Gt250 pe hmi manual (rev2)

Download Gt250 pe hmi manual (rev2)

Post on 10-Aug-2014

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DESCRIPTION

The interface consists of 3 areas: overhead menu, central display for values and the bottom area for Status display and utility buttons

TRANSCRIPT

<ul><li>rev. 2 GT-250-PE Operation </li><li>[GT-250-PE OPERATION] April 22, 2014 2 Contents Human-Machine Interface............................................................................................................... 3 Configuration Panel..................................................................................................................... 5 Bend History - Operator............................................................................................................... 9 User Selection Screen............................................................................................................... 10 Authenticate - Operator ............................................................................................................. 11 Authenticate - Supervisor .......................................................................................................... 12 Bend History - Supervisor.......................................................................................................... 13 Report Viewer - Supervisor........................................................................................................ 14 Operation - Hydraulic Check...................................................................................................... 15 Operation - Prepare For Bending............................................................................................... 16 Operation - Ready to Bend........................................................................................................ 17 Operation - Bend in Progress ................................................................................................... 18 Operation - PDF Report............................................................................................................. 19 Control Panel................................................................................................................................ 20 1.Touch Screen Display: ........................................................................................................... 20 2. L.E.D. Lamps (for status display)........................................................................................... 21 3. Selector Switches.................................................................................................................. 21 4. Push Buttons......................................................................................................................... 22 5. Push Buttons with LED Lamps ....................................................................................... 23 6. Emergency Stop Button......................................................................................................... 23 Auxiliary power.............................................................................................................................. 24 Monitoring video cam.................................................................................................................... 25 Calibration Sequence.................................................................................................................... 26 Calibration Sequence Application.............................................................................................. 31 </li><li>[GT-250-PE OPERATION] April 22, 2014 3 Human-Machine Interface The interface consists of 3 areas: overhead menu, central display for values and the bottom area for Status display and utility buttons. The main screen of the GT-250-PE Software consists of 3 Graph Bars, displaying the 3 measured and calculated values: Force, Bend and Speed, each displayed with 2 decimals their respective measuring units. These are used to display the Real Time value of the measurements. The sample rate of recording is 200 Hz, however for practical reasons the displayed value is only refreshed at a 10Hz rate, making the values shown readable. To the right of the graph bars there is a real time display of the end graphic which has an update rate of 5Hz, however the actual values are recorded at the 200Hz rate. </li><li>[GT-250-PE OPERATION] April 22, 2014 4 Above the real time graphic display, the user type, date and time are displayed. The Status area displays the current state of the machine, and has the following possible states: IDLE, Hydraulic Check, Prepare for Bending, Ready to Bend, Bend in Progress. Each will be discussed individually later on. The Slow Bend Test Setup displays the current setup and information about the rail about to be tested as the Operator has configured it. To the right of the "Slow Bend Test Setup" there are 2 buttons and 1 usb status display. The "print last report" button offers the Operator the ability to generate the PDF for the previous bend process. The process will be detailed later on. The "refresh graph" button refreshes the Real Time graph of the interface and should only be used for consecutive Bend Tests during the same session. If this is not used the result will be a comparative graph display of all the tests performed until this button is hit. This function is not available during the bend test. The" USB Ready" status is used to display the presence of a USB Mass storage device. The overhead menu contains 5 buttons: "Home", "Configure", "Bend History", "Log Off" and "Close". These can be accessed through-out the entire operation of the interface with a few exceptions that will be detailed later on. To return to the Main Screen you can always press the "Home" button. </li><li>[GT-250-PE OPERATION] April 22, 2014 5 Configuration Panel The configuration panel consists of 4 sub-menus that define both test and report parameters. All sub-menus have 3 buttons: "Set" , "Clear" and "Close". The "Set" button validates the changes made to the inserted parameters and returns the operator to the previous screen. The "Clear" button resets all parameters and leaves a blank space. The "Close" button returns the operator to the previous screen. The "Operator Details" sub-menu contains the Press Operator details that will be displayed on the final report. "Operator ID" is an exception as it is only used internally for database purposes. To complete each field press the keyboard symbol displayed in the sub-menu window, this will bring up the On-Screen Keyboard. Press (Enter) after each field is complete. As seen in the above image the Operator Details contains 4 fields: - First Name (Reported) - Last Name (Reported) - Job Title (Reported) - Operator ID (Not Reported) </li><li>[GT-250-PE OPERATION] April 22, 2014 6 The "Location Details" sub-menu contains the fields to be completed for the location details that will be displayed on the final Report. The "Country" field can be completed with either the country initials or the full name of the country. The "Bend Location" field represents the location of the press when the test is performed. These are important details as environmental parameters can affect both rail and slow bend test results. </li><li>[GT-250-PE OPERATION] April 22, 2014 7 The "Bending Setup" sub-menu contains the slow bend test parameters to be followed for the next test or until the parameters are changed. The "Required Force" field defines the minimum force to be reached for the rail coupon to pass as valid; the value entered here can be anywhere between 0 and 2500, value expressed in KN. The "Required Bending" field defines the minimum bending to be reached for the rail coupon to pass as valid; the value entered here can be anywhere between 0 and 50, value expressed in mm. The "Break Rail?" option defines if the test should continue until rail break, after the minimum requirements have been met. If this option is not selected the test will go on until the minimum value of each measurement + 1.5% are exceeded, and if the rail doesn't break the test will be evaluated as Passed. If the option is selected the test will continue until the rail breaks and evaluated according to the minimum requirements. </li><li>[GT-250-PE OPERATION] April 22, 2014 8 The "Welding Details" sub-menu is used to enter data regarding the welded rail coupon to be tested. As seen in the image above, the fields are as follows: - Rail Grade (Reported) - Rail Type (Reported) - Weld Type (Reported) - Welding Machine SN (Reported) - Welding Head SN (Reported) - Welding Contract (Reported) - Welding Operator (Reported) - Weld ID (Reported) The Rail Grade and Rail Type are displayed on the Main Screen, after being inserted, for reference. </li><li>[GT-250-PE OPERATION] April 22, 2014 9 Bend History - Operator The "Bend History" button will bring up the folder in which all the slow bend test reports are stored on the USB mass storage device. This will contain only the bend tests saved on the currently inserted USB mass storage device. To return to the interface simply close the window or press the touch-screen anywhere outside the history window. </li><li>[GT-250-PE OPERATION] April 22, 2014 10 User Selection Screen The "Log Off" button will bring up the User Selection screen. The interface provides 2 user levels: Operator and Supervisor. Either user is not properly logged off until the inactive user level becomes active. Each user level has a different level of control within the interface. Further detail will be provided at Bend History - Supervisor. By selecting either user level, the interface will bring up the appropriate login screen. </li><li>[GT-250-PE OPERATION] April 22, 2014 11 Authenticate - Operator By pressing the "Operator" button within the "User Select" screen the interface will bring up the authentication screen for the Operator user level. If this user was logged in when pressing the "log off" button and no user switch has occurred, the Login button will be active and offers straight login without the need to insert the appropriate password. In the event that this is an actual user switch, the "Login" button will be inactive, and password input will be necessary. For this, press the keyboard symbol and then select the password field. Press (Enter) after typing in the password. If the password is valid the "Login" button will become active. By default, on delivery, the interface is logged into Operator mode and ready for use. The Operator user level password, shall be provided by the client before SAT commences and should be of numerical value and of maximum 7 digits (cannot start with a 0 "zero"). Must be different than Supervisor level password. </li><li>[GT-250-PE OPERATION] April 22, 2014 12 Authenticate - Supervisor By pressing the "Supervisor" button within the "User Select" screen the interface will bring up the authentication screen for the Supervisor user level. If this user was logged in when pressing the "log off" button and no user switch has occurred, the Login button will be active and offers straight login without the need to insert the appropriate password. In the event that this is an actual user switch, the "Login" button will be inactive, and password input will be necessary. For this, press the keyboard symbol and then select the password field. Press (Enter) after typing in the password. If the password is valid the "Login" button will become active. The Supervisor user level password, shall be provided by the client before SAT commences and should be of numerical value and of maximum 7 digits (cannot start with a 0 "zero"). Must be different than Operator level password. </li><li>[GT-250-PE OPERATION] April 22, 2014 13 Bend History - Supervisor The "Bend History" button will bring up the internal archive of the interface and allow the Supervisor user level to access all slow bend tests performed using the present interface version. To bring up a specific report the Supervisor user must first select the graphic related to the desired report, press OK upon selection. After the graphic was selected, the Supervisor user must select the report to bring up, has to be the same selection as the graphic, press OK upon selection. This will bring up the Report Viewer. </li><li>[GT-250-PE OPERATION] April 22, 2014 14 Report Viewer - Supervisor The Report viewer can be used to generate the PDF file for the report in the event that there was no USB mass storage device present at the time the slow bend test occurred. If the graphic was not correctly selected, press the "Reload Diagram" button. This will bring up the graphic selection window again. In the event that data recorded on the report was not correctly inserted at the time of the slow bend test, the interface allows the Supervisor to temporarily modify the data and print out the PDF for the modified report. (Not recommended, to be used at your own risk). To edit any cell in the report, bring up the On-Screen Keyboard by pressing the keyboard symbol on the screen. The original report data will remain intact within the interface database. </li><li>[GT-250-PE OPERATION] April 22, 2014 15 Operation - Hydraulic Check Upon pressing the "Start Hydraulic Pump" button on the console, the interface "Status" will display "Hydraulic Check". During this time the PLC checks if the hydraulic station has started. If the hydraulic station is active, the button will be lit green, however operation will not be possible until the "Speed" switch is set to "Low" and "Mode" switch to "Manual". This is a safety precaution, set in place for user safety. After the above criteria have been met, the "Status" will display "Prepare For Bending". </li><li>[GT-250-PE OPERATION] April 22, 2014 16 Operation - Prepare For Bending Upon completion of the "Hydraulic Check" sequence, the interface will allow manual press operation from either control panel or the remote control mounted on the press. This can be selected by setting the "Control" switch to "Local" or "Remote" and by setting the "Speed" switch to either "Low" or "High". After rail coupon has been inserted, cylinder has been set into default position, press doors have been closed, the operator can set the "Speed" switch to "Run" and "Mode" switch to "Auto". If all the safety requirements and settings have been met, the interface "Status" will display "Ready to Bend" and the "Start" button will begin blinking green, on and off. </li><li>[GT-250-PE OPERATION] April 22, 2014 17 Operation - Ready to Bend Upon completion of the "Prepare For Bending" sequence, If all the safety requirements and settings have been met, the interface "Status" will display "Ready to Bend" and the "Start" button will begin blinking green, on and off. If any of the safety requirements become invalid for testing to proceed, or if the switches are moved out of the appropriate position, the interface "Status" will return to the "Prepare For Bending". To begin the slow bend test, press the "Start" button on the console. In this case the interface "Status" will display "Bend in Progress" and the "Start" button on the console will remain green lit. </li><li>[GT-250-PE OPERATION] April 22, 2014 18 Operation - Bend in Progress Upon completion of the "Ready to Bend " sequence, the bend...</li></ul>