Troubleshooting and Runoff

2D Code Reader Supplier

Problem:
Our barcode reader (and our customers) cannot read a marked code.

Generic Laser System

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

Additional Hardware 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 supplies 2D code readers that easily work in conjunction with our laser markers. In addition, several KEYENCE laser markers have built-in 2D code readers.

Hardware

Optional add-on software or KEYENCE barcode reader.

Labor

None

Marking Verification

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

Generic Laser System

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

Additional Hardware 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

MD-X and MD-U laser markers have a marking verification function to confirm that the entire mark was made. The built-in camera captures images before and after marking, then compares the contrast differences between the two images.

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

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

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

Additional Hardware 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 1Manually 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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