Maintenance Service Bulletin

Transcription

1 MAINTENANCE TECHNICAL SUPPORT CENTER / MAINTENANCE POLICIES & PROGRAMS ENGINEERING / UNITED STATES POSTAL SERVICE Maintenance Service Bulletin SUBJECT: TO: APPS Automated Address Recognition Subsystem (AARS) Knife-Edge Nose-Bar Verification and Adjustment Procedure All APPS_AA Sites DATE: NO: FILE CODE: June 16, 2008 R3 rrin:ms08001ah This Maintenance Service Bulletin (MSB) is the first of two that will address the presence of non-conforming Reverse-Crown Nose-Bars (Bar Weldment, Nose NSN ) and incorrectly positioned Knife-Edge Nose-Bars on Automated Package Processing System (APPS) (Phase I) machines. This bulletin is an equipment assessment only. No adjustments will be made at this time. The data from this assessment must be reported on-line in accordance with Section 9.3 in Attachment 1. Use acronym APPS and class code AA for emars reporting. The vendor, Sandvik (now known as Cinetic), manufactured the Reverse-Crown Nose-Bars and many were not made in compliance with the applicable specification. It is believed that this has caused, or contributed to, Data Collection System (DCS)/Automated Address Recognition SubSystem (AARS) tunnel conveyor belt tracking problems and the reduced service life of these belts. Also, the gap between the AARS 1 and AARS 2 Knife-Edge Nose-Bars is not correct on many machines possibly due to improper initial installation or as a consequence of the increased belt tracking and replacement activity in this area. This gap is used by the bottom camera for scanning the underside of packages. If the gap is too large, packages traversing the gap may bounce excessively, resulting in degraded image quality. Correction of this problem requires the Knife-Edge Nose-Bars be moved closer together. Unfortunately, this can cause an obstruction of the bottom camera's scan line, resulting in image degradation or the inability to capture images. A phase 1 (static) alignment of the bottom camera would then be necessary to restore image quality. The APPS AARS Knife-Edge Nose-Bar Verification and Adjustment Procedure includes instructions used to determine whether the gap that exists between the AARS 1 and AARS 2 Knife-Edge Nose-Bars is within specification and if not, whether a bottom camera phase 1 (static) alignment will be required after performing the specified adjustments. This procedure is to be performed prior to, and in preparation for, MSB (APPS Tunnel Conveyor Nose-Bar Retrofit Procedure with Belt Tracking Instructions) to be issued in July/August Note that the actual adjustments will not be made at this time. Instead, the information gathered will be used to ensure adequate time is budgeted for the performance of the required activities during the subsequent procedure in MSB Table 1-1 in Attachment 1 summarizes the relevant information and should be retained until both procedures have been completed. MSB will also cover the replacement of the non-conforming Reverse-Crown Nose-Bars and will provide a new and enhanced belt tracking method. Together, the two procedures form the basis of the vendor s response to these issues. Upon receipt of this MSB, sites are instructed to perform this MSB using the procedures in Attachment 1. Web Access:

2 The time required for two APPS trained maintenance employees to complete this MSB is approximately 45 minutes for a single induction and 90 minutes for a dual induction machine. Direct any questions or comments concerning this bulletin to the HelpDesk, Maintenance Technical Support Center, P.O. Box 1600, Norman OK ; telephone FTS 2000 (405) or toll free (800) ~aintenance Technical Support Center Maintenance Policies and Programs Attachments: 1. Automated Address Recognition Subsystem (AARS) Knife-Edge Nose-Bar Verification and Adjustment Procedure 2. emars Reporting Instructions 3. Local Record of Bulletin Completion

3 ATTACHMENT 1 AUTOMATED ADDRESS RECOGNITION SUBSYSTEM (AARS) KNIFE-EDGE NOSE-BAR VERIFICATION AND ADJUSTMENT PROCEDURE Attachment 1 i

4 Maintenance Technical Support Center Table of Contents 1. PURPOSE RECOMMENDED TOOLS SHUTDOWN AND LOCKOUT PROCEDURES AARS GAP MEASUREMENT DETERMINING DISTANCE TO MOVE KNIFE-EDGE NOSE-BARS FINDING THE BOTTOM CAMERA SCAN LINE POSITION POSITION GAIN TABLE TARGET STOP IMAGE CAPTURE SERVICE START THE INTENSITY/RESOLUTION/CENTERLINE TOOL LOCATE SCAN LINE DETERMINING SCAN LINE DISTANCE FROM EDGE OF AARS1 AND AARS 2 CONVEYORS MEASURING SCAN LINE DISTANCES CLOSING INTENSITY/RESOLUTION/CENTERLINE TOOL AND RESTARTING IMAGE CAPTURE SERVICE DETERMINING IF PHASE 1 (STATIC) BOTTOM CAMERA CALIBRATION IS NECESSARY DATA COLLECTION, RETENTION, AND REPORTING DATA COLLECTION DATA RETENTION DATA REPORTING RESTORE SYSTEM ii Attachment 1

5 1. PURPOSE This bulletin is an equipment assessment only and no adjustments are to be made at this time. Instead, the information obtained will be used to determine what, if any, additional work will be required during the completion of follow-up bulletin MSB , "APPS Tunnel Conveyor Nose-Bar Retrofit Procedure with Belt Tracking Instructions" to be released in July/August The focus of this document is on determining the length of the gap that exists between the AARS 1 and AARS 2 Knife-Edge Nose-Bars. If this gap is too large, small packages will bounce excessively while transiting from the AARS 1 to the AARS 2 conveyor, resulting in degraded image quality and Recognition System (RECO) performance. In this case, the nose bars will have to be moved closer together to bring the gap within specification. Unfortunately, doing so may cause the bottom camera scan line to become obstructed, also resulting in degraded image quality and Recognition System performance. This procedure will also determine if the bottom camera scan line would become obstructed as a result of bringing the Knife-Edge Nose-Bar gap within specification. If so, a phase 1 (static) camera calibration of the bottom camera would be required after nose bar repositioning. At the conclusion of this procedure the distance (if any) that the Knife-Edge Nose-Bars must be moved and whether this adjustment will necessitate the subsequent performance of a phase 1 calibration of the bottom camera will be known. However, any required adjustments will be performed during the completion of MSB and not at this time. As a phase 1 (static) camera calibration is projected to take roughly two hours to complete, the information provided here will ensure adequate time is budgeted for the performance of that procedure. This procedure must be performed on each FSD side on all APPS machines in the facility. 2. RECOMMENDED TOOLS 6-inch ruler Camera Calibration Kit (Calibration Kit, Camera, Toolkit, Set-up NSN ) Attachment 1 1

6 Maintenance Technical Support Center 3. SHUTDOWN AND LOCKOUT PROCEDURES WARNING Power down and lockout the Feed Singulation Distribution- Main Control Cabinet (FSD-MCC) for the FSD side being worked on according to the steps below, prior to performing any other procedure in this MSB. WARNING Power to the Discrete Distributed Source of Supply (DDSS) and all connected components will remain, even with the FSD-MCC cabinet locked out as prescribed below. Therefore, exercise extreme caution while working around any of these components to prevent personal injury or death. Properly power down and lockout the FSD-MCC using the steps below: 1. Notify supervisor and affected personnel that the FSD-MCC will be powered down and locked out and that the affected side of the machine will be inoperable. 2. Locate the main power disconnect switch on the right side of the FSD-MCC and place it in the OFF position (Figure 1-1). 3. Apply lockout device, personal locks, and Do Not Operate tag to the disconnect switch and verify the switch cannot be placed in the ON position. 4. Attempt to jog the AARS belts and verify they cannot be started. Figure 1-1. FSD-MCC Lockout 2 Attachment 1

7 4. AARS GAP MEASUREMENT Measure the width of the gap (nominally 1 ± 1/16 ) between the AARS 1 and AARS 2 conveyors from belt surface to belt surface at the widest point along the gap (Figure 1-2). Record this measurement as the AARS Gap Dimension in Table 1-1, located in Section 9.1 on page 16. The width should not be greater than 1-1/16 or less than 15/16. If the AARS gap width measured above is within specification or less than 15/16 the Knife- Edge Nose-Bars of the AARS 1 (Cx-2-1) and AARS 2 (Cx-2-2) conveyors will not have to be moved. Insert zeros on the lines for Distance to Move AARS 1 Knife-Edge Nose-Bar X1 (inches) and Distance to Move AARS 2 Knife-Edge Nose-Bar X2 (inches) in Table 1-1, located in Section 9.1 on page 16, then skip to Section 6 Finding The Bottom Camera Scan Line Position on page 5. AARS gap widths of less than 15/16 are generally not a problem as long as the bottom camera is currently able to capture images. If the AARS gap width measured above is greater than 1 1/16, either one or both of the Knife-Edge Nose-Bars of the AARS 1 (Cx-2-1) and AARS 2 (Cx-2-2) conveyors will have to be moved and the bottom camera scan line position will need to be obtained to determine if this movement will interfere with image capture. The distance to move the Knife-Edge Nose-Bars will be determined in the next section. Figure 1-2. AARS Gap Dimension Attachment 1 3

8 Maintenance Technical Support Center 5. DETERMINING DISTANCE TO MOVE KNIFE-EDGE NOSE-BARS Nominally the Knife-Edge Nose-Bars are 1/4 (± 1/16 ) away from the edge of the support weldment (Figure 1-3). Measure the distance that each end of the AARS 1 and AARS 2 Knife-Edge Nose-Bars are away from the edge of their support weldments. Using the greater of the two measurements for each Knife-Edge Nose-Bar, determine how much they must be moved towards the center of the AARS Gap so they are each within the specification. At this point, the AARS Gap should also be within the specification. If this would not be the case, determine how much each would have to be moved by equal amounts, so the AARS Gap would be within the specification (1 +/- 1/16 ). Record the total distance the AARS 1 and AARS 2 Knife-Edge Nose-Bars would have to be moved on the appropriate lines in Table 1-1, located in Section 9.1, on page 16. If a Nose- Bar required no movement, write in a zero for this dimension for the appropriate Nose-Bar. This distance will be used later to determine if the movement will interfere with the bottom camera scan line position. ¼ ± 1/16 ¼ ± 1/16 Figure 1-3. Knife-Edge Distance Reference 4 Attachment 1

9 6. FINDING THE BOTTOM CAMERA SCAN LINE POSITION 6.1. POSITION GAIN TABLE TARGET Obtain the Gain Table Target from the Camera Calibration Kit. Position it on the AARS 2 section conveyor belt so the upstream edge is flush with the edge of the AARS 1 section belt and the bottom edge of the Gain Table Target is flush with the justified edge of the conveyor (Figure 1-4). Upstream edge of Gain Table Target flush with edge of AARS 1 belt Bottom edge of Gain Table Target flush with justified edge of AARS 2 conveyor Figure 1-4. Initial Gain Table Target Placement for Scan Line Position Attachment 1 5

10 Maintenance Technical Support Center 6.2. STOP IMAGE CAPTURE SERVICE 1. Log on to the appropriate Image Capture computer as follows: a. Use the KVM Switch inside the Image Capture computer rack to select IC2 for side 1 or IC7 for side 2 (Figure 1-5). b. Press Ctrl-Alt-Delete keys at same time. c. Enter Username M2. d. Enter the M2 password. e. Click OK button. 2. When logged in, perform the following steps to stop the Image Capture service: a. Click MS Windows Start. b. Click Settings. c. Click Control Panel. d. Double-click Services. The Services window is displayed. e. Highlight Image Capture by clicking on it. f. Click Stop. The message, "Are you sure you want to stop the Image Capture service?" is displayed. g. Click Yes. h. Close the Services window by clicking on Close. i. Close the Control Panel window by clicking on File and then Close. 6 Attachment 1

11 KVM Switch FSD Image Capture Rack IC2 Side 1 Figure 1-5. FSD Image Capture Rack IC7 Side 2 Attachment 1 7

12 Maintenance Technical Support Center 6.3. START THE INTENSITY/RESOLUTION/CENTERLINE TOOL Start the Intensity/Resolution/Centerline Tool using the steps below. 1. Double-click on the Camera Calibration icon on the desktop. 2. Click on Calibrate and then click on Intensity / Resolution / Centerline from the Camera Calibration menu to put the program in live mode (Figure 1-6). Figure 1-6. Starting Intensity / Resolution / Centerline Tool in Live Mode 8 Attachment 1

13 6.4. LOCATE SCAN LINE 1. Once in live mode, verify the Gain Table Target is displayed in the Camera Calibration window as shown in Figure 1-7. If the Intensity/Resolution Tool window is in the way, click on its blue title bar. Keep the mouse button pressed and drag the window out of the way. Figure 1-7. Live Mode Display of Gain Table Target Attachment 1 9

14 Maintenance Technical Support Center NOTE The steps below require a second person to complete. The first person moves the Gain Table Target while the second observes the results on the monitor. 2. Slowly move the Gain Table Target downstream while keeping its edge parallel to the justified side of the AARS 2 conveyor until it is out of view in the Camera Calibration window as shown in Figure 1-8. Figure 1-8. Gain Table Target Not Visible 10 Attachment 1

15 3. Slowly move the Gain Table Target upstream toward the AARS 1 conveyor (Figure 1-9), keeping its edge parallel to the justified side of the AARS 2 conveyor, until the Gain Table Target first appears in the Camera Calibration Graphical User Interface (GUI) (Figure 1-10). Figure 1-9. Move Gain Table Target Upstream Figure Gain Table Target Visible Attachment 1 11

16 Maintenance Technical Support Center 4. Back off slightly and position the Gain Table Target so the streaked pattern is displayed all the way across the Camera Calibration GUI (Figure 1-11). The right side of the GUI can be viewed by sliding the slider bar to the right. The streaked pattern indicates the Gain Table Target s edge is at the scan line. Figure Gain Table Target Edge NOTE The scan line may not extend exactly straight across the entire gap, but should at least be within the gap through to the unjustified side of the Gain Table. If this is not the case, note any discrepancies in the Comments section of the on-line (machinespecific) checklist for the associated Nose-Bar and contact the MTSC for further instruction. 12 Attachment 1

17 7. DETERMINING SCAN LINE DISTANCE FROM EDGE OF AARS1 AND AARS 2 CONVEYORS 7.1. MEASURING SCAN LINE DISTANCES 1. Measure the distances between the upstream edge of the Gain Table Target and the edges of the AARS 1 (measurements 1 and 2) and AARS 2 (measurements 3 and 4) conveyor belts at BOTH sides of the Gain Table Target (justified and unjustified) (Figure 1-12). 2. The shortest of measurements 1 & 2 should be used as the scan line distance from AARS 1 Knife-Edge Nose-Bar and the shortest of measurements 3 & 4 should be used as the scan line distance from AARS 2 Knife-Edge Nose-Bar. Record both of these measurements on the appropriate lines in Table 1-1, located in Section 9.1, on page Remove the Gain Table Target and return it to the Camera Calibration Kit. Figure Scan Line Position Attachment 1 13

18 Maintenance Technical Support Center 7.2. CLOSING INTENSITY/RESOLUTION/CENTERLINE TOOL AND RESTARTING IMAGE CAPTURE SERVICE At the Image Capture computer, close the Intensity/Resolution/Centerline tool and restart the image capture service using the steps below. 1. Close the Intensity/Resolution Tool by clicking on the X in the upper, right-hand corner of the window. 2. Close the Camera Calibration Application by clicking on File and then Exit. 3. Click Start. 4. Click Settings. 5. Click Control Panel. 6. Double-click Services. The Services window is displayed. 7. Highlight Image Capture by clicking on it. 8. Click Start in the Services window. After a brief delay, status should change to Started. 9. Close the Services window by clicking Close. 10. Close the Control Panel window by clicking File and then Close. 11. Log off the Image Capture computer using the sub-steps below. a. Simultaneously press the Ctrl-Alt-Delete keys. b. Click Logoff. c. Click OK. 14 Attachment 1

19 8. DETERMINING IF PHASE 1 (STATIC) BOTTOM CAMERA CALIBRATION IS NECESSARY If the distance that a Knife-Edge Nose-Bar must be moved is greater than or equal to the distance that the scan line is away from that Knife-Edge Nose-Bar, then a phase 1 (static) calibration of the bottom camera must be performed after that Knife-Edge Nose-Bar is repositioned. Perform this check for both the AARS 1 and AARS 2 Nose-Bars and record whether a camera calibration will be necessary on the appropriate line in Table 1-1, located in Section 9.1 on page 16. Knife-Edge Nose-Bars that are repositioned to narrow the AARS gap, without performing this check, may obscure the camera's scan line and cause the system to stop capturing images. NOTE If a camera calibration is required based on the calculations above, it is generally not necessary to perform the entire four-part phase 1 (static) calibration procedure. Often, only the first (scan line position) and possibly second (bottom lamp and illumination mirror assembly positions) sections of the procedure will need to be performed (reference MS-202, Volume B, TL-1, Paragraphs and ). This work can take up to two hours to complete. Contact the MTSC for further assistance prior to performing this work during the completion of MSB , APPS Tunnel Conveyor Nose-Bar Retrofit Procedure with Belt Tracking Instructions to be issued in July/August Attachment 1 15

20 Maintenance Technical Support Center 9. DATA COLLECTION, RETENTION, AND REPORTING 9.1. DATA COLLECTION Ensure Table 1-1 contains all required data obtained during the completion of this procedure. Table 1-1. Checklist DESCRIPTION VALUE Machine Number: 1 Side Number: 1 AARS Gap Dimension (inches) Distance to Move AARS 1 Knife-Edge Nose-Bar X1 (inches) Scan Line Distance from AARS 1 Knife-Edge Nose-Bar Y1 (inches) Distance to Move AARS 2 Knife-Edge Nose-Bar X2 (inches) Scan Line Distance from AARS 2 Knife-Edge Nose-Bar Y2 (inches) Camera Calibration Required? (Yes/No: Yes if Y1 < X1 OR Y2 < X2)* Machine Number: 1 Side Number: 2 AARS Gap Dimension (inches) Distance to Move AARS 1 Knife-Edge Nose-Bar X1 (inches) Scan Line Distance from AARS 1 Knife-Edge Nose-Bar Y1 (inches) Distance to Move AARS 2 Knife-Edge Nose-Bar X2 (inches) Scan Line Distance from AARS 2 Knife-Edge Nose-Bar Y2 (inches) Camera Calibration Required? (Yes/No: Yes if Y1 < X1 OR Y2 < X2)* Machine Number: 2 Side Number: 1 AARS Gap Dimension (inches) Distance to Move AARS 1 Knife-Edge Nose-Bar X1 (inches) Scan Line Distance from AARS 1 Knife-Edge Nose-Bar Y1 (inches) Distance to Move AARS 2 Knife-Edge Nose-Bar X2 (inches) Scan Line Distance from AARS 2 Knife-Edge Nose-Bar Y2 (inches) Camera Calibration Required? (Yes/No: Yes if Y1 < X1 OR Y2 < X2)* Machine Number: 2 Side Number: 2 AARS Gap Dimension (inches) Distance to Move AARS 1 Knife-Edge Nose-Bar X1 (inches) Scan Line Distance from AARS 1 Knife-Edge Nose-Bar Y1 (inches) Distance to Move AARS 2 Knife-Edge Nose-Bar X2 (inches) Scan Line Distance from AARS 2 Knife-Edge Nose-Bar Y2 (inches) Camera Calibration Required? (Yes/No: Yes if Y1 < X1 OR Y2 < X2)* Machine Number: 3 Side Number: 1 AARS Gap Dimension (inches) Distance to Move AARS 1 Knife-Edge Nose-Bar X1 (inches) Scan Line Distance from AARS 1 Knife-Edge Nose-Bar Y1 (inches) Distance to Move AARS 2 Knife-Edge Nose-Bar X2 (inches) Scan Line Distance from AARS 2 Knife-Edge Nose-Bar Y2 (inches) Camera Calibration Required? (Yes/No: Yes if Y1 < X1 OR Y2 < X2)* Machine Number: 3 Side Number: 2 AARS Gap Dimension (inches) Distance to Move AARS 1 Knife-Edge Nose-Bar X1 (inches) Scan Line Distance from AARS 1 Knife-Edge Nose-Bar Y1 (inches) Distance to Move AARS 2 Knife-Edge Nose-Bar X2 (inches) Scan Line Distance from AARS 2 Knife-Edge Nose-Bar Y2 (inches) Camera Calibration Required? (Yes/No: Yes if Y1 < X1 OR Y2 < X2)* *For MSB : Add 2 hours to procedure for AARS 1 if Y1 < X1 or AARS 2 if Y2 < X2. 16 Attachment 1

21 9.2. DATA RETENTION Retain the information recorded in Table 1-1. It will be required when preparing for the second MSB in this series (MSB , APPS Tunnel Conveyor Nose-Bar Retrofit Procedure with Belt Tracking Instructions ) to be issued in July/August Each camera calibration will add an additional two hours to the procedure. Therefore, an adequate maintenance window encompassing the total time required must be assured before beginning DATA REPORTING The data from Table 1-1 must also be used to complete an on-line, machine-specific checklist for this bulletin. To complete the on-line machine-specific checklist, perform the following steps: 1. Log on to any ACE computer using your user name and password. 2. Start up the Internet Explorer browser by double-clicking its icon. 3. Go to the MTSC web site by typing in the Address bar and press the Enter key. 4. Click on the Equipment tab and then on APPS to get to the APPS Equipment page. 5. Click on MSB Checklist under the Related Links section and click the link that says MSB APPS AARS Knife Edge Nose Bar Verification and Adjustment Procedure. The checklist can also be accessed by typing the following link in the web browser address box: ( 6. Select the Checklist button for your site, system, and FSD side. Remember to match the form to that of the FSD system being modified, as there are separate forms for each side of a dual induction machine. 7. Fill in your data, name, and title (required), and then click Submit. A Thank You message is displayed briefly and you will be returned to the site list. As forms are completed, they are automatically removed from the list. If you are unable to locate a form for your site, it may have already been completed by someone else. If the wrong form is mistakenly selected, hit the back arrow key on the browser to return to the site list. Contact the MTSC if you have any problems finding, or using these forms. 8. When done entering data, log off of the computer by doing the following: a. Click the Start button at the bottom, left-hand side of the screen. b. Click the Log Off button on the bottom of the window that is displayed. c. Click the Log Off button in the pop-up window. Attachment 1 17

22 Maintenance Technical Support Center 10. RESTORE SYSTEM Properly restore the FSD system to operation by doing the following: 1. Check around the FSD and make sure any safety covers removed during the procedure have been replaced and that all employees are safely positioned. 2. Ensure all tools and materials have been removed from the work area. 3. Notify the supervisor and all affected employees that all personal locks and the lockout device are being removed and the FSD returned to operation. 4. Remove personal locks and lockout device from the main disconnect switch located on the right-side of the FSD-MCC and place disconnect switch in the ON position. 5. Verify the FSD operates properly by pressing the Clear Fault pushbutton on the front of the FSD-MCC and then starting up the system. 18 Attachment 1

23 ATTACHMENT 2 emars REPORTING INSTRUCTIONS Maintenance Policies and Programs (MPP) will be tracking modifications authorized by the Engineering Change Board (ECB) via emars. Information required on PS Form 4805, Work Record Sheet, must be reported for each individual equipment modified as follows: DESCRIPTION REMARKS Work Order Number Enter Work Order Number: 3383 Priority Enter Priority Code: Work Code Enter Work Code: 02 Acronym Equipment Class Estimated Work Hours Action Taken Code Enter Equipment Acronym: APPS Enter Equip. Class Code: AA Enter Estimated Time for Each Piece of Equip: 45 Min per Induction Side Enter: PLJ Direct any questions or comments concerning this bulletin to the HelpDesk, Maintenance Technical Support Center, P.O. Box 1600, Norman OK ; telephone FTS 2000 (405) or toll free (800) Attachment 2 1

24 Maintenance Technical Support Center THIS PAGE BLANK 2 Attachment 2

25 ATTACHMENT 3 LOCAL RECORD OF BULLETIN COMPLETION Complete one form for each piece of equipment that is modified/upgraded. Keep/maintain the completed forms in a Bulletin Completion File at your site. This file will be used by area office, and headquarters maintenance management personnel to verify bulletin compliance. Note: Comments regarding the content of the bulletins (i.e.: clarity/accuracy of instructions, illustrations, etc) can be sent to MTSC via cc:mail address: MTSC Bulletin. Upon receipt, the message will be forwarded to the author of the document. Bulletin Number: Installed on: Equipment Type APPS Model Number Serial Number Local Machine ID # Located at: Facility Name Facility Address City, State ZIP + 4 Code Work Order # Installation Completion Date: Completed By: Comments: Attachment 3 1