed by the Fas Trak Board F2 Set Dac File View Connect Help F3 Null Valve Board Address Comm Status Machine Part Monitor Status F4 Valve Test 1 192 158 254 99 Connected E20 VISITRAK Upload Complete F5 Test Alarms FB Status and Menu Terminal F8 Realtime Globals F10 Control Mods This program monitors the Fas Trak boards the computer as specified in the Monitor Setup W
135. ve Changes button 54 4 3 3 Save Shots Shot Skip Method In the following example the user wants to save 10 shots and then skip the next 20 to a maximum of 1000 shots 1 peo c ape Click Monitor on the Profile Screen menu Click Monitor Setup on the Monitor menu Select the machine and part that you want to edit Click the Dot alongside the Shot Skip label Enter 10 in the Acquire Count window Enter 20 in the Skip Shots window Enter 1000 in the Max Saved window Click on the Save Changes button 4 3 4 Save Shots Time Skip Method In the following example the user wants to save 5 shots every hour to a maximum of 1000 shots 1 p MIO Se ue Click Monitor on the Profile Screen menu Click Monitor Setup on the Monitor menu Select the machine and part that you want to edit Click the Dot alongside the Time Skip label Enter 5 in the Acquire Count window Enter 60 in the Skip Seconds window Enter 1000 in the Max Saved window Click on the Save Changes button 55 Visi Trak is Registered U S Trademark of Visi Trak Worldwide LLC Section 5 File 59 5 File Monitor Display Display Functions Production E File Choose Shots Choose Part Backup and Restore Clear Backup List File Add to Backup List F9 Export Parameter Data to the Windows Clipboard Export Alarm Summary Data to the Windows Clipboard Display Machine and Computer List sa
136. ve Shot As CSV File Set Total Stroke Length Text Editor Choose Language Passwords Restore Default Password Save Shot Y N Print Print Multiple Shots Minimize Exit Profile Main Screen The main screen of the plot program is shown above In normal hands off mode this screen will be set up as shown above with Live Shots displayed in the upper left denoting that new shots will automatically be displayed as they are completed The title of the plot shows the name of the die cast machine E20 the name of the part or die VISITRAK the shot number 49 and the date and time of the shot Choosing a Specific Profile If you wish to display an earlier shot or a shot from a different machine or part pull down the File menu and select Choose Shots as shown below The following dialog will appear allowing you to choose the machine and part that you wish to view If the Overlay is enabled under the Display Functions menu when you are in Time Based mode you will be able to select more than one shot to display Once you have selected a shot to view the button in the upper left of the screen changes to No real time updates will be displayed until you click on this changing it back to LIVE SHOT 60 Profile Main Screen E20 YISITRAK SHOT 49 Fri 07 21 2000 15 07 00 Click here to toggle real time updates on and off Appears when the cycle start signal is received from the machine at this computer 13 07 17 42
137. w it will be monitored The top of the screen is a list of the machines and a summary of the current settings 51 4 1 1 Upper Half of Screen Current Part Name M Post L T Impact Parameters Profiles Seconds Skip Acquire Max Skip Acquire Max Machines gu 01537965 Y Y 2 00 0 Shots 3333 3333 0 Shots 3333 9999 01537365 Y M 1 50 50 Shots 3 9999 0 Shots 0 N Alarm Monitoring Machine 1 will be monitored turned on Machine 2 will not The columns indicate Ma Machine Number Part Part currently setup to be monitored on that machine ALM Monitor alarms Y N MTR Which machines are being monitored indicated by Y N note on multiplexed systems more than one machine may be monitored Post Impact Seconds how long the shot will be monitored after the end of shot has been detected Parameters Profiles how the shot parameters and profiles are to be saved The details of this are explained below 4 1 1 Monitor A Different Part Method 1 Click Monitor on the Profile Screen menu 2 Click Monitor Setup on the Monitor menu 3 In the large upper window click on the machine you want to monitor 4 In the lower window click on the gt button to view list of available parts Select part 5 Click in the Monitor This Part box a tick will appear showing that this part is now being monitored 6 Ifrequired click on the Monitor Alarms box to turn on alarm monitoring a tick will appear 7 Enter a value for the
138. ximum pressure recorded 17 Impact Pressure to Peak PSI BAR The pressure recorded when the End of Shot Velocity EOSV has been detected and the monitoring changes from position based to time based Pressure on Profile 18 Intens Squeeze Distance IN MM The distance traveled by the plunger from the EOSV position intensification start to the final position recorded during monitoring Distance J on Profile 19 Sleeve Full Velocity IPS FPM CMPS MPS The plunger velocity measured at P1 Shot Sleeve Full Position P1 is shown on the Profile 20 Runner Full Velocity IPS FPM CMPS MPS The plunger velocity when the metal front is at the gate P2 Metal at Gate Position P2 is shown on the Profile 21 Avg Fill Velocity IPS FPM CMPS MPS The average plunger velocity measured between position P2 and the End of Shot Velocity EOSV position P3 Interval D on Profile 22 25 User Velocity Positions One Four IPS FPM CMPS MPS The velocity i e measured at the positions set on the Measure Velocity at these Positions on the Positions window in the Part Editor a total of 4 positions can be set The positions can also be marked on the trace as shown by the ticks on the bottom of the profile see Profile Marks 138 26 29 User Avg Vel Range One to Four IPS FPM CMPS MPS The average plunger velocity recorded between 2 set points entered by the user in Measure Average Velocity in this Range on the Positions Window i
139. ype the word of interest the list of topics will scroll to the matched word Closing Help Position the cursor anywhere on the screen except for the help window and click the left mouse button 1 Click x on the button 2 Select Exit from the File menu 1 6 About Details the version of software currently installed 19 Visi Trak is Registered U S Trademark of Visi Trak Worldwide LLC Section 2 Part Setup 23 2 Part Setup File Display Display Functions Production Help Part Setup Machine Setup Monitor Setup Real Time Machine List FasTrak Board Setup FasTrak Board Monitor SureTrak Control Interface Part Setup CE XI Create New Part Delete This Part Copy to Existing Parts Copy to Other Machines Calculator Machine Basic Setup Advanced Setup Parameters Positions Marks Channels SureTrak Control 3l Part 11160904 Distance Units Inches C Millimeters Centimeters 11330307 Velocity Units IPS C FPM CMPS C MPS 22 5 Total Stroke Lenath 85 Minimum Stroke Length fi 0 0 End of Shot Velocity Monitor This Part Save Changes Reload Saved Setup Print USED TO CONFIGURE THE PART SETUP CONSISTS OF 7 TABS Basic Part Setup Setup minimum data to monitor the part Advanced Part Setup Edit data to allow a number of parameters to be calculated Parameters Configure alarm limits warning limits define wires for sending out
140. zes or reduces a Window but does not close it Close Button Clicking this button will close a Window and terminate the program Menu Bar Located directly below the Title Bar of a Window The Menu Bar displays the names of any available menus within that Window Clicking a name will open up a menu Scroll Bar Windows that contain more information than can be displayed will usually have a Scroll Bar at the far right and or at the bottom To Scroll either click the directional arrows or drag the Bar with the mouse 10 Dialog Box Types Dialog Boxes require a user input of some kind There are several types shown on the picture of the previous page The True Trak Program uses all of the ones shown Understanding them is key to successfully using the program Drop Down List Box Command Buttons Scrolling List Box PetSeup 1171 ixi Create New Part Delete This Part Copy to Existing Parts Copy to Other Machines Machine MM Basic Setup Advanced Setup Parameters Positions Marks Channels SureTrak PPP Dialog Tabs 710 1174 Mark Sourte Description Color Line Type Label 805503 1 Calc Start Fast Shot None ima Position P1 C Vett NSDI Position P2 YELLOW el Position P3 GREEN Base N 801 33N CL VISITRAK el Range 1 Start Pos BLUE Vel Range 1 End BLACK WHITE Add Save Changes Reload juese 151

USER MANUAL - Visi-Trak

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