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section 1 - Apex Power Tools

1. Torque Angle Servo Gear Model No Max Max Calibration Calibration Parameter Ratio opeed RPM Torque Nm Factor Factor Set 225 Series Angle Tools EMR225RAYSGG30 1830 41 71 3 43 333 37 10 4 EMR225RAYSGG39 1645 53 70 7 55 750 37 13 38 EMR225RAYSGG44 1580 60 145 9 61 908 37 10 4 EMR225RAYSGG56 41450 76 143 1 79 647 37 13 38 EMR225RAYSGG72 1355 08 140 9 101 672 37 17 08 EMR225RAYSGG81 1315 110 140 1 113 578 37 19 08 EMR225RAYSGG92 1275 125 139 1 129 711 37 21 79 EMR225RAYSGG109 235 148 282 5 153 106 37 25 72 EMR225RAHYSGG92 275 125 139 1 129 711 37 21 79 EMR225RAHYSGG10 235 148 282 5 153 106 37 25 72 EMR225RAHYSGG13 190 183 280 4 189 833 37 31 89 EMR225RAHYSGG15 170 205 280 0 211 919 37 35 6 EMR225RAHYSGG17 145 233 278 7 242 158 37 40 68 EMR225RAYG195 125 264 365 0 282 694 37 61 05 EMR225RAYG230 105 312 365 0 331 364 37 71 56 EMR225RAYG250 100 339 462 3 357 992 37 61 05 EMR225RAYG290 88 393 462 3 419 619 37 71 56 EMR225RAYG340 T3 461 462 1 491 864 37 83 88 EMR225RAYG420 60 570 707 0 607 439 37 103 587 EMR225RAYG540 46 731 707 0 777 083 37 132 52 EMR225RAYGGAAMR 36 861 1767 0 990 542 37 10 4 EMR225RAYGG56MR 28 1037 1767 0 1274 753 37 13 38 EMR225RAYGG72MR 22 1342 1767 0 1627 156 37 17 08 EMR225RAYGG81MR 20 1485 1767 0 1816 978 37 19 08 EMR225RAYGG92MR 17 1702 1767 0 2075 758 37 21 79 EMR225RAYGG109M 15 2007 3611 2 2448 592 37 25 72 X Power Tools USER MANUAL Au
2. High evaluation torque _ 2 Threshold torque 1 4 Y i i Low evaluation torque 1 HP j m T Trigger torque 1 i d i Stat l T EH Angle f i Uinweighted angle high Block angle f Low evalua i i tion angle Unweighted angle low E Blanking angle Tightening angle i Graphic recording Maximum tightening time start pulse suppression The torque curve can be reverse analyzed after rundown is complete This reverse analysis starts at the shut off point the dwell time is not considered and is achieved using two separate angle ranges These angle ranges can be specified separately from one another by setting parameters for the end of the range unweighted angle high or low and the length of the range evaluation angle high or low The two evaluation angles can be in any order and also fully or partially overlap COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 19 version draft 0 5 Fastening Strategies The high evaluation angle of the torque curve is checked for overstep of the high evaluation torque and the low evaluation angle of the torque curve is checked for understep of the low evaluation torque
3. 15 1 O O Output amp O m OTP se Qutput 7 drei gli C 1 Inputs thru same as outputs Boo go Qoob oe e e e T Ce pe Leone un cn Le x Bb BHa 2 p E hj me aum o gru In order to set jumpers the CPU and Display Sub Assembly must be removed from the enclosure The jumpers are located on the top board There are 16 jumpers Starting from the top of the board the jumpers are labeled Output 0 thru Output 7 and Input 0 thru Input 7 Power Tools USER MANUAL Tork Trak TM Fastening Controller Automated Systems Section 12 8 version draft 0 5 Input Output Overview Tork Trak Default Public Configuration As shipped from the factory the standard default settings for Physical Discrete is e All OUTPUT jumpers on the I O Interface Board are connected to the Output Bus Common A e All INPUT jumpers on the I O Interface Board are connected to the Input Bus Common No wiring jumpers are installed for Internal or External 24 VDC No wiring jumpers are installed for Active High or Active Low Wire Jumpers for Public Setup within the I O Cable Connector Public Inputs and Outputs have 3 common buses designated A B and C There are a total of 6 Common Buses e Output Bus Common
4. High Angle Limit Final Speed 300 Backoff Settings Target Angle High Angle Limit Final Speed 300 sentes Save these Settings Xeno Cancel My Changes o pa stage Del Stage Sequence 80 Torque and Angle Control with Torque and Angle Monitoring COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 75 Fastening Strategy Programming Sequence 80 is a combination of Sequence 73 and Sequence 75 A shut off torque and a shut off angle can be programmed as target values If at least one of the two target values is reached the rundown is terminated Torque and Angle are both monitored Sequence 80 Set Point Definitions Parameter Definition Range of Values Shut off torque Torque as target value when it is reached the sequence is 0 Torque cal terminated Factor Max torque High limit of torque reached 0 1 2 x Torque If this limit value is exceeded the stage is evaluated NOK cal Factor Tq gt Torque too high Min angle Low limit of angle reached 0 9 999 If this limit value is not reached an NOK for the stage results ANG lt Angle too low Trigger torque When this torque is exceeded the recording for graphic 0 1 2 x Torque cal representation beings Factor If the trigger torque value is higher than the threshold torque the recording already beg
5. Tightening torque gradient __ EN pulse DA LA torque Low angle Maximum angle Angle Minimu angle Time Maximum tightening time Minimum torgue Dwell time In the electronic control system the lower gradient upper gradient percentage shut off value strobe multiplier filtering factor minimum torque maximum torque minimum angle maximum angle and speed are entered separately for each nutsetter The maximum torque maximum angle as well as the upper and lower gradients are also used as a safety shut down A maximum tightening time is entered as an additional safety shut down It applies to all nutsetters of a product group tightening process in this stage The measuring transducer integrated into the nutsetter measures the torque and rotation angle during tightening rundown The values are processed by the control system The nutsetter is stopped when the shut off gradient percentage rate of the currently measured maximum gradient search criteria is reached The dwell angle and peak torque during the dwell time are then measured and processed in the control system as the bolt tightening value together with the rundown evaluation The control system can display the values in tables on the monitor and can output them to a printer or transmit them to other system components by data communication COOPER PowerTools USER MANUAL Automated Syst
6. 2 COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 55 Fastening Strategy Programming Validity of individual parameters Sequenoe for evaluation Block angle blanking angle Safety torque shut down suppression Shut off angla Trigger torque When the values are equal the sequence for evaluation causes higher priority for evaluation for instance of the threshold torque before the trigger torque i e the threshold torque and thus angle counbing are actriated when the trigger Torque and threshold torque have the game numeric values even blanking angle is defined Bianking angle Trigger tongue Afer blanking angle Blanking angle degree Block After start pulse supe Adler black angle Black angle 0 pression degree Spead 1 At spindia start 1 Shut off point when speed 2 2 Threshold when apeed gt 0 Speed 2 From threshold torque Shut off paint Parameters that are analyzed reverse i e starting from the shut off point Parameier High valuation angie Shut off point minus Shut off point minus High ovaluation upper ursweighted uppser urmaeightbed angle 0 angle angle minus high eval uabon angle peer Shut paint rimus angle uppser ange High evaluation iorque Valid m the high evaluation angle High evaluation angie COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM
7. TEE Selected Panel Applications a go ka COOPER Tools PANEL APPLICATION 1 DEFINED ON THE PANEL Torque Units N m Stage Sequence Builder Stage 1 Seq 48 Backout with Angle Control Filter Factor 2 Backout with Angle Control This STAGE does not stop on ERROR Stage Timers MilliSeconds Hold Torque at End of Stage Start Delay Time Speed rpm Max Fastening Time 20000 Final Speed Setpoint pso Dwell Time m Torque Spike Filter lt Backoff Angle gt Torque Limits Max Fastening Time gt Trigger 3 000 Stage Retry Parameters Threshold 0 000 Stage Retry Type Touchup Min Torque at M1 Stage poo Max Torque at M1 Stage non Min Torque at M2 Stage 0 000 Max Torque at M2 Stage pon Min Torque at Shutoff pon Max Torque at Shutoff 0 000 After Retry goto Stage 1 Maximum Retries Global to the Application Relax the Tools on the Final Stage Backoff on ERROR Touch Up Settings Target Angle High Angle Limit Final Speed 300 Backoff Settings Target Angle High Angle Limit Final Speed 300 Angle Control Degree BackoffAngle 1000 Low Limit D Angle at n Angle atM2 0 High Limit 9998 c Save these Settings x Cancel My Changes pa Ada Stage Del Stage gt Sequence 48 Backoff Angle Control with Torque Monitoring COOPER PowerTools US
8. gt S 84 c 9 O X d c o S X ud gt ud d g 4 TMH SERVO MODULE 67 E approx 2 2 Replace handtool Internal error replace TMH Check tool cable for short circuit Check motor for short circuit phase impedances see failure 11 Internal error replace TMH Measures Remedy Check 52 Pin 1 2 for connections Internal error replace TMH Check handtool temperature if gt 60 decrease fastening time by increasing the speed Replace handtool Internal error replace TMH COOPER PowerTools Automated Systems Section 16 26 USER MANUAL Tork Trak TM Fastening Controller version draft 0 5 Resolver error The resolver signals are e Interrupted e Shorted e Not present The internal 12 V power supply is e shorted Intermediate circuit voltage X X X too high The voltage of the intermediate circuit of the power section is gt 400 VDC 8 Top Display 8 Bottom Display Error Explanation COOPER PowerTools Automated Systems Consequence Main and Startup Relay Output Section Off Brake Motor Output LED Ready off Permanent error During braking e oporadically e e Internal error replace TMH TMH SERVO MODULE Handtool connected Check tool cable for
9. Low evaluation angle Shut off point minus Shut off paint minus Low evaluation laser unseighted angle p angle angle minus bow evalu ahon angle Lower urvelghted amp hul alT peint Shut off point minua an angle upper unvweighbed angie Low evaluation bonae Low lad the angia angio 0 COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 38 Fastening Strategy Programming Switch Off Torque Control Sequence 33 Advanced Application Builder 16 x Navigate About Help Exit em Stations Tools Applications Selected Database are are E m nva LOCAL El COOPER PowerTools 243 APPLICATION 1 DEFINED THE PANEL Torque Units Nm Stage Sequence Builder Stage 1 33 Torque maintenance with shut off torque control Filter Factor 2 Tq Control with auto retighte This STAGE does not stop on ERROR Stage Timers MilliSeconds SEQ 33 t eet nT Torque Hold Torque at End of Stage Start Delay Time p Speed rpm Max Fastening Time 20000 A Min Torque me Final Speed Setpoint 200 Dwell Time 0 cycle lt Fastening Time gt Torque Control Stage Retry Parameters Stage Retry Type Touchup After Retry goto Stage Maximum Retries 0 High Limit 0 000 Target Shutoff 100 0 Low Limit 0 000 Thre
10. Output Bus Common B Output Bus Common C Input Bus Common Input Bus Common B Input Bus Common C Each individual common bus can be connected to 1 of 5 functions e Internal 24 VDC e External 24 VDC e Active High 24 VDC e Active Low 24 VDC return e 1to8INPUTS 1 to 8 OUTPUTS 3 Power Tools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 12 9 version draft 0 5 Input Output Overview Schematic of the typical photo isolated bi directional INPUT input Jumper o o D 7 n optolsolator input B f H Fin Pin Pin 23 24 25 Input Common Buses Schematic of the typical Relay OUTPUT m 0 relay do output Output Common B Buses Fin Pin Pin 27 12 Input Common Buses COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 12 10 version draft 0 5 Input Output Overview I O Setup Instructions Internal 24 VDC All Inputs and Outputs Active High 1 On the Public I O cable connector jumper pins 14 24 VDC to 2 Output Common A 2 the Public I O cable connector jumper pins 11 DC common to 23 input Common 3 On the interface Board set all jumpers to Input Common and Output Common A External 24 VDC All Inputs and Outputs Active High 1 On the Public I O cable connector connect the external 24 VDC to pin 2 Output Common A 2 On the Public I O
11. 3B approx 2 AD ANNnraw 4 Y Check motor cable for short circuit Short circuit in motor circuit N23 24 o 29 MEL Check motor for short circuit n motor phase impedances see failure e in 444 COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 24 version draft 0 5 TM12 and TM34 SERVO MODULES lt gt r 00 Top Display Bottom Display CO Error Explanation Motor temperature too high e Thermal switch in motor tripped 9 120 C Measuring line broken Measuring current misguided e Motor not connected l t monitoring Required motor output is too high Nutrunner is defective e g gearing bearing Resolver error The resolver signals are e interrupted shorted e not present The internal 12 V power supply is shorted Consequence D D Main and Startup Relay off Output Section Off Brake Motor Output Measures Remedy Motor connected Check motor temperature if gt 80 ensure sufficient ventilation of motor Check motor cable for continuity and short circuit Check continuity of motor thermal switch Internal error replace TM Check motor temperature if gt 80 decrease fastening time by increasing the speed Replace motor nutrunner Internal error replace TM Resolver connected Check resolver cable for continuity and
12. Low Limit 0 Gradient Monitoring High Gradient Limit 100 High Angle Limit Low Gradient Limit 0 000 Final Speed 300 Strobe Multiplier 2 Backoff Settings Target Angle High Angle Limit Final Speed 300 pa Ada Stage De Stage gt Sequence 75 Angle Control Torque and Gradient Monitor COOPER PowerTools Automated Systems NA USER MANUAL Tork Trak TM Fastening Controller Section 7 67 Fastening Strategy Programming Sequence 75 Setpoint Definitions Parameter Definition Range of values Shut off angle Angle as target value when it is reached the rundown is terminated 0 9 999 Min angle Low limit of angle reached 0 9 999 If this limit value is not reached an NOK for the stage results ANG lt Angle too low Max angle High limit of angle reached 0 9 999 If this limit value is exceeded the stage is evaluated NOK gt too high Trigger torque When this torque is exceeded the recording for graphic representation begins 0 1 2 x torque cal If the trigger torque value is higher than the threshold torque Factor the recording already begins when the threshold torque is exceeded Threshold torque When this torque is exceeded the angle counting and gradient calculation begin 0 1 2 x Torque cal Starting from reaching of the threshold torque one measuring Factor point in excess of the strobe multiplier must ha
13. 63 Fastening Strategy Programming Sequence 73 Setpoint Definitions Range of values Shut off torque Torque as target value when it is reached the sequence is 0 torque cal Factor Min torque Low limit of torque reached 0 Torque cal Factor If this limit value is not reached NOK for the stage results lt Torque too low Max Torque High limit of torque reached 0 1 2 x Torque cal Factor If this limit value is exceeded the stage is evaluated NOK gt Torque too high Trigger torque When this torque is exceeded the recording for graphic representation begins 0 1 2 x Torque cal Factor If the trigger torque value is higher than the threshold torque the recording already begins when the threshold torque is exceeded Threshold torque When this torque is exceeded the angle counting and gradient calculation begin 0 1 2 x Torque cal factor Starting from reaching of the threshold torque one measuring point in excess of the strobe multiplier must have been collected for the first gradient value to be computed If the threshold torque is lower than the trigger torque the recording for graphic evaluation begins already when the threshold torque is exceeded Min angle Low limit of angle reached 0 9 999 If this limit value is not reached an NOK for the stage results ANG Angle too low COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening C
14. Automated Systems North America 4121 N Atlantic Blvd Auburn Hills Michigan 48326 Phone 248 391 3700 Fax 248 391 7824 Version 0 5 DRAFT COOPER PowerTools Copyright Cooper Power Tools November 2005 All rights reserved CONTENTS CONTENTS SECTION ONE Introduction to the Tork Trak TM Controller Ease of Programming Tool Library LCD Display Graphics Fastening Strategies otatistics Reporting Other Features Unpacking Installation Enclosure Mounting Dimensions Connecting the Tool Electrical Requirements Power Drop Wiring RFI Filtering and Surge Suppression zd m aede uei au uu W SECTION TWO Overview of the Tork Trak TM Controller T3M Enclosure Top Assembly 2 1 CPU and Display Sub Assembly 2 3 Tork Trak TM Controller PC 104 Technology 2 4 Connector Plate Sub Assembly 2 8 Sub Plate Sub Assembly 2 9 TM Servo Module 2 10 Keyboard and Mouse 2 11 cos em Power Tools USER MANUAL Automated Systems Tork Trak TM Fastening Controller Section 0 i version draft 0 5 CONTENTS SECTION SIX Fastening Strategies Sequences Overview 6 1 Sequence 10 Engagement Stage 6 2 Sequence 11 High Speed Rundown 6 3 Sequence 13 Free Rundown 6 5 Sequence 15 Frictional Measurement 6 11 Sequence 16 Event dependent Turning 6 14 Sequence 20 Torque Control Torque Monitor 6 15 Sequence 30 Torque Control Torque and Angle 6 17 M
15. Internal error replace TM Transducer 1 rundown counter NOK Check transducer cable The rundown counter in the especially the RS422 data transducer does not work the lines maximum number of rundowns for Replace transducer the transducer have been exceeded Internal error replace Only on transducers with service memory e g 1 1 Transducer 1 rundown counter at limit The rundown counter in the transducer has reached its maximum number of rundowns of 107 or it is defective Only on transducers with service memory e g 1 1 Replace transducer COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 37 version draft 0 5 TM12 and TM34 SERVO MODULES Transducer 2 not present Is the transducer connected The transducer signal is Check transducer cable for e interrupted continuity and short circuit Shorted Replace transducer e not present Internal error replace TM COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 38 version draft 0 5 TM12 and TM34 SERVO MODULES O O 2 o a c lt gt r uvv Measures Remedy Top Display Bottom Display Error Explanation Main and Startup Relay Output Section Off Brake Motor Output Transducer 2 Offset NOK The zero point voltage is out of the admissible range between 200 mV 200
16. 0 100 Filtering factor 1 2 4 8 16 2 Definition Admissible percentage of deviation from the limit value in the evaluation angle Across the evaluation angle the torque values are checked for exceeding of the min evaluation torque If the deviation is more than the admissible percentage an NOK evaluation for the stage results P2UN FRTM Too much understep in phase 2 If there are deviations but less than admissible this will not lead to an NOK evaluation but only a warning will be output P2M gt FRTM Torque in phase 2 too small If there is too much overstep and understep the error message 200 Too much overstep and understep in phase 2 will appear Number of torque values used to find mean value With this number of torque values a mean value is calculated immediately upon measurement corresponding to filtering and dampening As soon as a new value is measured the oldest value is deleted and the mean value is recalculated The further evaluation shut off evaluation graph is made with these mean values A filtering factor of 1 results in no mean values being computed COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 16 Fastening Strategy Programming Sequence 13 Setpoint Definition cont d Value Range Max evaluation torque High torque limit value during the rundown phase 1 FRTM angle and in the subsequently evaluated
17. 300 Backoff Settings Target Angle High Angle Limit Final Speed 300 Sequence 51 Torque Control Self Tap with Angle Control COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 51 Fastening Strategy Programming Sequence 51 Shut off angle controlled fastening with angle and torque monitoring Sequence 51 is an angle contralled sequence which allows the rundown to be evaluated after the shut off angle has been reached by means of reverse analysis over two monitoring ranges Additionally fhe monitoring targue can be changed by angle range during the rundown Details Torque by Eire M borg La hi Eu Micon ange Uerum Tp Inr Angle 1 Liss bon i High ava khon angie ange qum Lite age ke 2 Manting mgs magie Graph iie i zhi M poi rur herrea Fires La m Sri muppression Dro eee Ft Tap The torque curve can be reverse analyzed after rundown i complete This reverse analysis sians at the shut off point the dwell time is nat considered and amp achieved using two separable angle ranges These angle ranges can be specified separately from ane anot
18. A Y 8 8 X LED Ready off Main and Startup Relay Output Section Off X Brake Motor Output 5 V supply in measuring board too high The 5 V power supply for internal supply of the measuring board is defective U gt 5 2 VDC Internal error replace TMH communication between servo and measuring board is defective Flash error servo X X X e Internal error replace TMH The flash memory is defective DPR error servo e Internal error replace TMH The Dual Port Ram for DPR communication to Torque X X e Internal error replace TMH interrupted The Dual Port RAM communication between servo and measuring board is failing COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 30 version draft 0 5 TMH SERVO MODULE Start signal sequence faulty e Internal error replace TMH Communication error between e Inform Cooper Tools service measuring board and servo department amplifier MOTIDerror Internal error replace TMH Error in motor identification mode Inform Cooper Tools service department Measuring board not ready Measuring board present The signal measuring board OK Measuring board firmly is not received by the servo secured to TMH section Error in program processing 4 Mathematic error illegal command e Internal error replace TMH Internal error replace TMH COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fas
19. Check all connector locks Check ARCNET cable for continuity and short circuit Internal error replace TM Refer to Display of Errors COOPER PowerTools Automated Systems USER MANUAL Tork Trak TM Fastening Controller Section 15 43 version draft 0 5 TMH SERVO MODULE SECTION 16 TM Servo Module for Handtools TMH 960902 COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 1 version draft 0 5 TMH SERVO MODULE General Information General Description of Tightening Modules TMH In the tightening module TMH the servo amplifier output section and the measuring section measuring board Torque are integrated in one housing he difference between the 12 34 and the TMH is the special adaption of the software in the servo amplifier and the measuring board of TMH to handheld tools There are separate processors for measuring and output section Motors are controlled digitally The control parameters for different motors or hand tools are saved permanently in the TMH and are selected by the measuring board Field of Application tightening module has been designed to operate Cooper Tools handheld angle nutsetters 17E ATE 67E e The tightening module is used in conjunction with the station controller m Pro 400 Touch screen e The TMH communicates with the station controller m Pro 400 Touch screen via
20. E d E 5 gi 12 E ii po Initial Torque Tightening angle Angle Cycle 1 Cycle 2 Cycle n 1 Cycle a Time o on am an att an att on gt Rb Masi mum running ti re This tightening procedure must be preceded by a pre clamping Sequence Sequences 30 31 50 51 63 73 75 and 80 show the clamping procedures The electronics for each spindle have separate parameters for number of repetitions on time off time the switch off torque maximum moment minimum moment maximum angle minimum angle damping factor trigger moment the threshold torque and the specified RPM s The maximum angle is used as a safety switch off Maximum running time is also specified as an additional safety switch off This affects all spindle drivers of a product group driving process in this stage COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 24 version draft 0 5 Fastening Strategies The torques and angles of rotation during an operation are measured and processed in a sensing element built into the drivers The angles are measured once the threshold moment has been achieved The driver is operated alternately between rotary motion and maintaining the desired torque Upon reaching Switch off Torque the driver is stopped and the switch off torque is maintained preventing mechanical relief of the spindle During the off time the mechanical s
21. Ihe corresponding angle the terque are compared to fhe minimunm rmisximum angle and the minimum maximum torque and evaluated accordingly as OK or Reverse analysis is also canned out The maximum angle maximum torque shut down torque and maximum lightening time Tor the stage are used s safety shut down COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 53 Description of parameters Sequence input value Filtering factor Trigger torque Nm Threshold torque Nm Safety shutdown torque Nm Shut off angle dag Blook angle deg Blanking angle deg Unweighted angle high deg Evaluation angle high deg High evaluation torque Nm Unweighted angle low deg Evaluation angle low deg Low evaluation torque Nin Maximum terque Nm Minimum terque Maximum angle deg Minimum angle deg Fastening Strategy Programming 51 Humber af torque values used far averaging Beginning of storing torque values for the graphic display reverse analysis and blanking angle Baginning af angle counting valid outside the blanking angle and black angle Montering targue valid after start pules suppres sion has finished and during the rundown and the value at which the drive is stopped when tt is exceeded Angle at which the drive is stopped and the dwell time begins Angle beginning t
22. In the evaluation phase phase 2 which is carried out after rundown the values recorded between threshold torque on and threshold torque off are evaluated Torque values within the unweighted angle starting from threshold torque off are not considered Torque values in the subsequent evaluation angle range are checked for overstep of the maximum evaluation torque and understep of the minimum evaluation torque Oversteps and understeps within the evaluation angle starting from the recorded measuring points are tolerated The portion of measuring points that may lay outside of the evaluation torques so as not to trigger a NOK is set with the above limit and below limit parameters A warning is output should this occur Any remaining measurements are not considered The error message no measurements present and NOK are output if the sum of the evaluation angle and unweighted angle is greater than number of existing measurements Error message FSMW FRTM Not enough measurement values The whole rundown evaluation is processed in the control system The control system can display the values as text or in tables on the monitor and can output them to a printer or transmit them to other system components by data communication When the spindle trigger torque is reached and at the latest when a spindle reaches threshold torque on recording of the torque curve starts and the curve can be viewed and evaluated in a graphic The control system
23. Mimm M 5 EE o a LE safety b torque i Graphic recording Backaff angle x E vo Maximum tightening time One check is carried out at each of the two points M1 and M2 in order to ascertain whether M1 min M1 max and M2 min M2 max torque limits are understepped or overstepped Points M1 and M2 are specified by the angle at M1 and angle at M2 from the threshold torque Should the torque at these points not lay within the corresponding min max limits the drive is stopped and the rundown data is evaluated as NOK The time sequence for the two points is not specified i e M1 can lay to the left or right of M2 or at V2 The torque check in the points M1 and M2 can be deactivated individually by setting the angle at M1 or M2 to zero COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 31 version draft 0 5 Fastening Strategies oafety shut down torque parameters are set as an additional safety cutout The drive is stopped when the safety shut down torque is exceeded which applies in the sequence from the end of the impulse suppression time up to the shut off point An error message with NOK evaluation is generated The torques at M1 and M2 as well as the maximum torques in the rundown are measured and the results are included in the statistical evaluation Angle counting starts from the threshold torque After switch off due
24. TM Servo Module There are three different TM Servo Modules available which supply different values of peak current The servos are matched to different tools to deliver specific ranges of rated torque The servo also evaluates outputs from the torque transducer and resolver All fastening strategies sequences are resident within the Servo Module firmware TMH Servo Used with all Cleco hand tools and Rotor Tools Rated at 40 amps peak current TM12 Servo Used with all Series 1 and 2 DGD fixtured spindles Also used with EMT 80 and EMT 200 fixtured tools Servo rated at 22 amps peak current TM34 Servo Used with all Series 3 and 4 DGD fixtured spindles Also used with EMT 400 EMT 600 and EMT 800 fixtured tools Rated at 66 amps peak current COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 2 10 version draft 0 5 Overview of the Tork Trak TM Controller Keyboard and Mouse The Keyboard is full function 88 keys and mouse trackball 2 keys Upper right corner for the trackball and upper left corner for the mouse function keys The end of the keyboard cable splits to two mini DIn 6 pin connectors One is for the keyboard function and the other is for the mouse function Both connectors plug into the external connector plate at the bottom of the enclosure The connector closest to the front connects the keyboard and the connector closest to the rear connec
25. The tightening process is assessed as being NOK if there were oversteps and or understeps The maximum torque is measured within the high evaluation angle and the lowest torque value within the low evaluation angle and statistical evaluation is carried out The evaluation torques can be deactivated by setting the corresponding evaluation angle to zero In the block angle range which begins directly after the start pulse suppression the torque must not exceed the shut off torque as this will stop the drive This serves to detect rundowns that are carried out on a tightened bolt The block angle can be deactivated by setting it to zero The torque curve is recorded for the graphic starting from the trigger torque 1 torque value per angle degree These values are also the basis for the reverse analysis Therefore the trigger torque must be parametrized so that the torque curve relevant for reverse analysis is always recorded An error message with NOK evaluation is generated if there are insufficient torque values for reverse analysis The torque curve can be output as a graphic Parameters can be set for a blanking angle that starts when trigger torque is reached During the blanking angle detection of the threshold torque and shut off torque is deactivated and is only reactivated after the blanking angle has finished It is permissible for the torque to be higher than the shut off torque in the blanking angle but the safety shut down to
26. Thereafter the resistor is bridged by the start up relay e TM34 must be operated on a three phase supply via an isolation transformer approved by Cooper Tools Connector 51 12 34 Nutrunner type 4B Supply voltage 1 X 230 VAC 10 3 230 10 Frequency 50 60 Hz Rated supply current 3X2 5A 3X2 5A RMS Peak supply current 16A 3X10A 3X16A RMS Internal fusing slow 10A 3X10A blow Starting current limit Intermediate Circuit of Logic Section All logic voltages and supply voltages for the communication functions are generated from the intermediate circuit of the logic section Connector 51 TM12 TM34 Supply current 1 X 230 10 Frequency 50 60 Hz Rated Supply current approx 0 1 A Internal fusingError 0 63 A Bookmark not defined slow blow Power loss standby 24 W COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 6 version draft 0 5 TM12 and TM34 SERVO MODULES Internal Power Supply Units Supplied by the intermediate circuit of the logic section galvanically separated All generated voltages are short circuit protected e The ARCNET output level is galvanically separated from all other supplies The clock speed of the DC DC converter is 80 kHz ee a voltage logic analog 1A Transducer excitation 12 V 0 2V Transducer excitation 12V 0 2 V Supply of ARCNET outpu
27. Torque Control Stage Sequence Builder Ang Tq Con Tq Grad Mon i Torque range 1 0 Ld INE Max Fastening Time gt mM High Limit p 000 Stage Retry Parameters Target Shutoff 5 000 Stage Retry Type Touchup Low Limit 0 000 Threshold p 000 Trigger 3 000 Angle Monitoring Degree Ta After Retry goto Stage 1 Maximum Retries 0 Global to the Application High Limit 9999 Relax the Tools on the Final Stage Shutoff Limit p Backoff on ERROR Touch Up Settings Target Angle High Angle Limit Final Speed 300 Backoff Settings Target Angle 0 High Angle Limit Final Speed 300 Low Limit 0 o Gradient Monitoring High Gradient Limit 1 000 Low Gradient Limit 0 000 Strobe Multiplier 2 Gs Adi Stage Del Stage setae satinas Save these Settings x Cancel My Changes Sequence 78 Torque Control Angle and Gradient Monitor Sequence 78 is a combination of Sequence 73 and Sequence 75 A shut off torque and a shut off angle can be programmed as target values If at least one of the two target values is reached the rundown is terminated COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 71 Fastening Strategy Programming Sequence 78 Set Point Definitions Parameter Definition Range of Values Shut off torque Torque as t
28. graphics supporting a wide variety of fastening system applications 1 GM COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 1 1 version draft 0 5 Introduction to the Tork Trak TM Controller Some of the features of the T3M controller include NEMA 12 enclosure design TM Multi Trak software which is the same software used on Cooper Power Tools Automated Systems multiple spindle panels so there s no need to learn different programming procedures on fixtured tools and handtools Improved PC 104 Celeron CPU with extremely compact design lower power consumption wide operating temperature range and very high reliability Improved Servo Amplifier design with accurate speed control as low as 3 rpm through max speed The new servo amplifier integrates transducer and resolver measurements with the servo power functions within a single compact module Remote support which has optically isolated inputs and relay contact outputs which are externally accessible fuse protected New firmware support which includes global memory graphical fastening strategy programming screens supporting Torque Control Angle Control Self Tap Prevailing Torque and Yield fastening strategies Software support to permit synchronization of multiple Tork Trak servos for multi spindle applications Increased support for an unlimited number of Applications Communications suppor
29. jammed position Check with test mode of station controller if values are out of admissible ranges if so replace transducer Internal error replace TM COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 35 version draft 0 5 TM12 and TM34 SERVO MODULES 7 Transducer 1 calibration voltage Transducer installed in 3 The calibration voltage is out of jammed position the admissible range between 4 85 V 5 15 V Check with test mode of station controller if values are out of admissible ranges if so replace transducer If deviation is extreme check transducer cable especially the calibration line Internal error replace TM COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 36 version draft 0 5 lt gt r 00 TM12 and TM34 SERVO MODULES O O 2 o a c Measures Remedy Top Display Bottom Display Error Explanation Main and Startup Relay Output Section Off Brake Motor Output Check at the station controller If no angle signals are detected in testmode Check transducer cable especially the angle lines Transducer 1 angle tracing NOK The angle signals are e interrupted shorted e not present not present part of the time opindle rotates more than 360 degrees Check angle factor Replace transducer
30. lower limit of achieved angle COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 25 version draft 0 5 Fastening Strategies Threshold torque Nm Threshold moment Nm Number of repetitions THC on time ms THC off time ms Damping factor RPM Threshold torque start of angle counter Trigger moment start of value recording for graphic display Number of repetitions of THC on time and THC off time The spindle remains switch on for the duration of this period as long as the switch off torque has not been achieved The spindle remains in hold mode as long as the minimum torque is maintained Damping factor number of measured values based on averaging applied to damping RPM selection in the range of specified maximum RPM s in the spindle constants COOPER PowerTools Automated Systems NA USER MANUAL Tork Trak TM Fastening Controller Section 6 26 version draft 0 5 Fastening Strategies Sequence 41 Shut off Angle Controlled Backoff with Backoff Angle Monitoring start pulse suppression Dwell time Maximum tightening time Shut off angle Angle Minimum angle Maximum angle Backaff torque Torque negative In the electronic control system the shut off angle maximum angle minimum angle filtering factor and speed are entered separately for each nutsetter A maximum tightening time is entered as the
31. max speed Threshold torque 0 1 2 x Torque cal factor Filtering factor 1 2 4 8 16 32 Low limit of torque reached If this limit value is not reached NOK for the stage results Tq Torque too low Angle as target value when it is reached the rundown is terminated High limit of angle reached If this limit value is exceeded the stage is evaluated NOK gt Angle too high Set speed of the spindle s output shaft When this torque is exceeded the angle counting and gradient calculation begin otarting from reaching of the threshold torque one measuring point in excess of the strobe multiplier must have been collected for the first gradient value to be computed If the threshold torque is lower than the trigger torque the recording for graphic evaluation begins already when the threshold torque is exceeded Number of torque values used to find mean value With this number of torque values a mean value is calculated immediately upon measurement corresponding to filtering and dampening As soon as a new value is measured the oldest value is deleted and the mean value recalculated The further evaluation gradient calculation shut off evaluation graph is made with these mean values A filtering factor of 1 results in no mean values being computed COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 77 Fastening Strategy Programming Relax
32. 17 Series Pistol Tools 17EP06Q 2600 6 7 0 21 333 32 7 5 17EP12Q 1200 12 12 9 46 886 32 16 484 17EP17Q 860 17 17 9 66 172 32 23 264 17EPOGD2 2600 6 7 0 32 7 5 17EP12D3 1200 12 12 9 46 886 32 16 484 17EP17D3 860 17 17 9 66 172 32 23 264 17EP22D3 650 22 32 2 86 612 32 30 45 47 Series Right Angle Tools 47EA33AM3 895 33 66 9 63 504 34 22 32613 47EA43AM3 685 43 65 5 82 831 34 29 12082 47EA60AM3 485 61 64 2 116 555 34 40 97653 47EA60AM4 485 61 64 2 116 555 34 40 97653 47EA90AH4 340 87 158 4 165 687 34 58 24998 47EA105AH4 230 104 156 7 248 086 34 87 21911 47EA135MH4 180 133 199 7 316 246 34 111 1821 47EA175AX5 130 176 231 2 441 626 34 155 261 47EA230AX5 100 230 228 7 576 034 34 202 5155 X LN Power Tools USER MANUAL Automated Svstems NA Section 17 2 Tork Trak TM Fastening Controller Tool Library Settings Torque Angle Servo Gear Model No Max Max Calibration Calibration Parameter Ratio opeed RPM Torque Nm Factor Factor Set 47 Series Inline Tools ATES12ZA 2600 12 19 8 21 333 34 7 5 47 52217 1490 22 43 6 38 095 34 13 393 47 52817 1145 28 42 7 49 689 34 17 469 47ES401ZA 810 40 41 9 69 919 34 24 581 47 56022 570 57 103 3 99 392 34 34 943 ATESTO2ZA 380 68 102 2 148 822 34 52 321 47 58022 300 82 153 7 188 271 34 66 19 47 511527 215 115 150 8 264 923 34 93 138 47 515022 165 150 149 1 345 551 34 121 485
33. 5 Fastening Strategies Post Rundown Fastening Strategy PTR Pulse torque recovery The Pulse Torque Recovery PTR function provides a way to program torque recovery by pulsing make up torque at the conclusion of a fastening rundown and is used most successfully on joints which are either gasketed springy sheet metal or soft metal aluminum where a make up torque is required If the joint begins to relax immediately following the rundown PTR can add a pre programmed amount of torque for a pre programmed time duration if the torque drops below a pre programmed value This strategy was awarded U S Patent 5 094 301 Pulse torque recovery is applied at the conclusion of a fastening rundown and is used most successfully on joints which are either gasketed or springy sheet metal where a makeup torque is required If the joint begins to relax immediately following the rundown Torque Recovery can add a pre programmed amount of torque for a pre programmed time duration if the torque drops below a pre programmed value This strategy was awarded U S Patent 5 094 301 PTR can be applied to the final stage attached to either Sequence 20 PTR Pulse Torque Recovery or Sequence 30 PTR Shut off Torque Controlled Fastening with Torque Monitoring and Angle Monitoring The rundown graphic for Sequence 30 PTR appears below Torque Maximum torgu PTR Angle Time pulse suppres
34. 7 8 9 NC Housing 1 Shield connection PE protected earth ground Short circuit protected Galvanic separation from all other functional assemblies of the TM Type 9 pole D Sub pins with slide lock systems Inotec 2 4 7 9 3 COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 19 version draft 0 5 TM12 and TM34 SERVO MODULES 5 GND ARONET 6 5V ARCNET 8 J DATAA Housing Shield connection PE protected earth ground Transducer No 1 XS6 Controlling Transducer Transducer No 2 XS7 Redundant Transducer for Cross checking Short circuit protected Type 15 pole D Sub socket with lock screws 4 40 UNC threads Measuring signal Analog input 5 5 V measuring range 6 25 6 25 2 _ Supply analog Calibration signal Output 5 V 0 5 V Imax 15 mA checking adapter Output 5 V 0 5 V 5000 TE track 1 Input 0 5 V 0 7 12 v 1 pull up 1 KQ Supply 12 V Output 12 V 0 2 V Imax 100 mA Supply 12 V Output 12 V 0 2 V Imax 200 mA 8 j SupplydigtalOV 0 0 0 9 5422 TxD Output 5000 V 1 pull up 1 14 Interface RS422RxD Inpt 5 Finterface RS422 RxD npt _ Housing Shield connection PE protected earth EE ground COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Con
35. 75 475 650 9 481 317 37 173 274 X Power Tools USER MANUAL Tork Trak TM F i Automated Svstems ork ira astening Controller Section 17 11 Tool Library Settings Torque Angle Servo Gear Model No Max Max Calibration Calibration Parameter Ratio opeed RPM Torque Nm Factor Factor Set EMR225RYSG435 60 590 650 9 594 428 37 213 994 EMR225RYSG450 55 610 650 9 648 886 37 233 599 EMR225RYSG535 43 725 1179 7 838 361 37 301 81 EMR225RYSG625 37 848 1179 7 982 694 37 353 77 EMR225RYSG775 30 1051 1179 7 1213 639 37 436 91 EMR225RYSG1050 722 1424 2595 3 1642 500 37 591 3 EMR225RYSG1230 109 1668 2595 3 1925 278 37 693 1 EMR225RYSG1520 115 2061 2595 3 2377 722 37 855 98 EMR225RYGM2400 19 3254 3390 0 4161 097 37 1497 995 EMR225RYGM3000 17 4068 10170 0 5145 633 37 1852 5 150 Series Offset Tools EMR150RFOGG7 1140 9 10 5 36 503 35 13 141 EMR150RFOGG9 920 12 10 4 45 342 35 16 323 EMR150RFOGG12 740 16 22 2 56 250 35 20 250 EMR150RFOGG16 585 22 21 9 70 833 35 25 5 EMR150RFOGG20 465 27 35 5 89 197 35 32 111 EMR150RFOGG23 415 31 35 4 100 000 35 36 0 EMR150RFOGG29 330 39 51 0 125 925 35 45 333 EMR150RFOGG33 280 45 50 8 147 964 35 53 267 X Power Tools USER MANUAL Automated Svstems NA Section 17 12 Tork Trak TM Fastening Controller Tool Library Settings Torque Angle Servo Gear Model No
36. 781 5 3126 23 48 84 EMT800 SERIES TOOLS 800 2 102 1074 9 1124 1 3126 28 48 84 2 Power Tools USER MANUAL Tork Trak TM F i Automated Svstems ork ira astening Controller Section 17 18 Recommended Spare Parts SECTION 18 Recommended Spare Parts mpm X length in feet X length in feet X length in feet 3 5 6191 1 SUBCON Connector for Public O Female 25 pin D shell with terminal blocks Mates with T3M Enclosure Public connector for customer application 4 5 6211 1 SUBCON Connector for Private O Male 25 pin D shell with terminal blocks Mates with Private connector for customer application 572636 Keyboard 88 keys includes touchpad 576140 1 Indicator Light Board Assembly including bulbs LCD brightness adjust circuit and connectors f qme Indicator Lamp 14 volts 100 ma 10 000 hour wire terminals 572660 1 PC 104 I O Module 8 input 8 Output Optocoupler Digital Inputs and Relay Outputs 9 575933 DeviceNet Board PC 104 Slave 8 4 inch XGA TFT Digital LCD Display 10 576165 Inverter DC to AC Inverter Low Profile Off board Dimming Dual Tubes Output 12 1 Profibus Board PC 104 Slave 13 J 1 interbus Board PC 104 Slave 2 442124414410 RS 232 Serial Connection Port Option COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 18 1 version draft 0 5
37. ATES1653ZA 150 165 3 5 8 380 672 34 133 8317 47 525037 100 247 371 7 569 987 34 200 3894 47 5120 2600 12 14 0 21 333 34 7 5 47ES12D2 2600 12 14 0 21 333 34 7 5 ATES25D3 1200 25 33 2 46 886 34 16 484 ATES36D3 860 36 37 8 66 172 34 23 264 47ES48D3 650 48 49 8 86 612 34 30 45 47 Series Pistol Tools 47EP12Q 2600 12 14 0 21 333 34 15 47EP12D2 2600 12 14 0 21 333 34 7 5 47EP25D3 1200 25 33 2 46 886 34 16 484 X Power Tools USER MANUAL Automated Svstems NA Section 17 3 Tork Trak TM Fastening Controller Tool Library Settings Torque Angle Servo Gear Model No Max Max Calibration Calibration Parameter Ratio opeed RPM Torque Nm Factor Factor Set 47EP36D3 860 36 37 8 66 172 34 23 264 47EP48D3 650 48 49 8 86 612 34 30 45 47 Series TubeNut Tools ATET20T2bDOO 950 20 36 0 59 732 34 21 ATET20T2MDOO 950 20 36 0 59 732 34 21 ATET20T2MGOO 950 20 36 0 59 732 34 21 47 680 30 49 9 82 772 34 29 1 ATET30T3MGOO 680 30 49 9 82 772 34 29 1 ATET30T3MMOO 680 30 49 9 82 772 34 29 1 ATETAOTAEKOO 515 40 66 2 109 865 34 38 625 ATETAOTAEMOO 515 40 66 2 109 865 34 38 625 ATETAOTAMROO 515 40 66 2 109 865 34 38 625 ATETAOTAMUOO 515 40 66 2 109 865 34 38 625 67 Series Right Angle Tools 67EA235AL6 145 230 278 7 247 942 36 87 16867 67EA255AL6 125 255 277 7 292 562 36 102 8554 67EA340AM6 100 335 462 3 366 696 36 128 9188 67EA460AM6 73 460 462 3
38. About Exit T n Applications Selected Panel valle valle LOCAL PANEL 7 DEFINED THE PANEL Torque Units N m COOPER Tools Stage 1 Seg 20 Torque Control Filter Factor D gt This STAGE does not stop on ERROR Stage Timers MilliSeconds Hold Torque at End of Stage Start Delay Time o Speed rpm Max Fastening Time 20000 Final Speed Setpoint 250 Dwell Time fo Torque Control Stage Sequence Builder Torque Control Tightening 020 Shut off Torque Li Max Fastening Time gt 1 High Limit p 000 Stage Retry Parameters Target Shutoff 5 000 Stage Retry Type Touchup Low Limit 0 000 Trigger 3 000 After Retry goto Stage li Maximum Retries lo Ta Global to the Application Relax the Tools on the Final Stage Backoff on ERROR Touch Up Settings Target Angle High Angle Limit Final Speed 300 Backoff Settings Target Angle High Angle Limit Final Speed 300 pa Ada Stage Del Stage gt E Save these Settings x Cancel My Changes Sequence 20 Torque Control COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 23 Fastening Strategy Programming Sequence 20 Setpoint Definitions Parameter Definition Range of Values Shut off torque Torque
39. During start up start time begins with start the minimum breakaway torque must be exceeded at least once Otherwise an NOK will result at the end of the stage lt DTM Breakaway torque not reached This minimum torque allows finding out whether or not all pistons are installed on a crankshaft turned Max breakaway torque High limit of the torque during start up start time and the measuring time 0 Torque cal Factor If the max breakaway torque is exceeded during start up start time begins with start or during the measuring time safety shut off the process is immediately terminated and an NOK results for the stage gt DTM Breakaway torque too high Min evaluation torque Low limit of torque in the measuring range measuring time 0 Torque cal Factor If the minimum evaluation torque is not reached during the measuring time an NOK results TQUN DTM Torque too low COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 19 Fastening Strategy Programming Sequence 15 Setpoint Definition cont d Parameter Definition Range of values Max evaluation torque High limit of torque in the measuring range measuring time 0 Torque cal Factor If the maximum evaluation torque is exceeded during the measuring time an NOK results DTM torque too high Start time Range from start across which the torque is monit
40. Fastening Controller Section 7 56 Fastening Strategy Programming Parameter Start End Deactreatiam Low evaluation angle Shut minus Shul of point minus Low evaluation lower Unig aver angle 0 angle angle minus low evalu alion angle Lower unweighted Shut off parri Shut off point minus ange upper unssaighbad Aree Low evaluation torque Valid in the ico evaluaton ange Low evaluabon angla D COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 57 Fastening Strategy Programming Yield Point Control Sequence 63 The purpose of the Yield Point Control Fastening Strategy is to provide the ability to control a fastening to stop after a yielding condition has been detected based on torque angle Yield point controlled fastening includes torque angle and gradient monitoring In Sequence 63 yield must be attained to declare a good fastening rundown Yield creates a permanent elongation of the bolt Typically the elongation from bolt to bolt should be consistent and in the range of 2 to 4 thousandths of an inch permanent elongation The bolt elongation is controlled by the calculated ratio of torque over angle This ratio is called gradient Advanced Application Builder Mavigate About Help Exit Stations Applications Selected Panel Ces 8 P PANEL APPLICATION 1 DEFINED ON THE PANEL Torque Units N m COOPER Tools
41. Section 7 78 Input Output Overview SECTION 12 Input Output Overview The Tork Trak TM Controller supports a variety of Input Output Functions Discrete Physical Discrete Virtual Refer to the Fieldbus Section 14 Active High and Active Low Discrete Physical Mappable User Programmable This Section on Input Output functionality provides an Overview of the TM Controller capability concerning Discrete Physical and programming There are two classes of Physical Discrete supported by the Tork Trak TM T3M controller The first class is the PRIVATE which is intended primarily as internal to the TM3 controller The private is not mappable and is hard wired to support Qty 8 Indicator Light Outputs Trigger Start Input Tool Reverse Input Tool In Cycle Output Cycle Complete Output PRIVATE is shipped as a STANDARD feature of the Tork Trak TM Controller The second class is PUBLIC I O which is intended primarily as external to the controller The Public is software mappable by the User PUBLIC 1 is shipped as an OPTIONAL feature of the Tork Trak TM Controller Each class of 1 is available to the User through two 25 pin connectors on the Connector Plate located below the enclosure door The Public connector male pins is mounted toward the front of the enclosure and the Private connector female pins is mounte
42. Separate 5 V supplyError Bookmark not defined measuring software is saved in a FLASH EPROM reload is carried out via ARCNET from the station controller Reset via servo amplifier or station controller warm start Two separate measuring channels for torque and angle tracing 2 tracks each Polling rate 5000 measurements per second Resolution 12 bit at 10 V Analog filter for torque measuring signals 1 kHz e Maximum angle frequency 9 kHz corresponds to 1500 revolutions per minute at the output attachment of the nutrunner spindle at a resolution of 1 pulse per degree Acquisition of motor angle signals transmitted by the servo amplifier via Dual Port RAM These are generated from the resolver signals Acquisition of the motor current transmitted by the servo amplifier via DPR COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 10 version draft 0 5 TM12 and TM34 SERVO MODULES Communication between Measuring Board and Servo Amplifier Section A Dual Port RAM DPR is used for communication between servo amplifier and measuring board For safety reasons the start signal is transmitted via a direct line as well as via the Dual Port RAM from the measuring board to the servo amplifier section Communication between Measuring Board and Station Controller Communication is made via the high performance field bus ARCNET Transmission spee
43. Sequence Parameter 193 Relaxes pressure on the spindle sockets for easy withdraw of the spindles from the part Stage 1 Filter Factor a Speed rpm Torque Control Target Shutoff 5 Don Stage Retry Type Touchup Low Limit 0 000 Afer Retry gota Stage Threshold 0 000 laximum Retries 1 Mer Hee Monitoring High Limit 9999 Target Shutoff Low Limit O IDE OE Li This STAGE does not Sind n ERROR Final Speed Setpoint 25 SA High Limit 0 000 StegeTimersiMiliSecond 7 Start Delay Ti Time p Max Fastening Time x Dwell Time D Stage Retry Parameters Global to the Application f Relax the Tools on the Final Seres on ERROR Touch Up Settings Target Angle 0 High Angle Limit p Final Speed Settings Target Angle p 0 High Angle Limit 0 2222 Final dus E Sequence Parameter 193 Relax Sequence Parameter 193 is applied to the last stage in the fastening rundown It is designed to relax pressure on the spindle sockets by reversing 1 to 3 degrees at the conclusion of a rundown This permits easy withdraw of the multiple spindles from the part Select Relax the Tools on the Final Stage by placing an X in the selection block COOPER PowerTools Automated Systems USER MANUAL Tork Trak TM Fastening Controller
44. The bottom display shows the selected fastening stage Overload display IP COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 21 version draft 0 5 TM12 and TM34 SERVO MODULES If current above the maximum admissible current is drawn during a fastening cycle the servo amplifier shuts off automatically and IP is displayed The overload error is reset by a restart Im test operation controlled by station controller drive active top display A bottom display not on LED READY Color green Indicates ready to operate condition of the TM f all supply voltages are present and no failure is present this LED is on LED Bus active Color green Displays ARCNET bus activity e f data is being transferred on the ARCNET bus this LED is on Troubleshooting To allow fast diagnosis of errors LEDs and a two digit 7 segment display are installed on the front panel Display of Errors e The errors are shown as codes The display 00 99 flashes at a frequency of approx 1 Hz e error occurs in the TM in the main power supply in the motor in the transducers the the error codes listed in the table below are immediately triggered e f several errors occur at the same time the failure with the highest priority that 5 the lowest number is displayed e Exceptions o Error 64 Torque 12 V NOK has priority over 15 16 17
45. The measuring transducer integrated into the nutsetter measures the torque and rotation angle during tightening rundown The values are processed by the control system The nutsetter is stopped when the shut off angle search criteria is reached COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 34 version draft 0 5 Fastening Strategies The dwell angle and peak torque achieved during the dwell time are then measured and processed in the control system as the bolt tightening value together with the rundown evaluation The control system can display the values in tables on the monitor and can output them to a printer or transmit them to other system components by data communication When the spindle trigger torque is reached recording of the torque curve starts and the curve can be viewed and evaluated in a graphic This tightening method normally follows a fast pretightening stage The parameters below are entered in the electronic control system Sequence input value Trigger torque Nm Trigger torque beginning of measurement recording for the graphic display Threshold torque Nm Threshold torque beginning of angle counting Shut off angle deg Shut off angle for the stage Maximum angle deg Maximum angle high limit of angle reached Minimum angle deg X Minimum angle low limit of angle reached Maximum torque Nm Maximum torque high limit of torque reached a
46. a serial high speed FieldBus ARCNET Thus decentralized arrangement of station controller and TMHs at a distance of up to 100 m is possible Service MH can be replaced without requiring calibration The station controller m Pro 400 Touch screen transmits all settings and adjustments automatically to the new TMH Fast precise diagnosis in case of failures is facilitated by displayed text at the station controller and coded messages displayed on a 2 digit 7 segment display at the TMH f the housing is opened the warranty is voided e TMH must always be replaced in its entirety COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 2 version draft 0 5 TMH SERVO MODULE Transport and Storage Only transport the device in the original packing The packing is recyclable e f the packing is damaged check the TMH for visible signs of damage Inform the carrier and Cooper Tools if required Mechanical Properties Description Rugged metal casing 1 Fastening with M6x20 cap screws to the mounting plate of the control cabinet through key holes in the TMH 2 e The measuring board be plugged in and out and is fixed with two screws in the hood 3 2 E L l eli J e 3 amp 1 p COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 3 version draft 0 5 TMH SERVO MOD
47. can display the values in tables on the monitor and can output them to a printer or transmit them to other system components by data communication This tightening method is normally used as the fast pretightening stage with checked tightening monitoring and subsequent evaluation COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 6 version draft 0 5 Fastening Strategies The parameters below are entered in the electronic control system Sequence input value 13 Trigger torque Nm Trigger torque beginning of measurement recording for the graphic display Filtering factor Filtering factor number of measured values used for filtering by averaging Shut off torque Nm Threshold torque On Nm Threshold torque Off Nm FRTM angle deg Evaluation angle deg Unweighted angle deg Shut off torque Nm Max evaluation torque Nm Min evaluation torque Nm Above limit 96 Below limit 96 Speed rpm Jointing point detection COOPER PowerTools Automated Systems Section 6 7 Shut off torque for this high speed rundown Threshold torque on beginning of the monitored range beginning of angle counting Threshold torque off end of recording for subsequent evaluation phase 2 FRTM angle length of the monitored range after the spindle start in phase 1 Range evaluated in phase 2 Range not evaluated in phase 2 Shut
48. criteria is reached The dwell angle and peak torque during the dwell time are then measured and processed in the control system as the bolt tightening value together with the rundown evaluation The control system can display the values in tables on the monitor and can output them to a printer or transmit them to other system components by data communication When the spindle trigger torque is reached recording of the torque curve starts and the curve can be viewed and evaluated in a graphic COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 46 version draft 0 5 Fastening Strategies This tightening method normally follows a fast pretightening stage The parameters below are entered in the electronic control system Sequence input value 75 Trigger torque Nm Trigger torque beginning of measurement recording for the graphic display Threshold torque Nm Threshold torque beginning of angle counting and gradient calculation Shut off angle deg Shut off angle for the stage Maximum angle deg X Maximum angle high limit of angle reached Minimum angle deg X Minimum angle low limit of angle reached Maximum torque Nm Maximum torque high limit of torque reached and shut off value Minimum torque Nm Minimum torque low limit of torque reached Minimum gradient Nm deg Minimum gradient low limit of the gradients Maximum gradient Nm deg Maximum gradient h
49. deg 1B050A 1K2A eS 73 30910 25 7727 7 59900 1 000 1ZA 1BO50A 1VK2A 258 150160 173 30910 27 1292 7 76200 1 000 1B050A 1K2A m 77 16750 27 1292 7 76200 1 053 1 1B050A 1K2A 254 50 78 19640 1 27 4909 7 54100 1 067 Size 2 DGD Tools 2B100A 2K1A 43 24590 15 2036 5 86400 1 000 27 2B100A 2VK1A 43 24590 16 2896 6 07400 1 000 2B100A 2K1A 46 33480 16 2896 6 07400 1 071 2VA 2B100A 2K1A 45 94870 16 1538 5 78000 1 063 2WA 2B150A 2K2A 64 94090 22 8307 8 62600 1 000 27 2B150A 2VK2A 65 57 95 24 4615 8 96200 1 000 2B150A 2K2A 65 57 95 24 4615 8 96200 1 071 2VA 2B150A 2K2A 206 150 170 68 99970 2B 24 2577 8 52800 1 063 2WA USER MANUAL put COOPER PowerTools Tork Trak TM Fastening Controller Automated Svstems NA Section 17 6 Tool Library Settings Torque Angle Servo Gear Static Torque Encoder Model No Max Max Calibration Calibration Parameter Ratio Factor Angle Factor opeed Torque Factor Factor Set pulses deg RPM Nm pulses deg Size 3 DGD Tools 3B180A 3K1A 339 180 200 41 91810 3B 14 7368 587800 1 000 3ZA 3B180 3VK1A 45 14260 15 8704 5 82400 1 000 077 3B180A 3K1A 45 14260 15 8704 5 82400 1 3VA 3B180A 3K1A 43 53060 5 61400 1 038 3WA 3B260A 3K2A 64 76580 22 7692 9 11700 1 000 3ZA 3B260A 3VK2A 69 74780 24 5207 9 03400 1 000 3B260A 3K2A 69 74780 24 5207 9 03400 1 077 3VA 3B260A 3K2A 67 25680 23 6450 8 70700 1 038 3WA Size 4 DGD Tools 4B360A 4K1
50. mV Transducer installed in jammed position Check with test mode of station controller if values are out of admissible ranges if so replace transducer Internal error replace TM Transducer 2 calibration voltage NOK Transducer installed in The calibration voltage is out of jammed position the admissible range between Check with test mode of station controller if values are out of admissible ranges if so replace transducer If deviation is extreme check transducer cable especially the calibration line Internal error replace TM 4 85 V 5 15 V Check at the station controller If no angle signals are detected in test mode Transducer 2 angle tracing NOK The angle signals are e Interrupted e Shorted e Not present e Not present part of the time e Check transducer cable especially the angle lines Spindle rotates more than 360 degrees e Check angle factor e Replace transducer e Internal error replace TM COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 15 39 version draft 0 5 TM12 and TM34 SERVO MODULES Consequence lt gt r 00 Measures Remedy Top Display Bottom Display CO gt amp 5 Yi rls 3 5 50 2 ud oz c 2 5 Clu C 5 S S S 5 S8 gt 0 Un Error Explanation Transducer 2 rundown counter NOK The rundown counter in the transducer doe
51. of the logic section Power loss of all additional heat sources installed inside the control cabinet in W Effective cabinet surface in m2 All free cabinet surfaces Heat transition coefficient of sheet metal 5 0 W m K At a calculated inside temperature Ti above 50 C additional cooling measures such as an air conditioner or heat exchanger are required Measuring Board e measuring board is part of the TMH and must not be replaced individually e It has separate processors for measuring and communication tasks angle tracing and ARCNET e Separate 5 V supply measuring software is saved in a FLASH reload is carried out via ARCNET from the station controller Reset via servo amplifier or station controller warm start Two separate measuring channels for torque Polling rate 5000 measurements per second Resolution 12 bit at 10 V Analog filter for torque measuring signals 1 kHz Angle signals are generated from the resolver signals of the servo amplifier and are output to the measuring port via the dual port RAM The angle inputs at 56 are not polled COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 10 version draft 0 5 TMH SERVO MODULE e Two angle inputs are available on 57 for cross checking e Maximum angle frequency 9 kHz corresponds to 1500 revolutions per minute at the output attachment of the h
52. off torque for the stage Maximum torque in the monitored range high limit in phases 1 and 2 Minimum torque in the monitored range lower limit in phase 2 Portion of measurements tolerated that lay over the high limit without triggering NOK phase 2 Portion of measurements tolerated that lay below the low limit without triggering NOK phase 2 Preset speed within the maximum speed range specified in the range for spindle constants Jointing point detection USER MANUAL Tork Trak TM Fastening Controller version draft 0 5 Fastening Strategies Joint point Detection Certain conditions apply that are necessary for exact joint point detection when this option is activated in free rundown torque monitoring with sequence 13 These are At least 256 torque values must have been measured during free rundown torque monitoring e Sequence 50 must be the sequence final fastening that directly follows this fastening stage here must have been a high increase in torque at the end of the free rundown torque monitoring This means that the contact torque shut off torque for the free rundown torque monitoring has to lay significantly above the tightening frictional torque A jointing point is defined as the point at which two or more parts in a severable connection make connection A strong increase in torque within a few fastening angles is indication that such an event has happened The precise jointing point in this pretightenin
53. once the threshold moment has been achieved The driver is operated alternately between rotary motion and maintaining the desired torque Upon reaching Switch off Torque the driver is stopped and the switch off torque is maintained preventing mechanical relief of the spindle During the off time the mechanical settling can take place When the off time has expired or if the torque falls below the specified minimum the spindle starts again with the specified RPM When the on time has expired or if Switch off torque has been exceeded the spindle is stopped again and the switch off moment is maintained One cycle consists of one on time and one off time The number of cycles equals the number of specified repetitions During the run down time the caster angle and peak torque are measured An automatic slow and controlled relief of the spindle takes place during the specified run down time until torque falls below the specified threshold The tightening values of the bolt and a reading of the fastened joint are sent to the value analyzer This Sequence can display the values in tabular form on the monitor and or output to a printer as well as transmit this information to other network clients Once a spindle reaches the specified trigger moment the rotation angle is recorded and can be displayed and evaluated via the graphic function The following parameters can be input to the driver electronics Diagram input value 33 Sw
54. range 0 Torque cal Factor phase 2 evaluation angle If this limit value is exceeded in phase 1 FRTM angle the spindle will shut off immediately and the stage will be evaluated NOK P1M FRTM Torque in phase 1 too much FRTM angle Monitored range during fastening phase 1 beginning with start 0 9 999 If the max Evaluation torque is exceeded in this range phase 1 the spindle will shut off immediately and the stage will be evaluated NOK P1M gt FRTM Torque in phase 1 too much This helps trace a misaligned fastener for instance opeed Set speed of the spindle s output shaft 1 max speed Joint detection Special sequence composed of the two sequences 13 and 50 If joint detection is activated sequence 50 must be programmed as the subsequent sequence COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 17 Fastening Strategy Programming Drag Torque Monitor Sequence 15 Time controlled torque measurement frictional torque measurement amp Advanced Application Builder Mavigate About Help Exit Applications Selected Panel Pen Te PANEL APPLICATION T DEFINED ONTHE PANEL Torque Units Nm COOPER Tools Stage Sequence Builder Stage 1 Seq 15 Drag Torque Monitor Filter Factor 2 Drag Torque Monitor DTM This STAGE does not stop on ERROR Stage Timers MilliSeconds SEO 15 Hold Torque at End of Stage S
55. safety shut down It applies to all nutsetters of a product group tightening process in this stage The measuring transducer integrated into the nutsetter measures the angle during back off The value is processed by the control system Angles are counted from the start The nutsetter is stopped when the shut off angle search criteria is reached The dwell angle achieved during the dwell time is then measured and the bolt backoff angle is processed in the control system together with the backoff evaluation The control system can display the values in tables on the monitor and can output them to a printer or transmit them to other system components by data communication The graphics function is not supported in this stage COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 27 version draft 0 5 Fastening Strategies The backoff torque is defined as being the force that must act upon a fastened joint in the specified direction in order to overcome the total of the pressing and frictional forces and thus back off the fastener The parameters below are entered in the electronic control system Sequence input value 41 Shut off angle Nm Shut off angle backoff angle Maximum angle deg Maximum angle high limit of angle reached Minimum angle deg Minimum angle low limit of angle reached Filtering factor Filtering factor number of measured values used for filtering b
56. su Rett Ps rz 4a po13u G2 1110060 UU BETTE Knie E NN ww 27 AE ds ER ac m c d rr SE oe ES a e E a Ear mn a nen Se n a MO A pad x aate MEM UD uua ENSIS ONIH zum uma 7 nae Ex MICI ree An dai 1 USER MANUAL Tork Trak TM Fastening Controller COOPER PowerTools Automated Systems version draft 0 5 Section 15 13 Explanation of Terms ADC Address Angle Controller ARCNET Bus plane Display Error detect voltage supply Filter Galvanic separation Galv sep Housing MK MUX Overvoltage limit Power Stage Power supply controller Resolver Resolver evaluation RS232 Printer Serial Com Transducer Signal conditioning analog digital converter address channel number processor for angle processing network field bus bus circuit board display error detection voltage supply filter suppressing EMC interfer ence galvanic separation galvanic separation housing measuring board multiplexer limit output section power supply controller motor position tracing re
57. the bolt b The durability of the bolt in connection with the mating nut thread COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 7 Fastening Strategy Programming Pressure applied to the components In the contact surface between bolt head or nut and the assembled components neither the tightening force nor the maximum force should lead to surface pressure resulting in creepage The surface pressure calculated from the maximum force should not exceed the crushing yield point of the material assembled Dispersion of the tensioning force The tightening factor is used in considering the dimensioning of the bolt to compensate for the difference between the tensioning force actually reached during tightening and the minimum tensioning force required Reduction of the tensioning force Reduction of the tensioning force in the joint or parts of the joint due to the operating force For instance when fastening the cover of a pressure vessel the tensioning force must be sufficiently dimensioned to compensate for the operating force resulting from the overpressure inside the vessel and additionally the required tightening function must be upheld Tightening methods The tightening method influences the required dimension of the bolt because the bolt must withstand a torque in addition to the axial force The various tightening methods in particular influence the variance in the tensioning f
58. the threshold torque has been reached the gradient is continuously computed of the torque and angle values The gradient calculation ends with the end of the sequence COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 66 Fastening Strategy Programming Angle Control Torque and Gradient Monitor Sequence 75 Shut off angle controlled fastening with torque angle and gradient monitoring bs Advanced Application Builder Navigate About Exit G Back PANEL 7 Stage Sequence Builder Ang Control Tq Grad Monitor c Save these Settings x Cancel My Changes DEFINED THE PANEL Selected Panel a Torque units Nm Tools Stage 1 Seq 75 Filter Factor 2 This STAGE does not stop on ERROR Stage Timers MilliSeconds Hold Torque at End of Stage Start Delay Time fo Speed rpm Max Fastening Time 20000 Final Speed Setpoint 250 Dwell Time fo Torque Monitoring High Limit p 000 Low Limit 10 000 Threshold 10 000 Trigger 3 000 Angle Control Degree Angle Control Torque Gradient Monitor Stage Retry Parameters Stage Retry Type Touchup After Retry goto Stage Maximum Retries 0 High Limit 9999 Global to the Application Shutoft 0 Relax the Tools on the Final Stage Backoff on ERROR Touch Up Settings Target Angle b
59. the yield point of the bolts in a given bolt lot The highest accuracy is reached when the yield point of the bolt material is exceeded Plastic deformation of the bolt is thereby tolerated limiting its fitness for reuse however A tightening factor is not required for this method since the bolts are dimensioned to accommodate the minimum tensioning force This results in optimum exploitation of the bolt material Yield point controlled tightening Yield point controlled tightening methods are based on the fact that the tightening torque does not rise linearly with the rotation angle after the yield point of the bolt material has been reached The joint is first tightened to an intermediate tensioning force to settle all jointing surfaces Thereafter the difference ratio is calculated for an adjustable chord length Tightening is actively terminated as soon as this difference ratio drops to a predefined amount of a maximum value when the bolt material yield point is reached The tensioning force resulting from tightening of a bolt lot or component lot is largely independent of friction and is only influenced by the variance in the yield point of the bolt material The plastic elongation that the bolts are subjected to lay in the order of magnitude of the values that define the Sigma 0 2 limit of materials with untypical yield point Therefore the fitness for reuse of bolts tightened with yield point control is practically not impaired A tightening
60. through the internal brake resistors TMH NENNEN ATEIGTE 320 VDC 10 Adjusted peak current Short circuit current shut Efficiency nutrunner torque outnut Clock speed of PWM 10 kHz Maximum temporary 4000 VA COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 8 version draft 0 5 TMH SERVO MODULE Power Loss Low power loss components limit heat radiation high admissible operating temperature of 50 reduces the need for additional cooling measures in many cases he position of the brake resistors ensures that no other components of the TMH are influenced by the heat dissipated by them TMH Nutrunner spindle type 4 6 BM rated output of Calculation of Temperature to be Expected inside Control Cabinet To ensure safe operation and reach the service life of 20 000 hours the TMH must be operated in a control cabinet with a maximum inside temperature of 50 The temperature to be expected inside the control cabinet must be calculated when the Formula P V additional heat sources Ti Ax k cabinet is designed COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 9 version draft 0 5 TMH SERVO MODULE Temperature to be expected inside control cabinet in Overall power loss of all TMs in W From the intermediate circuit
61. to 230 VAC e lf errors occur sporadically check the supply for voltage drops Internal error replace TMH Measure supply voltage lf gt 255 VAC decrease to 230 VAC lf error occur sporadically check the supply for voltage overshoot Internal error replace Supply DC DC converter overvoltage The voltage of the intermediate circuit of logic section is gt 440 VDC Intermediate circuit of the power Section Not supplied Check supply prefusing of TMH EMERGENCY STOP contactor etc Internal error replace TMH Check tool cable and connector board for continuity and short circuit Check motor for short circuit to PE and check phase impedance 17 7 ATE approx 4 Motor cable defective Cable in motor lines broken Interruption in the connector board Motor phases interrupted Test current of cable monitoring misguided NX x EE COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 25 version draft 0 5 Short circuit motor circuit e n cable e n motor e n TMH Top Display Bottom Display Error Explanation Motor temperature too high Measuring line broken Measuring current misguided e Motor not connected Not used in this application monitoring Required motor output is too high Handtool is defective e g gearing bearing Consequence gt 5 T
62. 0 Angle Control with Torque Monitoring Sequence 50 is a general fastening control strategy This strategy answers out to controlled angle and monitors torque Sequence 51 Self Tap with Angle Control Sequence 51 is designed to initially monitor the torque required for a self tap screw to cut a thread and then control angle for final clamp load COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 3 Fastening Strategy Programming Sequence 63 Yield Point Control Sequence 63 is designed to repeatably control a joint to several thousandth inches of permanent bolt elongation This is accomplisher by controlling gradient and monitoring torque and angle Sequence 73 Torque Control with Yield Monitoring Sequence 73 is designed to answer out to a control torque while monitoring yield Sequence 75 Angle Control with Yield Monitoring Sequence 75 is designed to answer out to a control angle while monitoring yield Sequence 78 Torque and Angle Control with Yield Monitoring Sequence 78 is designed to answer out to a control torque and angle which ever comes first while monitoring yield Sequence 80 Torque and Angle Control with Torque and Angle Monitoring sequence 80 is designed to control torque and angle which ever comes first with torque and angle monitoring Sequence Parameter 193 Relax Sequence Parameter 193 is designed to relax pressure on the spindle s
63. 2 and TM34 SERVO MODULES Description e Rugged metal casing 1 e Same housing size for all TM types Fastening with M6x20 cap screws to the mounting plate of the control cabinet through key holes in the TM 2 The measuring board can be plugged in and out and is held with two screws in the faceplate 3 COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 3 version draft 0 5 TM12 and TM34 SERVO MODULES Data _ 12 34 280 60 mm 200 mm Maximum depth with 280 mm plugs Spacing of mounting 260 mm to center holes 3400 g 3420 g Enclosure type IP20 Type of cooling Convection self cooling Ambient temperature 0 50 Storage temperature 20 60 C Humidity 0 90 Service life in operating 20 000 h Usability for storage 100 000 h approx 11 years Installation Guidelines closed steel plate control cabinet must be used A zinc plated mounting plate must be used it must not be painted Drilling sketch COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 4 version draft 0 5 TM12 and TM34 SERVO MODULES Electromechanical Properties All connections are located at the front Two transducers be connected redundant setup of measuring sensors according to VDI 2862 Fast error diagnosis with 2 digit 7 segment display Current fastening stag
64. 21 22 28 40 and 41 description see table COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 22 version draft 0 5 TM12 and TM34 SERVO MODULES Error 65 Torque 12 V NOK has priority over 15 16 17 28 and 40 description see table failure 40 Torque is not ready has the lowest priority since the errors 41 to FF cannot be described as a common error 40 to simplify error diagnosis All errors are reported to the station controller via the ARCNET and are then displayed on its monitor In the rundown data table the abbreviations FLT F Torque AN1F AN2F OFF1 OFF2 are shown in the ERROR column In the rundown data table the window Spindle monitor opens When the soft key i is pressed the error list is opened and all current errors are displayed as descriptive text Acknowledging errors When the error has been resolved press the RESET button to return the TM to the ready condition Upon each spindle start the measuring board sends an acknowledgement signal to the output section If the error is momentary only e g undervoltage the TM automatically returns to the ready state after the next acknowledgement signal Since all errors are archived by the station controller the error information can be displayed for troubleshooting However the display of the TM does not flash anymore once an error has been acknowledged When measu
65. 30 The purpose of the Torque Control Angle Monitor Fastening Strategy is to provide the ability to control a fastening rundown to stop after reaching a programmable target torque value Programmable torque limits above and below target torque are provided for OK or NOK evaluation In addition programmable limits for monitoring Angle are provided for OK or NOK evaluation Advanced Application Builder Mavigate About Help Exit Stations Applications a Ee m urvailible PANEL APPLICATION 1 DEFINED ON THE PANEL Selected Panel LOCAL This STAGE does not stop on ERROR Hold Torque at End of Stage Speed rpm Final Speed Setpoint 250 Torque units 5 Stage 1 seq 30 Torque Control Angle Monitoring v Filter Factor D Stage Timers MilliSeconds Start Delay Time o Max Fastening Time pono DwellTime D Torque Control High Limit 0 000 Target Shutoff 5 000 Low Limit p 000 Threshold 10 000 Trigger 3 000 Angle Monitoring Degree High Limit 9999 Low Limit p 5 Save these Settings x Cancel My Changes Add Stage Del Stage gt Stage Retry Parameters Stage Retry Type Touchup After Retry goto Stage 1 f gt Maximum Retries Global to the Application Relax the Tools on the Final Stage Backoff ERROR Touch Up Settings Target Mer High Angle Limit F
66. 503 614 36 177 0538 67EA5 70AM6 60 570 707 1 622 015 36 218 6806 X Power Tools USER MANUAL Automated Svstems NA Section 17 4 Tork Trak TM Fastening Controller Tool Library Settings Torque Angle Servo Gear Max Max Calibration Calibration Parameter Ratio opeed RPM Torque Nm Factor Factor Set 67EA 30AM6 46 730 707 795 705 36 219 7455 67EA860AH8 860 1768 2 1014 299 36 22 2672 67EA1035AH8 28 1035 1768 2 1305 194 36 28 67977 67EA1340AH8 22 1340 1768 2 1665 956 36 36 60673 67EA1700AH8 17 1700 1768 2 2125 475 36 46 7024 67EA2010AH8 15 2000 3612 0 2508 004 36 55 10939 DGD Tools Servo Parameter Set Torque Calibration Angle Calibration Factor Gear Static Torque Encoder Ratio Factor Angle Factor pulses deg pulses deg 59 18 43 05450 15 1364 4 46400 1 000 45 32060 15 9330 4 55900 1 053 1VA 1B030A 1VK1A 45 32060 15 9330 4 55900 1 000 1B030A 1K1A 45 92480 16 1455 4 43000 1 067 1WA Factor Model No Max Max Speed Torque RPM Nm Size 1 DGD Tools 1B030A 1K1A 462 30 1ZA 39 1B030A 1K1A 4 USER MANUAL Tork Trak TM Fastening Controller put COOPER Power Tools Automated Svstems NA Section 17 5 Tool Library Settings opeed Torque Factor Factor Set pulses deg Catalog Data Torque Angle Servo Gear Static Torque Encoder Model No Max Max Calibration Calibration Parameter Ratio Factor Angle Factor E RPM Nm pulses
67. 6 4 364 0 4690 12 73 28 200 2 95 363 5 261 3 3366 12 52 60 200 2 60 579 4 553 2 5367 12 83 85 EMT200 WITH ROTOR HEAD EMT200 4 4805 117 295 5 419 5 2736 12 42 76 400 SERIES TOOLS 400 10 1155 67 9 392 0 277 23 4 33 400 10 866 90 5 522 6 369 23 5 77 400 10 543 144 3 833 0 589 23 9 20 400 8 833 94 1 392 0 384 23 6 00 EMT400 8V 625 125 4 522 6 512 23 8 00 EMT400 8X 392 199 9 833 0 816 23 12 75 400 5 310 253 2 392 0 1034 23 16 15 EMT400 5V 232 337 6 522 6 1378 23 21 53 2 Power Tools USER MANUAL Tork Trak TM F i Automated Svstems ork ira astening Controller Section 17 17 Tool Library Settings Torque Angle Servo Gear Model No Max Max Calibration Calibration Parameter Ratio opeed RPM Torque Nm Factor Factor Set EMT400 5V 232 337 6 522 6 1378 23 21 53 EMT400 5X 146 538 1 833 0 2196 23 34 32 400 4 266 294 3 392 0 1201 23 18 77 400 4 200 392 3 522 6 1601 23 25 02 400 4 125 625 4 833 0 2553 23 39 89 400 3 192 407 7 392 0 1664 23 26 00 EMT400 3V 144 543 5 522 6 2218 23 34 66 400 3 90 866 4 833 0 3536 23 55 25 400 2 139 564 5 541 0 2304 23 36 00 400 2 104 752 5 522 6 3071 23 47 99 400 2 65 1199 6 833 0 4896 23 76 50 EMT600 SERIES TOOLS EMT600 3 149 537 1 600 0 2148 23 33 57 600 2 102 781 5
68. A 4WA 2 gt Torque deviation Nominal value is 1096 of transducer calibration factor unless otherwise specified Current adjustment Nominal value is 1 0 until adjusted by reference to a calibrated transducer USER MANUAL put COOPER PowerTools Tork Trak TM Fastening Controller Automated Svstems NA Section 17 8 Rotor Tools Tool Library Settings Torque Angle Servo Gear Model No Max Max Calibration Calibration Parameter Ratio opeed RPM Torque Nm Factor Factor Set 150 Series Angle Tools EMR150RAYSGG11 1060 15 17 1 39 167 35 9 4 EMR150RAYSGG13 1760 17 16 7 54 756 35 13 141 EMR150RAYSGG17 1610 23 35 5 68 014 35 16 323 EMR150RAYSGG22 1490 29 35 1 84 375 35 20 25 EMR150RAHYSGG17 610 23 30 5 68 014 35 16 323 EMR150RAHYSGG22 490 29 35 1 84 375 35 20 25 EMR150RAHYSGG26 390 35 34 7 106 250 35 25 5 EMR150RAHYSGG32 310 43 50 6 133 797 35 32 111 EMR150RAHYSGG36 275 49 50 6 150 000 35 36 0 EMR150RAHYSGG39 220 52 50 1 188 889 35 45 333 EMR150RAHHYSGG3 270 50 49 6 141 797 35 25 5 EMR150RAHHYSGGA 210 63 72 3 191 150 35 32 111 EMR150RAHHYSGG5 190 T1 72 0 214 300 35 36 0 EMR150RAHHYSGG606 150 88 103 9 269 858 35 45 333 EMR150RAHHYSGG71130 105 103 5 317 086 35 53 267 X Power Tools USER MANUAL Tork Trak TM F i Automated Svstems ork ira astening Controller Section 17 9 Tool Library Settings
69. A 74 84240 6 56200 1 000 AZA 4B360 4VK1A 79 83180 4B 7 28 0659 6 58000 1 000 4B360A 4K1A 79 83180 6 58000 1 067 AVA 4B360A 4K1A 77 61430 5 6 39500 1 037 AWA USER MANUAL pu COOPER PowerTools Tork Trak TM Fastening Controller Automated Svstems NA Section 17 7 Tool Library Settings Catalog Data Torque Angle Servo Gear Static Torque Encoder Model No Max Max Calibration Calibration Parameter Ratio Factor Angle Factor Speed Torque Factor Factor Set pulses deg RPM Nm pulses deg 4B460A 4K1A 209 460 N 95 06670 IUE 33 4219 8 51400 1 000 4B 101 40440 4 35 6500 8 35800 101 40440 35 6500 8 35800 1 98 58770 LI 34 6597 8 12300 1 037 4B 4B460 4VK2A 460 000 067 150 23840 52 8182 12 23800 1 000 000 460 4 1 460 4B460A AK1A 460 4B530 4VK2A 530 4B630A 4K2A 630 4B630A 4K2A 630 pg gt gt 140 84850 LN 49 5170 12 46700 1 150 23840 528182 12 23800 1 067 146 06510 51 3510 11 89400 1 037 NM X 0 73756 Ft Nm X 8 8507 In e Angle deviation 10 degrees if application requires torque control with angle monitoring Sequence 30 5 degree if application requires angle or gradient control with torque monitoring Sequence 50 or 63 unless otherwise specified Max angle deviation can be as much as 8 degrees per revolution depending on spindle type 4B630A AK2
70. After blanking angle Blanking angle 0 deqree Block angle After start pulse sup After block angle Block angle 0 pression degree At spindle start 1 Shut off point when speed 2 0 2 Threshold torque when speed 2 gt 0 Speed 2 From threshold torque shut off point Speed 2 0 or Speed 2 speed 1 Parameters that are analyzed in reverse 1 starting from the shut off point Res High evaluation angle shut off point minus Shut off point minus High evaluation upper unweighted upper unweighted angle 0 angle angle minus high eval uation angle Upper unweighted Shut off point Shutoff point minus angle upper unweighted angle Upper High evaluation evaluation torque Valid in the high evaluation angle angle 0 Low evaluation angle Shut off point minus Shut off point minus Low evaluation lower unweighted lower unweighted angle 0 angle angle minus low evalu ation angle Lower unweighted Shut off point Shutoff point minus angle upper unweighted angle Low evaluation torque Low evaluation Valid in the low evaluation angle angle 0 COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 23 version draft 0 5 Fastening Strategies Sequence 33 Switch off Torque Controlled Tightening Procedure with Torque Maintenance and Automatic Retightening 4 Torque Max Torque Switch aff Torque Min Torque Threshold Torque 5 Th
71. Check at station controller in test mode the value out of tolerances e Check transducer cable especially the 12 V and 0 V conductors Check resolver cable for short circuit Replace transducer Replace motor Internal error replace TM USER MANUAL Tork Trak TM Fastening Controller version draft 0 5 lt gt r uvv wo LL aa Top Display Bottom Display Error Explanation Torque 12 V The 12 V supply of the measuring board is out of tolerance limits between 1 1 1 V 12 9 V Torque Process Control Process sequence start stage graphics not adhered to Torque Initialization Initialization error in measuring board Torque access to DPR The measuring board cannot access the DPR in the servo Torque servotype not TM12 34 The TM type read by the measuring board is unknown 1 Main and Startup Relay Output Section Off TM12 and TM34 SERVO MODULES Consequence Brake Motor Output Measures Remedy Check at station controller in test mode the value out of tolerances Check transducer cable especially the 12 V and O V conductors Check resolver cable for short circuit Replace transducer Replace motor Internal error replace TM Inform Cooper Tools service department Internal error replace TM Inform Cooper Tools service department Internal error replace TM Inform Cooper Tools service dep
72. ER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 46 Fastening Strategy Programming Sequence 48 Shut off angle controlled fastening with backoff angle and residual torque monitoring Sequence 48 an angle contralled sequence in which the two pointe can be defined at bath of which a minimum and a maximum banque value must be understepoed or overstepped Details Torque Art al at i 3 mm rr Angle Trigger p e MZ min Manian mE 1 men 14 ore Cua phe diia gt lime Maximam tine 1 i pulse ss ppoessin Deas i tire 000 irm One check is carried out at each of the two points 1 and M2 in order ta amp scertain whether M1 mun M1 max and M2 min M2 max tarque limils are understepped or overstepped Points 1 and 2 are specified by the angle at 1 and angle at MZ from the threshold torque Should the torque at these points not lay within the corresponding minimax limits the drive ig stopped and the rundown data is evaluated as The time sequence for the two points 15 not specified M1 can lay to the left or right of M2 or at M2 The torque check inthe points M1 and 2 can be deactivated individually by setting the angle at M1 2 to zero M1 max also serves as safely shut down torque in the whole sequence When M1 m
73. Max Max Calibration Calibration Parameter Ratio opeed RPM Torque Nm Factor Factor oet 225 Series Offset Tools EMR225RFOGG26 970 35 44 2 37 178 37 13 38 EMR225RFOGG33 760 45 62 2 47 456 37 17 08 EMR225RFOGG37 680 50 62 0 53 000 37 19 08 EMR225RFOGGA2 595 57 61 6 60 539 37 21 79 225 50 505 68 93 8 11 442 37 25 72 225 56 450 76 93 4 79 772 37 28 2 EMR225RFOHGG54 485 13 66 8 71 442 37 25 72 EMR225RFOHGG61 1435 83 102 2 19 772 37 28 2 EMR225RFOHGG67 1390 91 101 8 88 583 37 31 89 EMR225RFOHGG75 4350 102 135 1 98 889 37 35 6 EMR225RFOHGG86 1305 117 134 7 112 986 37 40 68 EMR225RFOHGG90 290 122 134 5 119 408 37 42 99 EMR225RFOHGG102 260 138 134 5 133 333 37 48 0 EMR225RFOHGG115 225 156 173 9 152 322 37 54 84 EMR225RFOG122 205 165 230 5 169 575 37 61 047 EMR225RFOG143 175 194 230 0 198 767 37 71 556 EMR225RFOG168 150 228 297 0 232 989 37 83 876 USER MANUAL put COOPER PowerTools Tork Trak TM Fastening Controller Automated Svstems NA Section 17 13 EMT Series Fixtured Tools Tool Library Settings Torque Angle Servo Gear Model No Max Max Calibration Calibration Parameter Ratio opeed RPM Torque Nm Factor Factor Set TT 300 75 SERIES TOOLS TT300 75 5V 251 137 7 260 5 319 12 19 92 TT300 75 5X 157 220 0 416 2 509 12 31 83 TT300 75 4V 188 183 7 260 5 425 12 26 59 TT300 75 A
74. Minimum angle low limit of angle reached Maximum torque high limit of torque reached and shut off value Minimum torque low limit of torque reached Preset speed within the maximum speed range specified in the range for spindle constants USER MANUAL Tork Trak TM Fastening Controller version draft 0 5 Fastening Strategies Sequence 73 Shut off Torque Controlled Fastening with Torque Angle and Gradient Monitoring Gradient Torque Maximum torque shut off Monue Threshold torque Lowe er gradient Initial torque Maximum angle Angle ightening angle Time Start Maximum tightening time Start pulse suppression Dwell time In the electronic control system the shut off torque maximum torque minimum torque maximum angle minimum angle lower gradient upper gradient strobe multiplier filtering factor and speed are entered separately for each nutsetter The maximum angle is also used as a Safety shut down A maximum tightening time is entered as an additional safety shut down It applies to all nutsetters of a product group tightening process in this stage The measuring transducer integrated into the nutsetter measures the torque and rotation angle during tightening rundown The values are processed by the control system The nutsetter is stopped when the shut off torque search criteria is reached The dwell angle and peak torque during the dwell time are then measured and proce
75. NTS SECTION SEVENTEEN Tool Library Settings Cleco Handtools 17 1 DGD Fixtured Tools 17 5 Rotor Tools 17 9 EMT Series Fixtured Tools 17 14 SECTION EIGHTEEN Recommended Spare Parts Recommended Spare Parts 18 1 COOPER PowerTools USER MANUAL Automated Svstems Tork Trak TM Fastening Controller Section 0 v version draft 0 5 Introduction to the Tork Trak TM Controller SECTION 1 Introduction to the Tork Trak TM Controller The Tork Trak TM Fastening Controller T3M is a single channel nutrunner controller with software capability to run additional tools by connecting to satellite servo modules The T3M controller is the fifth generation design of this product and provides greater functionality than earlier models A number of improvements have been added The basic design of the controller includes the functionality of the Cooper Power Tool TM Servo Module combined with a Celeron CPU running TM Multi Trak Software Control signals from the CPU command the Servo Module which in turn controls the nutrunner to achieve user programmable torque and angle targets Statistical results are saved calculated sorted and can be viewed on screen In addition the controller can be used for joint analysis by displaying or saving a digital file of torque vs angle fastening rundown O scope graphics which can be read or printed by any laptop or desktop computer The high resolution LCD display provides the user with multi color
76. OOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 16 23 version draft 0 5 TMH SERVO MODULE Acknowledging errors When the error has been resolved press the RESET button to return the TMH to the ready condition Upon each nutsetter start the measuring board sends an acknowledgement signal to the output section If the error is momentary only e g undervoltage the TMH automatically returns to the ready state after the next acknowledgement signal Since all errors are archived by the station controller the error information can be displayed for troubleshooting However the display of the TMH does not flash anymore once an error has been acknowledged f an error is permanent the error mode cannot be acknowledged and quit A When measuring continuity impedance or checking for a short circuit in the motor or motor cable be sure to disconnect these from the TMH Fatal electric shock may occur COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 16 24 version draft 0 5 TMH SERVO MODULE Consequence lt gt r uvv Measures Remedy Top Display Bottom Display Error Explanation Main and Startup Relay Output Section Off Brake Motor Output Supply DC DC converter undervoltage supply DC DC converter undervoltage 150 VAC e Measure supply voltage If lt 200 VAC increase
77. Programming Sequence 20PTR Setpoint Definitions Parameter Definition Range of Values Shut off torque Torque as target value when it is reached the sequence is terminated 0 Torque cal Factor Min Torque Low limit of torque reached cal Factor If this limit value is not reached NOK for the stage results lt Torque too low a Torque High limit of torque reached 1 2 Torque If this limit value is exceeded the stage is evaluated NOK a gt Torque too high Trigger torque When this torque is exceeded the recording for graphic representation begins 0 1 2 x Torque cal Factor Speed Set speed of the spindle s output shaft 1 max speed Filtering factor Number of torque values used to find mean value 1 2 4 8 16 32 With this number of torque values a mean value is calculated immediately upon measurement corresponding to filtering and dampening As soon as a new value is measured the oldest value is deleted and the mean value recalculated The further evaluation shut off evaluation graph is made with these mean values A filtering factor of 1 results in no mean values being computed COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 26 Fastening Strategy Programming Sequence 20PTR Setpoint Definitions cont d Range of Values PTR High This is the upper torque level setting for PTR It shou
78. Stage Sequence Builder Stage E Seq 63 Yield Point Control Filter Factor 2 Yield N at This STAGE does not stop on ERROR Stage Timers MilliSeconds po Hold Torque at End of Stage Start Delay Time 0 Speed rpm Max Fastening Time 20000 Final Speed Setpoint Dwell Time Torque Limits High Limit 0 000 Low Limit 0 000 Threshold 0 000 Trigger 3 000 000 Stage Retry Parameters Stage Retry Type Touchup After Retry goto Stage 1 k Maximum Retries Angle Limits Degree TIL High Limit 5999 Global to the Application Low Limit o Relax the Tools on the Final Stage Backoff on ERROR Yield Control Touch Up Settings High Gradient Limit roo 000 Target Angle Shutoff Gradient 5o0 High Angle Limit Low Gradient Limit poo Final Speed Boo Strobe Multiplier Backoff Seting Target Angle bo High Angle Limit Final Speed 300 08 Stage Del Stage gt c Save these Settings x Cancel My Changes REESE Sequence 63 Yield Point Control COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 58 Fastening Strategy Programming At Yield Threshold the TM module begins collecting torque angle data and calculates a running slope gradient or rate of change The maximum slope is remembered and compared against the Gradient setpoint to see if th
79. Tool The field cable and tool can now be connected to the Tork Trak TM controller Proper engagement of the cable connectors is important Carefully align the connectors and the lock ring while firmly pushing the connector until it is fully seated Excessive force is not required Electrical Requirements The Tork Trak TM controller requires a power source of 230 Volts AC single phase or 230 Volts AC three phase 60 50 Hz with a ground wire capable of supplying 15 through 20 amperes depending upon the tool model being controlled Refer to the following chart for tool model number and power requirements Supply Peak Supply Average Tool Model Voltage Current Power VAC Amps KVA ee Ee BEEN NENNEN DGD Series 1 Nutrunners 230 10 58 075 Cleco Model 17 Series Handtools 230 10 8 75 d Figure 1 2 Controller AC Input Power Requirements COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 1 7 version draft 0 5 Introduction to the Tork Trak TM Controller Power Drop Wiring It is recommended that the fuse selection and conductor AWG gage be based on Average Supply Current shown in the Average Power column in Figure 1 2 Note that while most of the tools are single phase six of the tools are three phase If under sized conductors are used the delivered torque of the fastening nutrunner will be below the catalog torque rating It is recommended that Sl
80. ULE Data TMH 280 mm 60 mm 200 mm Maximum depth with plugs 280 mm Spacing of mounting holes 260 mm center to center 3400 g 3420 g Enclosure type IP20 Type of cooling Convection self cooling Ambient temperature 0 509 Storage temperature 20 609 Humidity 0 90 non condensing Service life in operating 20 000 h Usability for storage 100 000 h approx 11 years Installation Guidelines A closed steel plate control cabinet must be used A zinc plated mounting plate must be used it must not be painted COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 4 version draft 0 5 TMH SERVO MODULE Drilling sketch Electromechanical Properties All connections are located at the front Two transducers can be connected redundant setup of measuring sensors according to VDI 2862 Fast error diagnosis with 2 digit 7 segment display Current fastening stage and parameter set are displayed by 2 digit segment display e LED READY indicates ready to operate condition e RESET button Cooper Tools service interface 5232 ARCNET Addressing with 2 BCD switches LED for ARCNET bus activity he cable shields for the resolver cable between the TMH and the connector board are connected to the housing with shield connecting components Cooper Tools No 5960434 5960435 All connectors and housing openings ar
81. X 118 293 5 416 2 680 12 42 48 TT300 75 3V 127 271 9 260 5 629 12 39 34 TT300 75 3X 80 434 4 416 2 1006 12 62 86 TT300 75 2V 95 362 7 346 2 840 12 52 48 TT300 75 2X 60 5 9 4 551 9 1342 12 83 85 40 SERIES TOOLS 40 20 563 28 7 15 9 768 11 12 00 40 10 292 57 4 49 8 1536 11 24 00 EMT40 10 INLINE 438 38 3 33 2 1024 11 16 00 EMT40 7M 194 86 1 59 9 2304 11 36 00 EMT40 7 INLINE 292 57 4 40 0 1536 11 24 00 EMT40 5 INLINE 206 81 3 33 2 2176 11 34 00 X Power Tools USER MANUAL Trak TM F i I Automated Svstems NA Tork Tra astening Controller Section 17 14 Tool Library Settings Torque Angle Servo Gear Model No Max Max Calibration Calibration Parameter Ratio opeed RPM Torque Nm Factor Factor Set EMT80 SERIES TOOLS EMT80 10T 463 36 2 157 4 967 11 15 12 80 10 553 30 3 131 9 811 11 12 67 EMT80 10 INLINE 860 19 5 68 6 521 11 8 14 80 6 252 66 5 157 4 1780 11 27 82 80 6 300 55 8 131 9 1492 11 23 31 EMT80 6 INLINE 467 35 8 68 6 959 11 14 98 EMT80 4T 189 88 8 157 4 2376 11 37 12 EMT80 4P 225 14 4 131 9 1991 11 37 10 EMT80 4 INLINE 350 47 8 68 6 1279 11 19 99 80 3 127 131 4 157 4 3516 11 54 93 EMT80 3P 152 110 1 131 9 2946 11 46 03 EMT80 3 INLINE 237 70 8 69 2 1893 11 29 58 80 2 96 175 3 170 9 4690 11 73 26 80 2 114 146 9 131 9 3930 11 61 40 EMT80 2 INLINE 177 94 4 92 2 2525 11 39 46 2 Pow
82. a 2 stage rundown Selected Panel valle LOCAL PANEL APPLICATION 1 DEFINED ON THE PANEL Torque Units N m_ COOPER Tools Stage 1 S v Filter Factor 2 This STAGE does not stop on ERROR Stage Timers MilliSeconds Hold Torque at End of Stage Start Delay Time p Speed rpm Max Fastening Time 20000 Final Speed Setpoint Dwell Time o Torque Spike Filter p Torque Limits Target Shutoff 5 000 Trigger 3 000 Stage Retry Parameters Stage Retry Type Touchup After Retry goto Stage 1 Maximum Retries 0 Global to the Application Relax the Tools on the Final Stage Backoff on ERROR Touch Up Settings Target Angle p High Angle Limit p Final Speed 300 Backoff Settings Target Angle High Angle Limit Final Speed 300 c Save these Settings x Cancel My Changes n 5 Stage De Stage gt Sequence 11 High Speed Rundown COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 12 Fastening Strategy Programming Sequence 11 Setpoint Definition Parameter Definition Value Range Shut off torque Torque as target value when it is reached the sequence is terminated 0 cal factor Trigger torque When this torque is exceeded the recording for graphic representation 0 1 2 x Torque cal begins factor Filtering factor Number of torqu
83. ameter torque hul dawn Shut off torque Trigger longue Suppressed in Black angle nag drag When the values are equal the sequence for evaluation causes a higher priority for evaluation for af the threshold tanque before the trigger Torque ie the threshold terque and thus angle counting are activated when the trigaer torque and threshold terque have the same values evan if blanking angle is defined Automated Systems Parame Start End Deactivatsan Banking angle Trigger tongue Afer blanking angle Blanking angle degree anie After atan pulse supe Altar black angle Block angle 0 pression degree Spaad 1 At apindla start 1 Shut off point whan speed 0 2 Threshold torque wien 2 D Speed 2 Prom threahold torque Shut off paint Speed 2 O or Speed 2 speed 1 COOPER PowerTools USER MANUAL Tork Trak TM Fastening Controller Section 7 37 Fastening Strategy Programming Parameters that ara analyzed in reverse ig starting from the shut off pot san Seam High evaluation angle Shut off parit minus Shut off point minus High evalualian uppar unaipa d upper angla angle minus high awal uat amp on angle Upper unweighted Suto point Shut poing minus ange Upper ures kg hed angie High evaluation evaluation arque ir the Pigh even angie angle
84. andtool at a resolution of 1 pulse per degree Acquisition of motor angle signals transmitted by the servo amplifier via Dual Port RAM These are generated from the resolver signals Acquisition of the motor current transmitted by the servo amplifier via DPR Communication between Measuring Board and Servo Amplifier Section A Dual Port RAM DPR is used for communication between servo amplifier and measuring board For safety reasons the start signal is transmitted via a direct line as well as via the Dual Port RAM from the measuring board to the servo amplifier section Communication between Measuring Board and Station Controller Communication is made via the high performance FieldBus ARCNET Transmission speed is 2 5 MBd e Maximum network distance 100 m e Star and tree topologies are possible with bus amplifier module HUB Cooper Tools Ident No 960920 e Twisted and shielded two wire cable RS485 Bus termination at beginning and end of chain by bus termination adapter Cooper Tools Ident No 960951 and bus termination Cooper Tools Ident No 960959 Use only Cooper Tools ARCNET cables with Ident No 960950 XXX XXX length in m COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 11 version draft 0 5 TMH SERVO MODULE Block Diagram TMH f Ber T 2253 suma 8 3 Te gt
85. ansducer and angle encoder calibration values for that nutrunner LCD Display Graphics The Tork Trak has an LCD display using TFT LCD technology and high speed video communication with a resolution of 1024 by 768 pixels This display also provides the user with the ability to view an 8 gt inch screen full color with graphical representations of torque curves and set points Screens which graphically represent the Torque Angle curves allow you to edit set points for your specific fastening application Fastening Strategies The power of Cooper Automation s TM Servo Module allows you to program theTork Trak for basic or advanced fastening strategies The following fastening strategies are available and easy to program and are a subset of the two dozen available fastening strategies Torque Monitor Torque Control Angle Monitor Angle Control Torque Monitor Prevailing Torque Monitor Yield Point Control Yield Point Control with Gradient Monitoring COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 1 3 version draft 0 5 Introduction to the Tork Trak TM Controller Statistics Reporting The Statistical Process Control functions of the Tork Trak TM controller are capable of meeting your present production demands today and years into the future The RUN screen dynamically indicates Torque X bar Range Sample Number Sample Size and CpK after every fastening rundown Th
86. arget value when it is reached the sequence is terminated 0 Torque cal Factor Max torque High limit of torque reached If this limit value is exceeded the stage is evaluated NOK 0 1 2 x Torque cal Tq Torque too high Factor Min angle Low limit of angle reached If this limit value is not reached an NOK for the stage results 0 9 999 ANG Angle too low Trigger torque When this torque is exceeded the recording for graphic representation beings 0 1 2 x Torque cal If the trigger torque value is higher than the threshold torque the Factor recording already begins when the threshold torque is exceeded otrobe multiplier Step width for gradient calculation in angle pulses Starting from reaching of the threshold torque one measuring 1 30 point in excess of the strobe multiplier must have been collected for the first gradient value to be computed Collection is made per angle pulse With each new measuring point each angle pulse the oldest measuring value is deleted and a new gradient calculated A strobe multiplier of 1 corresponds to two measuring points in direct sequence Max gradient High limit of gradient If this limit value is exceeded the stage is evaluated NOK 99 99 99 99 gt Gradient too high The evaluation is made with the value in the max value memory not with the gradient prevailing at the time of shut off Min gradient Low limit of gradient If this limit value is no
87. arth ground PE protected earth ground Lo 1 O 2 3 4 20 Motor phase V o 5 O o 6 The motor phases the lines of the thermal switch must not be touched even if the TM is in failure mode Fatal electric shock may occur Resolver XS3 All resolver signals are short circuit protected also to PE protected earth ground e Cable breakage monitoring 9 pole D Sub socket with lock screws 4 40 UNC threads Type 9 pole D Sub socket with lock screws 4 40 UNC threads COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 18 version draft 0 5 TM12 and TM34 SERVO MODULES Pin Description _ Input Output Signal Level 1 S1cosinesignal Input 2 S3 cosine signal 4 82 sine signal 51 S4sinsigal X Input 0 8 R2camersignl Output OV 9 Connected to PE protected earth ground Housing Shield connection PE protected earth ground It is prohibited to short circuit the lines or connections of the resolver the interface RS232 the ARCNET and the transducers to the supply motor line or the temperature contact of the motor The TM will be destroyed Service Interface RS232 XS4 e Service PC interface via null modem cable Cooper Tools Id No 960007 Short circuit protected Type 9 pole D Sub pins with lock screws 4 40 UNC threads Pin Description E __ ee 1 4 6
88. artment Internal error replace TM Internal error replace TM COOPER PowerTools Automated Systems USER MANUAL Tork Trak TM Fastening Controller Section 15 33 version draft 0 5 TM12 and TM34 SERVO MODULES 6 Torque no cycle signal from servo Measuring board firmly The synchronization signal secured to the TM between servo and measuring board is not present Internal error replace TM COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 34 version draft 0 5 lt gt r 00 Top Display Bottom Display Error Explanation Torque servo parameters do not fit servo The parameter set selected by the measuring board is not available in the TM Transducer 1 not present The transducer signal is e Interrupted e Shorted e Not present Transducer 1 Offset NOK The zero point voltage is out of the admissible range between 200 mV 200 mV Consequence gt amp 5 5 2 2 5 c 25 Clu 2 9 5 S e x 5 S8 gt M 0 Un 009 TM12 TM34 SERVO MODULES Measures Remedy Check programming of system Internal error replace TM Is the transducer connected Check transducer cable for continuity and short circuit Replace transducer Internal error replace TM Transducer installed in
89. as target value when it is reached the sequence is terminated 0 Torque cal Factor Min Torque Low limit of torque reached 0 Torque cal Factor If this limit value is not reached NOK for the stage results lt Torque too low a Torque High limit of torque reached 1 2 Torque If this limit value is exceeded the stage is evaluated NOK a gt Torque too high Trigger torque When this torque is exceeded the recording for graphic representation begins 0 1 2 x Torque cal Factor Speed Set speed of the spindle s output shaft 1 max speed Filtering factor Number of torque values used to find mean value 1 2 4 8 16 32 With this number of torque values a mean value is calculated immediately upon measurement corresponding to filtering and dampening As soon as a new value is measured the oldest value is deleted and the mean value recalculated The further evaluation shut off evaluation graph is made with these mean values A filtering factor of 1 results in no mean values being computed COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 24 Fastening Strategy Programming Torque Control and Pulse Torque Recovery Sequence 20PTR Shut off torque controlled fastening with torque monitoring bs Advanced Application Builder Navigate About Exit T n Applications Selected Panel Avail
90. ase 2 0 9 999 The evaluation angle is the monitored range of the fastening of a fastener prior to its making contact looking back The range recorded generally ends when the torque rises above the threshold torque off value because the fastener s head has made contact To exclude this rise in torque from the evaluation an unweighted angle between the evaluation range and the end of the recording is ignored If the range recorded is smaller than the sum of evaluation angle and unweighted angle this results in an NOK evaluation of the stage FSMW FRTM Not enough measured values Unweighted angle Range between evaluation angle and the end of the recording that is not evaluated 0 9 999 Above limit Admissible percentage of deviation from the limit value in the evaluation angle 0 100 Across the evaluation angle the torque values are checked for exceeding of the max torque If the deviation is more than the admissible percentage an NOK evaluation for the stage results 2 FRTM Too much overstep in phase 2 If there are deviations but less than admissible this will not lead to an NOK evaluation but only a warning will be output P2M gt FRTM Torque in phase 2 too high COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 15 Fastening Strategy Programming Sequence 13 Setpoint Definition cont d Parameter Value Range Below limit
91. atal electric shock may occur COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 17 version draft 0 5 TMH SERVO MODULE Resolver XS3 All resolver signals are short circuit protected also to PE protected earth ground Cable breakage monitoring 9 pole D Sub socket with lock screws 4 40 UNC threads Type 9 pole D Sub socket with lock screws 4 40 UNC threads Input Output Signal Level 1 Stoosine signal Input 0 2 83 cosine signal oo 236 4 82 sine signal 5 S4sinesignal Input OV 8 BR2camersinal Ouptt OV 9 to protected earth ground It is prohibited to short circuit the lines or connections of the resolver the interface RS232 the ARCNET and the transducers to the supply motor line or the temperature contact of the motor The TMH will be destroyed Service Interface RS232 XS4 e Service PC interface via null modem cable Cooper Tools Id No 960007 Short circuit protected Type 9 pole D Sub pins with lock screws 4 40 UNC threads Description RxD TxD GND 1 4 6 7 8 9 Shield connection PE protected earth ground COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 18 version draft 0 5 TMH SERVO MODULE ARCNET XS5 Short circuit protected Galvanic separation from all othe
92. ax is exceeded the drive is stoppad and the rundown data is evaluated as Hote The safety shut down torque 1 max also remains active when 1 has been deactivated by setting the 1 angle zero The tarquea M1 and 2 as well as Ihe masimum tarquesa m the rndewn are measued and the results are included in the statistical evaluation Angle counting starts from the threshold tongue COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 47 Fastening Strategy Programming Afer switch off due to the backoff angle having been reacted the minimum maximum torque and the minimum maximum angle are used to evaluate the result as OK or Parameters be sel far maximum lime start pulse suppression ime and dwell bre When the trigger terque is reached viewed and evaluated in graphic Description of parameters Sequence input value Filtering factor Trigger torque Mm Threshold torque Nim Backoff angle deg Angle at Mi deg MI max MI min Men Angle at 2 dag MZ max Nev MZ min Merri Maximum torque Mr Minimum terque Mint Maximum angle deg Minimum angle de recording of the torque curve starts and the curve be 48 Number of measured values used for averaging Start af staring the barque value for the graphical view Beginning of anale counting Angle at which the dr
93. cable connector connect the external 24 VDC common to pin 23 Input Common A 3 On the I O interface Board set all jumpers to Input Common and Output Common A Internal 24 VDC All Inputs and Outputs Active Low 1 On the Public I O cable connector jumper pins 11 DC Common to 2 Output Common A 2 On the Public I O cable connector jumper pins 14 24 VDC to 23 Input Common A 3 On the interface Board set all jumpers to Input Common and Output Common A External 24 VDC All Inputs and Outputs Active Low 1 On the Public I O cable connector connect the external 24 VDC com to pin 2 Output Common A 2 On the Public I O cable connector connect the external 24 VDC to pin 23 Input Common A 3 On the interface Board set all jumpers to Input Common A and Output Common COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 12 11 version draft 0 5 Input Output Overview In order to setup some outputs active high and some outputs active low make use of all the Output Common Buses A B or C and Input Common Buses A B or C As an example if an output needs to be Active Low connect 24 VDV common to either output Common Buss A B or C and assign the output to the appropriate bus using the jumpers on the Interface Board If an input needs to be Active Low connect 24 VDV common to either input Common Buss A B or C and assign the input to the approp
94. check tool cable especially the calibration line Internal error replace TMH Is the tool connected Check tool cable for continuity and short circuit Replace transducer Transducer 2 not present The transducer signal is e interrupted shorted e not present Internal error replace TMH Transducer installed in jammed position Check with test mode of station controller if values are out of admissible ranges if so replace transducer Transducer 2 Offset NOK The zero point voltage is out of the admissible range between 200 mV 200 mV Internal error replace TMH COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 38 version draft 0 5 TMH SERVO MODULE Transducer 2 calibration voltage NOK Transducer installed in The calibration voltage is out of jammed position the admissible range between 4 85 V 5 15 V Check with test mode of station controller if values are out of admissible ranges if so replace transducer or handtool If deviation is extreme check tool cable especially the calibration line Internal error replace TMH COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 39 version draft 0 5 TMH SERVO MODULE QO O O 2 o a c lt gt r uvv Measures Remedy Top Display Bottom Display Error Explanation Check at the sta
95. continuity and short circuit especially the 12 V 0 V conductors Replace handtool Internal defect replace TMH Measure supply voltage If gt 255 VAC reduce to 230 VAC Capacitors in intermediate circuit are open Brake chopper is defective replace TMH The supply voltage is too high sporadically connect next higher tap of transformer if 3 phase isolation transformer is available Measures Remedy USER MANUAL Tork Trak TM Fastening Controller Section 16 27 version draft 0 5 TMH SERVO MODULE Intermediate circuit voltage too low Permanent error The voltage of the intermediate epee a ahaa AC circuit is 150 VDC During fastening e he supply is too weak or overloaded ensure more stable supply e g larger isolation transformer Capacitors in intermediate circuit are open replace TMH Internal error replace TMH Temperature in output section too X X X Measure temperature inside high The temperature in TMH is gt E net dd Hn me o 50 additional cooling e g 80 a air conditioner required Cooling slots of TMH must not be covered by cables or similar Internal error replace TMH Start up relay does not open Internal error replace TMH Due to an internal error the contact in the start up relay sticks Main relay does not open Internal error replace TMH Due to an internal error the contact in the main relay sticks COOPER PowerTo
96. d After the measuring time has been completed the frictional torque measurement is ended and transition into phase 4 is continuous Phase 4 Engage Upper Dead Center move to a defined end position During phase 4 the spindle is rotated until an initiator signals it has reached the upper dead center position upper dead center position DTM upper dead center OTINI The whole measuring cycle evaluation is processed in the control system The control system can display the values in tables on the monitor and can output them to a printer or transmit them to other system components by data communication The parameters below are entered in the electronic control system Sequence input value 15 Max breakaway torque Nm Safety shut down torque Min breakaway torque Nm Low limit of the breakaway torque for evaluation in the start time Max evaluation torque Nm High evaluation torque during the measuring time Min evaluation torque Nm Low evaluation torque during the measuring time Start time ms Time to overcome the breakaway and to monitor the backoff torque determines the length of phase 2 COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 12 version draft 0 5 Fastening Strategies Measuring time ms Time in which the frictional torque is checked determines the length of phase 3 Filtering factor Filtering factor number of measured values used for filte
97. d Systems NA Tork Trak TM Fastening Controller Section 16 21 version draft 0 5 TMH SERVO MODULE Operating conditions Upon power up or reset the following messages are displayed Lamp test that is all 2 x 7 segments are on 88 for 1 second Then the display is off for approx 0 5 seconds adjusted ARCNET address is displayed as 01 32 for 1 second Then the display is off for approx 0 5 seconds e Selected handtool control parameter set will be shown on the bottom display 2 will appear for 17E or 4 will appear for 47E or 6 for 67E for 1 second while the upper display will not be on During fastening operation Display during fastening 11 FF The top display shows the selected fastening program The bottom display shows the selected fastening stage Overload display IP If current above the maximum admissible current is drawn during a fastening cycle the servo amplifier shuts off automatically and IP is displayed The overload error is reset by a restart Im test operation controlled by station controller drive active top display A bottom display not on LED READY Color green Indicates ready to operate condition of the TMH f all supply voltages are present and no failure is present this LED is on LED Bus active Color green Displays ARCNET bus activity e f data is being transferred on the ARCNET bus this LED is on COOPER PowerTools USER MANUAL Au
98. d is 2 5 MBd e Maximum network distance 100 m e Star and tree topologies are possible with bus amplifier module HUB Cooper Tools Ident No 960920 Twisted and shielded two wire cable RS485 Bus termination at beginning and end of chain by bus termination adapter Cooper Tools Ident No 960951 and bus termination Cooper Tools Ident No 960959 Use only Cooper Tools ARCNET cables with Ident No 960950 XXX XXX length in m COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 11 version draft 0 5 TM12 and TM34 SERVO MODULES Block Diagram TM12 olf ni VR Buiuanipuaa auBin 51 4 daaegmant READY RESET COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 15 12 version draft 0 5 TM12 and TM34 SERVO MODULES Block Diagram 34 Nm SME Ba ME 1 IDLY E Ba ABI zu AZL E L TAG AELH AD Ag L3H2O amp V ld 9 upnupdas 1 E Vl Ea 1 mu er or pss onp aad 2 37 u ww 27 a E 09 TR 1 13539 T yh Oo 5 SES amp AC pz met GOXJOBEDH zTD HS monpj pone
99. d range for understep of the low evaluation torque Low evaluation torque Nm Low torque limit in the evaluation angle low that must not be understepped in reverse analysis Maximum torque Nm High limit of torque reached Minimum torque Nm Low limit of torque reached Maximum angle deg High limit for angle reached and safety shut off value Minimum angle deg Low limit of angle reached Speed 1 rpm Preset speed maximum speed specified in the range for spindle constants valid from the beginning of the sequence up to the threshold torque Speed 2 rpm opeed when the shut off torque is reached Must be lower than speed 1 Cutoff is deactivated when speed 2 0 or speed 2 gt speed 1 Parameter Start Evaluation Suppressed in sequence Threshold torque Block angle blanking angle Safety torque 2 shut down After start pulse Shut off point suppression reached Shut off torque 3 Block angle blanking angle When the values are equal the sequence for evaluation causes a higher priority for evaluation for instance of the threshold torque before the trigger torque i e the threshold torque and thus angle counting are activated when the trigger torque and threshold torque have the same numeric values even if a blanking angle is defined COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 22 version draft 0 5 Fastening Strategies Blanking angle Trigger torque
100. d toward the rear of the controller The Tork Trak TM supports operation from an external 24 VDC supply PLC or from the 24 VDC power supply internal to the Tork Trak TM Controller COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 12 1 version draft 0 5 Input Output Overview The Tork Trak TM also supports operation as Active High or Active Low Source or oink permitting a mix of Active High or Active Low Inputs and Outputs This setup is accomplished by positioning jumpers on the Interface Board located on the CPU and Indicator Light Sub Assembly Refer to the following illustration Details of the I O jumper positions will be discussed later in this Section 12 CPU and Display Sub Assembly Setup Jumpers Public 104 VO Board nm rH Private PC 104 VO Board Public iO Interface Board CPU amp PC 104 Motherboard Private 1 0 Interface Board COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 12 2 version draft 0 5 Input Output Overview PRIVATE OUTPUT Pinout Discrete Physical Connector Description FUNCTION Pin Assignment 24 VDC OUTPUT 9 Torque High Indicator Light OUTPUT 10 Angle High Indicator Light OUTPUT 11 Cycle Accept Indicator Light OUTPUT 12 Cycle Reject Indicator Light OUTPUT 13 Torque Low Indicator Light OUTPUT 14 An
101. dle bolt Navigate About Exit e Stations s are Availible M Applications Selected Panel i LOCAL PANEL X APPLICATION 1 DEFINED ON THE PANEL Torque Units N m COOPER Tools Stage Sequence Builder Stage 1 Seg 16 Set Position v Filter Factor 2 Prog d Angle from Ex Signal I This STAGE does not stop on ERROR Stage Timers MilliSeconds F Hold Torque at End of Stage Start Delay Time fa Mes re Speed rpm Max Fastening Time 20000 P Final Speed Setpoint 250 Dwell Time 0 xternal ist 255 H Torque Limits High Limit 0 000 Stage Retry Parameters Stage Retry Type px After Retry goto Stage 1 High Limit 9999 Maximum Retries lo Shutoff 0 Low Limit 0 Global to the Application Relax the Tools on the Final Stage Backoff on ERROR Touch Up Settings Target Angle High Angle Limit IT Final Speed Backoff Settings Target Angle High Angle Limit Final Speed 4 5 Add Stage Del Stage b gt Save these Settings Cancel My Changes Sequence 16 Set Position oequence 16 is usually used in a 2 stage rundown as stage 2 There are five parameters which can be programmed and these are each described with a range of parameter values in the following table The external discrete input can be a proximi
102. e Nm Maximum torque at which the engagement stage is prematurely stopped Engagement stage on time ms The nutsetter remains switched on throughout this time Engagement stage off time ms The nutsetter remains switched off throughout this time Engagement cycles Number of engagement stage cycles Filtering factor Filtering factor number of measured values used for filtering by averaging Speed rpm Preset speed within the maximum speed range specified in the range for spindle constants COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 6 2 version draft 0 5 Fastening Strategies Sequence 11 High Speed Rundown Shut off torque controlled fastening up to a contact torque Torque Shut off torque lime Start Maximum tightening time start pulse suppression Dwell time In the electronic control system the shut off torque filtering factor and speed preset are entered separately for each nutsetter A maximum tightening time is entered as the safety shutdown It applies to all nutsetters of a product group tightening process in this stage The measuring transducer integrated into the nutsetter measures the torque during tightening rundown The value is processed by the control system The nutsetter is stopped when the shut off torque search criteria is reached COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Sectio
103. e slope has dropped off enough to indicate that the fastener is yielding A filtering mechanism is provided to negate false yield detection and is described below However once the criteria for yield are met the TM module will command the fastening to stop and qualify the fastening Following Threshold Torque the yield control algorithm takes samples of the torque angle relationship These samples are taken at intervals defined by the Strobe Multiplier setpoint number of angle pulses sample The number of angle pulses defines how many samples are necessary per gradient slope calculation Note that every new sample will result in a new slope the oldest sample is discarded every time a new one is seen Every new slope is compared to the maximum slope that has been seen in that cycle If the slope is steeper it replaces the present value which then becomes the maximum slope If less steep it is checked to see if it falls below the maximum slope by a percentage defined by the setpoint Gradient As an additional guard against false yield detects the Strobe Multiplier setpoint defines the number of consecutive degrees that yielding slopes must be seen before an actual yield event is declared The Shut off Gradient terminates the sequence This is a target value and occurs when the Shut off Gradient percentage of maximum gradient is reached The following listing of parameters can be edited on the Sequence 63 Yield Point Control screen e Torq
104. e Stats Menu and Print Menu screens offer custom format options which allow you to produce reports specific to your needs Statistics Report Application History Report Chronological History Report Histogram X bar and Range Charts Fault Log Other Features Diagnostics Torque Angle Curve O scope Curve Tool Tests Tork Trak Self Tests Fault Log Outputs EtherNet port USB port Field Bus Support of Devicenet Profibus or Interbus options Six Fastening Accept Reject Indicator Lights Two User programmable Indicator Lights Peripherals e External Keyboard connector COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 1 4 version draft 0 5 Introduction to the Tork Trak TM Controller Options Public I O port and matching cable connector RS 232 Serial Connector port Laser Bar Code Reader External Application selector switch External control pendant External socket tray Batch Counting Capability Remote Light Box Remote Live Handle for Cycle Start Stack Light Connector Support GM Common Controller DeviceNet Profibus Interbus Ethernet IP Modbus TCP Interbus 2 channel Data Virtual Unpacking The Tork Trak TM controller is a fastening system with a minimum of components In its basic form the system consists of the Tork Trak TM controller enclosure the fastening tool and a field cable During unpacking it is advisable to inspect the equ
105. e and parameter set are displayed by 2 digit 7 segment display LED READY indicates ready to operate condition e RESET button Cooper Tools service interface 5232 ARCNET Addressing with 2 BCD switches LED for ARCNET bus activity he cable shields for motor and resolver cable at the housing are connected with shield connecting components Cooper Tools Ident No 5960434 5960435 All connectors and housing openings are contact protected IP20 Cooper Tools Electric Data The intermediate circuits of the power section and the logic section are supplied separately This allows separate power down of the intermediate circuit of the power section upon EMERGENCY STOP The logic power supply unit and therefore all communication assemblies continue to be supplied The internal fuses protect the conductor tracks inside the TM If defects CAUTION occur only replace with originally supplied fuses Do not change voltage or current ratings or fuse speed COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 5 version draft 0 5 TM12 and TM34 SERVO MODULES Intermediate Circuit of the Power Section Integrated starting current limit by two processor controlled relays The main relay is switched on after the initialization The intermediate circuit capacitors are charged through a starting current limiting resistor until a voltage of approx 300 VDC is reached
106. e contact protected 20 COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 5 version draft 0 5 TMH SERVO MODULE Electric Data Power Supply The intermediate circuits of the power section and the logic section are supplied separately This allows separate power down of the intermediate circuit of the power section upon EMERGENCY STOP The logic power supply unit and therefore all communication assemblies continue to be supplied The internal fuses protect the conductor tracks inside the TMH if defects occur or if the external fusing is too high The fuses must only be replaced by Cooper Tools Intermediate Circuit of the Power Section Integrated starting current limit by two processor controlled relays The main relay is switched on after the initialization The intermediate circuit capacitors are charged through a starting current limiting resistor until a voltage of approx 300 VDC is reached Thereafter the resistor is bridged by the startup relay TMH must be operated on an isolation transformer approved by Cooper Tools Connector 51 TMH Handtool type 17E 47E 67E Supply voltage 1 X 230 VAC 10 Frequency 50 60 Hz Rated supply current 0 5 A RMS Peak supply current RMS Internal fusing slow blow Starting current limit COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Sec
107. e for short circuit Replace transducer Replace motor COOPER PowerTools Automated Systems Section 16 34 USER MANUAL Tork Trak TM Fastening Controller version draft 0 5 TMH SERVO MODULE Internal error replace TMH Torque Process control Process sequence start stage graphics not adhered to Inform Cooper Tools service department Internal error replace TMH COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 16 35 version draft 0 5 TMH SERVO MODULE O 2 o a c lt gt r uvv Measures Remedy 8 Top Display 8 Bottom Display Error Explanation Main and Startup Relay Output Section Off Torque Initialization Initialization error in measuring board Inform Cooper Tools service department L Tani Internal error replace TMH Torque access to DPR Measuring board firmly The measuring board cannot screwed inside TMH access the DPR in the servo Torque servotype not TMH The TMH type read by the measuring board is unknown Torque no cycle signal from servo Measuring board firmly The synchronization signal secured to the TMH between servo and measuring board is not present Internal error replace TMH 6 A 6 Torque servo parameters do not fit Check programming of system servo The parameter set selected by the measuring board is n
108. e values used to find 1 2 4 8 16 32 mean value With this number of torque values a mean value is calculated immediately upon measurement corresponding to filtering and dampening As soon as a new value is measured the oldest value is deleted and the mean value recalculated The further evaluation shut off evaluation graph is made with these mean values A filtering factor of 1 results in no mean values being computed opeed Set speed of the spindle s output shaft 1 max speed COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 13 Fastening Strategy Programming Prevailing Torque Monitor Sequence 13 Tightening until the fasteners head makes contact with torque monitoring torque controlled shut off with subsequent torque evaluation bs Advanced Application Builder Navigate About Exit 22101 a Back Pale valle gt PANEL 7 Stage Sequence Builder Prevailing Torque Monitor Shut Off Torque Phase 1 Phase 2 Wu mue Max Fastening Time gt 1 Ta E Applications s DEFINED ON THE PANEL iani x Selected Panel ox p Torque units Nm COOPER Tools Stage 1 Seq 13 Filter Factor 2 This STAGE does not stop on ERROR Stage Timers MilliSseconds Hold Torque at End of Stage Start Delay Time o Speed rpm Max Fastening Time 20000 Final Speed Setpoint 250 Dwe
109. ed by the control system The nutsetter is stopped when the shut off torque or shut off angle search criteria is reached The dwell angle and peak torque during the dwell time are then measured and processed in the control system as the bolt tightening value together with the rundown evaluation The control system can display the values in tables on the monitor and can output them to a printer or transmit them to other system components by data communication When the spindle trigger torque is reached recording of the torque curve starts and the curve can be viewed and evaluated in a graphic This tightening method normally follows a fast pretightening stage COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 48 version draft 0 5 Fastening Strategies The parameters below are entered in the electronic control system Sequence input value 78 Trigger torque Nm Trigger torque beginning of measurement recording for the graphic display Threshold torque Nm Threshold torque beginning of angle counting and gradient calculation Shut off torque Nm Shut off torque for the stage Shut off angle deg Shut off angle for the stage Maximum angle deg Maximum angle high limit of angle reached Minimum angle deg X Minimum angle low limit of angle reached Maximum torque Nm Maximum torque high limit of torque reached and shut off value Minimum torque Nm Minimu
110. ed to find mean value 1 2 4 8 16 32 With this number of torque values a mean value is calculated immediately upon measurement corresponding to filtering and dampening As soon as a new value is measured the oldest value is deleted and the mean value recalculated The further evaluation gradient calculation shut off evaluation graph is made with these mean values A filtering factor of 1 results in no mean values being computed COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 65 Fastening Strategy Programming General Information Concerning Gradient Controlled Fastening Strategies Sequence 63 Sequence 73 Sequence 75 Sequence 78 Definition The gradient is the difference quotient of two measuring points consisting of torque and angle measured per angle pulse Gd ANn ANm m n index of respective measuring point n m spacing of measuring points polling rate Expressed for the practice of fastening technology The gradient is the change of torque per degree of angle A positive gradient means increase a negative gradient decrease of the torque with increasing angle Note that changing the strobe multiplier will affect the gradient calculation since a different quotient is computed thereby Higher strobe multipliers have a smoothing effect that is a change from a positive to a negative quotient will be detected later After
111. eg Minimum angle low limit of angle reached Maximum torque Nm Maximum torque high limit of torque reached and shut off value Speed rpm Preset speed within the maximum speed range specified in the range for spindle constants COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 14 version draft 0 5 Fastening Strategies Sequence 20 Shut off Torque Controlled Fastening with Torque Monitoring Torque Maximum torque 6 Initial torque Time Start Maximum tightening time Start pulse suppression Dwell time In the electronic control system the shut off torque maximum torque the minimum torque the filtering factor and the speed are entered separately for each nutsetter A maximum tightening time is entered as the safety shut down It applies to all nutsetters of a product group tightening process in this stage The measuring transducer integrated into the nutsetter measures the torque during tightening rundown The value is processed by the control system The nutsetter is stopped when the shut off torque search criteria is reached The peak torque achieved during the dwell time is then measured and processed in the control system as the bolt tightening torque together with the rundown evaluation The control system can display the values in tables on the monitor and can output them to a printer or transmit them to other system components by da
112. elp Exit Stations a Back are Applications Selected Panel PANEL APPLICATION 1 DEFINED ON THE PANEL Torque Units oom COOPER Tools Stage Sequence Builder Stage E Seq 50 Angle Control Torque Monitoring Filter Factor 2 Stage Timers MilliSeconds Start Delay Time o Max Fastening Time 20000 Dwell Time fo Angle ala anior This STAGE does not stop on ERROR Hold Torque at End of Stage Speed rpm Final Speed Setpoint 250 Torque Monitoring Low Limit 10 000 plebs rb aude Torque range Angle E Stage Retry Parameters Stage Retry Type Touchup After Retry goto Stage 1 Maximum Retries 0 Threshold 0 000 Trigger 3 000 Angle Control Degree High Limit 0999 Global to the Application Shutoff 0 Relax the Tools on the Final Stage on ERROR Touch Up Settings Target Angle 0 High Angle Limit Final Speed 300 Backoff Settings Target Angle High Angle Limit 00000 Final Speed 300 Low Limit 0 X Ada stage 1 Del Stage gt c Save these Settings x Cancel My Changes Sequence 50 Angle Control Torque Monitor COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 49 Fastening Strategy Programming Sequence 50 Set Point Definitions Range of Values is terminated 0 9 999 M
113. ems NA Tork Trak TM Fastening Controller Section 6 42 version draft 0 5 Fastening Strategies When the spindle trigger torque is reached recording of the torque curve starts and the curve can be viewed and evaluated in a graphic This tightening method normally follows a fast pretightening stage The parameters below are entered in the electronic control system Sequence input value Trigger torque Nm Threshold torque Nm Perc shut off value 96 Minimum gradient Nm deg Maximum gradient Nm deg Strobe multiplier Filtering factor Maximum angle deg Minimum angle deg Maximum torque Nm Minimum torque Nm Speed rpm COOPER PowerTools Automated Systems Section 6 43 63 Trigger torque beginning of measurement recording for the graphic display Threshold torque beginning of angle counting and gradient calculation Percentage shut off value percentage amount of the measured maximum gradients for the rundown produces the shut off value shut off gradient Minimum gradient low limit and safety shut off value for the gradient Maximum gradient high limit and safety shut off value for the gradient Strobe multiplier spacing in angle impulses of the fillered measured values used for gradient calculation Filtering factor number of measured values used for filtering by averaging Maximum angle high limit for angle reached and safety shut off value
114. en it is reached the sequence is terminated 0 Torque cal Factor Max Torque High limit of torque reached 0 1 2x Torque If this limit value is exceeded the stage is evaluated gt cal Factor Torque too high Min Angle Low limit of angle reached 0 9 999 If this limit value is not reached an NOK for the stage results ANG lt Angle too low Max Angle High limit of angle reached 0 9 999 If this limit is exceeded the rundown is terminated safety shut down and the stage evaluated gt Angle too high Filtering factor Number of torque values used to find mean value 1 2 4 8 16 32 With this number of torque values a mean value is calculated immediately upon measurement corresponding to filtering and dampening As soon as a new value is measured the oldest value is deleted and the mean value recalculated The further evaluation shut off evaluation graph is made with these mean values A filtering factor of 1 results in no mean values being computed COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 45 Fastening Strategy Programming Backoff Angle Control with Torque Monitoring Sequence 48 Controlled Angle reverse strategy with 2 Torque Monitoring Points bs Advanced Application Builder Mavigate About Help Exit Stations Tools G Back are Ayvailible M Ayvailible gt
115. eneral fastening control strategy This strategy answers out to controlled torque At the conclusion of the rundown pulse torque recovery PTR is run for a user programmable number of torque on off makeup pulses Sequence 30 Torque Control with Angle Monitoring Sequence 30 is a general fastening control strategy This strategy answers out to controlled torque and monitors angle COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 2 Fastening Strategy Programming Sequence 30PTR Torque Control with Angle Monitoring and Pulse Torque Recovery Sequence 30 is a general fastening control strategy This strategy answers out to controlled torque and monitors angle At the conclusion of the rundown pulse torque recovery PTR is run for a user programmable number of torque on off makeup pulses Sequence 31 Self Tap with Torque Control Sequence 31 is designed to initially monitor the torque required for a self tap screw to cut a thread and then control torque for final clamp load Sequence 41 Back off with Angle Control oequence 41 is a controlled reverse strategy using angle control Sequence 46 Back off with Torque and Angle Control Sequence 46 is a controlled reverse strategy using both torque and angle control Sequence 48 Back off with 3 stage Torque and Angle Control oequence 48 is a controlled angle reverse strategy with 2 Torque Monitoring Points Sequence 5
116. ent 5 094 301 COOPER PowerTools Automated Systems USER MANUAL Tork Trak TM Fastening Controller Section 7 32 Fastening Strategy Programming Sequence 31 Self Tap with Torque Control Initial monitor of torque for thread cutting followed by torque control for final clamp load amp Advanced Application Builder i Dl Navigate About Exit o lt Back fy o Applications Selected Panel s PANEL 7 DEFINED ON THE PANEL Torque Units N m COOPER Tools Stage Sequence Builder Stage 1 Seq31 SelTap with Torque Contro Filter Factor 2 Self Tap with Torque Control This STAGE does not stop on ERROR Stage Timers MilliSeconds Hold Torque at End of Stage Start Delay Time D Speed rpm Max Fastening Time Speed at Threshold pso Dwell Time D o Speed at Shutoff p Torque Spike Filter Torque Control Stage Retry Parameters Trigger 3 000 Stage Retry Type Touchup Threshold 0 000 After Retry goto Stage 1 Maximum Retries 0 Target Shutoff 5 000 Safety Shutoff Limit 75 00 Low Eval 0 000 0 000 High Eval Low Limit 0 000 0 000 High Limit Angle Limits Degree Self Tap Angle 0 Re Hit Detection Angle 0 low unweighted angle 0 high unweighted angle ft Low Eval 0 0 High Eval Low at End 0 9999 High at End 3 Adi Stage De Stage gt Global to the Applicat
117. eq 30 Pulse Torque Recovery Filter Factor od pl I This STAGE does not stop on ERROR SEQ 30 PTR Shut off Torque 1 Speed rpm 1 Final Speed Setpoint 250 Angle Monitor Torque Control Stage Timers MilliSeconds Start Delay Time 0 Fastening Time 20000 Dwell Time 0 Hold Torque at End of Stage High Limit 0 000 Stage Retry Parameters Target Shutoff 5 000 Stage Retry Type Touchup Low Limit p 000 After Retry goto Stage li Threshold 0 000 Maximum Retries Trigger 3 000 Global to the Application Angle Monitoring Degree High Limit 9999 Relax the Tools on the Final Stage Low Limit 0 Backoff on ERROR Touch Up Settings Target Angle 0 High Angle Limit 0 Final Speed 300 Pulse Torque Recovery Overall Time ms fi 000 10 Off Time High Limit o 000 0 000 Limit Backoff Settings 0 Pulses 7 0 Speed Target Angle High Angle Limit 0 Final Speed 300 4 3 Add Stage Del Stage b c Save these Settings x Cancel My Changes p Sequence 30PTR Torque Control Angle Monitor and Pulse Torque Recovery COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 30 Fastening Strategy Programming Sequence 30PTR Set Point Definitions Range of Values Shut off torque Torque as target value when it is reached the se
118. er Stage 1 Filter Factor 16 f This STAGE does not stop on ERROR sedes 1 inm Sta Delay Time Spend Fastening Time foo Final Spaad lm Dwell Time Terque Spike Filler iaa Stage Retry Parameters Shuto s 0n Retry Type 000 Global to the Application Relax ih 3 a Firal Stage Backaff on ERROR dog Settings B T eque fs Dn Final Speed Durstisnqma El m ass singe ama Final Speed 9000 COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 6 53 version draft 0 5 Fastening Strategies Post Rundown Fastening Strategy TOUCH UP and ERROR HANDLING The TOUCH UP ERROR HANDLING function provides a way to program Error Handling by programming a NOK not OK reject strategy Subsequent to touch up another fastening stage may be started while error handling leads to the end of the process This allows to back off joints in the touch up routine and to retighten these in the further fastening sequence to achieve an OK accept rundown Since no further stage can follow the error handling routine the fastening sequence is terminated with NOK it is often used to fully back out the fasteners Touch up and error handling can be programmed separately for each fastening stage that is group assignments a
119. er Tools USER MANUAL Automated Svstems NA Section 17 15 Tork Trak TM Fastening Controller Tool Library Settings Torque Angle Servo Gear Model No Max Max Calibration Calibration Parameter Ratio opeed RPM Torque Nm Factor Factor Set EMT200 SERIES TOOLS EMT200 10 614 56 2 196 0 521 12 8 14 200 10 331 104 5 364 0 967 12 15 12 200 10 461 75 0 261 3 694 12 10 85 200 10 289 119 5 416 5 1107 12 17 30 200 5 334 103 5 196 0 959 12 14 98 EMT200 5T 180 192 2 364 0 1780 12 27 82 200 5 250 138 0 261 3 1278 12 19 07 200 5 157 220 0 416 5 2037 12 31 83 200 4 250 138 1 196 0 1279 12 19 99 200 4 135 256 5 364 0 2376 12 37 12 2 Power Tools USER MANUAL Tork Trak TM F i Automated Svstems ork ira astening Controller Section 17 16 Tool Library Settings Torque Angle Servo Gear Model No Max Max Calibration Calibration Parameter Ratio opeed RPM Torque Nm Factor Factor oet EMT200 4V 188 184 1 261 3 1705 12 26 65 200 4 118 293 5 416 5 2719 12 42 48 EMT200 3 169 204 4 196 0 1893 12 29 58 EMT200 3T 91 379 6 364 0 3516 12 54 93 EMT200 3V 127 271 9 260 7 2518 12 39 34 EMT200 3X 80 434 4 416 5 4023 12 62 86 200 2 127 272 7 260 4 2525 12 39 46 200 2 68 50
120. ervice department COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 15 41 version draft 0 5 TM12 and TM34 SERVO MODULES Consequence Measures Remedy Top Display Bottom Display Error Explanation Main and Startup Relay Output Section Off Brake Motor Output Section Off gt T Overload not flashing Check system programming If a current above the admissible e Nutrunner selection maximum current is drawn during Required torque fastening the servo amplifier shuts off automatically Check motor position tracing e Check resolver cable and e Error in motor position tracing replace motor e g resolver cable e Internal error replace TM e Error in motor circuit e g motor does not reach required torque e Check motor cable e Replace motor LED s READY and Bus active Emo Measures Remedy e Check supply voltages 5 LED READY not on e Internal error replace The TM is not ready Refer to Display of Errors segment display flashes COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 42 version draft 0 5 LED Bus active flashes at approx 1 Hz frequency ARCNET communication interrupted LED Bus active not on otatus and diagnosis display flashes TM12 and TM34 SERVO MODULES Check ARCNET connection
121. es used for averaging Trigger torque Nm Beginning of storing torque values for the graphic display reverse analysis and blanking angle Threshold torque Nm Beginning of angle counting valid outside the blanking angle and block angle Shut off torque Nm Torque at which the drive is stopped and the dwell time begins valid outside the blanking angle Safety shut down torque Nm Monitoring torque valid after start pulse suppression has finished and during the rundown and the value at which the drive is stopped when it is exceeded Block angle deg Angle beginning at the end of start pulse suppression in which the torque must be lower than the shut off torque Blanking angle deg Angle range starting at the trigger torque in which the shut off torque and threshold torque are invalid Unweighted angle high deg End point of the evaluation angle high related to the shut off point reverse Evaluation angle high deg Length of the monitored range for overstep of the high evaluation torque High evaluation torque Nm High torque limit in the evaluation angle high that must not be exceeded in reverse analysis COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 21 version draft 0 5 Fastening Strategies Unweighted angle low deg End point of the evaluation angle low related to the shut off point reverse Evaluation angle low deg Length of the monitore
122. eted and the mean value recalculated The further evaluation shut off evaluation graph is made with these mean values A filtering factor of 1 results in no mean values being computed COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 29 Fastening Strategy Programming Torque Control Angle Monitor and Pulse Torque Recovery Sequence 30PTR The purpose of the Torque Control Angle Monitor Pulse Torque Recovery PTR fastening strategy is to provide the ability to control a fastening rundown to reach a programmable target torque value When shutoff at Target Torque has been achieved the PTR strategy is executed Programmable torque limits above and below target torque are provided for OK or NOK evaluation In addition programmable limits for monitoring Angle are provided for OK or NOK evaluation Sequence 30 PTR is exactly the same as Sequence 30 with the addition of Pulse Torque Recovery PTR This section will documents Sequence 30 and the Pulse Torque Recovery strategy Note that the Sequence 30 PTR screen is different than the Sequence 30 screen Refer to Figure 3 30PTR 1 Advanced Application Builder Mavigate About Help Exit Stations a Back m Applications Selected Panel d y LOCAL PANEL APPLICATION 1 DEFINED ON THE PANEL Torque Units N m COOPER Tools iius Stage 1 Seq 30ptr S
123. ethod to work correctly with jointing point detection Angle counting stops at the pre tightening stage shut off point diagram 13 and only continues when the threshold torque of the end fastening stage is reached diagram 50 shut off angle joint angle remaining angle The parameters for the pre tightening stage run on time diagram 13 the delay time between the stages and the end tightening stage start pulse suppression diagram 50 must be set to 0 here Additionally the threshold torque off should be selected for the pretightening stage sequence 13 so that the complete torque rundown is fully recorded in the graphic This is the only way to guarantee that the tightening force remains reproducibly constant COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 8 version draft 0 5 Fastening Strategies Torque Shut off angle residual angle jointing angle Maximum torque Mu veu c E _ _ _ L to que F Threshold torque 1 Sequence 13 l shut off torque Threshold torque Sequence 50 Dwell time Maximum evaluation torques start pulse suppress Jointing Minimum angle Maximum angle Threshold torque Sequence 13 Pai ae iu Residual angle Angle Shut off angle i i _ i angle Unweighted angle 2 Time Maximum tightening ti
124. ettling can take place When the off time has expired or if the torque falls below the specified minimum the spindle starts again with the specified RPM When the on time has expired or if Switch off torque has been exceeded the spindle is stopped again and the switch off moment is maintained One cycle consists of one on time and one off time The number of cycles equals the number of specified repetitions During the run down time the caster angle and peak torque are measured An automatic slow and controlled relief of the spindle takes place during the specified run down time until torque falls below the specified threshold The tightening values of the bolt and a reading of the fastened joint are sent to the value analyzer This Sequence can display the values in tabular form on the monitor and or output to a printer as well as transmit this information to other network clients Once a spindle reaches the specified trigger moment the rotation angle is recorded and can be displayed and evaluated via the graphic function The following parameters can be input to the driver electronics Diagram input value 33 Switch off torque Nm otage switch off torque Maximum torque Nm Maximum torque upper limit of achieved torque Minimum torque Nm Minimum torque lower limit of achieved torque Maximum angle grd Maximum angle upper limit of achieved angle and safety switch off torque Minimum angle grd Minimum angle
125. ever for short intervals can be repeated until the sockets are settled on the fastener No declaration of OK or is made during the jogs If the operator holds the cycle start lever down longer than the programmed jog duration time the rundown will automatically proceed to Stage 1 to the end of the rundown This procedure describes the enabling of JOG and the JOG parameter programming The JOG setup parameters are located on the Advanced Application Builder screen 1 Click on Navigate upper left of the screen 2 Click on Advanced Application Builder 3 Refer to the following illustration of the Advanced Application Builder screen 4 Onthe lower right of the Application Builder Screen is a section labeled Jog Settings 5 Place a check mark in the Enable block 6 Enter the Max Torque If the max torque is exceeded during JOG the jog process will stop 7 Enter the Final Speed This is the spindle speed during the JOG process 8 Enter the Duration in msec JOG intervals less than this interval will not start the rundown and can be repeated any number of times at the operator s discretion If the Duration time is exceeded the rundown cycle will begin automatically starting with Stage 1 As an example set the duration at 3000 for a 3 second JOG duration alal 22 Ej 5 fe ee STATION APPLICATION 1 DEFIMED STATION 2 Torque Units Nm Stage Sequence Build
126. factor is not required for this method since the bolts are dimensioned to accommodate the minimum tensioning force This results in optimum exploitation of the bolt material The text in this document is a shortened summary of excerpts from VDI 2230 and is meant for general understanding only The tightening methods described on the following pages are fully or partially implemented in the Cooper Power Tools Tork Trak TM controller and represent the tightening methods discussed above as well as extended and combined versions of these methods COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 9 Fastening Strategy Programming Engagement Stage Sequence 10 Turn spindles back and forth to engage the tool socket on the part fastener bs Advanced Application Builder Navigate About Exit 22101 a Back Pale PANEL Stage Sequence Builder Stage 1 Seq 10 Engagement Stage Filter Factor 2 Engagement a 2 0 x Applications Selected Panel y DEFINED ON THE PANEL Torque Units N m COOPER Tools This STAGE does not stop on ERROR Stage Timers Milliseconds Hold Torque at End of Stage Start Delay Time o Speed rpm Max Fastening Time 20000 Final Speed Setpoint Dwell Time fo Torque Spike Filter o Stage Retry Parameters Stage Retry Type Touchup Torque Limits High Eva
127. find mean value With this number of torque values a mean value is calculated 1 2 4 8 16 32 immediately upon measurement corresponding to filtering and dampening As soon as a new value is measured the oldest value is deleted and the mean value recalculated The further evaluation gradient calculation shut off evaluation graph is made with these mean values A filtering factor of 1 results in no mean values being computed COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 73 Fastening Strategy Programming General Information Concerning Gradient Controlled Fastening Strategies Sequence 63 Sequence 73 Sequence 75 Sequence 78 Definition The gradient is the difference quotient of two measuring points consisting of torque and angle measured per angle pulse Gd ANn ANm m n index of respective measuring point n m spacing of measuring points polling rate Expressed for the practice of fastening technology The gradient is the change of torque per degree of angle A positive gradient means increase a negative gradient decrease of the torque with increasing angle Note that changing the strobe multiplier will affect the gradient calculation since a different quotient is computed thereby Higher strobe multipliers have a smoothing effect that is a change from a positive to a negative quotient will be detected later After the
128. for the practice of fastening technology The gradient is the change of torque per degree of angle A positive gradient means increase a negative gradient decrease of the torque with increasing angle Note that changing the strobe multiplier will affect the gradient calculation since a different quotient is computed thereby Higher strobe multipliers have a smoothing effect that is a change from a positive to a negative quotient will be detected later After the threshold torque has been reached the gradient is continuously computed of the torque and angle values The gradient calculation ends with the end of the sequence COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 70 Fastening Strategy Programming Torque Control Angle and Gradient Monitor Sequence 78 Shut off torque and shut off angle controlled fastening with torque angle and gradient monitoring iBi x Advanced Application Builder Mavigate About Help Exit Stations T Applications Selected Panel Qe na 4 LOCAL PANEL APPLICATION 1 DEFINED ON THE PANEL Torque Units COOPER Tools Stage 1 seq 78 AngtIq Control Tq Gradient Monitor Filter Factor 2 I This STAGE does not stop on ERROR Stage Timers Milliseconds M Hold Torque at End of Stage Start Delay Time 0 Speed rpm Max Fastening Time 20000 Final Speed Setpoint 250 Dwell Time 0
129. g Strategies Sequence 10 Engagement Stage In the electronic control system the maximum evaluation torque on time off time and cycle number of the engagement stages are entered separately for each nutsetter A maximum tightening time is entered as the safety shut down It applies to all nutsetters of a product group tightening process in this stage The engagement stage facilitates the bit and bolt head having firm contact For this purpose the nutsetter is operated in both directions alternately The engagement stage on time sets the duration of the clockwise and counterclockwise movements of the nutsetter the engagement stage off time the length of time after each movement An engagement stage cycle consists of a clockwise movement stop counterclockwise movement stop The measuring transducer integrated into the nutsetter measures the torque during rundown The value is processed by the control system The nutsetter is stopped when the evaluation torque is reached or the set number engagement stage cycles has been completed The last measured torque is processed in the control system The control system can display the values in tables on the monitor and can output them to a printer or transmit them to other system components by data communication The graphics function is not supported in this stage The parameters below are entered in the electronic control system Sequence input value 10 Max evaluation torqu
130. g process in this stage The measuring transducer integrated into the nutsetter measures the torque and rotation angle during tightening rundown The values are processed by the control system The nutsetter is stopped when the shut off torque or shut off angle search criteria is reached The dwell angle and peak torque achieved during the dwell time are then measured and processed in the control system as the bolt tightening value together with the rundown evaluation The control system can display the values in tables on the monitor and can output them to a printer or transmit them to other system components by data communication COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 50 version draft 0 5 Fastening Strategies When the spindle trigger torque is reached recording of the torque curve starts and the curve can be viewed and evaluated in a graphic This tightening method normally follows a fast pretightening stage The parameters below are entered in the electronic control system Sequence input value 80 Trigger torque Nm Trigger torque beginning of measurement recording for the graphic display Threshold torque Nm Threshold torque beginning of angle counting Shut off torque Nm Shut off torque for the stage Shut off angle deg Shut off angle for the stage Maximum angle deg Maximum angle high limit for angle reached and safety shut off value Mini
131. g stage can be determined by reevaluating the recorded torque values and ascertaining the torque increase gradients The angle from the jointing point up to shut off of the pretightening stage is described as the jointing angle During jointing angle detection it is obligatory to use a shut off controlled tightening method with rotation angle and torque monitoring final fastening stage with sequence 50 jointing angle ascertained the pretightening stage reduces the shut off angle for the final fastening stage by the amount of the jointing angle This keeps the angle constant from the jointing point of the pretightening stage up to standstill of the built in nutsetter in the final fastening stage In turn this has the effect that the tightening force of the pretightening stage is also compensated for in the final fastening stage in order to prevent overstep of the maximum tightening force of the final fastening stage Errors within the tightening method with jointing point detection are evaluated and are processed in the control system together with the bolt tightening values The control system can display the values in tables on the monitor and can output them to a printer or transmit them to other system components by data communication Note The threshold torque in the final fastening stage sequence 50 should be parametrized so that it is below the shut off torque in the pretightening stage sequence 13 and allows the tightening m
132. gh limit of angle reached Minimum angle deg Minimum angle low limit of angle reached Shut off torque Nm Shut off torque shut off value that should prevent the screwed connection from backing off Maximum torque Nm Maximum torque high limit of torque reached Filtering factor Filtering factor number of measured values used for filtering by averaging Speed rpm Preset speed within the maximum speed range specified in the range for spindle constants COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 6 30 version draft 0 5 Fastening Strategies Sequence 48 Shut off Angle Controlled Fastening with Backoff Angle and Residual Torque Monitoring Sequence 48 is an angle controlled sequence in which the two points can be defined at both of which a minimum and a maximum torque value must not be understepped or overstepped Torque Angle at 2 E E Angle at V 8 _ Angle Minimum torque cR Ha i i Trigger torque dd Threshold torque ore 2 min 3 i sil 9 _ _ i H 2 max 2 EA rm MESE i 1 min 2 4 pd EE ZEE ta iti ii E
133. gle Low Indicator Light OUTPUT 15 In Cycle Cycle Complete opare Spare Spare Spare DC COMMON 24 V return from Internal Power Supply DC COMMON 24 V return from Internal Power Supply no connection All PRIVATE Outputs on the rear 25 pin female connector Mating male connector Cooper Power Tools 576211 Phoenix Contact Subcon 25 F SH 27 61 62 2 Functions are pre assigned and not changeable PRIVATE I O is Internal 24 VDC only connection to external 24 V is not recommended PRIVATE is Active High only COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 12 3 version draft 0 5 Input Output Overview PRIVATE INPUT Pinout Discrete Physical PRIVATE I O INPUT Pre Assigned Connector Description FUNCTION Pin Assignment 24 VDC INPUT 9 Trigger Start INPUT 10 Reverse INPUT 11 INPUT 12 INPUT 13 INPUT 14 INPUT 15 INPUT 16 Spare Spare Spare Spare DC COMMON 24 V return from Internal Power Supply DC COMMON 24 V return from Internal Power Supply no connection All PRIVATE Inputs are on the rear 25 pin female connector Mating male connector Cooper Power Tools 576211 Phoenix Contact Subcon 25 F SH 27 61 62 2 Functions are pre assigned and not changeable PRIVATE I O is Internal 24 VDC only connection to external 24 V is not recommended PRIVATE is Active High only COOPER Power Tools USER MANUAL Automated Sv
134. gle impulses of the filllered measured values used for gradient calculation Filtering factor Filtering factor number of measured values used for filtering by averaging Speed rpm Preset speed within the maximum speed range specified in the range for spindle constants COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 45 version draft 0 5 Fastening Strategies Sequence 75 Shut off Angle Controlled Fastening with Torque Angle and Gradient Monitoring Gradient Torque Maximum torque Threshold torque Lower gradient Initial torque Maximum angle Angle N mE Minimum angle Shut off angle Time Start Maximum tightening time Start pulse suppression Dwell time In the electronic control system the shut off angle maximum angle minimum angle maximum torque minimum torque lower gradient upper gradient strobe multiplier filtering factor and speed are entered separately for each nutsetter The maximum torque is also used as a safety shut down A maximum tightening time is entered as an additional safety shut down It applies to all nutsetters of a product group tightening process in this stage The measuring transducer integrated into the nutsetter measures the torque and rotation angle during tightening rundown The values are processed by the control system The nutsetter is stopped when the shut off angle search
135. he end of start pulse sup pression in which the torque must be lower than the maximum torque Angle range starting at the bigger torque in which the maximum torque and threshold torque are invalid End point ofthe evaluatian angie related to the shut off poirt reverse Length of the monitored range for overstep of the high evaluation torque High torque limit in the evaluahor anole Pigh that must not be exceeded in reverse analysis End point of ihe evaluation angie Ep related to ihe shut off point reverse Length af the monitored range for understep of the low evaluation torque Low torque limit in the evaluation ange lov thal must not be understappad in reverse analysis High linet of torque reached Low limit of torque reached High linn for angle reached and safety shut off value Low limit of angle reached USER MANUAL Tork Trak TM Fastening Controller COOPER PowerTools Automated Systems NA Section 7 54 Fastening Strategy Programming Spred 1 rpm Prasat speed maximum speed specified in tha range for spindle constante valid fram the beginning af Ihe up to the threshold torque Speed 2 rpm Speed when the maximum torque is reached Must be kewer than speed 1 Cutoff deactivated when speed 2 0 or speed 22 speed 1 The one ium fee normesi s nor nc hee thes torque ade on ieee ee ren inum go de spes wil nat ul cet mT 2n
136. her by setting parameters tor ihe end of the range unweighted angle high or low and the length of the range i evaluation angle high or low The bao evaluation angles be in any order and alae fully or partially ower lap The high evaluation angle ef the terque curve ia checked far aversteg af Ihe evaluation terque and the low evaluation angle of the torque curve is checked for understep of the low evaluation torque The lightening process is assessed as being if thera ware oversteps andior undar steps COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 52 Fastening Strategy Programming maximum torque measured within the high evaluation angle and the lowest torque value within the low evaluation angle and statistical evaluation is carried aut The evaluation torques can be deactivated by setting the corresponding evaluation ange zero In the blook angle range which begins directly after the start pulse suppression Ihe terque must nat exceed the maximum torque as thes will stop the drive This serves to detect rundowns that are carried out on a tightened bolt The black angle can be deactivated by setting to zero torque curve ts ee for gra phic wanting the trigger torque 1 torque value per angle degree Thes 3 are ag j analysis Therefore the trigger longue must be nma ex that terque Curve relevant far reverse analysis 5 alwa
137. icator Lights COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 2 5 version draft 0 5 Indicator Light Definitions Overview of the Tork Trak TM Controller TORQUE HIGH Indicates that the last fastening sequence has RED exceeded the acceptable final high torque set point TORQUE LOW Indicates that the last fastening sequence is YELLOW below the acceptable final low torque set point CYCLE REJECT Indicates that one or more characteristics of the RED last fastening cycle is unacceptable CYCLE Indicates that the last fastening sequence has ACCEPT fallen within the acceptable range of the torque GREEN and angle set points FINAL ANGLE Indicates that the last fastening sequence has HIGH exceeded the acceptable final angle high set RED point FINAL ANGLE Indicates that the last fastening sequence is LOW below the acceptable final angle low set point YELLOW UNMARKED Indicator can be mapped to any programmed BLUE available output by the User UNMARKED Indicator can be mapped to any programmed BLUE available output by the User Hard Drive The hard drive is a 40 Gb Hard Drive Laptop Notebook style This style of hard drive is very rugged with high reliability and low susceptance to shock and vibration The Hard Drive stores the TM Multi Trak application software the operating system and all database fields which includes rundown data and fastening setup parame
138. ich the drive stopped when it is exceeded Angle beginning the end of start pulse sup pression in which the torque must be lower than the shut off torque Angle range starting at the trigger torque in which the shut off torque and threshold torque invalid End point of the evaluation angie highs related to the shut off point reversa Length af the monitored range for averstep of the high evaluation torque High torgue limit in the evaluahor angle Pigh that must not be exceeded analysis End paint af the evaluation angie iow related to the shut off point reverse Length of the monitored range for understep of Ine low evaluation torque Low lens the angle low thal must not be undaerstepped m reverse analysis High limit af torque reached Low limit of terque reached High limit for angle reached and safety ehul off Low limit of angle reached USER MANUAL Tork Trak TM Fastening Controller COOPER PowerTools Automated Systems NA Section 7 36 Speed 1 rpm Speed 2 rpm Fastening Strategy Programming Prasat speed maximum speed specified in tha range for spindle constants valid fram the begin ning af the e dquenece up to the threshold torque Speed when the shut off torque is reached Musi than spaad 1 Cutoff ie deactivated when speed 2 Qor speed 2 gt speed 1 Validity of individual parameters Par
139. igh limit of the gradients Strobe multiplier Strobe multiplier spacing in angle impulses of the fillered measured values used for gradient calculation Filtering factor Filtering factor number of measured values used for filtering by averaging Speed rpm Preset speed within the maximum speed range specified in the range for spindle constants COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 47 version draft 0 5 Fastening Strategies Sequence 78 Shut off torque and shut off Angle Controlled Fastening with Torque Angle and Gradient Monitoring Gradient Torque Tightening torque Shut off torque pper gradien Besson Minimum torque Start puls suppr Threshold torgue gradient Initial torque Maximum angle Angle shut olr angle Tightening angle Maximum tightening time In the electronic control system the shut off torque shut off angle maximum angle minimum angle maximum torque minimum torque lower gradient upper gradient strobe multiplier filtering factor and speed are entered separately for each nutsetter A maximum tightening time is entered as the safety shut down It applies to all nutsetters of a product group tightening process in this stage The measuring transducer integrated into the nutsetter measures the torque and rotation angle during tightening rundown The values are process
140. ignal Output 5 V 0 5 V Imax 15 mA Cross checking Output 5 V 40 5 V adapter on 5000 V 1 pull up 1 Supply 12 V Output 12 V 0 2 V Imax ME Imax 200 mA 8 Supply digital 0 V_ Output Interface 5422 Output 5 V Ri 500 Q TxD COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 16 20 version draft 0 5 TMH SERVO MODULE Interface RS422 Output 0 V Ri 500 TxD 0 __ RxD eee ee RxD Shield connection PE Not used in this application 4 4200 Angle track 2 Input 0 5 V 0 7 12 V 1 pull up 1 KQ Housing Operating Elements RESET Button Processor reset for all internal functions of the TMH Used to acknowledge failures Pressing results in reconfiguration of all functions Selector Switch for ARCNET Address e Adjusts ARCNET address BCD code switch upper switch for tens digit 00 90 bottom switch for ones digit 00 09 e Admissible settings 01 to 32 Adjust only when supply is switched off f two or more modules have the same address the error code 50 is output The address adjustment can be checked upon power up or reset at the two digit segment display Displays Status and Diagnosis Display e Red segments two digit Operating conditions and error codes flashing are displayed COOPER PowerTools USER MANUAL Automate
141. in Angle Low limit of angle reached If this limit value is not reached an NOK for the stage 0 9 999 results lt Angle too low Max Angle High limit of angle reached If this limit value is exceeded the stage is evaluated NOK gt Angle 0 9 999 too high Max Torque High limit of torque reached If this limit is exceeded the rundown is terminated 0 1 2 x Torque cal Factor safety shut down and the stage evaluated NOK Tq gt Torque too high Speed Set speed of the spindle s output shaft 1 max speed Trigger torque When this torque is exceeded the recording for graphic representation O Scope begins 0 1 2 x Torque cal factor Threshold torque When this torque is exceeded the angle counting 0 1 2 x Torque cal factor begins Min torque Low limit of torque reached If this limit value is not reached for the stage 0 9 999 results Tq lt Torque too low Filtering factor Number of torque values used to find mean value With this number of torque values a mean value is 1 2 4 8 16 32 calculated immediately upon measurement corresponding to filtering and dampening As soon as a new value is measured the oldest value is deleted and the mean value recalculated The further evaluation shut off evaluation graph is made with these mean values A filtering factor of 1 results in no mean values being computed COOPER Power Tools USER MANUAL Au
142. inal Speed 300 T Backoff Settings Target ls High Angle Limit Final Speed 300 T Sequence 30 Torque Control Angle Monitor COOPER PowerTools Automated Systems Section 7 28 USER MANUAL Tork Trak TM Fastening Controller Fastening Strategy Programming Sequence 30 Set Point Definitions Range of Values sequence is terminated 0 Torque cal factor Min Torque Low limit of torque reached If this limit value is not reached NOK for the stage 0 cal factor results lt Torque too low Max Torque High limit of torque reached If this limit value is exceeded the stage is evaluated 0 1 2 x Torque cal factor NOK Tq Torque too high Max Angle High limit of angle reached If this limit is exceeded the rundown is terminated 0 9 999 safety shut down and the stage evaluated NOK ANG gt Angle too high 1 max speed graphic representation begins 0 1 2 x Torque cal factor 0 1 2 x Torque cal factor begins Min angle Low limit of angle reached If this limit value is not reached an NOK for the stage 0 9 999 results ANG Angle too low Filtering factor Number of torque values used to find mean value With this number of torque values a mean value is 1 2 4 8 16 32 calculated immediately upon measurement corresponding to filtering and dampening As soon as a new value is measured the oldest value is del
143. inle LOCAL PANEL 7 1 DEFINED 5 THE PANEL Torque Units N m COOPER Tools Stage 1 Seq 20ptr Seq 20 Pulse Torque Recovery Filter Factor gt This STAGE does not stop on ERROR Stage Timers MilliSeconds Hold Torque at End of Stage Start Delay Time o Speed rpm Max Fastening Time 20000 Final Speed Setpoint 250 Dwell Time fo Torque Control Stage Sequence Builder Torque Control Tightening SEQ 20 PTR Shut off Torque Li Max Fastening Time gt High Limit 0 000 Stage Retry Parameters Target Shutoff 5 000 Stage Retry Type Touchup After Retry goto Stage li Maximum Retries lo Low Limit 0 000 Trigger 3 000 Pulse Torque Recovery Overall Time ms fi 000 On Time 10 Off Time High Limit 0 000 0 000 Low Limit Pulses 0 Speed T Global to the Application Relax the Tools on the Final Stage Backoff on ERROR Touch Up Settings Target Angle b High Angle Limit Final Speed 300 Backoff Settings Target Angle b High Angle Limit Final Speed 300 Save these Settings K Corey cranes Cancel My Changes Ki 3 Adi Stage Del Stage gt Sequence 20PTR Torque Control and Pulse Torque Recovery COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 25 Fastening Strategy
144. ins when the threshold torque is exceeded otrobe multiplier Step width for gradient calculation in angle pulses Starting from reaching of the threshold torque one measuring 1 30 point in excess of the strobe multiplier must have been collected for the first gradient value to be computed Collection is made per angle pulse With each new measuring point each angle pulse the oldest measuring value is deleted and a new gradient calculated A strobe multiplier of 1 corresponds to two measuring points in direct sequence Max gradient High limit of gradient If this limit value is exceeded the stage is evaluated Gd gt 99 99 99 99 Gradient too high The evaluation is made with the value in the max value memory not with the gradient prevailing at the time of shut off Min gradient Low limit of gradient If this limit value is not reached the stage is evaluated NOK 99 99 99 99 lt Gradient too low The evaluation is made with the value in the min value memory not with the gradient prevailing at the time of shut off This input range applies to Nm for torque Recalculated input ranges apply other torque measuring units COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 76 Fastening Strategy Programming Sequence 80 Set Point Definitions cont d Min torque 0 Torque cal Factor 0 9 999 Max angle 0 9 999 Speed 1
145. ion Relax the Tools on the Final Stage Backoff on ERROR Touch Up Settings Target Angle High Angle Limit Final Speed 300 Backoff Settings Target Angle High Angle Limit Final Speed 300 c Save these Settings x Cancel My Changes Sequence 31 Self Tap with Torque Control COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 33 Fastening Strategy Programming sequence 31 Shut off torque controlled fastening with torque monitoring and angle monitoring Sequence 31 is a tarque cantralled sequence which allows the rundown to be evaluated after ihe ahiul off torque hga been reached by meane of revere anal yes over bec mornibernng ranges Details Torque Wigs iru Pi Donque cm ern onge Maximum angie Sela Tuus Minimum dorus High res sms ue Teresi hi icergus Lose boredom Angle Bick snple q aspe Ureetighied angie high i RR Tighiening angie Ennii ng en pie Graphie nodis Time Sheng Erik poba uzpneiracn FOSS ape The torque curve be reverse analyzed after rundown is complete This reverse analysis stars at the shut off point the dwell tima is not considered and ts achieved using two separate a
146. ion Off Error Explanation Driver supply of output section too low The power supply for internal supply of the output section is overloaded or defective Internal error replace TM Offset of current measurement too high The zero point of the integrated motor current measurement has been shifted 5 V supply in measuring board too low The power supply for internal supply of the measuring board is overloaded or defective U 4 8 VDC Internal error replace TM Internal error replace TM Lo NX 15 COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 28 version draft 0 5 TM12 and TM34 SERVO MODULES 2 SUPR in measuring board too Internal error replace TM Ig The 5 V power supply for internal supply of the measuring board is defective U gt 5 2 VDC DPR error servo Internal error replace TM The Dual Port RAM for communication between servo and measuring board is defective Flash error servo Internal error replace The flash memory is defective DPR communication to torque Internal error replace TM interrupted The Dual Port RAM communication between servo and measuring board is failing COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 29 version draft 0 5 lt gt r 00 TM12 and TM34 SERVO MODULES Top Display Bottom Display Error E
147. ions Fatal electric shock may occur use other connector types e Touse cables other than those approved by Cooper Tools Supply Supply XS1 The connector coding ensures that the plug for XS1 cannot be plugged into 52 Type PHOENIX Power Combicon PC4 6 7 62 Cooper Tools Id No 960942 incl coding on pin 1 Description Supply of intermediate circuit of logic section logic power supply 230 VAC Supply of intermediate circuit of logic section logic power supply PE COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 16 version draft 0 5 TMH SERVO MODULE It is prohibited to remove the coding on the power connector plug or on the TMH If the plugs are confused the TMH can be destroyed The TMH must be fastened to a zinc plated and earth grounded mounting plate gt gt High discharge current connect earth ground before servicing Fatal electric shock may occur Motor XS2 e connector coding on pin 1 and 2 ensures that the plug of XS1 cannot be plugged into 52 Cable breakage monitoring Integrated filtering of motor outputs Type PHOENIX Power Combicon PC4 7 7 62 not used in this application motor temperature monitoring signal not used in this application 6 PE protected earth ground The motor phases and the lines of the thermal switch must not be touched even if the TMH is in failure mode F
148. ipment for damage which may have occurred in transit and also to verify that the expected equipment has actually been received Check that you have received the proper tool model and the correct field cable length as well as any optional equipment you may have ordered The first step is to remove the Tork Trak TM controller unit from its shipping carton Installation The Tork Trak TM controller requires a secure mounting surface capable of supporting weight of approximately 40 pounds The selected location should be in an unobstructed area offering a clear view of the indicator lights and LCD display and access to the supplied keyboard Mount the unit away from major electrical systems electric motors arc welders and areas experiencing excessive vibration moisture and heat Install the Tork Trak TM controller utilizing the bolt template provided in Figure 1 1 and allow 12 inches of clearance on the bottom front of the unit for cable connection accessibility Mount the unit with four 1 4 inch diameter bolts COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 1 5 version draft 0 5 Introduction to the Tork Trak TM Controller 14 53 Figure 1 1 T3M Enclosure Outline and Mounting Dimensions COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 1 6 version draft 0 5 Introduction to the Tork Trak TM Controller Connecting the
149. it is reached the rundown is terminated 0 9 999 Angle counting begins with the spindle start Min angle Low limit of angle reached 0 9 999 If this limit value is not reached an for the stage results ANG Angle too low Max angle High limit of angle reached 0 9 999 If this limit value is exceeded the stage is evaluated ANG gt angle too high opeed Set speed of the spindle s output shaft 1 max speed Filtering factor Number of torque values used to find 1 2 4 8 16 32 mean value With this number of torque values a mean value is calculated immediately upon measurement corresponding to fillering and dampening As soon as a new value is measured the oldest value is deleted and the mean value recalculated The further evaluation shut off evaluation graph is made with these mean values A filtering factor of 1 results in no mean values being computed COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 43 Fastening Strategy Programming Backoff Angle and Torque Monitoring Sequence 46 Shut off angle controlled backoff with angle and torque monitoring bs Advanced Application Builder Navigate About Exit si Applications Selected Panel ik avalible M velie LOCAL PANEL DEFINED ON THE PANEL Torque Units N m COOPER Tools Stage 1 seq 46 Backout Angle Torque Monito
150. itch off torque Nm Stage switch off torque Maximum torque Nm Maximum torque upper limit of achieved torque Minimum torque Nm Minimum torque lower limit of achieved torque Maximum angle grd Maximum angle upper limit of achieved angle and safety switch off torque Minimum angle grd Minimum angle lower limit of achieved angle COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 40 Threshold torque Nm Threshold moment Nm Number of repetitions THC on time ms THC off time ms Damping factor RPM COOPER PowerTools Automated Systems Fastening Strategy Programming Threshold torque start of angle counter Trigger moment start of value recording for graphic display Number of repetitions of THC on time and THC off time The spindle remains switch on for the duration of this period as long as the switch off torque has not been achieved The spindle remains in hold mode as long as the minimum torque is maintained Damping factor number of measured values based on averaging applied to damping RPM selection in the range of specified maximum RPM s in the spindle constants USER MANUAL Tork Trak TM Fastening Controller Section 7 41 Fastening Strategy Programming Backoff Angle Monitoring Sequence 41 Shut off angle controlled backoff with backoff angle monitoring Advanced Application Builder Navigate Abo
151. ive is stopped and the dwell lime begins Angie at which the tarque im checked at a position between M1 max and M1 min the drive is shopped when the position laye outside of the range 1 min to M1 max Maximum torque allowed in the saquenca Minimum torque allowed at 1 Angie at which the torque rs checked at a position between 2 max and 2 min the drive is stopped when the position lays outside of the range 2 min t 2 max Maiorum torque allowed at 2 Minimum torque allowed at M7 High limit of torque reached in the shut off point Lyw limit of torque reached in the shut off point High limit of angle reached in the shut off paint and shut off value Low limit of angle reached in the shut aff Spead Preset speed within the maximum speed range spaci fied in the range for spindle constants COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 48 Fastening Strategy Programming Angle Control Torque Monitor Sequence 50 The purpose of the Angle Control Torque Monitor Fastening Strategy is to provide the ability to control a fastening rundown to stop after reaching a programmable target angle value Programmable angle limits above and below target angle are provided for OK or NOK evaluation In addition programmable limits for monitoring Torque are provided for OK or NOK evaluation Advanced Application Builder Mavigate About H
152. ld be programmed to a value less than the Torque High 0 1 2 x Torque cal factor Limit to prevent a Torque High NOK PTR Low This is the lower torque level setting for PTR It should be programmed to a value greater than the Torque 0 Torque cal factor Low Limit to prevent a Torque Low NOK PTR Time Time duration of the Torque ON plus Torque OFF pulses 1 ms to 3000 ms PTR Frequency Not programmable by the User Frequency is hard coded to 25 Hz 25 Hz PTR Speed Not programmable by the User Speed is automatically reduced to a fraction of maximum tool speed PTR Number of Pulses Not directly programmable by the User Number of pulses is dependant on programmed PTR Time The 0 25 to 75 pulses number of PTR pulses is approximately 25 times the number of seconds programmed for PTR Time Note Pulse torque recovery is applied at the conclusion of a fastening rundown and is used most successfully on joints which are either gasketed or springy sheet metal where a makeup torque is required If the joint begins to relax immediately following the rundown Torque Recovery can add a pre programmed amount of torque for a pre programmed time duration if the torque drops below a pre programmed value This strategy was awarded U S Patent 5 094 301 COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 27 Fastening Strategy Programming Torque Control Angle Monitor Sequence
153. les cycles A cycle consists of right hand rotation on time stop off time left 1 250 hand rotation on time stop off time This must be observed for programming of the monitoring time for the entire stage Engagement On Time during which the spindle is on in any direction Time 0 60 000 Engagement Off Time during which the spindle is off Time 0 60 000 Speed Set speed of the spindle s output shaft 1 max speed Sequence 10 Notes 1 The relationship for Sequence 10 Stage time is OCW ON CW OFF CCW ON CCW OFF times cycles 3000 maximum 2 f High Torque Evaluation Limit is exceeded the cycle is aborted and rejected 3 If Stage ON OFF times 2 times qty stage cycles exceeds the maximaum time the sequence is not run 4 Ifthe Max Evaluation Torque is exceeded the entire cycle is aborted and the following sequences will not be started COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 11 Fastening Strategy Programming High Speed Rundown Sequence 11 The purpose of the High Speed Rundown Strategy is to provide the ability to turn a nut or bolt at an initial high rotational speed prior to reaching snug torque This is usually stage 1 of a 2 stage rundown strategy The higher rundown speed reduces process cycle time A typical application for this strategy is to combine it with a Torque Control Angle Monitor fastening strategy in
154. leted and a new gradient is calculated A strobe multiplier of 1 corresponds to two measuring points in direst sequence Trigger Torque When this torque is exceeded the recording for O 0 to 1 2 x Torque Cal Factor ocope begins If the trigger torque value is higher than the threshold torque the recording begins when the threshold torque is exceeded COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 60 Fastening Strategy Programming Sequence 63 Set Point Definitions cont d Range of Values 0 to Torque Cal Factor the stage is evaluated NOK Filtering Factor Number of torque values used to calculate a mean 1 2 4 8 16 32 value used in all torque related parameters including gradient and shutoff The oldest value is deleted as soon as a new value is measured A filtering factor of 1 results in no mean value being calculated 1 to maximum rpm revolutions per minute 0 to Torque Cal Factor rundown is evaluated NOK Threshold Torque When this torque is exceeded angle counting and 0 to 1 2 x Torque Cal Factor gradient calculation begins After reaching threshold torque one measuring point in excess of the strobe multiplier value 1 to 30 must be collected before the gradient is calculated If the threshold torque is set lower than the trigger torque then O Scope evaluation begins when threshold torque is exceeded COOPER Power Tools USER MANUAL Automa
155. ll Time 0 Torque Monitoring Prevailing Torque Monitor Start Recording 0 000 Stage Retry Parameters End Recording p 000 Stage Retry Type Touchup High Evaluation Limit p 000 After Retry goto Stage li Low Evaluation Limit 0 000 Maximum Retries 0 Target Shutoff 5 000 Trigger 3 000 Global to the Application Relax the Tools on the Final Stage Backoff on ERROR Angle Limits Degree Evaluation p Free Run Limit D Touch Up Settings imi Target Angle Safety Limit 0 High Angle Limit Number of Overshoots 0 Number of Undershoots 0 Final Speed 300 Backoff Settings Target Angle b High Angle Limit Final Speed 300 3 Adi Stage Del Stage gt Sequence 13 Prevailing Torque Monitor COOPER PowerTools Automated Systems NA USER MANUAL Tork Trak TM Fastening Controller Section 7 14 Fastening Strategy Programming Sequence 13 Setpoint Definition Range Shut off torque Torque as target value when it is reached the sequence is naaa QO Torque cal Factor Trigger torque When this torque is exceeded the recording for graphic representation begins 0 1 2 x Torque cal If the threshold torque on value is higher than the trigger Factor torque the recording already beings when the threshold torque on is reached Evaluation angle Range for subsequent evaluation ph
156. lock angle Angle counting starts when the threshold torque is reached if detection of the threshold torque has not been deactivated by the block angle or blanking angle Note If the threshold torque trigger torque then angle counting starts when the threshold torque is reached and continues in the blanking angle Angle measurement and possibly also redundancy monitoring starts when the drive starts COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 37 version draft 0 5 Fastening Strategies After the shut off torque has caused a shut down the corresponding angle and or the torque are compared to the minimum maximum angle and the minimum maximum torque and evaluated accordingly as OK or NOK Reverse analysis is also carried out The maximum angle maximum torque safety shut down torque and maximum tightening time for the stage are used as a safety shut down Description of Parameters Sequence input value 51 Filtering factor Number of measured torque values used for averaging Trigger torque Nm Beginning of storing torque values for the graphic display reverse analysis and blanking angle Threshold torque Nm Beginning of angle counting valid outside the blanking angle and block angle Safety shut down torque Nm Monitoring torque valid after start pulse suppression has finished and during the rundown and the value at which the drive is stopped when it is e
157. luation Limit 0 000 After Retry goto Stage li Stage Cycles 1 i Maximum Retries 0 Stage Off Time 0 Global to the Application Relax the Tools on the Final Stage Backoff on ERROR Touch Up Settings Target Angle High Angle Limit Final Speed 300 Backoff Settings Target Angle 0 High Angle Limit Final Speed 300 3 Adi Stage De Stage gt Sequence 10 Engagement Stage p COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 10 Fastening Strategy Programming Sequence 10 Setpoint Definition Value range Max evaluation Maximum torque allowed both senses of rotation torque When it is reached the sequence is terminated If this limit value is exceeded the stage is evaluated NOK Tq 0 Torque cal Torque too high Factor Filtering factor Number of torque values used to find mean value 1 2 4 8 16 32 With this number of torque values a mean value is calculated immediately upon measurement corresponding to filtering and dampening As soon as a new value is measured the oldest value is deleted and the mean value recalculated The further evaluation shut off evaluation graph is made with these mean values A filtering factor of 1 results in no mean values being computed Engagement Number of engagement cyc
158. lysis Counter holding Torque control with torque and angle monitoring Torque control with torque and angle monitoring with Pulse Torque Recovery Torque control with torque and angle monitoring unsupported over two monitoring ranges Switch off torque controlled tightening 1 11x 117 procedure with torque maintenance and automatic mM Torque maintenance with shutoff torque control Angle controlled back off with back off angle monitoring Angle controlled back off with back off angle and residual unsupported torque monitoring Angle controlled releasing back off strategy with back off angle unsupported and maximum torque monitoring COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 5 Fastening Strategy Programming Sequence Sequence Description TUE PM NOTES Version Firmware Angle and shut off torque controlled releasing strategy with 1 4 2 07 lig HACC ON ec programmable parameter values angle and torque monitoring Angle controlled sequence in which the Angle control with back off angle 16 hs M be abes al both of and residual torque monitoring E M tal E dE torque value must not be understepped or overstepped Angle control with angle and 2 torque monitoring Angle controlled sequence which allows the rundown to be evaluated Angle control with angle and after the shut off angle has been Pure
159. m torque low limit of torque reached Minimum gradient Nm deg Minimum gradient low limit of the gradients Maximum gradient Nm deg Maximum gradient high limit of the gradients Strobe multiplier Strobe multiplier spacing in angle impulses of the fillered measured values used for gradient calculation Filtering factor Filtering factor number of measured values used for filtering by averaging Speed rpm Preset speed within the maximum speed range specified in the range for spindle constants COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 49 version draft 0 5 Fastening Strategies Sequence 80 Shut off Torque and Shut off Angle Controlled Fastening with Angle and Torque Monitoring Torque Maximum torque Tightening torque shut off torque Minimum torque Threshold torque Initial torque Maximum angle Angle shut aff angle Tightening angle Time Start Maximum tightening time Start pulse suppression Dwell time In the electronic control system the shut off torque shut off angle maximum angle minimum angle threshold torque maximum torque minimum torque filtering factor and speed are entered separately for each nutsetter The maximum torque and the maximum angle are also used as a safety shut down A maximum tightening time is entered as an additional safety shut down It applies to all nutsetters of a product group tightenin
160. me Maximum tightening time Final fastening stage Sequence 50 Pretightening stage Sequence 13 with Jomnting point detection In the figure above the process is shown correctly from the standpoint of measuring technology The more interesting representation for the user shows the tensioning force of the screwed connection which is shown as being equivalent to the tightening torque COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 9 version draft 0 5 Fastening Strategies Tightening force of the screwed connection Tightening force of the final fastening stage Tightening force of the pretightening stage Jointing point Start Jointing angle Residual angle PING Shut off angle of the final fastening stage Pretightening stage Final fastening stage sequence 13 with jointing point detection Sequence 50 Power Tools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 6 10 version draft 0 5 Fastening Strategies Sequence 15 Frictional torque measurement Torque Max breakaway torque Max evaluation torque o Min evaluation torque Min breakaway torque Phase 2 engagement time start ime Drag torque measuring time Upper dead center engagement time Frictional torque measurement is started in the same way as a normal rund
161. mum angle deg X Minimum angle low limit of angle reached Maximum torque Nm Maximum torque high limit of torque reached and shut off value Minimum torque Nm Minimum torque low limit of torque reached Filtering factor Filtering factor number of measured values used for filtering by averaging Speed rpm Preset speed within the maximum speed range specified in the range for spindle constants COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 51 version draft 0 5 Fastening Strategies Pre Rundown and Post Rundown Fastening Strategies There are several pre rundown and post rundown strategies which can be enabled which attach to a Fastening Sequence When a pre rundown strategy is enabled it will run before the Stage 1 Sequence begins When a post rundown strategy is enabled it will run when the last Programmed Stage n Sequence has completed the cycle Pre Rundown Fastening Strategies Jog Post Rundown Fastening Strategies e and Error Handling e PTR pulse torque recovery COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 52 version draft 0 5 Fastening Strategies Pre Rundown Fastening Strategy JOG The JOG function provides a way to rotate the tool spindle in short duration intervals for the purpose of locating the socket s on the bolt or nut Pressing the cycle start l
162. n 6 3 version draft 0 5 Fastening Strategies The peak torque achieved during the dwell time is then measured and processed in the control system as the bolt tightening torque The control system can display the values in tables on the monitor and can output them to a printer or transmit them to other system components by data communication When the spindle trigger torque is reached recording of the torque curve starts and the curve can be viewed and evaluated in a graphic This tightening method is normally used as the fast pretightening stage The parameters below are entered in the electronic control system Sequence input value 11 Trigger torque Nm Trigger torque beginning of measurement recording for the graphic display Shut off torque Nm Shut off torque for the high speed rundown Filtering factor Filtering factor number of measured values used for filtering by averaging Speed rpm Preset speed within the maximum speed range specified in the range for spindle constants COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 6 4 version draft 0 5 Fastening Strategies Sequence 13 Free Rundown Torque Monitoring FRTM Shut off torque controlled fastening up to a contact torque with partially monitored torque monitoring during tightening and subsequent torque analysis Torque Dwell time shut off torque 42 Threshold torque om d Sta
163. n angle Unweighted angle Unweighted angle low enm Blanking angle OO O OO O OO OoOO O Maximum tightening tima Time The torque curve can be reverse analyzed after rundown is complete This reverse analysis starts at the shut off point the dwell time is not considered and is achieved using two separate angle ranges These angle ranges can be specified separately from one another by setting parameters for the end of the range unweighted angle high or low and the length of the range evaluation angle high or low The two evaluation angles can be in any order and also fully or partially overlap COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 36 version draft 0 5 Fastening Strategies The high evaluation angle of the torque curve is checked for overstep of the evaluation torque and the low evaluation angle of the torque curve is checked for understep of the low evaluation torque The tightening process is assessed as being NOK if there were oversteps and or understeps The maximum torque is measured within the high evaluation angle and the lowest torque value within the low evaluation angle and statistical evaluation is carried out The evaluation torques can be deactivated by setting the corresponding evaluation angle to zero In the block angle range which begins directly after the start pulse suppres
164. n be either Active High or Active Low COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 12 6 version draft 0 5 Input Output Overview DISCRETE PHYSICAL I O Setup As previously discussed earlier in this Section the Tork Trak TM Controller supports several different discrete Input and Output configurations In addition to User mappable I O functions this also includes External 24 VDC Internal 24 VDC Active High Input Active Low Input Active High Output Active Low Output Mapping functions is accomplished by User programming of the controller Software Changes from Active High Active Low and External Internal 24 VDC are accomplished by moving jumpers located on the Public I O Interface Board and adding wire jumpers inside the external I O 25 pin cable connector The mating 25 pin I O connector is designed with miniature screw terminals making jumper changes very fast and easy External 25 Pin Mating I O Cable Connector with Screw Terminal Connections PUBLIC Female Cable Connector Shown COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 12 7 version draft 0 5 Input Output Overview Public Interface Board Showing Input and Output Common Bus Jumpers o Bus B BE Output 0 Bus Aye i di Cutout 1 Output 2 Output 3 T 1
165. n torque Nm Maximum torque allowed at M2 Minimum torque allowed at M2 High limit of torque reached in the shut off point Low limit of torque reached in the shut off point High limit of angle reached in the shut off point and shut off value Low limit of angle reached in the shut off point Preset speed within the maximum speed range specified in the range for spindle constants Monitoring torque valid after start pulse suppression has finished and during the rundown and the value at which the drive is stopped when it is exceeded COOPER PowerTools Automated Systems USER MANUAL Tork Trak TM Fastening Controller Section 6 33 version draft 0 5 Fastening Strategies Sequence 50 Shut off Angle Controlled Fastening with Angle and Torque Monitoring Torque Maximum torque Tightening torque B mum torque Threshold torgue shutoff angle Maximum angle Angle Tightening angle Time Maximum tightening time start pulse suppression well time In the electronic control system the shut off angle maximum angle minimum angle threshold torque maximum torque minimum torque filtering factor and speed are entered separately for each nutsetter The maximum torque is also used as a safety shut down A maximum tightening time is entered as an additional safety shut down It applies to all nutsetters of a product group tightening process in this stage
166. nd Display Sub Assembly The CPU and Display Sub Assembly contains the following major components e LCD Display Indicator Lights and Overlay Lens Hard Drive CPU Mother Board PC 104 Bus PC 104 I O Board PC 104 FieldBus Board e DeviceNet e Profibus e PC 104 ArcNet Board e Indicator Light Board Assembly e Private I O Interface Board Assembly e Public I O Interface Board Assembly cosfen Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 2 3 version draft 0 5 Overview of the Tork Trak TM Controller Tork Trak TM Controller PC 104 Technology Seno t Module Fieldbus Tork Trak Hard keyboard Touch Pad COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 2 4 version draft 0 5 Overview of the Tork Trak TM Controller CPU The CPU and Mother Board is an extremely compact low power design supporting the PC 104 bus with a wide operating temperature range 0 to 60 degrees C The CPU is a low voltage Celeron with a clock speed of 650 MHz The memory is 256 MB SDRAM The MotherBorad supports RS 232 serial USB 1 1 Ethernet 10 100 and an EIDE Hard Drive port The operating system is Microsoft Windows 2000 Professional The fastening application software is Cooper Automated Systems TM Multi Trak the same software used in the Cooper Power Tools larger 32 spindle panels Ind
167. nd blackout parameters can be entered in each stage for both touch up and error handling Touch up is performed immediately after the end of a fastening stage Error handling can be initiated by any fastening stage but will performed after the last fastening stage with the stage related back off parameters PITE Hue About Hep Exi _ iiaia Selected Database lt Back m E 4 EE COOPER PowerTools CPT 243 APPLICATION 1 DEFINED OM THE PANEL Torque Units Nm Stage Sequence Builder Stage 1 11 High runden Filter Factar gt Heg Spard Fred d This STAGE does nol siop on ERROR Stage Timers MilliSeconds Stan Delay Ting P Speed rpm Final Sp E 3 aans vol NN COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 54 version draft 0 5 Fastening Strategies From the Navigate drop down panel upper left corner of screen select Advanced Application Builder The Global to the Application area on the lower right of the Advanced Application Builder screen contains the parameter settings for Touch Up and Back out Touch Up Settings arget Angle e High Angle Limit e Final Speed Backoff Settings Target Angle e High Angle Limit e Final Speed COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 55 version draft 0
168. nd shut off value Minimum torque Nm Minimum torque low limit of torque reached Torque Filtering factor Filtering factor number of measured values used for filtering by averaging Speed rpm Preset speed within the maximum speed range specified in the range for spindle constants COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 35 version draft 0 5 Fastening Strategies Sequence 51 Shut off Angle Controlled Fastening with Angle and Torque Monitoring oequence 51 is an angle controlled sequence which allows the rundown to be evaluated after the shut off angle has been reached by means of reverse analysis over two monitoring ranges Additionally the monitoring torque can be changed by an angle range during the rundown Torque m 2 Safety shut down torque I a tnn a 1 eee g S 5 i 3 E Maximum torque a a 4 0 Minimum torque ien mal High ewyaluatio torg le pee ih A mM EEUUN er Threshold torque ER p M P e nee 4 Low evaluation torque pnp pa bi 221 IS Trigger torque Stat i Angle Low evaluation Ug evaluatio
169. ng Controller Section 2 1 version draft 0 5 Overview of the Tork Trak TM Controller Power Disconnect The power disconnect turns the AC drop single or three phase ON or OFF The disconnect switch may be padlocked in the OFF position The AC drop enters the enclosure through a connector mounted on the bottom surface of the enclosure in the rear left corner LCD Display The LCD Display is a high resolution color monitor with an 8 4 inch XGA TFT Digital LCD Display Module and 1024 x 768 pixels resolution TM Servo Module There are three different TM Servo Modules available which supply different values of peak current The servos are matched to different tools to deliver specific ranges of rated torque The servo also evaluates outputs from the torque transducer and resolver All fastening strategies sequences are resident within the Servo Module firmware TMH Servo Used with all Cleco hand tools and Rotor Tools Rated at 40 amps peak current TM12 Servo Used with all Series 1 and 2 DGD fixtured spindles Also used with EMT 80 and EMT 200 fixtured tools Servo rated at 22 amps peak current TM34 Servo Used with all Series 3 and 4 DGD fixtured spindles Also used with EMT 400 EMT 600 and EMT 800 fixtured tools Rated at 66 amps peak current COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 2 2 version draft 0 5 Overview of the Tork Trak TM Controller CPU a
170. ng Strategy Programming Sequence 30PTR Set Point Definitions cont d Parameter and Range of Values PTR High 0 1 2 x Torque cal factor PTR Low 0 Torque cal factor PIR Time 1 ms to 3000 ms PIR Frequency 25 Hz PTR Speed PTR Number of Pulses 0 25 to 75 pulses Note Definition This is the upper torque level setting for PTR It should be programmed to a value less than the Torque High Limit to prevent a Torque High NOK This is the lower torque level setting for PTR It should be programmed to a value greater than the Torque Low Limit to prevent a Torque Low NOK Time duration of the Torque ON plus Torque OFF pulses Not programmable by the User Frequency is hard coded to 25 Hz Not programmable by the User Speed is automatically reduced to a fraction of maximum tool speed Not directly programmable by the User Number of pulses is dependant on programmed PTR Time The number of PTR pulses is approximately 25 times the number of seconds programmed for PTR Time Pulse torque recovery is applied at the conclusion of a fastening rundown and is used most successfully on joints which are either gasketed or springy sheet metal where a makeup torque is required If the joint begins to relax immediately following the rundown Torque Recovery can add a pre programmed amount of torque for a pre programmed time duration if the torque drops below a pre programmed value This strategy was awarded U S Pat
171. nge for spindle constants valid from the beginning of the sequence up to the threshold torque Speed 2 rpm Speed when the maximum torque is reached Must be lower than speed 1 Cutoff is deactivated when speed 2 0 or speed 2 Z speed 1 The maximum torque is normally not reached the torque shut off value is lower than the maximum torque so the speed will not fully cut off to speed 2 COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 39 version draft 0 5 Fastening Strategies Validity of Individual Parameters Parameter Start Sequence for Suppressed in evaluation Threshold torque Block angle angle safety torque After start pulse Shut off point shut down suppression reached Shut off angle Trigger torque When the values are equal the sequence for evaluation causes a higher priority for evaluation for instance of the threshold torque before the trigger torque i e the threshold torque and thus angle counting are activated when the trigger torque and threshold torque have the same numeric values even if a blanking angle is defined NL NEL NN Blanking angle torque After blanking angle Blanking angle 0 degree Block angle After start pulse sup After block anale Block angle 0 pression degree At spindle start 1 Shut off point when speed 2 0 2 Threshold torque when speed 2 gt 0 Speed 2 From threshold torque sh
172. ngle ranges These angle ranges specified separately fram ane another by setting parameters for the end of the range i unweighted angle high or low and the length af the range evaluation angle high or lew The two evaluation angles be in order and ales fully er partially ower lap COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 34 Fastening Strategy Programming The high evaluabion angle of tha torque curve is checked for overstep of the high evaluation torque and Ehe low evaluation angle of the torque curve checked fer understep of the low ewal uatian torque The bghbening process is assessed as being NOK if there were overteps and or undereteps The maximum torque is measured within the high evaluation angle and the lowest torque value within the low evaluation angle and statistical evaluation is carried aut The evaluation torques can be deactivated by setting the corresponding evaluation angle to In tha Block angle range which begins diractly after the start pulse suppression the torque must exceed the shut off torque as this will stop the drive This serves to detect rundowra that are canted aut an a tightened The block angle be deachvated by setting it la zera The torque curvas is far the graphic seri iram Um torque value per angle degree These valu Therefore
173. nic control system Sequence input value 30 Trigger torque Nm Trigger torque beginning of measurement recording for the graphic display Threshold torque Nm Threshold torque beginning of angle counting Shut off torque Nm Shut off torque for the stage Maximum torque Nm Maximum torque high limit of torque reached Minimum torque Nm Minimum torque low limit of torque reached Maximum angle deg Maximum angle high limit for angle reached and safety shut off value Minimum angle deg X Minimum angle low limit of angle reached Filtering factor Filtering factor number of measured values used for filtering by averaging Speed rpm Preset speed within the maximum speed range specified in the range for spindle constants COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 18 version draft 0 5 Fastening Strategies Sequence 31 Shut off Torque Controlled Fastening with Torque Monitoring and Angle Monitoring Sequence 31 is a torque controlled sequence which allows the rundown to be evaluated after the shut off torque has been reached by means of reverse analysis over two monitoring ranges Torque Safety shut down torque L om M ai i 1 10 c jn Maximum torque 111 10MNN i 5 5 i Shut off torque ee 1 Olei i Minimum torq
174. ntrol system the shut off torque maximum torque minimum torque threshold torque maximum angle minimum angle the filtering factor and the speed are entered separately for each nutsetter The maximum angle is also used as a safety shut down A maximum tightening time is entered as an additional safety shut down It applies to all nutsetters of a product group tightening process in this stage The measuring transducer integrated into the nutsetter measures the torque and rotation angle during tightening rundown The values are processed by the control system The angles are counted once the threshold torque is reached The nutsetter is stopped when the shut off torque search criteria is reached The dwell angle and peak torque achieved during the dwell time are then measured and processed in the control system as the bolt tightening value together with the rundown evaluation The control system can display the values in tables on the monitor and can output them to a printer or transmit them to other system components by data communication When the spindle trigger torque is reached recording of the torque curve starts and the curve can be viewed and evaluated in a graphic COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 17 version draft 0 5 Fastening Strategies This tightening method normally follows a fast pretightening stage The parameters below are entered in the electro
175. ockets by reversing 1 to 3 degrees at the conclusion of a rundown This permits easy withdraw of the multiple spindles from the part COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 4 Fastening Strategy Programming TM MT 10 Engagement 00207 00207 High speed rundown 10 207 torque controlled fastening up to a contact torque Shut off torque controlled fastening up Free rundown torque monitorin Du contorno paa a q ring 1 4 2 07 monitored torque monitoring during CA Prevailing Torque Monitor i tightening plus subsequent torque analysis Frictional torque measurement 1 4 207 CA Drag Torque Monitor The purpose of this sequence is to stop the built in nutsetter after a specified Event dependent turning 14 2 07 initiator position or defined angle CA Set Position shut off value in order to obtain an exact upper dead center position for the machining workpiece Torque control with torque 14 207 monitoring Torque control with torque monitoring plus Pulse Torque 1 4 2 07 The purpose of this sequence is to be used as a counter spindle retaining spindle when counter locking rundowns The counter spindle applies the counter torque to the corresponding spindle Torque controlled sequence which allows the rundown to be evaluated after the shut off torque has been reached by means of reverse ana
176. ols USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 16 28 version draft 0 5 lt gt r uvv NEL UNE NENNEN TMH SERVO MODULE Top Display Bottom Display Error Explanation 5 V supply in servo too low The 5 V power supply for internal supply of the servo amplifier is overloaded U 4 8 VDC 5 V supply in servo too high The 5 V power supply for internal supply of the servo amplifier is defective U gt 5 2 VDC Driver supply of output section too low The power supply for internal supply of the output section is overloaded or defective Offset of current measurement too high The zero point of the integrated motor current measurement has been shifted 5 V supply in measuring board too low The power supply for internal supply of the measuring board is overloaded or defective U lt 4 8 VDC Main and Startup Relay Output Section Off 1 x 4 5 2 Consequence Brake Motor Output I Internal error replace TMH Measures Remedy Internal error replace TMH Internal error replace TMH Internal error replace TMH Internal error replace TMH COOPER PowerTools Automated Systems Section 16 29 USER MANUAL Tork Trak TM Fastening Controller version draft 0 5 TMH SERVO MODULE Measures Remedy Top Display Bottom Display Error Explanation 3 3 5 P L
177. on Builder Navigate About Exit eae a Back avalible valle Applications Selected Panel 2 LOCAL E PANEL 7 DEFINED ON THE PANEL Torque Units N m COOPER Tools Stage Sequence Builder Stage 1 seq 73 Torque Control Angle Gradient Monitor Filter Factor 2 Tq Control Ang Grad Monitor This STAGE does not stop on ERROR Stage Timers MilliSeconds SEQ 73 Hold Torque at End of Stage Start Delay Time o Max Fastening Time 20000 Dwell Time fo Speed rpm Final Speed Setpoint 250 Torque Control High Limit p 000 Stage Retry Parameters Target Shutoff 5 000 Stage Retry Type Low Limit 0 000 After Retry goto Stage 1 Threshold 10 000 Trigger 3 000 Global to the Application Angle Monitoring Degree High Limit 9999 Relax the Tools on the Final Stage Backoff on ERROR Touch Up Settings Target Angle Maximum Retries o Gradient Monitoring High Gradient Limit 100 High Angle Limit 0 Low Gradient Limit p 000 Final Speed 300 Strobe Multiplier 2 Backoff Settings Target Angle 0 High Angle Limit Final Speed 300 Save these Settings x Cancel My Changes 3 Add Stage Del Stage gt Sequence 73 Torque Control Angle and Gradient Monitoring COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7
178. onitor Sequence 31 Torque Control with Reverse Analysis 6 19 Sequence 33 Switch off Torque Control 6 24 Sequence 41 Angle Control Backoff 6 27 oequence 46 Angle and Torque Control Backoff 6 29 Sequence 48 Angle Control Backoff Residual 6 31 Torque Sequence 50 Angle Control with Angle and Torque 6 34 Monitor sequence 51 Angle Control with Reverse Analysis 6 36 Sequence 63 Yield Point Control 6 42 Sequence 73 Torque Control with Gradient Monitor 6 44 Sequence 75 Angle Control with Gradient Monitor 6 46 Sequence 78 Torque and Angle Control with 6 48 Gradient Monitor oequence 80 Torque and Angle Control Angle 6 50 and Torque Monitor Pre Rundown and Post Rundown Strategies 6 52 JOG 6 53 TOUCH UP BACKOFF SETTINGS 6 54 PULSE TORQUE RECOVERY 6 56 USER MANUAL Tork Trak TM Fastening Controller COOPER PowerTools Automated Systems Section 0 ii version draft 0 5 SECTION SEVEN Fastening Strategy Programming Advanced Application Builder CONTENTS Fastening Strategies 7 1 Sequence 10 Engagement Stage 7 10 Sequence 11 High Speed Rundown 7 12 Sequence 13 Free Rundown 7 14 Sequence 15 Frictional Measurement 7 18 Sequence 16 Event dependent Turning 7 21 Sequence 20 Torque Control Torque Monitor 7 23 Sequence 20PTR Torque Control Pulse Torque Recovery 7 25 Sequence 30 Torque Control Angle Monitor 7 28 Sequence 30PTR Torque Control Angle Monitor Pulse Torque 7 30 Sequence 31 Torque Control with Re
179. ontroller Section 7 64 Fastening Strategy Programming Sequence 73 Setpoint Definitions cont d Parameter Definition Range of values Max angle High limit of angle reached 0 9 999 If this limit is exceeded the rundown is terminated safety shut down and the stage evaluated ANG gt Angle too high Min gradient Low limit of gradient 99 99 99 99 If this limit value is not reached the stage is evaluated NOK lt Gradient too low The evaluation is made with the value in the min value memory not with the gradient prevailing at the time of shut off Max gradient High limit of gradient If this limit value is exceeded the stage is evaluated NOK Gd gt Gradient too high The evaluation is made with the value in the max value memory not with the gradient prevailing at the time of shut off Strobe Step width for gradient calculation in angle pulses multiplier Starting from reaching of the threshold torque one measuring point in 1 30 excess of the strobe multiplier must have been collected for the first gradient value to be computed Collection is made per angle pulse With each new measuring point each angle pulse the oldest measuring value is deleted and a new gradient calculated A strobe multiplier of 1 corresponds to two measuring points in direct sequence Speed Set speed of the spindle s output shaft 1 max speed Filtering factor Number of torque values us
180. ontroller is a Celeron CPU which under certain plant conditions could be susceptible to high levels of Radio Frequency Interference RFI or large transient voltage spikes Electro Magnetic Interference EMI Both RFI and transient noise are usually transmitted through the plant AC voltage distribution system A combination transient suppression and RFI suppression module is installed in the Tork Trak TM enclosure which will help protect the operation of the controller under these types of AC generated noise COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 1 9 version draft 0 5 Overview of the Tork Trak TM Controller SECTION 2 Overview of the Tork Trak TM Controller This section is an overview of the hardware components which make up the Tork Trak TM controller Each of these major components will be discussed in detail on a functional basis Some of the components under discussion are Optional and may or may not be installed in your controller The major components are Tork Trak TM Controller Major Hardware Components T3M Enclosure Top Assembly CPU and Display Sub Assembly NES NES Connector Plate Sub Assembly Sub Plate Sub Assembly e TMSevoModle e Keypard T3M Enclosure Top Assembly LCD Display Eheu Indicator Disconnect Lights B Tork Trak TM COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fasteni
181. orce It is therefore necessary that the tightening method that was the basis for the dimensioning of the bolt is actually applied Basic tightening methods Torque controlled tightening The total tightening torque results from the thread tightening torque and the frictional torque acting on bolt head or nut e With tightening factor 1 4 to 1 6 Empirical determination of the set tightening torque on original components for instance bymeasuring the bolt elongation e With tightening factor Q 1 6 to 1 8 Empirical determination of the set tightening torque by estimating the friction coefficient surface and lubrication conditions e With tightening factor 1 7 to 2 5 Adjust the nutsetter to the final torque comprising the set torque and an additional value COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 8 Fastening Strategy Programming Angle controlled tightening exceeding the fastener yield point Control by rotation angle indirectly is control by measurement of bolt elongation Since it measures also the plastic deformation of the assembled components this method reaches its best accuracy only when the joint is first tensioned to a defined force and is then further tensioned by a certain angle reaching into the range of plastic deformation of the bolt Since the yield point is always reached or exceeded the resulting tensioning will vary simply due to the tolerance of
182. ored against the breakaway torque 0 60 000 limit Measuring time Time during which the torque is monitored 0 60 000 against the min max evaluation torque limit values The measuring time immediately follows the start time If the torque min value is not reached or the max evaluation torque value is exceeded during the measuring time an NOK evaluation results for the stage Speed Set speed of the spindle s output shaft 1 max Speed Filtering factor Number of torque values used to find mean value 1 2 4 8 16 32 With this number of torque values a mean value is calculated immediately upon measurement corresponding to filtering and dampening As soon as a new value is measured the oldest value is deleted and the man value recalculated The further evaluation shut off evaluation graph is made with these mean values A filtering factor of 1 results in no mean values being computed COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 20 Fastening Strategy Programming Set Position Sequence 16 The purpose of the Set Position Control Fastening Strategy is to provide the ability to turn a pre programmed angle after receiving an external signal discrete input A typical application for this strategy is to tighten a castle hub nut on an axle so that at the completion of the strategy a castle cutout on the nut will line up with the drilled hole in the spin
183. orques or with certain mechanical fixtures The spindle motor release may possibly not be transferred to the workpiece adaptor when the motor is shut off For this reason a release can be carried out as the last operation in the automatic tightening process in the electronic control system This should allow disconnection from the workpiece to be problem free This is achieved by reversing the fastening unit COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 29 version draft 0 5 Fastening Strategies The releasing stage which can be switched on and off has fixed parameters that cannot be changed for this reversing oequence 46 must be used for individual configuration It is important here that the force closure for the fastened parts is released and never has more force applied in the reverse direction This would result in further tightening Furthermore the screwed connection can be backed off The angle range that occurs for release is dependent upon the mechanical construction of the fastening unit The stiffer the fastening mechanics and the more formfitting the tool bit square drive the smaller the releasing angle The graphics function is not supported in this stage The parameters below are entered in the electronic control system Sequence input value 46 Shut off angle deg Shut off angle backoff angle Maximum angle deg Maximum angle hi
184. ot available in the TMH Internal error replace TMH Transducer 1 not present Handtool connected The transducer signal is Check tool cable for continuity e interrupted and short circuit Shorted Replace handtool not present 7 1 LL MN Internal error replace COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 36 version draft 0 5 TMH SERVO MODULE Transducer 1 Offset Torque transducer defective or The zero point voltage is out of installed in jammed position the admissible range between Check with test mode of 200 mV 200 station controller if values are out of admissible ranges if so replace handtool Internal error replace TMH COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 37 version draft 0 5 lt gt r uvv 4 TMH SERVO MODULE J O O 2 o a c Measures Remedy Top Display Bottom Display Error Explanation Main and Startup Relay Output Section Off Transducer 1 calibration voltage NOK The calibration voltage is out of the admissible range between 4 85 V 5 15 V Torque transducer defective or installed in jammed position Check with test mode of station controller if values are out of admissible ranges if so replace handtool or transducer If deviation is extreme
185. ow Blow fuse protection be considered to prevent nuisance trips from peak current requirements The Tork Trak TM Controller is shipped with a power drop cable Cooper Power Tools Part Number 576166 This same cable can be used for single phase or three phase operation One end of the power cable is terminated with a 5 pin connector which plugs into the power connector bulkhead on the controller enclosure bottom left rear The other end of the cable is un terminated with a 4 conductor pigtail The following chart shows the wiring colors assigned for single and three phase operation Supply Voltage p Cable 576166 Wire Color LLL Single Phase 230 VAC 230 VAC single phase po 230VAC single phase _ _ Ground 0 2 4001400 21 230VAC 3phse 21 230 3phae 212 y Grund Power Connector Wiring The following illustration shows the pin view of the power cable connector In general wire Black Red for single phase controllers and Black Red White for three phase controllers COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 1 8 version draft 0 5 Introduction to the Tork Trak TM Controller Red 2 G h H white Power connector pin View Green Power Cable Connector Pin View Wiring RFI Filtering and Surge Suppression The central component of the Tork Trak C
186. own cycle and is carried out fully by the nutsetter control Frictional torque measurement is divided into four phases which are called up and run after one another The functions below are executed in the individual phases Phase 1 Engagement The nutsetter is started clockwise and turns until an initiator FindINI reports that the engaging device normally a bit has engaged The measuring transducer integrated into the nutsetter measures the torque and rotation angle during the sequence The values are processed by the control system For safety reasons whenever the Max breakaway torque oversteps the torque in any phase the nutsetter is stopped and evaluated as NOK COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 11 version draft 0 5 Fastening Strategies Phase 2 Start Time Slide out of interference range SIS must be set before the nutsetter is started clockwise breakaway torque is monitored in this phase It must lay within the Min breakaway torque and Max breakaway torque limits If this is the case the sequence continues into phase 3 if this is not the case there is an immediate nutsetter stop Phase 3 Frictional Torque Measuring Time During the frictional torque measuring time the torque is monitored for overstep and understep of the Max evaluation torque and Min evaluation torque and the maximum and minimum frictional torques are registere
187. pu Eig duh abet ces See xxn ph m D ul LI Han z gas m ma controller Micro Segment Display pP COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 12 version draft 0 5 TMH SERVO MODULE Explanation of Terms ADC Address Angle Controller Bus plane Display Error detect voltage supply Filter Galvanic separation Galv sep Housing Overveltage limit Power Stage Power supply controller Resolver Resolver evaluation RS232 Printer Serial Com Transducer Signal conditioning analog digital converter address channel number processor for angle processing network field bus bus circuit board display error detection voltage supply filter suppressing interfer ance galvanic separation galvanic separation housing measuring board m ultiplexer limit output section power supply cantrallar motor position tracing resolver evaluation serial printer interface internal serial data transmission to cam bined transducer signal conditioning Temp Test pins Transducer and meniteringn Transducer Calibration Voltage limit Voltage regulator motor temperature internal test eonnaections combined transducer for torque and angle and monitoring calibration signal for cam transducer vol
188. quence is terminated 0 Torque cal factor Min Torque Low limit of torque reached If this limit value is not reached NOK for the stage 0 Torque cal factor results lt Torque too low Max Torque High limit of torque reached If this limit value is exceeded the stage is evaluated 0 1 2 x Torque cal factor gt Torque too high Max Angle High limit of angle reached If this limit is exceeded the rundown is 0 9 999 terminated safety shut down and the stage evaluated NOK gt Angle too high 1 max speed Trigger torque When this torque is exceeded the recording for IEEE Neid 0 1 2 x Torque cal factor 0 1 2 x Torque cal factor begins Min angle Low limit of angle reached If this limit value is not reached an NOK for the 0 9 999 stage results ANG Angle too low Filtering factor Number of torque values used to find mean value With this number of torque values a mean 1 2 4 8 16 32 value is calculated immediately upon measurement corresponding to filtering and dampening As soon as a new value is measured the oldest value is deleted and the mean value recalculated The further evaluation shut off evaluation graph is made with these mean values A filtering factor of 1 results in no mean values being computed COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 31 Fasteni
189. r Tools e Toconnect fastening spindles and motors not made by Cooper Tools Supply XS1 e The connector coding ensures that the plug for XS1 cannot be plugged into 52 Type PHOENIX Power Combicon PC4 6 7 62 Cooper Tools Id 960942 incl coding on pin 1 12 34 Supply of intermediate circuit of logic section logic power supply L1 230 VAC 2 Supply of intermediate circuit of logic section logic power supply N 3 Supply intermediate circuit of the power section L 1 230 VAC power section L 1 230 Supply intermediate circuit of the power section L 2 230 Ka Supply intermediate circuit of the Supply intermediate circuit of the power section N 230 VAC power section L 3 230 COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 15 17 version draft 0 5 TM12 and TM34 SERVO MODULES It is prohibited to remove the coding on the power connector plug or on the TM If the plugs are confused the TM can be destroyed AN The TM must be fastened to a zinc plated and earth grounded mounting plate Hiah discharae current connect earth around before servicina Motor 52 e The connector coding on pin 1 and 2 ensures that the plug of XS1 cannot be plugged into 52 Cable breakage monitoring Integrated filtering of motor outputs Type PHOENIX Power Combicon PC4 7 7 62 Motor phase W Motor phase U PE protected e
190. r functional assemblies of the TMH Type 9 pole D Sub pins with slide lock systems 1 5 V ARCNET DATA A Shield connection PE protected earth ground Transducer No 1 XS6 Controlling Transducer Integrated the Handtool Short circuit protected Description Output Signal Level Pin Measuring signal Analog input 5 5 V measuring range 6 25 6 25 V 2 Supply analog OV Output OVA Calibration signal Output 5 V 0 5 V Imax 15 mA on 5000 V 1 pull up 1 KQ 100 mA COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 19 version draft 0 5 TMH SERVO MODULE Supply 12 V Output 12 V 0 2 V Imax 200 mA Supply digital O V Output Interface RS422 TxD Output 5V Ri 500 0 Interface RS422 TxD Output 0 V Ri 500 Q Angle track 2 Input 0 5 V 0 7 12 V 1 pull up 1 KQ Interface RS422 RxD Input Interface RS422 RxD Input Housing Shield connection PE protected earth ground Not used in this application 8 NC O 12 NC SOS 14 2 15 Transducer No 2 XS7 Redundant Transducer Short circuit protected Type 15 pole HD Sub socket with lock screws 4 40 UNC threads Input Output Signal level Data Pin Measuring signal Analog input 5 5 V measuring range 6 25 6 25 V 2 _ SupplyanalogOV Output OVA Calibration s
191. reached by means of reverse analysis torque monitoring NE over two monitoring ranges The monitoring torque can also be changed by an angle range during the rundown Frictional torque measurement unsupported with angle monitoring Yield point controlled fastening with percentage preset of the shut off gradients by the maximum gradient and torque rotation angle and gradient monitoring Yield point control with torque angle and gradient monitoring Torque and shut off angle control with torque angle and gradient monitoring Torque and angle control with angle and torque monitoring Direction center adjustment unsupported 1 0 1 6 Torque control with torque angle 14 and gradient monitoring Angle control with torque angle ee 1 4 and gradient monitoring Frictional torque measurement meore with external spindle pp COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 6 Fastening Strategy Programming General Information on Fastening Techology Overview A threaded fastener connection is a removable connection of two or more parts that utilizes one or more bolts The bolts and their tensioning forces must be properly dimensioned to ensure the resulting joint can serve its purpose and withstand the existing operating forces Calculation of a screwed connection is based on the operating force applied to the joint from outside This operating force result
192. riate bus using the jumpers the I O Interface Board Internal 24 VDC All Inputs Active Low and All Outputs Active High 1 On the Public I O cable connector jumper pins 14 to 23 Inputs Active Low 2 the Public I O cable connector jumper pins 14 to 1 Outputs Active High 3 On the interface Board set all Output jumpers to Common and all Input jumpers to Common B Internal 24 VDC All Inputs Active High and All Outputs Active Low 1 On the Public I O cable connector jumper pin 11 to pin 23 Inputs Active High 2 On the Public I O cable connector jumper 11 to pin 1 Outputs Active Low 3 On the I O interface Board set all Output jumpers to Common B and all Input jumpers to Common A COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 12 12 version draft 0 5 TM12 and TM34 SERVO MODULES SECTION 15 TM Servo Modules for Fixtured Tools TM12 960900 TM34 960901 COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 1 version draft 0 5 TM12 and TM34 SERVO MODULES General Description of Tightening Modules TM In the tightening modules TM12 and TM34 the servo amplifier output section and the measuring section measuring board torque are integrated in one housing There are separate processors for measuring and output sections Motors are controlled digitally he control parame
193. ring Filter Factor 2 This STAGE does not stop on ERROR Stage Timers Milliseconds Hold Torque at End of Stage Start Delay Time o Speed rpm Max Fastening Time 20000 Final Speed Setpoint 250 Dwell Time 0 Torque Monitoring High Limit p 000 Target Shutoff 5 000 Angle Limits Degree High Limit 8999 0 Shutof O Low Limit D Stage Sequence Builder Backoff with Ang Tq Monitor Stage Retry Parameters Stage Retry Type Touchup After Retry goto Stage 1 Maximum Retries o lt Fastening gt P Global to the Application Relax the Tools on the Final Stage Backoff on ERROR Touch Up Settings Target Angle High Angle Limit 0 Final Speed 300 Backoff Settings Target Angle 0 High Angle Limit Final Speed 300 ES Adi Stage Del Stage gt Save these Settings x Cancel My Changes Sequence 46 Backoff Angle and Torque Monitoring COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 44 Fastening Strategy Programming Sequence 46 Set Point Definitions Parameter Definition Range of values Shut off angle Angle as target value when it is reached the rundown is terminated 0 9 999 Angle counting begins with the spindle start Shut off torque Torque as target value wh
194. ring by averaging Speed rpm Preset speed within the maximum speed range set in the spindle constants COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 13 version draft 0 5 Fastening Strategies Sequence 16 Event dependent turning Positioning Stage The purpose of this sequence is to stop the built in nutsetter after a specified position initiator position FindINI after a defined angle shut off value in order for instance to obtain an exact upper dead center position for a machining workpiece When the input sequence begins in the tightening process the spindle starts to fasten or turn Angle counting begins after the initiator position has been reached The built in nutsetter stops when the entered shut off angle is reached The angle shut off values reached are processed in the OK NOK evaluation There is no provision to evaluate the reached torque value If the maximum torque is reached during fastening the spindle shuts off and is given a NOK evaluation The graphics function is not supported in this stage The parameters below are entered in the electronic control system Sequence input value 16 Filtering factor Nm Filtering factor number of measured values used for filtering by averaging Shut off angle Nm Shut off angle for the stage Maximum angle deg Maximum angle high limit for angle reached and shutoff value Minimum angle d
195. ring continuity impedance or checking for a short circuit in the motor or motor cable be sure to disconnect these from the TM Fatal electric shock may occur COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 23 version draft 0 5 TM12 and TM34 SERVO MODULES Consequence lt gt r UNTO Measures Remedy Top Display Bottom Display Main and Startup Relay Output Section Off Brake Motor Output Error Explanation Supply DC DC converter undervoltage Measure supply voltage If lt 200 increase to 230 VAC If errors occur sporadically check the supply for voltage Arone Measure supply voltage If gt 225 VAC decrease to 230 VAC If errors occur sporadically check the supply for voltage 8X 08 hant Check supply prefusing of TM EMERGENCY STOP contactor etc Supply DC DC converter undervoltage lt 150 VAC Supply DC DC converter overvoltage The voltage of the intermediate circuit of logic section is gt 440 VDC Intermediate circuit of the power section Not supplied LI _____ S s Motor cable defective OON X X Motor connected Check motor cable for continuity and short circuit Check motor for short circuit to PE and check phase impedance 1B approx 25 2B Cable in motor lines broken Motor phases interrupted Test current of cable monitoring misguided approx 8
196. rive and all PC 104 Boards COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 2 7 version draft 0 5 Overview of the Tork Trak TM Controller Connector Plate Sub Assembly EtherNet Port Public 1 Connector USB Port Keyboard Port Connector Mouse Private 1 Connector The Connector Plate Sub Assembly is located on the bottom front of the Tork Trak TM enclosure It provides eight connectors supporting the following functions EtherNet Port USB Port Keyboard Port Mouse port 24 VDC Fuse Public O Connector Private O Connector Tool Connector fixtured tool connector or hand tool connector cod m Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 2 8 version draft 0 5 Overview of the Tork Trak TM Controller Sub Plate Sub Assembly AC Power Line Filter Supply GFCI 4 Terminal Blocks amp Fuses Disconnect Switch The Sub Plate Sub Assembly is located on the rear vertical surface of the Tork Trak TM enclosure It supports the following functions Terminal Blocks Fuses GFCI Ground Fault Circuit Interruptor 1 or 3 phase Power Supply 24 VDC 5 VDC 12 VDC AC Line Filter AC Disconnect Switch COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 2 9 version draft 0 5 Overview of the Tork Trak TM Controller
197. rouncokata COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 15 version draft 0 5 TM12 and TM34 SERVO MODULES Block Diagram 34 MRCHET Cable EDSO ui 4 ARCHET Gable TEN SMS 2 Hb IEF E Hai E E Loon d EH m T pr MORE LL E LERLE E iA E L ransdupar Gab JEIKI 5 See Re ep m gt D I LI d rangducer an BBr xxx COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 16 version draft 0 5 TM12 and TM34 SERVO MODULES Connections All plug in connections are located on the front of the TM e All connections except XS1 Supply can be secured from unintentional unplugging with screws or slide locks The connections for motor resolver and transducer are compatible with the m 400 fastening system with measuring board S torque and servo amplifier BLS 2 _ It is prohibited To operate the TM and the nutrunner spindle without PE protected earth ground connections Fatal electric shock may occur To use other connector types To use cables other than those approved by Coope
198. rque one measuring point in excess of the strobe multiplier must have been collected for the first gradient value to be computed Collection is made per angle pulse With each new measuring point each angle pulse the oldest measuring value is deleted and a new gradient calculated A strobe multiplier of 1 corresponds to two measuring points in direct sequence opeed Set speed of the spindle s output shaft 1 max speed Filtering factor Number of torque values used to find mean value 1 2 4 8 16 32 With this number of torque values a mean value is calculated immediately upon measurement corresponding to filtering and dampening As soon as a new value is measured the oldest value is deleted and the mean value recalculated The further evaluation gradient calculation shut off evaluation graph is made with these mean values A filtering factor of 1 results in no mean values being computed COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 69 Fastening Strategy Programming General Information Concerning Gradient Controlled Fastening Strategies Sequence 63 Sequence 73 Sequence 75 Sequence 78 Definition The gradient is the difference quotient of two measuring points consisting of torque and angle measured per angle pulse Gd ANn ANm m n index of respective measuring point n m spacing of measuring points polling rate Expressed
199. rque Monitor Torque Control Ange Monitor 80 02 COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 1 Fastening Strategy Programming Fastening Strategies Short Description Sequence 10 Engagement Stage oequence 10 is designed to engage the nut runner on the fastener This is achieved by alternating the nut runner counterclockwise and clockwise to engage the fastener Sequence 11 High Speed Rundown Sequence 11 is designed to minimize the time to reach snug torque This is achieved by programming a higher speed prior to a lower speed control sequence Sequence 13 Prevailing Torque Monitor oequence 13 is designed to monitor fastening prevailing torque by enabling a high and low limit The prevailing monitor can be programmed between angle limits Sequence 15 Drag Torque Monitor Sequence 15 is designed as a special feature It is the measurement of bearing and shaft drag torque For example an engine crankshaft rotational measurement Sequence 16 Set Position Sequence 16 is a special purpose strategy which is used to line up a cotter pin hole in a bolt with the space in a castellated nut For example a wheel bearing nut assembly Sequence 20 Torque Control Sequence 20 is a general fastening control strategy This strategy answers out to controlled torque Sequence 20PTR Torque Control and Pulse Torque Recovery Sequence 20 is a g
200. rque must not be exceeded The drive is stopped when the safety shut down torque is exceeded which applies in the sequence from the end of the impulse suppression time up to the shut off point An error message with NOK evaluation is generated The blanking angle can be deactivated by setting it to zero If the block angle and blanking angle overlap the shut off torque is considered to be a termination criteria until the end of the block angle Angle counting starts when the threshold torque is reached if detection of the threshold torque has not been deactivated by the block angle or blanking angle Note If the threshold torque trigger torque then angle counting starts when the threshold torque is reached and continues in the blanking angle COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 6 20 version draft 0 5 Fastening Strategies Angle measurement and possibly also redundancy monitoring starts when the drive starts After the shut off torque has caused a shut down the torque and or the corresponding angle are compared to the minimum maximum torque and the minimum maximum angle and evaluated accordingly as OK or NOK Reverse analysis is also carried out The maximum angle safety shut down torque and maximum tightening time for the stage are used as a safety shut down Description of parameters Sequence input value 31 Filtering factor Number of measured torque valu
201. rt pulse supprek sia Maximum evaluation torqus H Phase 1 Threshold torque ws aI i 24 Angle FRTM angle i i Evaluation angle Unweighted angle 1 Start Time Maximum tightening time In the electronic control system the shut off torque threshold torque on maximum evaluation torque minimum evaluation torque threshold torque off FRTM angle unweighted angle evaluation angle filtering factor and speed preset are entered separately for each nutsetter A maximum tightening time is entered as the safety shut down It applies to all nutsetters of a product group tightening process in this stage The measuring transducer integrated into the nutsetter measures the torque and rotation angle during tightening rundown The values are processed by the control system The torque is monitored from the time when the nutsetter starts until the FRTM angle is reached Rundown is terminated immediately with NOK if the maximum evaluation torque is overstepped in this phase phase 1 COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 6 5 version draft 0 5 Fastening Strategies Rundown continues without interruption if phase 1 is error free The nutsetter is stopped when the shut off torque search criteria is reached The peak torque achieved during the dwell time is then measured and processed in the control system as the bolt tightening torque
202. s Check ARCNET cable for continuity and short circuit Internal error replace TMH Refer to Display of Errors COOPER PowerTools Automated Systems USER MANUAL Tork Trak TM Fastening Controller Section 16 43 version draft 0 5 Tool Library Settings SECTION 17 Tool Library Settings Cleco Handtools Torque Angle Servo Gear Model No Max Max Calibration Calibration Parameter Ratio Speed RPM Torque Nm Factor Factor Set 17 Series Right Angle Tools 17EA08AL2 2000 8 8 5 28 373 32 9 975 17EA15AM3 860 15 16 6 65 640 32 23 0776 17EA22AM3 610 22 23 0 92 640 32 32 5696 17EA28AM3 465 28 41 4 121 257 32 42 63 17 Series Inline Tools 17 5067 2600 6 7 0 21 333 32 7 5 17 5127 1200 12 12 9 46 886 32 16 484 17ES17ZA 860 17 17 9 66 172 32 23 264 17ES06Q 2600 6 7 0 21 333 32 7 5 17 5120 1200 12 12 9 46 886 32 16 484 17 517 860 17 17 9 66 172 32 23 264 17ESO6D2 2600 6 7 0 21 333 32 7 5 17ES12D3 1200 12 12 9 46 886 32 16 484 17ES17D3 860 17 17 9 66 172 32 23 264 17ES22D3 650 22 32 2 86 612 32 30 45 X Power Tools USER MANUAL Tork Trak TM F i Automated Svstems ork ira astening Controller Section 17 1 Tool Library Settings Torque Angle Servo Gear Model No Max Max Calibration Calibration Parameter Ratio opeed RPM Torque Nm Factor Factor Set
203. s in axial forces transverse forces bending force and torque Only on simple symmetric and relatively rigid joints it is possible to split up the operating force to develop a practical calculation method For eccentrically strained joints this is possible only to a limited extent or not at all The purpose of calculation of the screwed connection is to determine the size of the fasteners The following properties must be considered Shore hardness of the bolt The determining factor for the dimension of the bolt is the yield point Generally it should not be exceeded when the bolt is tightened to the rated tension and when the joint is exposed to strain Only under special preconditions such as angle controlled tightening it is admissible to exceed the yield point Further criteria are the elongation at rupture the tenacity of the head and the notched bar impact value see DIN 267 3 1967 and DIN ISO 898 Generally the following is true high strength bolts quality class 8 8 and higher can be mounted easier and more economically even when the size of the components cannot be reduced due to their application Reduced tension due to settling The amount of settling after fastening results from the yielding of the components assembled the number of joints and to a limited extent from the surface roughness of the joints Durability under changing load Two points must be observed in this regard a The amount of changing axial force acting on
204. s not work the maximum number of rundown for the transducer have been exceeded Only on transducers with service memory e g 1 1 Transducer 2 rundown counter at limit The rundown counter in the transducer has reached its maximum number of rundowns of 107 or it is defective Torque exception Error in program processing Check transducer cable especially the RS422 data lines Replace transducer Internal error replace TM Replace transducer Internal error replace TM Inform Cooper Tools service department Internal error replace TM Inform Cooper Tools service department Internal error replace TM Inform Cooper Tools service department Measuring board firmly secured to TM Internal error replace TM Check program selection Internal error replace TM Inform Cooper Tools service Torque General initialization error Initialization of internal communication interfaces is NOK Torque communication error Communication interfaces are NOK Servo not OK Ready signal from servo is not present Flash error Program update not possible The station controller is trying to send a faulty program vel wel eel Eo o Eo ob department COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 40 version draft 0 5 TM12 and TM34 SERVO MODULES Task ID error e Internal error replace TM Software monitoring e Inform Cooper Tools s
205. s when fhe drive stars After the shut off torque hae caused a shut down the torque and or the corresponding angle are compared to the minimumimaximum torque and the minimum maximum angle and evaluated accordingly as OK of Reverse analysis is also carried out The maximum angle safety shut down torque and maximum tightening time for the stage are ugad as a safety ahul dewn COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 35 Description of parameters Sequence input value Filtering factor Trigger torque Nm Threshold torgue him Shut off torque Mr Safety shut down torgue Nm Block angle dag Blanking angle deg Unweighted angle high deg Evaluation angle high deg High evaluation torque Nm Unweighted angle bow deg Evaluation angle low deg Low evaluation terque Nm Maximum torque Minirum terque Mm Maximum angle deg Minimum angle deg Fastening Strategy Programming 31 Number of measured tongue values used for averaging Beginning af staring terque values for the graphic display reverge analysis and blanking angle Beginning af angle counting valid outside the blanking angle and block angle Torque at which the drive is stopped and the dell time valid auteide Ine banking angle forge valid after start pulse suppres sion has finished and during the rundown and the value at wh
206. shold 10 000 Trigger 90 00 T Global to the Application Angle Monitoring Degree High Limit D Relax the Tools on the Final Stage Low Limit fo m Backoff on ERROR Touch Up Settings Target Angle son Cycle Control Number of Cycles 1 High Angle Limit 3999 p Final Speed 300 EE Backoff Settings 41 Target Angle 999 High Angle Limit 3999 Final Speed 300 GS act stage Del Stage 5 Save these Settings Cancel My Changes COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 39 Fastening Strategy Programming This tightening procedure must be preceded by a pre clamping Sequence Sequences 30 31 50 51 63 73 75 and 80 show the clamping procedures The electronics for each spindle have separate parameters for number of repetitions on time off time the switch off torque maximum moment minimum moment maximum angle minimum angle damping factor trigger moment the threshold torque and the specified RPM s The maximum angle is used as a safety switch off Maximum running time is also specified as an additional safety switch off This affects all spindle drivers of a product group driving process in this stage The torques and angles of rotation during an operation are measured and processed in a sensing element built into the drivers The angles are measured
207. short circuit Replace motor Check transducer cable especially 12 V and O V conductors Internal error replace TM COOPER PowerTools Automated Systems Section 15 25 USER MANUAL Tork Trak TM Fastening Controller version draft 0 5 TM12 and TM34 SERVO MODULES Consequence lt gt r 00 Measures Remedy 8 Top Display 8 Bottom Display Error Explanation Main and Startup Relay Output Section Off Brake Motor Output Intermediate circuit voltage too high The voltage of the intermediate circuit of the power section is gt 400 VDC Permanent error e Measure supply voltage If gt 255 reduce to 230 VAC During braking e Capacitors in intermediate circuit are open e Brake chopper is defective replace TM oporadically e he supply voltage is too high sporadically if transformer is available connect next higher tap e Internal error replace TM Permanent error 4 Intermediate circuit voltage too low 7 The voltage of the intermediate e Measure supply voltage if lt circuit is lt 150 VDC pply g 200 VAC increase to 230 VAC During fastening supply is too weak or overloaded ensure more stable supply e g larger transformer Capacitors in intermediate circuit are open replace TM On TM34 one phase missing X X EMEN a _ _ Internal error replace TM COOPER PowerTools USER MANUAL Automated Sv
208. sion the torque must not exceed the maximum torque as this will stop the drive This serves to detect rundowns that are carried out on a tightened bolt The block angle can be deactivated by setting it to zero The torque curve is recorded for the graphic starting from the trigger torque 1 torque value per angle degree These values are also the basis for the reverse analysis Therefore the trigger torque must be parametrized so that the torque curve relevant for reverse analysis is always recorded An error message with NOK evaluation is generated if there are insufficient torque values for reverse analysis The torque curve can be output as a graphic Parameters can be set for a blanking angle that starts when trigger torque is reached During the blanking angle detection of the threshold torque and maximum torque is deactivated and is only reactivated after the blanking angle has finished It is permissible for the torque to be higher than the maximum torque in the blanking angle but the safety shut down torque must not be exceeded The drive is stopped when the safety shutdown torque is exceeded which applies in the sequence from the end of the start pulse suppression time up to the shut off point An error message with NOK evaluation is generated The blanking angle can be deactivated by setting it to Zero If the block angle and blanking angle overlap the maximum torque is considered to be a termination criteria until the end of the b
209. sion Dwell time COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 56 version draft 0 5 Fastening Strategies For Sequence 30 PTR the only parameter to program is the qty of pulses The approximate pulse period of PTR is about 150 msec If the number of pulses was programmed as qty 14 the PTR duration would be 14 X 150 msec or about 2 seconds duration For Sequence 20 PTR the following parameters can be programmed On time in msec Off time in msec High Limit Torque Low Limit Torque Qty pulses Spindle speed COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 57 version draft 0 5 Fastening Strategy Programming Fastening Strategies This Section discusses twenty two different fastening strategies These fastening strategies are all resident within the TM Tightening Modules servos Some of the strategies are independent and are assigned a Sequence Number Some of the strategies are dependent and when enabled support an independent sequence An example of a dependent strategy is Pulse Torque Recovery PTR which can be assigned to Sequences 20 30 or 50 The following table lists each Fastening Strategy and the assigned Sequence number Fastening Strategy Name Sequence Number o 10 Torque Control Angle Monitor Pulse Torque Recovery Backoff Angle Control with 2 Torque Monitoring Points Angle Control To
210. solver evaluation serial printer interface internal serial data transmission to com bined transducer signal conditioning COOPER PowerTools Automated Systems TM12 and TM34 SERVO MODULES Temp Test pins Transducer and monitoringn Transducer Calibration Voltage limit Voltage regulator motor temperature internal test connections combined transducer for torque and angle and monitoring calibration signal for combined transducer voltage limit voltage regulator USER MANUAL Tork Trak TM Fastening Controller Section 15 14 version draft 0 5 TM12 and TM34 SERVO MODULES Block Diagram TM12 ARCHET Gable S3BDHSD XX d _ ARGHET Cable HE T us wl lll HT T Reamer Goble rl e 0 i Bam 7 Iis 5 Cable nml E w Bm ll ia pM IE mill mM 7 r Top a NEN a pE LL Cure _ 115 114 mlilllu Llls Sd illl hs m He H a 115 115 1 Lll mill iu E lew IE G
211. ssed in the control system as the bolt tightening value together with the rundown evaluation The control system can display the values as text or in tables on the monitor and can output them to a printer or transmit them to other system components by data communication COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 6 44 version draft 0 5 Fastening Strategies When the spindle trigger torque is reached recording of the torque curve starts and the curve can be viewed and evaluated in a graphic This tightening method normally follows a fast pretightening stage The parameters below are entered in the electronic control system Sequence input value 73 Trigger torque Nm Trigger torque beginning of measurement recording for the graphic display Threshold torque Nm Threshold torque beginning of angle counting and gradient calculation Shut off torque Nm Shut off torque for the stage Maximum torque Nm Maximum torque high limit of torque reached Minimum torque Nm Minimum torque low limit of torque reached Maximum angle deg X Maximum angle high limit for angle reached and safety shut off value Minimum angle deg Minimum angle low limit of angle reached Minimum gradient Nm deg X Minimum gradient low limit of the gradients Maximum gradient Nm deg Maximum gradient high limit of the gradients Strobe multiplier Strobe multiplier spacing in an
212. stalled Are the clients with the bus terminations switched on All cables plugged in Internal error replace TMH COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 33 version draft 0 5 lt gt r 00 TMH SERVO MODULE Top Display Bottom Display Error Explanation Torque measuring card parameters are wrong Fastening parameters in measuring board are NOK Torque Memory overflow Not enough RAM storage available Torque 12 V NOK The 12 V supply of the measuring board is out of tolerance limits between 11 8 V 12 2 V Torque 12 V The 12 V supply of the measuring board is out of tolerance limits between 11 8 V 12 2 V Un o 2 o a c LEDAReady off Main and Startup Relay Output Section Off Measures Remedy Check programming of station controller Handtool constants Calibration values Fastening strategy SEQ Fastening stage Parameter set Inform Cooper Tools service department Internal error replace TMH Check at station controller in test mode the value out of tolerances Check tool cable especially the 12 V and 0 V and the resolver conductors Replace handtool Internal error replace TMH Check at station controller in test mode the value out of tolerances Check tool cable especially the 12 V and 0 V conductors Check resolver cabl
213. stems NA Tork Trak TM Fastening Controller Section 12 4 version draft 0 5 Input Output Overview PUBLIC OUTPUT Pinout Discrete Physical PUBLIC I O OUTPUT Pre Assigned Connector Description FUNCTION Pin Assignment User Mappable User Mappable User Mappable User Mappable User Mappable User Mappable User Mappable User Mappable fuse on enclosure 24 V return DC common All PUBLIC Outputs are on the forward 25 pin male connector Mating female connector Cooper Power Tools 576191 Phoenix Contact Subcon 25 F SH 27 61 61 9 Functions are software mappable by the User PUBLIC I O can be either Internal 24 VDC or External 24 VDC PUBLIC I O can be either Active High or Active Low COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 12 5 version draft 0 5 Input Output Overview PUBLIC INPUT Pinout Discrete Physical PUBLIC I O OUTPUT Pre Assigned Connector Description FUNCTION Pin Assignment User Mappable User Mappable User Mappable User Mappable User Mappable User Mappable User Mappable User Mappable fuse on enclosure 24 V return DC common All PUBLIC Inputs are on the forward 25 pin male connector Mating female connector Cooper Power Tools 576191 Phoenix Contact Subcon 25 F SH 27 61 61 9 Functions are software mappable by the User PUBLIC I O can be either Internal 24 VDC or External 24 VDC PUBLIC I O ca
214. stems NA Tork Trak TM Fastening Controller Section 15 26 version draft 0 5 lt gt r 00 TM12 and TM34 SERVO MODULES Top Display Bottom Display Error Explanation Main and Startup Relay Output Section Off Brake Motor Output Temperature in output section too high The temperature in TM is 80 C Start up relay does not open Due to an internal error the contact in the start up relay sticks Main relay does not open Due to an internal error the contact in the main relay sticks 5 V supply in servo too low The 5 V power supply for internal supply of the servo amplifier is overloaded U 4 8 VDC 5 V supply in servo too high The 5 V power supply for internal supply of the servo amplifier is defective U gt 5 2 VDC LED Ready 4 eee 2 Consequence Measures Remedy Measure temperature inside cabinet below TM if 9 gt 50 C additional cooling e g air conditioner required Cooling slots of TM must not Internal error replace TM Internal error replace TM Internal error replace TM Internal error replace TM COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 27 version draft 0 5 TM12 and TM34 SERVO MODULES Consequence Measures Remedy Top Display Bottom Display Main and Startup Relay Output Section Off Brake Motor Output Sect
215. t for USB EtherNet Fieldbus and 2 channel Ethernet carrying Data and Virtual I O Ease of Programming Cooper Power Tools Automated Systems has designed the Tork Trak TM to provide an intuitive programming environment which helps reduce errors The main features of the Tork Trak TM which simplify and reduce your programming time are The Tool Library Support of tools with memory chip e Graphical display of Fastening Curves and Set Points e Ability to edit the program while continuing to perform fastening rundowns Statistics Reporting e Internal O Scope function for joint and process analysis e Histogram X bar and Range charts for process control e Diagnostics for tool transducer and communications cos em Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 1 2 version draft 0 5 Introduction to the Tork Trak TM Controller Tool Library The Tork Trak TM provides a user programmable tool library containing setup information for every electric tool manufactured by Cooper Power Tools If the tool is equipped with a memory chip the tool automatically identifies itself to the CPU and uploads the tool parameters If the tool does not have a memory chip the Tool Library can be manually accessed to install the correct tool parameters by choosing the tool Model Number After selecting a tool from the library the Tork Trak TM automatically programs the appropriate torque tr
216. t level 5V 0 2V analog section logic Motor Output Section e Short circuit protected phase phase phase PE earth ground phase temperature monitoring e Overvoltage protection e Minimal loss due to IGBT output section e Very good heat dissipation the entire housing serves as heat sink e Integrated electronically monitored brake chopper allows dissipation of brake energy through the internal brake resistors COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 15 7 version draft 0 5 TM12 and TM34 SERVO MODULES 222 MA 34 Nutrunner spindle type 4B Intermediate circuit voltage Uz 320 VDC 10 Error shut down at UZ 150 VDC UZ 400 VDC Rated output at 50 C 200 VA 400 VA 800 VA 800 VA Temporary peak output 1200 VA 2000 VA 2000VA 3500 VA Adjusted peak current 66 A Short circuit current shut off 100 A 100 A Efficiency 97 Power loss at rated nutrunner 4 W 11 W 19 W 19 W output Clock speed of PWM 10 kHz Maximum temporary brake 4000 VA 7200 VA output Power Loss Low power loss components limit heat radiation high admissible operating temperature of 50 C reduces the need for additional cooling measures in many cases he position of the brake resistors ensures that no other components of the TM are influenced by the heat dissipated by them COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fas
217. t reached the stage is evaluated NOK 99 99 99 99 lt Gradient too low The evaluation is made with the value in the min value memory not with the gradient prevailing at the time of shut off This input range applies to Nm for torque Recalculated input ranges apply other torque measuring units COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 72 Fastening Strategy Programming Sequence 78 Set Point Definitions cont d Parameter Definition Range of Values Min torque Low limit of torque reached If this limit value is not reached NOK for the stage results 0 Torque cal Factor Tq Torque too low Shut off angle Angle as target value when it is reached the rundown is terminated 0 9 999 Max angle High limit of angle reached If this limit value is exceeded the stage is evaluated NOK 0 9 999 gt Angle too high 1 max speed Threshold torque When this torque is exceeded the angle counting and gradient calculation begin 0 1 2 x Torque cal Starting from reaching of the threshold torque one measuring factor point in excess of the strobe multiplier must have been collected for the first gradient value to be computed If the threshold torque is lower than the trigger torque the recording for graphic evaluation begins already when the threshold torque is exceeded Filtering factor Number of torque values used to
218. ta communication When the spindle trigger torque is reached recording of the torque curve starts and the curve can be viewed and evaluated in a graphic COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 15 version draft 0 5 Fastening Strategies This tightening method normally follows a fast pretightening stage The parameters below are entered in the electronic control system Sequence input value 20 Trigger torque Nm Trigger torque beginning of measurement recording for the graphic display Shut off torque Nm Shut off torque for the stage Maximum torque Nm Maximum torque high limit of torque reached Minimum torque Nm Minimum torque low limit of torque reached Filtering factor Filtering factor number of measured values used for filtering by averaging Speed rpm Preset speed within the maximum speed range specified in the range for spindle constants COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 16 version draft 0 5 Fastening Strategies Sequence 30 Shut off Torque Controlled Fastening with Torque Monitoring and Angle Monitoring Torque Maximum torque Tightening torque Shut off torque E Minimum torque Threshold torque Initial torque f Maximum angle Angle Time Maximum tightening time start pulse suppression Dwell time In the electronic co
219. tage limit voltage regulator USER MANUAL COOPER PowerTools Automated Systems Section 16 13 Tork Trak TM Fastening Controller version draft 0 5 TMH SERVO MODULE Connecting Diagram TMH with Single Phase Supply E liy i ETZE ag o 4444 1444444 bad a TE area ren nitet 14 ul USER MANUAL Tork Trak TM Fastening Controller 1 COOPER PowerTools Automated Systems version draft 0 5 Section 16 14 TMH SERVO MODULE _ _ He H luz 1 Lam Tod m AE ETE Connecting Diagram TMH with Three Phase Supply COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 15 version draft 0 5 TMH SERVO MODULE Connections All plug in connections are located on the front of the TMH o adapt the TMH connections to the tool cable an extension cable is required Cooper Tools No 960948 XXX All connections except XS1 Supply can be secured from unintentional unplugging with screws or slide locks The connections for motor resolver and transducer are compatible with the m 400 fastening system with measuring board S Torque and servo amplifier BLSH It is prohibited To operate the TMH and the handtool without PE protected earth ground connect
220. tart Delay Time o Speed rpm Max Fastening Time 20000 Final Speed Setpoint 250 Dwell Time 0 Torque Spike Filter 0 Torque Monitoring High Evaluation Limit poo Low Evaluation Limit pon High Breakaway Limit pon Low Breakaway Limit non Trigger 3 000 Global to the Application Time MilliSeconds Measuring Time 0 Relax the Tools on the Final Stage Backoff on ERROR Touch Up Settings Stage Retry Parameters Stage Retry Type Touchup After Retry goto Stage 1 Maximum Retries lt Fastening gt Target Angle High Angle Limit Final Speed 300 Backoff Settings Target Angle 0 b High Angle Limit Final Speed 300 pa Ada Stage _J Del Stage gt E Save these Settings x Cancel My Changes ea Sequence 15 Drag Torque Monitor The sequence Sequence 15 Drag torque monitor has been developed as a special process for frictional torque measurements on crank shafts DTM Drag torque monitoring can also be used for other similar frictional measurements Sequence 15 Setpoint Definition COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 18 Fastening Strategy Programming Range of values for graphic representation begins 0 1 2 x Torque cal Factor Min breakaway torque Low torque limit during start up start time 0 Torque cal Factor
221. ted Svstems NA Tork Trak TM Fastening Controller Section 7 61 Fastening Strategy Programming General Information Concerning Gradient Controlled Fastening Strategies Sequence 63 Sequence 73 Sequence 75 Sequence 78 Definition The gradient is the difference quotient of two measuring points consisting of torque and angle measured per angle pulse Gd ANM m index of respective measuring point n m spacing of measuring points polling rate Expressed for the practice of fastening technology The gradient is the change of torque per degree of angle A positive gradient means increase a negative gradient decrease of the torque with increasing angle Note that changing the strobe multiplier will affect the gradient calculation since a different quotient is computed thereby Higher strobe multipliers have a smoothing effect that is a change from a positive to a negative quotient will be detected later After the threshold torque has been reached the gradient is continuously computed of the torque and angle values The gradient calculation ends with the end of the sequence COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 62 Fastening Strategy Programming Torque Control Angle and Gradient Monitoring Sequence 73 Shut off torque controlled fastening with torque angle and gradient monitoring bs Advanced Applicati
222. tening Controller Section 15 8 version draft 0 5 TM12 and TM34 SERVO MODULES Calculation of Temperature to be Expected inside Control Cabinet To ensure safe operation and reach the service life of 20 000 hours the TM must be operated in a control cabinet with a maximum inside temperature of 50 The temperature to be expected inside the control cabinet must be calculated when the cabinet is designed Formula tot PVedditional heat sources xk Temperature to be expected inside control cabinet in C temperature room temperature in tot power loss of all TMs W From the intermediate circuit of the logic section Power loss of all additional heat sources installed inside the control cabinet in W Effective cabinet surface in m2 Heat transition coefficient of sheet metal 5 0 W m K At a calculated inside temperature Ti above 50 C additional cooling measures such as an air conditioner or heat exchanger are required COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 15 9 version draft 0 5 TM12 and TM34 SERVO MODULES Measuring Board e The measuring board is part of the TM and must not be replaced individually e t has separate processors for measuring and communication tasks angle tracing and ARCNETError Bookmark not defined e
223. tening Controller Section 16 31 version draft 0 5 lt gt r uvv Top Display Bottom Display Error Explanation ARCNET multiple address The address adjusted on this TMH already exists ARCNET address faulty permissible range ARCNET Error Communication error ARCNET Recon network is unstable COOPER PowerTools Automated Systems O O 2 o a c Main and Startup Relay Output Section Off Brake Motor Output The selected address is not in the Too many reconfigurations Section 16 32 TMH SERVO MODULE Measures Remedy Check addressing that is switch settings of ARCNET each client must have a unique address Internal error replace TMH Change address to be in the range between 01 and 32 Internal error replace TMH Check ARCNET Bus terminators installed Are the clients with the bus terminations switched on All cables plugged in Check addressing of ARCNET that is switch settings Internal error replace TMH Inform Cooper Tools service department Check ARCNET Bus terminators installed All ARCNET cables plugged in Check addressing of ARCNET that is switch settings Are the clients with the bus USER MANUAL Tork Trak TM Fastening Controller version draft 0 5 TMH SERVO MODULE dl MEM ARCNET not connected to network X Check ARCNET The TMH is not connected to the Bus terminators in
224. ters ArcNet Coupler Board The ArcNet coupler board is a PC 104 bus board which plugs into the CPU Mother Board The ArcNet board communicates information and data between the Mother Board CPU and the TM Servo Module USER MANUAL Tork Trak TM Fastening Controller COOPER PowerTools Automated Systems Section 2 6 version draft 0 5 Overview of the Tork Trak TM Controller Input Output Board The I O board is a PC 104 board which supporting 8 Inputs and 8 Outputs The Inpits are opto coupled and the Outputs are relay contacts The Inputs are bi polar which support active high or active low inputs sink or source The board suports inputs and outputs to both the Public I O and the Private I O external enclosure connectors FieldBus Option DeviceNet Board The DeviceNet board is a slave to the plant public virtual fieldbus The DeviceNet board sends or receives virtual discrete signals between the Tork Trak TM controller and the plant PLC head end Devicenet software drivers are installed as part of the FieldBus DeviceNet option The DeviceNet plant cable drop enters the enclosure through a connector mounted on the bottom surface of the enclosure in the front right corner Power Supply The power supply is located in the upper right section of the enclosure mounted to the subplate and generates plus amp minus 5 VDC and plus amp minus 12 VDC The power supply is common to the PC 104 CPU Hard D
225. ters for different motors are saved permanently in the TM and are selected by the measuring board Field of Application he tightening modules have been designed to operate Cooper Tools fastening spindles size 1B and 2B TM12 3B and 4B TM34 EMT Series 80 and 200 TM12 EMT Series 400 600 800 and 1200 TM34 The tightening modules are used in conjunction with the station controller TM Multi Trak and Tork Trak TM Controllers he TM communicates with the station controller Tork Trak TM via a serial high speed field bus ARCNET Thus decentralized arrangement of station controller and TMs at a distance of up to 100 m is possible Service Ms can be replaced without requiring calibration The station controller m Pro 400 Touch screen transmits all settings and adjustments automatically to the new TM Fast precise diagnosis in case of failures is facilitated by displayed text at the station controller and coded messages displayed on a 2 digit segment display at the TM f the housing is opened the warranty is voided TM must always be replaced in its entirety e Only transport the device the original packing The packing is recyclable e f the packing is damaged check the TM for visible signs of damage Inform the carrier and Cooper Tools if required COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 15 2 version draft 0 5 TM1
226. that is switch settings Internal error replace TM Inform Cooper Tools service department Consequence Measures Remedy Top Display Bottom Display Error Explanation Main and Startup Relay Output Section Off Brake Motor Output LED Ready off Section Off ARCNET Recon Check ARCNET To many reconfigurations Bus terminators installed network is unstable All ARCNET cables plugged in Check addressing of ARCNET that is switch settings Are the clients with the bus terminations switched on ARCNET not connected to network Check ARCNET The TM IS not connected to the Bus terminators installed ARCNET Are the clients with the bus terminations switched on All cables plugged in COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 15 31 version draft 0 5 Torque measuring card parameters are wrong Fastening parameters in measuring board are NOK Torque Memory overflow Not enough RAM storage available Torque 12 V NOK The 12 V supply of the measuring board is out of tolerance limits between 11 4 12 6 V COOPER PowerTools Automated Systems TM12 and TM34 SERVO MODULES Section 15 32 Internal error replace TM Check programming of station controller opindle constants Calibration values Fastening strategy SEQ Fastening stage Parameter set Inform Cooper Tools service department Internal error replace TM
227. the trigger torque must paramet ed 50 that Ine torque c curve a far reverse analysis is always recorded An error message with NOK evaluation is generated if there are insufficient torque values Tor reverse analysis The tarque curve be output as a graphic Parameters can be set for a blanking angle that starta when bigger torque ie reached During the blanking angle detection of the threshold tarque and shul of torque is deactivated and is anly raact vated after the blanking angle has finished It is permissible for the torque to be higher than the shut off torque in the blanking angle but the safety shut down torque must not be exceeded The drive is slapped when the safety shut down torque exceeded which applies in the sequence from the end of the impulse suppression time up to the shut off point An error message wilh evaluation is generated The blanking angle can be deactivated by setting to zero Fi h black angle and blanking angle overlap the shut off terque is considered be tion criteria unti the end of the block angle Angle counting starts when Ihe threshold torque is reached if detection af the thresheld terque has not been deactivated by the block angle blanking angle IT the threshold torque x rigger terque then angle counting starte when the threshold torque is reached and conbnues in the blanking angle Angle measurement and possibly also redundancy monitoring stant
228. threshold torque has been reached the gradient is continuously computed of the torque and angle values The gradient calculation ends with the end of the sequence COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 74 Fastening Strategy Programming Torque and Angle Control with Torque and Angle Monitoring Sequence 80 Shut off torque and shut off angle whichever occurs first with torque and angle monitoring lani x Advanced Application Builder Navigate About Help Exit Applications Selected Panel di B 2 LOCAL EZ PANEL APPLICATION 1 DEFINED ON THE PANEL Torque Units N m COOPER Tools Stage 1 Seg 80 Torque Control Angle Monitor Filter Factor 2 I This STAGE does not stop on ERROR Stage Timers MilliSeconds Hold Torque at End of Stage Start Delay Time 0 Speed rpm Max Fastening Time 20000 Final Speed Setpoint 250 Dwell Time 0 Torque Control Stage Sequence Builder Torque or Angle Control SEO 80 Toi que Target Shutoff 5 000 Stage Retry Type Touchup v Low Limit p 000 After Retry goto Stage li 4 Threshold 0 000 Maximum Retries 0 Trigger 3 000 Angle Monitoring Degree High Limit 5999 Target Shutoff D Low Limit 0000 Global to the Application Relax the Tools on the Final Stage Backoff on ERROR Touch Up Settings Target Angle
229. tion 16 6 version draft 0 5 TMH SERVO MODULE Intermediate Circuit of Logic Section All logic voltages and supply voltages for the communication functions are generated from the intermediate circuit of the logic section Connector 51 TMH Supply current 1 X 230 10 Rated supply current Ca 0 1A Internal fusing slow blow 0 63A Power loss standby 24 W Internal Power Supply Units Supplied by the intermediate circuit of the logic section galvanically separated All generated voltages are short circuit protected e The ARCNET output level is galvanically separated from all other supplies The clock speed of the DC DC converter is 80 kHz Generated Internal supply servo section analog Internal supply servo section analog COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 7 version draft 0 5 TMH SERVO MODULE Internal supply measuring section 4 5V 0 2V logic Transducer excitation 12V 0 2V Supply of ARCNET output level 5 V 0 2V Motor Output Section Transducer excitation 12V 02V 0 Short circuit protected phase phase phase PE earth ground phase temperature monitoring Overvoltage protection Minimal loss due to IGBT output section Very good heat dissipation the entire housing serves as heat sink Integrated electronically monitored brake chopper allows dissipation of brake energy
230. tion controller If no angle signals are detected in test mode Check tool cable especially the angle signal lines Handtool rotates more than 360 degrees Check angle factor Replace transducer or handtool 11 Internal error replace TMH Main and Startup Relay Output Section Off Brake Motor Output Transducer 2 angle tracing NOK The angle signals are e Interrupted Shorted e Not present Not present part of the time Torque exception Error in program processing Internal error replace TMH Inform Cooper Tools service department Internal error replace TMH Inform Cooper Tools service department Torque General initialization error Initialization of internal communication interfaces is NOK Torque communication error Communication interfaces are NOK Internal error replace TMH Inform Cooper Tools service department eof we ee te COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 40 version draft 0 5 TMH SERVO MODULE Servo not OK Measuring board firmly Ready signal from servo is not secured to TMH present Internal error replace TMH Flash error Check program selection Program update not possible Internal error replace TMH The station controller is trying to Inform Cooper Tools service send a faulty program department Task ID error Internal error replace TMH software monitoring Inform Cooper Tools service depar
231. tment COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 16 41 version draft 0 5 Top Display Bottom Display Error Explanation Overload not flashing If a current above the admissible maximum current is drawn during fastening the servo amplifier shuts off automatically e Error in motor position tracing e g resolver cable Error in motor circuit e g motor does not reach required torque TMH SERVO MODULE n 9 Consequence Main and Startup Relay LED Ready off LED s READY and Bus active Emo Measures Remedy e Check supply voltages e Internal error replace TMH LED READY not on The TMH is not ready Refer to Output Section Off Brake Motor Output Measures Remedy Check system programming Handtool selection e Required torque Check motor position tracing Check tool cable and replace if necessary Replace handtool Internal error replace TMH Check tool cable Replace handtool Display of Errors segment display flashes COOPER PowerTools Automated Systems Section 16 42 USER MANUAL Tork Trak TM Fastening Controller version draft 0 5 LED Bus active flashes at approx 1 Hz frequency ARCNET communication interrupted LED Bus active not on otatus and diagnosis display flashes TMH SERVO MODULE Check ARCNET connection Check all connector lock
232. to the backoff angle having been reached the minimum maximum torque and the minimum maximum angle are used to evaluate the result as OK or NOK Parameters can be set for a maximum time a start pulse suppression time and a dwell time When the trigger torque is reached recording of the torque curve starts and the curve can be viewed and evaluated in a graphic Description of parameters Sequence input value 48 Filtering factor Number of measured values used for averaging Trigger torque Nm otart of storing the torque value for the graphical view Threshold torque Nm Beginning of angle counting Backoff angle deg Angle at which the drive is stopped and the dwell time begins Angle at M1 deg Angle at which the torque is checked at a position between M1 max and M1 min the drive is stopped when the position lies outside of the range M1 min to M1 max M1 max Nm Maximum torque allowed at M1 M1 min Nm Minimum torque allowed at M1 Angle at M2 deg Angle at which the torque is checked at a position between M2 max and M2 min the drive is stopped when the position lies outside of the range M2 min to M2 max COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 32 version draft 0 5 Fastening Strategies M2 max Nm M2 min Nm Maximum torque Nm Minimum torque Nm Maximum angle deg Minimum angle deg Speed rpm Safety shut dow
233. tomated Svstems NA Section 17 10 Tork Trak TM Fastening Controller Tool Library Settings Torque Angle Servo Gear Model No Max Max Calibration Calibration Parameter Ratio opeed RPM Torque Nm Factor Factor Set 150 Series Inline Tools EMR150RYSGG8 1140 10 11 7 36 503 35 13 141 EMR150RYSGG10 920 13 25 0 45 342 35 16 323 EMR150RYSGG13 740 17 24 7 56 250 35 20 25 EMR150RYSGG17 585 23 24 4 70 833 35 25 5 EMR150RYSGG21 465 28 35 5 89 197 35 32 111 EMR150RYSGG24 415 32 35 4 100 000 35 36 0 EMR150RYSGG30 330 40 51 0 125 925 35 45 333 EMR150RYSGG35 280 50 9 147 964 35 53 267 225 Series Inline Tools EMR225RYSGG29 970 39 70 2 37 178 37 13 384 EMR225RYSGG37 760 50 69 2 47 456 37 17 084 EMR225RYSGG47 595 64 65 4 60 539 37 21 794 EMR225RYSGG55 505 75 138 7 71 442 37 25 719 EMR225RYSGG62 450 94 138 79 772 37 28 718 EMR225RYSGG69 405 94 137 8 88 572 37 31 886 EMR225RYSGG77 365 104 137 4 98 889 37 35 6 EMR225RYSGG88 320 119 136 8 112 986 37 40 675 EMR225RYSGG104 270 141 136 4 133 333 37 48 0 EMR225RYSGG118 235 160 176 7 152 333 37 54 84 EMR225RYSG125 213 170 298 3 169 575 37 61 047 EMR225RYSG140 180 190 298 3 198 767 37 71 556 EMR225RYSG170 155 230 298 3 232 989 37 83 876 EMR225RYSG210 125 285 298 3 287 742 37 103 587 EMR225RYSG270 98 366 650 9 368 106 37 132 518 EMR225RYSG285 93 386 650 9 389 422 37 140 192 EMR225RYSG350
234. tomated Svstems NA Tork Trak TM Fastening Controller Section 16 22 version draft 0 5 TMH SERVO MODULE Troubleshooting To allow fast diagnosis of errors LEDs and a two digit 7 segment display are installed on the front panel Display of Errors he errors are shown as codes The display 00 99 flashes at a frequency of approx 1 Hz f an error occurs in the TMH in the main power supply the motor in the transducers or in the ARCNET the error codes listed in the table below are immediately triggered f several errors occur at the same time the failure with the highest priority that is the lowest number is displayed Exceptions Error 64 Torque 12 V NOK has priority over 15 16 17 21 22 28 40 and 41 description see table Error 65 Torque 12 V NOK has priority over 15 16 17 28 and 40 description see table failure 40 Torque is not ready has the lowest priority since the errors 41 to FF cannot be described as a common error 40 to simplify error diagnosis All errors are reported to the station controller via the ARCNET and are then displayed on its monitor In the rundown data table the abbreviations FLT F Torque AN1F AN2F OFF1 OFF2 are shown in the ERROR column In the rundown data table the window Spindle monitor opens When the soft key i is pressed the error list is opened and all current errors are displayed as descriptive text C
235. tomated Svstems NA Tork Trak TM Fastening Controller Section 7 50 Fastening Strategy Programming Sequence 51 Initial monitor of torque for thread cutting followed by angle control for final clamp load bs Advanced Application Builder Pub Navigate About Exit on Selected Panel a As on valle LOCAL PANEL DEFINED THE PANEL Torque Units N m COOPER Tools Stage Sequence Builder Seq 51 Self Tap with Angle Control Filter Factor 2 Self Tap Anaie Control This STAGE does not stop on ERROR Stage Timers MilliSeconds Hold Torque at End of Stage Start Delay Time Speed rpm Max Fastening Time ooo Speed at Threshold pso Dwell Time D ooo Speed at Shutoff D Torque Spike Filter 0 Stage Retry Parameters Stage Retry Type Touchup After Retry goto Stage li Maximum Retries 0 Torque Limits Trigger 3 000 Threshold 0 000 Safety Shutoff Limit 75 00 Low Eval 0 000 0 000 High Eval Low Limit 0 000 0 000 High Limit Angle Control Degree Self Tap Angle 0 Re Hit Detection Angle 0 Shutoff 0 low unweighted angle 0 high unweighted angle fi Low Eval 0 0 High Eval Low at End 0 9999 High at End pa Ada Stage De Stage gt Global to the Application Relax the Tools on the Final Stage Backoff on ERROR Touch Up Settings Target Angle 0 b High Angle Limit Final Speed
236. troller Section 15 20 version draft 0 5 TM12 and TM34 SERVO MODULES Operating Elements RESET Button Processor reset for all internal functions of the TM Used to acknowledge failures Pressing results in reconfiguration of all functions Selector Switch for ARCNET Address e Adjusts ARCNET address BCD code switch upper switch for tens digit 00 90 bottom switch for ones digit 00 09 Admissible settings 01 to 32 e Adjust only when supply is switched off f two or more modules have the same address the error code 50 is output The address adjustment can be checked upon power up or reset at the two digit segment display Displays Status and Diagnosis Display e Red segments two digit Operating conditions and error codes flashing are displayed Operating conditions Upon power up or reset the following messages are displayed Lamp test that is all 2 x 7 segments are on 88 for 1 second Then the display is off for approx 0 5 seconds adjusted ARCNET address is displayed as 01 32 for 1 second Then the display is off for approx 0 5 seconds e Selected motor control parameter set will be shown on the bottom display 12 1 2 will appear on TM34 a 3 or a 4 will appear for 1 second while the upper display will not be on During fastening operation Display during fastening 11 FF The top display shows the selected fastening program
237. ts the mouse COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 2 11 version draft 0 5 Fastening Strategies SECTION 6 Fastening Strategies Sequences Overview There are two dynamic measurements which occur when fastening joints using electric nut runners The two measurements are Torque and Angle Torque is the measurement of rotational force and Angle is the measurement of the square drive socket rotation angle in degrees measured after reaching a programmed level of torque Torque is measured in foot pounds or Newton Meters and Angle is measured in degrees In establishing a fastening strategy for tightening a threaded joint either Torque or Angle are chosen as the control function A strategy can control to a specific Target Torque value and also monitor the angle or a strategy can control to a specific Target Angle and monitor the resulting torque Using Torque and Angle as control or monitoring parameters can create a wide variety of specialized Fastening Strategies In this Section the terms Fastening Strategy or Fastening Sequence are used interchangeably The Fastening Sequences discussed on the following pages are included in the TM Multi Trak Fastening Control Software and are available to the Tork Trak TM Controller User COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 1 version draft 0 5 Fastenin
238. ty switch or limit switch sensor which is connected to a physical input The physical input pinout is user programmable COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 21 Fastening Strategy Programming Sequence 16 Setpoint Definitions Range of Values Shut off angle Target Angle value When this value is reached the rundown is terminated Angle 0 to 9 999 counting begins when the cycle start input is received 0 to 9 999 reached the stage is evaluated NOK 0 to 9 999 the rundown is evaluated NOK Filtering Factor Number of torque values used to calculate a mean value used in the torque evaluation 1 2 4 8 16 32 A mean value is calculated immediately upon measurement This factor is equivalent to filtering and dampening As soon as a new value is measured the oldest value is deleted and the mean value recalculated The shutoff evaluation is made with these values A filtering factor of 1 results in no mean value being calculated Torque High Limit High Limit of Final Torque reached If this 0 to 1 2 x Torque calibration factor limit is exceeded the stage is evaluated NOK COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 22 Fastening Strategy Programming Torque Control Sequence 20 Shut off torque controlled fastening with torque monitoring amp Advanced Application Builder Navigate
239. ue High Limit Torque Low Limit Threshold Torque start angle Turn Off Torque Stage 1 Trigger start O scope Angle Low Limit Angle High Limit otage 1 Speed initial e Stage 2 Speed final Minimum Gradient e Maximum Gradient e Shut off Gradient e Strobe Multiplier COOPER PowerTools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 7 59 Fastening Strategy Programming Sequence 63 Set Point Definitions Parameter and Definition Range of Values Shut Off Gradient Percentage of the maximum gradient as target 0 to 100 96 value When it is reached the sequence is terminated If the gradient drops to this percentage of the maximum value the sequence is terminated Minimum Gradient Low limit of gradient If this limit is not reached the 99 99 to 99 99 rundown is terminated safety shutoff and the stage is evaluated as NOK Maximum Gradient High limit of gradient If this limit is exceeded the 99 99 to 99 99 rundown is terminated safety shutoff and the stage is evaluated as NOK 0 to 9 999 the stage is evaluated NOK 0 to 9 999 rundown is evaluated NOK otrobe Multiplier otep width for gradient calculation in angle pulses 1 to 30 After reaching threshold torque one measuring point in excess of the strobe multiplier value 1 to 30 must be collected before the gradient is calculated Data collection is made per angle pulse With each new angle pulse the oldest value is de
240. ut ex se Applications Selected Panel lt 21 p PANEL APPLICATION 1 DEFINED ON THE PANEL Torque Units N m COOPER Tools Angle Monitoring SEO 41 jl lt Shutoff Angle gt Stage Sequence Builder Save these Settings x Cancel My Changes Help Exit Stage 1 This STAGE does stop on ERROR seq 41 Backout Angle Monitoring REVERSE Filter Factor 2 Stage Timers MilliSeconds Hold Torque at End of Stage Start Delay Time D o Speed rpm Max Fastening Time 20000 Final Speed Setpoint Dwell Time Angle Monitoring Degree High Limit pes Stage Retry Parameters Shutoff 0 Stage Retry Type Touchup Low Limit o After Retry goto Stage 1 Y Maximum Retries Global to the Application Relax the Tools on the Final Stage Backoff on ERROR Touch Up Settings Target Angle fo High Angle Limit p Final Speed Backoff Settings Target Angle T High Angle Limit IT Final Speed Ge Ada stage Del Stage gt Sequence 41 Backoff Angle Monitoring p COOPER PowerTools Automated Systems USER MANUAL Tork Trak TM Fastening Controller Section 7 42 Fastening Strategy Programming Sequence 41 Set Point Definitions Parameter Definition Range of values Shut off angle Angle as target value when
241. ut off point speed 2 0 speed 2 speed 1 COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 40 version draft 0 5 Fastening Strategies Parameters that are analyzed in reverse i e starting from the shut off point High evaluation angle Shut off point minus Shut off point minus High evaluation upper unweighted upper unweighted angle 0 angle angle minus high eval uation angle Upper unweighted Shut off point Shut off point minus angle upper unweighted angle High evaluation torque Valid in the high evaluation angle High evaluation angle 0 Low evaluation angle Shut off point minus Shut off point minus Low evaluation lower unweighted lower unweighted angle 0 angle angle minus low evalu ation angle Lower unweighted Shut off point Shut off point minus angle upper unweighted angle Low evaluation torque Valid in the low evaluation angle Low evaluation angle 0 COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 6 41 version draft 0 5 Fastening Strategies Sequence 63 Yield Point Controlled Fastening with Torque Angle and Gradient Monitoring Yield point controlled fastening with percentage preset of the shut off gradients by the maximum gradient and torque rotation angle and gradient monitoring Gradient Torque B measured maximum gradient C shut off value Maximum torque
242. ve been collected for the first gradient value to be computed If the threshold torque is lower than the trigger torque the recording for graphic evaluation begins already when the threshold torque is exceeded Min torque Low limit of torque reached 0 Torque cal Factor If this limit value is not reached for the stage results lt Torque too low COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 7 68 Fastening Strategy Programming Sequence 75 Setpoint Definitions cont d Parameter Definition Range of Values Max torque High limit of torque reached 0 1 2 x Torque cal If this limit is exceeded the rundown is terminated safety shut Factor down the stage is evaluated Tq Torque too high Min gradient Low limit of gradient 99 99 99 99 If this limit is not reached the stage is evaluated NOK Gd lt Gradient too low The evaluation is made with the value in the min value memory not with the gradient prevailing at the time of shut off Max gradient High limit of gradient 99 99 99 99 If this limit value is exceeded the stage is evaluated NOK gt Gradient too high The evaluation is made with the value in the max value memory not with the gradient prevailing at the time of shut off otrobe multiplier Step width for gradient calculation in angle pulses 1 30 Starting from reaching the threshold to
243. verse Analysis 7 33 Sequence 33 Switch off Torque Control 7 39 Sequence 41 Angle Control Backoff 7 42 oequence 46 Angle Torque Control Backoff 7 44 Sequence 48 Angle Control Backoff Residual Torque 7 46 Sequence 50 Angle Control Torque Monitor 7 49 Sequence 51 Angle Control with Reverse Analysis 7 51 Sequence 63 Yield Point Control 7 58 Sequence 73 Torque Control with Gradient Monitor 7 63 Sequence 75 Angle Control with Gradient Monitor 7 67 Sequence 78 Torque and Angle Control with 7 71 Gradient Monitor Sequence 80 Torque and Angle Control Angle 7 15 and Torque Monitor Parameter Relax 7 78 Set 193 A Power Tools USER MANUAL Automated Systems Tork Trak TM Fastening Controller Section 0 iii version draft 0 5 CONTENTS SECTION TWELVE Input Output Overview Input Output Overview 12 1 CPU and Display Sub Assembly 12 2 Private Output Pinout 12 3 Private Input Pinout 12 4 Public Output Pinout 12 5 Public Input Pinout 12 6 Discrete Physical Setup 12 7 Public Interface Board and Bus Jumpers 12 8 Tork Trak Default Public Configuration 12 9 Wire Jumpers for Public Setup 12 9 l O Setup Instructions 12 11 SECTION FIFTEEN TM Servo Modules TM12 960900 and TM34 960901 15 1 Fault Codes Table 15 24 SECTION SIXTEEN TM Servo Module TMH 960902 16 1 Fault Codes Table 16 25 COOPER PowerTools USER MANUAL Automated Systems Tork Trak TM Fastening Controller Section 0 iv version draft 0 5 CONTE
244. xceeded Shut off angle deg Angle at which the drive is stopped and the dwell time begins Block angle deg Angle beginning at the end of start pulse suppression in which the torque must be lower than the maximum torque Blanking angle deg Angle range starting at the trigger torque in which the maximum torque and threshold torque are invalid Unweighted angle high deg End point of the evaluation angle high related to the shut off point reverse Evaluation angle high deg Length of the monitored range for overstep of the high evaluation torque High evaluation torque Nm High torque limit in the evaluation angle high that must not be exceeded in reverse analysis COOPER Power Tools USER MANUAL Automated Svstems NA Tork Trak TM Fastening Controller Section 6 38 version draft 0 5 Fastening Strategies Unweighted angle low deg End point of the evaluation angle low related to the shut off point reverse Evaluation angle low deg Length of the monitored range for understep of the low evaluation torque Low evaluation torque Nm Low torque limit in the evaluation angle low that must not be understepped in reverse analysis Maximum torque Nm High limit of torque reached Minimum torque Nm Low limit of torque reached Maximum angle deg High limit for angle reached and safety shut off Minimum angle deg ym of angle reached Speed 1 rpm Preset speed maximum speed specified in the ra
245. xplanation Start signal sequence faulty Communication error between measuring board and servo amplifier Consequence Measures Remedy e Internal error replace TM e Inform Cooper Tools service department Main and Startup Relay Output Section Off Brake Motor Output LED Ready off gt lt gt lt error Internal error replace Error in motor identification mode Mathematic error illegal command etc Error in program processing Measuring board not ready The signal measuring board OK is not received by the servo section ARCNET multiple address The address adjusted on this TM already exists ARCNET address faulty The selected address is not in the permissible range COOPER PowerTools Automated Systems e Internal error replace TM Inform Cooper Tools service department Measuring board present Measuring board firmly secured to TM Internal error replace TM Check addressing that is switch settings of ARCNET each client must have a unique address Internal error replace TM Change address to be in the range between 01 and 32 Internal error replace TM USER MANUAL Tork Trak TM Fastening Controller Section 15 30 version draft 0 5 TM12 and TM34 SERVO MODULES ARCNET Error Check ARCNET Communication error Bus terminators installed Are the clients with the bus terminations switched on All cables plugged in Check addressing of ARCNET
246. y averaging Speed rpm Preset speed within the maximum speed range specified in the range for spindle constants In the figure above the process is shown correctly from the standpoint of measuring technology in which the measured torque is shown as being negative The more interesting representation for the user shows the tensioning force of the screwed connection which is shown below as being positive equivalent to the tightening torque Tightening force for the screwed connection torque C L Angle E Maximum angle E d E gt t 222 Start Maximum tightening time Start pulse suppression Dwell time COOPER PowerTools USER MANUAL Automated Systems NA Tork Trak TM Fastening Controller Section 6 28 version draft 0 5 Fastening Strategies Sequence 46 Shut off Angle and Shut off Torque Controlled Releasing Strategy with Angle and Torque Monitoring Releasing Backoff Strategy with Freely Programmable Parameter Values Maximum tightening time Start ____ shut off angle _ shut off torque Maximum torque Minimum angle Maximum angle Clamping force Breakaway torque Torque negative oeizing between the bolt head and bit often occurs during fastening It can then be difficult to separate the tool from the workpiece or an aid must be used for separation Seizing occurs very frequently at high t
247. ys recorded An error message wilh evaluation is generated if here insufficient torque values Tor reverse analysis The borque curve ouipul s graphic Parameters can be set fora blanking angle that starta when trigger torque is reached Dunng the blanking angle detection of the threshold torque and maximum terque deactivated and only reactivated after the blanking angle has finshed It i amp permisaible for the torque bo be higher than the maximum terque in the blanking angle but the safety shut down torque must nat ba excesded The drive stopped when the safety shut down torque exceeded which applies in the sequence from the end of the start pulse sup pressan birme up 16 Ihe ehul aff point An erar messege wih evalualian is generated The blanking angle can be deactivated by setting it to sera If the black angle and blanking angle overlap the maximum torque eensidered to be bermi criteria until fhe end af the block angle Angle counting starts when the threshold terqua is reached if detection of the threshold tanque hag not been deactivated by the block angle er blanking angle Note If the threshold terque trigger torque then angle counting starte when the threshold torque is reached and continues in the blanking angle Angle measurement and possibly alsa redundancy monitoring starts when the starts After the shut off terque has caused shut dewn

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