rtm x42 multi-channel radio transmission tension monitoring and

www.fms-technology.com

RTM X42

Multi-Channel Radio Transmission

Tension Monitoring and Control System

7th Jan 2015

Francisco Ferrer

http://www.fms-technology.com/



FMS Force Measuring Systems AG CH-8154 Oberglatt 08.01.2015 / Seite 2

Benefits of Tension Control

Variations in tension are responsible for a

variety of defects in different types cable

products:

• Ropes that aren’t straight because of

uneven tension in different strands

• Steel cables in elevators, cranes, cable

cars and such do not reach their

maximum strength because not all

strands are under the same tension and

therefore the load is not distributed

evenly amongst all strands

• Electrical properties can not be

maintained: resistance, cross-talk etc.

with tension control

without tension control


RTM-Systems

Radio Transmitted Tension Monitoring

• RTM is an innovative system that utilizes force measuring rollers to capture the

tension of individual wires or strands.

• All relevant control data is securely transmitted from the rotating to the static

portion of the machine via a radio link, without the use of troublesome slip rings.

• RTM offers a sophisticated range of interface options to integrate it quickly and

efficiently into the existing communication and control infrastructure of the

machines.

• It is the ideal upgrade of cable producing machinery to cutting edge technology

for tension measurement since it improves production rates and outgoing quality

level.

• The RTM-family offer both the machine builder and the machine user a basis for

efficient cost and quality management.

• 3 different RTM-Families are currently in use with more then 30 installations ww.

RTM 01/02 RTM X2 / RTM X2.MP RTM X42


The RTM-family

Bow

Force

Sensor

Twisting

Point

Bobbins,

Cradles

Force

Sensors

Bo

bb

ins, C

rad

les

Cage Twisting

Point

Force

Sensor

Bobbins,

Cradles

Twisting

Point

RTM 01/02 for: Planetary Cage Stranders Being replaced by RTM X42

RTM X2 and RTM X2.MP: Bow Type Stranders

RTM X42: Planetary Cage Stranders Tubular Stranders Rigid Stranders


Principal Schematics RTM System


RTM X42 General Overview

PC with RTM-software:

Tension Monitoring

System Configuration

PLC: Tension Control

Safety Technology

RTM Transmitter Channel

Extension


RTM X42 Sub-variants (i)

RTM X42.IO RTM X42.PC RTM X42.MODBUS

RTM X42.PC/IO RTM X42.MODBUS/PC RTM X2.MP


RTM X42 Sub-variants (ii)

• RTM X42.IO: Standard system with possibility to connect up to 42 force sensors. 42 analogue outputs and web browser for parameter setting.

• RTM X42.PC: 42 force sensors. RTM-PC Software with data processing capability and visualisation of up 42 channels on PC-monitor.

• RTM X42.PC/IO: The same configuration as RTM X42 PC but expansion of receiver to up to 42 analogue outputs

• RTM X42.MODBUS: Up to 42 force sensors. Interface Modbus TCP – Profibus DP Slave via Gateway on receiver side.

• RTM X42.MODBUS/PC: Interface Modbus TCP – Profibus DP Slave via Gateway on receiver side. RTM-PC Software with data processing capability and visualisation of up 42 channels.

• RTM X2.MP: Multi Purpose System with encoder signal processing for 2 channels (optional 4 channels), 8-16 dig. inputs/outputs and 2 force sensors.

The RTM X42 System bases on RTM X2 technology. The modular concept of RTM X42 allows an incremental expansion of the system by modules of 4 channels up to a maximum of 42 channels. It is offered in 6 different sub versions :


RTM X42.IO System with Analogue IOs • Expansion of the system by modules of 4 channels up to a maximum of 42 channels.

• Analogue outputs provide controlling capability over a PLC. Relay outputs for alarms.

• Parameter setting over a build-in Web browser.


Relay Functions RTMX42.IO

The RTM X42.IO System can be configured to trigger alarms, if certain tension limits are violated or system relevant functions such us supply voltage or radio link are out of range. This is realised by means of Relay Outputs. The alarm outputs are activated if one of the active channels over or under shots the pre-set limits. The Relay functions are described in the following table.

Relay Function EMGZ482R

Function EMGZ484R

Relay 1 Tension limit CH1 Tension limit CH3

Relay 2 Tension limit CH2 Tension limit CH4

Relay 3 SW-programmable: - Battery status OK - Tension limit Core - Radio link OK - Sum Error CH1-42

Tension limit CH5

Relay 4

Tension limit CH6


RTM X42.IO System Components

Cable to next EMGZ484T

Power Supply for

EMGZ482T.24 VDC

Force Measuring Rollers

CH1 and CH2

Bus Termination

4x

PLC

Ba

sic

I/O

24

VD

C

A.O

ut C

H 1

- 2

Re

lay C

H1

-2

An

al. O

ut C

H 3

-6

Re

lay C

H 3

-6

Re

lay C

H 7

-10

An

al. O

ut C

H 7

-10

RJ-4

5 P

atc

h -

ca

ble

Web browser

Parameters


RTM X42.PC System • Channel expansion done on transmitter side (up to 42 CH with EMGZ484T)

• EMGZ482R handles all transmitted channel data. PC runs FMS-RTM-Software package

• Visualisation, data log and quality reports of channels


RTM X42.PC System Components

24 VDC


Power Supply for

EMGZ482T.24 VDC

Force Measuring Rollers CH1 and CH2

RJ45 Connector

Patch-cable

Bus Termination

4x


RTM X42.PC/IO System • RTM X42.PC-System but with possibility to add analogue and relay outputs for PLC.

• The data processing software allows tension analysis of up to 42 channels

• Combines the versions RTM X42.PC and RTMX42.IO in one.


RTM X42.PC/IO System Components


Power Supply for

EMGZ482T.24 VDC


Bus Termination

4x

PLC

Ba

sic

I/O

24

VD

C

A.O

ut C

H 1

- 2

Re

lay C

H1

-2

An

al. O

ut C

H 3

-6

Re

lay C

H 3

-6

Re

lay C

H 7

-10

An

al. O

ut C

H 7

-10

RJ-4

5

Pa

tch-c

ab

le


RTM X42.MODBUS System • Enables to hook-up on any existing data bus system of machine

• Gateway module provides interface from Modbus to any other bus system

• Tension values are output as raw data and can be further processed on PLC


• Enables to hook-up on any existing data bus system of machine

• Gateway module provides interface from Modbus to any other bus system

Profibus

or any bus

RTM

Receiver

Gateway

PLC

RTM X42.MODBUS Interface Adaptation


RTM X42.MODBUS System Components

24

VD

C

Cable to next

EMGZ484T.MODBUS

Power Supply for

EMGZ482T.MODBUS.24 VDC


RJ45

Patch-cable

Bus Termination

4x

PLC

24

VD

C

RT

M X

42

Ga

tew

ay


RTM X42.MODBUS/PC System • Combination of the two subsystems RTM X42.PC and RTM X42.MODBUS

• On the receiver side data transmission via Gateway (Modbus – any bus system)

• FMS PC-RTM-Software package with data analysis and visualisation of 42 channels


RTM X42.MODBUS System Components

Cable to next

EMGZ484T.MODBUS

Power Supply for

EMGZ482T.MODBUS.24 VDC


Patch-cable

Bus Termination

4x

PLC

Gateway

24

VD

C

24

VD

C

Patch-cable


RTM X2.MP+ System • Multi Purpose System with encoder signal processing for max. 4 channels, 16 dig.

inputs/outputs and 2 force sensors. Transmitter and Decoding separated.


RTM X2.MP System Components

24 VDC

Force Measuring Rollers

Motor

24 V

DC

Driver

Slip rings


RTM X2.MP+ System • Multi Purpose System with encoder signal processing for max. 2 channels, 16 dig.

inputs/outputs and 2 force sensors. Combined Transmitter and Decoding Unit.


RTM X2.MP+ System Components

Force Measuring Rollers Driver

Motor

24

VD

C

Slip rings


Application Area RTM X2.MP The RTM X2.MP system enables wireless transmission and processing of encoder

signal, e.g. for:

• Closed loop control of drives

• The control of the traverse guide in pay-off stations.

• Control of spindle locks and proximity switches on traverses via dig. and analogue I/Os.

• Measurement of wire tension data for two channels.


Application Schematics RTM X2.MP+

Encoder 1

Encoder 2

Load cell

Motor


RTM X42 Software

• The RTM X42.PC is offered as a package including FMS configured PC, pre-set and tested RTM-Software.

• The SW runs on PC with Windows OS (office basic 2007 package or higher).

• Precise, consistent monitoring of all tension data relevant to production (42 channels)

• Visualization and synchronization of tension data to the product by running length

• Sophisticated software for tension data analysis (incl: limit violations, alarms, quality reports)

Operator Screen


Data Evaluation / Alarms

Histogram Sheet: • Shows all active channels

• Min. / Max. limits

• Errors (outliers) marked by point

Alarms: • Outlier clearly recognizable and

assigned to „running meter“.

• Min/max limit violations trigger an

alarm. The RTM X42 receiver

(EMGZ484R) switches a relay output

which can activate flash light or it

can also be used to turn off the

machine.

Central core

Channel 2

Channel 1


Data Log, Limit Violations

Contains: • Channel # where violation

happened

• Allocation of violation to

running meter / time

• Other production relevant data

Use of protocol: • Quality purposes

• Production lot documentation


Radio Certification RTM X42

The component certifications of

RTM X2 are also valid for the

RTM X42-System.

• Certification granted for Europe

(EU), EFTA-States, Switzerland

• RTM X42 passed FCC compliance

tests for USA / Canada.

• Certification granted for Japan

per 19 Aug. 2011.

RTM X2 System ● Radio Certification

Magnitude of Test Article 3.2 of Directive 1999/5/EC (R&TTE Directive)

Certification ETSI EN 300 440-2 V1.5.1 (2009-03) ETSI EN 300 440-1 V1.3.1 (2009-03)

RTM X2 System ● EMC Certification

Magnitude of Test ECM-Test according to 98/37/EC and 2004/108/EC harmonized

Emission/Immunity ETSI EN 489-3; EN 61326-1

RTM X2 System ● FCC Certification USA, Canada

Magnitude of Test Class A digital device, pursuant to Part

15 of the FCC Rules

Certification FCC Registration #: 0020311882

RTM X2 System ● CAB Radio Certification for Japan

Magnitude of Test Low power Data communication FXD Article 38-24, Paragraph 1 of radio law

Certification Article 2, Clause 1 Item 19 Certification ID #: 202WWSM10126721


RTM X2 Radio Certification for Japan

CAB - Japan

FCC - USA

rtm x42 multi-channel radio transmission tension monitoring and

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