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

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.

4. Press to launch the Menu Display.

1.5 HMI Main Control Screen

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

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

3. 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.

4. Cycle Time shows the time between 2 matrixes of bottles are place in the case.

5. This calculate the shippers are completed and out of the conveyor per minute.

6. User can set the running speed of the machine (it controls the servo motor speed) which can be set between 100% to 10%.

7. Shows the total count of the shippers out after start and before the production reset button is pressed.

8. It navigates to the Mimic screen.

1.6 Machine State Control

Top load case packer 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 8 Machine States and transition paths between states. The operator uses the control buttons on the main overview page to transition from state to state.

Top Load Case Packer Machine State Model States

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.
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.
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.

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 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. Mimic- Overview Display

2.1 Mimic Screen

1. Press to launch User Login Screen

2. Press to open mimic-sub assembly.

2.2 User Login

1. Enter username and password.

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.

2.3 Mimic –Sub Assembly

1.Press This for Components View

3. Recipe

3.1 Recipe Settings

3.1. Editing Recipe Setting

Any changes have to made in the recipe make sure you took the proper training from the BRML team and know the procedure.
Any changes made in this section will lead to machine disturbance in position of the matrices formation
So make sure if the position is misplace or while teaching is made then only edit the settings.

3.1. Loading Recipe Setting

While loading to a new recipe make sure the mechanical changes has made properly otherwise the there are chances of collision.
Before loading to a new recipe make sure you have saved all the previous change settings.

3.1. Saving Recipe Setting

After making the changes click save button otherwise all the changes made will not be saved.

3.2 Recipe Mimic

WhatsApp Image 2024-06-19 at 7.45.52 PM.jpeg

1. The arrow navigates through back and forth in the pages from 1 to 7.

2.Running value displays the on going edited value.

3.Recipe value shows the previous saved value.

4. Face Plates

4.1 Mimic – Device Legend

Cylinder

Servo Motor

Motor

Sensor

4.2 Cylinder

The lamp show the indication of which Reed and status is active.
By keep pressing the button Force command get activated and the Extend and Retract performs and by releasing it gets deactivated.
The Extend and Retract reed time allows delay in cylinders where preset is to set the time and accumulation calculate the time.
By pressing the Manual option command gets activated which allows us the continue motion.
If want to check the cylinder is working unusual put the value in the Extend and Retract time and test the cycle.

4.3 Motors

The lamp show the indication of which status is active.
By keep pressing the button Force command get activated and the motor starts to rotate to set polarity.
The Motor fault time allows us check if Motor the not starting at the set preset time.
By pressing the Manual option command gets activated which allows us the continue motion.

4.4 Servo Motor

The Home lamp indicates that the servo motor is in home position.
Actual Position gives the current location of the servo and the Actual Velocity shows the current running speed of the servo motor.
Jog Forward and Reverse use to move servo back and forth and by clicking on Jog to Position the servo will get the desired set jog position.
If machine is not resetting check for the servo motor home proximity, if they are not homed properly then press the home button (check before pressing the home button has anyone not disturbed the homing because it will as the new setting of the homing plate and set position of the matrix will be disturbed).
It allows to move the servo to desired position at desired velocity.
Use to set the Acceleration, Deceleration and jerk of the servo's.