DPCTouch DOGA GX/GY/DO/GA
Contents
1. ZOU DPC Touch INS TRUC TIONS MANUAL IMPORTANT The controller delivered with this manual may be modified for specific needs In this case please give us the controller serial number written on our shipping note or the approximate controller delivery date when you will place an order for a new similar controller or for spare parts In this way you will be sure to get the required controller and or spare parts WARNING This information has to be kept in a location known to all users Each operator has to read carefully this instructions manual before installing using and mending the product Be sure that the operator has understood usage recommendations and the meaning of signs put on the product Most accidents could be avoided respecting this Instructions Manual As a matter of fact they were created according to European laws and norms applied to the product In each case please respect and follow national safety norms Do not take off nor damage the stickers or notifications put on the product and above all the details imposed by the law SUMMARY 1 2 HE AR de SPECIFICATIONS suits een died tunis ester eurent lise dieneeuenc eine a a ee icieuset 3 HARDWARE sd oo land 4 2 1 DIMENSIONS and mounting interface inside AA AA 4 2 2 AEST ACO DON Sorn enan a iio 5 GETTING STARTED roinn a E A toast ciel 6 MAIN MENU aaa ii 6 JOB MANAGER cil 7 NEW JOB CREATION sn das 8 6 1 FASTENING step crea2. BR 7 NOTE ports shown in grey are not used in firmware v 0 2 8 I O port adaptor Encoders port adaptor supplied only for controllers with serial numbers This adaptor is used to split I O signals for starting with SC tool interface and other automation equipment see Electric wiring chapter for Encoders port adaptor is used to connect standard the wiring scheme DOGA positioning arms to DPC Touch ATTENTION Do not connect positioning arm directly to DPC Touch serial numbers starting with SC This may damage encoders DB25 female DPC Touch User Manual 6 3 GETTING STARTED 1 Connect power supply to the controller to turn it on Normal booting time is about 2 sec If controller is not booted the last booting step indicates the problem e g nit SD Card missing or damaged SD card 2 After first booting calibration screen may appear Follow instructions on the screen press and hold the center of the cross for 1 sec for each position of the cross ATTENTION if calibration is not correctly performed the touch screen may become unresponsive In this case turn off the controller take out the SD card access the SD card from your computer and delete the following file SD system setting Setting_posi dat 3 Controller is started automatically in operating mode If default job is selected it will start automatically 4 Tap on the HOME button in order to access to the main menu screen
3. on the screen to indicate parts to be Text or Image message is shown on the screen to indicate parts to be picked Logical Out One output signal continuous is sent to turn on pick to light indicator 1 EJ Logical In One input signal active high is expected for picking verification by sensor 1 Logical Out Pick to light indicator 1 is turned off once picking is performed 10 First fastening operations are performed screws are counted and tool position PAE is assured Text or Image message is shown on the screen to indicate parts to be picked Logical Out One output signal continuous is sent to turn on pick to light indicator 2 Logical In One eee a signal active high is expected for picking verification by sensor 2 operations to J perroomet position is assured assembly status light Job completion message Logical Out Pick to Pick to light indicator 2 is turned off once picking is performed indicator 2 is turned off once piesne is performed DPC Touch User Manual 15 7 SETTINGS dit Operating Screen 1 of 4 Management of interface Parameter Tool selection Screws counting up down Screws counting for step job Torque selection by binary outputs Job selection by binary inputs Default job number Default value Select one of the following option HDC SDC DOGA Hybrid or Current control tools HDC30i HDC35i HDC40i SDC24 SDC40 DC tools all electric digital control tools equipped
4. While not logged in JOB MANAGER and SETTINGS are not accessible 5 To log into the system tap on the LOGIN button Default factory password is 0 DPCTouch CEE Operation mode G CL The main screen provides access to the main menu with four buttons Job manager Provides access to the list of saved jobs and allows creation modification jobs This button is locked while user is logged out Operation mode Provides access to the operating screen Settings Provides access to the controller settings This button is locked while the user is logged out Login Logout Allows logging into the system by entering the password to access Job manager and Settings NOTE default factory password is O If the password is lost turn off the controller take out the SD card access the SD card from PC and delete the following file SD system setting Setting_posi dat After rebooting the controller will be reset to default factory settings DPC Touch User Manual 7 5 JOB MANAGER Job manager interface provides access to the list of saved jobs It also allows to Edit or to Delete saved jobs as well as to create new ones by pressing New button or by Copying an existing job Load button is used to load selected job into operating mode NOTE a job can t be loaded if it doesn t contain any steps wa Job manager No Job name Steps Screws 1 Chair_10 48 0 0 2 Chair_10 49 1 1 3 The_longest_name_01234567898765
5. fastening time is out of min max limits see programming Trigger released before torque up tool was stopped before reaching torque see settings Fastening NG tool alarm fastening NG alarm input signal is received from the tool System error operating system error reboot the controller 1 0 error error of management of inputs and outputs check logical and assigned I O s Job complete NG job was interrupted or completed with missing screws DPC Touch User Manual 22 9 ELECTRICAL WIRING 9 1 Encoder s port wiring scheme ruin oma a Jona ICC IC CN Ce wa e ET o Loue Lo CET 9 2 RS232 port wiring scheme NOTE for the firmware upgrade mode pins 7 and 8 have to be short connected refer to the firmware upgrade manual DPC Touch User Manual 9 3 Inputs wiring scheme DPC Touch inputs Input 1 Per Le ot Input 2 ESET n Input 3 i LP EU _ Input 4 AFCE 4 Input 5 Re JET AZ Input 6 Fi 7 td ee Input 7 Input 10 Lee ee OS Input 11 RA L FEEL Input 12 ALT I UN STE dd Return OV or Power 24V J External outputs INPUT COM 28 i Return OV or Power 24V 23 DPC Touch User Manual 24 9 4 Outputs wiring scheme DPC Touch Power 24V or Return OV outputs External inputs 100mA max Output 1 E Output 2 h Output 3 O co Outp
6. Motor run and Fastening OK signals have to be connected Optional Use Smart tolerance detection feature refer to Smart tolerance detection below 1 Position the arm on the first screw Monitoring fields are displaying the current position of the arm 2 Default tolerance values for the approaching Area and for the OK zone will be applied To change default values refer to encoders settings Tolerance values can be adjusted manually for each individual position or by using Smart tolerance detection feature 3 If necessary define Tightening and Retightening programs to be used for the current position feeding point see Pick Up position in encoders settings and the tool being used Perform a tightening operation as it has to be performed during production 5 Tightening time will be registered automatically Min and Max tightening time limits are calculated automatically by using default values in operating settings Tightening time control is not used if limits are equal to 0 6 Repeat 1 5 for each position 7 Activate Non sequential mode if there is no need to keep strict tightening sequence NOTE in non sequential mode retightenings can t be managed 8 Press SAVE button to save the step or CANCEL button to quit programming without saving changes 6 1 3 Smart tolerance detection feature This feature allows automatic detection of OK zone tolerance for each position Motor Run signal has to be connected in order to use this fe
7. depending on desired number of O s If DB9 connector is used then max 3 jobs can be selected on DPC Touch in binary logic by using 2 contacts In order to use independent power supply to DPC Touch do not connect 24V contact DPC Touch User Manual 9 8 Connection of Stanley Alpha and Kappa tools 28 DPCTouch Stanley Alpha Kappa I O adaptor I O port DB44 male to DB9 female and DB25 female DPC Touch DB44 VUE DD RL EE FERRIERE Tool DB9 female PLC DB25 female es A Gh eG BP ss t 6 6 d Output 1 TorqueSelect1 1t P o Output 2 TorqueSelect2 2 R Output 3 TorqueSelect3 3 S o O Output 4 Too Disable 4 M nput 8 D Motor Run 5 C nput 9 ToolAlarm 6 K Input 10 D Fastening OK 7 J o o o o IN_COM ES PR ES OUT_COM a oo Bb NOTE Select DC tool interface in DPC Touch operating settings ZIV WA O In order to use 24V supply from Stanley controller short connect pins A and Select Job bit B In this case DPC Touch will be powered by Stanley controller Don t connect DPC Touch to external power in this case To decouple DPC Touch power supply and 1 0 external power supply cut the bridges 15 35 and 30 31 in the DB44 connector of the I O adaptor in order to disconnect 24V power supply DPC Touch User Manual 29 99 Connection of Kolver EDU Series tools DPCTouch KOLVER EDU Series I O adaptor CN1 port DB44 male to DB9 fe
8. fastening operation completed wi Step OK Signal is provided after successful completion of a step Step NG Signal is provided after if a step was interrupted or mou completed with missing screws Tool Enable Signal is provided to enable the tool when position is OK Tool Disable Signal is provided to lock the tool when position is NOK or E during alarm mode D RUN Signal is provided when the tool is running D_Motor_Run a input has to be connected Signal is provided when Fastening OK signal is received from D TORQUE Impulse the tool D_Fastening_OK input has to be connected il D RESET Signal is provided when reset was made manually males automatically or via 1 0 Signals to select fastening presets on the tool in binary or Torque Select 1 8 direct logic see the table below Logic is selected in Continuous operating settings Job OK Signal is provided after successful completion of a job JNE signal is provided after if a job was interrupted or completed with missing screws Signal is provided when the controller is in operating mode System Ready and ready for selection of jobs Once a job is started the Continuous signal drops down Signal is provided when the controller is in Alarm mode The table below shows the relation between Torque select signals and Preset number in direct logic Torque select 1 Torque select 2 Torque select 3 Eoo Torque select 8 NOTE See Input s settings for binary logic e
9. modify manually if needed To disable tightening time control set min and max fastening time to 0 in fastening step programming NOTE control limits in operating settings are only applied to newly created jobs Check min threshold for trigger release control in operating settings screen 3 of 4 If start trigger is released after the min threshold the error is displayed To disable trigger release control set the threshold to O or to 9999 ON 8 avenue Gutenberg CS 50510 28317 Maurepas Cedex France T l 33 0 1 30 66 41 48 Fax 33 0 1 30 66 41 49 export doga fr afan Nous travaillons constamment l am lioration de nos produits Me re far les dimensions ef indications port es dans cette brochure peuvent parfois ne pas correspondre aux derni res ex cutions De convention expresse nos ventes sont faites sous b n fice de r serve de propri t les dispositions de la loi du 12 5 80 trouvent donc toute leur application CEE nl www e doga fr Gualin Doc 60290 11 15
10. with Del 24V 1 0 signals GX GY DO GA DOGA low voltage tools XS 40D XS 38D XT 30D XS 35D XT 35D Other special applications on request This parameter manages counting display Turn it ON to or count up 1 2 3 or OFF to count down 3 2 1 ON OFF This parameter manages counting display Turn it ON to display counting separately for each step or OFF to display counting for the whole job Selection of tightening presets for each position is done via Torque selection outputs These outputs can function in binary logic or in direct logic one output per preset Selection of Jobs of DPC Touch can be done via Job selection inputs These inputs can function in binary logic or in direct logic one input per job Default job is a job which is automatically started after booting of DPC Touch If default job number is set to O DPC Touch will not boot any jobs NOTE job selection via inputs has higher priority ON OFF O 999 1 Screen 2 of 4 Management of buttons in operating mode Skip button access without password Back button access without password Reset button access without password Display job reset button Job selection access without password Enables access to Skip button without entering password If turned OFF the password will be asked when Skip button is pressed Enables access to Back button without entering password If turned OFF the password will be asked when Back button is pr
11. 2 2 4 Chair_11 49 3 3 5 Chair_10 48 4 4 6 Chair_10 48 5 5 T The_longest_name_01234567898765 6 6 8 Chair_10 48 6 6 9 Chair_10 48 6 6 10 The longest_job name _012345678901234567890123456789 6 6 11 Chair_10 48 1 1 1 The_longest_job_ name _012345678901234567890123456789 1 1 ESEZ TOnga Each job has its sequential number No In order to change job number tap one more time on the selected job and then change its position in the list by using Up and Down buttons For information purposes number of steps and screws in ajob is displayed in corresponding line in the list Home button provides access to the main menu screen Maximum number of jobs is 999 NOTE while not logged in the only active buttons are Load and Home other buttons are locked 6 NEW JOB CREATION While in Job Manager screen press NEW button New job will be created and placed in the end of the list New job creation screen will be displayed automatically A job is represented by a sequence of steps These steps can be organized in any order which corresponds to the desired production sequence There are 5 types of steps and each one of them can be used multiple times if necessary Save Cancel No STEP NAME TYPE Y Fastening gt Logical In e gt Logical Out Delay Message Fastening this step contains fastening positions including information associated with these positions positioning tolerance tightening program ti
12. DB25 female potential free DPC Touch DB44 Electric screwdriver controller ALA AA AAA MMMM cP CPPCC A A A A SD E E E E EEEE EEEE E IN DOOR USE Tool DB9 female Br Taaie RoHS a 120 PLC DB25 female FRS ss LR se Input Output Assigned signal DB9 pin Ne HDC SDC pin Ne Signal Output 4 Tool Disable 4 5 river Lock input 9 Tool Alarm 6 18 Alarm _ __ _ _ IN COM 8 102 2 OJo 7 OUT COM Td O we O NOTE Select HDC SDC tool interface in DPC Touch operating settings Select PLC except Start and Reverse interface on HDC SDC controller DPC Touch User Manual 27 9 7 Connection of Atlas PF4000 DPCTouch DOGA HDC SDC series I O adaptor DB44M to DB9F DB25F I O connectors 12 10 contacts I O Signals assignment DE pe Signals assignment Conade i o number example pin pin example puts D Fastening OK 5 13 Tightening OK 1 NO REL 3 Ne input Jobselect 6 14 Selectiobo A 4 no g Hs fc E o nc motio Jobselect 7 15 Selectiobi A 7 no 8 sc ee Es in imparta Jobselett3 16 Selectiob2 10 no Nu fc rea Yu ne RESTE L PRICE PVR AA y Sapa asser 7 LE reas las 1 2 3 IEC LEO E ty rete E E E aje a Quiputa tocl meble 4 LE frooieneme Ke gt A ER ieee A IN COM GND 8 2122 Ground S2 ono NOTE Select DC Tool interface in DPC Touch operating settings Either DB25 or DB9 connectors can be used
13. SAVED NON SEQUENTIAL OFF Tolerance pts Current Saved ZONE EG DATE Channel 1 Tightening time ms Channel 2 max ms Channel 3 CAS Channel 4 Tightening job ran Retightening job Smart tolerance detection Pick up position 11 C12 Current field displays the number of position being programmed Saved field displays the total number of saved position in the fastening step being programmed Current channels fields display current values from analog encoders Only active channels are shown Saved channels fields display saved values from analog encoders Current values are saved when Apply button is pressed or when Fastening OK signal is received Tolerance fields display tolerance values for analogue encoders to be applied for each encoder for the current position Tolerance values can be automatically detected by using Smart Tolerance detection feature please refer to corresponding chapter for more details Approaching area orange Tool is disabled E Out of position area as Tool is disabled OK zone green tool can be enabled Screw NOTE real shapes of tolerance areas are not circular they depend on the geometry of the positioning arm being used To avoid overlapping of tolerance areas of different screws keep tolerance values as low as possible DPC Touch User Manual 10 Time control fields display measured Tightening time and calculated Min and Max limits Min and Max values are calculated according to
14. ature Press START button to begin smart tolerance detection Start the tool and move it around the screw to define OK zone the zone where operator is allowed to run the tool 3 Stop the tool and press STOP button on the screen Or perform a tightening operation as it has to be performed during production In this case tightening time will be saved automatically together with detected tolerance values and current position coordinates Next position teaching will start automatically 4 Continue with Manual or Automatic programming DPC Touch User Manual 12 6 2 Logical Input step creation While in Job modification screen tap on LOGICAL IN button The Logical In step creation screen will appear Select an available input from the list of Inputs If an Input was assigned for a specific function in Input settings it is not available to be used as a logical signal Select the type of the signal There are four types of input signals Active High for this type of signal it is necessary to detect a transition from O to 1 Active Low for this type of signal it is necessary to detect a transition from 1 to O Status High for this type of signal it is enough to detect if the signal is equal to 1 Status Low for this type of signal it is enough to detect if the signal is equal to 0 Logical input step is completed if the corresponding input signal matches the condition of the selected signal type If two or more signals are selecte
15. bly process with graphical instructions 12 inputs and 12 outputs with assignable functions 24V Os IMPULS ARO OUTRUN Logical 1 0 s for workstation automation 7 Analog encoders 4 channels 0 5V 8 Memory card Removable SD card 8Gb 9 Total jobs memory 999 jobs with open structure es 999 jobs x 255 steps x 99 positions per fastening step 10 Total se ur amena max 999 positions in one job counter limit 11 Programming Automatic and manual programming of a Fastening step fe paar A 0 09 for angular encoders 8 y lt 0 5 mm for linear encoders a Adjustable for each position and for each axis 13 Positioning tolerance Smart tolerance detection feature All tool with signals electric or pneumatic 14 bl i OMAN EROUE Min required signals Fastening OK Tool Lock is comminicaton RS232 for bar code scanner and firmware upgrade Ethernet not enabled in firmware v 0 2 8 DPC Touch User Manual 2 HARDWARE Dimensions and mounting interface 2 1 E 3 o gt oO a a a 5 93 9 Lasn asf Mounting plate with 4 x M3 screws is delivered with the controller as a standard accessory Weight of the controller 0 55 kg DPC Touch User Manual 5 2 2 Interface ports DPCTouch Power supply SD card CIO El 2 eee Productive solution for error proof assembly S DOGS MNO 5015600000 POS CONTROLLER Md DPC TOUCH fe SC 1200000 bpm VOC LA TOGA INC
16. d then AND condition will be applied for selected signals to complete the step Press SAVE button to save the step or CANCEL button to quit programming without saving changes 6 3 Logical Output step creation While in Job modification screen tap on LOGICAL OUT button The Logical Out step creation screen will appear Select an available output and its type from the list of Outputs If an Output was assigned for a specific function in Output settings it is not available to be used as a logical signal There are two types of output signals Continuous ON the signal is continuous until it is deactivated in the next Logical Out step To deactivate the signal create a new Logical Out step and deselect the corresponding signal Impulse the signal is an impulse with defined duration Duration of the signal is defined in ms Multiple output signals can be used in the same Logical Out step Press SAVE button to save the step or CANCEL button to quit programming without saving changes 6 4 Delay step creation While in Job modification screen tap on DELAY button The message step creation screen will appear The controller will stay on hold for the defined time Delay step can be used to manage timing between Logical In and Logical Out steps or between messages Press SAVE button to save the step or CANCEL button to quit programming without saving changes DPC Touch User Manual 6 5 Message step creation While in Job modification
17. essed Enables access to Reset button without entering password If turned OFF the password will be asked when Reset button is pressed Job reset button can be displayed or hidden by using this parameter NOTE if turned OFF and automatic reset is used then the current step will be reset instead of the current job Enables access to Jobs selection without entering password If turned OFF the password will be asked when Job selection button is pressed SE SE Sp a DPC Touch User Manual 16 Screen 3 of 4 Management of fastening time Lower limit of fastening time control in percentage of Min fastening actual fastening time detected during programming 0 100 25 time limit NOTE changes will be applied only to new jobs existing jobs won t be affected Upper limit of fastening time control in percentage of Max fastening actual fastening time detected during programming 0 100 25 time limit NOTE changes will be applied only to new jobs existing jobs won t be affected Start trigger Fastening time threshold after which trigger release will be release time considered as NG tightening Error message Trigger 0 9999 limit ms released before Torque Up will appear If fastening is started Motor Run signal is received then it is allowed to exit position OK zone green into approaching area orange for the specified time without Temporary locking the tool If this time limit is passed the tool will be position loss ins
18. f the arm 2 Press APPLY button to save current position of the arm Saved values from encoders will be displayed in corresponding fields If not satisfied with the result press APPLY button again to rewrite saved values from encoders 3 Default tolerance values for the approaching Area and for the OK zone are applied To change default values refer to encoders settings Tolerance values can be adjusted manually for each individual position or by using Smart tolerance detection feature 4 If necessary define Tightening and Retightening programs to be used for the current position feeding point see Pick Up positions in encoders settings and the screwdriver to be used for this tightening position used only for DOGA GX GY DO GA tools 5 If necessary enter Min and Max tightening time limits in corresponding fields Tightening time control is not used if limits are equal to O 6 Press NEXT button to pass to the next position 7 Repeat 1 6 for each position 8 Activate Non sequential mode if there is no need to keep strict tightening sequence NOTE in non sequential mode retightenings can t be managed 9 Press SAVE button to save the step or CANCEL button to quit programming without saving changes DPC Touch User Manual 11 6 1 2 Automatic programming of fastening step For automatic programming make sure that the tool is connected to the controller and signals are correctly assigned In order to register tightening time
19. ft fn fl ft ft ft 24V OV NO E A A A ATTENTION A O AS By default the controller provides 24V output on the A A pins 31 33 and 35 37 This power supply can only be a a eB O used to power I O signals max 100mA per output max OoOo a 500mA for all outputs The controller can also be powered by external power supply through 1 0 port Bridges 15 35 and 30 31 are made inside DB44 male connector Cut them if signals are to be powered by external power supply 10 Controller is not booted black booting screen Operating screen is not displayed after booting Controller is not responding after calibration Password is lost or forgotten Controller is unresponsive Input signal is not received Output signal is not sent Image message is overlapped with operating screen Image message is not displayed on the screen Job is locked in a loop with no end Error Fastening time is too short long Error Trigger released before torque up DPC Touch User Manual 33 Troubleshooting Check the boot log on the screen Last booting step indicates the problem Example SD card Init SD card is not found Check if SD card is inserted and not damaged SD card content can t be found Check if system and user folders are placed in the root directory of the SD card and not placed in other folders Check if names of folders are correct Rewrite the system folde
20. ghtening time etc Logical In this step is used to verify an input signal in order to pass to the next step e g signals from proximity sensors buttons etc Logical Out this step is used to send an output signal s to manage automation equipment on work station e g activation of pneumatic valves lights etc Delay this step allows to maintain the current state of O s for specified time e g a delay required between receiving an input signal and sending an output signal Message this step is used to display a graphical or text message on the operating screen during working cycle A job may contain up to 255 steps The maximum number of positions in a single fastening step is 99 In order to change sequence of steps in a job tap one more time on the selected step and then change its position in the list by using Up and Down buttons Created steps can be modified by using EDIT button or deleted by using DELETE button COPY button creates a copy of the selected step and inserts it in the end of the list Press SAVE button to save the job or CANCEL button to quit programming without saving changes DPC Touch User Manual 9 6 1 Fastening step creation NOTE it is useful to define encoder s reference point before creating a fastening step See encoder s settings for more information While in Job creation screen tap on FASTENING step button The Fastening step creation screen will appear POSITION CURRENT
21. ing zero point of encoders screen 2 of 2 Encoders reference point can be defined by using this function Definition of the reference point is useful when encoders have to be replaces after failure or when repeatability of position of the workpiece can t be assured The reference point can be defined by using Pick button or reset by using Reset button The reference point can also be defined by using external input signal in Operating mode DPC Touch User Manual 18 7 3 Inputs Activate necessary inputs by selecting corresponding check boxes Select required input function from the list Non assigned inputs can be used for Logical In steps Impulse signals duration must be between 100 and 500 ms Each input function can be assigned only once Input name Function description Signaltype ha Inputs to select jobs on DPC Touch in binary or in direct logic see the table below Logic is selected in operating settings to get back to previous step DPC Touch alarm reset If maximum number of retightenings mp Reset is reached it s not possible to reset the alarm Step or Job has Impulse to be reset Reset Step Reset Job Next Job Signal is used to select next job in the job manager list Previous Job Signal is used to select previous job in the job manager list Tao Ab Fastening NG alarm signal from the tool to indicate that Continuous fastening operation wasn t successful or Impulse Set Origin Signal is used to set zero of e
22. jobs will not be affected cot cots ot cd Ch1 Connected Position area Position OK channels tolerance pts tolerance pts Cho M Channel 1 zj E E E Reset Reset Reset M Channel 2 M Channel 3 a a M1 Channel 4 a Set zero position of encoders Pick Reset Encoder s activation and tolerance settings screen 1 of 2 Activate or deactivate corresponding encoders by selecting check boxes accordingly Enter default tolerance values for the approaching Area and for OK zone where tool is enabled Default tolerance values are applied automatically during Fastening step creation It is possible to modify tolerances manually for each individual position during creation of a fastening step If default tolerances are changed they will be applied only to new jobs existing jobs will not be affected See more information about approaching Area and OK zone tolerances in Fastening step creation chapter Pick up position 1 and 2 screen 2 of 2 It is possible to define two screw feeding positions or areas The tool can be enabled on the corresponding feeding position for easier screw picking Pick up position can be defined as a single point Corner 1 or as an area between Corner 1 and Corner 2 see below Corner 2 Pick up area Corner 1 NOTE the real shape of pick up area is not rectangular and depends on the geometry of the arm To register location of a corresponding corner position the arm and press Pick button Sett
23. lowing file SD system setting Setting_posi dat After rebooting the controller will be reset to default factory settings Controller reset to factory settings screen 4 of 4 Enter 77 to reset the controller to factory settings Saved jobs will not be deleted Firmware version screen 4 of 4 Current firmware version of the controller Upgrade the firmware regularly to keep the controller up to date Refer to the firmware upgrade manual for the upgrade procedure DPC Touch User Manual 21 8 OPERATING MODE Controller is started automatically in Operating mode after booting Default job is loaded automatically see operating settings Operating mode is accessible through the main menu and though Job Manager by pressing Load button In Operating screen functions are managed in Operating settings Job selection button Home button Previous job button Last image access button Job manager button Next job button Position indicators Green Position OK Orange Approaching Red Out of position STEP NAME CURRENT SAVED 2015 12 25 JOB RESET STEP RESET Text message area Job Step progress bar Lt AL Fastening status indicator Y Previous position button Job reset button Alarm reset button Step reset button a a Next step button Screws counting area In operating mode the following error messages can occur Fastening time is too long short
24. male and DB25 female 10 contacts DPC Touch DB44 E E EEEE EEEE EEEE 6 SE SE SE EE E E E E EEEE EEEE Tool DB9 female PLC DB25 female FRS ss LR se Input Output Assigned signal DB9 pin No CN1 contact No Y 1 Output 2 3 Signal RE IE G CO a E E IET E Output 4 Tool Disable 4 4 StopSVin Input 8 DFasteningOK 5 6 Torque2AVout input 9 D_MotorRun 6 7 input 10 ToolAlarm___ 7 8 O IN_COM IC CI ICI t OUT_COM 7 NOTE Select DC tool interface in DPC Touch operating settings A ATTENTION Cut the bridges 15 35 and 30 31 in the DB44 connector of the I O adaptor in order to disconnect 24V power supply before making the interface DPC Touch User Manual 9 10 Two tools wiring example Job select bit O A input Job select bit 1 ei Job select bit 2 input Tool disable H output Fastening OK 44 ouput Moorin Tool A is connected through DB9 connector Tool B is connected through DB25 connector Input Tool disable 4 Output FasteningoK H Output Fastening NG Hh DB9 pin 1 DB25 pin 19 Output 4 Torque select 1 Output 3 6 Torque select 2 Output 7 8 Torque select 3 DB9 pin 2 Output2 Logical out Lock A Output 11 Tool Disable DB25 pin 20 DB25 pin 13 DB25 pin 14 DB25 pin 15 DB9 pin 5 DB9 pin 6 DB9 pin 7 Tool disable Input 10 D Fasteni
25. ncoders in operating mode Signal from tool to indicate that the tool is in reverse rotation mode DPC Touch will lock the tool if the signal is received on D_Reverse the first tightening After NG tightening DPC Touch will not Continuous lock the tool if this signal is received to allow rework operation Signal from tool to indicate that the tool is running Signal is used to control fastening time and to assure functioning of Smart tolerance teaching feature and Temporary position loss feature Signal from tool after successful fastening operation Once the D Fastening OK PR hd Impulse signal is received current position is declared as finished The table below shows the relation between Job select signals and Job number in binary logic Job number Job select 1 Job select 2 Job select 3 Job select 8 D_Motor_Run Continuous un A TD 1 1 po po po po O A O LO o ES O O CA 08 1 0 _ 4 G NOTE See Output s settings for direct logic example DPC Touch User Manual 19 7 4 Outputs Activate desired outputs by selecting corresponding check boxes Select required output type from the list Non assigned outputs can be used for Logical Out steps Duration of impulse signals is 100 ms Each output function can be assigned to multiple outputs Output name Function description Signal type Fastening OK Signal is provided after successful fastening operation f f ti leted with Fastening NG is provided after a
26. ng OK gt DPC Touch DB44 Output 12 Logical out Lock B DPCTouch OE Tool A DB9 female Productive solution for error proof assembly ODOGA Inputs and outputs shown in bold text are mandatory others are optional Logical oulpuls Lock A and Lock B are used inside a job Corresponding oulpul should be enabled Continuous On signal in a Logical Out step to lock corresponding tool during fastening step that follows DPC Touch User Manual 9 11 Automation equipment wiring example Push button 1 Push button 2 max 100mA Proximity sensor 8 Light 1 pet max 100mA max 100mA Light 2 XE max 100mA I O adaptor DB25 DB9 DB44 DPC Touch GND GND GND DPC Touch User Manual 32 9 12 I O port adaptor DB44 gt DB25 DB9 wiring scheme DPC Example of Touch ss assigned signals Input 1 1 o ob selects Reset 6 Resetstep Input 7 Reset Job 13 5 D Motor_Run Tool Alarm Input 10 10 D_Fastening_OK Input 11 11 Logical In Input 12 2 Logical In AAA Out Com 0V RE E O Output 1 Torque Select 1 Torque Select 2 Torque Select 3 Tool Disable Tool Enable D_Run D_Torque Alarm ob OK ogical Out Logical Out Logical Out DIR IR W OO N UT N E 22 23 Output 7 Output 8 OUTPUTS N gt E 25 26 27 Output 10 Output 11 Output 12 N P o In Com 24V Ha O Elo N BlwWlN ee e See vu bull ee ee ef
27. percentages defined in operating settings Tightening job is a preset number to be selected for the current tightening position via 24V outputs direct or binary logic if supported by the tool Retightening job is similar to the Tightening job but it is used only for rework operation and it is automatically selected after NG tightening if retightening is enabled in operating settings Pick up positions 1 and 2 can be selected to allow to start the tool in a specific position or area outside position OK zone in order to pick up a screw Fastening OK signals and Motor run signals are not effective on pick up position Driver 1 and 2 selection is only applied to DOGA tools GX GY DO GA connected through RJ45 port This selection allows enabling and disabling tools for each individual position Reset button is used to reset current position data to default values To delete a position press Reset button one more time after resetting the position data to defaults NOTE there is no need to use APPLY button after modification of any of the above values APPLY button is only used to save current values from encoders for the current position A Fastening step can be programmed manually or automatically 6 1 1 Manual programming of fastening step 0 Optional Use Smart tolerance detection feature refer to Smart tolerance detection below 1 Position the arm on the first screw Encoders monitoring fields are displaying the current position o
28. r content if necessary Calibration is not performed correctly Turn off the controller and delete the following file from the SD card SD system setting Setting_posi dat Turn off the controller and delete the following file from the SD card SD system setting Setting_posi dat Turn off and on the controller Input signals should be between 20 and 30V in order to be detected by controller Check if signal is detected in Other settings real time monitoring Max current capacity of outputs is 100 mA per output and total of 500mA for all outputs To check wiring force output signal in Other settings real time monitoring Outputs are optically isolated Press on the screen where Image button is situated top middle in order to initialize the screen Use recommended pictures format 16 bit bitmap To convert images into 16 bit format use image converter utility Check image size and format Images have to be in bmp format of the following size 800x480 px Recommended bit depth is 16 bit To convert images into 16 bit format use image converter utility Turn off and on the controller If the job is assigned as default delete the job from the SD card Make sure that a job contains at least one Fastening or one Logical input step Otherwise the job will be stuck in automatic loop Check fastening time control limits in operating settings screen 3 of 4 Check saved min and max fastening time in corresponding fastening step Reprogram or
29. screen tap on MESSAGE button The message step creation screen will appear Enter the text to be displayed and activate the corresponding switch Select an image to be displayed from the list of available images and activate the corresponding switch To hide the displayed message it is necessary to create a new Message step without text and or image Images are stored on SD card in the following directory SD user images messages For the best result use pictures with the following format 800 x 480 px 16 bit RGB565 BMP NOTE standard 24 bit BMP images can be used but processing time will be longer Use provided converter utility to convert 24 bit images into 16 bit for better productivity Press SAVE button to save the step or CANCEL button to quit programming without saving changes Creating 16 bit bitmap images with Image Converter utility Open Image converter utility 2 Select the directory where converted images are to be saved NOTE Image Converter will create a new folder 16bit where converted files will be saved 3 Add image files to be converted by using Add button If necessary remove files by using Remove button NOTE images have to be in jpeg or bmp formats cropped to the size of 800x480 px 4 Press Convert button to convert images into 16 bit bitmap format Converted images will be saved in the specified directory in 16bit folder 5 Close Image Converter utility e Image Converter v1 0 2 ES DADocumen
30. tantly locked If position NOK zone red is entered the 0 3000 50 time ms tool will be instantly locked NOTE this parameter is used to avoid interruptions of fastening process when position is lost for short time due to vibrations Judging time Judging time is used if Fastening OK signal is delayed after O 500 100 ms the fall of Motor run signal Screen 4 of 4 Management of NG tightenings Maximum number of attempts to rework a NG fastening If the maximum number of attempts is reached the current Number of pe position can be skipped or Job Step can be reset according retightenings 0 10 1 Re to parameters selected P NOTE this parameter is not effective in non sequential assembly mode Skip NG Allows to skip automatically a NG tightening if rework is E E ON OFF OFF tightening not allowed or if rework wasn t successful Fastening NG If turned ON Fastening NG signal will be provided when a signal if position is skipped automatically by Skip button on the A E l ON OFF position operating screen or by external input If turned OFF skipped Fastening OK signal will be provided Alarm can be reset automatically after the specified delay Auto reset i If delay is equal to O than reset has to be done manually or O 9999 3000 delay ms by external input DPC Touch User Manual 7 2 Encoders 17 7 Encoders settings will be applied only to new jobs Pick up position 1 FIRE Up positian2 Existing
31. tion tant DA A 9 6 1 1 Manual programming of fastening step sise 10 6 1 2 Automatic programming of fastening step suisses 11 6 1 3 smart tolerance detection Te tur nr 11 6 2 logica lAPutstep Cle son iaa 12 6 3 Logical QUtput Step cr MON A ia 12 6 4 Delay step crea a 12 6 5 Message Step cresta dado 13 6 6 TA SI A 14 SETTINGS oessa A A as 15 7 1 Opera aia la Mai talca daa 15 7 2 EN e 17 7 3 DEVIOUS PR dance eae mum cgragiat anaes le escchgnl eieaies dc Sew Reale sinteoaielbolakote 18 7 4 CULDUES a Nod 19 7 5 PS EWC A O E OS 20 7 6 O 20 OPERATING MODE id 21 ELECTRICAL WIRING consi 22 9 1 Encoder sporte WINING scheme E eeu 22 9 2 RS232 port Wiring Sche ME nusen E a a ada 22 9 3 MEUS WNE SCE Ih CO snn es Ea A 23 9 4 Outputs WIFINBSCNeME SES AE ed 24 9 5 Connection of DOGA low voltage tools GX GY DO GA Re 25 9 6 Connection of DOGA Hybrid HDC and Current control SDC tools 26 9 7 Connection of Stanley Alpha and Kappa tools 28 9 8 Connection of Kolver EDU Series tools 29 9 9 TWO TOO WINE Example ario ss mae aes 30 9 10 Automation equipment wiring example inner 31 9 11 1 0 port adaptor DB44 gt DB25 DB9 wiring scheme rs 32 10 Troubles hO0tiNRsissssss sens tias 33 DPC Touch User Manual 3 1 SPECIFICATIONS 1 Input power EL eee AC 100 240V DC 24V adaptor is provided 2 Dimensions 202 W x 128 H x 38 D mm 3 Weight 0 55 kg 4 Screen 7 LCD Touch screen 800 x 480 px 5 Graphical interface Visualization of assem
32. ts Save to Add Remove l Convert DPC Touch User Manual 14 6 6 Job example A simple job may contain only a Fastening step which will assure screws counting and tool position control functions Example below illustrates a job for management of an automated station with multiple sensors and actuators This job uses 5 logical inputs 4 logical outputs 7 messages text and or image and 2 fastening steps No Steptype Step functions Text or Image message appears on the screen to indicate what workpiece has 1 Message to be assembled Image stays on the screen until replaced by next message or until screen is touched Three input signals active high are expected from proximity switch to detect 2 Logical In presence of the workpiece on the table and from two buttons which operator has to press simultaneously in order to keep his hands off the clamping device de Text or Image message is shown on the screen to worn the operator about closing clamping device oe A A short delay is used before activation of the clamping device l A short delay is used before activation of the clamping device is used before activation of the clamping device Two output signals continuous are sent to activate the clamping device to Logical Out lock the workpiece on the table and to turn on assembly status light Message Text or Image message is Text or Image message is shown on the screen to indicate parts to be picked
33. ut 5 a Output 6 an Output 7 l Output 8 Output 9 Output 10 a ha 1 Output 11 3 OUTPUT COM Return OV or Power 24V NOTE All outputs are optically isolated Max current capacity is 100mA per output Total of 500mA DPC Touch User Manual 25 9 5 Connection of DOGA low voltage tools GX GY DO GA Two tools can be simultaneously connected to corresponding ports DR1 and DR2 DPCTouch DOGA GX GY DO GA RJ45 1 0 port 1 and 2 2 Torque Up 2 gt Torque Up lr 3 Motor Run ix el O0 4 Motor Run 3 4 In COM la lt 120124 VDC J 5 A s Driver Lock External supply dr o mO 3 Driver lock o 30 i 1 6 Signal RIAS pinNe RI45 pinNe Signal AAA Controllers XT 30D XS 38D XS 40D XS 35D XT 35D NOTE Select GX GY DO GA tool interface in DPC Touch operating settings The tool is locked by short connecting contacts 5 and 6 1 Orange Not used White Orange stripe 3 Blue White Blue stripe Green White Green stripe 7 Brown White Brown stripe Not used I J vanat Co On On amp Co M A ATTENTION Use only straight RJ45 RJ45 cable not crossed DPC Touch User Manual 26 9 6 Connection of DOGA Hybrid HDC and Current control SDC tools DPCTouch DOGA HDC SDC series I O adaptor DB25 1 0 port DB44 male to DB9 female and
34. xample DPC Touch User Manual 20 7 5 Network Network communication is not enabled in firmware v 0 2 8 7 6 Other Real time monitoring of encoders and I 0 s screen 1 of 4 This interface helps to verify if encoders function correctly It also helps to check status of input signals and to force output signals to test wiring Touch screen calibration screen 2 of 4 Press on Start button to enter into touch screen calibration mode Press and hold indicated positions for 2 seconds in order to calibrate the screen ATTENTION if calibration is not correctly performed the touch screen may become unresponsive In this case turn off the controller take out the SD card access the SD card from your computer and delete the following file SD system setting Setting posi dat Sounds screen 2 of 4 Adjust the volume by using the slide bar Select desired sounds for Position Ok Alarm and Cycle complete signals Activate sounds to be used Date and time screen 3 of 4 Adjust current date and time The controller is equipped with internal battery to keep this data Language screen 3 of 4 Select language of the graphical interface Available languages in firmware v 0 2 8 English French German Spanish Password screen 4 of 4 Enter the new password and press Set Default factory password is 0 NOTE If the password is lost turn off the controller take out the SD card access the SD card from your computer and delete the fol
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