FUTABA MFS02 User manual

Whole or part of this manual may not be copied or reproduced without the written permission of Futaba Corporation.
This manual is a copyrighted work of Futaba Corporation and the copyright belongs to Futaba Corporation.
The contents of this instruction manual may be changed without prior notice.
Mold Marshalling System for Measuring
Melt Front Speed inside the Mold
Melt Front Speed Measuring Amplifier
Instruction Manual
Thank you for your purchasing a product of Futaba Corporation.
Please read this instruction manual carefully and patronize the
product for many years to come.
Do not use the product in any way other than explained in this
instruction manual.
MFS02

安全上のご注意
Safety Precautions
Preface 1
Standard Accessories 1
Handling Precautions 2
System Configuration 3
1. Names and Major Functions of Components 4
1-1 Front 4
2. Preparation 5
2-1 Setting up the Network Connections 5
2-2 Installing PC Software 5
2-2-1 Hardware requirements 5
2-2-2 Installation 5
2-2-3 Checking the version 5
2-3 Installing the System 6
2-3-1 Installing the flow velocity sensor 6
2-3-2 Installing the relay amplifier 6
2-3-3 Installing measurement amplifier 6
2-4 Connections in System 7
2-5 Connecting the I/O Signals 8
2-6 Connecting the Power Supply 10
3. Basic Operation of Measurement Amplifier 11
3-1 Turning Power ON/OFF 11
3-2 Operating the Amplifier 11
3-2-1 Operating the key switches 11
3-2-2 LCD window display 12
4. Basic Operation of Measurement Software 13
4-1 Starting and Exiting Software 13
4-2 Names and Functions of Screen
Component 13
4-3 Setting Conditions 14
4-4 Saving Settings As 17
5. Using the System 18
5-1 Adjusting Light Intensity 18
5-2 Selecting Setting File 18
5-3 Starting Measurement 18
5-4 Observing Flow Velocity Waveforms 19
6. Function Description 20
6-1 Displaying Template Waveforms 20
6-2 Overlaying Waveforms 21
6-3 Using the Cursor Functions 22
6-4 Waveform Display Settings 22
6-4-1 Enlarging waveforms (zoom) 22
6-4-2 Moving the waveform position 23
6-4-3 Displaying the entire waveform
(zoom out) 23
6-4-4 Changing the color of waveforms 23
6-5 Result Display Settings 24
6-6 Saving Data 25
6-6-1 Type of saved data 25
6-6-2 Setting the save holder 27
7. Checking the Operation 28
7-1 Checking the Communication between
Amplifier and PC 28
7-2 Checking the I/O Signal 28
7-3 Checking the Operation of Sensor 29
8. Specifications 30
9. Reference Materials 32
9-1 How to Connect Sensor to the Relay
Amplifier 32
9-2 How to Adjust Light Intensity 33
9-2-1 Adjustment of light intensity 33
9-2-2 Adjusting the light intensity of
relay amplifier 34
9-3 Other Search Algorithms 35
9-3-1 Variation Search 35
9-3-2 Percentage time search 36
9-3-3 Absolute time search 36
Contents

0
Safety Precautions (Be sure to read before use)
Before Use
Before using the product, read this “Safety Precautions” and the instruction manual carefully.
After reading the manual, keep it in a safe place so that it can be used whenever needed.
When using the product, be sure to observe the following safety precautions.
Futaba Corporation assumes no liability for the injury caused by using the product contrary to these
precautions.
This manual uses the following alert symbols for safe use of the product.
General Precautions
When starting product operation, make sure in advance that the functions of the product are normally working
with normal performance.
If the product fails, use adequate safety measures to prevent various types of damage.
Note that we cannot guarantee the functionality and performance for use of the product not conforming to the
specifications or any remodeled product.
When using the product in combination with other equipment, evaluate it thoroughly because the functionality
and performance may not be satisfactory depending on the use conditions and environment.
Precautions
Failure to observe the instructions with this symbol could result in death
or serious personal injury.
WARNING
Failure to observe the instructions with this symbol could result in injury
or only damage to property.
CAUTION
When installing the product or connecting cables, be sure to disconnect the
power cable from the outlet in advance.
It could result in electric shock or malfunction.
WARNING
Do not use a broken cable or a cable with a flaw in the covering.
It could result in fire, electric shock, or device damage or failure.
WARNING
Use the power to the AC adaptor within the range (100 to 240 V) stipulated in the
specifications. Using power outside the range could result in fire or device
damage or failure.
WARNING
Use the AC adaptor that comes with the product.
Using any other AC adaptor could result in device damage or failure.
WARNING
CAUTION
Keep the sensor, measurement amplifier and relay amplifier away from water.
It could result in electric shock or device damage.

1
Preface
“Mold Marshalling System MFS 02 series” is a system for measuring resin flow velocity inside
injection molds using an optical fiber sensor of Futaba Corporation.
Using the supplied measurement software, you can measure the flow velocity of the molten
resin and observe the waveforms generated when it passes over the sensor, store the data, and
set control outputs on the personal computer.
Major features are as follows:
●The system performs measurements using a single sensor.
●A measurement of up to 2 channels can be made at the same time.
●Flow velocity of each shot and historical waveform data are automatically saved.
●Data is saved in CSV format and can be easily read with commercially available
spreadsheet software.
●It can output a signal when the flow front of molten resin passes the sensor, which can be
used to control the injection machine.
●Waveforms being measured can be overlaid on the waveforms saved in the past.
Please read this instruction manual carefully and use the product correctly.
If you have any questions, please contact our sales department.
Standard Accessories
■This equipment comes with the following standard accessories.
After unpacking the equipment, make sure all accessories are included.
・Flow velocity measurement amplifier “MFS02” ･･････････････････････････････････････････ 1
・AC adapter “TAS8803” ･････････････････････････････････････････････････････････････････ 1
(One ferrite core for noise suppression is supplied with the adapter)
・LAN cable “WCL0020” ･････････････････････････････････････････････････････････････････ 1
・Software “PFS series” ･･････････････････････････････････････････････････････････････････ 1
(CD-ROM, the latest version at the time of shipment)
・Instruction Manual (this manual) ････････････････････････････････････････････････････････ 1
・Installation Manual ････････････････････････････････････････････････････････････････････ 1
・Warranty and Certificate of Registration ････････････････････････････････････････････････ 1
■Optional Accessories (Sold Separately)
・Relay amplifier “UPV01” ･････････････････････････････ 1 (or 2 if two amplifiers are ordered)
If you purchased this at the same time with the MFS02main unit, please make sure it is included in the package.

2
Handling Precautions
Turn on the power to the amplifier after connecting between the systems. Be sure to connect the power cable of
the amplifier to the AC outlet. Do not turn on/off the power supply by disconnecting and connecting the I/O cable
connector. It could damage the amplifier andAC adaptor.
When the power is once turned off, wait for at least 5 seconds before turning it on again. If the power is turned on
within 5 seconds or turned on and off repeatedly, power failure may be caused by rush current generated at
power on.
Warm up the system before use, for about 30 minutes after power on.
Before turning off the power to the amplifier, be sure to exit the measurement software. If the power is turned off
with the software running, communication operation may not be terminated normally and an unexpected failure
may occur.
When turning off the power after setting operation is performed, wait at least 3 seconds. The setting is stored in
the non-volatile memory in the amplifier but is not stored correctly if the power is turned off soon after the setting
operation.
This system stores the data measured by the amplifier in the storage device (such as a hard disk) of PC. To
prevent the degradation of PC performance or unexpected failure, move the data frequently.
When measurement is performed in monitor mode, “measurement” is executed when the signal (IN1) is input
from the molding machine or when the “SET” key on the amplifier is pressed.
Avoid using the system in an environment subject to remarkably high or low temperature. The allowable range of
operating temperature is 0 to 50°C. If it is unavoidable to use the system at a place subject to direct sunlight orin
a cold area, protect it from sunlight or keep it warm.
Use the system in the relative humidity range from 35 to 85%. Using it out of the humidity range or in an
environment subject to water splashes could result in performance deterioration or failure.
Do not use the system in a dusty place. Performance degrades if the dust gets inside. Prevent dust from getting
inside not only during operation but also during storage. Use the system in an environment in which personal
computers can be used.
If the environment changes drastically, do not operate the system soon. Leave the system in the new operating
environment to adapt it to the environment and then use it. If the ambient temperature or humidity is changed
drastically due to movement, condensation may cause performance degradation and failure.
Do not use the system in an environment subject to vibration or impact. Continuous vibration or large impact
could cause performance degradation or failure.
Do not use the system in strong electromagnetic fields. Use it in an environment in which personal computers
can be used. Using it in the vicinity of a radio, microwave oven, or electric furnace that generates a strong
electromagnetic field could cause performance degradation, malfunction, or failure.
Do not use the system in locations with poor power supply conditions. Use it with a power supply at 100 VAC,
50/60 Hz, free from momentary power failure and noise.
Do not pull connection cables. Connect each connection cable with a margin so that excessive force is not
applied to the connection. Pulling the cable or applying excessive force to it could cause failure, measurement
interruption, or abnormal measurements.

3
System Configuration
The following figure shows a system configuration that is required to measure the flow velocity inside the
mold using Mold Marshalling System “MFS02”.
As shown in the above figure, the “MFS02” is designed to connect an optical fiber sensor to the input.
The flow velocity sensor is connected to a relay amplifier, and connected to the connector of the MFS02
main unit amplifier via a junction cable.
The measurement amplifier and PC exchange data via the LAN cable. The measurement software that
comes with this equipment needs to be installed in advance in the PC. Resin flow velocity values and
velocity waveforms and historical data are stored in the PC.
An I/O cable is to be prepared by the customer. The system is connected to the molding machine and
peripheral control equipment using the cable. This enables to start measurement, output control signals
and clear control signals automatically. The “MFS02” has a voltage output feature, so a commercially
available data logger can be connected to measure velocity waveforms.
AC outlet
Data logger, etc.
Flow velocity sensor
Relay amplifier
AC adapter
AC
Voltage output
LAN cable
PC
Molding machine, controller
External trigger signal inputs
Control signal outputs

4
1. Names and Major Functions of Components
1-1 Front
①Display panel ･････････････････････・・・・・・・・Displays version information, IP address, input
voltage and flow velocity measurement values,
etc.
②Control keys”→”, “↑”, “↓”, “SET” ･･･・・・・･･･・”→” key: Changes the display contents when
held down.
“↑”, “↓” keys: Not used.
“SET” key: Used as manual trigger key.
③Relay amplifier connector ････････････････Connected to a relay amplifier using a dedicated
junction cable. Two relay amplifiers can be
connected.
④Grounding terminal ･･･････････････････････Terminal for ground.
⑤Voltage output terminal･･･････････････････Connected to the external measuring equipment
such as data logger and oscilloscope.
⑥I/O cable connector ･････････････････････Inputs trigger signals and clear control signals,
and outputs control signals.
⑦Wired LAN connector ･･････････････････････Connected to the PC using a LAN cable.
⑧AC Adapter connector ･･･････････････････ Connected to the AC adapter
②
④
③
⑤
⑥
⑦
⑧
①

5
２．Preparation
This section explains the preparation required before turning on the power.
2-1 Setting up the Network Connections
■Make settings for communication between the amplifier MFS02 and PC.
＊For the Network setting procedure, refer to the “Measurement Software (PFS)
Installation Manual”.
2-2 Installing PC Software
2-2-1 Hardware Requirements
■Supported OS
The operations of this software have been verified with the following operation systems.
Windows XP, Windows 7, Windows 8
■Capability
The following specifications are recommended.
CPU: Core2Duo or higher
Memory: 1GB or more
＊As a rough guide, the PC should have been released in 2007 or later and have 1GB or more memory.
2-2-2 Installation
＊For the installation procedure, refer to the “Measurement Software (PFS) Installation
Manual”.
2-2-3 Checking the version
The version of the software currently used can be checked.
＊Unless there is particular reason, always use the latest software for operation.
From the main menu, select [Help] →[About PFS].
PC software version on the upper row
Amplifier software version on the lower
row

6
2-3 Installing the System
2-3-1 Installing the Flow velocity Sensor
The following figure shows an example of the installation.
One fixation screw (sold separately) is required for one sensor.
A wrench (sold separately) is needed to tighten the fixation screw.
※Provided, however, that this does not apply to the cases where the customer determines the
fixation method of the sensor.
“Flow Velocity Sensor Reference Diagram”
2-3-2 Installing the Relay Amplifier
Install the relay amplifier near the mold. The temperature limit is 55℃. Be careful not to expose
it to temperature higher than this limit.
To fix the amplifier, prepare mechanical means such as DIN rail, etc by the customer.
Be careful not to allow the sensor cable to get caught in the molds or pulled by the movable
mold while it is in operation.
2-3-3 Installing measurement amplifier
Install the amplifier by fixing it on the molding machine or preparing a dedicated placing table.
Operating temperature range is from 0 to 50℃.

7
2-4 Connections in the System
■Connect the components in order of the numbers shown in the following figure.
Connect the power supply ⑥after completing the connections ①to ⑤.
①Connect the sensor to the relay amplifier (see “9-1 How to Connect Sensor to the Relay
Amplifier” on P. 32.)
Open the upper lid of the relay amplifier, pull down the lock lever forward to unlock the amplifier.
Insert the sensor and push up the lock lever back to lock the amplifier.
Ensure that the sensor plug is inserted to the bottom.
②Connect the relay amplifier to the measurement amplifier.
Insert the relay amplifier plug to the measurement amplifier connector by aligning the red marks on
the plug and the connector.
Ensure that the sensor plug is inserted to the bottom.
①
②
⑥
④
⑤
③
Data logger, etc.
AC outlet

8
③Connect the “GND” terminal to ground.
④Connect the trigger signals from the injection molding machine.
⑤Connect the LAN cable to the amplifier and PC.
Make sure that the connector is locked with a “click”.
⑥Connect the AC adapter.
2-5 Connecting I/O Signals
<<What is the input signal?>>
An input signal means a signal input to the amplifier from an external devices such as
a molding machine or ejector machine.
Trigger signal Required to start measurement. Upon the input of the trigger signal,
“measurement” is performed. Connect the “mold closing complete
signal”.
Clear control signal Connected to clear (or cancel) the control signal being output from the
amplifier. Connect the signal as needed.
＊The control signal can be cleared automatically by specifying the time in
the software settings (for details, see “Setting control outputs” on Page 17).
If automatic clear at the specified time causes no operational problem, the
connection of the clear control signal can be omitted.
<<What is the output signal?>>
An output signal means a signal input from the amplifier to an external device such as
a molding machine or ejector robot.
Control Output signal A Control Output signal is output when the molten resin passes
through the sensor. This signal is used to control the injection
molding machine.

9
●Input signal circuit specification (trigger signal, clear control signal)
Example 2: When the output of the molding machine connected to the amplifier is “voltage output”:
Connect the signal by using a relay adaptable to the output voltage of the output signal from the molding
machine.
＊When using an electromechanical relay, a relay equipped with the coil surge absorption circuit.
Example of connection of input signal using a relay when the molding machine output signal is DC★
V ON/OFF output.
Trigger or clear control
Trigger or clear control
Trigger or clear control
COM IN
COM IN
COM IN
Caution
注意
Input the signal to the amplifier via the electromechanical relay.
Do not apply voltage.
Example 1: When the output of the molding machine connected to the amplifier is ”relay output”:
Example of connection of input signal when the molding machine output signal is contact output
DC★V relay
Electromechanical relay
Solid state
relay
Molding machine
output signal
Molding machine
output signal
Molding machine
output signal
DC★V relay
Relay in molding machine
(close mold signal, etc.)

10
●Output signal circuit specifications (control output signal)
2-6 Connecting the Power Supply
■Supply power to this equipment through the AC adapter that comes with this equipment.
＊The amplifier does not have a power switch.
■Check the supply voltage before connecting the AC adapter to the AC power source.
The operating voltage of the AC adapter is 100 V AC.
＊If each terminal voltage of the power supply has higher potential than the supply voltage against the
ground, never connect it to the equipment. It could cause failure or accidents.
＊Warm up the system for over 30 minutes after power on. Insufficient warmup could make
measurements unstable.
Control output
Control signal
connection
destination
COM IN
Warning
The control output from the amplifier is up to 100 mA(30 V or less) in the
NPN open collector. Use the power supply with the negative side
connected to the ground.
Example: Connect I/O signals using the 24 VDC power supply and 24 VDC relay.
＊When using an electromechanical relay, use a relay equipped with the coil surge absorption circuit.
＊Use an independent power supply separate from the power supply for the molding machine.
←100 mAor less
24 VDC
power supply
24 VDC relay

11
３．Basic Operation of Measurement Amplifier
This section describes the basic operation of amplifier “MFS02”.
3-1 Turning Power ON/OFF
■Turning power ON
Turn on the power to the amplifier by referring to Section 2-6 “Connecting the Power Supply”
on Page 10.
■Turning power OFF
Disconnect the AC plug of the AC adapter from the AC outlet.
＊The amplifier does not have a power switch.
3-2 Operating the Amplifier
3-2-1 Operating the key switches
■Operate the keys on the amplifier as needed on the following cases.
●Checking the IP address of the amplifier or firmware version
●Starting measurement manually (Pressing the SET key starts the measurement)
①
“→” key
Changes the display content when held
down
②
“↑” key
Not used.
③
“↓” key
Not used.
④
“SET” key
Usable as the manual trigger
①
②
③
④

12
3-2-2 LCD window display
Turning on the power displays the following LCD window (The photo below shows the default
window when shipped).
■Holding down “→” key (for over one second) changes the display content.
Window changes as follows.
Start window
Input voltage
Measured
values
Version
and
IP address
Change
windows with
“→” key

13
４．Basic Operation of Measurement Software
This section describes the basic operation of measurement software.
4-1 Starting and Exiting Software
■Starting software
Double-click the shortcut “PFS” on the desktop.
＊If the shortcut “PFS” is not found, specify the “PFS” executable file in c:¥Program files¥Futaba¥pfs and click
“Create Link” to create a shortcut.
■Exiting software
Select “Quit” from “File”in the menu bar, or click close button “×” on the upper right corner of the screen.
4-2 Names and Functions of Screen Components
This section explains the basic screen components and the operations that are often used.
■Operation screen
When software starts up, the screen shown below appears. This screen is referred to as the
operation screen. Here, remember the concepts of individual screen components.
Frame window
Channel information
Counter display
Displays resin velocity
waveforms and template
waveforms.
Displays the status of
communication and
measurement
Displays the status
of control output
signal
Control output
display
Menu bar
Toolbar
Status display
Close button
Maximize button
Displays the menu to
execute commands
Provides buttons to
execute commands
Minimize button

14
■Toolbar
The frequently used commands are provided as buttons. The functions of individual commands
are explained below.
①
Show/Hide Template wave
Shows or hides the Template waveforms read into the frame screen.
②
Fit to measurement voltage
(selected waveform)
Enlarges the selected waveform in the Y axis (voltage axis) direction.
③
Fit to measurement voltage (all
waveforms)
Enlarges all waveforms in the Y axis (voltage axis) direction.
④
Fit to measurement time
Reduces only in the X axis (time axis) direction.
⑤
Fit to measurement conditions
Reduces along both the X axis (time axis) and Y axis (voltage axis).
⑥
Cursor tool
Displays the time and voltage value at the cursor position.
⑦
Zoom
Enlarges the specified view.
⑧
Hand tool
Drags and moves the enlarged view.
■Various buttons
Opens settings screen (For details, see Page 16).
Executes free run (For details, see Page 29).
Stops the measurement (For details, see Page 18).
Resets the counter.
Clears control output signal manually.
4-3 Setting Conditions
Here, set the conditions under which data is retrieved. The conditions once set are saved to the
setting file, so the same conditions are automatically set when the setting file is read next and
after.
■Set “measurement conditions”, “flow front”, “trigger conditions”, “waveform search
algorithm” and “control output conditions” sequentially in this order.
※Set ”control output conditions” as needed.
■Setting measurement conditions
①
②
③
④
⑤
⑥
⑦
取
扱
説
明
書
⑧

15
Click the “Settings” button. The Settings screen appears.
■Measurement conditions
Set the time to make measurements.
①
Measurement time
Set in units of seconds from 1 to 120. Set a shorter time than the molding cycle time.
②
Sampling interval
Select one from 1, 5, 10, and 20 ms.
■Flow front
Input the diameter of the fiber and the product thickness.
※When running two-point measurements, input the values for CH1 and CH2 respectively. The tab can be
switched by clicking the channel tag.
①
Fiber diameter
Use a fiber with a diameter of 0.50 mm.
②
Product thickness
Input the thickness of the molded part at the sensor mounting position.
①
②
②
①
Flow front
Optical fiber sensor
Cavity wall
Cavity wall

16
■Setting trigger conditions
Set trigger conditions for detecting velocity waveform.
※When running two-point measurements, input the values for CH1 and CH2 respectively. The tab can be
switched by clicking the channel tab.
①
Set a point to capture a
waveform
Time until a trigger occurs after the trigger conditions are met.
②
Time for ignoring trigger
conditions after a
measurement starts
Time for which trigger conditions are to be ignored after a measurement is
started(Use this condition when waveforms are distorted)
③
～
⑤
Select trigger conditions.
・Voltage drop after
measurement starts
Trigger the detection of a waveform when the voltage at
the time of starting the measurement drops by the
specified voltage value (④).
・Percentage of a
voltage drop after a
measurement start
Trigger the detection of a waveform when the voltage
drops by the specified percentage with the voltage at
the time of starting the measurement defined as 100%.
・Elapsed time
Trigger the detection of waveform when the specified
time (②) has elapsed after the measurement is started.
■Setting a waveform search algorithm
※When running two-point measurements, input the values for CH1 and CH2 respectively. The tab can be
switched by clicking the channel tab.
①
Select a search algorithm
Select least square method search.
※For the information for other search methods, refer to “9-3 Other Search Algorithms”
on Page 34.
②
Number of data samples
Set the number of data samples in the process range.
②
①
③
⑤
④
④
p
②
①
③

17
③
Number of contiguous
data on the decay wave
slope
The number of contiguous data on the decay wave slope
④
Set inclination of a
waveform
Set the angle of the inclination of a waveform for conditions of searching a
passage start point.
Calculate the inclination of the entire waveform by using
the least square method.
(t1) on the right figure is a passage start point whereas
(t2) is a passage end point.
The passage time is calculated by (t-2)－(t1).
■Setting control output
Output a signal at the timing when resin passes over the sensor. The output condition shall be
when the “high speed data capture” condition is satisfied.
①
Select an output mode
“None” ………No output
“Independent output” ……Output when output conditions are independently
satisfied in CH1 and CH2.
“Simultaneous output OR” …Output when output conditions are satisfied in either
of CH1 or CH2.
“Simultaneous output AND” …Output when output conditions are satisfied in both
CH1 and CH2.
②
Set external clear
Use this option when clearing the output with an external signal. Check the
checkbox to enable this option.
③
Set time clear
Check the checkbox when enabling the clear by elapsed time.
④
Clear time (output 1)
Output in CH1 is cleared automatically after the specified time elapses.
⑤
Clear time (output 2)
Output in CH2 is cleared automatically after the specified time elapses.
■Help mode
Click this button to display the help window (detailed explanations).
①
③
②
④
⑤