PPM Users Manual Signature Software
Contents
1. R6 Full Depth Fault N C R7 Ready N O R8 Piezo Sensor Reset FACTORY SETTING DO NOT CHANGE The signals that are assigned to each relay output can be changed See Edit Relay see technical manual in the Hidden Setup Menu Relay Outputs Button Functions Positions the cursor box Relay on the desired relay output 12345678 Toggle Toggles the state of the 74 7 ata relay MENU Returns the software to the Diagnostics Menu PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Pr fsysteme GmbH Berlin 27 PROMESS 5 2 Calibration In calibration the force transducer can be calibrated using a master load cell and meter The position transducer can be calibrated using a gauge block The force and position factors can also be reset and adjusted in the calibration screen To enter the calibration screen go to the Service screen and press the Calibration button The unit will then prompt you to enter the password Enter the password using the numeric keypad The default password is 123 To change the password go to the setup menu Password Protect Enter Password 123 Then Press Enter C co Once the password is entered correctly and the ENTER key is pressed the following screen will appear Calibration Calibrate Force Calibrate Position Reset Force Factor Reset Position Factor Edit Force Factor Edit Position Factor Calibrate Force A2. Pressing the Data Lists button will show the Data for the last eight 8 parts The most recent part will be at the top of the list W Peak Force List Prog Peak Force Status Prog Full Depth Status Full W Last Exit Depth Slice PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Pr fsysteme GmbH Berlin 22 PROMESS The following screen appears when pushing the W Last Slice button W Last Slice List Prog Last Slice Status W Peak Full Exit Force Depth To exit out ofthe Data Lists press Exit button PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Pr fsysteme GmbH Berlin 23 PROMESS 5 0 The Service Menu From the Control Menu the Diagnostics Setup Calibration or Main Menu can be accessed Button Menu Service Menu CALIBRATE Calibrate SETUP MAIN Calibrate software to nostics Menu 5 1 Diagnostics Function DIAGNOSTICS Selects the Diagnostics Selects the Menu Selects the Setup Menu Returns the the Main From the Diagnostics Menu the Analog Check Input Check or the Output Check can be selected Sensor Signal Displays the force and position in real time Inputs Displays the current states of the inputs Outputs Displays the current states of the outputs Diagnostics Menu Button Sensor Signals v i Inputs Outputs SEL Analog arrow Quadrature Input EXIT Serial Port the
3. fsysteme GmbH Berlin 38 5 3 4 Changing Language PROMESS Inthe Language Screen the Language for the text can be set for English or German Language Button Toggle Language English relay Menu Functions Toggles the language from English to German Toggles the state of the Returns the software to the Setup Menu PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Pr fsysteme GmbH Berlin 39 PROMESS 6 RS232 Serial Communication Using the RS232 port various data from the process can be obtained from the monitoring system in an ASCII format The data includes the force and position curve data actual and taught the peak force inside and outside the monitoring window the full depth measurements and the touch point data 6 1 Communication Settings Baud Rate 9600 19200 or 38 400 Data Bits 8 Stop Bits 1 Parity None 6 2 Signal Description TxD Transmit signal Data output RxD Receive signal Data input External Connector 9 pin dSub connector 1 1 a GER Machine PPM 3 3 Promess 4 4 Control Meter 5 5 PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Pr fsysteme GmbH Berlin 40 PROMESS 6 3 Command Format The Monitoring System looks for a string of three consecutive characters followed by a carriage return The three characters must be capitalized otherwise they are ignored The request for
4. 19 lt CR gt PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Priifsysteme GmbH Berlin 43 PROMESS Command PFW lt CR gt Description Peak Force Window The peak force value within the monitoring window is sent followed by a carriage return Data Format peak force window value lt CR gt Example 2343 lt CR gt Command PFG lt CR gt Description Peak Force Global The global peak force value is sent followed by a carriage return Data Format peak force global value lt CR gt Example 2580 lt CR gt PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Priifsysteme GmbH Berlin 44 PROMESS Command CWA lt CR gt Description Curve Window Actual The actual curve within the monitoring window is sent by sending the x axis and y axis values in pairs until all values have been sent followed by a carriage return Data Format x axis 1 y axis 1 x axis 2 y axis 2 x axis 3 y axis 3 x axis n y axis n lt CR gt Example 11 00 23 11 10 48 11 20 113 23 00 1678 lt CR gt Command CWT lt CR gt Description Curve Window Taught The taught curve within the monitoring window is sent by sending the y axis and x axis values in pairs until all values have been sent followed by a carriage return Data Format x axis 1 y axis 1 x axis 2 y axis 2 x axis 3 y axis 3 X axis n y axis n lt CR gt Example 11 00 23 11 10 48 11 20 113 23 00 1678 lt CR g
5. Limits Setup PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Pr fsysteme GmbH Berlin 12 PROMESS Zoom Window 0 00 to 25 00 mm to 100 Ibs Edit Global Window Exit Setup Setup 3 3 Window Limits Screen In the Program Limits Screen the following parameters can be changed The Start of Window End of Window and the Slice Width can be set The Start of Window and End of Window define where the system monitors the relative upper and relative lower signature limits The limits can be adjusted without having to reteach the system The following parameters can be changed Note The Peak Upper Limit Peak Lower Limit Absolute Upper Limit and Absolute Lower Limit will not appear if disabled in the hidden setup Relative Upper Limit End of Window Peak Lower Limit Relative Lower Limit Slice Width Absolute Upper Limit Start of Window Peak Upper Limit Absolute Lower Limit Window Limits Rel UpperL 10 Ibs Rel LowerL 10 Ibs Start Window 0 00mm End Window 25 00mm Slice Width 0 20mm Edit Global Zoom Exit Limits Setup PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Pr fsysteme GmbH Berlin 13 PROMESS To change a parameter setting press the Edit button to access the editing mode Button Function Window Limits N Moves the edit box up or Rel Upper L down Rel Lower L Clear Clears the current setting Abs Upper L Abs Lower L Exit
6. Memory Check Arcnet Check Function Moves pointer to desired option Selects the option the is pointing to Returns the software to Service Menu PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Pr fsysteme GmbH Berlin 24 PROMESS 5 1 1 Sensor Signals The Real Time screen will display the force and position values numerically and ina bar display This screen can be used when calibrating the system or to verify that the force and position transducers are working properly Sensor Signals Tare Position Button Function TIA Toggles between the Tare and Absolute modes Tare mode uses the current offset values as the zero value when the ZERO button is pressed The Absolute displays the actual analog values from the transducers A T or an A will be displayed in the upper right hand corner of the screen ZERO Pressing the ZERO button when the system is in the Absolute mode will tare zero only the force transducer When the system is in the Tare mode and the ZERO button is pushed then the current offset values for both the force and position transducers become the zero points and the readings displayed are relative to the values when the zero button was pushed MAIN Returns the software to the DIAGNOSTICS MENU Note When a Strain Gauge transducer is selected in the Hidden Setup Menu then the CAL button will be displayed on the screen When the CAL button is pushed a s
7. Montage und Pr fsysteme GmbH Berlin 31 PROMESS The analog display will be shown with the position factor calculated Edit Position Factor Tare Force 0 mm ER Factor 0 003391 mm ADC Press ENTER to edit Fee Absol If the position transducer is not moved then a fault message will be displayed WARNING Calibration Failed No gauge block inserted PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Priifsysteme GmbH Berlin 32 PROMESS 5 2 3 Reset Force Factor The Reset Force Factor is used to reset the force factor back to the default setting Reset Force Factor Reset force factor to full range 5 2 4 Reset Position Factor The Reset Position Factor is used to reset the position factor back to the default setting Reset Position Factor Reset position factor to full range PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Pr fsysteme GmbH Berlin 33 PROMESS 5 2 5 Edit Force Factor In the Edit Force Factor screen the Force Factor can be changed manually The following screen will be displayed Edit Force Factor Tare Factor 0 003391 Ibs ADC Press ENTER to edit Zero Tare Exit Absol Editing the Force Factor Press the Enter button to edit the force factor The following screen will appear Use the numeric keypad to edit the value Edit Force Factor Tar
8. from force and position sensors mounted on the machine Information obtained from these sensors is used to create a force position signature curve which is compared to an ideal taught profile If the force exceeds preset limits either upper or lower or if the part is not pressed to the correct depth a fault is indicated The assembly profile is monitored within an adjustable window which allows the user to define the critical portion of the assembly operation for precise in process quality information Individual stations can also be linked together to a single monitoring PC using a daisy chain method While each station is responsible for monitoring its own operations in real time the host PC collects all resulting data from each station for viewing editing and analysis The data acquisition software is Windows based and can be used in a single or multi station configuration SIGNAL CABLE PREAMPLIFIER wees POSITION TRANSDUCER CABLE POSITION TRANSDUCER FORCE Fa INTERFACE POWER TRANSDUCER CABLE CABLE FORCE TRANSDUCER MACHINE PLC CONTROLLER PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Pr fsysteme GmbH Berlin 2 PROMESS 2 Parameters The Promess Assembly Monitoring System has multiple parameters that can be used during the assembly monitoring process Note the Overload limit Forc
9. screen If necessary adjust the full depth tolerance Note this is just an example and each press fit application will have a different set of parameters If you have any questions about setting the window call Promess at 810 229 9334 for assistance lt Ram 10 Bearing en Monitoring Monitoring Window Window Force Force Position u Position PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Pr fsysteme GmbH Berlin 17 PROMESS 4 Automatic Mode In the Automatic Mode the monitoring of the press fit operation occurs The upper and lower limits the full depth position the touch point position are monitored in the automatic mode the Overload limit the Force limit and the Peak Force limits are also monitored if enabled in the hidden setup menu The force position curve is displayed on the LCD screen and is updated after each cycle The lighter lines are the upper and lower limits and the dark solid line is the actual press force curve An A is displayed in the upper right hand corner to indicate the system is in the Automatic mode The Full depth position is also displayed in the upper left hand corner of the screen Using the menu buttons there are four options in the automatic mode Force 980 Ibs PASS 21 45mm Prog 1 0 0 00 m Limits Informa soup ton Main Button Function Limits Setup Brings up the Window limits screen where the parameters can be changed or the Glo
10. the end of window is an absolute setting of the position axis If the touch point is used the end of window will be relative to the touch point 2 8 Slice Width This specifies how many slices the monitoring window will be separated into for analysis The monitoring window is sliced into position dependent slices and within each slice an average force is computed Each slice has an associated upper and lower limit which are used when certifying the part The Number of Slices can only be changed in the Teach mode PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Pr fsysteme GmbH Berlin 5 PROMESS 2 9 Slice Tolerance This parameter shifts each window increment to the right and left and takes the highest and lowest value to establish the limits This is used to compensate for variations in position causing the force curve to shift This parameter is set in the setup menu Force Monitoring Window Relative Upper Limit Relative Lower Limit Start of End of Position Window Window 2 10 Force Limit The Force limit is a real time limit that can be used to ensure a certain force is reached or to control the ram to press to a force The monitoring of the force limit is active when the monitored input is high Force Position PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Pr fsysteme GmbH Berlin 6 PROMESS 2 11 Peak Force Monitoring The Pe
11. the lower limit The full depth measurement can be either an absolute measurement or a relative measurement when touch point is used Note ifthe full depth measurement is not going to be used then set the limits large enough to give no faults Example Taught Full Depth is 15 20 mm Full Depth Tolerance 2 00 Full Depth Tolerance 1 20 So the full depth position must fall within 14 00 to 17 20 mm tolerance otherwise the part will not pass the full depth measurement Lower Tolerance Taught Upper Tolerance 00 00 14 00 15 20 17 20 25 00 Position PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Pr fsysteme GmbH Berlin 9 PROMESS 3 Teaching the System The TEACH function is used to teach the Monitoring System the force versus position signature The unit will switch to the automatic mode once the teach count has been reached The icon in the upper right corner will display a T for teach versus A for automatic The Overload Limit Force Limit and the Peak Force Limits are the only limits monitored in the teach mode If one of these faults occur in the teach mode the system will stay in the teach mode until a part is taught in with no faults To access the Teach Mode from the Main Menu press the button labeled TEACH To access the Teach Mode from the Automatic Mode press the button labeled MAIN to access the Main Menu and then press the button labeled TEACH to access the Teach Mode The software w
12. 2 PROMESS 5 1 3 Relay Output Cheese 21 52 ECH TE 28 3 2 1 Calibrate Poroe oe ke 29 5 2 2 Calibrate POsitiomssisisescccssscvsesssseniensiansseosansssoesassbacancasesosnsassavsnents 31 3 2 3 Reset Force Factor an 33 5 2 4 Reset Position Faller E 33 5 2 5 Edit Force Fair er 34 5 2 6 Edit Position Factor usa 35 5 3 Setup SELEEN i erio s a EE E E REE Derniers ee 36 5 3 1 Ch nging Pas Wild 37 5 3 2 Changing Date and Time nein 38 5 3 3 Serial Baud Rate een 38 5 34 Changing Tannen 39 6 RS232 Serial Communication 40 6 1 Communication ET 40 0 2 Signal Des CTOs een 40 63 Command Font sen ee 41 Command TP VCRs een leeren ee 42 Command Eegeregie 42 Command Ee Bieden 42 Command TPA lt CR gt nennen 42 Command FDA lt SCR gt one 43 Command ID CH ri 43 Command FDLSCR gt ea 43 Command PISS OR gt en 43 Command PEWCR E 44 Command E nennen 44 Command Keng Ee 45 Command CW T lt GR gt siasscccacsscavsccasisnaseasnavseesasssspesnsessacascasdeessontosensars 45 Command CWESCR gt ee 45 Command eendeiteg 46 PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Pr fsysteme GmbH Berlin 3 PROMESS 1 Introduction The Promess Assembly Monitoring System is designed to monitor in process the quality of a press fit staking or crimping operation or any other process requiring signature monitoring The system consists of a microprocessor based electronic unit which monitors the signals
13. PROMESS PPM Users Manual Signature Software 01 12 00 PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Pr fsysteme GmbH Berlin 1 PROMESS Contents 1 Introduction 2 2 Parameters 3 2 1 Overload EE 4 22 Relat ye Upper Lim nes 4 2 3 Rel tiye Lower Wenns 4 24 Absol te Upper E EN 5 2 5 Absolute Lower Limit a kan 5 2 6 Start of Window nn Enns ann Eee Re Teen Leere 5 2T Endof TE 5 2 8 Slice Will 5 SE 6 2 10 Force Ein 6 2 11 Peak Force Monitoring ons ans ae iea i 7 Peak BEE 7 Peak Lower Limit EE 7 2 12 Global Peak Force MOmitOr iti ss une 7 Global Peak Upper Em nenne en 7 Global Peak Lower Im een 7 2 13 Touch Point E EE 8 2 14 Touch Point Tolerance esse 8 2 15 POU Depth Toleranee ausiensenein 9 3 Teaching the System 10 3 1 Teaching The Signature Curve sn uneineineaeinene 11 3 2 Adjusting EE 12 3 3 Window Limits Sereen anne 13 3 4 Global Limits Senne 15 3 5 Zoom Window Screen deeg ent egeEg 16 3 6 Example Teach In Press Applteaton 17 4 Automatic Mode 18 4 1 The Fault List Bereit een 19 4 2 Information Screens EEN 20 4 2 1 Manufacturing Summary Sereen nennen 20 4 2 2 Part RE EE 21 4 2 3 Taught Data Seren een een 21 4 2 4 Data Lists Screen nie 22 5 0 The Service Menu 24 SE RE erkenne 24 Sl Sensor Signals nenne 25 5 12 Input reegen 26 PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Pr fsysteme GmbH Berlin
14. Returns to the previous Peak Upper L screen Peak Lower L Start Window End Window Slice Width Limits Setup Changing a Parameter Move the edit box up or down to the parameter to be changed Press the Clear button and type in the parameter setting Pressing the Enter button or the Exit button will save the value Press Exit to exit out of the edit mode and then press Exit to exit back to the graph screen When you scroll down to Slice Width the functions of the buttons change to up arrow and Exit see screen below Press Exit to exit out of the edit mode and the press Exit to exit back to the graph screen Window Limits Start Window 5 00 mm Button Function End Window 20 00 mm ft Moves the edit box up Slice Width 0 60 mm Increments the slice width Decrements the slice width Exit Returns the software to previous screen PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Priifsysteme GmbH Berlin 14 PROMESS 3 4 Global Limits Screen In the Monitoring Window screen the following parameters can be changed Overload limit full depth tolerance Global peak force limits and the force limit Note The Overload limit Global peak force limits force limit and the touch point will not appear if disabled in the hidden setup screen Global Limits Overload L 100 Ibs Full Depth 2 50 mm Full Depth 2 50 mm G Peak U L 0 Ibs G Peak L L 0 Ibs Force Limi
15. The analog display will be shown with the force factor calculated Edit Force Factor Tare Factor 0 003391 Ibs ADC Press ENTER to edit Eee Absol If no load is detected during this step a fault will be given WARNING Calibration Failed No load was applied PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Priifsysteme GmbH Berlin 30 PROMESS 5 2 2 Calibrate Position Using the Calibrate Position function the position transducer can be calibrated to a known position value using a gauge block To calibrate with a gauge block complete the following steps Note If a digital position transducer is being used there is not need to use the Calibrate position function When Calibrate Position is selected the following screen appears Make sure the position transducer is zeroed with gauge block installed and then press the Zero button Move to zero position then press Zero Next insert the gauge block enter the gauge block value and then press the Calibrate button After the unit has finished the calibration a message will appear and tell you to remove the gauge block and press the Enter key Insert gauge block and enter length of gauge block Calibration complete Remove gauge block and then press Enter mm to continue Then press Calibrate to calibrate to position ee brate PPM User Manual 11 18 02 Software Versions 0 0 27 Promess
16. ak Force value that is displayed is the highest force the unit recorded with the monitoring window during the process Peak Upper Limit The Peak Upper limit is a straight line limit If the peak force measured exceeds the Peak Upper limit then a Peak limit fault will occur at the end of the cycle Peak Lower Limit The Peak Lower limit is a straight line limit If the peak force measured is lower then the Peak Lower limit then a Peak limit fault will occur at the end of the cycle 2 12 Global Peak Force Monitoring The Global Peak Force value is the highest force that the unit recorded that was inside or outside the monitoring limit Global Peak Upper Limit The Peak Upper limit is a straight line limit If the peak force measured exceeds the Peak Upper limit then a Peak limit fault will occur at the end of the cycle Global Peak Lower limit The Peak Lower limit is a straight line limit If the peak force measured is lower then the Peak Lower limit then a Peak limit fault will occur at the end of the cycle PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Priifsysteme GmbH Berlin 7 PROMESS 2 13 Touch Point Limit The initial contact of the parts is recognized by this limit The start of window and end of window are relative to the touch point Force Touch Point Limit Touch Point Tolerance Monitoring Position Window 2 14 Touch Point Tolerance Based upon the taugh
17. bal Limits or the Zoom Setup can also be accessed Information Brings up the information screens Main Returns the software to the Main Menu PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Pr fsysteme GmbH Berlin 18 PROMESS 4 1 The Fault List Screen The Fault List screen lists any faults that occur during the last cycle This screen is updated after each cycle and the errors displayed are for the last part ran To access the Fault List screen press the button labeled Information To exit back to the graph screen press the button labeled EXIT The system still monitors when in the Fault List screen Fault List No Faults Sum Data Lists Note If the force limit is enabled then the following message will be displayed if the force limit is not reached Force Limit Not Reached This does not trigger the Fail output PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Pr fsysteme GmbH Berlin 19 PROMESS 4 2 Information Screens In the Information Screens the faults and part data can be viewed The Fault Lists screen will be displayed Fault List No Faults Sum Data Lists 4 2 1 Manufacturing Summary Screen Pressing the Man Sum Button will access the Manufacturing Summary Screen The Manufacturing Summary screen displays the Total number of parts Good Parts Bad Parts Relative Upper limit faults Relative Lower limit faults and the Full Dept
18. d 123 Then Press Enter Je The system will then prompt you to enter the new password New Password Enter New Password 123 Then Press Enter oe a de Type in the new 3 digit password and press ENTER A message will be displayed Password Changed Press Ok to exit PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Pr fsysteme GmbH Berlin 37 PROMESS 5 3 2 Changing Date and Time In the Date and Time Screen the date and time that is on the RAM chip can be changed Press the Edit button to access the edit screen Date and Time Button Function N Moves pointer to desired 11 18 1999 option ja Clear Clears the selected number Exit Returns the software to the Service Menu Move the edit box to the value to be changed and press the Clear button to clear the value Next enter the new value Press Exit to exit the edit screen and press Exit asecond time to go back to the Diagnostics Screen Note To change the year from 2000 back to 1900 s enter in 99 in the last two digits for the year 5 3 3 Serial Baud Rate The Serial Baud Rate screen lets you change the Baud Rate for serial communication Serial Baud Rate Button Functions Changes the setting inside gt the edit box Next Not Used Baud Rate ne Exit Returns the software to the Setup Menu PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Pr
19. d a carriage return Data Format touch point actual value lower touch point limit upper touch point limit lt CR gt Example 8 23 8 03 8 43 lt CR gt Command TPA lt CR gt Description Touch Point Actual The touch point location is sent followed by a Carriage return Data Format touch point x axis value lt CR gt Example 8 23 lt CR gt PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Priifsysteme GmbH Berlin 42 PROMESS Command FDA lt CR gt Description Full Depth Actual The full depth location is sent followed by a carriage return Data Format full depth location lt CR gt Example 23 74 lt CR gt Command FDT lt CR gt Description Full Depth Taught Value The taught in full depth location is sent followed by a carriage return Data Format full depth taught value lt CR gt Example 23 69 lt CR gt Command FDL lt CR gt Description Full Depth Limits The lower and upper full depth limits are sent out followed by a carriage return Data Format full depth lower limit x axis value full depth upper limit x axis value lt CR gt Example 23 19 24 19 lt CR gt Command FDS lt CR gt Description Full Depth Summary The full depth actual value is sent out followed by the lower and upper full depth limits and a carriage return Data Format full depth actual value lower full depth limit upper touch point limit lt CR gt Example 23 74 23 19 24
20. e Factor lbs ADC Press ENTER to edit PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Priifsysteme GmbH Berlin 34 PROMESS 5 2 6 Edit Position Factor In the Edit Position Factor screen the force factor can be changed manually The following screen will be displayed Edit Position Factor Tare Force 0 mm Boa Factor 0 003391 mm ADC Press ENTER to edit Zero Tare Exit Absol Editing the Position Factor Press the Enter button to edit the position factor The following screen will appear Use the numeric key pad to edit the value Edit Position Factor Tare Force 0 mm BREUER Factor 0 003391 mm ADC Press ENTER to edit PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Pr fsysteme GmbH Berlin 35 PROMESS 5 3 Setup Screen In the Setup Screen the Password Date and time and Language can be changed Setup Menu Button Function N Moves pointer to desired gt Change Password option Date and Time Serial Baud Rate Language SELECT Selects the option the arrow is pointing to EXIT Returns the software to the Service Menu PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Priifsysteme GmbH Berlin 36 PROMESS 5 3 1 Changing Password Inthe Change Password screen the password can be changed from the default setting Password Protect Enter Passwor
21. e Limit Absolute Limits the Peak limits are disabled as a default setting in the Limit Enable screen If any of and these limits are to be used they must be enabled in the Limit Enable screen in the hidden setup menu see technical manual Overload Limit Slice Tolerance Relative Upper Limit Force Limit Relative Lower Limit Peak Upper Limit Absolute Upper Limit Peak Lower Limit Absolute Upper Limit Global Peak Upper Limit Start of Window Global Peak Lower Limit End of Window Touch Point Limit Slice Width Full Depth Limit Monitoring Window Force Overload Limit Upper Limit Lower Limit Touch Point Limit Position m gt u 5 z OO C ro oo D oc cfc ES 5 rn Lu O s oz S 5 E c OO _ d o t Q gt 2 iL PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Priifsysteme GmbH Berlin 3 PROMESS 2 1 Overload Limit The over load limit is a real time limit and is active when the monitored input is high When the force exceeds the overload limit an overload fault output is triggered Force Overload Limit Position 2 2 Relative Upper Limit The relative upper limit is monitored from the Start of Window to the End of Window The relative upper limit is calculated by taking the relative upper limit setting and adding it to the taught in force profile If the force at any position during the monitoring window exceeds the upper limit a force fault wi
22. h faults Manufacturing Summary Button Function Total Parts oe Good Parts Fault List Returns software to Bad Parts Fault List screen Rel Upper L 1 Moves the edit box Rel Lower L down Full Depth Reset Counts Clears the current Full Depth setting Fault Reset Exit Exit Returns to the List d Counts previous screen If the Touch point the Overload limit the Force limit Absolute or the Peak force limits are enabled in the hidden setup screen then they will appear in the Manufacturing summary screen There is a separate manufacturing screen for every part number PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Pr fsysteme GmbH Berlin 20 4 2 2 Part Data Screen PROMESS Pressing the Part Data button will show the data for the last part ran Part Data Touch Point Full Depth G Peak Force W Peak Force W Peak Slice W Last Slice 13 14 mm 19 30 mm 9 Ibs 9 Ibs 9 Ibs 9 Ibs Fault Taught Data Exit List Data Lists 4 2 3 Taught Data Screen Pressing the Taught Data button will show the data for the taught in part Taught Data Touch Point Full Depth G Peak Force W Peak Force W Peak Slice W Last Slice 13 14 mm 19 30 mm 35 Ibs 35 Ibs 35 Ibs 35 Ibs List Data Lists PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Priifsysteme GmbH Berlin 21 PROMESS 4 2 4 Data Lists Screen
23. he previous screen Changing a Parameter To change a parameter move the edit box using the up and down arrow keys Press the Clear button and then type in the new value and press Enter or Exit to accept the value To exit out of the Zoom Window screen press the Exit button PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Pr fsysteme GmbH Berlin 16 PROMESS 3 6 Example Teach In Press Application Application pressing a bearing into a housing to a shoulder The bearing height is 10mm and the housing depth is 10mm The position transducer has a 25mm stroke length and touch point is not going to be used First put the Assembly Monitoring System into the Teach Mode and set the Start of Window to 00 00 and the End of Window to 25 00 full range in the parameter screen the other parameters can be left atthe default values Run a cycle teaching in the force position curve and the full depth position Note the full depth value show in the upper left hand corner of the screen and ignore the force position curve For our example the full depth value is 20 50 To set up the monitoring window to only look at the critical part of the press fit subtract 1mm from the full depth and use this as the End of Window value 19 50 Then subtract 8mm from the full depth value and use this as the Start of Window value 12 50 The critical part of the press fit is now defined and the force position curve will be shown on the
24. ignal will be sent to the preamplifier to activate the CAL Resistor PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Priifsysteme GmbH Berlin 25 PROMESS 5 1 2 Input Check The Input Check is used to view the current states of the 8 digital inputs 0 OFF 1 ON The Input Check can be used to verify that the Monitoring System is receiving the outputs from the PLC or output device Pressing the MENU button returns the software to the Diagnostics Menu 1 Monitored Input 2 Reset fault Input 3 Binary 1 Input 4 Binary 2 Input 5 Binary 4 Input 6 Binary 8 Input 7 Not Used 8 Lockout Input PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Priifsysteme GmbH Berlin 26 PROMESS 5 1 3 Relay Output Check The Relay Output Check is used to view the current states of the outputs The screen also permits the toggling of the outputs to verify that the PLC or other device is recognizing the outputs The outputs will be reset to their original states when exiting the output check Pressing the MENU button will return the software to the Service screen The default settings for the relay outputs are listed below Ifthe assignment of the relay outputs has been changed consult the system drawings for the correct output description R1 Pass N O R2 Failed N C R3 Overload N C R4 Relative Upper Limit Fault N C R5 Relative Lower Limit Fault N C
25. ill ask if you wish to reteach the part Press Yes to go into Teach or No to exit back to the Main Menu The system can store 8 different force position signature curves and parameters however when the system is put into Teach only the part number currently active will be taught With option memory up to 64 parts can be taught and stored The part number is displayed in the Main Menu in the lower right hand corner The part number is sent using the binary inputs via the interface cable a PROMESS E INCORPORATED Promess Panel Meter Version 0 0 9 May 11 1999 Station 99 Program 1 matic ice PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Pr fsysteme GmbH Berlin 10 PROMESS 0 Ibs Omm Prog 1 0 00 mm Es See Setup tion 3 1 Teaching The Signature Curve When in the teach mode the monitoring system collects and stores both the force and position data during working stroke of the position transducer In the hidden setup menu under Axis Value Setup the position range that you want data collected over can be adjusted if necessary This would only need to be done if you had a long stroke portion transducer but are only using a small amount of travel during the assembly operation To teach a signature into the system take parts that are close to the mean and press them together The two parts that are going to be assembled do not have to be exactly on the mean The upper and lower limi
26. information must be when the Monitored input is low Every command must be terminated by a carriage return lt CR gt lt CR gt ASCII lt 013 gt Line Feed lt LF gt after a carriage return lt CR gt will be ignored Command Description Availability PSO Part summary with out slices Later PSW Part summary with slices Later TPA Touch point actual TPT Touch point taught TPL Touch point limits TPS Touch point summary FDA Full depth actual FDT Full depth taught FDL Full depth limits FDS Full depth summary PFW Peak force window PFG Peak force global CWA Curve window actual CWT Curve window taught CWL Curve window limits CWS Curve summary VAC Value at cursor Later PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Pr fsysteme GmbH Berlin 41 PROMESS Command TPT lt CR gt Description Touch Point Taught Value the taught in touch point location is sent followed by a carriage return Data Format touch point taught value lt CR gt Example 8 23 lt CR gt Command TPL lt CR gt Description Touch Point Limits The lower and upper touch point limits are sent out followed by a carriage return Data Format touch point lower limit x axis value touch point upper limit x axis value lt CR gt Example 8 03 8 43 lt CR gt Command TPS lt CR gt Description Touch Point Summary The touch point actual value is sent out followed by the lower and upper touch point limits an
27. ll occur 2 3 Relative Lower Limit The relative lower limit is monitored from the Start of Window to the End of Window The relative lower limit is calculated by taking the relative lower limit and subtracting it from the taught in force profile If the force at any time during the monitoring window drops below the lower limit a force fault will occur Monitoring Window Relative Upper Limit Relative Lower Limit Position PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Priifsysteme GmbH Berlin 4 PROMESS 2 4 Absolute Upper Limit The absolute upper limit is monitored from the Start of Window to the End of Window Ifthe force at any position during the monitoring window exceeds the upper limit a force fault will occur 2 5 Absolute Lower Limit The absolute upper limit is monitored from the Start of Window to the End of Window Ifthe force at any position during the monitoring window falls below the lower limit a force fault will occur Monitoring Fe Window BEE Absolute Upper Limit i Absolute Lower Limit Position 2 6 Start of Window The position where monitoring will start If the touch point limit is set to 00 then the start of window is an absolute setting of the position axis If the touch point is used the start of window will be relative to the touch point 2 7 End of Window The position where monitoring will end If the touch point limit is set to 00 then
28. llows the force transducer to be calibrated to a known load Calibrate Position Allows the position transducer to be calibrated to a known gauge block value Reset Force Factor Resets the software force factor back to the default Reset Position Factor Resets the software position factor back to the default Edit Force Factor Allows the software force factor to be adjusted thru the faceplate Edit Position Factor Allows the software position factor to be adjusted thru the faceplate PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Priifsysteme GmbH Berlin 28 PROMESS 5 2 1 Calibrate Force Using the Calibrate Force function the force transducer can be calibrated to a known load This load can be a master load cell and meter To Calibrate with a known load complete the following steps When Calibrate Force is selected the following screen appears Make sure no load is being applied to the load cell ram and press the Zero button Remove all load then press Zero Next apply the known load and enter the load value applied Then press the Calibrate button to calibrate to the load Apply load and enter load applied Calibration complete Remove all load and then press Enter 100 00 Ibs to continue Then press Calibrate to calibrate the load KAES brate PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Pr fsysteme GmbH Berlin 29 PROMESS
29. t Command CWL lt CR gt Description Curve Window Limits The relative lower and upper limits within the monitoring window are sent out by sending the x axis value followed by the lower limit y axis value followed by the upper limit y axis value in triads until all values have been sent followed by a carriage return Data Format x axis 1 lower limit y axis 1 upper limit y axis 1 x axis 2 lower limit y axis 2 upper limit y axis 2 X axis n lower limit y axis n upper limit y axis n lt CR gt Example 11 00 0 123 11 10 0 148 23 00 1578 1778 lt CR gt PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Pr fsysteme GmbH Berlin 45 PROMESS Command CWS lt CR gt Description Curve Window Summary The actual curve within the monitoring window is sent out along with the relative ower and upper limits Data Format x axis 1 actual value y axis 1 lower limit y axis 1 upper limit y axis 1 x axis 2 actual value y axis 2 lower limit y axis 2 upper limit y axis 2 x axis n actual value y axis n lower limit y axis n upper limit y axis n lt CR gt Example 11 00 23 0 123 11 10 48 0 148 23 00 1678 1578 1778 lt CR gt PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Pr fsysteme GmbH Berlin 46
30. t 0 Ibs Touch Point 2 50 mm Touch Point 2 50 mm Edit Window Zoom Exit Limits Setup To change a parameter press the Edit button to access the edition mode Global Limits Button Function Overload L 100 bs Moves the edit box up Full Depth 2 50 mm or down Full Depth 2 50mm Clear Clears the current G Peak U L 0 Ibs setting G Peak L L O lbs Exit Returns to the previous Force Limit 0 Ibs screen Touch Point 2 50 mm Touch Point 2 50 mm Changing a Parameter Move the edit box up or down to the parameter to be changed Press the Clear button and type in the parameter setting Press the Enter button or the Exit button will save the value Press Exit to exit out of the edit mode and then press Exit to exit back to the graph screen PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Pr fsysteme GmbH Berlin 15 PROMESS 3 5 Zoom Window Screen In the Zoom Window the force and position settings for the zooming function can be set When in the graph screen pressing the button will toggle the screen from the full graph to the zoom window K Zoom Window 0 00 to 25 00 mm to 100 Ibs Edit Global Window Exit Setup Setup The following screen appears when entering the Zoom Setup Zoom Window Button Function N Moves the edit box up or 0 00 to 25 00 mm down Clear Clears the current setting O t 100 Ib i i Exit Returns to t
31. t in touch point position the user can set a plus minus tolerance that the initial part contact Touch Point must be within When the Assembly Monitoring System is taught the system stores the Touch Point Position The Touch point tolerance set in the parameter screen and the value entered is added and subtracted from the taught Touch Point position to create the tolerance Example Taught in Touch Point Position is 13 50mm Touch Point Tolerance is 2 00mm Then the lower limit is 11 50mm and the upper limit is 15 50mm So ifthe Touch Point position is less than 11 50mm or greater than 15 50mm then a fault will be sent Lower Tolerance Taught Upper Tolerance 00 00 11 50 13 50 15 50 25 00 Position PPM User Manual 11 18 02 Software Versions 0 0 15 Promess Montage und Pr fsysteme GmbH Berlin 8 PROMESS 2 15 Full Depth Tolerance Based upon the taught in full depth position the user can set a plus minus tolerance that the final press position must be within When the Assembly Monitoring System is taught the system stores the Full Depth Position The furthest value that the position transducer traveled There are two full depth tolerances that can be set in the monitoring system Full Depth Tolerance Full Depth Full Depth Tolerance Full Depth The Full Depth Tolerance is added to the taught in full depth value to set the upper limit and the Full Depth Tolerance is subtracted from the full depth value to set
32. ts are separate limits so if the taught in signature is above the mean then the upper limit will be set to a lower value than if a mean part was taught in The system will indicate when it is in the teach mode by displaying a T in the upper right hand corner of the screen An A is used to indicate the system is in the automatic mode After on part is taught the system will automatically switch to the automatic mode In teach the only limits that are monitored are the Overload Limit and the Peak Force Limits In either the teach mode or the automatic mode any of the monitoring parameters can be changed without having to reteach the system The screen in the teach mode PPM User Manual 11 18 02 Software Versions 0 0 27 Promess Montage und Pr fsysteme GmbH Berlin 11 PROMESS 0 Ibs Omm Prog 1 0 00 mm ee Se Setup tion 3 2 Adjusting Parameters There are three different screens where various parameter can be adjusted Window Limits Global Limits and Zoom Window Window Limits In this screen limits that are only for the Monitoring Window can be adjusted Global Limits In this screen limits that are monitored inside and outside the monitoring window can be adjusted Zoom Window This is the screen where the zoom window is set Window Limits Global Limits Rel Upper L 10 Ibs Full Depth Rel Lower L 10 Ibs Full Depth Start Window 0 00mm End Window 25 00mm Slice Width 0 20mm Limits Setup
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