Operation of Machine

1.Instructions

1.1 Operator Duties.

The Operator will:

Maintain an overview of the entire machine.
Monitor machine performance and investigate any alarms that occur and resolve or call maintenance.

1.2 HMI Navigation

Every page on the HMI has the same Top Banner on it.

Press to navigate to the Main Control Screen.
Displays the current logged in User
Displays an Active Alarms popup. Press to navigate to the Alarm Page
Alarm Acknowledge Button. If an alarm has already been acknowledged, the alarm can be found in the Main Menu under Alarm History.

1.3 Control Buttons

Operational Control Buttons on RML Machines use symbols that comply with the IEC-60417 standard. The colours do not comply with any standard, however we have implemented industry standards as a guideline.

Reference and Symbol

IEC Title

BRML Title

IEC Function

BRML Function

IEC 60417-5008

“OFF” (Power)

“Off”

(Not Ready for Safety Reset)

To indicate disconnection from the mains, at least for mains switches or their positions, and all those cases where safety is involved.

To indicate the machine is De-Energized and that there is a safety device preventing the machine from being Powered ON

IEC 60417-5009

Standby

Reset

To identify the switch or switch position by means of which part of the equipment is switched on in order to bring it into the Standby condition.

To indicate the machine is powered on but requires a Reset to bring it to an Idle State.

IEC 60417-5011

“ON/OFF” (Push button)

“Off”

(Ready for Safety Reset)

To indicate connection to the mains, at least for mains switches or their positions, and all those cases where safety is involved. "OFF" is a stable position, whilst the "ON" position only remains during the time the button is de-pressed.

To indicate the machine is De-Energized and that it is in a state where it can be powered ON

IEC 60417-5104

Start

To identify the Start Button.

IEC 60417-5110A

Stop

To identify the control or the indicator to stop the active function.

To identify the Stop Button. Stop will terminate all Sequences immediately, bringing the machine to a Rapid Stop.

IEC 60417-5111A

Pause, interruption

Hold

To identify the control or the indicator which stops operation intermittently and keeps the equipment in Operating Mode.

To identify the Hold Button. Hold will transition the machine to a Held State, allowing all the sequences to complete their current function

IEC 60417-5459

Eject

Complete

To identify the Eject Button.

To Complete a production run or eject the remaining product from the machine at the end of a production run.

1.4 Side Control Bar

The Side Control Bar provides access to common machine functions. I.e., Start, Stop and Off buttons may be accessed from any display.

Pressing the RML logo in the Top Banner opens and closes the Side Control Bar.

1. Start Push Button - Press to issue a Start command to the machine. When in the Execute state, this button will change to the Hold icon.

2. Stop Push Button - Press to terminate all Sequences immediately, bringing the machine to a rapid stop.

3. Off (Not Ready for Safety Reset) Push Button - This is shown when the machine is in the Aborted state and the E-Stop is pressed. When the E-Stop is released, the icon becomes the Off – Ready for Safety Reset button. If the machine enters the Stopped state, the icon becomes the Reset button.

1.5 HMI Main Control Screen

1. Machine State Model. Displays the current State of the Machine

2. Machine Status Bar. Provides information on the current machine state

3. Information on the Current Recipe. Press here to launch the Recipe Display

4. Machine selections. There are several different machine selections in this area of the screen. These are used to enable and disable different machine functions. 

Home button is pressed to reset all Sequences and home all Servo Motors. You would use this button if you need to home one of the Servo Motors, or if you wanted to reset all of the Sequences back to Step 0.

5. Vision Bypass: Press here to Bypass vision System

6. Robot High Power ON: Press the button twice to power ON Robot.

1.6 Machine State Control

PackML Machine State Model has been implemented for the overall control of this machine. There are three machine state types that define the current condition of the machine:

Acting State – represents a processing activity, i.e., Aborting, Clearing, Stopping, Resetting Un-holding, Holding, Un-Suspend, Suspending and Completing.
Wait State – identifies that a machine has achieved a defined set of conditions, i.e., Aborted, Stopped, Idle, Held, Suspended and Completed.
Dual State – a Wait State that is causing the machine to appear as an Acting State. There is only one Dual State: Execute.

The image above shows the 17 Machine States and transition paths between states. The operator uses the control buttons on the main overview page to transition from state to state.

PackML Machine State Model States

Aborting: An E-Stop has been pressed or a Door has been opened while in a running or Holding state. All power and air is being removed from the zone. The machine will be brought to a rapid, controlled safe stop.
Aborted: All power and air has been removed from the zone. The machine maintains relevant information to the Abort condition. A Safety Reset command will force a transition to the Clearing state.
Clearing: Machine is to clear faults that may have occurred when aborting and that are present in the Aborted state, before proceeding to a Stopped state.
Stopping: Machine executes a controlled and safe stop.
Stopped: Machine is powered and stationary.
Resetting: Machine enters an energized state awaiting a Start command. Machine will be homed in this State if necessary.
Idle: Machine Resetting is complete and ready to start-up.
Starting: Machines performs steps required to enter the Execute sate.
Execute: Machine is operating and producing product.
Holding: Machine is being brought to a controlled stop when executing.
Held: Machine is paused either by operator or a fault occurs in the Execute state.
Un-Holding: Machine is being prepared to re-enter the Execute state.
Suspending: Machine is being prepared to enter the Suspended state.
Suspended: Machine enters this state due to a request from out/in-feed.
Un-Suspending: Machine is being prepared to re-enter the Execute state.
Completing: Machine has run product to completion. Used at the End of a Production run to drain any remaining product from all machines within this zone. I.e. processing of product at the Infeed will stop.
Complete: Machine is waiting for a Stop command that will bring the machine into the Stopped state.

Restart after an Emergency Stop or Monitored Guard being opened

Check the machine to see if the reason for the E-Stop activation or Guard Door opening has been cleared.

If an E-Stop was activated, release all E-Stop buttons (Twist to release)
If a Guard Door was opened, close any Guard Doors that are open.

Once the E-Stop has been released and Guard Doors are closed, press the RESET button on the Side Control Bar or Main Control Display. This will reset the safety system and bring the machine into the Idle State.

1.7 Machine Restart from Held or Suspended State

From Machine Fault:

Check machine fault
Carry out necessary actions to resolve the fault
Once the fault has been cleared, press the START button on the Side Control Bar or Main Control Display.

From Line Fault:

Check line fault
Carry out necessary actions to resolve the fault.
Once the fault has been cleared, the machine should automatically restart.

Ensure the safety system is reset, Press the Start push button on the Side Control Bar to start the machine

2. Menu Layout and Screens

2.1 User Login

1. Current User

2. Touch to Login

3. Touch to Logout.

Following is a matrix of the level access for each user, please note the Level 1-3 passwords are able to be altered for customer preference. Level 4 and 5 are set aside for RML Engineering access only to enable machine setup.

2.2 Mimic - Overview Display

The Overview Display provides an overview of the machine layout. Specific areas of the machine can be navigated to by using the Arrow buttons.

1. Pressing this icon will launch the Mimic Overview Screen. This can be accessed from a display on the HMI

2. These icons around the display will launch the Mimic indicated in the Arrow box when pressed. E.g. pressing the “Infeed Buffer” arrow box will launch a mimic for that area of the machine.

Press on Sub-assembly area for manual operation for Example: -solenoid valve, motor, photo eye etc.…

2.4 Mimic Overview – Device Legend

Devices are shown in their approximate locations around the machine and have the following color indication.

Green is On 
Grey is Off 
Red is Fault

2.5 Mimic – Machine Module

1. Pressing a device icon will launch a popup for that object.

2. Pressing here will navigate to the display indicated in the Arrow box.

2.6 Sequences

Clicking on the Sequences button in the Menu launches this display.

Example: -

1. Sequence Status. This displays the Sequence Name, Current Step and description of the current action that is taking place. 2. Pressing this button launches another faceplate with more detail on that Sequence. That faceplate can be seen below.

4. Face Plates

4.1 Mimic – Device Legend

4.2 Cylinder

Tag name and description for the selected cylinder.
Number of times the cylinder has been actuated.
Cylinder status flags showing Output State, Reed Status, Alarm and Manual state.
Timer pre-sets for the cylinder alarms. If the cylinder is setup as having no reed switches, these timers become extend and retract times for the cylinder.
Test Cycle Time.
Press this button for start continues running cycle for cylinder

4.3 Miscellaneous Input

This will be Green when sensor is ON
De-bounce and Fault Times.
Press to mute the device alarms.

4.4 Miscellaneous Output

Tag name and description for the selected device.
Current State of the device.
Current Status of the device.
Fault timer and cycle counter.

4.5 Servo Motor

Tag name and description for the selected servo.
Velocity and Position feedback and current target position.
Current drive status
Pressing here will launch the servo settings display.
Pressing here will launch a home selection screen. This will provide information about the homing of the axis.
Manual Controls. You must be logged in as a technician to gain access to these controls.

4.7 Servo Setting

This display is launched from the servo faceplate and show the setpoints for the servo control. You must be logged in as a technician to gain access to these controls.