1、 CONTAINER INSPECTION SYSTEMS CASE TAPTONE II INSTALLATION,OPERATION AND MAINTENANCE MANUAL M-404-024 Rev.J TapTone Container Inspection Systems 49 Edgerton Drive North Falmouth,Massachusetts 02556-2828 USA Phone:508-563-5920 or 1-800-423-4044 Fax:508-564-9945 Note:Contents subject to change without
2、 notice.M-404-024 Table of Contents TapTone Division of Benthos,Inc.i Table of Contents Section Title Page 1.0 System Introduction.1 1.1 Introduction.1 1.2 Theory of Operation.2 1.3 System Specifications.3 2.0 Safety Precautions.5 2.1 General Safety Precautions.5 2.2 Specific Cautions and Warnings.5
3、 3.0 Installation Instructions.7 3.1 Off-Line System.7 3.1.1 Enclosure Assembly.7 3.1.2 Conveyor Assembly.7 3.1.3 Case Rejector Assembly.7 3.1.4 Roller Bed Reject Conveyor.8 3.2 On-Line System.8 3.2.1 Enclosure Assembly.8 3.2.2 Transducer Bridge Assembly.8 3.2.3 Junction Box Assembly.10 3.2.4 Shaft
4、Encoder Assembly.10 3.3 System Wiring.11 4.0 Initial Mechanical Set-up.13 4.1 Transducer Bridge and Rails.13 4.2 Transducer Heads.14 4.3 Spray Marker System(Optional).15 4.4 High Speed Pusher Assembly(Optional).15 4.5 Shaft Encoder Set-up.16 5.0 System Operating Procedures.18 5.1 System Shut-Down Pr
5、ocedure.18 5.2 Cleaning Requirements and Precautions.18 5.3 Controls.18 5.4 Displays and Indicators.22 5.5 System Programmable Parameters.23 5.5.1 System Run Screen.25 5.5.2 Change Product Menu.26 5.5.3 Password Screen.26 5.5.4 Counters Menu.26 5.5.5 Histogram Menu.27 5.5.6 Main Menu 1 of 2.28 5.5.7
6、 Parameters Menu.29 5.5.8 DSP Parameters Menu.32 5.5.9 Digital Filter Menu.37 5.5.10 Rejector/Spray Menu.39 5.5.11 System Values Screens.41 5.5.12 Main Menu 2 of 2.44 M-404-024 Table of Contents TapTone Division of Benthos,Inc.ii Table of Contents Section Title Page 5.5.13 Bridge Parameters Menu.44
7、5.5.14 Password Parameters Menu.46 5.5.15 Optional Input/Output Menu.47 5.5.16 Case Merit Values Screen.49 5.6 Initial Parameter Set-up.49 6.0 Product Changeover Procedures.53 6.1 Parameter Changeover.53 6.2 RS-232/RS-485 Remote Parameter Changeover.53 6.3 Mechanical Changeover.53 7.0 System Mainten
8、ance Procedures.54 7.1 Inspection.54 7.2 Lubrication.54 7.3 Spray Marker Head Repair Procedure.55 8.0 System Troubleshooting Guide.56 8.1 System Wiring Diagrams.56 8.1.1 Control Enclosure Door Wiring.56 8.1.2 Control Enclosure Chassis Wiring.57 8.1.3 Transducer Junction Box Wiring.58 8.1.4 Spray Mar
9、ker Valve Plumbing and Wiring.59 8.1.5 Inspection Conveyor Motor and Junction Box Wiring.60 8.1.6 High Speed Pusher and Roller Bed Conveyor Wiring.61 8.1.7 PLC Board Input/Output Module Wiring.62 8.1.8 RS-232 Port Wiring.63 8.1.9 RS-485 Port Wiring.63 8.1.10 Control Board I/O Jumper Settings Schemat
10、ic.64 8.1.11 Case TapTone/Case Tracker Interconnection Wiring.66 8.2 Troubleshooting Guide.67 8.3 Software Error Messages and Codes.71 9.0 Warranty.72 10.0 Parts Replacement.73 10.1 Recommended Spare Parts List.73 10.2 Parts List.73 10.2.1 Control Enclosure.74 10.2.2 Transducer Bridge Assembly.75 10
11、.2.3 Junction Box Assembly.76 10.2.4 Shaft Encoder Assembly.77 10.2.5 Spray Marker Bridge Assembly.78 10.2.6 Spray Marker Head Assembly.79 10.2.7 Case Rejector Assembly.80 10.2.8 Inspection Conveyor Assembly.80 10.3 Ordering Procedure.81 M-404-024 List of Figures TapTone Division of Benthos,Inc.iii
12、List of Figures Figure Description Page 1-1 Overall Case TapTone II Inspection System.1 2-1 Warning Labels.6 3-1 Enclosure and Stand.7 3-2 Control Enclosure Tripod Base Outline.8 3-3 Transducer Bridge Top View.9 3-4 Transducer Bridge Front View.9 3-5 Junction Box Assembly.10 3-6 Shaft Encoder Dimens
13、ions for Mounting.11 3-7 AC Control Switch.12 4-1 Off-Line Inspection Conveyor and Transducer Bridge Top View.13 4-2 Off-Line Inspection Conveyor and Transducer Bridge Front View.14 4-3 Case Parameters(ETC)and(CTC).14 4-4 Transducer Head Scale.15 4-5 High Speed Pusher System.16 5-1 Control Keypad.19
14、 5-2 Control Board Reset Button.19 5-3 DSP Board Jumper Settings.20 5-4 AC Control Switch.20 5-5 PLC Board Layout.21 5-6 Control Enclosure Layout.22 5-7 Reject Limits.29 5-8 LED Screen.30 5-9 Case Size Heads and Rows.31 5-10 Auto Track Reject Limits.31 5-11 Low/High Range Cutoff and Reject Limits.32
15、 5-12 Gate Time Signal.33 5-13 Gate Delay Signal.33 5-14 Amplitude Threshold Signal.34 5-15 Peak Value Spectrum.35 5-16 Spectral Power Spectrum.35 5-17 Tone Strength Signal.36 5-18 Digital Filter Diagram.37 5-19 Digital Filter with Control OFF.38 5-20 Digital Filter with Control ON.38 5-21 Case Meas
16、urement(ETC)and(CTC).46 7-1 Filter/Regulator/Lubricator Assembly.54 8-1 Control Board on Enclosure Door.56 8-2 Chassis Wiring of Enclosure.57 8-3 Transducer Junction Box Wiring.58 8-4 Spray Marker Valve Wiring.59 8-5 Spray Marker System Plumbing.59 M-404-024 List of Figures TapTone Division of Benth
17、os,Inc.iv List of Figures Figure Description Page 8-6 Inspection Conveyor Wiring.60 8-7 Rejector Roller Bed Conveyor and High Speed Pusher Wiring.61 8-8 PLC Board Input/Output Module Wiring.62 8-9 RS-232 Port Wiring.63 8-10 RS-485 Port Wiring.63 8-11 Control Board I/O Jumper Settings Schematic.64 8-
18、12 Control Board Optional I/O Jumper Settings.65 8-13 Case TapTone/Case Tracker Interconnection Wiring.66 10-1 Control Enclosure Parts List.74 10-2 Transducer Bridge Parts List.75 10-3 Junction Box Components.76 10-4 Shaft Encoder Parts List.77 10-5 Spray Marker Parts List.78 10-6 Spray Marker Head
19、Assembly Parts List.79 M-404-024 List of Appendices TapTone Division of Benthos,Inc.v List of Appendices Appendix Description Page A Fill-In Parameter List for All 8 Levels.82 B Sample Parameters for 12oz Beer Can.83 C Sample Parameters for 12oz Soda Can.84 D Sample Parameters for Glass Pop-Button.8
20、5 E Sample Parameters for Steel Vacuum Can.86 F RS-232 Port Commands.87 G Parameter List Command.89 H Histogram Sample Output.90 I Counters Sample Output.91 M-404-024 Chapter 1:System Introduction TapTone Division of Benthos,Inc.1 1.0 System Introduction 1.1 Introduction The Case TapTone II pressure
21、/vacuum monitoring system is used to test the integrity of a wide variety of food and beverage products.This user friendly system is designed for non-contact,non-destructive,100%automatic container inspection through a sealed case.The primary function of the Case TapTone II is to inspect containers
22、in closed cases for loss of internal pressure or vacuum levels.Any case with a container or containers that fall outside the user set limits will be rejected.In many applications,the Case TapTone II will detect defects other than low pressure or vacuum.Some examples are gross under or over fills,mis
23、sing cans,dented cans,missing lids,popped safety buttons,cocked caps or broken bottles.There are two configurations to choose from.The first style is an on-line system which mounts to an existing conveyor usually located after the case packer system.This system is compact and easy to integrate to an
24、 existing conveyor.The rejection system may be provided by us or integrated to an existing system.The second style is a self-standing system with a six-foot inspection conveyor.A typical application for this system is in the warehouse area.This system may have wheels for easy movement to remote area
25、s of the warehouse.There are optional infeed and exit conveyors for ease of de-palletizing and palletizing.An optional case rejection system with high speed pusher rejector is also available for this system.Overall View of Case TapTone II Inspection System Figure 1-1 M-404-024 Chapter 1:System Intro
26、duction TapTone Division of Benthos,Inc.2 1.2 Theory of Operation The Case TapTone II is a non-contact automatic inspection system for detecting defective pressure or vacuum containers in sealed cases.The Case TapTone II system works by applying a tap to the top of each container inside the sealed c
27、ase then listening to the tone of each container.The system determines whether the container is acceptable or faulty based on user-set parameters.A fiber optic photo beam is used to trigger the inspection process.A shaft encoder is used to track conveyor speed for accurate determination of the conta
28、iner location in the sealed case.The tap is produced by a large electromagnetic pulse generated by each transducer head which excites the container lid.The lid vibrates at a natural resonant frequency based on internal pressure or vacuum.Specific parameters for each type of container are stored in t
29、he microprocessor to achieve the best tone response for inspection purposes.The resultant tone signal is sensed by a microphone in each transducer head,sampled by an analog to digital converter,and stored in memory for processing.A frequency spectrum of the signal is produced using real-time Digital
30、 Signal Processing(DSP)techniques.The resulting frequencies are expressed in frequency bins ranging from 0 to 511 which corresponds to 0 Hz to 11.49 kHz range.The spectral characteristics of the lid indicate the pressure or vacuum in the container.The Fast Fourier Transform(FFT)peak bin value is com
31、pared to user set reject limits for unacceptable container pressure or vacuum.All peak values outside the high/low pass band are rejected.The resultant spectrum is then processed to find the peak frequency for each container.The spectrum can be modified using a digital band pass filter and frequency
32、 cut-off limits.These tools allow the user to extract desired frequency components while diminishing the effects of unwanted noise.The rejection of any container in the case will cause the entire case to be rejected.This is performed by the optional pneumatic case pusher rejector system.A 24V DC out
33、put is supplied with adjustable time delay and pulse width to trigger the rejector.There is an optional spray marker system to indicate the position of each rejected container in the case.The location is marked with a spray dot of water/dye solution.The LCD display,LED bank and reject lamp all provi
34、de information to the operator as the system inspects cases.The user interface is accessed by a membrane keypad and RS-232/RS-485 interface port for sending commands or collecting data.A PLC process monitoring option provides outputs for System Status,Rejector Status,Alarm Status,and Reject Pulse Ou
35、tput.Inputs control Rejector Status and three product type selection inputs.The optional software package CASEPLOT is developed to interface with the system through the RS-232/RS-485 port.This package provides complete control of all system parameters M-404-024 Chapter 1:System Introduction TapTone
36、Division of Benthos,Inc.3 through the computer.Statistical data with histograms and counter values is available on request or at user set timed intervals.M-404-024 Chapter 1:System Introduction TapTone Division of Benthos,Inc.4 1.3 System Specifications On-Line Configuration:Maximum Belt Speed:300 f
37、eet per minute(customer provided)Off-Line Configuration:Conveyor Belt Speeds:88 or 122 feet per minute Case Configuration:6 x 10 containers max.Container Capacity:3000 containers per minute(case dependent)Control System Power Specs:120 VAC/240 VAC,44-85 Hz,1-phase,12.5 amps,1500 watts Inspection Con
38、veyor:120 VAC/240 VAC,60 Hz,1-phase,12.5 amps,1500 watts,50 Hz optional Rejector System Power Specs:120 VAC/240 VAC,60 Hz,1-phase,12.5 amps,1500 watts,50Hz optional Air Supply Requirements:Spray Marker:60 psi at 2.0 CFM Rejector:60 psi at 10.0 CFM Control Enclosure Specs:Pedestal stand with tripod b
39、ase Construction:Stainless steel,NEMA-4X Wash down:High pressure water Keypad:Water proof membrane,tactile feedback LCD Display:Graphic 160 x128 pixel LED Display:Ten bright red Photo beam:Banner fiber optic,high speed Reject Signal:24 VDC,1 amp,variable pulse width and delay time Reject Lamp:24 VDC
40、 yellow lens,1/2 sec pulse per reject PLC Board Option:Outputs solid state 140 VAC 3.5 amp std.or solid state 60 VDC 3.5 amp opt.Output 0-System Status Output 1-Rejector Status Output 2-Alarm Status Output 3-Reject Pulse Four inputs solid state 140 VAC standard or solid state 3-30 VDC optional Input
41、 0-External Rejector Control Input 1-Product Type Input 1 Input 2-Product Type Input 2 Input 3-Product Type Input 3 M-404-024 Chapter 1:System Introduction TapTone Division of Benthos,Inc.5 Transducer Bridge Specs:Adjustable height with indicator Case Height:10.25 inches(260 mm)max Construction:ABS
42、plastic,hard coat anodized aluminum Wash down:High pressure water Shaft Encoder Specs:2540 pulses per revolution Construction:Hard coat anodized aluminum Wash down:High pressure water Inspection Conveyor:Dual speed rubber seamless belt Belt Speed:88 or 122 feet per minute Construction:Painted steel
43、Wash down:No wash down allowed Rails:Quick change,no tools required Case Rejector System:Dual Speed roller bed Roller Speed:90 or 128 feet per minute Pusher Speed:80 cases per minute(size dependent)Construction:Painted and galvanized steel Wash down:No wash down allowed Communications Port:RS-232 Po
44、rt to 100 feet RS-485 Port to 4000 feet Notice:Specifications subject to change without notice at any time.M-404-024 Chapter 2:Safety Precautions TapTone Division of Benthos,Inc.6 2.0 Safety Precautions 2.1 General Safety Precautions A.Read all installation and operating material before powering the
45、 system.B.Make sure all safety guards and shields are properly installed before operating the system.2.2 Specific Cautions and Warnings A.Check the AC power label for proper power requirements.Set the selector switch on each power board(C-401-12).Failure to do so will cause damage to the system.See
46、Figure 3-7.B.DANGER!-High voltage components are used inside the enclosure during operation.Do not operate the system with the door open.Turn power OFF before opening the door for any reason.C.Keep hands clear of the inspection bridge and case rejector ram whenever the system is in operation.D.Keep
47、all water and moisture out of the control enclosure and junction box by closing the doors securely at all times.E.Do not disconnect any electrical connections or boards while the system power is on.Damage to electrical components may occur.F.Before connecting an external device(printer,PC,or termina
48、l),power down both the Case TapTone II and external device.After power is off,connect device then turn power on.G.The internal electronics of this equipment are sensitive to electrostatic discharge(ESD)and proper precautions must be adhered to when handling any electrical components of the system.M-
49、404-024 Chapter 2:Safety Precautions TapTone Division of Benthos,Inc.7 H.The following warning and safety labels are mounted in specific locations throughout the system:Warning Labels Figure 2-1 M-404-024 Chapter 3:Installation Instructions TapTone Division of Benthos,Inc.8 3.0 Installation Instruct
50、ions 3.1 Off-Line System The Off-Line Case TapTone II system consists of a 6-foot trough bed conveyor,transducer bridge assembly,and an electronics enclosure.Figures 3-1 and 3-2 show the layout and foot print for each component in a typical installation.This system may be bolted directly to the floo