USER MANUAL - KVL Comp Kft.
Contents
1. 2 V PADDING til ea CONS l l een 2 VL DIE Amer ee 3 Mill Preca ii to AS ee 3 CHAPTER 5 ON ER VE Ve cars ee 5 1 1 Short introduction of pokayoke svstems ss seessenenenzznnnnnzznnnnznzznnnenzznntnnzzzntnenzznenenzznnnenaa 5 1 2 The location of the identification device in the pokayoke 5 CHAPTER i A ee ee ee 6 TECHMIE ALA J een ee re 6 ZL ee ee ea Sn 6 232 EIS ae ee ee ee ee 7 223 Ethernet NEWOLK are een 7 CHAPTER nennen 8 INSTALLATION AND 8 3 1 Installing the controller at the workplace 8 3 2 Connecting to mains and Ethernet network occccoocccnccnocnnnonanonnnnanonnnnnnonnnonaronnnnanonnnnnnoos 9 CHAPTER ee ee ee E 10 SETUP AND OPERATION zen 10 4 1 Switching on the controller ee 10 2 G ee ee 10 4 3 Devices attached to the controller oooonccnnnncnnconnocnnnnnnnnnnnonanonnnnnnnnoonnnarnnnnnnnnnnnnnnos 11 4 3 1 WIRELESS BARCODE 2 skon ci 11 45902 BARCODE READE tidad dias 12 4 3 3 MOBY U RFID ante a su ee 12 44 eo 13 AAAMOOO antenati A 13 4 4 2 Without REID antenna uud 13 4 4 3 RFID device with antenna and spare part checking function 14 4 4 4 RFID device without2. the bar code was not approppriate message to the operator the server did not find this car in the database 4 4 2 WITHOUT RFID ANTENNA The RFID according to the message from the server decides what working mode he has to operate on further In that case that the server sends that information that the car is al lready identified from the main line datas it sends a work done sign back to the server If the server does not get the information about the car from the main line the RFID indi cates to the operator that he has to identify the car with the bar code reader The identifi cation process described above 13 KVL RFIDO1 02 14 4 4 3 RFID DEVICE WITH ANTENNA AND SPARE PART CHECKING FUNCTION TVP The RFID devices primary role is to identify the car arriving to the workplace After this to check if the spare parts are the correct ones according to the data what he received from the server The RFID according to the message from the server starts to scan the datas from the tag After the succesfull scanning it sends the scanned data to the server The server makes search in the database according to this data After the successful search it indicates in a message that he found the car in the database The server sends a message to the device about the needed identification numbers of the spare parts what needs to be built in The device compares the spare part numbers to the saved data and if it finds a match it indicates a
3. cessary for further work The operator with the barcode reader scans the barcode of the bodywork and the device sends it to the server The server makes a search in the data base if it finds it than it informs the device in a message about the successful hit found After the device received the data it indicates to the operator that spare part identifica tion is necessary When the operator scanned all the spare part numbers with the barcode reader the device indicates that the work is done and sends a work done message to the server In case that the RFID is not ready to work according to INI2 and INI3 messages it gives sound and light signals showing the actual state of the work to the employee IDENTIFICATION DEVICE WITH ETHERNET NETWORK 4 4 5 RFID DEVICE WITHOUT ANTENNA ONLY WITH SPARE PART CHECKING FUNCTION The RFID devices only role is to check the spare part numbers what has to be built in After the INI1 signal received from the server the device is waiting for the data what is neces sary for the work If the device received this data it indicates to the operator that spare part identification is needed When the operator scanned all the spare part numbers with the barcode reader the de vice indicates that the work is done and sends a work done message to the server In case that the RFID is not ready to work according to INI2 and INI3 messages it gives sound and light signals showing the actual state of the work to
4. ETHERNET PATCH CABLE DATASHEET HI PUBLICATION HISTORY The number of the publication is also indicated on the cover of the publication NUMBER OF PUBLICATION KVL1143 EN 01 Date of Publication No of Publication Chapter Revised content 12 2010 KVLI143 EN 01 ________ Istedition KVL RFIDO1 02 IV WARRANTY AND LIMITATIONS OF LIABILITY WARRANTY KVL COMP s exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year or other period if specified from date of sale by KVL COMP LIMITATIONS OF LIABILITY KVL COMP shall not be responsible for special indirect or consequential damages loss of profits or commercial loss in any way connected with the products whether such claim is based on contract warranty negligence or strict liability In no event shall the responsibility of KVL COMP for any act exceed the individual price of the product on which liability is asserted In no event shall KVL COMP be responsible for warranty repair or other claims regarding the products unless KVL COMP s analysis confirms that the products were properly han dled stored installed and maintained and not subject to contamination abuse misuse or inappropriate modification or repair V APPLICATION CONSIDERATIONS SUITABILITY FOR USE The following are some examples of applications for which particular attention must be given This is not intended to be an exhaustive li
5. KVL RFIDO1 02 IDENTIFICATION DEVICE WITH ETHERNET NETWORK 3 2 CONNECTING TO MAINS AND ETHERNET NETWORK The sockets are located on the back of the controller Mains 230 V AC socket Glass tube fuse 5 20 glass tube 230 V 2A SLOW On off switch Ethernet socket MOBY U socket For connecting to the mains circuit we recommend the type KVL POW cable Ensure that the controller is switched off when you connect the cable A WARNING Risk of electric shock when using wrong or damaged mains connector cable A WARNING Risk of fire and human injury when using damaged repaired fuses or fuses not of the appropriate type For connecting to the Ethernet network we recommend the type KVL ETN cable KVL RFIDO1 02 CHAPTER 4 SETUP AND OPERATION 4 1 SWITCHING ON THE CONTROLLER The device is turned on with the switch located next to the power supply connector After switching off the device always wait at least 5 seconds before switching it on again 4 2 CONTROLS On the Pick to light controllers front cover a white light is installed what shows if the power is on 10 IDENTIFICATION DEVICE WITH ETHERNET NETWORK 1 POWER ON INDICATOR LIGHT If the controller is on the POWER labeled light glows 2 SIGNAL POST GREEN LAMP Glows if the worker successfully picked up all the necessary part 3 SIGNAL POST YELLOW LAMP In case of server error it glows with the red 4 one 4 SIGNAL
6. POST RED LAMP In case of error it glows 5 SIGNAL POST AUDIBLE SIGNAL In case of controling error and wrong spare part picking up audible signal can be heard 6 ACKNOWLEDGING ERRORS Errors are acknowledged using the E7 key switch 4 3 DEVICES ATTACHED TO THE CONTROLLER 4 3 1 WIRELESS BARCODE READER 11 KVL RFIDO1 02 The role of the wireless bar code reader e In RFID identification mode if there is a MOBY U reader failure the sequence number kennummer scanning from the worksheet nostrategy e In RFID identification mode when there s no data in the tag the sequence number kennummer scanning from the worksheet nostrategy e n spare part identification mode it reads the spare part numbers 4 3 2 BARCODE READER In case the cordless barcode reader is malfunctioning use this device to scan barcodes from worksheets Nostrategy 4 3 3 MOBY U RFID ANTENNA Performs the data scanning from the body part 12 IDENTIFICATION DEVICE WITH ETHERNET NETWORK 4 4 OPERATION The identification device is identifiing the bodywork spare parts as follows 1 Bodywork identification with RFID reader MOBY U and wired bar code reader nostrategy 2 Bodywork identification with wired bar code reader nostrategy 3 Spare part identification TVP with wireless and wired bar code reader nostrategy 4 Bodywork identification with RFID reader MOBY U and wired bar code reader nostrategy spare part i
7. the employee 4 5 LIGHT AND TONE SIGNALS During operation the RFID controller gives audible and visual warnings for the operator informs him about the operating regime and possible errors RFID or barcode reading res OK Barcode reading is necessary RFID reading error ON BUNK OFF 2X Barcode reading is necessary 1X HORN OFF x OFF RFID or barcode reading result OK OFF on OFF OFF x 15 KVL RFIDO1 02 4 6 DAILY CHECKS BEFORE WORK Daily routine check of control cabinet Cabinet door is closed Proper ventilation and protection of the inner parts are only provided with closed cabinet door Touching the inner parts can cause electric shock Via the open door dust can penetrate the cabinet The accumulating dust de creases cooling efficiency and leads to a higher probability of failure A WARNING In the following cases switch off the controlbox disconnect network cable and call a service technician immediately The network cable or its connector is damaged or worn Liquids penetrated the controlbox The controlbox was exposed to rain or other forms of water The controlbox fell or its case is damaged The operation of the controlbox is unstable or the controlbox is malfunc tioning The controlbox emits unusual noise smoke or unpleasant smell 16 KVL COMP s r o Komensk ho 35 94301 Sturovo SLOVAKIA Tel 00 36 33 501 616 Fax 00 36 33 501 6
8. the following problems has emerged and would like to develop a solution Frequently occurring errors in production processes Products must be called back due to installing parts of wrong type High scrap costs caused by selecting wrong part Workers often forget to tighten the screws fixing the part Workers forget to install one or more parts and this mistake is noticed too late The pokayoke systems of KVL COMP aid the effective troubleshooting of these errors KVL COMP 2010 All rights reserved It is forbidden to reproduce or store this document or part of it in any data retrieval system or transfer it in any form in any way mechanically electronically photocopying recording or with any other technique without prior written permis sion from KVL COMP We do no take patent responsibility for the information disclosed here Also as KVL COMP is constantly striving to improve its high quality products the information included in this guide can change without notice During the creation of this guide we try to be as accurate as possible but KVL COMP does not take responsibility for the possible errors or omissions Also KVL COMP does not take any responsibility for the possible damages resulting from using this guide IDENTIFICATION DEVICE WITH ETHERNET NETWORK CONTENTS About this Manual een 1 1 Related ei ee ee 1 PUDE CUON ee ee 1 IV Warranty and Limitations of Liability
9. 15 www kvicomp eu info kvlcomp eu KVL COMP Vez rl stechnikai H 2500 Esztergom Nagy Sandor Jozsef utca 3 HUNGARY Tel 00 36 33 501 616 Fax 00 36 33 501 615 www kvicomp eu info kvlcomp eu
10. ANCE DATA Performance data given in this manual is provided as a guide for the user in determining suitability and does not constitute a warranty It may represent the result of KVL COMP s test conditions and the users must correlate it to actual application requirements ERRORS AND OMISSIONS The information in this manual has been carefully checked and is believed to be accurate however no responsibility is assumed for clerical typographical or proofreading errors or omissions Vil PRECAUTIONS This section provides general precautions for using the related devices The information contained in this section is important for the safe and reliable applica tion of product You must read this section and understand the information contained before attempting to set up or operate a product INTENDED AUDIENCE This manual is intended for the following personnel workers trained to the specific task working on the assembly stations and on the assembly line operating the device work group leaders professionals responsible for the installation setup and maintenance of the device KVL RFIDO1 02 GENERAL PRECAUTIONS The user must operate the product according to the performance specifications described in the operation manuals Before using the product under conditions which are not described in the manual or ap plying the product to other systems machines and equipment that may have a serious in fluence on lives and p
11. KVL1143 EN 01 KVL RFIDO1 02 IDENTIFICATION DEVICE WITH ETHERNET NETWORK USER MANUAL KVL RFIDO1 02 USER MANUAL IDENTIFICATION DEVICE WITH ETHERNET NETWORK Notice The following conventions are used to indicate and classify precautions in this manual Always heed the information provided with them Failure to heed precautions can result in injury to people or damage to property A DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Additionally there may be severe prop erty damage A WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Additionally there may be severe prop erty damage A CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury or property damage Trademarks Windows is a registered trademark of Microsoft Corporation in the United States and oth er countries The other brand and product names are trademarks or registered trademarks of their re spective owners Introduction We design and manufacture our devices with the feedback from the enterprises of the in dustry and their specific needs in mind Our pokayoke systems elaborated this way are robust and due to the sophisticated solutions applied in them they provide a long main tenance free lifecycle These devices are recommended for those firms where one of
12. The occuring errors can be acknowledged with key switches in the VW groups case E7 key switches The controllers operation and the error messages are displayed on the light column The light column gives sound and light green yellow red signals KVL RFIDO1 02 CHAPTER 2 TECHNICAL DATA 2 1 DIMENSIONS The KVL RFIDO1 02 controller is installed in a plastic case Dimensions of the controller box 250 160 150 mm Colour of the controller box Grey RAL 7032 2 2 ELECTRICAL DATA Supply voltage Current drain Operating range Operating temperature Operating humidity Storage temperature Storage humidity Mains circuit connection Fuse Recommended mains connector cable IDENTIFICATION DEVICE WITH ETHERNET NETWORK 230 V AC 50 Hz 2A 100 240 V 48 62 Hz 5 40 C 20 90 RH non condensing 20 70 C 10 95 RH non condensing IEC standard connector with fuse and switch 5 20 glass tube 230 V 10 A SLOW KVL POW 2 3 ETHERNET NETWORK The controller can be connected to standard 10 100 Ethernet network The industrial Ethernet socket is of type VARIOSUB RJ45 The recommended Ethernet cable is of type KVL ETN KVL RFIDO1 02 CHAPTER 3 INSTALLATION AND WIRING 3 1 INSTALLING THE CONTROLLER AT THE WORKPLACE The control box wil be installed on TRILOGIQ shelf system The plastic clamps what is necessary for the installation is fixed to the back cover of the control box Accesory
13. als The description of operation provides information for the workers working with the pokayoke system 1 1 SHORT INTRODUCTION OF POKAYOKE SYSTEMS The meaning of the Japanese words Poka Yoke in free translation z Poka random unintentional error mistake fault Yoke elimination prevention Meaning mistake free error free work workstation technology process development in order to avoid human errors The aim of pokayoke is the full scale prevention of product defects waste avoidance minimization of quality control costs to provide error free working conditions and work To sum up pokayoke is a system that assists manufacturing and assembling that helps and simultaneously controls the workers Using pokayoke effectively improves waste avoidance The KVL RFID 01 02 is part of the Ethernet network based pokayoke system developed by KVL COMP 1 2 THE LOCATION OF THE IDENTIFICATION DEVICE IN THE POKAYOKE SYSTEM The identification device is identifiing the bodywork spare parts as follows 1 Bodywork identification with RFID reader MOBY U and wired bar code reader nostrategy 2 Bodywork identification with wired bar code reader nostrategy 3 Spare part identification TVP with wireless and wired bar code reader nostrategy 4 Bodywork identification with RFID reader MOBY U and wired bar code reader nostrategy spare part identification TVP with wired and wireless bar code rea der nostrategy
14. antenna with spare part cheking function TVP 14 4 4 5 RFID device without antenna only with spare part checking 15 des Liehbana tone siena ii een non 15 4 6 Daily checks before Work e a a 16 KVL RFIDO1 02 IDENTIFICATION DEVICE WITH ETHERNET NETWORK Read and Understand this Manual Please read and understand this manual before using the product Please consult your KVL COMP representative if you have any questions or comments I ABOUT THIS MANUAL This guide explains the installation and operation of the product Before installing and using the product read this guide carefully and be sure to understand its contents Also read and follow the safety information described in the next chapter The chapter titled Precautions contains general safety instructions of using the product and the related devices Chapter 1 Introduces the product and its structural units Chapter 2 Explains the structure of the product Chapter 3 Explains the installation of the product the wiring of the power supply and the I O lines and also the functional testing of the product Chapter 4 Explains the setup and operation of the product II RELATED GUIDES The following guides give information on the related devices You can find the necessary information in the following documents Title of Publication KVLLLAA MAINTENANCE MANUAL KVL1001 POWER CABLE DATASHEET KVL1002
15. dentification TVP with wired and wireless bar code rea der nostrategy The occuring errors can be acknowledged with key switches in the VW groups case E7 key switches The controllers operation and the error messages are displayed on the light column The light column gives sound and light green yellow red signals 4 4 1 WITH RFID ANTENNA The installed RFID devices primary role is to identify the incoming car According to the message from the server it starts to scan the data from the tag After the successful scanning it sends the data to the server The server based on the data makes a search in the database After the successful search the server indicates a messa ge that it found the car in the database After this the RFID turns on the green light on the light column and sends a Work done message to the server In case that the RFID is not ready to work according to INI2 and INI3 messages it gives sound and light signals showing the actual state of the work to the employee In case that the RFID can not scan the data from the tag the device automatically indicates to the operator that he has to identify the incoming car with a bar code reader for the interest of further work The scanned bar code data the RFID sends tot he server According to this data the server searches for the car it sends a successful or unsucsessful search meggase to the RFID Based on the con tent of the message the RFID indicates a work done or
16. roperty if used improperly consult your KVL COMP representative Make sure that the ratings and performance characteristics of the product are sufficient for the systems machines and equipment This manual provides information for setup and operating the product Be sure to read this manual before attempting to use the product and keep this manual close at hand for reference during operation A WARNING It is extremely important that a product be used for the specified pur purpose and under the specified conditions especially in applications that can directly or indirectly affect human life You must consult with your KVL COMP representative before applying a product to the above mentioned applications SAFETY PRECAUTIONS A CAUTION When power is ON or has just been turned OFF do not touch the power supply I O terminals or the surrounding areas A CAUTION Secure the AC power supply line to the terminal block with a 0 5N m of torgue Loosening the screw may result in a fire or malfunction APPLICATION PRECAUTIONS A CAUTION On modifying the program always ensure that switching to MONITOR or RUN mode does not lead to unexpected effects IDENTIFICATION DEVICE WITH ETHERNET NETWORK CHAPTER 1 OVERVIEW This guide explains the installation wiring and setup of the KVL RFIDO1 02Ethernet net work controller and describes its operation The installation wiring and setup of the prod uct must be accomplished by experienced profession
17. st of all possible uses of the products nor is it intended to imply that the uses listed may be suitable for the products Outdoor use uses involving potential chemical contamination or electrical interfe rence or conditions or uses not described in this manual Installations subject to separate industry or government regulations Systems machines and equipment that could present a risk to life or property Please know and observe all prohibitions of use applicable to the products PROGRAMMABLE PRODUCTS KVL COMP shall not be responsible for the user s programming of a programmable prod uct or any consequence thereof IDENTIFICATION DEVICE WITH ETHERNET NETWORK VI DISCLAIMERS CHANGE IN SPECIFICATIONS Product specifications and accessories may be changed at any time based on improvements and other reasons It is our practice to change model numbers when published ratings or features are changed or when significant construction changes are made However some specifica tions of the products may be changed without any notice When in doubt special model numbers may be assigned to fix or establish key specifications for your application on your request Please consult with your KVL COMP representative at any time to confirm actual specifications of purchased products DIMENSIONS AND WEIGHTS Dimensions and weights are nominal and are not to be used for manufacturing purposes even when tolerances are shown PERFORM
18. successful reading message to the operator In case that the read in spare part number is not between the saved data it indicates as an incorrect reading When the operator built in all the spare parts what he checked with the bar code reader the device sends a work done message to the server and the green light glows If it is more than one spare part from the same kind what needs to be built in the operator needs to scan the barcode from the spare part as many times as many spare parts are needed In case that the RFID is not ready to work according to INI2 and INI3 messages it gives sound and light signals showing the actual state of the work to the employee 4 4 4 RFID DEVICE WITHOUT ANTENNA WITH SPARE PART CHEKING FUNCTION TVP The RFID devices primary role is to check the spare part numbers what has to be built in and to identify the car arriving to the workplace The RFID according to the message what he receives from the server decides what operating mode he has to work on further In that case when the server sends a message that the incoming car is allredy identified it is waiting for the data needed for the further operation After receiving the data it indicates to the operator to scan the barcode number with the barcode reader what was built in If the server sends a message to the device that there is no information about the incom ing car than the device indicates to the operator that the identification of the car is ne
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