5.10Section Automatic Pick Controller (APC-II), Optional

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Optional

5.10 Automatic Pick Controller (APC-II), Optional... 5.10-2 5.10.1 Features of APC-II Control ... 5.10-2 5.10.2 APC-II System Configuration... 5.10-3 [ 1 ] System Configuration ... 5.10-3 [ 2 ] Regulators and Pressure Sensors... 5.10-3 [ 3 ] APC-II Circuitry (on the C board)... 5.10-5 5.10.3 APC-II Relating Function Panel Setting... 5.10-6 [ 1 ] Operation procedure ... 5.10-6 [ 2 ] Details of Setting Screens ... 5.10-9 5.10.4 Troubleshooting for APC-II Errors ... 5.10-11

[ 1 ] Checking the Pressure Sensors... 5.10-11 [ 2 ] Checking the Regulators ... 5.10-12

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5.10 Automatic Pick Controller (APC-II), Optional

The automatic pick controller (APC-II) automatically controls the air pressure of the main tank so that the actual weft arrival timing (Tw) approaches the desired timing previously entered.

5.10.1 Features of APC-II Control

Major features are shown below.

(1) The APC-II enables the stabilized picking since it constantly monitors the weft arrival timing (Tw).

(2) The APC-II may keep the optimum weft arrival timing regardless of the variation of the weft pulling-out tension as caused by the change in weft bobbin size.

(3) Once you enter the appropriate initial pressure from the function panel, the APC-II automatically adjusts the air pressure of the main tank at the time of warp change.

(4) The APC-II allows the user to set or check the Tw, system pressure, and main nozzle pressure on the function panel.

(5) Once you enter the lower boundary of the system pressure (System P.L. bound), the APC-II will stop the machine immediately if the system pressure drops below the specified lower boundary.

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5.10.2 APC-II System Configuration [ 1 ] System Configuration

[ 2 ] Regulators and Pressure Sensors

[ 2.1 ] Location (for 2-color drum shift) The regulators (motorized reduction valves), pressure sensors, and couplers used for the APC-II are located as shown below.

1: Left-hand side frame 2: Main tank M1 3: Main tank M2 4: Regulator M1 5: Regulator M2 6: Pressure sensors

(for M1, M2, and system pressure) 1

1

2

3 1 2

3

1 2

2

1 2

1

2 LH

control box

RH feeler Control signal

Data setting Data setting

Balloon sensor signal

Pressure sensor

Motorized reduction valve

High-speed solenoid valve High-speed

solenoid valve

Main control box

Sub nozzle Main nozzle

Sub tank

System pressure

Sub end tank Main tank 1

Main tank 2 Function panel

EDP control board

IN

OUT

6

4 5

2 3

1

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[ 2.2 ] Structure of regulators and pressure sensors

(1) Regulator (motorized reduction valve) 1: Regulator body

2: Motor 3: Air inlet 4: Spring

5: Adjustment screw 6: Poppet

7: Diaphragm 8: Sheet

(2) Pressure sensor

1: Pressure sensor body 2: Pressure inlet

3: Cord 4: Label 5: Connector 2

5

4

3

6 1

8

7

4

5 1

2

3

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[ 3 ] APC-II Circuitry (on the C board)

[ 3.1 ] Location of APC-II circuitry

The APC-II circuitry is integrated with LH1 board 2 and LH2 board 3 inside the LH control box 1 located at the left rear of the machine.

* For 4-color specification or more, LH1 board 2 and LH2 board 3 are used.

[ 3.2 ] Location of APC-II connector 2 : LH1 board

4 : Connector CN8 For stepping motor 5 : Connector CN10

For pressure sensor

(color-1 and -2 source pressure)

*3 : LH2 board

(for 4-color specification or more)

*6 : Connector CN8

For stepping motor and pressure sensor (colors 3 and 4)

*7 : Connector CN10

For stepping motor and pressure sensor (colors 5 and 6)

1 3 2

5 (LH1 board) 7 (LH2 board)

4 (LH1 board) 6 (LH2 board) LH1 board 2/LH2 board 3

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5.10.3 APC-II Relating Function Panel Setting

[ 1 ] Operation procedure

Carry out settings on the [ FIXER ] – [ MENU ] – [ TW CTRL ] screens.

(1) Checking the initial pressure settings

Touch the [ APC MANUAL ] switch to call up the screen shown at left.

Set the desired pressure here.

Then, touch the [ INITIALIZE ]. Switch to call up the screen shown at left.

Select the pressure to be initialized and touch the [ ENTER ] switch to set the tank pressure and return to the original screen.

Check that the tank pressure reaches the required level.

NOTE: It takes approx. 30 seconds until the pressure reaches the set level.

(2) Setting the APC-II control system

Touch the [ STANDARD ] switch to call up the screen shown at left.

• APC Control

Setting this to ON automatically controls the pressure instruction value for matching to the Tw target value.

• ATC Control

Normally set this to OFF during ordinary APC-II operation.

• Priority

Set this to APC.

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(3) Timing setting

• Target Tw (target weft arrival angle)

Usually set this value between 230 and 240°.

Determine an optimum value by observing the weaving condition.

The APC-II regulates the main pressure to control the weft arrival angle to approach the target angle.

• Tw limit (upper and lower boundaries from target weft arrival angle)

Warning or machine shutdown will occur upon detection of out of range.

Usually set the upper and lower boundaries to Target Tw ±15°

• If Exceeds limit

Select warning or machine shutdown upon detection of out of Tw limit.

• Limit gauge

In the example, the system determines an abnormality when 8 picks among continu- ous 10 picks are out of Tw limit.

For textiles that frequently cause loose weft, decrease the Tw upper and lower boundary to a value smaller than +15° or the Lmit gauge value so that the warning message will appear easily.

If warning message appears too often, increase the Tw upper and lower boundary or Tw criteria value.

(4) Preparation for operation

Touch the [ APC ] switch to call up the screen shown at left.

• Sampling (pick)

Enter a desired number of sampling picks for calculating the mean Tw.

Usually, enter 30 picks.

Increase this value when Tw values are instable due to large deviation between picks. Here, note that the response will be poorer as you increase the number of sampling picks.

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(5) Setting the pressure upper and lower boundaries

Run the machine and find out upper and lower boundary values where the pressure instruction value is stable on the APC Manual screen.

• Setting the upper and lower boundaries of pressure instruction value

Usual settings are as listed below:

For span yarn:

±0.05 MPa (±0.5 kgf/cm²) from the stable value

For filament yarn:

±0.1 MPa (±1.0 kgf/cm²) from the stable value

• Upper boundary of Main pressure

Set a value as the upper boundary of main pressure as:

i) A value smaller than the currently running source pressure –0.05 MPa (–0.5 kgf/cm²)

ii) Upper limit permitted from the textile quality viewpoint

• Determine a lower boundary of Main pressure to a value that does not cause loose weft.

• Enter a System Pressure Limit bound.

Usually this value is the same as lower boundary for the main pressure.

If the source pressure goes lower than the set lower boundary due to compressor fail- ure or other reasons, the machine automatically stops.

(6) Fixing the pressure

To fix the pressure, set the APC Control to OFF on the STANDARD screen.

The pressure instruction value is set to the current value.

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[ 2 ] Details of Setting Screens

Carry out settings on the [ FIXER ] – [ MENU ] – [ TW CTRL ] screens.

(1) STANDARD

• APC Control

Setting this to ON controls the Tw by con- trolling the pressure. Setting this to OFF runs the machine with the pressure instruction value when this is set to OFF.

• ATC Control

Setting this to ON controls the Tw by con- trolling the solenoid pin valve timing. Set- ting this to OFF runs the machine with fixed timing.

Normally set the ATC control to OFF when the APC control is ON.

• Priority

Determine which of the APC or ATC control has the higher priority.

Usually, priority is given to the APC control.

• Target Tw

Usually set this value between 230 and 240°.

Determine an optimum value by observing the weaving condition.

• Tw limit

Warning or machine shutdown will occur upon detection of out of range.

Usually set the upper and lower boundaries to Target Tw ±15°.

• If Exceeds limit

Select warning or machine shutdown upon detection of out of Tw limit.

• Limit gauge

In the example, the system determines an abnormality when 8 picks among continu- ous 10 picks are out of the Tw limit.

(2) APC

• Main pressure

Enter the upper and lower boundaries of main pressure. Usually, set these values to

±0.1 MPa (±1.0 kgf/cm²) of the stable operation.

There are cases that the values should be increased to ± 0.15 MPa (±1.5 kgf/cm²) such as when filament weft with great Tw deviation is used.

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(3) APC MANUAL

Enter pressure values as follows:

• Running

Enter a pressure value desired during operation.

• Initialize

When the pressure is set while the machine is stopping, it is set to a value higher by the value set here.

(4) ATC

• Main pressure

This denotes the range the solenoid pin timing is changed for the Tw control.

• Sampling (pick)

Enter a desired number of sampling picks for calculating the mean Tw.

Usually, enter 30 picks.

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5.10.4 Troubleshooting for APC-II Errors

[ 1 ] Checking the Pressure Sensors

1 : Pressure sensor body

2 : Label No. 281 ...Main tank 1 No. 282 ...Main tank 2 No. 287 ...System pressure 3 : Blue wire ... E (earth)

4 : Brown wire ...(+12V) power supply 5 : Black wire...Output voltage from the

sensor 6 : (Not connected)

The graph given at left shows the relationship between the output voltage (V) from the pressure sensor and the actual pressure (kgf/cm²).

2

4 5 3 6 1

START

Is the +12V developed across the red and black wires of the sensor?

Does the voltage developed across the white and black wires of the sensor correspond to the actual pressure?

Pressure sensor defective

APC-II circuitry or cable defective NO

NO

APC-II circuitry or cable defective YES YES

3 Output

(V)

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[ 2 ] Checking the Regulators

After checking that the pressure sensors work normally according to the previous item [ 1 ], proceed to the troubleshooting for the regulators.

7 : Motor shaft 8 : Stepping motor 9 : Connector 10 : Regulator 8

9

10 7

START

Disconnect the power cable connector and rotate the motor shaft 7 by hand so that the pressure comes in the range of 0.3 to 0.5MPa (3 to 5 kgf/cm²).

The connector 9 is

Does the entered value agree with the pressure detected by the sensor?

Enter a particular pressure value from the function panel.

The regulator is normal.

NO NO

Does the entered value agree with the pressure detected by the sensor?

NO YES

Stepping motor 8 defective

YES NO

Enter the pressure value from the function panel again.

YES Does the motor rotate?

Does the pressure come into the range of 0.3 to 0.5MPa (3 to 5 kgf/cm²) ?

YES