INTRODUCTION

In the realm of machine operations, the folding section emerges as a pivotal component. Its primary function is to adeptly fold both major and minor flaps before ushering boxes into the sealing section. This integral mechanism incorporates an array of components, finely tuned to orchestrate the vertical maneuvering of the folding section and impeccably discern specific positions for diverse sequences. Central to this orchestration are two inductive sensors, strategically aligned with the home position, thus fortifying their indispensable role. These sensors stand resolute in ensuring the precise alignment of the folding section within the prescribed height parameters.

ISSUE OVERVIEW

The customary operation of the machine involves initiating both the folding and sealing sections to journey towards the home position. However, if, upon this initiation, no motion is detected with all components at the home position, accompanied by the illumination of the "FA Home sensor failure" message on the HMI screen, it serves as a red flag indicative of complications within the integrated components of the folding section responsible for home position detection. In such circumstances, a comprehensive analysis of potential disrupting factors is essential, followed by meticulous identification and systematic troubleshooting measures.

CAUSES OF 'FA HOME SENSOR FAILURE'

1. Inductive Sensor (I:0/14) Misalignment: The intricate system includes a strategically positioned metal bracket on the folding section. During the journey to the home position, an inductive sensor (I:0/14) captures the presence of this metal bracket, transmitting a signal to the PLC. This signal serves as a definitive indicator that the machine has successfully reached the home position and is primed for operation. However, misalignment of the sensor impedes this detection process. Should the sensor fail to register the metal bracket's presence when the Folding Section reaches home, it obstructs the transmission of the crucial readiness signal, rendering the machine incapable of initiating operations.

2. Inductive Sensor (I:0/13) False Detection: This facet centers around a normally closed sensor linked to the system, designed to flag the machine when the folding section fails to fully exit the home position. The challenge arises when misalignment induces erroneous detection. Such a scenario curtails machine activation, necessitating a thorough troubleshooting endeavor to restore functionality.

3. Electrical Connection Issues: When alignment concerns with the inductive sensor are ruled out, the focus shifts to potential wiring anomalies. These could hinder the transmission of signals from the sensor to the PLC. The culprits might involve severed wires, improperly crimped Y-Terminals, or connections secured with insufficiently tightened screws.

TROUBLESHOOTING STEPS

1. Inductive Sensor (I:0/14) Misalignment:

a. Access the folding section by removing its side cover.

b. Loosen the sensor's securing nuts using two 17mm wrenches.

c. Engage the reset button, holding it for a minimum of 5 seconds to prompt the folding section's home position maneuver.

d. Precisely adjust the sensor by gently sliding it towards the metal bracket's direction.

e. Securely tighten the sensor nuts.

2. Inductive Sensor (I:0/13) False Detection:

a. Remove the side cover of the folding section.

b. Loosen the nuts securing the sensor with two 17mm wrenches.

c. Hold the reset button for at least 5 seconds, initiating the folding section's movement to the home position.

d. Skillfully adjust the sensor's position, ensuring it's outside the range of the metal bracket.

e. Securely tighten the sensor nuts.

3. Electrical Connection Issues:

a. Verify voltage between input I:0/14 and the negative terminal.

b. If the sensor detects a metal piece and yields a 24V reading on the multimeter, functional integrity is confirmed.

c. Should the voltage reading remain unchanged, conduct wire continuity checks to pinpoint potential breakage points.

MACHINE TESTING

Upon successful completion of the troubleshooting steps, merely press and hold the reset button for a minimum of 5 seconds to return the machine to its home position. Subsequently, pressing the start button signifies the machine's operational readiness. The absence of the 'FA Home sensor failure' message on the HMI screen confirms the machine's preparedness for action.