Production Process Support Software for Pokayoke Tools

INSTRUCTION MANUAL V3.10

Please use this Instruction manual correctly on reading well.
Please keep it carefully to be able to read immediately, when required.

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Before using
Thank you for purchasing the product.
Please read this Instruction Manual carefully and use this product correctly.
After reading the Instruction Manual, keep it handy and refer to it at any time when needed.
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Please note that reproduction of all or part of this product or distribution of copies without permission violates
copyright.
Be sure to read the license agreement of “POKAYOKE plus” in this document.

“POKAYOKE plus” END USER LICENSE AGREEMENTIMPORTANT: PLEASE READ THE TERMS AND CONDITIONS OF THIS LICENSE AGREEMENT (“LICENSE AGREEMENT”)
CAREFULLY BEFORE USING THE SOFTWARE (AS DEFINED BELOW). HERUTU ELECTRONICS CORPORATION IS
WILLING TO LICENSE THE SOFTWARE TO YOU AS THE INDIVIDUAL, THE COMPANY, OR THE LEGAL ENTITY THATWILL BE UTILIZING THE SOFTWARE (REFERENCED BELOW AS “YOU” OR “YOUR”) ONLY ON THE CONDITION THATYOU ACCEPT ALL OF THE TERMS OF THIS LICENSE AGREEMENT. THIS IS A LEGAL AND ENFORCEABLE CONTRACTBETWEEN YOU AND HERUTU ELECTRONICS CORPORATION. BY CLICKING THE “I AGREE” OR “YES” BUTTON OR
OTHERWISE INDICATING ASSENT ELECTRONICALLY, OR LOADING THE SOFTWARE, YOU AGREE TO THE TERMS AND
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The software (including any accompanying features) and documentation (including any product packaging) (the“Documentation”), that accompanies this License Agreement (collectively the “Software”) is the property of HERUTU
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This License Agreement governs any releases, revisions, updates or enhancements to the Software that HERUTU
ELECTRONICS CORPORATION may make available to You. Your rights and obligations under this License Agreement withrespect to the use of this Software are as follows.
a. use one copy of the Software on a single computer;b. use the Software in accordance with any additional permitted uses which may be set forth below;

POKAYOKE plus

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discretion, makes such features available with the Software. HERUTU ELECTRONICS CORPORATION continually strives toimprove the usability and performance of its products and services. In order to optimize the Software, HERUTU ELECTRONICSCORPORATION may, at its discretion and without notice, add, modify or remove features from the Software at any time.
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This License Agreement is the entire agreement between You and HERUTU ELECTRONICS CORPORATION relating to theSoftware and: (i) supersedes all prior or contemporaneous oral or written communications, proposals, and representations withrespect to its subject matter; and (ii) prevails over any conflicting or additional terms of any quote, order, acknowledgment, or
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This License Agreement shall terminate upon Your breach of any term contained in this License Agreement

POKAYOKE plus

and You shall cease use of and destroy all copies of the Software and Documentation. The disclaimers of warranties anddamages and limitations on liability shall survive termination.

This License Agreement may only be modified by theDocumentation or by a written document that has been signed by both You and HERUTU ELECTRONICSCORPORATION. Should You have any questions concerning this License Agreement, or if You desire to contact HERUTU
ELECTRONICS CORPORATION for any reason, please visit the HERUTU ELECTRONICS CORPORATION’s homepage
at https://www.herutu.co.jp/en/ .

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Table of Contents
1．Introduction ............................................................................................................................................ 1
1-1．Overview .......................................................................................................................................... 1
1-2．System Requirements .................................................................................................................... 7
1-3．Supported Devices ......................................................................................................................... 7
2．Mouting Method ..................................................................................................................................... 92-1．Equipment configuration ............................................................................................................... 92-2．Network Settings ............................................................................................................................ 92-3．Selection of Operating Mode ......................................................................................................... 92-4．Setting the receiver data type ....................................................................................................... 9
3．POKAYOKE plus .................................................................................................................................. 10
3-1．Installation ..................................................................................................................................... 10
3-2．Screen Configuration ................................................................................................................... 12
3-3．Menu Configuration ...................................................................................................................... 13
3-4．Flow of setting and operating POKAYOKE plus ....................................................................... 14
3-5．POKAYOKE plus Start up ............................................................................................................ 15
3-6．Default Settings ............................................................................................................................ 15
3-7．Recever Registration .................................................................................................................... 24
3-8．I/O unit Registration ..................................................................................................................... 27
3-9．Tool Registration........................................................................................................................... 30
3-10．Work Registration and Start ...................................................................................................... 36
3-11．Work Sequence Registration and Start .................................................................................... 48
3-12．Registration of safety protector group and Start of monitoring ........................................... 53
3-13．Work Execution Status Screen ................................................................................................. 59
3-14．Work Execution Screen.............................................................................................................. 62
3-15．Safety protectors wearing status screen ................................................................................. 67
3-16．History.......................................................................................................................................... 70
3-17．Transmission of error information to smartphones or other devices in real time(MQTT
output).................................................................................................................................................... 77
3-18．Specifications for external device interface ............................................................................ 79
3-19．Error Code ................................................................................................................................... 81
3-20．Product Information ................................................................................................................... 81
3-21．Exit POKAYOKE plus ................................................................................................................. 82
4．Actions When Receiver TW-800R-SCL Is Used ................................................................................ 83
5．POKAYOKE plus Viewer...................................................................................................................... 88
6．Troubleshooting ................................................................................................................................... 89

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1．Introduction
1-1．Overview
Explanation of terms
Term

Description

Tool

Tools or safety protectors with POKAYOKE transmitter “TW-800T”,” HRF2402”, etc. installed.

ReceiverOur POKAYOKE receiver with LAN connection.
A device for receiving the signal wirelessly transmitted from the transmitter
attached to the tool and transmitting the signal to the external device being
connected via LAN.
Compatible models：(1) Simple Pokayoke Counter TW-800R-SCL(2) LAN Connection Type Pokayoke Receiver TW-800R-EXL / TW-820REXL(hereinafter called “TW-8##R-EXL”)

Work“Work” refers to the content of tasks using one or more tools. For example,
you would register the content of a work as “tasks done 10 times with acordless power tool, 3 times with the Check Pen S, and 1 time with anapproval stamp.”

Work sequence

Reservation for work executions is called a work sequence.
You can reserve executions for up to 8 works as shown below.

Work B

Work C

Next
Scheduled Work

Subsequent
Scheduled WorkWork A
Currently
Running Work●●●The number of repetition times (1-99999 times) can be set for each work. Set
the number of repetition times according to the number of manufacturing
products.

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Tools available for POKAYOKE plus
Tool type

Description

Tool

Compatible with various tools used in the production processes.
Check Pen S, Cordless Power Tool, Torque Wrench, Pliers Wrench, Approval
Stamp, Cable Tie Gun, Riveter, Grease Gun and more

Safety protectors

Can be used with a hard hat.
Wearing status is OK ・・・ Wearing safety protectors correctly.
Wearing status is NG ・・・ Wearing safety protectors not correctly.
For use with a hard hat, NG wearing status includes:
The chin strap comes off. A hard hat is not worn.

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“Production Process Support Software for POKAYOKE tool, POKAYOKE plus” is a Windows- compatible
application that can be used with POKAYOKE receivers capable of LAN connection for customers whowant to ensure the traceability of “Tasks using tools” or “Wearing safety protectors” by workers at
manufacturing plants.
1.

You can log and save task results for each work via the TW-800R-SCL or TW-8##R-EXL installed inWork

multiple processes.

Process A

Process B
TW-8##R-EXL

Process C

Task Results

TW-800R-SCL●Work Title●Start Date and Time of Task ●End Date and Time of Task
●Judgment Result

2.

●Cause of FAIL, etc.

By using POKAYOKE plus, linked to TW-800R-SCL installed for multiple processes, you can set
work execution instructions, counting the number of tasks upwards, etc. Since you can register
installed TW-800R-SCL at up to 8 stations for one work, the system can prevent mistakes(pokayoke) for tasks that use up to 8 tools.

Work
Process A

Process B
Up to8
Stations

Process C

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3.

By linking the Pokayoke receiver without counter feature TW-8##R-EXL, the count can be displayed
at up to 16 stations by locating a Windows computer with “POKAYOKE plus Viewer” (Windowscompatible application with the counter feature excerpted from POKAYOKE plus) at your task site.

Work

Process A●●●

MAX. 8 Tools

Windows PC
Up to

16
StationsWork

TW-8##R-EXL
Process B●●●

MAX. 8 Tools

Windows PC*To use POKAYOKE plus Viewer, you need to purchase one license for each POKAYOKE plus
Viewer.

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4.

By linking works with external devices, you can control other facilities through the I/O port of the I/O
unit or call the person in charge in the distance using the two-way Silwatch, upon completion of thework or occurrence of FAIL.

Work
FAIL occurred!
Process A② Fail occurs
because the work
is not completed.

Process B① Input judge signal
LAN

USB

from PLC.

Contact
Input

PLC

OutputWCP-232-EXL③ Notifies the occurrence of FAIL

SWSR-P125

to the workplace by activating
the rotating light by a contact
output.

SWSR-2130④ Notifies the occurrence of FAIL
to people at some distanceusing the *two-way Silwatch system.

*Two-way Silwatch system can only be used in Japan.

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5.

Hard-hat-on Sensor ENS-HH01 (*1) is an IoT tool for customers who “Encourage employees towear hard hats correctly to ensure safety”, and supports customers on how to wear hard hats.

TW-8##R-EXL

You can see the wearing status by the color of
the icon.
Green・・・Wearing status is OK
Red ・・・Wearing status is NG

People who manage the tasks using tools cankeep track of “Whether safety protectors are worncorrectly or not by workers executing the tasks
using tools”.

(*1) Hard-hat-on Sensor ENS-HH01 is an IoT tool for customers who “Encourage employees to wear hard
hats correctly to ensure safety”, and supports customers on how to wear hard hats.
It senses the hard hat wearing status (whether the chin strap is securely fastened or not) in real time,and communicates with the receiver wirelessly.
For details, refer to “Hard-hat-on Sensor ENS-HH01 Instruction manual”.

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1-2．System Requirements
The following system requirements are necessary to use POKAYOKE plus.
Supported OS

Windows® 10 32-bit / 64-bit
Windows® 11 64-bit (*)

CPUIntel® Core™ 2.3GHz or above (*)

Memory4GB or above (*)

Screen Resolution

1366×768(FWXGA) or above

Storage free space

1GB (Excluding data / log)

Network Adapter

100Mbps or above(one or more network adapters available)

USB Port

1 port(For connection to the two- way Silwatch transmitter/receiver only.).NET Framework

4.6 or later installed* For Windows 11, the minimum system requirements of Windows 11 apply additionally.

1-3．Supported Devices
POKAYOKE plus can be used in combination with the devices with the following model.

Pokayoke Transmitter【Tools】 Pokayoke Transmitter
TW-800T/TW-810T/TW-820T/TW-850T/HRF-2402/HCP-2402T-MC/Check Pen S
The transmitter can be mounted on the torque wrench with a limit switch,
the check pen, the pliers wrench, the cordless power tool, etc.,
and a completion signal such as tightening can be wirelessly transmitted
to the receiver.
TW-800T

ENS-HH01【Safety protectors】 Hard-hat-on Sensor ENS-HH01
The device senses the hard hat wearing status in real time and wirelessly transmits the information to
the receiver. The device can be attached to any hard hat available in the market.
For the transmitter, this instruction manual describes only the contents required for using it with the receiver.
For details, refer to each transmitter manual.

Pokayoke Receiver
Simple Pokayoke Counter TW-800R-SCL
TW-800R-SCL is a receiver with a built-in wireless feature anda simple counter feature.
It communicates with the transmitter one to one.
For details, refer to “TW-800R-SCL Instruction manual”.

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TW-800R-SCL

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LAN Connection Type Pokayoke Receiver TW-8##R-EXL
A TW-800 series LAN connection type receiver.
The receiver is capable of communicating with multiple transmitters.
For details, refer to “TW-800R-EXL Instruction manual” or“TW-820R-EXL Instruction manual”.
TW-820R-EXL can only be used in Japan.

TW-8##R-EXL

I/O Unit
WCP-232-EXL
LAN connection type I/O unit with 32 contacts(16 input contacts and 16 output contacts).
To use the device by connecting it to POKAYOKE plus,
it runs according to the specifications below.
・Input: 1-8, 17-24 / Output: 9-16, 25-32

WCP-232-EXL(input signal must be 500ms or more)
・A-Contact

Silwatch
These products can only be used in Japan.
【Silwatch】 Two-way Silwatch Wristwatch type transmitter/receiver SWSR-2130
It receives a signal from the transmitter/receiver andtransmits the information in the form of up to 10 Chinese charactersin text and sound, light or vibrations to the receivers.
【Silwatch】 Two-way Silwatch transmitter/receiver SWSR-P125

For details, refer to each manual.
SWSR-P125

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SWSR-2130

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2．Mouting Method
2-1．Equipment configuration⚫

Connect the LAN connector of the receiver to the switching hub or the PC’s LAN connector with thecable. Please use the cable of the category 5 or higher standard.

⚫

The receiver or I/O unit is not equipped with AutoMDI/MDI-X function to determine the LAN port.
To connect the receiver to the PC’s LAN port directly, use a cross-wired LAN cable. "⚫

To connect the PC to the two-way Silwatch transmitter/receiver, install an FTDI driver separately.
Download the latest FTDI driver from FTDI’s website.

LAN cable

TW-800R-SCL

HUB

USB cable

TW-800R-SCL

SWSR-P125
WCP-232-EXL

TW-8##R-EXL

2-2．Network Settings
POKAYOKE plus communicates with the receiver via LAN. To connect the receiver to LAN, configure
network settings according to your network environment. For details of the settings, such as IP address,
contact the network administrator. For the setting method, refer to “TW-800R-SCL Instruction manual” or“LAN Basic Settings” attached to TW-8##R-EXL.

2-3．Selection of Operating Mode
To use TW-800R-SCL, the operating mode needs to be set.
With the TW-800R-SCL, you can select one of two operating modes: “stamd-alone mode” or “applicationinterlock mode.” When using TW-800R-SCL with POKAYOKE plus, select “application interlock mode”.
For the setting method of the operationg mode, refer to “TW-800R-SCL Instruction manual”.

2-4．Setting the receiver data type
There are two types of output data for the receiver "short data" and "long data".
When using in combination with the transmitter ENS-HH01, set to "Long Data".

For details, refer to transmitter manual.
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3．POKAYOKE plus
3-1．Installation
Install the application according to the following procedure.
① Insert the CD-ROM into the PC.
From “Explorer”, double click the “setup” file in the Installer folder in the CD-ROM drive.

② Click “Next (N) >” and follow the instructions on the screen.

③ When the “Installation is completed” screen is displayed, installation of “setup” file is completed.

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④ Install Visual C++ redistributable runtime packages.
◆When using a 64bit OS.
Directly double click “vcredist_x64”(a) file in the Installer folder of CD-ROM drive.
◆When using a 32bit OS.
Directly double click “vcredist_x86”(b) file in the Installer folder of CD-ROM drive.

(a)(b)
Installation is now completed.

Software Updates
Customers who purchased POKAYOKE plus / POKAYOKE plus Viewer can download the latest
version of the application free of charge from the download page of the website.
Previous Version： V1.0X、V2.00、V3.00
Latest Version： V3.01

Follow the steps below to update.
① The downloaded file is ZIP compressed, so decompress it.
② Open the Update folder and double-click the "setup" file directly.
③ Click “Next (N) >” and follow the instructions on the screen.
④ When the “Installation is completed” screen is displayed, installation is completed.
【Cautions for use】
The database of POKAYOKE plus is expanded with the addition of functions in V3.01.
Therefore, if you upgrade from V1.0X or V2.00 to V3.01, you cannot revert to the original version.
The registration information of V1.0X or V2.00 can be used as it is in V3.01.

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3-2．Screen Configuration
①

③

④

⑤

⑥

②

Item name

Description①HERUTU logo

Click this to display the “Work execution status” screen.

②Menu

Select a menu item.
Messages, such as error information, are displayed.
When a notification occurs, the number of messages is displayed on③Notifications

the top left of the bell icon.
Click this to check the details of the notifications. For details of themessages, refer to “6. Troubleshooting”.

④Zooming

To zoom in or out the screen.

⑤Display/hide menu

To hide or display the menu.

⑥Main screen

This is a main screen.

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3-3．Menu Configuration

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3-4．Flow of setting and operating POKAYOKE plus
Items marked with a circle(〇) in “Tools” are required for the tools with POKAYOKE.Items marked with acircle(〇) in “Safety protectors” are required for the safety protectors with POKAYOKE.

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3-5．POKAYOKE plus Start up
When the installation is completed, start up POKAYOKE plus from the icon on the desktop or from Program.

3-6．Default Settings
Click [Default] in the menu to display the default settings screen.

◆ToolsClick the “Tools” tab.

To save the settings in this screen, click the Setting button on the bottom right of the screen.
When moving to another screen without clicking the Setting button, the entries made on the Default
settings screen will be lost.
Item

Description

Setting value

Buzzer sounds for PASS

When the number of tasks completed reaches

ON (default)

judgmenta specified count, a “PASS” is assigned. Set

OFFwhether or not to sound the buzzer from thePC equipped with the POKAYOKE plus.
Buzzer type for PASS

Set the buzzer sound for notification of PASS

Buzzer1 (default)

judgment

result. Select a buzzer sound from five types.

Buzzer2

You can hear the buzzer sounds after clicking

Buzzer3

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Buzzer4

displayed on the right.

Buzzer5

Buzzer sounds for FAIL

When tasks are not executed according to theON (default)

judgment

execution instructions set in work registration,OFFor when there are remaining counts at the
input of the judgment signal, the work is
judged as FAIL.
Set whether or not to sound the buzzer fromthe PC equipped with thePOKAYOKE plus.
Buzzer type for FAIL

Set the buzzer sound for notification of FAIL

Buzzer1

judgment

result. Select a buzzer sound from five types.

Buzzer2 (default)

You can hear the buzzer sounds after clicking

Buzzer3
Buzzer4

displayed on the right.

Buzzer5

ToolReset timer

Time from when the tool is judged as PASS

1 sec. (default) – 30

(1-30 sec)

until when the next tool is started. When over-sec.

count is not permitted, by execution of task

(Set at one second

while the reset timer is running, the next tool(s)interval)

and work are judged as FAIL for overcounting.
WorkReset timer

Time from when the work is judged as PASS

1 sec. (default) – 30

(1-30 sec)

until when the next work is started.

sec.
(Set at one second
interval)

Judgment timing of work

Choose from one of the following:

・When all tools(TW-8##R-EXL)・When all tools complete the number of tasks

complete the number

specified by the count, the system judges theof tasks specified bywork.

the count, the system(When all tool counts reached the specified

judges the work.

value, the work is judged as PASS. The(default)

system move on to the next work after timeoutof the reset timer.)・Judges a work・Judges a work when the judge signal is input.

when the judge(Judges a work when satisfying the conditions

signal is input.

to “Judge work “in the external device interface
settings. When the predetermined number ofcounts for all tools is reached, start the next
work. If “Judge work” is not registered inExternal device interface settings, next work
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cannot be started.)
Judgment timing of work

Choose from one of the following:

・When all tools(TW-800R-SCL)・When all tools complete the number of tasks

complete the number

specified by the count, the system judges theof tasks specified bywork.

the count, the system(When all tool counts reached the specified

judges the work.

value, the work is judged as PASS. The(default)

system move on to the next work after timeoutof the reset timer.)・Judges a work・Judges a work when the judge signal iswhen the judge

input. (Judges a work when the signal issignal is input.

input into the judge input terminal box of TW800R-SCL or when the conditions to “Judgeworks” in the external device interface settings
are satisfied. When the predetermined
number of counts for all tools is reached, start
the next work.)

Processing method for reset

During occurrence of FAIL, select Terminate

Continue (default)

input

the work by reset input from TW-800R-SCL,

Exit

I/O unit or POKAYOKE plus Viewer, or selectContinue the work.
・Continue : Reset FAIL and continue the task.
・Exit : Finish the work in execution.
Counting method

Set a counting method on the work execution

Count upscreen of the application. This setting is also

Count down (default)

reflected to TW-800R-SCL and POKAYOKE
plus Viewer.

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◆Safety protectors
Click the “Safety protectors” tab.

To save the settings in this screen, click the Setting button on the bottom right of the screen.
When moving to another screen without clicking the Setting button, the entries made on the Default
settings screen will be lost.
Item

Description

Setting value

Buzzer sounds when the

Set whether or not to sound the buzzer whenON (default)

safety protector wearing

safety protectors are not worn correctly fromOFF

status is NG

the PC with POKAYOKE plus installed.

Buzzer type when the safety

Set the buzzer sound for when safety

Buzzer1 (default)

protector wearing status isprotectors are not worn correctly. Select a

Buzzer2NGbuzzer sound from five types. You can hear

Buzzer3
Buzzer4

the buzzer sounds after clicking

Buzzer5

displayed on the right.
Day of the week to monitor

Put a checkmark on the days to which theSun, Mon, Tue, Wed,

safety protectors

working hour pattern to be set in Create aThu, Fri, Sat (default：

safety protector group applies. Set the day for

Checked every day ofthe start time of the working hours.

the week)

Even when the day changes to the next during
working hours, the monitoring continues.
Example) When working from 17：00 on
Monday to 2：00 on Tuesday, put a checkmarkon Monday.
Time until when the safety

Time from when the wearing status actually

0 min. (default) – 30

protector wearing status isbecomes NG (e.g. the hard hat chinstrap

min.

judged as NG

comes off) until when “Alert generated” is(Set at one minute

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(0-30 min)notified. If you want to know the NG stateinterval)

immediately, set the time to 0 minute. To
accept the wearing NG state for a certain
period of time, such as a bathroom break, set
any desired time.
Output of safety protector

The wearing status sent from the safety

ON (default)

history data (CSV format)

protectors is automatically saved in CSV

OFFformat in the order received(*2). Output when
the wearing status changes.
[Output destination folder]
C:/HERUTU¥POKAYOKE plus/safety_log[File name]safety_log_yyyyMMdd.csv (y: year, M: month, d: day)
When the time set in “Update time for safety protector history file(hours : minutes)” below has reached, a new file is createdautomatically once a day.
*Do not open the file while executing POKAYOKE plus. When opening
the file while executing POKAYOKE plus, the receiver fails to write fromPOKAYOKE plus. Exit POKAYOKE plus, and then open the file.
Update time for safety

Time to create a new safety protector wearing

protector history file

history file.

00:00(default)(hours : minutes)(*2) The output contents are as follows.
Item

Description

ExampleTransmitter ID

Transmitter ID of safety protector.

010800002F

Tool name

Tool name registered in register POKAYOKE Tools.

Worker A

Tool model

Tool model registered in register

ENS-HH01

POKAYOKE Tools.
Safety protector types

safety protector type registered in register

HelmetPOKAYOKE Tools.
Wearing status

OK・・・Wearing safety protectors correctly.

OK

NG・・・Wearing safety protectors not correctly.
Date and time

Date and time when the wearing status changed.

2019/4/10 12:00:00

Safety protector group

Group name registered in register group.

Pressing Process G

name*To view a wearing history and also to avoid garbling, it is recommended to open the file by following theprocedure in “◆How to open History (in CSV file) “.
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◆CommonClick the “Common” tab.

To save the settings in this screen, click the Setting button on the bottom right of the screen.
When moving to another screen without clicking the Setting button, the entries made on the Default
settings screen will be lost.
Item

Description

Setting value

Language

Select a language to be displayed inJapanese

POKAYOKE plus.

English (default)

Output of all data transmitted

All task data is automatically saved in the CSV

ONfrom the tool (CSV format)

format in order of receiving the data from theOFF(default)

tools(*3).
[Output destination folder]
C:¥HERUTU¥POKAYOKE plus
[File name]]
raw_yyyyMMdd.csv (y: year, M: month, d: day)A new csv file is created each day.
When the date changes while executing POKAYOKE plus, a new fileis automatically created.
*Do not open the file while executing POKAYOKE plus. Whenopening the file while executing POKAYOKE plus, the receiver fails to
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POKAYOKE plus

write from POKAYOKE plus. Exit POKAYOKE plus, and then open the
file.
Character code(UTF-8)

Byte order markAvailable (default)

CSV file may be garbled by changing thisNonesetting. Do not change this setting unlessspecial reasons apply.
Network adapters

MQTT output

Select a network adapter to communicate withYour IP address is

POKAYOKE plus Viewer.

displayed in the

For details, contact the network administrator.

selection list.

By being linked to the IoT environment thatON

supports MQTT, when an error occurs, it canOFF(default)

be informed to the mobile terminal of theadministrator, etc. by email or SMS.
When an error occurs while working with a toolor while wearing safety protectors, the error
information is transmitted via the IoT standard
protocol MQTT.
MQTT communication settings

POKAYOKE plus runs as a publisher.

*For specifications, refer to “3-17．Transmission of error information to smartphones or other devices inreal time.”.

Broker URL

Enter the broker URL.

empty(default)

Port No.

Enter the MQTT connection port number.

8883(default)

Possible values：1883, 8883 and 49152 65535
Client ID

Enter a client ID to identify the client. (Only

GUID(default)

alphanumeric characters can be used.)
TLS 1.2

Turn ON to encrypt communication.

ON(default)
OFF

QoS

QoS setting that guarantees the arrival

0 (default)

between the publisher and the broker. Select1

from "QoS 0 (At least once)", "QoS 1 (At least2once)", or "QoS 2 (Exactly once)".
User Name

ID for authentication.

empty(default)Enter according to the broker settings.
Password

Password for authentication.

empty(default)Enter according to the broker settings.
Topic name for FAIL judgment

Enter the topic name when publishing withof the work or for resetting

MQTT.
21

Tools (default)

POKAYOKE plus

FAIL
Topic name for generation ofEnter the topic name when publishing with

SafetyProtectors

a safety protector alert or for

MQTT.

(default)

Set this to ON to call two-way SilwatchONwristwatch type transmitter/receiver when theOFF(default)

resetting the alert
Call Silwatch

conditions for setting “Call Silwatch” inexternal device interface settings are met.
When this is set to OFF, the call is not
executed even when the conditions for setting“Call Silwatch” are met.
Transmitter /receiver

Select a COM port that is connected to the

COM port existing inconnection port

two-way Silwatch transmitter/receiver and that

PC is displayed inis recognized by the PC.

the selection.

Select a time interval (seconds) of the call15

from the two-way Silwatch transmitter/receiver.

30(default)

Transmission interval

45(*3) The output contents are as follows.
Item

Description

ExampleReceived date

Date receiving the transmitter ID from the receiver.

2019/04/10

Received time

Time receiving the transmitter ID from the receiver.

12:00:00

Transmitter ID

Tool or safety protector transmitter ID

010100002F

Transmitter

Transmission type, battery information, safety[short data] 2byte

information(*4)

protector wearing status, error information …etc

01
[long data] 26byte
010100000000000000000
00000(*4) There are two types of output data for the receiver "short data" and "long data". The data size of thetransmitter information varies depending on the data type setting.
When using in combination with the transmitter ENS-HH01, set to "Long Data". When used in
combination with the transmitter TW-800T, both "short data" and "long data" will work.

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【Transmitter information detail】
Transmission

Safetytype, Battery

protector

information

wearing status

01

01

Ex)

Error

System area

information
00

00000000000000000000
NumberData name

Description

Transmission type,

Normal transmission “01”Battery information

Test transmission(battery capacity is normal） “02”[short data]/[long data]

Test transmission(battery capacity is low) “12”Safetyprotector

wearingof bytes

Wearing status is NG “00”status [long data]

Wearing status is OK “01”Error information

No error “00”[long data]

Error No. in sequential order from “01”

2

2

2

Contains system specific data.

System area

When using the output data in your environment, re[long data]

ad and discard the data in the system area.

Output data example[short data]"2019/04/10","12:00:00","010100002F","01"[long data]"2019/04/10","12:00:00","010800000A","01010000000000000000000000"

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3-7．Recever Registration①②

Click “Registration” on the menu, and “Receiver registration” (①) is displayed. Click “Receiver
registration” to display the receiver registration screen.
Click “Receiver registration” button (②), and the information entry screen to enter a new receiver isdisplayed.

Enter each information and click “Save” tosave the information. If you click “Close”
before clicking “Save”, the entered information
will be lost.
If you put a check in the box next to “Display
the previously entered information aftersaving.”, the entered data remains on thescreen after clicking “Save”. If you remove thecheck, after clicking “Save”, the entered data
will be cleared from the screen.

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Item

Description

Input example:

Receiver nameEnter the receiver name.

ASSY line A(Maximum 16 characters)
Receiver type

Select the receiver type.

TW-8##R-EXL(default)

TW-8##R-EXL / TW-800R-SCL
IP addressEnter the IP address of the receiver.

192.168.100.105

Port No.

Enter the port number of the receiver.

50001(default)

The possible setting range is 10001 and 49152 –65535.
Default value is 50001.

Edit registration information / Copy the registered information to make a registration
⑤

⑥

③
④

When the receiver is registered, the application starts connecting to the receiver automatically.
The connected receiver is displayed in white background (③) and the unconnected receiver is displayedin pink background (④). Soon after registration of the receiver, the connected receiver may remain
displayed in pink background. Display the receiver registration screen again after moving to anotherscreen, and the latest status is displayed. When the connection fails, the user is notified by notifications(⑤).
The possible cause of the connection failure is as below:
・The receiver is not turned on or the power cable is not connected.
・The LAN cable is disconnected.
・The receiver’s IP address/Port No. is not correctly set.
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POKAYOKE plus

ButtonDescription
The receiver name can be edited.
The receiver type, IP address or Port No. cannot be edited.
The registered receiver information can be copied and then newly registered.
When the receiver with the same IP address and Port No. is already registered, amessage asking if you want to overwrite with newly entered data is displayed.

Narrowing down of the receivers (registered information)
Enter the filtering conditions (⑥) and click, and the receivers satisfying the conditions are selected

and displayed.
You can enter any string in receiver name, IP address and port number. Receivers that match the enteredstring exactly or partially will be extracted. You can select either TW-8##R-EXL or TW-800R-SCL as thereceiver type, and the matching receiver will be extracted.
When several conditions are entered, the receivers that match all conditions are extracted.
Deletion of the receivers (registered information)
If you check here, all the displayed receivers
will be checked.

Put a check in the box for the receiver you want to delete and click
will be deleted.

26. The registered information

POKAYOKE plus

3-8．I/O unit Registration①②

Click “Register” on the menu, and “I/O unit registration” (①) is displayed. Click “I/O unit registration” todisplay the I/O unit registration screen.
Click “I/O unit registration” button (②), and the information entry screen to enter a new I/O unit isdisplayed. 16 of I/O units can be registered.

Enter each information and click “Save” tosave the information. If you click “Close”
before clicking “Save”, the entered information
will be lost.
If you put a check in the box next to “Display
the previously entered information aftersaving.”, the entered data remains on thescreen after clicking “Save”. If you remove thecheck, after clicking “Save”, the entered data
will be cleared from the screen.

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Item

Description

Input example:

I/O unit nameEnter the I/O unit name.

ASSY line A(Maximum 16 characters)
I/O unit type

Select the I/O unit type.

WCP-232-EXL(default)

Default value is WCP-232-EXL.
IP addressEnter the IP address of the I/O unit.

192.168.100.105

Port No.

Enter the port number of the I/O unit.

50001(default)

The possible setting range is 49152 – 65535.
Default value is 50001.
Edit registration information / Copy the registered information to make a registration
⑤

⑥

③
④

When the I/O unit is registered, the application starts connecting to the I/O unit automatically.
The connected I/O unit is displayed in white background (③) and the unconnected I/O unit is displayed inpink background (④). Soon after registration of the I/O unit, the connected I/O unit may remain displayedin pink background. Display the I/O unit registration screen again after moving to another screen, and thelatest status is displayed. When the connection fails, the user is notified by notifications (⑤).
When the connection fails, the following causes are possible.
・The I/O unit and LAN conversion unit are not connected.
・The I/O unit is not turned on or the power cable is not connected.
・The LAN cable is disconnected.
・The I/O unit’s IP address/Port No. is not correctly set.

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ButtonDescription
The I/O unit name can be edited.
The I/O unit type, IP address or Port No. cannot be edited.
The registered I/O unit information can be copied and then newly registered.
When the I/O unit with the same IP address and Port No. is already registered, amessage asking if you want to overwrite with newly entered data is displayed.

Narrowing down of the I/O units (registered information)
Enter the filtering conditions (⑥) and click, and the receivers satisfying the conditions are selected

and displayed.
You can enter any string in I/O unit name, IP address and port number. I/O units that match the enteredstring exactly or partially will be extracted.
When several conditions are entered, the I/O units that match all conditions are extracted.
Deletion of the I/O units(registered information)
If you check here, all the displayed I/O units
will be checked.

Put a check in the box for the I/O unit you want to delete and click. The registered information will

be deleted.
When the selected I/O unit is set to the external devices, the settings of the I/O unit are deleted from all
works using the I/O unit. Accordingly, some of the external device interface settings may not be executed.
The I/O units used in the work or work sequence in progress cannot be deleted.
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POKAYOKE plus

3-9．Tool Registration

①

③

②

④

Click “Registration” button on the menu, and “Tool registration” (①) is displayed. Click “Tool registration”
to display the tool registration screen.
Click “Tool registration” button (②), and the information entry screen to enter a new tool is displayed.
Unlimited number of tools can be registered.
When “Tool” is selected from the tool type, the tool
image can be registered. The registered image isdisplayed on the background of the count display
on the work execution screen.
Supported image format:
・Bitmap(*.bmp)
・JPEG(*.jpeg, *.jpg)
・GIF(*.gif)
・PNG(*.png)
When registering an image with a large file size, theregistration process may take some time.
Enter each information and click “Save” to savethe information. If you click “Close” before clicking“Save”, the entered information will be lost.
A preview of the tool image is displayed.
If there is no image to display, it will be "No Image".

If you put a check in the box next to “Display the

It is not displayed when the tool type is other thanpreviously entered information after saving.”, the"Tool".

entered data remains on the screen after clicking“Save”. If you remove the check, after clicking“Save”, the entered data will be cleared from thescreen.

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POKAYOKE plus

The tool type can be selected from "tool" or "safety protector". If you select "Safety protectors", "Safety
protector types" will be displayed.

Item

Description

Input example

Transmitter ID

Enter the 10-digit serial number indicated on the010100002F

transmitter.
Press the test switch of the transmitter pairedwith the receiver while the entry screen isdisplayed, and the serial number is automaticallyentered. Please note that long pressing the test
switch will reset the pairing.

Test switch

Type of the paired

Select the type of the paired receiver.

TW-8##R-EXL

receiverTW-8##R-EXL / TW-800R-SCL

Tool nameEnter the tool name. (Maximum 16 characters)PliersWrenchR01

Tool modelEnter the tool model. (Maximum 20 characters)

P200Y2Tool type

Select the tool type.

Tools

Tools / Safety protectors
Safety protector types

Select the safety protector type. This item is

Hard hats

displayed when "Safety protectors" is selected forthe tool type.
Tool image

Register and delete the tool image.

none(default)

It is displayed only when "Tool" is selected for the
tool type.
*If a tool with the same transmitter ID has already been registered, you cannot additionally register withthat transmitter ID. Delete the existing tool and try again.
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POKAYOKE plus

Export / import of tool (tool, safety protector) information
Capture the tool information*1 from the file in CSV format and save the registered tool information in CSV
format. You can register or edit multiple transmitters at the same time. It can also be used to transfer data
to POKAYOKE plus running on another PC.
*1 Tool images are not subject to export / import.
◆ExportClick the "Export" button (③) and save it in any folder. When the export is completed, the message "Toolexport is completed." is displayed.
Character encoding： UTF-8(with Byte order mark)Line feed code

： CRLF*Cautions for editing or saving the exported file・Use a text editor (eg Notepad) to edit.
・The header is inserted on the first line. Enter from the second line according to the order of the items in theheader.
・Enclose each item in double quotation marks (“).
・Insert a comma (,) between items. Continue to enter data without placing space before or after comma.
・When registering multiple tools, enter a new line.
・When saving the data, specify "UTF-8" as the character code.

Setting item
Item

Description

ExampleTransmitter ID

Transmitter ID

0101000001

Tool name

Tool name(Maximum 16 characters)

Check Pen S

Tool model

Tool model(Maximum 20 characters)

CP-02SType of paired receiverEnter 1 or 2.

1(1:TW-8##R-EXL、2:TW-800R-SCL)

1・・・TW-8##R-EXL / 2・・・TW-800R-SCL

Tool typeEnter 0 or 1.

(0:tool、1:safety protector)

0・・・Tool / 1・・・Safety protector

Safety tool typeEnter 0 or 1.

(0:other、1:hard hat)

0・・・Tool / 1・・・Hard hat

Example"010100350A","Check Pen S","CP-02S","1","0","0""0201000007","Worker A","ENS-HH01","1","1","1"

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0
0

POKAYOKE plus

◆Click the "Import" button (4) and select the file to import. A message appears when the import is complete.
You can see the tools that were successfully imported and the number of tools that were unsuccessfully
imported. For the reason for the import failure, check the content of the file output in "C:/HERUTU/Pokayoke plus/error_log". It lists the number of rows that failed and the reason.

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Edit registration information / Copy the registered information to make a registration⑤

ButtonDescription
The tool names, tool models and tool images can be edited. Transmitter ID, thetype of the paired receiver, tool type, safety protector type cannot be edited. If you
want to change the information, delete the existing tool and register the tool again.
The registered tool information can be copied and then newly registered.
If a tool with the same transmitter ID has already been registered, you cannot
additionally register with that transmitter ID. If you click the "Save" button withoutchanging the transmitter ID, the following error is displayed.

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POKAYOKE plus

Narrowing down of the tools (registered information)
Enter the filtering conditions (⑤) and click, and the receivers satisfying the conditions are selected

and displayed. You can enter any string in transmitter ID, tool name. Tools that match the entered string
exactly or partially will be extracted. Select the tool model, the paired receiver type, tool type and the typeof safety protectors from the displayed selection information. The tools matching the conditions are
extracted. When several conditions are entered, the tools that match all conditions are extracted.
Deletion of the tools(registered information)
If you check here, all the displayed
tools will be checked.

Put a check in the box for the tool you want to delete and click. The registered information will

be deleted. The work and work sequence using the selected tool are also deleted.
The tools used in the work or work sequence in progress cannot be deleted.

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3-10．Work Registration and Start
Work refers to the contents of tasks using one or more tools. For example, you would register the content
of a work as “task done 10 times with a cordless power tool, 3 times with the Check Pen S, and 1 time with
an approval stamp”.

①②

Click “Registration” on the menu, and “Work registration” (①) is displayed. Click “Work registration” todisplay the work registration screen.
Click “Work registration” button (②), and the screen for newly creating a work is displayed. Unlimited
number of works can be registered.
③

⑤

④

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POKAYOKE plus

Narrowing down of the tools (registered information)
Enter the tool filtering conditions (③) and click, and the tools satisfying the conditions are selected

and displayed.
You can enter any string in transmitter ID, tool name. Tools that match the entered string exactly or partiallywill be extracted. Select the tool model, the paired receiver type and tool type from the displayed selection
information. The tools matching the conditions are extracted. When several conditions are entered, thetools that match all conditions are extracted.
Work creation
1. Enter work information in “Create work” (⑤) on the right.
Itemexternal

deviceinterface

Description

Input example

Turn it ON to interface the work with the devices,OFF

such as I/O unit or Silwatch, according to thesettings. For detailed setting method, please refer
to "External device interface setting" describedlater.
・ON
・OFF(default)

Tool sequence

Click ON to control the tool use sequence. PlaceON

them in order of use from top to bottom.
・ON(default)
・OFFWork No.

Enter a desired work No. (Maximum 8 characters)

LU201-A

Work nameEnter a desired work name.

Large unit AD ASSY

(Maximum 20 characters)

2. Drag the tool in “Selection of tools” (④) on the left and drop it in the gray area of “Create work” (⑤) on
the right. You can drag and drop up to 8 tools.
You can drag the tools moved to the right side and move them up and down. When the tool sequence
is “ON”, arrange the tools in order of task from top to bottom.
To create works, follow the rules below.
・A work cannot contain both the tools paired with TW-800R-SCL and the tools paired with TW8##R-EXL.

・

When Tool sequence is “ON”, the same tool can be registered repeatedly in the same work.

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POKAYOKE plus

3. Set the contents of task with the tool.

Item

Description

Input example

Spec. valueEnter the task count.

6(Specified Count Value)

Range of the values that can be entered: 1 – 999

Over-countOver-count refers to execution of tasks more thanOver-countthe specified count.

permitted

isnotWhen over-count is permitted, executing the task
more than the specified count will not be judged as
FAIL.
When over-count is not permitted, executing thetask more than the specified count will be judged
as FAIL.

Example) When the contents of a work are “Task done 10 times with a cordless power tool”, ”Task done 3
times with the Check Pen S”, and “Task done 1 time with an approval stamp”.

Click “×” to delete the tool.

4. Click “Registration” button and work creation is completed.

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POKAYOKE plus

External device interface settings
To interface the work with external devices (e.g. I/O unit, Silwatch), settings need to be executed for eachwork before start of the work. The external device interface settings consist of conditions, events andactions.

・・・

Item

Description

Condition

The condition is a set of two events. An event selected by a user and theevent to remove the event are included. Conditions with exactly the same
events cannot be set for a work.

Event

Event means “Became a particular state”.
For example, "Work became PASS" and "Work became FAIL" represent one
event each. An event has one or more actions associated with it.

ActionActions are associated with an event, and indicate “What to do” when theevent is satisfied. For example, "Judge work" and "Call Silwatch" each
represent one action.

Example) When a work becomes FAIL, call a staff in charge using Silwatch, and inform people in all work
area by the rotating light. When the FAIL state is cleared, stop the rotating light.

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POKAYOKE plus

To perform external device interface settings, set External device interface settings to ON at the time ofwork registration. From the “Settings” button, open the Settings dialog to perform the settings.

Selecting ON enables the"Settings" button.

Click the "Set" button, the following external device interface setting dialog is displayed.
Click the “Add condition” button to add a new condition.

Click the “Add condition” button, and the “Add condition” button disappears and the display enters the edit
mode for the conditions as shown below. Set the event and the action you want to perform.

②

①

③

④

①

Description

Input example

Set the event. The event to be paired with the other event is automaticallyWork became

set.

“PASS”(default)

The events that can be set are as follows.
・Work became “PASS”
・Work became “FAIL”
・I/O port is turned ON *1
・I/O port is turned OFF *1②

Set the actions to be associated with the event. The actions that can be
40

Call Silwatch

POKAYOKE plus

set vary depending on the event type.
The actions that can be set are as follows.
・Do nothing *3・Call Silwatch
・Set I/O port to ON *1
・Set I/O port to OFF *1・Judge work *2
・Reset work *2③

A button that adds a new action below the position where the button exists-

or deletes an action that exists at the position of the button.
Click the "+" button to add a new action below the button position.
Click the "-" button to remove the action at the button position.
If it cannot be used, it will be automatically disabled.
④

This button saves or discards the edited condition. Click Save to save the-condition and exit edit mode. Click Cancel to cancel the edit mode inwhich all the edited contents are discarded.
If it cannot be used, it will be automatically disabled.
*1 Selectable only when one or more I / O units are registered.
*2 Selectable only when the event is "I/O port is turned on" or "I/O port is turned off".
*3 It can be selected only in the event paired with the selected event.
The selectable events and the occurrence timing of the events are as described below.
Event

Timing of the event occurring

Work became “PASS”

The work is completed properly and becomes PASS.

Work became “FAIL”
I/O port is turned ON
I/O port is turned OFF

The work becomes FAIL. After the work became PASS, it
becomes FAIL due to overcounting or other reasons.
A specific I/O port of a specific I/O unit changes from OFF
to ON.
A specific I/O port of a specific I/O unit changes from ON to
OFF.

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POKAYOKE plus

When setting an event, items for which additional settings are needed are as below.
Event

Additional setting items

Work became “PASS”

None

Work became “FAIL”

None

I/O port is turned ON
I/O port is turned OFF

The target I/O unit (mandatory and selective)
The I/O port of the target I/O unit (mandatory and selective)
The target I/O unit (mandatory and selective)
The I/O port of the target I/O unit (mandatory and selective)

The selectable event, the event to be paired with the selected event and the occurrence timing are as
below.
Event

Event to be paired

Timing of the event to be paired occurring

Work is reset from “PASS”

・PASS for the work is reset and the next work isready to be started.

Work became “PASS”

・ The work becomes FAIL immediately after
becoming PASS.
・The work is finished.

Work became “FAIL”
I/O port is turned ON
I/O port is turned OFF

Work is reset from “FAIL”

The work continue to FAIL. or FAIL is reset as
the work is finished.

I/O port is turned OFF

A specific I/O port of a specific I/O unit changes
from ON to OFF.

I/O port is turned ON

A specific I/O port of a specific I/O unit changes
from OFF to ON.

When setting actions, the items to be additionally set are as below.
ActionAdditional setting items
MID(Message ID, Required, Text input) *1

Call Silwatch

Message (Text input, Maximum of 20 characters (single or
double byte)) *2

Set I/O port to ON

Set I/O port to OFF

The target I/O unit (mandatory and selective)
The I/O port of the target I/O unit (mandatory and selective)
The target I/O unit (mandatory and selective)
The I/O port of the target I/O unit (mandatory and selective)

Judge work

None

Reset work

None

Do nothingNone*1) Enter the registered MID to two-way Silwatch wristwatch type transmitter/receiver to be called.
To check or change the settings of two-way Silwatch wristwatch type transmitter/receiver, use the two42

POKAYOKE plus

way Silwatch Settings application (Optional) or contact our Sales Department.
*2) The message can be displayed on two-way Silwatch wristwatch type transmitter/receiver at a time is
up to 20 single- byte characters or 10 double- byte characters. If this is exceeded, the message will be
displayed only in the visible part from the beginning.
Example) When the work FAILs, call a person in charge using Silwatch and notify the whole work areawith a rotating light at the same time. When FAIL is reset, stop the rotating light.
(Assume rotating light is connected to I/O port 9)

When editing the condition is completed, click the “Save” button, and the edited condition is confirmed andCondition edit mode is finished
①

②

③

④

Description①

The total number of actions set for the work.
If 10 or more actions are set in each work, new conditions or actions cannot be added.

②

This button discards all settings made after the external device interface settings screen is opened
and ends the settings. Click to display the following confirmation message, and click the "OK"button to discard the settings and close the dialog.
43

POKAYOKE plus③

Button to edit or delete the set conditions.
The "Edit" and "Delete" buttons of all conditions are hidden while in the condition edit mode.

Non-Editable

Only one condition
can be edited at thesame time.

EditableWhile

editing

conditions,

the
other

conditions cannot beedited or deleted.
④

This button saves all settings after opening the external device interface settings dialog andfinishes the settings. When the necessary settings are completed, click this button to close thedialog and save the work.

When the external device interface setting is completed, close the dialog and register the work.
At this time, make sure that the external device interface is turned on before registering.
If it is OFF, it will not work even if external device interface is set.
After registration of the work, start the work linked with the external devices to interface it with the external
devices according to the external device interface settings.
Please register after confirming that it is ON
after setting external device interface.

For specifications of the device controlled by external device interface, refer to “3-18. Specifications forexternal device interface”.

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POKAYOKE plus

Start work / Copy the registered information to make a registration

ButtonDescription
Start a work now. Enter the work execution count. (Task instructions are repeated
for the execution count.)

A work sequence and the safety protector group being monitored can be linked.
The tool work status and the safety protector wearing status are displayed on thesame screen. You can keep track of “Whether or not safety protectors are worncorrectly by workers executing tasks with tools”. Select a desired safety protector
group.(Safety protector group that are already associated with another work
sequence will not be displayed.) For details on registration of safety protector
group, refer to “ 3-12 ． Registration of safety protector group and Start ofmonitoring.”.

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POKAYOKE plus

Up to 16 works and work sequences in total can be started at the same time.
Once you click the Start button, you cannot click it until the work is completed.

When starting a work, the work is registered as a work sequence.
When starting a work, the work is registered as a work sequence.
When the tool contained in the work you want to start is used in the work or work
sequence in progress, you cannot start the work.
Example) When using the same tool in “Large unit AD ASSY” and “Mid unit AK
ASSY”.
When clicking the Start button of “Large unit AD ASSY”, the Start button of “Midunit AK ASSY” is automatically disabled.

The registered work information can be copied and then newly registered.

Narrowing down of the works (registered information)
Enter the filtering conditions (⑥) and click, and the works satisfying the conditions are selected

and displayed.
You can enter any string in work No., work name, tool name, transmitter ID. Works that match theentered string exactly or partially will be extracted. Select the tool sequence from the displayed selection
information. The works matching the conditions are extracted. When several conditions are entered, theworks that match all conditions are extracted.

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POKAYOKE plus

Deletion of the works (registered information)
If you check here, all the displayed
works will be checked.

Put a check in the box for the work you want to delete and click. The registered information will

be deleted.
The work in progress cannot be deleted. The work sequence containing the work you want to delete will
also be deleted.

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POKAYOKE plus

3-11．Work Sequence Registration and Start①②
Click “Registration” on the menu, and “Work sequence registration” (①) is displayed. Click “Worksequence registration” to display the work sequence registration screen.
Click “Work sequence registration” button (②), and the screen for newly creating a work sequence isdisplayed. Unlimited number of Work sequences can be registered.
③

⑤

④

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POKAYOKE plus

Narrowing down of the works (registered information)
Enter the work filtering conditions (③) and click, and the works satisfying the conditions are

selected and displayed.
You can enter any string in work No., work name. Works that match the entered string exactly or partiallywill be extracted. When several conditions are entered, the works that match all conditions are extracted.
Work sequence creation
1. Enter a work sequence name.
Item

Description

Input example

Work sequence nameEnter a desired work sequence name.

Display C(Maximum 20 characters)
2. Drag the work in “Selection of works” (④) on the left and drop it in the gray area of “Create work
sequence” (⑤) on the right. You can drag and drop up to 8 tools.
You can drag the works moved to the right side and move them up and down. Arrange the tools inorder of execute from top to bottom.
The work using TW-800R-SCL and the work using TW-8##R-EXL cannot be contained in the same
work sequence.
3. Set the number of work execution count. (The task instructions are repeated as much as theexecution count.)

Item

Description

Input example

Count

Enter the execution count.

100

Range of the values that can be entered: 1 99999
Example) When executing tasks in order from “100 units of large unit AD assembly” -> “10 units of
midrange unit AK assembly” -> “57 units of large unit RT assembly”.

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POKAYOKE plus

Click “×” to delete the work.

4. Click “Registration” button and work sequence creation is completed.
Start work sequence / Copy the registered information to make a registration⑥

ButtonDescription
Start a work sequence now. Up to 16 works and work sequences in total can bestarted at the same time.
A work sequence and the safety protector group being monitored can be linked.
The tool work status and the safety protector wearing status are displayed on thesame screen. Select a desired safety protector group.(Safety protector group thatare already associated with another work sequence will not be displayed.) For
details on registration of safety protector group, refer to “3-12．Registration of50

POKAYOKE plus

safety protector group and Start of monitoring.”.

Once the Start button is clicked, it cannot be clicked until the work sequence iscompleted.

When the tool contained in the work sequence you want to start is used in thework or work sequence in progress, you cannot start the work.
Example) When using the same tool in “DisplayASSYLine J” and“DisplayASSYLine G”.
When clicking the Start button of “DisplayASSYLine J”, the Start button of“DisplayASSYLine G” is automatically disabled.

When the work contained in the work sequence you want to start is used in thework sequence in progress, you cannot start the work.
When the work is started, execution instructions are sent to TW-800R-SCL or
POKAYOKE plus Viewer.
The registered work sequence information can be copied and then newly
registered.

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POKAYOKE plus

Narrowing down of the work sequences (registered information)
Enter the filtering conditions (⑥) and click, and the work sequences satisfying the conditions are

selected and displayed.
You can enter any string in work sequence name., work name, transmitter ID, tool name. Work
sequences that match the entered string exactly or partially will be extracted. When several conditions
are entered, the works that match all conditions are extracted.
Deletion of the work sequences (registered information)

If you check here, all the displayed work
sequences will be checked.

Put a check in the box for the work sequence you want to delete and click
The registered information will be deleted.
The work sequence in progress cannot be deleted.

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3-12．Registration of safety protector group and Start of monitoring
POKAYOKE plus can monitor up to 16 safety protector groups in parallel. Up to 16 safety protectors ineach safety protector group. Unlimited number of safety protector group can be registered.

①②

Click “Register” on the menu, and “Register Group” (①) is displayed. Click “Register Group” to display
the safety protector group registration screen.
Click “Register Group” button (②), and the information entry screen to enter a new safety protector groupis displayed. Unlimited number of Safety protector group can be registered.
③

④

⑤
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Narrowing down of the tools (registered information)
Enter the tool filtering conditions (③) and click, and the tools satisfying the conditions are selected

and displayed.
You can enter any string in transmitter ID, tool name. Tools that match the entered string exactly or partiallywill be extracted. Select the tool model, the paired receiver type and safety protector type from thedisplayed selection information. The tools matching the conditions are extracted. When several conditions
are entered, the tools that match all conditions are extracted.

Create safety protector group1.

Enter the working time. Click the "Input" button to display the working time setting screen. Working
time can be set for each safety protector group. The wearing status of the safety protectors ismonitored during working hours.

Item

Description

Input example

Working time nameEnter a desired working time name. (Maximum 16

ASSY line A_day shiftcharacters) Working time can be set for each safety
protector group.
Start time

Enter the work start time.

08：00

End time

Enter the work end time.

10：00*Working hours exceeding 24 hours cannot be set.

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POKAYOKE plus

Example) Settings for the following working hours
Start 8:00 ----- 10:00 ・・・ 10:10 ----- 12:00 ・・・ 12:40 ----- 15:00 ・・・ 15:10 ----- 17:00 End
Work

Break

Work

Break

Work

Break

Work

① Enter the working time name, start time (8:00) and the end time (10:00) after the break, and click plus“+”.

Click theto add the working hour segment.

② Enter the start time (10:10) and the end time (12:00) after the break, and click plus “+”.

Click Trash to delete the working hour segment.
Numbers can be directly entered into the textbox.
③ Add all working hour segments and click the “Settings” button, and the settings for working hours arecompleted.
*Please note that the entered information
will be discarded if you click the “×” in theupper right of the screen without pressing
the “Setting” button.
A maximum of 20 working hour segments canbe added.

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POKAYOKE plus

◆In addition to the above methods, there is also a method of setting working times by using the importfunction.
Click the “Import” button to copy the working
hours set in the registered safety protector groupand register the working hours.

1.

2.

Enter the safety protector group No. and safety protector group name.
Item

Description

Input example

Safety protector group

Enter a desired safety protector group No..

KA-01

No.

(Maximum 8 characters)

Safety protector group

Enter a desired safety protector group name.

names(Maximum 20 characters)

ASSY line A

Drag the tool in “Selection of tools” (④) on the left and drop it in the gray area of “Create safety
protector groups.” (⑤) on the right. You can drag and drop up to 16 tools.
You can drag the tools moved to the right side and move them up and down.

Click “×” to delete the tool.

3.

Click “Register” button and safety protector group creation is completed.

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Start monitoring / Copy the registered information to make a registration⑥

ButtonDescription

Monitoring

Click to switch monitoring ON / OFF. From the moment when switching from OFF to
ON during working hours, monitoring of the wearing status is started. When switchingfrom OFF to ON during non- working hours, monitoring of the wearing status is started
when the working hours start. The monitoring can be switched between ON/OFF
anytime during working hours.
Edits the information of the registered safety protector groups. Changes the working
hours, or adds/deletes tools. Edit is possible even during monitoring.
The registered safety protector group information can be copied and then newly
registered.

Narrowing down safety protector groups (registration information)
Enter the safety protector group filtering conditions (⑥) and click, and the safety protector groups

satisfying the conditions are selected and displayed.
You can enter any string in safety protector group No., safety protector group name, tool name, transmitter
ID. Safety protector groups that match the entered string exactly or partially will be extracted. Select thesafety protector type from the displayed selection information. The safety protector type matching theconditions are extracted. When several conditions are entered, the safety protector groups that match allconditions are extracted.

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Deletion of the safety protector groups(registered information)
If you check here, all the displayed safety
protector groups will be checked.

Put a check in the box for the safety protector group you want to delete and click.
The registered information will be deleted.
When Monitoring is set to ON, the groups cannot be deleted. Change the Monitoring setting to OFF todelete the groups.

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3-13．Work Execution Status Screen
The work and work sequence in progress are listed below. You can check the task execution status in realtime.
When linked with the safety protector group, the wearing

Click “Work execution status” on the menu.

status of the safety protectors is indicated by the icon
color. (Even if one person becomes NG, the icon color
turns to red.)Work name orWork sequence nameWork
(Large unit AD ASSY is repeated for 100 units)
The background color of the work varies depending on the task
execution status of the work.
Background

Description

color
White

Work in progress or to be executed.

GrayWork that has been finished.

Red

Work judged as FAIL.

Green

Displayed from when the work is judged as
PASS until the next work is started.

Work sequence
Up to 8 works can be set and they are executed from top to bottom. When all works arecompleted, they automatically disappear from the Work execution status screen.
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Up to 16 work sequences can be
●

●

●

●

●

executed in parallel.

Select POKAYOKE plus Viewer⚫

【For use of the receiver TW-8##R-EXL】
The display icon () is displayed below the work sequence name.
Click the icon and all of the connected POKAYOKE plus Viewer are displayed. Select your desired
POKAYOKE plus Viewer.
To use this function, POKAYOKE plus and POKAYOKE plus Viewer must be connected beforehand.
For details of POKAYOKE plus Viewer, refer to "POKAYOKE plus Viewer Instruction manual".

⚫

【For use of the receiver TW-800R-SCL】"TW-800R-SCL" is displayed.

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Delete work sequence
Clickon the top right of the Work execution status screen, and the following message isdisplayed.

Select the work sequence you want to delete and click “Delete” button.
Work sequence details screen

Click this area to display details of the work sequence (task contents of each work).

①
②
③
④
⑤

Item

Description①

Work nameName of the work.

②

POKAYOKE plus Viewer

When POKAYOKE plus Viewer is specified, POKAYOKE plus

or receiver name

Viewer name is displayed.
When the receiver is TW-800R-SCL, the receiver name registeredin receiver registration is displayed.

③

Tool nameName of the tool.

④

Transmitter ID

ID of the transmitter.

⑤

Specified countTask count of the tool.
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3-14．Work Execution Screen

Click the work in progress

Click the work in progress, and the Work execution screen is displayed.
When the task of the tool is completed,
the tool is displayed in blue frame.

(a)Tool during task

Tool nameCount value (Task count)
Specified countIndication of low battery-

Indicated when using the tool equipped with a transmitter with low battery detection and the battery is
lower than a set value. Replace the battery with a good one and use a tool to disable the indication.

(a) "Production number / set execution count" is displayed. The work order is repeated until the set number oftimes is reached.
*The production number is the number of works whose judgment result is PASS. If "Finish the work in execution."is selected when FAIL occurs, it will not be counted.

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When Tool sequence is ON, execute the tasks in increasing order from No. 1. When Tool sequence is OFF,No. is not displayed. Each time a task is executed, “Count value” counts up or down.
When the task is executed as much as the specified count, the task is judged as PASS and the frame of
the tool and the count value (task count) turn blue.
Task is completed (PASS)
When all tasks are completed and they are judged as PASS, the frame of each tool, the count value andthe outer frame of the whole work turn green.
Outer frame of the whole work
Frame of the tool
Count value

FAIL occurs
When FAIL occurs, the frame of the tool during task execution, the count value and the outer frame of
the whole work turn red.
【FAIL factors】●Over-count: Occurs when the task is executed more than the specified count.

When over-count occurs, the countvalue is displayed as “---“.
(When over-count is permitted, it is notjudged as FAIL.)●Tool sequence error: Occurs when the tasks of the tools are executed in the wrong sequence.
*It occurs only when the tool sequence is ON.

Example) When executing the task with
No.4 “Plier Wrench” without executing thetask with No.3 “Torque Driver”.
When the tasks are executed in thewrong sequence, the frames of the target
tools and the count values turn red.
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●Remaining count error: Occurs when a judgment input is provided when the task is not executed as muchas the specified count.
Example ） Judged and entered when thetask with No.6 “Marking Pen 2” is completed(remaining task is left)

The tools used for the tasks that are notcompleted will be displayed in red.

When FAIL occurs, the following message is displayed and the task is temporarily interrupted.
Enter a comment (optionally), select either “Continue” or “Exit” and click the Confirm button.
You can leave a comment, such as causes of
FAIL, in the “History (work)”. Enter comments
as necessary. (The number of letters is
unlimited)
Select whether to reset FAIL and continue thetask or finish the work in execution.
When Exit is selected, start the next work.
No matter which of continue and exit is chosen,
the occurrence of FAIL is logged as history.

FAIL can be reset also by the reset input from TW-800R-SCL, I/O unit or POKAYOKE plus Viewer locatedat the task site. Set whether to exit the work by the reset input from TW-800R-SCL, I/O unit or POKAYOKE
plus Viewer or continue the work according to “Processing method for reset input” in [Default
settings]/[Tools].

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Enlarge the tool in operation
When Tool sequence for the work is set to “ON”, clicking

will display only the tool in

operation in enlarged form. Use this function to display the count values larger at the task site.
* When Tool sequence for the work is set to “OFF”, this function cannot be used.
Click “Return” button to return to the original
screen.
Click “Hide menu” to display the count in the fullscreen.

For multiple tools are used for one work, when the task with each tool is completed, the outer frame andthe count value turn blue. After the reset timer has elapsed, the counter display changes to the count for
the next tool.

Task is completed (PASS)
When PASS judgment is made, the outer frame and the count value turn green.
When the next work is set
to be executed, after the
reset timer has elapsed, thecounter display changes tothe count for the next work.

If there is no more work to
be executed, after the reset
timer has elapsed, thescreen is switched to theWork execution status
screen.
FAIL occurs
When FAIL occurs, the outer frame and the count value turn red.
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Tool Replacement

Clickand the tool can be changed even in the middle of the work.

Enter the transmitter IDs (10 digits) before and after the tool change and click the Change button.
Use this function for the following.
・To replace the tool due to damage.

・

To replace the transmitter (TW-800T, TW-850T) attached to the tool due to the damage of thetransmitter.

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3-15．Safety protectors wearing status screen
The safety protector group being monitored are listed. You can keep track of the wearing status of thesafety protector in real time.
Click “Safety Protector Wearing Status” button on the menu. A maximum of 16 safety protector groups canbe monitored in parallel.

Working time name
Safety protector group name
The number of tools in the
OK/NG wearing state【Explanation of terms】
Wearing status is OK ・・・ Wearing safety protectors correctly.
Wearing status is NG ・・・ Wearing safety protectors not correctly.
During non-working hours, the number of tools in the OK/NG wearing state is reset to 0.
The wearing status can be checked for each safety protector group. Each frame shows one safety
protector group. The color of the icon changes depending on the wearing status.
Color

StatusBlack

Ready(off hours)

Green

Wearing status is OK

Red

Wearing status is NG

GrayAll tools in the safety protector group are temporarily
stopped. (*5)
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Click a safety protector group to check the detailed wearing status of the safety protector group.

Click safety protector group

Wearing status is NG
When the battery of the transmitter ENS-HH01 is getting low,
the icon indicating low battery level is displayed.

When the wearing status changes from OK to NG, it is indicated by a message and sound.
The alert is not cleared until the wearing status changes from NG to OK.

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POKAYOKE plus(*5) Click any tool to change the background color of the frame and the icon color to gray. This status iscalled a temporary stopping state.
Monitoring is not performed in a temporary stop state even during the working hours, and the wearing
history is not recorded. An alert is not generated even after change of the wearing status from OK to NG.
The temporary stop state is maintained even after restarting POKAYOKE plus. Click the tool again to reset
the temporary stop. Until then, the temporary stop state continues.

Click the tool again to reset the temporary stop.

Click the tool

The transmitter (ENS-HH01) mounted on the hard hat transmits the wearing status to the receiver at thetiming described below.
① A wireless signal is transmitted to indicate the wearing status each time the chin strap is fastened or
removed.
② The signal is transmitted every 5 minutes from when hard hat wearing was detected, and the wearing
status at that point is notified. When the chin strap is not securely fastened or not worn for 30 minutes,
the transmitter stops transmitting a signal at regular time intervals.
◆Cautions for display of the wearing status of the safety protectors⚫

When wearing safety protectors at the start of the working hours, an alert is generated. It may
take up to 5 minutes until the alert is cleared.

The reasons are as follows.
POKAYOKE plus ignores signals received during non-working times. Therefore, when workers are
wearing safety protectors at the start of working hours, the wearing status becomes NG and an alert
is generated. The transmitter transmits a signal every 5 minutes. When a signal is regularlytransmitted, POKAYOKE plus updates the display to the actual wearing status.
⚫

If workers enter an area where a wireless signal cannot reach the receiver while wearing safety
protectors, the display of POKAYOKE plus is not updated even after change of the actual wearing
status.

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3-16．History
Two types of historical data are available. “Tool History” displays the task history for each tool. “Work
Execution History” displays the task history for each work. The historical data of each type can be savedin the csv format.
●Tool History

Click “History”/“Tools”/“Tool History” button on the menu.

●Work Execution History

Click “History”/“Tools”/“Work Execution History” button on the menu.

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Search history●Common to tool history and work execution history
Enter a desired information in "History search conditions" and click
Click

.

while leaving the History search conditions field blank, and all of the stored data is displayed.

Search conditions are as below:
Item

Description

Input example

Working dateEnter the date the work was executed.

2018/8/1 ～ 2018/9/1

Search the historical data whose Start Date and Timeof Task is within the range of the specified Date of Task.
The search range should be from 00:00:00 on the
search start date to 23:59:59 on the search end date.
Work nameEnter a work name.

Large unit AD ASSY

Tool nameEnter a tool name.

Torque Wrench

Work No.

Enter a work No.

LU0101_AD

Transmitter ID

Enter the transmitter ID (10 digits).

000100002F

Judgement

Select judge result (PASS or FAIL).

FAIL

resultView history●The items of Tool History are listed below:
Item
Description
Transmitter ID
ID (10 digits) of the transmitter.
Tool nameName of the tool.
Judgement result
Judgment result (PASS or FAIL).
Cause of FAIL
FAIL factors (Over-count, tool sequence error andcount remaining error).
Start Date andDate and time when the task with the target tool
Time of Task
was started.
End Date and Time Date and time when the task with the target toolof Task
was completed.
Work No.
Number of the work.
Work nameName of the work.
Working sequence
Sequence of the target tools used in a work.
of tool
Spec. value
Specified count of the task.

71

Display example
000100002F
Torque Wrench
FAIL
Over-count2018/9/1 08:30:00
2018/9/1 17:30:00
LU0101_AD
Large unit AD ASSY
2
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●The items of Work Execution History are listed below:
Item
Description
Work No.
Number of the work.
Work nameName of the work.
Judgement result
Judgment result (PASS or FAIL).
Cause of FAIL
FAIL factors (Over-count, tool sequence error andcount remaining error).
Comment
A comment entered when FAIL occurred.
Execution
sequence of work

Start Date andTime of Task
End Date and Timeof Task

Set the number of work repetitions when the work
is started or a work sequence is created. Displays
the number of times out of the specified repetition
count that the task was executed.
Date and time when the task was started.
Date and time when the task was completed.

Display example
LU0101_AD
Large unit AD ASSY
FAIL
Over-countContinue work because
there is no problem.
3

2018/9/1 08:30:00
2018/9/1 17:30:00

Historical data size
For example, when manufacturing 100 units using 4 tools, 400 tool historical data items and 100 work
historical data items will be stored. In this case, the total data size of work history and tool history isapprox. 150KB.
Maximum number of data items to be stored in history
Approx. 11,000,000 data items of tool history and work history can be stored in total.

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Save history in the CSV format.
Click “Save search results in CSV format” button and the displayed history can be saved to any
destination in the CSV format. It cannot be saved in the CSV format during work execution. Executesaving after all works are completed.
(Work execution refers to the situation where one or more work sequences are displayed on the Work
execution status screen.)
A maximum number of output per file is 1 million. To save more than 1 million historical data, divide thedata into data sets of 1million and generate file output.
In this case, insert “_(n)” after the last digit (immediately before the extension) of the file name.
Example： tool_20180524_154122_1.csv, tool_20180524_154122_2.csv
The header indicating the item name of each information is not written to the file.
●History (tool)
File name: tool_yyyyMMdd_HHmmss.csv

Example: tool_20180901_083000.csv(Year: yyyy, Month: MM, Date: dd, Hour(s): HH,

Minute(s): mm,Second(s): ss)

The items are displayed in order from left to right: “Transmitter ID”, “Tool name”, “Judgment result”,“Cause of FAIL”, “Start Date and Time of Task”, “End Date and Time of Task”, “Work No.”, “Workname”, “Working sequence of tool” and “Specified count”.
●History (work)
File name: work_yyyyMMdd_HHmmss.csv

Example: work_20180901_083000.csv(Year: yyyy, Month: MM, Date: dd, Hour(s): HH,

Minute(s): mm,Second(s): ss)

The items are displayed in order from left to right: “Work No.”, “Work name”, “Judgment result”, “Causeof FAIL”, “Comment”, “Execution sequence of work”, “Start Date and Time of Task”, “End Date andTime of Task”.

◆How to open history(CSV file)
When opening history (CSV file) in Excel, in order to avoid garbling, it is recommended to open the file
following the steps below.
1.

Start excel.

2.

Select “Data” tab → “Get External Data”.

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POKAYOKE plus

3.

Select “From Text”.

4.

Select the target CSV file and import it.

5.

Select “Delimited

6.

Put a check in “Comma” in delimiters, and click “Next”.

-Characters such as commas or tabs separate each field.” and click “Next”.

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POKAYOKE plus

7.

Select a row containing the transmitter ID (10 digit character string) from data preview, and then select“Text” for column data format and click “Finish”.

8.

Select the destination to put the data to and click “OK”.

Delete history
Click “Deleted all history” button and a confirmation
message is displayed.
To delete all history, click “Confirm” button.

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POKAYOKE plus

All historical data of tools and works recorded in POKAYOKE plus as well as the history displayed on thescreen will be deleted. Click the button on the “History (tool)” screen or the button on the “History (work)”
screen, and all historical data of tools and works are deleted collectively.
Deleted history cannot be restored. Before deleting history, save data in the CSV format as necessary.
History cannot be deleted during work execution. Execute deletion after all works are completed.
Work execution refers to the situation where one or more work sequences are displayed on the Work
execution status screen.
Maximum capacity of historical data
・

When the historical data size approaches the maximum, the following message is displayed. In thissituation, works or work sequences can be started. However, please note once the maximum
capacity of historical data is reached, works or work sequences cannot be started.
“Historical data capacity is close to the maximum.
When the historical data capacity reaches the maximum, execution of works or work sequence
cannot be started.
Delete history and clear the historical data area.”・

When the maximum capacity of historical data is reached, works or work sequences cannot be
started. When the following message is displayed upon clicking the Start button for the work or work
sequence, delete historical data before starting the work or work sequence.
“The amount of history data has reached the maximum.
Cannot execute Work or work sequence, as no more history data cannot be written.
To start a work or work sequence, delete the history.”

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3-17 ． Transmission of error information to smartphones or other devices in realtime(MQTT output)
When an error occurs while working with tools or wearing safety protectors, the error information istransmitted via IoT standard protocol MQTT in a real time. By linking POKAYOKE Plus with the IoT
environment that supports MQTT, error information can be sent to the mobile terminal of the administrator,etc. by email or SMS at occurrence of an error.
POKAYOKE plus becomes MQTT publisher and sends messages to brokers.
*To use this function, enter the information required for communication in the default settings.
For details, refer to “3-6．Default Settings”.
MQTT specification

Value

Version

3.11

Keep Alive

45 secConnection Timeout

30 secWhen encrypting communication (TLS1.2), save the certificate file in the following folder. When using acurrent mainstream public cloud service, due to the requirements of encryption in many cases, receive a
certificate from the cloud service or obtain an access token.
Item

Setting value

CA certificate

ca.pemClient certificate

client.pem

Key of client certificate

client_key.pem

Save destination folder

C:/HERUTU/POKAYOKE plus/safety_cert

When "MQTT output" of the default setting ("Common") is set to ON, when you start POKAYOKE plus, theconnection to the broker is automatically started. You can check the connection status in "Connection
status" of MQTT communication settings in [Default Settings] / [Common]. The client ID used in MQTT isthe "Client ID" set in the default settings ("Common").

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MQTT output specification◆ToolsTransmission

When FAIL occurs during work execution, or when FAIL is released.

timing
Topic“Tools” (Set in default settings)

Payload

FAIL information (JSON format){“topic”:“Tools”,“work_sequence_name”:{Work sequence name},“work_name”:{Work name},“failure_factor”:{Cause of FAIL},“status”:{FAIL occurred(“1”) / Reset FAIL (“0”)},“datetime”:{Date and time of occurrence(UTC)(yyyy-MM-dd HH:mm:ss)},“utc_offset”:{Difference between local time and UTC time}}◆Safety protectors
Transmission

The wearing status changes to NG or the wearing status changes to OK.

timing
Topic“SafetyProtectors” (Set in default settings)

PayloadAlert information (JSON format){“topic”:“SafetyProtectors”,“transmitter_id”:{Transmitter ID},
“tool_name”:{Tool name},“tool_model”:{Tool model},“tool_category”:{Safety protector types},“status”:{Wearing status is OK(“1”) / Wearing status is NG(“0”)},“datetime”:{Date and time of occurrence(UTC) (yyyy-MM-dd HH:mm:ss)},“utc_offset”:{Difference between local time and UTC time}“safety_group_name”:{Safety protector group name}}78

POKAYOKE plus

3-18．Specifications for external device interface
The following explains about specifications for control of each device according to the external device
interface settings for the works.
I/O Unit-

The timing of the event occurring, which is triggered by the I/O port status
The I/O port and POKAYOKE plus are connected via TCP and controlled by a software. Actions in
the unit of milliseconds (ms) or faster are not guaranteed. In our ideal environment *1, it is confirmedthat an event occurs within 500ms after the port changed the status. However, the same level of
performance is not guaranteed in all environments.

-

The default status of the I/O port and status of the I/O port after work
All contacts of the I/O port are Form A, and the default state of the contacts is OFF (0).
When the work is finished, the status of the output I/O port controlled by the external device interface
settings of the work is not maintained.

-

Control of the same I/O unit and output I/O port used for different works
For several works, when setting the output I/O port of the same I/O unit to ON (1) or OFF (0),the final output result is OR (logical sum) of the default state of OFF (0) and all actions.
For example, when Work A and Work B become FAIL, set the I/O port10 of the I/O unit A to ON.
When FAIL for the work is reset, set the I/O port10 of the I/O unit A to OFF.
・If either Work A or Work B is in the FAIL state, the status of the I/O port10 of the I/O unit A is ON (1).
・Otherwise it will be OFF (0).

-When connection with the I/O unit is cut off during control of the output I/O port
When connection between the I/O unit and PC is cut off, the status at the time of being disconnected
is maintained until they are reconnected. When reconnected, all output I/O ports will be OFF due todevice initialization. After the initialization is completed, the control by the external device interface
setting is restarted.

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POKAYOKE plus

Silwatch-

Timing of call
Call Silwatch are stored in memory in order of occurrence (Up to 100 sets of data is stored. When thememory becomes full, new arriving data is discarded.) and transmitted in sequence at thetransmission intervals selected in the default settings. Thus, when the action of Call Silwatch is
executed, it may take some time to be actually called.
When several actions of Call Silwatch are executed at the same time, the one call action takes longer
than the transmission intervals selected in the default settings until the call is actually executed. Thisis a function to prevent communication interference and facilitate communication.

-

Specification of call Silwatch
Call Silwatch from POKAYOKE plus are always transmitted to all Two-way Silwatch Wristwatch typetransmitter/receiver.
To narrow down the calls to Two-way Silwatch Wristwatch type transmitter/receiver only, settings must
be made for Two-way Silwatch Wristwatch type transmitter/receiver.
To check or change the settings of Two-way Silwatch Wristwatch type transmitter/receiver, use thetwo-way Silwatch Settings application (Optional) or contact our Sales Department.

-

Guarantee of the call arrival to Two-way Silwatch Wristwatch type transmitter/receiver
Even if Call Silwatch is executed, whether the call reaches Two-way Silwatch Wristwatch typetransmitter/receiver or not is depending on the environment and the arrival of the call is not always
guaranteed.

*1) The environment satisfies the system requirements and is capable of dominating the bandwidth, andwhere other applications do not start up.

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POKAYOKE plus

3-19．Error Code
When an error occurs while communicating with TW-800R-SCL, an error code is notified by TW-800RSCL.
When an error code is received, please contact our sales department.

3-20．Product Information
The application information, including the version information, can be checked.

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POKAYOKE plus

3-21．Exit POKAYOKE plus

Click “X” on the top right of the screen, and a message “Do you want to exit?” is displayed. Click “OK”
and the application exits.
When executing a work or work sequence, a message “Work in execution exists. Do you want tosave the interrupted data?” is displayed.
⚫

When “Yes” is clicked
The work or work sequence in progress is interrupted and the current state is saved. At next startup,
the task can be started from the interrupted state.

⚫

When “No” is clicked
The work or work sequence in operation is all abandoned.

(This message uses Windows functions, the language of the “OK”, ”Yes”, “No” and “Cancel” buttons
depends on the language set in the OS. )82

POKAYOKE plus

4．Actions When Receiver TW-800R-SCL Is Used
Before registration of the receiver to POKAYOKE plus
When the receiver is registered to POKAYOKE plus, the communication
between the receiver and POKAYOKE plus is started.
The network monitor of TW-800R-SCL blinks until the communication
is established. (7 segment LED is OFF.)

Network monitor

After registration of the receiver to POKAYOKE plus
When the receiver is registered to POKAYOKE plus, the standby stateis displayed. The network monitor LED changes from blinking to lit.
This status continues until execution instructions from POKAYOKE plus
are received.
Start work or work sequence with POKAYOKE plus
Select either one of following work judgement timing in the Default settings of POKAYOKE plus.
When the work is judged as PASS, after the reset time is reached, the next work will be automaticallystarted.
(a) When all tools complete the number of tasks specified by the count, the system judges the work.
(b) Judge the work when the judgment signal is input to TW-800R-SCL.
Example: For the work to execute a task 2 times with the Check Pen
Work flow for (a)♪(Pi pi pi)♪(ping)♪(ping)Receiving asignal fromthe transmitter

Receiving asignal fromthe transmitter

The JUDGE LED iswhite during a task.

The JUDGE LED turns
green and the PASS output
is generated.

Work flow for (b)♪(Pi pi pi)♪(ping)Receiving asignal fromthe transmitter
The JUDGE LED iswhite during a task.

♪(ping)Receiving asignal fromthe transmitter
The JUDGE LED turns blue
and the receiver is waiting toreceive the Judgement input.

83

Judgement
input froman external
deviceThe JUDGE LED turns
green and the PASS output
is generated.

POKAYOKE plus

Use multiple receivers for one work
Since you can register up to 8 receivers for one work, the system can prevent mistakes (pokayoke) fortasks that use up to 8 tools.
Work
Receiver 1

Receiver 2

HUB

Up to
8
Receivers

Receiver 8

Standby state display

When Tool sequence is set to ON, the receiver is in the standby state until the task is ready to be
executed. When Tool sequence is set to OFF, the count is displayed on all receivers immediately after awork or work sequence is started.
Example: For the work to be executed in order tasks done 2 times with a torque wrench and 1 time with
the Check Pen

Tool sequence settings: ON

Work

Work

Work

Receiver 1

Receiver 1

Receiver 1♪(Pi pi pi)

Task done 2 times
with a torque wrench

Receiver 2

Task done 1 timewith the Check Pen

The JUDGE LED turns
blue. This status ismaintained until thework is completed.
Task done 2times with atorque wrench

Receiver 2

Task done 1
time with the
Check Pen♪(Pi pi pi)

The JUDGE LED turns
white and the task countis displayed.

The JUDGE LED turns
green and the PASS
output is generated.

84

Receiver 2

POKAYOKE plus

External output (PASS/FAIL)
When multiple receivers are used for one work, PASS or FAIL outputs are generated by all receivers.
External input (Judge/Reset)
When multiple receivers are used for one work, and even when any receiver receivers an external input,
the input signal will be adopted.
FAIL factors
FAIL factors consist of over-count error, remaining count error and tool sequence error. The actions of
TW-800R-SCL for these errors are as follows.
⚫

Over-count error

When creating a work with POKAYOKE plus and selecting “Over-count is not permitted”, executing tasks
more than the specified count will be judged as Over-count.
♪(Pi pi pi)♪(ping)♪(ping)Receiving asignal fromthe transmitter

Receiving asignal fromthe transmitter

The JUDGE LED iswhite during a task.

⚫

♪(ピピピ)♪(Pi-Pi-Pi-…)♪(ping)Receiving asignal fromthe transmitter

The JUDGE LED turns
green and the PASS output
is generated.

The JUDGE LED turns red
and the FAIL output isgenerated.

Remaining count error

When a judgment input is received during counting, a remaining count error occurs and the FAIL output isgenerated.
♪(Pi-Pi-Pi-…)♪(ping)Receiving asignal fromthe transmitter
The JUDGE LED iswhite during a task.

Judgement input
from an external
deviceThe JUDGE LED turns red andthe FAIL output is generated.

85

POKAYOKE plus⚫

Tool sequence error

When Tool sequence is set to ON, executing tasks in the wrong order will cause a tool sequence error.
Example) For the work to be executed in order tasks done 2 times with a torque wrench and 1 time with
the Check Pen, when the task with the Check Pen is executed first.
Work

Work
Receiver 1

Receiver 2

Task done 2 times
with a torque wrench

Task done 1 timewith the Check Pen

Receiver 1

Receive 2♪(Pi-Pi-Pi-…)♪(Pi-Pi-Pi-…)

Task done with
the Check Pen

The JUDGE LED turns red andthe FAIL output is generated.

FAIL reset method
Reset FAIL from POKAYOKE plus or the receiver. This section explains how to reset FAIL from the receiver.
Select either one of the processing methods for the reset input from TW-800R-SCL in the Default settingsof POKAYOKE plus.
(a) Continue: Reset FAIL and continue the task.
(b) Exit: Finish the work in execution.
(a) Continue task♪(Pi-Pi-Pi-…)

FAIL is occurring. (TheJUDGE LED lights up in red)Reset with the reset
button or by an
external input
The JUDGE LED turns white
and the task can be continued.

(b) Exit task♪(Pi-Pi-Pi-…)

FAIL is occurring. (TheJUDGE LED lights up in red)Reset with the reset
button or by an
external input

86

The work in progress is
terminated and is automaticallyswitched to the next work.

POKAYOKE plus

StatusJUDGE LED

BuzzerPASS output

FAIL output

Before the
task

OFF

-

-

-

Task inprogressWhite

Each time a signal isreceived, the sound“ping” is generated.

-

-

PASS

Blue

Pi pi pi

Time until the reset
timer expires

-

FAIL

Red

Pi-Pi-Pi-…
Synchronize with
JUDGE LED-

Until FAIL is reset

87

POKAYOKE plus

5．POKAYOKE plus Viewer
By linking to the receiver without counter feature TW-8##R-EXL, the count can be displayed at up to 16
stations by locating a Windows computer with “POKAYOKE plus Viewer” at your task site.
POKAYOKE plus Viewer runs based on work execution instructions from POKAYOKE plus. POKAYOKE
plus Viewer cannot accomplish the counter feature on its own. Be sure to use POKAYOKE plus Viewer
along with POKAYOKE plus.
In order to use POKAYOKE plus Viewer, you must register a license of POKAYOKE plus Viewer.
The instruction manual describes only license registration for POKAYOKE plus. For details of
POKAYOKE plus Viewer, refer to "POKAYOKE plus Viewer Instruction manual".
License registration
POKAYOKE plus manages the license information of POKAYOKE plus Viewer. Registering the license of
POKAYOKE plus Viewer to POKAYOKE plus will enable interactive communications.
To use POKAYOKE plus Viewer, you need to purchase one license for each POKAYOKE plus Viewer.
When you purchase licenses, a document containing a license key*2 will be issued. Enter the license key
described on the document into POKAYOKE plus.
Up to 16 licenses can be registered to one POKAYOKE plus.
When you use POKAYOKE plus Viewer for the first time or when you need to add licenses, be sure to
perform license registration.
*2: The document containing a license key is enclosed in the CD-ROM bag. A license key is a character
string in the format of “XXXXX-XXXXX-XXXXX-XXXXX-XXXXX”.
Click “License” (①) on the menu.

①③②

Enter the issued license key in “Current license key” (②) and click “Register” button.
Make sure that the number of the purchased licenses is added to the number of POKAYOKE plus Viewer
licenses (③).
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POKAYOKE plus

6．Troubleshooting
Error messages or symptoms

Cause and remedy

Cannot know the IP address ofClick the Windows Start button, type "cmd", and press the Enter key.

the PC on which POKAYOKE

At the command prompt screen that opens, type "ipconfig" and press

plus is running.

the Enter key. The value displayed in [IPv4 Address] is the IP addressof the PC.

Work can not be started.

The possible cause is as below:
・The receiver or I/O unit may not be turned on. Turn ON the powerof the receiver.
・The tool and the receiver are not paired. For the pairing method,
please refer to the instruction manual for the receiver.
・The receiver or the I/O unit may have been connected with another
POKAYOKE plus. Terminate POKAYOKE plus running on a different
computer or delete the target receiver from different POKAYOKE
plus.

Although workers are wearing

The possible cause is as below:

safety protectors, the alert is not

・The receiver may not be capable of receiving the signal from thecleared.

transmitter mounted on the safety protector. When the alert is notcleared after changing the wearing status, check the contents of thenotification message “The receiver cannot receive a signal from thetransmitter”.
・The output data type of the receiver may not be set to "long data".
To manage the wearing status of the safety protectors, you need to
set the output data type to “Long data”. For details on how to change
the settings, see the instruction manual for the receiver.
・When wearing safety protectors at the start of the working hours,
an alert is generated. It may take up to 5 minutes until the alert iscleared.
For details, refer to the display of the wearing status of the safety
protectors in “3-15．Safety protectors wearing status screen”.

Cannot connect to POKAYOKE

The POKAYOKE plus and POKAYOKE plus Viewer versions may

plus Viewer.

be different. Please use the same version POKAYOKE plus Viewer
as POKAYOKE plus. The application version can be displayed byclicking "Product Info" in the menu.

89

POKAYOKE plus

Is one of the following messages displayed in the notification of POKAYOKE plus?
MessageCause and remedy

Register receiver(s) to start a

The message is displayed when no receiver is registered.

work.

From menu, select [Register]/ [Register Receiver] and register thereceiver.
Click the message to display the receiver registration screen. The
message is cleared by clicking it.

Register tool(s) to start a work.

The message is displayed when no tool is registered.
From menu, select [Register]/ [Register POKAYOKE Tools] andregister the tool.
Click the message to display the tool registration screen. The
message is cleared by clicking it.

Register work(s) to start a work.

The message is displayed when no work is registered.
From menu, select [Register]/ [Tools]/[Register Work] and register
the work.
Click the message to display the work registration screen. The
message is cleared by clicking it.

Connection failed.

The message is notified when connection with the receiver or I/O

Failed to connect to TW-8##R-

unit failed or when the connection with the receiver or I/O unit is cut

EXL (IP address

off. The possible cause is as below:xxx.xxx.xxx.xxx / Port No.

・The receiver or I/O unit is NOT turned ON.

xxxxx)

・The LAN cable is disconnected.

(The above is an example

・The receiver’s IP address/Port No. is not correctly set.

when TW-8##R-EXL is used.)*Set the IP address so that it does not overlap in the network.
Click the message to display the receiver registration screen andclear the message.

Connection failed.

The message is displayed when the receiver is already connected

TW-8##R-EXL (IP address

to different POKAYOKE plus.

xxx.xxx.xxx.xxx /Port No.

You cannot connect POKAYOKE plus to the receiver being

xxxxx) is connected to otherconnected to different POKAYOKE plus. Perform the following

POKAYOKE plus.

operation, and you can cut off the communication of the receiver(The above is an example whenwith different POKAYOKE plus and connect the receiver and theTW-8##R-EXL is used.)target POKAYOKE plus.
1.Delete the target receiver from Receiver registration of different
POKAYOKE plus.
2.Turn OFF the power of the receiver and turn it ON.

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POKAYOKE plus

Click the message to display the receiver registration screen andclear the message.
Connection failed.

The message is displayed when TW-800R-SCL is set to stand-TW-800R-SCL (IP address

alone mode.

xxx.xxx.xxx.xxx /Port No.

When linking TW-800R-SCL to POKAYOKE plus, change the10001) is set to "stand-alone

operating mode of TW-800R-SCL to application interlock mode.

mode". Set TW-800R-SCL to

For the setting method of the run mode, refer to “TW-800R-SCL"application interlock mode"

Instruction manual”.

when using it in this application.

Click the message to display the receiver registration screen andclear the message.

Cannot receive a signal from the

The message is notified when the receiver does not receive a signaltransmitter.

from the safety protector for 12 minutes or more. Please check theTransmitter ID：0108xxxxxx

following contents.

Tool name：xxxxxxxxxxxxxxxx

・ Transmitter battery may be dead. Check the remaining battery

Safety protector type：Hard hats

capacity.
・Communication distance may be too long. Install the transmitter andreceiver in a location where they can communicate with each other.
・ Transmitter and receiver may not be paired. Check if they are
paired.
・Transmitter may have failed. Press the switch on the transmitterand check the LED lighting pattern. For lighting patterns, refer to“En-Guard ENS-HH01 Instruction manual”.
Click the message to clear the message.

91

HERUTU ELECTRONICS CORPORATION
422-1 Higashimikata-cho, Kita-ku, Hamamatsu, Shizuoka, 433-8104 Japan(Sales dept) TEL.+81-053-438-3555

Website URL https://www.herutu.co.jp/en/

FAX. +81-53-438-3411

E-mail info@herutu.co.jp