Sensors

Sensor Monitoring and Maintenance Guide

Tape Sensor

This sensor detects the star wheel attached to the one-way rotating roller in the tape dispenser. It detects any issues with tape dispensing and generates a tape failure if there are incorrect pulses.

If the tape is not dispensed properly or breaks, the sensor detects an incorrect number of pulses. Check the speed settings and time for tape check if the case comes out of the machine.

Tape Almost Empty Sensor

This sensor detects the amount of tape on the roll. When the tape is almost empty, it triggers a warning on the main screen, indicating the need to change the tape roll.

Discharge Free Sensor

This sensor checks downstream and is attached to the conveyor. It detects if the conveyor is blocked and stops the case erector. It should be located at a minimum distance of 1.5 times the maximum case length.

Flap Compressor Home Sensor

This sensor is used during machine initialization and each cycle when the machine is running in a stop/wait position. It serves as a reference for the zero position for the Digitax.

Encoder for Up/Down Movement

This encoder checks the performance of the Digitax. It compares the speed and feedback from the encoder and self-corrects the output speed if there is a difference.

Case Unfolded Sensor

This sensor is used to check if the case is unfolded properly. This sensor is mounted in the adjustable inner flap folder and checks if the blank held by the suction frame is folded correctly. If the sensor does not detect the blank, the vacuum drops and the blank falls down, triggering a "Failure suction frame" error.

Air Pressure Sensor

This sensor checks the air pressure, which should be at 6 Bar/83 PSI.

Check Main Power

This sensor checks the main power supply.

E-stop and/or Doors Open

This sensor checks if the emergency stop and/or doors are open.

Blank Magazine Almost Empty Sensor (Optional)

This sensor is located at the front underneath the lower separator plate. It detects if the blanks in the magazine are running low and triggers a warning light to refill the magazine.

Blank Magazine Almost Empty (Cycle Stop)

When the magazine runs almost empty, this sensor detects the slide unit and stops the machine. It triggers a message on the HMI to load the magazine.

Stop Position Case in Side Belts Sensor

This sensor detects the rear end of the case and is used when a hotmelt is applied to the machine. It helps to stop the side belts accurately.

Glue sensor

This sensor detects the inner flap of the case. It uses an optic fiber and has adjustable sensitivity. Different LED combinations indicate the detection status of the inner flap.

To troubleshoot the glue sensor, follow these steps:

1. Step 1: Localize the sensor.

2. Step 2: Tear off an inner flap of the case and place it on top of the optic fiber.

3. Step 3: Check if both LED lights (red and green) are on. If not, re-adjust the sensitivity.

4. Step 4: Ensure that the signal is not disturbed while moving the inner flap over the optic fiber.

Pusher Bar Home Position Sensor

This sensor is used to reset the counter in the program and serves as a home sensor during initialization. It has a detection distance of approximately 4 mm.

Position Impulse Pusher Bar Sensor

This sensor constantly monitors the movement of the pusher bar. Based on impulses, it activates different speeds or allows the pusher to go in reverse. It also detects any manual movement of the pusher bar when the door is open.

When replacing a sensor, make sure the high and low signal is as equal as possible during the rotation of the detection disc. This can be done by moving the sensor away or towards the detection disc.