FasTrak2 High Speed Data Collection Board with Ethernet Communications

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1 Presented to:

2 FasTrak2 High Speed Data Collection Board with Ethernet Communications

3 FasTrak2 Data Collection Board Features and Benefits Field Programmable Gate Array Logic (FPGA) Design provides extreme flexibility permitting future modifications and long product life cycle. Compatible with any computer platform. Complete monitoring capability with closed loop shot velocity and pressure control in single board. Future control axes for clamp proportional control and shot retract are contemplated. Six (6) programmable limit switch outputs available for sequence control. Different vacuum interfaces supported: MFT, High-Q-Cast Modular construction permits detachment from external interface sensor interface board, and dual axis servo controller for easier trouble shooting and maintenance.

4 FasTrak2 Data Collection Board Specifications Communication: One(1) 100 Base T, Ethernet Ports (RJ-45) Communication Protocol Ethernet UDP Two (2) 115,200 baud, RS-232 Ports Two (2) Alterra NIOS, 32 bit soft core processors operating at MHz, embedded in Cyclone II, Field Programmable Gate Array Logic (FPGA) Second processor dedicated to managing A/D interface. Memory: 1 MB of SRAM memory and 2 MB flash memory. Position based data sampling at 500 IPS/12 MPS velocity. Results stored in RAM memory. a.velocity Resolution 80 updates per inch with 20 tpi rod b. Eight (8) analog pressures sampled 20 times per inch with 20 pitch rod Time based monitoring: 2000 samples are taken once every user defined time interval and stored in RAM memory Cylinder position for monitoring ram creep during intensification is sampled Eight Dynamic Analog channels are sampled Position input: Full quadrature two (2) channels with possible future expansion. Quadrature input dividable by 1 to 15 to normalize to VTW 20 tpi rod resolution. Position resolution:.0125 with 20 tpi rod and.5 mm with 2 mm pitch rod. Other resolutions supportable. Units: Dimensionless allowing easy external software support for both English and Metric units. External I/O to machine PLC: 2 Opto DEC PB-32 I/O Board interfaces for a total of 32 optically isolated inputs and 32 optically isolated outputs. Modbus and other protocols can be used for direct Ethernet (UDP) access to PLC.

5 External Sensor Interface Board

6 External Interface Board Specifications Twenty four (24) Analog Input Channels supported. Four (4) Analog channels are wide input and support a -10 VDC to +10 VDC signal range. Four (4) channels are dedicated for control diagnostics command, LVDT, etc. Remaining sixteen (16) channels reserved for general purpose monitoring with input range of 0-5 VDC. Eight (8) general purpose analog inputs can be dynamically sampled at speeds up to 500 IPS/12 MPS. Remaining eight (*) general purpose analog inputs sampled once per cycle or on event basis (external I/O trigger) Analog Resolution - All channels 12 bit resolution. Two (2) quadrature inputs for position Four (4), 14 bit analog outputs provided

7 FT2 - High Speed Data Collection Board w/ External Sensor Interface OEM Price OEM Price $2, Add True-Trak Software $ (Single Use License) Total with Software $2, /23/2008

8 Sure-Trak2 Dual Axis Servo Amplifier Board

9 The Sure-Trak2 Dual Axis Servo Amplifier Board Features and Benefits Plugs directly into External Interface Board to permit expansion to fully integrated monitoring and shot velocity and pressure control system. Provides dynamically synchronized analog outputs to drive two (2) servo or proportional valves in response to command and error signals. All digital settings Potentiometers do not have to be adjusted to tune valve response. Jumper selection for various valve types. Two (2) Oscillator/demodulator outputs for valve LVDT signal conditioning. LVDT Oscillator output generated digitally by the FPGA on main board. Valve test diagnostic function - all digitally controlled.

10 Completely Assembled Board Set High Speed Data Collection and Dual Axis Servo Control

11 FasTrak2 High Speed Data Collection System 16 Channel Analog Sensor Inputs Sensor External Interface Analog Board Ethernet Monitor and Motion Control Board Ethernet Dual Axis Servo Amplifier Board True-Trak 2020 Local Data Acquisition & Programming PC Pressure Signal from Transducer Olmsted Slip-in Cartridge Valve w/ Servo Pilot Pressure Control Valve Remote Data Acquisition & Programming PC

12 Price List for FasTrak2 with Sure-Trak Control option OEM Price $4, True-Trak 2020 Software w/ Sure-Trak2 option $ (single use license) Total with Software $5, /23/2008

13 System Architecture

14 Fully Integrated Monitoring and Control System TM

15 TM Real Time, Programmable Velocity and Intensification Control Custom Sealed Enclosure FasTrak2 High Speed Data Acquisition Board External Interface/Analog Board Sure-Trak2 Motion Control: Opto Bit Digital I/O Dual Axis Servo Amplifier Board Sure-Trak2 Firmware Sure-Trak2 Control Software Industrial Power Supply (12Volt; 5 Volt; 24 Volt) Industrial Power Supply (+-12 Volt; +5 Volt) Ampro Industrial PC, Celeron 400 MHZ CPU 256 MB RAM Notebook (2-1/2 ) Hard Disk Drive 40 GB Ethernet Switch Terminal Blocks 12.1 Color Active Matrix LCD Display Industrial Keyboard with integrated Mouse True Trak 2020 Application Software Windows XP Embedded Operating System 18.00

16 Fully Integrated Sure-Trak2 Control Price TM OEM Price End User Price $14, $23, /23/2008

17 Olmsted 2-way Throttling Valves

18 Valve Price List 1. Description: 50mm In-Line Valve in a Cast Body. Part# X Model SV is a servo-piloted, 50mm, two-way throttling valve, supplied in a Cast Body, and includes LVDT and servo mounting footprint. This compact valve facilitates in-line mounting. End User Price: $ 10, OEM Price: $ 5, Notes: Mounting Flanges are not included. Recommended pilot valve is H.R. Textron R-DDV Servo Model 27E50F-4A Description: 50mm Cartridge Part# X A Model SV is a 50 mm cartridge, servo-piloted, two-way throttling valve. The Cartridge Kit is designed to reside in a standard 50 mm DIN cavity, to facilitate manifold mounting. LVDT is included. End User Price: $ 9, OEM Price: $ 5, Notes: Valve can be supplied in a standard DIN right angle cavity block, or in custom manifolds. Recommended pilot is H.R. Textron R-DDV Servo Model 27E50F4A Description: 80mm Cartridge Part# X A Model SV is an 80mm cartridge, servo-piloted, two-way throttling valve. The Cartridge Kit is designed to reside in a standard 80mm DIN cavity, to facilitate manifold mounting. LVDT is included. End User Price: $ 12, OEM Price: $ 8, Note: This valve can be supplied in a standard DIN right angle block, or incorporated into custom manifolds. Recommended pilot valve is H.R. Textron Servo Model 27G50F-3B Description: 100mm Cartridge Part# X Model SV is a 100 mm cartridge, servo-piloted, two-way throttling valve. It is designed to reside in a standard 100 mm DIN cavity, to facilitate manifold mounting. LVDT is included. End User Price: $ 14, OEM Price: $ 9, Note: This valve can be supplied in a standard DIN right angle block, or incorporated into a custom manifold. Recommended pilot valve is H.R. Textron Servo Model 27G50F-5A or 27G50F-9C Please consult Visi-Trak Worldwide, LLC 1/23/2008

19 Fully Integrated Monitoring System TM

20 TM Fully Integrated Monitoring System Custom Sealed Enclosure FasTrak2 High Speed Data Acquisition Board External Interface/Analog Board Industrial Power Supply (12Volt; 5 Volt; 24 Volt) Industrial Power Supply (+-12 Volt; +5 Volt) Ampro Industrial PC, Celeron 400 MHZ CPU 256 MB RAM Notebook (2-1/2 ) Hard Disk Drive 40 GB Ethernet Switch Terminal Blocks 12.1 Color Active Matrix LCD Display Industrial Keyboard with integrated Mouse True Trak 2020 Application Software Windows XP Embedded Operating System 18.00

21 True-Trak 2020 Monitor Price List OEM Price End User Price $10, $14, /23/2008

22 Total-Trak Human Machine Interface Total-Trak is a graphical user interface to the die casting machine s PLC. This HMI (Human Machine Interface) is fully integrated with our True-Trak 2020 and Sure-Trak2 Application Software, providing: Single Recipe Storage for the entire machine Easy backup of part files on True-Trak 2020 Network Data Archiver Quick and easy recovery in the event of hard disk drive failure Shot end parameter data and PLC process parameter data in one combined database

23 Total-Trak HMI option for True-Trak Monitoring or Sure-Trak2 Control Price List OEM Price End User Price $ $ Note. For the Total-Trak product, we are supplying the PLC 5 family, and the SLC 5/03, 5/04, and 5/05. Also, going forward the Compact Logix and other new Allen Bradley products as they become available will be supported. The method communication varies among different PLC/SLC products, so we have not used the KT card to date. All of our installations have utilized serial communication. So this will be and issue to discuss at the proper time. Whatever communication cable is required, Frech can purchase. 1/23/2008

24 Distributed System Alternatives

25 Machine #1 FT2 Optional Local connection of a Portable True-Trak 2020 Workstation or customer supplied Notebook PC with True-Trak 2020 Workstation Application Software for local set-up and diagnostics. Machine #2 FT2 True-Trak 2020 DCT Supports up to Eight (8) Machines per Data Collection Terminal. Machine #8 FT2 Visi-Trak is a registered U.S. trademark of Visi-Trak Worldwide, LLC.

26 TM Monitoring & Analysis System FasTrak2 Ethernet Based/PLD Data Acquisition Board External Interface Board for sensor signal inputs Power Supplies for Sensors Terminal Strip for sensor signal termination and alarm output access SnapTrak Mounting Hardware for installation of analog sensor signal conditioning modules Alarm Output Board with three optically isolated alarm output modules (12 or 24 Volt DC; 110 or 220 Volt AC) 20 x 33 x 8 NEMA 4 Enclosure with local Ethernet Connector 18.00

27 True-Trak DCT Monitoring Buhler & BuhlerPrince Machines with FT2 Data Collection PHB Die Casting, Fairview, PA

28 Representative List- Frech Customers using FT2 Data Collection and and/or True-Trak 2020 Monitors Thomas Industries, Sheboygan, WI True-Trak 2020 on Frech 400 ton cold chamber Product Technologies Division- Leggett & Platt; Maple Lakes, MN FT2-(Configuration 1) Monitoring (4-5) machines Sargent & Greeleaf, Nicholsville, KY 3 Frech 60 ton machines monitored by FT2 systems B & C Die cast, Jonesboro, AK True-Trak 2020 monitoring Frech Machine

29 Price list for FT2 OEM Price End User Price $4, $6, /23/2008

30 TM High Speed Data Acquisition FasTrak2 Ethernet Based/PLD Data Acquisition Board External Interface Board for sensor signal inputs Power Supplies for Sensors Terminal Strip for sensor signal termination and alarm output access 20 x 16 x 8 NEMA 4 Enclosure

31 Price list for FT2/L OEM Price End User Price $3, $4, /23/2008

32 TM Data Collection Terminal The DCT can accommodate data from up to eight (8) FT2 Systems. Standard Features Custom Sealed Enclosure Industrial PC rated for service at up to 85 degrees Centigrade with 256 MB RAM Memory Industrial 12 Color LCD Monitor 20 GB Hard Disk Drive or Flash Memory Full Function Fine Membrane Keyboard with integral mouse 225 Watt Power Supply Appropriate Windows Multi-tasking Operating System True-Trak 2020 DCT Application Software Internal Floppy Drive

33 Price list for DCT OEM Price End User Price $ 6, $ 8, /23/2008

34 Network Data Workstation Network Data Archiver The Network Workstation serves as a remote terminal Users can access (view) a copy of the information available at any True-Trak 2020 Data Collection Computer or Data Acquisition System: Parameter Data Shot Profiles Downtime Information All Data analysis features of the True-Trak 2020 application software can be invoked. Box Screen shows the die casting machine on the network, whether it is UP (running) or Down (not running). From the Box Screen, the user can click any machine to see the most recent data/shot profile available. As the machine makes new shots, the screen will refresh to show the shot profile. From the monitor screen, as new shots are made on any machines on the network, the screen will refresh with a new shot profile. There is no data storage feature incorporated into the Network Workstation. Automatic Backup and Compress Database for archiving Compress Directory De-Compress Data Merge and Analysis Historical Database for analysis Select and Restore

35 Price list for Workstation and Data Archiving Software OEM Price End User Price Data Archiver $10, $15, Workstation $1, $2, (Single User License) (Single User License) Workstation Site License $4, $6, /23/2008

36 Visi-Trak Worldwide, LLC 8400 Sweet Valley Drive Suite 406, Valley View, Ohio USA