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KEYENCE Advantage Troubleshooting and Runoff


2D Code Reader Supplier

Problem:
The barcode reader on the production line and at our customers are not able to read the marked code.

  • Generic Laser System

    1. STEP 1
      Visually check the codes being marked by the laser.
    2. STEP 2
      If the codes look good adjust the lighting and other barcode reader settings.
    3. STEP 3
      If the code still cannot be read, adjust the laser marker.
    4. STEP 4
      Make repeated adjustments to each system until all codes are read.

    Hardware Additional Cost

    $3,000 for code reader + cost of scrap or returned parts.

    Labor

    8 to 16 hours for installation, reprogramming and adjustments.
    $600 to $1,200 in engineering costs.

  • KEYENCE ADVANTAGE

    KEYENCE is a supplier of 2D code readers that easily work in conjunction with our laser markers. In addition, the MD-X Series lasers have optional built-in 2D code reader software: MD-XAD1A.

    Hardware

    MD-XAD1A software or KEYENCE SR-D100 Series.

    Labor

    None


Marking Verification

Problem:
Incomplete marking due to improper indexing or movement of the part.

  • Generic Laser System

    1. STEP 1
      Purchase, configure, and mount vision system.
    2. STEP 2
      Mark a part with the laser marker.
    3. STEP 3
      "Teach" the vision system to recognize the marked part.
    4. STEP 4
      Program the vision system to compare each mark with the registered image.
    5. STEP 5
      Set thresholds for OK and NG marks.

    Hardware Additional Cost

    $10,000 for vision system + cost of scrap or returned parts.

    Labor

    8 to 16 hours for installation, programming and adjustments. Will require a tech that can program the vision system to make any adjustments needed over time.
    $600 to $1,200 in engineering costs.

  • KEYENCE ADVANTAGE

    The MD-X Series laser markers have a marking verification function to confirm that the entire mark was made. The builtin camera captures images before and after marking then compares contrast differences between the two images.
    *MD-X1000/X1500 Series only

    Hardware

    None

    Labor

    None


Distance Pointer

Problem:
Need to confirm that the surface of part is at the correct working distance from the laser lens.

  • Generic Laser System

    1. STEP 1
      Physically measure distance from laser lens to surface of part with measuring device (ruler, stick, depth gauge).

    Hardware Additional Cost

    $5 to $500 depending on measuring device used.

    Labor

    0.5 to 2 hours Depending on complexity of part surface.
    Additionally, there is a risk of scratching the lens each time a measurement is done by hand.
    $20 to $100 Each time the focal distance must be realigned.

  • KEYENCE ADVANTAGE

    The distance pointer can be used to quickly and easily see that a part is at the correct height.

    Hardware

    None

    Labor

    $5


Terminal Monitor

Problem:
The inputs and outputs (I/O) are not functioning correctly with the PLC.

  • Generic Laser System

    1. STEP 1
      Find a voltmeter.
    2. STEP 2
      Access the terminals on the laser system.
    3. STEP 3
      Force outputs on and off from the PLC/laser and use a voltmeter to troubleshoot.
    4. STEP 4
      If no voltage is present, check the voltage on the ground or common terminals.
    5. STEP 5
      Repeat steps 3 and 4 until you have verified proper operation on all inputs on the laser system.
    6. STEP 6
      Return the laser to automatic operation.

    Hardware Additional Cost

    Voltmeter

    Labor

    4 to 24 hours Production delays for troubleshooting can last hours and even days in some cases.
    $300 to $1,800 In engineering costs.

  • KEYENCE ADVANTAGE

    The internal terminal monitor allows you to see the inputs and outputs change in real time. This is a great tool for troubleshooting the laser and controls setup.

    Hardware

    None

    Labor

    None


Communication History

Problem:
The laser system can mark, but production cannot run due to data change errors.

  • Generic Laser System

    1. STEP 1
      Connect the PLC or PC to a 3rd party terminal application (i.e. HyperTerminal).
    2. STEP 2
      Send data from PLC/PC to HyperTerminal and verify proper format.
    3. STEP 3
      Connect the laser system to HyperTerminal and send the data to the laser.
    4. STEP 4
      Test mark the laser and see if the data was changed or an error was returned.
    5. STEP 5
      Repeat steps 2 to 4 until issue is resolved.
    6. STEP 6
      Return the laser to automatic operation.

    Hardware Additional Cost

    Software

    Labor

    4 to 24 hours Production delays for troubleshooting can last hours and even days in some cases.
    $300 to $1,800 In engineering costs.

  • KEYENCE ADVANTAGE

    The communication monitor allows you to see the data strings being sent and received by the laser marker. Any errors in communication are highlighted for easy troubleshooting.

    Hardware

    None

    Labor

    None


Error History

Problem:
Errors on the laser marker caused production to shut down.
Maintenance is trying to troubleshoot the cause.

  • Generic Laser System

    1. STEP 1
      Manually keep a log of faults and errors on the laser system.

    Labor

    Operator needs to manually record all errors.

  • KEYENCE ADVANTAGE

    The error history tool allows you to keep track of the errors and the time those errors occurred.

    Hardware

    None

    Labor

    None

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