Operator manuals
Browse the books
Lining machine 9002426 and Vision System 9002426-06, organized the way the paper TOCs are. Open a section to read the floor procedure.
Safety
- 1-1Liningp.6
Safety guidelines I
Core operating rules before you touch the machine.
- 1-2Liningp.7
Safety guidelines II
Electrical awareness and lockout / tagout discipline.
- 1-1Visionp.6
Safety guidelines I
Same core rules as the lining machine — read them on this station too.
- 1-2Visionp.7
Safety guidelines II
Electrical awareness and lockout / tagout on the vision cell.
Specifications
- 2-1Liningp.8
Electrical and pneumatic requirements
Service ratings for power and compressed air.
- 2-2Liningp.9
Contacts
Big Sky Engineering service contacts and hours.
- 2-1Visionp.8
Electrical and pneumatic requirements
480 VAC service; vision air comes from the lining machine.
- 2-2Visionp.9
Contacts
Big Sky Engineering service contacts and hours.
Machine outline
- 3-1Liningp.10
Lining system overview
Major stations from feeder through vision and HMI.
- 3-2Liningp.11
Hardwired buttons
Cycle Start, Cycle Stop Reset, System On, and E-Stop.
- 3-3Liningp.12
E-stop locations
Five e-stops; reset by turning clockwise.
- 3-4Liningp.13
Power and LOTO
System On, panel disconnect, and lockout sequence.
- 3-5Liningp.14
Stack light indicator
Red, amber, green, and blue lamp meanings.
- 3-6Liningp.15
Doors
Five guarded doors reported on the status bar.
- 3-7Liningp.16
FRL / air location
Relief valve, regulator, and soft-start dump valve.
- 3-8Liningp.17
Tooling plate
Two actuators drive the stop flags.
- 3-9Liningp.18
Conveyors
Infeed pair, outfeed to the accumulator, and access guards.
- 3-10Liningp.19
Hand-wheel
Manual press positioning for jam recovery.
- 3-11Liningp.20
Spool unwinder
Lining-material supply with forward / reverse feed.
- 3-12Liningp.21
Feeding material
Nip roller, lining guide, and waste chopper.
- 3-13Liningp.22
Sensors I — fiber optic and lining verification
Cap-presence fibers and lining/paper verification.
- 3-14Liningp.23
Sensors II — index and infeed guard
Web-index correlation and infeed-guard state.
- 3-15Liningp.24
Sensors III — splice and low feed
Splice divert and unwinder demand.
- 3-1Visionp.10
Vision system overview
Reject chutes, unsensored guard doors, HMI, infeed, FRL, panel, outfeed, blower.
- 3-2Visionp.11
Hardwired buttons
Cycle Start, Cycle Stop Reset, System On, and E-Stop under the HMI.
- 3-3Visionp.12
E-stop locations
Two e-stops: outfeed corner and HMI console.
- 3-4Visionp.13
Power and LOTO
System On, red panel handle, and five-step lockout.
- 3-5Visionp.14
FRL / air location
Relief valve, regulator, and soft-start dump under the infeed.
- 3-6Visionp.15
Transparent guard view
Infeed, first and second inspection conveyors, cameras, flip track, spinner reject.
- 3-7Visionp.16
Flip track
Inverts the cap between the two inspection conveyors.
- 3-8Visionp.17
Cameras
Six cameras: tower, liner/top dome, four sides, and post-flip.
- 3-9Visionp.18
Sensors
Belt triggers, six cameras, encoder wheel, reject-gate confirmation.
HMI
- 4-1Liningp.25
Splash screen and status-bar colors
First HMI page and red / yellow / green status meaning.
- 4-2Liningp.26
Main / home screen
Lock, mode, controls, statistics, and status bar.
- 4-3Liningp.27
Screen select menu
Grid of all HMI destinations.
- 4-4Liningp.28
Feeder sorter screen
Start and stop feeder, sorter, and hopper processes.
- 4-5Liningp.29
System information screen
Scan times, lifetime cycles, Dry Run and Run Out modes.
- 4-6Liningp.30
Web feed screen
Jog, unwind, brake, and lining-usage reset.
- 4-7Liningp.31
Punch screen
Maintenance punch jog, position, clockwork, tamp, vacuum, kickers.
- 4-8Liningp.32
Cap feed conveyors screen
Infeed, outfeed, tool, and vision accumulator status.
- 4-9Liningp.33
Alarm history screen
Scrolling log of warnings and alarms.
- 4-10Liningp.34
I/O screen
Live input and output states.
- 4-11Liningp.35
Machine statistics screen
PackML-style process states and dwell times.
- 4-12Liningp.36
Alarm diagnostics screen
Select, enable, delay, count, and reset each alarm.
- 4-13Liningp.37
Recipe operations
Select, copy, and save recipes while logged in.
- 4-14Liningp.38
Additional setup screens
Clockwork, punch, web-feed times, fibers, and lanes.
- 4-1Visionp.19
Splash screen and status-bar colors
PRESS TO ENTER MAIN SCREEN; red / yellow / green status.
- 4-2Visionp.20
Main screen
Camera, mode, recipe select, reject statistics, ESTOP 1–2 and AIR.
- 4-3Visionp.21
Screen select menu
Liner, Top, Sides 1–4, All Images, Recipe Edit, Parameters, Conveyor & Reject.
- 4-4Visionp.22
All Images screen
Every available image and angle from the six cameras.
- 4-5Visionp.23
System information — Liner
Thresholds, defect area, dissimilarity, trigger; Lights and Trigger.
- 4-6Visionp.24
System information — Top
Top-camera page; Lights and Trigger.
- 4-7Visionp.25
System information — Side
One page per side camera (1–4).
- 4-8Visionp.26
History screen
Short rolling log of captured images — older frames are overwritten.
- 4-9Visionp.27
Analytics screen
Overall, liner, side, and top reject trigger counts.
- 4-10Visionp.28
I/O screen
Live inputs and outputs; green means active.
- 4-11Visionp.29
Alarm diagnostics screen
Select, enable, delay, count, and reset each alarm or warning.
- 4-12Visionp.30
Recipe Edit screen
New, copy, paste, delete, activate — while logged in.
- 4-13Visionp.31
Machine statistics screen
PackML-style process states and dwell times.
- 4-14Visionp.32
Parameters screen
Speeds, triggers, Setup Mode, and inspect enables.
- 4-15Visionp.33
Conveyor and Reject screen
Manual lights, conveyors, blower, diverter — maintenance only.
Changeover
Recipes
- 5-1Visionp.34
Changing recipes I
Log in as Setup or higher, pick the recipe, Activate Recipe.
- 5-2Visionp.35
Changing recipes II
Green name means loaded; verify liner contour reference.
- 5-3Visionp.36
Restoring a recipe from power-up I
Setup Mode, then Cycle Start and Teach Contour.
- 5-4Visionp.37
Restoring a recipe from power-up II
Send a lined good cap until the contour is a blue line.
- 5-5Visionp.38
HMI side interface — parameters
Thresholds, defect area, outer area, mask rectangle, ROI.
- 5-6Visionp.39
Side interface — binary threshold off
Look for bright pixels; defects show white.
- 5-7Visionp.40
Side interface — binary threshold on
Look for dark pixels; defects show black.
- 5-8Visionp.41
ROI creation
Left and upper boundaries plus width and height crop the raw image.
- 5-9Visionp.42
Mask creation
White overlay kills background; breaks should read as black.
- 5-10Visionp.43
Side reference images
Pages 43–45 show example side reference frames.
- 5-13Visionp.46
HMI liner interface — parameters
Threshold, defect, outer area, mask offset, dissimilarity, ovality.
- 5-14Visionp.47
Liner interface — reading pixels
Touch a region to read threshold or brightness in the corner.
- 5-15Visionp.48
Liner interface — threshold and defects
Black below min threshold; defects outlined in red.
- 5-16Visionp.49
Liner interface — outer area and mask offset
Blue min outer, red max outer, yellow mask offset / tabs.
- 5-17Visionp.50
Liner interface — dissimilarity and ovality
Taught vs found contour; 1.0 is a perfect circle.
Belt change
- 6-1Visionp.51
Changing the belts — prep
LOTO, mark cameras and sensors, gather tools.
- 6-2Visionp.52
Infeed conveyor belt change
Relieve tension, 10-32 plexi, 1/4-20 end plate, swap belt.
- 6-3Visionp.53
Second (first inspection) conveyor belt change
Transition plate, guide, two camera towers, reject chute, then the belt.
- 6-4Visionp.54
Third (second inspection) conveyor belt change
Transition plate, fiber-optic mount, cap escape, chute, plexi, end plate.
Maintenance
Parts
- 7-1Liningp.70
Lining machine parts
Full bill of materials, pages 70–111.
- 7-2Liningp.112
Recommended spare parts
Factory-recommended on-hand spares, pages 112–114.
- 8-1Visionp.56
Vision system machine parts
BOM on pages 56–60 of 9002426-06.
- 8-2Visionp.61
Recommended spare parts
Factory-recommended vision spares — belts, drives, cameras, fuses.
Drawings
- 8-1Liningp.115
Electrical drawings
Electrical drawing set begins on page 115.
- 8-2Liningp.157
Mechanical drawings
Mechanical drawing set begins on page 157.
- 9-1Visionp.62
Electrical drawings
Electrical drawing set begins on page 62 of 9002426-06.
- 9-2Visionp.84
Mechanical drawings
Mechanical drawing set begins on page 84. Controls assembly 9400267.