Operator manual

Priming Process Digitization Line-1

Project Name : Priming Process Digitization Line-1

Project Number : DA_2425_PR_012
Client Details : Hero Motors ,Sidcul, Haridwar
Developed by : DIA Automation
Address : 5-6-137/6/1/D, PUSHPA NILAYAM, Kukatpally, Hyderabad.
Contact Details : Mr. Prashanth
Mobile : 9059557762/3/4
Email : [email protected]
Website : www.diaautomation.com

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 Contents
1.Introduction .......................................................................................................................................... 2
1.1 Project Overview ................................................................................................................... 2
1.2 Purpose of the System ........................................................................................................... 2
2.Operation Procedure ............................................................................................................................ 3
3. Flow Chart .......................................................................................................................................... 4
4 IO List .................................................................................................................................................. 5
Images ..................................................................................................................................................... 6
7 BOM .................................................................................................................................................... 7
8 Maintenance Check List ......................................................................................................................... 8

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1.Introduction

Purpose of the Manual:

This manual provides essential guidance on the operation, maintenance, and

troubleshooting of the Priming Process Digitization for Poka Yoke. It aims to help
Operator’s effectively utilize to get the Current values of the vehicle to ensure precision
and reliability in the assembly process.

Intended Audience:

This manual is intended for production managers, operators, and maintenance

personnel involved in the Line. It is designed for users with varying levels of
experience, offering clear instructions to ensure safe and efficient operation.

1.1 Project Overview

The Priming Process Digitization Poka Yoke system is designed to verify and minimize the
errors of Current Limit Values in Vehicle. The main aim is to enhance production efficiency,
improving product quality, and minimizing the risk of errors in the assembly process.

1.2 Purpose of the System

Purpose: The purpose of the described process is to ensure efficient and safe
operation of a system by automatically controlling it based on vehicle-specific current
readings.
Functionality: Based on vehicle-specific current readings, ensuring vehicles within
acceptable current ranges proceed while integrating with existing PLC and HMI
systems for efficient and safe operation.

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2.Operation Procedure

Priming Process Digitization Poka Yoke for Different Models. The operator will begin
by selecting the appropriate vehicle model using the selector switch. After identifying
the vehicle model, the current limit ranges specific to that model are set in the HMI
(Human-Machine Interface). The system then reads the current values from the CT
(Current Transformer) coil and compares these values to the pre-set current limit
ranges for the selected model. If the current values fall within the set limits, the
vehicle is considered to be OK, a green lamp will glow. Conversely, if the current
values do not fall within the set limits, the vehicle is considered not OK, a red lamp
will glow, and gives the Purple Buzzer Indication. The existing PLC (Programmable
Logic Controller) is used to integrate and digitize the priming process. Additionally,
the HMI screen includes a bypass function that is protected by a password, and there
is an interlock with a hooter to ensure no stoppage of the conveyor.

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3. Flow Chart

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4 IO List

IO List
Sl. No I/O Details IO Address
1 Model -1 SPL + AAEP(Non techno/Techno) X30
2 Spare X31
Inputs
3 Model -3 SPL + AAEL(Techno 2.0) X32
4 Spare X33
5 Tower Lamp Red Y30
6 Tower Lamp Yellow Y31
Outputs
7 Tower Lamp Green Y32
8 Purple Buzzer Y33

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Images

Fig: Priming Process Digitization for Poka Yoke Images

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 7 BOM

S.No Description Model Number Make Quantity Unit

1 FX 5U RS232 BD Module FX5U RS232BD Mitsubishi 1 Nos

2 FX5- Analog Input Module FX5-4AD Mitsubishi 1 Nos

3 8 Channel Digital Output Module FX5 8EYT/ESS Mitsubishi 1 Nos

4 Shunt Coil (0-50A) Rishab 1 Nos

5 Signal Transducers TV808DUCER Rishab 1 Nos

6 Digital Indicator Display PIC152 Selec 1 Nos

7 1P 4 way Selector Switch with Box Kaycee 1 Nos

8 Communication Cable Required Meters

9 3 Core 1.5 Sqmm Cable Flexible Cable Required Meters

10 6 Core 0.5 Sqmm Cable Flexible Cable Required Meters

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 8 Maintenance Check List

S.
Activity Condition Frequency Action Period Method
No
Check the power
Should be in Do
cord &plug, After
working mode maintenance
1 Tower Lamp Bulbs & lamp every 4 Manual
like warning, whenever
holders, months
signalling. needed
Signaling circuit
Check the wire
Do
Wires connections, After
maintenance
2 Relay connections Coils and every 6 Manual
whenever
should be tight Tripping months
needed
currents
Wireless
Do
connections Check the After
Ethernet maintenance
3 should be proper communication every 12 Manual
Connection whenever
for wires months
needed
communication
Check cable Inspect and
Electrical After
connections in Tighten
4 Cable Every 12 Manual
panel and Electrical
Connections Months
counter display Connections

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