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1. e Select the latest version of the Station Controller application e g SC_v_1_4 using the drop down combo box labelled Project Name e Ensure that the Execution Mode is set to Real e Press the Start button User Manual Enhanced miniMACS Start up Instructions e 64 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 6 5 2 Auto start of the OpenControl Monitor By providing an argument to the OpenControl monitor when started it can automatically launch the Station Controller application started By placing a short cut to the OpenControl Monitor in the Autostart group the PC can then be configured to automatically start the Station Controller whenever the PC is started To do that do the following e Create a shortcut to the OpenControl monitor OCM EXE in C WINNT Profiles All Users Start Menu Programs Autostart The file OCM EXE is normally found in the directory C Program Files Nemasoft OpenControl e Edit the properties of the shortcut by adding ApSC_v_1_ 4 to the filed labelled Target Shortcut to OCM exe Properties 12 xi General Shortcut Security gt Shortcut to OCM exe Target type Application Target location OpenControl Target es NemaS oft OpenControl OCM exe ApSC_v_1_4 M Runin Separate Memnon space Start in E Program Files NemaSoft OpenControl Shortcut Key None Bun Normal window k Eind Target Change
2. Guaranteed 888 88 SOURCE www artisantg com Special Opens the Special dialogue for the currently selected spindle s M ox _ Relay function OK Cancel Controller OK C Overvoltage shutoff Check Hold servo in position between steps if you want the servo to control this for you Using the Relay function radio buttons you define which event that should activate the relay output Select current spindle Invokes the following dialogue Select current spindle x Select current spindle to communicate with Spindle 1 7 S ae 1 Here you select the current spindle Available spindles depends on the number of spindles that was set using the System dialogue This function is also available on the toolbar User Manual Enhanced miniMACS The WinQCM E e 14 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 3 4 Setup System This function is used to set the main parameters of a system Here you can set how many spindles there are in the system the type of servos used and the torque unit Communication Displays the parameters of the CAN communication You are able to set the baud rate of the CAN board in the PC If you change the baud rate here you must ensure that the corresponding parameters are set in all servos as well User Manual Enhanced miniMACS The WinQCM E e 15 Artisan Technology Group Quality Instrume
3. Memory ZMUB 8 Bit Unsigned amp File Edit Project Tools Window Help 18 x ole salg llel x al E visa zeu Flow Chart Insert a Delete Copy Sie po 446 16384 InterBus Configurator Logic Memory Alias Wire Label Initial Value Retain Constants MUB1 2 No hdl eos Inputs MUB2 0 No i Memory Setl_RM_MazFailedSpindles ZMUB3 0 No hd ZMB 8 Bit Signed Setl_RM_BackDifSet ZMUB4 0 No M ZMD 32 Bit Signed Setl _AM_ReTighteningSet ZMUB5S 0 No ZMF 32 Bit Real Setl_RM_2ndFailureAction MUBB 0 No hd ZMR 64 Bit Long Real ZMUB7 0 No Set2_RM_MazsFailSpindles ZMUBS 0 No bd ZMUD 32 Bit Unsigned A MUW 16 Bit Unsigned Set2_AM_BackDifSet MUBI 0 No zi ZMW 16 Bit Signed MUB10 Set2_RM_ReTighteningSet MUB10 0 No MX Bits MUB11 Set2_RM_2ndFailureAction MUB11 0 No ld Motion MUB12 MUBI2 0 No gt Outputs MUB13 Set3_RM_Maz F ailedSpindles MUB13 0 No bd PF Tags MUB14 Set3_AM_BackOffSet MUBI4 0 No gt I RMUs MUB15 Set3_RM_ReTighteninaSet MUBI15 0 No E Strings MUBIB Set3_RM_2ndFailureAction MUB16 0 No zi Timers MUB17 MUB17 0 No hdl ProfiBus Configurator MUB18 Set4_RM_MaxFailedSpindles MUBI8 0 No SDS Configurator MUB19 Set4_RM_BackOffSet MUBI19 0 No zi Seriplex Configurator MUB20 Set4_RM_ReTighteningSet MUB20 0 No ZMUB21 Set4_RM_2ndFailureAction MUB21 0 No
4. Spindle type Set default parameters for spindle Cancel m Parameters IGAIN fi 0 DGAIN 2000 PGAIN 100 Nominell speed 6400 1pm Ramptime 300 mSec Gear fa 574 Current scale factor fe00 Maximum torque faa Select a spindle type and press the Set default values for the spindle button Default parameters will then be automatically inserted With the Maximum torque parameter one select the range for the spindle If the Maximum torque is above 400 Nm Ftlb torque values can not be programmed with decimal Note The default value of Maximum torque is not stored in the servo meaning that if you read parameters from the servo WinQCM will only get the information Torque decimal or no Torque decimal The exact torque value is lost and the shown value will be lt 400 or lt 4000 Depending on the spindle type the default values of the parameters are as follows Spindle PGAIN IGAIN DGAIN Nom Cur scale Gear Max QMR speed See note 1 See note 2 torque 42 25 100 10 2000 7000 2000 6400 2000 6400 62 46 2000 6400 90 30 125 2500 5000 90 47 125 2500 5000 2000 6400 2000 6409 2000 6400 2500 5000 User Manual Enhanced miniMACS The WinQCM E e 12 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Note 1 If 0 lt Max torque lt 400 the values shall be multiplied with 100 If 400 lt Max torqu
5. The Profibus output buffer of the Station Controller and the Profibus input buffer of the FBU each holds 41 bytes of data As soon as any value in the Station Controller buffer changes the complete 41 bytes are sent over the Profibus to update the FBU buffer The buffers hold the following data 1 EUN code 16 bytes Buffer byte no 0 15 2 Spare 9 bytes Buffer byte no 16 24 3 Start Time 8 bytes Buffer byte no 25 32 4 No of Spindles 1 byte Buffer byte no 33 5 Stationword 2 bytes Buffer byte no 34 35 6 Inhibitmask 5 bytes Buffer byte no 36 40 The EUN code and StartTime data are sent to all servo drive units This is only information included for stamping report and trace data etc The Inhibitmask Stationword and No of Spindles data are combined to an 8 bytes control word which is also sent to all drive units In each servo drive unit this information is first unpacked and then the Stationword is combined with the bit in the Inhibitmask that corresponds to the drive units node number The modified Station word is then used as input to the local sequence handler in the servo drive unit User Manual Enhanced miniMACS Appendix 73 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com The control data included in the Station word no 5 above are listed below Machine Stop_N Logic zero will stop the tightening step in progress and put the servo in status NOK
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7. If you press the Information button ia dialogue box is presented where you can enter the UTL LTL su and sl values for the selected variable Results The menu alternative SPC Result invokes the View Statistics window which displays the statistical curves calculated by the SPC In the upper right corner you select which type of display you want e Average and Standard Deviation Range curves e Ditto for Short Term Trend e Histogram Select the variable you want to study with the controls Spindle Set and Variable When a selection is made the curves for Average and Standard deviation or Range SPC Statistics x Station satl_2sp v Setno 5 x a i C Short Term Trend Spindleno fi gt Variable Torque z Histogram Average UCL 031 LCL 0 04 Mean 0 13 Cp 6 49 Cpk 6 05 Standard Deviation UCL 0 23 Mean 0 09 3Sdev 0 27 3Sdev 0 27 3 2 Clear Data Delete Subaraup Print Refresh Close User Manual Enhanced miniMACS The WinQCN E e 21 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com are plotted for the variable in question To the left the current values of e g Cp and Cpk are displayed These values are either calculated on the SPC and TDA data buffer or the short term trend buffer dependent on the current selection in the form If you find a subgroup in the SPC and TDA buffer which have an abnormal value you can delete
8. A sequence of numerical characters and an optional dot as decimal point that can be interpreted as a float value lt dateStr gt A sequence of characters that makes up a date formatted as yyyy mm dd lt timeStr gt A sequence of characters that makes up a time formatted as hh mm ss Ht lt Horizontal tab gt decimal ASCII code 9 EOL lt Carriage return gt lt Line feed gt decimal ASCll codes 13 and 10 Example of the message body HEAD 99 Flywheel 11ABC 990260001 1999 01 28 152502911 2 NOK 2 SPINDLES I 2 2 T0 30 120 0 60 0 360 0 0 000000000011 2 2 3 1 0 33 0 420 0 60 0 360 0 0 001000000010 User Manual Enhanced miniMACS The MMS Interface e 36 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 3 6 End of cycle data This telegram is sent to the MMS server from WinQCM to indicate that there are no cycle data to transfer The telegram has the following format it has no message body lt telegram type gt 4 decimal ASCll code 52 lt message body gt not valid Example STX 4 ETX or as decimal ASCII codes 02 52 03 3 7 Unknown telegram received This telegram is sent to the MMS server from WinQCM to indicate that it has received an unknown telegram The telegram has the following format lt telegram type gt 0 decimal ASCIl code 48 lt message body gt MMS_SERVER Unknown message lt receivedTgmType gt lt receivedMsg
9. ETX where STX Start of text decimal ASCll code 2 One byte lt telegram type gt One byte identifying the type of telegram lt message body gt The message A message of variable length zero or more bytes The contents depends on the lt telegram type gt ETX End of text decimal ASCll code 3 One byte User Manual Enhanced miniMACS The MMS Interface e 32 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 3 2 Request for all cycle data currently stored This telegram is sent to WinQCM from the MMS server when it wants all cycle data currently stored The telegram has the following format it has no message body lt telegram type gt 4 decimal ASCll code 49 lt message body gt not valid Example STX 1 ETX or as decimal ASCII codes 02 49 03 WinQCM responds by sending one telegram for each cycle data currently stored The data for the oldest cycle will be sent first the second oldest is sent in the second telegram and so on until all cycles stored are transferred To indicate that all cycle data are transferred WinQCM sends an end of cycle data telegram If there are no cycle data recorded this is the only telegram sent 3 3 Request for all cycles not currently read This telegram is sent to WinQCM from the MMS server when it wants the cycle data of all cycles recorded since the last request for cycle data The telegram has the following format it has
10. Engine ID EUN Engine ID EUN Engine ID EUN EUN Plant code EUN Build year EUN Build year EUN Julian day ASCII Alpha Numeric ASCII Alpha Numeric ASCII Alpha Numeric ASCII Space ASCII Numeric ASCII Numeric ASCII Numeric ASCII Numeric oO ATA ATA EUN Julian day EUN Julian day EUN Daily seq No nm ASCII ASCII Numeric ASCII Numeric ASCII Numeric Numeric Jn EUN Daily seq No EUN Daily seq No ASCII Numeric ASCII Numeric Spare Spare Station Byte Spindle Bypass 1 8 For Potential 4 Byte Build Year For Potential 4 Byte Build Year Binary See description below Binary See description below Spindle Bypass 9 16 Binary See description below Spindle Bypass 17 24 Spindle Bypass 25 32 23 31 Spare Binary See description below 0 e so 9 EUN Daily seq No 16 20 Binary See description below Future Use Station Byte Description Byte 18 Bt Description Comment 0 Start Stop Stops the station i e Machine stop to all spindles Starts the station i e all spindles Parameter bitO Tightening set binary bit 1 Parameter bit1 Tightening set binary bit 2 User Manual Enhanced miniMACS Appendix 70 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Parameter bit2 Tightening set binary bit 4 Parameter bit3 Tightening set binary bit
11. No other operations are involved Note Not to be used with emergency stop Controller ON Set the input to logic one to enable the servo drive to runa parameter set When Controller ON is set to logic zero the panel alarm indicators are cleared and the servo drive unit is reset from any error condition except breakdown in the resolver connection In this case you must power down the servo drive correct the error and power up again to reset the error signal Please note The output signal Controller OK must indicate the servo drive running properly relay contacts closed at connector K7B 35 36 at the time Controller On is set to logic one The internal computer reads the transition from one logic level to the other Cycle Stop Logic one will stop the tightening step in progress and put the servo drive in status OK if the control mode for the step is of type END If the control mode for the step is of type Con for continue the next step program will be started No other operations are involved Designed with for instance positioning tasks in mind A limit switch can be used for the Cycle Stop input Set the input tologic one to start a tightening cycle beginning with the step program selected by the address on Select 1 2 4 8 16 32 and ending with the step program containing the control mode END The input signal Controller ON has to be set to logic one green LED Rady is lit b
12. Stores the data currently displayed in the MMS window to disk User Manual Enhanced miniMACS The WinQCN E e 29 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 3 11 Help menus File View Spindle Setup Loadparameters Accesslevel SPC Trace Repot MMS Help Topics Help Topics To be implemented About WinQCM E Displays the WinQCM E about box where you can se the version number of the program User Manual Enhanced miniMACS The WinQCM E e 30 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 3 12 Toolbar Following functions are in the toolbar New Open Save Print Select current servo On line Off line and Log Select current servo is a pop down menu with following selections Servo 1 servo 2 servo 32 On line Off line has the text on line In on line the button appears pressed and above the text three dots shows up and disappear When off line the button looks to be in its upper position A parameter change in On line mode is written directly to the spindle and it can be seen that the three dots change colour normally from blue to red during the transmission time New Open and Save are standard window symbols and will create open or save the set up Log will activate the saving of data to a file 2 3 13 Language The program is available in English German and French User M
13. miniMACS PC i Station WinQCM E Controller NT Open Control Lan 2 Trace data Profibus Results vO Status Status Error codes QCM2 Servo The miniMACS PC consists of three parts the WinQCM E GUI the Station Controller and a MMS interface User Manual Enhanced miniMACS Introduction e 1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com WinQCM E is the tool used to configure the servos including the tightening programs used WinQCM E is an enhanced version of the WinQCM 81 43 The Station Controller is responsible for the co ordination of the individual servos in order to make them act as a unit It mainly handles start and stop of a cycle and possible reject management actions In order to achieve real time performance the Station Controller is implemented using OpenControl OpenControl provides a framework to program and run machine control applications on Windows NT system See Ref 08 for a description of the OpenControl environment The MMS interface is used by other remote applications in order to access cycle data from the miniMACS PC The MMS interface is implemented as a separate application which is interfaced to the WinQCM E using a socket The Field Bus Unit or FBU receives control data from the Station Controller over the Profibus interface The FBU processes the control data and sends it to the servo drive units over the Lani bus The statu
14. rpm Nm deg a eld O Step ie Ternat 70n i mee Target ma a ulete ee i 1 10 0 ee 180 140 80 2 Delay 0 0 4 ja 0 R 3 ngle 10 0 0 0 5 i 180 0 60 No 4 Angle End 10 0 0 0 5 0 180 0 30 No 5 Angle 10 0 0 0 5 230 180 140 80 No 6 Delay 0 0 0 0 5 0 0 0 R Torque 10 0 3 0 0 0 5 0 0 100 No g Angle End 10 0 0 0 5 0 180 0 30 No R 9 Angle End 10 0 0 0 5 0 360 0 60 Yes R 10 Torque End 0 0 3 0 0 0 3 0 0 100 Yes R 11 Angle End 5 0 0 0 5 100 90 0 60 No R_12 Delay End 0 0 0 0 00 0 0 R 13 Delay End 0 0 0 0 0 0 0 0 R 14 Delay End 0 0 0 0 0 0 0 0 R 15 Delay End 0 0 0 0 00 0 0 R 16 Delay End 0 0 0 0 0 0 0 0 R 17 Delay End 0 0 0 0 0 0 0 0 R 18 Delay End 0 0 0 0 00 0 0 R 19f Delay End 0 0 0 0 0 0 0 0 R 20 Delay End 0 0 0 0 0 0 0 0 X a gt f Results A Tightening cycles MMS For Help press F1 NUM 09 40 4 A step is selected by clicking on it To change the parameters of a step double click on the step in question This will launch the Tightening steps dialogue to be opened in which you can do your modifications User Manual Enhanced miniMACS The WinQCN E e 5 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 2 3 The MMS Window Using the MMS window you can study the current status of the MMS queue The MMS queue contains the result of the last cycles executed The length of the queue is default 100 cycles but is configurable See The MMS Interfac
15. 8 lo Spare On pos edge station amp all spindles will be reset Spindle Bypass Byte 19 22 Description Comment Bypass Spindle 1 1 Bypass Bypass Spindle 2 1 Bypass Bypass Spindle 3 1 Bypass Bypass Spindle 4 1 Bypass Bypass Spindle 5 1 Bypass Bypass Spindle 6 1 Bypass Bypass Spindle 7 1 Bypass Bypass Spindle 8 1 Bypass 7 2 2 Outputs The interface to the overriding Automation PC consists of the following output signals Byte Description Comment Station byte 0 Binary See description below Station byte 1 Binary See description below Spindle 1 byte Binary See description below Spindle 2 byte Binary See description below Binary See description below Spindle 32 byte Binary See description below Station Byte 0 All spindles in the station have ended the cycle correctly All spindles in the station have not ended the cycle correctl Running Station is busy running the tightening cycle including RM actions RM back off started The first RM action started Bit is cleared of a new station start station start RM re tightening started The second RM action started Bit is cleared of a new User Manual Enhanced miniMACS Appendix e 71 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Communication with FBU or between FBU and spindles failed Parameter set failure Different s
16. BR Clear Data Delete Subaraup Print Refresh No matter whether you display SPC and TDA Short Term Trend or Histogram you may study a particular part of the curve by zooming it in Place the mouse cursor on the left most position that is of interest press the left mouse button and drag the cursor to the right until the wanted area is marked and release the left mouse button Click on the right mouse button zoom out again If you want to have the current view on paper press the button Print User Manual Enhanced miniMACS The WinQCM E e 22 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 3 8 Trace File View Spindle Setup Load parameters Access level SPC Report MMS Help Each servo records the current torque and angle values during the tightening cycle This trace is stored in the servo Each servo stores the traces of the10 last cycles as well as the 10 last NOK cycles Here a cycle is found to be OK NOK based only on the result of each individual servo i e spindle OK NOK The menu alternative Trace View Traces invokes the Trace viewing window which is used to present the traces Spinde Trace rere Sp 1 OK NOK Latest 1 Station satt_2sp 7 OK NOK Latest 1 7 Spindle no 2 7 C NOK Latest x i i Select saved trace Clear All 350 Less data Display angle Vs Time Refresh Print Save Close E
17. S Open Save Save As rimt bie Print Previevy Rant Setup 1 satl_2sp_v4 gel 2 satl_2sp_ 3 ge1 3 satl_2sp_v2 gel 4satl_2sp_v1 gel Exit Here you will find the standard functions for file handling New Open Save Save as Print and open any of last four files New Use this function to create and initiate a new set up When selected the System dialogue is displayed in which you must enter the main system parameters Open Opens an existing WinQCM E set up file This function is only available when the system is in OFF LINE mode Print If the currently displayed window is the Tightening cycles window then the current set up is printed The print out will list all parameters for each spindle included one spindle per page If the currently displayed window is the MMS window then current contents of the window will be printed Exit Ends the program If the current set up is modified you will be asked if you want to save the file User Manual Enhanced miniMACS The WinQCM E e 7 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 3 2 View Unine button v Status Bar v Results Tightening cycles MMS Using this menu you can customise the layout of the GUI i e which windows toolbars etc that should be displayed User Manual Enhanced miniMACS The WinQCM E e 8 Artisan Technology Group Quality Instrument
18. bd MUB22 MUB22 0 No lv lv 4 gt OpenContral 4 3 a Ready zl Ready Z e Inthe left panel select the item Logic Memory Memory MUB 8 Bit Unsigned User Manual Enhanced miniMACS Start up Instructions e 62 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com e Inthe right panel Locate the parameters listed below in column Alias and set the correct value in column Initial Value Setxx_RM_MaxFailedSpindles Setxx_RM_BackOffSet Setxx_RM_ReTighteningSet Setxx_RM_2ndFailureAction where xx is a number in the range 1 to 16 that represent the set that the parameters are valid for e Select the menu item File Save 6 4 3 Recompilation After giving the parameters above appropriate values the application must be recompiled Note If you do not have a dongle that enables the development environment you should not recompile the application It would create a runtime version that only executes for a period of 30 minutes Issue the following commands from inside OpenControl e Project Build Runtime e Project Activate Project Then close OpenControl and start The OpenControl Monitor User Manual Enhanced miniMACS Start up Instructions 63 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 6 5 The OpenControl Monitor 6 5 1 Configuring the OpenControl Monitor The OpenControl Monitor needs to be set
19. error If set it remains high until the system is reset Time out Error Set high if the maximum time out time parameter for a step is exceeded for a step executed If set it remains high until the system is reset or the next cycle is started Transducer Measure Error Set high if and when the servo spindle detects a calibration error an offset error or an overflow error If set it remains high until the system is reset DC Bus Low Set high when the DC Bus voltage drops below the critical level If set it remains high until the system is reset User Manual Enhanced miniMACS The Station Controller 44 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 5 3 Timing diagram for a typical case This timing diagram shows the valid time for signals and should be used as a help to understand how the enhanced miniMACS system works The diagram does not intend to reflect the absolute timing but more the order in which signal are set All input signals must be set when start signal changes from low to high can be set at the very same time as start OK cycle Repair cycle NOK cycle E stop OK cycle Input EUN Start Parameter set Reset Stop Output Parameter set Running OK i i RM back off i i ene I I i RM re tightening NOK l l E Stop l l l All outputs are valid when the Running signal goes low They will remain a
20. fetch cycle data from the spindles If all spindles finish with status OK then the tightening cycle is ended and the station output OK is set If the cycle finishes NOK and reject management is enabled then the spindles are first backed using the defined back off set If the back off User Manual Enhanced miniMACS The Station Controller e 40 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com cycle finishes OK then the spindles are re tightened using the defined re tightening set 7 If the re tightening cycle finishes with OK result the tightening cycle is ended and the station reports OK as the final result During this sequence the Station Controller continuously reports its status as well as the status of its spindles All sets are executed in a synchronised manner i e the execution of a step is not started for any of the spindles until all spindles have finished executing the previous step The execution of any on going tightening cycle is immediately terminated if the Automation PC raises the Stop signal If a spindle indicates an error not classified as a tightening related error it must be reset Generating a positive edge on the Reset input does this See section 4 6 for a more detailed description of operations of the Station Controller 4 4 Reject management The reject management is based on executing special sets for the back off and re tightening cycles For
21. it Click in the diagram on the subgroup you want to delete and press Delete Subgroup To reset the values of the SPC buffers and all values calculated for all variables do press the button Clear Data To update the window press the button Refresh If you select Histogram you will get a different view The histogram is automatically scaled so there is 25 of the screen left of LTL and 25 right of UTL The limits are shown The full screen is divided into 20 classes SPC Statistics x Station satl_2sp v Setno 5o H C SPC and TDA Spindleno fi 7 Variable Toque i A Eea Trend ee ee ee en a a a Taio Gaiy dase Gana aL Ge We Ut 2 Sd tated ate eee ae ie lel on ee E Lt 2 sod Si AGE RESETS GRE GEE UR LE THE Ss Gs Ga A A a E Sti benstotedeendwosd i Sedecdetecddscc gee ian cus cock ue Rawabi o ce haw ebm mod eam d slat ached Peat Healey Suelo Fede tad ated ata eats tata atid eel elec cei ieee rair A vinta ashen ey ee een eer ee ere mee eee cee org eee eee eee ee Sey See Sy Se es oat taeda elias olde Halla adadad hakahsio aai bled cata miudas italia Radda naen wii deter Aed tera doll Stebnca kan ad and ha dad na nda satacctaaa dt eadlan aneawsabacak cackunaheackacabonc2occs Bo bee Peet eee ee Be a ee he ek eS pe oe og eG See pres Tess ys Sey See qe SSE SSS Shey er See ar SS SSS Spe Sef espe Sep ese Aaaah y 4 ee ee Pe ey eer ee eee ee eee TET eee meee a e E E Seema Sperry Tamar aot ah ee Ae R5 11 R13 R
22. lt MaxAngleExceeded gt lt MinTorqueNotReached gt lt MaxTorqueExceeded gt lt MStopActivated gt User Manual Enhanced miniMACS The MMS Interface e 35 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com lt SpindleError gt lt CalibrationError gt lt OffsetError gt lt OverFlowError gt lt DCBusLow gt lt FinalTorqueOK gt lt FinalAngleOk gt lt TimeOutExceeded gt 1 0 1 indicates that the event occurred lt MinAngleNotReached gt 1 0 1 indicates that the event occurred lt MaxAngleExceeded gt 1 0 1 indicates that the event occurred lt MinTorqueNotReached gt 1 0 1 indicates that the event occurred lt MaxTorqueExceeded gt 1 0 1 indicates that the event occurred lt MStopActivated gt 1 0 1 indicates that the event occurred lt SpindleError gt 1 0 1 indicates that the event occurred lt CalibrationError gt 1 0 1 indicates that the event occurred lt OffsetError gt s 1 0 1 indicates that the event occurred lt OverF lowError gt r 1 0 1 indicates that the event occurred lt DCBusLow gt s 1 0 1 indicates that the event occurred lt FinalTorqueOK gt 1 0 1 indicates that the event occurred lt FinalAngleOk gt 1 0 1 indicates that the event occurred lt alphaNumStr gt A sequence of alpha numerical characters including space lt numStr gt A sequence of numerical characters lt floatStr gt
23. no message body lt telegram type gt 2 decimal ASCll code 50 lt message body gt not valid Example STX 2 ETX or as decimal ASCII codes 02 50 03 WinQCM responds by sending one telegram for each cycle data currently stored that has not been sent earlier The data for the oldest cycle is sent first the second oldest is sent in the second telegram and so on until all stored and unread cycles are transferred To indicate that all cycle data are transferred WinQCM sends an end of cycle data telegram If there are no cycle data recorded which have not already been read this is the only telegram sent User Manual Enhanced miniMACS The MMS Interface e 33 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 3 4 Cycle data This telegram is sent to the MMS server from WinQCM as a response to any of the cycle data requests Each telegram contains the information of one cycle data It consists of the following data Sequence number A sequence number Incremented for each cycle data read by WinQCM First cycle data read when WinQCM do not have any cycles in the buffer is given the value 1 New record 1 the record has not been returned earlier Station name The number of spindles in the station EUN Date and time for when the cycle yyyy mm dd hh mm ss was started Set number executed Overall cycle result OK NOK For each spindle in the station the following is add
24. panel of the servo drive unit The upper two are controlled by hardware e Power On Green LED lit when 5V is available in the controller section e CPU OK Green LED lit when the CPU has started up and is running The remaining eight LED s 1xGreen 3xYellow 4xRed are controlled by the application software 5 8 A short circuit is detected in the motor or the motor cables Other Faults R Overtemperature Red Overtemperature in the motor or in the servo drive unit Resolver Fault Red A resolver fault is detected ed ed A fault is detected other then the three listed above User Manual Enhanced miniMACS The Field Bus and Servo Units e 54 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 6 Start up Instructions 6 1 General This section describes typical tasks involved in commissioning of a miniMACS system 6 2 Hardware check 6 2 1 FBU Adjust the Profibus address of the FBU to 32 Switch location at back Mounting plate 2 switch at front 3 DIP Switch for the end resistor ON if last in chain and the connector do not have an end switch or end switch is off 6 2 2 Profibus cable Cable must be a shielded twisted par cable type AWG 24 The DIP switches on the connectors according to the amount off slaves 6 2 3 Discret IO card If discreet IO is used then check the addresses Normally the first card should have addres
25. software one for the QCM2 servo drive units and one for the FBU 5 2 Basic Operation From the FBU and Servo units a typical tightening cycle could look like this e A start command is sent from the Station Controller to the FBU through the Profibus interface The FBU processes the data and transfers the start command to the servo drive units through the Lan1 bus Each drive unit responds to the start command by setting status signals and performs the chosen tightening set The FBU retrieves status signals and qualitative data User Manual Enhanced miniMACS The Field Bus and Servo Units e 52 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com from all drive units through the Lani bus and transfers it back to the Station Controller through the Profibus interface e During the tightening cycle each drive unit stores quantitative tightening data in its internal register based memory as further described in chapter 5 4 1 When the tightening set is done the WinQCM E retrieves the quantitative tightening data from the servo drive units through the Lan2 bus This information is e g used for SPC Statistical Process Control calculations in the WinQCM E When the start signal is received the servo drive unit runs the motor according to a pre programmed operation sequence stored in its internal memory Each sequence or set contains one or more tightening steps where each step contain
26. the parameters are stored internally in an EEPROM memory Depending on which control mode see section 2 3 3 that is programmed into a step the included parameters are as follows Par1 Par2 Pars Par Par5 Par Par7 Par8 Par9 Par10 a O O E O ara an e ir Angle T_max T_ min Speed A trig A max A_min Delay Timeout Jog T_max Speed A_max A_min Delay Timeout T trig T_max T_slope Speed A_slope A_max Timeout Where e T_trig Nm 10 Target value for torque steps For yield steps this is the level where the reference slope is measured e T_max Nm 10 Max level for torque alarm level e T_min Nm 10 Min level for torque alarm level For yield steps this is the relative trig level on the slope e Speed rpm signed Speed set point for all steps s e A trig degrees Target value for angle steps For yield steps this is the base angle for slope calculations s User Manual Enhanced miniMACS Appendix 76 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com A_max degrees Max level for angle alarm level s A_min degrees Min level for angle alarm level e Delay 1 10sec Delay time for delay steps For all other steps this is a start delay currently the later function is not implemented in the WinQCM E e Timeout sec Timeout for all steps If a limiting parameter is set to zero that limit will not
27. to Waiting for start 4 6 7 State 2 Failure The Station Controller enters this state when the if the re tightening has failed and the 2 failure action is set to either back off all spindles or to back off only the currently NOK spindles The spindles are backed using the same set as used for the back off state When state is entered the servos are prepared to run the back off set on either all spindles that where not inhibited by the Automation PC right from the start no matter their current status or only the spindles that currently are not correctly tightened User Manual Enhanced miniMACS The Station Controller e 50 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com The servos are therefore set up with the following the number of set to back off with the original EUN code a new cycle start time and the inhibit information according to the above Then all currently not inhibited spindles are started The execution of the cycle and reporting to the WinQCM E are controlled the same way as for the states Running Back off and Re tightening except for that when the cycle is finished the following action is always taken e The tightening cycle is ended The station output NOK is set high Running is set low and the state of the Station Controller is changed to Waiting for start User Manual Enhanced miniMACS The Station Controller 51 Artisan Techn
28. to the installation instructions User Manual Enhanced miniMACS The Field Bus and Servo Units e 53 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 5 4 The QCM2 Servo Unit 5 4 1 Traces During each tightening cycle the servo drive unit stores measured torque and angle values in its internal memory with a resolution of ims sample A maximum of 2000 samples per trace can be stored Each such trace is stamped with Start of Cycle Time and combined with Stepstatus and EUN The servo drive unit will store the last 10 OK NOK traces plus the last 10 NOK traces in its internal memory Upon request by an operator the WinQCM E will ask a servo unit for retrieval of the selected trace over the Lan2 bus 5 4 2 Digital I O A digital I O port is available on the servo drive unit aimed for testing and commissioning Two modes are available e Operation mode This is the standard mode when running the system Discrete I O is disabled and replaced by the Lan1 signalling as defined in section Appendix 3 FBU Profibus interface e Commissioning mode Commissioning mode is selected by setting digital input X7A 8 to logic one Control over the Lan1 bus is disabled and the servo drive unit uses discrete I O signalling instead This mode is only to be used for low level testing and debug purposes with reduced functionality 5 4 3 Indicators There are ten LED indicators available on the front
29. window results are continuously collected from all spindles in the system and viewed on the screen E osatl_2sp qel WinQCH E File View Spindle Setup Loadparameters Accesslevel SPE Irace Repot MMS Help Epin 2 2 K ON LINE EEE EUN 01234 4990015678 Sasa Comm Sp Status Torque Angle Error off No E 1 0 3 E 2 0 0 180 180 A Results Tightening cycles MMS NUM 16 05 The results status torque values angle values and error messages are shown in one line for each spindle If the status is OK the status box is green and if it s NOK the status box is red and a text string explain type of fault If the spindle is running the box is white and the status is RUNNING By clicking in the Comm Off box the selected spindle will be ignored in the CAN communication This is useful e g when one of servos is defect The torque and angle values presented originate from the step marked in the Tightening cycles table see Tightening steps User Manual Enhanced miniMACS The WinQCN E e 4 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 2 2 Tightening cycles Window Using the tightening cycles window you can display and edit the tightening program satl_2sp gel WinQCM E of x File View Spindle Setup Loadparameters Accesslevel SPC Trace Report MMS Help Di Gel BS fepni x 2 r sume Sec
30. Body gt Example STX 0 MMS_SERVER Unknown message lt 8 gt lt xxxx gt ETX User Manual Enhanced miniMACS The MMS Interface e 37 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 The Station Controller 4 1 General The Station Controller is responsible for the co ordination of the individual servos It takes its input from the overriding Automation PC and controls the individual servos via a FBU Field Bus Unit The Station Controller is implemented as an OpenControl application and interfaces both the Automation PC and the FBU using Profibus For information on OpenControl see Ref 08 The following sections describes the function of the Station Controller It does not describe how it is designed or how it can be modified e g in order to handle group based reject management The interface to the Automation PC is described in Appendix 2 Interface to the Automation PC For descriptions of the interface to the FBU see Appendix 3 FBU Profibus interface 4 2 Common terms Term Definition The complete execution of a set May be terminated before all steps of the set have been executed Results are reported to the WinQCM E on cycle basis Tightening cycle A tightening cycle includes the execution of the normal tightening set as well as any reject management set l e a tightening cycle may consist of several cycles User Manual Enhanced miniMACS The S
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32. Icon User Manual Enhanced miniMACS Start up Instructions e 65 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 7 Appendix 7 1 Appendix 1 SPC Calculations 7 1 1 Calculations for subgroups Data in a subgroup is calculated as 2X Average X i l n n Range R max X min X i L n DX x y S tan dard deviation S 1 si lLin m 2 g AA i n n l1 S is approximated with i l n where n size of subgroup 7 1 2 Calculations When the specified number of subgroups to use for calculations have been collected the SPC function will start calculations to determine the statistical stability This will be repeated every time a new subgroup is ready Calculations are performed in following steps m number of subgroups User Manual Enhanced miniMACS Appendix 66 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Calculation of Average of Average values R i l m m and _ XS S si lim m Calculation of Control levels UCL X A R LCL X A R UCL D R LCL D R or UCL X A S LCL X A S UCL B S LCL B S A D D and A B B see table User Manual Enhanced miniMACS Appendix 67 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Calculation of the process
33. Max Angle then interrupt the cycle and set status NOK Run with the Speed value until pre set Target is reached If the angle ended below Min Angle or at any time exceeded Max Angle or if Max Time was reached before pre set Torque then interrupt the cycle and set status NOK User Manual Enhanced miniMACS The WinQCM E e 9 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Run with the Speed value until pre set Target is reached If the torque at any time exceeded Max Torque or if Max Time was reached before pre set Angle then interrupt the cycle and set status NOK Run with the Speed value as long as the Start input signal is logic one If the angle ended below Min Angle or at any time exceeded Max Angle or Max Torque or if Max Time was reached before the Start command was released then interrupt the cycle and set status NOK DynaTork Run with the Speed value until pre set Target is reached Then continue to the next step which is always a Delay step see above If during the DynaTork step the angle ended below Min Angle or at any time exceeded Max Angle or if Max Time was reached before pre set Torque then interrupt the cycle and set status NOK Run with the Speed value until measured torque slope is less than a pre set Torq
34. Set number etc and triggers the WinQCM E to fetch the rest of the data needed directly from the servos If the cycle was found OK when evaluated then the tightening cycle is ended The station output OK is set high Running is set low and the state of the Station Controller is changed to Waiting for start If the cycle was found NOK and there is a valid reject management back off set defined for the set then reject management is started This is indicated by setting the station output RM back off started high and changing the state of the Station Controller to RM back off If the cycle was found NOK and no back off set is defined then the tightening cycle is ended The station output NOK is set high Running is User Manual Enhanced miniMACS The Station Controller 48 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com set low and the state of the Station Controller is changed to Waiting for start If the cycle is not finished and no error is indicated then the controller just starts the execution of the next step 4 6 5 State RM back off The Station Controller enters this state when the first phase of reject management is started i e the execution of the back off set When state is entered the servos are prepared to run the back off set This is done as follows e if the normal cycle state Running resulted in that the number of failed spindles w
35. UN 01234 4990015678 Date 1999 06 22 Time 15 37 36 Sp 1 Set 3 T 0 1 Nm A 360 deg No errors Select the spindle you are interested in by use of the Spindle fields Then use the Trace fields to select which of the traces stored for that spindle to fetch Finally press the button Add to display the trace You can also add earlier saved traces using the Select saved trace button see below Up to six traces may be displayed as the same time When a trace is added all traces already displayed will be kept as well To remove one or more traces mark them in the list of currently displayed traces in the upper right corner of the window and press the button X To remove all traces press Clear All User Manual Enhanced miniMACS The WinQCM E e 23 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com If you press the More Data gt gt button the lower part of the window is unfolded and displays cycle data corresponding to the trace shown If more than one trace is displayed this field is cleared If several traces are displayed the x axis is scaled for the trace that is marked in the list of displayed traces The different curves are identified by different colors If you want to study a particular part of the trace you may zoom it in Place the mouse cursor on the left most position that is of interest press the left mouse button and drag the cursor to the right until the wanted a
36. Waiting for Start asisisscssecsconsasescseoseaeececaaeevovessnetesecoseau sy ovenabscastostbessynss 47 4 6 3 State Checking spindles sssssscsccssosssesnssassseacassenteaseesendnesasvassesuesesazstesenssoses 47 LGA State RUMMING jess ccssssevsstecssscicssosscaccevsnsscscosdsseevevesscsusscodesyslvasoasvesssdbaoeseded s 48 User Manual Enhanced miniMACS Contents e i Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 6 5 State RM back off cccccceccccccssssseccesscecccssssueeceesesaeeeseeesseeeeeeeesseeeeeeaes 49 4 6 6 State RM re tighteming eects cseeeetsesssessessessscsssessscsscesseseessscneees 50 HG 7 SinterS SE a shicnke essence aauehuaeoeneeweaeae 50 5 The Field Bus and Servo Units 52 3i G oi ol Pere reeeeete renee Pererrec a aa a E rae tree er pee EE errr rete 5 2 Basio Operation errorae sirier a E AEE RAE E at EERE E EAE TEER 9 3 Cabell g arrira ierann EE O AO EEA GA E T A 5 4 The QCM2 Servo Unit DAM Traces sirrg E RNE EE E T OEE OR OE DAD Digital W O viscscccetcceccacass vnanctcveducichcanes seastesnscaaduaspaszevestoudssateniyaeecuseucativeneeaceas SAPS Indicator Seen E E A E ee NTRS 6 Start up Instructions 55 62 6 LINZ oean eaa E E E EE E N 602 1 UPS cisssstecsints ssdeavedevaveustangieneecbssastedes 6 2 8 Servo connectors 6 3 SOPWALE cercei oiera aar aaae aS 6 3 1 Needed software and files cies eee sseeseeseceeeeseesecne
37. ansafe program Put in the CD and run Lansafe NTWin Setup exe Select NetUPS After this port COM1 willl not be available for any other program User Manual Enhanced miniMACS Start up Instructions e 59 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 6 4 Configuration of the Station Controller The Station Controller application program must be adopted to the current installation of the miniMACS system before it will work properly To do this you need to have access to an OpenControl development environment You get access to the development environment by using a special dongle Before the configuration can start you must start OpenControl and select the Station Controller as the current project Do the following e Start OpenControl e Select the menu item File Open Project This will display a dialogue Open Project x Cancel in which you select the latest version of the Station Controller application e g SC_v_1_4 using the drop down combo box User Manual Enhanced miniMACS Start up Instructions e 60 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 6 4 1 Setting the Profibus slave address Which slave address the Station Controller should have on the Automation PC s Profibus net varies from site to site To change it do the following lt gt OpenControl SC_v_1_4 B
38. anual Enhanced miniMACS The WinQCN E e 31 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 3 The MMS Interface 3 1 General The miniMACS MMS server running on the miniMACS PC will access the WinQCM application in order to read cycle data WinQCM keeps the 100 last cycles in memory and save this buffer on disk whenever the application is closed normally However if the application should terminate for other reasons the buffer data may be lost The number of cycles kept in memory can be changed in the ini file Section MMS key FIFOQUEUESIZE The interface available to the MMS server is implemented as a socket Only one client at the time is accepted The port number is default set to 5555 but can be defined in the ini file section MMS key PORTNO The interface only supports one task at the time meaning that a new request is not accepted until the previous is finished The interface supports the following telegrams e Request for all cycle data currently stored a FIFO buffer with 100 slots e Request for all new cycle data since last request e Cycle data response from WinQCM e End of cycle data response from WinQCM e Unknown telegram received response from WinQCM The telegrams are of variable length and their contents should be interpreted as ASCII characters i e as text All telegrams have the following basic format STX lt telegram type gt lt message body gt
39. as less or equal to the parameter MaxFailedSpindles then all OK spindles are inhibited This is done to ensure that only the NOK spindles are backed in this case Otherwise all spindles are backed off e the number of set to back off with the original EUN code and a new cycle start time is sent to the servos Then all currently not inhibited spindles are started The execution of the cycle and reporting to the WinQCM E are controlled the same way as for the state Running except for that when the back off cycle is finished different actions are taken depending on how it ends If the back off cycle was found OK when evaluated and there is a valid re tightening set defined for the original set then reject management continues with the re tightening phase This is indicated by setting the station output RM re tightening started high and changing the state of the Station Controller to RM back off If the back off cycle was found NOK or if no re tightening set is defined then the tightening cycle is ended The station output NOK is set high Running is set low and the state of the Station Controller is changed to Waiting for start User Manual Enhanced miniMACS The Station Controller e 49 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 6 6 State RM re tightening The Station Controller enters this state when the second phase of reject management is start
40. ation Guaranteed 888 88 SOURCE www artisantg com 2 3 3 Spindle File View am Setup Loadparameters Accesslevel SPC Trace Report MMS Help Tighteni Copy tightening sets Spindle parameters Torque reading Special Select current spindle Tightening steps Displays the Tightening step dialogue in which you can set the parameters of a step Tightening steps Spindle 1 x Step AAE Mode Angle 7 Insert step Delete step Torque Max 10 0 Nm Target Flin Min 10 0 Nm Angle Max fo deg Target fiso deg Min 0 deg Yield TC Hm ING den Ratio Max Time 5 Sec Speed feo 1pm I Reverse M Report Cancel Each tightening cycle is built up of different control modes such as torque angle jog etc Mode can be selected from one of the following step types Torque Angle Delay Dynatork Delay End Angle End Jog End Torque End or Yield To determine the last step of a set the control mode in that step should be of End type Such steps are displayed with a horizontal line under the step to indicate the end of a tightening set Available Control Modes are given by the following table Control Description Mode Continue with the next step after the Delay Time If the previous step was a Dyna Torque step keep the nutrunner current constant until the Delay Time is reached If the angle ended below Min Angle or at any time exceeded
41. be checked i e no fault trips will occur 7 4 2 Spindle Parameters For proper operation the servo drive unit needs to know the characteristics of the spindle it is supposed to operate The spindle characteristics are defined in 15 parameters numbered from 1 to 15 In the servo drive unit the parameters are stored internally in an EEPROM memory The parameters are as follows MTorq100 motorkt x servomaxcurrent x 100 265 15A servo and QMR42 spindle TraceT Sample time for traces default 1ms 0 10 IGain Integral gain for controller NrOfDecimals Number of decimals in torque parameters Relaymask Function of relay Par15 Holdmask Position hold function 7 4 3 Report Parameters After a set is completed a number of data will be available for retrieval by the Station Controller The retrieval is initiated by creating a report through marking a step in a set with a report tag as detailed in section 2 3 3 When a step fails a report is always created The report consists of 22 parameters numbered from 1 to 22 The first 10 parameter values represent the status and the result of the tightening cycle Parameters number 11 through 22 represent the EUN code par11 18 and the StartTime par19 22 The EUN code and the StartTime were transferred to the User Manual Enhanced miniMACS Appendix 77 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com drive units toget
42. capabilities Cp and Cpk R s i l m d see table d or s i L m c see table 4 _ UTL LTL su sl s UTL X X LIL Cpk min where for a normal distribution su sl 3 7 1 3 SPC constants The table below gives the constants to use in the mathematical formulas Subgroup Divisors for Factors for Control Limits Estimate of Standard Dev N 1 13 0 798 1 69 0 886 2 06 0 921 2 33 0 940 2 53 0 952 0 03 2 85 0 965 0 14 1 86 1 10 0 19 0 969 0 18 0 24 0 978 0 22 0 28 11 3 17 0 975 0 26 0 32 12 3 26 0 978 0 28 1 72 0 89 0 35 15 6 a 3 je o JN 0 982 0 35 1 User Manual Enhanced miniMACS Appendix 68 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 0086 o19 oso 0 69 0 52 o9s8 o17 049 0 65 3 90 0 989 0 16 0 45 1 55 0 62 0 56 2 3 93 0 990 0 15 0 46 1 54 0 61 0 57 17 18 19 20 at z oss o17 ome 158 ose 22 23 24 f 5 User Manual Enhanced miniMACS Appendix 69 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 7 2 Appendix 2 Interface to the Automation PC 7 2 1 Inputs The interface to the overriding Automation PC consists of the following input signals Description Comment EUN Comp ID EUN Comp ID ASCII Numeric ASCII Numeric EUN
43. casvecccascseceossaececcestedasenbaneedsvecedassasvarsaecass 4 2 2 2 Tightening cycles WindOW ee eee cess ceceseseceeseeeseeaecaesecseseeeaeeesseeanegs 5 2 2 3 The MMS Window D9 MES E E EEE pe E Fale ese E EE ES E E E E E A E E 2 3 2 View PE O REPOU E E A 2310 MMS erinra 2 3 11 Help menus 23 12 Toolbar sisser AS AS EEn aTe 0E N connate sdensssicesdednde stove skesseaddvoegoaeses 3 The MMS Interface 32 3 1 Generalno n E R A EEEE cided OEE 32 3 2 Request for all cycle data currently stored sessseeeeseeeesesreresrsrieresrisirrrrrssreresrereeees 33 3 3 Request for all cycles not currently read BA Cycle dataiccs c ccsncasvcscpusandectecslotivessainteivancoctssterns 3 5 Format of the cycle data message body 3 6 End of cycle data ieee eens 3 7 Unknown telegram received o cece ineas tecie iinan an 4 The Station Controller 38 AL 1 Generalii RA A eecasnsves ees tense AOI R aaa dade ad EEEE E 4 2 Common terms 4 3 Basic functionality sursson aere aeto rena EERE REEE TE EVERE 4 4 Reject Management cass c cciccsintecsascess caaa gt do vscesbceutessdods eE ia EEKE ECER S raana SE aaaea EAR 4 5 Interface to the Automation PC AD LIN Puts nsns ADD QUUPUUS sinnini 4 5 3 Timing diagram for a typical case weil cece cece ceeceeeeeeceeeseeeeeeeneeaeees 45 4 6 The logic of the Station Controller oo eeececc ee ceesecseeeceecsseeesesseseesaeeeseetanees 46 4 6 1 State Idle 462 State
44. character Only the traces with an EUN that matches the entered value will be displayed User Manual Enhanced miniMACS The WinQCM E e 25 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 3 9 Report File View Spindle Setup Load parameters Access level View Reject SPC Trace This function invokes the Reject Report window which presents a reject report based on the last 1000 cycles The data collected for each NOK cycle is stored on disk Percentage of NOKcycles of last 1000 cycles NOK NOK oo NOK NOK oo NOK NOK oo NOK NOK oo NOK NOK Motor stop Timeout Set 2 EW Motor stop Timeout Set 2 EW Motor stop Timeout Set 2 EW Motor stop Timeout Set 2 EW Motor stop Timeout Refresh Print 0 50 01234 4990015678 01234 4990015678 01234 4990015678 01234 4990015678 be a The Reject Report window displays a list of all NOK cycles For each NOK cycle the following are listed e Date and time for the start of the cycle e The EUN code And for each spindle in the station e The spindle number e Whether or not it is inhibited e Status OK NOK e The reject cause if status is NOK User Manual Enhanced miniMACS The WinQCM E e 26 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Above the list the percentage of NOK cycles n
45. d Note that the set number confirmed by the spindles also is evaluated when any reject management cycle is started This means that this signal may be set in the middle of a tightening cycle Confirmed set number This signal four bits is the set number confirmed by all the spindles if they all confirm the same set number If not this signal remains set to zero 0 and the signal Parameter set failure is set high All output signals above except for Running are cleared when a start is detected If set during the tightening cycle they remain set until either a reset or a new start command is issued In addition to the output signals on the station level the following signals indicates the status of the individual spindles Note that these signals are updated after each individual cycle Description Cycle NOK Cleared at cycle start Set high when the cycle finishes with an error Remains set until next start Spindle Bypassed High indicates that the spindle is inhibited This value is only changed at cycle start Torque NOK Cleared at cycle start Set high when a cycle is finished and the reported torque is out of limit If set it remains high until next start Angle NOK Cleared at cycle start Set high when a cycle is finished and the reported angle is out of limit If set it remains high until next start Controller OK Ready High if the servo spindle is OK and ready for start A low value indicates a servo spindle
46. dles to become NOK and report Machine Stop e If the cycle finishes with status NOK i e at least one spindle failed the reject management function is activated e Based on the number of NOK spindles either all spindles or only the NOK spindles will be backed using the back off set If the back off cycle ends successfully yet another set will be used to re tighten the joints Should the back off cycle fail then the station will not try to run the specified re tightening set but stop and report NOK for the overall cycle e Should the station status still be NOK after the re tightening cycle then there is a programmable choice to either back off all spindles the remaining NOK spindles or to leave the joint as it is Note From statistical point of view SPC Reject Report etc all cycles are treated the same This means that cycle data generated when executing a reject management set is recorded just as any for any other cycle However different set numbers may distinguish them User Manual Enhanced miniMACS The Station Controller e 42 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 5 Interface to the Automation PC The complete layout of the interface to the overriding Automation PC is presented in Interface to the Automation PC Here the most important features of this interface are described 4 5 1 Inputs The Station Controller implemented in OpenControl is cont
47. e lt 4000 the values shall be multiplied with 10 Note 2 For spindles where the motor has opposite rotation direction from the socket holder u gear or 2 wheel offset the values shall be multiplied with 1 minus one Torque reading This function is used to configure the torque transducer It is only valid for servos of QCM S 2 T type Torque scalefactor Spindle 1 x m Spindle type Select transducer z Get Gefault parameters rar spmadle j Cancel m Parameters Torque scalefactor fi 00 0 Filter constant 1 i Input gain 4 k Select a torque transducer and press the Set default values for the transducer button Default parameters will then be automatically inserted The Torque scale factor the Filter constant and the Input gain can be edited manually if you e g have another type of torque transducer Default values for Torque scale dependent on transducer type are Default value 100 0 200 0 1000 Default value for the Filter constant is 1 Available filter settings are 0 1 2 and 3 where 0 means the hardest filtering Default value for Input gain is 4 Available gain settings are 1 2 4 8 and 16 With gain 4 at least 100 of the transducer range can be used Increased gain means that usable transducer range decrease and the resolution of the signal increase User Manual Enhanced miniMACS The WinQCN E e 13 Artisan Technology Group Quality Instrumentation
48. e Test 1 disk Station Controller ver 1 4 or later Open SC_Setup EXE 1 disk Control application 6 3 2 Install Promotion ECT Run Install EXE and follow the instructions 6 3 3 Install WinQCM E Run Setup EXE and follow the instructions 6 3 4 Install the Station Controller Run the self extracting program SC_Setup EXE 6 3 5 Down load Servo software Copy the servo application software HEE to the directory ATLAS SERVO Repeat the following for each servo in the system 1 Plug PC into Host Port on front of each servo one at a time Start with left most servo and work to right 2 Make sure servo is powered up 3 Start ECT software on the PC 4 Select Window Terminal from menu you are now in terminal mode 5 Setup servo software Type CRTL Z X where X represents the address for the servo 6 Select Controller Force terminal mode from menu 7 Select Controller Download from menu Select the servo application software and press OK to download User Manual Enhanced miniMACS Start up Instructions 57 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 8 You can monitor the download status at the bottom left of screen 9 Type FSTORE to store new file in Servo memory 10 Type RESET SYSTEM to reset system Servo software will now restart again This always resets the node address to 1 11 If you
49. e for a description of the MMS queue and how the cycle data displayed is formatted satl_2sp gel WinQCM E of x File View Spindle Setup Loadparameters Accesslevel SPC Trace Report MMS Help Gl S fsm zA 2 OFFLINE HEAD 999 1l satl_2sp 01234 4990015678 1999 06 01 10 53 59 l 0K 3 SPINDLES 1 0 1 0 0 10 0 180 0 0 0 0 0 0 0000000000011 2 0 1 0 0 10 0 180 0 0 0 0 0 0 0000000000011 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0000000000000 HEAD 1000 l satl_2sp 01234 4990015678 1999 06 01 11 00 30 1 0K 3 SPINDLES 1 0 1 0 0 10 0 180 0 0 0 0 0 0 0000000000011 2 0 1 0 0 10 0 180 0 0 0 0 0 0 0000000000011 0 0 0 0 0 0 0 0 0 0000000000000 NUM 09 29 4 For Help press F1 There are two options for which cycle data that can be displayed in this window e All cycles currently recorded in the MMS queue e All cycles currently recorded in the MMS queue that have not been read yet by the MMS server The data currently displayed can either be printed or saved to disk by using the menu alternative File Print or MMS Save User Manual Enhanced miniMACS The WinQCN E e 6 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 3 Menus 2 3 1 File This section lists describes the functions that are available from the WinQCM E menu View Spindle Setup Loadparameters Accesslevel SPC Trace Report MMS Help Ctrl N Ctrl 0 Ctrl
50. each normal set to the reject management actions are defined with the following four parameters e Max number of failed spindles to allow only the failed spindles to be backed e The number of the set that will be used to back off the spindles e The number of the set that will be used re tighten the spindles e The second failure action 0 leave the joint as it is 1 amp back off the remaining NOK spindles and 2 back off all spindles The actual values of these parameters must be set in the Station Controller application program See section 6 4 2 for how to do this Reject management operates as follows e All steps are executed synchronously by all spindles i e the next step is not started on any spindle until the current step is finished by all spindles Whenever a step is finished on all spindles the Station Controller checks how many spindles that currently report NOK This User Manual Enhanced miniMACS The Station Controller 41 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com number is compared to the value of the parameter Max number of failed spindles to allow only the failed spindles to be backed e If itis less or equal the Station Controller will start the execution of the next step for all spindles that still have status OK If itis greater then the on going cycle is terminated by machine stopping all spindles This will cause all still OK spin
51. ed Spindle x Final Torque Unit as set up in WinQCM Spindle x Min Torque Limit Unit as set up in WinQCM Spindle x Max Torque Limit Unit as set up in WinQCM Spindle x Final Angle Unit as set up in WinQCM Spindle x Min Angle Limit Unit as set up in WinQCM Spindle x Max Angle Limit Unit as set up in WinQCM Spindle x Inhibited 1 spindle was inhibited Spindle x Status Status as returned by the servo Whenever this telegram is sent to the MMS server the corresponding cycle data stored in the WinQCM is marked as read This flag is used to figure out which cycle data that will be returned by the command Request for all cycle not currently read The telegram has the following format lt telegram type gt 3 decimal ASCIll code 51 lt message body gt See below User Manual Enhanced miniMACS The MMS Interface e 34 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 3 5 Format of the cycle data message body The cycle data message is an ASCII string following the syntax described below extended BNF Texts printed in boldface are to be taken literally lt message body gt HEAD EOL lt SeqNo gt EOL lt NewRecord gt EOL lt StationName gt EOL lt EUN gt EOL lt Date gt EOL lt Time gt EOL lt SetNo gt EOL lt CycleResult gt EOL lt NoOfSpindles gt EOL SPINDLES EOL lt optSpindleList gt lt optSpindleList gt lt spindle gt lt optSpindleLis
52. ed i e the execution of the re tightening set When state is entered the servos are prepared to run the re tightening set on all spindles that where backed The servos are therefore set up with the following the number of set to re tighten with the original EUN code a new cycle start time and the same inhibit information as set up for the execution of the back off set Then all currently not inhibited spindles are started The execution of the cycle and reporting to the WinQCM E are controlled the same way as for the states Running and Back off except for that when the re tightening cycle is finished the following actions are taken depending on how it ends If the re tightening cycle was found OK then the tightening cycle is ended The station output OK is set high Running is set low and the state of the Station Controller is changed to Waiting for start If the re tightening cycle was found NOK when evaluated and the 2 failure action is set to either back off all or the currently NOK spindles then reject management continues with the 2 failure action The state of the Station Controller is therefore changed to 2 failure If the re tightening cycle was found NOK and the 2 failure action is set to anything else but back off all or the currently NOK spindles then the tightening cycle is ended The station output NOK is set high Running is set low and the state of the Station Controller is changed
53. eeabaieeededassnds ecevsesscsatcrenesace 71 7 3 Appendix 3 FBU Profibus interface 0 0 0 cece eeee cee ceeeeeeeseseeseesessesseeeeeenaeeeees 73 T1 Control Input Data secsesssissssveisecsssseseessevavvesersaasesusevsesevevsoungvey vessvscveracobeseesess 73 7 3 2 QMalitative O tp t Data ccsssscssscscscsesessovectesssveesevnesesscovsodsesonseneoesovscisvevase tes 75 7 4 Appendix 4 QCM2 CAN Communication 0 0 eee cece ceeeseceeeeeeeceesseeeeeeeseeeees 76 PAL Step Parameters c5s ccccisevetesas tech cosnevessvpenve cecoenn seen EEEE ENNEN EEEE NEEE 76 PAD Spindle Parameters vis cssssssssesssssessscocavsessevessesssvtosnvsescescoupopedescaevenssvsssgsvenasstes 77 7 4 3 Report Parameters TAA Trace Parameters sisss goss esievsess dicsentavgasapsatovases i oat booieevis eteansegapanavarsetdaaaton niece 8 References 80 User Manual Enhanced miniMACS Contents e ii Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com This page is intentionally left blank User Manual Enhanced miniMACS Contents e iii Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 1 Introduction 1 1 Overview This manual describes the functionality of the enhanced miniMACS system The system consists of the following physical or functional parts e The miniMACS PC e Field Bus Unit FBU e QCM2 QCS2 Servo Drive Units Automation PC Profibus O EUN Ethernet
54. eeaeeeseeeeessesneeseeeaeeneees 57 6 3 2 Install Promotion ECT cccccccsssccsseccessecesseeeesseccessecesseecesseeseteeeesseeeeses 57 6 3 3 Install WinQCM E 6 3 4 Install the Station Controller eee eceseseeeceneeeecneeeseeseeeeeeeseesneeeeeeaeeneees 6 3 5 Down load Servo software ceeeecesscescceeceeeeeeseceeeeaeseeaeeeseesesneeeeeeeeeaeees 6 3 6 Down load FBU Software 6 3 7 Install NET UPS Lansafe program 6 4 Configuration of the Station Controller 6 4 1 Setting the Profibus slave address 0 ccc eseeeeeceseeeeecseceeseeeeeeeaneees 6 4 2 Setting the Reject Management parametefS 0 eee eee eeeeee eens 62 6 4 3 Recompilation 6 5 The OpenControl Monitor 0 eee cece csececee cee csesaeeeceessseessesseseeseesessesaeteseeeaeeaee 64 6 5 1 Configuring the OpenControl Monitor eee cece eee ese eeeeeeeneees 64 6 5 2 Auto start of the OpenControl Monitor o oo eee cesses eeeeeeeeeees 65 7 Appendix 66 7 1 Appendix 1 SPC Calculations cececesesesseeseceecseeeeeseeeeceseeeeeseseeseaesaeeeeseeseaeeaeeaees 66 7 1 1 Calculations for subgroups 0 0 0 cece eseeseceeeeeeeneeeceeeeseceeeaeenecseesaeeneeaeeneees 66 7 1 2 Calculations TALS SPC COMStAMS cesses sssececesscsssidve civccterschaytetosaie Ee EN EENE een Ieee 68 7 2 Appendix 2 Interface to the Automation PC cece cseeee eee ceeeeeseeeeeseeeeeetaeeeees 70 7 2 1 Inputs VoL 2 QUUPUUS ess cease nsdssessdoanescssnsdedesstscvanssssasaeddsacesapsuabed
55. efore the Start signal is activated Step Sync IN Logic one will inhibit a start of a tightening step Set the input to logic zero to enable start Use the input in conjunction with the Step Sync OUT output signal from the same servo drive or a combination of several drives Step Mode Set the input to logic zero to have a complete cycle with several steps run for each start signal normal mode If you want the servo drive to run only one step at a time for each start signal set this input to logic one Mainly used in test and start up situations 6 Inhibit Logic one will inhibit a start of a tightening cycle Set the input to logic zero to enable start 7 _ Notused ee 35 co with weight 1 in the address word for selecting a program set bit with weight 2 in the address word for selecting a program set zm with weight 4 in the address word for selecting a program set i with weight 8 in the address word for selecting a program set A with weight 16 in the address word for selecting a program set di with weight 32 in the address word for selecting a program set User Manual Enhanced miniMACS Appendix 74 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 7 3 2 Qualitative Output Data Each servo drive unit continuously updates an output buffer of 4 bytes with its cycle status The FBU retrieves these data once every 100ms from all the d
56. elag tele x Sle vial alels Flow Chart lt gt ProfiBus Configurator ProfiBus2 InterBus Configurator k 7 ee ae tw ote ra ProfiBus1 M Ranana D4000 SDS Configurator i Seriplex Configurator fo Local Seament ZUBI IAPC_EUN_Comp_ldi UB IUB2 IAPC_EUN_Comp_ld2 ZIUB2 ZIUB3 IAPC_EUN_Eng d1 ZIUB2 ZIUB4 IAPC_EUN_Eng_ld2 ZIUB4 ZIUB5S IAPC_EUN_Eng_ld3 UBS ABE APC_EUN_Space AUB PR he he de ee Ie OpenControl 4 3 Ready j 2 e Inthe left panel select the item Profibus Configurator Profibus2 e Inthe right panel set the correct slave address in the field Local Address e Be sure to press the button OK e Select the menu item File Save User Manual Enhanced miniMACS Start up Instructions 61 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 6 4 2 Setting the Reject Management parameters To use the Station Controller together with a particular tightening set up defined using WinQCM E the following parameter must be set up e The number of spindles in the system and for each tightening set defined for which reject management is wanted the following reject management parameters see also Reject management e Max number of failed spindles to allow only the failed spindles to be backed e The back off set e The re tighten set e The second failure action To do that do the following lt OpenControl SC_v_1_4
57. et numbers returned from the active spindles DC Bus low from all active spindles Station Byte 1 Description Comment Parameter bitO Confirm tightening set binary 1 Parameter bit1 Confirm tightening set binary 2 Parameter bit2 Confirm tightening set binary 4 Parameter bit3 Confirm tightening set binary 8 Spare Spare Spindle Byte Description Bytes 2 33 Description Comment Cycle NOK 1 NOK Spindle Bypassed 1 Servo was bypassed o Torque NOK 1 NOK 3 Angle NOK 1 NOK s 7 Controller OK Ready 1 OK Ready Time out Error Time out exceeded Transducer measure error Calibration Offset or Overflow error DC Bus low User Manual Enhanced miniMACS Appendix 72 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 7 3 Appendix 3 FBU Profibus interface The Station Controller controls the tightening system over a Profibus DP interface The control input data is sent from the Station Controller over the Profibus DP interface to the FBU where the signals are unpacked and distributed to all servo drive units over the Lani bus Qualitative output data or cycle status i e Running OK NOK from all drive units are continuously retrieved by the FBU and sent to the Station Controller over the Profibus DP interface For a more detailed description of the Profibus DP interface see Ref 05 7 3 1 Control Input Data
58. gnal is high when the station is executing a tightening cycle While this signal is high all inputs but stop are neglected When Running goes low the output signals are valid RM back off started This signal is set high when a back off set is started If set it will remain high during the rest of the tightening cycle See Reject Management for a description of back off RM re tightening started This signal is set high when a re tightening set is started If set it will remain high during the rest of the tightening cycle See Reject Management for a description of re tightening User Manual Enhanced miniMACS The Station Controller 43 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com This signal is low when a tightening cycle is started and is set high if it finishes without any errors This signal is low when a tightening cycle is started and is set high if it finishes with an error Communication error This bit is set high when the communication with the FBU fails or when the FBU fails to communicate with any of its spindles E stop This signal is set high if all spindles reports that the DC bus is low Parameter set failure This signal is set high if the all spindles do not confirm the ordered set number The evaluation is done when all spindles have started the execution of the cycle This time is normally within 200 300 ms from that a start command is issue
59. hen a step is Inserted the currently selected step and the steps following will be moved down one row The step added will be an empty step Max and Min Torque and Angle limits can be programmed to 0 meaning that the parameter is not used A click in the Report box means that the Torque and Angle result will be reported from this step A report step is indicated with an R before the step number in the Tightening cycles Window table Note One step in a set must be marked for reporting If a tightening ends NOK for a spindle the reported data comes from the step that was NOK Copy tightening steps This function is used to copy tightening steps from one spindle to other spindles Copy tightning steps x Source Lan Spindle i from step po to 5 __ Cancel Destination from spindle 2 to fio start with step Bo You select where you want to copy from Source and where you want to copy to Destination In the example above step 3 4 and 5 are copied from spindle 1 to spindle 2 10 Note The report setting is only copied correctly if all 64 steps of a spindle are copied at the same time User Manual Enhanced miniMACS The WinQCN E e 11 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Spindle parameters Displays the Spindle parameter dialogue in which you configure the spindle parameters for a spindle Spindle parameters Spindle 1 x
60. her with the control input data over the Profibus interface as described in chapter 7 3 1 Parameters 1 through 10 are as follows StepNumber The number of the reported step can differ from the report marked step when a step fails Par2 StepStatus The status of the reported step bit masked information on what went wrong see below Par3 ReportTorque The actual torque that was reached during the reported step ReportAngle The actual angle that was reached during the reported step Par7 Not used Par8 Not used Par9 Not used Parameter 2 StepStatus holds the following information Minangle Min angle not reached Maxangle Mintorque Maxtorque MStop Not used Calibration error Offset error Blo Overflow error Not used N Not used TT Not used Not used Not used User Manual Enhanced miniMACS Appendix 78 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 7 4 4 Trace Parameters Each tightening set is recorded into a trace buffer The angle and torque values are sampled with 1kHz parameter 7 TraceT of the spindle parameters in chapter 7 4 2 sets the sampling rate and pushed onto the buffer Each buffer has 2047 positions and if more samples are pushed the oldest will be lost The system supports 20 trace buffers Buffer 1 through 10 holds the latest OK NOK cycle recordings while trace buffe
61. iables to collect SPC Setup x Subgroup size E Range or Standard Deviation Standarddev 7 SPC and TDA Short Term Trend No of subgroups to save Bl No of subgroups to save Bs No of subgroups to calculate ae Frequency Samples Samples Minutes Bl Auto recalculation of limits V m Variables to collect Set 5 Torque Station satt _2sp v n satl_2sp 5p 1 Set5 Angle Spindleno fi aa satl_2sp Sp 2 Set 5 Torque Add gt satl_2sp Sp 2 Set 5 Angle Setno fi 7 Variable Torque aa n 4 gt x Cancel Specify Subgroup size and if you want to use Range or Standard Deviation In the SPC and TDA frame set up values for normal SPC Do the same for the Short Term Trend frame These values will be used for calculations on all spindles and sets In the Variables to collect frame add those variables you want to check Select Spindle Set and Variable For Spindle you could specify All Press Add The variable shows up in the list box To take away a variable from the list select it and press the remove button X If you want to rearrange the order select an item and press the up or down buttons to move it upwards or downwards in the list User Manual Enhanced miniMACS The WinQCM E e 20 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com iw SPC Variable Mi Eg UTL ETE Constants su 3 sl E
62. it possible to tailor data collection and calculations to suit most needs Data Collection for SPC Data for SPC is collected for all spindle cycles with OK status Data are collected only for those variables that have been set up using the SPC Set up function Data are collected in two main ways e as subgroups e as latest results When data are collected into subgroups data from a specified number of samples are used to calculate Average and Range or Standard deviation which are saved for the subgroup The original values are automatically deleted This is repeated with a selectable frequency either specified in number of samples or in time between start of subgroups If frequency is specified in time a subgroup is discarded if it is not complete within 30 minutes For a detailed view of the latest samples there is also a buffer for latest results This contains all the latest samples but for a much shorter period of time Which variables to collect are set up uniquely for each spindle and set The data currently collected and held by the SPC module is saved to disk whenever it is updated See Appendix 1 SPC Calculations for a description on how the SPC data is calculated User Manual Enhanced miniMACS The WinQCN E e 19 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Set up Use this alternative to define how calculation should be performed and which var
63. meters File View Spindle Setup Write all parameters to spindles Write all programmable parameters to the servos If the program is in off line mode it will automatically be set in on line mode after this operation Read all parameters from spindles Read all programmable parameters from the servos If the program is in off line mode it will automatically be set in on line mode after this operation User Manual Enhanced miniMACS The WinQCM E e 17 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 3 6 Access level File View Spindle Setup Load parameters SPC Trace Report MMS Help Logout User list The program has two different access levels The access level 3 is the highest with the right to modify everything In the user list you can add new users with an access level In the user list you also select a default access level This is the access level the program has when you start it If you select access level 3 as default access level the user doesn t need to login since the user automatically has the right to do everything User Manual Enhanced miniMACS The WinQCM E e 18 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 3 7 SPC File View Spindle Setup Load parameters Access level Trace Report MMS Help The built in SPC Statistical Process Control is very flexible and makes
64. ne is to initialise all not inhibited servos with the EUN code Set number and cycle start time according to the sampled value of the corresponding input values Secondly the servos spindles are ordered to start the execution of the cycle The Station Controller then supervises that all servos begin to execute the cycle within approximately 500 ms If this fails then the on going cycle is terminated by machine stopping all spindles If the cycle is started on all servos within the given time then the set number confirmed by each of them is read back and compared against the ordered one If an erroneous set number is detected then the output signal Confirmed set number is set high and the on going cycle is terminated by machine stopping all spindles The Station Controller then continuously scans the status of all the spindles participating in the cycle in order to detect when they all have finished to execute the on going step When that is the case it checks whether or not the cycle is finished and how many of the spindles executed during this cycle for which an error is reported If this number is greater than what is allowed set by the reject management parameter MaxFailedSpindles for the set then the on going cycle is terminated by machine stopping all servos If the cycle is finished the Station Controller evaluates the result of the cycle It then supplies the WinQCM E with parts of the cycle data EUN Cycle Start Time
65. ntation Guaranteed 888 88 SOURCE www artisantg com On line Off line Using this function you control the communication state of WinQCM E If the program is in Online mode it will be changed to Off line If the program is in Off line mode it will be changed to Online When going online you will be asked whether to Write all parameters to the spindles or Read all parameters from the spindles This is optional i e neither has to be checked See also Load parameters Read or Write registers for spindle 1 2 x Write all parameters to spindles C Read all parameters from spindles Cancel Log Settings Opens a dialogue in which you can configure how logging should be performed if enabled Log x Log settings o C s only NOK results only Log file JC Atlas LOG WinQCME log al Max size 10000000 bytes Cancel Select which cycles you want to log using the Log Settings radio buttons e OK results only means that all not inhibited spindles must be OK for the cycle to be logged e NOK results only means that if one not inhibited spindle is NOK then the cycle is logged Specify the location of the log file file name and directory using field labelled Log file and the size of it using the Max size field User Manual Enhanced miniMACS The WinQCM E e 16 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 3 5 Load para
66. ology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 5 The Field Bus and Servo Units 5 1 General The Field Bus Unit FBU is an intelligent communication controller manufactured by Atlas Copco Controls Ref 04 It can be equipped for communication through all common field buses on the market in this case the Profibus The information from the Profibus is processed and transferred to the CAN based communication bus called Lan1 used by the servo drive units This communication is further described in section Appendix 3 FBU Profibus interface The servo drive units for the Enhanced miniMACS System are based on the new standard QCM2 drive units by Atlas Copco Controls Ref 03 These units have a new control card called CPU2 which includes all functions and I O s necessary for the required performance without any modifications Up to 32 drive units can be connected together in a station with one Station Controller and one FBU The QCM2 units come in three different power ranges 340V 15 25 and 50A with or without internal power supply i e Master QCM2 or Slave QCS2 All sizes will be supplied with the same application software The servo units communicates directly with the WinQCM E using the CAN bus Lan2 See Appendix 4 QCM2 CAN Communication for a description of the protocol used The functionality control of the servo drive part of the tightening system is stored in two sets of application
67. rea is marked and release the left mouse button Click on the right mouse button zoom out again Select in which form you want to present the trace with the Display control The following choices exists e Torque Vs Angle e Torque Vs Time e Angle Vs Time Press the Refresh button to re read and re display all traces currently selected Note that this may cause completely new traces to be displayed since which trace to up load from a spindle is pointed out relatively to the most recently recorded Press the Print button to print the trace currently viewed If you see a trace that is interesting in some respect and therefore want to store it on disk press the Save button You will then be presented a form where you may enter an optional comment that will be stored together with the trace Save trace x Select trace to save Sp 1 OK NOK Latest Cancel if Comment le nter a comment here Saved traces can be displayed with use of the Select button When pressed the following form is displayed User Manual Enhanced miniMACS The WinQCM E e 24 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Select Trace M My Comment My Comment 2 My Comment The list shows all traces that are stored By use of the controls in the Show traces for frame you can filter out which traces to show The EUN code entered may start and or end with the wild
68. rive units over the Lani bus and combines all data in its Profibus output buffer Since up to 40 drive units can be connected in the same station the FBU output buffer can be up to 160 bytes As soon as any value in this FBU buffer changes the complete 160 bytes are sent over the Profibus to update the corresponding Profibus input buffer in the Station Controller The 4 bytes of cycle status similar for each drive unit are as follows Signal Name Description Cycle OK Cycle finished with parameters within programmed limits Cycle NOK Cycle finished with parameters outside programmed limits Spindle inhibited Confirming servo was inhibited Spindle Running Tightening cycle running Controller OK Servo drive unit ready for start Step Sync OUT Step finished i e wait until all spindles ready with step for paralleling in multiple nutrunner systems Not used z Spindle Com Err Spindle Communication Error MPMI o NI o S AJ MStop Error Bit 5 Not used Error Bit 6 o femne oO Offset error 1 DC bus low o O NIOJ wjn DC bus fault 1 DC bus low aN Not used Final torque OK 1 OK 0O NOK Set Confirm 0 Mirrors Set Select 0 bit above Set Confirm 1 Mirrors Set Select 1 bit above Set Confirm 2 Mirrors Set Select 2 bit above Set Confirm 3 Mirrors Set Select 3 bit above Set Confirm 4 Mirrors Set Select 4 bit above Set Confirm 5 Mirrors Set Select 5 bit abo
69. rolled by the Automation PC using the following inputs sioa oes OOOO The EUN code The value of this signal 16 byte sampled when a start is detected is used to mark the trace and cycle data generated during the execution of the complete tightening cycle The parameter set to This signal consists of four bits and specifies the number of the set execute that should be used as the normal tightening program Zero 0 correspond to the first set of the tightening program This input is sampled when a start order is detected Inhibit of individual spindles This signal consists of four bytes and is used to inhibit individual spindles This input is sampled when a start order is detected Start A positive edge on this signal starts the execution of a tightening cycle While the system is running indicated by the output signal Running new start orders are ignored Stop A high level on this signal stops the execution of a tightening cycle if executing All servos spindles will be machine stopped This signal has precedence over all other input signals Reset A positive edge on this signal resets the system i e the station controller logic as well as all servos spindles While the system is running indicated by the output signal Running new reset commands are ignored 4 5 2 Outputs During and after a cycle the Station Controller indicate its status using the following output signals Signal Description S Running This si
70. rs 11 through 20 holds the latest NOK cycle recordings When a new cycle starts the oldest trace buffer will be overwritten and called number 1 Trace buffer number 2 then holds the previous cycle recording If a tightening cycle fails trace number 1 which have just been recorded will be copied to buffer 11 The header of each buffer will contain the following data e Nr of samples max 2047 e TraceT sample rate e SpindleNo 1 40 e Stepstatus e EUN code e StartTime User Manual Enhanced miniMACS e 79 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 8 References miniMACS User s Manual Release 1 ASY 9834 0946 01 1997 02 CPU2 for Enhanced miniMACS Requirement ASY QSW99036 GF 990122 Specification 08 Opencontol User Guide Version43_____ NemaSon Ref Description Document Number 01 02 03 04 05 07 QCM2 User s Manual 4 0 ACC 9032 0019 01a Feb 10 1999 FBU User s Manual 1 0 ACC 9032 0016 01a Dec 9 1997 User Manual Enhanced miniMACS References e 80 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com This page is intentionally left blank User Manual Enhanced miniMACS References e 81 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com A rtisan Artisan Technology Group is your source for quality Tecmoogy
71. s e Start e Stop e Reset e Inhibit e EUN code The result and status of the station is the reported back with the following signals e Running e RM back off started e RM re tightening started User Manual Enhanced miniMACS The Station Controller 39 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com OK NOK Communication error E stop Parameter set failure Confirmed set number and for each spindle in the system Cycle NOK Spindle Bypassed Torque NOK Angle NOK Controller OK Ready Time out Error Transducer Measure Error DC Bus Low These inputs and outputs are described in more detail in section 4 5 A typical sequence performed by the Station Controller looks like the following 1 The Automation PC sets up the EUN code for the piece to be operated on inhibit any spindles that should not be used and defines the tightening set that should be used The Automation PC starts the tightening cycle by raising the Start signal The Station Controller checks that the system i e FBU and servos spindles involved is OK If not the tightening cycle is immediately terminated If the system is found OK the station starts the cycle If all spindles do not start or if they do not confirm the ordered set number within approximately 500 ms the tightening cycle is terminated When the cycle finishes the station triggers the WinQCM E to
72. s one control mode defined by up to six parameters for example torque angle speed time etc See Tightening steps for a description of the different control modes The program capacity of a servo drive unit allows for storing of parameters for 64 steps The steps can be combined in up to 64 sets Programming is performed using the WinQCM E and the parameters are sent to the drive units through the Lan2 bus Since each drive unit can perform up to 16 different tightening sets the appropriate set number has to be selected before the start signal is sent The selected set number is the same for all drive units in the station but the content of the set i e the steps can vary between the drive units Each drive unit can be bypassed by an inhibit signal implying that it will not run a cycle at the start command The Start of Cycle Time and EUN codes must be included in the start command signal At the end of each tightening cycle the servo drive unit will store the final torque and angle values in its internal memory These values together with Start of Cycle Time and EUN Engine Unit Number are then retrieved by the WinQCM E through the Lan2 bus for SPC calculations and reporting 5 3 Cabeling For proper operation and functionality of the servo drive system all cables must be connected according to the user s manuals for QCM2 Ref 03 and FBU Ref 04 Ground and shield connections must also be performed according
73. s set until a new start or a reset command is issued User Manual Enhanced miniMACS The Station Controller e 45 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 6 The logic of the Station Controller The Station Controller can be described as a state machine with following states and transitions Reset System initiated Spindles with error Waiting for Start Checking spindles Cycle OK or Cycle NOK RM re tightening Cycle NOK The actions taken in the different states are described in the following sections 4 6 1 State Idle The system is under initialisation The Station Controller enters this state only once and that is when the OpenControl Monitor starts the Station Controller application Here some global data are set and the servos spindles are initialised The next state is always Waiting for start User Manual Enhanced miniMACS The Station Controller 46 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 6 2 State Waiting for start In this state the Station Controller is ready to start a new tightening cycle It continuously scans the reset and start signals looking for a positive edge on either of them If a Reset order is detected then all Station Controller outputs are cleared and all servos are reset by generating a low pulse on the FBU input Controller On the timer Re
74. s 04 and the second 05 6 2 4 PC Open the cover of the PC and check the setting of the DIP switches on the Kvaser CAN bord They should be set as the following 1 ON and 0 OFF 1 2 3 4 5 6 7 8 9 10 Sw2 1 1 0 0 0 0 1 1 1 1 SW3 0 0 User Manual Enhanced miniMACS Start up Instructions e 55 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 6 2 5 Lan1 Check that the two end of chain connectors with 120 Ohm resistors are mounted 15 pol HD Connector Pin 13 14 At FBU marked with Host At the last Servo marked with Next 6 2 6 Lan2 Check that the 24 V power supply is supported to the last servo in chain Pin6 24V Pin9 GND 120 Ohm resistor between 2 7 6 2 7 UPS Check that the serial cable is connected to COM1 on the PC 6 2 8 Servo connectors K7A B Ensure that K7A 6 is connected with K7B 34 on all servos Attention For servos which should have servo addresses above 15 you must install a jumper as follows For addresses between 16 and 30 Connect K7B 27 with K7A 16 For addresses above 31 Connect K7B 27 with K7A 15 User Manual Enhanced miniMACS Start up Instructions 56 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 6 3 Software 6 3 1 Needed software and files Servo application Proda_03 HEE FBU application FBU_1 HEE ProMotion v3 xx ECT Edit Compil
75. s of the drive units is sent back the same way to the Station Controller This communication chain is essential for the operation of the tightening system The QMC2 servo units performs the actual tightening During the execution of a tightening cycle they records tightening information i e torque and angle data This data is stored in internal memory and can be retrieved by the WinQCM E application over the Lan2 bus A miniMACS system may consist of up to 32 spindles The rest of this manual describes the parts of a miniMACS system in more detail User Manual Enhanced miniMACS Introduction e 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 The WinQCM E 2 1 General The WinQCM E is mainly used for configuring the tightening program It displays result and status information from the tightening cycles calculates SPC Statistical Process Control values and retrives and displays traces recorded by the servos To do so it interacts both with the servos and the Station Controller WinQCM E also hosts the MMS interface User Manual Enhanced miniMACS The WinQCN E e 3 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 2 Windows WinQCM E has three windows the Result window the Tightening cycles window and the MMS window 2 2 1 The Results Window If the program is in on line mode and you switch to the result
76. setTimer controls the length of this pulse The Station Controller will in this case remain in the state Waiting for start If a Start order is detected the Station Controller will change state to Checking Spindles 4 6 3 State Checking spindles In this state the Station Controller checks for any error that should cancel a start It checks that e the communication with the FBU is OK e the communication between the FBU and all not inhibited spindles is OK e all not inhibited servos spindles report Controller OK and non of the following General Hardware error DC Bus down and Cycle Running If all conditions are found to be OK then following takes place e the value of the input signals EUN code Set number and Inhibit are sampled and stored e all Station Controller outputs are cleared e the output signal Running is set high and the Station Controller changes its state to Running If an error is found then the start is cancelled and the state is changed to Waiting for start The station output Communication error and or the corresponding output signals for each spindle indicate the error or errors that caused the cancelling User Manual Enhanced miniMACS The Station Controller 47 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 6 4 State Running The Station Controller is in this state while the normal tightening set is executed The first thing do
77. structions e 58 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 6 3 6 Down load FBU Software Copy the FBU application software HEE to the directory ATLAS FBU Then do the following 1 2 10 11 12 13 14 15 16 17 Setup FBU address and load down software into FBU Plug PC into host port on front of FBU Load the FBU application software onto PC hard drive this is FBU software Select Window Terminal you are now in terminal mode Make sure FBU is powered up If the FBU does not respond by displaying its address type CTRL Z X where X represents the current FBU address E g CTRL Z 0 opens communication with selected unit Then select Controller Force terminal mode and wait until FBU displays its address e g gt for address 0 1 gt for address 1 etc Download FBU software Select Controller Download Select the FBU application software and press OK to download You can monitor the download status at the bottom left of screen Type FSTORE to store new file in FBU memory Type RESET SYSTEM to reset system FBU software will now start Change the FBU Node address to 0 Default is F case sensitive Type CTRL Z F Type EEPROM 6 240 for FBU address 0 Type R50 1 Type RESET SYSTEM to reset and set node number Unplug the PC the FBU is now set up 6 3 7 Install NET UPS L
78. t gt NOTHING lt spindle gt lt spindleNo gt HT lt finalTorque gt HT lt MinTorqueLimit gt HT lt MaxTorqueLimit gt HT lt finalAngle gt HT lt MinAngleLimit gt HT lt MaxAngleLimit gt HT lt inibited gt HT lt Status gt EOL lt SeqNo gt lt numStr gt a sequnce number lt NewRecord gt 1 0 1 indicates that this cycle data is new lt StationName gt lt alphaNumStr gt name ofthe station lt EUN gt lt alphaNumStr gt EUN code as supplied from the Automation PC lt Date gt lt dateNumStr gt date when the cycle was started lt Time gt lt timeStr gt time when the cycle was started lt SetNo gt lt numStr gt set number executed for the cycle lt CycleResult gt OK NOK overall cycle result lt NoOfSpindles gt lt numStr gt number of spindles in the station lt spindleNo gt lt numStr gt the spindle number lt finalTorque gt lt floatStr gt the final torque reported for the cycle lt MinTorqueLimit gt lt floatStr gt min allowed torque lt MaxTorqueLimit gt lt floatStr gt max allowed torque lt finalAngle gt lt floatStr gt the final angle reported for the cycle lt MinAngleLimit gt lt floatStr gt min allowed angle lt MaxAngleLimit gt lt floatStr gt max allowed angle lt inibited gt 1 0 1 indicates that spindle was inhibited lt Status gt lt TimeOutExceeded gt lt MinAngleNotReached gt
79. tation Controller 38 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 4 3 Basic functionality The main function of the Station Controller is to start and stop the tightening cycles as ordered by the overriding Automation PC and to handle reject management It also co ordinates transferring of quantitative cycle data between the WinQCM E and the servos To use the Station Controller together with a particular tightening set up defined using the WinQCM E the following parameters must be set up in the Station Controller application before it will work properly e The number of spindles in the system and for each tightening set defined in the WinQCM application the following reject management parameters see section 4 4 for a description of reject management e Max number of failed spindles to allow only the failed spindles to be backed e The back off set e The re tighten set e The second failure action All four parameters are set to zero 0 by default The Station Controller application program must be modified with the correct value of these parameters and be recompiled using the OpenControl development environment The parameters may also be set using the OpenControl Monitor but then the values need to be set whenever the Monitor is restarted The execution of the station is controlled by an external controller e g a PLC or Automation PC using the following signal
80. tisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com cleared at the start of each shift and whether or not the report should be printed automatically at the end of the shift The field last cleared at shows the time when the buffers where last cleared Press the Print Current button if you want to force the printout of the report for the currently running shift The report will then be based on the data collected since the buffers where last cleared up till now It is also possible to print the previously generated shift report This is done pressing the Print Previous button The reports are printed to the printer set up as the default printer on the NT system User Manual Enhanced miniMACS The WinQCM E e 28 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 2 3 10 MMS File View Spindle Setup Loadparameters Accesslevel SPC Trace Report Ka Help 4ll records New records Save All records Fills The MMS Window with the records of all cycles currently stored in the MMS queue New records Fills The MMS Window with the records of all cycles currently stored in the MMS queue that have not yet been read by the MMS server Note To update the window with latest data you must actively select either of the two alternatives above The window is not automatically updated when new cycle data becomes available Save
81. ue slope percentage Ratio of the torque slope reference Torque slope is measured continuously over a pre set Angle INC Torque slope reference is stored when Torque Ref TC is reached If the angle ended below Min Angle or at any time exceeded Max Angle or Max Torque or if Max Time was reached before pre set Torque Slope then interrupt the cycle and set status NOK Depending of the selected mode the editable parameters change according to below Max Min torque torque Delay End Yes No Yes Yes Torque Yes Yes Yes Yes angeend Yes No ves ves Yes Yes The parameters TC INC and Ratio are only editable if the control mode is Yield Angles are programmed in degrees Max time is programmed in seconds Time for Delay and Delay End steps can be programmed with one decimal Speed is programmed in rpm In all steps except Delay and Delay End one can select to run in Reverse direction Torque is programmed in Nm or fl lb If Max torque is less than 400 Nm fl lb it can be programmed with one decimal User Manual Enhanced miniMACS The WinQCM E e 10 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Max allowed torque is set up in the Spindle parameters menu When a step is Deleted the step is removed and the steps following are moved up one row As step no 64 a new empty step is added W
82. umber of NOK cycles 1000 100 are shown Press the button Refresh to refresh the current list and press the button Print to have the current view on paper End of shift report You can set up that an End of Shift Report should be printed automatically at the end of each shift The report consists of the following data The number of cycles executed since buffers where cleared see below when buffers are cleared The number and percentage of NOK cycles executed since buffers where cleared The average 3 sigma Cp and Cpk for all variables currently set up to be monitored for SPC at the end of the shift These variables are calculated on the SPC and TDA data buffer Note The calculations of these variables are not reset when the other buffers are cleared e g at the start of a shift To set up when the end of shift reports should be printed select the menu alternative Report Define End of Shift It will cause the following form to be displayed Weekday Sunday 1 Monday 2 Tuesday 3 K Timeformat 00 00 23 59 _ Weekday Stat Stop l uy Cancel Print current iiel Print previous M Automatic clear at shift start last cleared at 1970 01 01 0 00 JV Automatic printout at shift end In this dialogue you can define the start and end of each shift using a weekly calendar You may also specify whether or not the cycle buffers should be User Manual Enhanced miniMACS The WinQCM E e 27 Ar
83. up with which default project it should execute when started To do this start the OpenControl Monitor lt OpenControl Monitor Iof x File Edit View Options Tools Help g Bs Print Help f Execution Mode Real Y Flowcharts Logic Memory Output Forces Threads ie Clear Output Hyperkernel 4 3 Trace Debug Kernel Copyright Imagination Systems Inc 1996 1997 1998 OpencControl Multiple Driver Execution Engine OCMDEE Yersion 2 0 Creating OpenControl database Loading logic solve Starting OpenControl Log Manager Synchronizing device driver s Logging to directory C Program Files NemaSoftiOpenControliProjects SC_v_1_4 Log Loading device configuration s ProfiCortrol Version 4 03 504 Copyright ICT Inc 1996 1997 1998 Portions Copyright Softing GmbH 19961997 1998 Consut the license agreement provided for terms and conditions regarding your use of this product Starting PROFIBUS Configuration ProfiBus ProfiControl DP Slave Interface Version 4 03 404 Copyright ICT Inc 19961997 1998 Portions Copyright Softing GmbH 19961997 1998 Consult the license agreement provided for terms and conditions regarding your use of this product Starting PROFIBUS Configuration ProfiBus2 Starting user program s User program C Atlas UserProg GetTime exe started Initializing device hardware OpenControl Multiple Driver Execution Engine started pF 000000 000000 4 31PM 4
84. ve Not used Not used N oO k AJOJN O N User Manual Enhanced miniMACS Appendix e 75 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com 7 4 Appendix 4 QCM2 CAN Communication The Station Controller uses the CAN communication interface to program drive parameters and retrieve quantitative tightening data The communication format is CAN version 2 0 which is further detailed in Ref 06 The parameters that have to be programmed before the tightening station can be started up are the tightening step parameters defining the tightening process torque angle and speed limits etc and the spindle parameters defining the characteristics of each spindle gear ratio scaling regulator parameters etc These parameters are programmed once when the station is being commissioned and don t have to be reprogrammed until changes are to be made to the tightening cycle or a different spindle is to be used The quantitative tightening data that can be retrieved by the Station Controller are of two types reports and traces The reports of up to ten parameters can be chosen to be retrieved after each cycle while the traces containing a lot more data are retrieved only on an operators request 7 4 1 Step Parameters The basics of the steps are described in section 2 3 3 Each one of the 64 steps has 10 parameters numbered from 1 to 10 In the servo drive unit
85. want to be certain that the downloaded version is the correct one continue with the following Type CTRL Z 1 Wait for response of servo select Controller Force terminal mode from menu then type DISP EEPROM 63 and hit ENTER As a result the version of the servo application software will be displayed It will look similar to the following 1999220401 12 Setup correct servo address Servos are addressed 1 15 starting from the left most servo going right When specifying the servo address using ECT software we must use hexadecimal notation Therefore 1 15 will be 1 F hexadecimal Type CTRL Z 1 Then select Controller Force terminal mode from menu and wait until the servo displays its address 13 Type CTRL C CTRL C to stop the servo software 14 Type EEPROM 6 241 for servo address 1 242 for servo address 2 etc Note 241 240 Node 240 1 See also the servo adress table below 15 Type RUNS to startup servo software with new node number 16 Unplug the PC the Servo is now set up Goto Next Servo Servo address table Servo or FBU Eeprom 6 Hex number Value Address o 0o 2 1 16 31 24 2 17 32 242 243 244 318 419 2 520 245 62 246 42 43 10 25 250 251 52 253 1 251 12 27 2 2 253 a4 E 13 28 14 29 254 15 30 255 F 18 11 26 12 27 User Manual Enhanced miniMACS Start up In

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