Electro Cam PS-6144 Series - Manual (Page 65)

5-1 Output Grouping & Modes
Introduction to Groups & Modes
I nput Signals In many industrial applications, the action of a machine component such as a glue gun,
solenoid, or pneumatic cylinder is related to an input signal from a limit switch, sensor,
or controller such as a PLC. Input signals are commonly used in two ways:
• Conditional Operation
The device being controlled is allowed to function only if an input signal occurs. A
typical example is gluing, where a photoeye senses the presence of a product imme-
diately before gluing should occur. If the product is not present, the glue gun is not
enabled to turn on at its programmed setpoints.
• Phase Adjustment
The device being controlled must maintain a certain relationship to other devices on
the machine. For example, web converting lines such as disposable diaper machines
usually have several machine sections each performing a different operation on a
continuous web of material. As line speed increases, the phase relationships be-
tween different machine sections are adjusted to compensate for stretching of the
web material. To keep a device synchronized within its machine section, a sensor is
used to detect a registration mark on a component such as shaft or disk. The sensor
signal “resets” the position of the device each revolution, ensuring that the device
operates at the correct position on the web of moving material.
Groups & Modes The PS-6144 controller includes powerful programming capabilities that allow output
channels to be linked to input signals from sensors or other devices. Output channels
can be divided into as many as six groups, each of which is associated with one of the
input terminals on TB 1, Figure 7. Each group can then be assigned to operate in one of
six modes which determines the relationship between the channels in the group and
the input signals.
Benefits Proper programming of output groups and modes can provide substantial benefits:
• Reduced Waste & Cleanup—By enabling devices such as glue guns to operate
only when a product is present, operating modes conserve glue and reduce mess
and cleanup.
• Increased Productivity—When used to compensate for phase adjustments between
machine sections, operating modes can improve the high speed accuracy of ma-
chine functions, allowing higher machine speeds, better product quality, and reduced
scrap.
Typical Applications Details on each of the six PS-6144 operating modes are included later in this section.
Following are a few types of industrial machinery which frequently benefit from the use
of operating modes.
Web Converting Machines—Disposable diapers, medical pads, office folders, and
similar products. Mode 1 can automatically change the timing of individual machine
sections to compensate for changes in phase relationships between sections.
Cartoners & Case Packers—Vacuum, material handling, loading and other functions
are usually controlled in Mode 0. Gluing functions are typically controlled in Modes 4 or
5 to prevent glue from being dispensed when containers are not present.
Vertical Form/Fill/Seal Machines—Package handling functions are controlled in Mode
0, while pump or fill functions are handled in Mode 1 to automatically correct for me-
chanical phase adjustments made between these two sections of the machine. This
allows one resolver to do a job that would otherwise require two.
Machines with Multiple Cycle Ratios—Some machines have different sections that
run at different cycle ratios per overall machine cycle. For example, one portion of a
machine may complete several cycles while another section makes only one cycle. By
using Mode 1 or 2, it is possible for some output groups to cycle multiple times while
others cycle once.