图案较正系统.doc

伊利公司液态奶事业部生产东北区域办公室
{0>DESIGN CORRECTION SYSTEM FOR TBA/19<}0{>TBA/19图案较正系统<0}

{0>Precorrection mode<}0{>预较正模式<0}

{0>*Allows paper tube “move upwards” in relation to the jaws approximate 10 to 20 mm each jaws stroke.<}0{>所有的纸管在每个夹爪冲程中相对向上移动10到20毫米。<0}
{0>*A certain number of packages are thrown away before the PLC starts its search for filling sector.<}0{>在PLC开始寻找灌注角度前要扔到一定数量的包。<0}
{0>*When register mark photocell pulse is found in this filling sector, the filling of product (“A” valve) is turned ON.<}0{>当条形码的电眼脉冲信号在灌注角度中被发现，灌装机的产品A阀被打开。<0}
{0>Regulating mode<}0{>调节模式<0}
{0>*When design error become less than +/- 8 mm, DCS19 program switch to regulating mode.<}0{>当较正错误少于正负8毫米时，DCS19程序进入调节模式。<0}
{0>*It tries to find the correct air cylinder position in one of the 3 possible position.<}0{>灌装机试图发现正确的气缸位置，这个位置有3种可能。<0}
{0>(both correction, both full paper feed and one correction one full paper feed)<}0{>（两个气缸都较正，两个气缸都全速供纸，一个气缸较正一个气缸全速供纸）<0}
{0>*Design system do not allow first 10 packs after filling “on” to drop into final folder even if error is +/- 1.5mm.<}0{>图案较正系统不允许头10包进入终端，即使较正错误少于正负1.5毫米。<0} {0>(check last 2 consecutive packs for +/-1.5 mm.)<}0{>（检查最后连续的两包在正负1.5毫米以内。）<0}
{0>*Design system allows another 25 packs in regulating mode to try to find design error +/-1.5mm<}0{>图案较正系统允许另外25包在调节模式去试图发现较正错误少于正负1.5毫米<0}

{0>*If +/-1.5mm could not achieved in 25 packs (after first 10 packs), filling turned off and is given only one more try in regulating mode again.<}0{>如果在25包内不能达到较正错误少于正负1.5毫米（在头10包以后），灌注关闭并只给一次机会尝试在调节模式。<0}

{0>Production<}0{>生产<0}
{0>*The mean of 2 packs design error used as an input to PID control algorithm <}0{>两包的较正错误被用作一个输入来进行PID控制计算<0}
{0>that will output a new values to minimise design error.<}0{>这个计算将输出一个新值来使较正错误减到最小。<0}

{0>*The mean of 2 consecutive packs design error are +/-1.5mm , design OK.<}0{>连续两包的较正错误在正负1.5毫米以内，较正成功。<0}
{0>*If design error more than +/-1.5mm but less than 20mm drop chute out of final folder.<}0{>如果较正错误大于正负1.5毫米而少于20毫米，机器将把滑槽退出终端。<0}

{0>*If photocell pulse missing for 4 consecutive packs, machine stop and drop to drying step.<}0{>如果电眼脉冲在4个连续的包丢失，机器将停止烘干步。<0}
{0>Function of DCS 19 program<}0{>DCS 19程序功能<0}
{0>Example:<}0{>举例：<0}
{0>When the photocell detected the register mark, <}0{>当电眼检测到条形码时，<0}
{0>DCS19 reads the machine encoder and converts into decimal number (example;72.95) <}0{>DCS19读取机器角度并把它们转换成十进制数（例如；72.95）<0}
{0>telling where the register mark is in relation to the jaw system.<}0{>这个数将告诉机器条形码相对夹爪系统的位置。<0}

{0>Calculated register mark angle (72.95) compared with the preferred design angle (example; 74.00).<}0{>计算过条形码角度(72.95)后还要与首选设计角度(例如；74.00)进行比较.<0}
{0>If MUPP set at –1.25.<}0{>如果 MUPP设定在－1.25.<0}
MUPP:Multi-Purpose Potentiometer:多用途电位器，在操作面板上，用于调整折痕位置。
{0>Design error ={[72.95-(74.00-1.25)] * 245 Repeat length} / 128 (no. of degreeper jaw)=(0.2 * 245) / 128=0.38mm<}0{>较正错误＝{[72.95-(74.00-1.25)]245重复长度}/128(每个夹爪的角度数)=(0.2*245)/128=0.38毫米<0}

{0>Basic Program Functions<}0{>基本程序功能<0}
{0>The DCS19 program for the TMCC is written in the C-language <}0{>TMCC卡的DCS19程序是用C语言写成。<0}
{0>and it is not possible to modify this without the proper knowledge and development tools <}0{>如果没有相关经验的人与开发工具的话它不可能被修改。<0}
{0>(this must be done in a technical development facility).<}0{>(它必须通过用专业开发工具来完成)<0}
The parameters that need to be changed (e.g. volume parameters) are controlled from the PLC.
参数如需要被修改（例如容量参数）则由PLC控制。

{Program flow:|程序流程：}

{At start-up or reset|在程序开始或复位时}
{(the TMCC may be reset manually by setting the SW1 switch on the front panel in position "0" for a few seconds, and then back to its previous position)|（TMCC卡可以手动复位，只需将面板前的SW1开关拨到0位保持一会儿，然后再将它拨到原来的位置即可。}
{the DCS19 program initiates all its internal variables|DCS19程序初始化所有的内部变量}
{and reads the volume parameters sent from the PLC.|并且从PLC那里读取容量数据。}
{After this first step the program enters an eternal loop,|在第一步之后程序就进入了一个永恒的循环，}
{i.e. it repeats the program over and over again.|也就是 它重复这个程序一遍又一遍。}
{This loop has the following basic functions:|这个循环有以下基本功能：}

{• Wait for a valid photocell reading of the register mark. |程序等待一个正确的由电眼读取的条形码。}
{This routine decodes the edges of the register mark
(and of the other part of the design as well) and for every edge (black to white, white to black)
it stores the photocell values in a shift register.|这个程序对条形码的边进行解码（其它部分的图案【这里指包材的印刷图案，图案中也有颜色、形状变化的情况，就像条形码的黑白相间的条纹一样。】也是如此）并且每个边（黑到白，白到黑，黑白条纹相邻的线就叫做边）的电眼读取值用一个移位寄存器来存储。}
{The shift register is a 26-bit single register
(compared to the first MultiStep routine that used two separate shift registers with 6 and 7 bits respectively, which in some cases could cause a false decoding).|这个移位寄存器是一个26位单位寄存器。
（容第一个多步程序相比，多步程序分别使用了两个单独的移位寄存器，一个是6位，一个是7位，在有些时候它能造成解码失败）。}
{This shift register is compared with a special pattern that corresponds to a correct register mark.|这个移位寄存器将同一个专用图案进行比较，这个图案相当于一个正确的条形码。 }{If they are equal a register mark has been detected and the program can proceed with its calculations.|如果它们相等就表示条形码已经被检测到了并且程序可以进行下一步的计算了。}

{• When the register mark has been detected the DCS19 program reads the machine angle encoder. |当检测到条形码后DCS19程序开始读取机器角度。}
{To get an acceptable accuracy of the machine angle
an interpolation is done by comparing the remaining time of the current angle (i.e. until the angle encoder changes to a new value) with the time for a complete angle.|为了得到精度可接受的机器角度，程序增加一个补充程序，它用当前角度的剩余时间（也就是 直到角度编码器改变到一个新值）与一个完整角度时间进行比较。 }{
This gives a decimal number (for example, 72.95) telling where the register mark is in relation to the machine jaw system.|然后程序给出一个十进制的数（例如，72.95），这个数来告诉程序条形码相对机器夹爪系统的位置。}
解释：增补程序
它是为了得到精确的机器角度（精确到小数点后两位，这是角度编码器等硬件达不到的精度。现在机器的角度编码器只能将一个圆周分为256（0～255，共256个八进制角度，如果按十进制等分，那么角度编码器改变一个角度相当于十进制的1.4度，360/256=1.4）等分，只能给机器提供八进制的整数）。具体的做法是用机器现在的角度到下一个角度改变的时间去除以一个角度的完整时间。
举例假设一个机器每小时生产7500包，那么一分钟生产125包，而凸轮转过一周机器就会生产2包，那么凸轮一周（角度编码器转动一周）的时间就是0.96秒，生产中角度编码器转过一个八进制角度的时间是0.96/256＝0.00375秒。
假设当电眼看到条形码时读到的机器角度是65度（八进制角度，下同），而这时凸轮已经转过了65度而没有到66度，又假设经过0.0025秒凸轮转到了66度，这样机器当时读到的角度其实是65＋（1－0.0025/0.00375）=65.33度。

• When the register mark has been detected the DCS19 program also sends the Register Mark
Photocell Pulse signal to the PLC. This signal is delayed a certain time from the actual register mark detection. The delay time depends of the current machine speed and corresponds to a distance on the paper tube. This distance is independent of volume settings.
The delay is a constant 32.7 mm in addition to a variable delay depending on the Design Adjustment Potentiometer position (±5 mm).

• The calculated register mark angle is now compared to the preferred design angle, i.e. the production angle set from the PLC offset by the Design Adjustment Potentiometer setting (for example, 74 - 1.25 = 72.75). The comparison gives the angle error and together with the repeat length it is possible to calculate the design error in millimetres for the current package (the example: 72.95 - 72.75 = 0.20; 0,20 * 245(repeat length) / 128(no of angle degrees per package) = 0.38 mm design error). The design error is positive if the register mark (the design) is too "high" in relation to the jaw system, and vice versa.
•
The design error is used as an input to the PID control algorithm. Actually, it is the mean design error of the two latest packages that are used, this giving a more smooth running system in case of different mechanical adjustments of the left and right side of the machine. The algorithm uses a quadratic P-part, which means that it has a faster response for larger design errors. Otherwise, it is a standard PID with integral and output range limitations. The P, I and D factors have been tested on filling machines to give a well working design control in both normal production and start/stop sequences.

• When the PID algorithm has calculated a new output value, ranging from 0 (precorrection), 1(minimal paper pull) to 255 (maximal paper pull), this is converted into an analogue signal for the bending roller and a digital setting of the air valves for the air cylinder controlling the folding flaps. The conversion is illustrated in the chapter "Output Signals".
• From the calculated design error the DCS19 program also decides whether it should accept the package or not. If the package is accepted the DesignOK signal to the PLC is set. The decision is based upon the following rules:
Design Error
Package Accepted
Design error of last package is less than ±1.5 mm
YES
Mean design error of last two packages is less than ±1.5 mm
YES
Otherwise
NO
Note: The window of ±1.5 mm is the Default value. It is possible to change by terminal (refer to
Chapter 13 for more details).
• The DCS19 program then start again to search for a new register mark.
Besides this main program flow the DCS19 program also checks if anything is sent from a terminal through the RS-232 serial interface. If so, it returns the appropriate answers to the terminal, refer to the "Terminal communication" chapter.
7. Other Program Functions
Besides the basic program functions described above the DCS19 program performs some other functions and decisions:
Precorrection vs. Regulating mode:
• The air cylinders and, consequently, the folding flaps can be set in five different positions, one
precorrection and four regulating positions. Two of the regulating positions are equal from the design
control's point of view, which practically means that there are three different regulating position:
1. Both sides: CORRECTION
2. Left: FULL PAPER FEED, Right: CORRECTION, or