Scratch 4 Operating Softwarex - Surface Machine Systems, LLC
Contents
1. 19 Normal Load Tangential Load X Postion Depth mport Scales Save Imported Scales Surface Machine Systems sus Import Scales J w i Smith Noah r Desktop Bl Organize 7 Faworite Links Name Date waned SE E Documents Af Recently Changed GE Recent Places More Folders i gnome gnome _private gnucash SunDownloadManager O Bluetooth Software F Finermmente File name configData ini 13 Click Open 3 4 2 Saving Calibration Scales To Save Calibration Scales 1 Click Tools Calibration Save Imported Scales 20 Surface Machine Systems sus Scratch 4 0 Operating Software Normal Load Data Visualization Tangential Load Automatic Scratch Visualization X Postion Find Scratch Machine Depth Reboot Motor Controllers MHE Reset Scratch Machine Import Scales Clear Emergency Halt Save Imported Scales End Load N 30 Length mm 100 MHC 250 100 Calibration Scales will be saved and automatically loaded in the future 3 4 3 Creating New Calibration Scales The general process for creating new calibration scales is as follows 1 Select the Scale you would like to create Normal Load Tangential Load X Position Depth Apply a known load or position to the sensor Take a measurement using the built in measurement reading tool Record the known load or position uk w N Use the automatic calibration processing tool Calibrat2. Enter 0 into the Value in text box and click Add Reading uU1 A w N Using a feeler gage delimited in inches for instance a 0 030 feeler gage set the head to the top of the gage referenced to the work surface 6 Enter 250 into the Samples text box and click Sample Enter 0 030 in the Value in text box and click Add Reading 8 Using a feeler gage delimited in inches which is different than that used in step 5 for instance a 0 005 feeler gage set the head to the top of the gage referenced to the work surface 9 Enter 250 into the Samples text box and click Sample 10 Enter 0 005 in the Value in text box and click Add Reading 11 Click the Create Scale button 12 Save the Calibration as in the section Saving a New Calibration Scale 3 4 4 Saving a New Calibration Scale 1 Inthe Calibrator Window click Calibration Commit o Jose 3 4 5 Clearing a Calibration Scale 1 Inthe Calibrator Window click Calibration Clear All 2 To permanently remove this calibration follow the steps in Saving a New Calibration Scale 24 Surface Machine Systems 3 5 Jogging the Scratch Head The head jogging functionality allows you to position the Scratch Head over the test piece for performing a test or to move the head to a more convenient location Additionally jogging the Scratch head can be used as a basic diagnostic tool for
3. b Remote Systems What do you want to do Manage my devices and interfaces Manage my installed National Instruments software Manage virtual channels or tasks for my devices Create scales for my virtual instruments Configure my lvl instrument drivers Import export my device configuration file ay Note Some categories are device specific For example the lvl category appears only if you have lvl installed For more information about using MAX select available help categories from the Help menu If you need further assistance or want to know more about your device visit the National Instruments Technical Support Web site 3 Click File Export 14 Surface Machine Systems x Configuration Export Wizard Welcome to the Configuration Export Wizard This wizard exports configuration data for Eks NI DAGms 9 0 Export from syetern x Mu Sustem File type E KMI C G rmx UTF 2 INI File ini lt Back_ oNas gt 29 4 Inthe To file text box enter the location on disk you would like to save the export file or use the button to select 5 Click Next gt 15 Surface Machine Systems h 4 NATIONAL P INSTRUMENTS di kz My System op m NI DAQ mx Tasks a lij NI DAQmx Global Virtual Channels The selected item requires the following d zg Devices and Interfaces 4 4 Scales p agg NI DAQmx Scales The following require s the selected item theca
4. EEEE EEE secu eaeccewsesces crease eeat ceed 28 3 10 Saving and Loading Scratch Test ParaMeters ccecccceccccececccccccececcesececsecececseces 28 3 11 Acces mE DRENOSC westie edo Pac OP Aoc od ORA WE 28 3 11 1 COMPONEN cee eee A EE GOO ai AG o GC 29 Surface Machine Systems 1 Introduction The Scratch 4 Operating Software 2 0 is the newest implementation of the operating software for your Scratch 4 Machine This version is a ground up rewrite designed to address the major outstanding issues of the 1 x series Scratch Operating Software as well as to reduce the complexity of using and maintaining the Scratch 4 Machine 1 1 Features Rising Load and Constant Load Tests you can still perform rising falling and constant load tests Jogging and Positioning the software allows you to jog or position the head above your samples The Scratch 4 Machine sample stage is 24 300 mm wide enough to allow for multiple samples to be arranged and tested without intervention Positioning has been made relative instead of conforming to the previous positive negative standard for jogging Projects the concept of a Project has been introduced which allows you to save your Scratch settings for use and re use at a later date Friendlier Data Acquisition saving your Scratch data is now easier and friendlier using recognizable data save behavior you are accustomed to in Windows Integrated Scratch Data Viewer th
5. as follows opens Surface Machine Systems Tangential Load NormalLoad E X Position C Depth Distance mm Comparator 5 If you receive an error Uninstall the software and follow the steps outlined above 6 Follow steps 1 through 3 of this section 7 Click Machine Finder A window as follows opens Details 8 Select the first COM Port in the drop down list 9 Select the Select Port button 10 The Details section should show the phrase Machine is responding on this port Make a note of which COM Pott you selected Surface Machine Systems gas Choose COM Port Select COM Port COM w Details Machine is responding on this port 11 If the phrase Machine is not responding on this port is shown try selecting other Ports from the list If no Ports find a machine check the following sus Choose COM Port a l me Select COM Port COM3 Details Machine is not responding on this port a The machine serial cable and data cable are firmly connected to this computer b The machine power cable is firmly connected and the machine is powered on green light c If the machine does not power on or does not respond refer to your Scratch 4 Machine User Guide for troubleshooting information Surface Machine Systems S M S d 3 Using the Scratch Operator Software 3 1 The Main Interface When you open the Scratch Operator you will be presen
6. into calibration profiles automatically A special screen is available just for Depth calibration Scratch Machine Finder now when the machine is power cycled you do not have to restart the Operating Software New operating logic allows the Operating Software to recover when the machine is halted and to discover the machine when attached Additionally the software includes options to clear emergency halts and to perform first boot operations to reset the Scratch 4 Machine without restarting the Scratch Operating Software Smaller Easier Installation the new Scratch 4 Operating Software is less than 1 MB in size and includes a basic Windows Installer This compares to the previous installations which were greater than 1 GB in size each almost 2000 times as big Extra Tools the Scratch 4 Operating Software includes two new tools with the installation a stand alone Scratch Data Viewer and a stand alone Machine Discovery Tool The first tool can be used to inspect and graph Scratch Data without resorting to third party tools or having to keep the Scratch Operating Software running The second tool allows you to determine if you Scratch Machine is appropriate connected and powered on without having to start the Scratch Operating Software Surface Machine Systems S M S we 2 Installing the Scratch Operating Software These instructions show you how to install the Scratch Operating Software and other Tools 1 Downloa
7. using the Calibration Scales for each sensor System Information Indicates some status about the real time internal system state gt Reset will reset the capture set gt Dump Data will dump the current set of records to disk as indicated by the Analog Record count gt Capture Data will begin to capture data for display in the Scratch Data Viewer The number to the left indicates the number of records captured Using this function will overwrite the previous in memory Scratch data Do not use this function if you have not saved the last set of Scratch data from a Scratch test Operations This section is used to exercise portions of the Scratch 4 Machine which are not typically available during normal operation Using these options without the direction of a technician can severely damage the Scratch 4 Machine Solenoid Open opens the solenoid valve on the air spring cylinder immediately releasing pressure Fan Power turns the fan on and off Apply Load will attempt to apply the target load Low High will move the load generator by load units approximately 150 in a full cylinder stroke E STOP sets the Emergency Halt State Reset Machine sends reboot and reset signals to the Scratch 4 Machine vY vV vV YV Y Y Y Unlock unlocks the interface even if the Scratch 4 Machine is not available Chart Data This area shows a real time chart display of the current sensor sta
8. Ciacci 6 Open the Scales item and check the four Scales shown Z Load scale X position scale Z position Scale and X load scale 16 Surface Machine Systems 9 Configuration Export Wizard SS 5 h 4 NATIONAL p gt INSTRUMENTS a E Data Neighborhood bG NI DAQmnx Tasks gt EH NI DAQm x Global Virtual Channels The selected tem requires the following a gl Devices and Interfaces vol ag X position scale Z position Scale The following require s the selected item Flan X load scale 7 Click Export gt 17 Surface Machine Systems QI NATIONAL p gt INSTRUMENTS Date 12 87 2009 3 32 46 PM User Smith File C UsersS mith Desktop conhgC ata ini Mas version 4 6 1 E sporting NI DA0ms 9 0 2 load scale position scale 2 position Scale A load scale ee Export complete Save Report 8 Click Finish 9 Close Measure amp Automation Explorer 10 Open the Scratch Operator program 11 Click Tools Calibration Import Scales 18 Surface Machine Systems aig Scratch 4 0 Operating Software Test Tools Diagnostics Calibration Data Visualization Automatic Scratch Visualization Find Scratch Machine Reboot Motor Controllers Reset Scratch Machine Clear Emergency Halt End Load N Length mm MHE Velocity mm s 12 Choose the export file from disk
9. Scratch Operating Software Surface Machine Systems Table of Contents Scratch Operating Software ssssssssssssoososooesessosssoosososoosesseseessssosssoosossososesesseseoo 1 1 aele T oo xcs E E EA So E E E AE AE sense EEA E 3 Li Foe e E E EE E ENEE 3 2 Installing the Scratch Operating Software cescsossececccsoosoooeccocosooscceeoosooooeeoooosoo 5 3 Using the Scratch Operator Software seeccscososesecccsooooosecoocooooosceecooooooecoooeoooo 10 EB THe Man Er a E ee E E ves E EE E EE ER 10 3 1 1 Primary Feo CS pareren ee A EE E EE E E OE 10 32 Finding the Scratch Machine ence ns OLO WCAG EN AOR R AO EPE 11 3 3 Scratch Machine INitlallZdt Olin ssa wadi ROA WOREK AGCA OE AR ACO R GO 13 52 GGIDTINO sawnsieswersuwenweceteaeaveteesersncveseces AO EPE EEA 13 3 4 1 importing 1x Calibration FIIES lt lt eb GE nrt 14 3 4 2 Sawin CGliBFOUON scales oai ROA AO PA A ERO EGLE A N EA 20 3 4 3 Creating New Calibration ScaleS addon caw svencssessieacaseeseseaasuutaeesassicueecevaeseuens 21 3 4 4 Saving a NEW Calibration Cale Rane ence EG E OE A ORA OE O GEO ses GG W GE 24 3 4 5 Clearing a Calibration SCalE Eco TGA FERRE EEE Ed AE ERC EENEN ia 24 35 AJODBINE the Scratch Head Sia e Oc Za EEEE ia dO ASKA 25 0 Clearing an Emergency at A oi R A A EGER EE TRG Geos RE GE Z 25 3 RUM NESSCOUNTESR GS E S E ee Za m E 26 3532 SAVIN SCTE CI Se Dae as crerettew wes ote esse E EE WAREZ OE 27 39 Viewing Saraich Dale SA aOE RO
10. can be used to halt all machine operations currently in progress Once the Emergency Stop button is pressed the machine will come to a complete halt The machine will not respond to any further operation requests until the Emergency Halt is cleared See Clearing an Emergency Halt below 3 2 Finding the Scratch Machine Your operating computer may have multiple communication ports with which to communicate with the Scratch Machine These ports are labeled COM Port 1 COM Port 2 etc By default the Scratch Operator attempts to find the machine on COM Port 1 If this is the wrong port you will have to use the Find Scratch Machine functionality to find the Scratch 4 Machine The machine will display a message and the interface will be partially inaccessible 11 Surface Machine Systems Test Tools Help Comments Start Load N End Load N Length mm MHC Velocity mm s If the Scratch Operating software is started prior to turning on the Scratch 4 Machine you will need to follow these instructions to initialize the software for the machine If the software displays the following message at startup then this procedure will need to be followed in order to initialize the software after the machine is powered on Machine Not Responding 1 Click Tools Find Scratch Machine 2 Follow the steps 7 through 11 in the section Installing the Scratch Operating Software 3 When the Sc
11. ch Right fload 7 F Fan Power Load Limit Switch Low X Position 335 733 ApplyLoad Load Limit Switch High Z Position 1686 1 m e Power On State C Fan Counter Load Generator Solenoid Unlock System Information Analog Records 961400 Chart Data Analog Record 1400 Hf Tangential Load NomalLoad X Position Digital Records 961400 Digital Record 1400 i Analog Capture Size 10 Liepth Digital Capture Size 10 3 11 1 Components Digital These components relay on off states of the machine gt Head Limit Switch Left a filled circle indicates that this switch is depressed normally by the Scratch Head gt Head Limit Switch Right a filled circle indicates that this switch is depressed normally by the Scratch Head Load Limit Switch Low a filled circle indicates that the load generator is in the lowest position Load Limit Switch High a filled circle indicates that the load generator is in the highest position Power On State indicates that the machine is powered on Fan indicates that the machine fan is turned on YvVY Y Y Load Generator Solenoid indicates the status of the Load Generator Solenoid 29 Surface Machine Systems S M S we Analog Displays the real time raw and scaled voltages from the sensors The column on the left indicates the real time raw voltage measured The column on the right indicates the real time scaled values
12. d the file Scratch4SystemSoftware msv or locate it on your Install Media CD or DVD The software can be acquired from a http www surfacemachines com swdist sos 2 Double click on the file Scratch4SystemSoftware msv jl Scratch 4 System Software eo Welcome to the Scratch 4 System Software Setup ww Wizard S M S The instaler will guide you through the steps required to install Scratch 4 System Software on your Computer WARNING This computer program is protected by copyright law and international treaties Unauthorized duplication or distribution of this program or any portion of it may result in severe civil ar criminal penalties and will be prosecuted to the maximum extent possible under the law 3 Follow the installation instructions Surface Machine Systems Installing Scratch 4 System Software Scratch 4 System Software is being installed Please wait 4 Ona successful install the following message will be displayed Surface Machine Systems Te Scratch 4 System Software Installation Complete Scratch 4 System Software has been successfully installed Click Close to exit Please use Windows Update to check for any critical updates to the WET Framework Testing the Scratch Operating Software Installation 1 Click the Windows Start Button or Start Orb Click All Programs Click Surface Machine Systems ue Click Scratch Viewer A window
13. determining if the Scratch Operating software is correctly communicating with the Scratch 4 Machine 1 Enter the number of millimeters of translation desired in the Jog Head form in the Operations panel 2 Press the Right or Left buttons to move the Scratch Head 3 6 Clearing an Emergency Halt If the E STOP button is pressed at any time the Scratch Operating software will immediately send halt commands to the Scratch 4 Machine and quit all active operations When this occurs the Emergency Halt state is set When the Scratch Operating software is in the Emergency Halt state it will indicate the state with bright red lettering as below While in this state no operations will be allowed until the state is cleared 25 Surface Machine Systems Test Tools Help Test Parameters Comments Start Load N End Load M Length mm MHC Velocity mm s To clear the emergency halt state follow these steps 1 Click Tools Clear Emergency Halt 3 7 Running a Scratch Test To run a Scratch Test follow these steps 1 Secure the system under test beneath the scratch styli as described in the Scratch 4 Machine User Manual 2 Enter the Scratch test parameters in the Test Parameters section a Start Load should be at least 0 5 N b End Load should be no more than 150 N c The length should be no more than 1200 mm d The Velocity should be no more than 400 mm s e The Capt
14. e operating software now includes an integrated Scratch Data Viewer which allows you to view your data without resorting to third party tools Additionally the Scratch Data Viewer can automatically find the onset of Scratch and display only the Scratch region of the Scratch Data The Scratch Data Viewer can also be used to load old Scratch Data files and is the mechanism by which new Scratch Data may be saved to disk Integrated Diagnostics real time machine sensory data and data capture are monitored Watch you scratch data in real time during a test This screen can also be used to help diagnose common scratch issues and hardware failures or problems NOTE the options on this screen can be potentially hazardous to your Scratch Machine Do not use the options unless directed to do so by a qualified technician Integrated Calibration calibration has never been simpler or more powerful The new calibration system allows for full range table based interpolation over the sensor range The sensors have a more sophisticated 3 Surface Machine Systems S M S PP response profile than previous versions of the Scratch Operating Software were able to exploit With the new calibration system these profiles can be more accurately traced Additionally calibration has become much easier to do with the new Integrated Calibration screen You can now take readings directly within the Operating Software and these readings are translated
15. ing the Normal Load Sensor 1 Place the calibration jig into the Scratch Head as shown in the User s Manual 2 Place a known load on the jig 3 Click Tools Calibration Normal Load 21 Surface Machine Systems Reading Dae Reading Value Low Samples 0 111 D Ae E pene AE 4 Enter a number of samples to Read 50 100 or 250 is reasonable Press the Sample button The system will automatically take and average voltage samples from the sensor 5 Enter the actual load presented on the sensor in the field Value N Press Add Reading 22 Surface Machine Systems 7 When you have completed at least 2 readings you may create a scale Do so by pressing Create Scale This scale will be used for processing sensor data Creating an X Position Calibration Scale Creating a Tangential Load Calibration Scale Creating a Depth Calibration Scale Creating a Depth Calibration Scale follows a slightly different procedure than other Scales The Depth Calibration Scale requires a single absolute point of reference and exactly 2 relative points of reference 1 Open the Depth Calibrator Window by clicking Tools Calibration Depth 23 Surface Machine Systems S M S d Set the Depth Calibrator to Zero following the instructions in the Depth Calibration Manual Enter 250 into the Samples text box and click Sample
16. les ot comma delimited files txt csv by using this tool 1 Click Tools Data Visualization 2 Inthe Scratch Data Viewer click File Open and select a file The Scratch Data Viewer can only read files created by the Scratch Operating Software versions 1 x and 2 x 3 10 Saving and Loading Scratch Test Parameters The Scratch Operating software allows you to save and load the Scratch test parameters of your current project To save your current settings follow these steps 1 Click Test Save Parameters 2 Choose a file name and location 3 Click Save To load the test settings of your project follow these steps 1 Click Test Load Parameters 2 Choose the parameters project file 3 Click Open 3 11 Accessing Diagnostics To access the diagnostics window click the Tools menu and select Diagnostics The Diagnostics window can be used to acquire real time information on the status of the Scratch 4 Machine NOTE Parts of the Diagnostic interface allow you to operate the machine without safety checks Use of the Diagnostics interface may cause permanent damage to the machine or leave it in an unusable state Please only use the Diagnostics window at the direction of a qualified technician 28 Surface Machine Systems sus Diagnostics Digital Analog Operations C Head Limit Switch Left 4 Load Solenoid Open 3 Head Limit Swit
17. ratch Machine is found the interface will become accessible as follows 12 Surface Machine Systems start Load N End Load N Length mm MHC Velocity mm s 3 3 Scratch Machine Initialization When the software first starts if the Scratch 4 Machine is found the software will perform an automatic hardware initialization If the software is started up before the Scratch 4 Machine is powered on then a manual reboot must be performed to initialize the Scratch Machine 1 Click Tools Reset Scratch Machine You will hear clicking noises and a soft electronic sound The interface will be inaccessible for a few seconds When the operation is complete the interface will become accessible again and ready to perform scratch tests or other operations 3 4 Calibration Calibration is now easier than ever You can import and save your old Calibration Files from the 1 x series of Scratch Operating Software or create new Calibration tables simply and easily 13 Surface Machine Systems 3 4 1 Importing 1 x Calibration Files 1 Close the Scratch Operating Software 2 x 2 Open Measure amp Automation Explorer File Edit Wiew Tools Help lt P Show Help p gf Data Neighborhood Ce National Instruments Measurement amp Automation Explorer p ull Scales Measurement amp Automation Explorer MAX provides access to your National Instruments gt Software products b E WI Drivers
18. ted with the following window ai Scratch 4 0 Operating Software Test Tools Help Test Parameters Comments Start Load N End Load M Lenath mm MHC Velocity mm s Capture Open Data 0 Yes 6 No This is the Main Control Window and all major functionality of the Scratch Machine can be accessed from this window 3 1 1 Primary Features Test Parameters This area is used to set Scratch Test Parameters during a Scratch Test Pressing the Run Test button will cause the Scratch 4 Machine to run a scratch test using the currently visible parameters 10 Surface Machine Systems S M S Pp Warning Running a test prior to calibration or without a sample and styli in the machine may cause permanent damage to your Scratch 4 Machine Please see the section Calibration to calibrate the Scratch 4 Machine prior to running your first test Please see the section Running a Test to see how to run a test Operations This section includes basic machine operations that are not part of a test These operations are gt Jog Head Jogging the head means to move it left or right The jog head operation works in millimeters Pressing the Left button will move the head to the left Pressing the Right button will move the head to the right Use these operations to position the head over a sample gt Emergency Stop The emergency stop button
19. tes You can choose to view one or more sensors by selecting the check box next to each sensor 30
20. ure rate should be no more than 2000 1000 is recommended for optimal performance 26 Surface Machine Systems S M S 3 f Select the Open Data option as either Yes or No If you select Yes the software will automatically open the Scratch Data Viewer to show the output from the test after the test has run 3 Click the Run Test button Test Tools Help Test Parameters Comments Start Load N gus Scratch Data Viewer Scratch 4 End Load N File Length mm Chart Data MHC 3 156 J Tangential Load Tangential Load NormalLoad XPosition Depth 10 890 J NormalLoad 14 470 X Position 938 139 Depth Velocity mm s a 14 250 Distance mm Ak wil ih Laas 0 467 Data Point Mav Y v Comparator wae 40 50 60 Distance mm 3 8 Saving Scratch Test Data If you ran the test with the Open Data option set to Yes the Scratch Data Viewer will be open as above Otherwise click Tools Data Visualization The Scratch Data Viewer will open displaying the data from the last scratch 1 Click File Save 2 Choose the name and location of the file you would like to save The scratch information from the Test Parameters will be saved in the file 27 Surface Machine Systems 3 9 Viewing Scratch Data The Scratch Operator includes a copy of the Scratch Data Viewer You can view Scratch Data Files text fi
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