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How to Program a Torque Control Strategy in Advanced Setup

1. J Page 8 Ingersoll Rand Company 2004 HD Assembly Solutions Section 1 Installation 475mm 00000000000 00000000000 285 mm Figure 7 Top Dimensional Drawing Electrical Connection Make sure the Main Power Switch is in the Off position In the United States the Insight controller enclosure comes pre wired with a power cord and the appropriate plug Insight systems sold outside the USA come with a pigtail cable tail and the user must supply the correct power cord connector Review the electrical circuit information on the Insight s label on the right side panel and in the specifications table Verify that your electrical circuit meets the Insight s power requirements and circuit breaker ratings Plug the AC power cord into an appropriate receptacle It is the user s responsibility to ensure that the Insight controller is installed and wired by a qualified electrician Attaching the Spindles Attach your Ingersoll Rand spindles or powerheads on the right side of the Insight enclosure One or two spindles may be attached At the end of each spindle s cable is a twist to lock multi pin connector designated Spindle 1 or Spindle 2 In general any spindle may be plugged into any spindle connector However you may have preferred locations for the spindles based on the fastening applications Plug each tool into the appropriate connector and lock it in place I
2. 07 20 2003 STATS 01 19 37 The Export function allows you to filter and send data out through the serial port The format and type of data sent can be changed to suit your specific needs Use this screen to select the criteria of the data to be exported Data Port BERN Select Spinde EI HB AllEntries Or from Last fd To 5000 Entries Ge GE C oniiguration e E Config a Separate Data Fields By amp Comma Space Figure 28 Stats Export Cycle Log Menu Ingersoll Rand Company 2004 HD Assembly Solutions Section A Quality Control Screen Element Description Wizard Box Displays information or instructions for the screen element that is highlighted Send After you have selected and formatted the cycle parameters using other elements on this screen click this button to send the data to an external device over the serial port Data Port Use this drop box to select the serial port for exporting data COM 1 COM 2 COM 3 or COM 4 or Ethernet All Entries Check this box if you want to export all cycle data in memory From Last If you want to export data from only a portion of the fastening cycles enter the range here Sort By Use this drop box to select the cycle sorting parameter Options include Configuration Cycle Results Torque Results or Angle Results Then Select This drop box will display different options depending upon the Sort By parameter If the user sorts by Config
3. TF Assembly Solutions INSIGHT IC1G IC2G DC ELECTRIC TOOL CONTROLLER USER MANUAL Document Part Number P7625 Document Edition Number 1 0 Edition Release Date Jan 2004 UD Assembly Solutions Table of Contents Precautionary Information icicccnnscnsnseosc ice ieee eee setae Lens oantoeeteentaanes vi Important Safety Information E vi Grounding Ee vii EU VVI O EE vii Warning Symbol le De e e viii Agency Symbol Identification scicstusvcsastecccnindsassarsdsandunencnndedsaansinselonmteruaassathincsdunniaede viii Explanation of Symbols USO ggeergeeeegteegen enteet eege viii Notice to Save IMSUIUCHOMS xaccssccccoeteccters dated ereer eeeeeeeeeeeertrtntnenrnrnnrnrnnsnssesssssree nennt viii Declaration of Conformity EE ix MOREE CEN IN eiei ia aea aaee e aa a Aa eaat eaae eaa aaae a 1 Menu DEENEN 2 Navigation Keypad ME 3 Numen E BEE A Orientation Screen Layout seeEESSERSSEEEEEEEEKEKESSEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEESEEEEEEEEENEn 5 Screen EIERE 6 Section 1 Installation csscss cos wccedensoes sc eectessdaaesnviadediareiccesesasiossstesdlarsdsiendiceeessesunaneas 8 DOUG UNG WEE 8 Elend dE 9 Attaching the EIERE EES 9 Attaching Peripheral Devices ssc cccncsncesnescecceespsndeesncecdoue dedicate demencndaneeianenrueeienee 10 Socket Tray Connection and Setup AE 10 How to lesta Socket Tresorier eege deeg e 10 External Configuration Switch Connection and Setup cc ceeeeeeeeeeeeeeeeeeeees 11 How to Te
4. System Parameters HR Assembly Solutions Angle Overshoot If tightenings are consistently overshooting the Angle Target the tool will be shut off this many degrees before the Angle Target User entered Angle Target The desired angle through which the fastener should turn User entered Avg Prevailing Torque The average prevailing torque calculated from the last 360 of torque data points prior to the seating torque System calculated Backout Angle The number of degrees the tool will reverse to achieve backout User entered Backout Speed The tool s speed during the backout phase or when the tools reverse button is pressed One of the basic Engage parameters that appears for every fastening strategy User entered Backout Torque Hi The maximum allowable torque for the backout step User entered Backout Torque Lo The minimum acceptable torque for the backout step User entered Baud Rate The data transfer rate Insight uses to communicate with external serial devices User entered Bits Per Character The number of bits per character used for external serial communications User entered CAM A statistical parameter used to measure system performance System calculated Capability A statistical parameter used to measure system performance System calculated Change Password Pressing this button brings up a box with the levels and the current passw
5. Procedure 1 Press the Setup Main Menu key The Quick Setup screen will be displayed 2 Goto the Select Spindle drop box Spindle 1 is the default value If you want to use Spindle 1 go to Step 3 If you want to use Spindle 2 open the drop box and select Spindle 2 3 Goto the Configuration drop box open it and select the configuration number you wish to program 4 The Strategy drop box will display Torque since this is the default strategy 5 Using the numeric keypad enter the desired torque value for your fastening operation into the Torque Target data entry box Make sure the torque units displayed are the units you want to use If not press the Spindle Initialization Sub Menu key and change the units in the Torque Units drop box 6 The Insight software automatically assigns values to the other torque control parameters displayed in the main menu screen If you want to edit any of these values navigate to the data entry box and enter a new value using the numeric keypad Page 28 Ingersoll Rand Company 2004 aim Assembly Solutions Section 2 Programming How to Program an Angle Control Strategy in Quick Setup Procedure 1 Press the Setup Main Menu key The Quick Setup screen will be displayed 2 Goto the Select Spindle drop box Spindle 1 is the default value If you want to use Spindle 1 go to Step 3 If you want to use Spindle 2 open the drop box and select Spindle 2 3 Goto the Configuration drop box
6. 2 Goto the Data Port drop box and select the communications port the bar code scanner will be connected to 3 Set the Baud Rate Parity of Data Bits and of Stop Bits to the same values as setup for your bar code scanner 4 Goto the Comm Protocol drop box and select Barcode SP1 for spindle 1 or Barcode SP2 for spindle 2 5 Navigate to the Barcode Setup button and press ENTER NOTE If this is the first time you have setup a scanner for this spindle you will get a warning message indicating that a bar code setup file was not found Press the ENTER key and a default file will be created 6 Enter the number of characters that are in the bar code scan into the box labeled Barcode Length 7 into the box labeled Use data From enter the position of the first character in the bar code that specifies the section that will determine which configuration the scan should switch the controller to In the box labeled to enter the last character in the bar code that specifies the section that will determine which configuration the scan should switch the controller to For example if your bar code has the following structure XXXYYYXXX Where X any character in the bar code Y characters whose values determine which configuration to switch to Then Use Data From 4 to 6 should be the entry as the first Y is at character position 4 and the last Y is in character position 6 The actual characters for the bar Page 18 Ingersoll R
7. 144 2 11 16 00 16 00 PASS 1 75 PASS 120 00 PASS F PASS 143 11 11 16 00 16 00 PASS 4 05 PASS 89 11 PASS 142 11 11 16 00 16 00 PASS 4 76 PASS 102 23 PASS 141 10 11 16 00 16 00 PASS 412 PASS 291 97 PASS 140 14 11 16 00 16 00 PASS 0 82 PASS 198 74 PASS 139 31 11 16 00 16 00 PASS 0 57 PASS 254 21 PASS 138 3 11 16 00 16 00 PASS 0 33 PASS 32 87 PASS 137 3 11 16 00 16 00 PASS 4 68 PASS 93 19 PASS 136 23 11 16 00 16 00 PASS 8 72 PASS 188 49 PASS 135 30 11 16 00 16 00 PASS 6 05 PASS 209 75 PASS 134 Page 6 11 16 00 16 00 PASS 4 9 43 PASS Figure 5 Screen Elements 184 70 PASS Ingersoll Rand Company 2004 HD Assembly Solutions Introduction Screen Element Description Button To click on a button navigate to it with the arrow keys and press either Enter key Drop Box Drop boxes are indicated by the Expand symbol To open a drop box navigate to it with the arrow keys and press the Expand key Use the arrow keys to move to the desired option then press either Enter key to select that option Data Entry Box Navigate to a data entry box with the arrow keys and then use the numeric keypa
8. 41 Engaging a Step snssnrcndiisniiiriar 31 EGRET enge eegen E ee ees 31 lire tele de EE 29 Jog Control Strategy 20 eeceeeeeeeeeeeeeeeeeees 41 Programming Angle Control Strategy ceeee 35 Backout Girategy 38 Drag Torque Control Strategy 40 Spindles in a Powerbead 30 Torque Control Strate 35 39 Yield Control Strategy c cece 37 Yield Override Strategy in Torque COMO TEEN 36 Retorque Parmeters ssssssessseerrerrenneeresren 41 WANS iat totini a En 30 Alarm Setup Gcreen 58 Ala Siesia i ad a 59 ANG EE 40 Angle Control Girategy 29 35 Assigning a Powerbead 24 Attaching Peripheral Devices 10 Attaching the Spindles c cc eeeeeeeeeeeeteeeeeeeeeee 9 Auto Calibration srein 20 22 Auto Increment ne 32 B Backout AnQle i isisccarses raii 33 34 Backout Speed ssssssnnesensrnensensseeestrrrrnnnnnnsrresrees 33 Backout Strategy eiia 38 Backspace Key s ccscchteseeecctetepeceeeetteseeecenetepene 4 Bal COG sivcccatestsceareveebeccutereaedsuns veehexede KAN 17 Active MOd6 jiiccctcicinadiice neces 17 18 Compatibility With Other Functions 19 Auto Increment aeesseesseeseerrresererrsse 20 Feld BUS atrcssi 20 Gang Count EE 19 Dowerbead 20 Description 17 Other Operations cecceceeeeeceeceeeeeeeeeees 19 Changing from Active to Passive Bar Code Mode c ccccccctieeetscesteentdeessiens 19 Ingersoll Rand Company 2004 UD Assembly S
9. Patallelntacasikiehindienninn wide ates 12 Genial 12 Se ls 16 Prog TOO Switch 21 Programming DEE 27 Angle Control Strategy cceeeeeeerreeeeee 29 Angle Control Strategy in Advanced Setup 35 Backout Strategy in Advanced Setup 38 Drag Torque Control Strategy in Advanced Setup ssssssseesseerrrnnsensseesrrennn 40 Prevailing Torque Control Strategy 39 Spindles in a Powerhead ceeeeeee 30 Tightening Gtraiegies eects 28 Torque Control Strategy cee 28 35 Yield Control Strate 29 Yield Control Strategy in Advanced e EE 37 Yield Override Strategy in Torque CONTON viistececteideniriit neva i aedasideiedie 36 Q Quality Control 44 Quick Setup Be operational in minutes sssesseeseeeeee nee 27 Page 93 Index Programming a Torque Control Strategy 28 Programming a Yield Control Strategy 29 Programming an Angle Control Strategy 29 Programming Tightening Strategies 28 R Receiving an Output 14 Reject BUZZ o nececrcrcanniea an 63 Reset TR and ASC Buttons aaae 21 Retorque Parmeiers 41 Retri S A 34 Retry Fault Action 00 cccccccseeeesecccseceenenccneeeeeeaes 34 Retry Fault Action Value cccceeeeesteeeeeeeeees 34 Run Main Menu 42 Run Men 2 R n MOUS wicedecicecseeisdiaeetecta setter od ESA ENEE 45 Cycle Log Gcreen 49 Main Gcreen 45 Statistics Summary Gcreen eee 48 Tightening Curves
10. Similar applications exist for measuring the frictional torque in bearings and hubs Peak cut in torque High torque limit Low torque limit Drag torque zone Angle Figure 20 Drag Torque Strategy Procedure 1 Press the Setup Main Menu key and then the Advanced Setup Sub Menu key 2 In the Select Spindle drop box select the spindle you want to program 3 In the Config drop box select the configuration you want to program 4 Go to the Engage step drop box and select Engage If the Engage parameter default values are acceptable you can skip to step 6 5 Goto the list of parameters just below the Engage step drop box and navigate down through the parameter list You must enter values or accept the default values for the Required Parameters As appropriate you may also enter values or accept the default values for the Optional parameters 6 Goto the Step 1 Strategy drop box and select Drag Torque Page 40 Ingersoll Rand Company 2004 aim Assembly Solutions Section 2 Programming 7 Goto the list of parameters just below the Step 1 Strategy drop box and navigate down through the parameter list You must enter values or accept the default values for the Required Parameters As appropriate you may also enter values or accept the default values for the Optional Parameters 8 You cannot program additional tightening steps after the Drag Torque strategy Delay Control Strategy The Delay Contr
11. open it and select the configuration number you wish to program 4 Goto the Strategy drop box and select the Angle strategy Using the numeric keypad enter the desired angle value for your fastening operation into the Angle Target data entry box 6 The Insight software automatically assigns values to the angle parameters displayed in the main menu screen If you want to edit any of these values navigate to the data entry box and enter a new value using the numeric keypad How to Program a Yield Control Strategy in Quick Setup Procedure 1 Press the Setup Main Menu key The Quick Setup screen will be displayed 2 Goto the Select Spindle drop box Spindle 1 is the default value If you want to use Spindle 1 go to Step 3 If you want to use Spindle 2 open the drop box and select Spindle 2 3 Goto the Configuration drop box open it and select the configuration number you wish to program 4 Goto the Strategy drop box and select the Yield strategy Using the numeric keypad enter the desired yield point for your fastening operation into the Yield Point data entry box 50 is recommended 6 The Insight software automatically assigns values to the yield control parameters displayed in the main menu screen If you want to edit any of these values navigate to the data entry box and enter a new value using the numeric keypad Advanced Setup Introduction to Advanced Setup The Advanced Setup Menu screen allows you to set
12. Insight IC to any directed output The outputs may be hyper terminal or any PLC based Applications D 8 After each successful data string is sent out the host should send an ACK message to the Insight IC 9 The host should send the Clear message to Insight IC in order to clear the EOR and the Insight IC will be ready for the next data out Descriptions The following format of the Custom Host Data Output will be sent out from the Insight IC to the directed terminals upon each request by the host after each tightening At the end of each request an ACK Message is sent from the Host to the Insight IC The Config Buffer Clear and Spindle Buffer Clear messages can be sent at any time to clear the specified buffer SSRTTTT TAAAAAUUUU VBBBBBCCCCC lt CR gt lt LF gt SS Spindle Number R Total Cycle Flag P Pass F Fail TTTT T Peak Torque measured value AAAAA Peak Angle measured value UUUU U Torque Hi Limit This is set at time of receipt of data request message Page 88 Ingersoll Rand Company 2004 aim Assembly Solutions Appendix 3 Communication Protocols VVVV V Torque Low Limit This is set at time of receipt of data request message BBBBB Angle Hi Limit This is set at time of receipt of data request message ecccc Angle Low Limit This is set at time of receipt of data request message lt CR gt Carriage Return lt LF gt Line feed e All torque data shall
13. Screen eee 47 View Parameters Green 50 S Save Data ainidi a sde e 25 Screen Elements 6 Screen Layout Orientation 5 Selecting the Configutation eeeeeeeeeeeees 42 Sequence Rules rrn nrenseeee 30 Serial Port 12 Serial Printer ssccccccccais ce ccenuessetecnrecccevseecesuccdnans 12 SOUUP EE E ET 27 Advanced MEET 29 Configuration Switch s es 11 Mentee 2 27 Socket Tray ee 10 TOCHNIQUES acisini eE Taa 27 Shutdown Codes 67 Socket CN 10 Spare Parts 77 Spare Parts List sisicect wei seailedanteeicecseriidiaen ies 81 Specifications cccceeeeeeceeeeeeceeceeeeeeeeeeeeeeeeeees 77 Spindle Initialization 20 2 eee e ee eeeeeeeeeeeeeeeeeeeeees 10 21 22 Initialization Gcreen nnen 20 Operation 10 Power Switches ccccccceceeeeeeeeeeeeeseneeeeeeees 1 Setup Screen cceeeeeeeeecceececeeeeeeeeeeeeeeeseees 20 Spindles Attaching c cceeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeenaeeeeeeeaaes 9 Programming E 30 Startup 0 15 Statistics Alarm Setup Green 58 Page 94 HR Assembly Solutions Alarms Discussion s ssseseeeseneseeeeererrnr rrenen 59 lebt E 2 51 SUMIMALY erci 48 Summary SCIOGCN a ceccceceeeceeececeeeteeeeeeeeneeenes 48 Statistics Menus Cycle Log Screen 57 Export Green 52 Statistics Alarm Setup Screen 00 58 Summary Green 51 Tightening Curves Screen seese 54 STATS AARM 43 Status DISPlAY 12 5 0 satis ot aditeedtnieetadineeieacees 1 Step Cleaning sie
14. a very broad range of tightening parameters This screen is used if a multi step fastening strategy is required and is more complex than the simple torque control angle control or yield control strategies offered under the Quick Setup Menu screen Advanced Setup may also be used if you want to use one of these three basic strategies but want to be able to adjust all the possible parameters for the strategy Ingersoll Rand Company 2004 Page 29 Section 2 Programming aim Assembly Solutions Advanced Setup also gives you access to all of Insight s other more complex tightening strategies such as prevailing torque and drag torque Finally Advanced Setup allows you to combine these strategies into a series of up to 128 separate and sequential steps allowing you to create complex and specialized fastening schemes tailored to your unique assembly requirements 01 02 2001 SETUP 00 16 00 Select Spindle Config Config Name Copy Configurati DEE corian SR Step 1 Step 2 Step 3 Angle Contro E E None BI None I5 Free Speed Insert After Above Step Insert After Above Step Insert After Above Step Clear All Steps Figure 18 Advanced Setup Menu Advanced Setup Tips In this section we discuss several topics that are essential to understanding the Advanced Setup function Strategy Sequence Rules The Insight s 128 possible tightening steps and up to 32 separate configurations can be programmed in virtually any
15. at vere i overensstemmelse med f lgende hovedstandard er SV Genom att anv nda f ljande principstandard NO ved bruke f lgende prinsipielle standarder FI esitetyt vaatimukset seuraavia perusnormeja k ytett ess PT observando as seguintes Normas Principais EL X nouomoumvtas ttg axorov0es Agx s Kavorop v Serial Number Range P04A 00001 gt FR No Serie DE Serien Nr Bereich IT Numeri di Serie ES Gama de No de Serie NL Serienummers DA Serienr SV Serienum mer Date January 2004 FR Date janvier 2004 DE Datum Januar 2004 IT Data gennaio 2004 ES Fecha enero 2004 NL Datum januari 2004 DA Dato Januar 2004 SV Datum januari 2004 NO Dato Januar 2004 FI P iv ys tammikuu 2004 PT Data Janeiro 2004 EL Huegounvia Iavovdetos 2004 Approved By FR Approuve par DE Genehmigt von IT Approvato da ES Aprobado por NL Goedgekeurd door DA Godkendt af SV Godk nt av NO Godkjent av FI Hyv ksytty PT Aprovado por EL EyxoiOyxe amo Harry Seddon lees Ain John Linehan Ll i E SIS SS 1S 61S 61S 6161S 61S 61S 1641S S1S161S 1661S 61516161 61S 21S 161615161616 1S16141S161S161 HD Assembly Solutions Introduction The Insight IC Fastening System with Graphic Display is an electronic tightening controller that can be programmed to operate one or two Ingersoll Rand DC spindles depending on the model to perfor
16. get a list of topics RUN Go to Help Topic STATS SETUP Summary Quick Setup Advanced Setup Tight Curves System Init Cycle Log Spindle Init Passwd amp Pwhds Stats Alarms Parameter x ter Figure 39 The Help Main Menu Help On Print System Test Event Log Tool Test Main Selecting this button will give an alphabetical listing of all topics in the Help Menu These can be accessed by scrolling through the topics until the desired one is located Each topic lists an explanation of its meaning 07 20 2003 01 17 45 D z D Help Go To Topic Choose the topic for help by selecting it in the list and pressing ENTER Topic Screen Location of Stop Bits 4 D Reference Voltage SYSTEM INITIALIZATION ie SYSTEM TEST Acceleration Help Main Menu ADVANCED SETUP Access Lockout Time Additional displayed Parameters PASSWORDS AND POWERHEADS RUN TIGHTENING CURVES SCREEN All Cycles All Cycles Check Box PRINT REPORTS STATISTICS EXPORT Amplifier Offset SYSTEM TEST Angle Constant PARAMETER TRANSFER amp SMART CH Angle Constant ASC SPINDLE INITIALIZATION Angle Control Angle Control QUICK SETUP ADVANCED SETUP Angle Control with yield override Figure 40 The Run Main Help Go To Topic Menu Ingersoll Rand Company 2004 ADVANCED SETUP Main Page 69 Section 5 Diagnostics and Troubleshooting am Ass
17. include General parameters such as plant name and display language Date Time parameters such as time date format and enable daylight savings and Communications parameters such as baud rate and communications protocols Below is a typical System Initialization screen 07 20 2003 SETUP 01 32 18 Enter a name for this system This will appear at the top of printed reports System Name IR INSIGHT O O Figure 10 The System Initialization Screen EOR Filter The End of Run EOR filter determines the data displayed in addition to torque and angle at the end of each tightening cycle Clicking on the EOR Filter button on the System Initialization screen displays a set of parameters that you can set Data Ports 1 Comm1 Comm4 2 Ethernet see Appendix 3 Communication Protocols on page 86 for further information 3 Devicenet optional 4 Profibus optional Communication Protocol Setup There are four options in the Comm Protocol drop box 1 None 2 Host Data Out is a handshaking protocol The host sends a request for data Insight sends the data and the host sends a response that the data was received Page 16 Ingersoll Rand Company 2004 HD Assembly Solutions Section 1 Installation 3 EOR Data Out sends one line of data after every cycle without a host request See Appendix 3 Communication Protocols on page 86 for further information 4 Bar Code Select this option if you have
18. programming parameters proceed to the Advanced Setup Menu Screen The Quick Setup screen allows you to set key parameters torque angle spindle speed etc for your tightening strategy You may pre program up to 32 separate tightening operations per spindle called Configurations The parameters displayed on the screen will vary depending upon the fastening strategy selected The goal of this section is to have your Insight IC Fastening System with Graphics Display up and running in just a few minutes Before proceeding with the steps below make sure you have completed the steps described in Initial Startup Ingersoll Rand Company 2004 Page 27 Section 2 Programming am Assembly Solutions Programming Tightening Strategies in Quick Setup 10 13 2003 SETUP we 4 06 48 55 Quick Setup Wizard Step 5 A default Torque Hi limit has been calculated for you To accept this value move to the next step To edit this value use the numerical key pad to enter the highest acceptable torque value See Graphical plot below Select Spindle 4 Torque Target 7 Angle Hi Limit 10 Free Speed spindle ET en 100 Contig 5 Hi Torque Limit 8 Angle Lo Limit 11 Shiftdown Point Configi S 3 Strategy 6 Lo Torque Limit 9 Torque Threshold 12 Shiftdown Speed Torque Control fe Torque Torque Control Hi Target Lo Shiftdown Pt Threshold Figure 17 Setup Quick Setup Menu How to Program a Torque Control Strategy in Quick Setup
19. retries have failed If Retry Fault Action is set to zero and a spindle fails then the controller will automatically go to the Final Fault Backout if programmed The parameters in the engage step that make up Final Fault Backout are as follows Final Fault Backout Angle This parameter defines the number of degrees the spindle will rotate during the final fault backout phase This parameter can be set to a different value for each spindle Final Fault Backout Hi Torque This is the high torque limit for the final fault backout operation This is usually set to the max torque of the tool Fault Action This parameter defines what spindles will backout when a final fault backout occurs If this parameter is set to zero then final fault backout operation is disabled This value must be the same value for all spindles in a powerhead Fault Action Value Operation 0 Faulted spindle stops no Final Backout 1 Only faulted spindles backout 2 All spindles in faulted group backout 3 All spindles in powerhead backout Page 34 Ingersoll Rand Company 2004 aim Assembly Solutions Section 2 Programming How to Program a Torque Control Strategy in Advanced Setup The Torque Control Strategy is based on reaching a programmed torque target For any of the Step n drop boxes if Torque Control is selected as the strategy a specific list of parameters is displayed See Appendix 1 System Parameters for definitions of th
20. status and provides warnings and alarms Note that the Cycle Log screen window is a display box You can scroll through the table in this window using the arrow keys Ingersoll Rand Company 2004 Page 57 Section 4 Quality Control dp Assembly Solutions The Cycle Log table parameters are defined in Appendix 1 System Parameters Statistics Alarm Setup Screen In many applications it is important to systematically monitor tightening performance using statistical parameters This screen allows the user to set alarms that will indicate deviations from selected fastening statistics thereby alerting the Insight operator to a potential quality problem Below is a typical Statistics Alarm Setup screen 07 20 2003 01 26 31 Please select the spindle for which you want to set statistical alarms Select Spindle Select Config Spinde 1 WU Config E Set Performance Criteria and Alarms for sample statistics Values for Stats Sample Size Good Only E Parameter Cp Cpk 6 Sigma Capability CAM oor Alarm Parameter cp aa Cpk E 6 Sigma 0 00 Capability 0 00 CAM 0 00 Figure 32 Statistics Alarm Setup Menu Screen Element Description Select Spindle Use this drop box to select the spindle for which the alarms will display This drop box will not be present if your Insight is a one spindle model Select Config Use this drop box to select the tightening configuration who
21. that parameter will not be exported Screen Element Description Make EOR Data Out Same Format Checking this box gives the End of Run Data Out serial protocol the same format as the statistics export data OK Clicking this button sets the data export order and returns the user to the main Export screen Cancel Clicking this button cancels all changes and returns the user to the main Export screen Message Box The Message Box summarizes system status and provides warnings and alarms Tightening Curves Screen To improve a fastening sequence or to resolve fastening problems it is often important to understand the tightening curve in detail With this screen the user can view tightening curves and zoom in on those curves to analyze them In addition important aspects of Page 54 Ingersoll Rand Company 2004 am Assembly Solutions Section 4 Quality Control the curve such as the number of data points peak torque value and so on are automatically calculated and displayed Below is a typical Tightening Curves screen STATS Re Tightening Curves Select Spindle Select Config Select Plot Type Select Capture Type Spinde S Config Bi Torque vs Anaig Next 5 Cycles Select Plot Replace Plot Plot Update Plot it z Full View ot 1 214 Data Points eak 20 16 Nm 117 9 deg Plot 2 191 Data Points Peak 20 10 Nm 119 6 deg lot 3 236 Data Points eak 20 0
22. the selected menu There are up to six sub menu options for each menu type and they are located to the right side of the main display Page 2 Ingersoll Rand Company 2004 HD Assembly Solutions Introduction 4 To enter numeric data into a field simply highlight the desired onscreen element use the numeric keypad to enter numbers and press the Enter key To enter alphabetic information highlight the desired onscreen element and press the Expand key Use the number keys to enter the desired letter The right arrow key will move the cursor to the next location When the entry is complete press the Enter key to confirm the entry Navigation Keypad The arrows on the navigation keypad see graphic below are used to navigate among the screen elements buttons drop boxes etc When you have navigated to a screen element it becomes highlighted with a border Pressing the Enter key on the navigation keypad or the one on the numeric keypad will activate the highlighted screen element The action is similar to clicking on a screen button with a computer mouse Escape Key Directional Arrow Keys Enter Key Expand Key Figure 2 The Directional Keypad If you activate or enter a screen element with the Expand symbol on it that symbol indicates the element can be opened to reveal additional options Pressing the Expand key located in the center of the navigation keypad will open the element and display the options You can
23. value unless the strategy is angle control in which case it will be the torque value Note that both the primary and secondary numbers show either a degree symbol or torque units making it clear which parameter is displayed Limit Values The three numbers to the right of the primary number are from top to bottom the high limit the target value and the low limit for the primary parameter The values displayed are those that were programmed during either the Quick Setup or Advanced Setup operations Var 1 This drop box has a list of tightening variables The user can select one of these variables to display here during each fastening operation Var 2 This drop box has a list of tightening variables The user can select one of these variables to display here during each fastening operation Message Box The Message Box summarizes system status and provides warnings and alarms The tightening variables that the user can display in the Var 1 and Var 2 drop boxes see graphic above are defined in Appendix 1 System Parameters Each drop box can display only one variable To select the desired tightening variable 1 Navigate to the drop box using the arrow keys 2 Press the Expand key to display the variables 3 Then use the arrow keys to scroll through the list to the desired variable or enter the number of the variable and 4 Press the Enter key to select the variable You can change the variable di
24. 0 00 5 00 i 0 00 5 00 0 48 0 0 48 0 0 61 365 0 61 365 0 14 365 0 14 365 6 6 6 6 0 177 0 000 i 0 194 0 000 1 061 0 000 i 1 162 269 4 0 0 ili 295 1 28 27 0 00 25 81 0 74 0 00 0 68 0 00 0 00 0 00 Stats Summary Hi Rejects Lo Rejects Figure 24 The Run Statistics Summary Menu Screen Element Description Select Spindle Use this drop box to select the spindle whose statistics will display Select Config Use this drop box to select the tightening configuration by number and name whose statistics will display Populations Statistics The statistics for the entire fastening population are displayed here Sample Statistics The statistics for the sample subset of the population are displayed here Message Box The Message Box summarizes system status and provides warnings and alarms Page 48 Ingersoll Rand Company 2004 aim Assembly Solutions Section 4 Quality Control Cycle Log Screen This is a view only screen that displays various tightening parameters monitored recorded and stored in memory for all readings in the current fastening series up to a maximum of 5 000 This screen displays the most recent 1 000 cycles To view the rest go to the Statistics Menus Cycle Log screen Below is a typical Run menu Cycle Log screen 07 20 2003 RUN 03 41 05 Select Spindle Spindle sd Clear Cycle Data Reset Cycle Number Cycle Torque Cycle Config Step Date Time Result Torqu
25. 0 02 2003 Discrete Inputs we 4 01 29 57 Select Spindle i Spindle 1 e Oo Oo Oo Q QO O QO Q QO O Q Configuration 1 Configuration 2 Spindle Disable Spindle Re_Enable Free Speed Soft Start Forward Reverse Tool Reverse Tool Throttle Prog Tool Switch Figure 34 Diagnostics Discrete Inputs Menu Screen Element Function Select Spindle Use this drop box to select either Spindle 1 or Spindle 2 for testing This drop box will not be present if your Insight is a one spindle model Main Window The spindle input signals are listed on the screen If the input signal is present the circle to the left of the signal will be filled in If no signal is present the circle will be white The spindle connector pin letter designation that corresponds to the signal input is also shown Message Box The Message Box summarizes system status and provides warnings and alarms Page 62 Ingersoll Rand Company 2004 am Assembly Solutions Section 5 Diagnostics and Troubleshooting Discrete Outputs Screen On the left side of the Insight controller are Spindle I O input output connectors With this screen you can artificially activate an output signal This function is typically used for troubleshooting for example to send a signal to an external device such as a PLC to verify the device is operating correctly To manually activate an output check the checkbox next to the ou
26. 5 Nm 133 5 deg Plot 4 211 Data Points Peak 20 06 Nm 123 1 deg Plot 5 231 Data Points Peak 20 10 Nm 130 1 deg Figure 30 Statistics Tightening Curves Menu Screen Element Description Select Spindle Use this drop box to select the spindle or powerhead whose tightening curves will display This drop box will not be present if your Insight is a one spindle model Select Config Use this drop box to select the tightening configuration whose curves will display The options include configuration 01 through 32 Select Plot Type Use this drop box to select the plot type Torque vs Angle Torque vs Time or Current vs Time Select Capture Type Use this drop box to select which fastening curves will be captured and displayed Options include Last Cycle Last Reject Next Cycle Next 2 Cycles to Next 5 Cycles Select Plot If you have multiple plots displayed on the screen use this drop box to select one for analysis The selected plot becomes a solid line distinguishing it from the other plots displayed Replace Plot Clicking this button replaces the plot selected in the Select Plot drop box with the next valid plot Load Master You may have tightening curves stored in memory that you want to use as a reference or master a curve against which you can compare other fastenings Pressing this button brings up a float box that allows you to select one of the s
27. A O DE CONFORMIDADE EL DHAQEH ANATNQPIZSH gt Supplier s Name Ingersoll Rand Address Hindley Green Wigan WN2 4EZ UK FR nom du fournisseur DE Name des Herstellers IT nome del fornitore ES nombre FR adresse DA adresse DE Adresse del proveedor NL naam leverancier DA naam leverancier SV leverant rens namn SV adress IT indirizzo NO adresse NO leverand rens navn FI Toimittajan nimi PT nome do fornecedor ES domicilio FI osoite NL adres EL voua mounOevth PT endere o EL dtevOuvon Declare under our sole responsibility that the product IC1G IC2G Insight Tightening System FR D clarons sous notre seule responsabilit que le produit DE Erkl ren hiermit gem unserer alleinigen Verantwortung da die Ger te IT Dichiariamo sotto la nostra unica responsabilit che il prodotto ES Declaramos que bajo nuestra responsabilidad exclusiva el producto NL Verklaren onder onze uitsluitende aansprakelijkheid dat het produkt DA Erkl rer som eneansvarlig at nedenst ende produkt SV Intygar h rmed i enlighet med v rt fullst ndiga ansvar att produkten NO Erkl rer som eneansvarlig at produktet FI Vakuutamme ja kannamme yksin t yden vastuun siit ett tuote PT Declaramos sob a nossa exclusiva responsabilidade que o produto EL DyxA voupe ott pe Bai Was eum To mgot v Model IC1G and IC2G FR Modele DE Modell IT Modello ES Modelo NL Mo
28. A data entry box for assigning a plant name or other plant identifier User entered Prevailing Angle Hi Prevailing Angle Hi Limit The maximum allowable angle of rotation for the prevailing torque phase of a Prevailing Torque fastening strategy User entered Prevailing Angle Lo Prevailing Angle Lo Limit The minimum acceptable angle of rotation for the prevailing torque phase of a Prevailing Torque fastening strategy User entered Prevailing Torque Hi Prevailing Torque Hi Limit The maximum permissible torque for the prevailing torque phase of a Prevailing Torque fastening strategy User entered Prevailing Torque Lo Prevailing Torque Lo Limit The minimum acceptable torque for the prevailing torque phase of a Prevailing Torque fastening strategy User entered Range The maximum value less the minimum value for a parameter System calculated Record EOR Data When checked data is recorded for this step in the configuration Rem Tool En Dis This parameter allows the tool to be remotely enabled and disabled through the I O connector options are Off 2 line En Dis 1 line En User entered MC Temperature Displays the temperature of the Motor Controller System calculated Page 74 Ingersoll Rand Company 2004 HD Assembly Solutions Appendix 1 System Parameters Shiftdown Point The point during the final stage of tightening at which the tool shif
29. Box Displays information or instructions for the screen element that is highlighted Select Spindle Use this drop box to select either Spindle 1 or Spindle 2 for testing This drop box will not be present if your Insight is a one spindle model Start Test This button initiates the system diagnostics test The test results are then displayed on the left hand side of the screen s main window Save Results This button stores the system diagnostics test results and displays them on the right hand side of the screen s main window Main Window When the user performs a systems test the results are displayed as a table on the left hand side of this window the side labeled NEW If there are test results already displayed there they are overwritten If the Save Results button is pressed the test results displayed on the left hand side of the window are moved to the right hand side and stored overwriting any stored test results previously displayed there Below is additional information on the specific test results displayed in this window Message Box The Message Box summarizes system status and provides warnings and alarms The following system test data displays in the main window For each data element the table shows the value measured during the test and whether that value is within allowable parameters PASS or FAIL Test Data Element Explanation TOOL Motor temperature Ch
30. Company 2004 Page 43 HR Assembly Solutions Section 4 Quality Control A variety of menu options allow you to monitor operations and the quality of the tightening operations as they occur or as historical data The following menus may be used to determine if operations are as required or if adjustments to programming must be made The Print Menus The Insight IC Fastening System with Graphics Display can print a large number of standard reports on fastening data statistics system settings and parameters and many other topics From within any of the controller s menus or sub menus the user can press the Print Main Menu key on the Insight front panel and a print menu displays The display is context sensitive That is Insight recognizes what menu it is in Run Statistics Setup or Diagnostics when the user presses the Print key and displays the appropriate report printing options While Insight offers many printed report options each one is self explanatory and it is not necessary to explain each print screen Simply use the arrow keys and the Enter key to navigate through and select the option you want Occasionally you may be asked to mark a checkbox use the Enter key to check or uncheck the box or enter a number in a data entry box use the numeric keypad Page 44 Ingersoll Rand Company 2004 aim Assembly Solutions Section 4 Quality Control The Run Menus The Run sub menus display fastening parameters and fast
31. Ingersoll Rand Company 2004 HD Assembly Solutions Appendix 1 System Parameters Cycle Each fastening is one cycle and is incremented by one to give it a unique number System calculated Cycle Measured Reading A data entry box for entering the measured torque when calibrating a spindle against an external torque transducer User entered Cycle Time The elapsed time for a fastening cycle System calculated Data Port The port for Insight s external communications User entered Date Data entry box to enter today s date User entered Date Format Data entry box to select the date format User entered Daylight Savings Drop box to allow the Insight to automatically adjust the time for the start and end of daylight savings User entered Direction Sets the forward direction the Insight spindle turns clockwise CW or counter clockwise CCW User entered Drag Torque Hi Limit Maximum permissible torque in the Drag Torque Zone of the drag torque fastening strategy User entered Drag Torque Lo Limit Minimum required torque in the Drag Torque Zone of the drag torque fastening strategy User entered EOR Filter The EOR End of Run Filter selects what parameters in addition to torque and angle will be recorded for each fastening User entered Excitation Voltage During self testing the Insight measures the spindle transducer s positive excitation vo
32. Installation the Insight controller and the shield should only be terminated at the controller end All inputs and outputs are activated received in the same way as discussed below Activating an Input All input signals operate at 24VDC The Return for the 24V signal must be connected to COM IN for each input bank It is recommended that you use the internal 24VDC located at the terminals marked 24VDC OUT Switch the 24VDC back to the desired input signal FORWARD REVERSE FREE SPEED etc To use the internal 24VDC you must connect a jumper wire from 24VDC OUT to COM IN of the input bank To activate an input you would then provide a contact closure between the desired inputs signals and 24VDC OUT You can daisy chain the COM IN signal to the next input terminal bank as shown in the Input Signal drawing USER SIGNALS OUTPUTS CONFIG1 CONFIG2 SP 1 DISABLE SP 1 ENABLE FREE SPEED SOFT START FORWARD wf e e SF e a i REVERSE MCE USER INTERFACE INPUTS CONFIGL CONFIG2 SP 1 DISABLE SP 1 ENABLE FREE SPEED SOFT START FORWARD SS e xs d d ss e REVERSE Figure 8 Input Signal Drawing Ingersoll Rand Company 2004 Page 13 Section 1 Installation am Assembly Solutions Receiving an Output All output signals operate at 24VDC The 24V signal and its return must be connected to the terminal blocks labeled 24VDC EXT on each output
33. Level 1 allows the least access to Insight s functions while Level 4 allows complete access The password levels have been designed to accommodate typical industrial job functions Those job functions and the factory set password default settings are shown in the table below Password Level Typical Job Functions SE Level 0 No password protection None Level 1 Operator Electrical or Mechanical Maintenance 1111 Level 2 Insight IC Programmer 2222 Level 3 Quality Control Engineer 3333 Level 4 Factory or Line Supervisor 4444 Ingersoll Rand Company 2004 Page 23 Section 1 Installation d Assembly Solutions If you do not wish to use any passwords that is allow all users access to every screen you must sign in at Level 4 and the set the Access Lockout Time drop box to OFF If a user attempts to access or change a screen to which he or she is not authorized a dialogue box will appear requesting the necessary password level To change a password the user must sign in on that particular level The table below shows the password level required to access the Insight IC Menu and Sub Menu screens Menu Sub Menu Password Level Required Run Main Tightening Curves Stats Summary Cycle Log View Parameters Statistics Summary Export Tightening Curves Cycle Log Stats Alarm Setup Quick Setup Advanced Setup System Initialization N NI N
34. N N olnI ninjlolniolojo E A BR AR BR to Spindle Initialization Password and Powerhead All passwords can change their value The Powerhead Function The powerhead function offers the user powerful control over tightening operations The first step in understanding this function is to understand the function s terminology A Powerhead is two spindles that both start with a common start signal and have a common configuration A Group is one or more spindles in a powerhead that have an identical number of fastening steps A Step is one fastening operation strategy such as torque control angle control etc A Configuration is a step or sequence of steps that define a distinct tightening operation For the Insight IC each spindle or powerhead can have up to 32 configurations A sync synchronization point is a parameter that can be set to require both spindles in a group to complete the step before starting the next step To perform various powerhead operations follow the steps below Assigning a Powerhead 1 Select On from the Powerhead Operation drop box 2 If desired enter a name in the Powerhead Name data entry box 3 Select the group number for each spindle To edit a powerhead follow the above steps changing the group numbers as desired Page 24 Ingersoll Rand Company 2004 HD Assembly Solutions Section 1 Installation Deleting a Powerhead 1 Select Off from the Powerhead Operation drop bo
35. PLANATION OF SYMBOLS USED Electrostatic Sensitive Devices Protective Conductor Terminal This symbol is to inform the user and Service personne to the Gg This symbol is to inform the user presence of electrostatic sensitive EE EE E devices ESD precautions should P 9 N t A be used when handling these presence of the protective ground devices or component damage point could result NOTICE The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards decreased tool performance and increased maintenance and may invalidate all warranties Repairs should be made only by authorized trained personnel Consult your nearest Ingersoll Rand Authorized Servicenter NOTICE SAVE THESE INSTRUCTIONS DO NOT DESTROY When the life of the Product has expired it is recommended that the product be disassembled degreased and the parts be separated by material so that they can be recycled Page viii Ingersoll Rand Company 2004 S1S1616161919191415 16 151416161619 19161915 1515161616 191916 1615 16 1516161616 1661616 1S 16161616 1e1e1 C DECLARATION OF CONFORMITY FR CERTIFICAT DE CONFORMIT DE KONFORMIT TSERKL RUNG IT DICHIARAZIONE DI CONFORMIT ES DECLARACI N DE CONFORMIDAD NL SCHRIFTELIJKE VERKLARING VAN CONFORMITEIT DA FABRIKATIONSERKL RING SV F RS KRAN OM VERENSST MMELSE NO KONFORMITETSERKL RING FI VAKUUTUS NORMIEN T YTT MISEST PT DECLAR
36. The Cycle Log table parameters are defined in Appendix 1 System Parameters Ingersoll Rand Company 2004 Page 49 Section 4 Quality HR Assembly Solutions Control View Parameters Screen This is a view only screen that displays a tabular summary of all of the parameters the user has set for all of the steps in a fastening configuration Below is a typical View Parameters screen RUN View Parameters Select Spindle UL Spindle 1g Programmed Steps Engage Step 07 20 2003 01 12 57 D Select Configuration NH Configi E Step Parameters Yield Override Enable High Angle Limit deg Low Angle Limit deg High Torque Limit Nm Low Torque Limit Nm Torque Threshold Nm Fogle Target deg Fogle Overshoot Compensation deg Torque Downshift Threshold Nm Free Speed RPM Torque Downshift Slope Interval RPM Yield Point of Peak Slope Fogle Into Yield deg Figure 26 Run View Parameters Menu Screen Element Description Select Spindle Use this drop box to select the spindle or powerhead whose parameters will display This drop box will not be present if your Insight is a one spindle model Select Configuration Use this drop box to select the tightening configuration by number and name whose parameters will display Programmed Steps Use this drop box to display all of the steps programmed for the spindle and configuration selected Step P
37. The top window in the front panel displays torque and angle information for each tightening operation See the Status Display callout in Figure 1 in the Introduction chapter Screen Element Description SPINDLE The Spindle 1 or Spindle 2 light will illuminate white indicating power is being applied to that spindle PASS The green PASS LED will light if the tightening met all of the programmed specifications and requirements Torque 7 Lights red if the torque exceeded the specified upper limit Torque 4 Lights yellow if the torque was less than the specified minimum value Angle Lights red if the angle exceeded the specified upper limit Angle J Lights yellow if the angle was less than the specified minimum value STATS ALARM Lights if the statistical parameters are outside the user entered limits If red or yellow lights come on stop operating the equipment until the problem can be resolved as a fault has occurred or follow the guidelines established for your department Each Ingersoll Rand hand held spindle also has an indicating light on the tool itself that mimics the Status Lights If the fastening is within specification the tool light will be green If either the torque or angle value is too high the tool light will be red if either value is too low the tool light will be yellow See the Menu Navigation section of the Introduction chapter for an image of the Status Display Ingersoll Rand
38. a bar code scanner connected to the COM Port When you select this option a button labeled Bar Code Settings appears on the lower right corner of the screen Bar Code use is fully explained in the following section Bar Code Description The bar code function allows the Insight IC controller to be connected to any serial ASCII bar code scanner Each spindle can be equipped with its own scanner or in the case of a powerhead one scanner can be assigned to the powerhead The bar code function has two main operating modes Passive Bar Code mode In this mode bar code data is attached to EOR data and stored in the cycle log but configurations are not selected via the bar code scan data Active Bar Code mode In this mode configurations are selected via the bar code scan data The scan data is also attached to the EOR data Bar Code in Passive Mode Bar Code Setup for Passive Mode To setup the controller for passive bar code operation follow the directions below 1 Goto the Setup System Initialization screen 2 Goto the Data Port drop box and select the communications port to which the bar code scanner will be connected 3 Set the Baud Rate Parity of Data Bits and of Stop Bits to the same values as setup for your bar code scanner 4 Goto the Comm Protocol drop box and select Barcode SP1 for spindle 1 or Barcode SP2 for spindle 2 5 Navigate to the Barcode Setup button and press ENTER NOTE If this is the first time you have
39. able 2 LA A LA Free Speed 2 l 5 4 l 5 Soft Start 2 l 6 4 l 6 Forward 2 l 7 4 l 7 Reverse 2 l 8 4 l 8 Outputs Insight IC Base System Spindle 1 Spindle 2 Inputs Block Pin Block Pin Accept 1 O 1 3 O 1 Reject 1 O 2 3 O 2 Cycle Complete 1 O 3 3 O 3 High Torque 1 0 4 3 0 4 Low Torque 1 O 5 3 O 5 High Angle 1 0 6 3 0 6 Low Angle 1 O 7 3 O 7 Programmable 1 0 8 3 0 8 Page 78 Ingersoll Rand Company 2004 aim Assembly Solutions Appendix 2 System Specs and Spare Parts Insight IC one or two spindle system with one optional UO board per spindle Below are the pinout tables for an Insight IC one or two spindle expanded system with one optional I O board per spindle Inputs Insight IC Expanded System Spindle 1 Spindle 2 Inputs Block Pin Block Pin Configuration 1 2 l 1 4 l 1 Configuration 2 2 l 2 4 l 2 Configuration 3 2 l 3 4 l 3 Configuration 4 2 l 4 4 l 4 Configuration 5 2 l 5 4 l 5 Configuration 6 2 l 6 4 l 6 Configuration 7 2 l 7 4 l 7 Configuration 8 2 l 8 4 l 8 Spindle n Enable 6 l 1 10 l 1 Spindle n Disable 6 l 2 10 l 2 Gang Reset 6 l 3 10 l 3 Config Reset 6 l 4 10 LA Safety Latch 6 l 5 10 l 5 Limit Switch In 6 l 6 10 l 6 Limit Switch Out 6 l 7 10 l 7 Bypass Spindle 6 l 8 10 l 8 Free Speed 8 l 1 12 l 1 Soft Start 8 l 2 12 l 2 Forward 8 l 3 12 l 3 Reverse 8 LA 12 4 Reset Outputs 8 l 5 12 l 5 Not Availa
40. ails of the terminal block numbers 2 Attach a tool to the Insight controller and turn the controller on using the rotary switch 3 Push the green Start button on the Spindle Power Switch on the front panel to power the Motor Controller and the tool Go to the Setup menu and the Spindle Initialization sub menu screen 5 If your socket tray has more than eight positions select External Binary from the Config Select drop box If your socket tray has eight or less positions select External Discrete from the Config Select drop box How to Test a Socket Tray 1 After you have connected and setup the device go to the Diagnostics menu and the Discrete Inputs sub menu screen 2 As you lift each socket you should see the appropriate indicator light up on the screen indicating activity on the configuration lines Note If you selected External Binary in the Config Select drop box on the Setup menu s Spindle Initialization screen then the first four configuration lines will indicate the binary encoded number for the configuration selection with 0000 indicating configuration 1 is selected Page 10 Ingersoll Rand Company 2004 HD Assembly Solutions Section 1 Installation External Configuration Switch Connection and Setup d Connect the configuration switch to the Insight controller s terminal blocks with the appropriate accessory cable See Appendix 3 Communication Protocols on page 86 for details on terminal block f
41. al 14 1002266 Label ESD High Voltage Illustrations with detail numbers are shown on the following pages Page 82 Ingersoll Rand Company 2004 am Assembly Solutions Appendix 2 System Specs and Spare Parts Inside the Panel Ingersoll Rand Company 2004 Page 83 Appendix 2 System Specs and Spare Parts dm Assembly Solutions Inside the Main Door Page 84 Ingersoll Rand Company 2004 di Assembly Solutions Appendix 2 System Specs and Spare Parts Right Side Ingersoll Rand Company 2004 Page 85 HR Assembly Solutions Appendix 3 Communication Protocols Overview of Host Data Out The Host Data Out is one of the features for the Insight IC The user can request the EOR after each cycle from the Insight IC This host data out can be directed to any one of the comport COM1 COM4 The detailed set up and its applications are explained below Setup Procedure The user should follow the following step by step procedure in order to setup the host data out protocol 1 Select the COM1 COM4 in the Data Port dropdown box of the System Initialization Screen Set the Baud Rate in the System Initialization Screen For Example 115200 Set the Parity Bit Select None for default option Set the Bits per Character Usually it should be 8 a Se Ps Select the Host Data Out in the Comm Protocol drop down box of the System Initialization Screen Assign the Multi Drop Add
42. and Company 2004 HD Assembly Solutions Section 1 Installation code section YYY are called the criteria Different criteria values will instruct the controller to switch to different configurations see steps 9 and 10 below 8 Select the first configuration to set criteria from the configuration selection drop box 9 Navigate to the top criteria box and press the Expand key Use the numeric keypad to enter in the criteria value Note the keypad will be in alphanumeric mode so once the desired character is on screen press the right arrow key to move to the next character position When all characters have been entered press the ENTER key The numbers of characters entered into each criteria entry box must match exactly the number of characters specified in the Data From and To entry boxes 10 Repeat steps 9 and 10 until all criteria for all configurations have been entered 11 Navigate to the OK button and press ENTER Other Bar Code Operations Disable Tool Until Scan Option In the Bar code settings screen there is a check box labeled Disable tool until scan When checked the tool will initially be disabled until a valid scan is received Once enabled the tool will run until either one good cycle is received or until a gang if programmed is complete The tool will then be disabled until another valid scan is received Changing from Active to Passive Bar Code Mode To change from active to passive mode go to the bar co
43. arameters This display box shows all the parameters and their values for the step selected in the Programmed Steps drop box Message Box The Message Box summarizes system status and provides warnings and alarms Note that the View Parameters main window consists of two display boxes The user can enter the Programmed Steps drop box by 1 Navigating to it with the arrow keys 2 Pressing the Expand key Page 50 Ingersoll Rand Company 2004 aim Assembly Solutions Section 4 Quality Control 3 Selecting a fastening step by using the arrow keys to scroll through the table until the desired step is highlighted 4 Press Enter The parameters and their values for the fastening step selected are then shown in the Step Parameters display box on the right side of the main window Definitions for the listed parameters in the View Parameters and Step Parameters screens are provided in Appendix 1 System Parameters The Statistics Menus The Statistics menu displays a variety of statistical data on completed fastenings The user can view actual fastening parameters as well as statistical measurements and can compare them to desired target values Individual tightening curves can be displayed and overlaid for comparison The user can set alarm values to alert the operator to fastenings that do not meet the required statistical parameters Finally cycle data is exportable to PCs or other devices for additional analy
44. atch Limit Switch In Limit Switch Out Bypass Spindle Control Outputs Accept Reject Reject Buzzer Gang Complete Cycle Complete High Torque High Angle Low Torque Low Angle In Cycle Statistics Alarm Spindle in Bypass Paint Marker Powerhead Accept Powerhead Reject Powerhead Cycle Complete Powerhead In Cycle Powerhead Paint Marker Indicators High intensity LED indicators for Torque High Torque Low Angle High Angle Low and OK Incandescent lamps for Spindle Power and Statistics Alarm Optional Devices PCMCIA Flash Card Floppy Drive Devicenet Card Profibus Card Additional I O card s Input Voltage Single Phase 120 Volts 50 60 Hz 20 Amp Single Phase 230 Volts 50 60 Hz 10 Amp Ambient Operating Conditions 0 50 C 20 90 non condensing humidity Enclosure NEMA 12 type System Weight 60 pounds 27kg 70 pounds 32 kg Ingersoll Rand Company 2004 Page 77 Appendix 2 System Specs and Spare Parts d Assembly Solutions Pinout Tables Insight IC one or two spindle system with no optional I O boards Below is the Pinout for an Insight IC one or two spindle system with no optional I O boards Inputs Insight IC Base System Spindle 1 Spindle 2 Inputs Block Pin Block Pin Configuration 1 2 l 1 4 l 1 Configuration 2 2 l 2 4 l 2 Spindle n Disable 2 l 3 4 l 3 Spindle n En
45. ation Screen Layout 5 Output Receiving cccceeeeeeeeeeeeeeeeetcteeeeeeeeees 14 Outputs Green 63 P Paint Marker 63 Etgen eene ee ve 83 Parallel Printer cccccccccsssseceeeeaseseseeeeeseaeees 12 Parameter Transler 25 Parameters Gcreen 50 Parameters System c ceseeceeeeeeeeeeeeeeeeees 71 Passive Mode Bar Code 17 Password and Powerhead Settings Screen 23 Ingersoll Rand Company 2004 Index Password Function sssssssesseesernnrensseesererrrrr renn 23 Password Level 23 Password Settings cccccceeeeeeeeeeeesenteeeeeeeeaas 23 Peak cut in toroue nenn 40 Peripheral Devices Attaching 0 0c 10 Pinout Tables isian 78 80 PLC Connection and Geiup 12 Powerhsad sneinen iae a 9 20 Assioning ee 24 Deleting cecicciesstiieiaeeceeestavecenectiaeeceneesieeeenectenet 25 Edting ia iaanianienas 24 FUN Le ME 24 Programming Spindles cece 30 Specific Operations and Functions 33 Fault Action 34 Fault Backout Ange 33 Fault Backout Speed ninsseseeeeeeeeeenne 33 Final Fault Backout Ange 34 General Final Fault Backout Eu CL KEE 34 General Retry Fault Backout wee VE 33 Number of HReirtes eee 34 Retry Fault Action cceeeeereeeeeeees 34 Powerhead Geitngs nnn 23 Prevailing ZOMGC cccccceesccceeeeeecccceeeseeaeeeeeeneenee 39 Preventative Maintenance Alarms Screen 23 EMS arn a ageet 2 44 Printer
46. barcode function to be used with a powerhead the powerhead must be created first Once the powerhead has been created set up bar code operation for spindle number 1 in the powerhead This will assign barcode operation to all the spindles in the powerhead The scan data will be added to all spindles in the powerhead Field Bus A bar code scan can be added to tightening data on a Device Net or Profibus equipped Insight IC In the field bus settings screen the user must specify where the scan data will come from The user has options to send the scan data to the controller via the field bus or via a serial port on the controller through a regular scanner With field bus equipped controller the bar code always functions in the Passive mode i e no configuration selection via bar code and the Disable tool until scan option is not functional This is because the field bus has control of the configuration selection and enable disable tool functions The Spindle Initialization Screen You will use this screen to identify which Ingersoll Rand spindles tools are attached to the Insight controller and to set certain basic spindle operating parameters such as torque units start mode tubenut and so on This screen also has an Auto Calibration button for calibrating the spindles against an external transducer Tool calibration information and preventative maintenance alarms can be entered into the tools internal memory Below is the Spindle Setup sc
47. be sent in the unit of torque selected on the Spindle Initialization Screen at the time of the request e If there is no data available in the buffer for the requested spindle and configuration then the controller shall respond with the following message indicating no data AASSCC lt CR gt lt LF gt Where AA is the address number of the controller SS is the spindle number whose buffer is empty CC is the configuration number whose buffer is empty lt CR gt is a carriage return lt LF gt is a line feed e The following format of ACK message is sent from the host to the Insight IC once the data has been received and verified AASSCC lt ACK gt Where AA is the address number of the controller SS is the spindle number whose data is being acknowledged CC is the configuration number whose data is being acknowledged lt ACK gt is an ASCII acknowledge s The following format of Config Buffer Clear message can be sent by host at any time to clear the buffer for a given spindle and configuration AASSCC01 lt CR gt lt LF gt Where AA is the address number of the controller SS is the spindle number whose data should be cleared CC is the configuration number whose data should be cleared Ingersoll Rand Company 2004 Page 89 Appendix 3 Communication Protocols d Assembly Solutions 01 is the config buffer clear command lt CR gt is a carriage return lt LF gt is a line feed Upon receiving this message the co
48. bel UO Configuration C PC80137524 Door assembly 1 Spindle PC80137540 Door assembly 2 Spindle PC80124035 Display Color 10 4 LCD PC89944383 Inverter LCD Backlight 6 PC89944391 PCB Assembly RISC Processor 11 PC89944409 PCB Assembly 5V Power Supply 9 PC89944417 Power Supply 12V DC 60W PC89944425 PCB Assembly I O 5 PC89944433 PCB Assembly Cycle Status 4 PC80117955 Motor Controller Assembly 1 PC89944565 Connector Terminal Block 10 Pin PC89944573 Power Supply 24V DC 100W 2 PC80123664 GFI PC80123672 Circuit Breaker 3 PC89944599 Floppy Drive Kit PC89944672 Cord Power 120V 20A 12 PC89944680 Battery Processor PC89944748 Shipping Carton PC89945331 Label Operation Manual CD ROM PC89945349 Label ICS Utility CD ROM PC89945455 Cover Safety 7 PC89945497 ProfiBus Kit 8 PC89945505 DeviceNet Kit 10 PC89946669 Flash Memory PCMCIA Card Ingersoll Rand Company 2004 Page 81 Appendix 2 System Specs and Spare Parts HR Assembly Solutions Detail Number Part Number Description PC89947642 Option Standard I O PC89947659 Option Single I O Board PC89947667 Option 2 I O Boards PC89947675 Option No Floppy Drive PC89947683 Floppy Drive PC89947691 Option Standard Communications PC89947840 Interface Card ProfiBus PC89947857 Interface Card DeviceNet PC89947865 Cord Power 230V 16A Pigtail PC80115793 240V US power cord 13 PC80090269 Label Warning Read Manu
49. ble 8 l 6 12 l 6 Not Available 8 l 7 12 l 7 Not Available 8 l 8 12 l 8 Ingersoll Rand Company 2004 Page 79 Appendix 2 System Specs and Spare Parts HR Assembly Solutions Outputs Insight IC Expanded System Spindle 1 Spindle 2 Outputs Block Pin Block Pin Accept 1 O 1 3 O 1 Reject Buzzer 1 O 2 3 O 2 High Torque 1 0 3 3 0 3 High Angle 1 0 4 3 0 4 Low Torque 1 O 5 3 O 5 Low Angle 1 0 6 3 0 6 Gang Complete 1 O 7 3 O 7 Cycle Complete 1 O 8 3 O 8 Reject 5 O 1 9 O 1 Stats Alarm 5 O 2 9 O 2 Programmable 5 O 3 9 O 3 Programmable 5 0 4 9 0 4 Programmable 5 O 5 9 O 5 Programmable 5 O 6 9 0 6 Programmable 5 O 7 9 O 7 Programmable 5 O 8 9 0 8 Programmable 7 O 1 11 O 1 Programmable 7 O 2 11 O 2 Programmable 7 O 3 11 O 3 Programmable 7 0 4 11 O 4 Programmable 7 O 5 11 0 5 Programmable 7 0 6 11 0 6 Programmable 7 O 7 11 O 7 Programmable 7 O 8 11 0 8 Page 80 Ingersoll Rand Company 2004 HD Assembly Solutions Recommended Spare Parts List See the illustrations following the Parts List Appendix 2 System Specs and Spare Parts Detail Number Part Number Description PC80114390 Insight Operations Manual CD ROM PC89944326 Label UO Configuration A PC89944334 Label I O Configuration B PC89944342 La
50. color as shown in the table together with the MAINS LIAL HEUG Mark on the Matchin matching terminal plug When connecting the mains lead to a Conductor Color 8 plug be sure to connect each conductor to the correct terminal as Terminal indicated Live Brown Red or letter L Neutral Blue Black or letter N Green Green Yellow Grounding Green Yellow Leute G or symbol L CAUTION 5 Do not allow chemicals such as acetone benzene Keep the exterior of the unit clean and dry thinner ketone trichloroethylene to come in contact with the housing as damage will result Ingersoll Rand Company 2004 Page vii Precautionary Information HR Assembly Solutions WARNING SYMBOL IDENTIFICATION A WARNING A WARNING This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death This symbol is to alert the user and service personnel to the presence of uninsulated dangerous voltage that will cause a risk of electrical shock A WARNING Read this manual before operating the tool AGENCY SYMBOL IDENTIFICATION European Community Mark Underwriters Laboratory Mark CE Indicates compliance with relevant EC directives NA US Indicates compliance with both Canadian and U S requirements EX
51. connector bank It is recommended that you use an external 24VDC supply The output signals will be switched back to you from the appropriate output signal ACCEPT REJECT HIGH TORQUE etc See the Output Signal drawing You can daisy chain the 24VDC to the next output bank USER SIGNAL Gene ACCEPT L x 2 REJECT en mmx tW CYCLE COMP n CAN t ER TORQUE CN ze HIGH ANGLE La Ze LOW ANGLE Ly rmx lt t RESERVE S Lx Figure 9 Output Signal Drawing Ethernet Connection See Appendix 3 Communication Protocols on page 86 for further information Page 14 Ingersoll Rand Company 2004 HD Assembly Solutions Section 1 Installation Field Bus Card Connection The Insight IC can connect to a field bus network using either a Profibus card or a Devicenet card Make sure one of these field bus cards is installed in your system Initial Startup Before starting the Insight IC Fastening System with Graphics Display for the first time you must go through the following checklist and verify that all of the steps have been completed If in doubt about any aspect of this checklist contact Ingersoll Rand LI LI LI LI The Insight controller enclosure is vertical level and securely mounted For every spindle location that will be used there is a spindle attached to that location in the connector panel located on the controller s right side and each
52. d on the tools internal memory chip Data stored on this chip includes model number serial number calibration values assembly date number of cycle runs etc Page 26 Ingersoll Rand Company 2004 UD Assembly Solutions Section 2 Programming The Setup Menus The Setup menu and sub menus are used to program tightening strategies and to seta broad variety of important system parameters Both basic tightening strategies as well as advanced customized strategies are created in the Setup menu In addition to strategies you can use the Setup menu to set many basic system parameters such as date and time display language measurement units and communications protocols The Setup menu is also used to create passwords for controlling access to Insight s software and data records Prerequisites for All Setup Techniques LJ You must know how to use the directional keys the Expand key and the ENTER key to navigate on the screen open a drop box and select a parameter LJ You must know how to use the numeric keypad to enter data Setup Quick Setup Be operational in minutes This menu screen is used to get you up and running quickly Many simple fastening operations can be set up from this screen These include single step torque control angle control or yield control fastening strategies Only basic fastening parameters are displayed with this screen If a more complex multi step strategy is needed or to get access to all possible
53. d to enter a value Press either Enter key to place that value in the data entry box Check Box Navigate to a check box using the arrow keys Press either Enter key to check or uncheck the box Display Box Display boxes may contain view only or editable information Navigate to the display box with the arrow keys and press Expand to enter the box Use the arrow keys to scroll up down and left right Press Expand again to move the cursor out of the display box Ingersoll Rand Company 2004 Page 7 HR Assembly Solutions Section 1 Installation Mounting Bolt the Insight controller enclosure to a suitable surface near the assembly area using the mounting brackets on the back of the enclosure See the drawings below for dimensions information on bracket hole spacing recommended mounting bolts door opening clearances and other mounting information Make sure the mounting is stable secure and level Attach the Insight enclosure to a structure capable of safely supporting its total weight Failure to follow installation instructions properly can result in structure collapse and personal injury Leave at least 6 150mm room for cables that attach to the right side of the cabinet 208 ee INSIGHT IC AagaaaaA iz AE DBE Figure 6 Front Dimensional Drawing I
54. de settings screen and press ENTER on the De Assign All button Changing from Passive to Active Bar Code Mode To change from passive to active mode go to the bar code settings screen and enter a range in the Use Data From and To entry boxes Then enter your criteria for each configuration Removing Bar Code Operation To remove bar code operation from a spindle first go to the System Initialization screen Then select the com port number that the bar code is connected to from the Data Port drop box Go to the drop box labeled Comm Protocol and select none Bar Code Compatibility With Other Functions Gang Count Bar code operation will function fully with gang count The scan data will be attached to all cycles in the gang count If Disable tool until scan is selected the tool will be disabled once the gang is complete If a gang count needs to be reset this must be performed through the UO or the Run Main screen A re scan of a part will not reset the gang count Ingersoll Rand Company 2004 Page 19 Section 1 Installation am Assembly Solutions Auto Increment Auto increment operation will not function when Disable tool until scan has been selected In all other cases both bar code and auto increment will operate together One bar code scan will allow all configurations in auto increment to operate when in active mode The scan should be set up to select the first configuration in the auto increment chain Powerhead For the
55. del DA Model SV Modell NO Modell FI Mallia PT Modelo EL MONTEAA To which this declaration relates is in compliance with provisions of Directive s 98 37 EC 92 31 EEC 89 336 EEC and 73 23 EEC FR objet de ce certificat est conforme aux prescriptions des Directives DE auf die sich diese Erkl rung bezieht den Richtlinien IT a cui si riferisce la presente dichiarazione conforme alle normative delle direttive ES a los que se refiere la presente declaraci n cumplen con todo lo establecido en las directivas NL waarop deze verklaring betrekking heeft overeenkomt met de bepalingen van directieven DA som denne erkl ring vedr rer overholder bestemmelserne i f lgende direktiver SV som detta intyg avser uppfyller kraven i Direktiven NO som denne erkl ringen gjelder for oppfyller bestemmelsene i EU direktivene FD johon t m vakuutus viittaa t ytt direktiiveiss PT ao qual se refere a presente declara o esta de acordo com as prescri es das Directivas EL ta oroia apog avt n Bidon civar o upova ue tis MEOPAEWEts twv Evtodov By using the following Principle Standards EN60335 1 EN55011 A EN610000 3 2 EN610000 3 3 EN61000 6 2 EN60204 FR en observant les normes de principe suivantes DE unter Anlehnung an die folgenden Grundnormen entsprechen IT secondo i seguenti standard ES conforme a los siguientes estandares NL overeenkomstig de volgende hoofdstandaards DA ved
56. displayed pressing the right arrow key places that character and moves the cursor to the next data entry space within that box If you want to enter a space simply press the right arrow key a second time If you make a mistake press the backspace key to delete the character When the correct character string is displayed press either Enter key to enter that value Page 4 Ingersoll Rand Company 2004 HD Assembly Solutions Introduction Orientation Screen Layout The Graphics Display Screen has six distinct sections or regions as shown in the graphic below SETUP System Initialization 07 20 2003 01 32 18 Enter a name for this system This will appear at the top of printed reports System Name IR INSIGHT Date Time Communications Data Port Comm tb Baud Rate 115200 S Plant Name sg Language English e Date Format Spring Forward Date MM DD YY IW Daylight Savings Fall Back Date Disabled __ Parity Bits Per Character Comm Protocol of Stop Bits Multi Drop Address A Figure 4 Graphics Display Screen Screen Element Description Header The Header shows the Insight s current menu and sub menu the date and the time and whether the system is locked or unlocked the padlock icon If the system is unlocked the password level to which the system is unlocked there are four levels is also shown Wizard Box The Wizard Box located under the header displays short desc
57. down through the parameter list You must enter values or accept the default values for the Required Parameters As appropriate you may also enter values or accept the default values for the Optional parameters 6 Goto the Step 1 Strategy drop box and select Prevailing Torque 7 Goto the list of parameters just below the Step 1 Strategy drop box and navigate down through the parameter list You must enter values or accept the default values for the Required Parameters As appropriate you may also enter values or accept the default values for the Optional Parameters 8 You must now program a torque or angle step after the prevailing torque step Ingersoll Rand Company 2004 Page 39 Section 2 Programming am Assembly Solutions How to Program a Drag Torque Control Strategy in Advanced Setup Description Drag torque is the torque required to overcome the inherent friction or pressure force resistance in the movement of an assembly or mechanical component through some predetermined angle This technique is often used as a quality inspection procedure A typical application is the measurement of engine crankshaft turning torque in the automotive industry In this application there is usually an initial high inertial peak cut in torque to get the crankshaft moving and while this value can be measured over the cut in zone it is actually the dynamic torque following this initial torque spike that is the parameter usually required
58. e Select Spindle Speed Spindle I l E Lamp Test On Off Torque Angle Degrees Current Amp Figure 37 Diagnostics Tool Test Menu Page 66 Ingersoll Rand Company 2004 aim Assembly Solutions Section 5 Diagnostics and Troubleshooting Shutdown Codes At the end of every cycle the Insight IC logs a shutdown code to the cycle that indicates under what circumstances the tool stopped This shutdown code can be viewed in the cycle log Below is a list of the Shutdown Codes Shutdown Description Code 0 Normal Completion of Cycle 1 Trigger released before system shutdown 2 Tool stop on torque high 3 Tool stop of angle high 4 Tool stop on yield override 5 Prevailing torque seating torque fail 6 Prevailing torque seating angle fail 7 Prevailing torque too high next step target prevailing gt next step limit 8 Prevailing torque sync shutdown forced shutdown because sync flag was set 9 Min drag torque fail 10 Motor stalled 12t limit reached 11 Hall transition error Hall fault 12 Motor controller IGBT driver fault bootstrap cap under voltage or IGBT short 13 Over current detected by software current loop 14 Low bus voltage 15 Cycle timeout cycle timeout time reached before end of cycle 16 Display processor issued a STOP command to Motor controller 17 Tool was disconnected 18 Communication was lost unable to send EOR or o
59. e parameters Procedure 1 Press the Setup Main Menu key and then the Advanced Setup Sub Menu key 2 In the Select Spindle drop box select the spindle you want to program 3 In the Config drop box select the configuration you want to program 4 Go to the Engage step drop box and select Engage If the Engage parameter default values are acceptable you can skip to step 6 5 Go to the list of parameters just below the Engage step drop box and navigate down through the parameter list You must enter values or accept the default values for the Required Parameters As appropriate you may also enter values or accept the default values for the Optional Parameters Go to the Step 1 Strategy drop box and select Torque 7 Goto the list of parameters just below the Step 1 Strategy drop box and navigate down through the parameter list You must enter values or accept the default values for the Required Parameters As appropriate you may also enter values or accept the default values for the Optional Parameters 8 If you want to program additional tightening steps repeat Steps 6 and 7 as appropriate for the desired step How to Program an Angle Control Strategy in Advanced Setup The Angle Control Strategy is based on a programmed angle of rotation after the torque threshold is reached For any of the Step n drop boxes if Angle Control is selected as the strategy its parameters are displayed See Appendix 1 System Paramet
60. e Compatibility With Other Functions ec cee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 19 Ee 0 E 19 PUT IER Sege 20 Powerhead WE 20 Field BUS ee 20 The Spindle Initialization Screen jcsscccvessssnccccacearsesscesecatosseenestsaacsanscecsatssasdsescetes 20 Reset TR and ASC EE 21 Prog Tool SWItCN EE 21 Auto e a 21 Preventative Maintenance Alarms Gcreen rnn nn 23 Password and Powerhead Settings Green 23 The Password RN ner e EE 23 The Powerhead e E 24 Assigning a VVC N A ese acoso accede seo at atest eee eect 24 Deleting a Powerhead sec shacccaicit occctscecetalactdtetonieMiadiaunieee tocol ties 25 Parameter Transfer geen e 25 Ors t 1s 1 10 002 ereire nee er ert e me ren eee per ery a eee eee eee or 26 Section 2 Programming BEE 27 The Setup MenUS suse asseaireexscevesauccSsourbavacauseagasiinsnsics vocniniacanseutsecpseassadcauasaneeereepiens 27 Prerequisites for All Setup Technoues ee 27 Page ii Ingersoll Rand Company 2004 HD Assembly Solutions PS UN aes leeds ca ected ated as E E E EER E 27 Quick Setup Be operational in minutes nnssnseeeeeeseeerenrnnnr nnne ntt nnrnennnenenn nnn 27 Programming Tightening Strategies in Quick Setup 28 How to Program a Torque Control Strategy in Quick Setup 28 How to Program an Angle Control Strategy in Quick Setup cccceeeeeee 29 How to Program a Yield Control Strategy in Quick Setup 29 Advanced SS MAD EE 29 Introduction to Advanced Setup ME 29 Advanced Setu
61. e Result Angle 07 20 2003 01 36 46 Pass 0 15 Pass 07 20 2003 01 36 39 Pass 16 Pass 07 20 2003 01 36 38 Pass 12 Pass 07 20 2003 01 20 56 Pass 24 Pass 07 20 2003 01 20 53 Pass 19 Pass 07 20 2003 01 20 51 Pass 19 Pass 07 20 2003 01 20 40 Pass 19 Pass 07 20 2003 01 07 28 Pass O16 Pass 07 20 2003 01 07 28 Pass 0 08 Pass 07 20 2003 01 07 27 Pass Pass 07 20 2003 01 07 26 Pass i Pass Figure 25 Run Cycle Log Menu Screen Element Description Select Spindle Use this drop box to select the spindle or powerhead for which the cycle log data will display This drop box will not be present if your Insight is a one spindle model Clear Cycle Data This button will clear the cycle log data table for the displayed spindle Reset Cycle Number This button will reset the cycle log number back to 1 for the displayed spindle Main Window This window displays the cycle log summary table Additional information on the parameters displayed is described below Message Box The Message Box summarizes system status and provides warnings and alarms Note that the Cycle Log main window is a display box You can enter this box to scroll through the table by first navigating to the Cycle Log main window with the arrow keys Then press the Expand key to activate the scroll function and use the arrow keys to scroll through the table
62. ecks motor temperature and reports PASS or FAIL Amplifier offset MC s offset voltage as of Shunt Cal voltage Shunt calibration Front end electronics gain as of ideal Shunt Cal voltage Sine Offset The offset in A D counts of the resolver sine analog input signal used for angle measurement Cosine Offset The offset in A D counts of the resolver cosine analog input signal used for angle measurement Motor Kt The peak torque divided by peak current in the units of Nm Amp Motor Controller MC temperature Displays MC s internal temperature Note that the System Test window is a display box The user can enter this box simply by navigating to the window with the arrow keys and using the arrow keys to scroll through the table As the user scrolls through the System Test parameters information on each parameter displays in the wizard box This includes an explanation of the parameter the expected range if applicable and guidance on what to do if the parameter test failed Ingersoll Rand Company 2004 Page 61 Section 5 Diagnostics and Troubleshooting d Assembly Solutions Discrete Inputs Screen On the left side panel of the Insight controller are Spindle I O Input Output connectors With this screen the user can run a test to determine whether any of the required input signals are absent Below is a typical Discrete Input Test screen graphic DIAGNOSTICS 1
63. ed Insight Reading When the reading appears type the peak torque as measured by your external torque transducer in the box labeled Measured Reading and press the Enter key After the enter key has been pressed the Insight system will collect another peak torque reading NOTE All torque values entered should be in the units indicated on the screen Status Waiting for next cycle Torque Units Nm Cycle 375 Measured Reading Remove Last Reading Measured Heading Insight Heading Hun Figure 13 The Second Auto Calibration Screen Follow the instructions in the wizard box to capture each calibration reading The Status box will remind you where you are in the calibration cycle Use the Insight s numeric keypad to enter the calibration readings in the Cycle Measured Reading box When you have entered readings for the correct number of cycles the Continue button will become active Pressing the Continue button will bring up the final auto calibration screen as shown below Auto Calibration Calibration Results Currently Programmed TR Yalue 75 00 Accuracy of Current TR Yalue 90 67 Recommended New TR Yalue 68 00 Accept New TR Value Retain Current TR Value Figure 14 The Third Auto Calibration Screen This third screen displays the calibration results You can either accept or reject the new calibration factor If you reject it the existing Transducer Range value is retained After making the selectio
64. egy In this mode the Insight re tightens the fastener to the same torque value until either the angle on the retorque tightening is less or equal to the Retorque angle programmed or ten attempts have been made Ingersoll Rand Company 2004 Page 41 HR Assembly Solutions Section 3 Operating the System Operating the System This section provides the information that will be needed for the assembly technician At this point the system should have been properly installed and sets of configurations already defined and programmed into the system Selecting the Configuration See the chapter on Menu Navigation in the Introduction chapter for instructions on moving through menu screens 07 20 2003 00 55 08 Select Spindle 3 Spindie1__Spinde2___FFF F F_ _ _ _ _ ______i OTEA Configi Tel Oe O O Angle Control Failed At Engage Step Step 0 Engage Step Vari I vol TTT Varz A o Figure 21 Run Main Menu The Main screen from the Run menu allows you to select the configuration to run for each of the two spindles For each spindle 1 From the Select Spindle pulldown menu select the spindle to which you will apply a configuration 2 From the Config pulldown menu select the configuration to apply to the selected spindle 3 Perform steps 1 and 2 for both spindles Page 42 Ingersoll Rand Company 2004 aim Assembly Solutions Section 3 Operating the System Monitoring Operation
65. embly Solutions Exit Selecting this button will return the user to the screen displayed when the Help key was pressed Page 70 Ingersoll Rand Company 2004 UD Assembly Solutions Appendix 1 System Parameters Definitions of System Parameters Below is a complete alphabetical list of all the parameters used by the Insight IC Fastening System with Graphics Display for Sigma The number of fastenings used to calculate sigma System calculated Hi Rejects The number of fastenings rejected because the target parameter s final value exceeded the acceptable maximum value System calculated Lo Rejects The number of fastenings rejected because the target parameter s final value did not reach the acceptable minimum value System calculated of Stop Bits The number of stop bits sent in the communications string when Insight communicates with a serial external device User entered Rejects Number and of fastenings that did not meet the tightening limits System calculated Rejects Hi Lo The number of fastenings that were rejected because they exceeded were under the tightening limits System calculated OK The number of fastenings that met the tightening parameters System calculated 6 Sigma Six times the value of sigma o System calculated See Sigma in Parameters listing A D Reference Voltage A voltage measurement used to test the Motor Controll
66. endix 1 System Parameters HD Assembly Solutions Motor Temperature The Insight spindle s motor temperature System calculated Motor Test The spindle motor s Kt value Peak Torque Peak Motor Current System calculated Multi Drop Address The address number for the network port s host Data Out protocol User entered Parity Sets the communications port parity User entered Password A button and a data entry box to enter a previously stored password to gain access to Insight s functions User entered Password Logout A button and a confirmation box to log out of the password screen and relock the Insight system User entered Peak Current The maximum current the tool drew during the fastening cycle System calculated Peak Cut In Torque The maximum torque measured during the cut in phase the initial high torque phase of the prevailing torque and drag torque strategies System calculated Peak Drag Torque The maximum torque measured during the drag torque phase of a drag torque strategy System calculated Tare Compensation If set to Enable then the torque for the next step will be offset by an amount equal to the average prevailing torque If set to disable no offset User entered Peak Prevailing Torque The maximum torque measured during the prevailing torque phase of a prevailing torque strategy System calculated Plant Name
67. ener tightening curves in real time during fastening operations It also provides quick access to statistics fastening logs and other useful information This section discusses each of the Run sub menu screens Run Main Screen This screen displays the actual torque and angle values following each fastening Below is a typical Run Main screen 07 20 2003 00 56 34 ee Select Spindle PENT 1 Config 1 A Angle Control Angle Control 365 Config UI Var DEET vu None Figure 22 Run Main Menu Single Spindle Screen Element Description Select Spindle Use this drop box to select the spindle for which the tightening data will display You can display the data for Spindle 1 Spindle 2 for both spindles or for a powerhead This drop box will not be present if your Insight is a one spindle model Configuration ID Automatically displayed beneath the Spindle drop box are the Configuration name the Configuration number and the Strategy name for the tightening sequence If it is a multi step sequence the Strategy name is that of the last step Ingersoll Rand Company 2004 Page 45 Section 4 Quality Control dp Assembly Solutions Screen Element Description Tightening Values The large primary number is the torque value for the last tightening unless the strategy is angle control in which case it will be the angle value The smaller secondary number is the angle
68. er Insight measures the voltage and assigns either PASS or FAIL System calculated Access Lockout Time If a user has logged into Insight with a password and no additional actions occur within the lockout time Insight returns to the Run Main screen and locks the software User entered Amplifier Offset The signal offset voltage generated by the Motor Controller s front end electronics expressed as of Shunt Cal voltage Insight measures the voltage and assigns either PASS or FAIL System calculated Angle at Seat The degrees of angle rotated when seating torque is reached applies to a drag torque strategy System calculated Angle Cnt at Drag TQ For a drag torque strategy the degrees of angle rotated when the drag torque step is complete System calculated Angle Constant A value used by the Insight to translate motor Hall pulses into spindle degrees of rotation Enter the Angle Constant value found on the tool s calibration label in the Angle Constant data entry box User entered Angle Hi Limit Angle Hi The maximum allowable angle through which the fastener may turn User entered Angle Into Yield The number of degrees the tool rotates beyond the onset of yield to constitute complete tightening User entered Angle Lo Limit Angle Lo The minimum angle through which the fastener must turn User entered Ingersoll Rand Company 2004 Page 71 Appendix 1
69. ere is no data then the controller will respond with AA where AA is the address No To clear the Host buffer for a configuration send the command AASSCC01 lt CR gt lt LF gt To clear the Host buffer for all configuration of a spindle send the command AASSCC02 lt CR gt lt LF gt Ingersoll Rand Company 2004 Page 87 Appendix 3 Communication Protocols d Assembly Solutions Overview of Custom Host Data Out The Custom Host Data Out is one of the features for the Insight IC This protocol is based off of the Standard Host Data Out serial protocol offered by the Insight IC The Insight IC will be interfacing with a PLC or PLC Based Applications This custom host data out can be directed to any one comport COM1 COM4 The detailed set up and its applications are explained below Setup Procedure The user should follow the following step by step procedure in order to setup the host data out protocol 1 Select the COM1 COM4 port in the Data Port dropdown box of the System Initialization Screen Set the Baud Rate in the System Initialization Screen For example 115200 Set the Parity Bit Select None for default option Set the Bits per Character Usually it should be 8 a eS Select the Custom Host 1 in the Comm Protocol dropdown box of the System Initialization Screen Assign the Multi Drop Address The default is OO 7 Connect a RS 232 Null Modem cable from COM1 COM4 of the
70. ers for definitions of all parameters Procedure 1 Press the Setup Main Menu key and then the Advanced Setup Sub Menu key 2 In the Select Spindle drop box select the spindle you want to program 3 In the Config drop box select the configuration you want to program 4 Go to the Engage step drop box and select Engage If the Engage parameter default values are acceptable you can skip to step 6 5 Go to the list of parameters just below the Engage step drop box and navigate down through the parameter list You must enter values or accept the default Ingersoll Rand Company 2004 Page 35 Section 2 Programming d Assembly Solutions values for the Required Parameters As appropriate you may also enter values or accept the default values for the Optional Parameters 6 Goto the Step 1 Strategy drop box and select Angle 7 Goto the list of parameters just below the Step 1 Strategy drop box and navigate down through the parameter list You must enter values or accept the default values for the Required Parameters As appropriate you may also enter values or accept the default values for the Optional Parameters 8 If you want to program additional tightening steps repeat Steps 6 and 7 as appropriate for the desired step How to Program a Yield Override Strategy in Torque Control or Angle Control Strategy in Advanced Setup As previously described the Torque Control tightening strategy and the Angle Control
71. etup 40 Delay Control Strategy E 41 Ingersoll Rand Company 2004 Page iii HR Assembly Solutions Jog COMING KEE VE 41 Bypass EE eege deg degt ee tanedrascalunssnchinianntainccuduatotndaakante 41 Re torqgue PARAMS LOIS EE 41 Section 3 Operating the System EEN 42 Selecting the Configuration E 42 M itoring Qperation EE 43 Section A Quality Control 44 The Print E UC 44 The Run dn 45 GREEN 45 dei lee ker TEE 47 Statistics Summary SCHESN vosceccincsencseisascndacdenadecnedcnascsdnadsnadsosacicssdecnsdentuntoasadaced 48 ee ET error attr rerea eran ree ee 49 VIEW Parameters Screen E 50 The Ste MenUS eeneg 51 S ummaly CUI E 51 EXPOR SD GMO Bi oeren e A E E AA A E E AE 52 Tightening CURVES Screen EE 54 Cy cle Log Bale lt 1 EE 57 Statistics Alarm Setup Screen ME 58 Main Window Statistics Alarms Discussion ssessseeesnneeennnnneettetenerreeenrnrnenr rnn enee 59 Section 5 Diagnostics and Troubleshooting eeeeeeseeeeeeeeeeeeerrrrerrrrenereeessene 60 The Diagnostics On 60 System TEE E a a a a EE 60 Discrete IMP ts Screen E 62 Discrete Outputs SCG SI BEE 63 Variable Timer Outputs Paint Marker and Reject Buzzer 63 Event Log S OPO E 64 Diagnostic Tool Test SCre Oi eletenteEeg E bEEEEE ees 66 Shutd wN n E 67 et Ee URC MON BEEN 68 Help Main IST E 68 G to TNC EE 69 E 70 Appendix 1 System Parameters snssssenennnnnerr ttr rt tt trrrerrrrrnnn rn
72. gang complete output signal on the spindle s I O connector There are two ways to reset the Gang Count 1 There is a dedicated reset conductor on the spindle I O connector 2 While on the Run Main screen pressing O zero and then the Enter key will reset the Gang Count for spindle 1 For a two spindle controller pressing 0 twice 00 and then Enter will reset spindle 2 Auto Increment Auto Increment allows the Insight to move through a specific sequence of fastening configurations For example if you have programmed six different configurations numbered 1 6 you can instruct the Insight to perform fastening in the sequence 1 4 6 and 2 3 5 To do this you set the Auto Increment parameter which is one of the parameters in the Engage strategy drop box By using this parameter to tell the Insight which configuration to go to next the system will continue to step through all Page 32 Ingersoll Rand Company 2004 aim Assembly Solutions Section 2 Programming programmed configurations until it reaches the configuration with the highest configuration number After completing that configuration the system will go to the first programmed configuration for the next cycle Note that the user still has to activate the tool for example pull the trigger on a handheld tool for each step in the Auto Increment sequence Auto Increment can be reset in various ways and has other operating features Contact Ingersoll Rand for additional i
73. hase This parameter can be set to different values for each spindle Fault Backout Speed This parameter sets the speed that the tool will run during the fault backout operation This parameter can be set to different values for each spindle Ingersoll Rand Company 2004 Page 33 Section 2 Programming am Assembly Solutions Number of Retries This defines the number of times a spindle can retry the fastening if a tightening fault occurs If set to one the spindle will retry once if a tightening fault occurs This value must be the same for all spindles in a group or if Retry Fault Action is set to 3 the value must be the same for all spindles in a powerhead Retry Fault Action This parameter defines what spindles will backout when a tightening fault occurs If this parameter is set to zero then retry fault backout operation is disabled If set to 0 1 or 2 this parameter must be set to the same value for all spindles in a group If this parameter is set to a value of 3 then it must be set to the same value for all spindles in the powerhead Retry Fault Action Value Operation 0 Faulted spindle stops no retry 1 Only faulted spindles retry 2 All spindles in faulted spindles group retry 3 All spindles in powerhead retry General Final Fault Backout Strategy This is a strategy that can be programmed in the engage step using various parameters that allows a controller to do a final backout if all
74. hdog timer 49 Comm Port 3 failure or not found 14 Invalid password entered 50 Comm Port 4 failure or not found 15 Removal Insertion flash card 51 Parallel Printer failure or not found 17 Removal Addition MC 52 Ethernet port failure or not found 18 Removal Addition disk drive 53 Devicenet port failure or not found 19 Removal Addition field bus card 54 Profibus port failure or not found 23 Change password values 56 PCMCIA Memory failure or not found 24 Keypad disabled 57 MCE 1 failure or not found 25 Keypad enabled 58 MCE 2 failure or not found 26 Change Target value Torque Angle limit Torque Threshold Chord length 63 Remote UO 1 failure or not found 27 Failure of system test 64 Remote UO 2 failure or not found 28 Load configurations from disk 65 Anybus Master is Offline 30 Tool Shutdown due to stall condition detected 66 Anybus Master is back Online 31 Tool Hall Fault Replace Tool 67 Ethernet received a NACK message Ingersoll Rand Company 2004 Page 65 Section 5 Diagnostics and Troubleshooting d Assembly Solutions Diagnostic Tool Test Screen This screen allows the user to interrupt regular tightening operations in order to perform several tool tests This is useful in troubleshooting any problems that appear to originate with an I R spindle or tool 12 08 2003 DIAGNOSTICS 02 56 47 Select a Spindl
75. he Insight controller and turn it on using the controller s rotary switch Push the green Spindle Power Switch on the front panel to power the Motor Controller and the tool If you are going to connect a socket tray to the light box connect it with the appropriate cable and follow the procedure to install the socket tray starting from Step 4 Ingersoll Rand Company 2004 Page 11 Section 1 Installation am Assembly Solutions Parallel Printer Connection and Setup 1 Connect your printer via a standard parallel printer cable to the 25 pin port labeled with a printer icon located on the left side of the Insight controller 2 Turn on the printer and make sure it is on line 3 Printa test report to ensure the printer is setup correctly Serial Printer Connection and Setup 1 Connect your printer via a standard 9 pin serial cable to a serial port located on the left side of the Insight controller labeled IOIOI 2 Goto the Setup menu s System Initialization sub menu screen and select the desired COM port from the Data Port drop box 3 On the same screen check that the settings for Baud Rate Parity of Stop Bits and Bits Per Character match those settings on the serial printer Change the settings as necessary 4 Tum on the printer and make sure it is on line 5 Print a test report to ensure the printer is setup correctly If you get odd characters on the printout verify the settings in Step 3 match those settings o
76. ig you want to select 4 Go to the Engage step drop box and select Engage If the Engage parameter default parameters are acceptable you can skip to Step 6 5 Goto the list of parameters just below the Engage step drop box and navigate down through the parameter list You must enter values or accept the default values for Page 36 Ingersoll Rand Company 2004 am Assembly Solutions Section 2 Programming the Required Parameters As appropriate you may also enter values or accept default values for the Optional Parameters Go to the Step 1 strategy drop box and select Torque or Angle as required Go to the list of parameters just below the Step 1 Strategy drop box and navigate down through the parameter list You must enter values or accept the default values for the Required Parameters As appropriate you may also enter values or accept default values for the Optional Parameters Scroll down to Yield Override check box to enable this feature Scroll to Fail on Yield Override to select this feature 10 If you want to program additional tightening steps repeat Steps 6 and 7 as appropriate for the desired step NOO o w How to Program a Yield Control Strategy in Advanced Setup The Yield Control strategy allows the tightening to be based on the onset of bolt yield For any Step n Strategy drop boxes if Yield Control is selected as the strategy its parameters will be displayed See Appendix 1 System Parameter
77. isaciee iis sneeeisane ceeded een stare 31 Blue EC EN Eine EE EN Strategy Sequence Rules n e 30 Sub Menu Names nnne 5 Sub Menu Optons 1 Summary SCION ENEE 51 System Initialization Green 16 Operating 2 ce eeeeeeeeeeteeeeeeesetteeeeeeetteeeeeeees 42 ParametefS ieaiaia 71 SPECS isncacedcccssnastevasenasee Geadaduaslccayaandsccsndaetaceacsad 77 Test SCN creia 60 T Technical Specifications cceeeeeeeeeeeeees 77 Tightening Curves SCION ccccceceececeeeeeeeeseeeeeeeaeees 47 54 STAJO S en 28 TOFQUE eee ee 39 Ki EE 39 Timer Outputs osssaeennenennee ne eeseererrnrnnnnnnenrneeene 63 TOO Memo oeccscncnennd nsn 26 Tool Test Gcreen 66 Torque Control 36 Control Strategy ccceeeeeeeeee 28 35 39 FUG eegen eee ccedee sua casuannsns aaia 33 Tightening EE 39 Troubleshooting eeeeeeeeeeceeeeeeeteteeeeeeettteeeeeeenea 60 T be NUT crac neki naileheenain indent 21 Tube Nut 2 21 V Variable Timer Outputs 0 c cccceeeeeteeeeeeeeeee 63 View Parameters Green 50 WwW WiZard BOX EE 5 Ingersoll Rand Company 2004 HD Assembly Solutions Index Y Yield Control Strategy 2era 29 37 Yield Override Fail on Yield Override 0 ccceeeeeeeteeeeeeeneee 36 Failure ececseeeeececceeeeeeeeeeeeeeceeecnaeeeeeeeeeeeees 36 MECH EE 36 Z Zone Tightening eseeesseeereseeerreserrrensrnnn 39 Ingersoll Rand Company 2004 Page 95
78. istorical logs of fastening performance Run screens provide quick view only access to information Statistics The Statistics menu displays raw fastening data as well as statistical analyses Individual tightening curves can be overlaid for comparison and analysis The operator can display statistical trends and set alarm functions to identify out of range fastening statistics Setup The Setup menu programs the fastening strategy A quick setup feature allows rapid programming of standard strategies while advanced setup offers customized strategies Setup also controls numerous basic system parameters such as selecting the display language setting torque measurement units and creating operator access passwords Diagnostics The Diagnostics menu controls Insight s self diagnosis programs Insight continually looks for operating problems or component failures It alerts the operator to problems with the tools or with the controller electronics and can even suggest root causes and corrective action Print The Print menu prints a variety of fixed format reports on fastening data statistics system settings and so on Help The Help menu accesses operating help and displays the information on the graphics display screen NOTE Selecting the Help option displays information about the highlighted menu topic Use this option whenever you have a question or need an explanation about any field on the screen 3 Then select the sub menu from
79. itialization Screen has been set to Internal To change the configuration currently being run scroll to the desired number Alternatively if the cursor is on this drop box then you can enter the configuration number on the keypad and press ENTER Main Display Window Beneath the spindle number the Configuration number and Configuration name are displayed Similarly the Strategy name is also automatically displayed In a multi step tightening the strategy name is that of the last step The main box one spindle displayed or boxes two spindles displayed are the dominant element located in the middle of the screen The large primary number is the torque value unless the strategy is angle control in which case it will be the angle value Note E Figure 38 The Run Help Menu Additionally there will be buttons for three options Help Main Menu If you navigate the cursor to the Help Main Menu button and then press the Enter key a new screen will be displayed that lists the main menu options with their sub menu options listed below them See the following figure The user can navigate to any sub menu option for an explanation of the terms on that sub menu Page 68 Ingersoll Rand Company 2004 HD Assembly Solutions HELP Main Menu Section 5 Diagnostics and Troubleshooting 07 20 2003 01 16 18 e Exit Help Select a button below and press the ENTER key to access Screen Help Text Press Go to Topic button to
80. ll Rand Q family of DC IMPORTANT SAFETY INFORMATION ENCLOSED SAVE THESE INSTRUCTIONS e READ AND UNDERSTAND THIS MANUAL BEFORE OPERATING THIS PRODUCT i ITIS YOUR RESPONSIBILITY TO MAKE THIS SAFETY INFORMATION AVAILABLE TO OTHERS THAT WILL OPERATE THIS PRODUCT FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN ELECTRIC SHOCK FIRE AND OR SERIOUS PERSONAL INJURY Electric Tools Keep your work area clean and well lit Cluttered benches and dark areas invite accidents 5 Do not operate this product in explosive atmospheres such as in the presence of flammable liquids gases or dust Electrical products can create sparks which may ignite the dust or fumes Grounded products must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances Never remove the grounding prong or modify the plug in any way Do not use any adapter plugs Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded If this product should electrically malfunction or break down grounding provides a low resistance path to carry electricity away from the user Avoid body contact with grounded surfaces such as pipes metal structures or other electrical products There is an increased risk of electric shock if your body is grounded Don t expose this product to rain or wet conditions Water entering this product will increase the risk of electric
81. ltage ve and negative excitation voltage ve System calculated Fall Back Date The date for the end of daylight savings User entered Fault Backout Angle Number of degrees the tool will automatically reverse on a tightening fault before a retry is started User entered Final Fault Backout Angle Number of degrees the tool will automatically reverse on a tightening fault when all retries have failed User entered Free Speed The maximum speed the tool will turn during fastening User entered Gang Count Some assemblies have multiple bolts that must be fastened in sequence called a Gang Setting the Gang Count tells the Insight how many tightenings bolts are required to complete the gang assembly User entered Hall Signal Test During self testing the Insight determines if the Hall sensor is operating correctly System calculated Language Specifies the language the Insight uses User entered Max Value The maximum value of the control parameter for the selected configuration System calculated Mean Slope The average value of the slope of the torque vs angle curve System calculated Meanshift The difference between the mean value and the control point value System calculated Minimum Drag Torque The minimum drag torque reached during a drag torque fastening strategy System calculated Ingersoll Rand Company 2004 Page 73 App
82. m repetitive fastening operations The spindles may be individual hand held tools or two may be mounted together called a powerhead for automated assembly tasks This manual addresses the Insight control unit only the spindles are supplied with their own operating manuals It is generally not necessary to access the Insight s interior components so they are not explained in this section This manual provides information about your Insight IC Fastening System with Graphics Display and how to install setup program operate and troubleshoot your controller __ Status Display Main Menu Sub Menu Options Options Spindle Power Graphics Switches Display Screen Cabinet Lockout Navigation Numeric Keypad Keypad Ingersoll Rand Figure 1 Main Panel Ingersoll Rand Company 2004 Page 1 Introduction HR Assembly Solutions Menu Navigation 1 Use the cursor arrow keys to highlight select a menu item and then press the Enter key to start that item 2 Select the menu section you want to view There are six sets of menu screens from which you can select These are located above the large window in the lower part of the front panel Run The Run menu displays fastening data torque angle and many other parameters in tabular form after each fastening operation Actual torque vs angle fastening curves can also be displayed In addition Run mode provides access to other useful data such as Statistical summaries and h
83. n the printer Computer Connection and Setup via the Serial Port NOTE To connect a computer to the Insight controller you will need a terminal software package such as Windows 95 98 or 2000 HyperTerminal or Win 3 1 Terminal 1 Connect your computer via a Null Modem 9 pin serial cable to the port located on the left side of the Insight controller labeled IOIOI 2 Goto the Setup menu s System Initialization sub menu screen and select the desired COM port from the Data Port drop box 3 On the same screen check that the settings for Baud Rate Parity of Stop Bits and Bits Per Character match those settings on the terminal software package of your computer Change the settings as necessary 4 Print a test report to ensure the computer is setup correctly If you get odd characters on the printout verify the settings in Step 3 match those settings on the computer PLC Connection and Setup NOTE All connections to a PLC are made via the Insight s terminal blocks except data collection Data collection is done via the serial ports For data collection follow the procedures for setup via the serial port To connect a PLC to the terminal blocks see the procedure below Through the terminal blocks a PLC can send and receive a variety of outputs to and from the Insight controller It is important to always use a shielded cable for all PLC signals to Page 12 Ingersoll Rand Company 2004 HD Assembly Solutions Section 1
84. n you are asked if you wish to print an Auto Calibration report Finally you will be returned to the main Spindle Initialization screen Page 22 Ingersoll Rand Company 2004 HD Assembly Solutions Section 1 Installation Preventative Maintenance Alarms Screen The preventative maintenance and alarms screen allows you to set alarm reminders for regular tool preventative maintenance Up to five different alarms can be set with either a number of cycles or days duration When an alarm is activated it will appear in the systems warnings and dialog box until it is reset from this screen All preventative maintenance data is stored in the tools onboard memory chip Password and Powerhead Settings Screen This screen is used to set the Insight s four levels of user passwords and to setup certain powerhead functions Below is the Password and Powerhead Settings screen 07 20 2003 SETUP Settings 01 38 08 Password Setup Powerhead Settings Select Powerhead Powerhead Name Powerhead 1 E Stop All Spindles on Reject Figure 15 Password and Powerhead Settings Screen The Password Function Access to Insight IC screens is password controlled A few screens require no passwords but most require a certain level of password authorization to make changes to the screen settings In addition to a no password option called Level 0 the Insight has four owner controlled access levels each requiring a unique four digit password
85. ned Seege D eg uge Sege ad tasers 16 Ethernet Connection c cccceceeeeeeeeeeeeeeeteeeees 14 Event Log Codes 2cticiiecccessiteten diteedetianeiereiiie 65 Event Log Green 64 Expand Ren sce ditadeetnidvea niet aeaiine 3 Expand Gwmbol 3 Export Sereen does genee 52 External Configuration Switch 11 Page 92 HR Assembly Solutions F Fault Action Value Heim 34 Backout ANnGl iiicsccccunedeeverideecceeteebs cine 33 34 Backout Speed ss sossnsensninneeneseeetenrrrrrrn rrene 33 Backout Strategy cccceeeseeeeeeeeeteeeeeeeenaees 33 Number of Reirtes 34 Retry Fault Action cceeeecseeeeeseeeeeeeenaes 34 Field Bus saasannnnnnnenneeaseeoseen nentrn nnnsresnreernnn nnen nen 20 Field Bus Card Conpnechon 15 Final Fault Backout Angle ceeeeeeetreeeeeeees 34 Final Fault Backout Hi Torque ssssessenseeneneneenn 34 Final Fault Backout Gtraiegy 34 G Gang AdVANCE nic ciccteeceneiticeeeviiacceeeeviniieeeesinnes 21 Gang Coumt rnnr nnne n 19 32 Graphics Display Green 1 5 H Handheld 10 Header inona en eee 5 Help er Le E 68 Go to Help Topie 69 Main dE 68 M tten 2 68 High Torque Limit eeeceeeeeeeeeeeeeeeeeeseteeeeeeeeaes 40 Host Data Out cc cceccccceeeseeeeeeeeeeeaees 16 85 87 l lege EE 32 Initial DOAK eee cee ee eee eeeeeeeeeeeeeeeeeeeeeeeeeeeeees 39 nitial StartUp ssis iaie Vases 15 Initialization Screen System 16 Input Signal Drawing 13 Input Activati
86. nformation Torque Filter The Torque Filter parameter is used to filter high frequency noise or ripple from the torque signal from the strain gauge transducer to provide a more accurate torque measurement The selectable values range from 75Hz to 750Hz and represent the bandwidth of the filter As a guideline use e Lower values for soft joints such as gasket applications or those that generate a high angle of rotation and e Higher values for hard joints or those that generate a low angle of rotation e The default setting is 150Hz When calibrating DC Electric tools it is advantageous to set the external transducer monitor to the same frequency as the Insight IC controller in order to get accurate correlation between the two devices The parameters marked with an asterisk are specific to the Powerhead function and are described below Powerhead Specific Operations and Functions General Retry Fault Backout Strategy This is a strategy that can be programmed in the engage step using various parameters that allows the controller to retry a spindle or spindles when a tightening fault occurs Whenever a retry fault backout is initiated the spindle s will backout the specified number of degrees and restart the tightening from step 1 The parameters in the engage step that make up retry fault backout are as follows Fault Backout Angle This parameter defines the number of degrees the spindle will rotate during the backout p
87. ng Curve This window displays the current tightening curve in real time When a fastening is completed and another fastening begins the previous curve clears and the new curve is drawn Parameter Display Box This display box located on the right hand side of the display has a list of tightening data parameters captured in real time The parameters are described below Message Box The Message Box located at the bottom of the display summarizes system status and provides warnings and alarms Ingersoll Rand Company 2004 Page 47 Section 4 Quality Control dp Assembly Solutions Definitions of tightening parameters that appear in the parameter display boxes are defined in Appendix 1 System Parameters Statistics Summary Screen This screen displays a large number of fastening statistics for either one or two spindles If you have a single spindle Insight IC system the Statistics Summary screen is as shown below Note that on the left side it displays the statistical data for all the fastenings performed since the statistics were last reset the Population statistics and on the right side the statistics for a subset of the cycle the Sample statistics 07 20 2003 RUN 01 02 12 Stats Summary Select Spindle Select Configuration 1 Spinde S HN Config E Population Total Cycle Count 6 Sample Statistics Size 6 Torque Angle Torque Angle Target 0 00 360 Target 0 00 360 0 39 365 00 0 39 365 00
88. ngersoll Rand Company 2004 Page 9 Section 1 Installation aim Assembly Solutions You can change your Insight Controller from handheld operation to machine mount or fixtured mode A fixtured tool or machine tool is one that receives the external start or throttle signal remotely through the Insight s I O connector on the left side of the controller To change from a handheld tool to a fixtured tool select Machine Mount from the Spindle Operation drop box on the Spindle Initialization screen To switch back to handheld mode select Handheld Tool from this drop box There should be a tool attached to each connector If no tool is present when the unit is powered up no power will be delivered to the empty connector This is a safety feature The Insight interprets the lack of a tool as a tool with a possible ground fault and does not energize that circuit If a connector is left empty and a tool is added at a later time first turn the Insight Main Power Switch off wait five seconds and turn it back on Never connect a spindle to the Insight Controller with the spindle power switch ON Attaching Peripheral Devices NOTE The current version of this system supports either serial or parallel printers Socket Tray Connection and Setup 1 Connect the socket tray to the Insight controller s terminal blocks located on the controller s left side with the appropriate accessory cable See Appendix 2 System Specs and Spare Parts for det
89. ntroller shall respond with the following AASSCC lt CR gt lt LF gt Where AA is the address number of the controller SS is the spindle number whose buffer is empty CC is the configuration number whose buffer is empty lt CR gt is a carriage return lt LF gt is a line feed e The Spindle Buffer Clear messages can be sent at any time by the host to clear all buffers for all configurations of a given spindle The message shall have the following format AASSCC02 lt CR gt lt LF gt Where AA is the address number of the controller SS is the spindle number whose data should be cleared CC is the configuration number ignored for this message 02 is the spindle buffer clear command lt CR gt is a carriage return lt LF gt is a line feed Upon receiving this message the controller shall respond with the following AASSCC lt CR gt lt LF gt Where AA is the address number of the controller SS is the spindle number whose buffer is empty CC is the configuration number whose buffer is empty will be set as 00 to indicate all Configurations cleared lt CR gt is a carriage return lt LF gt is a line feed Page 90 Ingersoll Rand Company 2004 Index A Activating an Input 13 Active Bar Code Mode 18 19 Advanced Getupe 29 Bypass Parameters iseeesseseerireerrrrrssrernne 41 Clearing a Configuration cceeeeeeeeeeees 31 Clearing a Step ceceeccccceceeeecceceeseeeceeeeeeteeee 31 Delay Control Strategy
90. ol strategy allows you to insert a time delay into the tightening For any of the Step n Strategy drop boxes if Delay Control is selected as the strategy Delay and Sync Enable parameters are displayed Jog Control Strategy The Jog Control strategy allows you to run the tool at a slow speed the Soft Speed defined in the Engage step so the tool s socket can easily engage the bolt head Jog Control must be used in the Step 1 Strategy box If Jog Control is selected parameters for Torque Setpoint Jog Angle and Sync Enable are listed Bypass Parameters The Bypass strategy is unique in that it is either off or on It has no selectable parameters The bypass mode applies only to powerheads It is used to allow a powerhead to operate with different spindles depending upon the tightening configuration selected When a powerhead is programmed with different configurations unwanted spindles can be bypassed so only the desired spindle is used The bypass strategy can only be programmed in the Engage Step Strategy drop box Retorque Parameters Sometimes a fastener will relax after it is tightened In the Retorque Control mode the controller reapplies torque to take up relaxation in the joint This mode can only be used following a Torque Control or Angle Control strategy The re torque set point is automatically set at either the Torque Control strategy s target torque value or the peak torque attained if this step follows an Angle Control strat
91. olutions Changing from Passive to Active Bar Code Mode ssssssnossnnsnnennennssessrerernnn nenn 19 Disable Tool Until Scan Option 19 Removing Bar Code Operation 19 Passive Mode snseeesseeseeesennnrennsnesreerteennnn 17 Setup for Active Mode 18 Setup for Passive Mode n se 17 Begin Calibration sssrinin oka 22 BUUOMN TEE 6 7 Bypass Parameters iseessseeeeerneseesrrsssrerneeerenness 41 Cc Cabinet Lockout 1 Calibration Le LU 22 Spindle Initialization cc eee 21 Check BOX acess sset eege Ad gesend deaevasecaetans 6 7 Clearing a Configuration 0 ccccccceeeseeereeeeees 31 Cleaning a Step assaia a 31 Communication Protocols 85 Custom Host Data Out 87 Descriptions ssneseeeseeoe eerren rre nsereseeeeene 86 87 Host Data OUt iirinn iaai aiaa 85 SETUD E 16 Setup Procedure 85 87 Computer Connection and Setup s ssssssssssseeee 12 Config Directory eocsnis noen 25 Configuration CIC ANING osea 31 Ee E 42 Le ET 11 Configuration Switch CONNECCION geseis Seen hsielldde aaa 11 SOLUS TE 11 T SUING BEE 11 Connections elle TT 12 Configuration Switch 11 Ethene tise egene ae aaa 14 Field BUS Card 15 Parallel ROM iicj cssciadteanauidad canvas eit gas seadadctansaded 12 Serial POM sess cscecetence ccdevsdenaidadescacnadceiaassactsaaseaze 12 SOCKET TAY ercon ceden ven cd sda AANEREN 10 Continue button ssssssssssssenseeeeeeenrrrrnennseessrrereene 22 Curves Gcreen 47 Custom Ho
92. ompany 2004 Page 37 Section 2 Programming am Assembly Solutions How to Program a Backout Strategy in Advanced Setup The Backout Control strategy allows the user to unfasten bolts for a programmed number of degrees and at a programmed speed If the torque encountered during the backout exceeds the Torque Hi Limit setting the operation is aborted For any of the Step n drop boxes if Backout Control is selected as the strategy its parameters are displayed See Appendix 1 System Parameters for definitions of the parameters Procedure 1 Press the Setup Main Menu key and then the Advanced Setup Sub Menu key 2 Inthe Select Spindle drop box select the spindle you want to program 3 In the Config drop box select the configuration you want to program 4 Go to the Engage Step drop box and select Engage If the Engage parameter default values are acceptable you can skip to step 6 5 Goto the list of parameters just below the Engage step drop box and navigate down through the parameter list You must enter values or accept the default values for the Required Parameters As appropriate you may also enter values or accept the default values for the Optional parameters 6 Atthe appropriate Step n Strategy drop box select Backout 7 Goto the list of parameters just below the Step n Strategy drop box and navigate down through the parameter list You must enter values or accept the default values for the Required Pa
93. on cccccccecececeeeeeeeeeeeeeeeeeseeaes 13 Inserta S16 Pie EE 31 Inside the Main Door 84 Inside the Panel 83 Installation cccecceececeeeeeeeeeeeeeseceecaeeeeeeeeeeeeeeeees 8 lge eler EE 1 J Jog Control Strategy eceeeeeeteeeeeeeseeeeeeeeeee 41 K Keypad Navigatoare 3 Kli A Ingersoll Rand Company 2004 HD Assembly Solutions L Light Box Connection and Setup eee 11 Load Data 25 Load Software 0 ccceeeeceeeeceaeeeeeeeeeaeeeseeeeeeeanees 25 LOG Codes 0 eceeeeeeeseeneeeeeeeeenaeeeeeseetaeeeeeeenaaees 65 Low torque mn 40 M Machine Mounted cccccesesseceeeeeeeseeeeeeeanees 10 Mar DOOM scat faves deere a E OE 84 Main Menu Opttons reene 1 Main Menu Run 42 Main Power Switch ccccccccessseeceeceeeseeeeeeeaeeenes 9 Main Screen Run 45 Main Window asssssssnnnnnsssnerrnsessrrrrsssnnrrrsresnrrrssesn 5 Menu Diagnostics 2 60 Discrete Input 62 Go to Help Topie rnn nen 69 Helpen 2 68 Navigation 2 PRIN idee cet des Zug ebe deeg de 2 44 DEE ee 2 SOUL PD EE 2 27 Setup Technioues 27 ee 2 48 51 Message BOX cccceeeeseeeeeeeeeeeeeeeeeseeeneeeeteeenaeeeees 5 Monitoring Operation eee eeeeeeeeeeeeneeeees 43 Mounting IC Controller 8 N Navigation CAV 0 6 ee 1 3 Menu Eeer 2 Number of Heite 34 Numeric Keypad sssossesssensrnnnsensrnesrerrnnnrnnnne 1 4 O Ohvmpus bin 25 Operating the System c cc eeeeeeeeetteeeeeeeenees 42 Orient
94. or a powerhead Clear All Press this button to clear both the population and the sample statistics Note that this clears the data for statistical analysis only the raw data remain in memory and may be retrieved using the Statistics Cycle Log screen Clear Sample Press this button to clear only the sample statistics Note that this clears the data for statistical analysis only the raw data remain in memory and may be retrieved using the Statistics Cycle Log screen Stats from Use this drop box to select the entire fastening population or a sample of that population Select Config Use this drop box to select the tightening configuration by number and name whose statistics will be displayed Main Window The statistical data display here Below is additional information on the parameters displayed Message Box The Message Box summarizes system status and provides warnings and alarms The statistical parameters displayed on the Statistics Summary are defined in Appendix 1 System Parameters These same statistical parameters display for both the fastening population and the fastening sample However if a powerhead is selected a different set of parameters is displayed Export Screen Using the Statistics Export screen you can select filter and format cycle data and export that data via the serial port to a PC or other device Below is a typical Statistics Export screen Page 52
95. ords The level 4 user can then change the passwords by entering a new value and then re entering it to confirm the change User entered Config Config Insight can be programmed with up to 32 separate fastening operations called configurations Each has a unique Configuration Number from 01 through 32 and may also have a name assigned User entered Config Name A suitable alphanumeric name can be assigned to any of Insight s 32 available configurations User entered Config Sel Type For those fastenings where the Insight increments through multiple configurations this parameter defines how the configuration is incremented User entered Config Select Use this drop box to select whether the configuration is selected internally through the Run Main screen or externally through the Insight s I O connector User entered Cp A statistical parameter used to measure system performance System calculated CpK A statistical parameter used to measure system performance System calculated Cut In Angle The angle from the start of cut in the initial high torque phase to the successful completion of the cut in phase applies to prevailing torque and drag torque strategies User entered Cut In Torque Limit The maximum permissible torque during the cut in phase the initial high torque phase of the prevailing torque and drag torque strategies User entered Page 72
96. p NN UN 30 Strategy Sequence RUGS sisrssisencieee deca aa 30 Programming Spindles in a Powerhead eeeeeeeeeeeeenetaaeeeeeeeees 30 MVS ONE el Steperi e E 31 Clearing a Step isien eaae an iaeaea a e ara Eanan SETAE 31 Clearing a Configuration E 31 End of R n Data EOR eegene 31 The Eng ge SU Pa acts ets te cee tect eases sett teen AREE 31 Gang e EE 32 Auto CREST EE EE 32 Torgue EE 33 Powerhead Specific Operations and FUNCTIONS ccccceeseseeeeeeeeeeseeeeeeeeeeeaees 33 General Retry Fault Backout Strategy cccccccccccceeeseesenesceeeeeeeeeeeeeeeeeee 33 Fa lt Backout e UE 33 Fault Backout SDS D 33 KT lege 34 Pete geet 34 General Final Fault Backout Strategy ccccccccccceecceeeeeeeeeeeeeseneneeeeeeeneees 34 Final Fault Backout e UE 34 Final Fault Backout Hi TORQue scscscsissaseswcais saicieiiernumsos dE Sebe ee 34 Fault ACON essen 34 How to Program a Torque Control Strategy in Advanced Getnp 35 How to Program an Angle Control Strategy in Advanced Setup 35 How to Program a Yield Override Strategy in Torque Control or Angle Control Strategy IN Advanced Setup E 36 How to Program a Yield Control Strategy in Advanced Setup eeeeeeeeeeessesseeneeee 37 How to Program a Backout Strategy in Advanced Setup ceeeeeeeeeeeeeeeeeeees 38 How to Program a Prevailing Torque Control Strategy in Advanced Setup 39 How to Program a Drag Torque Control Strategy in Advanced S
97. pecified supply voltage Incorrect voltage can cause electrical shock fire abnormal operation and may result in personal injury Be sure all electric cords and cables are the correct size and all plugs and connectors are tightly secured Under sized wire and loose connections can cause electrical shock fire and may result in personal injury Ensure an accessible emergency electric power shut off has been installed and make others aware of its location In the event of an accident this shut off may minimize personal injury Do not remove any labels Replace any damaged label Labels provide information required for safe use of the product Do not modify this product safety devices or accessories Unauthorized modifications may result in electric shock fire or personal injury Do not use this product for purposes other than those recommended Personal injury may result Disconnect power and lockout tagout machine prior to removal insertion or servicing of any component or module within this product Failure to follow instructions can result in risk of electric shock and personal injury aim Assembly Solutions aim Assembly Solutions Precautionary Information Install this product to a vertical structure capable of Do not attach or place external loads on any part of the safely supporting its total weight Failure to follow Controller Loading may cause hinge or mounting failure installation instructions properly can result in
98. que Target the tool will be shut off this many torque units before the Torque Target User entered Torque Target The desired final torque for the fastening operation User entered Torque Threshold also called Snug Torque The torque required to seat components in the joint also the torque point at which angle begins to be measured User entered Torque Units Use this drop box to select the units the Insight uses to measure torque User entered Transducer Range Every I R tool has a specific measured Transducer Range The Insight controller reads the Transducer range value from the tools memory when it is attached You may overwrite this factory set Transducer Range value if required System AND User entered Tube Nut Enable When checked the Insight controller will correctly operate a tube nut tightening tool User entered Tube Nut Rev Speed The reversing speed when the Insight is operating a tube nut tightening tool User entered Tube Nut Rev Thresh Torque value that a tool will shut off in the reverse direction when in Tube Nut Mode User entered View Password A button that allows a Level 4 user the highest level of access to the Insight s functions to view all the current passwords User entered X Bar The average value for the control parameter System calculated Yield Point The average decrease in the slope from the max value of the torq
99. rameters As appropriate you may also enter values or accept the default values for the Optional Parameters Page 38 Ingersoll Rand Company 2004 aim Assembly Solutions Section 2 Programming How to Program a Prevailing Torque Control Strategy in Advanced Setup Description This is useful for thread forming applications where the thread forming torque may have a value similar to or even greater than the final tightening torque This strategy monitors the initial peak prevailing or driving torque to ensure that it falls between expected limits cut in zone It then checks the subsequent mean and peak prevailing torque as the thread is formed prevailing zone Finally as the fastener seats the final tightening strategy is invoked which may be torque control angle control or yield controlled tightening tightening zone Final tightenin Initial peak g g t prevailing orque Os torque Prevailing Tightening Zone Zone Figure 19 Prevailing Torque Tightening Strategy Procedure 1 Press the Setup Main Menu key and then the Advanced Setup Sub Menu key 2 In the Select Spindle drop box select the spindle you want to program 3 In the Config drop box select the configuration you want to program 4 Go to the Engage step drop box and select Engage If the Engage default values are acceptable you can skip to step 6 5 Goto the list of parameters just below the Engage step drop box and navigate
100. reen 12 08 2003 SETUP 02 54 27 Select Spindle p og Switch Tube Nut e Calibration Info Auto Calibration None S AAD sab led TR Value Angli stant Reset TR prann PM Alarms 173 25 0 698 Reset ASC Spindle Parameters Torque Units Spindle Status Remote Tool En Dis Am Enabled Sore Config Select Spindle Operation Start Mode internal_ SB Handheld Toor Ieren SN Figure 11 The Spindle Setup Screen Page 20 Ingersoll Rand Company 2004 HD Assembly Solutions Section 1 Installation Reset TR and ASC Buttons Activating the Reset TR or ASC button will return the parameter back to the factory set value Prog Tool Switch The QE series tools have a user activated switch onboard that can be programmed to accomplish a particular function See below for functions that can be assigned to this switch Tube Nut 1 For this function to activated tube nut operation must be selected on this screen When this mode is selected activating the switch acts as the reverse and throttle for the tool Tube Nut 2 For this function to be activated tube nut operation must be selected on this screen When this mode is selected activating the switch selects reverse direction The tool throttle must then be pressed while the tool programmable switch is activated to run the tool in reverse Gang Advance The gang advance function allows the tool operator to manually advance a gang count by one Activation of the programmable
101. ress The Default is 00 7 The user should connect a RS 232 Null Modem Cable from COM1 COM4 of the Insight IC to any directed output The outputs may be hyper terminal or any PLC Based Applications D 8 After each successful data string is sent out the Host should send an ACK message to the Insight IC 9 The host should send the Clear message to the Insight IC in order to clear the EOR and the Insight IC will be ready for the next data out Page 86 Ingersoll Rand Company 2004 aim Assembly Solutions Appendix 3 Communication Protocols Descriptions The following format of the Host Data Output will be sent out to the directed terminals upon each request by the host after each tightening eeSSCCMMDDYYhhmmhhhhhjkkkkkimmnn lt CR gt lt LF gt ee Address Address No of Insight sent in Multi Drop Address entry box ss Spindle Number cc Configuration Number MMDDYY Month Day Year hhmm Hour Minutes 24 hr time hhhhh Torque Four digits plus decimal point j Torque status space OK H High L Low kkkkk Angle Five digits l Angle status space OK H High L Low mm Cycle Last two digits of the cycle count nn Check sum Two digits Mod 256 To request data Host sends message AASSCC lt CR gt lt LF gt e Where AA is Insight Address Number SS is Spindle number and CC in the configuration number System responds with data stream above if there is data e If th
102. riptions of whatever is highlighted on the screen or may provide abbreviated instructions for performing a task Sub Menu Names The sub menus are different for each of the four principal Main Menu keys Run Statistics Setup and Diagnostics Main Window The Main Window displays all the parameter selection and data entry fields and may display tabular or graphical tightening data Message Box The Message Box located at the bottom of the screen summarizes system status and provides warnings and alarms Ingersoll Rand Company 2004 Page 5 Introduction Screen Elements All the different menu screens that can appear on the Insight graphics display panel have certain design elements in common These design elements called screen elements appear in the Main Window section of the display and are shown in the graphics below HR Assembly Solutions In actual operation the user will use the arrows on the directional keypad to navigate the cursor to the individual screen elements A pale blue border around the screen element indicates that the cursor is at that screen element Button Clear Cycle Data Drop Box Spindiei_ Cycle Config Date Time Display Box Cycle Result Torque Data Entry Box 4 Torque Target Check Box fq All Cycles Torque Result Angle Angle Result Step 145 12 11 16 00 16 00 PASS 2 01 PASS 214 35
103. rn nrt r tr trrrnernne nen 71 Definitions of System ParaMeters s 00000 sseecenennenenenedenenseeeenendencesusceneneeesuenes 71 Page iv Ingersoll Rand Company 2004 HD Assembly Solutions Appendix 2 System Specs and Spare Parts nnnnnnnnnnenennnnenea nann n nnne re nereeenee nn 77 Insight Technical Specifications E 77 e EEN 78 Insight IC one or two spindle system with no optional I O boarcde 78 dee EE 78 QUIS ee 78 Insight IC one or two spindle system with one optional I O board per spindle 79 NIU E 79 MUONS ee Eege 80 Recommended Spare Parts LAS baa tbe 81 Inside the TT EE 83 tie the Nain ET 84 Rko liee pe seared Siecisareeerbaln ea lepaeleciee a naesseebadacadataap sadandesdtesesunidatepentdegadaut 85 Appendix 3 Communication Protocols annnnnnneneneeeeeeeerrr rnnr nnt tnrrrnrrnenneeennn nnn 86 Overview of Host Data e E 86 Setup PROCSOUNS oie a e e a E e A a E REE 86 DEE Egeter 87 Overview of Custom Host Data Out ccccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeseeeeeeeees 88 Setup PE OCS CUS Eer 88 Des rnipt on S sese E e EAE EEEE RER 88 TC E 91 Ingersoll Rand Company 2004 Page v dR Form P7709 Edition 1 January 2004 CCN 04580262 Instructions for Insight IC DC Electric Torque Management Controller NOTICE Models IC1G and IC2G controllers are designed for industrial torque angle or yield management of assembly operations Use only with Ingerso
104. s for definitions of all parameters Procedure 1 Press the Setup Main Menu key and then the Advanced Setup Sub Menu key 2 In the Select Spindle drop box select the spindle you want to program 3 In the Config drop box select the configuration you want to program 4 Go to the Engage step drop box and select Engage If the Engage parameter default values are acceptable you can skip to step 6 5 Goto the list of parameters just below the Engage step drop box and navigate down through the parameter list You must enter values or accept the default values for the Required Parameters As appropriate you may also enter values or accept the default values for the Optional Parameters 6 Go to the Step 1 Strategy drop box and select Yield 7 Goto the list of parameters just below the Step 1 Strategy drop box and navigate down through the parameter list You must enter values or accept the default values for the Required Parameters As appropriate you may also enter values or accept the default values for the Optional Parameters 8 If you want to program additional tightening steps repeat Steps 6 and 7 as appropriate for the desired step NOTE Yield Control R recommends setting the torque threshold value to 30 60 of the expected yield torque In general soft joints require high percentage values to ensure joint consolidation has occurred before yield detection calculations are commenced Ingersoll Rand C
105. s started successfully 07 20 2003 MC power up 07 20 2003 MC power up 07 20 2003 Power up 07 20 2003 MC power up 07 20 2003 All devices started successfully 07 20 2003 MC power up 07 20 2003 MC power up 07 20 2003 Power up 07 20 2003 Trigger Released 07 20 2003 MC power up 07 20 2003 All devices started successfully 07 20 2003 MC power up Figure 36 Diagnostics Event Log Screen Page 64 Ingersoll Rand Company 2004 HD Assembly Solutions Section 5 Diagnostics and Troubleshooting The following table provides a listing of Event Log codes and their explanations 1 Change in transducer range values 32 Motor Controller IGBT Driver Fault 2 Change in angle scale value 33 Tool Overcurrent Detected 3 Change in tool type 34 Low Bus Voltage 4 Power up 35 Tool Stop due to Cycle Timeout 5 Power down 37 Tool Disconnected from Controller 6 Corrupt or lost file 38 Communication Lost between MCE and RISC 7 Loss of CAN bus communications 39 All devices started successfully 8 MC power down 40 Flash Disk Failure or not found 9 MC power up 41 Floppy Disk Failure or not found 10 Retries on CAN bus 42 File INSIGHT BIN invalid or not found 11 Download new MC software 47 Comm Port 1 failure or not found 12 Download new RISC software 48 Comm Port 2 failure or not found 13 Software lockups Watc
106. se statistics alarms will display The options include configuration 01 through 32 Values for Stats Use this drop box to select what tightening results are included in your statistical calculation The options are Good Only All or All but hardware faults Sample Size Using the numeric keypad enter a sample size This will be the number of samples used to calculate the sample statistics Main Window This window has two boxes to set the alarms for both torque and angle The user can set alarms for all of the statistical parameters listed in these boxes and can individually turn those alarms on or off Below is additional information on these alarms Message Box The Message Box summarizes system status and provides warnings and alarms Page 58 Ingersoll Rand Company 2004 aim Assembly Solutions Section 4 Quality Control Main Window Statistics Alarms Discussion Using the arrow keys the user can navigate to the Statistics Alarm Setup screen s main window and scroll down through the statistics parameters listed under both Torque and Angle For each parameter the user can enter an alarm value using the numeric keypad Use the check box to the right of each parameter to either turn that alarm on or off Ingersoll Rand Company 2004 Page 59 HR Assembly Solutions Section 5 Diagnostics and Troubleshooting The Diagnostics Menus The Diagnostics menu allows the user to check the overall sy
107. sequence However there are a few sequence rules dictated by the purpose of certain strategies Those rules are 1 The Engage Step must be selected prior to any Advanced Setup tightening strategies See page 35 for details of the engage step 2 A Retorque Control strategy must always be preceded by a step programmed for Torque Control or Angle Control 3 A Jog Control strategy must be the first step after the Engage step 4 The Bypass strategy which applies only to powerheads must always be the first and only step Programming Spindles in a Powerhead You can program the two spindles in a powerhead in a variety of ways The spindles can be programmed identically or the spindles can be divided into groups If divided into Page 30 Ingersoll Rand Company 2004 aim Assembly Solutions Section 2 Programming groups those spindles in a group must be programmed the same The Insight IC keeps track of the spindles in a powerhead and how they are grouped and programmed If you attempt to change the programming for a spindle that is part of a powerhead the Insight will bring up a dialogue box for you to confirm the change If confirmed the Insight automatically changes the programming for the spindles in that group where appropriate Programming powerheads and their groups can be complex However the process is explained fully in the Password and Powerhead Settings section Insert a Step Sometimes in a complex tightening stra
108. setup a scanner for this spindle you will get a warning message indicating that a bar code setup file was not found Press the ENTER key and a default file will be created 6 Enter the number of characters that are in the bar code scan into the box labeled Barcode Length 7 Navigate to the OK button and press ENTER Ingersoll Rand Company 2004 Page 17 Section 1 Installation am Assembly Solutions Bar Code Operation in Passive Mode When the bar code function is activated for a spindle then a Bar code column will be added to the cycle log screen This column will contain the bar code data that is permanently attached to the cycle torque and angle data Wherever the cycle data is sent either export cycle log cycle log report EOR data or host data out the bar code data will be sent with it Upon bootup if a cycle is run before a barcode is scanned then the bar code data will be recorded as No Bcode When a barcode is scanned and is the valid length then the scan data will be recorded to all subsequent cycles until a new scan is initiated If an invalid barcode is scanned then Invalid BC will be recorded as the scan data The bar code data attached to each run can be seen in the Run Main Screen via the Var1 and Var2 variable boxes Bar Code in Active Mode Bar Code Setup for Active Mode To setup the controller for active bar code operation follow the directions below 1 Goto the Setup System Initialization screen
109. shock Don t abuse the cord Never use the cord to pull the plug from an outlet Keep cords away from heat oil sharp edges or moving parts Replace damaged cords immediately Damaged cords increase the risk of electric shock Stay alert watch what you are doing and use common sense when operating this product Do not use this product while tired or under the influence of drugs alcohol or medication A moment of inattention while operating this product may result in personal injury Use only accessories that are recommended by Ingersoll Rand for your model Accessories that may be suitable for one product may become hazardous when used on another product Refer All Communications to the Nearest Ingersoll Rand Office or Distributor Ingersoll Rand Company 2004 Printed in U S A Page vi Service must be performed only by qualified repair personnel Service or maintenance performed by unqualified personnel could result in a risk of injury When servicing this product use only identical replacement parts Follow instructions in the Maintenance Section of this manual Use of unauthorized parts or failure to follow Maintenance Instructions may create a risk of electric shock or injury Always install operate inspect and maintain this product in accordance with all applicable standards and regulations local state country federal etc Failure to follow standards and regulations can cause personal injury Always use s
110. sis This section discusses each of the Statistics sub menu screens The thumbnails will help you recognize each screen s layout Summary Screen Below is a typical Statistics Summary screen for a two spindle Insight IC system Note that both the left side and right side of the screen have boxes for selecting a spindle and a configuration and a box for displaying statistics The statistics boxes display either the Population statistics or the Sample statistics 07 20 2003 STATS 0 1 a 18 e 4 2 Summary Select Spindle Clear Clear Select Spindle Clear Clear spindle 1 Kl At I Senos MMM spindic ll Ten Select Config Stats From Select Config Config Population RR Configt Ni Parameter Torque Angle Parameter Torque Angle Target ooo 360 Target om 360 x Bar 0 28 365 30 x Bar 0 28 365 30 Meanshift nmn 5 30 Meanshift ooo 5 30 Range Range 0 53 1 Max Value 366 Max Value 0 61 366 Min Value i Min Value aos 365 for Sigma for Sigma 10 10 Sigma Sigma 0 195 0 458 E Sigma 1 167 2750 6 Sigma 1 167 2 750 sl Figure 27 Statistics Summary Screen for a Two Spindle System Ingersoll Rand Company 2004 Page 51 Section 4 Quality Control am Assembly Solutions Screen Element Explanation Select Spindle Use this drop box to select the spindle for which the tightening data will display You can display the data for Spindle 1 Spindle 2 for both spindles or f
111. spindle connector is locked down If the Insight is equipped for attaching external devices printers computers etc the proper devices have been attached to the appropriate ports in the connector panel located on the controller s left side The main enclosure is closed and locked The AC power cord is plugged into a properly rated electrical circuit See the Precautionary Information at the beginning of this manual Once the above checklist is verified you are ready to power up the Insight IC Fastening System with Graphics Display 1 Turn the Main Power Switch to On This switch sends power to the internal Motor Controllers the graphics display and the keypads but does not send power to the spindle s or powerhead Push the green Spindle Power Switch located on the front panel The Run Main screen will be displayed on the graphics display panel indicating the startup was successful and the Insight IC is ready to operate e When you want to turn the entire Insight system on or off use the Main Power Switch e After turning the system off wait at least five seconds before turning it on again e When you want to turn only the spindles on and off use the Spindle Power Switches Ingersoll Rand Company 2004 Page 15 Section 1 Installation am Assembly Solutions The System Initialization Screen You can use the Setup menu System Initialization screen to set a broad variety of basic Insight IC parameters These
112. splayed at any time Page 46 Ingersoll Rand Company 2004 am Assembly Solutions Section 4 Quality Control Tightening Curves Screen This screen is used to display tightening curves in real time during fastening operations It allows the user to view tightening curves freeze the curves for closer inspection and display selected parameters Below is a typical Tightening Curves screen RUN 06 27 01 Tightening Curves el 14 32 30 Select Plot Type Select Spindle Torque vs Angle SJ Spindic 1 E Config 4 Strategy Torque Tightening Figure 23 Run Tightening Curves Menu The information this screen displays depends upon how the Run Main screen is set Above the main window the spindle number configuration number configuration name and strategy name will be displayed as described under Run Main Screen on page 45 Screen Element Description Select plot type Use this drop box to select the type of plot you wish to display You can choose from e Torque vs Angle e Torque vs Time e Current vs Time Select Spindle Use this drop box to select the spindle s or powerhead whose parameters will display This drop box will not be present if your Insight is a one spindle model Freeze This button freezes the tightening curve for study Fastening will continue but the new curves do not display The frozen curve remains until the user presses the button again or until the user exits this screen Tighteni
113. st Data Out 87 Descriptions ainiin eens scaddutdaaraade 87 Setup PDorcedure 87 GUPEIN ZOMG tee ekd NEEN 39 40 Cycle Log Sereen cccccceccccnereeseeceeeeeeneeees 49 57 Page 91 Index D Data Entry BOX iicc cncliteieh sleidc 6 7 BEICEOIU OAN seis ccicsessauacoaridasdesaccweudaavencauaves 85 87 REIH 16 Definitions of System Parameters seeeeeeeen 71 Delay Control Strate 41 Deleting a Powerhead eseeeeeeeeeeeeeseeerseree 25 D VICEN Gls serai tet nehintiewndin 16 Diaonoseice ereere rrenernssreer ernennen 60 Men eegene ii E R 2 Shutdown Codes AAA 67 Diagnostics Menus 60 Discrete Inputs Gcreen 62 Discrete Outputs Green 63 Event Log Green 64 System Test Screen eceeseeeeeesteeeeeeenaees 60 Tool Test Green 66 Variable Timer Outputs eenean 63 Directional Arrow Keys 3 Discrete Inputs Green 62 Discrete Outputs osnnseseeeeeeseeseeenrtnrrrnnenneereerrene 63 Discrete Outputs Green 63 Display 210 AE gue di Heer Meena ees 6 7 Graphics Display Green 5 Drag Torque Control Strategy 0 eeeeeeeeeeee 40 Drag Torque Zone 40 Drop BOX EE 6 7 E Edit a Powerbead 24 Electrical Connection ee ceeeeeeeeeeeeeeeeeeteeeeeeeneaes 9 End of Run Data 31 End of Run Eiter 16 Engage Gren 31 Enter Key 2 ecadeecccesieiehcedeaenieecsiedieisienns 3 4 EOR eege doan aaen aiana E Ta aaia 31 Data Advanced Progoramming 31 Data Out 17 NIE 16 Escape key 3 Ethernet sicvesendececeti
114. st a Configuration Switch 000 cccccccccceereesseeeeeeeesesssensneneeeeenes 11 Light Box Connection and Setup vseccsiccnccensssnescsssnarenansneaeoenes eseecanadanntonpadenedadenmeds 11 Parallel Printer Connection and Setup 12 Serial Printer Connection and Setup AEN 12 Computer Connection and Setup via the Serial Port 12 PLC Connection and EE 12 Activating AVM acetic eae eet 13 R eiving El Re re 14 SEENEN 14 Field Bus Card COmme CO DE 15 Gell StartUp snserceie neea a a a a a eaa E 15 The System Initialization Screen AEN 16 Ingersoll Rand Company 2004 Page i HR Assembly Solutions EOR EEN 16 Data a 16 Communication Protocol Zeta EE 16 B r Code ee 17 Re E 17 Passive Bar Code mode ENEE 17 Active Bal COGS e EE 17 Bar Code in Passive Mode ccssisssisas cacaveiicnasdnccanioseaoleatieaommrse nana 17 Bar Code Setup for Passive Mode EE 17 Bar Code Operation in Passive Mode EEN 18 Bar Code in Active e TEE 18 Bar Code Setup for Active MOU Gis scscvsiicnsssaninesienniesciasnversmeorseabasasundsaarsedvarmenns 18 Other Bar Code Operations cccccccscsceecss secsseccseciccectecnccsscacauacsscsncanaceseasaseadooasaeces 19 Disable Tool Until Scan Option vciccccccssstcecswccnsssscacatesndencsandcoadiandsoddiatensecaecdaces 19 Changing from Active to Passive Bar Code Mode 19 Changing from Passive to Active Bar Code Mode 19 Removing Bar Code Operation osrcccccccccencsencncnsnsesesevenverectuecteeceeeeneceneeneeeenectee 19 Bar Cod
115. stem health of the Insight IC Fastening System with Graphics Display This function also diagnoses system problems The user can view diagnostic test results and store them for future reference The Diagnostics menu has five sub menu screens System Test Screen With this screen the user can request and display diagnostics test results on the tightening tools spindles and on the Motor Controllers MCEs Below is a typical System Test screen graphic 12 08 2003 DIAGNOSTICS 02 55 32 Diagnostic Wizard Expected Range Select the Spindle for which you wish to perform diagnostic tests on Recommended Action on Failure Select zue spine gi New Test value Result Time Date Stamp value Result Motor temperature 26 32 deg C PASS Motor temperature 27 08 deg C PASS Amplifier offset 0 87 Shunt Cal PASS Amplifier offset DES Shunt Cal PASS Shunt calibration 100 73 ideal PASS Shunt calibration 102 21 ideal PASS Sine Offset 167 00 Counts N A Sine Offset 167 00 Counts N A Cosine Offset 176 00 Counts N A Cosine Offset 176 00 Counts N A Motor Kt 0 00 Nm Amp NiA Motor Kt 0 00 Nm Amp NiA MCE Temperature 30 73 deg C MCE Temperature 2 23 deg C Figure 33 Diagnostics System Test Menu Page 60 Ingersoll Rand Company 2004 aim Assembly Solutions Section 5 Diagnostics and Troubleshooting Screen Element Function Wizard
116. structure and result in personal injury collapse and personal injury Replace battery with the same or equivalent type Verify the operation of the Earth Leakage Circuit recommended by the battery manufacturer Observe Breaker ELCB once per month with the test button A correct polarity when installing battery Dispose of used malfunctioning ELCB can result in risk of electric shock or batteries according to battery manufacturer s injury instructions Failure to follow instructions could result in personal injury GROUNDING INSTRUCTIONS FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN ELECTRIC SHOCK FIRE AND OR SERIOUS PERSONAL INJURY THE CONTROLLER MUST BE EARTH GROUNDED The controller is equipped with a three prong plug and cable Comply with all local electrical codes for connecting to Power Supply The Power Supply must be within voltage and frequency requirements as specified below DO NOT use the controller on a 2 prong plug outlet with an adapter Always check that your ground is operating properly on the outlet by a qualified electrician before using the controller GROUNDING SPECIFICATIONS Model Voltage Requirement Single Phase Identification Volts Hertz Amperage 115 50 60 16 Amps IC1G 230 50 60 8 Amps 115 50 60 20 Amps IC2G 230 50 60 13 Amps THIS APPARATUS MUST BE EARTH GROUNDED The three conductors of the mains lead attached to this apparatus are identified with
117. te Time Result Torque Result aka 07 20 2003 01 36 46 Pass 0 15 Pass 365 16 15 14 07 20 2003 01 36 39 Pass 0 16 Pass 07 20 2003 01 36 38 Pass 012 Pass 07 20 2003 01 20 56 Pass 0 24 Pass 13 07 20 2003 01 20 53 Pass 0 19 Pass 12 07 20 2003 01 20 51 Pass 0 19 Pass 11 07 20 2003 01 20 40 Pass 0 Pass 10 07 20 2003 01 07 28 Pass I Pass 07 20 2003 01 07 28 Pass 1 Pass 07 20 2003 01 07 27 Pass Pass Figure 31 Statistics Cycle Log Screen Screen Element Description Select Spindle Use this drop box to select the spindle or powerhead for which the cycle log data will display This drop box will not be present if your Insight is a one spindle model Sort By Use this drop box to select the criteria by which the cycle log data display in the screen s main window The options include Cycle Configuration Cycle Result Torque Result and Angle Result View By Use this drop box to select which fastening cycles display in the screen s main window The options here depend on the criteria selected in the Sort By drop box Main Window This window displays the cycle log summary table The row order of the data will vary depending upon the sorting criteria selected in the Sort By drop box Below is additional information on the parameters displayed Message Box The Message Box summarizes system
118. tegy you may want to insert one or more steps To do this select the Insert after above step button then program the desired programming strategy in that step Clearing a Step Sometimes you may want to clear a previously programmed step You do that by going to the Strategy drop box for the step and selecting None If you move to another screen and subsequently return to the Advanced Setup screen you will find that the Insight IC has removed that step from the sequence and left adjusted all of the subsequent steps Clearing a Configuration Sometimes you may want to eliminate an entire configuration that is the entire sequence of steps for a particular fastening sequence including the Engage step To do this simply click on the Clear All Steps button on the Advanced Setup screen A dialogue box will appear for you to confirm the deletion End of Run Data EOR Remember the Insight IC controller saves End of Run data at the end of each configuration If you program configurations with multiple steps you may only want to retain EOR data for the final step In which case EOR Data should be set to Disable which is the default setting for the intermediate steps NOTE However if a tightening fails for any reason the Insight IC controller always records the EOR data This is done to help you determine why the tightening failed So even if you have set EOR Data to Disable for the intermediate steps in a configuration if you have a fail
119. then use the arrow keys to move to the option you want and then select that option by pressing Enter The Escape key on the navigation keypad can be used to cancel certain operations Ingersoll Rand Company 2004 Page 3 Introduction HR Assembly Solutions Numeric Keypad If you have navigated to a screen element that requires data entry a data entry box you will use the numeric keypad to enter information numbers and or letters As shown on the graphic below selected number keys are also labeled with three letters 7 8 9 The Backspace Key GHI JKL MNO PRS TUV WXY 1 3 The Enter Key Figure 3 The Numeric Keypad Most of the data entry boxes are for entering numeric data only Simply enter a numeric value directly from the keyboard If you make a mistake press the backspace key to delete the number When the correct number is displayed press either Enter key to enter the value There are a few data entry boxes that allow you to enter alphanumeric information For example there are boxes that allow you to enter a plant name example Assembly Plant 2 or an assembly configuration name example Right Door When you are in these data entry boxes the Insight system automatically puts the numeric keypad in alphanumeric mode In that mode pressing a numeric key once will enter the first letter on that key twice the second letter three times the third letter four times the number When you have the correct character
120. ther asynchronous event 19 Bad torque reference the torque step reference tare overshoot was greater than the step limit 20 Watchdog monitor shutdown The MCE hardware watchdog faulted 21 When all re torque steps are completed without reaching the set point 22 When Yield Override is enabled and fail on yield is disabled if the final torque reached is below the torque low limit Ingersoll Rand Company 2004 Page 67 Section 5 Diagnostics and Troubleshooting am Assembly Solutions The Help Function The Help function is designed to assist the user in understanding the terminology required to setup and program the Insight IC Controller Pressing the Help key will give the user a screen with a description of all the terms associated with the screen on which the Help key was pressed See the following figure 07 20 2003 01 14 49 m Help Main Menu RUN MAIN SCREEN Go to Help Topic This screen is used primarily to display actual torque and angle values at the completion of each fastening The large box es in the middle of the screen show torque and angle values during tightening Spindle Selection Select whether data for one or both spindles is to be displayed NOTE Ona single spindle system the spindle selection drop box becomes a Label on the screen Configuration Selection This drop box will appear when more than one configuration has been programmed and the Configuration Selection drop box in the Spindle In
121. tightening strategy are based on reaching a programmed torque or angle target respectively The Insight IC Controller has an additional selectable feature in Advanced Setup for these two tightening strategies This is called Yield Override When selecting Torque Control or Angle Control in advanced setup there is an additional check box for Yield Override When this option is selected the tightening strategy works like a normal Torque or Angle strategy except it additionally checks that none of the joint components has yielded before the target torque or angle is reached If a yield condition is reached before the target torque or angle is reached a yield override condition is indicated If the torque or angle achieved at the yield override condition point lies within the programmed torque or angle limits the default condition is that the tightening will be accepted If the user does not want to accept this condition select Fail on Yield Override in which case the tightening will be rejected both torque Hi and Lo lamps will be illuminated and a Yield Override Failure will appear in the Message Box In cases where yield is detected before the low limit parameter Final parameter is below low limit in yield override appears in the Message Box Procedure 1 Press the Setup Main Menu key and then the Advanced Setup Menu key 2 In the Select Spindle drop box select the spindle you want to select 3 Inthe Config drop box select the conf
122. tool switch shall increment the gang counter by one The gang advance will only advance the gang count by one in between cycles This is in effect an operator override for one bad tightening operation in gang count Auto Calibration Auto calibration allows you to calibrate the Transducer Range for the Insight s tool s using an external torque transducer Clicking on the Auto Calibration button on the main Spindle Initialization screen brings up the first of three auto calibration screens as shown below Auto Calibration The Auto calibration function is a quick and easy way to calibrate your DC spindle to an external torque transducer by comparing readings between them First select spindle number you want to calibrate then select the number of readings you wish to compare When all settings have been made please press the Begin Calibrate button to continue Select Spindle to Calibrate SPINDLE 1 Humber of Readings to use for Calibration 1 25 SY Begin Calibration Figure 12 The First Auto Calibration Screen Ingersoll Rand Company 2004 Page 21 Section 1 Installation d Assembly Solutions Follow the instructions in the wizard box at the top of the screen When you press the Begin Calibration button the second auto calibration screen displays as shown below SEIP ites Spindle Setup Auto Calibration At the completion of a tightening the peak torque measured by the Insight will be placed in the column label
123. tools require the operator to activate two switches simultaneously to ensure his hands are safely away from the machinery User entered System Name A data entry box for assigning a system name or other system identifier maximum of 12 letters and numbers User entered Tare Compensation Mode If checked then the torque of the next step will be offset by an amount equal to the average prevailing torque User entered Target Inspection Angle The number of degrees of rotation required to complete the drag torque phase User entered Target Prevailing Angle The number of degrees of rotation required to complete the prevailing torque phase User entered Time Data entry box to enter the current time User entered Tool Data entry box to select the specific I R tool attached to the Insight s spindle User entered Torque at Seat Peak torque value when joint is seated User entered Torque Filter Removes high frequency noise ripple from the torque signal to improve measurement accuracy Torque Hi Limit Torque Hi The maximum permissible torque value for a fastening User entered Torque Lo Limit Torque Lo The minimum acceptable torque value for a fastening User entered Ingersoll Rand Company 2004 Page 75 Appendix 1 System Parameters HR Assembly Solutions Torque Overshoot If tightenings are consistently overshooting the Tor
124. tored curves and display it on the screen as the master plot Ingersoll Rand Company 2004 Page 55 Section 4 Quality Control dp Assembly Solutions Screen Element Description Plot Update Pressing this button removes any plots on the screen except a Master plot and places new plots on the screen as determined by the setting in the Select Capture Type drop box Zoom In Clicking this button will zoom in on the tightening curve displayed on the screen The button name then toggles to Zoom Out and now clicking it returns the display to normal scale When zoomed in use the left and right arrow keys to move along the plot Save Master You may have a particular tightening curve that you want to use as a reference or master a curve against which you can compare other fastenings Select the plot you want to save with the Select Plot drop box then press this button to save it as the Master plot A float box comes up that allows you to select a location to save the plot Full View This button expands the plot window to full screen Pressing the Close button on the bottom of the expanded screen will return the screen to normal view Plot Window The tightening curves you have selected with the buttons and drop boxes above display here Below is additional information on how to analyze the plot s displayed Plot Summary This window to the right of the tightening curves lists information about the Windo
125. tput name Below is a typical Discrete Outputs screen DIAGNOSTICS Q Be Discrete Outputs SEEM PER Duration Reject Buzzer 0 0 Paint Marker 2 0 HB 1 0 3 High Torque TREI Discrete Outputs C o Status Output Function H Not Active I Reject Buzzer E Not Active e E a Cycle Complete nl E Figure 35 Diagnostics Discrete Outputs Menu Variable Timer Outputs Paint Marker and Reject Buzzer The variable timer is one of the features of the Insight IC It is used to setup the programmable timer discrete outputs The timer can be set on the Diagnostics Menu Discrete Outputs screen by entering the required timer value from 0 1 seconds to 9 9 seconds The output will remain ON until the timer expires for any value other than zero The default value is zero and the timer is disabled Ingersoll Rand Company 2004 Page 63 Section 5 Diagnostics and Troubleshooting am Assembly Solutions Event Log Screen The Event Log screen is a large scrollable window that logs the date and time that certain important Insight events occur The events recorded include hardware and software faults such as a tool over temperature event and significant user actions such as changes to a tool s transducer range or angle constant This record of significant events can help users investigate and troubleshoot problems DIAGNOSTICS Q RE Event Log Date Description 07 20 2003 MC power up 07 20 2003 All device
126. ts to a lower speed to improve accuracy User entered Shiftdown Speed The tool s speed during the shiftdown phase User entered Shunt Calibration A system test that measures the front end electronics gain as of ideal shunt calibration voltage System calculated Sigma The standard deviation co used for statistical calculations System calculated Slope Chord Length The number of degrees over which the slope is calculated User entered Slope Deviation If the prevailing angle is set to zero then the Insight will define the end of the Prevailing Torque Zone by the slope value entered here User entered Slope Interval Number of degrees between each slope calculation User entered Snug Torque also called Torque Threshold The torque required to seat components in the joint also the torque point at which angle begins to be measured User entered Softstart Speed The speed the tool will run at when the Softstart input is activated Spindle Status Controls spindle operation Selecting Enabled allows the tool attached to the spindle to operate selecting Disabled prevents tool operation Spring Forward Date The date for the start of daylight savings User entered Start Mode Defines the type of signal initiating tool start For hand held tools select throttle Pulse indicates a momentary external signal Dual requires two switch closures because some
127. ue vs angle curve that signifies onset of yield User entered Page 76 Ingersoll Rand Company 2004 GD Assembly Solutions Appendix 2 System Specs and Spare Parts Insight Technical Specifications The specifications for the Insight IC Tightening System are shown below Measurement Accuracy 0 2 of torque full scale 1 count of angle degrees Measurement Resolution 0 025 of torque full scale Torque Transducer Bridge Excitation 5VDC GND Torque Transducer Zero Offset Drift Compensation 0 4 of full scale Input Signal Sensitivity 2 0 mV V Calibration Values read from tool memory Automatic digital correction Frequency Response Torque Filter Selectable 75 Hz 150 Hz 350 Hz 500 Hz 750 Hz Keypad Membrane keypad containing six hot keys six function keys numerical keypad and directional keypad Display 10 4 inches 256 color 640 x 480 pixels 50 viewing angle Parameter Sets 32 per spindle Number of Cycles Stored in Memory 5 000 per spindle 50 000 per spindle with optional PCMCIA flash card Statistics Data Memory 100 000 per spindle Communications 4 Serial RS 232 Ethernet Parallel printer optional Profibus and Devicenet Control Inputs STANDARD Free Speed Soft Start Forward Reverse Tool Disable Tool Enable Configuration 1 Configuration 2 OPTIONAL Configuration 3 8 Gang Reset Configuration Reset Safety L
128. unction numbers Ensure each tool is attached to the Insight controller and turn the controller on using the rotary switch Push the green Start button on the Spindle Power Switch on the front panel to power the Motor Controller and the tool Go to the Setup menu and the Spindle Initialization sub menu screen If your configuration switch has more than eight positions select External Binary from the Config Select drop box If your configuration switch has eight or less positions select External Discrete from the Config Select drop box Setup of the Configuration switch is now complete How to Test a Configuration Switch 1 After you have connected and setup the device go to the Diagnostics menu and the Discrete Inputs sub menu screen As you move the switch you should see the appropriate indicator light up on the screen indicating activity on the configuration lines Note If you selected External Binary in the Config Select drop box on the Setup menu s Spindle Initialization screen then the first four configuration lines will indicate the binary encoded number for the configuration selection with 0000 indicating configuration 1 is selected Light Box Connection and Setup 1 Connect the light box to the Insight controller s terminal blocks on the controller s left side with the appropriate accessory cable See Appendix 2 System Specs and Spare Parts for terminal block details Ensure a tool is attached to t
129. uration he can select either all configurations or a specific one by number from 1 to 32 If the user sorts by Cycle Result Torque Result or Angle Result he can select either Pass Fail or Pass High Low as appropriate Separate Data Fields by The user has three check boxes to specify data separation either a comma a space or a semi colon Send Header with Data Checking this box allows a data header to be specified Edit Data Format Clicking this button brings up a second Export screen to select the specific statistical data for export Below is additional information on this screen Message Box The Message Box summarizes system status and provides warnings and alarms Ingersoll Rand Company 2004 Page 53 Section 4 Quality Control dp Assembly Solutions Clicking on the Edit Data Format button on the screen above brings up the following Export screen ST AT S E 4 10 02 2003 Export Cycle Log 01 27 36 Use this screen to choose the order in which data is sent Number the parameters in the order they are to be sent Parameters set to zero will not be sent Make E OP Data Out Same Format Figure 29 Second Statistics Export Cycle Log Screen The screen above lists 26 statistical parameters As explained in the screen s wizard box you can select the specific statistical parameters and their order by entering a sequential number in each parameter box Entering a zero means
130. ure you will have the EOR data to review The Engage Step The Engage Step drop box only displays parameters for the Engage strategy These parameters allow you to specify exactly how the Insight spindle will engage the fastener The Engage parameters are listed below e Tool direction s Soft Speed e Reverse Speed e Acceleration Ingersoll Rand Company 2004 Page 31 Section 2 Programming d Assembly Solutions e Gang Count e Auto Increment e Cycle time out e Torque Filter e Fault backout speed e Fault backout angle e Final fault backout Hi torque e Retry fault action e Number of retries e Final fault backout angle e Fault action e Tube nut reverse speed e Tube nut reverse threshold Powerhead function only Some of these parameters are self explanatory or are described in the Appendix 7 System Parameters section of this manual The Gang Count Auto Increment and Torque Filter parameters require further description Gang Count Some assemblies have multiple bolts that must be fastened in sequence called a Gang For example if you have a four bolt assembly you can set the Gang Count to 4 Insight will then keep track of each fastening and when all four fastenings have been completed within specification a Gang Complete message will appear on the display screen If the Gang Count is successfully completed in addition to displaying Gang Complete on the screen the controller provides a
131. w plots displayed This includes the Plot Number the number of data points used to create the plot the Peak Angle and the Peak Torque or Peak Time or Peak Current depending upon the selection made in the Select Plot Type drop box Message Box The Message Box summarizes system status and provides warnings and alarms You can examine in detail the tightening curve displayed in the screen s main window by navigating to the plot window and pressing the Expand key This allows you to take control of the cross hairs in the plot window The cross hairs will appear on the curve selected in the Select Plot drop box Use the directional keypad s arrow keys to move the cross hairs to the region of interest on the tightening curve Note that the numerical values for the curve at the cross hairs location display on the screen Page 56 Ingersoll Rand Company 2004 HD Assembly Solutions Cycle Log Screen Section 4 Quality Control This is a view only screen that displays various tightening parameters that are monitored recorded and stored in memory for up to the last 5 000 tightening cycles This screen functions generally the same as the Cycle Log screen under the Run Menu but with the added ability to sort data Below is a typical Cycle Log screen ST ATS Q 07 20 2003 Cycle Log 03 42 05 Select Spindle Sort By View By Spindle 1 Cycle Prev 1000 Entries Cycle Cycle Torque Config Step Da
132. x 2 When the warning box appears select Yes Parameter Transfer The parameter transfer function is used to download or save Insight IC parameters and user upgradable versions of the Insight application software The Parameter Transfer screen is shown below 10 02 2003 w 4 01 25 40 Tool Memory Select Spindle 1 Spindle1 IN View Tool Memory Parameter Figure 16 The Parameter Transfer Screen The Load Data button allows data transfer data refers to Configuration Parameter Sets and System Settings using either a floppy disk inserted in the floppy disk drive or via a PCMCIA Flash Disk inserted in the PCMCIA slot in the Insight IC Controller The Save Data button allows data data refers to Configuration Parameter Sets System Settings and Tightening Data Reports from the Insight IC Controller to be downloaded and saved on either a floppy disk or PCMCIA Flash Disk The Load Software button allows user upgradable Insight IC application software to be uploaded e To upload via Floppy or PCMCIA select the relevant check box and then select Load Software e Only use the Flash Disk option to upgrade MCE Motor Control Electronics software after first loading Olympus bin to Config Directory via FTP Ingersoll Rand Company 2004 Page 25 Section 1 Installation aim Assembly Solutions Tool Memory The View Tool Memory button presents the user with a screen displaying all of the parameter values store

How to Program a Torque Control Strategy in Advanced Setup

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