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NOISE ANALYSIS USER MANUAL

1. absolute scaling you see the frequency order of the speed source input shaft at the position of the peak This difference results also in a different length of the curves With an absolute axis the relative rotation frequency assigns the length of the curves shafts which rotate with a smaller frequency produce shorter spectra With a relative axis the length of the curves is the real length of the spectra in general a power of 2 DISCOM Noise Analysis User Manual Page 29 of 63 You can switch between relative axis and absolute axis via the popup menu of the scope You can reach it by clicking into the grey area outside of the data panes e g between the labels 50 Sk 2 lit Sec Px TAS Kurven Einstellungen Scope Optionen eg SKS Treppen Darstellung Drive Eurven Maximum markeren 150 Dauerskalierung Y Achse Export als You select the menu entry absolute x Achse The symbol n front of the menu entry shows whether a relative or an absolute x axis is currently used 10 8 Problems with the scope display No spectra within the scope or curves do not move Spectra and time signals as well are being calculated and displayed if e A candidate has been inserted e A mode has been set e The rotational speed is n a valid range If a candidate has been inserted and a mode has been set you can check in the display Test bench control see chapter Supervising the test cycle
2. which process the noise signal and the rotational speed to carry out the noise analysis Depending on the test tasks of the PC t can be equipped with two or more such cards Different interfaces can be used to communicate with the test bench At the moment most of the test benches communicate with the measurement PC via serial interface COM2 Alternatively a variety of different interface cards can be used but such cards are additional equipment of the PC You can use a Profibus interface card for example and integrate the measurement PC directly into the Profibus network of the test bench Many test benches use also a serial protocol printer It is connected to port COMI then The following figure shows how most of the measurements PCs are equipped ROTAS Communication PC serial Test Bench DPM42 Rotational Speed Noise DPM42 Report Printer Screen etc DISCOM Noise Analysis User Manual Page 7 of 63 3 2 Electrical connections schematic representation View of the PC back The number and alignment of connections can vary depending on the actual equipment of the PC The connectors are labelled with a sticker below the connectors Furthermore you find the serial number of the PC on this sticker Analogue inputs 1 4 only 1 is normally used LPT2 Mouse COM1 COM2 Rot speed SCSI Soundcard USB Keyboard Printer PLC Monitor Network 4 Switching the PC ON and OFF 4 1
3. If a speed instrument exists check whether the right rotational speed is being displayed In case of doubt check speed sensor and its wires If these conditions are fulfilled close the scope window and re open it with the corresponding toolbar button Press the button Auto scale see above Make the window Stdout visible by clicking on its representation in the task bar Eventually the measurement program has written down error or status messages there Finally End the Rotas program and re start it Afterwards re start the test cycle at the test bench DISCOM Noise Analysis User Manual Page 30 of 63 10 9 Tracking values of single orders Some test benches carry out an additional analysis of single spectral components orders sometimes mesh orders relative to the rotational speed This measurement is displayed in a separate display window During the up and down measurement you can see how the measurement curve is being written There can be limit curves for these curves as well Alternatively you can evaluate the maximum or the mean value of the curve or of parts of the curve Whether such an analysis is performed which orders are involved and which kind of evaluation is being performed this is defined in the parameter database Track_H1 in SK1 Z 1000 1500 2000 2500 3000 3500 4000 4500 Track_H1 in SK1 S 1000 1500 2000 2500 3000 3500 4000 4500 DISCOM
4. se He HK KK KK KX X In the lower part of the dialog you can exclude the data of individual test modes from the storage process Double click on the name of a test step in the column Mode The symbol x in the column Report indicates that the values of this test mode will be stored Cancel DISCOM Noise Analysis User Manual Page 46 of 63 15 2 Creating Evaluations After you have loaded one or more databases press the button for display of data The evaluation form opens You can enter up to x Displays the Mode Object measurement values or limits For monitoring of the learning process Quantity Parameter Inst Char Yal Lim Crest Jf AA 12 z fGer uscz Ord fAbs 1 0 120 0 Abs Mix fs fean If Reno Mix I mM mM mM m U ve Curse title Time Interval Moments Display Result Average Stand Dev Database four values for parallel display Enter settings in each line for specification of a value Compare them with the protocol list in the parameter database Un checking temporarily hides the display of individual values Settings Distribution Caption a si lt isS Axis scaling rel V Frequency Density x 2 abs from 45 30 Frequency Sum Specifies axis settings to 10970 100 f 1000 Display Press Display or select Resolution 2 30 Density Sum Display Autoscale Auto scale Time series Axis sca
5. Insert 1 Starting test cycle type 1 PINS 1 1 Everything ok 0 Error e g unknown type _ pC BINSRT 1 INS Bitvalid O o DR 0 Z Direction Z MDSET 1 Mode Z activating test step Z 1 ok 0 Error pC EMDSET I RDY bitvalid o pL MEAS 1 Rottas started the measurement po Oz TO NIO FAL depending on evaluation current mode _ MEAS 0 Rotas stopped measurement evaluation result valid DRI S Direction S MDSET 1 Mode S activating test step S po RDY Seok O Error o po O EMDSET I RDY bitvalid o po MEAS 1 Rots started the measurement ps1 TO NIO FAL depending on evaluation current mode _ MEAS 0 ____ Rotas stopped measurement evaluation result valid pS FRVD 1 Rotas completed test cycle o o ooo Reset bits Reset The function Reset in the last but one line is equivalent to the Reset command That means 1f the bit INSRT gets the value 0 without bit RMV having set to 1 before the measurement program stops the test cycle without storing data abort DISCOM Noise Analysis User Manual Page 23 of 63 9 5 5 4 Special function Mark defect If a defect is detected during a gear test the sequence above changes as follows ifthe defect is detected in the first test step Z the second test step is skipped before the test bench ends the test cycle by sending RMV 1 it enquires the position of the defect as follows TTHGT 1 TH1 va
6. being reported DISCOM Noise Analysis User Manual Page 21 of 63 9 5 5 Example of a test cycle on a gear tester It s clear that a test cycle which 1s being controlled via control bits follows the same basic structure as a test cycle which is being controlled via commands This means in particular that the test bench needs to inform the measurement program when a new test cycle starts as well as which test step mode shall be tested next The following example shows a test cycle of a gear tester testing one gear 9 5 5 1 I O Area Configuration The following tables show the configuration of the I O lines of the interface Bits which are not labelled are unused Input lines Bis 0 1 2 3 4 5 6 7 In INSRT MDSET DR RMV TTHGT In l Type as Byte values Output lines Bis 0 2 E T ee ed Out I LIFE ONL INS RDY MEAS RVD Oow2 to No ra J T T O Out 3 EINSRT EMDSET ETTHGT THl defective tooth 1 9 5 5 2 State Information The measurement program can send information about its current state to the test bench That way the test bench can verify that a correct test can be made The following state information is frequently used o Life bit A life bit changes its value with fixed frequency That way a device signs that it is still alive Bit Out_ 1 0 LIFE in the example above is such a life bit Its value changes every 500m
7. manual The parameter database and the Statistics Tool are described more detailed in separate manuals also DISCOM Noise Analysis User Manual Page 5 of 63 2 Basics of Noise Analysis The noise analysis uses an acoustic sensor for structure borne noise which captures the noise signal from a candidate Additionally the rotational speed is necessary to carry out the analysis A candidate can consist of several components e g the inner shafts of a gearbox Each component contributes to the total noise read by the sensor RotasPro can separate each contribution from the total noise and assigns it to the different components The contribution of each component is being processed separately in synchronous channels To separate the signal components ROTAS needs the current rotational speed and constructional data of the candidate This data 1s stored in the parameter database For gearboxes three such rotationally synchronous signal components are generated and analyzed labeled SK1 SK2 SK3 As fourth signal the total signal Mix is also analyzed Noise Source For each of the four signal components a spectrum is calculated Some defects leave characteristically footprints in the spectrum Additionally further values RMS Crest see below are calculated which allows you to find further defects A main noise source is the contact of the teeth of the cogwheels gear mesh See the s
8. Drintme u se sn ke 33 11 4 Request One Time Long Report s sssssssssssuueeessssnnnnsnnnnnnsssnsnsssnnnnnnssssnnnnee 34 11 5 Storing Measurements in an Archive sssssssssssssssssssssnnnunnssssnnnsssnnnnnnsssssssssssnnnee 35 12 Measurement type definitions u0u0u000s000 nn 36 12 1 Measurement types from the time Signal cccccccssssssssssscccccsssssssssccccssseeeees 36 12 2 The Dentist and mesh Order ze 22 2u een 37 12 3 Measurement types from the order spectrum Harmonics and limit curves 38 12 4 Tracking values Of single orders ssssscccccoossssseccccocosssesccccosssssceceossssssssecesssssoo 39 13 Learnme Limit V Al GS eioen a aone REN 40 13 1 How the Limit Values are generated sssssseccccccsssssscceccocosssssceccosssssssceesessssoo 40 13 2 Controlling the Learning ProcesS sssseccccccssseseccccosssececccocssssssceceosssssssseeeossssoo 41 14 Testing a new Candidate Type sisccccsesssasscecessecsesscecssessisscassoeosseasecscceeseaseeoessssecasccesecees 42 14 1 How to create a new Candidate Type sscssssseeccccccosssececcoocssssssccccosssssescecesosssoo 42 14 2 Initial settings learning of a new type Of gearbox sessscssssesseccoooosssseseceoosssoo 44 14 2 1 Switching the Hats on and off in ROTAS eessssssennnnnnnnnnnnnnennnnnn 45 15 How to Use the Statistics Database ssssscscccccssssssssssssccccscesssssssscccecsesssssssecs 46 15 1 Controlling th
9. P At_Hl 5 k 48 4 120 0 P At_H2 5 5 50 2 120 0 Ari i O11 49 2 120 0 2 You find the list of all defined error Peak Rus i i codes and error texts in the file Donineliix 71 120 Errorcode set in the project Crest Peak folder C RotasData Your Rus project Errorcode set R Z Cor _ H1 Cor_H2 The range of the long report is defined in the database see report lists in the database documentation Only those values will be displayed for which a report has been requested in the database The data of the long report are stored in the report database and can be evaluated with the statistics tool DISCOM Noise Analysis User Manual Page 32 of 63 11 3 Report printing All data which is displayed in the Report window defect report long report can be sent to a serially connected report printer with endless paper You can set the amount of data in the printed stored report n a dialog of the program Open the dialog using the button in the toolbar If your project s toolbar does not show this button you can reach the dialog via the system configuration as well Right click on the symbol Print report and choose Options In the dialog select the sheet Output line Report Options x Output Line SmkNet Window H BJ pens2 siave m ED Dam Master Si l EN short 120 normal ET Measurement Data Defect Reports AEJ Table of Measurements mE Measure
10. Start the PC 1 Open the flap at the front of the PC The key can be found in the drawer with the keyboard or in the folder with the documentation 2 Press the ON key for approx 1 sec nu 3 The system starts The lamps above the ON key red and green 1 glow or flicker It takes approx 10 sec until the screen is displayed 4 If Rotas does not start automatically start the program as described below 4 2 Shut down the PC Close the RotasPro program Close all other open programs and windows Press the button Start in the left lower corner of the task bar Select Shut down from the menu A dialog appears Select Shut down and press OK The computer will switch off automatically Never use the ON key or the main computer switch to turn off the computer AS ee ee DISCOM Noise Analysis User Manual Page 8 of 63 5 Starting ROTAS with red profile for the database symbol with yellow D and for the statistics tool symbol with yellow S The labels of the links can vary the symbols are always as described and in shown in the figure see right s To start the analysis double click the symbol for the analysis program amp On the windows desktop are symbols links for the analys s program grey circle ROTAS can not be started twice Before you start the program check whether it is already running or has not yet been shut down completely In case you accidentally have started it t
11. a gear in a gear test With a gear box the measurement types refer to the gears of one shaft 12 1 Measurement types from the time signal fal Zeitsignal E Mie x Null pulse Smoothed Signal Pr flingZ Pr flingZ MullPuls i g Q Q rE 100 200 300 400 500 600 700 00 900 400 fel gt Qm Rev Q Q The figure above shows the time signal of a cogwheel with one defective tooth Such a defect Signal lee Messwert Tabelle 7 E loj x Mame simi untl leads to a ticking noise in a gear test and in an crest Pr fingz ioe An assembled gear box The figure on the r ght shows Peak Pr fling 1 61 1 50 P the table of measurements with the values PeakFuse Pr fling 2 53 7 00 calculated from this signal Rms Priflingz 0 24 0 40 q Rpmcheck Ski 169 41 Three different measurement types are calculated TickEval Pr flingz 18 57 15 00 TU from the time signal Peak RMS and crest The peak is defined as the maximum amplitude of the signal It is read directly from the time signal or the smoothed signal A high peak value results when the cogwheel has a defective tooth with a nick The RMS value reflects the energy contained in the signal The mean value of the smoothed signal tends to mirror the RMS value as you probably can imagine In other words The RMS value is high when you have many peaks on the signal On the other hand one isolated peak see above does not lead to a high RMS value s
12. figure above the x values of the curve range between 0 and 0 023 seconds 23 milliseconds but the visible cut out ranges between 2 and 16 milliseconds With the scaling and zoom function of the scope you can focus closely on the important parts of the curves The scroll bars and the buttons connected with it can be used to set and change the scaling of the display Each axis has its own buttons but similar labelled buttons on the axes have similar functions The axis itself shows the smallest visible value at the left end 2 0 ms in the figure and then the values marled by the gridlines At the right end of the axis the unit is displayed here s for seconds If you have very big or very small data intervals the values are transformed to a usual unit milli m micro u kilo k etc The scroll bar influences the visible interval in the usual way You can move the handle or click into the area to the left of to the right to move the visible interval The buttons next to the scroll bar have the following functions Zoom in enlarge scaling interval Zoom out reduce scaling interval Automatic scaling this axis only Set 0 at the beginning of x axis Set 0 at the bottom of y axis DISCOM Noise Analysis User Manual Page 25 of 63 If you zoom into the data by pressing the button the handle of the scroll bar becomes smaller to indicate that you see a smaller cut out of the data now If the size of a
13. linings in the printout e g dotted lines But this option also needs a warning Some printer drivers are unable to print different linings You will then see all curves printed in solid black Liniendicke im Ausdruck 2 I Ausdruck in Schwarzwei 10 6 Spectrogram Display The scope can not only display data as curves but also as colour density diagram If you have spectra as data the colour density diagram is called spectrogram This name is used for a colour density diagram with the scope DISCOM Noise Analysis User Manual Page 28 of 63 In a spectrogram each curve is transformed into a coloured pixel line of the image The colour of a pixel depends on the value of the curve at this point You normally use lighter and more intensive colours for high values When the scope receives a new curve the current image is moved by one pixel line to the top so that the image data of the older curves remain Thus the spectrogram display allows getting an overview about the nearest past On the other hand you can not read out the values as exactly as with the normal curve display You activate and deactivate the spectrogram display via the context menu of a data pane You click with the right mouse button into the pane and choose the topmost command Spectrogram Hier beobachten BMP Export Excel Export csv Html Tabelle In a spectrogram display the data values are transformed into colour values A colour map with a defi
14. modes and candidate types are defined n the in System Konto j5 xj database You can easily view them in the program and enter pr System temporary changes He Pa Doms Stave 2 Er IBY Dena sieve 1 Open the system configuration and double click on the module Eel BE Dom42 Master Trigger Decoder picture or name The trigger decoder dialog SP BB Wr will appear Ee Messergebnisse H Ea System E instellungern a g Datenbanken Ho Drehzahl Trigger Decoder This dialog lists the speed ranges of all test modes Pr fzustand von bis Up Bew Prutz andern E Grenzkuren Auswertung Select a line to view the a Ablaufsteuer Container interval in the entry ae Start jem 2 ae Sblaufsteuerung fields on the right 5 2500 0 15000 ne i700 6 5 2500 0 1500 0 B ae EES Steverungsmeldurdg E gt JENNA PENN nz el Kommandos wor Enter a new interval for Eontrollausgabe auf StdOut M Start trigger 7 externes Start Stop ber cksichtigen Interface Contrier the selected gear and viper erercuberacnaticacia M Stop trigger i ak Kommando Decoder click Apply to activate it iw ah Trigger Decoder ARE oo Ampel e If trigger ranges are defined in the database the new interval is valid only until the next update from the database Usually an update is being done when a new candidate is inserted Lasting modifications must be entered in the database then Some test benches use different analogue
15. the measured values are not absolutely valid they are compared with other values In a sense you do the same with weighing You compare a gearbox with something different where you know how heavy it s In practice a so called reference candidate By testing this candidate regularly reference measuring you make sure that the measured values for the reference candidate always remain the same within the standard deviation You can then compare the other candidates with the reference candidate As mentioned before the noise of a candidate in the test bench can not be measured objectively Nevertheless the measurement system itself consisting of noise sensor amplifier and measurement PC can be measured objectively If you press the noise sensor on a noise source which produces a noise of 103 dB you expect the measurement program to show this value Verifying this request and if necessary adjusting the system is called calibration The following sections describe how reproducible measurements are made how reference measurements are done and how you calibrate the system Except for calibration you need knowledge about the statistics database tool Make yourself familiar with this tool before you start DISCOM Noise Analysis User Manual Page 48 of 63 15 4How to make reproducible measurements First choose an appropriate candidate In fact soft noise varies more than loud noise Thus you should not choose a very good candida
16. 17 Mar 2000 11 08 22 Getriebe n i O i G Mw E O Tp Kx the program is shut down G00 Gerduschsignelfeht 2 0 0 02 00g Signaiche 0 Fehlercode nicht definiert 5 2 2299 6 0 0 0 0 RpmChe 600 Gerauschsignal fehlt 5 2 0 0 0 2 0 0 g SignalChe 600 Ger uschsignal fehlt 5 2 0 0 0 2 0 0 g SignalChe The Stdout window displays error or status messages of 00 Ger uschsignal tent 42 0 0 0 2 0 0g SignelChe 310 Beschaedigung 5 Gang Zug 5 2 1 5 7 0 1 4g Peal the program Furthermore you can monitor the serial communication with the test bench MQ350 P2 Typ 1 Palette 0 17 Mar 2000 11 39 25 Getriebe 1 0 4 DISCOM Noise Analysis User Manual Page 9 of 63 5 2 The Status bar Dr cken Sie F1 um Hilfe zu erhalten SerNr 0815 Era lt gt 7012 12 k 600 0 Upm N The status bar is located on the bottom border of the main window The fields of this bar display status information If the mouse cursor touches a button or a menu item a short description of its function is being displayed on the left of the status bar Otherwise you read the text shown above On the right you see five status fields containing the following information from left to right e Serial number master wheel ID This field shows the serial number of the actually tested candidate Rotas ZP systems show the name of the Master wheel here e Candidate Id This field shows the name or numerical ID of the actually tested candidate
17. 4 119_ pro ProtocolData For each tested base type a separate report database has been created Per default they are named BaseType_ prot Then select one or more databases from the list and Di g press Display the Data Display the data us Double click on a list entry to check the time period covered by the database The report database stores only the last for example 1000 measurements of each type If you want to use a report database over a longer period it can be useful to copy databases regularly into another directory to store it 15 1 Controlling the report database Open the measurement program and call the report database dialog vi x the toolbar button see figure Be 2_prot mdb This dialog sets the record cycle This is the number of measurements that the database may hold In the figure beside the last 2000 os Cmert index measurements are held The current index shows the position where 7 Report active IV Record in manual mode the current measurement is being stored You can see that data has been stored when the index is incremented at the end of a test Furthermore you can see the name of the current database at the top of the dialog Record any anal seperately Test modes to record Please ensure that the box Report active is checked For normal measurements n automatic test mode the function Record any analysis separately should be inactive
18. 63 1 Disconnect the cable which connects the acceleration sensor with the amplifier and connect the calibrator to the amplifier instead 2 Let the test bench and the measurement program run in manual mode Insert a gear box on the test bench the type does not matter and let the test bench run with a constant rotational frequency 3 Insert a type in Rotas manually and switch to one of the test modes Switch on the calibrator 4 Now you should see a distinct peak in the mix spectrum Use the scaling settings of the scope to read the exact height of this peak If you have a standard calibrator with an effective acceleration of 1g the maximum value should be at 103 dBg Generally you can assume that the measurement system runs stable for long time periods The acceleration sensors and amplifiers that DISCOM uses don t have a relevant drift Nevertheless t can happen that one of the components 1s defective e g the amplifier gets out of order or the tip of the sensor breaks off But you will notice such defects immediately because the measurement values will differ dramatically You should check the calibration with the measurement program and re calibrate if necessary The other parts of the system work digital and therefore will not vary In practice reproducible measurements and reference measurements are more important than calibration In case you do not have a calibrator at hand you can use the measurement system without rest
19. GES s s een 60 Controlling Gear Shift Force Measurement 2uuuessssseneesnnnnnnnnnnnnnnnnennn 60 REMIKS sa aan kei 6l Special Commands Noise Analysis User Manual Page 4 of 63 1 The Rotas Noise Analysis System The Rotas noise analysis system combines a noise analysis program with databases for parameter settings archiving and evaluation of measurement data The core is the RotasPro analysis application that carries out measurements RotasPro communicates with the external test bench control PLC receives information about the actual test candidate and issues messages on test analysis results Test Benc Control Further components are the parameter and test specifications database and the statistics database Sometimes there is also an archive available where measurement curves and measurement values are stored In the scale of this manual you will find a description of the following items o Structural overview of the test bench and the measurement PC connections etc Operation of the Rotas program normal test process Displays and windows of the measurement program Trouble shooting of typical malfunctions and errors Installation of software updates backups Definition of new candidate types in the RotasData parameter database test specification database o How to use the statistics database O O O O The subject measurement data archives and their presentation is described in a separate
20. NOISE ANALYSIS WISER MANUAL Industrielle MeB und Pruftechnik P 12 07 2004 Contents 1 5 10 The Rotas Noise Analysis System cccccccssssssssssscccccssssssssssssccccsssccsssssssscccssssseesssssecs 5 Basics OL Noise Anays s nase RER 6 TheRotaS PC nu Ran 7 31 Assemb y ansehe seen 7 3 2 Electrical connections Schematic representation cccccccssssssscccsssssssccccscesssecs 8 switching the PC ON and ORF use ee gt 8 4 1 Startthe PC inne east chain 8 2 Shutdown Ne PC 2 2 lesen 8 Srne ROTAS a2 9 ST ROTASI WINGO ceee a a eee 9 3 2 Ihe Stas Dar asie aaae Eae a aaaea hessen 10 S39 Print oraphiesauesisetkaaenn es A EENES 10 ROTAS System Con Moun atl Ons isseccsusceiecscesssenteseswececcnswosevsceSectdessseatescswocecsavunsevsceSectassses 11 The Toolbar a nu eure Ba 11 Thes rane No ht seen au E Ea Ea Eaa 12 SUDELVISINO THE LESE CY ClO cece eo nennen 13 1 TSstStalisznsisslsieenssseklisinsiusslsssenelissiesss isses 13 9 2 Rotational Speed Display u 13 95 Start and Stop Yaluesasanakasasiibhieieek 14 9 4 Command Orientated Control of the Test Cycle sscsssssccccccssssssssssccceoees 15 9 4 1 Supervise and test serial communication ce eeeccccccccceeceesseseeeecceeeesaaeeeeeeeees 15 9 4 2 Overview of the most important commands 2222sseseenenssssseeeeennnnnnnnnnn 16 94 5 Example Of a command segueneessaa nun 18 9 5 Bit orientated control Of a test cycle e
21. Noise Analysis User Manual Page 31 of 63 11 Measurement results 11 1 Table window In the table window the evaluation results of single measurement values are listed The values in the table are those if the last measured gear which is shown in the heading The evaluation result for single measurement quantities are labelled by colour symbols in front of the values li Messwert Tabelle 5 Z Crest GrAb TsAn Crest GrAn Crest Mix Crest TsAb Peak GrAb TsAn Peak GrAn ied en Peak TsAb Red symbol value failed Rms GrAb TsAn ee Green symbol value passed Rms GrAn Rims Mix No symbol not measured or without result e Fine Tot RomCheck Mix 2299 49 SignalCheck Mix 0 93 oo Q Q Q Q Q Q The values in the table are entered in the long report see below 11 2 Report window In the report window all defect messages and measurement report values are listed OOOO alo x MO250 Bratislava Typ Proto 1 No 0 07 Feb 2002 08 09 14 chybni In the top part you see the total code errortext gear value limit avg u O Tp ch 15 Laut im R Gang R Z 121 7 120 0 7 8 dBg 50 00 Mix result with time and date and the list l Ordnung zu laut R Z 121 5 120 0 16 4 dBg 50 00 Gan of found defects Measured Values paraneter are Ba eae In the bottom part the measurement ee er values are listed This list is called Prim H3 5 ie P 54 4 120 0 fs s rt a ong report Rus Mix
22. Transter Case connected types 9 Select the new type from the list in the upper left corner and press Design data Design data General analysis data Channel definition Sampling parameters General limit curves Crest Ams Start Stop Speeds List of Measurements Database extract lt DISCOM Noise Analysis User Manual Page 43 of 63 10 The form where you can enter design amp Design data x Base number comresponding J transfer cases data opens The exact appearance of FREE this form depends on the transfer case Aedsun 50 type and its construction Enter in the RedRing 82 yellow fields the number of teeth for RedPin 16 each cogwheel the green fields are a z Ditt Pin being filled with the calculated trans ocou MENZ MISSIONS Sprocket m dio M Speed difference in Ditt Now close all forms The new type s known to the system and can be selected by the measurement program For further details on the definition of new transfer case types and the maintenance of parameters see the database documentation 14 2Initial settings learning of a new type of gearbox If a completely new type of gearbox comes to your test bench proceed as follows i 2 In the database define the new type as described n the previous section Deactivate the Hats of the spectral limit curves in the measurement program see description below Make tests with at least 10 different ge
23. ands On request new commands for special measurements or can be defined Some commands don t differ formally from those listed above Others are called using the following form 1 The special command is indicated by the command ExtCmd The first parameter is the name of the command Other parameters define start or stop One or more spaces separate the parameters 2 The commands are answered with lt R gt Result 1 or 0 3 It may be necessary to have a test step activated using the mode command This depends on the implementation Example Ratio test At the end of an up ramp after the acoustical measurement has been completed with the Measure 0 command a ratio test is issued It tests the gear with has been set with the previous mode command Rotas Function ExtCmd Ratio Test The ratio test 1s carried out Depending on the evaluation result the answer is lt R gt Result 1 or 0 Example Alternate error code list The Rotas system enters all defect entries into a second error list which can be deleted on request This makes it easier for the test bench program to find errors which occurred in a defined part of the test cycle The second list contains the same errors than the first one which can be enquired with the Report commands After a special command which resets the list 1t contains only those which occurred after the reset Both lists are reset on the Insert command Rotas Function ExtCmd ErrcodeList2 R
24. arboxes Preliminary limit curves are learnt by that In the database use the function Translate hats automatically for the new type dialog Edit transfer case data Channel definition Translate hats Now you can re activate the hats in the measurement program At this moment preliminary limits have been learnt These limits can be used at this stage Test more gearboxes 100 and more Let the hats be set automatically again Use the statistics tool see next chapter to check and refine the other limit parameters as well Step 7 can be seen as a regular task It should be done frequently in order to have an eye on quality and evolution of the production DISCOM Noise Analysis User Manual Page 44 of 63 14 2 1 ie System Konfiguration ER System E By Doms slave 2 3 9 Dpm42 Slave 1 ED Dom e Master 7 Host Pec B E reren eWerlung EH a oo Spektrale MeRwerte SE7 H Spektr Grenzkurve SKZ Ee ea Spektrale Mehwerte Sh Hf Spektr Grenzkurve SKS EN Spektrale Melwerte SES FH Spektr Grenzkurve Mix H Spektrale Melwerte Mis F y Messergebnisse FH fy Swetem Einstellungen CH B5 Datenhank er SK2 SK3 Switching the Hats on and off in ROTAS iolxi Open the system configuration and find the section Host a You find the section Limit Curves there see figure Double click on the module Spectral Limit Curve SK1 The settings dialog for the sp
25. are not displayed in the table of measurements If you suspect that an order 1s defective you can check this by looking at the report window grey window Information concerning any defects and possibly additional test data is displayed in this window 12 4 Tracking values of single orders Some test benches carry out an additional analysis of single spectral components orders sometimes mesh orders relative to the rotational speed This measurement is displayed in a separate display window During the up and down measurement you can see how the measurement curve is being Track_H1 in SK1 Z dBmm s written There can be limit curves for these curves as well Alternatively you can evaluate the maximum or the mean value of the curve or of parts of the curve Whether such an analysis is performed which orders are involved and which kind of e rn 4 500 1000 1500 2000 2500 3000 3500 4000 4500 evaluation is being performed this is defined Track Hi in ski S in the parameter database 500 1000 1500 2000 2500 3000 3500 4000 4500 DISCOM Noise Analysis User Manual Page 39 of 63 13 Learning Limit Values 13 1 How the Limit Values are Mean value and standard deviation AN M ner AN ean Value ge ated Distribution of Limit values can be learnt from the statistics of a value Standard deviation the production process Learning is restricted by settings ma
26. ate of the type TYPE shall start The type the test instruction set TYPE must be defined in the database Otherwise it 1s impossible to test 1t When Rotas receives this command it reads the candidate specific data from the database and prepares itself for the test The Ready button in the window Test State reflects this fact by being displayed in pushed state The test bench receives the answer lt R gt Inserted 1 1if everything worked fine or lt R gt Inserted 0 1if something went wrong e g if the candidate is not defined in the database 9 4 2 2 Mode ABC With the command Mode ABC the test bench informs the measurement program which test step gear ramp shall be tested next When Rotas receives this command it adapts its analysis parameters according to the gear The actual test step will be displayed in marked state in the window Test state The test bench receives the answer Ready if everything worked fine or Mode if the mode command was unexpected or the test step unknown 9 4 2 3 Measure 1 0 Some test benches control the measurement directly with the command Measure The test bench issues Measure 1 to start the measurement and Measure 0 to end it When Rotas receives this command all received data between Measure and Measure 0 are evaluated to classify the candidate In the windows Test State the button Measure reflects the running measurement by bei
27. atus bits which are being refreshed from the control program frequently The labelling of the bits in a bit window is dependent on the settings made in the main window In 3 is labelled in byte view and shows the names of the bits Out_3 is labelled in function view and shows one function of the bit If a bit has more than one function only one function 1s being displayed You may notice that bit 1 between Busy and Inserted has not been labelled although it has a function The reason is that the functional dependency is different for this bit 9 5 3 Manipulating functional values As mentioned above the function view is used to display values in the form as the decoder reads them Sometimes you want to manipulate these values e g a serial number without having to manipulate single bits in several windows For this reason a window exists which is used universally to manipulate functional values consisting not necessarily of single bits The bit 1 of Out _3 which has been mentioned above is such a value If you click on the entry 3 1 in the main window you see the following window This window always displays the actual value on the I O card n the moment when you opened the window If you enter a value and click Apply this value is written to the I O card same exceptions like the bit windows How the value is formatted and which interval is valid depends on the processing module In the example shown abo
28. bove may be sent anytime between the Insert and the Remove command All commands except the timestamp commands may be sent multiple times to send different information to the Rotas system The commands ExtError and SetRItem accept additional optional information The form is as follows required entries bold A Code entry for ExtError has the following form ErrorNo Values Unit TestStep Channel An Item entry for SetRItem has the following form Values Unit TestStep Location Instrument Params Channel Description A Values entry for both commands has the following form Value Limit A verage Position If an optional entry is not given defaults will be taken If a list is sent the corresponding entry of the previous item is taken shortens commands DISCOM Noise Analysis User Manual Page 58 of 63 17 1 4 Read Out Rotas Defect Information and Evaluation Result Command Rotas Function Answer Result Enquires the partial evaluation Rotas send the answer Result Gear result If the optional parameter lt Re Result 1 Gear is given Rotas returns the Or evaluation result for that test step gear Example Result 3 U for test step 3 U Result 3 _ for 3 U and 3 D lt R gt Result O Report Type Enquires a report for the last Rotas sends the requested Type s test It contains defect report starting with the line Short or information The long report lt D gt Lone contains all measurement values The report ends wit
29. c analysis the candidate is just one part of a complex system consisting of test bench drives acoustical sensor and other components Even two similar test benches are not identical and tiny differences have influence on the noise already Just so two consecutive tests are not 100 identical It s like picking a guitar string several times You will produce similar tones each time but never exactly identical ones Furthermore the measured noise is dependant from the system thus acoustical Distribution of quantities do not have absolute validity in a value Standard contrast to the weight but are only valid relative to the test conditions of the test bench Mean value and standard deviation Mean value deviation If you get an almost identical result for each consecutive measurement you have If you collect a great number of measurements and reproducible measurements It is a quality of the depict how often which value has been measured whole measurement system and can as you get the distribution of the values From this you pes eee ai eae lade ih wean can calculate the mean value and the standard ee ADONE Oy ere w deviation It is defined that 2 3 of the measured restrictions as a matter of fact Thus you values lie in the area of the standard deviation request that the results of different around the mean value measurements must not differ more than a certain amount the standard deviation shall be small Since
30. cally of which type the current candidate is e g at automatic test benches for gear boxes you have to adjust it so that the new candidate type is issued to the measurement program instead of the original type of the candidate If your system has manual selection the tester himself is responsible for telling the measurement program that a reference candidate is to be tested If you test the reference candidate its values are collected in a separate protocol database If the reference candidate is tested e g once a day at the test bench you can find out with the statistics tool evaluation of the time row whether the test bench is stable or whether the measurement values drift during a period of time If you make this examination over a longer period of time you may find seasonable influences as well 15 6 Calibration Calibration ensures stability and exactness of the measurement system consisting of sensor amplifier and A D converter For calibration you need a calibrator This is a device which is able to produce a defined vibration on its surface You screw a noise sensor on this surface Then you can read the value either in the normal measurement program and make sure that the system is calibrated right or you can use a separate calibration program which is described in a separate handbook You check the calibration of a test bench for gear boxes with the measurement program as follows DISCOM Noise Analysis User Manual Page 50 of
31. cutively maybe a serial number these characters are being displayed as one string You need not supervise 10 single bytes In the function view you only see bits bytes areas which have an actual function Bits bytes areas which have several functions are being displayed once for every function In the figure above output bit 2 3 has the functions Insert Result and Result To be able to verify data n the function view you must know how the decoder reads the data Often a function is only valid under certain circumstances A ten byte string can be type information if bit Type is set or serial information if bit Serial is set DISCOM Noise Analysis User Manual Page 19 of 63 9 5 2 Supervising and manipulating single bits A single click on an entry in the first column of the table in out respectively opens another window in which you can supervise M In_3H and change the state of single bits referenced as bit windows in T In_3 6 x the following text The bits in these windows are ordered as Eo a w EN OFA M Life follows Bit 7 is the topmost bit Bit 0 is at the bottom Mr PEL rien If you click on a check box in one of the bit windows the value of T7 s L this bit is directly changed If this bit is an input bit the actual data I TIL nun from the I O card will overwrite this change in most cases Incase T ER of an output bit the change is written to the I O card directly except for st
32. de in the parameter database and can even be completely suspended Limit values are distinguished by test bench and If you collect a great number of measurements and candidate They are stored as files in the folder depict how often which value has been measured C RotasData Project LearnData you get the distribution of the values From this you 2 can calculate the mean value and the standard o deviation It is defined that 2 3 of the measured The limit value is calculated using the basic values lie in the area of the standard deviation value and the mean value Finally a multiple around the mean value value of the standard deviation value is added Standard deviation gt Mean value gt Measurement Value Statistics Limit Calculation Basic Value Mean n Standard dev Restricted by database presettings Learning can be classified into Base Learning and Additional Learning Base learning includes only a few candidates like 5 In the base learning process the program uses the maximum value from the database as limit value At the end of the base learning process provisional limits are set Additional learning includes a number of candidates like 100 Each candidate will be checked using the current limits first If it is assessed OK it is added to the statistics That way limit values are finely tuned DISCOM Noise Analysis User Manual Page 40 of 63 13 2 Controlling the Learning Process T
33. didate types that are defined in the parameter database If the test bench issues the message Insert it has to provide a valid type Below as an example we create a new transfer case type Please proceed as follows 1 Start the parameter database double click on the D symbol The main form of the database appears H Management of transfer case data Tc44 09 i Management of transfer case data Create erase and edit transfer case types x Copy transfer case data Create new transfer case type Erase transfer case type Directories Commentary Choose project User accounts Defragment Nr 2 Press Create new transfer case type E Create transfer case type x Create transfer case type Existing transfer case types Enter the name of the new transfer case type and assign an se transfer case type Base number existing base number from the list or enter a new base number New transfer case type FU Base number I 0 Pearl Create Copy transfer case data Choose the source and destination type from the yellow lists and define the volume of the copied data with the control boses Start the copy process by clicking on gt gt This will be copied ee T Design data Channel definition copy test states I Gen analysis data MT Sampling parameter ud Up ey 7 T Gen bound curves 4 Down O List of Measurements E Crest Ams Start stop speeds Transfer case type Eonneeted type
34. e If can be sent repeatedly to change the serial number The serial number can be any string with less than 30 Characters The val d type dentifiers are defined n the parameter database All other type identifiers are resigned on the Insert command The valid test steps modes are also defined in the parameter database You can skip test steps 1f necessary The sequence of test steps does not matter to Rotas You can also repeat test steps All results including errors of a previous measurement in a certain test step are deleted if you repeat a test step The Rotas program can be configured to control start and stop of the measurement depending on an analogue signal e g speed Such configurations don t need a Measure 1 0 command from the test bench The response time for all commands except Insert and Remove are much below 1 second The Insert command needs more time up to 10 seconds if changes have been made in the parameter database or a completely new candidate type shall be tested Otherwise the Insert command also takes not longer than 2 seconds The time the Remove command needs to process depends on the amount of data to store in database and archive files but should be less than 5 seconds Additional commands can be defined if special measurements shall be made on single test benches See the following chapter for more information DISCOM Noise Analysis User Manual Page 61 of 63 17 1 9 Special Comm
35. e Test Mode shows the current test mode e Evaluation running While evaluation is on this field shows an x e Rotational speed The most right field shows the rotational speed or a derivate value 9 3 Print graphics The Rotas system allows printing different scopes e g the scopes The database and the statistics tool print reports and graphics also Although this cannot be done on the serial report printer but requires a w ndows printer You can connect an additional windows printer e g color ink jet printer to the PC without further ceremony see electrical connections Please remind during the installation that the printer must not be connected to LPT1 since the Rotas program communicates via this port with the DPM42 signal processor cards Choose the menu File Print setup within the Rotas program to choose the right printer Then you can print to this printer Click on a scope window and choose the menu File Print The serial report printer is not being affected by the choice of a windows printer since it is controlled directly via serial port by the Rotas program DISCOM Noise Analysis User Manual Page 10 of 63 6 ROTAS System Configuration The window System configuration displays all modules functional elements of the Rotas program The modules are organized n a tree structure You can see in the configuration window which application function is active and how data processing is organized If the w
36. e report database sssscsssccccccrsssssssssscccccssccessssssscccosssssesssscecs 46 15 2 Creatine Evaluation 47 15 3 Reproducible Measurements Reference Measurements and Calibration 48 15 4 How to make reproducible measurements sssscccccsssssssccccsssssccccsscsssssccoes 49 15 5 Rererence cand datese u222 Eee 50 15 6 Calbraton aus essen nalen else 50 16 Backup Organisation of the Rotas Software essssssssssssssnnnnnessssssnssssnnnnnsssssssssnnnee 51 16 1 Hard Disk Folders range of a DaCKUp ccssscccccssssssssssssccccsscsesssssscccoeees 51 16 2 Organisation of files and folders 00000000000000000s000000000000000000000000000000000000000000 52 16 3 Mak n a back p C0py 2 u22 regnen 54 16 4 Re storing of a backup copy Installation of Updates ssssssssssseceooees 54 17 ADDENdIX 22 2 2 ee Bars 56 17 1 Complete list of the possible commands from a test bench ess000s00000 56 17 1 1 Exchange of information about the candidate ccsceeesecceccceeeeeeeeeeeeeaeees 56 11 2 Controlling the Test Cycle Test Step Measuring nn 57 17 1 3 Receivine Further Informalionseus een 58 17 1 4 Read Out Rotas Defect Information and Evaluation Result 59 DISCOM Noise Analysis User Manual Page 3 of 63 17 1 5 17 1 6 14 17 17 1 8 17 1 9 DISCOM Redd out Rotas Value a u ee ee andl EA 60 Display ina MESSA
37. ectral limit curve opens In this dialog you find the check box Use hats You can switch the usage of hats on the limit curve on and off If you want to look at the learnt limit curves you can select a test mode in the list and push the button Show curves Remember that you have to switch the hats on and off for each synchronous channel SK1 and for the mix channel separately You have to open one dialog for each channel totalling 4 dialogs at least DISCOM Noise Analysis User Manual EUVeEN zeigen Codes zeigen Eildungsregel 10 0 A 20 R der amp Hute lw Hute anwenden Gin gt je En jo Wwdh Messung Letzte Masinum Mitel OF Page 45 of 63 15 How to Use the Statistics Database The measurement program stores the values from the long report these are set in the report list of the parameter database in the Report database For each type the last 1000 measured values set individually are stored The statistics tool shows data evaluation lt gt After the start you will see the form for selection of the evaluated database Statistical analysis of the report data First you need to load the databases you want to Load a database Remove Sel Databases evaluate You find them in the project directory en Concatenate Sel Databases C RotasData xxxData In its subdirectory Label Origin C RotasData4M 250 engsProtocalD ata
38. eset Reset of List2 ExtCmd ErrcodeList2 Report Output of List2 See Report ExtCodFx DISCOM Noise Analysis User Manual Page 62 of 63 DISCOM Noise Analysis User Manual Page 63 of 63
39. f the mesh orders can be derived from the signal These are called harmonics The first harmonic H1 is located at the mesh order corresponding to the teeth number n this case 34 the second harmonic H2 at twice the mesh order double teeth number in this case 68 etc For this reason the harmonics can be separately set the so called hats The following figure shows the order spectrum of a cogwheel with 34 teeth Hl H2 H3 H4 K Ordnungs Spektruny EB O x 105 90 Fr flimg SK lim 45 15 RA 20 4g 60 50 100 120 140 160 150 OP t G ord A noise component that is generated from all teeth in the same way is reflected in the harmonics A surface defect on all teeth e g not refined rough or wrong angle etc will show up with consistently high values in the harmonics Limit curve Spectrum Ph E gt PEB gt DISCOM Noise Analys s User Manual Page 38 of 63 Candidates of the same type should produce similar noise The amount similarity is checked using the learned limit curve A candidate that has a measured order spectrum exceeding the limit curve will sound differently to the previously tested parts This could be the result of a change in the manufacturing process e g a tool replacement but it could also result from a surface defect see above on just some of the teeth of a cogwheel or from surface waviness It is worthy to note that measurement values from the order spectrum
40. formation ProdType e g prototype DISCOM Noise Analysis User Manual Page 56 of 63 17 1 2 Controlling the Test Cycle Test Step Measuring Command Rotas function Answer Mode Gear The parameters of the test step The successful change of Gear are activated by the parameters is answered with the measurement system The line names of the test step must be Ready defined The following texts can be used for a manual gearbox If the change of parameters did Ramp up not succeed the line 1 U 2 U 3 U 4 U _ Mode Ramp down Is sent 4 D 3 D 2 D 1 D Measure 1 Switching the evaluation on This command does not have an Measure 0 and off answer MeasureA 1 Switching the evaluation on Answer MeasureA 0 and off like above On for MeasureA 1 and Off for MeasureA 0 MeasureAF 1 Switching the evaluation on Answer MeasureAF 0 and off like above On for MeasureAF 1 Of for MeasureAF 0 Remove The test cycle has been The answer for this command completed The Rotas system includes the total evaluation prepares the total evaluation result result lt R gt Result 1 if the result is o k lt R gt Result 0 if the result is n o k The system aborts the current The system sends the line measurement if necessary lt R gt Status Reset and takes initial position No evaluation is being made RequestStatus Enquiry of the measurement s Rotas sends the line system state lt E gt SstaLusz O
41. from a backup copy all settings are re set to the state when the backup was made The folder RotasData contains a subfolder for each one of your projects e g for different production lines but not for parallel test benches in the same line In this project folder you find the files and folders listed below This list shall give you an overall view and help you to take the right steps in case of problems In particular Rotas install or repair instructions can refer to it DISCOM Noise Analysis User Manual Page 52 of 63 RotasApp sea sometimes Application sea This file is called Application sea All settings that you do within the Rotas program are stored here Errcode set sometimes with suffixes Errcode En set for an English version in this text file the error codes and error texts are listed If you want to change a text you can do it here If you need to add a new error code model it on the existing entries e RotasPro sea sometimes RotasProDpm sea or different suffix This filename must be passed to the Rotas program as an argument If you open the properties of the desktop link right mouse button you will find that it refers to the file RotasPro sea Database The parameter database files are stored in this folder They contain the gear box construction data the limit values and further parameters xxxRatio mdb xxxParams mdb xxxEvaluationTables mdb Keep in mind that you cannot o
42. h axes Store current scaling settings Re activate stored scaling settings Freeze the curves The curves are not refreshed any more This button is displayed in pushed state as long as the curves are frozen Opens the dialog to set the curve colours and panes see above Opens the options dialog Opens the window where you can focus on data points ERE bs lef The Freeze curves function allows making a photograph of the current measurement curves You can have a closer look at the curves then e g zoom at points of interest read out values or print the curves while the measurement continues in the background If the scope is part of a regular analysis application e g transfer case analysis the scopes are automatically un frozen at certain points of the automatic measurement cycle 10 4 Display Options 10 4 1 Rectangular Display or Display Polygons You can choose between two forms of the curve display As polygons or rectangular Display as Polens 2 E Rectangular display 7 If you display curves as polygons each point of the curve is directly connected with the next point Thus each corner of a curve stands for a data point This display form allows reading out the x position of a data point very well If you display curves in a rectangular display for each data point gets a horizontal line which is centred at the x position of the data point This display form allows reading out the y position of data
43. h the line Long for all test steps also lt D gt Report Line The Rotas system sends only one line of the long report As an Contents of the requested line or option a line number can be given to request relevant lines Report Line No only If the command 1s sent without line number Rotas send the next line of the report The short report ends with two empty lines Then the measurement values follow The long report ends with two empty lines also Report ExtCodes The Rotas system sends a report The report starts with the line of the external error codes Up to lt D gt 50 error codes can be sent and ends with the line These error codes can be stored lt D gt by the test bench In the report each error code is given at the beginning of a separate line Report ExtCodFx The Rotas system sends a report The answer is given in one of the external error codes Up to line starting with lt D gt 10 10 error codes can be sent in one three digit error codes follow line Error codes which are not lt D gt ends the line Example set are filled with zeros lt DD gt O00 L007 0OS00400500600 7008000000 lt D gt 8 Errors to 8 are being sent the code positions 9 and 10 are not set DISCOM Noise Analysis User Manual Page 59 of 63 17 1 5 Read out Rotas Values Command Rotas Function Answer GetRItem Key Enquires the measurement value Rotas answers identified by Key including Value Value s li
44. hapter Report normally one file per day This folder should be cleared up from time to time as well to save disk space In particular if you have set Rotas to send a long report by default e ProtocolData In this folder the protocol databases are stored ordered by type as well These databases can be opened directly or with the statistics tool e ProductionData This folder stores the production statistic You can open it directly or with the Rotas program DISCOM Noise Analysis User Manual Page 53 of 63 16 3 Making a backup copy Before making a backup copy you should close all running open components of the Rotas system This includes the measurement program RotasPro and the parameter databases to ensure that all changes of settings in the measurement program and in the database have been written to hard disk After that you should make a clean up as described above if necessary Now create a folder with name of your choice e g Rotas220403 for Rotas backup made 2003 April 3 and copy the folders mentioned above into this folder pulling with pushed ctrl key The backup copy is even more valuable if it is stored elsewhere not on the internal hard disk of the measurement Pc but on another Pc via network on an external hard disk CD Rom etc 16 4 Re storing of a backup copy Installation of Updates On Request you can get a Software update from DISCOM in order to carry out further measurements Bef
45. he learning of spectral limits and of limits for Energy values Crest RMS is controlled by separate modules in most applications You can open the dialog for learning control via the toolbar of the measurement program If you want to learn new limits for a candidate type that 1s currently not inserted select Hand control in the dialog Test x status see ch 9 select the type for new limit learning and activate Subject Ready olen 200 total to learn Open the learning dialog for spectra or for Crest RMS see B base learning figure In th s dialog you can see how often the learning fog fective exponential oo averaging number process was started for individual gears Select the gear s you want to have learnt new and press Test Leaned so New Learn An asterisk behind the learning cycle shows the gear is i being learnt new 0 If you needed to activate the type of candidate manually deactivate Subject ready now and set automatic control i AS 0 AZ 0 H Use alternatively for new learning of all limits Stop New Leam No New Lean RotasPro Go to the project directory C RotasData xxxData open its subdirectory p LearnData and delete the file corresponding to that type which shall be leant new Now restart RotasPro DISCOM Noise Analysis User Manual Page 41 of 63 14 Testing a new Candidate Type 14 1 How to create a new Candidate Type RotasPro will only measure can
46. here is only one possibility why the measurement program is unable to process test bench commands In the window Test state the mode Manual has been selected Thus the answer is lt R gt Stat s Handc ontrol when Rotas can not process test bench commands at that moment DISCOM Noise Analysis User Manual Page 17 of 63 9 4 3 Example of a command sequence The following table shows an example of how a complete test cycle of a four gear gearbox can be controlled by the test bench The measurement itself is controlled by trigger values Insert 4711 lt R gt Inserted 1 Mode R Z Mode R S Mode 4 Mode 4 S Mode 3 Z Mode 2 Z Mode 2 S Mode 1 Z Mode 1 S Remove Mode 3 S DISCOM Noise Analysis User Manual Page 18 of 63 9 5 Bit orientated control of a test cycle Some test benches e g the gear testers communicate not or not only with the Rotas program using control commands but use control bits These control bits are transferred to the measurement program either via digital I O cards or directly via a Profibus interface card You can supervise these communication lines in the Rotas program as well 9 5 1 The Main Window of the Parallel Control Unit Open the system configuration and then go to MeasureCourseControl Container Double click on the module Command Decoder or Bit Decoder Two windows will be opened One of them is this one x Buffer Manager Function Dis
47. hive gets extracted and a folder C XX XXX XRotas is being created At the end an error message 1s displayed which can be ignored results from the invalid password A part of the zip file is secured by password In C XXXXXXRotas you will find a folder IDisc then which you must move to C DISCOM Noise Analysis User Manual Page 54 of 63 Unpacked on CD Copy all files and folders onto your hard disk to C They get the attribute Read only from Windows You need to remove this attribute You can do this by right clicking the folder and choose Properties from the menu Then you can un check the property Read only Alternatively you can use the DOS Command attrib r s If everything worked fine so far you should have a folder c ldisc on your hard disk now which contains the software of the update To complete the update you have to execute the file Register bat in the folder C ldisc by double clicking All messages must be accepted with OK Note Except on Windows98 systems you need administrative rights to do this In case of problems after a software update delete the new Disc etc and re install your backup copy Don t forget to complete this installation by executing Register bat as well DISCOM Noise Analysis User Manual Page 55 of 63 17 Appendix 17 1 Complete list of the possible commands from a test bench The following tables list all valid commands fort the Rotas
48. iger E System Konfiguration nach Wochen nach Typen nach Tagen Typen amp wochen e Wochentage alles in Zieldatei lel erzeichnis EH Fp System Einstelangen Verify again that the check box C RotasData Mq200 OrderTrackey Ee fg Datenbanken Concatenation is active has been ow GH QS Diehan checked if you want the module to Letzte Datt 0 BEE SPSntertace concat s ngle files ehte Laute Fehlermeldungen abgeben You can choose between different sorting methods Consider that the zu ub ok archive files will pile up on the hard disk Depending on the amount of the test a single measurement archive can have the size of 50 150 Kbytes If you let a test bench store archives for some weeks the hard disk will be full one day Two strategies exist against this You can copy the data to a server and burn it on a CD if you wish or you can select the sorting option week days If you do so the measurements of one weekday are stored in one file you will get a Monday file a Tuesday file etc After one week the old file is deleted and a new one 1s created That way you have all the measure ments of the previous week at hand without having an unlimited need for storage capacity DISCOM Noise Analysis User Manual Page 35 of 63 12 Measurement type definitions This chapter describes how the most frequently used measurement types are calculated and what they tell about a candidate especially
49. ignal component spectra to clearly identify these mesh frequencies gear mesh orders RMS Peak and Crest A ALALLA A A we INHTARBRINHLBANRUNNN The RMS value is calculated as the mean energy of the signal gear mesh loud RMS value high The Crest value is calculated as Peak value to mean value RMS A single Tick within a mainly normal signal produces a high Crest value Such Ticks are typical for a defective gear tooth For each spectrum ROTAS provides limit curves If a spectrum exceeds the limit curve in one place the system takes this position to identify the kind of defect and issues a cor responding defect message Likewise the single values Crest etc have limit values Each candidate type has its own limit values and limit curves Limit curves and limit values can be gene rated by automatic learning You can control and restrict this process through settings in the parameter database Only measurements with an OK result are used for learning For each defect you must assign an error code in the parameter database To supervise the production process and the limit values ROTAS has two statistics databases the production statistics and the protocol database Additionally measurement data can be stored in a measurement archive DISCOM Noise Analysis User Manual Page 6 of 63 3 The Rotas PC 3 1 Assembly The measurement PC s equipped with special signal processor boards DPM42
50. ince its effect is negated by the predominance of the signal s lower parts The cogwheel is generally loud or sounds rough when you have a high RMS value The crest value is roughly calculated as the ratio of peak to RMS A high peak value compared with a low RMS value see above leads to a high crest value This characteristic DISCOM Noise Analysis User Manual Page 36 of 63 makes the Crest value the standard criterion for finding defective cogwheels that have only one defective tooth Cogwheels with more than one defective tooth may not be distinguishable from a high Crest value because of the following reason A signal with many peaks will be generally louder Consequently the RMS value will rise Thus the ratio RMS to peak will result n a small crest value Therefore another measurement type has to be used to find multiple defects This type is called the tick eval value This value is not calculated directly from the time signal but from the short time spectra Its calculation takes some time For this reason this value is seldom used n with gear boxes It will be high if defects especially multiple defects are present Additionally the time signal display shows the null pulse signal This signal results from an impulse that is given off once per revolution zero position of the test part The Rotas system needs to receive this signal in order to mark defective teeth During a measurement run Z pull or S pu
51. indow System Configuration is not open open it via the menu File Open System configuration Maybe it is just hidden behind other windows Then you can make it visible via the menu Window In normal test mode you will not need to deal with details or the whole range of modules contained in the configuration Nevertheless for trouble shooting or to make special settings it can be helpful to check a module in the tree Most of the modules in scope are listed in the section Host see figure sis Configuration S nce Rotas applications vary depending on the project and test bench used its configurations will also be different Especially the ranking of objects can be different some might even be lacking or have additional objects cH Men Slave 1 H H A Domt2 Master m Host Pc EH EL Spectral Limit Curves H E Measurement Data A module of high importance is the module Bench Control that is part of every system configuration Click the small to visualize sub modules of this module AET System Settings E Databases HAA Rev Speed EEE The module Bench DR Fer System H D Dpm Slave H Dpm Master e Host Pc H ES System Setup HEF Databases H 59 Limit Curves Evaluation A Bench Control 2 lt IntErrcodes gt Test Status 3 PLE Decoder E RPM Display HB pme Measurement Display DS Defect Reports 4 Database Report Generator H amp Report Display Prink m fig Sa
52. ion E DJ Dpm42 Master _ Host Pc E Grenzkurven Auswertung caf Messergebnisse fo Fehler Berichte Messwert T abelle Zs Messwerte Protokoll ay Protokoll See Export iol x Hessungen Archivieren a 4 x Verify that the check box 2 gas Write files has been checked ee DEG euer you want to store Verzeichnis C RiotasData Mq200 OrderT rack measurements in an archive 4 numerierte Dateien Basisname e H Berichtsausdruck Furthermore you set 1n this z hlerstand 123 Z hler auf FH Messungen Archivieren dialog in which folder the EB Systen Einstelungen H E Datenbanken ZA Drehzahl HA SPS Interface measurements are stored Messungen pro Datei 1 gt 0 Normally one file is generated Abbruch for each measurement each gear box If you check enumerated files the filenames are generated using the entered base name and the counter Otherwise the actual serial number transmitted from the test bench is used instead of the counter In the system configuration you find directly below the Store measurements a module gt jojx Concat files This module is able to CF Messwerte Protokal merge single files single measurements m cherie aktiv y ri PratakolHSee E par to larger files Double click on Concat H Betchtsausduck files to choose how the measurements PA Messungen Arctivieren shall be sorted m TE Files zusammenfi
53. ling Caption ZH Avis sealing 00 x axis y axis IV Time linear C Index Time fom 27 06 2001 10 50 57 8810 Display to 03 07 2001 13 26 40 108 10 Display Autoscale The distribution in the bar diagram shows the accumulation of measured values in certain value intervals e g the marked bar shows that ca 40 of the measurements for the blue quantity are around 85 Use this diagram to set a limit value or sane restrictions for the learning process A time series shows single measurement values over a certain time period Here tendencies become visible like slow and quick rise of values for example when a tool for tooth production wears off You will easily detect accumulations of abnormalities as peaks in the curve profile at certain times You can have time series printed using the index counting of measurements or using the real time of the measurement o 10 20 30 90 500 6500 700 so So DISCOM Noise Analysis User Manual Page 47 of 63 15 3 Reproducible Measurements Reference Measurements and Calibration Like with every measurement system it is desired and required that the measurement values comply with certain objective criteria Unfortunately in acoustics it is not as easy as the measuring of a weight for example If you put a gearbox on a balance you can measure objectively that its weight is 31 kg Each calibrated balance will produce this result as often as you like In the acousti
54. list you can change the properties in the frame Darstellung on the right side of the dialog Select the colour for the curve from the list and select the pane where the curve shall appear The pane at the top is pane 1 the next pane below is No 2 etc The maximum number is 12 panes All panes up to the highest selected number are painted even if this contains empty panes If you disable the check box display the corresponding curve 1s being hidden Hidden curves do not have an x n the column Show Nevertheless hidden curves are displayed within brackets in the list of curve labels to indicate that a pane contains hidden curves All hidden curves are re activated when you close the scope window and re open it The Zeichen Reihenfolge allows influencing which curve is painted last This curve appears in the foreground and is listed on top of the list T TA io 5 FE aio w EN a 10 3 The Functions of the Function Buttons a am a In the bottom right corner of the scope window you find eight njaj function buttons The button shows or hides the curve labels If you hide the curve labels more space is available fort he data panes The button is displayed in pushed state as long as DISCOM Noise Analysis User Manual Page 26 of 63 the curve labels are enabled If you hide the labels the four leftmost buttons also disappear for special reasons The other four buttons have the following functions Automatic scaling bot
55. lue of position Enquire defective tooth Po BTTHGT 1TH valid o The value that the measurement program sends defines the position of the defective tooth relative to the Null pulse The Null pulse is an additional signal given to the PC for this reason It has one pulse per revolution always at the same position Since the position of Null pulse and marking instrument differ between machines the measurement program allows entering a value correcting this difference The setting dialog for this function can be opened by double clicking on the Sps Decoder n the section HOST gt Measurement Control Container Y Verwende Z hrezahl faoa Pulse pro Umdr Markierung in Messrchtung Korrektur 7 Urmdr Verzahnung 1 Verzahnung 2 ja 37 Schub D jo a 20 Zug OF Abbruch DISCOM Noise Analysis User Manual Page 24 of 63 10 The Scope Displays Measurement curves time signals and spectra are displayed n Scope windows The figure below shows some of the essential control elements of the scope window fel Zeitsignale _ x ie Y unit Data area 0 030 Y Axis Y Scroll bar Zero Mark 0 015 0 030 Labels lt d 0 045 20 35 50 65 10 125 140 15 m Alle x el d jof leo a x Axis x Scroll bar Control buttons 10 1 Setting the Scaling Zoom An important control function of the scope as display tool is the setting of the scaling the value interval In the
56. measurement program If a command unknown to Rotas 1s sent Rotas will answer with lt R gt Status Command The following commands are accepted 17 1 1 Exchange of information about the candidate Command Rotas Function Answer Insert Type The parameters of a new The measurement system candidate are loaded into the answers by sending the line measurement system SRalnsertea 1 Type is the name of the if the candidate name has been candidate e g DP001 DP002 found in the parameter This name must be defined as database and the parameters the name of the candidate in the have been successfully loaded parameter database Example or by sending Insert DP001 lt R gt Inserted 0 if the candidate name is nknown or an error occurred This command will not be answered Serial Serial The Rotas system receives the serial number of the candidate This command must be sent after Insert and before sending Remove You can use any string with a maximum length of 30 characters as serial number Serial change ChangeSerial Serial SerialA Serial Serial change Function as described above ChangeSerialA Serial Insert Type Serial Combination of the commands This command is answered Insert and Serial see above like the regular nsert or The type identifier and the serial command see above number are separated by a Insert TypelSeriall vertical line ProdType As an option you can add a piece of additional in
57. ment Report be Print bh sea lee System Configuration C long i Output in Manual Mode too M Bench controlled Form feed for defect reports Print a line SEE Me Options l Comment H H archiv Modul Info cH 6 System Sett H Ef Databases In the dialog choose between the following options for report printout e None no report is printed e Short for OK tests only the serial or palette numbers are printed on one print line Therefore the length of a print line can be set in the field For NOK tests the defect report is printed e Normal for each test a full line is printed indicating type serial number test time total result etc For NOK tests the defects are listed additionally e Long see normal but the long report containing the measured values is printed additionally Output in manual mode normally printout is done in automatic mode only Use this checkbox to print reports when Rotas is in manual mode too DISCOM Noise Analysis User Manual Page 33 of 63 Bench controlled Some test benches have a button directly at the test bench to indicate that a long report is required This button gets activated by this checkbox Form feed for defect reports If this option is active a form feed page break is generated after and before a NOK test This will have the effect that the defect report of a candidate is printed on a separate page Prin
58. mit and position If the requested value has not been measured Rotas answers No Val Remark The valid keys are a matter of definition 17 1 6 Displaying Messages Displays a message from the test bench in No answer Rotas message window Messagelnfo Message MessageInfo and MessageWarn also set an adequate background colour SeaMessage Key Arg Displays a predefined message identified by Belr Telr Key Arg 1s an argument for the message Bclr and Telr set individual colours for the message Hex 0xBBGGRR with BB Blue GG Green and RR Red 17 1 7 Controlling Gear Shift Force Measurement Rotas Function Answer SGW gearl gear2 Indicates a gear shift from gearl Answer to gear2 The gear names are Ready physical gears e g R 1 2 etc L and N identify the neutral position The gear shift is complete The Answer evaluation result of the gear shift lt B gt Resultr 1 or 0 force analysis is returned Section name Indicates the start of a measurement section Gear shift OK force curves are stored with the appendix name Section SKN DISCOM Noise Analysis User Manual Page 60 of 63 17 1 8 Remarks The system stores all measurement results error messages etc until a new test cycle is started by sending the Insert command This means all kinds of reports multiple times either can be requested after Remove The Serial command must be sent between Insert and Remov
59. nLine if the system reacts to commands Re ote cus HangcCcont ro otherwise RequestStatusF Enquiry of the measurement s Rotas sends the lines system state R gt StAtUs Onilane or lt R Status Hanact See above RequestStatus DISCOM Noise Analysis User Manual Page 57 of 63 17 1 3 Receiving Further Information Command Rotas function Answer Timestamp DateTime Setting the time stamp for the No answer current measurement Rotas expects the form YYYY MM DD HH MM SS YY will be expanded to 20YY Rotas sends the line OK TimeA DateTime Example Timestamp 03 10 04 10 14 02 sets the time stamp Oct 4 2003 10 14 02 SetAddInfo Key Value Sending information to the otas sends the answer Rotas system which is neither InfoStored or error of value information The Rotas system stores the SetAddInfo Keyl Valuel information in the archive files Key2 Value2 Each piece of information is identified by a Key ExtError Code Sending errors to the Rotas system which were detected by the test bench The Rotas system ExtError Codel stores the information in its Code2 CodeX database and archive files SetRItem tem Sending value items to the Rotas Rotas sends the answer system for measurements made Ready by the test bench The Rotas Or Or SetRItem tem system stores the information in Item2 ItemX its database and archive files Remark All commands in the table a
60. nch Therefore you should check first f all commands of the test bench are received by the Rotas program 9 4 1 Supervise and test serial communication Open the system configuration and the Bench Control Double click the module PLC Interface having a telephone icon and press the button Characteristics in the dialog In the second dialog you can activate the function Monitor Comm Now you can watch the serial communication in the window Stdout lel System Konfiguration A Serial Communication System Characteristics Test Printout a D Dont Slave 2 D Epm42 Master 5 Host Pc FB Messergebnisse ET System Einstellungen Send Hecewe H E Datenbanken HAA Drehzahl H ay srenzkurven Auswerturg x Lomm Port No 1 Handshaking ne Test Settings 3600 N 8 1 oK V Append Newline T Binary Transfer MW Monitor Comm Cancel In the dialog Serial Port Settings you can also specify the parameters for the serial interface The figure shows the Windows standard settings for the serial interface 9600 Baud No parity 8 bits of data and I Stop bit J Steuerungsmeldung HE Kommandos von As InterF If you do not receive any data from the test bench check first whether the serial cable from the test bench has been connected to the correct interface port of the ROTAS PC compare with settings made in the above dialog of the Rotas program and whether the se
61. ned number of entries is used for this transformation This colour map is used in a way that it covers the currently visible interval of the y axis If you change the range of the y axis by zooming or moving the colours transformation of the spectrogram will change either but you will see the change only with new curves If you use the button to adjust the scaling of the y axis automatically the colour transformation is adjusted either to cover the range of the y axis The x axis is set for all curve plots and spectrograms at the same time as long as the spectrogram runs vertically see the spectrogram options below for details If you change the scaling for the x axis by zooming or moving the spectrogram will change as well only for new curves either 10 7 Relative and Absolute Scaling of the x Axis Some curve data especially the order spectra of a transfer case analysis can be displayed using two different scaling factors These scaling factors define the relations between the spectra of different shafts at different speed The two scaling factors you can use are as follows If you use relative scaling the x axis of the spectra in the scope refers to the speed of the shaft If you use absolute scaling the x axis of the spectra in the scope refers to the speed of the speed source In other words if you see a peak in the scope you see the frequency order of that peak on the x axis if you use relative scaling If you use
62. ng displayed in pushed state DISCOM Noise Analysis User Manual Page 16 of 63 This command is not answered by the measurement program but there exist answered variants of this command see appendix If the measurement program itself controls the measurement with Trigger values see above the test bench must not send this command 9 4 2 4 Remove With the command Remove the test bench ends a regular test cycle The measurement program will react by storing all cumulated evaluation values and sends the test result to the test bench with the answer lt R gt Result 1 Candidate o k or lt R gt Result 0 Candidate n o k The button Ready in the window Test state will no longer be displayed in pushed state 9 4 2 5 Reset The Command Reset ends a test cycle w thout Rotas storing ts evaluat on data It s used to get Rotas n a defined state after a failure Initial position It is answered with the line Reo tabus Reset Many test benches send before issuing the Insert command a Reset command to ensure that Rotas is in initial state 9 4 2 6 RequestStatus With the command Request Catus the test bench can enquire whether the measurement program is capable of processing commands from the test bench at that moment It is answered with lt R gt Stat s Onlane if the measurement program is currently capable of processing test bench commands Except on startup when initializing the program t
63. not markedly higher than non defective teeth To compensate for this one can selectively filter out pull teeth from the signal with the dentist allowing for easier detection of defective teeth At this point let s take a quick look at acoustical units The usual unit for frequency is the Hertz Hz 1 Hz is defined as 1 peak per second A signal of 34 Hertz shows 34 peaks per second The signal described above shows 34 peaks n the time signal not per second but per revolution The rotationally synchronous unit corresponding to the Hertz is the order Ord 1 Ord is defined as 1 peak per revolution When a cogwheel has 34 teeth you would expect a noise signal with relevant frequency contribution of the 34 order which is the so called mesh order DISCOM Noise Analysis User Manual Page 37 of 63 Of course rotationally synchronous frequencies can also be given in Hertz as well Remember that they are dependent on the current revolution When you have a revolution of 180 rpm the 34 order represents the frequency of 102 Hz calculated as follows 180 revolutions per minute correspond to 3 revolutions per second The 34th order corresponds to 34 peaks per revolution Together you get 3 revolutions with 34 peaks each correspond to 102 peaks per second Or as a formula faz fora fupm 60 12 3 Measurement types from the order spectrum Harmonics and limit curves In most cases not only the mesh order but multiples o
64. ontrol check the connection to the test bench PLC Please note that you have to change to operating mode Bench control before the test bench inserts the candidate You can change to a smaller version of this dialog by pressing the small aa button below the close button X This display shows current type and current test mode as well Typ Frufvorschnft 1 i it Frufzustand Gang E Messung 9 2 Rotational Speed Display The display instrument Rev Speed views the current rotational speed Additionally the rotational speed is displayed in the status bar of the program lower I edge of the window If you do not receive any rotational speed check the speed sensor on the test bench and the connection to the ROTAS PC Without rotational speed information no spectra will be displayed DISCOM Noise Analysis User Manual Page 13 of 63 9 3 Start and Stop values Many test benches control the noise analysis via so called Start and stop values That means that an analogue signal is taken as control value for starting stopping the analysis In general this analogue signal value is the current rotational speed from the test bench The range for the acoustic analysis in a certain test mode has been preset in the Rotas system For example it can have been preset that the acoustic analysis in the 3 gear speed up starts at 1200 Rpm and stops at 3500 Rpm Start Stop rotational speeds for different test
65. ore you install them you should make a backup copy of the current software as described above Then you are able to restore the current version if the update fails Please follow an included installation manual absolutely since it is sometimes necessary to carry out further preliminary tasks Rotas Updates always contain extracts of folders and files mentioned above Almost always you will find a folder Disc included often files which have to be written to RotasData Before you install a folder Disc you should delete existing folders lDisc and Mps32 have you been making a backup copy To do this no component of the Rotas software must be open like Measurement program or parameter database Windows warnings can be answered by Delete all or OK Update files for the RotasData folder mostly replace only some existing files In general deleting this folder before an installation is not advisable Exception Re Installing of a backup copy In this case you should delete the current RotasData folder because sometimes a newer software version alters settings n the application sea which do not fit for the prior version afterwards The folder LDisc can be included in the update in two ways Either packed in a Zip file XXXXXXRotas zip or unpacked on CD Unpacking of an XXXXXXRotas zip Open the file by double clicking Choose Extract To gt C A password is being requested click Ok Then the zip Arc
66. oxes you typically examine the values of the orders Hl of the different wheels and synchronous channels and the RMS value n the Mix channel With wheel testing machines values like Crest and TickEval are relevant DISCOM Noise Analysis User Manual Page 49 of 63 In the main formula of the statistic tool you can directly read the mean value and the standard deviation of the chosen values Display the time row and print it out On this sheet you see mean value and standard deviation as well Furthermore you can see the dispersion of the values These printouts can help you to document the reproducible measurements In these fields are displayed the mean value and the standard deviation of the chosen scalars within the chosen time interval Momenta Displey Stand 0 Display the time row The lines should not vary much fueage Sand Dev n _H Aali HEN OM9 AMA 11 161 8 0 208 11 4 n H alui aa OMe AMA 11 161 28 00 2082 11 4 15 5Reference candidates To ensure the stability of a test bench over a longer period of time reference candidates are used in practise These are selected candidates who are specially marked e g painted red or green You should separate its measurements by defining a separate Type Id with separate base type in the parameter database Just make a copy of the settings made for the original type If the test bench control tells the measurement program automati
67. pen these database files directly Use the Desktop Link Database instead Backup In this sub folder on each change backups of the Rotas database files are stored with a preceding consecutive number In case a change of settings in the database fails completely you can restore the state of the last automatic backup as follows Move the most recent database files should be those with the highest number into the folder above Database Delete the bad database files Remove the consecutive number from the moved databases by renaming them From time to time this folder should be cleared up to save space in particular before you make a backup e CacheData This folder contains temporary database extracts You can delete the contents of this folder if you want to make or restore a backup copy e LearnData In this folder the program stores the learnt values and limit curves You find for every type a file Typename arc If you delete one file the corresponding type loses its learnt values and limit curves gets re taught except if the program tests this type at the moment Thus close the program before you make changes in this folder OrderTracks or Archives Rotas stores measurement archives suffix rdt in this folder Depending on the settings this folder should be cleared up from time to time PrinterFiles In this folder Rotas stores text files containing the report texts as they are sent via output line see c
68. play Byte Display Function Display Byte Display In this window referenced as main window in the following text you can supervise all the I O lines as from fi Normal from fi Normal hole byt h t a Ti Simulation vm 7 C Simulation whole OYES c arac ers Monitor I Monitor Furthermore there are different options Insert Aes Process A ExtE res Online Inserted Process Busy Measuring Life The left side of the window shows the input lines the right side shows the output lines D D oe tee You choose with the settings from and to which interval of the I O lines are being displayed About 16 Lines fit into the window The first byte of the input output area respectively has number 1 In addition to that you can have a byte 0 This is not a real output address but a dummy address for internal use of the control program 2 3 4 E T E In the figure the input area is displayed in Byte V iew the output area is displayed in function view The Byte view shows one byte with its actual value as number and character in one row You use it to supervise whole bytes directly The function view shows one function with ts actual value n one row The last line of the output list displays that Byte 3 Bit 4 with Function Life has the value 1 In the function view you see the data in the decoder s interpretation If a test bench sets 10 characters conse
69. points very well 10 4 2 Further Options The dialog Scope options allows adjusting different visualization options of the scope You open the dialog with the button a DISCOM Noise Analysis User Manual Page 27 of 63 Scope Optionen Ea Darstellungsoptionen Teilung der y Achse I Hilfslinie bei y 0 einzeichrien Hintergrundfarbe Es Farbe des Gitters Ei ee Druck Optionen Titel Typ 043 _0 8 in 3 0 kK ommentarzeilen Pr fstand F1 Liniendicke im Ausdruck 2 Tl Ausdruck in Schwarzwei Spektrogranmm Laufnchtung horizontal ie vertikal 2 Pinel pro Kurve Skalierung s4chse Ti verwende innere Kurver skallerungen absolute Achze Skalierung v Achse T Automatisch nachf hren Minimales Intervall BE zeitkonstante Sekunden 1 Windows Metafile Export Optimale Gro e der MF Gratik H 5cm 15 cm 30 cm The section Darstellungsoptionen in the top left corner allows setting the number of gridlines on the y axis Furthermore you can enable or disable the drawing of the additional zero gridline and set the colours for background and gridlines 10 5Print the Scope You can print a scope window in the usual windows way by clicking on it and choosing the command Print from the menu File Printing a scope is not a real snapshot of the window The printout will have the data panes on the piece of paper in a way that the pos
70. rictions nevertheless 16 Backup Organisation of the Rotas Software You get the ROTAS PC pre installed with the RotasPro Software During the operation of the Test Bench there will be changes made in the software e g new types in the database For this reason we advise you to backup the RotasPro Software in regular intervals Maybe you only need to backup a part of the RotasPro Software e g databases 16 1 Hard Disk Folders range of a backup Rotas Software is located mainly in two rs folders lDisc L Disc and Datei Bearbeiten Ansicht Wechseinzu Fevorten 2 W eres imig Yv v Zur ck vorw rts Aufw rts Laufwerk Trennen RotasData LDisc contains the software gt itself RotasData the settings databases and learnt values You may also find additional folders Mps32 and Dpm42Data or files like XXXXXXRotas zip and XXXXXXMps32Base zip All these files and folders must be on top level C They must not be moved or renamed 8 Objektfe aj Arbeitsplatz Z A full backup should contain all these folders and files DISCOM Noise Analysis User Manual Page 51 of 63 Since you do not want to waste backup space we advise you to clear up before you make a backup see below 16 2 Organisation of files and folders All settings and parameters and the learnt values too are stored in files in the folder RotasData or its subfolders So if you restore RotasData
71. s Transter case type Connected types Giramatic DISCOM Noise Analysis User Manual Page 42 of 63 3 Enter name of the new type in the entry field in the upper left corner in the figure FCU and a new basic number in the field below that has not been used Press Create 4 Now the fields in the lower half of the Choice aii form become active Check all the boxes in the section This will be copied 5 In the dialog Choice of fields opens for each box that you check check all boxes as well a a a a a 6 Select a type in the left column Transfer case type that is mostly similar to the new type Please make sure that in the right column Transfer case type the new type is selected Now press gt gt Copy transter case data Choose the source and destination type from the yellow lists and define the volume of the copied data with the control boses Start the copy process by clicking on gt gt This wil be coped a fr Design data Channel definition copy test states m Gen analysis data 4 Sampling parameters Hg Gen bound curves W List of Measurements Crest Fime om Transfer case type Connected types Transfer case type Connected types PEG i Proto a irom to ee 7 Close the form xi form You will have access to the Choose the transfer case type which you want to modify in the yellow list bos Choose then one or more blocks of data following form
72. s when the measurement program runs correctly o Online bit The online bit tells the test bench when it is set that the measurement program currently accepts and processes control bits It is 0 especially when manual mode has been selected in the dialogues of the measurement control Test state Bit Out_1 1 ONL in the example above has this function A test bench using the command interface can get this information by sending the command RequestStatus see above o Ready bit and Measuring bit These bits show the state of the corresponding buttons in the dialog of the measurement control Test state Especially the Measuring bit is of interest since this function can be controlled by the measurement program itself whereas the Ready bit normally changes its state on test bench request In the example above bit Out_1 6 MEAS is such a Measuring bit Before the test bench starts a test cycle 1t can check using life bit and online bit whether the measurement program runs correctly and is accepting control bits DISCOM Noise Analysis User Manual Page 22 of 63 9 5 5 3 Example of a sequence of control bits A general fact is that a value change initiates an action For this reason the NEW value of a bit is given in the following example The function explanation includes as far as possible the command of the command interface having a similar function Typed BE INSRT 1
73. scroll bar handle is incorrect after the start of the program click on a zoom or arrow button at the end of the scroll bar to get the scaling re calculated Sometimes zooming sets the zero position beside regular scaling marks see figure on the right If this happens you can correct the axis by clicking the handle of the scroll bar The zero position is moved to the next regular scaling mark by that 10 2Panes and Labels The data area can be split in several panes and the curves can be assigned to different panes In a spectra scope of a standard gear box test system you normally see four panes The upper three panes show the noise components of the different shafts the fourth pane show the overall signal If the data area is split into several panes the x axis 1s valid for all panes The y axis of each pane is labelled individually Right of each pane you see a label box showing the names of the curves n the curve s colour The button ZU you find it among the function buttons in the bottom right corner opens the dialog where you can set panes and curve colours This dialog shows all curves which are known to the scope Scope Kurven Einstellungen x Darstellung Farbe r Fl che E Zeichen E Reihenfolge J Iv Anzeigen Co T The list shows the curve s names their current colour and the pane where they are displayed If you select a curve in of the
74. sh measurement the null pulse signal should not move if it does check the current type and tooth number In the table of measurements shown above you see a Peak Fuse value and an Rpm Check value They are defined as follows e Rpm Check Checks the speed during the measurement In order to make proper measurements the speed has to be within a certain range and should not vary too much If you get an Rpm Check Error it means that something is wrong with the test bench e g pinion or speed sensor defect e Peak Fuse There are security mechanisms 1n place that help protect the master wheel If extreme measurement values are recorded in this case the peak value the test is immediately stopped One thing that could cause such an interruption would be an improperly made cogwheel or a wrong type does not fit the master wheel 12 2 The Dentist and mesh order One would normally expect that the cogwheel s teeth would produce noise in the same manner For example f a cogwheel has 34 teeth you would expect 34 times per revolution the same noise impulse In certain situations this noise impulse is clear enough that a peak for each tooth can be seen in the time signal display Thus when the cogwheel has 34 teeth you would see 34 peaks However it is not always desirable to have all of these peaks since they could complicate the detection of defects As an example a slightly defective tooth may have a value that is
75. sible space is best used regarding the paper format portrait or landscape No background colour will be printed either Each pane gets its own labelled axis and the curve labels will not be printed beside but in the top right corner of the gridlines You can use a title and two comment lines in a printout to explain the shown data The options dialog of the scope button l see above has a section Printing options which controls several options 1f the printout ee Here you can enter the title and the comment lines In most cases the itel yp U 6 In 3 ee measurement program generates an automatic title and sometimes even a rufstan 1 i en comment line But you can change these presets ererenzmessun Printers naturally have a finer resolution than the display on the screen This can result in curves which have light colours e g yellow being difficult to distinguish in the printout For this reason you should set a line width for printout greater than pixel We advise to use the preset of 2 pixels On the other hand some printer drivers have problems to print coloured lines with a line width of 1 and might produce black lines instead You normally get a coloured printout of the scope If you use a black and white printer the coloured lines appear in greyscale Sometimes curves in greyscale are not distinguishable very well If you activate the option printout in black and white different colours result in different
76. signals to start stop the test e g start on speed stop on timer Then you find different trigger decoders for each control signal Anwenden Abbrechen Please note For accurate test results speed up and speed down test runs must not be done too quickly Per 400 Rpm rotational speed change at least 1 sec must be counted Example For a speed up run of 1200 to 2400 Rpm the range of 3 x 400 Rpm is crossed and must not last less than 3 sec To guarantee safe process control the rotational speed limits must have some 100 Rpm distance from the actual switch over rotational speed values of the test bench Furthermore please note that the trigger values have to fit the speed ranges from the test bench During a ramp the speed range defined in the trigger dialog has to be measured completely by the test bench Other test benches transmit commands for start and end of the noise analysis directly If so please ignore this chapter DISCOM Noise Analysis User Manual Page 14 of 63 9 4 Command Orientated Control of the Test Cycle Most test benches control the Rotas test system with commands These commands are normally transferred to Rotas via the serial interface Some test benches transfer these commands directly via a Profibus interface card Nevertheless the basic system of communication is the same for both interfaces If the Rotas program shows unexpected behaviour the reason is mostly a communication problem with the test be
77. soossessssssssssnsssnnnnnnsssssnnnnnnnnnnnnsssnnnnnnsnnnnnnnnnn 19 9 5 1 The Main Window of the Parallel Control Unit 19 9 5 2 Supervising and manipulating single Dits ee eeeeceeseeeecccceeeeeeeeeaeeeeeeeeseeeees 20 9 5 3 Manipulating functional values cuueeeeeesesessnnnnnnnnnnnnnsssnnnnnenneeeeeennnnenn 20 OSA olmulalon arid MOn Or Modes ana nee 21 955 Exainipleor atest Cycle On a gear Lister nr 22 The Scope Displays aranira na aaa a ak 25 10 1 Setting The Scal n L00Diessrisin eos e EEN EEEa 25 10 2 Panes and Tia IS seccina Dar 26 10 3 The Functions of the Function Buttons sssssssssssssnsssnnnnnsssssnnnnsnnnnnnsssssssnsssnneee 26 10 4 Display OPOODS sesesccccedsccctesescesictedicecescel ics ceeds Gcesecsekevecadsteceut Ni A 27 10 4 1 Rectangular Display or Display Polygons sss0sseeeeeseeeeeeeeeeeeeeenns 27 DISCOM Noise Analysis User Manual Page 2 of 63 10 4 2 Further ONS ae ee 21 10 5 Print he SCOPE ae 28 10 6 SPectrogram Display nenne 28 10 7 Relative and Absolute Scaling Of the x Axis ccccccsssssssssscccccccscessssssscccoeees 29 10 8 Problems with the scope display 0s00000s00000000000000000000000 000000 000000000 0000000000 30 10 9 Tracking values of single orders 22 22 22 sebsadeeedcocerecetbesdcteadesecetee 31 11 Measurement resulls ze 3r s seriellen 32 11 1 Table wndoW a 2 in 32 11 2 Repr WIT OW ieies aE E E E 32 11 3 Report
78. t a Line Press this button to print a horizontally dotted line Use it to mark printouts or to test the printer 11 4Request One Time Long Report You might have the situation that you want to have a long report printout only for the currently tested candidate like a calibration type or a prototype This function can be activated via a button in the toolbar amS alaj Press the indicated button using the mouse Doing so will request a long report for the current test or the directly following test The protocol is printed at the end of the complete test h b d h h b d d rae o oG The button stays pressed until the report has been printed an el We indicates that a long report has been requested If you release l RE ee ku fe the button before the end of the test run using the mouse BER a press again you cancel the request and the program prints as preset in the dialog see previous page DISCOM Noise Analysis User Manual Page 34 of 63 11 5Storing Measurements in an Archive In some installations you can configure Rotas in a way that all measurements curves evaluated spectra protocol values etc are stored in archive files You can evaluate these archive files with the presentation program later Find the module Store measurements in the system configuration to activate archive storage You find this module in the section Host Double click this module to get the settings dialog imi SystemKonfigurat
79. te rather a sample whose noise is nearly at the limit values In practise this is the scope as well If a candidate 1s silent 1t does not matter exactly how much silent it is Near the good bad border the results should not differ Let the candidate do some tests ca 10 before the real examination That way slight remainders on the cogwheels can scale off Additionally warm gear boxes are more silent than cold ones If you started with a cold gear box the noise would become more and more silent during the measurements which increases the standard deviation without telling anything Determine in which protocol database the values for this candidate are written Normally you find them in the folder C RotasData Your Project ProtocolData and the name includes the base number of the candidate as it is defined in the parameter database Close the Rotas program Then remove the protocol database by moving renaming or deleting Restart Rotas and carry out 10 or more measurements complete measurement cycles Then rename the newly made protocol database appropriately e g in Repro01 mdb This database includes all the data that you need to show the reproducible measurement The renaming at the end prevents Rotas from filling more measurements into the database which are not part of the examination Now open the protocol database with the statistics tool Choose the relevant measurement scalars in the main formula With gearb
80. ttings for the serial Ee Up Trager Decoder interface of the test bench match with those of the Rotas it program Is everything ok Check whether the test bench sends CR LF at the end of each commando Maybe the length of the commando buffer is not correct H ma Foe Schalter Eingang Hy Schalter Ausgang EH a Konmando Deccoder You can use the input line Test see above to distribute data by hand The button Send sends the data in the input line to the test bench the button Receive gives the data to the Rotas program as if 1t had been received from the test bench DISCOM Noise Analysis User Manual Page 15 of 63 9 4 2 Overview of the most important commands There are multiple commands with which the test bench can control the Rotas test system enquire data from the Rotas program and transfer data to the Rotas program For this reason the used commands can differ significantly between different test benches Nevertheless you will find a basic set of commands on all test benches These commands are shortly explained in the following chapters Basically all commands use the following format Command Argument CR LF A colon follows each command separating command and arguments At the end of EACH command line a Carriage Return and a Line Feed must be sent ASCII 13 10 9 4 2 1 Insert TYPE With the command Insert Ube the test bench informs the measurement program that a new test cycle with a candid
81. ve it is a single bit to be more exact a number between 0 and 1 Under other circumstances it can be a number between 0 and 65565 or a string Sometimes you prefer one view to the other If you want to check the state of single bits on the I O card you choose the byte view and additional bit windows If you want to check how Rotas reads the data from the I O card you choose the function view and watch the entries in the main window DISCOM Noise Analysis User Manual Page 20 of 63 9 5 4 Simulation and monitor mode You can choose simulation in the main window and test functions manually In this mode no values are being read or written from to the I O card Don t forget to switch back to normal after you finished your tests in simulation mode To supervise the processing of the bits you can activate the monitor function When you activate one of these check boxes you get a report written to the Stdout window for each value change in every open bit window In 3 e g All value changes which Rotas notices simultaneously are listed with the name of the bits In addition to that the new value of the whole byte is reported at last A short line separates this byte s data from next byte s data At the end a long separator line finishes the list The reported changes between one long separator line and the next have been noticed simultaneously by the Rotas program Manual changes in the bit windows are not
82. ve Order Tracks DISCOM Noise Analysis User Manual Control and its sub modules are responsible for communication with the test bench and test process control Therefore different or a number of other sub modules can appear depending on the existing test bench interface and the process 7 The Toolbar You can easily access displays and windows or other important functions v a the toolbar underneath the menu bar The toolbar can have different appearance depending on the ROTAS installation you use concerning labelling and range of buttons The following figure shows the most important buttons you will find in most installations Further buttons are described in following chapters Page 11 of 63 sa mje a aez S Jea eea 6 Gee wuss Rotational Speed display Report Window see ch 11 see ch 9 Traffic light see below Scopes Spectra Time Signal see ch 10 Table window see ch 11 8 The Traffic light Ampel I The actual result of the evaluation is displayed n the traffic light window It is being updated at the end of each test mode gear test As long as the light is green the test result is ok It turns red if a defect has been found Some installations display red light in the bottom area of the traffic lights as well This happens if a defect has been found in the actual gear Other installations use three signals red yellow green Green is sho
83. wice kill the program by means of Ctrl Alt Del and the Task Manager Always wait until ROTAS has been started up completely before you access it start a test or to shut down the program Please note that the second window Stdout see below some times needs some more time to disappear While the windows of the program are being opened the system starts the signal processors The two LEDs on the processor cards must show green light If the program shows the error message from the figure on the right on start up the system 1s not able to start x Mpswritew error 3 in DneBootMag Timeout 3 the signal processors This is a serious problem please contact DISCOM If the program shows other error messages on start up like could not find the current installation is defective or incomplete If this happens you should contact DISCOM as well Maybe the LEDs on the processor cards show different colour red or yellow or blink instead of static green light Don t worry about this Our latest software shows the status of the processor system this way 5 1 ROTAS 2 window If you start ROTAS you will see that a small window Stdout is opened first and minimized almost immediately but will appear in the Windows task bar Afterwards the program s main window opens The Stdout window is linked with the main window it 10 x can not be closed It 1S automatically closed as soon as MQ350 P2 Typ 1 Palette 0
84. wn if the test is ok Red is shown 1f a major defect has been found yellow is shown if only a minor defect has been fond test can be repeated maybe after refinement DISCOM Noise Analysis User Manual Page 12 of 63 9 Supervising the test cycle In the Rotas system each Step of a test different gears separated in speed going up and speed going down is defined as a test mode Indicated by the external test bench control PLC these test modes are accepted and evaluations are being made But first of all the test bench control has to inform Rotas which type of candidate 1s being tested preparing Rotas to calculate the right frequencies of the cogwheels 9 1 Test Status The display Test Status shows how the automatic noise analysis is being processed Use the toolbar button SJE to open the dialog Ablaufsteuerung Please note that the operating mode is Controlled by Bench control The list box displays the type of the currently tested candidate type 1 in the example If the candidate is within the test bench Ready will be marked appears pushed You can watch in the list how the different test modes are selected During the noise analysis the field Measure will be marked pushe As soon as the mark disappears evaluation has been done and the result is issued If the right type of candidate is not displayed or the modes are not being selected although the operating mode is Bench c

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