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Table of Contents
1 Introduction............................................................................................................................................2
2 Machine Description..............................................................................................................................2
3 Startup And Shutdown...........................................................................................................................5
4 Using The Remote Console in Jog Mode..............................................................................................5
5 Gap Line Up...........................................................................................................................................7
6 Head Homing.........................................................................................................................................7
7 End Gripper Adjustment........................................................................................................................8
8 Coil Production......................................................................................................................................9
9 Creating a Program..............................................................................................................................10
10 User Interface.....................................................................................................................................11
10.1 Production Screen.......................................................................................................................12
10.2 Workcell Status...........................................................................................................................14
10.3 Axis Status..................................................................................................................................15
10.4 Head Controller Status...............................................................................................................16
10.5 Guide Roll Status........................................................................................................................17
10.6 End Support Status.....................................................................................................................18
10.7 Remote Console Status...............................................................................................................19
10.8 Production Setup........................................................................................................................20
10.9 Homing Screen...........................................................................................................................21
10.10 Program Screen........................................................................................................................23
10.11 Inputs Status.............................................................................................................................26
10.12 Outputs Status...........................................................................................................................27
10.13 Motors Status............................................................................................................................28
10.14 Change Password.....................................................................................................................29
10.15 Edit Process Parameters...........................................................................................................30
10.16 Edit Zone Location...................................................................................................................32
10.17 Edit Production Parameter........................................................................................................33
10.18 Low Resistance Tape................................................................................................................34
10.19 Stop Tape..................................................................................................................................35
10.20 Guide Roll................................................................................................................................35
10.21 Edit Path...................................................................................................................................36

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Introduction

This manual describes the use of the TAPLE software that control the taping machine. The machine is
able to tape bar or coil. For the TAPLE software, a bar is like a single leg coil with some minor
difference. Because of that, this manual will mostly refer to coil and will only refer to bar when there
is difference with coil.
This manual will describe the two main tasks that an operator need to do with the TAPLE software.
They are the production of coils and the programming of their shape. A password is required to
activate the programming section of the software. This way, it's possible to train personnel only on the
production part of the software since it's the task most often used.

Machine Description

The machine is able to tape two coils at the same time using two taping heads. There is a single motor
that rotate both heads. The heads can be moved along the bar using three motors. One is along the
width of the machine and is called the X direction. The second motor move along the length of the
machine and is called the Y direction. The third motor rotate the heads around their central axis and is
called the R direction. There is also four more motors used to raise or lower the coil which are called
Z1, Z2, Z3 and Z4. Each of these eight motors are controlled using a DMC-4080 motion controller
made by Galil. The amplifier for each of these motor are Sigma V series made by Yaskawa.

Illustration 1: Head Front View

Illustration 2: Head Back View

On each of the head, there is a motor used to adjust the angle of the roll, one magnetic break per roll
used to apply the correct tension on the tape and a sensor measuring the radius of each of the two rolls
of tape. Another sensor on each roll is used to detect tape break by making sure the roll is turning
during production. For the taping head to rotate, a gap must be closed manually. A detector is installed
on each head to make sure the gap is closed. There is also an optional guide roll that can be installed
on each of the two heads.

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Illustration 4: Head Micro-Controller

Illustration 3: Galil Remote Module

Each head are controlled by a custom made micro-controller that communicate with the TAPLE
software using a wireless modem (one for each head). To connect the various inputs and outputs
located around the taping head, there is a RIO-47100 module made by Galil which is installed on the
non-rotating part of the head.

Illustration 5: Head Button Box

On the side of the taping heads, there is a four buttons box used to move the head along the coil when
the production is paused. It can also be used to turn the head slowly while attaching tape to the coils.

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Illustration 6: Operator Panel

The TAPLE software runs on a standard PC computer using Windows XP. The operator panel contain
a touchscreen interface, a mouse and a keyboard. There is also various button around the screen used
to power up the machine and to start and stop the production. There is an emergency stop button on the
side of the panel.
There is two doors, one on each side of the machine, and a light curtain in front of the machine. There
is also an emergency stop button on the right side of the fence which act the same as the one on the
operator panel. Opening any of the two doors, crossing the light curtain or pressing an emergency stop
will stop motion and disable all motors by deactivating the Yaskawa amplifiers. This will also power
off all pneumatic valves.

Illustration 7: Remote Console

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A remote console is used to move the head manually while not in production. This console
communicate with the PC using a wireless modem. The emergency stop button on this remote console
is only active when the machine is in manual mode (when the selector on the operator panel is at the
Manual position).

Startup And Shutdown

To start the TAPLE software, just press the Power On button on the operator panel. This will power up
the computer which will eventually start the TAPLE software after Windows is started. To shutdown
the machine, press the Windows button (
) on the keyboard to display the Windows task bar. Then
press the Turn Off Computer button followed by Turn Off. The TAPLE software will shutdown
followed by the shutdown of Windows and of the computer. Once the screen is black, press the Power
Off button on the operator panel to power off the whole machine.

Using The Remote Console in Jog Mode

When the machine is not in production, the operator can move the head using the remote console. To
active it, turn the Auto/Manual selector to the Manual position. Make sure the emergency stop button
on the operator panel or the one on the fence is not pressed and that the two doors are closed. Then
press the Reset button on the operator panel to reset any fault caused by the opening of a door or by
any emergency stop. The light curtain is not active when in Manual mode so there is no need to reset
this fault.
Make sure the emergency stop button is not pressed on the remote console (twist it to release the
button). Then activate the remote by turning the green selector to the On position. Finally press the
Start button twice to activate the remote console and to reset the motor fault. At this point, the green
light on top of the operator panel should be lit indicating that the motors are allowed to move. If not,
press the Workcell button on computer screen to find out the source of the problem (see description of
the Workcell Status screen at the end of this manual).

If no button is pressed on the remote console for more than a minute, a fault is triggered and the red
light on top of the operator panel will lit. Just press any button on the remote console to re-enable the
motors. If the emergency stop button is pressed on the remote console or if the green selector is turned
to the Off position, operator will have to re-activate the console as explained in the previous paragraph.

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Illustration 8: Machine Coordinate System

The coordinate system used with the machine is illustrated above. There is a button for each direction
on the remote console. Each button can be pressed at two different depths which correspond to the
slow and fast speed for each direction. Pressing gently on the button will activate the slow speed while
fully pressing the button will activate the fast speed.

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The Z direction is special because it is linked to four different motors called Z1, Z2, Z3 and Z4. It's is
possible to move them in sync or to move one motor at a time depending on the current Z mode. This
mode can be changed using the MZ- and MZ+ button on the remote console. To see the current Z mode,
press the Remote icon on the computer screen to display the Remote Console Status screen (see
description of this screen at the end of the manual). The current mode is displayed next to the Mode
keyword. It can be Sync All Z where all four motors move together, Sync Bottom Z or Sync Top Z
where only the two bottom or two top motors move together. It can also be Only Z1, Z2, Z3 or Z4
where only the specified motor move. Note that for an operator, the Z mode is always Sync All Z and
cannot be changed even by pressing the MZ- or MZ+ button on the remote console. Operator need to
get access to the programming screen using the required password in order to activate the various Z
mode.
A programmer can toggle the remote console between the Jog and Path mode using the Start button on
the console. The current mode is displayed on the Remote Console Status screen next to the Mode
keyword. When in Path mode, the white light on top of the taping head will also be lit. The meaning
of all other buttons on the remote console change when in Path mode. This mode will be explained in
the programming section of this manual.

Gap Line Up

In order to install or remove the gap filler on the taping head, the head must be rotated at the position
where the gap on rotating part of the head and the gap on the body of the head are lined-up perfectly.
When the gap is closed with the gap filler, this line up process can be done automatically by pressing
the Home button on the production screen followed by the Line Up Gap button. The Auto/Manual
selector must be at the Auto position and any fault must be reset using the Reset button. Once gaps are
lined-up, it is possible to install or remove the gap filler on each head. Note that once the gap is open
on any of the two heads, the brake is applied on the head motor and rotation of the head is prohibited.
There is also a manual procedure to release the head brake and rotate the head manually. This should
be done only in case the gaps are open but the head is not lined-up properly. In this case, the automatic
line up procedure won't work because the brake is applied on the head prohibiting it from turning. In
order to release the brake manually, operator must go on the programming screen and press the In/Out
button. Select the Output screen using the right arrow at the bottom of the screen. Press on the Allow
Modification check box and then press the yellow bulb left of Release Head Brake. When rotating the
head manually without the gap filler in place, make sure not to rotate the gap in front of any of the three
brush holders or damage to the brush may occur. Once the head is lined-up properly, re-apply the brake
by pressing the dark bulb on the left of Release Head Brake.

Head Homing

Production normally starts and ends in the homing zone located on the right side of the machine. If for
some reason the head is moved manually out of the homing zone, there is a procedure to return it to the
homing zone. From the production screen, press the Home button. If the gap is not lined-up, follow
the procedure explained in the previous section. Once the gap is lined-up, remove the gap filler on both
heads and press the Move Home button. The Auto/Manual selector must be at the Auto position and any
fault must be reset using the Reset button. The motion can be stopped by pressing the red stop button
on the right side of the screen. The speed of the motion depends on the Speed Ratio located in the

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Production Setup screen.

Illustration 9: Safe Homing Zone

If the head is not along the taping path of the bar, the computer may request to manually move the head
in the safe zone before proceeding with the automatic homing motion. This is to avoid any contact
with the coil or other hardware in the workcell. The safe zone is highlighted in red in the previous
illustration. See section about using the remote console for more information about moving the head
manually.

End Gripper Adjustment

In order to install a coil in the end grippers, the height of each of the four end grippers must be adjusted
properly. This can be done manually using the remote console and moving each of them using the
proper Z mode. It can also be adjusted automatically by first loading the correct program using the
Open button and then pressing the End Grip button on the production screen.

This will display the status of each of the four end grippers. By pressing the Rotate At 0 button or the
Rotate At 180 button, the machine will perform the correct rotation for all four end grippers and it will
then adjust the Z for each of them so that the coil can be loaded in the end grippers. The Auto/Manual
selector must be at the Auto position and any fault must be reset using the Reset button. The motion

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can be stopped by pressing the red stop button on the right side of the screen. The speed of the motion
depends on the Speed Ratio located in the Production Setup screen.

Coil Production

The first step to begin production is to select the correct program by pressing the Open button (refer to
the Production Screen in the User Interface section). Once loaded, adjust the height of all four end
grippers by following the procedure described in the End Gripper Adjustment section. If needed, return
the head at the home position by following the procedure described in the Head Homing section.
Once the coil is installed in the end grippers, select the starting leg by pressing the Production Leg
keyword. Then select the starting pass by pressing on the Pass keyword. To specify the low resistance
tape, enter a starting pass that is one more than the total number of pass for the insulation tape.
To start production, press the Start button on the screen or the green start button on the right side of the
screen. Make sure that the machine is not in fault (the red light on top of the operator panel is off).
Otherwise press the Reset button to clear any fault. If needed, press on the Workcell light in the
Production Screen in order to find out the source of the error. For the production to start, all four lights
at the bottom of the screen must be green (Workcell, Axis, Bottom Head and Top Head). If not, press
on the light that is not green to get additional information on the source of the problem (refer to the
User Interface section for more information about each of these screens). The green light on top of the
operator panel must also be lit for the head to move.
During production, follow the information displayed next to the Operator Task keyword. The operator
can pause the production at any time by pressing the Pause button on the screen or the red stop button
on the right side of the screen. To resume the production, press either the Start button on the screen or
press the green start button on the right of the operator panel. Note that the green start button on the
operator panel works only when the Production Screen is displayed.
If the production is paused during the taping sequence, the operator can move the head backward and
forward using the two arrows on the screen. He can also use the button box installed on the taping
head. When this box is active, the top green button is illuminated. Operator must press and hold this
green button to activate the other three buttons of the box. Release this button to stop the motors
immediately like an emergency stop button would do. The first two buttons move the head backward
and forward. When using these buttons, the speed of the motion is reduced compare to using the
Backward/Forward button on the computer screen. The last button on the box start the rotation of the
head while moving forward. This is useful when attaching the tape to the coil.
To cancel the production in the middle of the sequence, first press the Pause button. Once the
production is paused, press the Abort button. To restart the production after an abort, press the Start
button.
The operator can adjust certain parameters related to the production by pressing the Setup button (refer
to the Production Setup screen in the User Interface section) . From this screen, it is possible to adjust
the overall speed of all motion by changing the Speed Ratio parameter. When the machine is powered
up, the speed ratio is adjusted at 10%, meaning that all motion will be slow down to 10% of the normal
production speed. When a program is well tested, it should normally be run at 100%. This ratio
control the taping speed and all other motion related to production (ex.: moving the head to the home
position). The backward and forward motion of the head during a pause is not affected by this ratio
and is always at the same slow speed for security reason.
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The two other adjustments available to the operator is the Overlap Adjustment and the Tension
Adjustment. These two values let the operator change the process parameters by a certain amount of
percentage to adjust the taping quality to any variation in the tape. For example, if the tape is a bit
larger than expected, it is possible to adjust the overlap ratio a little bit to achieve the correct lap
without having to change the program. Also, if some wrinkle appear during the taping, operator can
increase tension a little bit to compensate.
The next two parameters specify the minimum diameter, for each of the two rolls, at which the machine
will pause for a change of roll. The value can be different for each roll if not using the same type of
tape on both roll holder. The program will monitor the roll diameter only if the tape break detection is
activated for the specified roll. There is one check box for each of the four roll holders (two per head).
When the tape break detection is activated for one roll, the machine will stop if it detect that the roll is
not turning when the head is rotating.

Creating a Program

This section describe how to create a new program for a coil. The first step in creating a new program
is to install the coil in the machine using the end supports. Refer to the mechanical manual for an
explanation of this procedure. Once the coil is installed, go on the Program Screen by pressing the
Program button. The initial password is 1234 but it can be changed from the program screen by
pressing the Password button (refer to the Program Screen described the User Interface section).
The best way to start a new program is to load one of the base program that best match the kind of
program to create. This is done by pressing the Open button located on the Program Screen. There is
one program for a coil called BaseCoil and another one for a bar called BaseBar. These two programs
contain a set of default parameters for each type of program but with no trajectory. The first step after
loading the base program is to rename it by clicking on the pencil next to the Job Name keyword. This
is to avoid overwriting the base program.
The first parameter to adjust is the offset between the left and right side of the coil. The coil should be
installed so that its slot section is level. This may require to raise or lower one side of the coil compare
to the other. Once the coil is adjusted, record the offset in the program by going in the Edit Production
Parameter screen and pressing on the down arrow located to the right of the Offset Z Left/Right
keyword. This will record the difference between the Z2 and Z1 axis.
The next step is to record all the positions along one leg of the coil. This is done by moving the head
manually to the correct location and pressing and holding the Edit button followed by the Rec button
on the remote console. The buzzer will do a short beep each time it accept a new position. The
positions can be recorded in any order because the program always sort them in ascending order along
the Y axis. To delete a position, use the Delete button located on the Edit Path screen or move the head
at the position that need to be deleted and press and hold the Edit button followed by the Del button on
the remote console. In this case, the buzzer do a small beep to acknowledge the action. Note that two
positions cannot be closer than a millimeter otherwise the program will only keep the last recorded
position. During production, the head will move in a straight line between each of the recorded
positions. In the curve part of the leg, there should be around 15 mm between each position. In the slot
section, there is only a need for one position at each end. When using this spacing, the number of
position that need to be recorded for one leg should be around 20. The program only record the X, Y,
Z1 and R axis. The other Z axis (Z2, Z3 and Z4) are computed based on offset with the Z1 axis. To see

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the list of positions recorded for each leg, press on the pencil next to the Path keyword (refer to the
description of this screen in the User Interface section).
To move the head in jog mode, refer to Using the Remote Console in Jog Mode. To record position,
the remote console need to be toggle in Path mode by pressing the Start button on the console. When
in Path mode, the white light on top of the head will be on. In Path mode, all buttons on the console
change their function. The Rev and Fwd button will move the head reverse or forward toward the
closest recorded position. The Prev and Next button will do the same except that the head will stop
once it reach a recorded position. Operator need to release and press the button again in order to move
to the previous or next position. This mode is useful to edit or delete an existing position. The Del and
Rec button are used to delete and record position. To avoid pressing them accidentally, operator need
to first press and hold the Edit button before pressing the Del or Rec button. The Dir and Tape button
are used once the program is ready for production to be able to test the program manually. The Dir
button will select the taping direction (left to right or right to left) while the Tape button will start the
rotation of the head.
Once the two legs have been recorded, the operator must enter all production parameters. This is done
by clicking on the pencil next to each of the field located on the Program Screen. Each of these screen
are describe in the User Interface section. Once all parameters are valid, the Job Status field will
display Ready For Production. Otherwise, this field will display the invalid parameter.
When the job is ready for production, the operator can try it manually by using the Tape button on the
remote console. When taping in manual mode, the speed of the head is either slow or fast depending
on the pressure on the Tape button. When pressing only half way on the button, the head will rotate
slowly. When fully pressing on the button, head will rotate faster. During real production, the speed of
the head will depend on the parameters listed in the Process Parameters section. If the head do not
start turning when pressing the Tape button, go on the Remote Control Status screen to see the reason
why the head is not turning. During manual taping, the parameters used for tension, overlap and angle
are defined by the Process Parameters section. The machine can use either the insulation tape
parameters or the low resistance tape parameters depending on the setting located in the Edit Path
screen next to the Parameters keyword.
To save the job at the end of the testing, press the Save button on the Program Screen.

10

User Interface

This section display an image of each screen available in TAPLE along with a description of all field
on the screen.

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10.1

Production Screen

Open:

Let operator select the production program to run.

Guide Roll:

Let operator access the Guide Roll Status screen describes further
down.

End Grip:

Let operator access the End Support Status screen describes

further down.

Remote:

Let operator access the Remote Console Status screen describes

further down.

Setup:

Let operator access the Production Setup screen describes further

down.

Home:

Let operator access the Homing screen describes further down.

Program:

Let operator access the Program screen describes further down. A

password is required to access this screen. The initial password is
1234 but it can be changed from the program screen.

Job Name:

Display the name of the current job in memory.

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Job Type:

Display the type of the job in memory between Bar and Coil.

Production Leg:

Display the leg currently in production between Leg At 0 and

Leg At 180. If not in production, it is possible to change it to
specify on which leg to start production.

Pass:

Display the current production pass between 1 to the number of

pass or Low Resistance Tape if this type of pass is defined. If not
in production, it is possible to change it to specify on which pass
to start production. Use one more than the total number of pass to
specify the Low Resistance Tape.

Tape Width:

Display the width of the tape for the current pass.

Start:

Pressing this button will either start a new production or resume

the current one after a pause. This is equivalent to the green start
button on the right of the operator panel.

Pause:

Pressing this button while in production will pause the current

motion. This is equivalent to the red stop button on the right side
of the operator panel.

Backward:

Pressing this button while the production is paused will move the
head backward along the taping trajectory. It is equivalent to the
backward button located on the taping head. The only difference
is the speed of the motion which is slower when using the button
on the taping head.

Forward:

Pressing this button while the production is paused will move the
head forward along the taping trajectory. It is equivalent to the
forward button located on the taping head. The only difference is
the speed of the motion which is slower when using the button on
the taping head.

Abort:

Pressing this button while in production will abort current

production immediately. Production can be restarted by pressing
the Start button again.

Production State:

Display the current state of production between Not in Production,

Pausing, Paused, Running.

Operator Task:

Display the next task for the operator or None if no task to

perform at the moment. Example of task can be Move Head To
Home, Turn Selector to Auto, Attach Tape + Press Start, etc.

Production Sequence:

Display the current production sequence. Example of production

sequence are Move Onto Bar, Line up Gap, Adjust Head Angle
And Tension, Wait Attach Tape, etc.

Production Message:

Display supplemental information about the production sequence.

For example, if the production sequence is Wait Communication
OK, the production message will display which component is in
error (ex.: Communication Error (Axis Controller)).

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Workcell:

Display the state of the workcell. Should be green when no fault

is detected. Pressing on the light will display the Workcell Status
screen describes further down.

Axis:

Display the state of the linear axis. Should be green when no

fault is detected. Pressing on the light will display the Axis
Status screen describes further down.

Bottom Head:
Top Head:

10.2

Display the state of each of the two taping heads. Should be

green when no fault is detected. Pressing on the light will display
the Head Controller Status screen describes further down.

Workcell Status

Communication:

Give the status of the communication between the PC and the

Galil motion controller. When flashing red, no other inputs,
outputs or position information can be obtained. In this case,
check the wiring between the PC and each of the two Galil
modules. Try cycling the machine off and on if nothing else
work.

System Ready:

This signal is green when the main contactor for all the motors is
closed, meaning that the motors are active. This happens only
when all faults are cleared using the Reset button on the right
side of the screen.

E-Stop Panel:

When red, the emergency stop button on the operator panel or the
one located on the right side of the fence is depressed. Twist the
button in order to release it.

Auto/Manuel:

These two lights indicate the state of the Auto/Manual selector

located on the right side of the operator panel.

Remote Enabled:

This light is blue when the remote console is enabled, meaning

that the green selector is at the On location, the emergency stop
button is not depressed and the Start button on the remote console
has been pressed once during the last 60 seconds. The remote
console must be enabled to activate the other button on it.

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10.3

Left/Right Door:

These two lights are green when each of the door is closed.

Light Curtain:

This light is green when the light curtain is not blocked.

Axis Status

Amplifier Ready:

Give the status for each of the eight amplifiers connected to each
motor. If no fault is present (ex.: emergency stop), all lights
should be green. Otherwise, refer to the amplifier status code
displayed on each of the amplifier inside the electrical cabinet.

Limit Error:

These lights are flashing red when one of the eight axis reach a
limits. If this happens, use the remote console to jog the axis out
of the limits.

Position Error:

These lights are flashing red when one of the eight motors is not
following the command sent by the Galil motion controller. This
may indicate that a motor is blocked by an obstacle. It may also
happen if the light curtain is crossed when the head is rotating at a
high speed. In this case, pressing the Reset button should clear
the fault.

Current Position:

Display the current position for each axis. The linear axis (X, Y
and Z) are displayed in millimeter while the rotational axis (R and
Head) are displayed in degrees.

Current Speed:

Display the current speed for each axis. The linear axis (X, Y and
Z) are displayed in millimeter per second, the R axis is displayed
in degrees per second and the Head axis is displayed in RPM
(revolution per minute).

Communication:

Give the status of the communication between the PC and the

Galil motion controller. When flashing red, no other inputs,
outputs or position information can be obtained.

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10.4

Head Controller Status

Current Tension:

Display the current tension for each of the two rolls. This should
normally match with the target tension unless the roll diameter is
too small to be able to apply the requested tension. Note that
there is no sensor on the head to measure the actual tension. The
displayed tension is computed based on the diameter of the roll
and the characteristic of the brake used to apply the tension.

Target Tension:

Display the target tension for the two rolls. When not in
production, this value can be changed by clicking on it or on the
pencil. During production, the tension displayed is the one that
has been set in the program for the coil.

Current Angle:

Display the current angle for the two roll holders. It correspond
to the value of the encoder located on the angle motor. Note that
this value is meaningful only once the homing is done (see
below).

Target Angle:

Display the target angle for the two rolls. When not in
production, this value can be changed by clicking on it or on the
pencil. During production, the angle displayed is the one that has
been set in the program for the coil.

Current Diameter:

Display the current diameter for each of the two rolls of tape.

Communication:

Give the status of the communication between the PC and the

head's micro-controller. When flashing red, no other inputs,
outputs or position information can be obtained.

Setup Done:

This light should be green once all the setup parameters has been
sent from the PC to the head's micro-controller. This happens
once each time the head is power on.

Set PID Done:

This light should be green once the head's micro-controller has

accepted the motion parameters. This happens once each time the
head is power on.

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10.5

Homing Done:

This light should be green once the head's micro-controller has

completed its homing sequence. This happens once each time the
head is power on. During this sequence, the two roll holders are
moved toward one of the limit switch in order to record the zero
position for the angle motor. There must be no fault on the
machine for the motor to move.

Position Error:

This light is flashing red when the angle motor is not following
the command sent by the micro-controller's motion controller.
This may indicate that the motor is blocked by an obstacle.
Pressing the Reset button should clear the fault.

Overcurrent:

This light is flashing red when the angle motor is using too much
current to move. This may indicate that the motor is blocked by
an obstacle. Pressing the Reset button should clear the fault.

Servo On:

This light is green when the angle motor is enabled (it 's under the
control of the micro-controller's motion controller). This does not
means that the motor is moving if it is already at the targeted
position.

Moving:

This light is green when the angle motor is moving.

Limit1/Limit2:

These lights are on when the angle motor reach one of its
hardware limit. In this case, move the motor in the opposite
direction.

Tape Break1/Tape Break2:

These two lights are on when the plates holding the roll are
rotating. When the plates are not turning, the light goes off after a
couple of second.

Gap Close:

This light is on when the gap filler is installed in the gap of the
head.

Guide Roll Status

Top/Bottom Head State:

TAPLE Software Manual

Display the current state for the top and bottom guide roll. The
state can be either Backward or Forward and Open or Close.
When the guide roll is not present, the program assume a
Backward and Open state. When the state cannot be deduce from
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the inputs, a question mark is displayed.

10.6

Backward:

Pressing this button will open the gripper and move the guide roll
away from the coil. There must be no fault on the machine for
the output to be activated. If a fault is present, there will be no
action until the fault is cleared by pressing the Reset button on
the operator panel.

Forward:

Pressing this button will move the guide roll toward the coil and
then close the gripper. There must be no fault on the machine for
the output to be activated. If a fault is present, there will be no
action until the fault is cleared by pressing the Reset button on
the operator panel.

End Support Status

Top/Bottom Left:
Top/Bottom Right:

Display the current state for each of the four end grippers. The
state can be either At 0 or At 180 and Open or Close. When the
state cannot be deduce from the inputs, a question mark is
displayed.

Rotate At 180:
Rotate At 0:

TAPLE Software Manual

Start the action of rotating all four end grippers at the 0 or 180
position and then adjusting all the Z properly for the head to come
onto the bar from the home position. This is the Z value recorded
for the middle of the taping trajectory. To make sure that the two
coils do not touch each other during the rotation, the top coil will
be move at the maximum Z position before performing the
rotation. After the rotation, the top coil will be returned at the
correct distance from the bottom coil. Note that during
production, the raise distance can be controlled by adjusting the
Offset For Rotation parameter located in the Edit Production
Parameter screen. When doing a rotation manually, the program
will always use the maximum distance instead of using parameter
Offset For Rotation. The speed of the motion is controlled by the

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Speed Ratio parameter located in the Production Setup screen.

10.7

Remote Console Status

Communication:

Give the status of the communication between the PC and the

Galil motion controller. When flashing red, no other inputs,
outputs or position information can be obtained.

X, Y, Z, R:

Give current position for each axis. The linear axis (X, Y and Z)
are displayed in millimeter and the R axis is displayed in degree.
The light on the right of each axis should be green when no fault
is present for the axis, meaning that it can be moved manually.

Mode:

Display the current mode for the remote console. It can be either
Jog or Path. The Start button on the remote console is used to
toggle between the two modes. The meaning of the other buttons
on the console change based on this mode. The white light on top
of the taping head is on when the remote console is in Path mode.
The Path mode is available only from the Program Screen (a
password is required to access this screen). When in Jog mode,
the current Z mode is also displayed. It can be Sync All Z, Sync
Bottom Z, Sync Top Z, Only Z1, Z2, Z3 or Z4. This indicates
which end support will move when the Z- or Z+ button is pressed

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on the remote console. The Z mode can be changed using the

MZ- and MZ+ button but is only available from the Program
Screen. When not on the Program Screen, only the Sync All Z
mode is available.

10.8

Status:

Display the next step to perform in order to move the motor using
the remote console. Will display Motion Allowed once all the
steps are done.

Position:

Display the current position along the taping path. If the head is
not along the taping path within 50 mm and is not near the home
position, the program will display Not Near Path or Home.

Teaching:

Display the state of the teaching mode. Teaching is allowed only

from the Program Screen. If the teaching is allowed but not with
taping, this field will display No Taping along with the reason
why taping is not allowed (ex.: Head Not on Path). If taping is
allowed, it will display Taping Allowed along with the current
taping direction. The taping direction can be changed using the
Dir button on the remote console. To start taping, operator must
press and hold the Tape button on the remote console. If the head
does not start to rotate, this field will display the step that is
blocking the taping sequence (ex.: Wait Bottom Gap Closed).

Production Setup

Speed Ratio:

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This is the speed ratio used for the various motion. The
maximum speed of each motion is defined in the program and

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cannot be changed. The operator can decide to move slower than

the defined maximum by adjusting this ratio. At startup, this ratio
is set to 10%.

10.9

Overlap Adjustment:

This parameter let the operator change the overlap by a certain

percentage during production without having to change the value
in the program. For example, if the overlap in the program is set
at 50%, an adjustment of +10% will set the overlap at 55% during
production. At startup, this ratio is set at zero.

Tension Adjustment:

This parameter let the operator change the tension by a certain

percentage during production without having to change the value
in the program. For example, if the tension in the program is set
at 60 Newtons, an adjustment of +10% will set the tension at 66
Newtons during production. At startup, this ratio is set at zero.

Low Tape Diameter:

This parameter specify the minimum radius of the tape for each of
the two rolls installed on one of the head. When the diameter of a
roll reach this limit, the machine is paused automatically and the
operator must change the roll. This avoid running out of tape
during taping which make splicing more difficult. The Tape
Break check box must be checked for this test to be performed for
a specific roll.

Tape Break:

These four check box enable the detection of tape break and low
tape for a specific roll on a head. When it is checked, the
machine will verify that the roll holder is turning when the head is
rotating otherwise it will stop the machine and display a message
about which tape is broken. It will also monitor the low tape
condition for each of the selected roll.

Homing Screen

Top Gap State:

Bottom Gap State:

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Display the current state for the alignment of the gap for each of

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the two heads. The gap is considered lined-up when the encoder
on the head motor report an angle near zero degree and the Head
At Home sensor for the head is on.
Line Up Gap:

Pressing this button will start the rotation of the head until both
gaps are lined-up. There must be no fault on the motors and the
machine must be in Auto.

Homing State:

Display whether the head is within the home zone or exactly at

the home position.

Move Home:

Pressing this button will initiate the homing sequence of the head.
The gap must be open on both heads and the guide roll must be
retracted before pressing this button (refer to the Guide Roll
Status screen). The head must be along the normal production
trajectory (either along the taping or the homing trajectory)
otherwise the operator will have to move the head in the safe
homing zone before pressing this button (refer to the Head
Homing section). There must be no fault on the motors and the
machine must be in Auto. The speed of the motion is controlled
by the Speed Ratio parameter located in the Production Setup
screen. To stop the motion, use the red stop button located on the
right side of the operator panel.

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10.10

Program Screen

Open:

Used to select the production program to edit.

Save:

Used to save all modifications to the selected program.

Guide Roll:

Let operator access the Guide Roll Status screen describes further
down.

End Grip:

Let operator access the End Support Status screen describes

further down.

Remote:

Let operator access the Remote Console Status screen describes

further down.

Home:

Let operator access the Homing screen describes further down.

Ins/Outs:

Give access to the Inputs/Outputs/Motor Status screen describes

further down.

Password:

Give access to the Change Password screen described further

down.

Job Name:

Display the name of the program in memory. The name can be

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changed by pressing on the pencil. The name is followed by an

asterisk symbol (*) if the job has been modified since the last
save.
Job Type:

Display the type of the job in memory between Bar and Coil. The
job type can be changed by pressing on the pencil. Note that
going from one type to the other will automatically discard any
parameters not needed by the selected type.

Process Parameters:

Display all of the process zones along with their respective

parameters. A coil has three zones while a bar has five. There is
also the low resistance tape zone denoted by the LT keyword.
These parameters can be change by clicking on them or on the
pencil. Refer to the Edit Process Parameters screen for more
information.

Zone Location:

Display the location of the various process zones for each of the
two legs. The value is the Y axis at the end of each zone. The
start of each zone is located at the end of the previous zone. The
location of the end of the last zone is not needed because it must
ends at the end of the taping trajectory. These parameters can be
change by clicking on them or on the pencil. Refer to the Edit
Zone Location screen for more information.

Production Parameters:

Display the list of parameters related to the production. These

parameters can be change by clicking on them or on the pencil.
Refer to the Edit Production Parameters screen for more
information.

Low Resistance Tape:

Display the list of parameters related to the application of the low

resistance tape at the end of the production. These parameters can
be change by clicking on them or on the pencil. Refer to the Low
Resistance Tape screen for more information.

Stop Tape:

Display the list of parameters related to the automatic stop

position used during the production. These parameters can be
change by clicking on them or on the pencil. Refer to the Stop
Tape screen for more information.

Guide Roll:

Display the list of parameters related to guide roll activation zone.

These parameters can be change by clicking on them or on the
pencil. Refer to the Guide Roll screen for more information.

Path:

Display the number of positions recorded for each of the two legs.
Position can be recorded or edited by clicking on the line or on
the pencil. Refer to the Edit Path screen for more information.

Job Status:

This line should display Ready For Production if all the

parameters for the job are valid. Otherwise it will display the
reason why the job is not ready.

Workcell:

Display the state of the workcell. Should be green when no fault

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is detected. Pressing on the light will display the Workcell Status

screen describes further down.
Axis:

Display the state of the linear axis. Should be green when no

fault is detected. Pressing on the light will display the Axis
Status screen describes further down.

Bottom Head:
Top Head:

TAPLE Software Manual

Display the state of each of the two taping heads. Should be

green when no fault is detected. Pressing on the light will display
the Head Controller Status screen describes further down.

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10.11

Inputs Status

Axis Controller Inputs:

Display the state of all inputs connected to the Galil motion

controller located inside the main operator panel. When all lights
are flashing red, this means that communication with the Galil
components is not established and that no input information is
available.

Remote Inputs:

Display the state of all inputs connected to the Galil RIO-47100

remote module located inside the taping head. When all lights are
flashing red, this means that communication with the Galil
components is not established and that no input information is
available.

Left/Right Arrows:

These two arrows cycle the screen between the Inputs, Outputs
and Motor Status screen.

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10.12

Outputs Status

Axis Controller Outputs:

Display the state of all outputs connected to the Galil motion

controller located inside the main operator panel. When all lights
are flashing red, this means that communication with the Galil
components is not established and that no output information is
available.

Remote Outputs:

Display the state of all outputs connected to the Galil RIO-47100

remote module located inside the taping head. When all lights are
flashing red, this means that communication with the Galil
components is not established and that no output information is
available.

Left/Right Arrows:

These two arrows cycle the screen between the Inputs, Outputs
and Motor Status screen.

Allow Modification:

This button activate the manual operation of the outputs. It

display two buttons next to each output that can force an output
Off or On. Note that when output modification is allowed, the
normal updating of the output by the program is stopped. The
program will regain control of the output when Allow Modification
is unchecked or when the screen is closed using the Close button.
Production must be aborted in order to gain manual control of the
output. Extreme caution is required when activating the output

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manually because minimal test is done to avoid invalid sequence.

For example, it could be possible to move the guide roll backward
without first opening the gripper. There must be no fault on the
machine for the outputs to be electrically active. When in fault,
the program will let operator change the state of an output but
nothing will happen because the valves connected to the outputs
won't have power.

10.13

Motors Status

Reverse/Forward Limit:

Display the state of the limit switch connected in the reverse and
forward direction for each axis. Not all axis have physical limit
switch. When all lights are flashing red, this means that
communication with the Galil components is not established and
that no input information is available.

Encoder Count:

Display the current position of each axis in unit of encoder count.

Amplifier Enabled:

Display the state of the output signal sent by the Galil motion
controller to the Yaskawa amplifier in order to activate each of the
motor. When all lights are flashing red, this means that
communication with the Galil components is not established and
that no output information is available.

Amplifier Ready:

Display the state of the input signal received by the Galil motion

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controller from the Yaskawa amplifier indicating that the

amplifier is not in fault meaning that it is ready to accept motion
command for the motor. When all lights are flashing red, this
means that communication with the Galil components is not
established and that no input information is available.

10.14

Amplifier Out:

This is the current command sent by the Galil motion controller to

the Yaskawa amplifier. The command is in volt which is
converted in speed by the amplifier. The sign of the voltage will
control the direction of the motion.

Left/Right Arrows:

These two arrows cycle the screen between the Inputs, Outputs
and Motor Status screen.

Change Password

Current Password:

Operator must enter the current password before being able to

change it. The default password is 1234.

New Password:

Field use to type the new password. It must be a number between

1000 and 9999.

Retype Password:

Operator must retype the new password in this field in order to

confirm that no mistake has been made when entering it the first
time.

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10.15

Edit Process Parameters

Section:

Display the name of the selected section. Other parameters on the

screen refer to this selected section. A coil always have three
sections (L1, L2 and L3) while a bar has five sections (L1, L2, L3,
L4 and L5). The drawing show the order and location for each
section. Each section sharing the same name will use the same
set of parameters. The LT section is for the low resistance tape
which is applied at the end once all the insulation passes are done.
This section is defined using an offset of the L1 zone, which
could be positive or negative (see parameter Offset From L1 in the
Low Resistance Tape screen). Use the left and right arrows to
cycle through the various section.

Speed:

Define the speed of the head in RPM (revolution per minute) for
the selected section. The head will accelerate or decelerate
smoothly when it reach the transition between two sections.

Overlap:

Define the overlap used for the selected section. The range of the
value is between 0% and 75%. A 0% overlap is also called a butt
lap. The new overlap will take effect immediately at the
transition between two sections.

Tension:

Define the tension used on the tape in Newton for the selected
section. Note that since the tension is in fact applied on the core
of the roll and not on the tape itself, the core normally have to
sustain more tension than the value specified in this field. A
bigger roll will have to sustain more tension at it core than a
smaller one to obtain the same tension on the tape. For some roll,

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it may be too much tension at the core an operator will have to

reduce tension on the tape. Having a roll unable to sustain
tension at its core will trigger false tape break detection because
the roll holder will not be rotating in this case. Instead, the
diameter of the roll will contract without rotation of the roll
holder. The new tension will take effect immediately at the
transition between two sections.
Angle:

TAPLE Software Manual

Define the angle used for the roll holder in degree for the selected
section. The value is always positive and the sign is computed by
the program based on the direction of taping. By pressing on the
calculator at the right of this field, the program will compute the
angle based on the overlap for the selected section and the tape
width and coil size (see the Edit Production Parameter screen).
The value should be chosen so that when applying tape, the edge
of the tape does not touch the side of roll holder to avoid
damaging the tape. The motor controlling the angle of the roll
holder will accelerate or decelerate smoothly when it reach the
transition between two sections until it reach the requested angle.

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10.16

Edit Zone Location

Leg:

Display the name of the selected leg. Other parameters on the

screen refer to this selected leg. Use the left and right arrows to
cycle between Leg At 0 and Leg At 180.

L1, L2, L3, L4 and L5:

These fields display the end position for the various section along
the coil. A coil has only three different types of section while a
bar has five. Some section appears more than once along the leg.
The drawing show the order and location for each section. The
value displayed is the Y axis where each section ends. The last
section ends at the end of the coil and cannot be edited. It's
possible to enter the value directly or to move the head at the
correct location using the remote console and then press the down
arrow on the interface to record the current Y position.

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10.17

Edit Production Parameter

Number of Pass:

This is the number of pass for the insulation tape. The machine
always tape in two directions with the first pass starting on the left
side of the machine.

Taper Length:

When taping with more than one passes, this parameter define the
total length of the taper created at each end of the leg. A value of
zero means to start and stop each pass at the same location. Other
value will instruct the machine to start and stop each pass at a
different location in order to create a taper that will have the
specified length. For example, if the number of pass is 6 and the
taper length is 25 mm, each pass along the leg will be 5 mm
shorter at each end compare with the previous pass. The last pass
will end up being 50 mm shorter than the first one (25 mm less at
each end).

Tape Width:

Define the width of the insulation tape. The overlap is computed

using this parameter. Note that if a low resistance tape is used
after the insulation tape, the width of this low resistance tape is
defined in the Low Resistance Tape screen.

Offset Z Left/Right:

This is the difference between Z1 and Z2. This value is chosen so

that the slot section of the leg is level. A positive value will place
Z2 higher than Z1. Pressing the down arrow on the right of the
field will record the current offset between Z1 and Z2.

Offset For Rotation:

This field define the raise distance needed for Z3 and Z4 when
rotating the coil during production. A value of zero mean that
there is no need to raise the top coil to rotate it. The value is
chosen so that there is no collision between the two coils during
the rotation between the front and back leg. Pressing the down
arrow on the right of the field will record the current offset
between Z1 and Z3.

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Size:

10.18

These two fields defined the dimension of the cross section of the
coil. The size is used mainly to compute the roll angle during
production (see Angle in the Edit Process Parameters screen).

Low Resistance Tape

Apply Low Resistance Tape: If this check box is checked, the program will do a last pass with

a different tape than the insulation. This tape is normally applied

only in the slot section of the leg. Process parameters for this low
resistance tape can be different than the one used for the
insulation tape (see Section on the Edit Process Parameters
screen).
Tape Width:

Define the width of the low resistance tape. The overlap is

computed using this parameter . Note that this value can be
different than the one used for the insulation tape (see Edit
Production Parameter screen).

Offset From L1:

Define the dimension of the low resistance tape section as an

offset from the L1 section. A negative value will make the low
resistance tape section shorter than the L1 section by twice the
value (the section is reduced at each end by the specified value).

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10.19

10.20

Stop Tape

Use Stop Tape:

If checked, the program will do a pause at the two specified

locations during the application of the insulation tape. This can
be useful to perform some operation at known location along the
leg. The machine won't pause when applying the low resistance
tape.

Start/End For Leg:

Specified the Y axis for the first and last pause along the leg. The
position can be different for the two legs. The start position must
be before the end position. It's possible to enter the value directly
or to move the head at the correct location using the remote
console and then press the down arrow on the interface to record
the current Y position.

Guide Roll

Use Guide Roll:

If checked, the program will use the guide roll between the two
specified locations during production. This is used to reduce
vibration in the slot section of the coil.

Start/End For Leg:

Specified the Y axis for the start and end position where the guide

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roll will be activated. The position can be different for the two
legs. The start position must be before the end position. It's
possible to enter the value directly or to move the head at the
correct location using the remote console and then press the down
arrow on the interface to record the current Y position.

10.21

Edit Path

Leg:

Display the selected leg. Other parameters on the screen refer to

this selected leg. Use the left and right arrows to cycle between
Leg At 0 and Leg At 180.

Position:

Display the list of positions for the selected leg in ascending order
of the Y axis. The up and down arrows on the right of the list
move the selection line up and down the list. The X, Y and Z1
axis are expressed in millimeter while the R axis is in degree.

Delete:

Pressing this button will delete the currently selected position.

Parameters:

Display the set of parameters that will be used when the Tape
button is pressed on the remote console. It can be either
Insulation Tape or Low Resistance Tape.

Remote:

Let operator access the Remote Console Status screen describes

further down.

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