Roland R4000 User manual

Weld Seam Detection System R4000 SND40
►Drivemonitoring andcontrol ofdetection reliability
►Industrial standard interfaces for automation
►Graphical user interface with 10 inch touchscreen
►Data backup via USB or Ethernet
Weld Seam Detector SND40
QUICK MENU:
Start-up ........................................... 63
Menu tree ........................................ 64
Operation ........................................ 69
Technical data ................................ 87
Timing diagrams ............................ 143
Order data .......................................167
Service ............................................ 154
Troubleshooting ............................. 169
for Tubes, Cans and Drums
►For positioning applications
►Material diameters from 5 to 500 mm
►Magnetic Leak Flux and Eddy Current
measuring principles

Copyright
©2019ROLAND ELECTRONIC GmbH
Otto-Maurer-Str. 17
DE 75210 Keltern
All rights on this document are at Roland Electronic GmbH.
Reproduction (also partly), electronical coverage, translation, transmission to third parties,
only with our prior permission.
Subject to change without further notice.

Manual
Weld Seam Detection System R4000 SND40
for Tubes, Cans and Drums
B0059001 / Rev. 2.3 Table of content
ROLAND ELECTRONIC GmbH ·Otto-Maurer-Str. 17 ·DE 75210 Keltern ·Phone [phone] ·Fax [phone]
3
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Table of content
Declaration of conformity according to EC directives .....................................................................................7
1Safety advice .......................................................................................................................................... 9
1.1 Safety instructions and warnings for user ..........................................................................................9
1.2 Declaration of icons ............................................................................................................................9
1.3Fieldbus terminology ........................................................................................................................10
2System description ..............................................................................................................................11
2.1 Introduction .......................................................................................................................................11
2.2 Station for Weld Seam Detection .....................................................................................................12
2.3 Important information for planning and operation.............................................................................13
2.4 Important notes for machine manufacturers.....................................................................................18
2.5 Important notes for software and hardware of the plant control.......................................................22
2.6 Details of the dB-value .....................................................................................................................23
2.7 Measures for improvement of Weld Seam Detection.......................................................................25
3Mounting ...............................................................................................................................................27
3.1 Mounting of sensor ...........................................................................................................................27
3.2 Mounting of Eddy Current probes.....................................................................................................31
3.3 Mounting the SND40 Control Unit ....................................................................................................32
4Electrical installation ...........................................................................................................................35
4.1 Cables...............................................................................................................................................35
4.2 Mains connection..............................................................................................................................36
4.3 Connection of PLC ...........................................................................................................................37
4.4 Connecting of sensor........................................................................................................................40
4.5 Connecting of probe .........................................................................................................................40
4.6 Connection schedule – Leakage flux sensors..................................................................................42
4.7 Connection schedule - Combination sensors...................................................................................43
4.8 Connection schedule – Eddy current sensors and Encircling coil systems .....................................44
4.9 Connection schedule – Eddy current probes ...................................................................................45
5Communication with the PLC .............................................................................................................51
5.2 Output „Ready”via Fieldbus.............................................................................................................55
5.3 Monitoring the Inputs / Outputs of the Control..................................................................................61
6Start-up..................................................................................................................................................63
6.1 Prerequisites for Start-up..................................................................................................................63
6.2 Menu tree..........................................................................................................................................64
6.3 Basic settings / Standard values ......................................................................................................65
7Operation ..............................................................................................................................................69
7.1 Switching on and Powering up .........................................................................................................69
7.2 Measuring operation.........................................................................................................................70
7.3 Setup – Program selection ...............................................................................................................71
7.4 Setup – Test operation .....................................................................................................................72
7.5 Setup X/Y diagnosis .........................................................................................................................73

Manual
Weld Seam Detection System R4000 SND40
for Tubes, Cans and Drums
Inhaltsverzeichnis B0059001 / Rev. 2.3
4 ROLAND ELECTRONIC GmbH ·Otto-Maurer-Str. 17 ·DE 75210 Keltern ·Phone [phone] ·Fax [phone]
7.6 Statistics function ............................................................................................................................. 74
7.7 System Parameters ......................................................................................................................... 76
7.8 Creating and editing of measuring programs .................................................................................. 77
7.9 Optimizing the positioning of the Weld seam .................................................................................. 78
7.10 Setting-up and changing the system / program password .............................................................. 78
7.11 General parameters......................................................................................................................... 79
7.12 Special parameters for sensor signal „Eddy current“ ...................................................................... 80
7.13 Setup – Test operation X/Y.............................................................................................................. 81
8Fault messages, causes and remedies ..............................................................................................83
8.1 Troubleshooting at problems ........................................................................................................... 85
8.2 Creation of a sample tube................................................................................................................ 85
9Technical data.......................................................................................................................................87
9.1 Control unit SND40 .......................................................................................................................... 87
9.2 Mechanical drawing control unit SND40.......................................................................................... 91
9.3 Designation of sensors .................................................................................................................... 93
9.4 Leak flux sensor NS9S .................................................................................................................... 94
9.5 Combination sensor NS9-EC8x60NT10-100-S ............................................................................... 94
9.6 Combination sensor NS9-EC8x60NF10-100-S ............................................................................... 95
9.7 Leak flux sensor NS9-GMR-S ......................................................................................................... 95
9.8 Combination sensor NS9-EC5x30NT10-100-S ............................................................................... 97
9.9 Combination sensor NS9NH-EC8x18NT10-100-S.......................................................................... 99
9.10 Eddy current sensor EC9-8x60NT10-100-S .................................................................................. 101
9.11 Eddy current sensor EC9-8x60NF10-100-S .................................................................................. 101
9.12 Leakage flux sensor NS12S .......................................................................................................... 102
9.13 Combination sensor NS12-EC8x80NF10-100-S ........................................................................... 102
9.14 Combination sensor NS12-EC8x80NT10-100-S ........................................................................... 103
9.15 Combination sensor NS12NH-EC8x80NT10-100-S...................................................................... 103
9.16 Sensor NS24-EC18x185NT10-100-S............................................................................................ 105
9.17 Sensor NS24-EC30x185NT10-100-S............................................................................................ 107
9.18 Cooling water for NS24-EC30 sensors.......................................................................................... 107
9.19 Eddy current probe EC12x30IT10-100-S ...................................................................................... 112
9.20 Eddy current probe EC20x25IT10-100-S ...................................................................................... 113
9.21 Eddy current probe EC30x25IT10-100-S ...................................................................................... 114
9.22 Eddy current probe EC12x40IRT10-100-S.................................................................................... 115
9.23 Eddy current probe EC4x40IRF50-400-S...................................................................................... 116
9.24 Eddy current probe EC5x30IF10-100-S ........................................................................................ 117
9.25 Sensor cable KNS9S ..................................................................................................................... 118
9.26 Sensor cable SKNS8S................................................................................................................... 119
9.27 Sensor cable CECM18S-G............................................................................................................ 120
9.28 Sensor cable SM18CECM18S-GG................................................................................................ 120
9.29 Sensor Switch Box SSB-SND40.................................................................................................... 121
9.30 Sensor Connection Box SCB-EC-S............................................................................................... 123
9.31 Rubber mounts for NS9 and NS12 ................................................................................................ 124
9.32 Rubber mounts for NS24 ............................................................................................................... 125

Manual
Weld Seam Detection System R4000 SND40
for Tubes, Cans and Drums
B0059001 / Rev. 2.3
ROLAND ELECTRONIC GmbH ·Otto-Maurer-Str. 17 ·DE 75210 Keltern ·Phone [phone] ·Fax [phone]
5
10 Maintenance........................................................................................................................................127
10.1 Control unit SND40.........................................................................................................................127
10.2 Sensors...........................................................................................................................................127
10.3 Regular wearing and increased wearing ........................................................................................128
10.4 Program status / Operational status...............................................................................................129
10.5 SND40StoreV2 ...............................................................................................................................130
10.6 Setting the System Time / Date......................................................................................................136
10.7 Calibrating the touchscreen............................................................................................................138
11 Technical records...............................................................................................................................143
11.1 Timing Diagrams – Round material application..............................................................................143
11.2 Service............................................................................................................................................154
11.3 Hints on Hardware and Software versions .....................................................................................163
11.4 Other informations ..........................................................................................................................165
12 Order data ...........................................................................................................................................167
12.1 Control units....................................................................................................................................167
12.2 Sensors...........................................................................................................................................167
12.3 Cables / Accessories ......................................................................................................................168
13 Appendix .............................................................................................................................................169
13.1 Checklist for fault identification .......................................................................................................169
=== Ende derL istefür Textmarke IVZ ===
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Manual
Weld Seam Detection System R4000 SND40
for Tubes, Cans and Drums
Safety advice B0059001 / Rev. 2.3
6 ROLAND ELECTRONIC GmbH ·Otto-Maurer-Str. 17 ·DE 75210 Keltern ·Phone [phone] ·Fax [phone]
Blank page
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Manual
Weld Seam Detection System R4000 SND40
for Tubes, Cans and Drums
B0059001 / Rev. 2.3 Safety advice
ROLAND ELECTRONIC GmbH ·Otto-Maurer-Str. 17 ·DE 75210 Keltern ·Phone [phone] ·Fax [phone]
7
Declaration of conformity according to EC directives
Manufacturer: Roland Electronic GmbH
Otto-Maurer-Str. 17
75210 Keltern / Germany
Product name:
SND40
Product type:
Weld Seam Detection System
R4000
Roland Electronic GmbH declares that the product listed above complies with the requirements of
the directives listed below.
Applied Directives:
2014/35/EU Low Voltage Directive
EN 61010-1:2010
2014/30/EU: EMC Directive
EN 61000-6-2:2005/AC:2005 EN 61000-6-4:2007/A1-2011
Date of mark’s apposition: 10.05.2016
Keltern, 10.05.2016
Managing Director
Place, Date Signature Function of the signer
The declaration confirms the compliance with the cited directives. However, it is not any implied warranty of fitness for a
particular purpose especially as it may relate to product liability.
The safety instructions and warnings must be observed.
ISO 9001 : 2008
Reg.-no. 5152 QM08
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Manual
Weld Seam Detection System R4000 SND40
for Tubes, Cans and Drums
Safety advice B0059001 / Rev. 2.3
8 ROLAND ELECTRONIC GmbH ·Otto-Maurer-Str. 17 ·DE 75210 Keltern ·Phone [phone] ·Fax [phone]
Blank page
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Manual
Weld Seam Detection System R4000 SND40
for Tubes, Cans and Drums
B0059001 / Rev. 2.3 Safety advice
ROLAND ELECTRONIC GmbH ·Otto-Maurer-Str. 17 ·DE 75210 Keltern ·Phone [phone] ·Fax [phone]
9
1 Safety advice
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1.1 Safety instructions and warnings for user
This manual contains all information required for the correct operation of the Roland Electronic
equipment. It has been written for technically qualified personnel.
Unauthorized tampering with the unit, especially ignoring the warnings in this handbook, can cause
malfunction and damage to the unit. Only authorized personnel should be allowed to make
changes to the unit and perform cable connections especially the power supply.
Should it be necessary, e.g. in case of service or repair, to make measurements within the unit,
then all customary accidents prevention procedures should be observed. Only professional
electrical tools should be used.
Note The factory pre-settings – especially the upper / lower limit values – have
been chosen such that an optimal machine protection is ensured.
Diverging settings can impair the machine protection.
Safety advice for persons with cardiac pacemakers!
Persons with cardiac pacemakers are to stay away from the sensors!
The strong magnetic / electromagnetic fields of the sensors can cause malfunction
of cardiac pacemakers and other such apparatus!
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1.2 Declaration of icons
Warning - general dangers!
Reference to imminent hazards, which can result in severe bodily harm or death.
Warning - dangers by high voltage!
Reference to imminent hazards due to electricity, which can result in severe bodily
harm or death.
Attention - Damage of construction units!
Reference to a potential imminent situation, which can result in damage to the
product or environs.
Note
Useful reference to an application or deepening information.
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Manual
Weld Seam Detection System R4000 SND40
for Tubes, Cans and Drums
Safety advice B0059001 / Rev. 2.3
10 ROLAND ELECTRONIC GmbH ·Otto-Maurer-Str. 17 ·DE 75210 Keltern ·Phone [phone] ·Fax [phone]
1.3 Fieldbus terminology
Within this manual the following Fieldbus specific expressions are used:
Term used in the manual Fieldbus specific expression
Master Scanner
Slave Node
Baud rate Data rate
Bus address Mac ID / node address
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Manual
Weld Seam Detection System R4000 SND40
for Tubes, Cans and Drums
B0059001 / Rev. 2.3 System description
ROLAND ELECTRONIC GmbH ·Otto-Maurer-Str. 17 ·DE 75210 Keltern ·Phone [phone] ·Fax [phone]
11
2 System description
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2.1 Introduction
Prior to automatic forming or processing of longitudinally welded tubes the long seam detection and
positioning to a predetermined position is a preventive measure the motive being a fault free
product.
The SND40 is specially designed for this task, and provides:
• High flexibility with regard to material, tube processing condition and machine integration
• Self-monitoring of weld seam detection with superior evaluation methods
• Monitoring of the sensor and of the tubular drive
• Easy positioning with adjustable set angle
• Convenient operation and control interfaces
The highest flexibility of SND40 is achieved using magnetic flux leakage and eddy current
methods. In addition, special signal filters and a wide range of sensor models have been developed
which lead even in challenging cases to success.
Prior to the implementation of a station for weld seam detection the following steps are required,
with which Roland Electronic can provide assistance:
• Feasibility studies on representative samples in the Roland laboratory
• Review of the requirements of cycle time, positioning accuracy and process reliability
• Conception of the weld seam detection station
Once a station is built, Roland Electronic can offer support during commissioning of the SND40.
In addition, services for setting up new types of tubes, maintenance inspections, sample tests and
training courses for operators, maintenance personnel and plant engineers are offered.
The Weld Seam Detection System SND40 typically consists of:
• the control unit
• a weld seam detection sensor
• the sensor cables
• if required a separate power supply
Fig. 1: Weld Seam Detection System SND40
The control unit and the weld seam sensors are available in different versions. Which version fits
the particular weld seam detection is determined in advance by the feasibility study in the
laboratory. Only the decision whether I/O or fieldbus interface implemented needs to be taken by
the customer.
Note:
Specify the number of the application report when ordering the system and the
required settings will be made before shipping. For each required type of tube, i.e. any
wall thickness, diameter and type of material a separate data record will be available.
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Manual
Weld Seam Detection System R4000 SND40
for Tubes, Cans and Drums
System description B0059001 / Rev. 2.3
12 ROLAND ELECTRONIC GmbH ·Otto-Maurer-Str. 17 ·DE 75210 Keltern ·Phone [phone] ·Fax [phone]
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2.2 Station for Weld Seam Detection
For a weld seam detection station following components which are not supplied by Roland
Electronic are required in addition to the SND40:
•a loading system to provides tubes from a magazine into a rotating device
•a rotating device, which is able to receive and rotate the tube
•an adjusting device, to turn on and off the weld seam sensor on the tube
•a clamping device which holds the tube, after the positioning process has been completed
and before the sensor is retracted
•a sorting device to remove any tubes which are classified as weld seam detection
inadequate by the SND40
•an unloading device which takes over the oriented tube from the clamping device and
transports without changing the Azimuth (angular position)
•a control system for operation of the components and the linking with the production line
It is useful to obtain the appropriate equipment by an experienced manufacturer of special
machines.
2.2.1 Operational sequence of a Weld Seam Detection
Here is a proven 8 step sequence which provides an initial over of the required functions:
1. the system places the tube into the rotational drive.
2. the tube is fixed in the rotating drive for example in a chuck or with cones.
3. the rotation device places the sensor on the tube so that the rollers are in contact.
4. the SND40 is started via the PLC (signal “measurement start”).
By this, the SND40 activates the drive (signal "motor") and the magnetization.
5. after the settling time has expired, the rated speed is achieved and the magnetic field is in
full strength. Internally the recording of the measurements which can be set via the SND40,
begins (a measuring cycle lasts at least 3 tube rotations). Is the weld seam detected, the
positioning phase begins, which lasts approx. one tube rotation.
6. the positioning phase is completed, if the drive of the SND40 is switched off and has come to
standstill. The unloading system now fixes the tube or the container in this position.
7. the sensor is withdrawn and the tube or container is now ready for unloading.
8. if the weld seam cannot be detected, the SND40 stops the drive and releases the signal
"reduced detection". Since the tube is not reliably positioned, it must be sorted out by the
unloading system.
Important:
When the weld seam of a tube is not recognized immediately, the sorting out might be
eventually prevented as it cannot be passed on to the next process. See chapter 2.7
„Measures to improve the Weld Seam Detection“
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Manual
Weld Seam Detection System R4000 SND40
for Tubes, Cans and Drums
B0059001 / Rev. 2.3 System description
ROLAND ELECTRONIC GmbH ·Otto-Maurer-Str. 17 ·DE 75210 Keltern ·Phone [phone] ·Fax [phone]
13
2.3 Important information for planning and operation
2.3.1 Send tubes before planning
Before conception of weld seam detection send the tubes to the Roland Electronic application
laboratory. The purpose is to review the general feasibility.
For each dimension, and each tube type, 3 to 10 examples should be provided, ideally from
different production batches.
Important:
Send 3 to 10 test tubes of each dimension and type to our laboratory.
Note:
Sample tubes should have a length greater 150 mm but not exceed 1500 mm. For
other lengths please contact the Roland laboratory.
Provide additional necessary information about:
•welding processes, materials and post weld treatment
•maximum cycle time or number of pieces per minute
•positioning accuracy – Set value
•reliability of detection – Set value
•Roland Electronic provides a Questionnaire to enter all available data.
2.3.2 Send tubes during operation
Reason:
•new tube dimension or tube type to be introduced
•changing of the supplier
•the tube specification is changed, concerning welding methods, materials and post weld
treatment
•a type of tube shows strong batch dependence and the results are not satisfactory.
Note:
Please inform about the installed type of sensor and unit. The laboratory analysis
will be performed with the same equipment.
2.3.3 Tube diameter and wall thickness
For tube diameter and wall thicknesses to be processed, the correct sensor type is determined in
the laboratory. Some information for guidance see chapter "Technical Data - Sensors".

Manual
Weld Seam Detection System R4000 SND40
for Tubes, Cans and Drums
System description B0059001 / Rev. 2.3
14 ROLAND ELECTRONIC GmbH ·Otto-Maurer-Str. 17 ·DE 75210 Keltern ·Phone [phone] ·Fax [phone]
2.3.4 Cycle time and Duration of weld seam detection
Die cycle time is the sum of all times in the course of a weld seam detection. See the chapter
„Sequence of a Weld Seam Detection“- Steps 1 to 8.
Note:
Typically, the cycle time is initially calculated based on the number of units per
minute. If the cycle time is very short, it remains limited time for the individual steps.
The detection time TDincludes the steps 4 to 6 from „ Sequence of a Weld Seam Detection “.
The influences are:
•tube diameter
•rotation speed
•wall thickness / settling time
•measuring methods
The following diagram shows the duration of weld seam detection in dependence of the tube
diameter and rotation speed. The settling time TSof 1.5 seconds is considered here.
Fig. 2: Duration of weld seam detection in dependency of tube diameter and rotation speed
Note:
Not valid for the type of filter "cross correlation".
To calculate the detection time TDfor another settling time TSuse following formulas:
For drives with clamping chucks or cone points:
N
200
TT
SD +=
TS = Settling time of system
N = Number of rotations of the tube [rpm] *
TD= Detection time [s]
*Conversion of the rotation rate from rpm to rps is not required.
For drives:
V
5,10D
TT SD
⋅
+=
TS = Settling time of system
TD= Detection time [s]
D = Tube Diameter [mm]
V = Speed [mm/s]
However, the settling time cannot be set arbitrarily small. Following information for orientation:
NS12 sensors: TS > 0.5 s per 1 mm wall thickness
NS9 sensors: Ts > 0.7s per 1 mm wall thickness
Number of rotations [RPM]
400
200
100
50
20
10
5
Time requirement detection T [sec.]
D
2,0
2,2
2,5
3,5
5
6,5
11,5
21
40
Work area
Tube diameter [mm]
100 200 250 300 500 1000510 20 30 40 50 70

Manual
Weld Seam Detection System R4000 SND40
for Tubes, Cans and Drums
B0059001 / Rev. 2.3 System description
ROLAND ELECTRONIC GmbH ·Otto-Maurer-Str. 17 ·DE 75210 Keltern ·Phone [phone] ·Fax [phone]
15
2.3.5 Rotary speed of the tube
The rate of tube turns is mostly determined by the cycle time. See previous chapter „Cycle time
and duration of weld seam detection“.
However, it may happen that a very short cycle time requires a very high tube rotation speed N.
This can lead to system-related limitations. To check use the formula below:
DA
K
N
DA
750
⋅
<
<
⋅
however > 5 rpm and < 300 rpm
N= Rate of tube turns [rpm]
D = Tube Diameter [mm]
A = Scanning values per cm
(item in program parameter 5… 120)
K = 1.000.000
There are no restrictions if the rate of tube turns N is within the limits.
Important:
During the detecting procedure the rotation rate of the tube must be
constant.
2.3.6 Speed
At friction roller drive the speed of the surface / of the periphery is specified.
Whether system related limitations are observed can be checked using the following formula:
A
K
V10 <<
V= Speed [mm/sec.]
A = Scanning values per cm
(item in program parameter 5… 120)
K = 50.000
There are no restrictions if the velocity V is within the limits.
Important:
During the detecting procedure the speed must be constant.

Manual
Weld Seam Detection System R4000 SND40
for Tubes, Cans and Drums
System description B0059001 / Rev. 2.3
16 ROLAND ELECTRONIC GmbH ·Otto-Maurer-Str. 17 ·DE 75210 Keltern ·Phone [phone] ·Fax [phone]
2.3.7 Weld seam positioning and positioning accuracy
A good positioning accuracy can only be achieved if:
•the response time for the controller is short enough
•the driver rotates the tube with a constant rotation speed / surface velocity and with no
slippage
•the drive stops reproducibly
•the weld seam detection is reliable
•for friction rollers the diameter tolerances should be close
•the SND40 is correctly adjusted
Accuracies better than +/- 8° require additionally:
•rotation of the tube with chuck and servo drive
•check for feasibility in the application laboratory
•an optimum setting of the SDN40
Important:
the "blue discoloration" at the seam is for checking of the position roughly suitable!
Measurement errors of 10 ° or more may occur.
2.3.8 Reliability of detection
Due to steady progress in the welding technology and in the production processes of tubes, the
detection of weld seams is a constantly increasing challenge. Therefore some tubes can be
encountered, where the weld seams are not reliably detectable.
Reliable weld seam detection can be affected by a variety of factors, such as grooves, deviations
from concentricity, material defects, or hard spots in the tube wall from roll forming.
In the most unfavourable case this can result in false weld seam positioning. Such tubes cannot be
processed further and must be sorted out..
Therefore, for such tubes the SND40 supplies the signal "reduced detection capability" to the PLC
interface. This signal instructs the PLC to initiate the removal of the tube. The decision therefore is
done automatically by the SND40.
High detection reliability means:
•no incorrectly positioned tubes (ideal case), but
•depending on tube class, a relatively large number of rejected tubes.
Low detection reliability means:
•relative large number of incorrectly positioned tubes
•few or no rejected tubes
The detection reliability can be adjusted in the SND40 with the parameter "detection grade".
The reliability of detection increases with high dB values.

Manual
Weld Seam Detection System R4000 SND40
for Tubes, Cans and Drums
B0059001 / Rev. 2.3 System description
ROLAND ELECTRONIC GmbH ·Otto-Maurer-Str. 17 ·DE 75210 Keltern ·Phone [phone] ·Fax [phone]
17
Fig. 3: High reliability at a high dB-value
Important:
The plant must sort out tubes if the dB value is too low!
The thresholds for sorting-out can be set in three / five levels (from software version 10-1.04):
Thresholds for sorting-out Nominal value of
signal/noise ratio
ultra larger 18 dB (factor 8:1)
extra larger 12 dB (factor 4:1)
very good larger 6 dB (factor 2:1)
good larger 2.5dB (factor 1,33:1)
satisfactory larger 1.1dB (factor 1,14:1)
If the measured dB value falls below the value for the selected stage, the message “critical
detection” is displayed and the signal "reduced detection capability" is set to sort out the tube.
Note:
Setting the sort-out threshold to the levels extra or ultra may lead to an extremely
large amount of discarded tubes.
It must therefore be concluded that there are different tube classes. Tubes with clearly detectable
weld seams generate high dB values; poorly detectable weld seams generate low dB values.

Manual
Weld Seam Detection System R4000 SND40
for Tubes, Cans and Drums
System description B0059001 / Rev. 2.3
18 ROLAND ELECTRONIC GmbH ·Otto-Maurer-Str. 17 ·DE 75210 Keltern ·Phone [phone] ·Fax [phone]
The following table shows how the number of discarded tubes and the number of
wrong positioned tubes are influenced by the tube class and the chosen sort-out-threshold:
Risk of critical detection1) Risk of wrong positioning2)
Good detectable Bad detectable Good detectable Bad detectable
Ultra
Good
Satisfactory
1) Possibility that the position of the weld seam can not be detected with sufficient certainty. With
the signal "reduced detection capability" the discarding starts.
2) Possibility that a tube is stopped at wrong position.
*Tubes with a high dB-value are „good detectable“, tubes with a low dB-value are
„bad detectable“.
Note Please also refer to chapter 2.7 „Measures for improvement of
Weld Seam Detection“
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2.4 Important notes for machine manufacturers
•The following components have decisive influence on the function of the system:
•the rotation device for the tube
•Bending mandrels within the tube
•the positioning device for the sensor
•the clamping device for the tube
•the unloader device for the tube
•
2.4.1.1 Rotation device and drive
The main requirements are:
•stable tube holder
•slip-free drive of the tube
•constant rotation speed on the tube
•low starting time of the drive
•stopping behaviour of the drive or the constant brake
A stable tube holder means a device that takes the tube reproducibility and allows a smooth
multiple rotation of the tube.
Here, the weld seam sensor should not be carrying part of this device. Often, the tube drive is
designed so that it forms the tube receptacle.
Sorting-out
threshold
Tube class*

Manual
Weld Seam Detection System R4000 SND40
for Tubes, Cans and Drums
B0059001 / Rev. 2.3 System description
ROLAND ELECTRONIC GmbH ·Otto-Maurer-Str. 17 ·DE 75210 Keltern ·Phone [phone] ·Fax [phone]
19
Available drives, possibilities and guidelines for setting the devices:
Clamping chuck Cone drive Friction roller drive
•ideal for all tube diameters
●also for oily and greasy tubes
●mandatory for positioning
accuracy better than + / - 8 °
●access to at least one
end of the tube, a further
bearing for support
●SND40 is set at drive type to
"constant rotation speed"
●reasonably usable from
tube diameter > 20 mm
●access to both ends of the
tube is necessary
●not for positioning accuracy
better than +/-8°
●SND40 is set at drive type to
"constant rotation speed"
•ends of tubes must not be
accessible
●tube diameter at least > 15mm
●separate clamping device necessary
●higher maintenance because
cleaning and abrasion of the rollers
●not suitable for oily and greasy tubes
●not for positioning accuracy
better than +/-8°
●SND40 is set at drive type to
"constant rotation speed"
When selecting the drive motor follow the rules below:
1. Dimension the torque so that the tube reaches quickly the nominal speed
2. Servo motor is obligatory for positioning accuracy better than + /- 8 °
3. If no servo motor, use speed-controlled motor with precise brake
4. Without speed control: dimension the motor drive larger so that dependence on the speed
of the engine and transmission temperature is as low as possible
5. Without any speed or brake control, the positioning error can reach + /- 20 °
Note:
The stopping behaviour of the drive or the brake is adjusted with the parameter
"Position offset" at the SND40 so that the desired angular position can be achieved.
This assumes that the stopping behaviour is always constant because the SND40 has
no angle or rotary encoder information.
For drive units without brakes the temperature response of the machine can
dramatically affect stopping behaviour because changing of the transmission oil
viscosity or lubrication of rolling bearings.
Important:
Keep the rotation speed / speed / braking behaviour constant!
2.4.2 Mandrels inside the tube
Magnetic material, such as mandrels may disturb the measurement inside the tube sustainable so
that regular weld seam detection is not possible. In special cases, the usage of a mandrel is
possible. However, this is to clarify in the conception of a station for weld seam detection with the
application laboratory.

Manual
Weld Seam Detection System R4000 SND40
for Tubes, Cans and Drums
System description B0059001 / Rev. 2.3
20 ROLAND ELECTRONIC GmbH ·Otto-Maurer-Str. 17 ·DE 75210 Keltern ·Phone [phone] ·Fax [phone]
2.4.3 Placement device for the sensor
The decision at which position the sensor should measure along the axis of the weld is very
important. Especially for tubes with a length > 50 cm the twist of the weld can affect the weld
positioning (weld start and weld end have different circumferential positions). For tubes with small
diameter / wall thickness a variation of up to 10° per meter can be observed. on 1m length. In such
cases it is advisable to place the sensor either at the centre of the tube or at the place where the
weld position is considered to be most important.
Important:
When placing the sensor take into account the twist of the weld seam!
Other requirements are:
•Stable, good reproducibility of placement
•path compensation for different tube diameters
•Soft, shock-and impact-free touchdown on tube surface
•Availability of compensation of mounting tolerances and tube geometry
•Availability of lateral displacement of the axis
•Clear view on sensor
NS9S, mounted with rubber buffers in a tube
rotator
Fig. 4: NS9S Application
A stable placement device is considered to be a device which can place the sensor correctly on the
tube with a high degree of reproducibility. Proven solutions are:
•a parallel guide that guides the sensor at right angles to the tube surface
•the entire device can be aligned with the tube admission, to compensate for mounting
tolerances
•damping elements and air pressure adjuster when using pneumatic cylinders to enable a soft
touch down and allow for sideways movement (adaption) during placement and removal of the
sensor.
•the adjusting force is approximately the same as the weight of the sensor
•the sensor is mounted using the supplied rubber buffers, so compensation for deviations in the
tube geometry is possible. This includes ovality and banana effect
•the rubber buffers are mounted on the two narrow sides
•the placing device is mounted on a separate axis so that it can be placed on another measuring
spot providing the length of the tube allows for this