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SICK MQCS Operating instructions

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OPERATING INSTRUCTIONS
MQCS
Modular Quality Control System
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Subject to change without notice
Product described
Product name: MQCS
Document identification
Title: MQCS operating instructions
Part number 8024015
Manufacturer
SICK AG
Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany
Legal notes
This work is protected by copyright. The associated rights are reserved by SICK AG.
Reproduction of this document or parts of this document is only permissible within
the limits of the legal provisions of copyright law. Any modification, abridgment, or
translation of this document is prohibited without the express written permission of
SICK AG.
The trademarks mentioned in this document are the property of their respective
owners.
© SICK. All rights reserved
Original documents
This document is an original document from SICK AG.
CONTENTS
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Contents
1 About this document ........................................................................................................ 6
1.1 Limitation of liability ............................................................................................. 6
1.2 Purpose of this document .................................................................................... 6
1.3 Target groups........................................................................................................ 6
1.4 Further information .............................................................................................. 7
1.5 Other relevant technical documentation/information ....................................... 7
1.6 Document conventions ........................................................................................ 7
2 Important safety notes ..................................................................................................... 8
2.1 Safety conventions ............................................................................................... 8
2.2 Supplementary safety note .................................................................................. 8
2.3 Requirements for the qualification of personnel................................................ 8
2.4 Intended use ......................................................................................................... 9
2.5 RoHS directive ...................................................................................................... 9
2.6 Safety notes ....................................................................................................... 10
3 System description ........................................................................................................ 11
3.1 Scope of delivery ............................................................................................... 11
3.2 System components.......................................................................................... 13
3.2.1 Cabinet ............................................................................................... 14
3.2.2 TDC-E control and evaluation unit ..................................................... 15
3.2.3 Flexi Soft safety controller ................................................................. 17
3.2.4 Integrated screen ............................................................................... 18
3.2.5 Photoelectric retro-reflective sensor ................................................. 18
3.2.6 Image-based code reader (optional) ................................................. 20
3.2.7 Signal lamp with horn (optional) ....................................................... 22
3.3 Operating principle ............................................................................................ 23
3.3.1 Components and process .................................................................. 23
3.3.2 Code matching ................................................................................... 25
3.3.3 Counting ............................................................................................. 27
3.4 Integration into the existing infrastructure ...................................................... 30
4 Mounting ........................................................................................................................ 31
4.1 General requirements ....................................................................................... 31
4.1.1 Location of use ................................................................................... 31
4.1.2 Conveyor system/objects .................................................................. 32
4.2 Mounting the code reader ................................................................................ 33
4.3 Mounting the photoelectric retro-reflective sensor ......................................... 35
5 Electrical installation .................................................................................................... 36
5.1 Connection overview ......................................................................................... 37
5.2 Connecting the cabinet to the voltage supply ................................................. 39
5.3 Connecting the photoelectric retro-reflective sensor ...................................... 40
5.4 Connecting the code reader ............................................................................. 41
5.5 Using the digital outputs of the Flexi Soft ........................................................ 42
5.6 Connecting the signal lamp with horn.............................................................. 43
5.7 Connecting the customer interface .................................................................. 44
CONTENTS
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6 Configuring the system..................................................................................................45
6.1 Starting up the MQCS ........................................................................................45
6.2 Connecting the configuration PC to the MQCS ................................................46
6.3 Configuring the IP address of the sensors in SOPAS .......................................47
6.3.1 Installing SOPAS .................................................................................47
6.3.2 Assigning IP addresses .......................................................................48
6.4 Configuring MQCS using TEMS Manager .........................................................52
6.4.1 Starting TEMS Manager on the configuration PC .............................52
6.4.2 Importing the standard configuration ................................................53
6.4.3 The user-interface of the live view .....................................................55
6.4.4 Switching to editing mode ..................................................................57
6.4.5 Configuring the reading station details .............................................59
6.4.6 Adjusting the system properties of the code reader .........................60
6.4.7 Configuring the counting function .....................................................62
6.4.8 Configuring the digital interfaces of the TDC-E .................................63
6.4.9 Backup and restore settings ..............................................................64
6.4.10 FTP data transfer settings ..................................................................65
6.4.11 Maximum number of error images ....................................................66
6.4.12 Defining plug-ins .................................................................................67
6.4.13 Configuring in TEMS Manager............................................................68
6.4.14 Saving the TEMS configuration ..........................................................69
6.5 Configuring the customer interface in the TDC-E Device Manager .................70
6.5.1 Start the TDC-E Device Manager .......................................................70
6.5.2 The configuration interface ................................................................70
6.5.3 Adjusting Ethernet interface for data output ....................................71
6.6 Configuring the Flexi Soft safety controller .......................................................72
6.6.1 Establishing a connection with the configuration PC .......................72
6.6.2 Installing Flexi Soft Designer ..............................................................73
6.6.3 Importing the configuration file ..........................................................74
6.6.4 Editing the standard parameters .......................................................75
6.6.5 Transfer the configuration to the controller ......................................80
6.6.6 Verifying and saving the configuration ..............................................82
7 Operation .........................................................................................................................84
7.1 Working with the Viewer ....................................................................................84
7.1.1 The user interface ...............................................................................84
7.1.2 Switching user .....................................................................................85
7.2 Configuring the scanners for use ......................................................................86
7.2.1 Selecting the scanner .........................................................................86
7.2.2 Setting the scan characteristics of the code reader .........................86
7.3 Configuring code matching ................................................................................90
7.3.1 Setting the reference code for each scanner....................................90
7.3.2 Working with recipes ..........................................................................91
7.4 Evaluating counting results ...............................................................................94
7.4.1 Displaying a list of counting results ...................................................94
7.4.2 Exporting count results .......................................................................96
7.5 Checking the scanning performance of the code readers ........................... 100
7.5.1 Live view and statistics .................................................................... 100
7.5.2 Error analysis using error images ................................................... 101
7.6 Evaluating sensor events in groups ............................................................... 102
7.7 Backing up/restoring data ............................................................................. 105
7.8 Switching to TEMS Manager .......................................................................... 106
CONTENTS
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8 Maintenance and repair ............................................................................................. 107
8.1 Visual inspection ............................................................................................. 107
8.2 Maintaining the scanners ............................................................................... 107
8.2.1 Cleaning the scanners ..................................................................... 107
8.2.2 Replacing scanners .......................................................................... 108
8.3 Replacing TDC-E .............................................................................................. 109
8.4 Replacing a photoelectric sensor ................................................................... 110
8.5 Cleaning the screen ........................................................................................ 111
9 Fault diagnosis in TEMS Manager ............................................................................. 112
9.1 Warning and fault visualization ...................................................................... 112
9.2 Analyzing the error situation in TEMS Manager ............................................ 113
9.3 Detecting system errors using log files .......................................................... 114
10 Annex ............................................................................................................................ 115
10.1 Technical data ................................................................................................. 115
10.2 Dimensional drawings for the cabinet ........................................................... 117
10.3 Users and authorizations ................................................................................ 119
10.3.1 TDC-E Device Manager .................................................................... 119
10.3.2 TEMS Manager / Viewer .................................................................. 120
11 Disposal ........................................................................................................................ 124
1 ABOUT THIS DOCUMENT
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1 About this document
This document contains information that is important during the life cycle of the MQCS
quality control system
▸
The document must be made available to all those who work with the system.
▸
Read through the document carefully and ensure that you have full understood the
content before working with the system.
1.1 Limitation of liability
Applicable standards and regulations, the latest technological developments, and
our many years of knowledge and experience have all been taken into account when
assembling the data and information contained in this document.
The manufacturer accepts no liability for damage caused by:
• Failure to observe this document.
• Non-compliance with notes and regulations.
• Unauthorized mounting and installation.
• Unauthorized technical and other changes.
• Use of unauthorized spare parts, wear and tear parts, and accessories.
• Unauthorized changes, adjustments and/or manipulations of software.
The actual scope of delivery may differ from the features and illustrations shown here
where special variants are involved, if optional extras have been ordered, or as a result
of the latest technical changes.
1.2 Purpose of this document
The document is designed to give technical personnel instructions on the safe mounting,
parameterization, electrical installation, commissioning, operation, and maintenance of
the MQCS.
1.3 Target groups
This document is intended for qualified persons who perform the following tasks with the
MQCS
• Installation
• Commissioning
• Operating
• Repairing
ABOUT THIS DOCUMENT 1
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1.4 Further information
Special local conditions
The local laws, regulations, technical rules and internal company operating instructions
at the usage site must be observed.
Storage of documents
This document and other relevant technical documentation/information:
• Must be kept available for reference.
• Must be handed on to new operating entities/new specialist personnel.
1.5 Other relevant technical documentation/information
• Operating instructions for the following system components:
Component Manufacturer
TDC-E (TELEMATIC DATA COLLECTOR) operating
instructions
SICK
LECTOR620 image-based code reader SICK
Lector63x / Lector64x / Lector65x operating
instructions
SICK
Flexi Soft modular safety controller hardware
operating instructions
SICK
Flexi Soft Designer configuration software operating
instructions
SICK
Tab. 1: Other relevant technical documentation/information
1.6 Document conventions
▸
Instructions.
Instructions complete.
LED icons describe the status of a diagnostics LED.
2 IMPORTANT SAFETY NOTES
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2 Important safety notes
▸
Read and observe all safety notes in this document.
2.1 Safety conventions
Safety symbols on the system and on the system components, as well as safety notes
and safety labels, correspond to the current guidelines and standards.
The safety conventions for signal words used in this document correspond with
ANSI Z535.
DANGER! Refers to a hazard with a high level of risk that will result in serious injury
or death if not avoided.
WARNING! Refers to a hazard with a medium level of risk that may result in serious
injury or death if not avoided.
CAUTION! Refers to a hazard with a low level of risk that will result in a minor or
moderate injury if not avoided.
NOTE! indicates possible damage to property or material and provides useful information.
2.2 Supplementary safety note
WARNING!
▸
Only qualified persons from the relevant departments are permitted to work on the
system.
▸
Follow operating processes.
▸
Follow local regulations.
▸
Only authorized persons are permitted access to the system.
2.3 Requirements for the qualification of personnel
• Qualified persons have the specialist training, skills, and experience, as well as
knowledge of the relevant regulations and standards, to be able to perform work
assigned to them and to identify and avoid any potential dangers independently.
• Electricians have the professional training, skills and experience, and knowledge of
the relevant standards and provisions to work on electrical systems and to detect
and avoid any potential dangers independently.
IMPORTANT SAFETY NOTES 2
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2.4 Intended use
The MQCS modular quality control system comprises a number of different hardware and
software components for product and process optimization in the manufacturing industry.
Objects are identified by their code and checked against defined quality requirements.
The base components of the system are a control and evaluation unit with pre-installed
MQCS software, and a touchscreen for operation and configuration. Both components are
installed in a cabinet with an integrated Ethernet switch. Any of the supported code
readers from the SICK product portfolio can be used as scanners.
• The Counting module determines the usage counts of arbitrary assets or products by
reading their code. These usage counts can be used, for example, to monitor
maintenance cycles or optimize quality processes.
• The Code Matching module ensures that the right packaging is used for the right
product by reading a code on the object. The scanned codes are compared with the
reference codes stored in the system.
The MQCS is a stand-alone solution that is easy to integrate into existing systems. The
modular design of the quality control system with multiple code readers opens up a wide
range of applications, including in multi-track conveying systems.
WARNING! The MQCS quality control system must only be used for the intended use.
Non-intended use of the system can pose a hazard to people and cause damage to the
system.
2.5 RoHS directive
This system has been designed for specific applications in industrial plants according
to article 2 (4) e, RoHS 2011/65 / EU, and must therefore only be used in such plants.
The product is neither suitable nor approved for use outside of these plants. SICK
therefore cannot provide any warranty or accept any liability whatsoever for such use.
2 IMPORTANT SAFETY NOTES
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2.6 Safety notes
DANGER!
HAZARDOUS ELECTRICAL VOLTAGE
The system is supplied with line voltage. Risk of electrical shock. Contact will result in
death, burns or shock.
▸
Electrical work may only be performed on the system by qualified specialist
personnel.
▸
Interrupt the voltage supply.
▸
Check residual voltage on the system components.
▸
Use additional caution.
▸
Always connect equipotential bonding (earthing).
▸
Do not disconnect or remove the protective conductor.
WARNING!
DANGEROUS LED RADIATION
The Lector6xx image-based code readers feature an integrated LED illumination unit.
Temporary irritating optical effect on the human eye.
▸
Do not look into the illumination unit for a long period of time.
▸
Never point the light source at people.
▸
Prevent light source reflections caused by reflective surfaces.
▸
Do not open the housing.
▸
Comply with the regulations on photobiological safety of lamps and lamp systems.
WARNING!
DANGEROUS LASER RADIATION
The Lector6xx has an aiming laser as a setup aid.
Serious damage to retina.
▸
Do not look into the light source when it is switched on.
▸
Do not view the laser directly with optical instruments (e.g., magnifying glasses,
microscopes).
▸
Applicable regulations regarding laser protection must be observed.
SYSTEM DESCRIPTION 3
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3 System description
3.1 Scope of delivery
NOTE!
▸
After delivery, inspect the system for transport damage and report any such damage
immediately.
▸
Check that the delivery includes all components listed on the delivery note.
Fig. 1: Scope of delivery of the MQCS with Ethernet switch
Quanti
ty
Part no. Description
1 1097861 1 MQCS quality control system consisting of:
• 1 cabinet with 1 Ethernet switch
• 1 integrated control and evaluation unit with pre-installed
MQCS software and touchscreen
• 1 WL9 photoelectric retro-reflective sensor with reflector
• 1 Flexi Soft safety controller with configuration cable
• Configuration files with standard configurations for the
Code Matching and Counting modules
• Code matching using 1 to 8 scanners, 1 conveyor belt
• Code matching for round objects using up to 4 scanners,
1 conveyor belt
• Code matching for up to 4 parallel conveyor belts using
2 components each
• Counting using 1 to 4 scanners, 1 conveyor belt
• Counting on 4 parallel conveyor belts using 2 scanners
each
• Matching and counting using 3 scanners
Tab. 2: Scope of delivery of the MQCS with Ethernet switch
Basic package
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Fig. 2: Sensor package with Lector 6xx scanners
• The code can be identified using one or more image-based code readers from the
Lector family, depending on the reading scenario.
• MQCS supports the devices in the Lector62x, Lector63x or Lector65x family.
Part no. Description
1050589 Lector62x / Lector 620 Professional
1085372
1085375
1085377
Lector 62x / Lector 621
1080070
1080078
Lector63x / Lector631
All devices with mounting brackets and connection cables
Tab. 3: Sensor package with Lector 6xx scanners
Part no. Description
2104654 Signal lamp with horn
Tab. 4: Signal lamp with horn
The customer must supply suitable item profiles for mounting the system components
onto the conveying equipment.
Sensor package
(optional)
Signal lamp
with horn
Customer-supplied
SYSTEM DESCRIPTION 3
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3.2 System components
Fig. 3: MQCS system components
Legend
1 Cabinet
2 Photoelectric retro-reflective sensor
3 Scanners from the Lector6xx family (separate package)
• The MQCS quality control system is a modular system.
• The basic version consists of a cabinet with monitor and integrated control unit as well
as a photoelectric retro-reflective sensor.
• To read codes, the basic version needs to be supplemented with suitable scanners.
The MQCS supports a variety of Lector6xx code readers.
Component overview
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3.2.1 Cabinet
Fig. 4: Cabinet components
Legend
1 Touchscreen for configuring and operating the MQCS
2 TDC-E with MQCS software (TEMS recorder)
3 Ethernet switch for interconnecting the system components
4 Flexi Soft safety controller for digital output of events in real time
5 Terminal blocks for connecting the system components
• Includes a TDC-E, which provides the central control and evaluation unit and the
Ethernet interface for FTP data transfer to the customer system.
• Includes a monitor for visualizing the read results and for configuring the system.
• Includes an Ethernet switch and terminal blocks for connecting the system components
to the 24 V voltage supply as well as interconnecting the system components.
• The Flexi Soft safety controller installed in the cabinet provides the digital interface for
the customer-side rejection of products with an incorrect code or a No Read (Code
Matching only).
Features
SYSTEM DESCRIPTION 3
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3.2.2 TDC-E control and evaluation unit
Fig. 5: TDC-E Telematic Data Collector
Legend
1 TDC-E with MQCS software (TEMS recorder)
2 Interfaces
3 Status indicators
• The TDC-E with pre-installed MQCS software (TEMS recorder) is the central control and
evaluation unit of the MQCS.
• The TDC-E receives the scanned codes and evaluates them.
• Depending on the configuration, the TDC-E either compares the codes with a reference
code or assigns the relevant count values to the codes.
• The codes and count values are outputted to the customer system using FTP data
transfer (Counting only).
• Comes with digital interfaces for forwarding events to acoustic or visual signaling
devices.
• Factory pre-installed tools (TEMS Manager, Viewer) on the device are used to configure
the system and to visualize the read results in a web-based interface.
Function
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Fig. 6: Signaling of events via digital outputs
• The digital outputs of the TDC-E can be used to signal specific events.
• These events can include, for example, Good Reads or No Reads, count values being
exceeded (Counting only), the read rate of the code reader, or system status
information.
• Which outputs are switched by what events and under what conditions is defined in
TEMS Manager.
• The threshold values for the count values are also set in TEMS Manager.
• The control of an optionally included signal lamp with horn is pre-configured.
• The Linux operating system that has been pre-installed on the TDC-E is based on a
powerful ARM processor and utilizes Docker container technology.
• Docker is a tool that makes it easier to create, deploy, and execute applications by
using containers. A container does not just hold the application itself but also all of the
resources required by the application during runtime.
• Thanks to the container technology, the MQCS can be rapidly extended by adding
customer-specific applications.
• To this end, the application is loaded into a container as a compiled image file and
executed immediately.
NOTE! For more information, please see the operating instructions for the TDC-E.
Digital outputs
of the TDC-E
Docker technology
SYSTEM DESCRIPTION 3
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3.2.3 Flexi Soft safety controller
Fig. 7: Flexi Soft safety control components
Legend
1 CPU0 main module
2 STIO I/O expansion module
• The controller consists of the CPU0 central main module and the STIO I/O expansion
module.
• The main module is the central logic unit of the controller.
Here, all signals are analyzed and evaluated within the configured logic.
• The I/O expansion module provides the digital inputs and outputs.
• The scanners are connected directly to the expansion module via an I/O cable.
Fig. 8: Output of control signals via the Flexi Soft safety controller
• The direct connection of the scanners to the digital outputs of the Flexi Soft safety
controller enables – in addition to signaling via the TDC-E – the direct output of control
signals to the customer’s control system or the conveying equipment.
• This allows time-critical actions to be triggered directly independently of the read result.
• Objects with an incorrect or missing code can be separated out from the production
process in a targeted manner by this means.
Features
Function
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3.2.4 Integrated screen
Fig. 9: Integrated screen
• Touch-sensitive screen
• Integrated into the door of the cabinet.
• Used to input and output information.
• Offers a convenient means of configuring and operating the MQCS via a web-based
interface.
• The Viewer can be used, amongst other things, to configure the scanner for the specific
reading scenario, and to visualize the read results during operation.
• It is also possible to switch to TEMS Manager.
3.2.5 Photoelectric retro-reflective sensor
Fig. 10: Photoelectric retro-reflective sensor with reflector
Legend
1 Photoelectric retro-reflective sensor
2 Reflector
• The emitted light band is reflected back by a reflector.
• Sender and receiver are arranged parallel to one another in the housing.
• Transmits a trigger signal to the connected sensors as soon as the leading edge of an
object interrupts the light band.
Features
Function
Features
SYSTEM DESCRIPTION 3
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Fig. 11: Processing of the trigger signal
Legend
1 Trigger line
2 Transmission of trigger signal to TDC-E
3 Activation of the code reader
• Enables the MQCS to be operated in triggering mode.
• Activates the connected code reader or readers and opens the reading interval.
• The reading interval determines the start and end of the reading process when using
triggered code reading.
• Between the start and end of code reading, multiple objects are not distinguished and
only one code is read and assigned to the initially detected object.
• In the standard configuration, the reading interval is closed when a valid code has been
read and assigned to the object.
• If no valid code is read between the start and end of the reading process, a No Read
result is outputted.
Function
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3.2.6 Image-based code reader (optional)
Fig. 12: Lector6xx image-based code reader
Legend
1 Code reader
2 Lens
3 Status indicators
4 Aiming laser
5 Integrated LED illumination ring
• The MQCS supports a variety of code readers from the Lector 6xx family.
• The Lector is an optical sensor with integrated LED illumination for scanning codes.
• The Lector supports the omnidirectional reading of bar codes on one side of an object,
even with varying object heights and code positions.
Features
/