Web Width Measurement with Roll-2-Roll® Controller: RTI and SCU5

hello everyone today we are going to talk a little bit about the web width measurement application and how we can use the scu5 controller to measure the web width and also use another plc to collect that data log that data and also save it in a csv file on a usb thumb drive in order to do this what we're going to do is we're going to first set up our se5 controller for width measurement mode and then we also offer the rti which is the plc which has a special program that would actually talk to the scu5 controller and then allow the user to connect a usb drive to the plc so that the data can be logged automatically in the plc and the communication between the plc and the sco5 controller is being done through ethernet ip and then the user also has the ability to set up lot numbers so that when they are tracking different product codes they can enter that and that information is saved in the usb file automatically and the plc also allows the user to start and stop the data collection based on a line signal so that the data is only collected when the web is running and when it's not running the data can be automatically stopped from data collection and then finally we can also connect that plc to a stack light directly so that we can provide the alarms for warning error and then all good signals so all of this can be done uh through the plc and that's what is shown here this is the plc that we would be using to do that the first step in this process is to make sure that we have the suv5 controller set up for web width measurement mode and then the second step is to make sure that the ethernet settings on the sc 5 controller and the plc matches and then the third step is basically setting up the parameters on the plc so that you have everything for triggering the stack light as well as data logging so those are the three main things that we are going to cover so first we'll start off with setting up the se5 controller for width measurement mode as you can see here we have the sco5 controller now ready and then we also have the two sensors up on the top right corner and we're using two sensors one for detecting each edge of the web we'll go through this process so that we can set up the controller for width measurement as you can see if a web is presented you can see that both edges of the web are seen by the two sensors and then once that is there we just need to set the controller for width measurement mode and that can be done by following these steps first we're going to go into the tools icon right here and then go on the bottom power user and then go into the analog mode and make sure that the width is selected here and when we select this as the width now the home screen now shows the width as the output the controller still doesn't know the distance between the two sensors so in order for us to do that we need to teach the controller for the width so if i present the web here it's going to give some random values there so in order for us to teach that the distance between the two sensors we're going to go into the tool cycle and again and then the top right icon is the operator icon we're going to click on that and we're going to click on the width mode and then a few things that we are going to set so that we can teach the controller for the right measuring mode first of all the output type we're going to change it to absolute and then the nominal width this is going to be the width of the product that you're going to present while you're teaching so in this case the width of the product is approximately about 5 inches so i'm going to set in 5 inches right there and you can use this icon to change that and then the upper limit and lower limit it does not matter for this application because we're going to use the data raw data through ethernet to take care of that so we don't have to worry about that and now at this point all that we have to do is to present the web and then teach that while the web is presented so that's what i'm going to do right now so once we present the web and the teaching is accepted now we can go back to the home screen and now the controller is set up for width mode with two sensors and then now it's showing you the absolute width of the product as we move the web when the weight changes you can see that the width of the product also changes so the next the second step is that now the data is being collected in the scu5 the data is sent through the ethernet it's not being logged so in order for us to log that data we need to be able to set up the network parameters so that we can take care of these so the second step is to make sure that the network parameters are set up the easiest way for us to find out what is the ip address of our device and also set the network parameters is through the operator interface directly so we can do that by going into the tools icon the power user icon and then go into the communication we want to make sure that the ethernet is on as shown here and depending upon your network settings you may or may not want to have the dhcp on and then ftp on that really doesn't matter for this application if a network device is present then the controller will actually show the type of industrial network that is here and this is called ethernet ip and for in our case ethernet ip is the type of industrial network that we are using depending upon the firmware version you might have something here that says what type of module that we have we have two types of modules hms as well as hillshare depending upon what module you have that will show up if you have a older version of the firmware let's say version 3.6 d or maybe even 3.6 a then the type of module will not show up there the ip address of the module is shown here the subnet mask is shown here the gateway is shown here and then the mac address is shown here if you want to change the ip address of this module then you can just press this ip button and then type in the ip address that you want to change so i'm going to say 192 0 0 and 1 100. this is just for illustration purposes i actually put it as 2.100 if you want to set this you can press the set button to set it because i set the ip address wrong so i'm going to go back in and put the right at the address so again press on that one ninety two one sixty eight zero zero one and one hundred once we do that we need to press the set at the address to have the ip address set based on what you have entered and then if the ip address is different than what you had before you can hit the refresh button just to be sure that the controller has taken the ap address in some of the cases we might have to restart the whole controller especially with older firmware we might have to anytime we make a network change we might have to restart the power cycle the call controller with the newer firmware and the chip that we have we don't have to do that but likewise you can do the same thing for the mask and gateway and then if you have a controller or network where you are setting the dhcp then you would turn on the dhcp and anytime you turn on or off the dhcp you do need to power cycle the controller but essentially that's the easiest way for us to set the ip address the network information and also to view what controller or what module that we have on this particular controller there's also ways in which we can set these network information through a computer we're not going to talk about it today but this is the easiest way in which we can set this up now the second step in in this process is once we have this set up now we're going to go to the plc and make sure that the plc has the right parameters for communicating between the seo 5 and this controller the easiest way to make sure what the plc network information is and what the ip address for the plc is is done by actually pressing on the top left and the sorry the bottom left and the top right corner of the plc several times okay once you have that then you can go in and click on the offline so once you get into this offline mode you can also ensure that the ip address for the plc is set properly and make sure that it matches with the network information on the su-5 controller you have the ability to connect the suv5 controller to a managed or unmanaged network likewise you can do the same thing with the plc or you can directly connect the plc to the sc 5 controller without going through a switch if you do that what we need to make sure is that the network information on the plc matches the network information on the sco5 controller and then plc has a distinct ip address compared to the sco5 controller and then the plc also knows the explicit ip address of the seo 5 controller so in order to check all of these things what we can do is we can go into the offline mode as shown here once you are in this offline mode we can go into the main unit and then click on the ethernet and then click on the lan and now this shows the information for this plc so this is the ip address subnet gateway for this plc we just need to make sure that this information is similar to the information on the scu5 controller so let's go ahead and look at that c5 controller communication and the ip address for the se5 controller is not the same as the plc which is what we want the subnet mask matches the gateway matches and then if you compare that with the plc has an ip address of 10 the sg5 has an ip address of 100. so once that is done we can go back into the peripherals and then look at the device plc settings ethernet ip and then go into that device and this is actually the device that we are trying to connect in our case scu5 so that ip address of that u5 matches the ip address on the plc now we have set up the plc and the se5 with the right network information so that they can talk to each other okay once we have all the ap address set up now we need to go into the steps that are necessary for data logging and also to start the communication first and foremost what we want to do is we want to make sure that the communication between the plc and the sg5 controller is going properly and for that we're going to go into that communication screen and then right now it says the ethernet ip is actually off so let's go ahead and turn it on now the ethernet ip is on if you don't see any error messages then it means that the sg5 controller and the plc is communicating properly just to show you what happens if it doesn't communicate i'm going to remove the ethernet connection from the se5 and you can see that there will be an error message that will show up saying that the tcp connection is lost or things like that so if you see that error message that means that the either the device is not set up properly to communicate with the seo 5 controller and this would be the error message that you would see um and it shows that that's not the plc it's basically it's not able to connect to the sco5 controller so as soon as we connect the cable back this error should disappear within a few within a minute or so and then yeah likewise now it's communicating with the plc with the suv so once that is set up so when you have a web in front now this should provide you the width of the web on the plc but it's also showing that width on the su-5 controller so in order to change the units what we are going to do is actually go into the setup screen and then go into the other setup as well and then the units are here you can set that to inches even though scu5 may be set to inches the plc can be set to another unit irrespective of what the unit of the scu5 is and in this screen you can also change the language currently we support english and spanish so if you press spanish it's going to go to all the icons would change to spanish and then if you want to set things back to english then you can do that so this is where you would set the units and you can go back to the home screen and now if we present the web now the units would be in inches just like what the sc5 is now we know that the sco5 is communicating with the plc and then you are able to see the data now we can add more things to it so as you can see on the home screen there are the three lights that are available these are the three digital outputs so in order for us to run up a stack light what we do is we take the data from the scu5 and then use the recipe or the settings that are there on the plc so that you can set up upper limit and lower limits for the alarms and warnings that way you can connect it to a stack light and the stack light would go on based on that so in order to do that we're going to go into this screen and then go into the width setup and we can set the upper limit and lower limit for the alarms and all the units are going to be in the respective units for the alarm and as well as the width so the first step that we want to do when we are in this which setup screen to trigger the stack light is to set up the nominal width the alarm warning and all this information so in our case we have set the nominal width to 5 inches but if you want to change it to some other value you can just press that button upper limit and lower limits for the alarm and the warning doesn't have to be symmetrical so it can be asymmetric the alarm value should always be greater than the warning value uh that's the precondition when the width value exceeds the alarm value or goes above the upper limit of the alarm value or goes below the lower limit of the alarm value then the red light is going to be indicated and then likewise if it's in the range for the warning it will be in the amber and then if it is within the nominal width that's going to show the um essentially the green so once we have it set up we can go to the home screen you can see that right now the alarm is enabled and then when the width is within the nominal range you have it as green and then if the width changes to some value that is outside those limits amber and then if it's really off then it goes to red and that's the way in which this works now you can also plot this data so you can see that in a real time graph it's going to show you the the limits for the width as well as the limits for the alarm showing that in red so you can have a visual indication of how it's been doing starting with the graph like that now that we have set up these alarms and warnings and stuff like these are not used for data logging purposes but these are just for triggering out triggering the stack in order to lock the data you can start logging by connecting a usb and if you want to have some lot information you can go in and press that and enter your lot number so that when we log the data that lot number is also allocated there so in order to log the data we need to be able to connect the thumb drive there's a usb port underneath the plc that we can use to connect that thumb drive so i have an extension cable here so i'm going to connect the thumb thumb drive through an extension cable but as soon as we connect that thumb drive to the plc there should be a blue icon that appears in the bottom right as you can see in the bottom right hand corner that icon appears and if you want to take a look at it go inside right now it has disappeared but that lets you know that the usb has been recognized and connected to the device once you are ready with that what we can do is go into the plc and start data logging so we have the web here and we have presented all the uh the settings for the upper limit and lower limit and all those kind of things so since they're all set up right now we can go ahead and start collecting the data and when the web is there you can see that it's measuring that we're going to go away and then communication data log now it's saying no data logging is being done so in order for us to do the data logging i'm going to start and now this is started data logging the remote data log is off right now but if you want to have a another interface or a signal that would tell us when to lock the data i went to start i'm going to stop then you're going to enable that if you want the operator to start and stop the data logging then you can just go here and do it since the logging is being done it says logging data on the top left hand corner and then once you're done data logging you can just press the stop button right there and then if you want to remove the usb you can safely remove the usb by pressing the top and the bottom just like what we did before and then now it shows up the usb icon at the bottom there so we're going to click on that icon and then say remove usb storage device and press yes on it and then the storage device has been removed successfully because that icon on here has disappeared now you are able to disconnect the usb thumb drive and once you connect it to the computer then you have the ability to take a look at the data so let's do that next okay we're going to switch over to the computer screen now the usb is connected and you can see that the thumb drive has been recognized and it shows the different files that are there so today is the 25th so we have that file right there showing the 25th and if you double click on that file you can see that it has collected the data the lot number has been assigned and then you also have the sorry about that you also have the width data that is being presented here as you scroll down okay as you scroll down you can see the actual width measurement that was done so right now the time scale is about in this particular program it's about once per second so the width at that time was 4.735 inches and the units is basically the same units that we have on the controller so if you had units the unit shows up and if you have inches it shows up the lot number shows up and then the time when it was recorded and then the date when it was recorded so that's as simple as that to be able to log the data through the rti plc um in from our scu5 controller one other feature that we have is that we also have the ability to provide some recipes the recipes are used when you are running different web with products and you don't want to change the nominal with the alarm and the warning information every time you change the width you can create your own recipes and that's done here and um anytime you want to load a recipe you click on that product product number and then you're going to press load recipe and whatever that value is going to be loaded it's going to be displayed it will not be presented or pushed to the home screen until you press the accept so now once you press the accept that value is being loaded anytime you want to save a new recipe you're going to go in there press on load and then press the values for those so if i want to change that nominal width to 5 inches i'm going to enter that nominal width and then the all the other settings are set now i am happy with this recipe so what i'm going to do is i'm going to save that now product one every time we go to product one it's gonna have the five inches so we go back to product two load that recipe that shows up there and product one come back here and load that recipe now it's five this is just displaying it so if you want to push this to the home screen you still need to press accept and we're gonna do that now if you go back to the home screen that's gonna show you that the new alarm and warning signals and you can see that here if i present the web you can see that it's good now and it's an alarm now i think so that's essentially it