1. Active Jam Detector (AJD) Travis Bailey Mike Pyne Dave Willis Advisor: Dr. Bradley Bazuin Sponsor: Ron Kelley GPC

2. Active Jam Detector (AJD) Presentation Outline Introduction …………………………….Mike Pyne Decision Logic of the Active Jam Detector …………………………….Dave Willis Active Jam Detector Testing …………………………….Travis Bailey Results and Conclusions …………………………….Mike Pyne

3. Opening The purpose of the AJD is to reduce cost to graphic packaging corporation due to die damage and down time. With current production speeds of up to 45 cartons per second, fast reliable jam detection is necessary. Mike Pyne

4. Background Continuous web offset printing with a high speed rotary die.

5. Graphic Packaging Video

6. Background Continuous web offset printing with a high speed rotary die. Actual carton jam at press speed.

7. Jam Video

8. Background Continuous web offset printing with a high speed rotary die. Current method of Jam Detection. Actual carton jam at press speed.

9. Problems with current method of jam detection Not truly speed sensitive.

10. Speed ranges on Passive Jam Detection Jog/Phase run3.70 seconds Slow run1.50 seconds Normal run (<180 m/min)1.20 seconds Normal run (>180m/min)0.13 seconds

11. Problems with current method of jam detection Not truly speed sensitive. Photo-eyes operate in parallel to one common input.

12. Passive Jam Detection (PJD) Photo-Eyes

13. Problems with current method of jam detection Not truly speed sensitive. Photo-eyes operate in parallel to one common input. Not enough photo-eyes for all jobs.

14. Why Jam Detection Is Necessary

15. Actual Cost To Graphic Packaging Cost at Graphic Packaging Corporation Kalamazoo Michigan, are estimated at $250,000 This includes damage to the die and lost production due to down time.

16. Goals of a new system Device must be able to process different flow speeds. Device must be able to select carton size. Device must be able to interface with current equipment. Device must have override switch for start-up and maintenance. Device should be able to operate at 150% current speeds. Device should have user-friendly Human Machine Interface. Device design should cost less than $2000.00. Device should have alarm history/parts counter.

17. Background Continuous web offset printing with a high speed rotary die. Actual carton jam at press speed. Current method of jam detection. Solution to the PJD problem.

18. Active Jam Detection is the solution to the problem Actively looking for each carton as it is produced is the only way to ensure all cartons are accounted for. At high productions speeds keeping track of each carton is quite a challenge. Xilinx Microcontroller. 95108-7

19. Decision Logic of the AJD Dave Willis NO STOP YES GO

20. How the AJD Works… 1.Calculate 2 consecutive carton lengths and store the values. 2.Multiply the current carton length by 25% and store the value. 3.Take the absolute value of the difference between carton lengths. 4.Examine if the difference is less than 25% of current length. YES = OKNO = JAM

21. Basic Overview Flow Chart

22. Complete AJD Representation With the logic formulated, we can now examine each of the different subsystems

23. Subsection #1- Counter

24. Subsection #2 – Data Control

25. Subsection #3 - Shift Register

26. Subsection #4 - Registers

27. Subsection #5 - ABS(A-B)

28. Subsection #6 - Compare

29. AJD Testing Travis Bailey

30. Phase One –XiLinx Simulation Phase Two –Bench Testing Phase Three –“Real-World” Simulation Testing Process

31. XiLinx Simulation XiLinx Foundation Series Software

32. XiLinx Simulation

33. Limitations –XiLinx Testing Only –Lack Of “Real-World” Influences Benefits –Graphical View of Software Flow –Timing Simulation Capabilities –Convenience

34. Bench Testing Location –3038 Kohrman Hall Equipment Used –Digital Multi-meter –5 Volt Power Supply –Function Generator –Logic Analyzer –Oscilloscope

35. Multi-meter Power Supply Function Generator Logic Analyzer Test Circuit Oscilloscope Bench Testing

36. Benefits –Available Equipment –Convenience –Circuit Testing Beyond XiLinx Simulations Bench Testing Limitations –Generated Input Signals –Testing of “Perfect” Conditions

37. “Real-World” Simulation Location –Graphic Packaging Company, Kalamazoo,MI Components –Carton Line Representation –XiLinx Integration –Switchboard

38. “Real-World” Simulation XiLinx Integration Carton Line Representation Switchboard Test Stand

39. “Real-World” Simulation EncoderCarton Simulator Variable Frequency Motor Controller Carton Line Representation Photo EyeMotor

40. “Real-World” Simulation XiLinx Integration 5 & 12 Volt Power Supplies XiLinx Micro-Controller Terminal Strip Power LED

41. “Real-World” Simulation Switchboard

42. “Real-World” Simulation Benefits –Similarity to Actual Carton Press –Photo Eyes, Encoder, Switches –Effects of Outside Influences Limitations –Difficult to Modify Design

43. Results and Conclusion to the Active Jam Detector Project Mike Pyne

44. Results and Conclusion to the Active Jam Detector Project Device must be able to process different flow speeds. Device must be able to select carton size. Device must be able to interface with current equipment. Device must have override switch for start-up and maintenance. Device should be able to operate at 150% current speeds. Device should have user-friendly Human Machine Interface. Device design should cost less than $2000.00. Device should have alarm history/parts counter.

45. Results: Device is able to process different flow speeds. Carton size does not effect AJD system. Device is able to interface with current equipment. Device has an override switch for start-up and maintenance. Device can operate at 150% current speeds. AJD proof of concept design did cost less than $2000.00. Total cost of AJD project …….$2370.58 Actual Spent ….….……$213.79

46. Results: Device is able to process different flow speeds. Carton size does not effect AJD system. Device is able to interface with current equipment. Device has an override switch for start-up and maintenance. Device can operate at 150% current speeds. AJD proof of concept design did cost less than $2000.00. Device should have user-friendly Human Machine Interface. Device should have alarm history/parts counter.

47. Wonder-Ware Touch Screen Human Machine Interface.

48. Conclusion

49. Questions ? ? ? ? ? ? ?