Home

User Sep-03-2004dist.. - Signature Technologies

1. Press control Light Stack Sensor Programmable Outputs Outputs Inputs Cam Outputs 5 ollo fofo gt 2 E Ie S lo l Lom Lo 6 ane Oe pa AG U E FAE K pE I e 2 ISSSSISISISISSISIS SHIELD ra HELD Ssescess ge Week dese eS Watt ett tlt is ne tot te Wty S sho E Z E a AT fu Sot e Bg E E MHAE a al i st Resolver E FAULT UGHT STACK J SD z Ba SED Gan OUTPUTS I Encoder z 2 el MEAE rat Input E S zZ 5 Z ma ma Z eee ol GND Pare eae 71 el Petit aS i i j Fadi Pa v ms on em em mn em em me em Ge ee om om om n Peek REA 0 BEEE S MRO KEHE s g A O GO O SENSOR CABLE GI amp H Gi S H S OH OH OO HO HO HO KS CONTROL CABLE ees Power Supply Machine Unassigned Auto Zero a Status Indicators Control Inputs MOSTO Inputs P Cycle indicator Cam Outputs Figure 159 TEC I O terminal organization The resolver Encoder connections The position transducer resolver encoder terminals are Multiple Use depending on which position input module has been installed on the SA2000 unit If a RES position module is installed The terminals are used for Sine Cosine amp Reference windings on a resolver They are also used for the inputs from the HiRes resolv
2. ti ae cat S _ Machine Unassigned x 7 Programmable Control Inputs Auto Zero Cam Outputs Inputs Cycle Indicator Figure 32 TEC Version C Terminations Valid for A08 and A6D input cards The TEC is the green printed circuit board with the terminal strips mounted in the small enclosure The channel numbers and connection points are listed on a label inside the cover AND printed directly on the circuit board A detailed presentation of the connections is found in Appendix 1 below NOTE The terminal locations on the D16 the A D and the A08 versions of the product are all the same HOWEVER the terminal location for Dieview sensor 1 D1 IS DIFFERENT For the A6D card The version C TEC modules are Silk screened with the terminal designations for the A08 and A6D modules only and for the other two types A D amp D16 Paste on labels are applied to correct the designations accordingly Signature Technologies Inc 55 General Installation amp Programming Guide Section 2 Programming the FIRST press The following are the step by step procedures for entering the FIRST press into the system The steps must be followed exactly as presented Items designated as optional need not be performed or they can be done later without complication NOTE The following assumes that there is NO existing press or tool and that the database
3. Interval End 171 608 Figure 76 Static Cushion pressure on the draw ring This feature calculates the average signature value for a defined window The window can be as extensive as the entire data collection window note the Error Check for this feature or as little as a single point In any event only a single value is returned for this feature Selected channel data to calculate the average from can be real or virtual Window start in degrees or position off BDC Window end in degrees or position off BDC At the end of the drawing operation in the first station the only force on the part is the pressure of the nitrogen cushion cylinder located behind the draw ring By taking the average value of the signature between the end of the draw and before the die closure the condition of the cylinder can be monitored Refer to the If a Programmed Feature Doesn t Work section below at page 101 fora description of the overflow error that could occur using this feature In addition the most common type of error that is encountered using the average feature is computational overflow when calculating the sum of each signature data point in the interval To avoid this situation make sure that the following relation holds for the average SUM Xi lt 32 767 N Where SUM Xi the summation of all the signature data points in the interval N number of the signature data points in the in
4. Priority Level 0 oo no password Signature Technologies Inc 363 User Manual Markionin iia vane ied Press operator e Priority level 2 1234 A aa EREET EE E TEETE Tool amp Die man Priority level 3 5678 ROJO aniar iiie Floor Supervisor Priority level 4000 4321 Ralph a a beard eae nes S T serviceman Priority level 5 AAAA Let s also assume you have performed your Password level assignments as shown below Level Assignment LOG OR ii ntnihiitaadeti nail ant dette 0 Go To Control aint anise n ea a 2 Reset Warning cenir R 3 Reset Fault v 5 natn ele aie 4 Goto MONITOR cinch sents ar ni ected ade deca 4 Exit SAMView 0 ee eceeccceeceeeeeeeneeeeceeeeeeeeeesenaeees 5 SYSLOM SOCUIILY oa E 5 Configure Toolsi iaiia 3 Log OM rcns i a A 5 etc Therefore The listed selected functions would be open only to the following individuals Menu Selection Log Off O iii ted enter eee eid Everybody Go to Control 2 orior a N Everybody but John 0 Reset Warning 3 eserse eroi EE i Jim 3 Roger 4 Ralph 5 Reset Fault 4 c cccccesseeseceececeeseneeceeeteceeeeteaes Roger 4 amp Ralph 5 Go to Monitor 4 00 eeeeeeeeeeeeeeeeeeeeeeeeeeteeeeeeeeeeereae Roger 4 amp Ralph 5 System Security 5 2 eee eeeeeeeeeseeeeeestneeeeeene Ralph 5 only Configure Tool 3 osiensa aE TA Jim 3 Roger 4 Ralph 5 LOG ON 5 iia niee
5. Conventional Feature Build Tool 2092 SPC Point Title Peak Peak B amp D 003 Interval Peak SPC Point Units Tons Channel Select z Graph Rzis Status Ranae H Ris He ees Feature Control Status Control AA dg np beg Monitor 674 00 T T T T T at T 115 0 128 1 141 3 154 4 167 6 180 7 193 9 207 0 220 2 Interval Start 170 608 Interval End 199 608 Figure 72 Die closure on the in die sensor Signature Technologies Inc 93 General Installation amp Programming Guide Description Parameters Use Error Check Conventional Feature Build Press PRS_50 Tool 2092 SPC Point Title Peak Peak LC SPC Point Units Tons 03 Interval Peak 200 0 Channel Select T Graph Rzis Status 116 77 Riernate Ris sepees Em Feature Control Status 33 34 Control veal Lee Monitor 50 158 34 75 94 oF T T T p T T T 115 0 4128 1 4141 3 154 4 167 6 180 7 193 9 207 0 220 2 Interval Start 179 608 Interval End Figure 73 Die closure on the Left connecting rod Conventional Feature Build Press PRS_50 Tool 2092 B93 Interval Peak 200 0
6. The Auto Zero circuit will ALWAYS successfully bring the input level down to zero BUT if the input amplifier which is outside the Auto Zero loop is saturated there will be NO signature as illustrated below aa Lh Lal ikii He 0 Figure 254 Noisey Flat signature severe excessive offset Excessive imbalance in a strain gage is not a serious problem with the gage and is quite common when gages are bent around a circular load cell structure or applied to an uneven surface NOTE If the Line is ABSOLUTELY FLAT no matter how close in you zoom then excessive offset is probably 328 Signature Technologies Inc signatureACE NOT the problem UNLESS the Auto Zero has been turned OFF for the affected channel s A totally flat line with an operational auto zero is impossible unless there has been component failure somewhere internal to the SA2000 module or if the Data rate refresh parameters have been corrupted in the Tool Information screen Acceptable offset values In HIGH range the static offset voltage should be LESS THAN 0 004 volts 4 millivolts AND more than 0 003 volts 3 millivolts for FULL RANGE capability In LOW range the static offset voltage should be LESS THAN 1 75 volts AND more than 1 0 volts for FULL RANGE capability How to diagnose remedy the situation The best way to see whether the gage is throwing too much offset at the SA2000 is by applying a millivoltmeter Like a Fluke Dig
7. gt If there is noise roll the press again See if a NEW pattern of Noise is drawn gt If new noise appears then you ARE taking data However no Signature information can be seen Since you are looking at the entire press stroke you can t miss the force signature because of a narrow window The assumption must be that no force data is coming to the system from the sensors The SA2000 the TEC Board Cables or the strain sensors are suspect 6 With a Voltmeter measure the voltage between points EX and EX on a STRAIN GAGE channel on the TEC board There should be either 10 V D C or 5 V D C depending on the setting of the excitation jumpers on the SA2000 If you measure 24 volts you re looking at a Die Protection input point gt If there is no voltage and the 5V and 5V lights are on the TEC is defective replace it gt If there is voltage disconnect the Strain gage wires belonging to the channel you were looking at from the terminal strip points Read with an Ohmmeter across 7 The wires that were in Points Ex and Ex should measure around 350 Ohms of resistance Note 350 Ohms is the normal value for S T supplied Strain Gages Other values are possible under special order situations If there is any doubt call S T We will know 8 The wires that were in Points Sx and Sx should measure around 350 Ohms of resistance or the same as 20 above if non standard gages were used 9 Check be
8. oa a 2 N _ signatureACE TEESE D D orld lid Pre be c t r e c A 5 c a t c c t e c g a SIC S id gt 3 i 4 3 5 A nannaa aes SENSOR CABLE Figure 246 TEC With I O b Have ahelper cycle the press The Input 1 light should come ON when the clutch engages and go OFF when the clutch disengages If the 1 input light lights the press wiring and the I O module are O K There is probably a problem with the connecting cable or the SA2000 Module If the light doesn t light check with a voltmeter set to the appropriate range to see if there is 110 A C volts between Terminals 3 and Terminal 4 whenever the clutch engages If there is 110 V A C voltage then the wiring to the press control is O K and the input conditions are right There is an apparent problem with the OPTO 22 or the connecting cable a See if the 5V and 5V lights on the TEC are on If not check for shorts in the encoder if there is one and Sensor wiring b Ifthe lights are on Replace the Input module and try again If there s NO 110 V A C voltage straighten up the machine wiring and try again How to see if your SA2000 is taking data even if you don t see any signatures THE ASSUMPTION IS MADE that your press is ON LINE and that you have confirmed the operation of your POSITION REFERENCE SYSTEM IN Checks 2 3 and 4 REMEMBER The SAMView program will
9. oo a i i age J 19 020 6001 GERIR 1O aaee ye iN uaa Ney Ee eoa dois s CAE ias fe Patos eoureze seir LEDIO Channel 8 Channel 8 Gain Excitation Figure 204 A08 Jumpers 264 Signature Technologies Inc signatureACE Jumper IN 1000X Jumper OUT 2X Channel 1 Gain Channel 2 Gain 10 Volts eat Channel 3 Gain 5 Volts Channel 1 Excitation Channel 4 Gain Channel 2 Excitation Channel 3 Excitation Channel 4 Excitation verre HAIN Figure 205 A D Input board jumpers Channel 1 Gain Channel 1 Excitation Ground ag Channel 6 Excitation o STGMATURE TECHNOLOGIES INC COPYRIGHT 2008 TARDE IH USA A2000 S19 020 5006 Us PATENTS 4987520 491647 Figure 206 A6D Input board Jumpers Shunting the gage can reduce the signal from the High output gage Signature Technologies Inc 265 User Manual For example The strain gage pressure sensors from Sensotec have the following spec 3mv v This terse statement translates to At full rated input pressure the output of the strain gauge bridge will be 3 Millivolts for every volt of D C excitation applied With a 10 volt excitation then the output of the Sensotec unit would be 30 Millivolts The ST system at high range only can stand only 5 Millivolts Obviously we ll overload the input if we try to put this much into the SA2000 input Reducing the excitation to 5 volts still gives us 15 Millivolts at full
10. Press PRS_50 Tool 2092 SPC Point Title R1 Draw Ratio B amp D as Ratio SPC Point Units N A Channel Select 40 00 Blank and Draw 34 67 Graph Ris Status 23 33 Renate H Ris teres E 15 00 Feature Control Status 6 67 Control Monitor 1 67 10 00 Tressel T T T T T 115 0 128 14 141 3 154 4 167 6 180 7 193 9 207 0 220 2 Force Location 137 0AA Figure 80 Ratio 1 Conventional Feature Build Press PRS_50 Toot 2092 SPC Point Title R2 Draw Ratio B amp D 008 Ratio SPC Point Units N A Channel Select 40 00 m Blank and Draw 31 67 Graph Ris Status 23 33 Riternate Reis tegrees E 15 00 Feature Control Status 6 67 Control Monitor 10 00 T 7 T T T T T 115 0 128 14 141 3 154 4 167 6 180 7 193 9 207 0 220 2 Force Location 142 Figure 81 Ratio 2 The ratio feature is used to return the percent of deviation from the mean value Average value of the point when the limit set was collected To calculate the ratio feature the system calculates the signature value at a particular angle subtracts the process mean for this signature value and divides this quantity by the process mean The following equation describes this operation F ratio signature x Mean signature x Mean signature x
11. TOOL Database PRESS Database Signature Limit Setup SPC Limit Setup OVERVIEW Screen CAMview Screen Signature Screens SIGNATURE Screens Views 1 6 DIEview Screen SPC Screens Screen Screen Fo SPC Screens Views 1 6 Quick ALL Pick Screen Figure 29 System Navigation Block Diagram Signature Technologies Inc 49 General Installation amp Programming Guide The System Navigation Diagram Figure 29 is a graphic representation of the way things are hooked together in the system Notice for example that You can go directly FROM Signature Screens to Tool Database But you can t get back to Signature Screens without passing through Overview You also Can t get from Signature Screens to Press Database without going through Tool Database OR Overview Calibration IS ONLY accessible from the Peak Screen in the Signature Screen set In order to keep the diagram manageable some infrequently used utilities have been omitted but generally in these cases they will be accessible from the Configure pull down menu SAMview System Setup From Scratch If you elect to set up your system From Scratch starting with NO presses or tools defined the following procedure sections will take you through the process step by step It s important that each step be performed in the order given and that step
12. 31 Tornas Channel 6 Signal D P Input 3 oo eens D P Input 11 oo ees 13 I2 arsi Channel 6 Signal D P Input 4 oo eee D P Input 12 oes 32 14 EE Excitation aa 24 Volt COMMON ossee 24 Volt Common 2 eee 14 SETAE Shield k respetaron eai SMUG aaie en atea iein Shield a iieiaei 33 1 a eee Excitation 0 eeeeeeeees 24 V Power Supply 24 V Power Supply 2 15 Maigi Channel 7 Signal D P Input 5 oes D P Input 13 oes 34 16 iini Channel 7 Signal 0 D P Input 6 eens D P Input 14 oes 16 Irae Excitation ie 24 Volt COMMON ossee 24 Volt Common 2 eee 35 argia Excitation ia eeeeeeeeee 24 V Power Supply 24 V Power Supply 2 17 JO aii Channel 8 Signal D P Input 7 ccecce D P Input 15 cecen 36 18 ee Channel 8 Signal D P Input 8 oo eee D P Input 16 leee 18 IT atine Excitation i 24 Volt COMMON ossee 24 Volt Common 2 sece 37 Trnina Auto Zero indicator line Auto Zero Indicator Line Auto Zero Indicator Line 19 SA2000 37 pin FEMALE Connector I O and resolver Encoder connection This connector is where Everything else connects The I O listed here are the default assignments Inputs 4 7 are Firmware programmable and can be used for special purposes The Cam Outputs 0 7 are fixed by firmware and can not be user re a
13. T sm 2 OI EXt A EX st 2 y t5 gL O O Ex SHD O sH EXt amp EX st 3 fs 56 L lo EX s A OI sH EXt J 1 Q EX s AS ee EX M Rb 7 SHD J O SHD EXt J Q EX sf Al SH Los L B o EX SENSORS gt N gt Channel 5 Analog lt gt Sensor Inputs gt Channel 6 J A T 24 Volts Channel 1 Channel 2 Die Protection Common Sensor 24 Volts Inputs Channel 3 Channel 4 Common J Figure 157 Analog Sensor AND Die Protection Sensor Terminal layout A6D version Signature Technologies Inc 206 signatureACE Special Label Special Label a SHD lt o S i s 7 y 24 Volts 24 Q 24V 24 Volts Input 9 D 9 4 IB H D Input 1 Input 10 D 10 7 1B QI D 2 Input 2 Common COM 1O amp 1 H COM Common SHD D Q SHD 24 Volts 24 O Q H 24V 24 Volts Input 11 1 4 O H D 3 Input 43 Die Protection Input 12 D 12 QI D 4 Input 4 Die Protection Common COM HlO amp H COM Common Sensor Sensor Inputs SHD 7 1 Q SHD Inputs p 24 Volts 24v I T OTH 24 24 volts P Input 13 D 13 llO O D 5 Input 5
14. 5 Volts to Encoder Comman to Encoder DO NOT USE Figure 161 Encoder connections Single ended Nig Ma f a aE ER Fas O9 SHD HW Shield connect this end only LQ 52 Encoder A Track LG Th Encoder A Track O S a Encoder B Track LI OS s Encoder B Track U RI E Encoder Z Track O R2 Encoder Z Track i LO 5 ee Volts to Encoder O GND Common to Encoder O 5V DO NOT USE TT ee Figure 162 Encoder connections Complementary Appendix 2 37 Pin D Shell connectors on the SA2000 SA2000 P 37 Pin MALE D shell Sensor Input connections 210 Signature Technologies Inc signatureACE Wserisoariieile Shield s ctoascsiceedisavneneeeds Shield i nan iaa Shield iiinn dene 1 20 isiin Excitation oe eeeeeeeee Excitation oo eeeeeeeees 24 V Power Supply 1 20 2 vregsethersties Channel 1 Signal Channel 1 Signal D P Input 1 ccecce 2 Po EEEE Channel 1 Signal Channel 1 Signal D P Input 2 oo eee 21 Siesceiessiect Excitation o Excitation oo eee eeeeeeeee 24 Volt Common 1 3 DD science Excitation a se Excitation s ni i 24 V Power Supply 1 22 4 etnies Channel 2 Signal Channel 2 Signal 0 D P Input 3 oo eee 4 QS essences Cha
15. Black Red Rad Orange Pe rng Red Red o eow ee Yella Rad Rad Cn 14H Cd Ct Ca an LE aa Sere ip feet ed ba bh bo ke njiha Mo i t 19 19 Figure 165 I O Cable Assembly 214 Signature Technologies Inc signatureACE Cable STB Q02 6013 DWG Belden 9873 3 Pr Indiv Shid 20 Connector MS 3106A 16S 158 SSS Green A A ib lt a lt i Black Seas A White i i ane Black An Red f a re Black shield Figure 166 Resolver Cable Assembly Appendix 3 LP CX files For Press Curve and Slide Motion The Press Curve LP file Is used to tell the signatureACE system what the force capability of the machine is relative to the rotation of the drive mechanism The curve can be ANY shape and can consist of as many or as few points as you wish The system will interpolate between existing points and create the best curve fit rather than simply connecting points with straight line segments NOTE If signatures are to be displayed in inches mm furlongs of slide motion the LP file MUST be installed whether or not it s wanted since it calls in the CX file In these cases just program a straight line at the press capacity Format I is used as a comment delimiter and tells the system not to interpret anything that follows on the line as data Data is entered Angle Value where Value is
16. Configure from the Menu Bar A sub menu will appear 15 Select Exit Configuration from the sub menu options A message will appear Save current Changes 16 Select the YES button A message will appear Save Changes to Channel 17 Select the YES button The system will exit to the Press Line Overview screen that will be largely blank since it hasn t been configured yet 62 Signature Technologies Inc signatureACE Section 3 Programming the first tool The following are the step by step procedures for entering the tool into the system The steps must be followed exactly as presented Optional items will be indicated 1 Select Configure from the Menu Bar of the Press Line Overview screen A drop down sub menu will appear 2 Select Tool from the sub menu Figure 37 The SAMview system will display the Select a Press screen 3 From the list displayed on the Select a Press window Figure 37 Click on the press name you just created and then click on the Select button Overview Configure Batabase faalysis Sereen Options m e E C MOTHER Dirs Files Prises p1286 prs Figure 37 Select a Press Window 4 The display will then show the Select a Tool window Signature Technologies Inc 63 General Installation amp Programming Guide Overview Configure Batahase fnalysis Screen Opti
17. ON It is an almost lt 1 second update real time indication of the Cam signal Signature Technologies Inc 171 General Installation amp Programming Guide On Angle This window defines the point at which the Cam switches ON according to the rules in the Programmable Cam Protocols section below Off Angle This window defines the point at which the Cam switches OFF according to the rules in the Programmable Cam Protocols section below Dwell Time ms This window displays the Length of Time that the Cam will stay on after the machine passes the ON angle The Small Box to the left of the Dwell Time Window is a push button toggle that Activates the Dwell Time option when pushed If this box shows Color the Dwell Time option has been selected for the Cam The time is selected in Milliseconds The Minimum setting is 20 milliseconds 0 02 Seconds The Maximum is 9 999 Milliseconds 10 seconds NOTE If the Dwell time is set longer than the time required to perform one rotation of the machine the output will come on at the Start angle and STAY ON CONTINUOUSLY until the machine stops Editing procedure Any data entered into the fields will be saved in the database ONLY if the Save Changes button is pressed before exiting the Cam View Screen At the same time any problems with the programmed settings will be flagged and nothing will be saved until necessary errors have been repaired NOTE
18. Reference lead from a resolver OR the Z Bar track connection for an incremental encoder If the incremental encoder doesn t have the complementary signals this terminal may be left open Is used for the power supply to a 5V Encoder or the 5 volt supply for the HiRes resolver converter Is the Common reference for the 5v and 5v supplies and is connected to chassis ground at the Host Computer Is used ONLY for the HiRes Converter power supply DO NOT connect to this terminal for any other reason NOTE In rare cases the Sine windings of resolvers are marked S1 and S2 The Cosine S3 and S4 If the installation appears to be correct but you re getting Strange angle readings this is a possibility contact ST for advice resolver input Connections nig om Sy ND Jol E Cable SC 002 8013 XX as g Q SHD TEETE Shield connect this end only O 524 ac Ea E S 4A Green 2 SINE Winding C Black x white X COSINE Winding ee Black x ae Red X REFERENCE Winding i LI 5V OO GND DO NOT USE O 5v pmj pam N Signature Technologies Inc 209 User Manual Figure 160 resolver connections Encoder input Connections a2 Al 1 A i o Ty gt Shield connect this end only He Encoder A Track NO connection m Encoder B Track NO connection He Encoder Z Track NO connection
19. Remove SAM Ch Description Channel 61 00 Left Connection TN Editing Edit 01 01 i Connection 01 82 Enter gt gt 01 03 Description Capacity Units Calibration Offset Curve File c 2100 lt uncal gt p 0000 9 900 lt none gt 100 00 Figure 41 Available tooling channel selected NOTE if you re dealing with a 1000 ton machine with FOUR pull down rods each rod would have a capacity of 250 tons etc E Hit the lt Tab gt key again The cursor will jump to the Units box Figure 41 The default is lt uncal gt Click on the FIRST Character position and enter the units you want to work in Example Pounds THIS IS ONLY ALABEL no numerical significance is associated with the Units name NOTE if you don t know the calibration factors for the machine at this point go to item J below and continue from there F Hit the lt Tab gt key again The cursor will jump to the Calibration Box Figure 41 The default value is 1 0000 If you know the calibration factor for the sensor see the Section under Calibration in the signatureACE Maintenance Manual you may enter it here If the sensor will only be used as an uncalibrated unit then leave the cal factor at 1 0000 G Hit the lt Tab gt key again The Capacity Button will be selected Figure 41 A black rectangle will appear on the button If you left the
20. SPC Point Title Peak Peak RC SPC Point Units Tons Channel Select W Right Connection Graph Rus Status 116 75 Rernate H Ris tepees Em Feature Control Status 158 34 75 04 33 34 Control apy eames Noo ERES Monitor Z 50 T T T T nef T 115 0 128 1 141 3 154 4 167 6 180 7 193 9 207 0 220 2 Interval Start 170 668 Interval End Figure 74 Die closure on the Right connecting rod This feature returns the value of the maximum Peak between the start and the end of a defined window not the data collection window of the tool If there are multiple peaks in the window only the greatest peak will be returned Note that a peak is defined as a point at which the slope of the signature changes from positive on the left to negative on the right Selected channel data to calculate the peak from can be real or virtual Window start in degrees or position off BDC Window end in degrees or position off BDC In this example the peak of the blanking operation on the in die sensor located in the blank and draw station and the left connecting rod are being monitored In addition the system has been configured to monitor the peak force on the in die sensor and the two connecting rods Excessive variation in these features could indicate excessive variation in material thick
21. Where signature x signature value at a user defined location x Mean signature x process mean for the signature value at location x It is important to note that the ratio feature typically returns a small number lt 1 that falls in a small range centered about the origin 100 Signature Technologies Inc signatureACE If the historic mean value of the point is 2 and the point has increased in value to 4 the ratio will return 1 0 which is an increase of 100 Parameters Selected channel data to calculate the ratio feature from can be real or virtual Location in degrees or position off BDC to calculate the ratio Use The ratio feature is used as a means of scaling the deviation from the process mean for a particular location Typically the ratio feature is not used as a direct measure of the process but in a relation combining multiple ratios to quantify a process variable that cannot be directly measured Currently only the algorithms for thickness and hardness developed by FMC utilize the ratio feature For the thickness and hardness calculation two ratio features need to be defined for a drawing operation The first one located at the bottom of the forming slope when work begins and the second close to the end of the forming portion but before the die closes metal on metal and starts its compression peak Program the features with as much horizontal distance between them as possible Error Check Re
22. Xbar Yellow limit and Red limits are in multiples of Sigma B The Xbar Offset and Widening constants are defined in terms of the features units These are values that are added to the Sigma value to provide Hard adjustment of the limits C The Xbar Drift Constant is in percentage contribution of the latest sample to the limits The larger the percentage the more rapidly the system will Follow a drifting feature value 7 The R Range limit setting can be varied by selecting the up and down arrows in the Confidence Level box to select the interval When the interval changes the system displays the multiplication factor shown in the field to the right of the interval selection 7A If you would rather insert the multiplication factor itself A Select the up or down arrow in the Confidence Level box until the other entry appears B Select the field to the right of the Confidence Level box Signature Technologies Inc 117 General Installation amp Programming Guide C Use the key pad to enter the desired multiplication factor 8 Select Return to save any modifications made to the parameters or Select Cancel to exit the pop up without saving any changes Setting SPC feature limits The SPCview system allows the user to set limits for the Features TWO ways 1 By selecting the Set Limits pushbutton at the lower right corner of the Signature SPC and Overview
23. arrows and a numeric display IF you select the arrows the display will increment or decrement once for each click IF you select the numerical display you will get a list of numbers which you can select by clicking on the number you want B Set the start time and date Use one of the methods described below and select the Clear button if you make a mistake 1 To set the start date as the current date and time select the Now button THEN select the yy box or arrows and decrement to the year the period begins select the mm box and decrement to the start month select the dd box and decrement to the start day select the hh box and decrement to the start hour select the mm box and increment or decrement to the minute the period begins enter your settings by selecting the Set button 2 Set the ending time and date Use one of the methods described below and select the Clear button if you make a mistake 1 To set the end date as the current date and time select the Now button THEN select the yy box or arrows and decrement to the year the period ends select the mm box and decrement to the end month select the dd box and decrement to the end day select the hh box and decrement to the end hour select the mm box and increment or decrement to the minute the period ends enter your settings by selecting the
24. at the bottom of the screen will display the channels that are available for programming The first digit will be the address entered under ID followed by the channel number For Example if the SAM ID is 1 the channel list will start with 01 00 through 01 07 Channel 01 00 Channel 1 Channel 01 07 Channel 8 12 Putthe OFFSET NUMBER that you generated during the resolver test above in a previous section in the Position Offset window at the upper right corner of the screen Click on the first character position and enter the number Be sure to hit the lt Enter gt key when the number is entered 13 Define appropriate PRESS sensor channels While in the Press Database screen define the sensor channels that are connected to transducers if any that are permanently mounted on the press frame or connections NOTE At the beginning of this procedure in Section 1 Channel Assignments P 49 you were instructed to define the channels and their assignments This information is needed now for the Machine configuration A B Click on the channel you want to program from the SAM Ch Description list shown in Figure 35 The channel will Hi light The box directly under Editing Figure 35 will display the number of the channel being programmed As previously noted 01 00 Channel 1 etc Click on the first left character position in the box under Description Figur
25. DB Saving Display Job Lim Param Line Press Refresh Rate SAMnhet Security Tool Tool Setup Virtual Channel Delete Signatures Exit SAMview Log Off signatureACE Requires a password to command the system to enter the Control Mode by selecting the Control Button Requires a password to permit modifications to the Database saving protocols Requires a password to permit modifications to the Display Requires a password to create or change the Job setup i e to insert different tools into the presses The password will not be needed until an attempt is made to SAVE the created or edited job Requires a password to change the parameters used to calculate limits The password will not be needed until an attempt is made to SAVE the edited data for the selected channel s Requires a password to define or change a Press line setup The password will not be needed until an attempt is made to SAVE the created or edited Press line Requires a password to create or change a Press data file The password will not be needed until an attempt is made to SAVE the created or edited Press Requires a password to permit modifications to the Data Refresh Rate Setup screen that controls the transfer of specific data items from the SAM Module to the Host computer This is a System Setup adjustment that is preset at the factory and requires no adjustment unless operations
26. Figure 129 Function Selector Buttons 166 Signature Technologies Inc signatureACE If any changes are required to the setup the directions for that are found in the Programming the Signature Technologies CAMview system section later in this manual To get to the CAMview OPERATOR Screens just hit the Cam View selector box at the bottom center of the screen Figure 130 Your system may have all four of the illustrated functions or if the options weren t installed or operator enabled some boxes may be missing This Function Selection Box appears on all the user screens in the system and gives you immediate access to the operation you want Querviewt Configure Database Analysis Screen Options SPC View all TEST TEST Refresh Hit Subgroup Size 1 Current SPC Hit Graph View ait Control Status Running Reset Fault Bypass Set Limits Control Figure 130 Signature ALL view If you click on the box that says Cam View then the Cam View Pop Up will appear as illustrated in Figure 131 below Signature Technologies Inc 167 General Installation amp Programming Guide Overview Configure Database Analysis Screen Options Signature View all TEST DUMMY 5000 4000 Press Tool ID SAM SAM Desc Angle TEST DUMMY B2 test EES 30 ROER Description State Post Aisle Dwell time ms 01 Feed Initiate 200 joo fm 02
27. Figure 44 Select Press pop up 6 Choose the Select button after you have highlighted the desired press The system will return to the normal overview mode with the press shown in the View press box and the _ DEFAULT tool in the Tool Box Overview Configure Batabase Analysis Sereen Options Current Job i imi ii PEE TERA Set Line Limits Set Line in Bypass Set Line in Control Pad View Press Tool Stroke Count Run Baseline Control m e1 perau ee oor O O O Selected Press p4296 Setup Info Control Status Reset Fault Figure 45 Overview screen default tool 7 Select Configure from the menu bar A drop down sub menu will appear Select Exit Configure Answer YES to Save Current Changes 8 Select Configure from the menu bar A drop down sub menu will appear 70 Signature Technologies Inc signatureACE 9 Select Job from the sub menu The Overview screen will change to edit mode with Select buttons next to the Current Job and Tool boxes re Figure 46 Qverview Configure Database Analysis Sereen Optiens Press Line Overview Corrent Jeb e Set Line in Bypass Set Line in Control Elg View Press Tool Stroke Count Run Baseline Control mOra pe b O O O Selected Press P1286 Setup Info Control Status Reset Fault Figure 46 Tool select Buttons 10 Click on the Select button next to the tool
28. Remove SAM Ch Description im Channel SDA OR Tat I Editing lt lt Edit 05 01 Rear Right Upright 05 02 Enter 05 03 Description Capacity Units Calibration Offset Curve Rear Left Upright 2100 lt uncal gt a 9000 0 900 lt non Figure 30 Channel Labeling Signature Technologies Inc 53 General Installation amp Programming Guide 54 Press control Light Stack Sensor Programmable Outputs Outputs Inputs Cam Outputs OORO OO OOO SHIELD SHIELD O O O Ex e le le Ie Ie e te La Ihe Noes Veo SS 6 sesseeessee a ee a ee oj E I Bz Resolver FAULT UGHT STACK Encoder yf GOON rm lea Kn a ane Pe a SENSORS ome me Fem em fe fe fem em em fm ee em os ee fe D POOoHOOLOTOLOTOLOSY I Gil Gi Sil Gil Sl Sl i E Yo OM OM OW OHO O Wo CONTROL CABLE ESTU p Power Supply Machine i Status Indicators Control cro Auto Zero Programmable Inputs P Cycle indicator Cam Outputs Figure 31 TEC Version B Terminations Valid for A08 and A D input cards Signature Technologies Inc signatureACE Press Control Light Stack Sensor Programmable Outputs ee Outputs ne
29. Reset Fault Bypass bg Set Limits Control Figure 57 Peak View Pen selection 5 Hit the lt Enter gt key The channel name will appear in the box to the right of the Select box in the Pen Sensor Setup window 6 Select the Return button The Pen Sensor Setup window will disappear and the channel name will appear on the button you identified 7 Repeat steps 3 through 6 of this procedure to configure as many pens as you want displayed on the Peak View screen 8 Select Configure from the menu bar when you have finished setting up the Peak View screen A sub menu will appear 9 Select Exit Configuration from the sub menu The message Save current view for this press will appear in a pop up window 10 Hit the lt Enter gt key The message Save as default for this press will appear in a pop up window 11 Hit the lt Enter gt key to accept or the NO Button to decline At this point you have completed the configuration of the signature screens and the peak view screen 80 Signature Technologies Inc signatureACE Section 6 Machine Calibration In order for the signatureACE system to display ACTUAL force values the calibration procedure must be carried out There are several different methods by which this may be accomplished Please contact us for details on our calibration service For more information on calibration philosophies and proc
30. Section 10 Adding SA2000 modules to the same machine 131 System Setup Section 11 Considerations for multiple SA2000 units 133 System Setup Section 2 Programming the FIRST press 55 System Setup Section 7 Adding Tools amp Jobs 83 System Setup Section 8 Programming SPCView 88 System Setup Section 9 Adding Machines to the system 129 System Setup Section Channel Assignments 52 System Setup Select a Pen 78 System Setup Signature Collection Area 65 System Setup From Scratch 50 System Setup Programming the first tool 63 System Software 287 System software Loading 40 System Software Samview installation 39 System User Removing 168 T T D C 381 Table of Contents 3 Table of figures 12 TEC 284 TEC Encoder connections 210 TEC I O terminal organization 208 TEC Resolver connections 209 TEC Enclosure 140 TEC Terminal Enclosure 18 TEC terminations 54 TEC to SA2000 Cable assembly 212 Technical Info SA2000 TEC 258 TEC Technical Info 258 TEC Board Analog input 258 Terminal layout A D version 206 Terminal layout A08 version 205 Terminal layout D16 version 207 Terminal Name definitions 203 Terminal name designations Resolver Encoder 208 Terminal Organization TEC I O 208 Termination Board 142 Termination Enclosure 140 Terminator jumper for the SA2000 31 Terminator jumper for the SAMnet
31. Setup Wizard This will get the system into an operable condition rapidly so that the user can experience the advantages of Signature Analysis without having to learn all the ins and outs of the full programming procedure Table of Contents Install the signatureACE Equipment our SAMnet equipment nstall your host Computer system Software ccccccccscscscscscrssssssssssocceceseees power to the system elements and turn on the Host Computer Set the angular Offset SAMview System Set Section 7 Adding Tools amp Jobs to a system which is already set up Signature Technologies Inc 3 General Installation amp Programming Guide Zero Deviation Failure to fulfill the feature requirements ONE OTHER THING To Pro To remove a Feature from a summation list Prog ing SPCview limit parameters c cccccccscscssssssssssscscssssssscssscsssesesevsvsvsssssssssssssssssssssesevsssssssssssssssesevevssaseas View SPC limit To modify the Limit parameters for the Xbar limits Setting To set the SPC limits with the To set SPC limits To recalculate SPC limits using Moving Viewing Using Display a single feature Display multiple features Section 9 Adding Machines to the system Section 10 Adding Section 11 Foundation of signature anal What is a signature 4 Signature Technologies Inc signatureACE SAMvie
32. inside the window What happens Outside the window is ignored The window can be 360 degrees wide Always OFF MUST be OFF with ANY change in state during the window producing a fault sometimes called Yellow Protocol If the signal enters the window in the ON state A Fault will be issued Immediately A fault will be issued immediately If the input goes ON inside the window What happens Outside the window is ignored Signature Technologies Inc 193 General Installation amp Programming Guide The window can be 360 degrees wide On OFF Normally ON with at least one change to OFF expected during a programmable position window in the stroke Multiple ON OFF cycles during the window are O K Lack of a transition during the Window produces a fault at the Window END angle The state of the signal when leaving the window is unimportant If the signal enters the window in the OFF state A Fault will be issued Immediately The window MUST be at least 5 degrees wide What happens Outside the window is ignored The window MUST NOT BE more than 350 degrees wide On OFF OFF Normally ON with at least one change to OFF expected during a programmable position window in the stroke Multiple ON OFF cycles during the window are O K Lack of a transition during the Window produces a fault at the Window END angle The state of the signal
33. to maintain the sensor at zero potential statically The Piezo sensor is then connected to the Signal inputs as shown and the gain of the channel is adjusted by shunting the input with the capacitor C What we re looking for is to limit the signal level to either 2 5 volts in LO Range or 0 005 volts in HI range selected by the jumper at the channel input In general it s better to run HI range as this minimizes the sag in the signature at lower speeds C Capacitor values in the 1 10 Mfd range are normally required 270 Signature Technologies Inc signatureACE Coaxial Hookup Piezo Sensor Signal Signal Figure 214 Piezo Coaxial sensor interfacing The illustration above at Figure 213 features a Twinax or two conductor shielded configuration such as would be used with InSitu Strip type sensors If you purchase from other sources a coaxial hookup will probably be supplied It s connected as shown in Figure 214 If your machine always runs fast then you could use the LO range fine for 200 S P M and up use capacitors in the 0 02 0 047 range to start and trim to suit If you flattop use a bigger capacitor If sag is a problem try increasing the value of the 1 Meg resistor Some channels of the SA2000 will have less leakage current and can be used with values as high as 10 Megs other channels can t You ll have to find this out for yourself The 1 Meg value works
34. 164 Signature Technologies Inc signatureACE CAMview user guide EEVA ARN l N G The Signature Technologies CAMview product IS NOT a device designed for or rated for use in personnel safety related applications CAMview by design DOES NOT meet Signature Technologies interpretation of the CONTROL RELIABILITY requirements of OSHA 1910 217 b 13 for Punch Press control and SHALL NOT be used without proper backup and or point of operation guarding systems in any application where unexpected failure of the CAMview system could either produce sudden unexpected movement of unguarded machine elements or fail to stop machine motion in a controlled fashion Signature Technologies Inc WILL NOT support any use of the CAMview system for the control of hazardous machine functions Signature Technologies Inc WILL NOT be held responsible for Physical or Psychological injuries resulting from applications of the CAMview system to control equipment functions for which it was not intended Signature Technologies Inc WILL NOT be held responsible for loss of revenues or machine damage resulting from equipment failure in approved applications EXVV ARN N G Certain of the procedures in this manual could cause unexpected motions from portions of the machine system Before performing ANY programming procedures make sure ALL personnel are standing clear of the machine as well as any parts transfer or co
35. 174 WELD PAD mounting method for Strain Links Weld pad mounting is used wherever the machine surface is not particularly flat and can t be evened out practically There is no penalty either in loss of sensitivity or accuracy with this method that is generally the most common way to install on running presses Signature Technologies Inc 227 User Manual Step No Step No 2 Step No 3 Step No 4 Step No 5 Step No 6 Step No 7 Step No 8 DRILL AND TAP METHOD FOR MOUNTING SENSORS Paint must be sanded off and or grease removed from sensor mount area If the machine surface is flat total indicated reading of 002 and smooth 125 u in the load sensor can be bolted directly to the surface Drill and tap the center hole for mounting the fixture to the press member This hole should be 1 2 of an inch deep BE SURE THE SENSOR LOCATION FOLLOWS THE BEST LOCATION DESCRIBED ON THE PRINT Bolt the drill guide to the press member using the 1 4 28 by 1 1 4 inch M6 1 X 35 long socket head cap screw in the center of the guide Insert the number 3 drill Smm into the smaller hole and drill out all four holes to a depth of 3 4 of an inch Loosen the drill guide Rotate the drill guide 180 degrees such that the larger holes line up with the fresh drilled holes in the press member Insert a tap to be sure the holes line up Lock the drill guide by tightening the center socket head screw Insert the tap into the lar
36. 21 Position Module Jumpers Reference Jumpers The SA2000 IS shipped as a MASTER for use with a HiRes resolver with the Reference Jumpers INSTALLED If you are using an existing resolver with an ST HiRes converter the Reference jumpers MUST be REMOVED If you are going to SLAVE the SA2000 to another SA2000 unit the Reference Jumpers MUST be REMOVED The Channel Input Module Jumpers Channel Gain jumpers All channels ARE shipped in HIGH gain with the Jumpers INSTALLED If you are using any input devices with high level signals gt 0 5 volts the jumpers for the corresponding channel MUST be REMOVED for LOW gain on that channel Signature Technologies Inc 35 General Installation amp Programming Guide Jumper IN 1000X Jumper OUT 2X Channel 1 Gain Channel 2 Gain Channel 3 Gain Channel 4 Gain 10 Volts o 5 Volts E gt Channel 1 Excitation Channel 2 Excitation Channel 3 Excitation Channel 4 Excitation PE igs PreTr LLY Mirererir if 33933399 033333333184 FREER ERR ORER EE aarti J nS a a ii Ta Oe Figure 22 Channel jumpers A D unit Channel 1 Gain Channel 1 Excitation Ground Channel 6 Excitation Channel 6 Gain f SIGHITURE TECHNOLOGIES INC COPYRIGHT 2008 PFOE IN USA SA 2808 STB 020 5006 US is y S431647 NC PATENTS 4987529 ii Ld SE Figure 23 Channel jumpers A6D unit 36 Signature Technolog
37. 344 ONE SHOT log on 147 Operational Mode selection 152 Oscilloscope connection to Network 306 OSHA 1910 217 17 Output PartTrack option 373 Output RED Fault process limit 372 Output White Press Curve limit 372 Output YELLOW Warning process limit 372 Output shunting 328 Outputs Cams 1 thru 8 373 Outputs Light Stack 5 thru 8 373 Overview screen setup 69 Packet Waveform 308 PartTrack option Output 373 Password Changing 371 Password Level Assignment Changing See Passwords If you forget or ERASE 371 Peak location 101 Peak Screen Setup 79 Peak View Load Monitor screen 75 Peak View configuration 75 Pen Color Selection 78 Pen selection 78 Personnel 203 Piezo devices Interfacing 269 Playback Selecting Signatures 161 Playback Utility 161 Position Input Daughter Boards 284 Position Reference Board Jumpers 292 Position reference information 309 Position reference jumper 134 Position Boards 284 Press Capacity Curve files 215 Press Capacity Curve files installing 61 Press Curve LP file 215 Press Curve definition Files 55 Signature Technologies Inc 379 General Installation amp Programming Guide PRESS CURVE limit Output 372 Printer 145 Printing 207 Printing a Selected Group of Signatures 208 Printing One Signature 207 Printing Press and Tool Information 207 Problems Features 109 Procedure Correcting the in
38. 42 43 Samtest utility 218 SAMTEST utility 41 SAMtest Utility Software 298 Samview installation System Software 39 SamView Software 19 144 SAMview Sub directory structure 341 380 Signature Technologies Inc signatureACE SAMview System Setup From Scratch 50 SAMview directory structure 40 SAMview system maintenance 205 Save current view 79 Save current view as default 79 Saving Automatic 170 Saving Manual 170 Saving Scheduled 171 SB 027 8006 Cable 251 Scope connection to Network 306 Screen Navigation 126 Security The controlled items list 368 Security regions 164 Security set up 164 SeeOFF Self amplified Analog sensors Interfacing 273 Sensor Calibration strain gage type 277 Sensor Connections 260 Sensor input Cable 213 Sensor Interfacing Guide 257 Sensor Mounting In Situ on frame 219 Sensors 139 Set SAMview limits 156 Set the limits for an individual press 159 Setting feature limits 124 Setting the limits for the entire press line 160 Setup Wizard 46 Setup Wizard preconditions 46 Shunt resistor value calculation 266 329 Signal Conditioning Daughter boards 283 Signal Inversion 325 Signature Definition 136 Signature aberrations 324 335 Signature Analysis Definition 137 Signature Collection Area 65 Signature is unstable vertically 337 Signature View screens All screen 74 Signature View screens configu
39. 8 Go back to Section 3 of this manual and proceed starting at Step 7 to define your new tool and save it Programming JOBS Optional A JOB is our name for the ability to load multiple presses with multiple dies simultaneously instead of having to load the TOOL files for each press separately NOTE There is sometimes some confusion due to similar terminology To Load an individual Tool into an individual Press OR To load a JOB into ALL the presses In either case you must first select Configure from the menu bar and Job from the pick list 82 Signature Technologies Inc signatureACE This will cause Select boxes to appear next to EACH of the tool names on the press list AND next to the Current Job box at the upper left IF you click on the Select box next to the Tool name you ll get a Select a Tool list of available Tools and you can put only ONE tool into the selected press only IF you click on the Select box next to the Current Job window you ll get a Select a Job list of JOB files Selecting one will download ALL the presses shown in the Overview screen simultaneously NOTE If JOBS will be used they must be individually defined according to the procedure below Creating a JOB file 1 2 From the Press Line Overview screen select Configure from the menu bar A drop down sub menu will appe
40. 885 606 pA 888 Aisin gt Anny l Anny Anny Message H W Ver 0x1906 S N 0X46AA4D 017 818 019 826 821 822 823 824 Nise gt Znz gt nese gt nsn2 gt Figure 128 The SAMnet Summary Screen Accessing the SAMnet Summary screen The following procedure will move you to the SAMnet Summary screen Follow each step in the order presented 1 Select Overview from the menu bar if you are not already in the Press Line Overview screen 2 Select Configure from the menu bar A sub menu will appear 3 Select SAMnet from the sub menu The summary screen will appear 4 A list of SAM nodes will be displayed on the SAMnet Summary screen along with an LED anda description of the press attached to that SAM Look at the LED above that SAM if green it is active Signature Technologies Inc 163 General Installation amp Programming Guide 5 To determine whether a SAM has been defined in the SAMview database look for the name of that SAM in the selection box If there is a name the SAM has been defined 6 To display the current firmware revision of an individual SAM choose the selection box that contains a Press ID by the SAM unit that interests you Select the This Node button to display the current software revision number 7 When you re finished click on Configure from the menu bar A sub menu will appear 8 Click on Exit Configuration from the sub menu
41. C SAMDATA directory is where the data needed AND generated by SAMVIEW automatically when Samview is run When you create a Press its file goes in C SAMDATA and the system creates a subdirectory with the press name In the example above the press name would be PRESS1 When you create a tool for PRESS1 The tool file is located in the C SAMDATA PRESS1 subdirecotory and the system makes another subdirectory with the tool name TOOL1 would be the first tool name in the example above All data collected by the system when TOOL1 is running will be put in the C ASAMDATA PRESS1 TOOL1 subdirectory For a more exhaustive explanation of the SAMview directory structure see the Appendix 11 Maintenance Manual Check out the operation of the system elements Make sure your resolver is hooked up properly Note Make sure the machine can be moved in INCH mode At the C gt prompt type SAMTEST lt Enter gt After SAMTEST loads it will display at the TOP of the screen a message a If you get the message SAMtest x x No Arcnet card found at I O address 2E0 hex Then the SAMnet Communications card is defective not plugged in properly or not being recognized by the Host Computer since the host PC node should come back as 16 Give ST a call or refer to the Troubleshooting guide for appropriate procedures b If you get the message SAMtest x x Arcnet base 2E0 Host PC node is 10 hex 1
42. Excessive positive readings will limit the amount of deflection you can see without running out 354 Signature Technologies Inc signatureACE of span Step 9 Step 10 Step 13 Step 14 Step 15 Step 16 Install press stands if necessary and apply the hydraulic jacks to the ram You should use one jack for small machines unless they are very wide in which case two jacks would be better For large machines and particularly those with four point drive Four jacks are needed The jacks should be positioned directly under the pressure point s if possible If positioning under the pressure point is NOT possible due to cutouts or T slot locations the jacks should be positioned as close to the pressure points as possible and kept Symmetrical If you have to be 4 outside a pressure point in one corner the other three cells should also be 4 outside If the Jacks are not symmetrically located the calibration will be inaccurate The Jacks must all share the same hydraulic power source Independent jacks won t work Use Spreader plates under the jacks and between the Jack Ram and the Slide face to avoid marking the press surfaces The spreader plates should be of sufficient size and thickness to limit the surface loading to 10 000 P S I Watch out for T slots They crush easily Use a piece of heavy cardboard not corrugated between the jack and the surface it is sitting on Use another piece between the Jack Ram and the Sli
43. Industrial I O structure This structure provides an isolated interface between the logic level I O on the SA2000 module and the heavy duty 110 V A C or 24 V D C Real World devices The I O system uses the Generation 4 series of modules from OPTO 22 gt There are 4 Inputs and 12 outputs available all pre assigned to control functions gt There are an additional 4 Inputs and 4 outputs which are available for special functions like Light Stack operation gt The individual I O points can be loaded with the appropriate voltage modules for any external requirements The HiRes Resolver Converter The HiRes Resolver Converter is one of the ways that we allow the SA2000 system to use an existing resolver as its position input alternatively see Resolver Converter under the RSCB Section The HiRes converter gt Couples with a supplied cable to an existing resolver system without loading the existing system or causing problems gt It uses the Reference Sine and Cosine signals from the existing system to feed the Resolver to digital 284 Signature Technologies Inc signatureACE converter in the SA2000 gt It feeds the resolver signals to a SA2000 which must be configured as a Slave unit gt Itis connected with a supplied cable to the 9 Pin Communications connector on the SA2000 module gt It has Three adjustments which are performed using indicator lights built into the co
44. On the bottom line the F indicates that the resolver is moving Forward 4 The 234 6 indicates that the angle of the resolver is 234 6 degrees 5 The BLUE Fine pointer will move along under the angle markers moving ONE COUNT per resolver increment in this case 1 out of 4096 as the machine is turned The lower WHITE Coarse pointer is an analog indicator of the exact angle in degrees as the machine is turned It s shown just right of 225 to indicate 234 6 6 The Position Offset number indicates the correction factor needed to correct the resolver position with the actual machine position It will be 0 00 until the needed position offset is developed as described later in this section c Go to the next step below 5 Note the angular position of the machine as shown at the lower left of the display 6 Bump the machine several degrees forward See if the angle reading increases or decreases 9 If the angle display doesn t change there is a problem with the wiring to the resolver the resolver Converter or with the resolver mechanical drive Consult the Appendix 10 Troubleshooting Guide for diagnostic procedures 7 If it decreases and the letter before the angle changes to R you re going backwards reverse the electrical Direction of the resolver Signature Technologies Inc 43 General Installation amp Programming Guide If you have an ST resolver ins
45. Output CaM FS onii diia 11 PC GOMMONS cc E EE AEE AE A ieee meee 29 Fused 5 Volgii mi e ea eerie 10 DC Common 06 Encoder Common 0s0ce 24 Shield nii Shield esin eee tits 5 resolver S2 Sine Encoder A Track 23 resolver S4 Sine Encoder Bar A Track 006 4 resolver S1 Cosine Encoder B Track 22 resolver S3 Cosine Encoder Bar B Track 0000 3 resolver R1 Ref Encoder Z Track 21 resolver R2 Ref Encoder Bar Z Track seese 2 Fused 5 Volts Encoder Powe eseeeeeeeeeees 20 Fused 5 Volts 0 DO NOT USE ooo eee 1 212 Signature Technologies Inc signatureACE Computer End Coble assembly STC 039 8010 18 Inches 3 Inches Pin 1 Pin 1 324 Inches Cable Assembly Va ii STC 039 8014 L Pin 1 Lock Nut 18 Inches 30 feet Pin 1 Figure 163 TEC to SA2000 Cable assembly SA2000 End TEC End NOTE Drain wire from ONLY ONE of the cables in terminated at both ends The Other drain is cut off at TEC end Black Auto Zero Figure 164 Sensor input Cable Signature Technologies Inc 213 User Manual Crain Draln SALOU Ei aaa Se et TEC End Red Red a Black Black CYalow O Ji OCU Tow Black Black Black Black
46. SPM 69 Angle 153 eae eae ig eee Af a 2 3 a 5 rome see go 6 7 8 Enter Level needed fa One Shot a 2 lt a E F Ford oa Log Off Cancel Refresh Zoom Graph View E Control Status Running a 2 3 Peak Reset Fault Bypass a 5 6 All Set Limits Control Figure 114 Log On Window The Log On window is available from anywhere within the program However if the system has just been started it will be necessary to select the Proceed button from the About screen before you can continue The steps that follow allow the user to access the system for a single operation or for multiple operations Single operation access ONE SHOT Preferred Overview Configure Database Analysis Screen DRUAN Print LI 3271 Log On Show Event Log About SAMView Reset Stroke Count Quit SAMNView Figure 115 Menu Bar 1 Select Options from the menu bar and a sub menu will drop down 2 Select Log On from the sub menu and the log on window will appear 3 Enter your password in the Log On window then select the Enter button or hit the lt Enter gt key 4 Select the One Shot button that appears within the log on window 140 Signature Technologies Inc signatureACE Access for multiple operations Warning This type of access leaves the system OPEN until YOU log off when you re done Any operation performed will be recorded against YOUR Identification LOG O
47. Stock Lubricator 200 zoo o Biou O0 190 250 o4 Pilot sensor Chk psoe fio Refresh Graph View Cancer Return afefe S Set umts Figure 131 CAMview Operator screen display RRunning Bypass Control This is the user screen for CAMview It is an Information Screen ONLY and is your indicator of what s going on Nothing can be changed from this screen The information on the CAMview Pop up is as follows Press This field indicates which Press is being displayed Tool ID This field indicates Which Tool is installed in the press SAM This field shows which of the installed SA2000 modules is being displayed Sam Description This field shows the Description that has been given to the SA2000 being displayed Angle The Angular Position of the machine is displayed here when the press is stopped This field will display an angle that updates periodically when the machine is running BUT it will only be accurate about a second after the machine has stopped 168 Signature Technologies Inc signatureACE Channel Active column This column lets you know Physically where the Cam connection to the system is Feed Initiate is wired to CAMview channel 1 that according to the connection table below is Terminal points 17 and 18 on the I O strip Cam View Press Tool ID SAM SAM Desc Angle TEST DUMMY een fo Off PE ie Ly Description State esis Angle Dwell time
48. The terms ON and OFF There is always confusion about On and Off when discussing specific voltage levels and whether the logic is positive or negative In the ST system the user can software select the Input state either High or Low which will be considered ON The user can also invert the signal at will Basically if the STATE indicator on the Die View Screen is LIT THE INPUT IS ON Definition The term Window Window is used to denote a portion of the machine cycle expressed in degrees during which the Die Protection function is active Windows are given START and END angles in degrees The angle can cross the 360 0 degree boundary For example A Window programmed from 10 degrees to 50 degrees is 40 degrees wide A Window programmed from 50 degrees to 10 degrees is 320 degrees wide A Window programmed from 340 degrees to 20 degrees is 40 degrees wide A Window programmed from 20 degrees to 340 degrees is 320 degrees wide ANY Window MUST be at least 5 Degrees wide For a 360 always active Window you MUST program it Start 0 End 360 Standard Protocols Always On MUST be ON with ANY change in state during the window producing a fault Sometimes called Red Protocol If the signal enters the window in the OFF state A Fault will be issued Immediately A fault will be issued immediately If the input goes OFF
49. amp Programming Guide files MUST exist If one doesn t everything downstream of it Tools and Signatures will disappear to the SAMView program The SUMMARY DAT file that specifies the configuration of the Press Line The JOB files with the JB suffix One of these files will exist for each JOB collection of presses and tools that has been defined The Press Curve Data files With the LP suffix These files give the crank angle vs available tonnage curves of the machines The Alternate X files with the CX suffix These files give the ram position vs crank angle data for the machines They are used to create horizontal axes in Inches instead of degrees The Algorithm files with the AL suffix These files contain the algorithms that are used in the SPCView feature to produce statistical data The SETUP DAT file that contains the Field names chosen for the Tool Summary Pop Up The LOG TXT file that contains the chronological log of the system operation The SECURITY LOG file that contains the priority assignments for all the system features The PASSWORD LOG files that contains the Names Passwords and Priority Levels of all password holders The CURRENT STS file that contains the location in the program that you were operating in when you exited the program This file puts you back where you were on re entry The next level of Sub directories is called The PRESS directory this is where
50. but I ll give you the constraints that you must live within 9 In keeping with the ARCNET protocol the system when powered will pass a Token around to all the units on the network This will happen whether the machines are running or not just as long as the SAM modules are powered The Token is passed around in a burst of R F called a Packet The amplitude of the Packet is important With the Oscilloscope connected as per Figure 242 adjust the sweep and trigger as noted below Packet Packet Facket Packet from from Host from from 2 54M 1 5AM 2 54M Horizontal Sweep rate 10 Microsecond cm Set scope to trigger an Highest Packet Figure 243 Waveforms as Token Packets are passed around 10 The scope display will look similar to the waveforms above in Figure 243 although the number of different Packets will equal the number of units that are communicating The Pattern will repeat as shown above The order of the packets is unimportant and may vary on successive startups but when the network is running the order will be repetitive Obviously if you have 7 units and only see 5 packets before the pattern repeats 2 of the units aren t communicating 11 What s important here is the amplitude of the packets The spec is 6 volts P P but we have found that 5 5V P P is about the absolute minimum In the example above remember that the network length is 1500 Your network is probably much shorter i
51. ms I 04 Feed Initiate 200 100 m J 02 Stock Lubricator 200 300 I 03 Blow oFF 190 250 I o4 Pilot sensor Chk 350 10 Eancel Return Figure 132 CAMview Operator Pop Up Description This field indicates the specific use of the Cam State Indicator This indicator shows the state of the Cam Lit ON Not lit OFF On Angle amp Off Angle These fields show the angular positions during which the Cam in question will be ON See the section below on Programmable Cam Protocols for more information If the Cam has been selected to be a Time OFF cam there will be NO OFF Angle displayed as in Cam 1 Above Dwell Time ms If Time OFF is the mode of operation for the cam in question there will be no OFF Angle displayed Instead there will be a value shown in the Dwell Time window and the small box to the right will be colored in Cancel This Pushbutton Exits the CAMview user screen Return This Pushbutton Exits the CAMview user screen Signature Technologies Inc 169 General Installation amp Programming Guide Programmable Cam Specifications The CAMview system operates at a resolution of 256 increments per turn or 1 406 Degrees per increment Any entries made to the system in Degrees will be divided by 1 406 and truncated to the 1 part in 256 increment Example Program 74 Degrees Divide 74 by 1 406 52 63 increments Truncate to 52 incremen
52. screens This method not only sets the SPC limits but also calculates the Signature limits The system will automatically sets limits for new tools if A No limits have ever been set for them B No MASTER limits have been stored when the tool is brought in C This is the first time the feature definitions are downloaded 2 Alternatively the system allows the user to modify the current limits through changing the parameters in the Limit Setup pop up for a Feature and THEN have the system recalculate the limits based on the Feature values for the last process sample set THAT HAD BEEN COLLECTED EARLIER by hitting the Set Limits button at the lower right corner of the Signature SPC Peak and Overview screens The SPCview system also allows the user to manually adjust the limits To set the SPC limits with the Set Limits button 1 From any of the Signature screens SPC graph screens or the Peak screen click on Set Limits at the lower right hand corner of the screen 2 From the Press Line Overview screen A Select a press by selecting a Press ID button located on the left side of the screen B Select Set Limits at the lower right hand corner of the screen In either case the Set Limits Green indicator will go out while the data collection is occurring and come back on when the process sample set has been collected 118 Signature Technologies Inc signatureACE To set SPC limits for the entir
53. 18 Work Blank B amp D 62 11 Work Draw B amp D Feature Control Status Control Monitor Figure 85 Spread calculation at the die closure Description This MACRO calculates the range of difference between two or more features The user chooses at least two already defined features as inputs to this feature After all of the features in the input set are calculated this MACRO determines the largest and smallest numerical values The return value for the spread calculation is then the difference between these two values Parameters At least two features calculated by the current SAM Use In this example the spread calculation is being used to monitor the forces that can lead to non parallel motion of the slide during the blanking operation drawing operation and die closure Error Check Refer to the If a Programmed Feature Doesn t Work section below at page 101 for a description of the overflow error that could occur using this feature 104 Signature Technologies Inc signatureACE If a Programmed Feature Doesn t Work Computational Overflow The most common type of error that is encountered using the Feature Extraction software is computational overflow when setting limits or calculating a subgroup mean and standard deviation To avoid an overflow situation make sure that the following relation is satisfied for each defined feature Maximum Feature X Minimum Feature X lt S
54. 31 TERMINATORS network cabling 30 TEST Switch 38 Tests for data acquisition 322 The Clamped Signature 334 The Basic User s Role 146 The Input Output system assignements 372 The Security System 146 Threshold Detector 106 Timing Belt Design considerations 239 Tool loading 86 Tooling sensors externally calibratable 358 Tooling sensors non calibratable 358 Tools Changing 148 Tools Loading in ONE press 154 Tools loading into Multiple presses Job 155 Transferring selected signatures 205 Typical SIgnature Problems 324 U Unexpected machine motions 17 Universal Proximity Switches Interfacing 272 UpGrade utility 219 User s Role 146 Using the signatureACE System 146 Using the Zoom utility 77 Utilities GetIni 219 Utilities GetLOD 219 Utilities GetNet 219 Utilities InOut 219 Utilities Playback 161 Utilities UpGrade 219 Utilities Resolver 219 Utility Master menu Samtest 218 y Viewing SPC charts Quick Pick 127 WwW Warning YELLOW Limits 138 WELD PAD mounting method for Strain Links 227 Where to get the data for LP and CX files 217 Whetstone Bridge connection 262 White Press Curve limit Output 372 Wingwalking 50 Wiring SA2000 347 Wiring Connections 203 Wiring Diagrams 346 Wiring SAMS500 348 Wiring the SignatureACE 27 X Xbar Limit parameters Programming 122 382 Signature Technologies Inc s
55. 4 20 ma current loop 274 Interfacing D C Proximity Switches 272 Interfacing Data Instruments Strain Links 269 Interfacing Digital signals 271 Interfacing Piezo devices 269 Interfacing Self amplified Analog sensors 273 Interfacing to existing Load Monitors 276 Interfacing to Load Monitors 276 Interval average 99 Interval Maximum 92 Interval Minimum 94 Interval Peak 95 Interval valley 98 Interval Work 102 Introduction 281 Introduction 3 INTRODUCTION 257 Inverted Signature 325 Job loading 86 Job loading into Multiple presses 155 Jumper Position Reference Master Slave 134 Jumper Locations SA2000 264 327 Jumpers Communications cards 296 Jumpers RSC1 RSC2 292 Jumpers A D Input board 265 328 Jumpers Analog channel Gain 36 Jumpers Gage excitation level 36 378 Signature Technologies Inc signatureACE Jumpers REF 293 Jumpers Resolver excitation 35 Jumpers Resolver position module 35 L liability warning CAMview product 173 Light Stack Outputs 5 thru 8 373 Limit parameters Adjusting 156 Limit parameters Xbar Programming 122 Limit Types list 137 Limits Setting for the entire press line 160 Limits Definition 136 Limits Feature Setting 124 Limits Setting 156 Limits setting for an individual press 159 List of the available SPC features 91 Load an existing tool in ONE press 154 Load an existing tool
56. 486DX or better processor and 8 Meg of memory Using SAMview software the host computer Signature Technologies Inc 137 General Installation amp Programming Guide 1 Downloads parameters trigger location signature size resolution etc to the SA2000 module s for data collection 2 Provides programming screens to allow parameters to be entered 3 Provides the database function so that multiple Tools can be entered stored and recalled 4 Links signature data from the SA2000 to stored process limit tables 5 Allows the user to recall sort and review all stored data for reference or comparison 6 Provides the ability to upload manually edit and download process limit arrays to and from the SA2000 Printer A Printer can be plugged into the Parallel port on the computer and configured to permit signatures to be printed out 138 Signature Technologies Inc signatureACE Using the signatureACE System The Basic User s Role The user is responsible for loading different tools when necessary and operating the system Users must quickly familiarize themselves with Seven basic processes involved in using SAMview system These processes are 1 Starting the SAMview system 2 Fulfilling the requirements of the Security System Log On Log Off 3 Changing Tools in the SAMview system Configure Job 4 Reading and adjusting the signature graph Zoom 5 Operat
57. 6 7 and 8 No Label Signature Technologies Inc 365 User Manual These are Optional inputs that have NO FUNCTION in the standard system They are optionally used for several different operations Contact ST 972 488 9777 for details Output position 1 RED This Is a Standard Output It is a normally open device HELD CLOSED whenever the SA2000 system is in MONITOR Mode or whenever the SA2000 is in CONTROL Mode and the signatures are running within and not breaking the RED Fault process limits In CONTROL Mode this output will turn OFF whenever the signature runs outside the RED Fault process limits and remain OFF until the system is RESET This output is normally wired in series with the IMMEDIATE STOP line unless doing so would run the risk of sticking the press on BDC Output position 2 YEL This Is a Standard Output It is a normally open device HELD CLOSED whenever the SA2000 system is in MONITOR Mode or whenever the SA2000 is in CONTROL Mode and the signatures are running within the YELLOW Warning process limits In CONTROL Mode this output will turn OFF whenever the signature runs outside the YELLOW Warning process limits and remain OFF until the system is RESET This output is normally wired in series with the TOP STOP line Output position 3 WHT This Is a Standard Output It is a normally open device HELD CLOSED SA2000 is in either MONITOR or CONTROL Mode and the signatu
58. 8 146 0 135 3 154 5 Interval Start 165 722 Interval End 198 719 _ Figure 91 Completed Peak feature 16 Configure the Units of the Feature Click SPC Point Units at the top of the utility and use the keyboard to enter the Units for the feature 17 Configure the Current Channel by Clicking Channel Select from within the Conventional Feature Build The Pen Sensor Setup pop up will appear Signature Technologies Inc 109 General Installation amp Programming Guide Querview Configure Batahase Analysis Sereen Options Conventional Feature Build l Q CRE TIE NITES 5 Tool spc Point Title O 093 Interval Peak spc Point Units B Channel Select Frame sensor Assigned Channels 02 00 Frame sensor 62 61 InSitu Strip A2 82 Z Left Connection 82 83 Right Connection Pn aww r arv Interval Start 166 377 Interval End cos _ Figure 92 Pen Sensor Pop up Window 18 Use the pointing device to select a sensor from the Assigned Channels list shown in the Pen Sensor Setup window MAKE SURE the selected channel shows up in the window at the right of the screen 19 Click Return to save the selected channel and return to the build utility Otherwise Click Cancel to return to the build utility without modifying the current channel assignment Note For Feature algorithms that are position based e g peak location the system can return the Feature
59. BDC Window end in degrees or position off BDC Positional transfer function degrees to slide position off BDC In this example the work feature is used to determine the condition of the blanking ring and the drawing tool in the first station Typically when a punch or blanking ring begins to wear the peak 98 Signature Technologies Inc signatureACE force does not change by a significant amount but rather the amount of work required to shear the material increases In this example as the blanking ring wears the spike would begin to elongate with the peak remaining the same thus increasing the area beneath the curve This would also be the case with the draw tool As the tool begins to wear the shape of the curve would change thus changing the area beneath the curve Error Check Refer to the If a Programmed Feature Doesn t Work section below at page 101 for a description of the overflow error that could occur using this feature In addition to the overflow error the second most likely error to occur using the work feature is data under flow Since the work calculation is based on the positional transfer function it is important to make sure that there is a significant change in the position of the slide for all or part of the defined interval Signature Technologies Inc 99 General Installation amp Programming Guide FeatureView 008 Ratio Description Conventional Feature Build
60. Copy the Signature and Limit files by name onto the floppy Restoring Signatures to the Hard Drive It may be desired to restore selected signatures back onto the hard disk from floppy disks The procedure below can be used to Append signatures from floppy discs into an existing database To transfer signature data from the floppy disk drive to the hard disk drive i e restore signatures to the hard drive execute the following steps Step 1 Insert a floppy disk containing historical signatures in the floppy disk drive Step 2 Exit the SAMView program Step 3 Change directory to C SAMDATA lt Press Name gt lt Tool Name gt Step 4 Using the DOS command Copy the chosen Signature and Limit files by name onto the Hard drive COPY A lt directory name gt lt File Name gt OR COPY A lt directory name gt Restoring Masters to the Hard Drive There can only be one Last Master the SM and LM files with the latest time stamp for any tool and this will be the file that is brought in as a master signature limits If you wish to use a recorded file from a floppy disk for a master then you must eliminate any master signatures from the tool directory that have later time stamps Step 1 Insert a floppy disk containing the master signature limit files you want in the floppy disk drive Step 2 Exit the SAMView program Step 3 Change directory to C SAMDATA lt Press Name gt lt Tool Name gt 346 Signature T
61. Die Protection Fault that has occurred during the last machine cycle If there is no color there is NO Die Protection Fault Clicking on the rectangular button will reset the Die Protection Fault and allow machine operation This control function can be assigned Password protection see User manual sections on System Security and User Passwords Sensor Type description This is a text field that explains the sensor protocols as they are selected Cancel This Pushbutton allows an Exit from the DIEview user screen without Saving any changes that were made turning channels on or off etc Return This push button Exits the DIEview screen and saves anything that was changed Types of Die Protection Functions Loop Loss Loop Runaway Typical Die Protection devices and applications are shown in Figure 140 below On the far right in the illustration there are a pair of sensors Loop Loss Detector and Runaway Loop Detector that are Normally OFF and will turn ON whenever the Stock Strip gets close to their sensing areas These are wired into the die protection system which senses any problems and stops the operation of the system if the straightener system quits and the stock supply to the press is lost or if the straightener runs away and dumps strip stock all over the floor The Always OFF or OFF ON OFF protocols are the choices depending on whether dynamic checking recommended is used or not End of Stoc
62. Electronic Cam product It gives the user the ability to provide actuating signals to his auxiliary control functions without having to do mechanical adjustments to a rotary cam limit switch It also enables the user to store his cam programs against a Tool or Part number and instantly call them back into use without having to adjust anything the next time the job is run The CAMview system IS NOT an OSHA rated control system suitable for actual control of the press motion It is intended to operate machine auxiliary equipment and Non Personnel safety related aspects of the press control For example CAMview can provide a signal to operate the feed system of the press It SHOULD NOT be used to provide the TOP STOP since it doesn t meet our interpretation of the OSHA 1910 217 requirements for Control Reliability which include redundancy and Sealed Programming which can t be changed by the user Quick Start Section This section is for MACHINE OPERATORS and makes the assumption that the system is completely set up and operational that the equipment controlled by the CAMview system is installed wired and programmed and that actually operating the system is your prime concern When you loaded your Tool using the Configure Job utility from the Overview screen The CAMview settings for the job were downloaded into the system along with all the other job setup parameters sc Wiews Dieview Res
63. Enter the press name it must be a DOS compatible name not more that 8 characters in length The _ character will be inserted in the place of any unacceptable characters When you are done press lt Enter gt twice OR click on OK A window that tells you to Enter a description for the press will appear Enter the press description When you are done press lt Enter gt twice If you don t want to enter a description then just press lt Enter gt twice NOTE If a message comes up at this time saying No free SAMs on the network Working off line 10 11 STOP Immediately Quit SAMview F10 key Answering NO to any saving questions and cycle power to the computer Attempting to Use the wizard without doing so will result in a setup which WILL NOT WORK The Power cycle will free your SAM s to respond properly to the wizard Go Back to the Would you like help adding a press question and start over at step 1 A window that asks the Number of Press Mounted Sensors will appear Press mounted sensors are those that are PERMANENTLY mounted to the press frame OR drive mechanism like Connecting rods etc Enter the number of sensors up to 8 When you are done press lt Enter gt twice If there are no press mounted sensors then just press lt Enter gt twice A message will appear that tells you that your press has been configured and the number of sensors Press lt enter gt once A win
64. Exit Configure from the pull down 13 Answer Yes to any questions that come up and you will be returned to the Tool Information screen 14 Select Exit Configure again from the pull down 15 Answer Yes to any questions that come up and you will be returned to the Overview screen NOTE You MUST set limits before any of the programmed features will operate after the feature removal or any other change for that matter Assign a Macro Feature algorithm to the current Feature set The Macro Feature definitions are designed to implement special features that do not fall within the Conventional Feature category There is only ONE Macro feature Spread calculation Spread calculation uses EXISTING Features to achieve a combination result a reporting of the maximum difference between existing features as explained in the section above 1 Select an empty Feature Position from the Feature List by clicking on the up and down arrow in the Feature List until the desired entry is highlit 2 Click Build Macro Feature 3 The Virtual Feature Build utility should appear It differs from the Conventional Feature Build in that there s NO graphic display ONLY a list of features already programmed on the left side of the screen Virtual Feature Build Press PRS_50 Tool 2092 SPC Point Title Blank Spread 1 1 Spread Calculation SPC Point Units Tons See oe Pa a Active Feautres 82 02 Draw Mi
65. Figure 113 shows the HiRes Converter that allows the signatureACE system to use an existing resolver as its position input The HiRes converter serves several functions The converter 1 Couples to an existing resolver system without loading the existing system or causing problems 2 Uses the reference sine and cosine signals from the existing system to feed the resolver to digital converter in the SA2000 RES module 3 Provides easy setup through three adjustments that are performed using indicator lights built into the converter SAMnet Communications Network This is the networking method for the signatureACE system It provides the ability to link at 2 5 megabaud speeds the signatureACE units with the host computer used in the system It is capable of transmissions over considerable distances The network operates according to the ARCNET protocol and uses RG 62 A U 93 Ohm coaxial cabling to tie the elements together in a daisy chain connection A communications module installs in an expansion slot in the host computer providing the connection for the SAMnet coaxial cable The SAMnet communications module is part of the SAMview software package SAMview Software This program resides on the hard drive of the host computer The SAMview package produces the screens and the database that run in the host computer Host Computer System The host computer is an IBM compatible computer with a
66. IN LONG J OR 12 5 LB FT LOAD SENSOR TWO ANTI TORQUE WASHERS FOUR LOC WEL BOLTS 3 74 INCH LONG TORQUE EACH 1 4 28X 3 4 IN LONG SOCKET HEAD SCREW TO 150 LB IN OR 12 5 LB FT Figure 172 Strain Link installation kit options 225 Signature Technologies Inc User Manual Machine Drilling Cover Mounting Layout holes 4 Ea 1 750 6 31 Optional mount hole for drill guide if used 1 50 N Drill and tap 1 4 28 X 0 625 deep 8 or 9 places Figure 173 Strain Link Drilling layout The Key to proper Connection mounting is the application of TWO strain links mounted SYMMETRICALLY on opposite sides of the connection The illustration shows links mounted on the SIDES of a connection but a front back mounting is just as good if the physical layout of the machine seems to dictate that as a choice Make sure the location is symmetrical as accurately as you can 1 8 difference won t make much of a difference but 1 probably will BOTH strain links should be hooked in parallel color to color Red to Red Green to Green etc The paralleling can be done right at the connection if there s room or in the junction MAKE SURE to check the cable for interference with other press elements through the stroke with the adjustment all the way up and all the way down Be careful of the clearance of the links with the crown openings and oil control apparatus WATCH the cable in the hydraulic t
67. INI text file A list of the registers commands and instructions is given in the MAINTENANCE MANUAL Since manipulation of the INI files is highly technical in nature and absolutely non intuitive we suggest you contact Signature technologies for further information about their use The INI file s can be written using the Edit command in DOS The file must be located in the SAMDATA directory to operate so the command is from the C gt prompt edit SAMDATA samview ini When the edit window comes up write the file and when done pull down the File menu and Exit The system will ask you if you want to save the file you say yes and it s done There will be a SAMVIEW INI file in the Samdata directory When SAMview starts it looks for this file in the database directory typically C SAMVIEW SAMVIEW INI If found it will search it for instructions If instructions commands are found the normal configuration of the system is altered to match the new requested settings The SAMVIEW INI file is placed in the database C SAMDATA SAMVIEW INI for settings that are universal in character And OR Assigned to The Press C SAMDATA pressiID INI for settings unique to that press And OR Assigned to The Tool C SAMDATA press D tool D INI for settings unique to a tool in the press The TOOL INI will override the Press INI which overrides the SAMVIEW INI files Note In
68. Initialization 371 Force Calibration Philosophies 354 Full Floating Hookup 249 G Gain Selection Analog Channels 36 Gauge utility 218 GetIni utility 219 GetLOD utility 219 GetNet utility 219 GetNet Utility 41 42 Graph programming 149 Ground detectors 194 Grounding Caution 247 Grounding considerations 258 H Hardware sketches 287 Hazardous Voltages 18 Heartbeat Indicator 38 High Power Digital Inputs and Outputs 207 HiRes Resolver Converter 284 Home Made Sensors Calibration 278 Host Computer 144 285 T O Cable Assembly 214 I O structure 284 If you forget or ERASE your passwords 371 Ifa Programmed Feature Doesn t Work 109 If there s a HiRes Converter in the system 293 Indicator Buffer Full 38 Indicator Heartbeat 38 Indicators SA2000 143 Industrial I O structure 284 INI files 55 INI Files for modifying the operation of Samview 218 Initialization Floppy Disk 371 InOut utility 219 Input Clutch Signal 372 Input terminals Analog amp Die Protection Sensor 205 Inputs analog 139 Inputs and Outputs 207 Inputs to the system 30 InSitu Sensor Mounting on frame 219 Installation SAMnet 30 Installation Computer Host hardware 33 Installation Machine Control 30 Installation SignatureACE Equipment 28 Interfacing 3 wire D C Proximity Switches 272 Interfacing Universal Proximity Switches 272 Interfacing
69. Jump to Step 15 and re calculate the Signal values Divide the Rated load value by the Count values generated in Step 15 These are the calibration factors for that channel Exit Configure without saving anything Go to Configure and select Press In the Press Database screen enter the Calibration numbers in the appropriate channels Exit Configure saving the data Worked EXAMPLE The press is a Single action Danly Underdrive Its capacity is 1000 tons The Pull Down Rods are 7 75 in Diameter You are calibrating the Left Front Corner Loading of Left Front 250 Tons 500 000 pounds force Area of Pull Down rod 47 173 Square Inches Young s Modulus for the Pull Down rod 29 000 000 Displayed value at no load for the sensor averages about 136 counts Displayed value with 324K Ohm shunt applied from Excitation to Signal terminals averages about 943 counts Difference 1079 counts The 324 000 Ohm shunt produces 198 4 Apparent microstrain SO 1079 counts 198 4 Microstrain Full Load stress in Pull Down rod 500 000 pounds 47 173 sq Inches 10 599 28 P S I Full Load strain in Pull Down rod 10 599 28 P S 1 29 000 000 0 0003655 inches per inch 365 5 Microstrain resulting from a 250 ton load 365 5 Microstrain 198 4 shunt Microstrain 1 84224 This is the ratio between the shunt microstrain and the Load Microstrain 1 84224 1079 shunt counts 1988 counts at 250 tons Signature Tec
70. K Quality Limit K Current Limits 3 00 Eois o0 EUG W243 64 CE eanit Widening konstant 240 80 CE AEN Hbar Drift Factor J sree ere 0 000 Percent 9232 28 PR eet Tal tet Control Limit for R red Hbar Limit Offset ee te Baseline Mean 235 12 Lo Control Limit Bar yellow R Limit R Limit Confidence level calculated GRR i 2 97s E se f Default R Limit Widening Constant i Figure 96 SPC Limit Setup Screen Jaseline Standard Deviation View SPC limit parameters The SPCview Limit Parameters are accessible ONLY from one of the SPCview screens You will get a DIFFERENT limit Parameters pop up from the signature screens To go there from the SPCview sceens 1 Select Configure from the menu bar A sub menu will appear 2 From the sub menu select Limit Parameters The SPCview parameters pop up will appear in the center of the screen Figure 96 3 Choose the feature by selecting from the List of SPC points highlighting the desired feature Whena Feature is selected the current limit parameters and limits are displayed on the screen Calculation of SPCview limits The SPCview system automatically sets the Xbar and R limits when a tool is run for the first time or when the user initiates a process limit recalculation The Xbar and R limits are calculated automatically by the SPCview system using the formulas in the box below Referring to equations 1 and 2 as sh
71. KIPRAD sj JaKjosal ayy saualalad Jo JAGA ak Bi SINPOW BSN PUG PUAS ODS NYS BUD juD W PEN GUD EBINPCW DESKS B zy UBL Figure 263 SAM500 system generic diagram 1 Signature Technologies Inc 343 General Installation amp Programming Guide E q AMEME apenas bapa rE 10 L00B ZOI US 19 suopecyddo syowRY BGE MY ou 2 TO A N API BSH OF NS 18 sae BSH PUP DOSNYS WDUDPIQ FAUIS on alate eet eee SISO IONHOAL TN gt u salbojouysa ainpoubis MAYNLVNOIS z TERRE S661 Z66L peyoucdsoou eej ojouyos eunjpoubs pYyBptdog P mp Pee wpe jy So Daoue araous jo paaa pjp i my PCM peepep JO pn So Ris fe 40u 1048 a panoda padou SM OLD Jo Aledo BAND ou LUSWUNOOP PAUEPUUDO LL te SH IRIE E oO a THB 2468 moa u Japeay au n a ugle 4507 ing Wy CBE lol ea oO 2 jess grel npg pg ajowsy souu ta a basis fts be kafee eales Pesas al EIS AM OE A DUM SUPPLY OLL oy UJ EUI PRHE NI 2 8k BRP EE TIKH ILS Squinu pod m vagou z WED A D S WEY TRAYA S ASY TRA Y j CEE TE u ws edg wnomg L sp tp pp Tt yy a He iph HYNDE wo EIGEN ady UNDUE ag PRES ALA Ay eA ype Ed papal E YU perpe appa PENN UNE npu g D eg jenu appo Ice Ay pucog Bul depay gA Ot quy pie Bq 0 e A GIgg BAY IPO pur edly a59 unng anm bg pepeau e BUA sonipa ED yane epe Wypis d H WAE BA SECON 40 YDA eupd pays cy U prina Pappy Igang MO 69 JEP AYO JHI UES
72. Microstrain in the Pull Down rod Strain Gages are precision devices and have electrical characteristics which are repeatable from one gage to another to within 0 5 Consequently if the gage installations are done perfectly the calibration factors for all identical steel components with gages mounted in the same locations should be the same to within at least 2 3 The Strain gages used on underdrive machines are different than those used for overdrives and general press uses They are gages pre bonded to steel shim stock and are applied to the surface of the Pull Down rods by spot welding them directly to the surface of the rod They are used in pairs with each half of the gage bridge applied symmetrically to opposite sides of the rod to cancel bending effects When the gage is applied and wired back to the SA2000 unit a 324 000 ohm 1 shunt is applied across one of the gage legs This will cause an apparent 198 4 Microstrain signal into the SAM unit This number can then be used to generate the calibration factors for the system as outlined in the procedure below The problem with this type of calibration is that it assumes things to be a certain way which may not be The calibration will be affected by the alignment of the strain gage installation and the integrity of the Pull Down rod If the gage is not mounted absolutely in line with the force improperly welded or if the Pull Down rod is flawed the resultant calibration factor
73. ONLY show you the data gathered within the Window defined in the Tool Database for the tool that s in the machine For example Let s say that you have a window set so that you collect data for 40 degrees of the machine rotation Let s also say that the Position Sensor has Slipped 60 degrees due to a loose coupling What you wind up with is NO signature even though the system is taking data normally The solution is to tighten up the coupling and reset the position offset My first suggestion for diagnoses is to open up the data collection so that it covers almost the whole rotation of the machine so that if a signature is there you will be able to see it am also assuming that you have at least one press configured Signature Technologies Inc 319 General Installation amp Programming Guide gt gt Unless it already exists MAKE A TOOL CALLED FINDIT From Configure get into Tool Database Enter FINDIT in the Tool ID window The From Green line should be at about 5 degrees The To Red Line should be at about 355 degrees Exit Configuration saving the Tool 10 Go to Configure click on Job select the FINDIT tool 11 Exit Configure saving the setup 4 Tests for data acquisition 1 Go to the Signature View and Zoom Default You should see a Graph with a horizontal scale starting at about 5 degrees and extending to somewhere around 355 degrees If you don t chec
74. Pulses number in the Press Database screen is wrong for the Position Sensor or SAM jumper configuration Go to Check 4 3 If the Angle display behaves as in d above the chances are you have a SAM unit jumpered to be a MASTER which is fighting another Master unit in a multiple SAM setup or fighting a HiRes converter The jumper configurations are given at Figure 230 and text following 4 For ALL Resolver Versions see step 5 for Encoder NOTE The Resolver board on the SAM module is internally capable of creating several resolutions from the same Resolver Refer to Figure 230 That is gt If the SAM is set internally with jumpers to perform a Resolver to Digital R D conversion of 12 bits the system will see 4096 increments per rotation gt If the SAM is set internally with jumpers to perform a Resolver to Digital R D conversion of 10 bits the system will see 1024 increments per rotation 316 Signature Technologies Inc signatureACE gt The number that you enter in the Press Database screen in the Pulses window does NOT control the resolution of the SA2000 it only sets up the Host Computer to properly interpret what the SAM is doing The number must correspond to the internal resolution setting of the SAM The SAM Resolver board resolution is set internally with jumpers If for example the SAM is jumpered to perform a Resolver to Digital R D conversion of 12 bits the Pulses must be
75. RC 62 03 Peak Blank B amp D 2 04 Peak Blank LC 62 05 Peak B amp D 06 Peak LC 7 Peak RC 68 Valley Blank RC 09 Hitro Pressure B amp D 16 Work Blank B amp D 11 Work Draw B amp D Feature Control Status Control Monitor Figure 83 Spread calculation at the blanking operation Virtual Feature Build Press PRS_50 Tool 2092 SPC Point Title Draw Spread 101 Spread Calculation SPC Point Units Tons 02 00 Draw Maximum B amp D Active Feautres 2 61 Draw Maximum LC 02 02 Draw Minimum RC B2 81 Draw Maximum LC 02 03 Peak Blank BaD 62 82 Draw Minimum RC 02 84 Peak 2 85 Peak 02 6 Peak 2 87 Peak RC 62 88 Valley Blank RC 02 09 Hitro Pressure BaD 62 10 Work Blank B amp D Feature Control Status Control Monitor Figure 84 Spread calculation at the drawing operation Signature Technologies Inc 103 General Installation amp Programming Guide Virtual Feature Build Press PRS_50 Tool 2092 SPC Point Title Closure Spread 181 Spread Calculation SPC Point Units Tons a2 82 Draw Minimum RC 02 03 Peak Blank B amp D 02 87 Peak RC 2 04 Peak Blank LC 2 05 Peak B amp D 2 086 Peak LC 2 07 Peak RC 2 88 Valley Blank RC 62 89 Nitro Pressure BaD 62
76. SAM module is energized When the position input passes the software corrected ZERO position For large step changes in the value of the offset while the machine is running more than one auto zero cycle may be required to null out the offset completely If the machine is stopped an analog clamp will deploy after 4 seconds and tie all inputs to Zero internally there is no change in the input impedance or loading when the analog clamp deploys 260 Signature Technologies Inc signatureACE Standard Sensor Connections The normal sensor for use with the signatureACE system is a pre packaged Strain LINK The strain link is normally a simple Whetstone bridge having two of its four elements mounted in such a way that they are IN LINE with the stress in the measured machine element The other two are mounted ACROSS Perpendicular to the direction of the stress gy 100 000 Pounds Force Poisson effect cross section growth 0 26 0 33 Strain Figure 199 Stress Strain Poisson s ratio illustration Fig 2 illustrates the physical effect of STRESS on a column of material Starting with two identical columns STRESS is applied to one of them Higher Resistance t Lower Resistance Figure 200 Strain Gage illustration The STRESS produces a dimensional change in the column that is called STRAIN It also causes the stressed column to Bulge or increase its cross section
77. TOOL channels that are connected Overview Configure Batabase Analysis Sereen Options Che ual ID Tool Description View another Press ange Tool M3705 Right Supp Brkt New Tool Signature Collection Area Data Collection Rate Size 0 35 363 From To 118 83 246 09 Channel List mG Channels Remove SAM Ch Description Channel 61 00 Left Connection Editin 7 01 01 Right Connection 1a lt a _ are i Enter gt gt 1 83 F R Kiss Block Description Capacity Units Calibration Offset Curve File gt R L Kiss block 2100 lt uncal gt 1 0000 o 034 lt none gt 100 00 Setup Selections Virtual Channel Tool Setup Inf CELI Figure 42 Tool Database Programmed 16 All Tool sensor channels have now been programmed Select Configure from the Menu Bar A sub menu will appear 68 Signature Technologies Inc signatureACE 12 Select Exit Configuration from the sub menu options A message will appear Save current Changes 13 Select the YES button Another message will appear Save Current Changes 14 Select the YES button The system will exit to the Press Line Overview screen Section 4 Putting the press and the tool together 1 Select Configure from the menu bar A drop down sub menu will appear 2 Select Screen from the sub menu The Press Line Overview screen will change to edi
78. The signatureACE system collects a signature for each stroke of the press The signature represents the load profile of the press during the process SignatureACE 08 The generic term for the signature analysis system manufactured by Signature Technologies Inc The SA2000 Signature analysis module and the SAMview Signature analysis software system are the main components of the signatureACE product Signature Database The memory area in the line computer into which the Signature Process limits and Master limits are stored The data stored herein can be selectively retrieved by the Historic Analysis utility found on the Program Selector Menu Signature Length In the System Parameters utility on the Program Selector Menu the number that the system user enters into the Signature Length field sets the size of the array into which the signature data is stored when it is taken This establishes a maximum total number of readings that can be taken by all channels during a data acquisition cycle The Signature Length is normally 2048 which would permit 8 channels of data at 256 samples per channel to be taken Signature Limits Continuous curved lines similar in shape to machine force signatures and located above and below the normal machine signatures When the machine signature crosses the boundary of a process limit some control action is typically taken by
79. This growth in cross section is referred to as the Poisson effect Signature Technologies Inc 261 User Manual As shown in Figure 200 the strain gage element is a series of columns connected in series electrically As the machine to which the strain gage is attached changes its length the strain gage changes along with it Under compression the gage columns grow shorter but thicker This growth in cross section with reduced length reduces the electrical resistance of the element The strain link bar that is being gauged is also experiencing this Poisson effect under compression the bar become shorter but increases cross section normally 0 285 times Strain dimensional change for Steel The gage element mounted perpendicular to the stress will respond to this dimensional change by going into tension i e getting longer but reducing its cross section This Across gage will increase its resistance with conversely the gage element mounted perpendicular to the stress When these gage elements are connected together as shown below Under Compression EXCITATION 2 5 Inline 72 ih Ye 1 ii ee oo 4 ar E 5SIG MAL SIGNAL ov T er AN ETa aia te a ss inline 1 Across 2 oN EXCITATION Figure 201 Whetstone Bridge connection A full Whetstone bridge is created Under compression the gage elements IN LINE with the stress application will REDUCE their resistance while the elements perpendicular to the Stress
80. Units Calibration Offset Curve File e p Left Connection 2100 xuncal gt 1 0000 fo 000 ona 00 00 Figure 40 Tool Database Empty 6 The first left character position in the Tool ID box located in the upper left hand portion of the screen will have a Cursor Figure 40 7 Create a Tool ID name The Tool ID name is the key entry that identifies the tool Once the name has been entered it cannot be altered This name can be 1 to 8 characters long and must be a DOS compatible file name If you accidentally use unacceptable characters the system will substitute the _ character in place of the character you specified 8 Optional Use your pointing device to click on the first left character position in the Tool Description box Figure 40 A cursor will appear on the left side of the box Enter up to an 18 character description for the Tool 9 Set the Signature Collection Area This defines for the system where data collection starts and ends in relation to press movement in degrees There are a couple of ways to do this A You can position your pointing device near the line you want to move and drag the lines on the graph Figure 40 After sizing the From and To boxes on the right will indicate the angular position of the line B You can enter degree values directly if you know the range that you want to see Click on the first character position in th
81. When changing data in Description and Start End fields highlighting the First Character position in the field will cause the entire field to erase when the first key is struck Otherwise the characters will insert at the cursor position In the example below 4 CAMview channels have been set up Note that the 01 is an Angle ON Timed OFF Cam while the 02 03 and 04 Cams are Angle ON Angle OFF in nature 172 Signature Technologies Inc signatureACE Overview Configure Options Tool Database for Press TEST Tool ID Tool Description View another Press Change Tool aa DUMMY test New Tool ection Size Press Tool ID SAM SAM Desc Angle 225 TEST DUMMY a2 test 0 To Channel On Off 2 20289 Active x Description State Angle Angle Dwell time ms J 04 Feed Initiate joo fp oo jm J 02 Stock Lubricator 200 300 ep fa 1 03 Blow ore 190 250 eam ms J o4 Pilot sensor Chk 350 ao E w _ os fabs an ee oe SS ee a T EE 3 2 gt 2 00 fam view Descriptio Edit Save Changes Cancel Return Bee ears lez AA of curve RA Figure 134 Programmed CAMview system Cam 01 will turn On at 200 degrees and turn OFF 0 1 seconds later Cam 04 Is programmed ON at 350 degrees and OFF at 10 degrees This means it will be ON for 20 degrees from 350 through 10 degrees Cam protocols Definition The terms ON and OFF Th
82. accommodate any horizontal migration thus reducing the sensitivity of the Signature Analysis system to actual process variations which may be smaller than the mechanical uncertainty of the resolver drive system Signature Technologies Inc 229 User Manual NOTE The resolver unit is an industrial package with excellent specifications as are listed on the next pages It is however a precision instrument and must be treated as such if proper service is to be obtained NEVER strike the resolver shaft in any way from any direction This includes DRIVING ON pulleys or couplings that are more than a push fit on the shaft The 95 pound limit on the shaft end is really easy to exceed when driving a coupling on with a hammer In general if it s too tight to slip on by hand IT S TOO TIGHT Open the bore before installing it NEVER install belting by Stretching it over the pulley edge without loosening the adjustment This can overload the bearings and cause premature failure NEVER Over tighten the drive belt Tighten only until there is no perceptible slack Belt deflection under light finger pressure should be in the 3 8 to 1 2 range NEVER Modify the resolver shaft Machining drilling or other modification of the resolver shaft VOIDS THE WARRANTY ONLY Use couplings or pulleys that affix using a set screw IF the pulley coupling has a properly fitted key and the setscrew bears down on the key surface Under any other circum
83. amp Programming Guide 6 10 11 12 13 Go to Steps 6 through 17 under Setting up the first machine Section 2 page 52 and add the next press THEN RETURN TO STEP 7 Below From the Overview screen select Configure from the menu bar A drop down sub menu will appear Select Tool from the sub menu The Tool Database screen will appear All the data for the current press tool will also be displayed From within the Tool Database select the View Another Press button in the upper right corner of the screen The Select a Press window will appear with the new machine you just added now present in the list Click on its name that will appear in the File Name box on the top of the window Click the Select button All the data that was on the tool screen will disappear and the name of the new machine will appear in to the title bar at the top Click on the first character position left in the Tool ID window A cursor will appear Go to Step 6 of Setting up the first tool Section 3 and continue through Putting the Press and the Tool Together Section 4 124 Signature Technologies Inc signatureACE Section 10 Adding SA2000 modules to the same machine The following task assumes that you have at least one press and one tool defined already and that they are functional You can then add an additional 5 SA2000 modules
84. and following text for Module identification and address settings The Host Computer will show up as This Node written on the button below the Green light NOTE You should start by making sure that This Node shows up If the Host Computer is NOT recognizing its own Network Card then you re not going to get anything else to work Since duplicate addressing can Knock off the Host Network card you should start by disconnecting the network coax from the Host and establishing the This Node indication on the SAMnet Summary screen Possibly the Network card may have an address selected that Signature Technologies Inc 303 General Installation amp Programming Guide won t show up on the screen which only shows the first 24 addresses Check the switches through the window on the module between the LED s and the Coax connector HEARTBEAT Indicator TEST oe Buffer Full Connector avaten Indicator RESET Button Test F Switch TEST Button meee B E Slaving C ctor as aa gee ei Sensor Gain Gage Excitation Jumpers Jumpers Figure 241 SAMnet Card Address switch Address 000 is ILLEGAL The first SA2000 on the network would then be 001 and so forth The NAME of the SA2000 The name you entered in the Description window next to the ID in the Press Database for that unit should show in the button below the light As an additional check you should be able to Click on the Button below the Green light and g
85. and loaded to 200 tons ZERO Readings Loaded Readings First Reading 534 1062 Second Reading 543 1053 Third Reading 539 1065 Average 538 7 1060 0 Difference 1598 7 200 Tons Divided by Difference 0 12510 Calibration factor for Tons Signature Technologies Inc 355 User Manual Step 17 Step 18 Step 19 Step 20 Go back into the Press Database Enter the calibration numbers you developed in the appropriate channels Now perform a Linearity check Go back to the Peak View screen in Static Acquisition and perform the check by jacking the press to progressively lower loads recording the readings on the displays which will now be reading out in tons The results from the display should follow the pressures applied Diversions of 5 aren t unusual but 10 or more is getting pretty large and could indicate bearing tie rod or frame problems In the example above I d take readings at 175 tons 150 tons 125 tons 100 tons 75 tons 50 tons and 25 tons Re pressurize the Counterbalances and re install the tooling It s a good idea to create graphs of the calibration and the linearity check and save them for comparison Calibration Procedure Dynamic Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Get the tooling out of the press and clean up the slide and bolster surfaces The CALIBRATE OPERATE dip switch on the RSCB unit should be in the OPERATE position it probably already i
86. application will INCREASE their resistance Since the gage elements are reversed on each side of the bridged under compression the Signal terminal will move in a positive direction while the Signal terminal will move more negative There will then be a differential between the and Signal terminals which is then fed to the signatureACE system as an input of the force in the machine structure The connections for these links are fairly standardized For the ST Toledo T400 LINK or HELM HT400 links the hookup for Compression sensing as would be found in the connections Pitmans of a punch press is as illustrated below in Figure 202 262 Signature Technologies Inc signatureACE Under Compression Connection Mounting Excitation Inline 2 4 JAacrass 1 Signal ee Eh SHIELD Figure 202 Standard Strain Link Hookup Compression Under Tension Upright Mounting Excitation i Across aes F Inline 2 wea 5 ah F EAF amp Signal WHITE F g 5igna l PER e dee Inline 1 og Excitation SHIELD Figure 203 Standard Strain Link Hookup Tension For Tensive sensing the signal wires are simply flipped as illustrated in Figure 203 above Data Instruments Strain links are amplified units that require a totally different hookup as illustrated in Figure 212 later in this publication If you don t have colors as illustrated above or just don t r
87. be reading out in tons and should agree with the readings from the cell s Record the readings along with the change in shutheight that yielded them Diversions of 5 aren t unusual but 10 or more is getting pretty large and could indicate bearing tie rod or frame problems Continue rolling and raising down to about 10 of capacity Re pressurize the Counterbalances and re install the tooling Turn off automatic signature saving Signature Technologies Inc 357 User Manual Step 18 It s a good idea to create graphs of the calibration and the linearity check and save them for comparison Step 19 Archive off the signatures that were taken during the procedure When you inspect the signatures they should all be a symmetrical smooth Hump centered on 180 degrees without discontinuities or high frequency features Lack of symmetry extra lumps or jerks in the calibration signature would give indication of problems in the machine Calculated Calibration Factor Procedure Underdrive presses Step 1 The Gages are attached to the press Pull Down rods and the cabling has been returned to the SA2000 system and is connected to the appropriate points on the RSCB board Step 2 Move the CALIBRATE OPERATE dip switch on the RSCB unit to the CALIBRATE position Step 3 Goto the Press Database screen and change all the calibration factors to 1 000 Step 4 Go to the Peak View screen initiate Calibrate from the Configure Pull D
88. bring a pop up box where you can type in the title you would like to see at the Bottom center of the graph This can only be done in Configure Screen mode c y axis title selecting this will bring a pop up box where you can type in the title you would like to see written vertically at the Left center of the graph This can be done only in Configure Screen mode Signature Technologies Inc T7 General Installation amp Programming Guide d x axis Grid selecting this will cause the system to draw vertical grid lines corresponding to the calibrations on the x axis scale This can be toggled from the signature screen temporarily but if done in the Configure Screen mode it can be saved as current e x axis Grid selecting this will cause the system to draw horizontal grid lines corresponding to the calibrations on the y axis scale This can be toggled from the signature screen temporarily but if done in the Configure Screen mode it can be saved as current 13 If you want to set up additional views Select another view button and adjust as needed Remember you can always change the view set up later 14 When you re finished Select Configure from the menu bar A sub menu will appear 15 Select Exit Configuration from the sub menu The message Save current view for this press will appear in a pop up message box NOTE Current view is the view appearance that the system will Go back to if the zooms o
89. calibrated must have the force applied to it in exactly the same way and by the same parts by which that the force is applied when the component is in place in the die and parts are being made This results in quite a bit of fixturing but it s the only way to guarantee accuracy Maintenance of Calibration Settings Once a press is calibrated further calibration is normally necessary whenever e The Zero level of one of the channels changes 352 Signature Technologies Inc signatureACE e The signature from one of the channels seems to change its size radically from earlier signatures obtained from the same part This may mean that a strain gauge has failed e Mechanical damage to the strain gauges necessitates replacement e In cases where the strain gauge is mounted on the press upright any disassembly of the press for service or to alleviate a stuck press condition should be followed by a re calibration Signature Technologies Inc recommends that re calibration be performed at least once per year This will ensure the greatest possible degree of accuracy for the SignatureACE system applied to your stamping process High quality standards require strict adherence to calibration requirements Calibration Procedures Zero Offset checking Procedure Preparation Make a Tool called CALIBRAT and use it anytime you are doing Zero Offset checking or Calibration Note The CALIBRAT tool should have t
90. came up with the INI file to begin with NOTE This section begins with the assumption that the Host Computer ALREADY HAS the Signature Technologies Software installed as detailed in the previous sections The assumption is also made that the system is wired and the operation of the SA2000 the network and the resolver has been checked and found to be operational When the system is started up initially NOTE Preconditions for running the Setup Wizard are 1 Before proceeding with the setup Shut the Host Computer OFF wait 10 seconds and turn it back on again to clear everything out of the system 2 The System MUST have an EMPTY database with NO presses or tools 3 The SA2000 modules that comprise the system MUST be On line as discussed above and operational 4 The ADDRESS settings of the first SA2000 module should be 1 If there are more than one the second should be set to 2 and so on If there is no press in the database the system will automatically open to the Press database screen and ask Would you like help adding a press A NO answer will ABORT the Setup WIZARD and drop you into the Press Database screen for manual setup which is covered in detail in the next section below SAMview System setup From Scratch A Yes answer will bring up a window that tells you to 1 Enter the Press Name 46 Signature Technologies Inc signatureACE
91. click The numerical displays at the bottom of the screen will update to the final position of the cursor line B By editing the numerical displays at the bottom of the screen Interval Start etc Click on the FIRST Character position and enter the desired location for the cursor line The cursor lines will automatically move to the programmed position 23 To save the current configuration Click Return or to disregard all changes to the Feature Click Cancel 24 you will be returned to the SPCview configuration screen and your new feature will be displayed Queruiew Configure Patabase Analysis Sereen Options PCview Configuration Press P1286 Tool M3705 Pid A2 86 Left Conn Peak Interval Peak m Build Conventional Feature Budd Macrae feature Subgroup Sample Size Cycles between subgroups O Strakes Figure 93 programmed SPCview config Window 25 If you want to program additional features go back to step 8 above and repeat the process 26 If you are done select CONFIGURE from the menu bar 27 Select Exit Configure from the pull down 28 Answer Yes to any questions that come up and you will be returned to the Tool Information screen 29 Select Exit Configure again from the pull down 30 Answer Yes to any questions that come up and you will be returned to the Overview screen Signature Technologies Inc 111 General Insta
92. close together or far apart force readings may be taken A high number as entered in the Sample Rate field in the Tool Information utility could allow readings to be taken as often as every 0 089 of rotation A much lower resolution would be one that took data only every 1 4 of rotation A value used by the computer that has not been converted to engineering units This value is typically an integer value ranging from 32768 to 32767 The RED Process limit curve is farthest from the machine force signature These are referred to as Fault limits since they normally announce major variations in the machine signature They are programmed so that if broken the user can be sure that something has happened that precludes any further operation of the machine until the fault is corrected Depending on the machine they may be used either to perform a Top Stop or an Immediate stop A position sensing device used to track the rotation of a machine Screen button that saves data and or completes an action Remote Signal Conditioning Board A circuit board used to amplify and condition force and position signals sent from the strain gauges and position sensing device to the computer In current versions of the product the TEC Terminal Enclosure unit has largely replaced the RSCB which is only used when long cable runs are needed A highly complex DSP based card set used to monitor and control the operation of any ro
93. component in its resting state There must be some care taken to avoid Railing the input amplifier on the SA2000 The Auto Zero circuit will always successfully bring the input level down to zero BUT if the input amplifier which is outside the Auto Zero loop is saturated there will be NO signature Excessive imbalance in a strain gage is not a serious problem with the gage and is quite common when gages are bent around a circular load cell structure or applied to an uneven surface Acceptable offset values In HIGH range the static offset voltage should be LESS THAN 0 004 volts 4 millivolts AND more than 0 003 volts 3 millivolts for FULL RANGE capability In LOW range the static offset voltage should be LESS THAN 1 75 volts AND more than 1 0 volts for FULL RANGE capability How to diagnose remedy the situation The best way to see whether the gage is throwing too much offset at the SA2000 is by applying a millivoltmeter Like a Fluke Digital multimeter which has a 300 millivolt scale across the Signal plus probe to Signal Negative probe leads and measuring the static voltage Excitation Shield Excitation s 7 Signal Signal Signal Excitation Signal Excitation I Millivolt Meter Figure 208 Gage out of balance AS stated above in HIGH range If the static offset is larger t
94. configuration do the following NOTE Amplified strain links from Data Instruments will interface directly to the SA2000 Refer to the section in the Appendix 9 Interfacing Manual that deals with the special considerations for these sensors NOTE Make sure that the Shield Braid is NOT connected to Ground at the Strain Link End Measure from the shield braid of the Strain link cables to the machine frame with an OHMETER There should be NO connection very high resistance If the Shield is connected to the machine frame there will likely be noise problems in the signatures If the shield is grounded you have two alternatives 1 Change the strain links to ungrounded shield types of the same brand as the existing ones 2 Strip back the cable jacket up close to the strain link probably inside the cover box and cut the shield away so it has no connection into the strain link and then tape the cut portion so that it can t short against anything Either remedy will work equally as well and 2 is generally cheaper Find out what the wire color code for the sensor is If you re not totally sure of the internal wiring of the strain link then check with an ohmmeter between the four wires coming from the strain link There should be TWO pairs of wires that will give a higher resistance than other pair combinations For example if the strain link is a 350 OHM bridge two of the pairs probably RED amp WHITE GREEN amp BLAC
95. device designed for or rated for use in personnel safety related applications CAMview by design DOES NOT meet Signature Technologies interpretation of the CONTROL RELIABILITY requirements of OSHA 1910 217 b 13 for Punch Press control and SHALL NOT be used without proper backup and or point of operation guarding systems in any application where unexpected failure of the CAMview system could either produce sudden unexpected movement of unguarded machine elements or fail to stop machine motion in a controlled fashion Signature Technologies Inc WILL NOT support any use of the CAMview system for the control of hazardous machine functions Signature Technologies Inc WILL NOT be held responsible for physical or psychological injuries resulting from applications of the CAMview system to control equipment functions for which it was not intended Signature Technologies Inc WILL NOT be held responsible for loss of revenues or machine damage resulting from equipment failure in approved applications k EEVVARN N G Certain procedures in this manual could cause unexpected motions from portions of the machine system Before performing ANY programming procedures make sure ALL personnel are standing clear of the machine as well as any parts transfer or coil handling apparatus Failure to observe these safety precautions can result in serious injury or death 18 Signature Technologies Inc signatureACE It i
96. disk 7 As signatures are deleted from the list the appropriate file counts will be adjusted If during the deletion process you wish to stop removing the signatures pressing any key will abort the delete Printing Configuring SAMview for your printer Before printing any signatures the SAMview software must be configured to the proper printer settings This must be done only once after the software has been installed Following is a step by step procedure for configuring the SAMview software for a selected printer 1 From the DOS C prompt enter the configure option by typing the following c samview samview config This will bring up the LabWindows Run Time System Configuration Utility pop up From the Configuration screen click on Configure Output button to display the Output Device Configuration 2 Select the appropriate printer connection from the Available Device list usually Graphics Printer This will bring up the Graphics Printer Configuration pop up The Current Graphics Printer will be displayed at the top of the pop up 3 If this is not the correct printer click Select a New Printer button and choose the desired printer from the Available Printers list 4 Complete the process by selecting OK until you have exited back to the DOS prompt The printer is now configured and will remain so until you re install new SAMview software Printing Press and Tool Information You ar
97. for every channel Use a good quality capacitor Polyester type to limit leakage Don t use electrolytic or Tantalum capacitors Interfacing Digital signals to the signatureACE Digital signals can be brought into the signatureACE and displayed limited just like analog signals You must take a couple of things into consideration though The AUTO ZERO function will make whatever state the digital signal is in at Top Dead Center zero degrees to be ZERO If the signal is HIGH at Top Dead Center it will be displayed as a rectangular wave dropping to 2048 from Zero when it goes LOW when the calibration factor is set to 1 If the signal is LOW at zero degrees it will be displayed as a rectangular wave jumping to 2048 when it goes high The AUTO ZERO function can be disabled selectively through the use if the INI files Contact ST for more information about this if needed If the AUTO ZERO function on a channel is disabled the result will be a rectangular wave jumping between 2048 to 2048 on the screen with the calibration factor set to 1 A simple way to interface digital On Off signals to the ST system Signature Technologies Inc 271 User Manual SHIELD 2400 Ohm i e m Event Signal from Machine Figure 215 Relay Digital Input This is a simple method that would effectively interface with an existing event signal The relay coil is wired so that when the event occurs the rel
98. functions are handled by different parts of the system To begin with the term SA2000 refers to the Cardset and Interface assembly that is the hardware portion of the product The terms SAMView SPCView FeatureView and SAMtest refer to the Software packages that run in the HOST Computer 282 Signature Technologies Inc signatureACE The main functional parts of the SA2000 and their primary functions are The SA2000 Motherboard The SA2000 is the Workhorse element of the SignatureACE system It is based on a DSP56002 Digital Signal Processor from Motorola and is programmed in Assembler Its program runs in FLASH Programmed Memory and is not accessible without special access software it can t be corrupted by accidental keystrokes The SA2000 module does the following gt It plugs into 2 consecutive ISA slots and draws its power from a standard computer motherboard gt It does all the sampled data acquisition for the signatures gt It calculates the Process Limit Arrays The Process Limit arrays are uploaded to the Line Computer for display and permanent storage gt It compares the Sampled Signature data arrays with the Process limit arrays between each sample gt It issues logic level digital outputs in response to the outcome of the comparisons made between the Signature data and its limits gt It accepts logic level digital inputs from the machine gt It d
99. got to flow through these elements except in high speed machines where inertia takes over the calibration simply consists of centrally loading the press to a known force level and dividing that force over the members that react to it For instance if you apply 100 000 pounds right in the center of a press whose slide is driven by two connections each connection will be carrying 50 000 pounds For systems that ONLY have sensors on the machine frame amp require machine frame calibration the SignatureACE system has built in routines that enable the system user to automatically ZERO and calibrate his press based on striking a known load centrally located in the die space The Downside of Machine structure sensing is that the force produced by the tooling is NOT STATIC but dynamic with complex force patterns The tooling force has to travel through a lot of hardware to get to the sensors This guarantees that resonances attenuations and contributions from other sources will modify the force pattern DRASTICALLY by the time it gets to the force sensor If Machine structure sensors are used they should be as close to the point of operation as possible This is normally accomplished by attaching the sensors to the Pittmans of the press down where the pittman connects to the pressure point in the slide It is suggested that that the Pittmans be double gauged for the highest accuracy Two strain links should be installed on each Pittman located
100. ground there shouldn t be any If you don t find any other problem change the SAM500 SA2000 Check 9 The Machine won t run and of course you blame us The SA2000 system operates Machine control outputs which are CONDUCTING whenever the SA2000 hasn t seen a limit violation If a violation Occurs and the system is in CONTROL mode the control outputs corresponding to the fault condition will become electrically OPEN and remain so until the Reset box is clicked or the Reset Button is pressed 1 If the system is in the MONITOR mode but the machine won t run gt Check to see if the Lights are ON in the Outputs in RED YELLOW and WHITE positions in the I O chassis It they are ON the SA2000 is ENABLING machine operation gt Measure the Voltage between the RED YELLOW and WHITE terminals If the lights are ON on the Modules there should be NO or very little voltage across the terminal sets If you find 110 V A C the module in the corresponding slot is BAD Replace it gt Check the control wiring to the press Look for broken connections related to the wiring on the Outputs in RED YELLOW and WHITE positions in the I O chassis NOTE In some cases only ONE of the outputs may actually be used The Output in the RED Position operates when the RED limit set is violated while the Output in YELLOW Position operates when the YELLOW limit set is violated etc Obviously if there s no w
101. hookup must be watched for loading effects The position displayed on the existing system may change significantly when the CNV Converter is connected See the procedure in the installation steps below Signature Technologies Inc 249 User Manual i cm a un a 5 WP a Li pa BLACK a s Resolver H Converter Cable y Ground BLUE Panel Ground Figure 191 Full Floating connection Resolver Converter typical installation steps The installation will consist of several major steps Installing the CNV Converter 1 Inspect the wiring diagram for the resolver system already installed on the machine Compare with the typical schematics in this publication If nothing seems to match we suggest that a copy of the existing system technical details be Faxed 972 488 2924 or mailed to us so that we can render assistance 2 When the requirements of the installation are understood and the CNV Unit is used decide on a location for the CNV Converter unit and mount it to the machine or electrical panel NOTE Take notice of the location of the Adjustment potentiometers and indicator lights Make sure they are visible and that you can get to the adjustments The unit can be left loose on the panel until after the setup is done 250 Signature Technologies Inc signatureACE Installing the INPUT Cable 3 With the machine stationary take note of the angular reading on the existing syst
102. ig 4 a E 72 zz 12 p F z g ge T ISNOISIAJH Figure 264 SAM500 generic system diagram 2 Signature Technologies Inc 344 Appendix 11 Maintenance Manual There are several areas that are subject to periodic attention Each is explained in the body of this document below in detail This is a list of recommended intervals 1 Every 2 Weeks a Change the 4 5 level passwords b Take a look at the historical storage make sure that things aren t filling up Archive off or erase as needed TRY NOT to have more than 100 or so signatures on the Hard drive for any given tool for best accessability c Check the Filters on ventilated enclosures Wash if necessary 2 Every 2 Months a Check HiRes resolver converter adjustment Re adjust as necessary b Check sensors for proper operation Schedule service as needed c Archive off the LOG TXT file in SAMDATA directory Erase the file The system will automatically start a new one for you d Make an archive copy of the SAMDATA directory and any Press Directories that exist so that the system can be restored in case of a crash e Check the displayed press position for accuracy with actual press position 3 Every year a Check Zero offset on sensor channels If drift has occurred schedule sensor service as needed Follow the instructions under Calibration procedures for checking Zero Offset b Check the condition of the shock mounts if used replace any br
103. in the upper right corner of the window A list of available options will be displayed in a pop up window The DEFAULT is ALL NOTE The List of Available Signatures in the Right window of the playback screen will ONLY show 100 signature REGARDLESS of how many signatures are available in memory Furthermore The list will default to the MOST RECENT 100 signatures With the NEWEST signatures at the bottom of the available list Older signatures will have to be sorted chronologically to be seen at all Signature Technologies Inc 153 General Installation amp Programming Guide e All All saved signatures for the current tool and press e Trend Signatures Automatically saved by SAMview e Warning Signatures Automatically saved by SAMview when a Yellow limit violation was detected e Fault Signatures Automatically saved by SAMview when a Red limit violation was detected e Press Curve Violations Signatures saved Automatically by SAMview when a White limit violation was detected e Master Signatures All signatures MANUALLY saved as the master signature for the tool and press e Requested Manually saved signatures 4 If desired Set the Start Date and the End Date for the signature collection period A Select the Start Date button to specify the beginning of the collection period A calendar entry table will appear Each one of the Calendar windows has Increment and Decrement
104. installed in your C gt directory when the Signature Technologies SAMview software is installed Loading SAMview System software 1 When you are at the DOS C gt prompt put the SAMview disk in the computer 2 Type A INSTALL lt Enter gt 3 Follow the on screen instructions 4 When finished take the SAMview disk out of the drive and store it in a safe place You won t need it again unless the SAMview program is erased or becomes corrupted 5 Repeat steps 1 through 4 for any other supplied software disks The system will load up a directory structure like the following C gt Root Directory C SAMVIEW BAT CA SAMTEST BAT CASAMUTIL gt CASAMVIEW gt DATA gt CA SAMDATA PRESS 1 gt C A SAMDATA PRESS I TOOL 1 gt CASAMDATA PRESS 1 TOOL2 gt TA PRESS1 TOOL3 gt CASAMDATA PRESS2 gt CASAMI DATA PRESS2 TOOLI gt CASAMDATA PRESS2 TOOL2 gt C gt Root Directory 40 Signature Technologies Inc signatureACE Figure 28 SAMview directory structure C ASAMUTIL directory is where the Utility and test programs are installed They are invoked by typing SAMTEST lt Enter gt From the C gt Prompt C ASAMVIEW directory is where the Signature Technologies SAMVIEW system files are installed The program is started by typing SAMVIEW lt Enter gt From the C gt Prompt
105. keeping with the first great and general rule of Wingwalking i e Make sure you have a goo grip where you are before establishing a good grip somewhere else We suggest that any INI files in the system be copied so that in an emergency you can restore them if need be 218 Signature Technologies Inc Appendix 5 SAMview diagnostic utilities The Samtest utility Is invoked by quitting the SAMview program going to the ROOT directory C gt prompt and typing SAMTEST lt Enter gt Samtest will permit access to all the test utilities listed below from a menu format The different utilities have text that provides explanations of their operation and what the controls are for each function 1 DiEview utility Is used to exhibit Whether there are DIEview digital die protection channels available the states of the DIEview inputs and verify that the pull up pull down resistors are functional 2 Gauge utility The gauge utility operates the data collection portion of the SA2000 and displays the numerical status of the individual analog channels that are present on the input module Auto zero is also available for both the earlier Analog system and the present digital one The amount of correction is displayed as a percentage of full range 3 InOut utility Shows the status of all Press inputs amp Press amp Cam Outputs The utility also allows the forcing of Press and Cam outputs by togglin
106. most of the operating screens If there are no features assigned to the current tool the Upper left portion of the Function Selector will not display the SPC Views label Qveruiew Configure Batabase Analysis Sereen Options Press Line Overview m MS37B4 E O PRS 354 Setup Info sreeus neve fesetraut ss Simars come setts Figure 100 SPCview Access Buttons 1 To move from the Press Line Overview screen A Select the desired press by clicking the appropriate button under View Press A colored box to the left of the button will indicate your press selection B Select the SPC Views button from the Function Selector area at the bottom center of the Press Line Overview screen The system will then display the SPC Xbar amp R 1 view screen UNLESS you have saved a different view as your default 120 Signature Technologies Inc signatureACE 2 Select the desired SPC View button from any of the following screens SPC View Screen SPC Quick Pick Screen SPC View all Screen Verify the Press and Tool description located at the top of the screen to make sure you are looking at the correct SPC strip chart s When you enter a SPC graph screen from any screen other than another SPC graph screen the system will automatically display the default trace assignment However if you enter the graph screen from another SPC graph screen the system displays the trace assignment
107. name The Select a Tool Pop up will appear Conf igure Analisis lt Press Line Overview Ut A Select Set Line Limits Set Line in Bypass Set Line in Control View Press Select a Tool m P1286 File Hame n3705 t1 C MOOSE P1286 Dirs Files default tl Aseline Control O Prises pak i n9812 t1 p6754 t1 Selected Press FPP atus Bypass Siggiatures Set Limits Control Figure 47 Select Tool pop up 11 Choose the appropriate tool by selecting the tool s name from the Dirs Files list The name should highlight when selected AND appear in the File Name window at the top Signature Technologies Inc 71 General Installation amp Programming Guide 12 Choose the Select button after you have highlighted the desired tool Within several seconds the press name should appear on the button Additionally the tool name should appear in the box to the right of the Press button Overview Configure Database Analysis Sereen Options Press Line Overview Current dok e Set Line Limits Set Line in Bypass Set Line in Control Pad View Press Tool Stroke Count Run Baseline Control m es hows EE 1 OO O Selected Press P1286 Setup Info Control Status Reset Fault Figure 48 Overview screen programmed 13 Exit the configuration mode NOTE If you have only ONE press the system will exi
108. now show on the Capacity button J Hit the lt Tab gt key again and the cursor will appear in the of curve box Figure 35 Enter the percentage of the curve to be applied to the channel For example for a 1000 ton machine with four uprights each upright should not see more than 250 tons or 25 of the curve K Click on the Enter gt gt button under Channel Figure 35 The description will appear in the large window next to the address L Repeat steps A through K for each of the PRESS channels that are active and connected Signature Technologies Inc 61 General Installation amp Programming Guide Overview Configure Batabase Analysis Screen Options Press Database _ Press ID Press Description Change Press Local OCS P1286 158 ton Minster a New Press ID Description Position Offset ID SAM Description Remove ol First SAPAA 76 43 EES Erde SAM Position Device Pulses _tait gt gt Resoluer 1824 Enter Channel List JA11 Channels Remove SAM Ch Description Channel ARS ALGAS Cam Outputs 7 Editin 5 61 61 Right Connection DieWatch Inputs 8 A1 ost 01 02 Sensors fje z Enter gt gt 01 03 Description Capacity Units Calibration Offset Curve File 4 Left Connection 2100 lt uncal gt 4 0900 o 000 TEA 100 00 Figure 36 Programmed Press Database screen 14 All fixed sensor channels have now been programmed Select
109. number in the Calibration box at 1 0000 then DON T do anything here now we ll come back later Signature Technologies Inc 67 General Installation amp Programming Guide If you DID enter a calibration factor then click the box and a pop up menu will appear with the available Capacity curve files for the tool NOTE While Capacity curves are generally meaningless for tooling they MUST BE Called in order to have access to the Alternate X Axis files so that the horizontal axis for a tool sensor can be displayed in inches instead of degrees and the Work Calculation in FeatureView will work properly Tooling curves are generally Flat lines at appropriate levels NOTE If there are NO capacity curve files shown select the Cancel button and go to step J below And continue from there 1 Select the curve file you want to use It will be highlighted 2 Choose the Select button The pop up will disappear and the file name you chose will now show on the Capacity button H Hit the lt Tab gt key again and the cursor will appear in the of curve box Figure 41 Enter the percentage of the curve to be applied to the channel For tooling sensors the percentage is normally left at 100 J Click on the gt gt Enter button under Channel Figure 41 The description will appear in the large window next to the address K Repeat steps A through J for each of the
110. o0 smo Current Limits 243 64 DIT el 240 80 Hi Control Limit HBar yellow 237 96 Baseline Mean 235 12 Lo Control Limit HBar yellow 15 Hbar Limit Widening Constant 1 30 Hbar Limit Offset Hbar Drift Factor 232 28 DOT eta er 0 000 Percent Control Limit for R red eae Baseline Standard Deviation SEN gt ER E os ET R Limit R Limit Confidence level R Limit Widening Constant Recalculate Cancel Return Figure 99 SPC Limit par Pop Up Signature Technologies Inc 119 General Installation amp Programming Guide 4 Modify the desired limit parameters For information on how to modify the limit parameters refer to Limit Parameters in this section 5 Select Limit Recalc at the bottom of the pop up If any of the parameters have been modified the system will return with a prompt to save the new parameters and reset limits 6 At the prompt to save limit select Yes to save the new limit parameters and recalculate limits or select No to cancel the limit parameter save and abort the limit recalculation 7 The system will return to the graph screen to view the new limits Note that the limits are not updated while in the Limit Setup window Moving between screens The lower left corner of all the operating screens Signature Peak and SPC screens is reserved for the View access buttons The Function Selector is located in the bottom center of
111. on may have decreased Check for feed failure short feed Shut height drift overload system faulure Excessive C balance pressure etc 3 If the Force has risen significantly 10 or more and hits at the same time then something has caused the apparent hardness of the workpiece to increase It could be a Slugged scrap passage Hard spot in the material Wrong material Weld in the material stickey cushion siezed Nitrogen units etc 4 If the force has decreased significantly and the machine hits at the same time then the apparent hardness has decreased OR the area that the tooling operates on may have decreased Check for Short Signature Technologies Inc 145 General Installation amp Programming Guide feed overload system faulure Soft spot in material Wrong material loss of pressure in nitrogen cushions broken springs etc 5 If the positive portions of the force are the same but you have grown some negative force spikes there may be a problem with stripping the part Look for loss of finish on tooling galling on punches loss of lubricant breakage of die buttons etc 6 If the signature or SPC starts showing unusual drift or high hit to hit variation or grows Spikes on the signature which are of variable amplitude but stable in their location then look for Galling on the tooling dirty die Machine problems looseness bearing problems crank breakage lube problems galling or seizing in the die struc
112. or from the Press Control inputs 2 Gauge used to look directly in real time at the Analog inputs to the SA2000 SA2000 modules Auto zero and gage balance are available 3 InOut used to display the states of the Press Control input and output OPTO devices Additionally the outputs can be Forced 4 Resolver used to display the operation of the resolver position conversion to the System Digital offsets can be generated and displayed 5 GetNet Looks out on the SAMnet to see what s connected and what configuration and firmware version it is 6 CheckNet Sends and receives messages of increasing length out to all the units on line and grades their responses to assist in troubleshooting the integrity of a multi drop network 7 Getlni Looks in the host computer but NOT in the Windows directory if there is one for files with the INI suffix The list of INI files is displayed and the user can select any file to be displayed with explanations of what the file does in terms of CHANGING the operation of the SA2000 from its normal default programming 8 GetLOD Looks in the host computer for files with the LOD suffix The list of LOD files is displayed and the user can select any of the files and display its contents with some explanation which will mean little to the user but a lot to us 9 Upgrade enables the user to change the software that s running in the Sam5
113. pressure so some other way of reducing the input voltage must be found The Bridge resistance is given as 350 Ohms Connecting a parallel resistance across the bridge is a good way of limiting the output of the bridge The way to calculate the shunting resistor is Where R the strain gage bridge resistance in Ohms Att the reduction factor desired Sh the value of the shunt resistor in Ohms Sh 1 2 eel cl R Att i Figure 207 Shunt resistor value calculation In the case above I d like to run at 10 volts excitation but I d have 0 030 volts of output and need to get down to 0 005 volts for a proper input need then to cut the signal from the sensor to 1 6 of what it normally is This is a reduction factor of 0 16666 The gage resistance is 350 Ohms Example 7 e 350 0 1666 350 1 Sh Z eS a 55 31 350 i A 0 0171497 0 002857 l Sh 0 014292 266 Signature Technologies Inc signatureACE 69 97 Ohms sh A shunt resistor of 69 97 Ohms use the 0 1 resistor value of 69 8 Ohms connected in parallel with the strain gage bridge across the amp Signal inputs will achieve the proper reduction of the gage output Dealing with excessive balance offsets When dealing with strain gages that have static offset voltages a voltage present between Signal and Signal when under no load which is due either to basic gage imbalance or due to a significant mechanical pre load on the gaged
114. prevent accidental injury is MANDATORY xxx N ARN N G Hazardous Voltages are present in the cabinet housing the Signature Technologies Equipment Make sure ALL power is shut off to the SA2000 itself AND to the machine that the SA2000 is connected to before opening the equipment enclosures The Signature Technologies system normally will have voltages present that originate in OTHER SYSTEMS Consequently interrupting power to the SA2000 only will NOT be sufficient to avoid electrical shock Qualified personnel MUST perform all system service The Die protection function Die Protection is a generic term used to denote use of monitoring equipment sensors that seek to insure that the operation of a machine is proceeding properly This equipment is normally DIGITAL either ON or OFF in nature and is Fundamentally different from Load Monitoring and Signature analysis in that it has the capability to confirm BEFORE a cycle is made that conditions prevail that will permit proper operation of the machine For example In a pressing application a sensor can be set that indicates the point in the machine rotation when the strip stock comes into the proper position to form the next part This occurs before the press closes and also should occur at the same position in the press stroke cycle after cycle The ST Die Protection system can set up a Window range of angular machine positions during which the sensor should see the st
115. quality or capacity is saved to the database for future analysis Follow the procedure described here to configure automatic fault saving 1 You should be in the Signature Save Setup window If you are not follow the procedure outlined in Accessing the Save Signature Setup pop up window 2 Slide the switch under the Automatic Fault Saving label with your pointing device selecting one of the following options A Of does not save any violations to the database B Save saves any limit violation to the database but only when the system is in control C Save with comments requires that the user enter a comment to be saved with the signature before the fault can be reset Configuring scheduled saving of signatures When the system is set up for scheduled saving of signatures signature information valid signatures are also saved is saved to the database for future analysis Follow the procedure described here to activate the scheduled saving of signatures 1 You should be in the Signature Save Setup window If you are not follow the procedure outlined in Accessing the Save Signature Setup pop up window 2 Slide the switch under the Scheduled Saves label with your pointing device to select On 3 Select the box below the Default Comment label 4 Use the keyboard to enter a comment to be saved with all saved signatures Scheduled Save Etc 5 Select the box to t
116. ruth ralph LP The Slide Motion CX file Is used to tell the signatureACE system what the motion of the slide is relative to the rotation of the drive mechanism The curve can be ANY shape and can consist of as many or as few points as you wish The system will interpolate between existing points and create the best curve fit rather than simply connecting points with straight line segments Format The CX curve MUST HAVE the same name as the LP curve Since we named the LP curve Ralph LP the CX curve MUST be named Ralph CX I is used as a comment delimiter and tells the system not to interpret anything that follows on the line as data Data is entered Angle Value where Value is the STROKE REMAINING 180 degrees is ALWAYS ZERO no stroke remaining The downstroke is expressed in NEGATIVE NUMBERS and the upstroke in positive numbers Example This is the Press motion Alternate X file for press slide motion expressed in inches of stroke remaining for a machine with a 6 inch stroke 216 Signature Technologies Inc signatureACE 0 6 20 5 84 40 5 36 60 4 61 80 3 67 100 2 62 120 1 61 130 1 16 140 0 76 150 0 44 160 0 198 170 0 05 180 0 190 0 05 200 0 198 210 0 44 220 0 76 230 1 16 240 1 61 260 2 62 280 3 67 300 4 61 340 5 84 360 6 The file can be written using the Edit command in DOS Let s say you want to call the file Ralph Th
117. set Job into multiple Presses 155 Load Monitors Interfacing to 276 Loading a Tool or JOB 86 Loading System Software 40 LOG ON Multiple operations 148 Log On Window 147 LP Files 55 LP files For Press Curve 215 M Machine Control 30 Machine Angle correction 44 Machine Calibration Dynamic Procedure 83 Machine Capacity WHITE Limit 138 Machine Control 138 Machine control modes 138 Machine doesn t stop on a fault 339 Machine Position Sensor 140 Machine structure Calculated Calibration Underdrive machines 356 Machine structure calibration 355 Machine structure DYNAMIC FORCE method 356 Machine Structure STATIC FORCE method 356 Machine won t run 338 Macro Feature algorithms Programming 118 Maintenance SAMview system 205 Maintenance Manual 350 Maintenance of Calibration Settings See Make sure you re on line 253 Making the displayed Angle unit agree 255 MASS backup of the database See MASS Restoration of the database 353 MASTER SA2000 definition 133 Master Signature 136 Master Signature Definition 136 Mounting the SignatureACE 26 Mounting the TEC 26 Moving between screens 126 N Navigation Block Diagram 49 Needed personnel 203 network 285 Network ARCNET 144 Network indicator 38 Network Module 286 Noisey Flat Line 331 Noisey Flat Top Signature 331 O Offset values Acceptable range 267 332 one of the Tools has disappeared
118. set to 4096 Refer to Figure 230 Typical combinations If the press when it turns only counts up to 90 before re setting to 0 then the number in the Pulses field is Four Times as big as it should be i e You thought you had a SAM configured for a R D conversion of 4096 but you don t It s actually 1024 If the press when it turns counts up to 360 in 90 degrees of rotation and stays at 360 for the rest of the rotation then the number in the Pulses field is One Quarter as big as it should be i e You thought you had a SAM configured for a R D conversion of 1024 but it was actually set to 4096 5 ENCODER Version NOTE The SAM module is internally capable of doubling the pulse count from a normal incremental encoder That is if the SAM is set internally with jumpers to perform a 2 times pulse multiplication then a 3600 line encoder will produce 7200 pulses per revolution The number that you enter in the Press Database screen in the Pulses window does NOT control the resolution of the SA2000 it only sets up the Host Computer to properly interpret what the SAM is doing The number must correspond to the internal resolution setting of the SAM If a 900 line encoder is connected to the system and the SAM is internally set for X2 multiplication the Pulses Window should say 1800 Typical combinations gt If the press when it turns only counts up to 180 before re setting to 0 then the number in the Pulses fi
119. the SA2000 is powered up and communicating to the Line Computer it is considered to be ONLINE The system can immediately know whether a certain SA2000 is ONLINE by going to the Network screen and checking the color of the indicator light above the box having the identification of the SA2000 in question If the indicator is NOT GREEN the SA2000 in question is NOT ONLINE OptlOnS nopiaa This is a Menu Bar selection that allows the user to log On to the security system exit the SAMview program or reset the displayed stroke count for the tool OVEIVICW iirinn iie This is the Clearing House screen of the system You can get to any of the Configuration utilities the signature screen or SPCview screens for any of the connected machines from this central location Modifications to the Line Job Press or Tool database files are made from here you can access different machines through the Overview screen Position Sensor As the press being monitored is rotated the signature readings are collected at precise angles of rotation In order to track these angles accurately an electronic device such as an encoder or a resolver sends the signals to the computer These devices are referred to generically as Position Sensors 372 Signature Technologies Inc signatureACE Press Database Process Limits SA2000 SAM Module The term used to describe the action of a press in motion The
120. the TEC and the Host Computer should be held to 100 or less The two interconnecting cables will be supplied in 10 lengths unless otherwise specified The BOX enclosure can be mounted solidly in the control stand or on shock mounts if machine mounted Note We suggest the use of Vibration mounts between any machine mounted enclosures and the machine structure in cases where there is shock or vibration see step list below signatureACE Wiring Wiring is brought into the signatureACE TEC through Pre punched conduit holes in the enclosure The TEC enclosure is mounted using Vibration Mounts if it is applied to the machine frame and you should make sure to terminate any conduit to the enclosure using a link of FLEX conduit Attaching rigid conduit directly to the TEC will destroy the effect of the vibration mounts Signature Technologies Inc 27 General Installation amp Programming Guide signatureACE typical installation steps Install Strain Links IF you are using Strain links Appendix 6 to measure the forces on the Machine frame this is the time to install them If you are using InSitu sensors from Signature Technologies using sensors according to the recommendations in the Interfacing Guide or rolling your own sensors l Il assume that they are already in place and wired to the vicinity of the TEC terminal box Refer to Appendix 6 in this publication for details on Strain Link installati
121. the line to the end The problem is that just like miniature Christmas lights one bad station or Coax along the way can bring the whole system down Also since the SAMnet system is a high speed bus there must be proper coax used and proper terminations applied at the ends to prevent data corruption NOTE The network may also behave strangely with certain units ON Line properly and others OFF Line DON T automatically assume that the units that are OFF Line are defective or even necessarily involved in the problem There may be coax problems in a totally different location that are causing the problem NOTE There is a possibility that the Network communication may be O K but the SA2000 processor has gone to space and is not operational The Network operates somewhat independently of the processor in the SA2000 module so you must be careful to establish that the SA2000 is actually running before assuming that a presence on the network means everything is O K The tests up in Check 1 Page 297 above using the Bypass button will tell you what you want to know You can check the condition of your network by 1 Go to the Configure Pull Down and click on SAMnet 2 The Green indicators will appear next to the station numbers for any units that the network recognizes 3 Compare this indication with the stations you SHOULD have As a general rule the Host Computer is assigned address 16 See Figure 241 below
122. the monitored parameter is given by the vertical elevation of the point The degrees of machine rotation are displayed at the horizontal displacement of the point The point may also be displayed through post processing in inches of stroke remaining theoretical Using the two scales the signature provides information about the amount of force displacement temperature and pressure that is developed at a specific point of machine rotation Signature Analysis is a practical method of assuring quality in the industrial workplace through the monitoring and control of manufacturing processes What is a master signature A master signature is a picture or signature showing the manufacturing parameters for optimum machine operation using a specific tool The master signature is created and saved during the initial tooling setup and may be updated by appropriate personnel when necessary 130 Signature Technologies Inc signatureACE What are limits Overview Configure Database Analysis Screen Options Signature View em o o uan 300 LO Front _ TF eter riers tear eset roun eums E Figure 107 Signature with limits Limits thresholds as shown in Figure 107 above are based upon the master signature and are established under operator control by SAMview computer software If the machine operating signature moves beyond any of the upper or lower limits a warning indicator will illuminate an
123. there should be NO or very little voltage across the terminal sets If you find 110 V A C the module in the corresponding slot is BAD Replace it Check the control wiring to the press Look for broken connections related to the wiring on the Outputs in the RED YELLOW and WHITE positions in the I O chassis Check 10 The machine doesn t stop on a fault If the system is in the CONTROL mode and the Machine doesn t stop when a fault occurs 1 Check the Output indicator lights on the Modules located in Pos 4 and 5 on the I O chassis The output indicator light corresponding to the fault should be OFF gt The output in YELLOW position should be OFF if a Yellow Fault has occurred The outputs in RED amp YELLOW Positions should be OFF if a Red Fault has occurred The outputs in RED YELLOW and WHITE Positions should be OFF if a White Fault has occurred 2 If they aren t something may be wrong with the output module the I O Cable or the logic level outputs from the SA2000 3 If they are check with a voltmeter across the output terminals corresponding to the modules see the cover label If the outputs are not OFF even though their lights are OUT there will be no voltage across the terminals gt Check for shorts in the wiring that would allow the run circuits to remain closed even though the contacts are open gt If You are running D C I O MAKE SURE the polarity through the module is acc
124. they do there s a shorted sensor If they don t the CONTROL cable from the TEC to the SA2000 is suspect 18 On the Converter INPUT cable STB 027 8002 STB 027 8004 see Appendix 8 for cable details Measure the D C voltage from the White Green wire to the Red Wire and the White Green wire to the Black Wire There should be very little less than 1 volt on either measurement and they should both be about the same If the voltage is high 3 5 volts one of the ground connections is improper Call ST 972 488 9777 for advice 19 Then on the A C Scale measure between the Red and the Black wire You should see voltage between 2 5 and 10 volts If there is voltage The reference signal is present at the existing system but not getting to the Converter the Converter or the INPUT cable is probably defective If there s NO voltage the existing system is either shut off or defective When you get the lights operating Go Back to C2 b and adjust the lights properly Then jump to below to 36 to continue the checkout 20 Rotate the machine slightly 20 40 in its normal direction of motion 21 If after moving the machine in step C2 d the position display increases then the HiRes Converter hookup is O K go to Check 3 below 22 If it decreases reverse the connections of the Green and White wires on the Input Cable STB 027 8002 to the existing system Perform steps 20 21 again to check for proper rotation If the ro
125. this box 8 Select Configure from the menu bar A drop down sub menu will appear 9 Select Exit Configuration from the sub menu To load a different Tool or JOB into the machine 1 From the Press Line Overview screen select Configure from the menu bar A drop down sub menu will appear 2 Select Job from the sub menu This will cause a select button to appear next to each press as shown in Figure 60 To load a SINGLE tool in a single press Refer to section 4 above Putting the press and the tool together To load a JOB to ALL the machines shown in the overview screen 1 Choose the Select button next to the Current Job box at the upper left of the screen Figure 61 The Select a Job pop up window will appear Conf igure Sakae ia select Set Line Limits Set Line in Bypass Set Line in Control View Press Select a Job m ai File Hame 410 jb n __ 32 __ WAYHE Lad 3_3 Dirs Files Prises test jb m 7 Aseline Control Selected Press Ex atus Bypass Set Limits Control Figure 61 Job Selection pop up 84 Signature Technologies Inc signatureACE 2 Highlight the appropriate job name from the Dirs Files list on the left side of the window The name should appear in the box next to File Name at the top of the window 3 Choose the Select button to return to
126. to Resolver cable is connected to the Resolver 12 On the TEC end of the TEC to Resolver cable check with an Ohmmeter the points listed Below a Measure between the wire that was in terminal S2 6 amp the wire that was in terminal S4 7 You should measure about 125 Ohms b Measure between the wire that was in terminal S1 4 amp the wire that was in terminal S3 5 You should measure about 125 Ohms c Measure between the wire that was in terminal R1 8 amp the wire that was in terminal R2 9 You should measure about 17 Ohms 13 If you Measure the correct values The TEC is suspect Install another one Go back to Step 1 14 If some of the measurements in Step 12 were wrong The TEC to Resolver cable is defective Install another one temporarily Go back to Step 1 and Check system operation 15 If you are still not working properly at this point Give S T I a call Signature Technologies Inc 311 General Installation amp Programming Guide ase HiRes RESOLVER CONVERTER Checklist WARNING There are TWO versions of the resolver converter The one that is used for the SA2000 has the designation CNV on its label while the SAM500 unit does not If one is accidentally used in place of the other no damage will occur BUT the adjusting lights will not give a true indication of the signal status 1 Make sure the RESOLVER shaft is turning when the machine does One easy way to do this is t
127. to set up the data collection parameters for each feature A maximum of 16 features for a single SA2000 system and 32 features for a double SA2000 system are available Used to define the method for extracting the feature from the signature data The SPCview package provides the means for extracting Peaks Valleys Load Averages and locations of Peaks The FeatureView package provides more complex algorithms such as work calculations and normalized ratio calculations A software module for the signatureACE system The FeatureView module provides complex feature extraction capability In addition FeatureView provides a virtual feature building utility that allows the user to define new features The flexible magnetic disk used to store computer information for archive or backup purposes Sometimes referred to as a Flexible Disk A task running in view of the user Usually the user may directly interact with a foreground task Function keys lt F1 gt through lt F12 gt allow the user to select specific options without a pointing device Keys labeled F1 through F12 These keys perform specific functions that are defined by the SAMview software package A printed copy of what is displayed on the screen Pressing the Print Screen button located in the upper right corner of the keyboard will send an image of the screen to the printer The rigid magnetic disk installed in the computer and used to store com
128. when leaving the window must be OFF If the signal exits the window in the ON state A Fault will be issued immediately If the signal enters the window in the OFF state A Fault will be issued immediately The window MUST be at least 5 degrees wide What happens Outside the window is ignored The window MUST NOT BE more than 350 degrees wide OFF On Normally OFF with a change to ON expected during a programmable position window in the stroke Lack of a change during the proper positional window produces a fault at the angle of window closure The state of the signal when leaving the window is unimportant If the signal enters the window in the ON state A Fault will be issued Immediately The window MUST be at least 5 degrees wide 194 Signature Technologies Inc signatureACE What happens Outside the window is ignored The window MUST NOT BE more than 350 degrees wide OFF On On Normally OFF with at least one change to ON expected during a programmable position window in the stroke Multiple OFF ON cycles during the window are O K Lack of a transition during the Window produces a fault at the Window END angle The state of the signal when leaving the window must be ON If the signal exits the window in the OFF state A Fault will be issued immediately If the signal enters the window in the ON state A Fault will be issued immediately Th
129. 00 Eprom version or SA2000 module The user can choose from available LOD files display their contents with some explanation and cause them to be loaded into selected units over the network 298 Signature Technologies Inc signatureACE Q Quits the SAMtest program NOTE Any version of SAMtest Supplied BEFORE June 1999 may leave the Sam500 or SA2000 in an inoperable state when exited To remedy this situation cycle power to the SA2000 AFTER using the SAMtest program to insure proper register initialization If you re NOT SURE which version you have CYCLE POWER to the SA2000 after exiting SAMtest for safety s sake Check 1 See if the SA2000 SAM is ON LINE IF EVERYTHING IS O K the SAM s will automatically come On Line when the system is powered At the lower right hand corner of the Signature View screen there is a Bypass Button which has a Yellow indicator on its LEFT See if the indicator is Yellow NOTE The Network screen will indicate whether the SAM is talking on the SAMnet network but NOT necessarily whether the unit in question is Actually Alive This is why I ve suggested the following method of diagnoses because it forces the unit to respond to a command which it won t do if the processor has quit 1 If it is Yellow Click on the Bypass Button The Indicator should Blink Off and then come back On If it does the SA2000 is ON LINE
130. 01 Whetstone Bridge connection Fi Figure 203 Standard Figure 204 A08 Jumpers Fi Fi Fi Fi Fi error larger Fi g error less but resistor too small Fi Figure 212 Data Instruments Strain Link Hookups Figure 213 Piezo Twinaxial Fi Fi Figure 216 NPN type 3 wire D C Proximity switch Figure 217 P N P Type 3 wire D C Proximity Switch 16 Signature Technologies Inc signatureACE Figure 218 Hookup for 2 wire universal Proximity Switch Fi Fig Figure 221 Toledo Model 260 Interface Hookup to signatureACE i Figure 233 SA2000 Figure 234 HiRes Resolver Converter Fi Fi Figure 246 TEC With I O Fi i Fi Fi Figure 250 A08 Jumpers Fi Fi Fi Figure 254 Figure 255 Gage out of balance Figure 256 Resistor hooked the wrong way error larger i iz igure 267 SA2000 module End indicators Signature Technologies Inc 17 General Installation amp Programming Guide What follows is a step by step look at the scope of installation of a signatureACE When you get to the actual installation section the steps are written in the order that they would be performed System operator information is NOT included See the System Operator s Guide Safety Precautions EEVA ARN N Girt The Signature Technologies CAMview product IS NOT a
131. 1 From the Security Setup Screen select the user from the User Name list Signature Technologies Inc 159 General Installation amp Programming Guide 2 Select Remove From List 3 Select Return The message Save changes to Security Screen will appear 4 Select Yes to save and exit or select No to exit w o saving Password problems Passwords are read by the system on a character by character basis and matched to the passwords stored in the database The program will change any lower case characters to Upper Case automatically The Password is NOT case conscious ABCD is the same as abcd If you forget or ERASE your passwords Signature Technologies has provided a backdoor into the system that will let you in When entering passwords the password field will display the asterisk to indicate that a character has been received Some computers respond slowly so it s a good idea to MAKE SURE the appears each time you enter a character If you get messed up use the Clear button to clean out the password field Selecting events to be logged 1 From the Security Setup window select the box to the right of the Log Events of Security Level label 2 Select one of the following All Events 1 and above 2 and above 3 and above 4 and above 5 No Logging 3 After an option has been selected only security region accesses with that level requirement will be
132. 2 S4 points are then received as a return from the resolver If the existing system does not operate this way the Resolver Converter can t be used and another Resolver must be fitted For example if the Sine and Cosine windings are driven with reference signals and the resultant return signal is from the rotor The Resolver Converter wouldn t give us anything we could use in our system If there is doubt about the way the existing system operates contact the manufacturer of the system and ask Does your system supply a reference to the resolver ROTOR and accept back Sine and Cosine signals Alternatively if you will supply Signature Technologies with the Make Model and manufacturer s name and location of the existing system we will research the installation for you The Existing Resolver mechanical drive system must meet the criteria outlined in the S T I publication Resolver installation considerations In general the resolver MUST be driven in a manner that insures a true crankshaft position reference Programmable limit switches can and do operate acceptably with 1 2 degrees of slop or position ambiguity Signature Analysis is not so forgiving The result of a sloppy resolver drive will be horizontally unstable signatures 244 Signature Technologies Inc signatureACE ICNV Converter Mounting The CNV Converter requires no mounting in order to operate properly There are mounting holes provided to enable t
133. 3 Select Exit Configuration 14 Answer lt enter gt to all the message boxes that come up 15 The system will automatically go to the Overview Screen where the press name and a tool named Default will be shown 16 Select Signatures at the bottom of the screen 17 The system will drop into the Signature view screen 1 and any channels assigned to the first press will be displayed IF NO CHANNELS were assigned to the press ONE channel 1 will have been automatically added to the tool with the name _DEFAULT USE IT The system should now display signatures when the machine is operated The idea is that while everything isn t exactly the way you would do it yourself the system is Up and running and you have an opportunity to get a little familiar with the way it operates before stepping into a Full Bore configuration of your own What you have is At least one active channel Each active channel has a Window defined in the Load Monitor Peak screen The Signature view 1 is configured to display all the channels Default values are in the limit setting functions and the system will automatically set its limits after it has made 5 strokes The system IS NOT calibrated SO the numbers on the left side of the graph DO NOT indicate actual force values only relative numbers 48 Signature Technologies Inc signatureACE SYSTEM NAVIGATION DlEview CaMview Programming Programming
134. 4 Signature Technologies Inc signatureACE Die Protection Sensor connections NPN or PNP 3 wire BROWN Proximity Sensar ua punu arsil a e S S 24V UR Sensor Probe N COM hg NG SENSORS Workpiece J Machine Frame N NAANAN ANA NANA ANAAK Grounding or Cat s Whisker Contact Sensar Figure 141 Typical DIEview Inputs Grounding Switch connection The Good Old Original method for Die protection sensing depends on Grounding detectors which are normally based on spring wire Cat s Whiskers These are insulated from Machine ground and positioned so that the object to be sensed will touch the Sensor spring and ground the signal to the press frame The ST system supplies 24 Volts D C at 0 005 Amps to the Grounding sensor and senses Part Presence when the voltage drops below 10 Volts as a result of the sensing spring being grounded through the workpiece Sensor Probe G Workpiece mmm Machine krame SS VARANUS ESS SA NN ASN Figure 142 Cats Whisker Ground Detecting sensor Signal To D P Input s Common To 24V Common a Grounding sensors are used to sense proper feed length with the whisker positioned to pick up the end of the stock at the outgoing side of the die They are also used for Stock Buckle detectors and Short long Loop detection Th
135. 5 Count Tee W Left Connection SPI z i 8407 Right Connection 2107 R L Kiss block F R Kiss block 4207 lt pen off gt lt pen off lt pen of F gt 118 8 150 6 182 5 214 3 246 1 lt pen of f gt Zoom in out flerew ox Position 134 736 Force 262 500 Control Status Running ra O O ems Drim JO O a Figure 53 Zoom Cross Hairs Graph View HARE Haa 7 Select the Default button Figure 53 The vertical scale will change to reflect the capacity setting in the press or tool databases 2100 The horizontal scale will also change to reflect the data collection window values assigned in the tool database 8 Select the OK button Figure 53 The cross hairs will disappear 76 Signature Technologies Inc signatureACE 10 11 12 Select a Pen button by clicking on it Pens already assigned will have the Channel name displayed unassigned pens will display lt pen off gt on the column of pen off buttons that appear on the right side of the screen Figure 53 The Pen Sensor Setup pop up window Figure 54 will appear on the screen with a list of available channels Querview Configure Database Analysis Screen QOptiens Signature View P1286 M3705 Pen Sensor Setup S Assigned Channels ae Left Connection A
136. 5000 P S I The calibration factor will be calculated as follows The SAM gives one A D count for each 0 002441406 volts of input With a 5000 P S I input to the gage the signal to the SA2000 will be 0 005 volts The SA2000 multiplies the signal X 1000 and passes 5 volts to the SAM module The 5 volts will create 2048 A D counts 5 volts divided by 0 002441406 volts per count 2048 counts 2048 A D counts 5000 P S I The Calibration factor 2 441406 5000 P S I divided by 2048 counts When this factor is programmed into the channel used by the Pressure sensor the signature will display the value in calibrated P S I G On the other hand the Analog prox couldn t be calibrated by the signatureACE system since it s characteristic is non linear 0 1 mm distance is 0 3 volts 1 5 mm increases linearly from 0 3 to 10 volts With a characteristic like this there s no way to get the system to read out in mm directly The best that could be done is to read out in voltage and develop the distance with a chart If direct readout in mm was required software could be written to perform that conversion Contact ST for details Calibration of Home Made Sensors In cases where you are attempting the Calibration of homemade sensors you must make sure of the following You must make sure the sensor is calibratable There are cases where a sensor may not be calibratable due to the way force flows to it In general if ALL the forc
137. 6 decimal This is an indication that the host recognizes the existence of the SAMnet Communications card SO FAR SO GOOD in some cases the ARCNET base will be 260 instead of 2E0 in cases where 2E0 conflicts with equipment already installed in your computer Signature Technologies Inc 41 General Installation amp Programming Guide c Below the message should be a menu at the top of which is Signature Technologies Y2K compliant Field Diagnostics And followed by On line 0x Hex Note 0x will be what the address of your SAM2000 is set to This indicates that the SAM2000 is also in communication with the Host If the message is On line none Then the SAM2000 is not connected not working or not plugged in properly 4 If step 3 results in everything being O K then Select option 5 GetNet The display will become GetNet x x Arcnet base 2E0 Host PC node is 10 hex 16 decimal 7 06 0 xxx xx firmware Gauge Cam SPCview Auto warn reset 25 Arcnet regions 7 06 0 diagnostics OK SA2 Processor version 8 8 cams optically isolated I O A08 Sensor version 6 LTC1276 ADC 8 gages RES Position version 2 Resolver 12 bits resolution Everything s O K This is an indication that The Host computer is in communication with an SA2000 at Node 1 of the SAMnet network The remainder of the text gives the firmware version the card serial number and the hardware configuration and revision l
138. 91647 Figure 231 SLV Slave Daughterboard position input module If there s a HiRes Converter in the system If the system uses a HiRes Resolver Converter to tap the resolver signals from an existing system the SA2000 uses a RES module which should have the REF jumpers removed in order to function because the Reference signal will come from the HiRes Converter Signature Technologies Inc 293 General Installation amp Programming Guide Terminator Jumper IN Terminated OUT Open Pa X Figure 232 SA2000 SAMnet Termination jumper 7 RESET Button Access through hole Control Connector Input Connector SAMnet Network Indicator Zero Indicator SAMnet Network Connector Figure 233 SA2000 module end view controls indicators 294 Signature Technologies Inc signatureACE The HiRes Resolver Converter unit Mounting holes Indicators amp Adjustments Connector Hiktes Resolver 3 25 Converter OUTPUT Connector Figure 234 HiRes Resolver Converter Signature Technologies Inc 295 General Installation amp Programming Guide The SAMnet Communications cards Jumpers Switches There are THREE Communications modules which were used at different times in the SAMView product offering The unit detailed below under Figure 235 is the current unit If your unit has a different physical appearance give us a call a
139. E Overviewt Configure Batabase Analysis Screen Options Tool Database for Press TEST View another Press Change Tool Durie Press Tool ID SAM SAM Desc TEST DUMMY a2 test On Off A E ee Description State Angle Angle 01 PC Feature CEECEE OL EECCEELE E mj E Ej ml aj E El tair Save Changes Cance Return 2 Figure 133 CAMview Programming screen The illustration shows the screen with ALL Cams turned off At the extreme left of the screen is a vertical column of small square boxes with the word Active at the top Click on the Active box next to the Channel 01 label The entire row will be highlighted and ready for programming You will fill in the Description the ON Angle and the OFF Angle or Dwell Time items to complete the programming process NOTE You are programming the Cam Protection for the Tool whose name is showing in the box at the upper left under the label Tool ID The field names are Description This field is a verbal identification of the purpose of the Output that is operated by the Channel 1 Cam You should be descriptive in terms the floor personnel will relate to easily CR 143 may not say much to the operator Part Blow off Valve is clearer State This is another INDICATING ONLY field It is the State indication for Cam BY DEFINITION If this light is lit the Cam is considered
140. E connected to each machine the SAMview user interface software allows the user to monitor and control up to eight machines on a single press line SAMview software is a DOS application that runs in a host computer that is an IBM compatible PC SAMview communicates over a 2 5 Mbaud SAMnet ARCNET architecture communications system to the SA2000 and SAM500 modules providing a real time network that monitors and controls a machine to user defined parameters OQuerview Configure Sstabase Analysis Sereen Options SAMnet Summary a4 H W Ver 0x1906 5 N 0x46AA4D 017 018 819 826 821 822 823 424 Figure 109 SAMview Interface The SAMview system user interface is shown in Figure 109 Using a touch screen mouse or a track ball the user can view operations and set parameters all with the touch of a button Operation of the signatureACER system Each of the major components of the signatureACE system has been described in the paragraphs that follow They are divided into the three basic levels of computer operation Input Processing Output As a user it is best to think of the operation of the system on a simplified level Information is gathered by sensors and is provided as input to a special purpose high speed computer The computer processes the information comparing sensor input to stored data and user defined limits The computer produces output based on proces
141. Excitation Channel 3 Excitation Channel 4 Excitation Figure 227 A D Input Daughterboard module jumpers 290 Signature Technologies Inc signatureACE Sr cy eres gl l ae fi SAILERA Bers Ne Sisin a OPYAIGHT 2000 MACE IN USA SA 2008 STB 020 NTS 4987528 5491647 tiddttidididdiidii tiii Figure 228 A6D Input Daughterboard module jumpers GROUND Channel 1 Channel 1 Gain DN Excitation To paa R Ri sane Ww ay A g gt Sette ir po iH cise ei ER aima 22 05 gr F ii ia s 3 iii FE bis t P gai Soiree 5 _ A o e A Channel 8 Channel 8 Excitation Gain Figure 229 A08 Input Daughterboard Board jumpers 291 Signature Technologies Inc General Installation amp Programming Guide a i Excitation iar EY EAI LA iE 3 A Jumpers ww Bios Compe Ee CSL Se IN for Master conic ae OUT for Slave aa L amen OUT for HiRes Conv cea BHi Aa G Resolution SS Jumpers Compensation Jumper Ground ee i ey 1997 IN for 4096 Terminal 3 ANS 49870381 S191647 OUT for 1024 Figure 230 RES Resolver Daughterboard input board jumpers SA2000 Position reference Jumpers RSC1 RSC2 Jumpers These jumpers set the base resolution of the SAM when a resolver is used as a position sensor They function as follows A For a resolver resolution of 1024 counts 10 bits per revolution RSC1 amp RSC2 are installed This setting is for press speeds from 250 S P M
142. HANNELS ONLY should be tied externally to MACHINE GROUND DO NOT connect an EX Die protection terminal to an EX analog sensor terminal Hardware damage may result porto aS 2 Inline L 1 Poisson L 2 Poisson E E eer ee es ec TEC Analog Sensor Connectian sb fai Shield is NOT connected at the Load cell end Figure 153 Typical Strain Gage Load Cell Input 204 Signature Technologies Inc signatureACE NPN or PNP J wire Proximity Sensar BROWN BLACK Sensor Probe o Workpiece mi Ma NAS chine Frame X CHING RONEY Grounding or Cat s Whisker Contact Sensar Figure 154 Typical Die Protection Inputs Analog amp Die Protection Sensor input terminals The Connections for the wiring are printed directly on the connection board AND displayed in printed form on the cover label for the TEC enclosure a mo Olm N EXt Q EX Channel 1 lt S 2 Q 455 gt Channel 5 EX NOl S Ex a mO s0 EXt O Q m EX Channel 2 lt oot D amp 56 gt Channel 6 Analog as ATS T Analog Sensor NOI OU Et Sensor inputs me 1116 een Lee Inputs Channel 3 lt s3 a S HD1 o gt Channel 7 D2 i QD Q Ex mw loe s lt X Q EX Channel 4 lt o D p 3 ke Cha
143. High Power Digital Inputs and Outputs The resolver Encoder connections 8 Signature Technologies Inc signatureACE Find out what the wire color code for the sensor is Sensor hookup RR resolver Mechanical Environmental Specifications Do s and Don ts IDESIGN PRACTICES Mounting Sin SmartPa Full Floating i he SB 027 8006 Cable Color Code is Make Sure your SA2000 is confi g Jif your Cable color code doesn Appendix 9 Sensor Interfacing INTRODUCTION Technical Information about the SA200 Standard Sensor Connections lif the Strain Gag RESETS eer aie rec meee ee E en ene 267 Signature Technologies Inc 9 General Installation amp Programming Guide Interfacing Self amplified Analog sensors to the si Interfacing Calibrating Interfacing to existing Sensor Calibration Appendix 10 Troubleshooting _ Introduction _ Who does what in the Si The Analog Dig The Position Input Daughter Boards The The The The The The TEC Module Connection points SA2000 Position reference Jumpers The HiRe The SAMnet Communications cards Jumpers Switches Using Check 1 See if the SA2000 SAM is ON LINE J RESOLVER CHECKLIST PERRET re AiRes RESOLVER CONVERTER Checklist 10 Signature Technologies Inc signatureACE Excitation Reduction Jumper Loc
144. Inc signatureACE Light Stack Output position 7 YEL This Is a Standard Output It is a normally open device Whenever the SA2000 is in CONTROL Mode and the signatures break the YELLOW Warning process limits this output will turn ON and remain ON until the fault is reset This output is normally wired in to the YELLOW indicator on the ST light Stack Light Stack Output position 8 GRN This Is a Standard Output It is a normally open device Whenever the SA2000 is in CONTROL Mode this output will turn ON and remain ON until the SA2000 is switched to MONITOR mode This output is normally wired in to the GREEN indicator on the ST light Stack Cam Output position 1 thru 8 These are Optional Outputs These are normally open devices Whenever the SA2000 detects the presence of the CAMview product in the system AND the fulfillment of the conditions calling for the actuation of the individual CAM channels These outputs will respond accordingly System indicator LED s SAMnet communications card Network Activity Indicator Internal Bus Activity Indicator SAMnet Connector Figure 265 Samnet Communication module indicators SA2000 module set There are 8 indicator lights on each SA2000 Following is the description of each light Signature Technologies Inc 367 User Manual HEARTBEAT Indicator TEST Address Buffer Full Connector Switch Indicator RESET But
145. Input 14 D 14 j E H D 6 Input 6 Common COM 16 H COM Common SHD io Q SHD 24 Volts 24 QI H 24V 24 Volts Input 15 D 15 D 7 Input 47 Input 16 D 16 1 0 8 Input 48 Common COM Ol 4 H COM Common _J Figure 158 Die protection Sensor Terminal layout D16 version High Power Digital Inputs and Outputs The Connection to the outside world is done with terminal strips on the TEC Board Each I O terminal is marked as either or The Terminal amp Terminal Polarity needs to be followed ONLY in the case of DC OUTPUT Modules With DC OUTPUT Modules the ODD numbered connection is ALWAYS the Terminal If the connections to a D C Output module are reversed the output WILL NOT turn OFF AC Modules and DC Input Modules are Non Polarized Each Input and Output point is Totally floating and optically isolated and has TWO connections Signature Technologies Inc 207 User Manual
146. Inputs eam Outputs AF olj O O olo SHO EX Y A fe lle lle le lo be pa 2 0 a ala RESOLVER gt SFE ENCODER S2 sssissessecsss9 eal Ae a cl jp E E a FAULT LIGHT STACK SHD EXt J i 4 st Resolver a Encoder GRN 8 OUTPUTS fy f sib CAM OUTPUTS ASISSISSISSISSIS SISSSS SY SSs decel eeek adada D U L p3 R2 5 2 s4 Cpa 8 45 Input a S oe EX eno nN Ge ir oy NSO Pe i a 45 i I ti tit t t ti I Lit t Ij 1 OOO JOOS IgI ooo leolelcolcojco ojoj eeeeebedcececeeeee Je SESS 0 ERO GED O E SENSOR CABLE S amp S OH IO p oO CONTROL CABLE l Oll ollo ot ps C Oo oO _
147. K will give a resistance reading of 350 ohms approximately and any other pair like GREEN amp WHITE will measure around 267 Ohms If you can t find two equal relatively high resistance pairs measure and record the combinations and give ST a call It could be that your link is damaged or of a self amplified type like Data Instruments see the Interfacing Manual Sensor hookup Select one of the high resistance pairs to be the Excitation pair and hook to the EX and Ex terminals on the TEC unit according to the wire list below With an non amplified Whetstone Bridge type of strain link also called Full Bridge it does not matter which high resistance pair is connected to the Excitation and which high resistance pair is connected to the Signal The other high resistance pair will go to the and Signal terminals Toledo and ST Strain Links are normally connected EX GREEN A Signal in Compression RED in Tension WHITE A Signal in Compression WHITE in Tension RED EX BLACK Helm Strain Links are connected 224 Signature Technologies Inc signatureACE EX RED A Signal in Compression BLACK in Tension GREEN A Signal in Compression GREEN in Tension BLACK EX WHITE FIVE HOLES DRILLED AND TAPPED IN PRESS MEMBER LOAD SENSOR TWO ANTI TORQUE WASHERS FOUR LOC WEL BOLTS 374 INCH LONG SOCKET HEAD SCREW TO 150 LB IN TORQUE EACH 1 4 28X 3 4
148. KA ANAK gt N Figure 147 Ground detector dynamic checking In the case above the Normally OFF Buckle sensing switch sensor set is being bridged by an additional contact that closes briefly during the time the stock is stationary probably something like 140 160 degrees The Die Protection input is configured OFF ON OFF with a window from 130 170 degrees When the machine runs the system will REQUIRE that the Buckle detector Turns ON and then goes back OFF During the window and doesn t come ON at any other time The wires from the Checking contact are connected AT the Actual switch and the signal comes in over the same wiring that the Switch signal would 3 Wire Proximity or other Sensors ne Checking Contact To 24V Power Sup s F4 To D P Input tput o6 PNP Prox To 24V Common Common Figure 148 Checking N O PNP Prox switch For 3 Wire Prox switches used in N O applications the Checking contacts can be applied across the Apparent switch Contacts in the Prox In the case above the Checking Switch Shorts the Proximity and delivers a signal to the die protection input The OFF ON OFF protocol would be used and the window selected during a portion of the cycle when a process signal couldn t occur 2 Wire Universal Prox switches The next switch considered is the Universal style of Prox These are somewhat
149. MALE connector at the end going to the TEC On the SAM end of the cable check with an Ohmmeter gt Pin 3 to Pin 22 should measure about 175 Ohms gt Pin 4 to Pin 23 should measure about 175 Ohms The resistances measured at A and B should be almost the same gt Pin 2 to Pin 21 should measure about 60 Ohms EVERY resolver will have 6 wires for the Three windings If you re not using an Signature Technologies supplied resolver you can determine your own resistance values as follows gt Disconnect the resolver cable from the TEC and find the three windings Three pairs of wires will show continuity and there should be NO connection between the pairs or between any wire and ground or the shield gt TWO of the pairs will show identical resistance gt The third pair will be different but maybe not by very much gt Reconnect the Resolver to the TEC or RSCB making sure that the two equal pairs are connected to Terminals S2 S4 4 5 and Terminals S1 S3 6 7 it doesn t matter which goes where The Different pair goes to terminals R1 R2 8 9 gt Now perform the Tests in step 3 above substituting the values you found in the above measurements 4 Ifthe tests in Step 3 come out O K The Resolver its cabling the RSCB board and its cabling are probably O K The condition of the SA2000 Module is suspect Install another one and execute steps 1 again to check 5 Ifsome of the tests in Step 3 were in erro
150. N 1 Select Options from the menu bar and a sub menu will drop down 2 Select Log On from the sub menu 3 Enter your password in the Log On window then select lt Enter gt 4 Select the Log On button that appears within the log on window 5 Do not forget to log off when you finish Note If you attempt to do something beyond your security level the Log On window will appear It will display your security level and the level required for that operation LOG OFF 1 Select Options from the menu bar and a sub menu will drop down 2 Select Log On from the sub menu 3 Select the Log Off button that appears within the log on window System security during normal operation As you operate the system the Log On window may appear when you try to do something If this window appears during operation enter your password and select the Enter Button or the lt Enter gt key 1 If your security level allows you to perform the operation the One Shot and Log On buttons will be available to you Select the one you want 2 If your security level is too low the system will display the message Password Too Low The One Shot and Log On buttons will not be available to you disabled The system will display your clearance level and the required level see the system manager 3 If you enter an invalid password the message Invalid Password will appear and the One Shot and Log O
151. ND the power is cycled to the SAM leaving it off for about a minute to allow the A D converter to cool down Then go back to 1 and check again 3 If both lights are lit and of equal brilliance then exit SAMview and start SAMtest by typing SAMtest lt Enter gt at the C gt prompt Then select 5 GetNet to see what s out there You should find two things at least The SAMnet interface module which will display its base address and its SAMnet address 300 Signature Technologies Inc signatureACE on the top line of the display Under this GetNET should return the identity address and firmware data from the SAM unit s on line and give the SAMnet ARCNET address A If it finds the appropriate hardware out there then run CheckNet to insure that the data transmission is robust Ideally ALL the CheckNet tests should run without omissions or errors If the longer messages have errors check the terminations and condition of the coaxial cable between units B If it Doesn t find hardware then go to 3 below 4 Check that the SAMnet Coaxial cable is attached properly at both ends 5 Check the SAMnet cable for damage 6 Check to see if Terminator jumpers are installed at the end of the SAMnet daisy chain and at the Host computer Terminator Jumper IN Terminated OUT Open Figure 238 SA2000 termination Jumper Signature Technologies Inc 301 General Installati
152. NY characters or symbols you want Signature Technologies Inc 57 General Installation amp Programming Guide Overview Configure Options Press Database 3 3 SER Press Description Change Press Press ID Local OCS al a New Press ID Description Position Offset ID SAM Description Wena B ee 0 00 SAM Position Device Pulses Eat Resolver 1824 lt lt Enter Channel List k All Channels Remove SAM Ch Description Channel Editing lt lt Edit Enter gt gt Description Capacity Units Calibration Offset Curve File 2100 1 0000 0 000 lt none gt 100 00 Cam Outputs DieWatch Inputs Sensors lt uncal gt Figure 34 Press Database Empty 8 Select the first left character position in the ID box A cursor will appear Type in the SAMnet address number for the press per the instructions below NOTE To find out what the SAMnet address is HEARTBEAT Indicator TEST Address Buffer Full Connector Switch Indicator RESET Button ae TEST B Switch X utton Slaving Connector Sensor Gain Gage Excitation Jumpers Jumpers Figure 35 SA2000 Switches Indicators A With the cover off the Host Computer if the SA2000 is inserted into the Host computer find the SA2000 module you are using 58 Signature Technologies Inc signatureACE B There are TWO small round rotary switches that face up away f
153. Press Cycle is generally held to start at O degrees of rotation or TDC and continue through 180 degrees or BDC where the work is done It then returns back up to 0 where the Press cycle ends whether or not the press actually stops at TDC A name given to a file in the SAMview system that defines against a discreet identification code a number of machine related variables such as Resolution of the Position Sensor Position Sensor offset Network Bus address number of SAM modules number of channels number of data points per channel and so forth These variables are programmable in the Press Information utility on the Program Selector Menu The computer uses the Press Identification field as the Key field to distinguish the different Presses stored in the computer s database The term used to describe the action of a press in motion The Press Cycle is generally held to start at O degrees of rotation or TDC and continue through 180 degrees or BDC where the work is done It then returns back up to 0 where the Press cycle ends whether or not the press actually stops at TDC Continuous curved lines similar in shape to machine force signatures and located above and below the normal machine signatures When the machine signature crosses the boundary of a Process Limit some control action is typically taken by the computer user to correct the deviation This term refers to how
154. RILL no 70p zos BED CoE ew SAMnet Address Switch min x SAMnet Connector mehia i Termination Jumper Figure 18 Communications card controls Signature Technologies Inc 33 General Installation amp Programming Guide Network Activity Indicator Internal Bus Activity Indicator SAMnet Connector SiN Bar Code an Card Figure 19 Communications card Address switch settings Communications Switches ey ft i AEE q at t i OCR IRQ 9 Jumper Figure 20 Communications card Internal switches amp jumper settings 3 Verify that the jumper settings on the SA2000 module set are proper for your applications reset if necessary The default settings will be O K for most slow to medium speed applications using Strain Gage inputs Call ST if there are questions about proper selection a Position Board Jumpers 34 Signature Technologies Inc signatureACE The Resolution jumpers The SA2000 is shipped at 12 bits 4096 counts This is valid for machines running up to 200 S P M If you are running faster reset the jumpers for 10 bits 1024 counts The jumper settings are printed on the card as shown below The Compensation Jumper This Jumper is INSTALLED for 12 bits 4096 counts and should be removed for 10 bits 1024 counts Reference Resolution Jumpers Jumpers Qx aoe ine Compensation Jumper Figure
155. RUN CONDUIT NEAR TIE ROD HEATING OPENNGS eo Ti Terminiantion Enclosure CROWN OF PRESS COLUMN UPRIGHT ee BEST BR EOCATION ISIN THE MDOLE ENGTH OF COLUMN i UPRIGHT On bit CENTER LINE OF THE TIE ROD THE CLOSER A SENSOR IS TO THE TE ROD THE BETTER ITS Jil PERFORMANCE WALL PTT or POSSIBLE NST ALL Sgor ON 173 i il THE NSDI FRAME IF LL ITIS A DOUBLE WALL FRAME PRESS RESS WAL AVOID INSTALLING re GEOR THAN 12 FROM THE T BOTTOM EDGE OF HOLES THAT ARE CUT OUT IN THE PRESS FRAME 173 L 173 L L LENGTH OF COLUMN iL OR UPRIGHT RULE OF THUMB FOR CAST TRAME PRESSES OR VERY HEAVY FRAME PRE INSTALL SENSORS IN AN AREA SE LEAST CROSS SECTION AVOID HOLES AS DESCRIBED ABOVE IN ALL CASES IF POSSIBLE AVOID LOCATING SENSORS CLOSER THAN 1 COLUMN WIDTH FROM THE CROWN OR BOLSTER Figure 169 Upright sensing locations If you re installing the links in an area of the machine that is vulnerable to flying parts or runaway lift trucks then the Protective cover box is needed and available from ST under special order 6 75 9 250 Dia a 6 31 4 places Drill amp Tap 6 32 ii 5 50 g 6 places 3 25 270 2 as arae EN Ep ETERE e aE ae aia ee eee ae iia is 2 88 2 38 1 88 1 50 amp e Lj 4 ioe ripe ES l OA EN E E Ledio e e 1 2 conduit knockou
156. Red Reset SPC Fit Wht Reset SPC Fit Yel Reset Stroke Count Save Master Sig Save Signature Requires that the user have a certain level of password priority before being permitted to Log On opening the system permanently to the user s security level The operation of this is automatic If the user has a Priority 3 and Log On requires Level 4 the Log On button won t be available when the user s password is confirmed Requires that the user have a certain level of password priority before being permitted to Log On in One Shot mode opening the system to the user s security level for ONLY one protected action The operation of this is automatic If the user has a Priority 3 and Log On One Shot requires Level 4 the Log On One Shot button won t be available when the user s password is confirmed Password required to reset the system and to permit press operation after a Die protection violation that was directed to the RED output Should be a high priority Password required to reset the system and to permit press operation after a Die protection violation that was directed to the WHITE output Should be a high priority Password required to reset the system and to permit press operation after a Die protection violation which was directed to the YELLOW output Password required to reset the system and to permit press operation after a RED Signature limit violation Should be a high p
157. SIGNATURE TECHNOLOGIES User Documentation General Installation and Programming Guide for the signatureACE System SAMview Software Version 3 xx Rev 06 08 01 SAMview MPMview SPCview FeatureView SA2000 SAM500 SAMnet InSitu FlexStrip and SmartSAM are trademarks of Signature Technologies Inc signatureACE and Signature Technologies are registered trademarks of Signature Technologies Inc Dallas TX USA All other trademarks are the property of their respective companies 2004 Signature Technologies Inc All Rights Reserved Printed in the USA No part of this publication may be reproduced via any means print electronic or other without the written permission of the publisher Signature Technologies Inc 1225 Yacht Club Road Oak Point Texas 75068 USA Telephone 972 488 9777 Fax 214 242 2924 Website www signaturetechnologies com email mo signaturetechnologies com General Installation amp Programming Guide 2 Signature Technologies Inc signatureACE Introduction This publication is designed to help the user of Signature Technologies equipment successfully install use troubleshoot and maintain their signatureACE system This manual deals with the mounting wiring and initial setup procedures necessary to get the system into operation We suggest that the user accomplish the initial programming of his system using the built in
158. ST moves up a little Make a note of the air pressure value If the pressure gauge for the counterbalance doesn t work properly FIX IT This is one pressure gage you really need to have in working order Step 4 From the Peak View Screen pull down the Configure menu and select Calibrate Step5 Answer YES to Do you want to do Static Calibration Step 6 Watch the screen and see what the digital displays do They should all display numbers which should be relatively steady with only the Least Significant Digit dancing a little NOTE If one or more of the Numerical displays goes to or 2047 Your sensors are too far out of static balance to permit calibration by this method Contact the Signature Technologies Inc at 972 488 9777 for alternatives NOTE If one or more of the numerical displays is Going Wild displaying a large range of numbers this is a sign of problems in that channel related to the sensor itself or problems in the wiring Correct the situation before proceeding with calibration Step 7 Note down the unloaded values for each of the channels in the maintenance record Include in the record the counterbalance pressure and the upper die weight in the entry Step 8 See if there has been a significant change in the Zero offset readings since last readings Of so there may be a problem with the sensor in question NOTE The readings MUST be either positive within 500 counts of ZERO or down to Negative 2000
159. Set button 154 Signature Technologies Inc signatureACE 5 The Playback List upper left of screen will then regenerate to display the signatures that fall within the constraints of your selection If the number in the OF box just above the Available list is larger than 100 then ONLY the EARLIEST 100 of the selected signature will actually be available A To Playback ALL of the signatures found in the Available List click the lt lt Add All button between the two lists B To Playback specific signatures from the Available List 1 Select the desired signature from the Available List by single clicking on it The selected signature will Hi Light 2 Click on the lt lt Add button C To remove all of the signatures from the Playback List select the Remove All button between the two lists This ONLY removes the signature from the playback list Not from memory B Toremove specific signatures from the Playback List 1 Select the desired signature from the Playback List by single clicking on it The selected signature will Hi Light 2 Click on the Remove button Select the playback speed from the items at the bottom left of the screen Click either on the arrows to change the time or on the time Itself for a list of options Select the Return button to save your changes and return to the previous screen to review the selected signatures or Select the Cancel button to retu
160. The box directly under Editing Figure 40 will display the number of the channel being programmed As previously noted 01 04 Channel 5 etc C Click on the first left character position in the box under Description A cursor will appear Enter the description of the sensor connected to that channel Example LN 2 First Form D Hit the lt Tab gt key The cursor will jump to the Capacity box Figure 40 The Capacity box will display the default value 2100 Do not change it at this time UNLESS you have developed calibration factors mathematically and will enter them at this time Normally in the case of supplied In die sensors and commercial load 66 Signature Technologies Inc signatureACE cells calibration information is supplied and can be used to generate ST calibration numbers See the Section under Calibration in the signatureACE Maintenance Manual If you WILL be entering calibration numbers Click on the first character position and enter the machine capacity in the chosen units Overview Conf igure Options Tool Database for Press P1286 Tool ID Tool Description View another Press Change Tool DEFAULT Default Tool New Tool Data Collection Rate Size 0 35 997 From To ja 92 555 08 Signature Collection Area Channel List SJA11 Channels Setup Selections Virtual Channel Tool Setup Inf
161. The system will return you to the Tool Information screen 13 Click Configure from the menu bar 14 Click Exit Configuration Answer Yes to any questions that come up The system will return you to the Overview screen Programming SPCview limit parameters For each feature assigned to the tool the system returns and graphs two values the subgroup average Xbar and the standard deviation R 1 For the Xbar values there are two sets of limits the upper and lower control limits yellow and the upper and lower quality limits red 2 For the R value there is only one limit the upper control limit red From any of the SPCview graph screens or the Feature configuration screen the user can access the SPC Limit Setup screen From this screen the user can modify any of the parameters to set the limits The user can also modify the limits themselves The system also provides a utility to recalculate the limits without collecting a new sample set This allows the user to modify the limit setting parameters and recalculate new process limits based on a previous sample set If NO sample set has been collected since the last time the system was powered down OR since the present Tool was called in the system will do NOTHING 114 Signature Technologies Inc signatureACE 02 00 Peak capture 02 01 Average load VAL An A GETI _ Hbar Limits yellow red _ Control Limit
162. a Busa pug o sanca priu sy TE pdg UWS RWO PU BPOV WD WLEGUW S Tinea p pamed ui 0 aww wo PB aha di a Lay ja pun iien pfmac ap y Eupun g ead ag og ag ewy qiy ey iE pda I l Wop pU IP A UPURI BA Keo ag powod Pu a pdy ap a HOD pigno meocyad ey o paxo Ipo ag ph sho wap ag ag pasad q o my 4 Z TD pun H O ghg yo ege puo ap mya pi ay aF pda can ULA WB A UA BURT Sei RUD WARO ARULD l BJ LR BAL POA ANY UI SONNI IT O D A ApoU IAO BALL SYLA ID WUT U A WCE M AA OG H WE AU ANY f UHA ANAO BRUISES PUD EIPJ HEN A hno h HOW HR UI l WDAP ANTEC A AU POPA WL AI GL POU NG aL BF INO ymha aul WPO SEYALG 3I ALNG U a Weta aig IAA XD YA RAD SUL PADA a AU VAN SSF H Lel E pidu og payed puts oq geam eg ganu pue WHEA MPO Uy seee PUD UIN Hour y phre gy z Inno PE HUY HOTTER MI J wpop enjpeutya e aj puwa BuLE dap ap q0 qia OF Eg q lp gpu reno Gy H mro BP LN 9 pad joule o ig ae ay 0 100 Amps Sup bo VOC ppu KY 4 ue pud E El eer par ta if OY RAL LUKE PUD AOE AH Uy 33N IIT a a pu qy vA mope ugoda ely GROW VLKK Ul US mpiga aeee PUD UIK Aoun 4 peiro my AF A Papaauuoa aq 0 shy Jo Jaquinu ay Si Vay Xr lOR ZGO ALS fa sequinu lt jquipaso ejo dw euj Se JJOO BUD Sayjquiasso B i ag pdun pads Jopaauuos if 24 ybnouyy Laer ala BOUUIBJE JAL ADU PUD SINS HaNTOSaY BC pesn yuog ir pera ein fad euo jousryppo E 0 dn TEEL NE INO Ol AA AGISHH YIATCSIY D SO par puco yoh DOSS AK 6 Pa AUND
163. above installed the 10 volt signal becomes 2 48 volts and the 25 volt signal becomes 0 062 volts Let s say we want to calibrate this sensor to read out in relative thousandths of an inch 1mm 0 03937 5mm 0 19685 so the difference is 0 15748 The voltage output goes from 0 062 to 2 48 over this range so the voltage difference 2 418 The ST system has a sensitivity of 1 A D count for each 0 0012213 Volts in LOW range 2 418 0 0012213 1979 counts equals a displacement change of 0 15749 or 159 5 thousandths 157 5 1979 0 079586 which is the thousanths calibration factor for the ST system 4 1979 0 002021 is the Millimeters calibration factor Experimentally developed If the target is not per the test criteria but the approach is perpendicular and parallel then the calibration must be arrived at experimentally Follow the detailed procedure Step 1 Go to Samtest Step 2 Select gauge selection 2 Step 3 Turn OFF the auto zero for the analog prox channel Make sure the display for the channel is in counts Step 4 Put a sheet of heavy paper over the sensor Step 5 Apply the target to the sensor thru the paper Step 6 Note the reading on the screen Signature Technologies Inc 275 User Manual Step 7 Add another piece of paper Note the reading on the screen Step 8 Repeat for 7 8 additional pieces of paper Step 9 Measure and note the paper thickness Step 10 Plo
164. ace on which you want to mount the resolver bracketry 5 If you are going to use a drive stub from the end of the crankshaft give details of the shaft end including location and dimensions of holes keyways and other features If the shaft is center drilled and tapped give size and thread specifications of the center hole 6 If possible a photograph of the mounting area would be helpful 7 Include at least a sketch along the lines of Figure 184 below Signature Technologies Inc 241 User Manual Include information about any apparatus attached to the crankshaft or any machining to the crankshaft SUCH as Keyways or unusual drilling Crank hole diam amp thread Include dimensions amp location of any irregularities in the crown face mounting pads tapped holes bearing covers electrical conduit Plumbing etc Figure 184 resolver mounting area dimension sketch Appendix 8 Resolver Converter installation and setup 242 Signature Technologies Inc signatureACE HiRes Convertor Model CNV TECHNOLOGIES S N 109501 W SIGNATURE SAMview SPCview FeatureView InSitu MPMview and HiRes are trademarks and Signature Technologies ST Statistical Process Controller are registered trademarks of Signature Technologies Inc Dallas TX 75234 SmartPac is a registered trademark of Wintriss a Div of Honeywell Various technologies herein are either patented or p
165. ai a iets yi P me Pate Tg Fe Sef SAMnet Address Switch 4 SAMnet Connector Termination Jumper Figure 14 Terminator jumper for the SAMnet card In the case where two SA2000 units and a SAMnet card are all together in the same computer termination is unimportant On the other hand where there s significant lengths of external cable and multiple drops for the network it s more important to terminate the cable properly In general there should be only two terminators in place on a SAMnet network that covers multiple machines The terminators should be located AT THE ENDS of the network The following diagrams illustrate the proper location of enabled terminators for different network configurations Signature Technologies Inc 31 General Installation amp Programming Guide SAMnet Card INSTALL Termination SA2000 SA2000 SA2000 SA2000 SA2000 SA2000 SA2000 Jumper REMOVE REMOVE REMOVE REMOVE REMOVE REMOVE INSTALL Terrnination Termination Terrnination Termination Terrninatiori Termination Terrnination Jurnper Jurnper Jurnper Jumper Jurriper Jumper Jumper da O a a e a o E Figure 15 Computer at the end SAMnet configuration SAMnet Card REMOVE SA2000 SA2000 SA2000 Termination SA2000 SA2000 SA2000 SA2000 INSTALL REMOVE REMOVE durnper REMOVE REMOVE REMOVE INSTALL Termination Termination Termination Termination Termination Termination Termination du
166. ake sure you have a good grasp on the next point before letting go of the first one The First Great and General rule SignatureACE programming Sf you foul up the selup DONT try to back out DELETE the SAM DATA directory and start again from scratch If you are going to attempt a From Scratch configuration The SAMDATA database MUST be empty If you already have a system that s running with a simpler setup maybe from the Setup Wizard we suggest you archive the present database to give you a fallback position in case the re configuration hits a snag Use the following procedure 1 from the c gt root directory type MD SAMDATO01 lt Enter gt 2 Type CD SAMDATO1 lt Enter gt 3 From the C SAMDAT01 gt prompt Type xcopy samdata s This will cause the system to copy everything in SAMDATA and its sub directories to SAMDATO01 as a backup 4 Type cd lt Enter gt 5 From the C gt prompt type deltree samdata lt Enter gt This will erase the SAMDATA directory and all its subdirectories The next time SAMview is started it will construct a NEW EMPTY SAMDATA directory NOTE If at any time you want to return to the old database for any reason use the following procedure to maintain a safe backup of data 1 from the c gt root directory type MD test lt Enter gt 2 Type CD test lt Enter gt 3 From the C TEST gt prompt Type xcopy samdata s This will cau
167. al point is the POSITIVE side of the module If the polarity is reversed the Output will appear to be ON all the time Available Output Module Types Type OAC5 12 140 V A C 3 Amps 45 C Type OAC5A 24 280 V A C 3 Amps 45 C Type ODC5 5 60 V D C 3 Amps 45 C Odd Terminal is connection Type ODCSA 5 200 V D C 1 Amp 45 C Odd Terminal is connection Type ODCS5R Dry Contact Max 100 V D C 130 V A C 0 5Amps Signature Technologies Inc 175 General Installation amp Programming Guide DIEview user guide xxx N ARN N G Certain of the procedures in this manual could cause unexpected motions from portions of the machine system Before performing ANY programming procedures make sure ALL personnel are standing clear of the machine as well as any parts transfer or coil handling apparatus Failure to observe these safety precautions can result in serious injury or death It is the responsibility of the EMPLOYER to provide point of operation guarding and Peripheral safety devices for all power equipment x x xN ARN N G Since the installation and adjustment of Die Protection sensors sometimes requires the insertion of body parts into the point of operation the press must be stopped with the drive system switched off and the flywheel stationary before any service work or adjustments are made to equipment mounted in the tooling The use of DIE SAFETY BLOCKS to
168. allation amp Programming Guide If the SAM is showing up at the proper address check to see that the NAME of the SAM that you gave in Press Information is displayed clearly on the box under the light If the SAM is there but it s name doesn t show click on the box under the light You should immediately get a message box giving the firmware revision number of the SAM firmware If the SAM doesn t answer it may not be functioning properly A normal SA2000 should automatically come ON LINE when it is powered up If it doesn t 1 Make sure the SA2000 Heatbeat Figure 235 is running HEARTBEAT Indicator TEST Address Buffer Full Connector mee Indicator RESET Button Test Switch TEST Button ieee gt La a ae i A f Slaving Connector i asor GAs 4 a Sensor Gain Gage Excitation Jumpers Jumpers Figure 237 SA2000 Heartbeat indicator If it isn t hit the reset button on the SA2000 and see if this corrects If it doesn t try another SA2000 module 2 IF the Heartbeat is running check the power supply lights in the TEC enclosure they re the ones under the cables a Red and a Green light marked 5 and 5 Both should be on with equal brilliance If one is either dim or out then the chances are that the excitation to one of the strain gage sensors is shorted to ground This will kill the communications AND lock up the A D Converter until the situation is corrected A
169. amming the Die Protection for the Tool whose name is showing in the box at the upper left under the label Tool ID The field names are Description This field is a verbal identification of the sensor actually connected to the Channel 1 input terminals You should be descriptive in terms the floor personnel will relate to easily SW 143 may not say much to the operator Part Eject Sensor is clearer 190 Signature Technologies Inc signatureACE Fault Condition This is an INDICATING ONLY field When the sensor has violated its protocol the Fault Condition indicator will be lit If the sensor is directed to a STOP Output the machine will NOT operate whenever the Fault Condition indicator is lit At the bottom of the Fault Condition Column there is a Box that is labeled Reset Faults Clicking on this box will reset all fault conditions and allow operation again State This is another INDICATING ONLY field It is the State indication for the connected sensor BY DEFINITION If this light is lit the sensor is considered ON It is an almost 1 second update real time indication of the sensor signal If the sensor state is backwards it can be inverted with the Invert Polarity switch discussed later Invert Polarity This is a toggle when it is BLACK the apparent polarity of the sensor is reversed If you have a sensor that is always ON and pulses OFF and you rea
170. and draw station In this case the Blanking takes place on the outer circumference of the draw ring while the draw takes place down the middle The cell is located such that the inner diameter of the draw punch is in line with the gauging location while the blanking portion is more in line with the outside diameter of the load cell Force tends to flow straight from its source to the place where the support occurs The force required to draw and the force required to blank will reach the gages in the load cell differently and will not produce the same effect If the load cell is calibrated for the drawing force the blanking force will indicate MUCH lower than it actually is since it flows through the outer diameter of the load cell and the support block Alternatively if the load cell is calibrated for the blanking force the Draw force will show MUCH higher that it actually is since it flows directly through the gauging location This cell design in short can t be calibrated accurately for both operations but can function comparatively so that you can tell that something has changed in the process 280 Signature Technologies Inc signatureACE 8 Lea ne ne ee eens TTT TT DEEA Bae eed E E d Reece Recents E Hass Roe d Hepp MMA A M ME E Bs Roars EEE Ea E i H rd EE p d 8 Peeper eee HHHH HEETE S88 peppers BR Sas Si ie eee Behera S85 mi pii ed Ba
171. anual Saving Automatic Fault Saving pe Ll Off Save Save Save with comment Save with comment Select Fault types to save Oi Fress Curve Ci Fault red E Warn Cyellow Default Comment Scheduled Saves Trending new material Off On 1000 Cycles between saves Database Backup warning Warn after 999 Brummer are stored to disk Figure 127 Signature Save Setup Window Configuring manual saving Enabling this feature will allow the user to save signatures with or without a comment via a menu selection This feature is independent of the Scheduled Saves and Automatic Fault Saving options Follow the procedure described here to configure manual saving of signatures 1 You should be in the Signature Save Setup window If you are not follow the procedure outlined in Accessing the Save Signature Setup pop up window Signature Technologies Inc 161 General Installation amp Programming Guide 2 Slide the switch under the Manual Saving label with your pointing device selecting one of the following options A Of does not allow the user to access the manual saving utility B Save allows the user to access the manual saving utility C Save with comments requires that the user enter a comment when accessing the manual saving utility Configuring automatic fault saving When the system is configured to automatically save fault signatures any signature that violates a limit control
172. any other ground 4 Die Protection Inputs amp 6 Signature Input Option The A6D module is a daughter board for the SA2000 product that has the capability of providing 6 Signature channels and 4 Digital Die Protection inputs 182 Signature Technologies Inc signatureACE Each of the A6D Die Protection inputs has multiple Software selectable modes and internally supplied wetting power at 24 Volts 5 Ma The input impedance is 4 7K Ohms The inputs are software selected to be PNP Sourced to 24 Volts or NPN Sinked to Common All 4 Die Protection inputs share the same common that is FLOATING and optically isolated with relation to any other ground There is also provision for 24 volt D C power to operate 3 Wire devices A Grand Total of 125 ma is available for wetting and device power 16 Die Protection Input Option The D16 module is a daughter board for the SA2000 product that has the capability of providing16 Digital Die Protection inputs Each of the D16 Die Protection inputs has multiple Software selectable modes and internally supplied wetting power at 24 Volts 5 Ma The input impedance is 4 7K Ohms The inputs are software selected to be PNP Sourced to 24 Volts or NPN Sinked to Common The Common for Die Protection Inputs 1 8 is independent of and isolated from the Common for inputs 9 16 Each group of 8 inputs shares the same common that is FLOATING and optically isolated with rel
173. ar Select Job from the sub menu This will cause a select button to appear next to each press as shown in Figure 60 Conf igure Selected Press SEE Setup Info Control Status Reset Fault Set Limits Press Line Overview Select Set Line Limits Set Line in Bypass Set Line in Control View Press Tool Stroke Count Run Baseline Control m 31 Select 0 al 32 Select 93 El 33 Select 0 Bypass Control Figure 60 Configure Job screen options Choose the Select button next to the first Press button 3_1 in Figure 60 The Select a Tool pop up window will appear Highlight the appropriate tool name from the Dirs Files list on the left side of the window The name should appear in the box next to File Name at the top of the window Choose the Select button to return to the Press Line Overview screen The box next to the press button under the Tool heading should now display the tool number assigned to the press Signature Technologies Inc 83 General Installation amp Programming Guide Note The Cancel button will clear the tool assignment and exit the Select a Tool window 6 Repeat steps 3 4 and 5 for the remainder of presses in the press line 7 Position the cursor in the first left position of the Current Job box Use the keyboard to enter a one to eight character Job ID for the current job in
174. at least 300 2100 0 1407 295 47 WHY you ask Because the largest Raw number that the SAM Analog to Digital converter can produce is 2048 What the screen shows is this 2048 Multiplied by the Calibration factor If the Channel input card SA2000 or RSCB SAM500 is defective or if the A D has died in the SAM it could be throwing out a large number that would draw a line that wouldn t show up if the screen is zoomed in too tight The above exercise guarantees that If there s a line there you can see it Signature Technologies Inc signatureACE gt If there is a line at a constant HIGH or LOW level across the screen then something has probably died either in the SAM Module or in the RSCB board The TEC board is passive so other than bad connections there s nothing that can go wrong go wrong go wrong go wrong there gt If you then unplug the RSCB from the SAM500 the 25 Pin D shell connector in the bottom connector The line should move closer to zero if the RSCB is bad or stay at a High or Low level if the SAM is bad 5 If you have a line drawn across the screen at Zero but it appears to be flat gt Zoom in vertically from the top and the bottom as tight as you can on the line gt When you have zoomed see if the line is still DEAD Flat or whether there is noise showing gt If the line is still dead flat you re NOT taking data The SAM is probably Dead Try a new SA2000 SAM500
175. at the entries in the row labeled Auto Recalculate is not Zero If it is the system will not modify the scale factors for the limit b Highlight the channel you want to alter the limit parameters on 150 Signature Technologies Inc signatureACE ONE If you want to automatically recalculate the scale factors for only one channel do not select the small button to the left of the All Channels heading Highlight the channel you want recalculated ALL If you want to automatically recalculate the scale factors for all of the channels Click the small button to the left of the All Channels heading A small box will appear within the button to indicate that this option is on Make sure ALL the channels have percentages entered in the Auto Recalculate row C Use the Tighter or Looser buttons to modify scale height and width factors a Tighter Decreases scale factors thus tightening the limits b Looser Increases the scale factors thus loosening the limits 5 To adjust the number of signatures used for the process limit calculation Click the box to the right of the Number of Samples heading Use the keypad to enter a new value 6 For single stroke presses make sure that Ramp up Cycles is set to zero and Simultaneous is selected 7 Click the Return button to exit the Limit Parameters window To set the limits for an individual press One of the places this can be ac
176. at the extremes of the envelope are required Should be assigned the highest priority DEFAULT SETTING 5 Requires a password to enter the SAMnet Summary screen to see which of the network nodes are active Requires a password to enter the Security Utility This should be the HIGHEST priority Requires a password to create or change a Tool data file The password will not be needed until an attempt is made to SAVE the created or edited tool Requires a password to create or change a Tool data file The password will not be needed until an attempt is made to SAVE the created or edited tool Requires a password to create or change a Virtual channel The password will not be needed until an attempt is made to SAVE the created or edited Virtual channel Requires that the user have a certain level of password priority before being permitted to Permanently delete signatures from the Hard Drive DEFAULT SETTING 5 Requires a password to Exit the SAMview program Should be assigned only to users with high priority Requires that the user have a certain level of password priority before being permitted to Log Off and return the system to Security level 0 Signature Technologies Inc 157 General Installation amp Programming Guide Log On Logon One Shot Reset DIE Fit Red Reset Die Flt Wht Reset Die FIt Yel Reset SIG Flt Red Reset SIG Fit Wht Reset SIG FIt Yel Reset SPC FIt
177. ata If your machine is ON LINE go into the Signature View screen and see what is going on there NOTE You must have at least one Press defined and one Tool defined in your database Additionally the Tool must have been Installed in the press with the Press Operations function before you are permitted to enter the Analyze function If there is a lack of one of the above elements you won t be able to get into the Signature View Screen 1 Assuming that you have gotten into Signature note the value of the Count window Upper Right side of screen 2 Roll the machine over at least one full cycle Look at the color of the RUN Indicator for your press In the Lower Right hand portion of the screen It should turn to GREEN when the press rolls and back to CLEAR when the press stops If the color does change this is one indication that the I O portion of the SA2000 software is Running since the Machine running signal comes through the I O and is processed by the SA2000 and that the SA2000 is communicating to the Host Computer It also indicates that the Machine Clutch input is properly powered and working Go to step 10 3 If the color doesn t change a Watch the indicator on the input module located in position 1 Lower left corner in Figure 246 below of the OPTO 22 chassis it will be OFF when the press is stationary If it is ON there is a control wiring problem 318 Signature Technologies Inc
178. atable signals throughout all operating conditions A task that is running behind the scenes while another task is displaying information on the screen Under certain conditions the rotation of a machine will be interrupted momentarily An example of this would be when a punch press snaps through some material The force being released in the press will resonate back through the press and cause it to move in a backward direction for an instant Enabling backlash compensation would cause the SAM to inhibit data collection during any reverse direction of the press Key that deletes the character to the left of the cursor moving the cursor to that position A hit or signature is considered bad if the Press which generated that hit was in Control Mode the Press was running and the Signature generated by that hit exceeded the Warning or Fault control limits for any portion of its collection Bottom Dead Center The position of a press when it is at bottom of stroke Generally B D C is located at 180 degrees A rectangular box on the screen that offers system features The system mode where ALL machine control actions are disabled EXCEPT Press Curve violations See also Monitor Assigning a number known as a conversion factor which will convert a raw strain gage reading to units of force such as tons or pounds This button will take you back to the previous screen without saving changes Refers to the user pr
179. atent pending in the US and Foreign Countries This appendix is a step by step look at the installation of a Signature Technologies Signature Analysis system using an existing Resolver system for position reference This resolver system may be a programmable limit switch system or an integrated subsystem of the press control The CNV Resolver converter unit can be used to provide position input from the existing resolver system It is used when the cable run from the existing system would be long over 15 feet or when the existing system is sensitive to external connections The CNV Converter is remotely mounted on the machine close within 30 of the resolver system wiring The purpose of the Resolver Converters is to enable the Signature Technologies SA2000 module to use the Reference and Sine Cosine signals from another resolver based electronic system without loading or interfering with the existing system Signature Technologies Inc 243 User Manual Mounting holes Connector SASdtdAStSRSHtHtSteeseteteeenseseteeeseraetacesaraeensasaeteetsacaentstsasnes ndi cato rs E Hi Pes Adjustments Resolver Converter OUTPUT Connector Figure 185 Resolver Converter dimensions There are TWO basic requirements For the Resolver Converter 1 The system to which the Resolver Converter is attached MUST supply a reference signal to the ROTOR R1 R2 points of the resolver The Sine and Cosine signals S1 S3 amp S
180. ation The Signature View All screen can t be adjusted since it takes its graphics from the six individual Signature View screens When configuring the screens be aware that If you select a view that has not yet been configured with pens and saved no signature or channel buttons will show until you select Configure and Screen turn on pens and adjust the view the way you want it Note To save peak screen configuration at least one pen must be assigned The system will not save a view where the pens are all shut off IF all pens are shut off the system will AUTOMATICALLY enter Configure Screen each time you go to Peak screen until at least ONE display is assigned The following step by step procedures will take you through the setup of one of the six signature view screens and the peak screen Follow each step in the sequence given Let s start from the Overview Screen 1 If you are not in the Press Line Overview screen select Overview from the menu bar The Press Line Overview screen is shown in Figure 48 2 If you have multiple presses on the system select the appropriate Press Name button from the list below the View Press label on the upper left A colored LED will appear next to your selection and the Selected Press box Lower Left will contain the name of the press If there s only one machine It will automatically be selected 3 Select the Signature button in the box at th
181. ation about the SA2000 TEC module combination The SA2000 Module is the engine that actually performs the data acquisition limiting I O control and network communications The TEC unit is an enclosed Printed circuit board assembly that provides connectivity for the external system elements signatureACE System common grounding considerations NOTE Signature Technologies Common points both Analog and Digital AND the Excitation points if 5V excitation is selected are connected to EARTH GROUND The signatureACE system commons CANNOT be floated This means you ve got to be careful when connecting the signatureACE to a system that has a floating common like the Square D Press control systems In these cases The signatureACE common should be connected to Earth ground like the sheet metal of the control enclosure In most cases the wide Common mode range of the SA2000 will provide clean signals When you connect Analog inputs or Resolver inputs to the ST system even when you use the HiRes resolver converter connecting to the Excitation See note above or AGND signals to a system with a floating common will tie that floating common in the other system to earth ground and may cause the existing system to malfunction In the case of the HiRes converter if you re not sure whether the resolver system you re connecting to has a floating common tie the AGND to EARTH GROUND probably the nearest hand
182. ation engineering for high speed solutions Programming the Signature Technologies DIEview system DIEview Programming Utility This utility is located in the Tool Database To get there select Overview from the top menu bar The system will display the Overview screen Select Configure from the top menu bar and then select Tool The system will display the Tool database screen Signature Technologies Inc 189 General Installation amp Programming Guide At the lower right side of the Tool Database screen there is a Box labeled Die View Click on it and the Die View programming screen will appear Overview Configure Batabase Analysis Sereen Options Tool Database for Press P1852 Press Tool ID Angle P1852 M3705 74 79 Fault State Start End Invert PNP Sensor Type Output Relay Sensor Type Description Cancel Return Reset Faults Figure 151 DlEview Programming screen The illustration shows the screen with ALL channels turned off At the extreme left of the screen is a vertical column of small square boxes with the word Active at the top Click on the Active box next to the Channel 01 label The entire row will be highlighted and ready for programming You will fill in the Description the Start the End Sensor type and Output Relay items to complete the programming process NOTE You are progr
183. ation to any other ground There is also provision for 24 volt D C power to operate 3 Wire devices Each group of 8 inputs can use a total of 125 ma for wetting and device power Input Device Configurations NOTE You ll notice that have avoided the use of the terms OFF and ON in this section Dealing ONLY in switching points This is because OFF and ON are logical terms to us and can be easily inverted in the software setup The criteria for ON is that the State light on the System Die View screen is LIT if you don t like the polarity of the input REVERSE IT with the Invert Polarity button on the Die View screen Ground detector cat s Whisker Input This is an NPN type input device A 4 7K load resistor to 24V is software connected to the input terminal This configuration switches state when less than 4 5K ohms exist between the Input and the Common connection which is normally hooked to the Machine frame for ground detection It returns to its quiescent state when the resistance rises above 6K ohms The internally applied wetting voltage is 24 V D C This input is generally used to sense continuity between the machine frame and cats whisker type probes The universal switching delay for all inputs is Software Switch selectable to either 0 002 second 0 012 second or 0 020 second Grounding Switch Input This is an NPN type input device A 4 7K loa
184. ations on the SA2000 Output shunting MASS backup MASS Restoration of the database Topical Index Contact us with an Signature Technologies Inc 11 General Installation amp Programming Guide This Page has been intentionally left blank 12 Signature Technologies Inc signatureACE Table of figures Signature Technologies Inc 13 General Installation amp Programming Guide Fi Figure 81 Ratio 2 Fi Fi Fi g Figure 85 Spread calculation at the die closure Fi Fi Fi g Figure 89 Conventional Feature Build Window Figure 90 Algorithm Assignment Window Figure 91 Completed Fi Figure 93 programmed SPCview config Window Figure 94 SPC Configuration Screen Fi Fi Fi Fi Fi Fi Fi Figure 102 Two SA2000 system in a Figure 103 Type Fi Fi Figure 106 Signature Figure 107 Signature with limits 14 Signature Technologies Inc signatureACE Figure 108 signatureACE Screen Machine Control Buttons Fi Fig Figure 111 TEC Connection Board Version B Fi Fi Fig Figure 119 The Press Line Overview screen Figure 123 Configure Sub Menu Figure 124 Press Line Overview Screen Fi Fi Fi Fi Fi Fi Figure 132 CAMview Operator Pop Up T Figure 136 Function Sele
185. ature DOESN T cross the threshold line within a Threshold feature window or maybe there s NO PEAK within a Peak feature window The system will return a 32767 which will be WAY off screen and fail to produce a plot ONE OTHER THING In Some cases the WRONG version of firmware will disable the operations of certain features EVEN THOUGH the system may allow you to program them Call us with software and firmware version s if you feel this may be an issue Now that that s out of the way Signature Technologies Inc 105 General Installation amp Programming Guide The SPCview system allows the user to add Features to an existing tool at any time However the system requires that the user calculate limits for the tool prior to controlling the press with the new Feature configuration The user should also note that when the tool configuration is modified either the data collection parameters or the Feature configuration the tool should be reloaded from the Job configuration NOTE YOU MUST have a master signature saved for a tool before attempting to program features since the signature displayed in the feature window is the MASTER To Program a Feature 1 Go to the Overview screen if you are not already there by selecting Overview from the menu bar Querview Configure Batabase Analysis Sereen Options tl Set Line Limits Set Line in Bypass Set Line in Control View Press Tool Stro
186. ay is actuated The contacts of the relay are wired into one of the Channel inputs on the TEC module according to the labels as shown above Be sure to set the channel switch to LO position The channel should be set up with a calibration factor of 0 01 and a maximum of 25 I d set the limits originally at three for the yellow and 5 for the red Starting out with yellow and red both set at 2 degrees seems O K Set your window wide to begin with until you find where the digital signature occurs The signature will look like a rectangular wave going from 0 tons to 20 tons when the digital signal changes Interfacing D C Proximity Switches to the signatureACE Proximity switches can be interfaced to the system to permit the Roman Key signaturing of digital events pilot hole detection feed length confirmation etc Some external components are required as follows 272 Signature Technologies Inc Excitation Shield Excitation Signal Signal Excitatiori Shield signatureACE Power Cormon Figure 216 NPN type 3 wire D C Proximity switch Shield PNP Prox Figure 217 P N P Type 3 wire D C Proximity Switch Shield Excitation Signal Signal i 2 Wire B C amp Universal Prox Excitation Figure 218 Hookup for 2 wire universal Proximity Switch Inter
187. be connected directly back to the Excitation point on the signatureACE The Toledo Analog Track Outputs are numbered as follows Channel 0 Outer Slide Total Total for S A Machines Channel 1 Outer Slide Left Rear Left Rear for S A Machines Channel 2 Outer Slide Right Rear Right Rear for S A Machines Channel 3 Outer Slide Left Front Left Front for S A Machines Channel 4 Outer Slide Right Front Right Front for S A Machines For 8 channel units additionally 276 Signature Technologies Inc signatureACE Channel 5 Inner Slide Total Channel 6 Inner Slide Left Rear Channel 7 Inner Slide Right Rear Channel 8 Inner Slide Left Front Channel 9 Inner Slide Right Front In general the recorder outputs are available on any of the commonly available load monitor units and the hookup is identical to the one shown above except that the method of connection is probably going to be different HELM uses double circuit 1 4 Phone jacks Data Instruments uses Phoenix plug in terminal strips One side of the signal is usually grounded Refer to the manual for the Load Monitor you have for the connections Toledo Channel 0 TOTAL Tolede Channel 1 Left Rear Toledo Channel 2 Right Rear Toledo Channel 3 Left Front Toledo Channel 4 Right Frorrt 0123456789 Toledo Comrnon Si k Figure 221 Toledo Model 260 Interface Hookup to sig
188. be issued immediately The window MUST be at least 5 degrees wide The window MUST NOT BE more than 350 degrees wide On OFF On check Normally ON with at least one change to OFF and a subsequent return s to ON expected DURING a programmable angular window in the stroke If the signal enters the window in the OFF state A Fault will be issued immediately Lack of a transition during the Window produces a fault at the Window END angle If the signal Leaves the window in the OFF state A Fault will be issued Immediately If the sensor makes a transition to OFF outside the window A Fault will be issued immediately The window MUST be at least 5 degrees wide 196 Signature Technologies Inc signatureACE The window MUST NOT BE more than 350 degrees wide Die Protection Fault output Options All I O in the SA2000 is software configurable as to assignment and state The descriptions below reflect the DEFAULT internal settings of the I O as supplied by ST unless specific alterations in the protocol are incorporated by special order NOTE The Control Bypass mode control HAS NO EFFECT in DIEview DIEview in its standard configuration CANNOT be bypassed If bypass is requires contact ST for details There are FOUR assignment choices that can be made for each channel 3 Digital different output devices can be assigned to the Die Protection Signals or the No Connection
189. be real or virtual Window start in degrees or position off BDC Window end in degrees or position off BDC In this example the valley feature is used to capture the minimum force during the blanking operation or the peak tension force in the right upright Due to the large amount of force required for the blanking operation at the far left end of the slide there is a bending moment in the slide i e the left end is in compression and the right end is in tension By comparing the peak on the left end to the valley at the right end the force that lead to non parallel motion of the slide can be monitored Refer to the If a Programmed Feature Doesn t Work section below at page 101 fora description of the overflow error that could occur using this feature Signature Technologies Inc 95 General Installation amp Programming Guide SPCview 005 Interval average Description Parameters Use Error Check Conventional Feature Build Press PRS_50 Tool 2092 SPC Point Title Nitro Pressure B amp D 005 Interval Average SPC Point Units Tons Channel Select z Graph is Status esaa Aitarnate 8 RIS negrees E 15 005 Feature Control Status 6 674 Control sea Monitor E 19 00 T T T a T T T 115 0 4128 14 141 3 154 4 167 6 180 7 193 9 207 0 220 2 Interval Start 166 608 49 00 31 674
190. been configured for high speed operation requiring a 1024 increment setting 2 If the angle rises from zero to 360 in only 90 degrees of press rotation the SA2000 is configured for 4096 but the SAMview system is programmed for 1024 3 If the angle rises from zero to 90 degrees with 360 degrees of press rotation the SA2000 is configured for 1024 while the SAMview system is programmed for 4096 4 Changing the entry in the RESOLUTION or PULSES window in the SAMview Configure PRESS utility to the appropriate value will remedy the problem Make sure that the press is programmed for RESOLVER input while you re in the Configure PRESS Utility Making the displayed Angle unit agree with the actual machine angle 1 Go to the PEAK display 2 Look at the angular position display on the existing system Signature Technologies Inc 255 User Manual 3 Select Configure Calibration from the Configure item on the menu bar 4 Answer NO to the Enable Static calibration Pop Up 5 Click on the SET box to the left of the Angle display 6 Enter the press angle 7 The displayed angle will change probably rounding off what you enter somewhat 8 Select Exit Configure from the Configure item on the menu bar 9 Answer Yes to any saving questions that appear Make sure that the SAMview angle display TRACKS with the existing system display 10 Bump the machine around a c
191. box Enter up to an 18 character description for the SAM Confirm the type of position sensing device that is installed on the press It will typically be a resolver but could also be an encoder or other type of unit The default Position Device setting is resolver This procedure will only address resolver based setups Contact Signature Technologies for encoder initialization information if necessary When the data above has all been entered as needed Click the lt lt Enter box under the SAM label NOTE If the resolution jumpers in the SA2000 are set to produce a resolution OTHER THAN the numerical value programmed in the Pulses field in Press Database a series of messages will display first Message Resolution setting conflict ID 1 Hit the lt Enter gt key Message Current Setting 1024 Hardware Setting 4096 Hit the lt Enter gt key Message Auto correct conflicts in SAM 1 Hit the lt Enter gt key Signature Technologies Inc 59 General Installation amp Programming Guide This will cause the SAMview system to MAKE the press database agree with the jumper settings on the SA2000 module Three things should happen A B C The green light to the left of the ID box should come on The large box on the left side of the screen under the SAM Description label should show the data you just entered The large Box under SAM Ch Description
192. ce jumper In the example above there are two SA2000 units the top cardset unit is the MASTER since it has a type IRES resolver module installed and the lower cardset with a type SLV module is the SLAVE Each one of the SA2000 units has an associated TEC The resolver is connected ONLY to the TEC belonging to the MASTER SA2000 128 Signature Technologies Inc signatureACE There are resolver terminals on both TEC units but the SLAVE TEC has NO resolver wired into it The 2 Input devices marked RUN on the TEC Board for ALL TEC units on the machine must be powered in parallel from the Clutch or Machine running signal This Input MUST BE USED since the SA2000 units WILL NOT operate properly otherwise The 1 Input devices IF USED marked CON on the TEC Board for ALL TEC units on the machine must be powered in parallel from the signal that indicates continuous or production operation i e the machine IS NOT in either Inch or Setup mode Signature Technologies Inc 129 General Installation amp Programming Guide Foundation of signature analysis What is a signature High limit points igs Force Signature points Low limit points Typ 0 087 degrees of Crank rotation Figure 106 Signature A Signature as shown in Figure 106 above is an electronic plot of the force or other pattern of the manufacturing process The value of
193. chines running in the same Host Computer the machine name NI file can be put in the C SAMDATA directory allowing re configuration of the system for the chosen press only E If you want to modify the operation of the SAMview software or override default system configurations for One of the Tools ONLY the tool name INI file can be put in the C SAMDATA machine name directory allowing re configuration of the system for the chosen tool only NOTE If multiple INI files are used in case of overlap the tool name INI will override the machine name INI which will override the SAMVIEW INI see Appendix 4 2 Start the SAMview software if it is not already running A Type cd samview lt Enter gt B Type samview lt Enter gt 56 Signature Technologies Inc signatureACE 3 The first screen that the system will display is the About screen Figure 33 About SAMview tm Version 3 08 Release Pal A Signature Technologies Product INTEGRATED PRODUCTS SAMview tm FeatureView tm SPCview tm PATENTS This Software is licensed under a separate agreement US 4 987 528 to the user by Signature Technologies Inc The Soft US 5 311 759 ware including it s functionality display design EP 0481971 and certain terminology is protected by United States US 5 491 647 Copyright laws and international treaty provisions Certain portions of this software are protect
194. chnologies Inc 45 General Installation amp Programming Guide SAMview System Setup Setup Wizard Version The SAMview package Beginning with version 3 08 INCLUDES a Setup Wizard that you can use to get started with the system without having to enter all the press and tool data required in a full configuration The Setup Wizard is invoked automatically if the system detects an Empty database The Setup Wizard does not do an extensive system setup but will get the system into operation easily so that signatures can be seen and subsequent setup enhancements can be made with a better familiarity of the system operation NOTE The instructions for a full configuration are included later in this manual See also Appendix 3 that deals with additional LP and CX files that define the Press available Tonnage Curve and the Slide Motion curves These require the creation of additional files in order to operate the writing of which is detailed in Appendix 3 See also Appendix 4 that deals with additional INI files that can be used to MODIFY the operation of the SAMview system These ARE NOT particularly intuitive so while the writing of and the command structure of INI files is deceptively simple as detailed in Appendix 4 It s general a good idea to call us into any attempt to use the INI modifications in order to avoid frustration and stress the urge to murder the software folks that
195. city of the machine BE CAREFUL since the force will build faster as you load more heavily Drop the slide only 0 003 0 005 per try to avoid overloads With multiple cells If you notice a corner that is hitting lighter than the others shim it with either metallic shim stock or paper to bring its force up Do this as you drop the shutheight adjustment to avoid eccentric loading of the machine Try to keep the force on all corners within 2 3 Keep a watch on the Peak View screen to make sure that none of the channels are getting too close to 2048 which is as high as they can go If one of them does the Gage sensitivity must be reduced The easiest way to do that is to switch the excitation from 10 Volts to 5 volts This will reduce the sensitivity by a factor of 0 50 When you reach capacity do a final shim adjustment to get all the corners as close as practical From the Peak View Screen pull down the Configure menu and select Calibrate Roll the press once more make sure the load cells are all still reading close to the same value then Click on the channels one at a time and enter the values shown on the load cells for the appropriate location Exit Configure saving the data Now perform a Linearity check Perform this check by Raising the shutheight 0 010 at a time or whatever gives you about a 10 reduction in load and rolling the press Don t change the shimming Note the readings on the displays which will now
196. complished from is the press line overview screen Configure sexeen Options Current Job Set Line Limits Set Line in Bypass Set Line in Control View Press Tool Stroke Count Run Baseline Control m P142 3669 E P143 E P144 A P145 A P146 P149 0 0 0 E EELE E OEO COO GL o Selected Press Piz Setup Info Control Status signatures Set Limits Control Figure 124 Press Line Overview Screen 1 Select a press by clicking on the appropriate Press ID button These buttons are located on the upper left portion of the screen Signature Technologies Inc 151 General Installation amp Programming Guide 2 Click the Set Limit button from the lower right side of the screen After the number of samples has passed as defined in the Limit Parameters screen the LED located at the upper right portion of the screen will come back on and the limits for all channels on the screen will be displayed if you re in the signature screen The selected SA2000 unit will then be operating under these new limits To set the limits for the entire press line 1 Click Overview from the menu bar to change to the Press Line Overview screen 2 Click the Set Line Limits button from the top center portion of the screen After the number of samples has passed as defined in the Limit Setup screen the LED located at the upper right portion of the scr
197. condition visibly SA2000 Module set The SA2000 Module set is the double ISA slot PC card set that plugs into the Host PC Computer The SA2000 is the workhorse element of the signatureACE system It is based on a Motorola DSP56002 CPU and is programmed in Assembler Its program cannot be corrupted by accidental keystrokes The SA2000 module does the following 1 It provides power to operate the load sensors This power is known as the excitation voltage It provides the excitation for up to eight individual strain gage load sensor inputs either at a five or ten volt level Each gage channel is independently adjustable Signature Technologies Inc 135 General Installation amp Programming Guide 2 It provides filtration and amplification of the sub microvolt signals from the load sensors Channel amplification is individually selectable to either X1000 for strain gages or X2 for self amplified devices having high level outputs 2 5 volt swing 3 It provides offset bias cancellation so that any imbalances in the strain gage channels are automatically set to zero This continuous function is performed at 0 TDC during each stroke and also each time the machine clutch engages 4 It converts the analog strain gage data to a digital signal 5 It provides the with a RES module in place excitation and data conversion for the resolver position sensor The resolver input can be converted at a jumper s
198. count rises EVENLY all the way to 360 before falling to 0 You don t actually have to look for 360 to be sure if the count rises to 342 and drops to 12 on the next motion you re O K NOTE There are FOUR Possibilities a The angle display will evenly increase its angle all the way to 359 over a full revolution of the machine then return to 0 and start it all over b The angle display will change its angle evenly over a full revolution of the machine to LESS THAN 360 degrees then reset to 0 c The angle display will change its angle evenly to 360 degrees over a Portion of a revolution of the machine and stay at 359 as the machine turns through the remainder of the rotation d The angle display will act strangely sometimes moving forward sometimes holding sometimes moving backward or some combination of the preceding effects as the machine is rotated through a complete rotation NOTE The position display is not a real time display but one that updates several times a second After moving the machine be sure that you wait long enough for the update to occur before you draw any conclusions You should see new data within 1 second The data will also not be accurate if the system has just been powered up and the machine hasn t moved yet 1 If the angle behaves as in a above the position portion of the system is working O K Go to Check 4 2 If the angle display behaves as in b or c above chances are that the
199. ct the Tool Job you want so that its name appears in the window at the top of the pop up and then click on the Select button you can also just double click on the Tool Job name 9 The Pop up will disappear and shortly thereafter the Overview screen will change to display the Tool Job selection you made 10 THEN one of two things will happen A If you chose to change the Job OR if you changed a Tool and there s only ONE machine shown in the Overview Screen then the system will automatically drop out of Configure mode back into normal operation when the tool download is complete B If you chose to change a Tool and there are two or more machines shown in the Overview window the system will remain in Configure mode when the download is complete In this case you must from the Menu Bar Select Exit Configuration from the pull down menu Answer yes to the Save question The system will drop out of Configure mode back into normal operation Reading and adjusting the signature graph As auser you will need to monitor and review signatures produced by the operation of the press or press line Follow these procedures to look at the signatures 142 Signature Technologies Inc signatureACE Conf igure Current Job Press Line Overview Options Set Line Limits Set Line in Bypass Set Line in Control View Press Tool Stroke Cou
200. ctor Buttons Fi Fi Fi Figure 140 Typical Die Protection Signals Fi Fi Fi Figure 144 Figure 145 Figure 146 UNIVERSAL 2 wire Proximity switch Sourcing connection Fi Figure 148 Checking N O PNP Prox switch Fi Fi Fi Fi Ei Fi Figure 157 Analog Sensor AND Die Protection Sensor Terminal layout A6D version Figure 158 Die protection Sensor Terminal layout D16 version Fi Fi Signature Technologies Inc 15 General Installation amp Programming Guide Figure 163 TEC to SA2000 Cable assembly Fi Fig Figure 166 Resolver Cable Assembly Fi Fi Fig g Figure 170 Strain Link Cover Box Fi Fi Fig Figure 174 WELD PAD mounting method for Strain Links Figure 175 Direct Bolting method of Strain Gage Mounting Figure 176 ST Standard resolver Package Fi Figure 178 Top view resolver end drive Figure 179 Cushion Mounts Fi Fi Fi Fi Fi Fi Fi Figure 187 Standard Converter SB 027 8006 OUTPUT cable assy Figure 188 Single ended Hookup Fi Fi Figure 191 Full Floating connection Fi j Fi Fi Figure 195 Obsolete Converter INPUT SB 027 8002 cable assy Fi Fi Fi Figure 199 Stress Strain Poisson s ratio illustration Figure 200 Strain Gage illustration Figure 2
201. d EITHER for the Positive Excitation to the strain gage OR wetting power for the Die Protection Inputs gt For Analog sensor channels It is ALWAYS 5 Volts with relation to Shield chassis Ground gt For Die Protection Channels It is ALWAYS 24 Volts with relation to EX All EX terminals for DIE PROTECTION CHANNELS are hooked together And FLOAT with relation to any ground Normally the EX terminal FOR DIE PROTECTION CHANNELS ONLY should be tied externally to MACHINE GROUND Dx Sx Is used EITHER for the Signal connection OR a Die Protection input depending on the system configuration The x s will be numbers that designate the Analog OR Die Protection channel Dx Sx Is used EITHER for the Signal connection OR a Die Protection input depending on the system configuration The x s will be numbers that designate the Analog OR Die Protection channel EX Is used EITHER for the Negative Excitation to the strain gage OR common reference for the Die Protection Inputs Signature Technologies Inc 203 User Manual gt For Analog sensor channels It is EITHER 5 Volts with relation to Ground if 10 Volt excitation has been selected default condition for all Analog sensor channels OR Ground if 5 Volt excitation has been selected gt For Die Protection Channels All Die Protection EX terminals are hooked together And FLOAT with relation to any ground Normally the EX terminal FOR DIE PROTECTION C
202. d reasons to establish actual tonnage values for the signals that are acquired by the system e The calibration process documents the integrity of the strain link installation The strain link when installed symmetrically on the machine structure deflect the same amount for each channel when the press frame is stressed When two links are used on the two connections of the press and the press is loaded at its center producing 1 000 counts of strain at one link the other link should show a strain in the same range 900 1 100 counts If a great difference exists the reason should be investigated for a damaged link a mechanical problem in the machine or other problem with the press e Calibration allows you to ensure the correct loading of the press When the display is in actual tons and channels are scaled the same it is easy to establish that the machine is properly loaded and operating within the allowable limitation ratings of the press e Periodic ZERO checking allows some gage condition confirmation Strain Gage related problems will often manifest early by causing shift in the ZERO offset value from the link Periodically checking this Offset can be done easily without affecting the operation of the press of unduly interrupting production Machine structure calibration The simplest calibrations are those that are applied to sensors which are attached to the Machine Frame or Connections Since ALL the force produced by the press has
203. d resistor to 24V is software connected to the input terminal The Switch must pull DOWN the input to common This configuration switches state when less than 12 Volts DC exist between the Input and the Common connection It returns to its quiescent when the voltage rises above 13 2V The switch wetting power is 24 V D C 5 Ma Signature Technologies Inc 183 General Installation amp Programming Guide The universal switching delay for all inputs is Software Switch selectable to either 0 002 second 0 012 second or 0 020 second Sourcing Switch Input This is an PNP type input device A 4 7K load resistor to Common is software connected to the input terminal The Switch must drive the input UP to 24 Volts This configuration switches State when More than 13 2 Volts DC exist between the Input and the Common connection It returns to its quiescent state when the input falls below 12 Volts 5 Ma Of supply current 24 Volts DC is applied switch The universal switching delay for all inputs is Software Switch selectable to either 0 002 second 0 012 second or 0 020 second 3 Wire PNP Proximity or Sourcing Input This is an PNP type input device A 4 7K load resistor to Common is software connected to the input terminal The Proximity Switch must drive the input UP to 24 Volts This Configuration switches state when more than 13 2 Volts DC exists between the Input and the Common It returns to its quiescent s
204. d the machine may stop if the system has been configured to do so What is Signature Analysis Signature analysis is the comparison of process signatures developed during normal machine operation with a process limit set Deviations between a process signature and the limit set indicate variances from the conditions that were present when the process limit set was created A sensor known as a resolver records the actual machine position in degrees The signal produced by this machine position sensor allows for the synchronization of the operating signatures and the process limit set Limit types There are three types of Process limits Signature Technologies Inc 131 General Installation amp Programming Guide a Warning Limits b Fault Limits c Machine Capacity Limits Warning YELLOW Limits Warning limits are continuous curved lines similar in shape to the machine process signature They are located closest to the process signature both above and below and are displayed in Yellow Violation of the Yellow limit set will cause in Control Mode an output device to actuate Fault RED Limits The Fault limits are the process limit curves located outside the Yellow limits both above and below the normal machine process signature Quality limits are displayed in Red Violation of the Red limit set will cause in Control Mode an output device to actuate Machine Capacity WHITE Limit The mach
205. d the third will be different but maybe not much different 0 5 Ohms possibly The DIFFERENT pair is connected to the R1 and R2 terminals it s the rotor connection The other two pairs are connected to the S2 S4 SINE terminals and the S1 S3 COSINE terminals Which pair goes on what set of terminals doesn t matter And which wire of each pair goes to which terminal doesn t matter At some point It s a good idea to make a measurement of the voltage coming back from the resolver on the Sine and Cosine terminals Rotate the press with a A C Voltmeter connected across the terminals and see how high the voltage goes it will go to a maximum value twice ina revolution It shouldn t exceed 2 0 volts R M S or 5 5 volts Peak to peak An excessive measurement warrants a call to ST for advice on the interface Excessive voltage within reason won t hurt the ST system components but may result in inaccurate angular information from the resolver The system will appear to operate normally however NOTE If you are using a resolver electronic package already on the machine like a programmable cam switch you must use a HiRes resolver Converter to interface it to the SA2000 unit Refer to Appendix 8 at the end of this publication for the installation of the HiRes resolver Converter interface unit Perform the steps there then return to THIS list at step 8 below 8 Provide a clea
206. damaging vibrations without compromising the angular accuracy of the resolver Signature Technologies Inc 235 User Manual Mounting bracket Flat washer reunting Gort ill Hose bushing ei i a a PPE EE a a a Gaa a a a 1 4 Fabreeka washers Figure 179 Cushion Mounts for Resolver Bracketry 5 Make sure your mount design allows some means to correct for Parallel Misalignment between the resolver and the crankshaft If the shafts don t line up broken couplings will be the inevitable result Something as simple as shims under the resolver or slotted holes allowing the pieces of the mount to be adjusted slightly will do the job 6 The drive stub is preferably a machined part that adapts the threaded hole generally found in the end of the crankshaft to a shaft 0 6250 in diameter onto which the drive coupling of the resolver can slip In case there is not a threaded hole available a drive flange can be used as shown in the illustration on the next page Note that the drive flange has a Guide rim that accurately centers the flange on the crankshaft This configuration should be used wherever possible 236 Signature Technologies Inc signatureACE Guide rim suggested for accurate centering Mounting bolts Crankshaft Figure 180 Drive flange arrangement Auxiliary Drive resolver mounting In some cases an auxiliary drive may be mounted to the end of the crank with an exposed end t
207. data in the units specified by the Alternate X axis defined for the selected channel or in degrees For position dependent Feature Algorithms the Display Status switch determines the return format For all other Feature Algorithms it only selects the signature display format for the build screen 20 Select the signature display mode To display the signature in degrees Click Degrees under the Display Status switch To display the signature in distance off bottom or Stroke remaining format Click Distance off Bottom under the Graph Axis Status switch NOTE The system will default to Degrees as a normal display mode 21 Select the CONTROL mode of the feature if you want to control the press based on the Features output data Click Control under the Feature Status switch Otherwise monitor the process without controlling the press based on the feature data by selecting Monitor under the Feature Control Status switch 110 Signature Technologies Inc signatureACE NOTE The system will put each feature in MONITOR mode as a default state 22 Configure the collection parameters for the Feature Algorithm There are two ways to do this A By moving the bars on the graphic display click on the little x s at the bottom and left edge for threshold of the cursor lines and DRAG the lines to the desired location The x closest to the pointer will jump to it when you
208. de surface This is to prevent marking of the surfaces Jack the press if you have dial indicators handy this is a good time to take the clearances of the machine make sure your counterbalances are de pressurized though so the clearances won t be taken up already Apply sufficient pressure to load the press to its rated capacity Go to the Peak screen and note down the figures you get from the display Make sure that none of the channels are getting too close to 2048 which is as high as they can go If one of them does the Gage sensitivity must be reduced The easiest way to do that is to switch the excitation from 10 Volts to 5 volts This will reduce the sensitivity by a factor of 0 5 Release the jacks Check to see if the readings went back to the original ZERO value Make sure the Counterbalance pressure hasn t shifted Repeat steps 11 through 14 two more times recording the results each time What we re looking for is repeatability If you can t get the same results then the jacking apparatus may be defective or be indicating improperly The press also may have some defect like broken bearing shells or a cracked crankshaft Take the average of the zero readings and the average of the loaded readings for each corner Subtract the ZERO value from the loaded value Then divide the force by the number you get from the subtraction The result will be the Calibration factor for that corner EXAMPLE Right Front Corner ZERO
209. designed with provision for tying down the resolver cable within 6 8 inches of the connector so excessive lengths are not allowed to wave in the breeze Simply attaching the cable to the bracket with drilled holes and tie wraps can prevent a lot of cable maintenance in the long run Signature Technologies Inc 233 User Manual Driving the resolver from the END of the crankshaft If the end of the crankshaft is unencumbered with feed drive or auxiliary apparatus and there is a solid surface to mount the resolver bracket to we prefer to end drive the resolver as illustrated below Crankshaft extention Drive Stub Flexible coupling Resolve Resolver Cable Figure 177 Side view resolver end drive Design considerations for end driving the resolver 1 Be careful of the end float of the crankshaft In older presses 1 8 or more of end float isn t uncommon If you are using a helical coupling you can only absorb about 1 16 3 32 inch of end play and when the clearances close the crankshaft will attempt to push the resolver shaft out the back of the resolver We have seen several cases where this has actually happened Needless to say the crankshaft always wins In cases where excessive end float exists the RENBRANDT type of multiple plate coupling possibly used in pairs can provide more clearance On the other hand if you have got a lot of end float maybe more than 1 4 then DON T end drive the resolver
210. dicated Press Position 367 Procedure Calculated Calibration Factor 364 Procedure for calculating the cal factors for purchased load cells 366 Program Xbar Limit parameters 122 Programmable CAM function 173 Programmable Cam Specifications 177 Programming CAMview 177 Programming DIEview 195 Programming Macro Feature algorithms 118 Programming a Feature 111 Programming JOBS 84 Programming SPCview features 89 Programming SPCview limit parameters 120 Programming the FIRST press 55 Programming the first tool 63 Protective covers for strain link Mounting 228 Pushbutton Reset 38 Pushbutton Test 38 Putting a tool in the machine 69 Q Quit SAMview 153 Ratio 104 Recalculate limits 125 RED Fault process limit Output 372 Reduction of signal through lower excitation 327 Reduction of Signal through output shunting 328 REF Jumpers 293 Remove a Feature 117 Removing a user from the system 168 Resetting a fault 153 Resolution Setting Jumpers 35 Resolver 140 Resolver Check out 41 Resolver Encoder connections 208 Resolver Cable Assembly 215 RESOLVER CHECKLIST 309 Resolver connections TEC 209 Resolver Converter 284 Resolver Converter requirements for 29 RESOLVER CONVERTER Checklist 313 Resolver Converter installation and setup 242 Resolver Convertor 144 Resolver Drive Auxiliary Drive Mounting 237 Resolver Drive from the END of the cran
211. different since they are actually designed to be POWERED at all times and draw their operating power through the load they are connected to Both N O and N C checking methods are shown in the next two figures 188 Signature Technologies Inc signatureACE Output Universal Prox To 24V Power Sup a To DR ia Co Oo Checking Contact Figure 149 Checking N O Universal Proximity Switch In both cases the power across the Prox switch disappears during the checking interval This introduces a delay called Time Delay Before Availability into the switch operation For Example If the switch is normally actuated in use the N C protocol would apply and the Checking switch would be wired in Series with the Prox as illustrated below yon Contact Output Poh ete ee To 24V Power Sup a Universal Prox Figure 150 Checking N C Universal Proximity Switch When the checking switch opened the Die Protection Input would go OFF and the ON OFF ON protocol would be used However when the checking switch closed again the Prox would take some time to re initialize itself and re actuate This time delay is typically equal to or less than 0 010 seconds 10 Milliseconds This isn t much problem in 30 S P M applications but wouldn t be at all practical at 600 S P M There are ways around the Time Delay Before Availability situation Please contact Signature Technologies Applic
212. dow will appear that asks if you re Finished adding SAMs for this press If there is only ONE SAM2000 the answer is YES If there are multiple MULTIPLE SA2000 units assigned to the same machine the answer is NO If you answer NO A A window will appear that asks the Number of Press Mounted Sensors for the second SA2000 B Enter the number of sensors up to 8 When you are done press lt Enter gt twice C Amessage will appear that tells you that your press has been configured and the number of sensors Press lt enter gt once D The Finished adding SAMs question will re appear E Repeat the process for all SA2000 units answer YES when you re done When you answer YES the system will drop back into the Press Database screen with all the blanks filled in and the proper channels called into the press channel list The channels will be named Channel SA2000 address Channel Number WHILE YOU RE IN THE PRESS DATABASE SCREEN put the OFFSET NUMBER that you generated during the resolver test in the previous section in the Position Offset window at the upper Signature Technologies Inc 47 General Installation amp Programming Guide right corner of the screen This will synchronize the position display of the signatureACE to the actual press position Be sure to hit the lt Enter gt key when the number is entered 12 Select Configure from the upper menu bar 1
213. e From box on the right side of the screen When the cursor appears type in the degree value you desire Repeat the process with the To box The system will round up or down slightly Note Do not set the from point EARLIER than 5 And Do not set the to point LATER than 355 gt If you accidentally put the to point earlier than the from point the system will display a Pop Up message End point must be greater than trigger Select OK and try again Signature Technologies Inc 65 General Installation amp Programming Guide gt In order to help you set your tools up properly the first time we suggest making a tool called Findit The window of this utility tool should be set as 5 From and 355 To Use this utility tool to range in on signatures NOTE If the From and or To points are moved after signatures have been stored in memory for future reference ANY signatures stored before the move will only be viewable with difficulty procedures are found below Avoid changing the From and or To points unless ABSOLUTELY necessary It s better to make ANOTHER TOOL if a different window of acquisition is desired The reason for this is that IF the acquisition window is changed it becomes difficult not impossible but DIFFICULT to look at signatures that were saved before the window was changed 10 Define appropriate TOOL sensor channels The T
214. e 35 A cursor will appear Enter the description of the sensor connected to that channel example F L Upright Hit the lt Tab gt key The cursor will jump to the Capacity box Figure 33 The Capacity box will display the default value 2100 Do not change it at this time UNLESS you have developed calibration factors mathematically and will enter them at this time Normally in the case of underdrive machines with Strain gages applied to the Pull down rods See the Section under Calibration in the signatureACE Maintenance Manual If you WILL be entering calibration numbers Click on the first character position and enter the machine capacity in the chosen units NOTE if you re dealing with a 1000 ton machine with FOUR pull down rods each rod would have a capacity of 250 tons etc 60 Signature Technologies Inc signatureACE E Hit the lt Tab gt key again The cursor will jump to the Units box Figure 35 The default is lt uncal gt Click on the FIRST Character position and enter the units you want to work in example Newtons THIS IS ONLY A LABEL no numerical significance is associated with the Units name NOTE if you don t know the calibration factors for the machine at this point go to item J below and continue from there F Hit the lt Tab gt key again The cursor will jump to the Calibration Box Figure 35 The default value
215. e Configure pull down and selecting the SAMnet option Click on the box under the light having the press name you are working with There will be a pop up displaying the firmware data When contacting us about a problem or question please have the Software and firmware version information so we ll know what we re dealing with Optional Sofware modules can be incorporated to add functionality to the basic system In most cases upgraded Firmware is also part of the addition The SPC SPCView Program addition Enables the basic Feature Extraction functions The FEX FeatureView Program addition Expands the Feature Extraction capability The above list is not entirely inclusive but does give you an IDEA of the individual functions of the system elements This should allow you to concentrate more fully on the probable cause of your problems instead of getting entangled with areas of the machine that probably aren t involved Example The System is showing you Beautiful signatures but not stopping the machine when the limits are broken You needn t look for a fault in the Host Computer since it just ain t involved in that part of the operation On the other Hand take a look at the screen and be sure you re in CONTROL mode Nothing will happen if you re in MONITOR If you re in CONTROL you probably have a problem with the I O portion of the system You should first take a look at the status lights on the I O modu
216. e press is jacked In addition the compliance of the press frame can be measured and applied to the instantaneous tonnage readings to calculate actual stroke position as the press closes The Machine structure DYNAMIC FORCE method The Dynamic force method uses load cells which are struck by the press as it rotates The Shutheight of the press is adjusted until the load cell s display a loading close to the rated capacity of the machine If multiple load cells are used they must be positioned symmetrically and ideally directly under the pressure points of the press They must also be shimmed so that all the load cells see the same force to avoid deflections in the machine The best thing about Dynamic calibration is that it requires less equipment only load cells and spacer blocks to make up the space in the press between the bolster surface and the slide face Electrical load cells are usable at all soeeds and can be used in combination with calibration display units While hydraulic load cells are available and less expensive they are also less accurate 3 and only suitable for the slowest of presses running not faster than 10 15 strokes per minute Faster cyclic rates than this will cause rapid gauge deterioration due to shock Machine structure Calculated Calibration Underdrive machines In cases where the drive to the slide is supplied by bars or rods which have a constant cross section a known material and a length which i
217. e Pop Up The only difference in settings is for the Signature entry which should be set to 500 ms in cases where you are running over 500 S P M Signature Technologies Inc 341 SAIDOIONHSOSAL ZAC BBF ZLA ed eet a SEP ZB Nd FLLS VETSL 20x0 BDIIOg me 4 AL Vv N 3 IS oul SaIboOUYse sunjpUBis you noya ET mA ETATEN wraoubige do SUedod onarnoxa HA aj QUBWNOOD HIPIO BILL Way ARY WX sy ODD 0 1 ary Ap DL Tbupyo z uOAd amen ISNOISIAJH General Installation amp Programming Guide SYSTEM Diagrams Amoy HASSHIHO p PUY Yo sipa poo sya ngs yo cequinu pues good WPAN ANY Up ueg BUD SUU ILHA TPA VALKO U app wog an guay GIH fuuu q ayipo ap LY HTH A iA SA2000 system generic diagram Figure 262 Signature Technologies Inc 342 signatureACE r nolegee Inc All rkghix read Shet T pares 95 imme Ba Incorporated It ehaol not Carrollton Taxae 75006 Phen 214 242 6803 FAG 214 242 6729 He Generic diagram SAMS00 STB 002 3014 Signature Technologies Inc and RSCB connectivity amp 1 0 tog ogles Incorporated 1992 1995 Sqpsenat Pes L TECHNOLOGIES REMSIONS Ossoription of ahange property of Aqnowre Teohne be vee or checlcend without the epee wiiten coret of Slancture Ta gnature Technol Tha oonfdantia document ka the excucive pawo i mA h 00s y ag 4 Epa p mipi yey pusy Suo sanma pamici WOU uapa di sy oF pida pwwad Apoyo u y wawy pupu oq o ys
218. e SPCview Configuration screen should appear Qverview Configure Database Analysis Sereen Options PCview Configuration Press P1286 Tool M3705 YT Feature List Build Conventional Feature Build Macro Feature Subgroup Sample Size Ea Cycles between subgroups lStrokes Figure 88 SPCview Configuration screen 7 The current Feature configuration for the tool should be listed in Feature List Signature Technologies Inc 107 General Installation amp Programming Guide A The feature designations i e 01 00 indicates that this is the FIRST feature programmed for the SA2000 module with the SAMnet address of 01 8 Prepare to program a feature by clicking on a blank feature designation on the list If you select a feature designation with a title see 01 00 figure 88 then you can CHANGE the chosen algorithm for the feature If the title is BLANK then you can program a new feature 9 Click Build Conventional Feature 10 The Conventional Feature Build utility should appear Overview Configure Osatabase Analysis Sereen Options Conventional Feature Build Press P1286 Tool M3705 SPE Paini THe Eee ager 55 lt none gt secant units _ Expected Value 32767 00 Figure 89 Conventional Feature Build Window 11 If the Feature has been built prior to this point the current configuration is displayed on the screen In the illustration above there a
219. e able to print Press Tool or Signature information Press and Tool information is in tabular format Signatures will be printed with both the signature graph and channel information If the signature is an archived signature the time stamp and comment will be printed with the signature as well NOTE If you wish to export Signature data to a spread sheet application or to view the data in tabular form the file must be converted to a format that the spreadsheet program recognizes The XLATE EXE utility available from ST will convert Signature AND SPC files into Tab delimited ASCII format that will import to most spreadsheets without difficulty 1 From the Press Database or the Tool Database screens select the Print menu selection under the Options menu The appropriate information will be printed in a tabular format Printing One Signature From the Signature screen or the Signature Overview screen 1 You can print the currently displayed signature by selecting the OPTIONS PRINT menu item This will bring up the Print Utility pop up Signature Technologies Inc 201 General Installation amp Programming Guide In the pop up the Press and Tool are displayed Additionally you may add a title to be printed along with the Signature If you prefer to get the entire screen printed select the Screen Dump box 2 SAMview has no way of knowing if you want a print out of the faulting signature or a normal signatu
220. e as pictured below Press control Light Stack Sensor Programmable Outputs Outputs Inputs Cam Outputs OJO OIOI O I O le le le le Ie EX 2 Ws Ws We We Ws tiie e a E ce ep a ISS Jolo SS ISK a m ma ma SHIELD Wea ees e Mee Lak ae x ao eS N 9j E g e E amp E Resolver EN FAULT UGHT STACK J Encoder i la z g Input ATARATA 2 SENSORS 222222222227 TE e at SENSOR CABLE J SS e S TOEA Oloo eI CONTROL GABLE Power Supply Machine i Status Indicators Control ee Auto Zero Programmable Inputs i Cycle indicator Cam Outputs Figure 135 CAMview Output connection points The output devices indicated are available for the Cam Outputs with 2 terminals for each Cam Output The Outputs are all totally isolated from each other Each individual output can be electrically customized to its use by plugging in the correct output module type 174 Signature Technologies Inc signatureACE NOTE When D C Output Modules are Used the ODD numbered termin
221. e coax connecting two units of the SAMnet Daisy Chain With the ohmmeter check the resistance between the shell of the BNC connector and the center conductor It should read infinity ANY other reading is unacceptable With the ohmmeter check the resistance between the shell of the BNC connector and the Shell at the opposite end of the cable It should read close to zero ohms With the ohmmeter check the resistance between the center conductor of the BNC connector and the center conductor at the opposite end of the cable It should read close to zero ohms This test is NOT totally definitive unless the resistance is grossly off It is only a first step It will be possible to measure Resistances that seem pretty reasonable while still having Coax connections that have Questionable integrity at 2 5 MHz Make sure your Ohmmeter is in good shape and your probes are in good condition and clean e If you measured resistance on any cable that was a lot different than it should be then disassemble and re terminate the cable ends being sure that the stripping and shield preparation was done O K I ve found that sometimes replacing the coax connector can make all the difference Possibly the center conductor didn t engage properly or there was a strand of shield braid where it shouldn t be The Coax Connector for the RG62 A U coax is AMP Type 221984 1 Cambridge CPFI UG88 2 Radio Shack 278 104 Make sure that the typ
222. e coupling or the shaft is broken in a way that allows backlash in the resolver shaft gt Check to see if the locking screws on the coupling are tight gt Twist the coupling body by hand and see if there is any lost motion back to the drive If you can feel any play it s too much gt Check for loose couplings worn bearings loose drive components in the system that turns the resolver One Danly Press we saw had the entire bearing for the drive pinion missing so that the gear shaft had about 1 2 of side play gt See if the resolver body is loose in its mounting so that the resolver body can turn slightly gt The Position Sensor drive should be of an approved type 332 Signature Technologies Inc signatureACE Don t use Roller chain Large pitch Timing belts Small diameter timing 3 8 pitch belt pulleys Separable couplings which might have backlash like Oldham or multi jaw types Any shaft which has gearing between the drive point and the Position Sensor Any shaft that drives a mechanical rotary limit switch there will be LARGE torque reversals DO use XL type 1 5 pitch timing belts with a trapezoidal tooth form miniature timing belts of 0 0816 pitch are O K in fact preferable if you can use them Timing belt pulleys of 4 dia or greater 2 5 if 0 0816 pitch is used Direct connection off the end of the crankshaft if possible Shaft Couplings with a high radial stiffness like wafer sprin
223. e file must be located in the SAMDATA directory to operate so the command is from the C gt prompt edit SAMDATA ralph cx When the edit window comes up write the file and when done pull down the File menu and Exit The system will ask you if you want to save the file you say yes and it s done There will be a RALPH CX file in the Samdata directory If you have Tooling sensors If there are tooling sensors the CX file MUST ALSO be copied to the Press directory Example if the press name is RUTH You want to from the C gt prompt copy SAMDATAIralph cx SAMDATA ruth ralph cx Where to get the data If the machine is a normal crank driven press Signature Technologies can develop generic curves for your machine with the following data Length of stroke 2 Length of connecting rod oO Diameter of Main bearing journal BS Single or double ended drive Signature Technologies Inc 217 User Manual Alternatively the press manufacturers can get the information for you although sometimes you have to be insistent Get the data in TABLE form if possible If that s not possible the points can be extracted from motion and force curve graphs For Link drive or other non sinusoidal drive mechanisms information from the press company will be totally necessary Appendix 4 INI Files for modifying the operation of SAMview SAMview has some flexibility provided via the SAMVIEW
224. e involved in a die part can be made to flow directly through a load cell and then calibration is possible 278 Signature Technologies Inc signatureACE Figure 222 Extrude station load cell calibratable The example above is for a station that extrudes a hole in the bottom of a cup The Extrude punch is mounted in line with and directly below the punch itself The force in the punch flows exclusively through the load cell In order to calibrate this cell a calibrated force possibly from a hydraulic press should be applied to the cell just as it would be when the cell is mounted in the die Differences in surface finish of the tool elements that contact the cell can change the concentrations of force through the cell We would recommend that the actual components are used i e place the load cell on the backing surface it will have in the die and apply pressure with the extrude punch Following the instructions for calibration in the user s manual apply the force calibrate then apply the force several more times as a check On the other hand sometimes the force flows both through the cell and through the matrix of the die as well In this case the calibration is only valid for force applied in a SPECIFIC WAY Signature Technologies Inc 279 User Manual DIE SET UPPER WORKPIECE Figure 223 Combination Blank amp Draw load cell Uncalibratable The illustration above is for a combination blank
225. e main problem with this type of detector is its fragile nature It is easily damaged or bent by out of position stock A secondary concern is that in applications where you NEVER want the switch to be grounded as in Buckle detection A broken wire tells the system Everything is O K whether it is or not see the note below on Dynamic Checking for static sensors On the other hand repair is easy and everybody easily understands the sensor Signature Technologies Inc 185 General Installation amp Programming Guide Sourcing Switch connection The Next step up in sensing is the Mechanical switch It is used in a variety of ways Feed length confirmation using the French Stop Spring loaded Pilots for sensing mis feed Short Long Loop Cry ee To 24V Power Sup u switch Switch To D P Input ten ee O Workpiece Machine Frame A ERRERA E A Figure 143 Mechanical Switch sensor Sourcing Hookup NOTE Other devices such as Photo Optical devices amplified Piezo Impact sensors and the like with contact outputs fit into this category as well as Mechanically actuated switches The illustration here is of a switch hooked up Sourcing The only way to get a signal to the Die Protection system is for the switch to close and connect the 24 Volt supply to the die protection input If the wiring is broken NO signal If the wiring is shorted NO signal The same co
226. e middle bottom of the screen The system will display Signature View number one Unless you have already been in the signature screen in which case the system will go back to whichever view you left from NOTE The View you re in is displayed as a number immediately above the Peak button on the lower left of the screen labeled Graph View 4 Select the view you want to configure if it s different from the view you re in 5 Select Configure from the menu bar A sub menu will appear 5 Select Screen from the sub menu Pen set up options will appear on the right side of the screen as shown in Figure 53 Signature Technologies Inc 75 General Installation amp Programming Guide vervies Configure Batabase Analysis Screen Optiens Signature View P1286 M3705 ost Count 0 sem o0 angie o 1000 Graph View 2 Control Status Running Hebe Tera Loa oaiae Dorm JO OL ma Figure 52 Signature View Configuration Screen 6 The vertical scale will default to 1000 5000 and the horizontal scale will default to 0 360 degrees To make changes select the Zoom button located on the left side of the screen just below the signature graph Yellow cross hairs will appear on the signature graph as shown in Figure 46 Overview Configure Database Analysis Screen Qptiens Signature View P1286 M3705 2100 14707
227. e press line 1 Change to the Press Line Overview screen select Overview from the menu bar 2 Select Set Line Limits near the top of the screen The Set Limits indicator will go out on all the presses and after the number of samples has passed as programmed in the Signature Limit Parameters pop up and displayed at the top right of the SPCview Limit Parameters pop up the limit set indicator LED s will come back on and the limits for all channels on the screen will be displayed The SA2000 units will then be operating under these new limits To recalculate SPC limits using new limit setting constants but an old process sample YOU MUST FIRST have a process limit sample in the memory If you have taken a sample by hitting the Set Limits button at the lower right corner of the Signature SPC Peak and Overview screens SINCE the tool was loaded OR since the system was shut down then there is a process sample set in memory If there is NO process sample set in memory and you try to recalculate NOTHING WILL HAPPEN 1 Go to any of the SPC graph screens if you are not already there by selecting SPC from the box in the bottom center of the screens 2 Select Configure from the menu bar 3 Select Limit Parameters Baseline SPC Setup Press P142 Peak capture 62 00 02 01 Average load A2 02 Work load Kbar Limits yellow re Control Limit K Quality Limit K ERT Eas
228. e window MUST be at least 5 degrees wide What happens Outside the window is ignored The window MUST NOT BE more than 350 degrees wide On OFF On Normally ON with at least one change to OFF and a subsequent return s to ON expected DURING a programmable angular window in the stroke Signal MUST remain ON outside the window If the signal enters the window in the OFF state A Fault will be issued Immediately Lack of a transition during the Window produces a fault at the Window END angle If the signal Leaves the window in the OFF state A Fault will be issued Immediately The window MUST be at least 5 degrees wide The window MUST NOT BE more than 350 degrees wide OFF On OFF Normally OFF with at least one change to ON and a subsequent return s to OFF expected DURING a programmable angular window in the stroke Signal MUST remain OFF outside the window If the signal enters the window in the ON state A Fault will be issued Immediately Lack of a transition during the Window produces a fault at the Window END angle If the signal Leaves the window in the ON state A Fault will be issued Immediately The window MUST be at least 5 degrees wide The window MUST NOT BE more than 350 degrees wide Signature Technologies Inc 195 General Installation amp Programming Guide Always OFF check MUST be OFF within the window A change
229. e wired identically but have different color codes associated with them The alternates are listed below 256 Signature Technologies Inc signatureACE Connector 9 Pin D Female with shell amp Jack screws Cable 4 Twisted pair sheilded 20 Manhattan M14604 White Black Red White Black on EE TA Red R2 Connect to the E of the system being coupled to Figure 195 Obsolete Converter INPUT SB 027 8002 cable assy Shields Shield u oo wl o Cable 4 Pr Indiv Shld 20 Converter End Connector 9 Pin D TEC Enclosure Male with shell amp jack Manhattan M14604 Terminals screws OLD Current style Style Sine 6 White Red ig ee ae he White Red 2 S2 45V I White Black White Black 5 5 Coat 7 White Green White Green oe A White Yellow White Yellow Ref Red __q oo Red 6 RI AGND T ee Shield 2 Shield 1 SHD z yite W cD fs Ae ME Green 5 CND Figure 196 Obsolete Converter OUTPUT SB 027 8007 cable assy Appendix 9 Sensor Interfacing Guide INTRODUCTION Signature Technologies Inc 257 User Manual The signatureACE system hardware is specifically designed to operate with resistive strain gages in full Whetstone bridge configuration To this end we supply precision regulated D C excitation voltage and full floating differential sig
230. e you use strips the center conductor 9 16 and the shield 1 4 There are types out there that only strip the center conductor 1 8 and they tend NOT to install properly e Re connect the coax cable s when you re done with this phase of testing 5 If the resistance seemed to come out O K then the next step is to substitute a KNOWN GOOD section of Coax up along the line suggest making a 100 or longer if need be Test Cable of RG62 A U with BNC connectors at each end and keeping it around as a troubleshooting tool 6 If The Network is DEAD or maybe has one or two units showing Signature Technologies Inc 305 General Installation amp Programming Guide e Start at the HOST computer and substitute the Test cable for the existing coax between the Host Computer and the First unit in line Disconnect the cable between the First unit and the Second and install a 93 ohm termination on the open BNC port for the First unit since the only termination should be on the unit at the end of the daisy chain e Make sure the first unit is On Line and operational Re install the original cable from the Host to the First unit and transfer your test cable and terminator to the link between the First and Second units disconnecting from the Third unit and terminating the empty Tee connector on the Second e Take notes or have a good memory about what happens as you work along EXAMPLE When you reach 4 unit the network fails comple
231. echnologies Inc signatureACE Step 4 Step 5 Step 6 Enter DIR A LM The system will display the files on the A drive with the dates and times of creation showing Make a note of the desired master file and its date and time Enter DIR LM The system will display the files in the C drive database with the dates and times of creation showing Any Master files both LM and SM with later dates than the desired Master files must be deleted from the C drive you could copy them off to a floppy if you don t wish to lose them for good Delete files by using the command DEL lt filename gt This will take out both the LM amp SM files Using the DOS command Copy the chosen Master Signature SM and Limit LM files by name onto the Hard drive COPY A lt directory name gt lt File Name gt Deleting Signatures Cleaning out the Hard Drive Step 1 Step 2 Step 3 Step 4 Exit the SAMView program Change directory to C SAMDATA lt Press Name gt lt Tool Name gt Enter DIR P The system will display the files in the C drive database with the dates and times of creation showing The system will automatically display the signatures a page at a time This will let you get a feel for how many and what type of files are stored The file types are identifiable by their suffix ST Automatically recorded or Trend signatures No limits are recorded SSW LW Warning signatures limit
232. echnologies Inc 353 User Manual Step 9 Note down the values for each of the channels in the maintenance record Include in the record the counterbalance pressure and the upper die weight in the entry Step 10 Perform this test every 6 months and compare the values you get The Idea behind this procedure is to make sure that the gages haven t unbonded or the element that they re attached to hasn t stretched or started to fail In general a significant change in zero offset is the first sign of impending gage failure Example If the signature on a certain channel changes radically to a higher or lower gain the cause could be sensor failure If the zero offset of the sensor hasn t changed though then the sensor may be O K and something has changed in the machine like a cracked crosshead or a broken bearing shell Calibration Procedure Static Preparation Perform the Zero Offset Checking Procedure in the preceding section Step 1 Goto the Press Database screen and change all the calibration factors to 1 000 Step 2 Position the Press at B D C Step 3 Adjust the pressure of the counterbalances to balance the slide weight alone This value should be on one of the Information plates on the press If the information isn t there the Press manufacturer can provide it If all else fails blow the counterbalances down completely put a dial indicator under the slide then add counterbalance pressure slowly until the slide JU
233. ed under US and Foreign Patents including additional patents pending and or Trademark law Copyright National Instruments Corporation All Rights Reserved You may not reverse engineer decompile disassemble or create derivative works from this Software Signature Technologies Inc 13375 Stemmons Frwy Suite 320 Dallas TX 75234 U S A voice 972 488 9777 fax 972 488 2924 www SignatureTechnologies com Copyright 1997 Signature Technologies Inc Figure 33 About Screen Read the information about licensing copyright and patent protection When finished click the Proceed button 4 The Press Database screen will appear This screen is shown in Figure 34 below 5 The Cursor a Gray Block will appear in the First Character Position of the Press ID box 6 Type in a Press ID name The Press ID name is the key entry that identifies the press Once the name has been entered it cannot be altered This name can be 1 to 8 characters long and must be a DOS compatible file name If you accidentally use unacceptable characters the system will substitute the _ character in place of the character s you specified 7 Optional To add more detail click the first left character position in the Press Description box See Figure 34 A cursor will appear there Type in a long description of the press This description can use up to 18 characters and can include A
234. edures see Appendix 11 Maintenance Manual in this book Section 7 Adding Tools amp Jobs to a system which is already set up Adding tools to the system is a simple procedure Once graphic defaults have been saved they apply to any tools that are created for that press This eliminates much of the setup necessary to establish the system initially Graphic default set up is covered above in Section 5 1 This procedure begins from the Press Line Overview Screen as shown in 58 Select Overview from the menu bar if you are not currently in the Press Line Overview screen 2 Click on the appropriate Press Name button It is found under the View Press label Overview Configure Patabase Analysis Sereen Options Press Line Overview Panrent sou E Set Line in Bypass Set Line in Control Pad View Press Tool Stroke Count Run Baseline Control m ens hors ee Oo Oo O Selected Press P1286 Setup Info Control Status Reset Fault Figure 58 Press Line Overview Screen 3 Select Configure from the menu bar A drop down sub menu will appear 4 Select Tool from the sub menu The Tool Database screen will appear as shown in Figure 59 Signature Technologies Inc 81 General Installation amp Programming Guide Overviewt Configure Batahase Analysis Screen Options Tool Database for Press P1286 change Toor_ 100 ID Tool Desc
235. eee LI 3271 Log On Show Event Log About SAMView Reset Stroke Count Quit SANView Figure 118 Menu Bar If you have the required security clearance and it becomes necessary to actually Quit SAMview proceed as follows 146 Signature Technologies Inc signatureACE 1 Press lt F10 gt or Select the Options group from the menu bar and click Quit SAMview from the sub menu 2 Fulfill the security requirements when the Log On screen appears Click either Log on or One Shot To Load an existing tool into ONE press Conf igure Options cerven rae Set Line Limits Set Line in Bypass Set Line in Control View Press Tool Stroke Count Run Baseline Control m P142 3669 E 0 CRO m ce C O m o O u E p oe o oO Selected Press Pia2 Setup Info Control Status Signatures Set Limits Control Figure 119 The Press Line Overview screen Queruie Options Job ess Line Overview k Urol Cool Limits Set Line in Bypass Set Line in Control Press View Press Tool Stroke Count Run Baseline Control mE s 0 Limit Parameters g 95 SS m 3 0 O Screen Security SAMnet Selected Press Control Status Reset Fault set Limits Figure 120 Configure Sub Menu Bypass Control A normal part of the operation of the syst
236. een Overview 69 Configure Screen Peak View 75 Configure Screen Signature view 74 Configuring Job 69 Configuring SAMview for your printer 207 Configuring signature saving 169 Connection Enclosure 140 Connection Strain Link 263 Connection Board 142 Connections 2 wire Universal Proximity 193 Connections 3 wire NPN Sinking Proximity 193 Connections 3 wire PNP Sourcing Proximity 192 Connections CAMview 181 Connections Grounding Switch 191 Connections Resolver Encoder 208 Connections Sensor 260 Connections Sourcing Switch 192 Connections System Wiring 203 Connections TEC terminations 54 Connectors on the SA2000 37 pin D shell 210 Considerations for multiple SA2000 units 133 Control Bypass Mode Selection 152 control of hazardous machine functions 17 Controls SA2000 143 Converter Resolver 284 Converter Cable color code doesn t match 256 Converter Full Floating Hookup 249 Converter Single Ended Hookup 248 Converter SmartPac by Data Instruments hookup 248 Convertor Resolver 144 Correcting Excessive balance offsets 267 331 Correcting the indicated Press Position 367 CX Files 55 CX files For Slide Motion 215 D D Shell connectors on the SA2000 210 Data Acquisition module 142 Data for LP and CX files where to get it 217 Data Instruments Strain Links interfacing 269 Data Rate Refresh Setup 345 Database Arc
237. een will come back on and the limits for all channels on the screen will be displayed All the SA2000 units will then be operating under these new limits HOT keys to make operation simpler FUNCTION KEYS F1 Show Current Fault if not reset F2 Show Current Limits F3 Show Current Signature F4 Save Signature if enabled in the Edit Saving screen F5 Refresh the screen F6 Display last RECORDED White Fault F7 Display last RECORDED Red Fault F8 Display last RECORDED Yellow Fault F10 Quit SAMview Shift Key Combinations Shift Refresh button 180 degree Ref line on screen Shift F1 Print In SPC Shift Reset button Clear Magenta fault SPC Setting problem Shift Quick Pick button Shows status of that SPC channel Shift Cancel Reset Acknowledge the SPC problem Control Key combinations Cntrl L Loop playback forever Cntrl O Toggle Overlay display mode Cntrl Q Resume Playback Cntrl R Restart Playback from beginning Cntrl S Pause Playback Complex functions Shift click on Channel name while in the Peak screen automatically program the position offset SO THAT the peak will be at 180 degrees 152 Signature Technologies Inc signatureACE The Playback Utility of the SAMview System The playback function of SAMview allows you to select previously saved signatures up to 100 for analysis of press operations The playback feature i
238. een HAS NO ACTIVE PENS configured the system WILL AUTOMATICALLY enter the Configure Screen Mode each time you go to Peak and won t allow you to leave the Peak screen until Configuration has been performed and Configure Screen has been exited 1 If the Peak screen default setup IS NOT to your liking you may re configure it 2 If this is the case Select Configure from the menu bar then select Screen Conf igure Screen 7654 _DEFAULT oa Angle 0 SPM 0 paR oR Force Tart Angle Control Status Running Reset Fault Bypass Set Limits Control Figure 56 Peak Screen Display positions shown 3 ALL the possible Display positions will be shown select a button under one of the numerical displays Figure 56 Select the most appropriately positioned button for the channel you want to display For example the lower left corner would be the most appropriate place to display information about a sensor Signature Technologies Inc 79 General Installation amp Programming Guide on the left front connection etc After you select a button the Pen Sensor Setup pop up window will appear Fig 54 4 While in the Pen Sensor Setup pop up highlight the channel you want to display in the Peak View window by selecting the channel lt pen of F gt lt pen off gt lt pen off gt Control Status Running
239. eezed but will also Extract the same amount of energy when it is released What is required to properly see the output of a Piezo device is a Charge Amplifier which can be formed by connecting a capacitor across the and Signal inputs of the TEC module There is some belief that a Piezo device is Rate Sensitive i e they produce a greater output when squeezed quickly than they do if squeezed slowly In fact they don t It is the leakage of the Charge amplifier that creates the Rate Sensitivity not the sensor A High quality Charge amplifier shows little difference related to Rate of change The signatureACE input is not Instrumentation grade but is superior to most front ends due to its low leakage and high amplification enabling the use of large capacitive loads to store the charge from the sensor When a Piezo device is connected to the TEC Unit some external components are required as illustrated below First the Piezo signal must be centralized in the common mode range of the input amplifier The connection shown from Excitation to Signal accomplishes this MAKE SURE the SA2000 inputs used for Piezo devices are set to 5 volt excitation BEFORE hooking the sensors up Failure to do this can result in system damage Twinaxial Hookup Signal Signal Excitation Piezo Sensor Figure 213 Piezo Twinaxial sensor interfacing Preferred The 1 Meg resistor R acts as a Drain
240. el 2 Gain Channel 3 Gain Channel 4 Gain 10 Volts Channel 1 Excitation Channel 2 Excitation Channel 3 Excitation Channel 4 Excitation k ernie nmam Y ain TAT aa 43333435 0 0 010 0 0 0 0 OFO OO 1 tad r tee mw je m te ind r e re nad HT 1997 SERIAL 387528 5491647 Figure 251 A D Input board jumpers Output shunting Shunting the gage can reduce the signal from the High output gage For example The strain gage pressure sensors from a certain manufacturer have the following spec 3mv v Signature Technologies Inc 325 General Installation amp Programming Guide This terse statement translates to At full rated input pressure the output of the strain gauge bridge will be 3 Millivolts for every volt of D C excitation applied With a 10 volt excitation then the output of the sensor unit would be 30 Millivolts The ST system at high range only can stand only 5 Millivolts Obviously we ll overload the input if we try to put this much into the SA2000 input Reducing the excitation to 5 volts still gives us 15 Millivolts at full pressure so some other way of reducing the input voltage must be found The Bridge resistance is given as 350 Ohms Connecting a parallel resistance across the bridge is a good way of limiting the output of the bridge The way to calculate the shunting resistor is Where R the strain gage bridge resistance in Ohms At
241. eld is TWICE as big as it should be i e You thought you had a SAM configured for a 2X multiplier but you don t If the press when it turns counts up to 360 and re sets to 0 twice per rotation then the number in the Pulses field is HALF as big as it should be i e You thought you had a SAM configured with no multiplier but you have a 2X Change the number in Pulses and roll the press again to check If the results are O K Go to Check 4 Check 4 Check the agreement between Displayed and Actual Position Stop the press at a known position and See if the angular position display agrees with actual press position 1 If it does the position system is calibrated O K and can be considered fully operational Signature Technologies Inc 317 General Installation amp Programming Guide Go to Check 5 2 If it doesn t 3 Go to the Peak View Screen 4 From the Configure pulldown click on Calibrate 5 A Box labeled Set Angle will appear to the Left of the Angle Window 6 Click on the Set Angle Box Enter the actual press position in the Message box that appears followed by a click on the OK button lt cr gt 7 From the Configure Pulldown click on Exit Configuration and answer Yes to the Message Box 8 Rotate the press completely going back to a known position 9 Make sure that the displayed position agrees with the actual position Check 5 See if your SA2000 is transmitting Status d
242. electable 10 bit 1024 positions per revolution or 12 bit 4096 positions per revolution level Ten 10 bit position resolution is normally used for machine speeds over 200 strokes per minute SPM Twelve 12 bit resolution is used for machines running at slower speeds 6 It calculates process limit arrays uploading them to the host computer for display and storage 7 It compares sample signature data arrays with process limit arrays between each sample 8 Itissues logic level digital outputs in response to the outcome of the comparisons made between the signature data and its limits 9 It accepts logic level digital inputs from the machine 10 The SA2000 gets its operating power from the Host Computer power supply HEARTBEAT Indicator TEST Address Buffer Full Connector Switch Indicator RESET Button Test TEST Button Switch ii Slaving Connector Sensor Gain Gage Excitation Jumpers Jumpers Figure 112 SA2000 136 Signature Technologies Inc signatureACE Note Ifthe sensors are in distant locations their output will be too weak to reach the system In this case an external RSCB Remote Signal Conditioner Board can be mounted up to 100 feet from the signatureACE unit Contact Signature Technologies for details HiRes Resolver Converter Mounting holes Connector i Indicators amp Adjustments 25 OUTPUT Connector Figure 113 HiRes Converter
243. elow for a description of how to add SA2000 units toa machine You can have up to 6 SA2000 units 48 channels assigned to a single machine Each signature file would contain all 48 individual signatures BUT each SA2000 unit will produce its own separate SPC file 1 Select Overview from the menu bar if you are not currently in the Press Line Overview screen 2 Select Configure from the menu bar A drop down sub menu will appear 3 Select Press from the sub menu The Press Database screen will appear All the data for the current press will also be displayed 4 From within the Press Database select the New Press button in the upper right corner of the screen All the screen data will disappear and you can proceed to program the second etc machine Overview Configure Yatabase Analysis Sereen Options Press Database Messe Press Description Pas Change Press ieee p Local 0C O Dar ID Description Position Offset ID SAM Description ol a oa A SAM Position Device Pulses E z Channel List IAL Channels SAMZCh Description Channel Al Cam Outputs L Editing a L z Description Capacity Uni ts Calibration Curve File Z 2100 kuncal gt 1 0000 Figure 101 Press Database 5 Click on the first character position on the left of the Press ID window A cursor will appear Signature Technologies Inc 123 General Installation
244. em and write it down somewhere handy 4 Power the system down and connect the CNV Converter Input cable SB 027 8004 to the existing system Don t plug the input cable into the CNV converter yet or worry about the direction of rotation at this time 5 Power the system up again Look again at the displayed angle on the existing system and then plug the INPUT cable into the CNV converter Make sure the angle displayed on the existing system doesn t change significantly A degree or so isn t important although you may have to reset the offset slightly in the existing system to compensate for the CNV Converter loading If the reading displayed on the existing system changes by 5 10 degrees the converter may not be usable with the existing system Call ST for further details 6 Run the Converter OUTPUT cable SB 027 8006 from the CNV Converter back to the Signature Technologies TEC enclosure 7 When the OUTPUT cable is in place between the Converter and the TEC enclosure connect the wiring to the 10 pin terminal strip at the end of the enclosure as follows Installing the OUTPUT Cable The SB 027 8006 Cable Color Code is One wire of each of the pairs is Black The color in parenthesis is the other color in the pair Wire Color Current TEC Signal Name OLD TEC Shield nean needed SHD reihi Shield Ground 0 1 White iniii iirin aki S2 ie nein SING i eied 2 AAE zdea antec eran OE ea S asad dan NICS ge ee
245. em is the loading of existing tools The steps that follow describe how to load an EXISTING Tool into ONE press Signature Technologies Inc 147 General Installation amp Programming Guide 1 Move to the Overview screen by selecting Overview from the menu bar located at the top of the screen See Figure 118 2 Once you are in the Overview screen Click Configure from the menu bar located at the top of the screen A sub menu will appear as shown in Figure 120 3 Click Job from the drop down list The drop down list will disappear The Press Line Overview screen will remain 4 The Select button will appear beside the box found under the Tool heading Choose the Select button The Select a Tool window will appear 5 A list of the available tools will be displayed along the left edge of the Select a Tool window Select the tool you want to load from this list Then Click the Select button to save your choice of tooling The tool you identified should appear in the tool box within a few moments 6 IF you have more than one press showing in the OVERVIEW screen then click Configure from the menu bar A drop down list should appear 7 Click Exit Configuration from the drop down list NOTE If you have only ONE press the system will automatically drop out of Configure mode NOTE SAMview will automatically set limits if you load a tool that does not have masters stored fo
246. emember the code you can generally perform checks on strain links with an Ohmmeter to find out what the internal connections are Signature Technologies Inc 263 User Manual There will be two pairs of wires that have higher resistance than any other pair Generally you can hook the excitation to one of the high resistance pairs and take the signal from the other pair Strain links typically don t have compensation components so they don t care how they re connected In the case of high precision load cells there are normally compensation components that make it necessary to connect to the proper sets of wires to get accurate results If you don t have the information call the cell manufacturer If the Strain Gage output is too high for the ST system Since the signatureACE doesn t have any provision for input gain adjustment outside of the 1000X 2X gain switch sometimes the output of a strain gage bridge in highly strained applications can exceed the input range of the SA2000 in HI range One way of cutting the output of the Strain gage is to reduce the excitation voltage from 10 volt to 5 volts with the switch provided for that purpose This is a valid way of cutting the input level down to 0 5 times its 10 volt value This is good if you have a lot of signal the noise level will be significantly increased on the lower level signals Jumper Locations on the SA2000 GROUND Channel 1 Channel 1 Gain DN Excitation Sey
247. er converter and its power supply If a ENC position module is installed the terminals are used for A B and Z tracks either single ended OR complementary on an Incremental encoder If a SLV position module is installed they are NOT USED at all since the position reference comes from another SA2000 module Terminal name designations SHIELD Is used to connect the Shield braid of the position transducer S2 Is used EITHER for the S2 Sine lead from a resolver OR the A track connection for an incremental encoder S4 Is used EITHER for the S4 Sine lead from a resolver OR the A Bar track connection for an incremental encoder If the incremental encoder doesn t have the complementary signals this terminal may be left open 208 Signature Technologies Inc S 1 93 7 RI R2 5 Vy GND 5V signatureACE Is used EITHER for the S1 Cosine lead from a resolver OR the B track connection for an incremental encoder Is used EITHER for the S3 Cosine lead from a resolver OR the B Bar track connection for an incremental encoder If the incremental encoder doesn t have the complementary signals this terminal may be left open Is used EITHER for the R1 Reference lead from a resolver OR the Z track connection for an incremental encoder Is used EITHER for the R2
248. er revolution this is a good indication that the Z track of the encoder is O K 13 If the preceding tests came out O K The Encoder is probably O K proceed with steps A thru F below a Drop out of Samview and type Samtest lt enter gt at the C gt prompt b Select 4 Resolver on the Resolver screen tell the system how many pulses per revolution your encoder is c Turn the encoder by moving the machine See if the position arrow moves d If it does not select the Right arrow key and put the screen in Raw input data mode At the bottom of the screen under the word output there will be 3 dots which will change to 1 whenever the track thay are connected to goes on Turning the encoder slowly you should be able to see the two leftmost dots change with the A and B tracks in the 90 degree relationship described before The third right most dot should blip 1 once per revolution Signature Technologies Inc 315 General Installation amp Programming Guide e Ifthe dots perform properly and there is no count the SA2000 is defective If the dots do not perform properly but the tests in 14 came out O K there is also a failure in the SA2000 OR the CONTROL cable connecting it to the TEC Check 3 Make Sure your SAM jumpers match the Pulses number To do this continue to rotate the machine incrementally in 20 Degree jumps and check the digital display in the Signature View screen to see if the
249. ere is ONLY ONE MASTER SA2000 on the machine and the rest must be SLAVE units Whether an SA2000 is a MASTER or a SLAVE depends on which Position Interface card is plugged onto the processor board Figure 103 below is a resolver position interface board It has the ability to convert the resolver signals into a digital position and makes the processor that it s connected to a MASTER il VEEL a dg Connector JT J ayi a p 3 3 Po 4 Reference Resolution i FAET m cee nen Jumpers Compensation Jumper Figure 103 Type RES resolver position interface module Signature Technologies Inc 127 General Installation amp Programming Guide The illustration below at Figure 104 is a Slave position interface It is essentially a passive module that only accepts position information from a MASTER SA2000 card set AE AAA Position Data PE Y y Connector wats Nas Pill we Oeruvouvuuvovevegus y SERIAL WO L oe 6 NDE IH USA SIGHATURE TECHNOLOGIES INC COPYRIGHT 1997 A 2000 STB 828 5004 US PATEHTS 4987528 5491647 Figure 104 Type SLV Slave position interface module This is done with a flat cable Position Reference jumper hooked between the Position Data Connectors on the SA2000 modules as shown below in Figure 105 Position Reference jumper N Master Cardset Slave Cardset lt SAMnet Network card Figure 105 Position referen
250. ere is always confusion about On and Off when discussing specific voltage levels and whether the logic is positive or negative Basically if the STATE indicator on the Output Module is LIT THE OUTPUT IS ON Angle ON Angle OFF This is the Standard Protocol for cams and works exactly like their mechanical counterparts When the press is moving forward the cam will turn ON when the ON Angle is passed and remain ON until the OFF Angle is passed If the machine moves in reverse rotation the OFF Angle will be the point at which the cam turns ON and the ON angle will be the point at which the cam turns OFF The ON OFF angle MUST be at least 2 degrees wide Signature Technologies Inc 173 General Installation amp Programming Guide Angle ON Time Off This protocol is used when the Cam is used to Trigger another device that should have the same activating pulse regardless of machine speed The Shortest time interval that can be set is 0 02 seconds and the longest time is 9 999 seconds If the machine cycle is shorter than the Dwell time the output will simply remain On Angle ON Time OFF cams ONLY Operate when the machine is moving forward Angle is increasing numerically as the machine moves When the machine is moving in reverse the Timed Cams will NOT activate CAMview Connections All versions of the CAMview system use the same standard output structur
251. es six programmable screens for viewing feature data These screens are similar to the signature screens On each screen the user can display up to eight features individually or simultaneously Pen trace selection works the same way as signature pen selection One major difference between signature and SPC graphs is the way limits are displayed gt Inthe signature screen the user can select when to display limits and when to clear the screen gt In SPC graph screens limits are displayed when one trace is selected but not when two or more traces are displayed simultaneously View data for a different feature The available features for the current SPC graph are displayed on the right side of the SPC graph screen Signature Technologies Inc 121 General Installation amp Programming Guide Display a single feature 1 Determine which feature to display 2 Select the appropriate pen Select the rectangular button that contains the appropriate feature name The system will clear the strip charts and display only the selected feature with its limits Display multiple features 1 Determine which features to display 2 Select the appropriate pens Select the small square boxes to the left of the rectangular feature buttons for each feature desired The system will clear the strip charts and display all of the selected features Note No limits will be displayed if more than ONE feature is displayed SPCview fault stat
252. esistor is sized to draw 0 005 Amps at 24 Volts 4 7K Ohms The switch point is at 12 Volts Negative going and 13 Volts Positive going The DEFAULT condition is SINKING The assignments of the individual inputs can be modified using the PNP button in the Setup screen Figuring available Wetting power 125 ma of Wetting and Supply Power is available for each group of 8 Die Protection Inputs Each used Sinking input draws 5 ma of Wetting power Each used Sourcing input draws 5 ma of wetting power IF the power to source up the input comes from the SA2000 24 Volt supply If the Sourcing device supplies its own 24 volt power there is NO draw from the SA2000 A Three wire NPN or PNP Prox draws about 15 ma when Off and 20 ma when On Signature Technologies DIEview System Is available in two different versions 8 Die Protection Inputs amp 4 Signature Input Option The A D module is a daughter board for the SA2000 product that has the capability of providing 4 Signature channels and 8 Digital Die Protection inputs Each of the A D Die Protection inputs has multiple Software selectable modes and internally supplied wetting power at 24 Volts 5 Ma The input impedance is 4 7K Ohms The inputs are software selected to be PNP Sourced to 24 Volts or NPN Sinked to Common All 8 Die Protection inputs share the same common that is FLOATING and optically isolated with relation to
253. ess Limit files with the LP suffix These are the limits automatically saved with the Press Limit signatures The SPC Data files with the Fn suffix where n is the SAMnet address number of the SAM These files contain the SPC chart data taken with the SPCView feature What to do if you seem to lose the data that you had and the Press has disappeared Exit the SAMView Program Call up the SAMDATA sub directory and run a directory on it Look for the lt press name gt PRS file for the press that is missing If you don t find it it probably has been erased accidentally In order to restore it change to the sub directory that has the missing Press s name Copy any one of the TL files in that directory back to the SAMDATA directory to the name of the press that was missing EXAMPLE You had a press named RALPH that disappeared Ralph had a tool named 12345 that you were running Type CD samdata ralph lt cr gt The system will change to the SAMDATA RALPH sub directory Type COPY 12345 tl samdata ralph prs The system will copy the SAMDATA RALPH 12345 TL file to SAMDATA RALPH PRS Restart the SAMView program and you ll find that the press and all its associated tools and signatures are back If one of the Tools has disappeared Go to the Press sub directory and look for the lt tool name gt TL file If it isn t there rename the BAK file that has the tool name to be a TL file EXAMPLE You have a p
254. essing the left mouse button once also refers to the selection of an item with the pointing device This Item on the Menu Bar is where the utilities are found that allow the editing and configuring of the system setups and databases Configure is a Mode which when entered must be exited later in order to return the system to normal operation If changes were made the system will prompt the user to save the data that was edited This is the mode of operation wherein the signatureACE system is enabled to take control action whenever Signatures that violate their limit sets are detected The operator using the Control Button on the screen selects this mode An external switch can also control it if Local OCS has been selected in the Press Database screen Signature Technologies Inc 369 User Manual Conversion Factor A value used to convert raw counts i e strain gage readings into engineering units of force such as tons or pounds GRU seca Serie eee Central Processing Unit This is the brain of the computer The SAM uses a Motorola DSP56000 CPU LEME eaa Symbol representing the Enter Return or Carriage Return key on the keyboard Cross Hairs cccceeeeeeeee Thin vertical and horizontal lines that may be moved on the screen to Zoom identify locations or move the start and end points for a signature GR Turra Cathode Ray Tube The viewing screen used to display g
255. et a Pop Up window giving you the Firmware revision number for the unit It may take a couple of seconds for the system to respond to this request If the Green light is on but you can t get a Firmware number the SA2000 unit is NOT operational Cycle power to the SA2000 and see if it comes back If your system is DOWN the first things to check 1 Check the addresses of ALL the units in the system including the Host There should be NO duplication e Remove the cover from the Host Computer and look at the Address rotary switch on the SAM Make sure it is in the proper position for the machine you are inspecting There is also a TEST rotary switch and it MUST be pointed to 0 You can find out by going to Press Database for the press in question The entry in ID will tell you where the Network assignment has been made The position of the rotary switch should 304 Signature Technologies Inc signatureACE correspond the switch is marked 1 9 A F where A 10 B 11 etc 2 Check to make sure that the Terminator jumper is in place on the SAMnet card in the Host Computer If it s at one end of the network daisy chain If it s in the middle of the daisy chain the terminator jumper should be OFF 3 Check to see if Terminator is installed on the End unit s in the Daisy Chain 4 Perform the following Resistance test with a Digital Ohmmeter NOTE NOTE NOTE e Remove both ends of th
256. evel of BOTH the firmware and internal diagnostics It also lists the accessory items included in the firmware package NOTE If there is an ERROR message displayed in any part of the GetNet response give us a call with the exact text of the message Your text will probably be a bit different but should have a similar appearance Hit Q to exit GetNet and return to the Samtest menu Then go to the next step below 5 At the prompt SELECTION Type 4 no lt Enter gt is required a If you get the message Resolver x x Arcnet base is 2E0 hex Host PC node is 10 hex 16 decimal Resolver data from node 01 hex Hit any key to quit No resolver found 42 Signature Technologies Inc signatureACE Then the SA2000 module is not equipped with a resolver input module or it is not plugged in properly b If you get the message Resolver x x Arcnet base is 2E0 hex Host PC node is 10 hex 16 decimal Resolver data from node 01 hex The RES card is for 12 bit resolution The smallest angle increment is 0 09 degrees Followed by a screen full of directions ending with Direction Position Offset is 0 00 register 74 0x0 Angle Io 0 45 90 135 180 225 270 315 f F 234 6 A This is the proper appearance of the resolver diagnostic utility The information given is 1 The node that s being displayed 1 in this case 2 The resolution setting of the position board 12 bits 4096 counts 3
257. f EVERYTHING MASS backup of the database The only practical way to backup a large database is through the use of the PKZIP utility which will allow the archiving of the entire database on multiple disks PKZIP PKUNZIP software is available from PKWARE Inc 9025 N Deerwood Dr Brown Deer WI 53223 www pkware com shareware pkz250dos html If the database is small less than 175 signatures total you will be able to fit it on a single floppy by using the DOS XCOPY command Step 1 Insert a formatted floppy in the A drive Step 2 CD to the SAMDATA directory on the C drive Step3 Type XCOPY S A lt Enter gt Step 4 Wait till it finishes NOTE If it comes back with a message saying that the disk is full before all the data is archived then you ll have to use the PKZIP program to get it all Typically the PKZIP program is located in a directory called PKWARE Assuming this is true execute the following steps Step 5 Insert a formatted floppy in the A drive Have additional formatted floppies available Step 6 CD to the SAMDATA directory on the C drive Step 7 Type pkware pkzip rp s a samzip lt Enter gt Step 8 Wait till it finishes changing disks according to the screen directions Step 9 There will then be a file on each disk called SAMZIP ZIP which is the archive of the database Step 10 Mark each disk of the set with appropriate information and store in a safe place MASS Restoration of
258. f it only covers a single press line This means that your levels should be somewhat higher than the ones shown If you are getting close to or under the 6V P P level this would be an indication of Coax problems 12 The next step is to look at the Packet more closely Increase the sweep speed to 0 5 Microseconds per Centimeter and look for the waveform shown in Figure 244 below If the terminations and coax are all in good shape there shouldn t be much reflected signal after the main burst is over As shown a P P reflection of less than 0 75 volts is acceptable Signature Technologies Inc 307 General Installation amp Programming Guide ee a signal approx 20 P P Oe signal Reflections about 0 75 P P Figure 244 Packet Waveform Properly Terminated 13 If however there are problems that affect the Impedance of the network such as crushed coax damaged shield high resistance terminations or missing terminator jumpers then there will be excessive signal reflections In the waveform below Figure 245 the terminator was removed from the Host Computer end This causes reflections up in the 5V P P range which is enough to thoroughly confuse the network ee signal approx 20 P P zeroes Signal Reflections about 5w P P Figure 245 Packet Waveform Missing Termination 14 Unfortunately the order of the packets on the network is random so you can t attach a low packet to a given SAM unit but if you
259. f the 2 SA2000 ID s are 1 and 3 the channel list will start with 01 00 through 01 07 then jump to 03 00 through 03 07 Channel 01 00 Channel 1 Channel 01 07 Channel 8 Note Ifthe data you entered in the Pulses window DOES NOT agree with the jumper setting in the SA2000 module a pop up window will appear stating that there is a resolution mismatch Hit the F10 key to exit the SAMview program shut the host computer off check and correct the setting of the resolution jumpers on the SA2000 module Then go back to step 1 above NOTE The channel list in any Tools for the machine will Grow the additional channels in their selection window NOTE It is necessary to have at least ONE active channel in EACH SA2000 for the system to accept the configuration For this reason the system will automatically 1 Program a dummy TOOL channel 1 in the new SA2000 2 It will name the channel 0X 00 where X is the address of the new SA2000 If you add at least one Real channel to the new SA2000 you can go back to the tool Database and delete the Dummy tool channel 126 Signature Technologies Inc signatureACE Section 11 Considerations for multiple SA2000 units on the same machine Figure 102 Two SA2000 system in a Tower computer chassis The use of more than one SA2000 has some special considerations connected with it The most important is that th
260. f the resolver 2 Note the Angular Position of the press as shown in the box at the upper right side of the signature screen 3 Bump the press several degrees forward See if the Angle reading increases or decreases 4 Ifit decreases swap the SINE S1 S3 wires on the INPUT cable from the existing system and go back to step 2 5 Ifthe Position Increases numerically the connection is O K 6 If it doesn t move there is a problem with the wiring to the resolver or with the resolver drive If the existing system angle display behaves normally and the lights on the CNV unit are normal the Output Cable connection or the SA2000 Module is suspect Make sure the Resolver Resolution is set Properly Continue to bump the press around Make sure that the angle display increases each time you move the press and that you see the angle reading rise to 360 degrees in one press revolution before re setting to 0 degrees and climbing again 1 If the angle doesn t make it to smoothly to 360 in one full revolution the Jumper settings of the SA2000 module is in disagreement with the Resolution value you entered for your press in the Configure PRESS utility SA2000 Modules are normally configured for 4096 increments per revolution This is valid for machines running up to 200 S P M and in some cases for machines running even faster with reduced channel usage If you are running a faster application say 500 600 S P M the SA2000 will have
261. facing Self amplified Analog sensors to the signatureACE Analog proximity switches like the Turck type LU illustrated or other self amplified sensors Pressure sensors temperature se considered nsors etc can be interfaced to the SA2000 Module Two things must be First is the input voltage requirement of the sensor In the case of the Turck unit illustrated 15 volts D C is required Since the available excitation voltage is only 5 or 10 V D C you must provide an external power supply for the sensor Signature Technologies Inc 273 User Manual Second the output voltage range of the sensor must be considered The Turck according to its specifications swings from about 0 5 volt to 10 volts 15 Volt Power Supply A Browrt Power Shield Shield Excitation Turck 4 Sahai LU Series Signal Analog Prox Excitation Common Figure 219 Analog Proximity hookup Since the input of the SA2000 can only tolerate 2 5 to 2 5 volts some attenuation of the Turck signal is necessary The resistive divider shown reduces the 10 volt swing of the Turck down to 2 48 volts into the SA2000 R1 R2 13300 Ohms E 10 volts I E R 10 13300 0 000752 ER2 IR2 R2 0 000752 3300 2 4816 Interfacing 4 20 ma current loop to the signatureACE system This is done by converting the 4 20 ma current loop to a voltage mode signal using a precis
262. fer to the If a Programmed Feature Doesn t Work section below at page 101 for a description of the overflow error that could occur using this feature In addition to the overflow error the feature can return an error condition if the process average for the signature at the user defined location is zero Signature Technologies Inc 101 General Installation amp Programming Guide FeatureView 010 Threshold Detector Description Parameters Use Error Check Conventional Feature Build SPC Point Title T Hold Blank B amp D SPC Point Units Degrees Channel Select Blank and Draw Graph Ris Status 23 33 Renate H Ris teres E 15 00 Press PRS_50 Tool 2092 Betest algorithe gt 010 Threshold Detector 40 00 34 67 Feature Control Status 6 67 ran Control Monitor 41 67 10 00 ap A a T T T T T 115 0 128 1 141 3 154 4 167 6 180 7 193 9 207 0 220 2 Interval Start Force Threshold 125 608 5 668 Interval End Figure 82 Threshold detector for the blanking operation This feature returns the angle or position off BDC at which the signature exceeds a user defined value When defining this feature the user has the option of selecting a window in which to monitor the signature for the level crossing In the event that the signature does not cross
263. fferences caused by the calibration shunt and are the values produced by a 198 4 Microstrain change in the strain level at the gages Step 10 Measure the Pull Down rod cross section carefully Step 11 Multiply the Thickness of the rod by the width OR multiply the SQUARE of the radius by 3 14159 The result will be the cross section area in square inches 358 Signature Technologies Inc signatureACE Step 12 Step 13 Step 14 Step 15 Step 16 Step 17 Step 18 Divide the press capacity by the number of Pull Down rods This is the rated load value for each of the Pull Downs Divide the Load value from Step 12 by the cross section form step 11 This is the STRESS in the Pull Down rod in P S I Divide the Stress value from step 13 by the Young s Modulus for the Pull Down rod material it s 29 000 000 for most steels This will be the Strain Value for the Pull Down rod at capacity in inches per linear inch multiply by 1 000 000 to get the value in Microstrain Divide the Microstrain value by 198 4 and multiply the result by the display value gotten from the shunt application in Step 9 This will be the calculated value of the signal that would result from the strain at full capacity If any of the resultant values are larger than 2048 the strain output from the press will be TOO high for 10 volt excitation Switch the Excitation level from 10 volts to 5 volts and repeat step again to generate new Shunt numbers
264. first operations If this pin moves against its spring pressure it would indicate that the Stock at this location isn t in the proper position for forming The Die protection system senses this and stops the machine The Always OFF or OFF ON OFF protocols are the choices depending on whether dynamic checking recommended is used or not Signature Technologies Inc 181 General Installation amp Programming Guide Part Ejection Finally all the way to the Left there is a Part Ejection Sensor This sensor watches the parts dropping off down the chute and makes sure that a part comes out every stroke instead of flipping into the die and causing a wreck This sensor is normally OFF but turns ON momentarily whenever the part passes through it This should happen during the upstroke of the machine and if it hasn t occurred by about 300 degrees the Die Protection system faults and shuts down the machine The OFF ON Off protocol is used For this function Die Protection Specifications Input Definitions Sourced PNP Inputs have an internal Pull Down Resistor to Common and must be Driven to 24 Volts to activate them The resistor is sized to draw 0 005 Amps at 24 Volts 4 7K Ohms The switch point is at 13 Volts Positive going and 12 Volts Negative going Sinked NPN Inputs have an internal Pull UP Resistor to 24 Volts and must be Grounded to Common to activate them The r
265. first operation allows you to define different passwords for persons who will be operating the system Each individual will be awarded a password and a Level The password levels are 1 through 5 The second operation allows you to assign any of the 6 available password levels 0 through 5 to the items on the Program Selector Menu level 0 requires NO password for entry The items are Change Limits iosia Requires a password to command a limit recalculation by clicking the Set Baseline Button Change System Info ccesceeeseeeeees Requires a password to edit the Tool Setup Information field names or to Delete the Event Log Change to Bypass 00 eeeeeeeeeeeeeesteeeeeenaes Requires a password to command the system to exit the Control Mode by clicking the Bypass Button This should be a high priority since it takes the SA2000 out of the control loop Change to Control ccceeeeteeeeseeees Requires a password to command the system to enter the Control Mode by clicking the Control Button Configure DB Saving ccceeeeeeeeees Requires a password to alter the settings in the Edit Saving menu screens Configure Display cceeeeeeeeeeeeeeeneees Requires a password to save any changes in the Current Display format for the screens Configure JOD zarren ATAG Requires a password to create or change the Job i e to insert different tools into the presses se
266. for a total of 6 to the SAME machine All 6 SA2000 units will share the SAME position reference They can have different data collection windows however The Signature data collected for a given machine cycle from all units will go into a common file SPC data is recorded in separate files for each SA2000 unit Most of the steps in adding a machine are essentially the same as those performed in Programming the First Press so they will not ALL be enumerated here only the differences in the procedure will be given NOTE See the section above for a description of how to add machines to a Host computer system NOTE Before proceeding make sure the resolution jumpers of the new SA2000 are set the same as the jumpers on the first SA2000 Select Overview from the menu bar if you are not currently in the Press Line Overview screen 2 Select Configure from the menu bar A drop down sub menu will appear 3 Select Press from the sub menu The Press Database screen will appear All the data for the current press will also be displayed 4 Select the first left character position in the ID box A cursor will appear Type in the SAMnet address number for the press according to the instructions in the Programming the first press section Step 8 page 37 NOTE When specifying addresses be advised that four conditions apply a SAMnet address 16 is normally reserved for the host com
267. formation from the Host Computer to the SA2000 Control limits and data gathering information are Downloaded from the Host Computer to the SA2000 on power up Emergency Stop 0 A legally loaded term which defines a control process that not only performs an Immediate Stop but also normally kills the drive motor and all electrical power to the machine control circuits An Emergency Stop normally requires a separate resetting action before machine operation can continue ENCOd Oftiss aeni eae A position sensing device having pre defined increments which is used to track the rotation of a machine Engineering Unit A unit of measure which is used in a given situation For example when a strain is created on the press it sends out a signal to the computer in Volts An A D converter converts those volts to Raw Counts These raw counts are the digital 370 Signature Technologies Inc signatureACE lt Enter gt or Enter Feature Algorithm FeatureView Historical Files Host Computer Immediate Stop representation of the voltage A conversion factor is applied to this value to convert raw counts to pounds Pounds is the engineering unit Keyboard Key or screen button that saves data and or completes an action See RED Limits A feature is a calculated value using data from one or more signatures for a given hit using a predetermined algorithm The SPCview system allows the user
268. g bellows or helical types Hydraulic hose works pretty well as long as there isn t much end float in the drive Call S T I 972 488 9777 if you don t find anything It is generally good to hard copy the screen and fax it to us If the Signature floats horizontally around on the screen grossly changes its shape position or sometimes doesn t show up at all This is an indication of a looeness that allows continuous slippage of the resolver shaft in relationship to the machine in the case of a resolver OR a incremental encoder in the process of failing losing pulses Signature Technologies Inc 333 General Installation amp Programming Guide Check 8 Ifthe Signature is unstable vertically The Input module in the SA2000 system or the RSCB Board for the SAM500 provides as part of its function an automatic gage bias cancellation function This works as follows Each time the Position Sensor passes ZERO a pulse is issued to the Auto Zero circuits instructing them to compensate You can see this pulse occur by watching the small red Auto Zero LED on the TEC This LED should flash each time the machine passes its zero degree point reference point in the case of a linear machine A zero pulse is also issued whenever the machine clutch engages If the machine stops and stays stationary for more than 13 seconds an analog clamp engages which holds all the analog inputs to the ZERO level The first Zero pulse that the s
269. g Guide If you click on the box that says Die View then the Die View Pop Up will appear as illustrated in Figure 138 below Overview Configure Database Analysis Screen Options Signature View Press Tool ID Angle P1852 M3705 74 79 H Ch I itke a Description Fault State Start End Invert PNP Sensor Type J o4 Feed In Position lt gt poo 55 0 jm A J o2 Pilot Histeead Det 120 0 2000 m J o3 Part Ejection _ 130 0 280 0 I o fBuckle n O eo 250 0 Output Relay Off On Red Always Off Yellow Off On Off Yellow sklis klikik OD E Always Off check Red Sensor Type Description Reset Faults Figure 138 DlEview User screen display This is the user screen for DIEview and is your indicator of wha s going on Nothing can be re programmed from this screen The only Control actions that can be taken is the Disabling of selected channels and the re setting of Die Protection Faults These actions are done with proper password authorization The information on the DIEview Pop up is as follows Press This field indicates which Press is being displayed Tool ID This field indicates Which Tool is installed in the press Angle The Angular Position of the machine is displayed here when the press is stopped Channel Active This is an Indicator If a Green color is disp
270. g device or keyboard Toggling once turns the item On toggling again turns the item Off A check mark will appear to the left of items that have been toggled On AOOW ait A A name given to a data file that defines against a discreet identification code a number of variables that depend on the tooling that is mounted in the machine These are variables such as Signature Trigger point Sample Rate eight tool information fields and number of parts per hit The computer uses the Tool ID field as the Key Field to distinguish the different Tools stored in the computer s database TOP SIOP aei aaeh ieaie A normal punch press function wherein the press control causes the press to come to a stop at the top of its stroke close to the TDC position regardless of when the actual stop signal was issued TOUCH iaaea Applies to systems with touch screen monitors The operator touches the screen to select an option etc Track Ball nnana A pointing device used to select or size an option by rolling the ball in the direction you want the pointer to move See mouse for explanations of selecting and sizing Trigger Location The entry in the From field under Data Collection in the Tool Database screen that tells the system at what angle of rotation to begin data collection YELLOW Limits The YELLOW Process limit curve closest to the machine force signature These are referred to as Warning
271. g them between OFF and ON from the keyboard 4 resolver utility Operates the resolver portion of the SA2000 and displays the direction of rotation Resolution and Absolute position of the resolver in degrees The utility also allows the development of an Offset Number which is the numerical correction for the resolver position vs the actual machine position 5 GetNet utility Is a utility that goes out and interrogates all the nodes present on the SAMnet network and checks for compatible versions of Software Firmware The characteristics of all active SAMnet nodes will be displayed 6 Getini utility Goes into the Host Computer and finds the files related to SAMview that have the INI suffix and displays them by name in a list When a file from the list is chosen the contents that file will be displayed and explained 7 GetLOD utility Presents a list of available Firmware and diagnostic download modules available on the system When a file is selected it will display the features and revision data for it 8 UpGrade utility Presents a list of available Firmware and diagnostic download modules available on the system and enables them to be downloaded to the SA2000 module on command Appendix 6 InSitu Machine frame Sensor Mounting Process monitoring sensors Strain Links on the Uprights The Uprights of the machine are the LEAST DESIRABLE location for sensors They are far from the
272. ger tap guide holes and tap each hole BE SURE TO USE PLENTY OF TAPPING FLUID Remove the tap guide and continuc with more holes where needed Mount the sensor with raised rib to the press The anit torque washers should go between the screw and the sensor body ROTATE FIXTURE 180 DEGREES 30RIL1 Smm 1 4 28 TAP ia METRIC amp 1 DRILL THROUGH FOUR SMALL HOLES PUT RAISED RIB TO PRESS TAP THROUGH FOUR LARGE HOLES 144 28 X 1 1 4 SCREW METRIC 6 1 X 35 Figure 175 Direct Bolting method of Strain Gage Mounting In cases where the press is apart OR you re gauging to an existing machined surface go ahead and drill tap the Links on Appendix 7 resolver Mounting and driving requirements GENERAL Information 228 Signature Technologies Inc signatureACE This write up is intended to provide information on what is required in order to properly mount and drive a Signature Technologies resolver While it is impossible to enumerate all the possibilities several illustrations are provided of common types of mountings Signature Technologies always stands ready to provide installation support all the way from a helpful phone call to a turnkey installation and anywhere in between Normally very specific information is needed about the machine in order to design a resolver drive A concept can be arrived at with nothing more than photographs of the machine but a complete des
273. gies Inc 197 General Installation amp Programming Guide A Sturdy Bench with a wood surface Instrument shelf Storage drawers and backstop Such as the McMaster Carr 9054T82 with accessories A good quality Volt Onmmeter Fluke Model 87 is good A multi axis calibrated Positioning device Such as the McMaster Carr 60935K35 with 1 travel in three axes calibrated to 0 001 An Adjustable Holding fixture for the sensors Such as the McMaster Carr 52015A676 An Adjustable power supply with a range up to 24 Volts D C 1 2 Amps like the LEADER LPS 152 from Allied Elecronics An assortment of sensors Proximity switches in Shielded and Unshielded Configuration in sizes from 8mm through 18mm Photoelectric sensors both thru beam retro reflective and fiber optic Mechanical switches and ground detectors Needed personnel An individual should be delegated as the in house Guru for sensing He is given the responsibility of setting up and equipping the test bench and becoming familiar with the sensing characteristics of the various types of devices that are available He is exposed to training and seminars on the subjects and becomes the company expert in die sensor application He conducts training and guidance sessions for the other involved personnel to increase their awareness of the installed equipment what it is doing for them and how to care for it properly His educational specialty is relatively
274. gnature Playback Setup pop up select Return 4 When you select Restart Playback from the Analysis menu the signatures will be displayed and then printed A pop up message will come up after each printing allowing you to cancel the operation at any time This pop up will go away automatically 202 Signature Technologies Inc signatureACE Appendix 1 SignatureACE Conventional Wiring Connections In the conventional versions the Field Connections are made to the TEC unit that consists of terminal strips and I O devices mounted in an enclosure The terminal strips are connected by a cable set to the SA2000 Module The sensor connections to the system are made by means of 40 terminals located in the middle of the TEC enclosure The terminals are Multiple Use depending on which input module has been installed on the SA2000 unit The terminals are arranged in groups of 5 Depending of the input board each group of 5 may be EITHER one analog sensor channel OR two die protection channels NOTE The EX and EX terminals ARE NOT COMMON will have DIFFERENT VOLTAGES present depending on which input module is installed DON T Connect ANY EX terminal to any other without checking with us first Destruction of terminated devices OR SA2000 board damage may result if these rules are not followed Terminal Name definitions SHD Is used to connect the Shield braid of the sensor EX Is use
275. han 4 millivolts or less than 3 millivolts then it s too far out and must be brought in with balancing resistors The best way to bring the offset down is 1 Connect the meter as above to the Signal and Signal terminals Signature Technologies Inc 267 User Manual 2 Hook a resistor of 100K ohms between ANY Excitation connection Either or and ANY Signal Either or connection ay 100K ANN 4 a Excitation Shield Excitation A Signal i Signal Signal Signal i Excitation C C Excitation Unit O Millivolt Meter o Figure 209 Resistor hooked the wrong way error larger 3 When the resistor is connected the offset will either get better or worse 4 Ifit gets worse try the hook the resistor to the OTHER Excitation connection Verify that the offset gets better when the resistor is applied If the voltage goes from a POSITTVE value to a NEGATIVE value or vice versa the resistor connection is right but the resistor value is too low SS 100K DAG Excitation Shield A Excitation z Signal i aia Signal Signal Exeitation Excitation TOZ Millivolt Meter Figure 210 Resistor hooked the right way error less but resistor too small 5 Then adjust t
276. hat can be used to support a drive flange In these cases a simple bracket can be used to support the resolver directly to the auxiliary drive housing The same concerns as above about end float apply here also See Figure 181 below for general arrangement Signature Technologies Inc 237 User Manual Mount bracket Cable Crankshaft Resolver Coupling Drive stub Cable Clamps Figure 181 Auxiliary drive resolver mounting Driving the resolver with a Timing Belt In cases where the end of the crankshaft is not free or there is no easily accessible rigid mounting surface for the resolver bracket the alternative is to use a Timing Belt drive as illustrated in Figure 182 238 Signature Technologies Inc signatureACE Crankshaft Extension Drive Bn Side View Drive pully Resolver gT Cable attachment P cat ie ae eee Figure 182 General arrangement for a Timing Belt resolver drive Design considerations for Timing Belt driving the resolver 1 Use ONLY fine pitch Timing Belts The Type L 0 375 pitch belts are preferred for most industrial applications If space is a consideration then Type XL 0 200 pitch belts are fine Larger pitch belts get progressively more sloppy in terms of their angular accuracy Use LARGE diameter pulleys The large pulley diameter minimizes inaccuracies due to tooth clearance We recommend at least 4 P D in the L 0 375 pitch type be
277. he Network module is in place and operating properly You should also see another light generally at location 1 and the text below this light should be the name you gave your press when you set it up If there is NO other light then the SA2000 is NOT communicating with the network module Make sure your short coaxial cable is installed between the SA2000 and the network module If you see another light but NO text that you recognize underneath then the address of the SA2000 may be different than you programmed The Light will come on in the address location that the SA2000 is set for It causes all sorts of problems to re program the address in Press Information screen so CHANGE THE SETTING of the ADDRESS Switch on the SA2000 module to match the address you gave it during setup If the Switch on the SA2000 module is turned to a different address position RESET Button see Figure 194 must be pushed to allow the new address to be recognized by SAMnet c If everything looks O K but the system still doesn t function do a Grand Power Cycle turn off the host computer Wait 20 seconds then turn the computer on again d If you still can t get on line give us a call at 972 488 9777 254 Signature Technologies Inc signatureACE Make sure your Resolver is hooked up properly 1 When you have the system on line you can Click on the BYPASS box and have the yellow light flicker but stay on check the rotation o
278. he description of the sensor calibration factors etc will be set according to the values in the individual tool program These channels are connected to sensors that are physically disconnected and removed with the tool whenever the tool is changed NOTE It is possible to program a channel in BOTH the machine AND the tool In case a tool is installed with channels active that are also programmed as machine channels THE TOOL WILL WIN This is not a recommended procedure but will generally not Crash the system if it occurs ALSO It would be a good idea to make out a list of the channels and the NAMES of the sensors that will be Note connected to the channel since that will be needed in the setup procedure If you re not sure where physically on the machine the sensor cables are coming from it happens NOW is the time to find out For example The sensor mounted on the Rear Left Upright is wired into the Channel 1 Terminals in the TEC box which is cabled to the SA2000 with ARCNET Address 5 Channel 1 on SA2000 Address 1 is displayed as 05 00 the 05 refers to the SAM2000 Arcnet address setting and the channel number 00 is computerese for channel 1 the channels in this field are numbered 00 thru 07 instead of 1 thru 8 In the example above Channel 05 00 should be labeled Rear Left Upright In the channel definition list so you will know what its signature comes from PER A11 Channels
279. he following features 1 Fault reporting turned OFF in the Refresh Rate screen Figure 245 2 The Saving set to record EVERY hit you make for support in case something goes wrong in the calibration process Step 1 Get the tooling out of the press and clean up the slide and bolster surfaces Step 2 Log on to the security system at level 5 Step3 When you make the tool you must go into the DATA REFRESH RATE SETUP utility in the Configure Tool screen and DISABLE Data Item 1 FAULT with the switch provided Step 4 Install the CALIBRAT tool in the press you are Checking Step 5 Position the Press at T D C so there is no force on the ram Step 6 From the Peak View Screen pull down the Configure menu and select Calibrate Step 7 Answer YES to Do you want to do Static Calibration Step 8 Watch the screen and see what the digital displays do They should all display numbers which should be relatively steady with only the Least Significant Digit dancing a little NOTE If one or more of the Numerical displays goes to or 2047 Your sensors are too far out of static balance to permit Balance checking without some adjustment Contact Signature Technologies Inc at 972 488 9777 for methods NOTE If one or more of the numerical displays is Going Wild displaying a large range of numbers this is a sign of problems in that channel related to the sensor itself or problems in the wiring Signature T
280. he left of the Cycle Between Saves label 6 Use the keypad to enter the number of consecutive strokes between saves to the database Setting the maximum number of signatures to be saved to the database This feature provides a warning when the total number of saved signatures becomes excessive allowing for efficient archiving of signature data When the number of stored signatures exceeds the maximum number of saved signatures a pop up message will appear on the screen the next time the tool is loaded This would indicate someone should archive and or delete the excess signatures 1 You should be in the Signature Save Setup window If you are not follow the procedure outlined in Accessing the Save Signature Setup pop up window 162 Signature Technologies Inc signatureACE 2 Select the box to the left of the Maximum number of Saved Signatures label 3 Use the keypad to enter the maximum number of signatures to be saved to the database To exit the save signatures setup screen Select the Return button to exit the window and save the changes If you wish to exit without saving the changes select the Cancel button SAMnet Summary screen This screen provides information about the status of the SAMnet network current communications amp the SA2000 hardware AND firmware revision levels Overview Configure Options sAMnet Summary 061 B82 083 a4 Anny P1427092 ES nme
281. he lower right hand of the signature screen and be sure it goes Green when the clutch engages IF IT DOESN T troubleshoot the clutch signal to the second and probably ONLY input module on the TEC to make sure the clutch signal is getting through Check 6a Normal Aberrations in the signature display Oxymoronic though that may sound there are some visual oddities that will occur which do not indicate malfunction but may seem confusing to you unless you know in advance what to expect Without going into excessive detail the first few signatures that you take after modifying anything in the Press or Tool screens will probably be questionable This is because it takes the SA2000 at least two strokes to get everything straight after a re programming In general after a re programming roll the press at least three times before you look at anything critically EXCEPTION If the First Signature after a start is radically different from normal See the section above on The Clamped Signature Check 7 If your Signatures are unstable horizontally This just about ALWAYS indicates a problem with the Position Sensor or its drive The first thing to check is the mechanical coupling of the resolver to the drive system of the machine 1 If the Signature JITTERS but stays pretty much in the right location This ALWAYS is an indication of free backlash in the Resolver Drive or inside the resolver package gt Check to see if th
282. he resistor value by applying LARGER resistor values for LESS effect or lower resistor values for more effect The aim is to get the offset close to zero volts within the values given above Fine adjustments can be made by using parallel or series combinations of resistors 268 Signature Technologies Inc signatureACE oe 150K Excitation Shield 3 Excitation Signal i Signal Signal Excitation 5 c Excitation Unit 0 5 Millivolt Meter Ss Sl t O P Figure 211 Balance within acceptable limits 6 Finally permanently install a fixed resistor or resistor combination of the proper value permanently across the same points The most practical way to do this is to clamp the resistor leads in the terminals and solder the Strain gage wires to the resistor If series or parallel resistor combinations are used be sure to SOLDER all the joints Inexpensive resistor assortments can be obtained from your local Radio Shack electronics shop NOTE If you apply balancing resistors to a commercial load cell to correct an out of balance situation you will alter the calibration values for the cell requiring an experimental calibration to be performed if calibrated values are needed Interfacing Data Instruments Strain Links COMPRESSION Hookup Shield shie
283. he user to fasten the unit to a panel but the unit can simply be placed into existing panel channel when the setup procedure was finished or attached with Velcro to any flat surface The Converter should be mounted within 3 feet of the existing system and wired directly to the point where the existing resolver is connected using the supplied input cable You can also install the CNV Converter in junction boxes on the machine frame in places where the resolver cable passes through This is possible in large machines particularly if the cable brought through several sets of terminals on its way back to the machine control enclosure In cases where the Resolver is feeding a Tonnage monitor such as the Data Instruments or Helm Instruments units there is normally room inside the instrument enclosure for the CNV Converter In general the idea is to minimize the length of the cable at the SOURCE end This is why the Converter INPUT cable is 30 long This cable should NOT be lengthened without consultation with ST Engineering at 972 488 9777 The CNV Converter contains line drivers so that the cable length between the Converter and the Signature Technologies system is not important The Standard Converter OUTPUT cable is 30 Feet long but can be much longer if necessary ICNV Converter Wiring The CNV Converter is supplied with two cables which are used to perform ALL the interconnection Input Cable The Converter INPUT cable is 30 lo
284. hich of the network Nodes are active Requires a password to enter the Security Utility This should be the HIGHEST Priority Requires a password to create or change a Tool data file The password will not be needed until an attempt is made to SAVE the created or edited tool Requires a password to create or change a Tool data file The password will not be needed until an attempt is made to SAVE the created or edited tool Requires a password to create or change a Virtual channel The password will not be needed until an attempt is made to SAVE the created or edited Virtual channel Requires a password to permanently delete signatures from the Hard drive with the Playback Utility Requires a password to Exit the SAMView program Should be a High Priority Requires a password to Log Off the security system shut it down to level 0 This should be assigned a 0 Priority Requires the Operator to have a certain level of password priority before he is permitted to Log On open the system permanently to his security level The operation of this is automatic If the operator has a Priority 3 and Log On requires Level 4 the Log On button won t be available whenever the operator s password is confirmed NOTE Ifa priority level is attached to this selection the Log On One Shot Priority should be 0 Requires the Operator to have a certain level of password priority before he is permitted to Log On One S
285. hiving amp Restoring 350 Database Archiving amp Restoring 205 Database Restoration from a ZIP file 354 Daughter Boards Position Input 284 Daughter boards Signal Conditioning 283 Definition Limits 136 Definition Master Signature 136 Definition Signature 136 Definitions Terminal Name 203 Deleting Signatures 352 Deleting Signatures from the Database 206 Designations Terminals Resolver Encoder 208 Diagnose the fault 152 Diagnostic utilities 218 Diagrams 346 Die Protection Functions 187 Die Protection Inputs 205 Die Protection Quick Start Section 184 DieView utility 218 DIEview Off On Off 201 202 DIEview On Off On 200 202 DIEview Standard Protocols 199 DIEview Always OFF 199 201 DIEview Always On 199 201 DIEview Grounding Switch 190 DIEview Off On 200 DIEview On OFF 199 200 DIEview Sourcing Switch 190 DIEview 2 Wire Universal Proximity 191 DIEview 3 Wire NPN Proximity 190 DIEview 3 Wire PNP Proximity 190 DIEview Definition The term Window 199 DIEview Fault output Options 202 DIEview Ground detector cat s Whisker 190 DIEview Input Device types 190 DIEview Input protocols 199 DIEview Inputs 191 DIEview Programming 195 DIEview Sensors Applications 203 DIEview user guide 183 Digital signals Interfacing 271 Direct Bolting me
286. hnologies Inc 359 User Manual 250 tons 1988 counts 0 12575 Tons calibration factor for Left front 0 12575 Procedure for calculating the cal factors for purchased load cells Commercial load cells normally come with a specification in Millivolts per Volt of excitation at a specified load level If you have this information you can generate Calibration factors directly in the following manner Basics 5 millivolts into our system 2047 counts You can excite at EITHER 10 volts or 5 volts Commercial load cells normally require attenuation of their signal to operate with the SignatureACE system The cell per the cal sheet delivers 3 0227 mv volt of excitation at 10 000 pounds force So with 10 volts of excitation 30 227 mv will go to the ST system this is obviously too much so some means of limiting the voltage must be used probably the most accurate would be a precision resistor in series with the Excitation Anyway reducing the excitation below 1 6542V would result in less than 5 mV being delivered to our system at 10 000 pounds force This could be accomplished by hooking a 412 ohm 1 2 watt resistor in series with the Excitation lead to the Excitation terminal and reducing the excitation to 3 volts with the slide switch on the RSCB Board 412 ohms should reduce the excitation voltage to something like 1 640 volts HOWEVER the excitation supply is not particularly accurate so measurements must be made to co
287. hot open the system for one event to his security level The operation of this is automatic If the operator has a Priority 3 and Log 362 Signature Technologies Inc signatureACE On One Shot requires Level 4 the Log On One Shot button won t be available whenever the operator s password is confirmed NOTE Ifa priority level is attached to this selection the Log On Priority should be 0 Reset DIE Flt Red eseeseeeneeeeees Requires a password to reset the system and permit press operation after a RED Die Protection limit violation Should be fairly high priority Reset DIE Flt Whit 0 ceeeeeeeeeeereeees Requires a password to reset the system and permit press operation after a WHITE Die Protection limit violation Should be Highest priority Reset DIE FIt Yel ccceeeeeeeeeeeeeees Requires a password to reset the system and permit press operation after a YELLOW Die Protection limit violation Reset SIG FIt Red ceeeeseeeeceeeeeeees Requires a password to reset the system and permit press operation after a RED Signature Limit violation Should be fairly high priority Reset SIG Flt Wht iien Requires a password to reset the system and permit press operation after a RED Signature Limit violation Should be Highest priority Reset SIG FIt Yel cccccceceeecseeeeceeeeeeees Requires a password to reset the system and permit p
288. iala liza 01 01 Right Connection spen ott 1 02 R L Kiss bfock _ 81 03 F R Kiss block V Cancel 1000 4 1 1 1 0 30 360 lt pen of f gt Refresh Zoom Graph View 2 Control Status Running HAE era O Lous palaima ame JO Ofa Figure 54 Pen Sensor Setup Window Highlight the desired channel from the list by selecting it with your pointing device Figure 54 Hit the lt Enter gt key The channel name will appear in the box in the upper right corner of the window to the right of the Select box When finished the signature will be displayed in the color shown in the background of this box To change the color select the colored box next to the Pen Color label Figure 54 A color chart will appear Use your pointing device to select the color you want from this chart Select the Return button The signature line will appear on the screen and the channel name will appear on the pen button If additional pens are to be programmed modified select the next pen button and repeat steps 7 through 10 of this procedure for each pen Under the Screen item on the upper menu bar there are other customizing options including a Graph title selecting this will bring a pop up box where you can type in the title you would like to see at the top center of the graph This can only be done in Con Screen mode b x axis title selecting this will
289. ies Inc signatureACE GROUND Channel 1 Channel 1 Excitation Gain a oc oo oc oo Se io oc oc oc Channel 8 Channel 8 Excitation Gain Figure 24 Channel Jumpers A08 unit d Excitation level jumpers All channels are shipped in the 10 volt mode Removing the excitation jumper from a channel drops the excitation to 5 Volts The excitation should only be dropped at this point if you KNOW that the 10 volts would result in excessive gain on the signal OR the Load Cell for that channel is rated for 5 volt excitation 4 Install the SA2000 Card set in TWO ISA Bus slots in the Host Computer Check the SA2000 module set as shown below in Figure 25 to be sure of the Terminator jumper status See the section on SAMnet hookup above for proper jumper placement Terminator Jumper IN Terminated OUT Open Figure 25 Terminator jumper SA2000 Only one of the cards has a ISA type edge connector for Host Computer Motherboard The other slot could be a PCI style connector or no connector at all since it s not used 37 Signature Technologies Inc General Installation amp Programming Guide 2 RESET Button Access through hole Control Connector Input Connector SAMnet Network Indicator Zero Indicator SAMnet Network Connector Figure 26 SA2000 connection area 5 If there s only the ONE or TWO SA2000 units to be connected Install the sho
290. ign depends on having quantitative information For example the end of the crankshaft on a straight side press probably has a tapped hole that could be used for the installation of a drive stub Before the stub could be designed though the size of the hole and its thread configuration would have to be known The information needed is easy to come by if the machine is sitting in your facility but must be transmitted to a designer who works off site Normally if Signature Technologies Inc is to be involved in installation design at least one trip to the customer s site previous to the start of application design or delivery of materials will be required The trip will be made in order to take the measurements that will be required and visually inspect the proposed application for feasibility Alternatively if the installation is really simple we can try to work from information supplied to us by the customer sample worksheet is included at the back of this publication When working from customer supplied specifications however Signature Technologies Inc will not accept the responsibility for or any penalty resulting from installation problems resulting from the existence of obstructions clearance situations or dimensional incompatibilities resulting from inaccurate or missing data from the customer MOUNTING REQUIREMENTS The function of the resolver in the Signature Technologies Inc signatureACE SmartSAM system is to pr
291. ignatureACE Y Zero position indicator 38 i ora ZIP file backup of the database See YELLOW Warning process limit Output 372 ZIP file database restoration 354 Z Zoom Default 77 Zoom utility 77 Zero Offset checking Procedure 359 Signature Technologies Inc 383 General Installation amp Programming Guide HOT KEY quick Reference FUNCTION KEYS F1 Show Current Fault if not reset F2 Show Current Limits F3 Show Current Signature F4 Save Signature if enabled in the Edit Saving screen F5 Refresh the screen F6 Display last RECORDED White Fault F7 Display last RECORDED Red Fault F8 Display last RECORDED Yellow Fault F10 Quit SAMview Shift Function KEYS Shift Refresh button 180 degree Ref line on screen Shift F1 Print Control KEYS Cntrl L Loop playback forever Cntrl O Toggle Overlay display mode Cntrl Q Resume Playback Cntrl R Restart Playback from beginning Cntrl S Pause Playback Contact us with any questions at Signature Technologies Inc 1225 Yacht Club Road Oak Point TX 75068 USA Phone 972 488 9777 FAX 214 242 2924 l Website www signaturetechnologies com 384 Signature Technologies Inc signatureACE email mo signaturetechnologies com Signature Technologies Inc 385
292. il handling apparatus Failure to observe these safety precautions can result in serious injury or death It is the responsibility of the EMPLOYER to provide point of operation guarding and Peripheral safety devices for all power equipment xxx N ARN N G r Signature Technologies Inc 165 General Installation amp Programming Guide The installation and adjustment of the devices operated by the Programmable Cam system sometimes requires the insertion of body parts into the point of operation Because of this before installing or working on St equipment the press must be stopped the drive system switched off and the flywheel stationary before any service work is performed on the system The use of DIE SAFETY BLOCKS to prevent accidental injury is MANDATORY keEEV ARN N Hazardous Voltages are present in the cabinet housing the Signature Technologies Equipment Make sure ALL power is shut off to the SA2000 itself AND to the machine that the SA2000 is connected to before opening the equipment enclosures The Signature Technologies system normally will have voltages present that originate in OTHER SYSTEMS Consequently interrupting power to the SA2000 only will NOT be sufficient to avoid electrical shock Qualified personnel MUST perform all system service kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk The Programmable CAM function The CAMview system is a classical Programmable
293. in Windows 95 or later versions you must drop completely OUT of Windows and restart in DOS mode in order to use Signature Technologies Software The SAMview application WILL NOT run in the Windows DOS window To start your Windows 95 or later system in DOS The following procedure will boot your Windows 95 computer in the DOS mode and start the SAMview application automatically NOTE lt Enter gt means to press the Enter return carriage return Key 1 RESTART the computer Control Alt Del twice or hit the reset button 2 When you see the Starting Windows 95 message press the F8 key 3 On the menu that appears choose the Safe Mode Prompt Only item 4 Type attrib s h r msdos sys lt Enter gt edit msdos sys lt Enter gt 5 Change the line in MSDOS SYS that reads BootGUI 1 to BootGUI 0 6 Save the MSDOS SYS file and close the editor 7 Type attrib s h r msdos sys lt Enter gt 8 Restart the computer again Now when the computer starts up it will go into the DOS mode automatically Signature Technologies Inc 39 General Installation amp Programming Guide To run Windows Drop out of SAMview generally with the F10 key password and type WIN lt Enter gt at the C gt prompt and Windows will start To make the SAMview system start automatically on power up add the line SAMVIEW to the end of your AUTOEXEC BAT file This will invoke the SAMVIEW BAT file that is
294. indicator to zero and note the angle shown on the signatureACE screen THEN bar the machine in reverse until the ram comes to the same dimension and note the angle reading as shown on the signatureACE screen When you have the two angular readings then subtract the smaller from the larger divide the difference in half and add the result to the angle taken in the FORWARD direction EXAMPLE 1 The Forward reading was 126 degrees and the Reverse reading was 198 degrees 198 126 72 degrees between readings 72 divided by 2 36 126 36 162 SO Rotate the machine to 162 degrees and you are at B D C EXAMPLE 2 the Forward reading was 320 degrees and the Reverse reading was 32 degrees This is trickier since we re crossing the 360 0 boundary BUT figure it this way 320 40 degrees before 360 0 degrees 360 320 40 40 32 72 degrees between readings 72 divided by 2 36 320 36 356 SO Rotate the machine to 356 degrees and you are at B D C 44 Signature Technologies Inc signatureACE B When the machine is at B D C Hit the A key and enter 180 lt Enter gt C The ANGLE display will now indicate 180 degrees and the Position Offset number will change from 0 00 to a different value MAKE A NOTE of the displayed Position Offset number You will need it later 2 Hit the Q to quit the resolver test utility and hit Q again to exit SAMtest Signature Te
295. ine capacity limit is based on a percentage of the actual machine capacity It is a single User configurable ABSOLUTE MAXIMUM limit located above the signature and other limit sets The Machine capacity limit is displayed in White Violation of the White limit will cause an output device to actuate REGARDLESS of mode Machine Control Selection The signatureACE system can be configured to control or to simply bypass monitor the operation of the machine or pressline The buttons displayed in Figure 108 are found on the SAMview screens and are available to authorized users Reset Fault Bypass Set Limits Control Figure 108 signatureACE Screen Machine Control Buttons Control Mode This mode of operation allows the signatureACE system to take control of the machine when a signature violates its limits Yellow Red and White limit Violations all produce control outputs that can be connected to affect the machine operation appropriately Signature violations are also Automatically recorded in the system database if the operator has configured the system to do so Bypass Mode Operating in this mode the signatureACE system will not affect the operation of the machine OR record Yellow or Red limit violations White limit violations will produce a control output and the violating signature will be recorded SAMview user interface 132 Signature Technologies Inc signatureACE With a signatureAC
296. ing operation Error Check Refer to the If a Programmed Feature Doesn t Work section below at page 101 fora description of the overflow error that could occur using this feature 92 Signature Technologies Inc signatureACE SPCview 003 Interval Peak Conventional Feature Build Press PRS_50 Tool 2092 SPC Point Title Peak Blank on B amp D 003 Interval Peak SPC Point Units Tons Channel Select 49 00 W Blank and Draw 31 674 Graph Rzis Status seki Ranate H Ris beg ees ZZ 15 004 Feature Control Status 6 674 Control brie Monitor 1 674 10 00 7 T r T T T T T 115 0 128 1 141 3 154 4 167 6 180 7 193 9 207 0 220 2 Interval Start 125 668 Interval End 135 608 Figure 70 Blanking operation on the in die sensor Conventional Feature Build Press PRS_50 Tool 2092 SPC Point Title Peak Blank LC 003 Interval Peak SPC Point Units Tons Channel Select 200 m Left Connection 158 Graph Rzis Status ane fiternate 8 Ris tepees Em 75 Feature Control Status 33 Control Monitor 8 50 0 t 115 0 128 1 141 3 Interval Start 125 668 Interval End 135 868
297. inishes changing data disks as requested on the screen Step 6 There will then be a database on the system hard drive in a directory called RALPH Step 7 To use this new database from the C gt Prompt type set samdata c ralph lt Enter gt and then start samview in the normal manner The system will start and use the RALPH database until you return to the original by typing at the C gt prompt setsamdata lt Enter gt Force Calibration Philosophies The Force Calibration Utility is used to assign values to the signature points in calibrated engineering units You can choose to display your signatures in tons kilograms pounds or the uncalibrated unit During force calibration the force sensors mounted on the machine elements are stressed to known levels of force The resulting signals from the sensors are modified by assigned calibration values that result in the presentation of the force data to the system user in his choice of units It may be useful from an engineering point of view to know that the signal from the 2 sensor has a no load value of 165 units and a loaded value of 1 357 units but for practical use it is better if the data is displayed in pounds or tons Signature Technologies Inc 349 User Manual While the SAMView SA2000 system does not require Force Calibration to operate performance trends are evident even when the sensors are not calibrated to the system there are several goo
298. ioal Mode selection Control Monitor 6 Restarting after the SAMview system stops the machine Reset 7 Shutting down the SAMview system Starting SAMview The SAMview system is normally configured so that it will automatically start whenever the computer is powered up However if you find the system is NOT in SAMview for some reason do the following lt Enter gt the Enter key 1 Enter the following at the keyboard CD SAMVIEW lt Enter gt 2 At the C SAMVIEW gt prompt enter SAMVIEW QQ lt Enter gt 3 SAMview will start immediately The Security System The security system allows the SAMview System Manager to restrict access to selected operations by password Additionally the SAMview system maintains a list of who did what and when You will need a password to access appropriate SAMview functions There are two ways to work the system as a user Users can access the system for a single operation One Shot or for multiple operations Log On We strongly recommend that you use the One Shot method If you Log On and do not log Off anyone else can access the system BUT only your name will appear in the security log Optionally you can have the system automatically log you off after a short period of inactivity Signature Technologies Inc 139 General Installation amp Programming Guide Overview Configure Database Analysis Screen Options P142 LI 3271 Count 2368
299. ion resistor to maintain calibration The 4 20 Ma current loop will normally allow a certain amount of voltage to be generated without affecting to accuracy of the analog data Using the SA2000 input in LO range permits a peak signal of 2 5 volts 20 ma applied across a 100 Ohm precision resistor produces 2 volts of signal The circuit is 100 Ohm 4 20 01g Hilliamp OS watt Current Loop 274 Signature Technologies Inc signatureACE Figure 220 4 20 Ma Current Loop Hookup The connection between Signal and Excitation is necessary if the 4 20 Ma current loop is floating to keep the signal inside the common mode range If the loop isn t floating and has one side grounded then you should break the connection between Signal and Excitation Calibrating Analog sensors for measurement Calculated In cases where the target for the Analog device is according to the test conditions in the manual and the target approaches perpendicular to the sensor and is parallel to it the figures in the sensor manual can be used to generate a theoretical calibration for the sensor Referring to the TURCK manual for the LIU series analog proxes specifically the Ni8 M18 LIU the output of the sensor is 0 25 volts until the gap between the sensor and the target grows to 1 millimeter As the gap increases the voltage output grown to 10 volts at 5 millimeters of gap With the resistive divider as described
300. ire field to erase when the first key is struck Otherwise the characters will insert at the cursor position In the example below 4 DIEview channels have been set up Overview Configure Yaiahase Saginsis Screen Options g i p Tool Database for Press P1852 m Press Tool ID Angle P1852 M3705 Channel pii Active Description Fault State Start End Invert PNP Sensor Type Output Relay J 04 Feed In Position pse fo Wm Eoo E J 02 Pilot Hisfeed Det 120 0 200 0 aways off E vetw J o3 Part Ejectin 190 0 so _ Eloronort E vetw J 04 Buckle 170 0 250 0 always off check Sie Sensor Type Description Always Off Check The sensor must remain OFF while in the window The sensor must transition at least Cancel once somewhere outside of the window Reset Faults Ih Return E Figure 152 Programmed DlEview system 01 Feed in position is a RED or Immediate stop because if the stock is not in the proper position you WILL have a wreck and maybe die damage The criteria for selecting the stop is related to the likelihood of Sticking the press If an Immediate Stop issued at 105 degrees is likely to Stick the machine possibly the feed can be re timed so it gets into position earlier or maybe a Top Stop is the best economic alternative Die protection Input protocols 192 Signature Technologies Inc signatureACE Definition
301. iring to an output it probably isn t the problem 2 If the system is in the CONTROL mode and the Machine won t run OR If the machine stops immediately when CONTROL mode is initiated NOTE It is customary to start most machines in MONITOR mode since the first hits it will make after a start will be unstable and will probably cause a fault The EXCEPTION to this is in cases where the machine is run in Single Stroke mode Signature Technologies Inc 335 General Installation amp Programming Guide See the explanation of the SEQUENTIAL Baseline generation Mode in the User Manual This mode allows the machine to start up with the YELLOW limits TURNED OFF temporarily until the machine stabilizes Check the screen to see if there is a Fault If there is Click on the Reset Fault button at the lower Right corner of the screen The Fault indication should go OUT If SPC and DIE PROTECTION are used check that there is no fault in one of those systems also The Signature fault reset WILL NOT clear SPC or DIE PROTECTION faults Try to run the machine again If the machine Won t start with No Faults showing Check to see if the Lights are ON in the Outputs in the RED YELLOW and WHITE positions in the I O chassis It they are ON the SA2000 is ENABLING machine operation Measure the Voltage between the terminals for the RED YELLOW and WHITE I O modures on the I O Chassis If the lights are ON on the Modules
302. is 1 0000 If you know the calibration factor for the sensor see the Section under Calibration in the signatureACE Maintenance Manual you may enter it here If you are going to calibrate the machine by loading it and letting the ST system generate the calibration for you then leave the cal factor at 1 0000 G Hit the lt Tab gt key again The Offset box will be selected Offset is a value that can be added to or subtracted if it s a negative number from the sampled value The number is applied to the CALIBRATED value SO Example If you had a situation where an input of 0 was actually equal to 4572 pounds and you wanted to read this out on the graphs and numerical displays you would program in 4572 in the Offset screen H Hit the lt Tab gt key again The Curve File Button will be selected Figure 35 A black rectangle will appear on the button If you left the number in the Calibration box at 1 0000 then DON T do anything here now we ll come back later If you DID enter a calibration factor then click the box and a pop up menu will appear with the available Press Capacity curve files for the machine NOTE If there are NO capacity curve files shown select the Cancel button and go to step K below And continue from there 1 Select the curve file you want to use It will be highlighted 2 Choose the Select button The pop up will disappear and the file name you chose will
303. is Screen Options PRS_128 3330 50 Signature View Log Events of Security level K Select gt 2 and above Delete Log Summary Level Change to Bypass Change System Info 2 Change to Control od Auto log off after 0 0 minutes 0 never Auto log off Security Level lt lt Add Hame tains Sa Password Edit gt gt R Rackstraw T 1775 6 Clow 0 9 A F Remove From List Cancel Return bypass Control set Limits Figure 126 Security Setup Screen Security regions SAMview functions are grouped in regions allowing the system administrator to assign or restrict access to each region by security clearance level Initially all regions except Configure refresh rate and Delete Signatures are set to level 0 This allows any user to access most regions Security regions are Change Limits Requires a password to command a limit recalculation by selecting the Set Limit Button Change System Info Requires a password to permit modifications to system information Change to Bypass Requires a password to command the system to exit the Control Mode by selecting the Bypass Button This should be a high priority since it takes the signatureACE out of the control loop 156 Signature Technologies Inc Change to Control Cnfg Cnfg Cnfg Cnfg Cnfg Cnfg Cnfg Cnfg Cnfg Cnfg Cnfg Cnfg
304. is totally empty 1 Verify the following a The signatureACE system is connected properly to the machine the Host Computer and the sensors b The Signature Technologies system software has been loaded into the Host Computer c The SA2000 in the Host Computer is powered up Heartbeat running and on line as covered above Additional files needed for full operation a If you want to use the Press Capacity Curve function a LP press capacity file must exist in the CASAMDATA directory And in the C SAMDATA machine name directory See Appendix 3 below for details about creating this file b If you want to use the Alternate X Axis Function a cx press rotation stroke position file must exist in the C SAMDATA directory And in the C SAMDATA machine name directory This function allows you to see the signature plotted against the distance above BDC This file MUST have the same name as the Press Capacity LP file in item a above See Appendix 3 below for details about creating this file c If you want to modify the operation of the SAMview software or override default system configurations the SAMVIEW INI file can be put in the C SAMDATA directory allowing re configuration of the system d If you want to modify the operation of the SAMview software or override default system configurations for One of the Machines ONLY in cases where there are several ma
305. ital multimeter which has a 300 millivolt scale across the Signal plus probe to Signal Negative probe leads and measuring the static voltage Excitation Shield es Excitation a Signal r Signal l Signal Signal E Excitation Tr C Excitation Unit r 9 7 Millivolt Meter ai im a LO Figure 255 Gage out of balance AS stated above in HIGH range If the static offset is larger than 4 millivolts or less than 3 millivolts then it s too far out and must be brought in with balancing resistors The best way to bring the offset down is a Connect the meter as above to the Signal and Signal terminals b Hook a resistor of 100K ohms between ANY Excitation connection Either or and ANY Signal Either or connection Signature Technologies Inc 329 General Installation amp Programming Guide fee a 100K Excitation Shield Excitation A Signal 5ignal Signal Excitation Signal F C Excitation Unit 1 3 Millivolt Meter e ge e 2 Figure 256 Resistor hooked the wrong way error larger c When the resistor is connected the offset will either get better or worse d If it gets worse try the hook the resistor to the OTHER Excitation connection Verify that the offset gets bet
306. itches offer a simple connection that is polarity insensitive and can be applied in either the Sourcing or Sinking configuration We suggest sourcing hookups for Always ON and Dynamic applications since a Short No Signal fault Output To 24V Power Sup e birmi ore P Universal Prox Figure 146 UNIVERSAL 2 wire Proximity switch Sourcing connection Most manufacturers supply switches that will operate at the 24V D C level The switch you purchase should indicate EITHER 2 Wire DC or 2 Wire Universal voltage as 20 250V AC D C 2 Wire AC Only Switches will not operate properly See the special note under Dynamic checking for static switches below for 2 wire proximity switches Dynamic Checking for static sensors Ground detectors In cases where the sensor is ALWAYS in the same state as in Buckle Loop detection end of Stock etc Signature Technologies suggests that provision be made to cause the signal from the sensor to change once per cycle to insure that the wiring to the sensor is O K and neither open or shorted This can be done using either the Programmable CAM switch option from the ST System or operated by the Rotary cam switch on the press Signature Technologies Inc 187 General Installation amp Programming Guide Checking Contact ee C To ba Input ss 9 Sensor Probe qa Stock Strip Sensor Probe S To 24V Common a e Sivachine Frame X VS ANNANA NAAN AA
307. ith the SA2000 version of the Signature Technologies Product The previous SA2000 product was current through Mid 1997 and the SA2000 version from Mid 1997 to the present The versions are essentially the same operationally but are quite different hardware wise The test points and connection data in this publication refers exclusively to the SA2000 with TEC configuration SAMtest diagnostics are also presented This is a software package specifically designed to be used in diagnostic and setup operations To use SAMtest quit SAMview start SAMtest from the C gt prompt in the DOS environment We ll go into the menu details later in this publication strongly suggest that you review the information in SECTION 1 which is a Whiz bang introduction to the system arrangement and should leave you with some understanding of where things actually happen have organized this publication into major sub divisions of procedures that follow during system commissioning and field service calls This manual ASSUMES and you know how dangerous that is that you are already familiar with the business of navigating through the screens of the SAMView package Consequently won t complicate the text with keystroke by keystroke lists on how to get certain places I ll just say go to Signature View and you will understand what that entails The most common recurring question from a hardware standpoint has been the Pos
308. ition Sensor and its interface to the machine This is why the See if you have Position Information section is so detailed If You re not sure where to start just go down the Sections starting with 1 and note your findings Some things have to be established to be in good working order before other things can be diagnosed For example if the SA2000 is not ON LINE and communicating with the Host Computer there s no sense in checking the Resolver wiring Since the SA2000 SAMView system is so flexible the operator can sometimes program functions which may cause unexpected results We have probably been through some of these ourselves and can suggest other methods for accomplishing what you want For information please contact us giving as many details as you can of the problem Never hesitate to call us at S T I 972 488 9777 with specific questions You may also contact us through the website at www signaturetechnologies com In the unlikely event that you encounter a Fatal Error message on the screen a SAMView lockup or the dreaded LWERR Dump as you operate the system please record all the data on the screen if there is any and the events that led up to the problem before resetting the fault and inform us by phone or FAX This way we ll be able to respond more knowledgeably to the problem Who does what in the SignatureACE System The SA2000 Samview System is a multi processor system in which different
309. ity Level number bar slide to the desired level 5 Select Return The message Save changes to Security Screen will appear 6 Select Yes to save and exit or select No to exit without saving NOTE Password maintenance It is suggested that the level 4 and 5 passwords be changed every week Adding a new user to the system _ Select the Name entry at the bottom of the Security Setup window 2 Use the keyboard to enter the user s name 1 to 18 characters 3 Use the pointing device to move the slide bar for the Security level 4 Select the box below the Password label 5 Use the Keyboard to enter the user s password 1 to 4 characters 6 Select the lt lt Add button to update the User Name list with the new entry Changing an existing password Passwords should be changed periodically or whenever system security may have been compromised 1 Use your pointing device to select the user from the User Name list from the Security Setup window N Select the box below the Password label oO Use the Keyboard to enter the user s password 1 to 4 characters B Select the lt lt Add button to update the User Name list with the new entry oa Select Return The message Save changes to Security Screen will appear O Select Yes to save and exit or select No to exit without saving Removing a user from the system
310. k Moving to the Left there is an End of Stock detector that is normally OFF but is HELD ON by the presence of stock against its sensing surface This sensor makes sure that there is a supply of stock available and should the stock disappear the switch will turn OFF and stop the machine The Always ON or ON OFF ON protocols are the choices depending on whether dynamic checking recommended is used or not Buckle Next to the left is another pair of sensors that are downstream of the Feed Rolls which are normally OFF and will turn ON if the stock gets close to their sensing surfaces These are Buckle detectors and are used to detect jamming of the stock strip in the die If there is a jam the stock will Hump up between the die and the 180 Signature Technologies Inc signatureACE feed rolls and Turn ON one of the Buckle sensors This will signal the Die Protection system to Stop the machine The Always OFF or OFF ON OFF protocols are the choices depending on whether dynamic checking recommended is used or not Slide Parallelism Slide parallelism sensors are typically applied to the Lower die half and are precision Proximity switches that watch the lower surface of the upper die half or of the moveable stripper They are set to switch ON just as the slide stripper reaches its lowest point in the stroke The idea is that if there is a slug on the stock the stripper slide won
311. k the programming of your FINDIT tool 2 Roll the press Three times making sure it is hitting a normal load i e It should be making a part if possible instead of just turning empty 3 After the first two strokes take a look at the Count window It should indicate the strokes you just made If it does the SA2000 is taking data gt If it doesn t count the Position reference to the SA2000 may be running backwards check the angle to make sure it gets bigger as the machine turns gt Ifthe angle isn t changing the SAM Module may have Quit or you re not On Line Check the appropriate sections of this write up 4 Hit the Refresh Button You should see a Signature OR AT LEAST a line drawn across the screen NOTE If all you see is a LINE then try the other active channels If there are Signatures occurring on some of 320 the other channels there is NO problem with system as a whole but there may be a problem with the hardware for the particular channel you re looking at If there s NO line Go to ZOOM and Zoom OUT until the Scale on the Left side of the Graph has numbers amp at least as large as 2100 times the Calibration factor for the channel you re looking at Then hit Refresh again Example The channel you re looking at is the left front upright Its Calibration factor out of the Press database is 0 1407 You then want to zoom OUT so that the Vertical scale numbers above and below the zero are
312. ke Count Run Baseline Control P142 3669 P143 P144 P145 P146 P149 E CELLE p p p p S eG OMe els Selected Press p12 Setup Info Control Status signatures Set Limits Control Figure 86 Press Line Overview Screen 2 Select the press you want to put features in Click the desired Press ID in the View Press column of the Press Line Overview screen 3 Click Configure from the menu bar A sub menu will appear 4 Click Tool from the sub menu 5 From the tool database go to the SPCview configuration utility Click SPC Feature on the lower right hand side of the screen Figure 87 106 Signature Technologies Inc signatureACE Querview Configure Options Tool Database for 286 oi Tool ID Tool Description View another Press ange Tool DEFAULT Default Tool New Tool Signature Collectign Area Data Collection Rate Size 0 35 387 From To 103 718239 41 Channel List 3 ALT Channels Setup Selections SPC Feature SAM Ch Description Virtual Channel Tool Setup Inf Channel JA RARA AAAS Editing 61 61 Right Connection Refresh Rate die view _ Cam View thes 01 03 7 Description Capacity Units Calibration Offset Curve File 3 gt Left Connection 2100 lt uncal gt 1 0000 9 900 Anne 100 00 Figure 87 Tool database screen 6 Th
313. ked filters to avoid overheating Monthly Check the condition of the shock mounts replacing them as needed Replacement mounts are available from ST as repair parts Check the HiRes resolver converter adjustment re adjusting as required following procedures contained in Appendix 8 of this manual Check the sensors for proper operation scheduling service as required Six months Check offset on sensor channels according to procedures in the Appendix 11 Calibration Procedures section If drift has occurred schedule sensor service Yearly Check offset on sensor channels and re calibrate the sensors according to procedures in the Appendix 11 Calibration Procedures section Archiving amp Restoring the Database using external media There are two methods of recording restoring signature data on floppies Method 1 If you want to save a few signatures with their limits onto a floppy disk or restore a few records from a floppy back onto the hard disk you may use the methods as described under Transferring selected signatures Method 2 If on the other hand you want to store MAJOR SECTIONS on floppy disks in an expeditious fashion a DATABASE BACKUP RESTORE utility is available Consult the SAMview maintenance guide available from Signature Technologies Inc Transferring selected signatures Saving to a floppy disk Occasionally it may be desired to record a small number of selected signatures onto flopp
314. kshaft 234 Resolver Driving with a Timing Belt 238 Resolver excitation disabling 35 Resolver Mechanical Environmental Specifications 232 Resolver mount design Required information 241 Resolver Mounting and driving requirements 228 Resolver mounting cautions 230 Resolver Mounting Design Practices 233 Resolver mounting Do s and Don ts 232 Resolver Mounting Requirements 229 Resolver Physical Specifications 230 Resolver position interface module Type RES 133 Resolver utility 219 Resolver Utility 42 43 Restarting after a fault stop 152 Restoring Master Signatures 351 Restoring Signatures to the hard drive 206 Restoring Signatures to the Hard Drive 351 RSC1 RSC2 Jumpers 292 RUN input necessity for 30 S SA2000 283 SA2000 Address Switch 38 SA2000 Jumper Locations 264 327 SA2000 Module 142 SA2000 system generic diagram 347 SA2000 Technical Info 258 SA2000 module set 18 SA2000 Motherboard 283 Safety Disclaimer 17 Safety Precautions 17 SAM5S500 generic system diagram 2 349 SAM5S500 system generic diagram 1 348 SAMNet See SamNet Communications cards Jumpers 296 SamNet Network 144 SAMnet Summary screen 171 SAMNet Network Module 286 SAMnet address how to find it 57 SAMnet communications module 18 SAMnet network termination 30 SAMnet Troubleshooting 302 Samtest the GetNet Utility 41 42 Samtest The Resolver Utility
315. l system service 20 Signature Technologies Inc signatureACE Systems Overview Figure 1 Host Computer Console The Signature Technologies signatureACE system provides manufacturing process monitoring capability The Signature Analysis process software SAMview is the heart of the signatureACER system The Signature Technologies system is a non continuous profile Signature comparison process to ensure that machines that have a repetitive cycle of operation keep doing the same thing as production continues Basically any machine that produces a pattern of electrical signal that repeats at the same point each time the process cycle occurs can be monitored and used to control the process Various things can change the manufacturing process Work piece material Lubrication Temperature Tool condition Machine adjustment condition etc Signature analysis allows for on line real time monitoring of Machine Material and Tooling operation to identify changes from expected operation Figure 2 displays a sample signature Just as a doctor watches an EKG to monitor heart functions a signature analysis user can watch the signatureACE screens as SAMview monitors machine and die operations Signature Technologies Inc 21 General Installation amp Programming Guide Configure Database Analysis Screen Options Ouerview Signature View Figure 2 signatureACEB Signature signatureACE e
316. layed the channel is ACTIVE and will test its signal conditions every machine cycle If there is no color the channel is INACTIVE The State indicator will still operate but NO condition tests are performed 178 Signature Technologies Inc signatureACE Overview Configure Database Analysis Screen Options Signature View Press Tool ID Angle P1852 M3705 74 79 Ch I es Description Fault State Start End Invert PNP Sensor Type Output Relay T o1 Feed tn Position lt gt eoo peo m _ Gomo Gfa B J opi msan i200 2000 m Efawasor Efvenw A os Part Ejection O O O poopoo _ foromo Efenw H apee OO eefe _ Efawaus ortreneek fea Sensor Type Description Reset Faults Figure 139 DIEview User Pop Up Description This field indicates the specific use of the channel sensor Fault Indicator This indicator indicates whether or not the channel has faulted by lighting in the color assigned to the channel NO color indicates NO fault State Indicator This indicator shows the state of the channel Lit ON Not lit OFF Start Angle amp End These fields show the angular positions or Window during which the Channel testing is active See the section below on Die Protection Protocols for more information BOTH ANGLES CANNOT BE THE SAME Invert The Invert Indicator displays whether or not a logical inversion of the input signal sta
317. ld Excitation Ked A Data Instruments Signal H Amplified a I gt A Signal Black ra Strain Link Excitation TENSION Hookup Shield shield Excitation i A Data Instruments Signal 7 us Amplified Signal reen Strain Link Excitation Black Figure 212 Data Instruments Strain Link Hookups Data Instruments links are fundamentally different that other links since they have a built in amplifier Since DI links operate on 5 V D C excitation the Excitation of the SA2000 MUST be reduced to 5 Volts BEFORE the DI units are connected Failure to do this will permanently damage the DI strain links This hookup is for compressive application as would be experienced on the Connections Pitmans of a press For Tensive application swap the Green and White wires NOTE Since the DI link is self amplified the gain switch on the SA2000 Unit must be set to LO position on DI link inputs Signature Technologies Inc 269 User Manual Interfacing Piezo to the signatureACE system Piezoelectric transducers like IMCO HELM Load Plugs or load probes or Kistler Piezo load sensors or Accelerometers require a different technique than Strain gages The Piezo device is a self generating sensor that produces energy that is proportional to deformation of the Piezo element Note that used the word ENERGY not current or voltage The Piezo device will produce a certain amount of energy when it is squ
318. le Signature Technologies Inc 287 General Installation amp Programming Guide Hardware sketches The SA2000 internal arrangement HEARTBEAT Indicator TEST Address Buffer Full Connector Switch Indicator RESET Button TEST Button Test Switch as gp OO gn uud tuto Slaving Connector Sensor Gain Gage Excitation Jumpers Jumpers Figure 225 SA2000 internal arrangement 288 Signature Technologies Inc tureAcE The TEC Module Connection points PAGHOGSOOGHDGHHOGH PODHHOVHOH AHH ONHH OOH SENSOR CABLE fooansoaccanesaneea i P oocaocooosooncoanoonn CONTROL CABLE LIGHT STACK fl Figure 1 Figure 226 TEC Terminal board 289 Signature Technologies Inc General Installation amp Programming Guide Jumper IN 1000X Jumper OUT 2X Channel 1 Gain Channel 2 Gain 10 Volts Channel 3 Gain SVE Channel 4 Gain Ai N AT an a reyes Tie va E prane IAI Bie xy d _ m sonst a 2929937 i KU a J w re rf Tid re im hte re ya jr re re z r g ro 33333333 33333233 qth HT 1997 SERIAL 87528 5491647 3 0 o ozo 0 0 00 0 O o O10 oo Cpe Channel 1 Excitation Channel 2
319. le ON Angle OFF 180 Angle ON Time Off 180 Appendix 1 SA2000 Conventional Wiring Connections 203 Appendix 2 37 Pin D Shell connectors on the SA2000 210 Appendix 3 LP CX files For Press Curve and Slide Motion 215 Appendix 4 INI Files for modifying the operation of Samview 218 Appendix 5 SAMview diagnostic utilities 218 Appendix 6 InSitu Machine frame Sensor Mounting 219 Appendix 7 Resolver Mounting and driving requirements 228 Applying a security level to a region 167 Applying Sensors for Die Protection 203 Archive the present database 51 Archiving amp Restoring the Database 205 350 Archiving Selected Signatures 350 ARCNET Network Module 286 ARCNET Packet Waveform 308 Attenuated Signature 334 Automatic start for Samview 39 B backup of the database to a ZIP file See Block Diagram System Navigation 49 Booting the computer in DOS 39 Buffer Full Indicator 38 Cable assembly 212 Cable Assembly I O 214 Cable Assembly Resolver 215 Cable Assembly Sensor input 213 Cable color code doesn t match 256 Calculated Calibration Factor Procedure 364 Calculating the cal factors for purchased load cells 366 Calculation Shunt resistor value 266 329 Calibrating Analog sensors 275 Calibration 354 Calibration Machine structure 355 Calibration Machine structure DYNAMIC FORCE method 356 Calibration Machine Structure STATIC FORCE
320. learly defined Blank and Draw Die closure Blanking operation Drawing operation Static Nitro Pressure Clamping Ring 115 130 145 160 175 190 205 220 Figure 66 Blank and Draw station From the preceding signatures it is possible to configure the feature extraction software to monitor the following process variables Peak force generated at the die closure Peak force generated by the blanking operation Work required in the blanking operation 88 Signature Technologies Inc signatureACE Peak force generated by the drawing operation Work required to draw the part Force differential between the left and right connecting rod during the blanking operation and die closure Material properties such as material thickness and hardness Condition of the nitrogen spring Now A list of the available features and what they do Signature Technologies Inc 89 General Installation amp Programming Guide SPCview 001 Interval Maximum Conventional Feature Build Press Toot 2092 SPC Point Title Draw Maximum B amp D O1 Interval Maxinun SPC Point Units Channel Select m Blank and Draw Graph Bris Status Riernate H eis Hep ees Feature Control Status Control Monitor Figure 67 Drawing operation on the in die sensor Conventional Feature Build Press Tool 2092 SPC Point Title Draw Maximum LC O01 Interval Haxinun SPC Poi
321. lel resistor combinations are used be sure to SOLDER all the joints Inexpensive resistor assortments can be obtained from your local Radio Shack electronics shop NOTE If you apply balancing resistors to a commercial load cell to correct an out of balance situation you will slightly alter the calibration values for the cell requiring an experimental calibration to be performed if calibrated values are needed The Clamped Signature EE LEA HER pEi HEERE Figure 259 Clamped or Lazy Z signature Compare this illustration to Figure 247 and you ll see the effect of the ST Analog Clamp on a normal signature Basically the Analog Clamp is used to HOLD the input at Zero whenever the machine is not running so that it doesn t drift off scale and issue a fault when the machine starts Signature Technologies Inc 331 General Installation amp Programming Guide TWO things will release the clamp 1 The machine position passing the 359 0 degree boundary 2 The Clutch input signal to the TEC module going high IF the Clutch is not wired into Input 2 properly OR if the input module is defective AND the machine starts from a position AFTER 0 degrees the SignatureACE will not be aware that the machine is running and the distorted signature in the illustration will be displayed on the FIRST STROKE of the machine The next stroke if there is one will be normal To see what s happening look at the RUN indicator at t
322. len a edie Ralph 5 only etc Changing a Password Step 1 In the Overview Screen select Configure from the menu Bar and click on Security Step 2 Enter a password of the proper priority level should be the highest priority only Step 3 Click on the name of the individual you want to change Then click on the FIRST character position in the Password field Step 4 Enter the new password Step 4 Click on lt lt Add to enter the change Step 5 Press the Return button to Exit Configure and answer Yes to the Save Changes question Changing a Password Level Assignment Step 1 In the Overview Screen select Configure from the menu Bar and click on Security 364 Signature Technologies Inc signatureACE Step 2 Enter a password of the proper priority level should be the highest priority only to enter the security screen Step3 Click on the name of the individual you want to change Then drag the Slide Switch to the desired Priority level Step 4 Click on lt lt Add to enter the change Step 5 Press the Return button to Exit Configure and answer Yes to the Save Changes question NOTE Passwords are read by the system on a character by character basis and matched to the passwords stored in the database The Program will change any lower case characters to Upper Case automatically The Password is NOT Case Conscious however ABCD is the same as abcd If you forget or ERASE your passwo
323. light on the SAM lights and stays lit as long as the machine turns the Z track wiring must be reversed f the ZRO light stays lit while the press moves the position display will indicate 0 all the time and no signature data will be taken Normally the Z track is wired to terminal R2 if the ZRO light mis behaves try wiring it to terminal R1 If your Encoder has Complimentary outputs exchange the wires on terminals R1 and R2 Go back to Steps 1 amp 2 and check again If the ZRO light doesn t flash at all something is amiss with the Encoder or its wiring Make sure the ENCODER shaft is turning when the machine does Inspect the plug on the ENCODER for broken wiring or cable fatigue where the cable exits the connector 10 Inspect the connections of the Encoder cable to the TEC terminals 11 If a visual inspection of the wiring doesn t reveal anything then perform the following tests a Check with a D C voltmeter to see if there is excitation voltage for the Encoder at terminals 5V and 5V of the Resolver Encoder terminal strip on the TEC If there is voltage go to step 14 b If there is no voltage but the 5V and 5V lights are on theTEC board is probably defective Replace it Go to steps 1 2 above and try again 314 Signature Technologies Inc signatureACE c If there is no voltage and one or both lights are out remove the 5V and 5V wires from the terminal strip and see if the light
324. limits since they normally announce minor variations in the machine signature They may only be used to light a warning light or at an extreme perform a Top Stop EEEE AT Button confirms an action or closes a window Warning Limits 0 See YELLOW limits Topical Index 3 D shell connector I O 211 37 pin FEMALE Connector I O 211 HOT keys 160 3 wire D C Proximity Switches Interfacing 272 66 4 D shell Connector Sensor Input 210 4 20 ma current loop Interfacing 274 Signature Technologies Inc 375 General Installation amp Programming Guide A A D Input board jumpers 265 328 Aberrations in the signature display 324 335 Absolutely flat top on signature 327 Acceptable offset values 267 332 Adding a new user to the system 167 Adding Machines to the system 129 Adding SA2000 modules to the same machine 131 Adding Tools amp Jobs 83 Address Switch location SA2000 33 Adjusting Displayed Machine Angle 44 Adjusting Limit parameters 156 Adjusting the Resolver Signal levels 252 Adjusting the signature graph 149 Adjustment Strain Gage output 264 327 All screen Signature View 74 Alternate X Axis definition Files 55 An Overview of the SPC Process 89 Analog amp Die Protection Sensor input terminals 205 Analog inputs TEC Board 258 Analog sensors Calibrating 275 Angle Signature Collection 65 Angle Software correction 44 Ang
325. llation amp Programming Guide NOTE You MUST set limits before any of the programmed features will operate To remove a Feature from a summation list 1 Go to the Overview screen if you are not already there by selecting Overview from the menu bar 2 Select the press you want to put features in Click the desired Press ID in the View Press column of the Press Line Overview screen 3 Click Configure from the menu bar A sub menu will appear 4 Click Tool from the sub menu 5 From the tool database go to the SPCview configuration utility Click SPC Feature Setup on the right hand side of the screen 6 The SPCview Configuration screen will appear Qverview Configure Batabase Analysis Sereen Options PCview Configuration Press P1286 Tool M3705 Feature List Interval Peak H Build Conventional Feature Budd Manro Foge Subgroup Sample Size Cycles between subgroups SfSrrekes Figure 94 SPC Configuration Screen 7 Click on the feature you want to remove so that it hi lights 8 Click Remove next to the summation list title 9 The selected feature will be removed and all ocurrences of it in the SPC screens will vanish 112 Signature Technologies Inc signatureACE 10 If you want to remove additional features go back to step 7 above and repeat the process 11 If you are done select CONFIGURE from the menu bar 12 Select
326. lly want the opposite this button when pushed will yield an always OFF that pulses ON instead To Repeat the terms ON and OFF relate to the State light ONLY If the State light is ON the sensor is On as far as the DIEview system is concerned PNP This is also a toggle The PNP indicator indicates the connection of the internal Pull Up resistor for the input NORMALLY the pull up resistor is connected to 24 volts and must be brought low or grounded to actuate the input This is an input configured to connect to SINKING or NPN devices This includes Cat s whisker and grounding switches NPN Proxes and any device that GROUNDS power from the input If the Indicator is DARK itis indicating PNP mode where the resistor is connected to ground This is an input configured to connect to Sourcing or PNP devices This includes PNP Proxes and any other device that FEEDS power into the input Start This window defines the point at which the Window opens for sensing according to the rules found below under Die Protection Protocols In general the die protection system becomes active for the sensor AFTER the machine has moved past the Start angle for the window see exception under ON OFF ON and OFF ON OFF protocols If a 360 degree OPEN window is desired this MUST be set to 0 End This window defines the point at which the Window closes and ends the sensing operation
327. logged to disk for display in the Show Log report Reviewing the current user log 1 From the top menu bar choose Options 2 From the Pull Down choose Show Event Log 3 There are 5 buttons that control the display of the log which IS ALWAYS presented from the OLDEST entry to the newest one A The Log button will cause the log to scroll by continuously until it reaches the most recent entry B The Pause Button will toggle the scrolling on and off C The More Button will cause the Log to scroll by Page by Page D The Clear display button will erase the log from the screen 160 Signature Technologies Inc signatureACE E The Save As button will cause the LOG TXT file to be saved under other names and at different locations on the hard OR floppy drives F The Print button will cause the Log to print on a connected printer in the same form it has on the screen G The Delete button allows the erasure of the LOG TXT file which will be automatically re started by the system Configuring Signature SPC saving 1 If you are not in one of the signature SPC screens access one by selecting Signature or SPC in the box at the bottom center of the screens 2 Select Analysis from the menu bar at the top of the screen A sub menu will appear 3 Select Edit Saving from the sub menu The Signature Save Setup window will appear M
328. lt Use double flanges only on the DRIVE pulley Signature Technologies Inc 239 User Manual We don t use flanges on the resolver pulley to avoid the weight Since there is a lot of shock and vibration in any press installation Weight on the resolver shaft translates to bearing load even without the belt tension See Figure 183 below Type L tiring belt pully 32 tooth NO flange Resolver Bracket Wy Ya ies as n MACHINE resover E FRAME O Type L Drive Belt CRANKSHAFT 3 4 Dio drive stub Type L timing Uf belt pulley 32 tooth Double Flange Fenrier Marinhieirn Trantorque Shatt Clarnp 620160 Figure 183 Gear Belt drive detail 4 We have found the TRANTORQUE device from FENNER MANNHEIM to be a good way to affix the drive pulley onto the crankshaft drive stub Since there is a lot of shock at the end of the crankshaft setscrews don t hold terribly well even if the shaft is flatted The Trantorque device is a double expanding device that seems impervious to vibration See Figure 183 above 5 If the end of the crankshaft is not clear you can use split pulleys although they will have to be specially made to order 240 Signature Technologies Inc signatureACE 6 If the drive is taken from the crankshaft end make sure that the drive stub runs concentrically with the crankshaft If there is any problem with lack of concentricity due to inaccuracie
329. m plug the Output cable into the CNV converter and make sure the angle display on the existing system doesn t change significantly When the output cable is connected to the terminals in the TEC unit and the system is powered some combination of lights on the converter will probably come on Don t worry yet if they don t 2 Adjust the REFERENCE signal level on the CNV Converter To do this take a look at the REF lights on the CNV converter REF COS SN _ 829 8c Ee 8 Figure 193 Indicators Adjustments on the Resolver Converter a If Green only or both Red amp Green lights are on turn the REF adjustment potentiometer CCW until they both are OUT If both lights are out go to step 2 THEN b Turn the REF adjustment CW until the Green light just comes ON NOTE If you can t get the REF light to come on make sure you have power to the SAM Module and that the wiring connection are O K c Continue turning the REF Adjustment CW until the Red light just comes ON 252 Signature Technologies Inc 3 signatureACE d Turn the REF Adjustment screw CCW until the Red light goes out e At this point the Green light should be ON and the Red light should be OUT Next adjust the SIN and COS signal levels on the CNV Converter The machine should be running in continuous mode if possible although repeated single strokes will work also The SIN and COS signals will vary their amplitude as the machine turns and
330. may be different from what is shown on the drawing for assistance contact ST at 972 488 9777 Single Ended Hookup A Single Ended Hookup as shown below As used in the Data Instruments SmartPac is where one side of the Sine Cosine and Reference windings on the resolver are each hooked to system common Existing System Resolver Coriverter INPUT Cable Parel Ground Figure 188 Single ended Hookup SmartPac by Data Instruments hookup This is a Single Ended Hookup as shown above but with specific terminal numbers given for the connection to the WPC board in the Data Instruments SmartPac 248 Signature Technologies Inc signatureACE Data Instruments WPS Board Term s 52 BLACK 40g 412 407 410 409 411 Panel Ground Resolver Coriverter INPUT Cable Figure 189 SmartPac Hookup Mixed Hookup A Mixed connection is shown below As used by AMCI amp Autotech where the Sine and Cosine windings are connected to system common for a return while the Reference wires are driven in Push Pull mode Existing System Resolver Coriverter INPUT Cable Panel Graurid Figure 190 Mixed mode connection Full Floating Hookup A Fully Floating connection is shown below like Helm uses One version of this is where transformers to couple the resolver windings into the electronic system Connect the Ground wire to the chassis of the external system This type of
331. method 356 Calibration Philosophies 354 Calibration Procedures 359 Calibration Underdrive Machine Calculated 356 Calibration Zero Offset checking Procedure 359 Calibration of Home Made Sensors 278 Calibration Procedure Dynamic 362 Calibration Procedure Static 360 Calibration Settings Maintenance See Cam Outputs 1 thru 8 373 Camview Cam protocols 180 CAMview Programming 177 CAMview Connections 181 CAMview product liability warning 173 CAMview user guide 173 Changing Tools 148 Changing a Password 371 Changing a Password Level Assignment See Channel Assignments 52 Channel Assignments Machine Channels 52 Channel Assignments Tool Channels 52 Check out Resolver Operation 41 Check out System operation 41 Check out The Resolver Utility 42 43 Check out the SAMTEST utility 41 Clamped Signature 334 Cleaning out the Hard Drive 352 Clutch signal input 372 CNV Converter Mounting 245 CNV Converter Wiring 245 Communications card Address switch 34 Communications card controls 33 Communications card Internal switches amp jumpers 34 Communications cards Jumpers 296 Communications network 285 Computational Overflow Features 109 Computer Host 144 Computer installation 33 376 Signature Technologies Inc signatureACE Computer at the end SAMnet configuration 32 Computer in the middle SAMnet configuration 32 Configure Scr
332. move up the network from the farthest point shortening it progressively but re connecting the Oscilloscope and terminator to units closer and closer to the Host you would be able to tell if you pass a Defective point since the lowest Packet amplitudes should rise and the reflections fall dramatically 15 Since the procedure listed above approaches brain surgery in general complexity feel free If you need further advice on Network troubleshooting to give us a call at 972 488 9777 308 Signature Technologies Inc signatureACE Check 2 See if you have position reference information Refer to the generic drawings on pages 335 337 These are generic system wiring diagrams for the A2000 AND SAM500 versions of the product which will give you insight into the system wiring The following list enumerates the steps to be taken in determining whether the Position reference portion of the system is in proper order The terminology for this section will refer to the TEC unless specific points are different on the RSCB version Connection points on the RSBC will be enclosed in parenthesis 1 Go to the Signature View Screen 2 Check the Displayed Angle Take note of the angular position shown in degrees at the Angle window at the upper right side of the screen NOTE Be careful of this reading since the Angle display will ONLY display the correct angle if the machine has been moved since coming ON Line If you re not sure
333. mper Juniper dumper Jurnper Jumper Jumper Jumper Figure 16 Computer in the middle SAMnet configuration Since there is only ONE BNC connection on the SA2000 and SAMnet modules it is permissible to use T fittings to achieve the network connection No more than 15 feet of coax between the SA2000 or SAMnet coaxial fitting and the T fitting is permitted MAKE SURE that the addresses of the SA2000 modules are each different and that NONE are the same as the Host Computer which is normally 16 or set to ZERO which is illegal 32 Signature Technologies Inc signatureACE HEARTBEAT Indicator Communications Address Buffer Full Connector Switch Indicator RESET Button Test Switch TEST Button Slaving Connector Sensor Gain Gage Excitation Jumpers Jumpers Figure 17 Address Switch location IF problems are encountered achieving SAMnet communication see the Appendix 10 Troubleshooting Guide for diagnostic procedures The Node that is off line MAY NOT be the one causing the problem Set up your host Computer system Hardware 1 Install the Host Computer apparatus wherever you like and remove its cover 2 Install the network card into an empty ISA slot in the Host Computer The network card is already set up properly before it is shipped Communications Selection Switch STANDARD MICROSYSTEMS CORP ARENET PC goows ASSY 710 204 9L EF i p E O D
334. n buttons will disabled Select clear then re enter your password See the system manager for assistance Changing Tools in the SAMview system Tools are changed ONLY from the Overview screen by using Configure Job The procedure is Signature Technologies Inc 141 General Installation amp Programming Guide 1 Select Overview from the menu The system will change to the Overview screen 2 Select Configure from the Menu bar A pull down menu will appear 3 Select Configure Job from the pull down menu 4 lf the security Pop Up appears enter your password in the Log On window then select lt Enter gt 5 Select the One Shot button that appears within the log on window 6 The security pop up will disappear and Select buttons will appear on the overview screen next to the Current Job window at the upper left and to the right of EACH Tool window in the center area of the screen A If you have a Press line where the tools in several machines change at the same time use the Select button next to the Current Job window B If you only want to change the tool in ONE machine use the Select button next to the Tool name you want to change 7 Depending on which choice you make either the Select a Tool or the Select a Job Pop up will appear with a list on the left of the available Tools Jobs available in the system 8 Sele
335. n Uninterrupted if possible 110 V A C or 220 V A C to a location where the Host Computer can be plugged in Signature Technologies Inc 29 General Installation amp Programming Guide If the power is taken from the machine it should come from an auxiliary transformer wired in before the main breaker or from a plant lighting source and be relatively clean Install a 7 conductor at least cable or separate wires from the TEC Terminal Enclosure to the press control enclosure and wire into the press circuit according to the appropriate convention in the Appendix 1 section below The MACHINE CONTROL cable standard minimum requirement is Two conductors for Clutch INPUTS Strip RUN 2 amp 2 Two conductors for Top Stop OUTPUTS Strip YEL 2 amp 2 Two conductors for Immediate Stop OUTPUTS Strip RED 1 amp WHT 3 with a jumper between RED 1 amp WHT 3 NOTE If you are using A C signals to the I O the polarity doesn t matter If you are using D C the polarity is Important make sure it s connected as shown If the outputs are connected backward with D C power they will NOT turn OFF One Green Bonding Conductor from the TEC Chassis to the machine frame use one of the board mounting bolts as a connection point NOTE NOT connecting the outputs will not effect the operation of the signatureACE except that you 10 11 won t be able to con
336. nal input We also provide sufficient amplification of the strain gage signals so that dimensional changes as low as 30 uStrain yield usable signatures Sensor inputs are brought into the TEC unit and hooked to the terminals on the Green printed circuit board in the TEC enclosure This board is a passive connection device with a few indicators and a fuse tester NO signal processing is preformed The TEC can be mounted up to 100 feet from the SAM module Our standard preferred bridge resistance is 350 Ohms but we can excite and use gages of virtually any resistance Our standard excitation levels are 10 V D C and 5 V D C They are jumper selectable Each individual channel can be configured to the desired excitation level Each input channel can be individually selected to either HIGH or LOW range HIGH range provides an amplification of 1000X that is used for Strain gage inputs LOW range is a 2X amplification that is used for interfacing high level signals Often the user wishes to interface various other types of devices into the system This publication is submitted for the purpose of instructing the user on the proper methods and additional components that may be required for successful operation of other types of input devices In some cases modifications to the TEC or SA2000 hardware may be needed Such work can only be done by Signature Technologies personnel if the hardware warranty is to be preserved Technical Inform
337. natureACE If the specific Load monitor you are using doesn t have grounded recorder return then the connection shown above to the Excitation on channel 1 should be removed The connecting cable from the Load monitor should be shielded and the shield should only be connected at the TEC end It s also generally a good idea to run a heavy bonding conductor between the computer chassis where the signatureACE is located and the Load Monitor Chassis Sometimes the Recorder Outputs will act as antennae for electrical noise and cause nuisance trips in the Load Monitor In this case if you trust the indications on the existing load monitor system calibration is a breeze since you can simply make the ST unit readout the same as the Load Monitor using the calibration utility described in the system user s manual Optionally you can install load cells and check calibrate both units Sensor Calibration Signature Technologies Inc 277 User Manual If the sensor that you are attempting to calibrate comes with a statement of what the output of the device is in volts per unit of pressure or volts per ton etc then you can use that factor to generate calibration factors for the signatureACE SAMview system Using the SENSOTEC pressure gage that we discussed back on page 263 we had at 10 volts excitation 30 Millivolts of signal at 5000 P S I We then shunted the gage to get its signal down to a usable level of 5 Millivolts at
338. ncerns relate to applications where the switch should always be OFF no signal Everything s O K see the section below on Dynamic Checking for static sensors 3 wire PNP Sourcing Proximity switch Connection The Sourcing three wire Prox is the best Three wire option since it feeds a voltage to the Die Protection inputs when activated short circuits will disable the switch from operation and cause missing signal faults To 24V Power Sup at Hower To D P Input wUtout lt Common PAP PTOX To 24V Common lt Figure 144 PNP Sourcing 3 wire Proximity switch 3 wire NPN Sinking Proximity switch Connection The Sinking three wire Prox is another option In this case when the Proximity switch is ON the output line is pulled down to common One might say that Zero ON voltage wise The obvious problem with this type of 186 Signature Technologies Inc signatureACE sensor is that a Short circuit appears to be an ON signal Power To 24V Power Sup NPN Prox Output To D P Input s 16 24 Common a_ommon Figure 145 NPN Sinking 3 wire Proximity switch In cases where the normal state of the sensor is ON As in the End of Stock detector a PNP sensor would be a better idea since a short circuit to ground would be a FAULT 2 wire Universal Proximity Switch Connection The 2 Wire Universal Voltage Prox sw
339. nd we ll get the proper settings for your module The operation of all units is identical from the user standpoint but the Jumper and Switch configurations are different Settings for the Current SAMnet Communications Module Communications Selection Switch STANDARD MICROSYSTEMS CORP 423 SI iamMBI IMMA FCC COMPLIANT SEE GUIDE OS E 74 94 8 e ARCNET PC goews ASSY 710 204 SRY g ALEI f 2 ate a z s An y 4 A a r a SAMnet Address TAZ T srles slza ce Hell Switch Z S teninin way gt qt bad Joao Be a pesbeabbaabssssenadad Barta i 19 ome Fiii giU m SAMnet gt me pinin i YAI l h Connector Termination Jumper Figure 235 SAMnet Card Switches jumpers side view gt There are several adjustments on the Communications card none of which require user attention since we pre set them before they re shipped In case you supply your own replacement however these are the Switch Jumper settings that work for us SW1 Located at the top rear of the board On Toward the top of the P C Board Off Toward plug on the Board S1 1 ON S1 2 ON S1 3 OFF S1 4 OFF 296 Signature Technologies Inc signatureACE S1 5 ON S1 6 ON S1 7 OFF S1 8 ON S2 Located at the Coaxial connector end of the board between the Connector and the lights This switch controls the address of the Host Computer Normally we use 16 for an address The SAMView program can display addres
340. ndow is accessible from any of the six programmable SPC graph screens or the SPCview configuration screen To access the limit parameters screen 1 Select Configure from the menu bar 116 Signature Technologies Inc signatureACE 2 Select Limit Parameters 3 The SPCview parameters pop up will appear in the center of the screen Baseline SPC Setup Press P142 Collection Information 62 08 Peak capture Subgroup size 02 01 Average load 92 82 Work load Number of Samples ZI Mini Baseline Samples EE Xbar Limits _ yellow red Control Limit K Quality Limit K Current Limits 3 00 Eos 00 EG 243 64 EAE G LMT Ena creas AES tan 240 80 CEAT 237 96 Ebeealiemacnn 235 12 Reem rt Hbar Drift Factor ua ends 0 000 Percent 232 28 QROUTE eet et Hbar Limit Offset Control Limit for R red Baseline Standard Deviation R Limit R Limit Confidence level Ba Slo 5 calculated gt lo 975 Ed OE Crs Default R Limit Widening Constant Recalculate Cancel Return Figure 98 SPC Limit setup screen 4 Select the up arrow and down arrow on the List of SPC points to highlight the desired Feature When a Feature is selected the current limit parameters and limits are displayed on the screen 5 Select the desired limit data field Click on the FIRST character position 6 Use the keyboard or the key pad to enter the desired Xbar Process Mean parameter value A The
341. ness including double blanks broken or excessive tool wear and improper slide adjustment Refer to the If a Programmed Feature Doesn t Work section below at page 101 fora description of the overflow error that could occur using this feature 94 Signature Technologies Inc signatureACE SPCview 004 Interval valley Description Parameters Use Error Check Conventional Feature Build Press PRS_50 Tool 2092 SPC Point Title Valley Blank RC 004 Interval Val ley SPC Point Units Tons Channel Select m Right Connection Graph Ris Siafus 116 75 Rigrnate Reis Heep eas 75 04 200 0 158 34 Feature Control Status 33 34 Control 8 34 Monitor E 50 0 TES a T T T T T 115 0 128 14 141 3 154 4 167 6 180 7 193 9 207 0 220 2 Interval Start 125 Interval End 135 Figure 75 Blanking operation on the Right connecting rod This feature returns the value of the minimum valley between the start and the end of a defined window not the data collection window of the tool If there are multiple valleys in the window only the least valley will be returned Note that a valley is defined as a point at which the slope of the signature changes from negative on the left to positive on the right Selected channel data to calculate the valley from can
342. ng and should not be extended to avoid loading of the existing system with excessive cable capacity This cable CAN be shortened if the installation warrants Just make sure that the SHIELD is insulated at the termination end to prevent accidental contact with metal components This cable should NOT be lengthened without consultation with ST Engineering at 972 488 9777 The INPUT cable connection to the existing system is where the confusion in installation may occur There are several configurations of resolver hookups all the way from single ended SIN COS and REF signals to transformer coupled systems with NO common reference at all Signature Technologies Inc 245 User Manual Connector 9 Pin De Coble fil gle 4 Pair Shielded 24ga BELDEN 9504 External System Connection 3 53 Si SI R R R2 ri 9 Rt a Connect to CHASSIS in ae system being coupled to h 4 9 me oe Figure 186 Standard Converter SB 027 8004 INPUT cable assy Output Cable The Converter OUTPUT cable will be supplied in a 30 foot length unless different lengths are specified If different lengths are required the cable can be ordered by adding the length in feet to the Cable part number Example If an output cable 80 feet long is needed Order a SB 027 8006 80 The Output cable is supplied with the Converter end connector in place and should be pulled into conduit STARTING AT THE Converter end When the cable is pulled in the pre termina
343. nirun RC O2 04 Peak Blank LC 02 03 Peak Blank B amp D 62 88 Yalley Blank RC 2 04 Peak Blank LC 2 85 Peak B amp D G2 46 Peak LC 2 87 Peak RC 42 68 Valley Blank RC 2 89 Nitro Pressure B amp D 2 18 Work Blank B amp D 2 11 Work Draw B amp D Feature Control Status Control Monitor Figure 95 Macro screen Spread calculation 4 Click on Select Algorithm then select Spread Calculation 5 Click on the first character position of the SPC Point Title box and add the title Signature Technologies Inc 113 General Installation amp Programming Guide 6 Click on the first character position of the SPC Point Units box and type in the units name 7 THEN from the list of channels on the left click on a channel you want to compare in the spread calculation and click on Move To The channel name will be displayed in the list at the right 8 Repeat step 7 until all the channels you want are displayed in the list on the right 9 Select Control by moving the switch to the Control position if you want to CONTROL with this feature 10 When finished hit the Return box at the lower right corner You will go back to the SPCview Configuration Screen 11 Click Configure from the menu bar 12 Click Exit Configuration Answer YES to any questions that come up
344. nnel 2 Signal Channel 2 Signal D P Input 4 oo eee 23 Dense Nie Excitation o Excitation oo eee eeeeeeee eee 24 Volt Common 1 5 D4 ides te eats Shield 3 oae aaie Shieldi sppe taiese eteni Shieldi iraa tri ees 24 EER Excitation o Excitation ee eeeeeeeees 24 V Power Supply 1 6 P EEEE Channel 3 Signal Channel 3 Signal D P Input 5 ccecce 25 rarius Channel 3 Signal Channel 3 Signal 0 D P Input 6 eee 7 26 ween Excitation oee Excitation 24 Volt Common 1 26 REA TTEA Excitation a se Excitation c 24 V Power Supply 1 8 20 ER Channel 4 Signal 0 Channel 4 Signal 0 D P Input 7 eee 27 Seer eee Channel 4 Signal Channel 4 Signal D P Input 8 cn 9 28 EER Excitation a Excitation 24 Volt Common 1 ecce 28 NON irai Shield eann annt Shield araen Shields dii erates aas 10 Ae PREES Excitation siirinsesi 24 V Power Supply 24 V Power Supply 2 29 4 E PEER Channel 5 Signal D P Input 1 rioni eee D P Input 9 oo ees 11 IOa Channel 5 Signal D P Input 2 ccce D P Input 10 ccce 30 Tiii Excitation ie 24 Volt COMMON ossee 24 Volt Common 2 cee 12 Iia Excitation 0 eeeeeeeees 24 V Power Supply 24 V Power Supply 2
345. nnel 8 D4 C LL e i fe J SENSORS Figure 155 Analog Sensor Terminal layout A08 version Signature Technologies Inc 205 User Manual Analog Sensor Inputs Special a SHO J Ae SHO a x 1 QI 24V 24 Volts Channel 1 lt ar D i D 1 Input 1 D Q f D 2 Input 2 A Ex Q H COM Common SHD J I Y SHD EXt 2 QT H 24V 24 Volts Channel 2 lt eae l OT i 0 3 Input 3 D Q H D 4 Input 4 CL Ex 4 I2 Y COM Common m 2 Q s EXxt 1D QI 24V 24 Volts Channel 3 lt ar Q 1 f D 5 Input 5 3 D Q H D 6 Input 6 S EX QI COM Common SHD sH EX Q amp I H 24V 24 Volts Channel 4 lt st D 7 Input 7 a s a D 8 Input 8 EX COM Common Si SENSORS ee Label Die Protection Sensor Inputs Figure 156 Analog Sensor AND Die Protection Sensor Terminal layout A D version Analog Sensor Inputs Channel 1 lt Channel 2 lt Channel 3 lt Channel 4 lt iz
346. ns ele tan arden GION rnesa decider daina STi debs COSINE ainil id es 4 E A E S3 eee NIC eee S66 GND Below ROG atic tee tea ee ea dey Rees eet Reference 6 AE E E E E E S EAA PER ETTA NIG E E ET A i Black White PIa dees Aakn FS VOMtS sar re AE RA 8 Black Blue amp Black Red GND eee AC Ground 0 eeeeceeeeeeeeeee 5 Black Green HO ap aaiae S VORS ona T 9 8 Make sure the SA2000 is powered up but DON T plug the 9 pin D shell OUTPUT connector into the CNV converter yet Make Sure your SA2000 is configured for SLAVE operation It is ABSOLUTELY necessary that the SA2000 position module that is used with the Resolver converter is a RES Resolver input card with BOTH reference jumpers as shown below REMOVED In cases where the Resolver Converter and SA2000 module are shipped together as a system the SA2000 will be configured correctly when received Signature Technologies Inc 251 User Manual JOLO O 5 Reiko lems itelt lololo Reference Jumpers Figure 192 Reference jumpers on RES board Be careful when replacing SA2000 units individually to insure that they are equipped with RES Resolver input adapters and that the jumpers as shown are REMOVED Improperly configured SA2000 units will not operate properly and may cause adverse reaction in the existing resolver system Adjusting the Resolver Signal levels 1 Again looking at the position display on the existing syste
347. nt Run Baseline Control Note m P142 3669 P1453 P144 P145 P146 P149 HEE sE Selected Press i i Setup Info Control Status Figure 116 View Press Buttons Bypass Control From the Press Line Overview screen select the appropriate View Press button Once you have identified a press a box to the left of the button will indicate your selection With the press identified choose the desired signature view 1 6 All or Peak by selecting the appropriate button After the Signature View screen has been displayed make sure a signature is showing by rolling the press through a couple of times When a signature is showing Click the Zoom button from below the signature window The system will then enter Zoom mode Zoom mode is a bit different since normal signature display updates are suspended and only faulted signatures will be displayed as they happen Click the Default button The signature will immediately be adjusted so the the Vertical axis on the screen will be the largest capacity value from the Tool Database or Press Database screen for the signatures that are turned on The Horizontal axis will reflect the width of the window selected in the Tool Database Screen If you want to Adjust the display of the signature use your pointing device to Click and drag the yellow cros
348. nt Units Channel Select m Left Connection Granh Bris Status Riernate H Reis Hew ees Feature Control Status Control Monitor T T T T 167 6 180 7 193 9 207 9 220 2 Figure 68 Drawing operation on the Left Connecting rod Description This feature returns the maximum value of the signature between the start and the end of a defined window not the data collection window of the tool Note that the maximum can occur anywhere in the interval 90 Signature Technologies Inc signatureACE Parameters Selected channel data to calculate the maximum from can be real or virtual Window start in degrees or position off BDC Window end in degrees or position off BDC Use In this example the returned value is a measure of the maximum force required to draw the blank into acup The maximum is also collected from the left connection for comparison to the right connection The maximum not the peak feature is used since the draw will most likely not result in a sharp peak Error Check Refer to the If a Programmed Feature Doesn t Work section below at page 101 fora description of the overflow error that could occur using this feature Signature Technologies Inc 91 General Installation amp Programming Guide SPCview 002 Interval Minimum Conventional Feature Build Press PRS_50 Toot 2092 SPC Point Title Draw Minimum RC 002 Interval Minimum SPC Point Units T
349. ntains the playback format for the signature display how fast loop forever etc e The lt tool name gt PF file that contains the playback format for the SPCView display how fast etc f The Requested Signature files with the SR suffix These are the signatures that were saved manually by the operator g The Requested Limit files with the LR suffix These are the limit sets automatically saved with requested signatures h The Trend Signature files with the ST suffix These are the signatures automatically saved when the system is programmed to do periodic collection i The Warning Signature files with the SW suffix These are the signatures that are automatically saved in CONTROL mode when the system faults on the YELLOW limit set j The Warning Limit files with the LW suffix These are the limits automatically saved with the Warning signatures k The Faulted Signature files with the SF suffix These are the signatures that are automatically saved in CONTROL mode when the system faults on the RED limit set 1 The Fault Limit files with the LF suffix These are the limits automatically saved with the Faulted signatures Signature Technologies Inc 339 General Installation amp Programming Guide m The Press Limit Signature files with the SP suffix These are the signatures that are automatically n 340 saved in ANY mode when the system faults on the Press Curve Limits The Pr
350. ntinue Measure the voltage from pin A to pin C on the load cell at the connector Measure as accurately as possible and note the voltage Then multiply the cal factor by the measured voltage This will be the voltage into the ST system at 10 000 pounds force Divide the voltage by 0 0000024426 0 005 2047 The result will be the number of A D counts at 10 000 pounds force Then divide 10 000 by the number of counts and you will get the pounds cal factor for the system Let s say the voltage from A to C is 1 641 volts 1 641 3 0227 4 9603 mV 0 0049603 0 0000024426 2031 10 000 2031 4 9237 as a pounds cal factor Correcting the indicated Press Position If the position encoding device connected to the press is not aligned with the press T D C it will be necessary to set the Press Position in the SignatureACE system This is accomplished by performing the following steps Step 1 Go to the Signature View or Peak View Screens 360 Signature Technologies Inc signatureACE Step 2 Move the press crankshaft to a known position i e TDC or B D C Step 3 Select Calibrate From the Configure Pull Down A Button marked Set will appear next to the Angle display Step 4 Click on the Set button A Message Pop Up will appear Step 5 Enter the actual press angle and click on OK Step 6 Exit Configuration saving the data System Security The System Password utility has 2 different operations The
351. nverter for easy setup The SAMNet Communications network This is the networking method for the SA2000 system It provides the ability to link at 2 5 megabaud speeds the SA2000 units with the Host computer used in the system It is capable of transmissions over considerable distances and when used with the proper RG 62 A U 93 Ohm cabling has proved to be bullet proof in the manufacturing environment SAMnet operates with ARCNET protocol There is a communications module ARC that installs in an ISA expansion slot in the Host Computer that provides the connection for the SAMnet coaxial cable The Host Computer This unit is the Nerve center of the SA2000 SAMView product The Host Computer operating SAMView provides the following functions gt It downloads parametric data the Signature Trigger Location signature size signature resolution etc data to the SA2000 so that it knows how to take its data gt It provides all the data scaling and translation to make it understandable to the user What this means is that the SA2000 works with RAW data and is not involved in the transformation of the readings into Tons or Pounds or the trigger point into Degrees All that functionality is part of SAMView in the Line Computer gt It provides the ability to display graphically the data taken by the SA2000 The SA2000 produces only tables of raw numbers gt It provides
352. o take a look at the digital display if there is one from the existing system If it s operating O K then the existing system is probably O K including the resolver drive 2 Go to the Resolver converter and check the condition of the 6 lights on the end opposite the connectors 3 The Green light in the REF group should be ON 4 If NO light is on turn the REF potentiometer CW until it comes on 5 If the Green amp Red REF lights are ON turn the REF potentiometer CCW until the Red light goes OUT 6 The Green light in EITHER the SIN or COS group MAY be ON 7 NO Red Lights should be ON 8 If any Red lights are ON Turn the Potentiometer for that group CCW until the Red light JUST goes out 9 As the press turns the green light for the REF should stay lit The Red Light should stay OFF 10 The Green light for the SIN should come ON and Go OFF twice If the Red light comes ON turn the SIN Potentiometer CCW until it just goes OFF 11 The Green light for the COS should come ON and Go OFF twice If the Red light comes ON turn the COS Potentiometer CCW until it just goes OFF NOTE The green lights for the SIN and COS groups should light alternately If BOTH SIN and COS green lights are on together it indicates that the converter is NOT hooked up to the source system properly that something is wrong with the source system or there is problem with the Converter to SAM cable or its connectors Refer to the HiRes Resolver Conver
353. ock come into position If the stock either hits the sensor too early excessive feed length or later failure to complete feed than the window the Die protection system will stop the machine and avoid a wreck in the tooling that would be the result of the stock being in the wrong position when the die closes In general in any manufacturing process there are certain conditions that should NEVER occur certain conditions that must ALWAYS be present and certain other operations which must REGULARLY happen during the same portion of every machine cycle The Signature Technologies Die Protection System allows the monitoring and control of the machine based on these conditions In the illustration below Figure 140 several typical Die Protection areas are presented in their general locations on a Punch Press system 176 Signature Technologies Inc signatureACE The types of sensors illustrated are mostly Proximity devices but Grounding detectors or Photo optical devices are also options The Sensor part of Die protection is discussed separately later in this document NOTE In general ST does NOT recommend the use of Static sensing for applications that should ALWAYS be in one state or another like the Stock Buckle detector detailed below that should ALWAYS be OFF If the wire to the sensor is broken or damaged then the sensor will ALWAYS be OFF and indicate that all is well It is recommended that ALL Die Protection
354. oes the position comparisons with the Programmable Cam data tables and actuates the Cam outputs at the proper angular positions gt It collects and processes the Digital Die Protection input data and Sets the appropriate control outputs The Analog Digital signal Conditioning Daughter boards There are FOUR versions of the signal conditioning board The A08 provides 8 channels of Analog signal conditioning The A D provides 4 channels of Analog signal conditioning and 8 channels of digital signal conditioning for Die Protection The A6D provides 6 channels of Analog signal conditioning and 4 channels of digital signal conditioning for Die Protection The D16 provides 16 channels of digital signal conditioning for Die Protection The Signal conditioning board provides the following functions gt It provides the excitation for up to 8 individual strain gage inputs either at a 5 or a 10 volt level The channels can be individually configured for excitation voltage gt It provides the excitation for up to 16 individual digital inputs at a 24 volt level The channels can be individually software configured for input mode Sourcing or Sinking gt It provides the analog to digital converter for the incoming Strain gage data voltage range 5 volts Signature Technologies Inc 283 General Installation amp Programming Guide common mode gt It provides filtration and amplification for
355. of the machine or on the front rear edge of the frame IF POSSIBLE the best frame location is in the center of the gap on the edge of the frame facing the die space using cover boxed for mechanical protection of the strain link This tends to be the truest location for signatures It s also quite an active area with heavy pieces moving around during die set operations and may not be a practical location The next best location is at the front of the gap in the center of the gap on the side of the frame If symmetrical locations on each side of the machine can be found the units should be installed here using cover boxes for mechanical protection signatureACE a 2 8 a 5 S s x 2 r 2 T E bo S E 2 ra COMPRESSION TENSION Under Load Under Load Figure 167 Gap frame press sensor locations On a Straight Side Machine You need to find the Loaded area of the upright in order to mount the link in an area that will see strain changes as the machine works Not so Good Terrible X Tie Rod Good Not so Good Figure 168 Upright sensitive areas Typically somewhere in line with the center of the tie rods will be a good location see illustration above In general the farther from the tie rod you get the more questionable the results will be 221 Signature Technologies Inc User Manual TIE ROD AND NUT CONDUIT FOR LOAD SENSOR WIRES ONLY CAUTION DO NOT
356. oints of the rotation We DON T RECOMMEND driving the resolver with any Timing Belt drive where the sprockets are smaller than 4 in diameter This is because as the sprocket diameter gets smaller the positional uncertainty at the resolver resulting from tooth clearance gets larger Normally only one of the sprockets will require flanges for 232 Signature Technologies Inc signatureACE We APPROVE OF resolver drives that couple directly to the crankshaft through a flexible coupling The simplest coupling where there is NO or VERY little end float in the crankshaft is a 3 piece of hydraulic hose applied with worm drive hose clamps Better are the machined aluminum Helical type couplings like MICRON or HELICAL In cases of extreme end float the disk type coupling like RENBRANDT is a good bet We APPROVE OF resolver drives that use type XL 0 200 pitch or 3 5 or greater diameter type L 0 375 pitch Timing Belt drive systems from the crankshaft These are slightly less accurate than direct coupling but still very acceptable In this case watch for radial play in the crankshaft to avoid over stretching and possible damage to the drive belt and resolver bearings We APPROVE OF resolver drives from the auxiliary drive shafts on larger machines as long as the ST resolver drive is either directly coupled to the auxiliary drive gear shaft or Timing Belt driven from it before any additional coupling or gearing is done The auxiliar
357. oken ones Make sure ground straps are intact Archiving amp Restoring the Database using external media There are two methods of recording restoring signature data on floppies If you want to save a few signatures with their limits onto a floppy disk or restore a few records from a floppy back onto the hard disk you may use the methods as found in Archiving Selected Signatures on a floppy Disk below If on the other hand you want to store MAJOR SECTIONS on floppy disks in an expeditious fashion The use of the PKZIP and PKUNZIP utilities is recommended User Manual Archiving Selected Signatures onto a Floppy Disk Occasionally it may be desired to record a small number of selected signatures onto floppy disks To accomplish this execute the following steps Step 1 Perform a search in Edit Playback for the selected signatures to be backed up Select Show Limits if you want to save the limits as well Select Master Limits to see what the master sets are The last one chronologically will be the current master Step 2 Verify using playback on the Signature View screen that the signature you ve chosen is the right one Step 3 Copy down the File names of the signature and limit sets that you want to archive off Step 4 Exit the SAMView program Step 5 Change directory to SAMDATA lt Press Name gt lt Tool Name gt Step 6 Place an initialized floppy disk in the disk drive Step 7 Using the COPY command
358. omplete rotation in short moves and compare the position on the existing system with the position displayed on SAMview There should be no significant difference at any machine angle The systems should agree to about 1 degree at all positions NOTE Don t be surprised if the Existing System displayed angle is different from the Machine actual angle In many cases the existing system wasn t set up properly to begin with so you may have to adjust the ST angle differently 180 degrees should be absolute Bottom Dead Center for the Main Ram or Inner Slide this has safety implications since if somebody s stuck in the press near B D C you NEED TO KNOW whether to reverse the drive to free him without doing further damage In general where there is bending or coining performed by the tooling in the press there will be a well defined rounded Hump in the signature with its peak exactly at 180 degrees If this Hump AT LOW SPEED lt 100 S P M doesn t line up with the 180 degrees the position offset is a little off and can be corrected most easily by editing the Position Offset value in the Configure Press utility See the User s Manual for details When you have passed the above tests you should be able to Roll the press and see the force signatures It will take a couple of revolutions before anything will show up If your Cable color code doesn t match There are some other cable types still in circulation that ar
359. on Install the signatureACE Equipment 2 Install the TEC Terminal Enclosure in an appropriate location Use double stud Vibration mounts like LORD J 4624 32 or Barry Controls A22 142 to attach the enclosure if it is attached to the machine If you are using strain links already on the machine you should make sure that the existing Strain link cables would reach to the TEC location When connecting conduit to the TEC make sure to use Flex conduit so that the action of the vibration mounts is preserved Run the TWO cables with the 37 Pin D Shell connectors from the TEC back to the vicinity of the Host Computer where the SA2000 modules are to be located Connect the Strain links into the appropriate terminal strip according to the appropriate list in the Appendix 1 section below While connecting the Strain links make a note of which sensor goes to which channel so that you will be able to properly name the channels later NOTE The Normal industry connection plans are For TWO point presses Channel 1 Left Channel 2 Right For FOUR point presses Channel 1 Left Rear Channel 2 Right Rear Channel 3 Left Front Channel 4 Right Front For Double Action Presses 8 point Channel 1 Left Rear Outer Channel 2 Right Rear Outer Channel 3 Left Front Outer Channel 4 Right Front Outer Channel 5 Left Rear Inner Channel 6 Right Rear Inner Channel 7 Left Front Inne
360. on amp Programming Guide Communications Selection Switch a ry STAI za sT E i SAMnet Address RRR i Switch ai AMUNT a SAMnet EPEAN an a tor Connector Termination Jumper Figure 239 SAMnet Communication card termination jumper 7 Check also that the Test rotary switch see Figure 240 for location is in Position 0 HEARTBEAT Indicator TEST Address Buffer Full Connector Switch Indicator RESET Button TEST Button Test Switch Slaving Connector Sensor Gain Gage Excitation Jumpers Jumpers Figure 240 SA2000 Address switches 5 If you have multiple SA2000 units in a daisy chain hookup make sure that each one has a different address setting and that all the addresses are different than the Host which is normally set to 16 6 If problems in any of the above are found hit the RESET button on the SA2000 when repairs 302 Signature Technologies Inc signatureACE are made to attempt to bring it ON LINE 7 If you have a situation where there are multiple SA2000 units on a SAMnet network and there are problems check the next section for procedures in troubleshooting 8 Call S T I 972 488 9777 for assistance SAMnet Troubleshooting The SAMnet Communications network is an ARCNET system which is hooked up in Daisy Chain bus fashion This is great in that the cabling is simple just jump unit by unit from the beginning of
361. on shown below ii g i Ratatat t Figure 121 Set Limits Button amp LED The LED will go out indicating that the limits are being set When the limit calculations are complete the LED will come back on and new limits will be drawn on the screen The procedures that follow explain how to set process limits for an individual press or a press line Adjust Limit parameters SignatureACE automatically sets process limits based on user programmable values IF they are stored as MASTER Signatures they will come up automatically when their job tool is loaded The values used to calculate the process limits are located in the Limit Setup window for each press a Number of Samples EX A2 AA Left Front 2 81 Right Front Ramp up cycles A 02 02 Left Rear Sequential n 82 03 Right Rear Simultaneous Limit Constants yellow red Default Warning Limit Fault Limit Auto Recalculate A ss h Recalculate Return Figure 122 Limit Setup Window The figure above shows the limit parameter window of the SAMview system Set and adjust the limit parameters for the current press as follows 1 From any signature screen the tool screen peak screen or the press line overview screen Click Configure from the menu bar A drop down sub menu will appear NOTE On the Press OVERVIEW screen the limit setup box will display the channels for the press already selected for viewing If you want to change a different p
362. onfigure utility from the Overview screen Each Tool can have only ONE set of Master Limits If new Master Limits are stored the old Master Limits are overwritten and lost Each time new Process Limits are calculated the system user has the opportunity to save them as Master Limits for that Tool Master Signature A signature that is representative of the signature collection that was used to create the Master Limits Monitor Mode 0 06 A mode of operation wherein the signatureACE cannot affect the operation of the machine The SA2000 still analyzes the signatures as they come in but only flashes its lights when a process limit violation occurs Only the Press Curve White fault is able to affect machine operation MOUSE tesserae inane A pointing device used to select an option by rolling it on a firm flat surface such as a mouse pad May also be used to size an item selectins wakiaieane Center the pointer above the item you want Click or double click as required Sizo aeae Center the pointer on the appropriate spot on the border or adjustment window Drag Press and Hold the left mouse button while moving the mouse Release the mouse button when the desired size is achieved Nopi een Takes you back to the previous screen without saving data or changes IOK i ei rereer ree Button that is used to confirm an action close a window or exit a function ONLINE Jna etadi When
363. ons Channel Select m Right Connection Graph Reis Status 116 75 Riernate Reis tegrees E 75 04 200 0 158 34 Feature Control Status 33 34 Control Se een a aan Monitor 50 0 7 T t T T T T 115 0 128 14 141 3 154 4 167 6 180 7 193 9 207 0 220 2 Interval Start 137 BAA Interval End Figure 69 Drawing operation on the Right Connecting rod Description This feature returns the minimum value of the signature between the start and the end of a defined window not the data collection window of the tool Note that the minimum can occur anywhere in the interval Parameters Selected channel data to calculate the minimum from can be real or virtual Window start in degrees or position off BDC Window end in degrees or position off BDC Use In this example the drawing operating occurs in station one at the far left hand side of the press When this operation occurs the left connecting rod is in compression and the right connecting rod is in tension i e there is a bending moment in the slide during the blanking and drawing operations The minimum feature is used to capture the minimum force or maximum tension force in the right connecting rod By comparing the maximum on the left connecting rod and the minimum on the right connecting rod a relation can be made to any non parallel movement of the slide during the draw
364. ons mi C MOTHER P1286 Dirs Files default tl Figure 38 Select a Tool Window Click on the _default tl and hit the Select button 4 The system will now display the Tool Database for press X screen X denotes your press name This screen is shown in Figure 39 Overviewt Configure Para Sere Options daeta pa i Tool Description View another Press DEFAULT Default Tool New Tool Signature Collection Area Data Collection Rate Size 0 35 996 From To ja 92 554 73 Channel List All Channels SAM Ch Description Channel Editing 01 01 Right Connection EE a7 01 02 a 61 63 A Description Capacity Units Calibration Offset Curve File 8 Left Connection 2100 xunea gt 1 0000 0 000 100 00 Figure 39 Default tool window 5 Hit the New Tool button the resultant screen will look like Figure 40 64 Signature Technologies Inc signatureACE Overview Configure Options Tool Database for Press P1286 Gienge Tool IOUE Tool Description View another Press New Tool Data Collection Rate Size 0 35 996 From To 4 92 Ried to cre Signature Collection Area Channel List All Channels Setup Selections SAM Ch Description irtur chonne Channel JALEA OaS C mea Editing 01 01 Right Connection E Refresh Rate a0 ae z Description Capacity
365. ool Database screen is used to define the sensor channels that are connected to transducers if any that are incorporated into the removable tooling NOTE What must be known before this process can be completed is the location of the sensors in the tooling and where they are connected For example The sensor integrated into the First Form station in the Center Lane of a Three Out die is wired into the Channel 5 A5 and A5 Terminals in the TEC box input Channel 5 which is 01 04 could be labeled LN 2 First Form In the channel definition list so you will Know what it s signature comes from The TEC is the green printed circuit board with the terminal strips mounted in the small enclosure The channel numbers and connection points are listed on a label inside the cover AND printed directly on the circuit board For more detail see Appendix 1 below When you have the list of sensors and their location information you can program the channels 10 Program the Channel Data while in the Tool Database screen NOTE Any channels that have already been assigned to the machine ARE NOT programmable from the tool database screen When A Machine channel is hi lighted there will be NO Remove lt lt Edit or Enter gt gt buttons and clicking on the fields will do nothing A Click on the channel you want to program from the SAM Ch Description list shown in Figure 40 The channel will Hi light B
366. option can be chosen which is a indicate only setting The Yellow output Is a Normally Closed Output that Latches open whenever a Fault Occurs The Red output Is a Normally Closed Output that Latches open whenever a Fault Occurs The White output Is a Normally Closed Output that Latches open whenever a Fault Occurs lt no connect gt The State indicator is functional and the Fault Condition indicator operates but the indicator down by the Reset Faults box won t indicate anything for this channel The fault will automatically reset at T D C Each of the Die protection signals can be directed by software to the output best suited to its function Typically in a Normal machine interface The Yellow Output is connected to the Top Stop line The Red and the White Output are connected In Series to the Immediate Stop line Applying Sensors for Die Protection Needed equipment If you will be doing the application of sensors into the tooling at your shop certain things are necessary The first thing is that a space be set aside for the actual application work and a TEST BENCH be projded with the following equipment adapted from the recommendations first advanced by George Keremedjiev in his PMA presentations 1 Tecknow Education Services P O Box 6448 Bozeman MT 59771 USA Ph 406 587 4751 Fx 406 587 9620 email bitenbyte aol com Signature Technolo
367. or the channel The result of this math should be something VERY close to 2047 which is the highest internal number that the system can produce Normal signatures should always produce numbers lower than this Since the signatureACE doesn t have any provision for input gain adjustment outside of the 1000X 2X gain switch sometimes the output of a strain gage bridge in highly strained applications can exceed the input range of the SA2000 in HI range ST designed sensors in order to have a high robustness purposely have a small signal output so that under severe overload conditions common in the stamping industry the sensor will not be damaged Excitation Reduction One way of cutting the output of the Strain gage is to reduce the excitation voltage from 10 volt to 5 volts with the switch provided for that purpose This is a valid way of cutting the input level down to 0 5 times its 10 volt value This is good if you have a lot of signal the noise level will be significantly increased on the lower level signals 324 Signature Technologies Inc signatureACE Jumper Locations on the SA2000 Channel 1 Channel 1 Gain DN Excitation GROUND A e00000 lt a E 1 kzi AA Sii Ea Sh 2e0e T9 020 9001 SERIA MO n y SATURN TEOMELOGIES INC CRIST 1887 AS mice yo 0 0 Channel 8 Channel 8 Gain Excitation Figure 250 A08 Jumpers Jumper IN 1000X Jumper OUT 2X Channel 1 Gain Chann
368. ording to the and marks on the TEC board If It s backwards the module WILL NOT turn OFF The Module won t be harmed and can be fixed by reversing the wires 336 Signature Technologies Inc signatureACE gt Replace the affected output module and try again Check 11 What if your database disappears It probably hasn t actually disappeared at all The Press definition file or a Tool definition file may have been deleted accidentally which destroys the ability of the system to find any of the tools or signatures that used to belong to the press The Bailout can be pretty easy though Let s look first at the file structure that the SAMView program uses ROOT directory Press Tool 2 Press 7 Tool 2 SAY LEW Figure 260 Sub directory structure of the SAMView program The Tree above gives the arrangement of the sub directories that SAMview creates when it runs 1 The SAMVIEW sub directory is where the program software is resident 2 The SAMDATA sub directory is created by the SAMview program and contains ALL the data and configuration information generated by SAMview 3 The SAMDATA sub directory itself contains a The Press Data Files with the PRS suffix These files contain the information that defines the presses there will be one of these files for each press that is programmed into the system These Signature Technologies Inc 337 General Installation
369. ould be displayed on the signature graph 9 Select Database from the menu bar Overview Configure PAARE Analysis Screen Options Database Manager P1286 ST ab Last White Fault Last Red Fault Last Yellow Warning 147075 Show Master Sig count od Show Master Limits sem oJ angie 0 840 7 moe Save Signature ee Save as Master Limits a aco Save as Reference Creer vier 4207 1050 118 8 150 6 182 5 214 3 246 1 Graph view 1 _ Control Status Running oojaa eraa O Oies Hpi eras JO OL ora Figure 62 Database Sub Menu 86 Signature Technologies Inc signatureACE 10 Select Save as Master Limits Programming SPCview features the whole story Don t Panic Contrary to Popular Belief this is NOT Brain Surgery First an overview of the Process The following is an example of how features can be configured for a progressive tool with an in die sensor The features have been configured to monitor the blank and draw operations in the first station looking for tool wear and breakage Additional features have also been defined to monitor peak forces nitrogen spring performance and material variations The following signatures were collected from a five station progressive die running on a 300ton Bliss at 60 SPM The press has two sensors mounted on the connecting rods and one sensor mounted beneath the blank and draw sta
370. overs Mounting 228 Strain links on the Connection s 222 Strain links color code 224 Strain Links Data Instruments 223 Strain links Existing units 223 Strain Links Helm Instruments 224 Strain links hookup 224 Strain Links installation 28 Strain links note the physical location 28 Strain Links on a Gap frame Machine 220 Strain Links On a Straight side Machines 220 Strain links Shield Braid 223 Strain Links Toledo and ST 224 Strain links on the Uprights 219 Strain seansors 139 Sub directory structure of the SAMView program 341 Switches SA2000 143 Switches SAMnet address 34 Switches SAMnet card 34 System Administration 164 System Grounding Caution 247 System Navigation Block Diagram 49 System Operation Loading a different Tool or JOB 86 System operation modification files 55 System Security 367 System security during normal operation 148 System Setup archive the present database 51 System Setup Before you start 50 System setup Machine Calibration Dynamic 83 Signature Technologies Inc 381 General Installation amp Programming Guide System Setup Needed Files 55 System Setup Peak Screen Setup 79 System setup Pen Color 78 System Setup Programming JOBS 84 System Setup Putting the press and the tool together 69 System Setup Save current view 79 System Setup Save current view as default 79 System setup
371. ovide positional information generally of a rotary type to the SAM500 statistical Analysis module The data from the machine process is gathered based on the positional signals that the resolver produces If the resolver data is an accurate representation of actual machine motion the signature data produced thereby will accurately reflect the process status If there are differences in the position data caused by rotary vibration lost motion or drive inaccuracies the Signature data will be flawed and sensitivity to process changes will be lost The primary thing we are always after is a torsionally rigid connection between the press CRANKSHAFT and the resolver Preferably the resolver will be driven directly by the crankshaft through a flexible coupling to absorb radial and axial movement of the crankshaft While the resolvers that are used with programmable limit switches and stroke position auxiliaries are often hooked in behind the Cam Limit Switch our resolver must not be mounted this way A programmable switch normally runs at a 1 2 degree accuracy and generally not more than 0 36 degrees of basic resolution This type of accuracy is fine for programmable switches but is well outside the requirement for Signature Analysis activities The SAM500 module operates normally at 0 088 degrees resolution and any inaccuracy in the resolver drive will immediately show up as horizontal migration in the signature The process limits must be widened to
372. own and initiate static data collection Step 5 Watch the screen and see what the digital displays do They should all display numbers which should be relatively steady with only the Least Significant Digit dancing a little NOTE If one or more of the Numerical displays goes to or 2047 Your sensors are too far out of static balance to permit calibration by this method Contact Signature Technologies Inc at 972 488 9777 for alternatives NOTE If one or more of the numerical displays is Going Wild displaying a large range of numbers this is a sign of problems in that channel related to the sensor itself or problems in the wiring Correct the situation before proceeding with calibration Step 6 Note down the unloaded values for each of the channels in the maintenance record Include in the record the counterbalance pressure and the upper die weight in the entry Step 7 See if there has been a significant change in the Zero offset readings since last readings If so there may be a problem with the sensor in question Step 8 Apply the 324K resistor calibration shunt across the Excitation to Signal terminals on one of the sensor channels This will produce a change in the displayed numbers for the channel you applied the resistor to Make a note of the new number Repeat for all the active channels Step 9 Subtract the numbers you recorded in step 6 above from the corresponding new numbers recorded in step 8 These are the di
373. own in Figure 97 below note that there are four constants for the Xbar limits There is a multiplication constant for the Control limits y and one for the Quality limits z and there is an offset and widening constant for both sets of limits The multiplication constants define the confidence level or probability that the system is running in statistical control For example if y in equation 2 is set to 3 read as 3 sigma there is a probability of 0 9973 that Xbar will fall within the control limits provided that Upj X and ap closely approximate the true mean and standard deviation of the Feature In other words on the average only 27 observations out of 10 000 should fall outside of the control limits The other two parameters are provided for handling special situations The limit widening constant provides a minimum envelope for the control and quality limits This constant can be used when the process standard deviation is very small The Limit Offset is provided to account for changes in the Feature mean By changing Signature Technologies Inc 115 General Installation amp Programming Guide the Offset constant the user can modify the limits without collecting a new process sample set e g the offset constant can be used to account for small material variation between blank lifts Xbar Control Limits Where ub X OffsetK y ShI X n XbarWideK Xbar Quality Limits Where Hpi X OffsetK Zz o
374. p X n XbarWideK R Control Limit Where Bn Sp X XbarWideK up X OffsetK y op X n 0 5 XbarWideK 1 Baseline average of the feature Offset constant for the control and quality limits for the feature Control Limit scale factor Baseline standard deviation of the feature Number of hits in the subgroup Widening constant for the control and quality limits for the feature p X OffsetK z opj X n 0 5 XbarWideK 2 Baseline average of the feature Offset constant for the control and quality limits for the feature Quality Limit scale factor Baseline standard deviation of the feature Number of hits in the subgroup Widening constant for the control and quality limits for the feature Bn opj X RWideK 3 R control limit scale factor Baseline standard deviation of the feature Widening constant for the control and quality limits for the feature Figure 97 Xbar amp R Limit Calculation Formulas Any out of range condition in the R chart will be indicative of change in process capability This condition may not be correctable by shifting the process mean by simply resetting the die and may possibly require process or machine maintenance Size of Subgroup OONDOBRWND Upper Limits B 999 2 33 2 15 2 02 1 92 1 85 1 79 1 74 1 70 1 67 To modify the Limit parameters for the Xbar limits The SPCview Limit Parameters wi
375. point is NOT possible due to cutouts or T slot locations the cells should be positioned as close to the pressure points as possible and kept Symmetrical If you have to be 4 outside a pressure point in one corner the other three cells should also be 4 outside If the cells are not symmetrically located the calibration will be inaccurate 356 Signature Technologies Inc signatureACE Step 8 Step 9 Step 10 Step 11 Step 12 Step 13 Step 14 Step 15 Step 16 Step 17 Use Spreader plates under the cells and between the cells and the Slide face to avoid marking the press surfaces The spreader plates should be of sufficient size and thickness to limit the surface loading to 10 000 PSI Watch out for T slots They crush easily Use a piece of heavy cardboard not corrugated between the cell and the surface it is sitting on Use another piece between the Cell and the Slide surface This is to equalize the force across the face of the load cell and prevent marking Reduce the press speed to minimum and roll the press to B D C Adjust the shutheight down until you are almost in contact with the load cells Roll the press back to T D C and drop the shutheight 0 01 Roll the press a complete revolution If there s no force indication on the cells Drop the shutheight another 0 01 and try again Continue until force starts to build up on the cell s Continue dropping the adjustment until you reach the capa
376. point of operation and will exhibit heavy filtering due to the damping or ringing effects of the frame structure The same effects also compromise the accuracy of peaks in the signature This means that while the signature can exhibit reasonable sensitivity to changes on the process the displayed signature will in all likelinood not be capable of analysis since it will not change in any intuitive fashion Signature Technologies DOES NOT recommend Press frame mounting of sensors on any machine that operate in excess of 150 S P M or in operations where blanking or other highly dynamic operations are performed on the workpiece Signature Technologies ABSOLUTELY DOES NOT recommend mounting sensors on ANY PART of a machine that exceeds 400 S P M If it is desired to do general machine sensing instrumented Kiss Blocks should be used since they will exhibit some sensitivity to what goes on in the die at higher speeds as long as they contact each stroke The press frame strains bear little or NO relationship to what s going on in the process due to their own resonance characteristics If you are installing Strain links on the uprights of a press you need to find the Loaded area of the upright in order to mount the link in an area that will see strain changes as the machine works ON a Gap frame Machine The choice is either to position on the front of the gap close to the die space OR at the back of the gap either on the side wall
377. programming screens so that parametric data can be entered gt It provides the database function so that setups presses Tools and Master Signature Limit sets can be entered stored and re called gt lt stores Signature Data tables from the SA2000 into memory and links the stored signatures to their corresponding stored Process limit tables gt It provides the ability to sort recall and view any and all stored Data for reference or comparison gt It provides the ability to upload manually edit and download Process limit arrays from to the SA2000 Signature Technologies Inc 285 General Installation amp Programming Guide The ARC SAMNet Network Module The network module is installed in the Host Computer in one of the ISA expansion slots It provides the SAMnet communications between the Host Computer and the SA2000 unit The network operates according to the ARCNET standard and uses RG 62 A U 93 Ohm coaxial cable to tie the system elements together in a daisy chain connection 286 Signature Technologies Inc signatureACE System Software The system software is composed of two elements Software that resides in the Host Computer and Firmware that resides in the SA2000 You can find out What the version of the software is by looking at the Copyright screen which is the first screen displayed when SAMview starts The Firmware version can be found by going to th
378. properly and functional GO TO Check 2 on page 307 2 If it isn t Yellow or if it goes OFF and stays OFF when you Click on Monitor you are OFF LINE THERE ARE TWO MAJOR POSSIBILITIES a The SAM is talking properly BUT has the wrong address setting b The SAM is not communicating Click on CONFIGURE on the menu bar then select SAMNet The system will display everybody that s on line There should be AT LEAST two stations lit ONE will be called This Node and is the SAMNet module plugged into the computer The other one will be the SAM See if the SAM you are checking out shows up on the Network Display with the address selected in Press Information Let s say the Press Information has a SAM programmed at address 2 The This Node light is on at 16 and the 8 light with no label under it is on in the Samnet screen This would mean that the Network card is operating at Address 16 and the SAM is probably set to 8 refer to the illustration below at Figure 237 for the address switch location Check the setting of the address switch It should be the same as the address in Press Information If it isn t change the switch to what is in Press Information and cycle the power to the computer that the SAM is plugged into Or the power to the SAM if it s not plugged into the computer Then go back to step 1 above Signature Technologies Inc 299 General Inst
379. puter b address 0 is ILLEGAL c Multiple SA2000 modules Must Not have the same address on a network Check to make sure that the SA2000 addresses on a multi SA2000 installation are all different d If you change an address setting at a SA2000 module that is powered up you must RESET the SA2000 to allow the new switch setting to be recognized Press the push button closest to the mounting bracket on the SA2000 to reset When this is done the new address will be communicated to the system 5 Optional Use your pointing device to click the first left character position in the Description box Enter up to an 18 character description for the new SA2000 6 Don t change the data in the Position Device Position Offset or Pulses fields 7 When the data above has all been entered Click lt lt Enter under the SAM label Three things should happen A The green light to the left of the ID box should come on Signature Technologies Inc 125 General Installation amp Programming Guide B The large box on the left side of the screen under the SAM Description label should show the data you just entered C The large Box under SAM Ch Description at the bottom of the screen will display the additional channels that are available for programming The first digit will be the address entered under ID followed by the channel number For Example i
380. puter information Signatures stored to the hard disk The designation by which the computers that are connected into a SAMnet system network are known The Host Computer provides the system database and a display on which the signature data can be viewed Input Output Through the I O section the computer receives and sends information to and from the machinery The I O connection point for the signatureACE System is the TEC unit A control condition that causes the immediate release of the machine clutch causing the machine to stop irrespective of its position in the cycle Sometimes erroneously referred to as Emergency Stop Limit setup is a means of programming the system for the creation of process limits using a predetermined number of machine cycles This data is used to calculate Signature Technologies Inc 371 User Manual the process mean and standard deviation for each of the defined features as well as to set signature limits The user programs the parameters used to calculate the limits and sets the mode of limit setting and the number of machine cycles to use Load Cell A calibrated measuring device used to create a correlation between a force exerted on a strain gauge and the actual voltage output caused by the force Master Limits The Master Limits are those limits which are installed into the SAM module by the SAMview system whenever a Tool is installed into a Press with the C
381. quareRoot 8 300 000 N Where N the larger of the subgroup size found in the SPCview setup screen or the number of samples taken for the limits found in the Limit set Pop Up for the Signature Screen Feature X A defined feature such as Peak Force on a press corner Maximum Feature X the largest expected value for the defined feature Minimum Feature X the smallest expected value for the defined feature As an example if a Peak Feature was defined for a press frame upright sub group collection of 5 and limit setting sample of 25 the following relation would need to be satisfied The Difference between the Highest Peak value and the Lowest peak must be less than the Square root of 8 300 000 25 OR in the example above 575 Where N 25 from the Limit Setting Sample Size Zero Deviation If the limits are set and the system sees NO deviation in the samples then it will fault and fail to present a graph for that feature This normally occurs if a very small feature is being read such as RATIO that can return VERY small numbers if the operation is stable A way to check if this is the case is to pull down the Configure menu and select Limit Parameters If all the limit values in the table on the right side of the screen are 0 then there was zero variation Failure to fulfill the feature requirements If the signature does not fulfill the requirements of the chosen feature Like maybe the sign
382. quipment can be installed on a single machine or a whole machine line It can detect a variety of problems such as variations in metal thickness tonnage part quality etc SignatureAce i Figure 3 Basic signatureACE System Signature Technologies Inc 22 signatureACE pe M y 19 75 ain Required Clearance to open cover 319 99 l 12 60 i A g S g TH 5 2 8 Ge as 5 HW ae Ver gt i er bees ola EI 100 0 3 5 4 0 yz at 8 100 0 1 Sle S 4 0 H 4 0 E SZ S iG 2 oe t Primary Mount ola Optional Mount Holes for 5 16 mount bolts 299 99 S Feet for 5 16 mount bolts m 10 24 Recommended wiring clearance Figure 4 TEC enclosure dimensions 498 99 Recommended wiring clearance 19 65 100 0 340 77 4 0 13 42 siz 299 99 Sls EN 11 81 94 00 3 70 HED S 2 ED ee Figure 5 TEC enclosure side view Signature Technologies Inc 23 General Installation amp Programming Guide 24 a fl A t iia c f a c g c C 7 k C EEATT Pih A EI ilak aikeik Figure 6 TEB Interface board 11 50 mmi mpi p 1s Finish Dia 0 200 Clearance zone 0 31 Rad Provide 0 25 claarance betwean board and mounting surface Use a sheet of insulating material between back of board and conduc
383. r Channel 8 Right Front Inner 28 Signature Technologies Inc signatureACE 6 Fabricate the necessary brackets and drive hardware and install the Resolver on the press Refer to Appendix 7 Resolver Mounting and Driving Requirements for suggestions Call ST with questions 7 Install the position sensor cable NOTE Perform this step ONLY if you have a Signature Technologies HiRes resolver as a position sensor If you are using a HiRes resolver converter with the signatureACE system go to the resolver Converter Installation section at Appendix 8 below then return to this list at step 8 below Install the cable SC 002 8013 XX from the resolver into the TEC enclosure No additional shielding is necessary beyond what the cable itself provides follow your normal installation practices Connect the cable to the TEC terminals according to the Wiring connection diagrams found in Appendix 1 below NOTE If you have the EXCLUSIVE use of a non ST resolver already on the press you can find out its internal connections as follows 1 Using a digital Ohmmeter like a FLUKE test the resistance of the resolver connections You should find Three Pairs of connections that will give resistance readings The pairs should not be connected to one another or to the case of the resolver If they are you probably have a defective unit on hand Two of the pairs will measure EXACTLY the same resistance an
384. r it To Load an existing tool set JOB into a press line A normal part of the operation of the system is the loading of existing tools The steps that follow describe how to load an EXISTING SET of Tools into ALL the displayed presses 1 Move to the Overview screen by selecting Overview from the menu bar located at the top of the screen Fig 116 2 Once you are in the Overview screen Click Configure from the menu bar located at the top of the screen 3 Click Job from the drop down list Figure 120 The drop down list will disappear The Press Line Overview screen will remain 4 A Select button will appear beside the Current Job box at the upper left corner of the screen Choose the Select button The Select a Job window will appear 5 A list of the available JOBS will be displayed along the left edge of the Select a Tool window Select the tool you want to load from this list Then Click the Select button to save your choice of tooling The tool set you identified should appear in all the tool boxes within a few moments NOTE SAMview will automatically set limits on any press that gets loaded with a tool having NO Master limits stored for it Set SAMview limits 148 Signature Technologies Inc signatureACE The signatureACE system will automatically set limits using current settings Limits may be set from the signature screens by pressing the Set Limits butt
385. r pen selections are changed 16 Select the lt Enter gt key to accept or the NO button to decline NOTE If you answer NO to the Current View question the configuration will terminate leaving the screen as you adjusted it ONLY until you go to another screen set and return When you leave this screen set to go to Peak View or Overview for example the view will revert to the last saved Current View 17 If you answered YES to the Current View question The message Save as default for this press will appear in a pop up message box NOTE Default view is the view appearance that the system will automatically apply to all new tools that are programmed into the system based on the Default tool 18 Select the lt Enter gt key to accept or the NO button to decline Peak Screen Setup Select the Peak button from under the Signature Views label The system will display the Peak View screen Figure 55 The system will AUTOMATICALLY assign the first 8 channels to this screen in normal Load monitor rotation 78 Signature Technologies Inc signatureACE 7654 _DEFAULT Angle SPM 0 peas D Tr Forte Left Right Angle tet Rent Stroke Count p raph View Peak Control Status Running 2 z Peak Reset Fault Bypass k 5 5 All Set Limits Control Figure 55 Peak Screen Default Configuration es Ee NOTE If the Peak scr
386. r then Remove the cable from the resolver connector and measure on the Resolver according to steps below see note after C above Resolver Pin A to Pin B should measure about 125 Ohms Resolver Pin C to Pin D should measure about 125 Ohms Resolver Pin E to Pin F should measure about 17 Ohms If some of the measurements were wrong The Resolver is suspect Replace it with another Resolver Go back to Step 1 and Check system operation 310 Signature Technologies Inc signatureACE 6 If you Measure the correct values at the resolver The resolver is Probably O K Go To Step 7 7 Re connect the TEC to resolver cable to the resolver Disconnect the TEC end of the SA2000 to TEC cable 8 On the connector on the TEC board check with an Ohmmeter see note after C above a Pin 3 to Pin 22 should measure about 175 Ohms RSCB pins 8 21 b Pin 4 to Pin 23 should measure about 175 Ohms RSCB pins 9 22 c Pin 2 to Pin 21 should measure about 60 Ohms RSCB pins 10 23 9 If you Measure the correct values The TEC to SA2000 cable is suspect Install another cable temporarily Check system operation by executing step 1 10 If some of the measurements in Step 8 were wrong Either the TEC or the TEC to Resolver cable is defective Go to step 11 11 Disconnect the TEC to Resolver cable from the TEC board terminal block Make a note of the wire colors so that you can get back easily Make sure the TEC
387. raphic and text information CUISOf nien iiei A blinking line on the screen indicating where text will be entered CUVE ate nE Several analog readings indicating force and plotted over either position degrees of rotation or time Also known as a signature DIA aw aA ARa Digital to Analog Pertaining to conversion of a digital signal from the computer ones and zeros to something usable by the outside world a voltage Database This is a Menu Bar selection in the Signature View screen that allows the operator to save signatures save masters or display selected faults DBI iaaa a a A 37 pin D shell connector There are two DB37 connectors on each SA2000 cardset The LEFT female connector is used to collect the analog input signals and the position information from the TEC The RIGHT male connector is used to receive the digital inputs indicating the status of the press operation and send out the digital outputs indicating faults and limit setting information lt Delete gt iini Key deletes text at the current cursor position Digtal crnini A value which can be described as a discreet value Digital Signal Processor DSP A very fast microprocessor capable of collecting data and doing computations on that data at a very high rate of speed Double Click 0ce Refers to the operator rapidly pressing the left mouse button twice in succession Download 00eeeee The act of shipping in
388. rds it happens Signature Technologies has provided a backdoor into the system which will let you in if you just plain can t find your password list and everybody else has forgotten Have the proper authorities at your location call us in case you need to know Floppy Disk Initialization The SignatureACE system uses standard HD high density 3 1 4 disks formatted to a 1 2 Megabyte capacity in its floppy drive Format blank disks by exiting the SAMView program and using the FORMAT A or B command in DOS on the Host Computer Floppy disks formatted on any computer to the 1 2 Meg IBM standard will work The Input Output system The Input Output capability is modular There are 8 Inputs and 16 Outputs available All of the outputs and 4 of the inputs are already pre configured for the SignatureACE application The voltage ratings of the I O is selectable by point This is done by plugging in selected modules The SignatureACE is normally supplied with 110 V A C Inputs and Outputs The I O points for the STANDARD System are Input position 2 RUN This Is a REQUIRED input which is used to inform the SA2000 that the machine is running It is normally connected to the Clutch signal in a punch press When power is applied to this input the SA2000 will know that the machine is in operation and perform the required initialization processes for proper signature display Input position 1 3 4 5
389. re 74 Signature View screens Six Views 74 SignatureAce Hardware 20 SignatureAce Operation 139 SignatureAce System Overview 19 Signatures are unstable horizontally 335 Single Ended Hookup 248 Slave position interface module Type SLV 134 SLAVE SA2000 definition 133 Slide Motion CX file 216 Slide Motion Curve files 215 SmartPac by Data Instruments hookup 248 Software package 144 SPC Features Interval average 99 SPC Features Interval Maximum 92 SPC Features Interval Minimum 94 SPC Features Interval Peak 95 SPC Features Interval valley 98 SPC Features Interval Work 102 SPC Features Peak location 101 SPC Features Ratio 104 SPC Features Spread Calculation 107 SPC Features Threshold Detector 106 SPC limit parameters Viewing 120 SPC Zero Deviation Failure 109 SPCView an overview of the Process 89 SPCview fault status 128 SPCview features Programming 89 SPCview limit parameters Programming 120 SPCView Programming 88 Spread Calculation 107 Standard Sensor Connections 260 Start Samview automatically 39 Starting SAMview 146 Starting the computer in DOS 39 Static Calibration Procedure 360 Strain Gage output adjustment 264 327 strain gage sensor Calibration 277 Strain Link Drilling layout 226 Strain Link Hookup 263 Strain Link Mounting Direct bolting 228 Strain Link mounting Weld Pads 227 Strain Link Protective c
390. re If you wish to get a hard copy of the fault signature select the box beside the desired item Print Signature or Print Fault The default is to print the signature 3 Once the selections have been made press the Print Report button for the printout to begin Note that it is normal operation for the screen to go monochrome black amp white while it re draws the signature Also the screen will go blank for a moment while it dumps signature to the printer This time varies depending on the speed of the computer and the internal memory buffer of the printer If the Print option is selected from the Signature View all screen and Screen Dump is not selected each of the six graph displays will be printed Note that only the graphs with active pens will be printed sae Printing a Selected Group of Signatures At times it is useful to create a batch printout of several selected signatures as you would play them out to the screen These signatures may be printed via the Playback screen 1 From the Analysis menu select the Edit Playback menu item to invoke the Signature Playback Setup pop up From this screen select the desired signatures to play back by adding them to the Playback List 2 When the selection is complete press the Playback to Printer box to bring up the Print Utility pop up described above Configure this as desired and select Print Report to return 3 From the Si
391. re NO features you re starting with an empty system Note Before ANYTHING can be configured a Feature Algorithm must be selected 12 Click Select Algorithm The Algorithm Assignment pop up will appear Clear Algorithm a03 Interval Peak AAL Interval Maximum san Interval Minimum HL 984 Interval Valley O45 Interval Average Cancel Return 108 Signature Technologies Inc signatureACE Figure 90 Algorithm Assignment Window 13 Use the pointing device to select an algorithm from the Conventional Algorithm list Hit lt Enter gt to MAKE SURE the name of the algorithm shows in the window at the upper right side of the pop up 14 Click Return to save the selected algorithm and return to the build utility The system will return to the Feature Build screen 15 Assign a Title to the Feature Click SPC Point Title at the top right corner of the utility and use the keyboard to enter an ID for the feature Querview Configure Database Analysis Screen Options Conventional Feature Build Press P1286 Toot M3705 SPC Point Title Left Conn Peak 003 Interval Peak SPC Point Units 500 Channel Select fal Cet conection Graph fis Status Histance Off Better fegrees Feature Control Status Control Monitor 21 Expected Value BATE T T T 173 8 193 0 242 3 231 5 250 8 388 54 125 7 T T T 36
392. reACE system 1 The SA2000 module set which Plugs into 2 ISA Slots in the Host Computer motherboard Fig 93 The SA2000 draws its power from the Host Computer and communicates to it via SAMnet 2 The SAMnet communications module is a half length ISA card that requires 1 slot in the Host Computer motherboard The SAMnet card communicates to and draws its power from the Host Computer It is connected via the SAMnet coax to the SA2000 module set 3 The TEC Terminal Enclosure which is a separate enclosure containing terminals to which the Field connections are made The TEC is connected to the SA2000 by two cable sets that can be up to 100 in length although the standard length is 10 4 The SENSORS used to generate measurement information for the System to use for display and control Additionally there is the BOX option which can either be a remote mounting scheme for the SA2000 modules OR a complete computer with as many as two SA2000 units for 16 Analog Channels or 32 Digital die protection inputs PLUS computer in one industrial enclosure Fig 8 k EEV ARN N G The Signature Technologies system TEC terminal enclosure normally will have voltages present that originate in OTHER SYSTEMS Consequently interrupting power to the Host Computer where the signatureACE SA2000 modules are installed only will NOT be sufficient to avoid electrical shock Qualified personnel MUST perform al
393. reen displays all six views simultaneously Figure 50 Signature Technologies Inc 73 General Installation amp Programming Guide Overview Configure Database Analysis Screen Options Signature View all T T T T T 0 90 180 270 360 180 270 360 5000 4000 3000 2000 1000 10004 1 1 1 10004 1 o T T T T 30 180 270 360 30 180 270 360 0 20 180 270 360 Control Status Running rn O O aes rime JO O eer Figure 50 Signature View All Screen Peak View Load Monitor The Peak View screen looks and acts like a conventional Tonnage Monitor Up to eleven windows display the highest value that each signature attained during the press stroke Figure 51 Overview Configure Database Analysis Screen Options Peak View M5205 Ful angie a sem fo Force Left Connection Right Connection Angle pd R L Kiss block FAR Kiss block Control Status Running aran O O ams Dime JO O tara Figure 51 Peak Screen G raph View Peak LIE o c aN 74 Signature Technologies Inc signatureACE To Begin the screen setup Note The system will AUTOMATICALLY assign the 1st 8 channels to View 1 AND turn ON the pens the 2nd 8 channels will go into view 2 the 3rd 8 into View 3 etc It will also AUTOMATICALLY assign the 1st 8 channels to the Peak screen in normal Peak Monitor rot
394. res are running within the PRESS CURVE limits In either MONITOR or CONTROL Mode this output will turn OFF whenever the signature runs outside the PRESS CURVE limits and remain OFF until the system is RESET This output is normally wired in series with the IMMEDIATE STOP line unless doing so would run the risk of Sticking the press on BDC Output position 4 No LABEL This Is an OPTIONAL Output with no standard programmed function Several Standard Options use this output gt The PartTrack option uses this output as an Eject output gt It may be used to give the Bypass Control status of the machine gt It can be invoked and assigned to a specific limit set through the use of INI files Light Stack Output position 5 RED This Is a Standard Output It is a normally open device Whenever the SA2000 is in CONTROL Mode and the signatures break the RED Fault process limits this output will turn ON and remain ON until the fault is reset This output is normally wired in to the RED indicator on the ST light Stack Light Stack Output position 6 BLU This Is a Standard Output It is a normally open device Whenever the SA2000 is in CONTROL Mode and the signatures break the WHITE Capacity Curve process limits this output will turn ON and remain ON until the fault is reset This output is normally wired in to the BLUE indicator on the ST light Stack 366 Signature Technologies
395. ress operation after a RED Signature Limit violation Reset SPC Flt Red cceeeeeseeeeeees Requires a password to reset the system and permit press operation after a RED SPC Limit violation Should be fairly high priority Reset SPC Flt Wht 0 eeeeeeceeeeeeees Requires a password to reset the system and permit press operation after a WHITE SPC Limit violation Should be fairly high priority Reset SPC Flt Yel ceceeeeeceeeeeeees Requires a password to reset the system and permit press operation after a SPC Signature Limit violation Reset Stroke Count cceeeseseeeeeeees Requires a password to Reset the Stroke counter to ZERO Save Master Signature ccceee Requires a password to perform a save of a Master Signature Should be fairly high priority since it establishes the Benchmark signature and limits for the job in that press Save Signature ccccccccceceeeeeeeeeseseees Requires a password to perform a manual save of a signature When attempting to enter a SAMView selection which has been assigned a password level greater than 0 you will be prompted to enter a password Entry to the selection will be granted to any password with level equal to or greater than the assigned level of the selection For example let s say you have defined your system Passwords as follows Password Distribution JONN Rae anna eee Fork lift operator
396. ress you will need to drop out of Configure and select the press you want to adjust then re enter 2 Click Limit Parameters from the sub menu The Limit Setup window will appear Signature Technologies Inc 149 General Installation amp Programming Guide Overview Shige Database Analysis Screen Options P142 l Tool Signature View Limit Parameter gt Screen Security SAMnet Figure 123 Configure Sub Menu 3 Select a channel from the channel list that appears directly below the List of heading in the Limit Setup window The limit parameters for each channel are independent of each other that is each channel has its own set of six parameters 4 Use the procedures that follow to adjust limit parameters This can be done by the system automatically or the user can adjust them manually or by percentage A To manually adjust limits a Select the channel you wish to edit by clicking on the channel name in the list at the top of the window b Click the FIRST character position in the data entry field for the desired parameter c Use the keypad to enter a new value for the entry repeating steps b and c for each of the remaining scale factors MAKE SURE you hit the lt Enter gt key after each value is added d When you re done click on the Return button at the lower right corner B To adjust limits by percentage change a Make sure th
397. ress Curve Data files With the LP suffix These files give the crank angle vs available tonnage curves of the machines This is needed in the Press directory so that the SPC alternate X data can be called in for TOOL Sensor Channels i The Alternate X files with the CX suffix These files give the ram position vs crank angle data for the machines they are used to create horizontal axes in Inches instead of degrees This is needed in the Press directory so that the SPC alternate X data can be called in for TOOL Sensor Channels The next level of Sub directories is called The TOOL directory This is where the Signature and Limit data lives There will be one of these Sub directories for each defined Tool These sub directories have the SAME names as the Tool files the files in the Press sub directory with the TL suffix Most of the file names like 2FC81156 ST are actually time and date stamps followed by a suffix which tells what the files contain according to the list below This sub directory level contains a The PLAYBACK DIR file which is the list of signatures that shows up in the Right hand window in the Edit Playback Pop Up b The PLAYBACK DAT file which is the list of signatures that appears in the playlist window on the Left side of the Edit Playback Pop Up c The PLAY_SPC DAT file which is the SPCView equivalent of the PLAYBACK DAT file above d The lt tool name gt PB file that co
398. ress named RALPH Ralph had a tool named 12345 that has disappeared Type CD samdata ralph lt cr gt The system will change to the SAMDATA RALPH sub directory Do a directory You should find a file named 12345 BAK Type REN 12345 bak 12345 tl lt cr gt The system will change the name of 12345 BAK to 12345 TL Signature Technologies Inc signatureACE 9 Restart the SAMView program and you ll find that the tool is back although it will be the tool as it was before the last edit Check 12 The Data Rate Refresh Setup Pop Up This is a screen that Nobody should ever see It is configured at the factory and normally never needs to be changed as long as the world stands Sometimes there are inquisitive folk at plants and things that should never change do anyway If things just don t seem to be running right or certain features don t seem to work like maybe your Stroke count quits working even though you are still seeing new signatures as the machine runs This is one place to look NOTE You must be logged on to security level 5 to gain access to this screen Fal ID Tool Description View another Press j Data Refresh Rate Setup Default K O hanne ug ug ug ug ug ug ug ui Figure 261 Data Refresh Rate screen Default condition The settings if wrong can be corrected individually or reset to the default values by hitting the Default Button at the upper Left corner of th
399. ress speeds rise If the machine runs in excess of 500 S P M the likelinood of even seeing changes due to process variations becomes more remote This is primarily due to the fact that the inertia of the slide itself does a greater percentage of the work and the uprights may not actually experience any forces directly related to the process ST does NOT recommend ANY Press frame sensor installation on high speed machines Connection signatures can exhibit good sensitivity to changes on the process and in some instances the cause of the change can be derived for the signature changes TORQUE WASHER LOAD SENSOR TWO SENSORS REQURED LOCATED SYMMETRICALLY ON BOTH SIDE OF CONNECTION STRAIN RELEIF CLAMP FOR HOSE 1 4 D HYDRAULIC TUBING STRAIN RELIEF CONNECTOR WTH LOCK NUT TUBE TERMINATION BOX BY CUSTOMER CONNECTION TORQUE EACH 1 4 28X 3 4 n SENSOR BOLT TO 150 LB IN r OR 12 5 LB FT NOTE PROVIDE A LOOP THAT HAS CLEARANCE WITH ALL PRESS ELEMENTS THROUGH THE STROKE AND AT THE SLIDE ADJUST EXTREMES CONDUIT TO NEXT TUBE TERM BOX AND THEN RUT OF THE MOVING SLIDE RAMASLIDE Nn Alt A PRESSURE POINT VIEW TO SHOW BOTH SENSORS Figure 171 Connection mounting of Strain Links Signature Technologies Inc 223 User Manual Considerations about connecting EXISTNG Strain links If you will be using existing strain links on your machine and aren t totally sure of their
400. riority Password required to reset the system and to permit press operation after a WHITE Signature limit violation Should be a high priority Password required to reset the system and to permit Press operation after a YELLOW Signature limit violation Password required to reset the system and to permit press operation after a RED SPC limit violation Should be a high priority Password required to reset the system and to permit press operation after a SPC limit Fault that is mapped to the WHITE output Should be a high priority Password required to reset the system and to permit press operation after a YELLOW SPC limit violation Password required to reset the stroke counter to ZERO Password required to perform a save of a Master Signature Should be fairly high priority since it establishes the Benchmark signature and limits for the job in that press Password required to perform a manual save of a signature Applying a security level to a region 1 To access the Security pop up window select Configure from the menu bar A sub menu will appear 158 Signature Technologies Inc signatureACE 2 Select Security from the sub menu The Security Setup window will appear 3 Highlight the desired region from the Region list by clicking it with your pointing device 4 With the desired region highlighted use the pointing device to select the new security level 0 5 by moving the Secur
401. ription Ful M3785 Right Supp Brkt Signature Collection Area Data Collection Rate Size 0 35 From To It 118 83 246 09 180 360 Channel List Setup Selections All Channels SAM Ch Description Virtual Channel Tool Setup Inf Channel 1 00 Left Connection Editin 01 01 Right Connection sual 01 02 Z R L Kiss block 01 03 F R Kiss block Description Capacity Units Calibration Curve File Z B L Kiss block 1000 Pounds p 0342 lt none gt 100 08 Cam View Figure 59 Tool Database 5 Select the New Tool button in the upper right corner of the screen All the information except the Press channel data will disappear NOTE If you want to make a tool that is essentially identical to the tool that is installed in the press already skip step 5 and go right to Step 6 6 Select the first left character position in the Tool ID box located in the upper left hand portion of the screen A Cursor will appear on the left side of the box 7 Create a Tool ID name The Tool ID name is the key entry that identifies the tool Once the name has been entered it cannot be altered This name can be 1 to 8 characters long since it will be used as a DOS compatible file name If you accidentally use unacceptable characters the system will substitute the _ character in place of the character you specified
402. rn to the previous screen without saving your changes to the playback list View the signatures you put into in the playback list FROM THE BEGINNING of the list A Select Analysis from the menu bar B Select Start Playback C While playback is active the comment time date and stroke count will be displayed on the screen In addition the file name associated with the signature currently being played back will be displayed To Hold the playback You CAN T HOLD an SPC Playback once started it will run to the end A Press lt S gt Control S on the keyboard 10 To Re start the playback A To Resume from where you stopped press lt Q gt on the Keyboard B To Restart from the beginning of the playlist press lt R gt on the keyboard 11 Exit the playback utility Exiting isn t completely necessary but cleans up the signature screen display when performed Signature Technologies Inc 155 General Installation amp Programming Guide A Select Analysis from the menu bar A sub menu will appear B Select Exit Analysis from the sub menu signatureACE System Administration SAMview security set up The Security screen is provided to set up passwords for individuals set up security levels for specific utilities of the system i e setting limits and to review the history of events which have taken place on the system Overview Configure Database Analys
403. rom the Computer Motherboard These switches control the network address of the SA2000 Module The switches have numbers 0 9 and letters A F The letters A F are hexadecimal for 10 15 Therefore A 10 B 11 C 12 D 13 E 14 and F 15 An arrow in the center of the switch will be pointing to one of the characters NOTE The Service Switch farthest BACK on the module is always set to 0 C Locate the rotary switch closer to the bracket end of the cardset There will an arrow point at one end of the adjusting slots The character that it points to will be the address number you will enter as the SAMview ID The switch is in hexadecimal so A 10 up to F 15 NOTE When specifying addresses be advised that four conditions apply 11 D SAMnet address 16 is normally reserved for the host computer E SAMnet address 0 is ILLEGAL F Multiple SA2000 modules Must Not have the same address on a network Check to make sure that the SA2000 addresses on a multi press line are all different F If you change an address setting at a SA2000 module that is powered up you must RESET the SA2000 to allow the new switch setting to be recognized This can be done by pressing reset push button refer to Figure 35 above When this is done the new address will be communicated to the system Optional Use your pointing device to click the first left character position in the SAM Description
404. rt coax s between the Network card and the SA2000 coax Network Connector s If There are multiple SA2000 units on the SAMnet network see the section above that deals with Installing your SAMnet equipment which deals with the special requirements of larger network systems 6 Connect the two 37 Pin D shell connectors to the SA2000 P modules and tighten the holding Screws 7 Power the computer and make sure that the Heartbeat light on the SA2000 is operating This LED should flash about once per second HEARTBEAT Indicator TEST serra Buffer Full Connector al a Indicator RESET Button Test Roa e Oak Switch I P Button ee tasers ap OO ee a i Slaving Connector wihara A Sensor Gain Gage Excitation Jumpers Jumpers Figure 27 SA2000 indicator lights and controls No flash or SLOW flashes are both indications of trouble Contact Signature Technologies with description of symptoms for further assistance if necessary 38 Signature Technologies Inc signatureACE 8 If everything is correct then turn off and re assemble the computer Install your host Computer system Software Bring up the power to the system elements and turn on the Host Computer gt If your computer comes up in Windows 3 x you must CLOSE the Windows session before starting SAMview The SAMview application WILL NOT run within Windows in the DOS window gt If your computer comes up
405. rval Start 139 688 Interval End Figure 78 Work performed by the blanking operation Conventional Feature Build Press PRS_50 Tool 2092 SPC Point Title Work Draw B amp D Betect algorithe gt gt 087 Interval Work SPC Point Units In Ton 40 00 Channel Select C Blank and Draw Graph Ris Status 23 33 Renate H Ris tegrees E 15 00 34 67 Feature Control Status 6 67 Control 1 67 Monitor 19 00 Tt i T T T T 115 0 128 14 141 3 154 4 167 6 180 7 193 9 207 0 220 2 Interval Start 135 608 Interval End Figure 79 Work performed by the drawing operation This feature calculates the amount of work performed during a portion of the signature Work is defined as a force exerted through a distance From this definition of work it follows that the slide must be moving for work to be done on the part In addition for most presses excluding linear systems the distance that the slide moves per degree of crankshaft rotation is not linear Therefore the work calculation must rely on the position off BDC transfer function to calculate the work feature However note that the feature can be defined according to degrees or position off BDC Selected channel data to calculate the work from can be real or virtual Window start in degrees or position off
406. s Go to the Press Database screen and change all the calibration factors to 1 000 Make a Tool called CALIBRATE with a window from 120 through 240 degrees Install the tool in the press and set the automatic signature save function to save EVERY hit Go to the Peak View screen and observe the displays as you roll the machine Position the Press at T D C Adjust the pressure of the counterbalances to balance the slide weight alone This value should be on one of the Information plates on the press If the information isn t there the Press manufacturer can provide it If all else fails move the press to 90 degrees Then blow the counterbalances down completely put a dial indicator under the slide then add counterbalance pressure slowly until the slide JUST moves up a little Make a note of the air pressure value if the gauge doesn t work properly FIX IT for future reference Install the press stands if needed and apply the Load cells to the slide You should use One Cell right under the center of the Pressure Point for small single point machines Two load cells under the pressure points for two point drives unless they are very narrow in which case one Cell in the exact center in line with the pressure points would be O K For large machines and particularly those with four point drive Four cells are needed The load cells should be positioned directly under the pressure point s if possible If positioning under the pressure
407. s same name different suffix These are YELLOW limit violations Also SW0 SW1 etc SF LF Fault signatures limits These are RED limit violations SP LP Press Curve signatures limits These are PRESS CURVE limit violations This storage CAN T be shut off by going into monitor mode SM LM MASTER signatures limits The SM LM combination with the LATEST date time is the reference called in when the system is started or a new tool is loaded Earlier masters are present but will not be used as long as later version are there Generally you don t want to delete LM or SM Master Files SR LR Requested signatures limits These are the signatures you asked for by hitting Save Signature F x SPC databases These are the files that the SPCView FeatureView utilities produce The x is the address of the SAM that generated the file If there is more than 1 SAM running there will be multiple F x files with the same name but different suffixes Using the appropriate DOS command Delete the files you don t want Signature Technologies Inc 347 User Manual del lt filename gt lt Enter gt to delete individual files and their limit sets del lt suffix gt lt Enter gt If you want to get rid of ALL the files of a certain type del lt partial filename gt lt Enter gt to get rid of certain collections of files within a type group del lt Enter gt to get rid o
408. s SY n Be Beet oer Ketch Phir Ree EE H es ae te ft noe oe fet crate ag ne ae at Soe i Strain Gages pee it cook Strain jk Gages Figure 224 Combination Blank amp Draw load cell Calibratable In Figure 224 the design of the cell and the station have been altered to give a calibratable result There are strain gages both on the outer and inner diameters of the load cell and they are connected in parallel to cancel out the effect of force being thrown to the inside or outside of the cell body Also the complete force of the station flows through the cell without any assistance from other supports This cell requires much more wiring than the structure in Figure 224 but will more accurately indicate the forces from both operations Appendix 10 Troubleshooting Guide Introduction This Troubleshooting guide is not intended to be good reading Unless you enjoy reading phone books It is also not a complete treatise on troubleshooting skills It is assumed that the user has a level of technical expertise commensurate normal electronic service requirements We stand ready to provide assistance with specific techniques This manual is rather an indexed way to get a little insight into the way our system works and how you can verify your parameters and settings Signature Technologies Inc 281 General Installation amp Programming Guide This manual deals w
409. s are not skipped Section 1 Defining Channel assignments Section 2 Setting up the FIRST machine in a NEW system that has not been programmed before Section 3 Setting up the FIRST tool ina NEW system that has not been programmed before Section 4 Putting the press and tool together Section 5 SAMview Screen Configuration Section 6 Machine Calibration Section 7 Adding TOOLS to a system that is already in use and equipped with existing presses and tools Section 8 Programming the SPC Feature Extraction utility Section 9 fom PRESSES to a system that is already in use and equipped with existing presses and ools Section 10 Adding SA2000 units to a system that is already in use and equipped with existing presses and tools Sections 1 through 8 will address ALL the procedures necessary to bring up a system with One Machine and One SA2000 module set Additionally a single Host Computer can handle up to 8 SA2000 module sets AND the SA2000 modules can be applied to either 1 For 8 separate machines Section 9 details adding machines to the Host 2 For a single machine with up to 64 channels Section 10 details adding SA2000 module sets to the SAME machine 50 Signature Technologies Inc signatureACE Before you start The First Great and General rule of Wing walking Take sure you have a firm grasp where you are before you grab on to something else and conversely m
410. s at least 10 times their perimeter measurement a theoretical method can be used whereby the Modulus of Elasticity Young s Modulus of the pull rod is used to calculate just what the strain elongation of the rod will be under rated load and that dimensional change is used to develop the magnitude of the electrical signal that would result from being stretched that amount This can then be used to generate a calibration number that will when programmed into the system result in information displayed in engineering units Tons Pounds as needed The procedure is to precisely measure the pull rod and develop its cross section The rated tonnage of the press is then divided by the number of pull rods and applied to the formula Force in pounds Cross section in square inches Young s Modulus Strain This formula will yield the elongation of the pull rod in inches of elongation per linear inch Example You have 4 steel Pull Down rods each of which is 4 X 6 in a press that is rated 500 tons Each rod must exert 125 tons at rated load 125 tons 250 000 pounds The cross section area of the rod is 24 square inches this makes the force Stress 250 000 24 10 417 pounds square inch Young s Modulus for steel is 29 000 000 pounds per square inch for a 1 inch deflection Signature Technologies Inc 351 User Manual 10 417 P S I 29 million 0 000359 The dimensional change Strain is 359 microinches per linear inch OR 359
411. s come on If they do there s a short in the Encoder or its cable If they don t come on and the TEC to SAM2000 cables are plugged in and the power is ON then disconnect the sensors to see if the lights come on If they don t there s a SA2000 or a Cable problem 12 Check the Encoder input to the system with an Oscilloscope a Isolate the Oscilloscope from ground by using a three to two prong 110 V A C adapter with the ground wire cut off WARNING DO NOT CONNECT A GROUNDED OSCILLOSCOPE TO ANY PART OF THE SA2000 System b Connect the Oscilloscope Common to point GND of the Encoder Resolver terminal strip c Connect Channel 1 to point S2 on the same strip A track d Connect Channel 2 to point S1 on the same strip B track e Turn the machine You should see a Square wave with a 50 duty cycle and a 10 Volt P P amplitude on both channels Channel 2 should be 90 degrees out of phase with Channel 1 If one or both channel signals are missing the encoder is probably at fault Replace the encoder and try again f Connect channel 2 to point R2 on the same strip Z track g Turn the machine You should see a predominantly zero level with one positive pulse per revolution to 12 Volts This will be hard to see so turn slowly if possible or disconnect the Encoder from the machine and turn by hand If this pulse is missing replace the encoder and try again Note Ifthe ZRO light on the SAM module flashes once p
412. s from positive on the left to negative on the right Parameters Selected channel data to calculate the location of a peak from can be real or virtual Window start in degrees or position off BDC Window end in degrees or position off BDC Position units degrees or position off BDC Use In this example the location of the peak is being used as a measure of the blank thickness In the case that a thicker blank is used the location of the peak would move to the left For thinner blanks the location of the peak would move to the right The location of the peak for the blanking operation should not be affected by the hardness of the material Error Check Refer to the If a Programmed Feature Doesn t Work section below at page 101 for a description of the overflow error that could occur using this feature Signature Technologies Inc 97 General Installation amp Programming Guide FeatureView 007 Interval work Description Parameters Use Conventional Feature Build Press PRS_50 Tool 2092 SPC Point Title Work Blank B amp D Eiet algorithe gt gt 007 Interval Work SPC Point Units In Ton 40 00 Channel Select Blank and Draw Graph Ris Status 23 33 Renate H Ris teres E 15 00 34 67 Feature Control Status 6 67 Control bs Monitor 10 00 Th T T T T T 115 0 4128 1 141 3 154 4 467 6 180 7 193 9 207 0 220 2 Inte
413. s hairs to frame the signature the way you would like When you click the mouse the NEAREST crosshair set with the x at the intersection will Snap to the mouse position Then just move the mouse to set the crosshair set to the desired locations As a diagnostic aid when the mouse button is released after moving a crosshair set the two small windows at the lower right corner of the screen will display the location of the cross hair intersection in degrees inches off bottom for the horizontal axis and force in the vertical axis 143 Signature Technologies Inc General Installation amp Programming Guide Overview Configure Database Analysis Screen Options Signature View P142 LI 32 1 Count 3757 SPM 69 Angle 204 g Left Front Right Front Left Rear Right Rear OS ol 09 473 Force 1077 647 oa i v Control Status Running Reset Fault Bypass Set Limits Control Figure 117 Signature View Adjustment 7 When the crosshairs frame the view you want Click the Zoom button The screen will then display the expanded signature 8 Repeat steps 6 and 7 until the signatures are displayed the way you want 9 When you have the view that you want Click the OK button The system will then drop OUT of Zoom mode back to normal operation 10 If you want to set the zoomed view as the CURRENT VIEW The one the system will al
414. s in the crankshaft end threading or hole location use a drive flange as in Figure 180 above 7 Make sure you include adjustment capability for the resolver so that you can tighten the drive belt when need be The drive belt should be as tight as allowed for the belt size you are using See the manufacturer s data for guidance The resolver shaft is rated 400 pounds radial load so you don t have to worry about over stressing the bearings there NOTE Watch out for radial motion of the crankshaft in older presses that would cause excessive tightness or looseness in the belt at certain rotational positions as the crankshaft moves around in its bearings Yes know that you d never let your press get that loose but check it anyway just to make us feel better please Required information for resolver mount design If you are planning to submit information to Signature Technologies Inc so that we can assist you in the design of your resolver mounting make sure to include the following 1 The brand model designation and SERIAL NUMBER of the machine 2 Quantitative measurements of the features in the area where you believe the resolver should be mounted It s not enough to say that there s a junction box about a foot from the crankshaft and slightly above it 3 An actual measurement to within 1 32 of the end float and radial motion of the crankshaft 4 An actual measurement of any oil canning or flexing motion of the surf
415. s often used to check the current setup against previous setups review bad hits or investigate archive trends This feature also assists you in creating a playback file that can be used to playback selected signatures in any of the three signature screens The action of the Playback utility is similar for Signatures OR SPC The differences are that you can select MANY signatures up to 100 for playback BUT only ONE SPC Chart at a time Also the display of signatures can be paused at any time but the display of SPC Points cannot Once started the ENTIRE SPC file will play back W Match Tool to Signature Show 3 All Signatures Show Limits i Playback List lt lt Add All ETS ry aia 98 07 22 88 58 35B6ACAA ST lt lt Add 96 07 22 88 57 35B6ACA7 ST 98 07 22 08 58 35B6ACAD ST 928707722 88 58 35B6ACHA ST 98 07 22 08 58 35B6ACAD ST 98 07 22 88 58 35B60C11 ST FA EE ee Signature Comment Wed Jul 22 08 58 85 1998 aa E AE 3 559 Row Ey ca gaea bi Playback Delay seconds MM Playback to Printer elete Signatures TEE Cancel Return delete all eA listed in the Playback List Figure 125 Playback Configuration Window Selecting Signatures for Playback 1 Select Analysis from the menu bar and a sub menu will appear 2 Select Edit Playback from the sub menu 3 If desired Select one of the options in the Show window Click on the box to the right of the Show heading
416. s the responsibility of the EMPLOYER to provide point of operation guarding and Peripheral safety devices for all power equipment WARNING since the installation and adjustment of the devices operated by the signatureACE SAMview SPCview CAMview and DIEview Systems sometimes require the insertion of body parts into the point of operation the press must be stopped with the drive system switched off and the flywheel stationary before any service work or adjustment are made to equipment mounted in the tooling The use of DIE SAFETY BLOCKS to prevent accidental injury is MANDATORY Signature Technologies Inc 19 General Installation amp Programming Guide Signature Technologies Hardware or Who s SAM You ll notice the term SAM bandied about in this manual in several forms SAM Module SAMnet SAMview etc Basically we sell a double module set that plugs into the computer which is legitimately named a SA2000 module Some time ago when the first modules came out they had no names and during a train trip down the Colorado River valley we decided to figure out what to call it suggested we call it Ralph which as far as I m concerned is a good all purpose name However since they were a Signature Analysis Module set it was suggested that SAM was a good shorthand name for the thing so SAM it became and named my pool cleaning robot Ralph as a backlash reaction There are Four major components of the signatu
417. se the system to copy everything in SAMDATA and its sub directories to TEST and it s subdirectories as a useable database 4 Type cd lt Enter gt 5 From the C gt prompt type set samdata c test lt Enter gt Signature Technologies Inc 51 General Installation amp Programming Guide Then run SAMview and you will be back in the old database until either a power cycle OR entering the command line set samdata lt Enter gt which will remove the effects of the SET command and go back to the normal SAMDATA database 52 Signature Technologies Inc signatureACE Section 1 Channel Assignments Channels can be assigned to either the machine or the tool Since Backing out of a setup once underway can be difficult that s a lie it s impossible it s important that the MACHINE vs TOOL sensor decision be made FIRST with some forethought It would be VERY disruptive to change your mind later with 100 tools programmed and thousands of signatures in the database The difference between the types is this 1 Channels that are assigned to the Machine will always be active They will have the same calibration regardless of which tool is being used These channels are connected to sensors that are permanently mounted on the press such as sensors that are mounted to uprights or a connection Channels that are assigned to the Tool will be active only when the tool the sensor belongs to is in use T
418. sed input This output may take the form of machine control a screen image printed output etc Signature Technologies Inc 133 General Installation amp Programming Guide Input Machine Mounted Load Sensor s Electronic load cells sensors are precision devices attached to the machine These sensors experience stress during machine operation Load sensors convert mechanical strain into an electrical signal that serves as a tonnage input for the signatureACE Load sensors can take a variety of forms They may be built into a Tooling component a bolt an inserted sleeve etc The signatureACE system is designed to operate with resistive load sensors in full Whetstone Bridge configuration The basic operation of a load sensor is as follows 1 Power excitation voltage is applied to the load cells Power is supplied by the SA2000 or the TEC Module these components are described under processing 2 Mechanical stress on the load cells changes the electrical resistance of the load cells 3 The output of the load cells is in millivolts The amount of strain tonnage the sensor is exposed to relates directly to the output in millivolts Load cells are precision devices When they are installed on identical steel components the deviation between sensors should not exceed 5 Machine Position Sensor A machine mounted electronic sensor tracks the movement of the machine This input creates a direct relationship bet
419. see exception under ON OFF ON and OFF ON OFF protocols If a 360 degree OPEN window is desired this MUST be set to 360 Under other conditions it must be set lt gt 5 degrees from the Start angle Sensor Type This field sets the protocol that the sensor channel will have These protocols are described at length in the following section Die Protection Input Protocols and will not be addressed here There are 6 different protocols that can be used depending on the application ANY Protocol can be applied to ANY channel Output Relay This field allows the selection of Output Device for the channel Any channel can be assigned to any of the available output devices that are listed below in detail under Die Protection Fault Output Options below As many channels as desired can share the same output If the No Connection option is chosen the channel will indicate but not take control action Signature Technologies Inc 191 General Installation amp Programming Guide Editing procedure Any data entered into the fields will be saved in the database ONLY if the Save Changes button is pressed before exiting the Die View Screen At the same time any problems with the programmed settings will be flagged and nothing will be saved until necessary errors have been repaired When changing data in Description and Start End fields highlighting the First Character position in the field will cause the ent
420. sensors be Dynamic in nature and that both states of the signal be confirmed EVERY cycle The Signature Technologies ON OFF ON and OFF ON OFF protocols are especially useful for this as mentioned later in this publication Quick Start Section This section is for OPERATORS and makes the assumption that the system is completely set up and operational that Die Protection sensors are installed and wired and programmed and that actually operating the system is your prime concern Figure 137 below is a view of one of the signature view screens specifically the ALL view screen At the bottom center of the screen there is the Function Selection Box with all four items shown Figure 136 Res signatures Com view set Figure 136 Function Selector Buttons Your system may have all four or if the options weren t installed some boxes may be missing This Function Selection Box appears on all the user screens in the system and gives you immediate access to the operation you want Overvieut gt Database Analysis Screen Options SPC View all 120 00 87 50 55 00 22 50 10 00 Refresh Hit Subgroup Size 1 Current SPC Hit Graph View AaLt Control Status Running Adels gt Mc meus mewew pesetroutf oups af s fm set Limits controt_ Figure 137 Signature ALL view Signature Technologies Inc 177 General Installation amp Programmin
421. ses 1 thru 24 The switches are in binary configuration where OFF 1 and ON 0 The least Significant bit 1 BIT is switch IDO and the MOST significant bit 128 bit is switch ID7 Example You want your host as address 22 then switch ID1 is OFF switch ID2 is OFF and switch ID4 is OFF All other switches are ON 2 4 16 22 Network Activity Indicator Internal Bus Activity Indicator SAMnet Connector Figure 236 SAMnet card address switch indicators NORMALLY for Address 16 S2 ID0 ON 2 ID1 ON 2 ID2 ON 2 ID3 ON 2 ID4 OFF 2 ID5 ON S2 ID6 ON S2 ID7 ON JP1 Jumper JP1 Terminator is ON for large networks see the section in the user manual 1 about terminators for exceptions JP2 Jumper JP2 Twisted pair Coax a 4 point jumper is installed in the COAX position Signature Technologies Inc 297 General Installation amp Programming Guide JP3 JP7 EMPTY JP8 INSTALLED JP9 JP13 EMPTY JP14 INSTALLED NO Boot ROM is installed Using the SAMtest Utility Software The SAMtest utility is actually 10 different programs accessed from the SAMtest menu The SAMtest utilities are somewhat self explanatory so this write up will cover only the stuff that s not patently obvious The Utilities are 1 Dieview used to diagnose the operation of the Dieview inputs and indicate where they come from physically whether from the normal DieView input points
422. severity of the problem If you are not looking at the channel that faulted you may find it this way 1 If the channel that faulted is available on the View that you are using then click on the colored channel selector box to display up the proper channel The system will display the faulted channel only 2 If the Channel that is faulted is NOT on the View that you are using then click the view that is colored and then click on the coloered channel in that view 3 If the Problem is NOT in the signature section but in the SPC or Die Protect then click on the colored function selector then on the colored view and then the colored channel 4 If the problem is on ANOTHER MACHINE then go to the OVERVIEW screen and select the press that is faulted then follow the color trail back to the faulted channel Diagnose the fault When you get the faulted channel in display attempt to understand what the signature is telling you 1 If the Force has risen significantly 50 or more and hits early then something has caused the apparent thickness of the workpiece to increase a double hit will increase by 500 700 It could be a Slug Out of position part Loose or out of position tooling Shut height drift Double load Feed up fault Weld in the material Wrong material etc 2 If the force has decreased significantly and the machine hits late then the apparent thickness has decreased OR the area that the tooling operates
423. ssigned Signature Technologies Inc 211 User Manual Signal Name cceeee Normal USAGE ceeceseeeeeeeeeeeeeees Pin Fused 45 VoltS in cscieioew sii den a A a aa 19 Input O riene nS Continuous Mode s e 37 Input I sii Clutch input 0 ceeeeeeeeeeeees 18 Input 2s e eesi ees Set Limits Switch ceeee 36 Input Sse sscceneeleceticg Reset Fault Switch eee 17 Input 4 wooo Not Assigned 0cceeeeeeeeeeeeeeeeee 26 Input D enen Not Assigned c eeeeeeeeeeeeeeeeee 7 Input GO iiini Not Assigned eeen 25 NPU T ee i Not Assigned eeen 6 Output O lecce Red Fault Output 35 Output 1 accented Yellow Fault Output 16 Output 2 0 0 White Fault Output 34 Output 3 ooo eee Green OUtDUE sisii 15 Output 4 oe Light Stack RED 0 eee 28 Output 5 0 eee Light Stack BLUE eeeee 9 Output 6 oo Light Stack YELLOW 27 Output 7 0 Light Stack GREEN 0 e 8 Cam 0 Output CaM ATi duet 33 Cam 1 Output Cam 2 aoc irea iiras ikea aieia 14 Cam 2 Output CAMBS piirete a ieas 32 Cam 3 Output Cam HA eves ciudad e a a 13 Cam 4 Output Cam 5 wh hein eel ie eels fees 31 Cam 5 Output Cam HO iomann ta nan i 12 Cam 6 Output Cam Hio Be i ie Ae iaie 30 Cam 7
424. stances use CLAMP Hubs 230 Signature Technologies Inc signatureACE Resolver Physical Specifications 174 20 x 0 50 deep 8 places 0 187 sq 41 00 long 2 kegay Figure 176 ST Standard resolver Package 231 Signature Technologies Inc User Manual resolver Mechanical Environmental Specifications Max Starting TOrqQue eccceceeeeeeseeeeeeeseeeeeeseeeeeeeeeeaeees 3 0 Oz In Moment of imettiasctis8colasevctatcccnied mae tacnee aistessantean 15Gm Cm 0 08199 Oz In2 Max Slew speed ccccccccceceeeeeceeceeceeeeeeeseeenaeeeeeeeeeteees 3000 R P M Max Shaft loads 7 NAT BBP PERE E ETP RP PS RECHT PROSTREET TERETE RTT 95 Lb Radial A c s aitecsndeaM aetna a whist 400 Lb Veg r r ae creme a a ETES 2 5 Lb Shock toler nsan da 50G for 11 msec Vibration tolerance serran aana aa 15G to 2000 Hz Operating Temperature cccccccecseececeeeeeteeetceeeeeteees 20 C to 125 C Radiatio gne e E 106 Rad Protection sni a E NE AE E Ea NEMA 4 Do s and Don ts NEVER drive the resolver by coupling to the extension shaft of a mechanical rotary cam limit switch Mechanical cam limit switches normally throw bi directional torque spikes into the drive system that they are connected to This can cause as much as 3 degrees of uncertainty in the resolver drive NEVER drive the resolver by coupling to shafting driven by general purpose right angle gear drives Right angle gear sets of the
425. symmetrically on opposite sides The two sensors are then hooked into one channel of the Signature analysis system in parallel This will act to cancel out any bending of the pittman as the press rolls The Machine Structure STATIC FORCE method The Static force method uses a hydraulic cylinder which applies force to the press frame to produce the stress levels in the sensored machine elements The cylinders are installed in the die space of the press and tonnage is applied to the press frame by pumping pressure into the cylinders If the hydraulic pressure in the system is multiplied by the area of the cylinder s the force applied to the press can be calculated 350 Signature Technologies Inc signatureACE This method has some inaccuracies because of machining tolerances in the cylinders gage inaccuracies or sticktion in the system Normally several successive readings should be made to insure repeatability of results A version of static calibration that is quite accurate involves the use of Load Cells in conjunction with the hydraulic equipment In this case the hydraulic system only applies force but the measurement is done with the load cells in this way the inaccuracies of the cylinders etc are no longer an issue One side benefit of static calibration is that readings of bearing clearances and a subsequent evaluation of press condition can be made if dial indicators are positioned on the press frame between members as th
426. t the reduction factor desired Shunt Value Re delet R Figure 252 Shunt resistor value calculation In the case above I d like to run at 10 volts excitation but I d have 0 030 volts of output and need to get down to 0 005 volts for an proper input need then to cut the signal from the sensor to 1 6 of what it normally is This is a reduction factor of 0 16666 The gage resistance is 350 Ohms 326 Signature Technologies Inc signatureACE Example i Shunt Value 350 0 1666 350 TE Shunt Value 58 31 350 ee eee 0 0171497 0 002857 Shunt Value Shunt Val Oana a ee 69 97 Ohms Shunt Value A shunt resistor of 69 97 Ohms use the 0 1 resistor value of 69 8 Ohms connected in parallel with the strain gage bridge across the amp Signal inputs will achieve the proper reduction of the gage output Signature Technologies Inc 327 General Installation amp Programming Guide Dealing with excessive balance offsets Noisey Flat top Ant gee 4 H Figure 253 Noisey Flat Top caused by excessive D C Offset When dealing with strain gages that have static offset voltages a voltage present between Signal and Signal when under no load which is due either to basic gage imbalance or due to a significant mechanical pre load on the gauged component in its resting state There must be some care taken to avoid Railing the input amplifier on the SA2000
427. t 4 places 2 00 Figure 170 Strain Link Cover Box 0 88 222 Signature Technologies Inc signatureACE This enclosure IS NOT sealed against liquids but the Strain Link does not require protection from oils or moisture normally encountered in the manufacturing environment The cover can also be used as a strain relief for moving wiring Find a location that is clear ON ALL the uprights in the same relative position It doesn t have to be EXACTLY the same but should be VERY close Avoid locations where the Section of the uprights varies from corner to corner Strive to get the links in the center of the Window areas of the uprights For example let s say the right side of the machine has no feed mounting rails but the left side does The feed mounts will stiffen the left side of the machine Consequently the links should not be mounted in an area of the upright where the feed mounts are located Strain links on the Connection s The connections of the machine will provide a superior signature with displayed force patterns much closer to the actual force signature at the point of operation While Connection signatures will be inferior to actual In The Die sensors there s less mechanical filtration and the signatures will be freer from ringing and drive noise Connection signatures are useable at press speeds up to 300 400 S P M with rapidly deteriorating performance as p
428. t Configuration automatically and you can go directly to section 5 below If there is more than one press then when you re done selecting tools Select Configure from the menu bar and select Exit Configuration from the sub menu 14 The Save Current Changes pop up message will appear Select the Yes button 72 Signature Technologies Inc signatureACE Section 5 SAMview screen configuration We ll now set up your screen graphics Before you proceed you should be aware that there are three different ways to look at signature data There are 6 Views Each of the six individual Signature View screens can display different mixes and magnifications of up to eight sensor channel signatures see figure below The system Allows the user to assign any of the 8 available Pens in each window to any Sensor channel defined for the machine AND to assign different Zooms for each of the six windows Overview Configure Database Analysis Screen Options P1286 M3 05 Signature View a Count 0 i i SPM Angle W Left Connection Right Connection R L Kiss block F R Kiss block Se eS ee ee 118 8 150 6 182 5 214 3 246 1 Refresh Zoom Control Status Running ran O O m erie JO Ofa Figure 49 Signature Screen Graph View G a KEEL Signature View All The Signature View All sc
429. t come to its normal position but stop higher up causing one or more of the parallelism switches to remain OFF This triggers a fault in the ST Die Protect system and stops the machine The OFF ON OFF protocol would be used Feed Length Confirmation After the Buckle detectors there is a sensor labeled Feed Length Confirmation This sensor watches the motion of the stock as it is fed in It is a normally OFF sensor that turns ON whenever the stock comes into the proper position for another part to be formed This should happen at the same time every cycle of the machine and the Die Protection system makes sure not only that the stock comes into position but that it comes in at the proper point in the stroke If the stock either doesn t make it or comes in late the die Protection system will stop the machine The OFF ON protocol is used to sense this event Feed Length Contirrnation Detector Stock Buckle Detector Feed Rolls Loop Loss End of Stock Detector Detector Pilot Punch Misfeed Detector Part Ejection Detector 4 Loop Ruriaway Detector Slide Porallelisrr Detectors 4 Figure 140 Typical Die Protection Signals Pilot Pin Misfeed On the top Die half there is a Pilot Pin Misfeed Sensor This is a Normally OFF sensor that turns ON if a Spring Loaded Pilot Pin doesn t properly enter the pilot hole that was punched in the stock as one of the
430. t is happening The problems will probably fit into one of the following categories 1 The Signatures are O K when the press starts running but the entire signature quickly staircases vertically to a different constant offset value NOTE Some migration of the points of the signature is normal after all that s why you bought our system so you could see that stuff The ENTIRE signature should not migrate however A good check is to look at the signature just after the Trigger point i e the left most portion This portion of the signature should be very Thin vertically If it becomes a thick line you have a problem Replace the SA2000 2 The signatures are O K but CONSISTANTLY offset the same amount from zero Replace the SA2000 334 Signature Technologies Inc signatureACE 3 The signatures are O K but drift vertically in an erratic fashion generally centered on ZERO It is possible that the gage connections to the TEC RSCB are defective the TEC RSCB itself is defective the Strain sensor Load cell has failed or the sensor cabling has developed Shorts or broken conductors Before replacing the TEC check for loose wiring to the TEC terminals If there are Ferrules on the Strain gage wires where the cables plug into the RSCB remove them They tend to change their resistance in corrosive or wet environments and cause drift Check the sensors for change of resistance Check the sensors for leakage to machine
431. t mode 3 A column of buttons marked lt none gt will appear under the View Press label on the left side of the screen Conf igure Carrent dob Set Line Limits Set Line in Bypass Set Line in Control View Press Tool Stroke Count Run Baseline Control j lt none gt lt none gt lt none gt lt none gt lt none gt lt none gt lt none gt He lt none gt Figure 43 Press Overview Screen Ready for configuration 4 Select the top lt none gt button Figure 43 The Select a Press pop up window will appear Note When adding additional presses existing presses will show the press name on the button of the Press Line Overview screen Figure 43 Select the first vacant button lt none gt down the row 5 Choose the appropriate press by clicking the press name from the Dirs Files list The name should highlight when selected AND appear in the File Name window at the top Signature Technologies Inc 69 General Installation amp Programming Guide Conf igure Press Line Overview Garnant ivet Set Line Limits Set Line in Bypass Set Line in Control View Press Select a Press seline Control lt none gt _ File Wane p1286 prs x ___Snone gt _ C MOOSE snone Dirs Files Br ives lt none gt lt none gt lt none gt Select lt none gt lt none gt
432. t the points that you developed Vertical scale is the output of the sensor as displayed on our system in counts Horizontal scale is the thickness of the paper stack that resulted in the readings If the plot is a straight line you re home free If it s not straight make the best estimation of a straight line that averages the differences by eye Step 11 Then take the difference between the thinnest and thickest stack in counts Take the dimensional difference between the thinnest and thickest stacks in thousandths of an inch Divide the dimensional difference by counts The result will be your thousandths calibration factor Worked Example The paper is 0 01 thick With one piece of paper you got 1023 counts With 9 pieces of paper you got 593 counts There s 80 thousanths difference between 1 sheet and 9 sheets There s 430 counts of difference between 1 sheet and 9 sheets 80 430 0 18605 the thousanths cal factor for that sensor Note The channel will read out relative units not actual dimensions Interfacing to existing Load Monitors Sometimes you may want to connect the signatureACE unit downstream of an existing load monitor In general the load monitors have Recorder or Track outputs available Also in general one side of the output will be GROUND On the Toledo units there is a double row 0 1 pattern male header that carries the signals The bottom row of pins is all grounded and can
433. talled swap the wires to the S1 and S3 terminals on the resolver terminal strip OR If you re using the resolver from another system swap the SIN wires GREEN amp WHITE on the INPUT cable to the Signature Technologies HiRes Converter 8 Bump the machine several degrees forward again to make sure the angle display increases and the letter F is shown for Forward 8 If it increases the connection is O K go to the next section Make sure the resolver operation is proper Continue to bump the press around Make sure that the angle display increases each time you move the press and confirm that you see the angle reading rise to 360 degrees in one press revolution before re setting to 0 degrees and climbing again If the indicated angle doesn t increment smoothly to 360 in one full revolution then the resolver is either defective or wired improperly See the Appendix 10 Troubleshooting Guide for remedies Set the angular Offset This is so that the angular position of the SA2000 unit agrees with the actual machine position 1 Developing the Position offset is done as follows A Rotate the machine to a KNOWN position generally B D C The BEST way in my humble opinion to get to a known B D C position is if the machine can be barred to position a dial indicator in the die space and rotate the machine forward till the ram is exactly 2 above it s B D C point Set the dial
434. tate when the input voltage drops below 12 V 24 V D C is used to supply power to 3 wire proximity switches The universal switching delay for all inputs is Software Switch selectable to either 0 002 second 0 012 second or 0 020 second 3 Wire NPN Proximity or Sinking Input This is an NPN type input device A 4 7K load resistor to 24V is software connected to the input terminal The Proximity Switch must pull DOWN the input to common This configuration switches state when less than 12 Volts DC exist between the Input and the Common connection It returns to its quiescent state when the voltage rises above 13 2V 24 V D C is used to supply power to 3 wire proximity switches The universal switching delay for all inputs is Software Switch selectable to either 0 002 second 0 012 second or 0 020 second 2 Wire Universal Proximity Input This is an PNP type input device A 4 7K load resistor to Common is software connected to the input terminal The Proximity Switch must drive the input UP to 24 Volts This Configuration switches state when more than 13 2 Volts DC exists between the Input and the Common It returns to its quiescent state when the input voltage drops below 12 V 24 V D C through the 4 7K resistor is present as Wetting power for the Proximity switch in its OFF state The universal switching delay for all inputs is Software Switch selectable to either 0 002 second 0 012 second or 0 020 second 18
435. tating machine as well as the work that goes on within the machine The SA2000 module is the core of the signatureACE system The coaxial cable software and hardware used to communicate at a high transmission rate between the Host Computer and the SA2000 The numerical field in the Tool Information utility that set the interval at which force readings are read by the computer See Resolution above Signature Technologies Inc 373 User Manual Srei eo tien shes This is a Menu Bar selection that allows the user to set up the screen display with scales grids and titles and also allows the display of limit sets and masters Search Key Fields To review historic data the user can call back stored data in a variety of ways The user can specify that only signatures that meet a certain criteria be retrieved These criteria are the Key Fields that the Search function uses to select signatures out of the Signature Database Examples of Search Key Fields are Date Status Press Identification and Tool Identification Selecione Button saves data or changes taking you back to the previous screen Selesta aaa When used without specific reference to the Select button the term select means choose SOCNSOF iiai A device used to communicate position force or motion to the computer Signature ceeeeee An array of data points collected at specific positions in the press stroke
436. tation is now O K Go To Check 3 below 23 If the position doesn t change and you have successfully performed all the tests to this point The SA2000 module is suspect Signature Technologies Inc 313 General Installation amp Programming Guide wase ENCODER CHECKLIST Rotate the machine slightly 20 40 in its normal direction of motion If after moving the machine in Step 1 the position display increases then the encoder phase A and B hookup is O K go to Check 3 below If it decreases reverse the A and B phase wiring to terminals S2 and S1 4 and 6 NOTE Encoders may be wired either Single ended or with complimentary outputs A single ended hookup will only have 5 wires while a complimentary output hookup would have 8 If you have a complimentary encoder Phase A would be wired to terminals S2 and S4 6 7 and Phase B would be wired to S1 and S3 4 5 If your rotation is reversed the wires on S2 amp S4 would be exchanged with the wires on S1 amp S3 Perform steps 1 amp 2 of this section again to check for proper rotation If rotation is O K go to Check 3 If the position doesn t change a Turn the Machine and consequently the encoder and check to see if the Green AutoZero light on the TEC flashes once per revolution b If it does the Z track of the encoder is hooked up properly and operating properly Go to step 15 below If however the ZRO
437. te is in effect If the input signal meets the requirements for OFF and the Invert button is dark then the sensor will display the ON state PNP The PNP indicator indicatesthe connection of the internal Pull Up resistor for the input NORMALLY the pull up resistor is connected to 24 volts and must be brought low or grounded to actuate the input This is an input configured to connect to SINKING or NPN devices This includes Cat s whisker and grounding switches NPN Proxes and any device that GROUNDS power from the input If the Indicator is DARK itis indicating PNP mode where the resistor is connected to ground This an input configured to connect to Sourcing or PNP devices This includes PNP Proxes and any other device that FEEDS power into the input Signature Technologies Inc 179 General Installation amp Programming Guide Sensor type This field sets the protocol that the sensor channel will have These protocols are described at length in the following section Die Protection Input Protocols and will not be addressed here There are 6 different protocols that can be used depending on the application ANY Protocol can be applied to ANY channel Output Relay This field indicates which of the three available output devices will be actuated when the channel goes into a fault state Reset Fault This is an Indicator Control pushbutton If a Color is displayed it will indicate the HIGHEST level
438. ted wire ends can be inserted into the terminal strip according to the wire list below The cable is brought into the TEC enclosure by punching appropriate holes for conduit or glands If the TEC enclosure is mounted using Vibration mounts make sure to terminate any conduit to the enclosure using a link of FLEX conduit This will prevent the rigid conduit from destroying the effect of the vibration mounts 246 Signature Technologies Inc signatureACE Converter End Cable Connector 9 Pin D 4 Pair Shielded 24ga TEC Enclosure Male with shell amp jack BELDEN 9504 Terminals Screws OLO Current l Style Style Sine Fe EONA u 2 5 5V ae a 8 5 Cosi Green II l Green Sonel L FB DCT o g Ref 6 RI AGND Shield 1 SHD Male end OGND 5 GND b Cable length Xx suffix in feet 5 Figure 187 Standard Converter SB 027 8006 OUTPUT cable assy System Grounding Caution NOTE The COMMON connection for the CNV Converter is connected to EARTH Ground in the SmartSAM SignatureACE system It may be that the existing system you are connecting to has a fully floating Common connection which would make hooking the CNV converter COMMON to this point inadvisable In general it s SAFER to connect the CNV common wire to the machine frame rather than to connect it to the existing system common or even the system Shield connection which also sometimes floats NOTE Yo
439. tely Maybe there s something wrong with 4 Run your coax around 4 to 5 instead If the Network stays up the suspicion falls heavily on 4 Try another SA2000 unit in 4 make sure you set the address properly If the network now stays up there was a problem in the SA2000 7 If the network is generally UP but there are one or two units that won t come on e Change the SAM module in the units that are OFF Line Make sure you set the address properly e Try substituting the Coax along the line with the entire network hooked up Sometimes a coax problem at 2 will knock off 5 6 amp 7 e f you re dealing with a NEW cabling job there may be more than one problem Having two test cables may help 8 If all else fails get out an oscilloscope that is capable of at least 25 MHz a length of coax about 4 feet and a BNC TEE fitting With the presses not running if possible tap into the coax at the most distant unit from the Host and note the waveforms that you see NOTE Since there are a large variety of network configurations Can t discuss them all In the examples below a network with 3 Units connected and a total coax length of 1500 is used This is about the maximum length of Coax you would be using without installing repeaters Terminatar Terminator Figure 242 Scope connection to Network 306 Signature Technologies Inc signatureACE The results you get may be somewhat different than we saw
440. ter installation manual Appendix 8 for the proper hookup 12 When the press can be rotated through a complete cycle and the threegreen lights behave as outlined above the HiRes converter is functional and properly adjusted 13 If there are NO lights on or ALL the lights are on and you can t get them to act properly with the adjustments 14 The lights are powered by voltages coming from the SAM SA2000 module so check to see if the SAM is powered 2 Power lights showing on the TEC 15 Check to see if the Converter to TEC cable is terminated at both ends 16 Remove the Converter to TEC cable from the Converter and measure with a digital voltmeter 5 volts between Pin 1 and pin 5 Com 12 for SAM500 systems 312 Signature Technologies Inc signatureACE 5 volts between Pin 4 and pin 5 Com 12 for SAM500 systems 17 If you measure the proper voltages re install the cable then check the input from the existing resolver system If there are NO voltages or one is missing check the 5V and 5V Lights on the TEC If they are both there the cable is defective If one or both of the lights are out there may be a short in the wiring This could be EITHER in the sensors OR the resolver converter wiring Disconnect the resolver converter first If the lights come ON then there s a short in the cable If the lights DON T come on disconnect the force sensors one at a time and see if the lights come on If
441. ter when the resistor is applied If the voltage goes from a POSITIVE value to a NEGATIVE value or vice versa the resistor connection is right but the resistor value is too low a 100K MAAS itati Excitation Shield Ezcit tioni Signal j ELTE ji Signal Signal Excitation UW C Excitation Unit 6 J Millivolt Meter T o P Figure 257 Resistor hooked the right way error less but resistor too small e Then adjust the resistor value by applying LARGER resistor values for LESS effect or lower resistor values for more effect The aim is to get the offset close to zero volts within the values given above Using parallel or series combinations of resistors enable you to make fine adjustments 330 Signature Technologies Inc signatureACE SS 150K Excitation Shield 7 Excitation Signal j re Signal Signal fr Excitation c Excitation Unit 0 5 Millivolt Meter oS re C Figure 258 Balance within acceptable limits f Finally permanently install a fixed resistor or resistor combination of the proper value permanently across the same points The most practical way to do this is to clamp the resistor leads in the terminals and solder the Strain gage wires to the resistor If series or paral
442. terval As a quick check to determine if the feature definition might encounter an overflow condition make sure the following relations are satisfied for an interval of less than 256 data points Xbar lt 32 767 else Xbar lt 8 300 000 N Where Xbar the approximate mean value for the signature within the interval N number of the signature data points in the interval 96 Signature Technologies Inc signatureACE SPCview 009 Peak location Conventional Feature Build Press PRS_50 Toot 2092 SPC Point Title Max Loc Blank B amp D ieee 009 Maximum Location SPC Point units 40 00 Channel Select m Blank and Draw Graph Ris Status 31 674 23 334 Riernate H Reis Hepeos Em 15 004 Feature Control Status 6 674 Control Monitor 1 674 10 00 S E i T T T T T 115 0 128 14 141 3 154 4 167 6 180 7 193 9 207 0 220 2 Interval Start 125 608 Interval End 135 009 Figure 77 Location of the blanking peak Description This feature returns the location degrees or position off BDC of the maximum Peak between the start and the end of a defined window not the data collection window of the tool If there are multiple peaks in the window only the location of the greatest peak will be returned Note that a peak is defined as a point at which the slope of the signature change
443. that was selected the last time the screen was entered From the SPC Quick Pick screen the user can select a feature and view the most recent data collected for the feature Feature data is displayed on strip charts and is updated in real time as new data is collected by the signatureACE system When selecting a feature from the SPC Quick Pick screen only one feature can be reviewed at a time Viewing SPC charts using the Quick Pick option 1 Click the Quick Pick button from the SPC Views group in the lower left corner of the screen 2 Click any of the SPC point buttons in the center of the SPC View Summary screen Each feature assigned to the current tool is displayed on the SPC View Summary screen The SPCview Graph screen will appear displaying only the data for the selected feature Using the SPC View All screen SPCview provides six programmable screens to view the feature data The operation of these screens is similar to the operation of the signature screens In this section it is assumed that each of these screens has been configured prior to operation The SPC View All screen displays all six screens in their default state The graphs displayed correspond directly with the six SPC View buttons labeled 1 6 For example the graph in the upper left corner of the screen corresponds to button 1 The graph in the upper right relates to button 3 Using SPC View Graph screens 1 6 SPCview provid
444. the threshold or the signature is greater than the threshold at the start of the window the feature will return an error condition In the event that the signature crosses the threshold multiple times the feature only returns the first crossing Selected channel data to calculate the location of a threshold from can be real or virtual Window start in degrees or position off BDC Window end in degrees or position off BDC Signature threshold value Position unit degrees or position off BDC By monitoring the location at which the blanking ring exceeds the force threshold the user can determine if the blanking ring depth is too great or if it needs to be backed off assuming proper thickness Refer to the If a Programmed Feature Doesn t Work section below at page 101 for a description of the overflow error that could occur using this feature In addition to the overflow possibility the feature will return an error condition if the signature does not cross the threshold within the defined window or if the first value of the signature inside the window has exceeded the threshold 102 Signature Technologies Inc signatureACE FeatureView 101 Spread Calculation A MACRO Feature Virtual Feature Build Press PRS_50 Tool 2092 SPC Point Title Blank Spread Betect Algorithme gt gt 101 Spread Calculation PC Point units Tons 02 00 Draw Maximum B amp D Active Feautres 62 61 Draw Maximum LC 62 62 Draw Minimum
445. the Press Line Overview screen The box next to the Current Job button should now display the job name selected AND each of the Tool buttons will change to the tools for the new Job All the stroke counters will reset to Zero Note The Cancel button will clear the tool assignment and exit the Select a Tool window When the Job Tool has been loaded 1 Select Configure from the menu bar A drop down sub menu will appear 2 Select Exit Configuration from the sub menu And the system is ready for production with the new tooling configuration Signature Technologies Inc 85 General Installation amp Programming Guide Section 8 Programming the SPCview FeatureView utility This section details the programming of the SPCview FeatureView utility The procedure below will guide you through the programming of Features for one of your tools PRE CONDITIONS Install the die set in the press and properly align it 2 Perform the normal adjustments to the press amp equipment 3 Start the machine in normal operation 4 Confirm that the part quality is to specification 5 Verify that a valid signature is displayed on the screen 6 Select Set Limits Figure 62 lower right corner 7 Cycle the press for the number of signatures defined at the baseline size 8 When the limits have been set the Green LED next to Set Limits will light and the new limits sh
446. the best one to have It simply means that your signal lines from the sensor have been hooked to the Signal inputs A and A in reverse Normally just flipping them will correct the situation 322 Signature Technologies Inc signatureACE Signature Inversion Figure 248 Signature inversion HOWEVER Before doing so MAKE SURE you check your position display Confirm that the position display is accurately displaying the machine position i e if the ram in up at the top of its stroke the display should be saying something between 350 and 10 degrees In some cases with complex signatures upside down MAY NOT be an obvious situation and if the press position is wrong and the signal is zeroed at the wrong place the results on the screen may be TOTALLY confusing Signature Technologies Inc 323 General Installation amp Programming Guide If the Strain Gage output is too high for the ST system _ ABSOLUTELY flat top Wid Pa E Mngt Figure 249 Absolutely flat top on signature Flat tops DON T grow in nature If the highest points on your signatures display ABSOLUTELY flat tops i e no matter how tight you zoom in on them they are still nothing but a straight line with no noise showing you are railing the system channel The input signal is TOO BIG to display and the system goes as high as it can and flat tops If there s any doubt read the level of the flat top and divide by the calibration factor f
447. the computer user to correct the deviation SPCVIOW AE A software module for the signatureACE system The SPCview module allows the user to trend normal SPC functions such as Peak and Average Loads This program enhancement allows the user to window specific portions of the signature and performs analytical and statistical functions on selected features of that signature For example you could window the area of the signature that has a peak and track the value of that peak on X bar amp R charts Strain Gage eee A device used to measure deflections STRAIN in the structure of a machine and convert this force into measurable voltages Sub group 0 eeeeeeee A specified number of consecutive hits that are averaged to make up a single data point for process monitoring TD isdn Bees Top Dead Center The position of a press when it is exactly at the top of its stroke Conventionally this occurs at Zero degrees but may occur at another angle in 374 Signature Technologies Inc signatureACE machines with complex drive linkages Bottom Dead Center MUST occur at 180 degrees TEC E Terminal Enclosure refers to the TEC assembly which is a Printed circuit board with terminations for all the input and output signals needed or created by the SignatureACE system AND an enclosure to provide industrial protection TOJI irdi Turns an option On or Off using the pointin
448. the database We suggest that you restore the database into a directory with a different name than SAMDATA unless you are for some reason wanting to overwrite the main database 348 Signature Technologies Inc signatureACE The system can reference other databases by using the DOS SET command Let s say you want to leave your SAMDATA database alone and restore into a database called RALPH instead If the data you have is on a single disk made with XCOPY Step 1 Insert the data floppy in the A drive Step 2 From the C gt Prompt type md ralph lt Enter gt Step 3 From the C gt Prompt type cd ralph lt Enter gt Step 4 Type xcopya s lt Enter gt Step 5 Wait till it finishes Step 6 There will then be a database on the system hard drive in a directory called RALPH Step 7 To use this new database from the C gt Prompt type set samdata c ralph lt Enter gt and then start samview in the normal manner The system will start and use the RALPH database until you return to the original by typing at the C gt prompt setsamdata lt Enter gt If the data you have is on a single disk or multiple disks made with PKZIP Step 1 Insert the first data floppy in the A drive Step 2 From the C gt Prompt type md ralph lt Enter gt Step 3 From the C gt Prompt type cd ralph lt Enter gt Step 4 Type pkware pkunzip d a samzip lt Enter gt Step5 Wait till it f
449. the max force capability at that angle Bottom dead center is always 180 degrees Example This is the Critical Curve file that gives the shape of the available force curve for the machine The program will extend a horizontal line from 0 to the first specified angle and extend a horizontal line from the last angle to 360 This curve is in US Tons Signature Technologies Inc 215 User Manual 98 203 5 107 242 134 330 142 391 154 550 158 660 199 660 245 550 214 390 220 330 252 203 5 The curve above is a simple one that indicates the press available tonnage on a 660 ton machine rises from only 203 tons at 98 degrees reaches full value from 158 to 199 degrees then falls back to 203 tons at 252 degrees The file can be written using the Edit command in DOS Let s say you want to call the file Ralph The file must be located in the SAMDATA directory to operate so the command is from the C gt prompt edit SAMDATA ralph Ip When the edit window comes up write the file and when done pull down the File menu and Exit The system will ask you if you want to save the file you say yes and it s done There will be a RALPH LP file in the Samdata directory If you have Tooling sensors If there are tooling sensors the LP file MUST ALSO be copied to the Press directory Example if the press name is RUTH You want to from the C gt prompt copy SAMDATA ralph LP SAMDATA
450. the sub microvolt signals from the Strain Gages The amplification for each channel is individually selectable to either X1000 for strain gages or X2 for self amplified devices having high level outputs 2 5 volt swing gt It provides strain gage offset bias cancellation so that any imbalances in the strain gage channels are automatically adjusted to zero This is a continuous function performed each stroke at zero degrees and also each time the machine clutch engages The Position Input Daughter Boards There are THREE versions of the Position Input board The RES is used to interface Resolvers to the SA2000 system It provides the excitation and data conversion for the Resolver Position Sensor The Resolver input can be converted at a jumper selectable 10 12 or 14 bit level We normally use it at 10 bits 1024 positions per revolution for press speeds over 250 S P M and 12 bits 4096 positions per revolution for slower speeds For extremely slow presses 14 bits is available 16384 positions per revolution The ENC Is used to interface digital incremental encoders to the SA2000 system It provides input signal processing and position counting if an Incremental Encoder is used as the Position Sensor An internal 1X or 2X multiplication is jumper selectable The SLV Is used to slave additional SA2000 units to the Master unit in cases where multiple SA2000 s are used on the same machine The TEC
451. the tool definition information lives There will be one of these Sub directories for each defined Press These sub directories have the SAME names as the press files the files in the SAMDATA sub directory with the PRS suffix Each Sub directory contains the definition files for the Tools that have been created exclusively for the press which has the same name as the sub directory This sub directory level contains 338 The _DEFAULT GR file that contains the default graphics setup for the signature view and Peak view portions of the display The _DEFAULT GT file that contains the default graphics setup for the SPCView displays The Tool definition files with the TL suffix These files contain the data pertaining to the tools their assigned sensors virtual channels and acquisition windows The Tool Backup files with the BAK suffix These files are automatic backups of the tool files having the same name They contain the tools as they were before the last edit The Feature definition files with the FET suffix These files contain the data pertaining to the SPCView features The Tool Graphics files with the GR suffix These files hold the graphics setups for the tools how the views are set up zoom data and peak screen setups Signature Technologies Inc signatureACE g The SPC Graphics files with the GT suffix These files hold the graphics setups for the SPCView features h The P
452. then bump the machine in INCH mode a little THEN read the Angle window Checklists for The Position sensing system wawe RESOLVER CHECKLIST If you are using a HiRes Resolver converter Skip the RESOLVER CHECKLIST and go to the HiRes RESOLVER CONVERTER Checklist below at page 310 If you have an Encoder as a Position Sensor Skip down to the Encoder Checklist below 1 Rotate the machine slightly 20 40 in its normal direction of motion a If after moving the machine in step 1 the position display increases then the Resolver hookup is O K go to Check 3 below b If it decreases reverse the connections on points S2 and S4 on the position input terminal strip on the TEC board 2 Perform step 1 again to check for proper rotation If the rotation is now O K go to Check 3 below 3 Ifthe position doesn t change a Make sure the RESOLVER shaft is turning when the machine does NOTE THERE ARE NO active components between the plug on the Resolver and the Plug on the SAM Module The condition of the external resolver circuit can be checked with only an Ohmmeter b Perform the following series of Ohmmeter checks The values given below are for the standard resolver supplied by S T I See Note below Signature Technologies Inc 309 General Installation amp Programming Guide NOTE NOTE At the SA2000 remove the CONTROL cable the SINGLE Cable with the FE
453. thod of Strain Gage Mounting 228 Directory structure SAMview 40 Disabling Windows automatically 39 Displaying the fault 152 Drilling layout Strain Link 226 Dynamic Calibration Procedure 362 Dynamic Checking for static sensors 194 E Editing procedure Die View 198 ENCODER CHECKLIST 316 Encoder connections 208 Encoder connections TEC 210 Encoder input Connections 209 Event Log Selecting events to be logged 168 Event log viewing 169 Excessive balance offsets 267 331 Excitation Reduction 327 Excitation Selection Strain Gage Channels 36 Exit the SAMview program 153 Signature Technologies Inc 377 General Installation amp Programming Guide F Failure SPC Zero Deviation 109 Failure to fulfill the feature requirements 109 Fault RED Limits 138 Fault Displaying 152 Fault Diagnoses 152 Fault Reset 153 Feature Control Mode 116 Feature Doesn t Work 109 Feature Limits Recalculating 125 Feature limits Setting 124 Features Computational Overflow 109 Features Interval average 99 Features Interval Maximum 92 Features Interval Minimum 94 Features Interval Peak 95 Features Interval valley 98 Features Interval Work 102 Features Peak location 101 Features Programming 111 Features Ratio 104 Features Removing 117 Features Spread Calculation 107 Features Threshold Detector 106 FeatureView Programming 88 Floppy Disk
454. through 1200 S P M The Compensation jumper is removed B For a resolver resolution of 4096 counts 12 bits per revolution RSC1 only is installed This setting is for press speeds from 50 S P M through 250 S P M The Compensation jumper is installed C For a resolver resolution of 16384 counts 14 bits per revolution RSC2 only is installed This is a special setting is for press speeds that don t exceed 20 S P M 292 Signature Technologies Inc signatureACE The Compensation jumper is installed Talk to S T before setting up a SAM this way D For a resolver resolution of 65536 counts 16 bits per revolution NO JUMPERS are installed This is a special setting is for press speeds that don t exceed 8 S P M The Compensation jumper is installed Talk to S T before setting up a SAM this way SAMtest Will read out the resolution jumper configuration REF Jumpers These jumpers are for selecting whether a RESOLVER input card will be used to interface directly to an dedicated resolver OR be used as a slave to an existing resolver system In cases where more than 1 SA2000 is used in a system One of the will be set up as the MASTER with a RES card and the other SA2000s will be configured as SLAVES with a SLV card antes ee o i a j l a sis s gt bd 2 gt gt gt gt gt s gt gt SIGNATURE TECHNOLOGIES INC COPYRIGHT 1997 SA 2000 STB 828 5004 US PATEHTS 4987528 54
455. tion Left Connection Blanking Operation i Drawing Operation Static Nitro Pressure Figure 63 Left Connecting Rod Right Connection 200 Die Closure 80 Drawing Operation N 20 Blanking Operation T T T T T 115 130 145 160 175 190 205 220 Figure 64 Right Connecting Rod In the figure below both the left and the right connecting rods are shown From these signatures we see the action of the blanking operation in the left connecting rod and the reaction in the right connecting rod This is Signature Technologies Inc 87 General Installation amp Programming Guide also true of the drawing operation In addition to the features noted on the previous graphs the signatures also contain information about the other operations that are occurring at the same time Unfortunately these features are not as well defined and are only displayed as noise on the signature Left and Right Con Die Closure Left Nitro Pressure Left Blanking Operation Left A s Drawing Operation Lefi Die Closwe Right a Drawing operation Right Blanking Operation Right 115 130 145 160 175 130 205 220 Figure 65 Left and Right Connecting Rods The signature below was collected from an in die sensor located under the first station the blank and cup draw station In comparison to the connecting rod signatures the blank and draw operations are more c
456. to ON within the window immediately produces a fault If the signal enters the window in the ON state A Fault will be issued Immediately The sensor MUST make a transition to ON outside the window at least once or it will fault entering the window even if it enters OFF The window MUST NOT BE more than 330 degrees wide to allow for the check function The Check function will operate after one full machine rotation Always On check MUST be ON with within the window A change to OFF within the window immediately produces a fault If the signal enters the window in the OFF state A Fault will be issued Immediately The sensor MUST make a transition to OFF outside the window at least once or it will fault entering the window even if it enters ON The window MUST NOT BE more than 330 degrees wide to allow for the check function The Check function will operate after one full machine rotation OFF On OFF check Normally OFF with at least one change to ON and a subsequent return s to OFF expected DURING a programmable angular window in the stroke If the signal enters the window in the ON state A Fault will be issued Immediately Lack of a transition during the Window produces a fault at the Window END angle If the signal Leaves the window in the ON state A Fault will be issued Immediately If the sensor makes a transition to ON outside the window A Fault will
457. ton TEST Button Test Switch i Mia fi Se a Slaving Connector Sensor Gain Gage Excitation Jumpers Jumpers Figure 266 SA2000 Indicators internal RESET Button Access through hole Control Connector 9 P A N Input Connector SAMnet Network Indicator Zero Indicator SAMnet Network Connector Figure 267 SA2000 module End indicators Appendix 12 Glossary AID iene ee ees Analog to Digital Pertaining to conversion of an analog signal a voltage to something the computer can understand ones and zeros The practical device normally used is referred to as an A D Converter A D Counts The raw data right out of an A D converter before it is scaled In the signatureACE system this can have a value between plus 2047 and minus 2048 368 Signature Technologies Inc signatureACE Background Task Backlash Compensation B DiG wsstaasdesain oio A continuous signal measured in volts This is a selection on the Menu Bar that allows the operator to access historic data The Edit Saving option allows the system to be set up to save signature data while the Edit Playback item allows the operator to choose from the database signatures for display on the screen in playback mode Automatic means of canceling thermal or physical offsets in the analog signal generated by a strain gauge The Auto zero function is useful to maintain repe
458. trol the machine NOT connecting the RUN input would prevent certain functions from operating correctly so it s not optional To review at this point you have Everything mounted The Machine control wires are hooked to the I O chassis Clutch AT LEAST is wired in The resolver resolver converter Encoder cable 3 or 4 pair cable is connected to the Position input terminals The Sensors are connected to the Sensor input terminals The 2 cables with the 37 Pin D shell connectors have been run back to the vicinity of the host computer Then let s get it finished and start it up The next steps will take you through setting up the host installation of ST Software and system configurations Installing your SAMnet equipment If you have only ONE or TWO SA2000 modules installed in a computer side by side you can skip this section altogether and move on to the Set up your host Computer system Hardware section below The SA2000 modules and the SAMnet network cards are shipped with internal TERMINATORS which are ENABLED but which can be DISABLED by removing jumpers The two following Figures illustrate the location of the Terminator jumpers on the modules 30 Signature Technologies Inc signatureACE Terminator Jumper IN Terminated OUT Open Figure 13 Terminator jumper for the SA2000 module Communications Selection Switch Wn 2 FCC COMPLI T SE ANORRO MICROS 3 p
459. ts Actual programmed switch point 52 1 406 degrees 73 13 degrees The system will provide Logic level outputs that are accurate to the actual programmed value as noted above to within 2 degrees at 1000 S P M The AC Output devices have Zero Crossing detection that introduces an 8 33 millisecond ambiguity to the switch points At 100 S P M 8 33 Milliseconds 4 8 degrees Ambiguity At 200 S P M 8 33 Milliseconds 9 6 degrees Ambiguity etc The D C Output Devices have a 50 Microsecond Turn ON Turn OFF time At 100 S P M 50 Microseconds 0 03 Degrees consistent delay on set point NO Ambiguity The Dry Contact Devices have a 500 Microsecond Turn ON Turn OFF time with a 250 Microsecond Bounce time At 100 S P M 500 Microseconds 0 250 Microseconds bounce 0 3 Degrees delay on set point with up to an additional 0 15 degrees switching Ambiguity Programming the Signature Technologies CAMview system CAMview Programming Utility This utility is located in the Tool Database To get there select Overview from the top menu bar The system will display the Overview screen Select Configure from the top menu bar and then select Tool The system will display the Tool database screen At the lower right side of the Tool Database screen there is a Box labeled Cam View Click on it and the Cam View programming screen will appear 170 Signature Technologies Inc signatureAC
460. tup The password will not be needed until an attempt is made to SAVE the created or edited job Configure Lim param cccceceeeeeeees Requires a password to change the parameters used to calculate limits The password will not be needed until an attempt is made to SAVE the edited data for the selected channel s Signature Technologies Inc 361 User Manual Configure Line Configure Press Configure Refresh Rate Configure SAMnet seeen Configure Security ecceeeeeeeeeneeeeeeee Configure Tool Configure Tool Setup n Configure Virtual Channel 0 eeeeeee Delete Signatures Exit SAMView Logon One Shot Requires a password to define or change a Press line setup The password will not be needed until an attempt is made to SAVE the created or edited Press line Requires a password to create or change a Press data file The password will not be needed until an attempt is made to SAVE the created or edited Press Requires a password to permit modifications to the Data Refresh Rate Setup screen which controls the transfer of specific data items from the SAM Module to the Host computer This is a System Setup adjustment which is preset at the factory and requires no adjustment unless operation at the extremes of the envelope are required Should be assigned the highest priority Requires a password to enter the SAMnet Summary screen to see w
461. ture or Loose die components 7 If the Die protection system has faulted the cause will generally be obvious The Die protection channels can also be displayed as signatures and thus give clues about what caused the problem If you locate the source of the problem then perform the repair and put the machine back into operation On the other hand if you can t pin down the fault to anything tangible but everything appears to be in order then put the machine back in operation BUT keep a Weather eye on the channel that stopped you to see if there are other clues to be found To reset the fault To do this go to the function that has faulted as indicated by its color by clicking on the appropriate selection in the box at the bottom center of the screen When the function opens click on the RESET button and repeat the process for any other functions that have faulted The three fault types Signature SPC and Die Protection must all be reset separately in their own screens When NO COLORED BOXES are displayed the system will permit the machine to be re started To Quit SAMview Do not confuse Quit SAMview with Logging off at the end of your operation see also Log on the security system Normally the user does not Quit SAMview as this shuts off the operator interface for the system making the viewing of what s going on impossible Querviewt Configure Database Analysis Screen DRUGA i
462. tween the Shield wire and any other wire There should be a OPEN circuit 10 If any of these combinations read other than the normal value the Strain gage or its cable is defective Replace it 11 You can repeat the steps 19 23 for other gages or channels The sensor terminals repeat every five positions Signature Technologies Inc 321 General Installation amp Programming Guide Check 6 Aberrations in the signature display Typical Problems There are several broad categories of problems which can be caused by either wiring problems or properly wired signals which have either too much D C Offset at rest common in customer created sensors OR sensors which have excessive signal output in use common with commercial sensors Let s take a simple example of a signature showing a coining peak Normal shaped Peak tnd Rode Penn wht wl nada Figure 247 normal coining force peak The Rounded shape of this signature is typical for compressive type operations which typically are the highest force features on normal signatures The coining peak is generally located right at 180 degrees and is caused by either significant coining operations in the die like flattening setting corners or other operations which require some cold flow of material It can also be caused by metal to metal closures in the tooling designed to control the B D C position of the ram Signal Inversion If you re going to have a problem this is
463. tye surface Figure 7 TEB interface Board dimensions TEC without enclosure Signature Technologies Inc signatureACE Figure 9 BOX with 1 and 2 Sams installed Signature Technologies Inc 25 General Installation amp Programming Guide Figure 10 BOX With Computer card and Back View 7 23 00 Required Clearance 0 91 s 2 to open cover od pay I T n l m 25 00 als 9 als l Se S p cf aE ap LN Reape ee oe No HE 150 00 e Required Clearance ais 6 00 5 l 4 SS y Rs for Ventilation alr AN a Re a d y m H i 1 305 00 12 00 E 398 40 A 15 70 E 568 40 22 38 Suggested Wiring Clearance Figure 11 BOX enclosure Dimensions 26 Signature Technologies Inc signatureACE ye Required Clearance to open cover Suggested Required Clearance Wiring Clearance for Ventilation i T l 25 00 oe sig 1 00 gle m2 B ss L 150 00 N 00 aes 6 00 Figure 12 BOX Side View signatureACE Mounting The SA2000 and the SAMnet module are installed by plugging them into ANY free physically compatible ISA slots in the Host Computer The TEC Terminal Enclosure can be located anywhere on the machine that is available although mounting it in an accessible location would make it easier to service and hook up The length of cable between
464. type normally used in auxiliary normally have a large amount relatively of back lash new and this backlash only gets worse as the drive wears NEVER drive the resolver with a roller chain Roller chains stretch and develop loads of play rapidly You can expect 2 3 degrees of uncertainty from a roller chain drive after a little wear NEVER strike the resolver shaft with a hammer or other appliance If the pulley or coupling you are trying to use won t slip on the shaft by hand IT S TOO TIGHT Relieve the bore a little so it slides on Premature resolver failure will result from shaft abuse See also the list of warnings on page 226 NEVER drive the resolver with a coupling that doesn t tolerate Parallel Misalignment We DON T RECOMMENDED driving the resolver from auxiliary shafting driven by Timing Belt drive from the Crankshaft Timing Belt drives are tighter but normally show in the larger sizes as much as one degree of uncertainty In addition even though there is essentially no backlash in a Timing Belt drive there is some stretch which translated to positional uncertainty if a variable torque load like an indexer or a roller cam feed is being driven On the other hand torque induced positional uncertainty in a Timing Belt drive tends to be repeatable from revolution to revolution and may not constitute a serious problem The user should be aware however that his position reference may be distorted by several degrees at certain p
465. u MUST determine whether the existing System COMMON is acceptably related to EARTH GROUND This can be done as follows 1 Connect with the system power turned ON a VOLTMETER between the Common connection and the panel sheet metal 2 Set the voltmeter to AC Volts If the voltage you measure is a fraction of a volt up to 1 or 2 volts go to the next step If there is significant gt 5 voltage present call Signature Technologies 972 488 9777 for further information 3 Set the Voltmeter to DC Volts If the voltage you measure is a fraction of a volt up to 1 or 2 volts you can connect the CNV Common to the Chassis common If there is significant gt 5 voltage present call Signature Technologies 972 488 9777 for further information Signature Technologies Inc 247 User Manual In Current production are the SB 027 8004 INPUT and SB 027 8006 OUTPUT cables Make special note that there are THREE BLACK wires in the Input cable and FOUR Black wires in the OUTPUT Cable one in each pair Make sure you have the right one as shown in the pairing in the diagrams below Hookup Type Variations for the CNV Resolver Converter There are quite a few different system configurations just about all of which can be serviced equally well by the ST Resolver converter can t be all inclusive but the following section gives typical types of resolver connection for popular Existing systems The terminal names on the Existing system
466. ubing for signs of localized bending and adjust so there is a smooth rolling action to the cable as the press strokes A properly dressed cable will last for YEARS 226 Signature Technologies Inc signatureACE WELD PAD METHOD FOR MOUNTING SENSORS Step No 1 Remove all paint grease or rust from surface to be welded Surface should be flat T LR 1 32 of an inch Step No 2 Bolt the weld pads to the fixture with the socket head cap screws provided The user may want to drill and tap for the center holding screw The center hole may be used to hold the fixture down flat and tight while welding the weld pads to the press member Step No 3 Hold the fixture flat and tight Weld the weld pads to the press member BE SURE TO ONLY WELD THE WELD PADS ON THREE SIDES AS SHOWN A single pass is sufficient Do not remove fixture until slag is removed and or assembly has cooled The 4 screws may be discarded Do Not Use Screws To Assemble Sensor When welding to cast iron use a dry nickle rod such as Lincoin Electric Soft Weld Hobart NI Cast 99 MB Weld Prod MG 210 Strike arc on steel then puddle into the cast iron Step No 4 Remove weld fixture Weld Pad surface must be clean no weld bumps scratches etc Be sure tapped holes are clean and Step No 5 Mount the sensor with raised rib to the press The anti torque washers should go between the screw and the sensor body 144 28 X 1 1 4 SCREW METRIC 6 1 X35 Figure
467. uctions require If nothing is found there note down how the lights are acting as the press turns and give ST a call at 972 488 9777 Make sure you re on line 1 2 The Yellow light just to the LEFT of the BYPASS box at the lower right side of the SIGNATURE screen should be on If it isn t You re Off line Click on the BYPASS box The Yellow light just to the LEFT of the box should blink out momentarily and then come back on If it does the Host Computer is Talking to the SmartSAM unit normally proceed to the next section BUT If it just goes OUT and stays OUT You re Off line There is no communication over the Coaxial cable between the Host and the SmartSAM In this case a Check to see that the address of the SA2000 as shown on the ADDRESS rotary switch as shown below matches the address for the press that you have made If they re different change the switch position to match Signature Technologies Inc 253 User Manual HEARTBEAT Indicator TEST Address Buffer Full Connector pitch Indicator RESET Button a TEST Button Slaving Connector Sensor Gain Gage Excitation Jumpers Jumpers Figure 194 Switches on SA2000 Module set b Select from the menu bar CONFIGURE Then select Configure SAMnet You will be shown a screen with 32 locations on it The location 16 green light should be ON and the text below the light should say This Node This indicates that t
468. unimportant as is his level of scholastic achievement The sensor Guru is an intensely practical position requiring primarily a good mechanical sense one who repairs his own auto will probably be superior to one who has a doctorate in mechanical engineering but wouldn t dream of changing his own oil and might not be sure how to The old axiom is that Navy Submariners are some of the best folks to have BECAUSE when you re 1000 feet down and something s not working right you gotta get innovative to survive Tool and die folks are generally better at visualizing the operation and intuitively figuring out where the sensing should go than electrical engineers Mechanical sense and enthusiasm for the challenge will go a lot further than book Learn in generally 198 Signature Technologies Inc signatureACE Basic SAMview system maintenance There are several areas that require periodic attention A schedule of basic maintenance requirements is listed here Appendix 11 has some additional details for some of the following procedures Weekly Change level 4 and 5 passwords Take a look at the historical storage to make sure that the hard drive is not becoming too full Archive off as needed following procedures contained in Appendix 11 under Cleaning out the Hard Drive Check the filters on ventilated enclosures Wash off or replace the filter elements as necessary depending on the type used NO NOT operate the system with bloc
469. ure and limit sets that you want to append to the hard disk 4 Exit the SAMView program 5 Change directory to SAMDATA lt Press Name gt lt Tool Name gt 6 Using the DOS command copy the Signature and Limit files by name onto the hard drive Deleting Signatures from the Database After saving signatures of interest to an archive disk it is often useful to delete these signatures from the operational database This procedure is useful in speeding up operation of the software as well as clearing the clutter from the useful information The following section describes how to remove selected signatures from the database forever This capability is password protected to the highest level by default 1 Select the Signature Playback Setup screen from the Options pull down menu 2 Use the time stamps and Show filters to determine which signatures are to be deleted 3 Remove all existing signatures from the playback list by pressing the Remove All button 4 Copy the signatures to be deleted to the Playback List by selecting lt lt Add All or selective add individual signatures from the Available List 5 Press the Delete Signatures button If you are not already logged on as a level 5 user a password pop up will appear Entering a valid password will allow you to continue 200 Signature Technologies Inc signatureACE 6 You will be prompted twice to delete these signatures from
470. us The SPCview system is similar to the SAMview system It displays the system fault status on the 1 through 6 buttons at the bottom of the screen It also displays the feature pens on the right side of the SPC graph screens When features are assigned to a tool they are assigned an operating mode Control or Bypass Control Mode When a feature is in Control mode and the current press is in control the SPCview system will shut down the press when a feature exceeds its limits Bypass Mode When a feature is in Bypass mode the SPCview system will not affect the operation of the press regardless of the system operating mode 122 Signature Technologies Inc signatureACE Section 9 Adding Machines to the system The following task assumes that you have at least one press and one tool defined already and that they are functional You can then add an additional 7 Machines for a total of 8 to the host computer While each machine will then be viewable on the same Host Computer one at a time except in the Overview screen They will all be totally independent in operation and will each produce their own separate databases Most of the steps in adding a machine are essentially the same as those performed in Programming the first Press so they will not ALL be enumerated here only the differences in the procedure will be given NOTE See the Adding SA2000 units to an existing press Section 11 b
471. use a Timing Belt drive instead 234 Signature Technologies Inc signatureACE 2 Be careful of oil canning in the mount surface We don t recommend attaching the resolver mount tripod to a sheet metal end cover as would be installed over a drive gear Excessive horizontal motion of the mounting surface will cause bearing problems and broken couplings Use a Timing Belt drive instead Crankshaft Drive stub Coupling Resolver Resolver X1 Cable 3 Ht exe Resolver support Figure 178 Top view resolver end drive 3 Make sure you tie the cable down to the support members as close to the connector on the resolver as possible to eliminate swing Any motion between the cable and the connector will eventually result in a broken cable The strain relief on the connector is a help but won t do the job alone The cable must be tie wrapped to the support structure 4 Watch out for excessive vibration at the resolver mounting position If the press really hammers it is advisable to cushion the shock transmitted to the resolver The best way of doing this is to install Pads of FABREEKA or similar material between the tripod legs and the press The idea is not to overly cushion the resolver bracket but merely to eliminate high frequency shock The type of shock energy that will hurt the resolver normally has a high frequency but very little amplitude actual motion A relatively stiff isolation technique can eliminate the
472. w user interface Operation of the signatureACE system Machine Mounted Load Sensor s Machine Position Sensor The Security om Single operation access Display the fault Diag To reset the fault To Quit SAMview To Load an existing Control Key combinations Complex functions Signature Technologies Inc 5 General Installation amp Programming Guide Configuring manual Configuring automatic fault saving CAMview user g The Programmable CAM function QUICK Start SECU OM siectcvssssscecsseuPasscssscsisisvscasesesesieedsotssvsssadbetedscsuvbusievedoosasidsssstsslvosoasus vesdioasbaviedaselisbsstisvectensebielestesoboose Channel Active column Description State Indicator On An Dwell Time ms Cancel Pro Pro Editing procedure Cam protocols Definition The terms IDIEview user The Die protection function Quick Start Section Sensor type Output Relay 6 Signature Technologies Inc signatureACE ROR ee ee 180 End of Stock Buckle Slide Parallelism Ground detectors B Wire Proximity 2 Wire Universal Prox switches Die protection E protocols D eniron The terms Signature Technologies Inc T General Installation amp Programming Guide The The Kno connect gt AmA Press and Tool Information Printing Printing a Selected Group
473. ways return to do the following A Click Configure from the top menu bar B Click Screen on the pull down menu C Click Configure from the top menu bar D Click Exit Configure from the pull down menu E There will be a Pop up that asks if you want to save this view as the Current View Answer Yes F There will be another Pop up that asks if you want to save this view as the Default View Answer Yes if you want all your tools to have the same appearance Operational Mode selection 144 Signature Technologies Inc signatureACE The System has TWO major operational modes CONTROL and BYPASS 1 Control and Bypass modes ONLY affect the SAMview and SPCview FeatureView functions 2 Control and Bypass affect only the RED and YELLOW limit sets The WHITE Press curve or capacity limit CANNOT be bypassed 3 DIEview fault outputs CANNOT be bypassed In Control mode breaking either the RED or YELLOW limit sets for either the Signature or the SPC functions will cause the associated output module to OPEN until the Reset Fault button is Clicked on Restarting after the SAMview system stops the machine Display the fault If the signatureACE System stops the machine you should first attempt to find out WHY the system took that action The Channels that faulted will be highlighted in YELLOW RED or WHITE Depending on the
474. we must set the maximum levels that are fed to the SA2000 module Both the SIN and COS signals will reach peak amplitude twice each revolution but 90 degrees away from each other In order to adjust the levels do the following a Adjust the SIN signal looking at the SIN lights b If Green only or both Red amp Green lights flash on as the machine turns turn the SIN adjustment potentiometer CCW until they both stay OUT If both lights are always out go to step 3 THEN c Turn the SIN adjustment CW until the Green light just flashes ON d Continue turning the SIN Adjustment CW until the Red light just flashes ON e Turn the SIN Adjustment screw CCW until the Red light doesn t flash on f At this point the Green light should flash ON and OFF and the Red light should stay OUT g Repeat steps 2 thru 6 for the Cosine signal looking at the COS lights and adjustment If there is a problem getting the lights to behave properly or if the SIN and COS lights tend to come and go off together instead of 90 Deg apart the Resolver Converter connection to the existing system may be non standard For example C amp A programmable cam units use S1 S2 as the SINE and S3 S4 as the COSINE windings instead of the more standard S1 S3 and S2 S4 In this case reverse the GREEN and BLACK White wires and try re adjusting the levels If you have continued problems check the wiring of the OUTPUT Cable to make sure it s just as the instr
475. ween the strain sensor input and the position of the machine in degrees of rotation The machine position sensor is normally a resolver and is an input to the SA2000 Module TEC Assembly Figure 110 TEC unit 134 Signature Technologies Inc signatureACE The Termination Equipment Cabinet TEC as shown in Figure 110 is the small metal box with the printed circuit card and terminal strips mounted in it ALL electrical connections to the signatureACE unit are made to the TEC 9 i ol of o of olf 94 of of Oo o n E o o jo jo o 2s beet o of of of o aus EX IBISBSSGISISSIODS 7 4 Sof ij j o wV NAISIIN Bae de wee deheasdaagadaal X lt seo rt r es es eS eS Ie N o w W N 5 2 8 a B 5 LIGHT_STACK SHIEU x D13 A 01478 EX SH ELD PAL LA SOLA AER RA J i z D ery Figure 111 TEC Connection Board Version B This component can be mounted up to 50 away from the SA2000 module set The TEC unit is a PASSIVE device that serves to make connection to the SA2000 module set easier by providing termination points for all system signals It provides the following functions 1 The TEC provides Screw terminals for all inputs and outputs needed for system operation 2 It also provides power supply status and zero passing indication on internal LEDs 3 A fuse tester is provided since the output module fuses don t indicate their
476. would be in error Calibration by either the Static or Dynamic methods as detailed below can be used with underdrive machines but normally isn t due to the higher amount of labor and time required to do it Tooling sensors non calibratable There are some cases where meaningful force calibration may be practically impossible This is normally in cases where In Die instrumentation is used in such a way that Hot Spots of force sensitivity are created Load probing is one technique wherein holes are drilled into the die and implantable sensors or Load Probes are inserted It is impossible to then apply a calibrated force to the die such that quantitatively interpretable results would be obtained from the Load Probe Since the force reading would depend heavily on the location of the force relative to the sensor In these cases the system user will probably want to use the Force Calibration utility to adjust the displayed sizes of the sensors just for convenience of viewing Tooling sensors externally calibratable There are other cases where it may be difficult to apply calibrated force to an instrumented tooling element when it is installed in a die If this is the case the instrumented component can be calibrated externally and the numeric data thus acquired can be processed and entered numerically into the SignatureACE Force Calibration system to achieve calibration of that element In general the gauged component when it is
477. y disks To accomplish this execute the following steps Signature Technologies Inc 199 General Installation amp Programming Guide 1 Perform a search in Edit Playback for the selected signatures to be backed up Select Show Limits if you want to save the limits as well Select Master Limits to see what the master sets are The last one chronologically will be the current master 2 Verify using playback on the Signature View screen that the signature you ve chosen is the right one 3 Copy down the File names of the signature and limit sets that you want to archive off 4 Exit the SAMView program 5 Change directory to SAMDATA lt Press Name gt lt Tool Name gt 6 Place an initialized formatted floppy disk in the disk drive 7 Using the DOS command copy the Signature and Limit files by name onto the floppy Restoring to the hard drive It may be desired to restore selected signatures back onto the hard disk from floppy disks The procedure below can be used to Append signatures from floppy discs into an existing database To transfer signature data from the floppy disk drive to the hard disk drive i e restore signatures to the hard drive execute the following steps 1 Insert the floppy disk containing historical signatures in the floppy disk drive 2 Verify using playback on the Signature View screen that the signature you ve chosen is the right one 3 Copy down the File names of the signat
478. y drive system on larger presses is generally not ultra tight but due to the large diameter of the gears and a lot of flywheel effect they still have a relatively good accuracy We want however to be driven right from the auxiliary source without any interposed gearing or couplings that can generate play On larger machines this is often the only alternative for resolver drive since the shafts that carry the drive cams don t turn DESIGN PRACTICES In general you should go for rigidity and very low torsional compliance in the resolver drive The primary thing that you want to accomplish is that the resolver shaft should always move in total synchronism with the crankshaft or other final drive element of your machine Mounting the resolver It is not necessary to shock mount the resolver in any but the most brutal applications We suggest that the resolver be mounted using the four 14 20 tapped holes in its side The screws should be installed with medium strength Loctite to prevent loosening It is generally a good idea NOT to use END mounting for the unit even though provision has been made for it END mounting tends to produce a large cantilevered load on the mounting screws which will be likely to cause them to loosen in the long run It will also cause amplified vibration at the connector end of the resolver unit that is not good for either connector or cable life Resolver cable control The mounting bracket should be
479. y screw in the chassis The common mode inputs of the HiRes converter will sort the signals out properly in spite of not having a good common reference 258 Signature Technologies Inc signatureACE TEC Board Analog input SHIELD OAA se H Ex IO SHIELD D15 A4 D16 A4 EX SENSORS Figure 197 TEC Version B Input connections Signature Technologies Inc 259 User Manual z Channel 1 lt gt Channel 5 lt Channel 2 lt gt Channel 6 Analog Analog Sensor A Sensor Inputs Inputs Channel 3 lt gt Channel 7 Channel 4 lt gt Channel 8 i AZ SENSOR Figure 198 TEC Version C Input connectionsError Not a valid link Differential Mode LO range 2 5 volts 1 A D count 1 2212 Millivolts Differential Mode HI range 0 005 volts 1 A D count 2 4425 Microvolts Auto Zero Is a built in system which cancels out any static voltage offsets on the sensor inputs primarily to eliminate the effects of thermal drift For Auto Zero to operate properly In HIGH range the static offset voltage should be LESS THAN 0 004 volts 4 millivolts AND more than 0 003 volts 3 millivolts for FULL RANGE capability In LOW range the static offset voltage should be LESS THAN 1 75 volts AND more than 1 0 volts for FULL RANGE capability Auto Zero occurs either When the clutch input to the
480. ystem sees thereafter will release the clamp The first step is to look for the flashing LED If you don t see it look at the SA2000 module The ZRO light Under the connector on the left most board should flash once per rotation at ZERO degrees It should also flash once each time the clutch engages a Ifthe light flashes everything here is O K read on b If the SA2000 ZRO light flashes and the TEC RSCB light doesn t the cable is bad c If neither the SA2000 or the TEC RSCB light flashes the SA2000 probably is defective am assuming that at this point you have confirmed or fixed the operation of the ZERO light Keep the following in mind If all is working O K it is impossible for any signatures to have a CONSTANT offset from ZERO NOTE The machine performs the offset compensation at ZERO degrees of rotation The signature generally starts more than 100 degrees later It is possible that forces can build up in the machine frame so that the signature starts at a point either above or below zero counterbalance force for example You can check this by putting in your FINDIT Tool and seeing what the machine force is doing close to zero degrees You should not see much vertical jitter at this point and if there is any it should be centered at zero Of course you wouldn t be reading this if you didn t have a problem unless you like reading phone books so Watch the machine for long enough to see all tha

User Sep-03-2004dist.. - Signature Technologies

Contents

Download Pdf Manuals

Related Search

Related Contents