Many manufacturing processes use printed registration marks (sometimes called Q-marks, eye marks, or eyespot marks) on the product to trigger actions related to the process. These actions are initiated by electronic signals that are normally generated by photocells, proximity switches, or mechanical sensing devices. Sometimes, and for many different reasons, these signals can be unreliable. They can be affected by: dirty, damaged or mis-adjusted photocells; webb creep or print fade; dirty or corroded switch contacts; extraneous signals generated by static electricity; the potential problems are many and varied.

The WIZARD 500 system is a low cost computerized Q-mark filter and processor that eliminates the problems associated with this type of system.

Q-marks (or eye marks) are a fact of life in many manufacturing processes. They are used extensively on webbs and films to maintain register, to set cut-offs, to trigger pumps, fillers, or extruders, and to initiate many other down-line processes. If you are familiar with this type of manufacturing, you are aware of the pitfalls that await when the Q-mark sensor gets dirty, or mis-aligned, or the Q-mark itself fades out or walks from under the sensor. That's right... WASTE! And it's waste that continues until the operator notices it, diagnoses the problem, and corrects it. The faster the process, the higher the waste ratio.

The WIZARD 500 Q-mark processor is a small computer system that fits between the Q-mark sensor (electric eye) and the controller. By incorporating a combination of application specific hardware and expert system software techniques, the WIZARD 500 refines the signal generated each time the Q-mark passes under the electric eye. By providing a cleaner, more reliable signal, the WIZARD 500 helps the embedded controller do it's job.

The WIZARD 500 does far more than clean up the Q-mark signal however. Based on a computer, The WIZARD 500 contains the logic required to recognize that expected input signals are missing based on historical statistical processing. That is, it will " learn" or memorize the pattern of the signal. Upon recognizing faulty, noisy or missing input signals, The WIZARD 500 will generate appropriate signals as required to maintain production. While the replacement signals are being generated, an alarm sounds to alert the operator that an error condition exists, giving him the opportunity to correct the problem before it becomes a waste-maker. He can usually correct the error without losing production time, allowing the manufacturing process to continue producing good quality product. The alarm function is programmable, and the WIZARD 500 can be instructed to halt the machine if desired.

A common use of the WIZARD 500 System is performing Quality Control monitoring. The WIZARD 500 may be configured to initiate corrective action, sound alarms, activate reject gates, or stop the line when out of tolerance conditions are detected.

Another major use of the WIZARD 500 is that it allows tolerances unheard of in the packaging and converting industries. For example, if 1/16th is 'good enough' to ship to your customer, the WIZARD 500 may be configured to hold tolerances of 1/32 or better (up to 5/1000ths, depending on your application). In todays quality conscious market, this gives your company the capability of supplying products which exceed customers' specifications, and most likely, also exceed your competitors' capabilities.

The advantages of integrating the WIZARD 500 to your manufacturing system will be higher production, reduced waste, increased quality, and greater profit for your company.

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