Basic e DART Setup and Use 2010 4 1

1 - Basic eDART™

eDART System™ Application Training

Rev. 4.0

2 - Basic eDART™

Table of Contents

Introduction………………………………………………………………………………..3Interfacing the eDART™ with your Machine….……………….….…………………9Machine Sensors…………………………………………………………....…………...20Mold Pressure Sensors…………………………………...……………….…………...25Flush Mount Sensors…………………………………………………….……………...33Sensor Placement Strategy……………………………...……….…………………….40Starting up the eDART™……………………………………….……………………….44

Navigating the eDART™ Software…………………………………………………….55Alarm Settings and Part Diverter………………………………………………………73Troubleshooting…………………………………………...…….……………………….84Security……………………………………………………………………………………..94Using Saved eDART™ Data……………………………………...……………………..99

3 - Basic eDART™

RJG Insight System®

eDART™ Cavity Pressure

Sensors Machine Sensors Machine Timing

Inputs Machine Transfer

and Sorting Outputs

4 - Basic eDART™

Benefits

Process Monitoring – Complete process history for each part

Part Containment – Quality to the Customer

Cavity Pressure Control – Process Consistency

Process Setup Match – Verify the right process setup is running

Can you tell which are the good parts?

With RJG Insight System®, you can.

5 - Basic eDART™

Monitoring Points

Cavity Pressure Injection Pressure Stroke Position/Velocity Barrel and Mold Temperatures

6 - Basic eDART™

Insight System® Layout

7 - Basic eDART™

eDART™ Components

Essentially a Computer

Data Storage/Memory

Keyboard/Mouse ports

Video output Ethernet / Modem Insight Software

8 - Basic eDART™

eDART™ Connections Power: 120VAC Lynx Ports: Sensors and Machine Interface

Modules Serial (COM) Port: Remote Access, Touch

Screens Phone Line: Dial-In Support Ethernet (NIC): Network

9 - Basic eDART™

Interfacing the eDART™ with Your Machine

10 - Basic eDART™

Mounting Guidelines for eDART™

Mount eDART™ to Non-Vibrating Surface – (Temperature not to exceed 122°F/50° C)

Position eDART™ with connectors facing down (Reduce the chance of fluids getting in the ports)

Keep eDART™ and associated cables away from high voltage and static (e.g. Material feed lines, high voltages, motors, solenoids, etc.)

11 - Basic eDART™

Machine Interface Modules

Module FunctionID7-D-SEQ Seven sequence digital input module (universal voltages).

Gets machine StateIA1-D-VI 0-10V or 4-20mA isolated analog input module for signals

from machineOA1-D-V 0-10V isolated analog output, feeds signals to machine

controller for transferOR2-D Dual relay output, Contact rating – 2A at 24V or 0.5A at

120VAC for control, sorting, or lights.

12 - Basic eDART™

Sequence ModuleID7-D-SEQ

35mm DIN rail mountable input module

Machine signals connect to terminal 1 through 7, Common to 8

Operates at 24VDC

13 - Basic eDART™

Sequence ModuleID7-D-SEQ (24VDC or 120VAC)

Terminal - Importance

Comes On Goes Off Purpose

1. INJ Forward (2) Injection Starts

End of hold Search for peaks, hold pressure. (Required for control)

2. 1st Stage (5) Inj. Starts Inj. goes to hold

Creates internal inj. Forward, pack, & in 2-Stage “Fill”

3. Screw Run (1) Screw motor Starts

Stops Stroke direction, Zero, Material variation information (Required for control)

4. Mold Clamped (3)

Mold clamped to pressure

Mold cracks Accurate cycle time, integration limit (Reset Piezo Adapter & UMPI)

5. Mold Opening (4)

Mold opening

Mold fully open

Pinched part detection (Resets Piezo Adapter & UMPI)

6. Manual (6) Machine in manual

In Full/Semi Automatic mode

Prevents parts counts and data storage while in this mode

7. Shuttle Position (7)

Start of cyclePosition 2

Start of cyclePosition 1

Detects mold position in 2-position shuttle molding

8. Input CommonMold Closing (8) Mold begins

to closeMold clamps up

Cycle time with mold opening (Resets Piezo Adapter and UMPI)

Mold Open (9) Mold fully open

Mold begins to close

Cycle time and integration limit (Resets Piezo Adapter and UMPI)

Second Stage (10) Start of hold

End of hold Creates internal injection forward and pack

Fill (11) Inj. Moves forward after decompress point

Inj. speed changes from fast fill (V1) to slow pack (V2).

Measuring of material viscosity (Rare machine signal)

14 - Basic eDART™

Analog InputIA1-D-VI (0-10v)

Connection Function Wire Color

Terminal 1 N/A -Terminal 2 N/A -Terminal 3 Jumper 1 -Terminal 4 Jumper 1 -Terminal 5 Jumper 2 -Terminal 6 Jumper 2 -Terminal 7 0V BlackTerminal 8 0-10V RedJ1, J2 Communi-

cations-

DIN rail mountable 0-10V/4-20mA signal Input Module

Monitors signals i.e. Electric Machine Injection Pressure

Requires user input at initial setup

15 - Basic eDART™

Dual Relay Output Module OR2-D (Relay Module with 2 Dry Contact)

Terminal

Function Wire Color

1 N/A -2 N.C. CR2 -3 COM CR2 Black4 N.O. CR2 Brown5 N/A -6 N.C. CR1 -7 COM CR1 Black8 N.O. CR1 Green

J1, J2 Communications

-

35 mm DIN rail mountable module

Has 2 independently configurable dry contact outputs

Each set of relay contacts has spare fuse at bottom

16 - Basic eDART™

Relay Output Module OR2-D (Dry Contact Relay)

Part Containment Configure one or both of OR2-D contacts to be setup for part containment

Define contacts as a 'Good Control' output or a 'Reject Control’ output depending on the application

Robot Interface

17 - Basic eDART™

Relay Output Module OR2-D (Dry Contact Relay)

Machine Transfer Implement RJG, Inc. DECOUPLED MOLDINGSM by

transferring from velocity to pack At setup page define one side of the

module contact as Velocity to Pressure

18 - Basic eDART™

Indicator Light TreeLT3-1/2-(24VDC or 120VAC)

Machine mountable 3 colors (red, yellow, green) light-tree that visually indicates if process is running within limits.

The lights are controlled based on process limits set in Alarm Settings

19 - Basic eDART™

Analog OutputOA1-D-VI (0-10V/0-20mV)

Terminal

Function Wire Color

1 N/A -2 N/A -3 0-10V COM Black4 0-10V +SIG Red5 N/A -6 N/A -7 0-20mV COM Black

8 0-20mV +SIG

Red

J1, J2 Communi-cations

-

DIN rail mountable module that outputs 0-10V/4-20mA signals

Outputs an analog signal i.e. Machine Transfer Option

Requires user input for initial setup

20 - Basic eDART™

Machine Sensors

21 - Basic eDART™

Screw Position/VelocityLE-R-30

Monitors Stroke/Position, Volume

Standard Travel 30”

22 - Basic eDART™

Mounting the LE-R-30

23 - Basic eDART™

Plastic Pressure for Injection

The eDART™ uses the intensification Ratio (Ri) of the machine and a direct hydraulic measurement to display the Injection Pressure in actual plastic pressure at the nozzle.

This allows the data to be machine independent.

This Module gives us: Fill Pressure Viscosity Back Pressure Hold Pressure

Electric machines are always in plastic pressure

24 - Basic eDART™

Water based coolant differential pressure sensor between two NPT fittings.

Delta Pressure SensorLS-DP-100

25 - Basic eDART™

Mold Pressure Sensors

26 - Basic eDART™

Behind the Ejector Pin SensorsButton Style (Strain Gauge and Piezoelectric)

Installed behind an ejector pin Pin transfers force to sensor Sensor transfers pressure readings to

eDART™

27 - Basic eDART™

Indirect Mold Pressure

Sensors that sit behind a pin read pressure indirectly. To get the correct cavity pressure the force exerted on the pin is divided by the area of the pin

The pin size must be input in the eDART™

Pressure = Force / Area

28 - Basic eDART™

Strain Gauge: Button Style

Force Range (Overload Capacity) LS-B-127-50........................................................................50 lb (75 lb) LS-B-127-125...............................................................125 lb (187.5 lb) LS-B-127-500..................................................................500 lb (750 lb) LS-B-127-2000............................................................2000 lb (3000 lb) LS-B-159-4000............................................................4000 lb (6000 lb)M aximum Temperature - Sensor............................................250°F [121°C]M aximum Temperature - Sensor (-H suffix)...........................425°F [218°C]M aximum Temperature - Connector........................................140°F [60°C]Temp. Comp.of Zero & Sensitivity Accuracy.............2% F.S./100°F [38°C]Accuracy (LS-B-127)......................................................(50 lb.) .75% FS,(125, 500, 2000 lb.) .5% FS, (4000 lb.) .75% FSRepeatability........................................................................0.1% of OutputStd. Connector....................................................M icrostyle DC Receptacle

29 - Basic eDART™

Choosing the Correct Model

Key element – expected pressure vs. pin area

Pin size references the surface that contacts plastic part

How to select a sensor:1. RJG recommends using more than 10% of the usable

range for an individual sensor: i.e. Expected plastic psi should generate more than 50# for a 500# sensor.

2. RJG will base most recommendations on the 10,000 psi column: i.e. 10,000 psi on a 6.0mm pin generates 438#'s of force. Use a 2000# sensor.

Note: RJG also has a selection of flush mount sensors for applications

where an under-the-pin sensor is not practical.

Refer to chart on next page

30 - Basic eDART™

31 - Basic eDART™

Installation Issues Upside down Shallow pocket

(Pre-Load) Narrow pocket Pinched cables Uneven pocket

bottom Rounded corners

in pocket Web Resource:http://www.rjginc.com/resources/choosin

g_the_right_sensor

http://www.rjginc.com/resources/choosin

32 - Basic eDART™

Piezoelectric: Button Style

Uses Quartz Element Outputs Charge When Pressed 9211, 9204

33 - Basic eDART™

Flush Mount SensorsLynx Flush MountPiezoelectric

34 - Basic eDART™

Flush Mount SensorDirect Mold Pressure

Sensor becomes part of cavity

Plastic applies pressure to sensor

The sensor transfers the pressure readings to eDART™

All RJG flush Direct sensors 30K PSI Maximum Rating

35 - Basic eDART™

Flush Mount Sensor Installation

RJG, Inc.

www.rjginc.com

231.947.3111

Model: LS-F-40-20K

SN: XX284XXXXX

L4M in. Cable Bend 17,5 m m

25,4 m m

5,6 m m

8,7 m m

L1L2

L3

T132

Drill & Tap for8-32 x 1.75" Screws

4 Holes

D3

D2

D1 H7

0,3 m m M in. 0,4 m m M ax.60° Angle Relief

36 - Basic eDART™

Choosing the Correct ModelFlush Mount Sensor Installation

Consideration How large a witness mark allowed Good to 30,000psi in cavity

Sensor Sensor Diameter LengthLP-F-25-30K 2.5mm (0.0984”) 12”, 24”,

36”, 48”LP-F-40-30K 4.0mm (0.1574”) 12”, 24”,

36”, 48”6157, 6159 2.5 mm/ 4.0 mm (cables sold

separately)

37 - Basic eDART™

Installation IssuesFlush Mount Sensor Installation

Don’t over-tighten nut

Ensure bores are centered

Avoid pinching cables

Keep connectors clean

38 - Basic eDART™

Sensor AdaptorSG/LX1-S

Medium between Analogsensors and eDART™

Needs setup

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Mold IdentifierID/LX1-S

Identifies un-instrumented molds

Does not measure mold pressure

40 - Basic eDART™

Sensor Placement Strategy

Conventional Runner Hot Runner/Hot Drop

41 - Basic eDART™

Area of Influence

Incorrect

Correct

Control sensors should be located in the “Area of Influence”.

Correct

42 - Basic eDART™

Conventional Runner Multi-Cavity Mold

Best Approach End of Cavity Sensor in each Cavity

Guarantee Quality in each cavity

Good Approach End of Cavity sensor in last cavity to fill

Use last cavity to fill to predict quality in other cavities

How would you instrument this tool?If you could only have 1 sensor?If you could have 2 sensors?

43 - Basic eDART™

Hot Runner/Hot Drop Multi-Cavity Mold

Choose a location at the end of fill in every cavity due to “Multi-Process Disease”

Example

Click on Picture to run animation

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Starting Up the eDART™

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Setting up eDART™

Attach Mold Sensors and Machine Interface Modules via Lynx Ports

Apply Power to eDART™

46 - Basic eDART™

Job Setup Screen First Screen to Appear

Top of the window indicates sensors were found

Enter Mold Number (Material and Cavities are Optional)

Enter Plant, Cell and Machine name Choose Accept when finished

47 - Basic eDART™

Job Setup Screen Key Concepts

Descriptive name with Standardized naming system

If the material and cavities never change, enter the Mold Level only. This will allow the use of automatic job start tools.

48 - Basic eDART™

Sensor LocationsDisplays all Sensors Attached

Serial#: SignalUnique serial number with available contacts

Senor Type:Kind of sensor

Sensor Location:Where it goes

Identifier:Uniquely Identifies

SetupAnalog input/output, sensor adapter

Click Accept when finished

No Duplicate Entries

49 - Basic eDART™

Sensor LocationsSensors by Type

ID7-D-Seq (Sequence Module Inputs): Connect up to 7 machine signals Watch under the Value column for green lights to come

on Name signals Not Used if they are wrong or not

connected.

50 - Basic eDART™

Sensor LocationsSensors by Type

OR2-D: Two sets of dry contacts per unit Each set can be setup for different functions

51 - Basic eDART™

Ejector Pin Sizes

Choose/Enter Ejector Pin(s) Size Click Match Pins (if all pin sizes are equal)

Choose Accept when finished

52 - Basic eDART™

Machine Size

Enter Screw Diameter and Intensification Ratio (Cylinder Diameter will be calculated)

or Enter Screw and Cylinder Diameters

(Intensification Ratio will be calculated) Choose Accept when finished

53 - Basic eDART™

Zero Injection Pressure

Click “Zero Now” to zero injection pressure manually

Click “Zero On Signal” for it to be done by the machine

54 - Basic eDART™

Viewing Your Process“Standard” View Screens

Cycle Graph Summary Graph Cycle Values Statistics

55 - Basic eDART™

Navigating the eDART™ Software

Standard Software Views Cycle Graph Use Summary Graph Use Using Summary Statistics Setting Alarms Configuring the Part Diverter Shutting the System Down

56 - Basic eDART™

Saved ViewsChoose or Save a Standard View

Arrange how tools are displayed on the monitor

Views can be stored or deleted

57 - Basic eDART™

Cycle GraphShows Real Time Cycle

DataInjection Pressure

Shot VolumeCavity PressureCurves

Machine Sequences

58 - Basic eDART™

Adding CurvesCycle Graph

To add curve choose “Graph Controls” then “Add a Curve”

Choose the Type and Location

Choose “Apply” to add more curves or “Apply and Close” to close window

59 - Basic eDART™

Sequence SettingsSetting the Machine Fill Value

Make a “Fill Only” shot and click this button.

Click this button to set the zero volume point before decompress (if screw run unavailable)

60 - Basic eDART™

Set Screw BottomAllows the system to display and set

alarms on a cushion value

Drive the screw all the way to the bottom and click the Bottom the screw button

61 - Basic eDART™

Zoom/UnzoomCycle Graph

Choose “Graph Controls”; “Zoom”

Choose a Portion of the Cycle Graph to Zoom in on

May also change times on Cycle Graph

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Auto scale Cycle Graph

Brings curves to a scale Automatically adjusts curves to fit on the Cycle Graph

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Template ControlsCycle Graph

Matching Template equals the same plastic part Match Process from machine to machine Match Process from tool makers/sister companies

Select Template to apply existing template

Save TemplateTo create a template from the current process

Manage TemplateTo move, copy, delete existing template

64 - Basic eDART™

Cycle Values Shows Actual Values of the Cycle Peaks Integrals Sequence Times

Comparative Template Values

65 - Basic eDART™

Adding/Removing ValuesCycle Values

Select “Add a Value” Choose Value Types and Locations

Choose “Apply” or “Apply and Close”

To Remove: Select the value to be removed

Choose “Remove Value(s)”

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Summary GraphShows Data Over Time

Collects historical data of a process

Good for detecting variations over time

Add Alarm/Warning limitsAlarm Limits

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Statistics

Average Maximum Minimum Std. Deviation Expected Variation CPK PPK, etc.

Gives Statistics of Process

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Adding/Removing a ValueStatisticsTo add

Choose “Add A Value”

Select Type of stats

Choose Type and Locations

To Remove Highlight thevalue(s)

Choose Remove Value (s)

69 - Basic eDART™

Documentation of Process Changes Hold Pressure Fill Speed Screw RPM Material Change

Put cursor overthe note to view

Adding NotesSummary Graph

70 - Basic eDART™

Setting AlarmsSummary Graph

You may set Alarms/Warnings from summary graph

Choose the curve and select “Add New Alarm” or “Add New Warning”

71 - Basic eDART™

Alarm Setting Entry and Part Diverter Settings

Using the Alarm Settings Tool Configuring the Part Diverter

72 - Basic eDART™

Alarm Wizard sets the Upper/Lower limits to 6σ for Alarms and 3σ for Warnings over last 20 shots

Setting AlarmsSummary Graph

73 - Basic eDART™

Go to Alarms Settings page to view values

Alarm levels can be manually entered

Setting AlarmsAlarm Level Entry

74 - Basic eDART™

Activating Alarm Outputs

eDART™ is set to calculate the integral at the end of screw Run by default Good if NO Cavity

Pressure is present at the end of Screw Run

If Cavity Pressure IS present at the end of Screw Run the integral area will vary with screw run time variations Noisy Summary

Data Hard to set good

alarm

75 - Basic eDART™

Part Diverter ControlsSorting good parts from the bad

SortDiverter control is

enabled Don't Sort

Diverter control is disabled

GoodValue is within alarm

limits Susp

Both Good andReject output are OFF

Rej.The value crossed alarm

limit Diverter Settings

Configuring diverter functionalities

76 - Basic eDART™

Part Diverter ControlsTesting the Diverter Output

Manual Diverter Test Manually test

diverter/flipper direction

Press the “Good” button, did the robot or diverter go to the right position.

Press the “Reject” button, did the robot or diverter go to the right position.

77 - Basic eDART™

Part Diverter ControlsSet diverter operating times

Hold Diverter Position Until Alarm Changes

Change direction only if the alarm is different

Hold Diverter Position for a timeAdd needed time for thepart to reach proper box

78 - Basic eDART™

Part Diverter ControlsSet diverter disabled operation

Set Part Diverter Operation when the Part Diverter has been disabled (Don’t Sort Pressed).

Consider the parts reject if the Part Diverter is disabled.

79 - Basic eDART™

Part Diverter ControlsOptional Part Diverter Functions

Set the number of parts to Reject After the Machine has been Down

Set the number of cycles to delay the Part Diverter Action

Allow the eDART™ to reject pinched parts (Mold Opening or Mold Clamped signals are required.

80 - Basic eDART™

Stop Job Always stop job when mold is removed

Go to “Main Menu” - “Stop Job”

You will receive a warning screen, confirm job stop

Always stop job when mold is removed!!

81 - Basic eDART™

System ShutdownPowering Off System

Click on “QNX” menu and choose “Shutdown System”

At warning screen, confirm shutdown

Message appears saying you may power down system

Pull power cord or fuse

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Troubleshooting

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TroubleshootingRaw Data Viewer

Select from the Main Menu View status of ports and sensors Diagnose when failures occur

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TroubleshootingRaw Data Viewer, Data Details

Check details on sensor calibration The current offset can indicate installation issues. The initial offset is ideal.

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TroubleshootingRaw Data Viewer, Data Details

Check Lynx ports for communication stability and statistics

The short streams and CTS timeouts should remain at zero after selecting Reset.

86 - Basic eDART™

Sequence SettingsInjection Forward Tab

ON: Indicates how accurately the eDART™ is able to do the OFF to ON switch of Injection Forward sequence signal

OFF: Indicates how accurately the eDART™ is able to do the ON to OFF switch of Injection Forward sequence signal

Each bar block is one level. A blank bar is 0 and a full bar 5.

87 - Basic eDART™

Sequence Lights

Shows the actual hard

wired sequence signals

Shows the sequence signals as

calculated by eDART™

88 - Basic eDART™

Sequence SettingsWorking with inaccurate machine sequence

inputs

When one or more machine sequences are lost or are reset.

Enter a time after injection forward goes off to wait before looking for a rising edge again.

Check this box if your system has inaccurate sequence signals coming from the Sequence Module (ID7-D-SEQ).

89 - Basic eDART™

TroubleshootingLynx Cables

Bad cables will give communication problems between eDART™ and sensors

Swap out cable(s) to see if problem persists

Keep connectors clean Keep away from high traffic areas Keep away from material lines, pumps, and motors

Avoid pinch points

90 - Basic eDART™

TroubleshootingMouse

If mouse is not working, check to make sure it is connected to the proper input

Verify that the a good connection is being made

Choose QNX Menu, Reset Keyboard and Mouse - (you must use keyboard)

Swap out the mouse

91 - Basic eDART™

TroubleshootingKeyboard

If keyboard is not working, check to make sure it is connected to the proper input

Verify that a good connection is being made

Choose QNX Menu, Reset Keyboard and Mouse

Swap out the keyboard

92 - Basic eDART™

Security SettingsSecuring Your System

Apply authorization requirements

Track changes made in the tools you have secured

93 - Basic eDART™

Security SettingsAdministrative Log In

Select Log In from the Main Menu

Type the administrative password

94 - Basic eDART™

Security SettingsSecurity Maintenance

Choose Security from the Main Menu Create/Rename/Delete User and Group Accounts

Assign User(s) to Group Set general security settings

95 - Basic eDART™

Security SettingsGeneral Security Settings

Enable/Disable security Set security parameters Select Functions for securing

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Secured Functions Setting Permission

Lists all tools that can be secured

Check the tool and its sub-feature to secure

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Using Saved eDART™ Data

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Extracting eDART™ Data

Connect your PC or Laptop to the eDART™ with a Cross Over Ethernet cable

Choose eDART™ Data Extractor from the RJG Insight Folder

Select the Mold, Desired Dates and choose Get Data

99 - Basic eDART™

Extracting eDART™ Data

Select the Mold, Desired Dates Choose Get Data

100 - Basic eDART™

Review Data in Analyzer

Select the Mold, Desired Dates Double Click the Summary Graph Icon



Select the desired date and time with the mouse

Click the Get Cycle button on the Summary Graph



Move one cycle forward or backward using the black arrows.

Replay data automatically by using the green button.

Overlay cycles using the OV button.


Exporting Data into Excel ®

Select the desired date and time span with the mouse

Click the Export button on the Summary Graph



Add the desired data with the ADD button



Select Export on the Summary Export Tool

Manipulate the data in Excel

Basic e DART Setup and Use 2010 4 1

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Transcript of Basic e DART Setup and Use 2010 4 1