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User manual 6159930290-01.
Contents
1. 23 13 5 1 Forward recording NEE 24 13 5 2 Backward recording 24 13 6 How to add copy paste delete a Pset 24 14 STEP PROGRAMMING 24 14 1 How to create a step 24 14 2 Step type selection 24 14 2 1 Tightening 24 14 2 2 LOOSNINQ is nisnmsenmrenamnencrane 24 12229 JUMP se 24 14 3 MONO EE 25 14 3 1 Peak or Final Torque Angle 25 14 3 2 Current Check at end 25 14 3 3 Slip nr me 25 14 3 4 Stick E e E 25 143 5 Ten 25 14 3 6 Rundown angle 26 14 4 Options LR 26 14 4 1 Latch threshold 26 IA A Z Andlereset 26 14 4 3 TIorouereset eee 26 14 5 Motor control sese 26 14 5 1 Auto set Up 26 14 5 2 Speed settings sss eee 27 14 6 General parameters e e 27 14 7 How to add copy paste delete a step 27 15 ASSEMBLY PROCESS PROGRAMMING 28 15 1 Simple Assembly Process 28 15 2 Advanced Assembly Process 28 15 3 Start ee el e nn 28 15 3 1 Logical operators 29 15 3 2 Start by number 29 15 3 3 Start by identifier AA 29 15 3 4 Start by input event 29 15 4 Process Le le noms 30 15 4 1 Assembly action snannnneneenneennennnnennn 30 15 4 2 Set
2. Threshold 32 00 counting Nm amp Deg i Angle with Number of sips 5 latched threshold Target angle eee N R L A Angle without Eet latched threshold Parameters S Threshold torque from where the number of slips starts to be measured Number of number of times where the torque goes slips over and under the threshold Stick slip is detected if the torque does not succeed in exceeding the stick slip monitoring threshold without going over and under this threshold N times Stop conditions Stick slip detected Report OK No stick slip detected For each channel the 3 report controller LEDs will light as follows LED EE esignation Stick slip detected Angle lt Max angle AND Torque lt Remove fastener limit Stick slip detected Angle gt Max angle OR Torque gt Remove fastener limit Result data Error IF stick slip detected 6159930290 01 03 2012 41 12 MOTOR CONTROL Speeds are set manually or by using the Auto set up function Speed units rpm or of max tool speed are to be selected in the controller user interface In any case a minimum speed of 30 rpm is always recommended Stop conditions for all tightening strategies Timeout Pset start signal going down Hardware failure max current max temperature 12 1 2 speed Speed applied from Downshift torque Downshift speed to the 2nd Downshift to break inertia or very hard joints Speed applied from the 2nd Downshift
3. oi DO EL AIR EZZ als X Assembiyine x Assembly ine Singletool Tightening unit Parameter set 1 Parameterset 1 Tightening Ja N Aer ine IP sep pe Deeg S dere ine GL H Single tool S Tightening unit Equipment CR Parameter set 7 1 Parameter set Control Torque Re zen Le E cont Assembly process Nm 11 Assembly process Maxtorque 5 50 Targettorque 5 00 PENN A Min torque 4 50 i sep Management Angle threshold 2 50 Hae E Paste Legend Menu area Tool bar Assembly line build area Assembly line tree view Details Log area OO Om P GAMM The open padlock shows that all displays and settings are available for anybody Contact your CVIKEY administrator for support Use this key to view the user guide Version 1 30 1 9 Current software version Click these buttons to collapse or BUNNS El 5 expand the trees How to quit CVIPC Click Exit in the Menu area 4 READ BEFORE STARTING In a network connection mode settings and A programmings made in CVIPC will be effective in the controllers only when data are transferred from the PC to the controllers Only one user is allowed to make changes at once i e if someone is modifying one controller the user CVIPC connected to the same controller is not allowed to make changes This is the case for several CVIPC connected on the same controller
4. OK Gei identifier tables e Click on Single tool Click on Assembly line in the Build tree and enter an e Enter an unique name up to 40 characters the controller unique name up to 40 characters model and the tool model e Click on Change to customize the comment up to 100 characters The next step is to configure the controllers and tools EE If the controllers are already connected to the network use the Scan icon to get all data and re arrange them if 10 1 User interface necessary If not click on the Single tool icon to configure your Mee controllers and tools and proceed as described in the Ie G following chapters User interface ges R5232 Date and Time 2 Controller user interface 9 HOW TO SCAN Torque units DEE Speed units pm Language Engish Q e Before starting refer to chapter Menu area Options Preferences to decide the extent of the scan whole network or specific controller CVIPC is able to scan all networks and collect information from the controllers Keypad beep en EI Back light auto off 7 Back light timeout 2 min Connected controllers are then imported in the Assembly line build tree as single tools Nm ft Ib in Ib kg m kg cm oz in Speed unit rpm of max tool speed Scan for VB control English by default D fe Keypad beep If selected this function enables a Beep Dese IP A
5. e Move the cursor to get the best adjustment until you can click on Apply The Downshift torque value will fit accordingly e Click on Advanced to select the degrees from 50 to 100 of target torque e Click on Apply to valid your selection 6159930290 01 03 2012 14 5 2 Speed settings e In case you are familiar with speed settings click on Speeds There are 2 possibilities 2 speed 3 speed ergospeed 2 speed Strategies Motor control General Speeds Auto setup 2 Speed control 2 speeds 4 Tooltype EAD32 900 Maxtool speed 900 mm Extemal stop None X Auto set up Nm Downshift torque 4 50 Cycle start torque m 0 40 Acceleration time NN Q FN 9 2 speed motor control is the most popular and the simplest to use lt runs high speed up the downshift torque and finishes the tightening operation at lower speed Fill in the values Select the Rotation direction Clockwise Counterclockwise Select External stop to stop the current phase and shifts to the next one as soon as one of the following signals shifts to 1 on rising edge on falling edge on change on high level on low level 3 speed ergospeed Strategies Motor control General Speeds Auto setup Tooltype EAD32 900 Maxtool speed 900 rpm Extemal stop None Auto set up Rundown s
6. Data mapping where is defined what is the meaning of data exchanged e g final torque tightening result 6159930290_01 03 2012 PLC Memory Mapping CVI 3 Memory Mapping PLC DATA INTPUTS CVI3 PLC DATA OUTPUTS controller Fieldbus 3 2 Example default configuration As example of hardware mapping here is the default hardware mapping a C Jelete In this mapping the PLC can read PLC inputs 14 bytes organized as follows The PLC can write PLC outputs 2 bytes organized as 16 bits at address 0 Here is the default data mapping Tightening result Final current FLOAT UINTS A meaning a variable has been associated to each address e g Pset selected Torque Trend Note that the hardware mapping and the data can be completely different The only rule to respect is to put a variable only at the address where a hardware item has been declared In the screenshot above are represented the PLC s inputs i e data coming from CVI3 to PLC 6159930290_01 03 2012 The default configuration is Address Name Description Format Size CVI3 State of the 8 CVI3 UINT8 8 bits outputs outputs By default there are no ouputs activated on CVI3 In CVIPC you can active a default output configuration by clicking on set default in I O and acce
7. Select one Single tool and click on that icon to get information about the controller and the tool Controller 2 Se Part number 6159360079 Manufacturing date 07 f vr 06 Serial number 07B0014577 Software version 1 3 1 6 Tool Identification Characteristics Tooltype EAD50 900 Gearratio 25 11 Serial number N A Max tool speed 900 mm Version 2 2 7 Max motor current 45 A Manufacturing date 01 janv 10 Maxtorque 50 00 Nm Commissioning date N A Parameter release 9 Manufacturer Desoutter Nm 0 Motortype EB6 Max reindex torque 0 Motor direction Output Direction Yes Inverter No Main torque transducer Calibration value Nm Initial calibration value 49 93 Nm Unbalanced reference 1513 Unbalanced tolerance 3 Max offset 2252 Min offset 1844 Data updated successfully Update Exit 11 1 Controller Available information about the controller are manufacturer information Manufacturing date 11 2 Tool Available information are Identification Tool type manufacturer information Manufacturing date Commissioning date This date is automatically recorded after 2 000 tightening Psets It is used to initialise the warranty period manufacturer information Motor type Characteristics Gear ratio Max tool speed Max motor current manufacturer information Max torque Parameter release Max reindex torque Motor direction output direction Main torque transducer Calibrati
8. When keep alive activity control is enabled the user must specify the keep alive inactivity timeout Once this duration is expired without new keep alive activity the disconnection actions are executed When keep alive activity is detected AND data from PLC are present re connection actions are executed 6159930290 01 03 2012 Keep alive Behaviour Force PLC to force a new read of PLC outputs mode output reading Identifiers which normally need to No keep alive control change to be taken in account are also forced Bit change If there is no change in keep alive input during a duration longer than keep alive inactivity time out then the Fieldbus is considered as disconnected 4 4 Assembly process When using assembly process with Fieldbus the user can select some specific behavior associated to the item AP SELECTION tt Fieldbus Mapper File View Fieldbus general configuration Results Management Fieldbus Status management Assembly Processes Options Abort the running AP when another AP number is requested Restart finished AP when same AP number is requested by PLC Bit falling edge If the input keep alive stays at low level during a duration longer than the than keep alive inactivity time out then the Fieldbus is considered as disconnected KEEP_ALIVE sae em Bit rising edge If the input keep alive stays at hi
9. in Process actions by using Sense input OP external input 1 8 Inputs controlled via Open Protocol 2 4 Socket tray ans Deserption s Socket lifted bit 0 4 Only used with CVI II sockets Informs which socket has been lifted Binary coded 6159930290_01 03 2012 51 APPENDIX USER INFO CODES Error Description Resolution procedure no Tubenut open 1 The tubenut tool is detected as open Tool connected 1 The tool has been connected and recognized correctly by the controller No tool connected 1 The tool has been disconnected 2 If the tool is not physically disconnected check the tool cable Span failure 1 Span value from torque sensor is outside bounds 2 Try once again to start the tool without any mechanical constraints If the problem occurs again contact your Desoutter representative for support 5 Offset failure 1 Offset value from torque sensor is outside bounds 2 Try once again to start the tool without any mechanical constraints H the problem occurs again contact your Desoutter representative for support Tool motor rotor locked 1 Unable to start tool motor rotor is locked change your tool 2 Contact your Desoutter representative for support Tool motor too hot 1 Tool is locked because its maximum motor temperature has been reached to avoid any damage 2 Tool will remain locked as soon as motor temperature comes back to its normal value Tool angle fault 1 Problem detected with the tool angle
10. To enlarge the display of work remove the Build area by unticking it in the View menu 15 3 Start conditions There are 3 types of starting actions start by This is the Assembly Process number It number can be selected by the controller HMI by an I O selector box by Fieldbus or Open Protocol start by E g a barcode This implies that you have identifier already set up an identifier in CVIPC Refer to chapter Identifier table to create an identifier start by input This implies that you must pick an input event event and assign it to a physical output 6159930290 01 03 2012 Start conditions OR Start conditions vil By identifier ga g 1 Start by number 4 By input event AND forced order un By identifier amp E By assembly number By input event 1 Assembly AND free order Mi By identifier SE ES By assembly number Post processing 0 4 By input event Manage actions aJ Delete General dr Export to file Sj Import from file Description Start by number Comment Selected by Assembly Process number Selection source 1 0 Z 15 3 1 Logical operators You can add up to 7 parallel or sequential actions linked by one of the following logical operators The process starts if 1 or the other condition is fulfilled For example backup mode handling The Assembly Process normally starts by an identifier If the identifier i
11. 209 Pset conversion failed 1 Software internal error 2 Pset is corrupt Try to download it to the controller If the error persists contact your Desoutter representative for support 210 Invalid Pset selected 1 The Pset currently selected does not match the selectable one in the Assembly Process 211 Invalid trigger configuration 1 The tool currently connected to the CVI3 is not equipped with the trigger required by the tool trigger configuration 2 Adjust your tool trigger configuration to the tool connected or change the tool according to the expected trigger configuration 212 Result could not be persisted 1 It was not possible to persist the tightening result in the controller 2 Contact your Desoutter representative for support 213 Drive connection lost 1 Connection with the drive has been lost 2 Reboot the controller 3 If issue remains contact your Desoutter representative 214 RS232 power short circuit 1 Serial peripheral default 2 Disconnect and reconnect 3 Check the serial peripheral 215 Drive current calibration failed 1 Current calibration failed 2 Try once again 3 If the problem occurs again contact your Desoutter representative for support 216 Drive current too high 1 Max current exceeded 2 Contact your Desoutter representative for support 1 Drive disabled 1 Drive disabled by external source 2 Contact your Desoutter representative for support Drive gate voltage too low 1 Drive hardware f
12. 0x63 99 0x63 0x00630063 som o Un ooo 6 3 Multiplier coefficient This coefficient is a value which is multiplied with the variable before being copied in memory For example you set Multiplier Coefficient to 10 then if the variable is equal to 2 then PLC will read 20 2x10 6 4 Inputs variables Inputs variables are data coming from CVI3 to PLC Description ASCII value Numerical Reset condition Set condition value Constant constant value freely settable New config New config by user loaded loaded CVI3 outputs State of the 8 CVI3 outputs mm ey IO change IO change Pset selected Id of Pset currently selected i l Pset selection Pset selection AP selected Id of Assembly process currently AP Selection AP Selection selected Final torque Final torque in Nm last step i Tight start Result received Target torque Target torque in Nm last step NN Tight start Result received Min torque in Nm last step EE Tight start Result received Max torque in Nm last step SE Tight start Result received Torque trend Torque trend last step 0 no result Tight start Result received 1 min 2 max 3 accepted Final Angle Final angle in degrees last step dd Tight start Result received Target Angle Target angle in degrees last Tight start Result received step Angle trend Angle trend last step no result Tight start Result received min 2 max 3 accepted Final current in Amps last ste
13. Install date Now you get the registration code that you need to activate on the target PC in the CVIPC Service Registration menu If you buy 5 licences you will have to register CVIPC once and activate the registration code on 5 different PCs contact Form e In case of any problem click this icon Contact Form to contact Desoutter support In this example CVIPC is to be used for 1 user 2 2 3 How to uninstall CVIPC e Click Start click Control Panel and then double click Add or Remove Programs e In the Currently installed programs box click the program that you want to remove and then click Remove e If you are prompted to confirm the removal of the program click Yes 2 2 4 How to unregister your license e Login to the website https licensing desouttertools com License Management e Click this icon to view the following screen Manage existing licenses Install date License Number User XXXX XXXX XXXX XXXX AAAABBBBCCCCDDDD XXXX XXXX XXXX XXXX Type Serial number name Installs remaining Add 1 6159276010 x 11 e Click on Delete to suppress your registration code Industrial Welcome Benoit Marembert Software uninstall r Software uninstall Uninstall Key Comment r Send an email If you have any problem check the reason and click on submit button We received an email and tried to help y
14. Maxtorque 2200 Target torque 20 00 Min torque 18 00 Angle threshold 10 Stop conditions IF Torque 2 Target torque OR Angle gt Abort angle IF Min torque lt Peak or Final Torque lt Max torque AND IF Min angle lt Peak or Final Angle lt Max angle For each channel the 3 report controller LEDs will light according to the following diagram Nm Remove and replace fastener Max torque Target torque Min torque Angle threshold Min Max Abort angle angle angle Result data Peak OR Final torque Peak OR Final angle 6159930290_01 03 2012 37 4 2 Angle control A tightening angle control strategy is adapted for assemblies requiring tension accuracy It offers the insurance that the tightening operation is correctly done a regular joint quality accurate amp repeatable tension inside the joint This strategy provides a better control of the tension and a better repeatability and accuracy than the torque control strategy Example of usage Safety critical components and high reliability internal engine parts Connecting rods and engine main bearings Fly wheel Engine cylinder head Break calipers Steering components Abort torgue 28 00 Maxtorque 22 00 Min torque 18 00 Angle threshold 10 Cycle start torque Min angle Max angle 60 00 gl Target angle Stop conditions IF Angle 2 Target angle OR IF Torque 2 Abort torque I
15. Use this icon to return to the previous status Use this icon to transfer data from the PC to the controller Use this icon to transfer data from a controller to the PC Use this icon to get information about the controller and the tools When the controller is connected the icon is completed with a green tick Use this icon to display results and statistics To display the result of a particular controller select it first in the tree area This tool opens a menu to display the curves which have been transferred from the controllers To display the curves of a particular controller select it first in the tree area Dynamic Fieldbus mapping Click on this icon to start the Fieldbus mapper application Refer to CVIPC user manual to get more information about the Fieldbus modules installation Click on this icon to open CVIMonitor software which offers you to monitor results and curves in real time maintenance trouble shooting and user information history 6159930290 01 03 2012 7 ASSEMBLY LINE BUILD AREA In this area you will find the means to build your assembly processes ie tools and tightening programs 7 1 Assembly line An assembly line is a group of tightening devices which are executing simple or complex tightening operations 7 2 Equipment Equipment means tools and controllers It is composed of 1 single tool as a minimum A single tool represents the controller D CVI3
16. message every Time out on Detect controllers 5000 Ping 5000 Change IP on controller 5000 Frame response 20000 Connection to controller 10000 Front panel enabled If you want to prevent users from connecting on the controller front panel uncheck this box e Tick Scan at CVIPC startup to automatically scan the network and display all the controllers available at CVIPC launch The Scan Ping and Timeout on values are configured by default e Click on Default if you want to restore the initial values e Save and quit by pressing OK 5 2 3 3 Network or single controller scanning Network interface J Scan on all network interfaces Scan only on this interface e Choose if you want to scan the controllers on all network interfaces or on a specific interface e Click on Default if you want to restore the initial values e Save and quit by pressing OK 5 3 About This menu displays the current software version To update CVIPC software please contact your Desoutter representative for support 5 4 Help e Click the question mark to display the user manual 6 TOOL BAR In this area you will find the means to manage your work Data transfer from the PC Data transfer from the controller Information Results and statistics Curve D collection and display Fieldbus a Use this icon to save the modifications in the database
17. tool trigger or external start or reset input New start tool trigger or external start or reset input New start tool trigger or external start or reset input New start tool trigger or external start or reset input New start tool trigger or external start or reset input Batch running A batch process is running A batch operation is The batch is finished enabled or the input reset Batch count increment Batch finished new Current batch count bit 0 6 Bit indicator of current batch count Binary coded Remaining batch count bit 0 6 Bit indicator of the number of remaining tightenings in the batch Assembly Process selected bits 0 7 The Assembly Process currently selected start tool trigger or external start reset input new AP selection Batch count increment Batch finished new New AP selected or AP aborted start tool trigger or external start reset input new AP selection New AP selected or AP aborted AP finished The Assembly Process is complete whatever the reports AP finished New AP start or reset input Assembly The Assembly Process is successful AP finished and OK New AP start or Process OK reset input Assembly The Assembly Process is complete with reject tightenings or AP finished and NOK New AP start or Process NOK the Assembly Process has been aborted or AP aborted reset input Assembly The Assembly Process is being processed AP start AP finished
18. 50 00 60 00 70 00 100 Min angle Target angle Max angle Stop conditions IF Torque 2 Target torque OR IF Angle 2 Target angle IF Min torque lt Peak or Final Torque lt Max torque AND IF Min angle lt Peak or Final Angle lt Max angle Min angle Target angle Max opge Abort angle Stop conditions IF Torque 2 Target torque AND Angle 2 Target angle OR IF Torque 2 Abort torque OR IF Angle 2 Abort angle IF Min torque lt Peak or Final Torque lt Max torque AND IF Min angle lt Peak or Final Angle lt Max angle For each channel the 3 report controller LEDs will light For each channel the 3 report controller LEDs will light according to the following diagram according to the following diagram Nm Nm Remove and replace fastener 9 Max torque AS S JI Target torque Remove and remplace fastener Abort torque St E Max torque Min torque Target torque Min torque Angle threshold Angle threshold Min Target Max Start torque EE angle angle angle Min Target Max Abort angle angle angle angle Result data Peak OR Final torque Result data Peak OR Final torque Peak OR Final angle Peak OR Final angle 38 6159930290 01 03 2012 5 LOOSENING The loosening function allows un tightening the joint according specific events The tightening operation is made on another station The present station first loosens the joint a
19. 8 00 Min current 2 Value to monitor Peak T Parameters Max current Min current Value to monitor Peak OR Final current The Current information varies from one tool to another and is not calibrated against the torque It is therefore necessary to establish a similarity on an experimental basis for each tool First read the value of the maximum current reached at the end of a Pset Then execute the Pset at least 3 times to define the minimum current and maximum current values e Enter these values Report OK IF Min current lt Current lt Max current For each channel the 3 report controller LEDs will light as follows esignation 1 Max current monitoring Angle lt Max angle AND Torque lt Remove fastener limit Min current monitoring Angle lt Max angle AND Torque lt Remove fastener limit Min current monitoring Angle gt Max angle OR Torque gt Remove fastener limit Result data Peak OR Final current Max current monitoring Angle gt Max angle OR Torque gt Remove fastener limit 40 8 TIME The Time monitoring is made to frame the tightening operation duration Example of usage to differentiate different screw lengths Min time 1 00 5 00 Max time 9 SLIP OFF Associated to a tightening step the Slip off monitoring is made to detect abnormal torque drops during the torque progress Threshold 32 00 Torque drop 22 00 Slip
20. 80 of Target torque to motor stop to optimize quality on very hard joint Rotation direction Forward Reverse Final speed Starting at the start signal the spindle runs with a programmed acceleration up to Rundown speed The spindle keeps running at Rundown speed Once Downshift torque has been reached the speed changes to Downshift speed Once 80 of the Target torque has been reached the speed changes to Final speed Downshift torque 15 00 1 ta n 0 40 Acceleration time Cycle start torque Parameters Acceleration time Time to increase speed from 0 to Rundown speed Rundown speed Speed applied from start to downshift torque to optimize productivity Be die Torque where speed moves from q Rundown to Downshift speed Downshift speed Speed applied from Downshift torque to motor stop to optimize quality Rotation direction Forward Reverse Starting at the start signal the spindle runs with a programmed acceleration up to Rundown speed The spindle keeps running at Rundown speed Once Downshift torque has been reached the speed changes to Downshift speed 12 2 3 speed Downshift torque 15 00 C 1 gr DAD Acceleration time Parameters Time to increase speed from 0 to Acceleration time Rundown speed Speed applied from start to downshift Rundown speed N Ke torque to optimize productivity Torque where speed moves from DOUNE AIGUES Rundown to Dow
21. Sa 4 4 Socket tray st EME Inputs Outputs The I O expander has 8 Input and 8 output which can be configured as standard physical I O e Save and quit by pressing the Save icon 6159930290_01 03 2012 10 3 5 Stacklight configuration The stacklight has 3 Input and 5 output which can be configured as standard physical I O 10 3 5 1 Inputs z 1 0 Overview Input events Inputs E D I internal vo E O General commands Push Button direct kan Start Stop Tightening on state Acknowledge eror 4 pan Reverse direction 5 Key Right Position direct Outputs Pset selection bit 0 D 6 Stack Light Pset selection bit 1 Pset selection bit 2 SES Pset selection bit 3 Outputs Pset selection bit 4 Pset selection bit 5 Pset selection bit 6 1 Pset selection bit 7 L Enable spindle forward F Enable spindle reverse Acknowledge eror Reset Reset only status Extemal stop to next Pset Restart controller Ack eror message Keep alive PFCS End Of Cycle Process commands Tool commands H Fytemal imr de Select next Pset Key Left Position direct Reverse direction There are 3 inputs Push button Key right position Key left position e Assign an input event to each output 10 3 5 2 Outputs 2 1 0 Overview Output events Outputs DI internal 1 0 2 0 FEES a GJ
22. bit 0 Inputs Reverse direction DB input 2 direct Outputs Pset selection bit 0 Pset selection bit 1 Pset selection bit 1 BB input 3 direct Pset selection bit 2 Pset selection bit 2 Pset selection bit 3 Input 4 Pset selection bit 4 Input 5 direct Pset selection bit 5 Pset selection bit 6 Pset selection bit 7 Stat Stop Tightening on state Enable spindle forward S GD input 7 direct Enable spindle reverse Reverse direction Acknowledge eror ul Input 8 direct Reset Reset Reset only status Extemal stop to next Pset Restart controller Ack eror message Keep alive Process commands Byte 1 Byte 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 d O Assembly process commands 0x0000 O Tool commands O External inputs 4 Socket tray Socket lifted bit 0 Socket lifted bit 1 U ernal Out PLC Bit 0 ernal Out PLC Bit 1 ernal Out PLC Bit 2 ernal Out PLC Bit 3 ernal Out PLC Bit 4 ernal Out PLC Bit 5 ernal Out PLC Bit 6 ernal Out PLC Bit 7 ernal Out PLC Bit 8 ernal Out PLC Bit 9 0000000000 EEE E S Er You can now read in PLC the state of CVI3 physical input The principle is the same for the outputs 7 MODULES DETAILED DESCRIPTION 7 1 DeviceNet Network Status LED Module Status LED DeviceNet Connector Network Status Not online No power Green On
23. gateway 127 0 0 1 Please enter a correct IP address You are going to set controller network configuration In order to connect to the controller please enter its current IP address The IP address Internet Protocol address is an unique address that electronic devices use for identification and communication with each other on a computer network using the Internet Protocol IP standard The controller will obtain its IP address via a DHCP server If Obtain an IP address automatically is selected this function scans the network allowing for an easy set up of the network The controller automatically finds the IP address etc The controller must be connected to the network before selecting the option This function is only possible with one Network When 2 networks are configured one can be selected as being automatic The other one needs to be configured manually If Use the following IP address is selected data have to be entered manually 10 2 2 Default gateway The default gateway is a node that serves as an entrance to another network 10 2 3 Subnet mask It is used in conjunction with the network address to determine which part of the address is the network address and which part is the host address 10 2 4 Network name By default the network name is CVI3 10 2 5 Data collection e Select the data you want to collect Results Curves for good tightenings Curves for reject
24. is measured from the Pset start torque Angle is measured from the angle threshold 2 4 General advice The start of the angle threshold counting should lie within the linear area of the torque increase We recommend to adjust the angle threshold in order to get the final angle around 60 or 80 In case of an angle control strategy the angle threshold must be as low as possible to minimise the uncertainty on the tension at the angle threshold value 36 3 CVI3 CONTROLLERS LEDS COLOR CODE Incomplete rundown Tighten again Reject report Loosen and tighten again Above High Angle Remove and replace fastener 6159930290_01 03 2012 4 TIGHTENING 4 1 Torque control torque control strategy coupled with an angle monitoring is adapted for most assemblies It offers the insurance that the tightening operation is correctly done a regular joint quality To reach this performance the angle is monitored to detect joint issues i e cross threads missing washer broken bolt different lengths of bolts rehit Example of usage Safety critical joints without particular requirements on the tension accuracy where angle monitoring is recommended Wheel assembly rear and front wheel hub assembly connections car body to sub frame assembly seat belt Quality critical to standard joints Car body components instrument panels accessories engine assembly gear box assembly H m
25. off angle 10 00 KN Parameters Threshold starts the angle measure of torque drop from the threshold 0 Torque drop within the slip off i 0 Slip off angle angle window where the torque drop is measured The torque decrease during a certain angle is monitored The angle is measured from the moment the torque reaches the slip off monitoring threshold When the slip off is detected the torque drops by x below the torque threshold within the slip off angle Stop conditions IF slip off detected Report OK IF no slip off detected For each channel the 3 report controller LEDs will light as follows LED B esignation Slip off detected Angle lt Max angle AND Torque lt Remove fastener limit RE Slip off detected Angle gt Max angle OR Torque gt Remove fastener limit Result data IF slip off detected 6159930290 01 03 2012 10 STICK SLIP 11 LATCH ANGLE THRESHOLD Associated to a tightening step the Stick slip monitoring is There are 2 types made to detect abnormal series of torque drops vibrations during the torque progress Without latched threshold default mode The controller stops counting the angle when the torque Nm falls below the angle threshold With latched threshold The controller starts counting the angle as soon as the torque rises above the angle threshold If the torque should fall below the angle threshold the controller proceeds
26. on the tool model to select the tool accessories and nn the triggers Tayettoque HE Nm Assembly line DC Assembly line VW36 2 Tightening unit Tool 1 Tool EAD50 900 ll Assembly line RB mw 62 Setup Accessories 2 Y Tightening unit Tool 2 General parameters r EZET Parameter sets DEER EAD50 900 x Options E Assembly process Help Next gt Cancel z e Click on Next riggers Options Start with handle trigger x 5 RONA ENS 2nd step enter the monitoring angle values Start with front trigger Start with push start EGGE Safety mode start with handle trigger and front trigger GI us Safety mode start with handle trigger and front trigger with timer All triggers disabled Maxtorque 5 50 Target torque 5 00 Min torque 4 50 e Save and quit by pressing the Save icon Angle threshold 2 50 13 PARAMETER SET PROGRAMMING This chapter will teach you to Min angle 0 00 create a Pset within 3 steps adjust the parameters to refine the tightening sequence Hep lt Back Net gt Cancel set up the curves display e Fill in the values and Click on Next copy paste and delete Psets Last step 13 1 How to create a Pset Parameter set has been successfully created e Select a Tightening Unit and click on Parameter set e Click the right mouse button to display the following screen Assemblyine TK Assembly ine
27. or Process running aborted Assembly Process aborted The Assembly Process has been aborted Assembly Process aborted A new Assembly Process start or reset input 6159930290_01 03 2012 1 2 General The Tightening Unit is ready to run No internal error Quick stop activated tool controller Error coming from communication tool ne torque or hardware span error Yellow report State of yellow light on controller The yellow light is on new tightening operation starts Green report State of green light on controller The green light is on Anew tightening operation starts Red report State of red light on controller The red light is on A new tightening operation starts Manual reverse The reverse direction is active or a loosening operation is Run reverse selected The tool is not in progress running and tool running running Fastener The fastener is loosened within the Run reverse limits Result generation New start tool loosened trigger or external start Fieldbus Fault The fieldus communication is lost due to Communication lost Communication cable disconnection established cable failure Fieldbus module disconnection keep alive timeout Reporting Alarm The Toolsnet or CVINet FIFO threshold alarm has been FIFO Threshold Alarm FIFO under reached The results are stored in the controller FIFO memory reached threshold alarm and are erased once sent to Toolsnet or CVINet To detect c
28. output action 30 15 4 3 Reset output action 31 15 4 4 Sense input achon 31 15 5 Post eier Te BE 31 15 6 Assembly Process import export 31 16 PC TO CONTROLLER DATA TRANSFER 31 16 1 Transfer menu 31 162 eeh eT 32 DS ROUES a e 32 17 1 How to get the last results curves 32 17 2 Viewercvipc application 32 17 2 1 Results display 32 17 2 2 Results filtering 32 17 2 3 Barcode reader connection 33 17 2 4 Printing results sees 33 17 2 5 Curves display 33 17 2 6 Exporting ies 33 17 2 7 Statistics COoMPUINO 5 33 6159930290 01 03 2012 18 MAINTENANCE 33 18 1 CVIMONITOR software 33 18 2 Database back up ER 19 APPENDIX TIGHTENING SIRATEGIE anata esea 35 TSTSINTRODUCTIONS 35 19 2 Main parameters sse 36 19 3 General advice Abu 36 19 4 cvl3 CONTROLLERs LEDs color code 36 RER e e nur in O7 VE LOOSENING T 39 VIP a a a 39 19 8 Current CHECK AT END 40 ONE oer 40 TO re Of E 40 19 11 SIC RS WEE 41 19 12 Latch angle threshold 41 19 13 Motor control BEE 42 20 APPENDIX STATISTIC COMPUTATION nenunnnrnnunnnennnennuvnnennn 43 20 1 List of Standards 43 20 2 E SAY rosas a 43 20 3 CNOMO standard 43 20 4 ISO standard e
29. settable by user Abort AP to abort the current AP Reset PLC to consider that all data coming from Outputs PLC are equals to zero 6159930290_01 03 2012 59 6 DATA MAPPING e Once the hardware mapping has been defined click on Data mapping to enter the screen _ Byte 1 Byte 0 RO RECHERCHER RECHNEN NEG WR 0000 FAN Address Name Type Size bit e Drag and drop the variables to the selected address The following screen appears rir AP selected zl You can specify different parameters for this input output Type uINTs v Multiplier coefficient 1 L a Jane 6 1 Data type e Choose the type of the data representation in memory Integer part on 16 bits decimal part on 16 bits 6 2 Char ASCII string If you choose Char extra parameters are necessary to set the ASCII string rir S lection Process d assemblage You can specify different parameters for this input output Type CHAR P Multiplier coefficient 1 Association with Spindle ID 1 v Char options Integer part 4 Number of decimals 1 RH Unsignificant zero is presen Non v Dot format Point v Alignment Right M Sze j Fomitol 128 e ASCH overview 9999 9 CD Cars The Size is automatically computed However you can put a value to truncate value in memory 60 6 2 1 UINT32 UINT16 UINT8 Data are represented as unsigned integer binary If value exceeds the
30. to create a step e Click on Parameter set and expand the tree e Click on 1 Tightening to display the following screen Assembly line x Assembly line Singletool Tightening unit Parameter set 1 Parameter set 1 Tightening x a h Assembly line 2 Step Cal BJ i Single tool Tightening unit Tool Steptype Tightening Strategies Motor control General Control Torque 5 1 Tightening 2 Control ae Assembly process A Torque si D Nm Angle Maxtorque 5 50 Target torque 5 00 Min torque 4 50 Angle threshold 2 50 You are now ready to select the tightening strategy the motor control and the general parameters 24 14 2 Step type selection Refer to Appendix Tightening strategies to get more information about the strategies 14 2 1 Tightening Assembly line Singletool Tightening unit Parameter set 1 Parameter set 1 Tightening 2 Step Lal LK Step type Tightening Strategies Motor control General Control Torque Monitor Time 2 Control Mor a Torque Angle ma Jorque OR Angle Torque AND Ange EST a e First select Tightening in the Step type box e Select the type of Control in the Control box Torque Angle Torque OR angle Torque AND angle e Fill in the values according to your selection 14 2 2 Loosening Assembly lin
31. up to 40 characters 12 1 Running mode e Select the Running mode according to your assembly configuration The tool will run accordingly to the selected Pset Assembly The tool will run according to the selected Process Assembly Process Mo e Select the Pset selection source 2 Normal settings for tightening unit Total spindles 1 Comment Running mode Running mode PSet e PSet selection source Og 1 0 CVI3 Front panel CVILogix C Execute identifier enablec Open Protocol Fieldbus C Store identifier in results Store non tightening rest Intemal Socket Abort running AP when ane e Tick Store identifier in results enabled to ensure traceability e g to save the operator ID at the beginning of a shift e Tick Execute identifier enabled to trigger an action linked to the reception of an identifier It is possible to store up to 4 different identifiers in the same result e Tick Store non tightening results to record and display results other than tightening results such as loosening results batch increment results 12 2 Curves distribution per spindle e Select your own curve distribution by sliding the cursor The maximum number of curves is 20 12 3 Run reverse parameters e Select the Reverse mode to reverse the tool direction before starting Reverse once Pushing the reverse button the reverse direction is selected the tool starts
32. 000 SP1 minimum 150 Mo available on hard disk Monitor resolution 1280 x 1024 Administrator rights required for installation Insert the supplied CDrom If AutoRun is activated on your PC click on Install CVI3 If AutoRun is disabled double click on the drive and click on CVI3 icon 5 cv Desoutter o 23 Industrial Install software CR viPC CVIMONITOR e Click Contact us to display our headquarters address and phone numbers as well as our website e Click User manual to display the literature available on the CDrom 2 1 CVIMONITOR installation This version of CVIMONITOR can be run in standalone e Click Install software then CVIMONITOR to launch the setup wizard You will be asked to select the language to be used by the installation wizard e Follow the instructions until you click on Finish At program startup a scan is automatically performed to detect the connected controllers e Select the IP address of the controller you want to monitor e For more information about CVIMONITOR refer to the user manual 6159930290 01 03 2012 Ta 2 2 CVIPC installation e Click Install software then CVIPC to launch the set up wizard If CVIPC is already running on your computer a maintenance program will be displayed and you will be allowed you to modify repair or remove CVIPC software e If not follow the instructions until you click on Finish 2 2 1 How to regis
33. 59930290 01 03 2012 APPENDIX TIGHTENING STRATEGIES 1 INTRODUCTION 1 1 Step type selection Select a STEP TYPE Assembly step Management step Tightening 1 1 1 Tightening Tightening is the main function of the CVI3 1 1 2 Loosening The loosening function allows un tightening the joint according specific events 1 3 Options Latch angle threshold When there are a lot of ripples on the torque progress it might happen that the controller starts measuring the angle and stops for short times because the torque becomes below the angle threshold The result is that the measured angle is below the real angle Using the latched threshold option the controller starts measuring the angle when the torque crosses the angle threshold for the first time The measure then continues until the end even if the torque becomes below the threshold The measured angle is therefore closed to the real angle The angle is measured starting at a torque value called Angle threshold Angle reset When this option is selected the angle measurement is reset at the beginning of each step This is generally the case However e g for multi step applications it may be useful not to reset the angle measured during the previous step Torque reset When this option is selected the torque measurement is reset at the beginning of each step The tightening operation is made on another station The present station firs
34. 7 8 ASSEMBLY LINE PROGRAMMING 14 2 1 CVIMONITOR installation 7 2 2 CVIPG IMS ANAM OM Se aaa rT egstnsana T 9 HOW TO SCAN 14 2 2 1 How to register your licenses T 2 2 2 How to activate your CVIPC 8 2 2 3 How to uninstall CVIPC 8 10 SINGLE TOOL CONFIGURATION 14 2 2 4 How to unregister your license 8 EEE NEE IENE OPERE T EE 9 10 1 US r INerace ni 14 2 3 1 Point to point e 9 10 2 Networks E 14 232 Ethernet networks ese coe oe at 9 10 2 1 IP address Ab 15 10 2 2 Default gateway 15 10 2 3 Subnet mask eee 15 3s OVERVIEW ene ene eee ere nee ener rere 10 10 2 4 Network name 15 10 2 5 Data collection 15 4 READ BEFORE STARTING NE 10 10 2 6 FIFO settings usunn eee 15 10 3 I O and accessories 15 10 3 1 I O management 15 5 MENU AREA 11 10 3 2 Add delete accessories 16 10 3 3 Socket tray configuration 16 5 1 View management 11 10 3 4 I O expander configuration 17 5 2 Options le doser tt bless mater ec ibid oi 11 10 3 5 Stacklight configuration EE ATN 17 EE Eegenen 11 10 4 RS232 serial port USB ports 18 5 2 2 E mail configuration 11 10 5 Date and WING sss eee ee 18 5 2 3 af 1 5 519 6 a sn 11 10 6 Identi
35. Angle threshold 14 4 2 Angle reset e Tick this option to reset the angle measurement at the beginning of each step This is generally the case However e g for multi steps applications it may be useful not to reset the angle measured during the previous step 26 14 4 3 Torque reset e Tick Torque Reset to reset the torque measurement at the beginning of each step This is generally the case However e g for multi steps applications it may be useful not to reset the torque measured during the previous step 14 5 Motor control Refer to Appendix Tightening strategies to get more information about the motor controls 14 5 1 Auto set up In case you are not familiar with speed settings we recommend you to let you guide by the software The motor control parameters are calculated by using the inputs from the Strategies settings e Click on Auto set up Strategies Motor control gabal Speed S S Auto setup 2 Auto set up Motor speed parameters are calculated from curent settings in the strategies screen To adjust the calculated values you may change the strategies settings or change the Joint hardness value on this screen Curent settings Targettorque 0 00 Nm Max tool speed 900 rpm Calculated motor control settings Joint hardness Advanced D cum gt gt Hard L Soft Downshift torque 0 00 Nm Rundown speed 180 rpm 20 Downshift speed 45 rpm 5 Amy JI e
36. C Link an Modbus IDA the aroitecture for distributed automation INDUSTRIAL ETHERNET NIE T 1 port Module type 56 Fieldbus type Module type P RJO JF I INDUSTRIAL ETHERNET NIEIT 2 ports 6159275970 2 2 Module installation e Power off the controller e Locate the Fieldbus connector at the bottom panel see picture below The cover is protected by a grey cover a E Lei Ler er Ler Legend 1 Fieldbus connector e Remove the cover e Carefully drive the Fielbus module into its location e Tighten the 2 screws by using a T9 Torx screwdriver e Power on the controller 3 CONFIGURATION 3 1 Principle of operation The purpose of Fieldbus is to share reliable data between the controller and the PLC Generally the PLC is the master and the controllers are slaves i e the PLC is in charge of writing or reading data in the controller memory when needed Fieldbus e Depending on the Fieldbus type you will have to select the Identification method station address IP address station name the speed media and expected performances To establish the communication the controller and the PLC must agree about the data they exchange the user must define exactly the same thing on both sides There are 2 mappings to configure Hardware mapping where is defined which raw data types are exchanged e g byte words double words
37. EAN e 6159930290 01 03 2012 5 MENU AREA This area leads to View management Options language e mail configuration preferences Information about the current software version Display of the user manual The other topics such as data back up data transfer and service are covered in most relevant sections 5 1 View management The view menu allows to adapt the display to the user needs Transfer Service Build Area Options Tree Details Log area All Restore default layout e Matani E Build area The build area serves as a tool box to create Assembly lines associate equipments to the Assembly line set the tightening process and allows the process management The tree area shows the current configurations It displays the architecture of the assembly groups the controllers the tools and the tightening parameters Details The detail area displays the details belonging to the item selected in the tree area To set the parameters for the item selected in the tree area Log area History view Display in real time e Tick the selected area or all areas to display the views at your convenience e In case of any problem tick Restore default layout 5 2 Options File View Transfer Service About 3 Options Language EMail 5 2 1 Language The language by default is English e Se
38. F Min torque lt Peak or Final Torque lt Max torque AND IF Min angle lt Peak or Final Angle lt Max angle For each channel the 3 report controller LEDs will light according to the following diagram Nm Remove and replace fastener Abort torque Max torque EEE Min torque Angle threshold Start torque Va Min Target Max angle angle angle Result data Peak OR Final torque Peak OR Final angle 4 3 Torque AND angle control 4 4 Torque OR angle control The tightening torque AND angle control strategy is adapted The tightening torque OR angle control strategy is adapted for for assemblies requiring tension accuracy assemblies requiring tension accuracy It offers It offers the insurance that the tightening operation is correctly done the insurance that the tightening operation is correctly done a regular joint quality a regular joint quality a better control of the tension a better control of the tension a better repeatability a better repeatability a better accuracy a better accuracy An angle control the tool stops when both torque AND angle An angle control the tool stops when either the torque OR the reach their target values angle reaches its target value Nim Abort torque 28 00 Maxtorque 22 00 Target torque 20 00 Min torque 18 00 Maxtorque 22 00 Target torque 20 00 Min torque 16 00 Angle threshold 10 00 Angle threshold 10 00 deg
39. Fieldbus configuration The following screen is displayed Fieldbus general configuration Results Management Fieldbus Status management Assembly Processes Options Fieldbus type No Fieldbus 4 1 Fieldbus general configuration In this panel you can configure the main parameters needed to communicate between the PLC and CVI3 controller 4 1 1 Endianness By default CVI3 express all binary values in Big Endian endianness For example the representation in the CVI3 memory of the 32 bits value 0x11223344 is ass o 1 2 30 Of course the PLC can have different representation of binary values in its memory To allow CVI3 to cope with this different configuration the user can choose different formats of binary representation examples for value 0x11223344 Address po 1 2 87 0x22 0x11 4 1 2 Addressing plan In this panel the user can set size of data exchanged between PLC and CVI3 Addressing plan 0x0000 0x000d PLC input 0x0000 4 2 Bytes 0x0001 PLC output I In this example 14 bytes of data start at address 0x0 until address OxD included are defined for data coming from CVI3 to PLC 2 bytes of data start at address 0x0 until address 0x1 included are defined for data coming from PLC to CVI3 58 4 2 Result management Once a tightening has been done the result is present in the PLC input memory area If a new tightening o
40. G CVIPC for CVI 3 File View Transfer Options Service About 2 Tools Industrial CVIPC V 1 30 1 9 User manual Part no 6159930290 Issue no 01 Series Date 03 2012 Lis es gt m d ae I D BS Ear EES 2 Build X Assembly line X Assembly line Singletool Tightening unit Parameter set 1 Parameter set 1 Tightening D SE ak ite 2 we DEI Step ype Tightening Kee E Al Single tool S Tightening unit Equipment SE G SS Strategies Motor control General Parameter set 7 1 Parameterset Control Torque Scan Tall 1 Tightening 2 Control Monitor Torque M Assembly process Torque v Tightening Peak Angle Assembly process Maxtorque 5 50 Final E Target torque 5 00 C Curent Parameter set Min torque 4 50 C Sip off Cl Step Stick slip C Time CI Rundown angle Management E Angle threshold 2 50 Copy Paste deg D D v Joe Min angle 0 00 Max angle 360 00 Abort angle 600 00 Options V Latch threshold 2 v Angle reset Torque reset Status Log Waiting 5 seconds for responses Finished waiting Controller connected on Rear www desouttertools com CONTENTS 1 SAFETY AND STATEMENT OF USE 7 7 4 Management PE NN La er 13 7 5 Yellow and red messages 13 2 INSTALLATION ennnnnnnnnnevnnennnnnnnnnnnnennn
41. J IT Cap ap 6Sp 6 NORMAL DISTRIBUTION TESTS Normal distribution test population of less than 50 measurements SHAPIRO WILK test Calculation of N S2 3 xj x i 1 where n gt Xi EE 1 Xz N N number of measurements of the population Calculation of 6159930290_01 03 2012 k b 291 di IEN where d X N i 1 Xi al see table K N 2 if N is even K N 1 2 if N is odd PN 15 20 25 4 05150 0 4734 04450 0 4254 0 4096 0 3964 0 3850 0 3751 ZIL 03306 03211 03069 0 2944 0 2834 02737 0 2635 0 2574 A 01878 0 2085 02148 0 2148 0 2127 02098 0 2065 0 2032 5 01353 0 1686 0 1822 01870 0 1883 0 1878 0 1865 0 1847 6 00880 0 1334 0 1539 01630 0 1673 0 1691 0 1695 0 1691 8 00000 00711 0 1046 01219 0 1317 01376 0 1410 0 1430 8 00422 00828 01036 01160 01237 0 1286 01317 10 00140 00610 0 0862 0 1013 01108 01170 01212 nm 1 00408 00697 0 0873 00986 0 1062 01113 12 1 00200 00537 0 0739 00870 0 0959 0 1020 183 1 00000 00381 0 0610 00759 0 0860 0 0932 29 pp 00227 00484 00651 0 0765 0 0846 28 pp 00076 0 0361 00546 0 0673 0 0764 28 Ill 00239 00444 0 0584 0 0685 2 li ll 0019 0 0348 0 0497 0 0608 aB oo 0 0000 00244 0 0412 0 0532 29 PP 00146 0 0328 0 0459 2 p
42. Lamp 4 Red o f ra inputs Span failure Oo SE A Outputs No tool connected S Lamp 1 Blue 5 6 Stack Light Angle measurement fault Inputs invalid spindle settings 2 L 7 Outputs Invalid Pset selected Keep alive ack Num Interval Sec H O Extemal outputs 3 Nomal H There are 5 outputs Lamp 4 Lamp 3 Lamp2 Lamp 1 Buzzer e Select the color of the LEDs by clicking with the right click on the stacklight picture LC a JP fell Lamp 3 Green el Lamp 2 Orange Bes H fel Lamp 1 Blue Green F fs Buzzer Orange FI Red U Indefined E e Assign an output event to each output P Changing output settings can affect actuators connected to the controller e Save and quit by pressing the Save icon T 2 10 4 RS232 serial port USB ports User interface RS232 E Serial port 1 an T0 pas See 105 pany es Serial port 2 e e as DER bander Bz Senter 05 Poty es 2 Enable power supply Bi pre omme US lt gt USB 2 Equipment Nons 7 Select an equipment for each serial port and fill in the data required for the exchange In case of a computer or serial printer select the Report format PC4 or CS5700 Click Enable power supply to provide 5V to a barcode reader for example Select the equipment to connect to the USB ports The setting is done automatically Save an
43. Process 4 Sense input Description Sense input Comment Input event Extemal inputs AP Extemal Input 1 v e Enter a description up to 40 characters e Enter a comment up to 100 characters e Select an Input event among the AP external inputs bit 0 9 15 5 Post processing Process actions can be sequential or parallel The logic operators are AND and OR Assembly line Singletool Assembly process 1 Assembly Process 2 Assembly process 1 Description Assembly Process Change Post processing 3 Reset output A Actions n Set output 4 4 Sense input I Reset output SS Repeat Manage actions Post processing Delete General OP Export to file 76 Import from file 2 t e Click on the grey square located under Post processing to display the available actions Assembly line Singletool Assembly process 1 Assembly Process 2 Assembly process 1 Description Assembly Process Change Post processing Actions n Set output Reset output f Repeat Manage actions CH Delete General OF Export to file fh Import from file 6159930290_01 03 2012 There are 3 possible actions Set output At the end of the process the CVI3 triggers an output event AP external output bit 0 9 this event can be linked to a 24 V output Reset output At the end of the process the CVI3 reset an output event AP external output bit 0 9 t
44. Rising edge Assembly Process To select an Assembly Process up to 250 Rising edge selection bit 0 7 Abort Assembly To stop the current Assembly Process The Assembly Process is finished Rising edge Process Tightening AP aborted and AP NOK outputs are set unit Restart Assembly The Assembly Process restarts at the beginning when Restart Assembly Process is set Rising edge Process Tightening unit Restart batch To re start the current batch of the current Assembly Process step batch count o x Rising edge Restart action batch event is set 2 2 Tools Name Description L t Tool stop To stop the tool Rising edge Tool blue light 1 tool blue light is set to on State 0 tool blue light is set to off Tool green light 1 tool green light is set to on State 0 tool green light is set to off Tool red light 1 tool red light is set to on State 0 tool red light is set to off Tool yellow light tool yellow light is set to on State tool yellow light is set to off Tool white light tool white light is set to on State tool white light is set to off Reset tool locks tool locks To reset tool locks Only the non safety locks are affected Rising edge edge 2 3 External inputs Name Deserpion s PLC external input 1 10 Inputs are controlled by PLC via Fieldbus like a remote I O AP external input 1 10 Inputs used in Assembly Process Rising edge in Start conditions by using Input event
45. Singletool Tightening unit Parametersets Tightening System Singletool Mk Assembly line Parameter set re ae BH Single too sg E Tightening unit Pier set Tool e Parameter sets Assembi Add Z Parameter set Eh Copyal Ba Paste CH Delete e Select Simple Setup and let you guide by the software The tightening operation will be done within 3 steps The tightening strategy is Torque control with angle monitoring by default e Click on Exit to finish 6159930290 01 03 2012 21 The following screen is displayed Assembly line Singletool Tightening unit Parameter set 1 Parameter set x D Parameter set Lal gt Description Parameter set General Cycle stat stop Curves 2 Nm Remove fastener torque limit 6 60 Cycle start torque 0 50 Overall angle mode Disabled v Overall time mode Disabled Wi Run reverse direction Extemal stop abort PSet None 1 Le Now you can adjust the parameters if required to refine the tightening operation 13 2 Pset general parameters 13 2 1 Cycle start torque The Cycle start torque is the torque value that must be reached to declare the Pset as started Below this value no result will be generated 13 2 2 Remove torque fastener limit The remove fastener torque limit is the torque limit above which the fastener bolt and screw may have suffered d
46. Vision CVI3 Function A single tool is composed of tightening units A tightening unit associates one tool with one ore more Psets or A tightening unit is a group of spindles working synchronously A Each single tool has its own environment user interface networks etc A tightening unit is composed of tools 1 or 2 tools Each tool will run according to its own program All CVB range tools can be connected CVI II range tools can also be connected providing they are equipped with the CVI II adaptor 7 3 Tightening 7 3 1 Assembly Process res An Assembly Process is commonly called AP REX and shown by this icon A Simple Assembly Process is made of 1 Parameter set repeated n times The batch is the number of times the Parameter set is repeated An Advanced Assembly Process is a sequence of actions to run a complete assembly The Assembly Process describes the workflow to assemble two parts and has 3 phases Start conditions Identification of the pieces to assemble selection of the process by IO Fieldbus 6159930290_01 03 2012 13 Process actions Sequence of tightenings which is using Psets as tightening recipes Post processing e g repeat tool locking Each Assembly Process includes a maximum of 99 actions 7 3 2 Parameter set Parameter set is commonly called Pset and shown by this icon A PSet is combining one or several step
47. ailed 1 Network configuration failed 2 Check your settings 3 If the problem occurs again contact your Desoutter representative for support CVI3 Software update failed 1 The SW upgrade failed 2 Do not remove the USB key and try to restart the CVI3 3 If the upgrade is still failing contact your Desoutter representative 901 CVI3 Software image not found 1 The SW upgrade failed no CVI3 image cvi3 was found at the USB key root directory 2 Check your USB key it must have only one CVI3 image CVI3 Software image invalid 1 The SW upgrade failed the CVI3 image copied on your USB key is corrupted 2 Remove and copy again your CVI3 image 3 Try another USB key 4 Contact your Desoutter representative for more information 903 CVI3 Software updater missing 1 The SW updater is not available or broken 2 Contact your Desoutter representative for more information 904 CVI3 save parameter utility not 1 The save parameters utility is not available found 2 Contact your Dessouter representative for upgrade 905 CVI3 save parameter to key 1 Your USB key is full all data was not saved failed Key is full 2 Delete your old backup files and try again 54 6159930290_01 03 2012 Error Description code no CVI3 save parameter failed 907 Wrong USB port 908 Too many USB HID devices connected USB HID device error 6159930290 01 03 2012 Resolution procedure 1 An error occurred during data backup all data was not s
48. ailure 2 Safety issue contact your Desoutter representative for support 219 Hardware channel failure 1 Drive hardware failure 2 Safety issue Contact your Desoutter representative for support 220 Hardware trip 1 Drive hardware failure 2 Safety issue contact your Desoutter representative for support Drive heart bit error 1 Drive hardware failure 2 Safety issue contact your Desoutter representative for support 222 Drive heatsink temperature high 1 Heatsink too warm 2 Let the controller cool down 223 Drive init failure 1 Software failure 2 Restart the controller 3 If the problem occurs again contact your Desoutter representative for support 224 Drive junction temperature high 1 Power electronics too warm 2 Let the controller cool down 2 Drive missing angle 1 Tool communication error Check tool and cable connections 2 Try once again if the problem occurs again contact your Desoutter representative for support Drive missing torque 1 Tool communication error Check tool and cable connections 2 Try once again if the problem occurs again contact your Desoutter representative for support Drive motor stalled 1 Motor stalled could be missing phase wrong motortune or power electronics failure 2 Try once again if the problem occurs again contact your Desoutter representative for support 6159930290_01 03 2012 1 O0 NO N N N 2 5 26 227 Error Description Resolution proc
49. amage and must be replaced By default the value is set to 120 of the target torque This torque value may lie above the maximum tool torque 13 2 3 Overall angle mode The overall angle can be measured during the complete tightening operation i e starting at the overall angle threshold and until the end This option excludes an Overall time mode Disabled the overall angle is not measured Monitoring the overall angle is simply measured Control if the overall angle gets out of limits the result of the tightening operation is NOK the tool stops 13 2 4 Overall time mode The overall time can be measured during the complete tightening operation i e starting at the overall time threshold and until the end This option excludes an Overall angle mode Disabled the overall time is not measured Monitoring the overall time is simply measured 13 2 5 External stop abort Pset e Select one of the following onrising edge on falling edge on change on high level on low level 00 13 2 6 Run reverse direction e Select if clockwise counterclockwise e Click on Save to quit 13 3 Cycle start e Click on Cycle start stop to display the following screen Cycle start stop Curves Start stop general S Torque offset and span check Torque check Me Jog enabled Rehit enabled Cycle stop Socket release enabled Ergostop enab
50. aved 2 Check available space on your USB key delete some old backup and try again 3 If the issue is persistent contact your Dessouter representative for more information 1 Your USB device is plugged into the wrong port 2 If your device is a USB key plug it into the USB front port 3 If your device is a USB barcode reader or keyboard plug it into the bottom USB ports 1 Too many USB devices barcode reader or keyboard are attached on your controller 2 Remove all devices and plug again on bottom USB ports only 1 Your USB device is not supported by the CVI3 controller 2 Only USB barcode reader and USB keyboard are supported if you use one of them contact your Dessouter representative for upgrade 55 APPENDIX FIELDBUS USER MANUAL 1 GENERAL 1 1 Statement of use This document is a user manual about the Fieldbus module installation and the programming of the CVI3 range controllers No other use permitted For professional use only 1 2 Terminology AP Assembly Process PLC Programmable Logic Controller TU Tightening Unit 2 HARDWARE INSTALLATION 2 1 Module selection To be able to communicate on Fieldbus the controller needs a dedicated Fieldbus module The following modules are available Fieldbus certificates are available on request Contact your Desoutter representative A 6159275980 6159275990 6159275940 6159276150 6159275950 JOGL 6159275960 Fieldbus type C
51. be re executed according to the selection e Select the batch count type count OK cycles only count all cycles If you want to decrement the batch counter after a loosening operation select Always or After OK If not select Never If you want to allow the joint loosening select Always or After NOK If not select Never e Click on Save 15 4 2 Set output action Assembly line Singletool Assembly process 1 Assembly Process 2 Description Set output Comment Output event Edemal outputs AP Edemal Output 1 L e Enter a description up to 40 characters e Enter a comment up to 100 characters e Select an Output event among the AP external outputs bit 0 9 6159930290 01 03 2012 15 4 3 Reset output action Assembly line Singletool Assembly process 1 Assembly Process at EE ce Process Actions Sequential actions 4 2 Set output 7 Assembly Set output re 3 Reset output Reset output Sense input 3 4 m EE 2 Description Reset output Comment Output event Extemal outputs AP Etemal Outp Extemal outputs AP Etemal Output 10 e Enter a description up to 40 characters e Enter a comment up to 100 characters e Select an Output event among the AP external outputs bit 0 9 15 4 4 Sense input action Assembly line Singletool Assembly process 1 Assembly
52. capacity of selected type then the maximal value of the specified type is used Negative can not be represented Examples CVI3 Data in PLC memory value UINT8 UINT16 UINT32 99 99 99 0x63 99 0x0063 99 0x00000063 99 99 O 0x00 0 0x0000 0 0x0000000000 999 9 255 OxFF 999 0x03E7 999 0x000003E7 9999 255 OxFF 9999 0x270F 9999 0x0000270F 9999 9 255 OxFF 9999 0x270F 9999 0x0000270F 99999 255 OxFF 65535 OxFFFF 99999 0x0001869F 6 2 2 SINT32 SINT16 DINT8 Data are represented as signed integer binary If value exceeds the capacity of selected type then the maximal value of the specified type is used Examples CVI3 Data in PLC memory 6 2 3 BOOL Data are represented as a boolean using 1 byte 8 bits signed integer binary If value is equal to zero then value seen by PLC is 0 otherwise value is 1 Negative values cannot be represented using this type Examples memory o 0 an Ir 6 2 4 INT16 DEC16 In this format the integer is expressed in binary format in 16 bits and decimal part in the remaining 16 bits The total number of digits is 4 and maximum number of digits is 2 which can be summarized as follows Digits for Digits for integer part decimal part 6159930290 01 03 2012 Negative values cannot be represented using this format Examples CVI3 Data in PLC memory value Integer part Complete value part 99 99 99
53. ck There is no tool lock in forward direction Tool unlocked in New lock in forward forward forward direction direction Tool not lock There is no tool lock in reverse direction Tool unlocked in New lock in reverse reverse reverse direction direction Tool ready Tool is ready to tight Tool connected and Tool disconnection Pset Tool is present and controller is ready valid Pset selection valid Pset is selected The tool is rotating The tool rotates The tool stops 6159930290 0 59930290 01 1 032012 249 Tool middle The tool middle course trigger is detected Main trigger middle Main trigger is released course trigger course Is reached Tool main The tool main trigger is detected Main trigger is Main trigger is released trigger pushed Tool reverse The tool reverse trigger is detected Reverse trigger is Reverse trigger is trigger pushed released Tool push or The tool push or front trigger is detected Push or front trigger Push or front trigger is front trigger is pushed released 1 5 Socket tray Socket Used with CVI II socket tray BSD only Binary code A new socket has to No socket to be taken selectable 0 4 Informs the user which socket can be taken be taken by the user by the user 2 CVI3 LOGICAL INPUTS 2 1 General Name Description Status Start Stop Tightening Initiates a tightening operation State on state A rising edge must be detected to initiate a tightening o
54. d ergonomics for that particular step Auto setup This type of control is the easiest to start tightening for beginners There is no speed or power parameter to set The user defines joint type from hard to soft or joint angle in degrees and the system automatically defines rundown amp final speed based on a 2 speed step type Torque mandatory Angle mandatory sm 6159930290 01 03 2012 35 2 MAIN PARAMETERS 2 1 Control Target torque The Step is stopped when this torque value is reached Abort angle The step is aborted if this angle value is reached 2 2 Monitor Max torque torque value which defines the max torque limit Min torque torque value which defined the min torque limit angle value which defines the max angle limit torque value which defines the min angle limit torque threshold value to start counting angle usually 50 of target torque Max angle Min angle Angle threshold Peak or Final torque For all control strategies torque and angle are systematically monitored Generally the peak value is used for the torque and the final value for the angle Peak or Final angle Angle Torque Max angle Peak angle Final angle Min angle Angle threshold Time 2 3 Start conditions The Pset starts as soon as the Pset start signal is active AND the Pset start torque is reached if set to a value different from 0 Torque
55. d quit by pressing the Save icon 10 5 Date and time User interface Date and Time Date and Time set up Date Time syne source Nome ei e Select the Source of the time synchro to synchronize with CVIPC e Save and quit by pressing the Save icon 18 10 6 Identifier table It is possible to use identifiers to start a process to trace parts 10 6 1 Add Edit an identifier e Click on Identifier table to display the following screen Ge Le Sonica chances Pome e Click on Add to add an identifier Add identifier 2 Add identifier Description Identifier 0 Accept any E eric bylengh 0 C Identification by significant characters e Describe the identifier up to 40 characters e Select one of the following Accept any Any length or content is allowed Identification The identifier must fulfil a specified length by length Identification Significant characters must be found in the by significant received identifier The user has to enter the characters significant characters into the grid 2 Add identifier Description erter D E Accept any l Identification by length 0 Identification by significant characters Identifier mask grid frfzlafafsjelzjefejolil2 alalsjel z e sjol i 2 ajal sje 7ja ejo Read code Enter the identifier mask manually in the grid OR use your barcode reader directly then set the si
56. ddress Type Add enabled sound each time a key is pressed Back light auto The screen will be automatically turned off Click this icon to start the scan process after the timeout The screen will turn on as soon as the screen is touched for the CV13 Vision a key pressed for the CVI3 Function the tool trigger is activated 22 11 2011 12 16 41 Searching fo ages on 192 168 5 240 Broadcasting requested to 255 25 22 11 2011 12 16 41 Waiting 5 Se responses Copy all Clear Back light The timeout value for the automatic back timeout light switching off can be set between 1 and 99 min e Save and quit by pressing the Save icon Select a controller in the list and click on Add to copy it in the tree view of the selected Assembly line 10 2 Networks Or click on Copy all to add the connected controllers in e Please refer to chapter Ethernet networks at the the tree view It will be now possible to re order them per beginning of this manual Assembly line and re set them if necessary i N e Select the type of network and fill in the requested Click on Clear to erase the screen before starting a new information scan Below are the main information you may need to fill in the Click on Exit to quit the screen screens 14 6159930290 01 03 2012 10 2 1 IP address TCP P Ene B Ethemet 1 IP address 192 168 5 211 Subnet mask 299 255 259 0 Default
57. e General Cycle start stop Curves Start stop general Rehit sn hr 0 25 Rehit enable DS e Fill in the screen Ergostop time min 0 25 s Rehittorque 000 e When finished tick the box on the top left to valid your selection and click on Save to exit Rehit threshold 0 00 13 4 3 Reject on trigger lost Es e Tick this option yes no Fill in the screen The Pset will be rejected if the start signal is released before rehit torque the end of the tightening operation If this option is not rehit threshold checked the result is reported on the calculation of trends rehit angle e Save and quit by pressing the Save icon When finished tick the box on the top left to valid your selection and click on Exit to quit 13 5 Setting up the curves display This chapter will allow you to set the curves as they will 13 4 Cycle stop appear when uploading curves from the controllers General Cycle start stop Curves 13 4 1 Socket release enabled FE This is used to release the constraint between the socket E and the screw When relaxation is enabled the tool rotates in Start step reverse a few degrees in order to easily remove the socket Start torque General Cycle start stop Curves Start stop general Socket release 2 Socket release enable Tooltype EAD32 900 Lal Max tool speed 900 rpm Backward recording Speed Start torqu
58. e gt 0 deg 0 00 Release angle e Enter a comment to customize your selection up to 100 characters Exit Fill in the screen torque limit acceleration time speed in of the tool max speed When finished tick the box on the top left to valid your selection and click on Exit to quit 6159930290_01 03 2012 23 13 5 1 Forward recording The torque and angle values are saved from the start torque till the end of the tightening during a set time Enter the Start torque If set to 0 the curve is recorded starting at the end of the tightening operation e Enter the Time Curve recording time curve has a maximum of 2 000 points Start step enter the step number from where the curve recording begins 13 5 2 Backward recording The curve is recorded from the start torque to the end of the tightening and rewinds for a set time e Enter the Time A curve has a maximum of 2 000 points e Save and quit by pressing the Save icon 13 6 How to add copy paste delete a Pset e In the Build area click on Parameter set then use the right click of the mouse to add a new Pset e To copy paste or delete a Pset select first the relevant Pset and use the tools in the Buid area 14 STEP PROGRAMMING This chapter will teach you to create your own tightening strategies set up the motor controls adjust the parameters to refine your work 14 1 How
59. e Singletool Tightening unit Parameter set 1 Parameter set 1 Tightening 2 sep Lal Step type Loosening 4 Strategies Motor control General Control Torque Lal Loosening A e Select Loosening in the Step type box e Select the type of Control in the Control box Torque Angle e Fill in the values according to your selection 14 2 3 Jump Assembly line X Assembly line Singletool Tightening unit Parameter set 1 Parameter set 2 Jump lj Assembly line 2 seo Q2 ag Je el Single tool E Tightening unit Tool Jump Parameter set wm H 1 Parameter set EN Jump cl 1 Tightening LA en e M Assembly process 1 Tightening j e Select Jump in the Step type box e Select the step number to jump to 6159930290_01 03 2012 14 3 Monitor e Select the monitoring strategy and tick the box to open the corresponding screen Refer to Appendix Tightening strategies to get more information about the monitoring strategies 14 3 1 Peak or Final Torque Angle For all control strategies torque and angle are systematically monitored For torque and angle monitoring it is possible to choose either the peak value or the final value to be monitored Generally the peak value is used for the torque and the final value for the angle 14 3 2 Current Check at end Strategies Motor control G
60. ean range W of the samples of 5 measurements which form the population REP AA a 9 122 W wir where W d5 K W Range of measurements on each sample max value in value es K Number of samples of 5 measurements err Ty 645 x 0 4 14 EE d5 2 326 ike VK 20 to 22 coefficient for a 95 confidence threshold ies 26 to 31 32 to 36 Instantaneous dispersion Dj 6 X Or 36 to 44 45 to 51 Oj 6159930290 01 03 2012 Coefficient of position and dispersion X Tolmin CPK min Lelmax X 2 0 300 The station is capable if the CAM is higher than the specified CAM The setting is correct if the CPK is higher than the specified CPK 4 ISO STANDARD Standard deviation N 2 00 X N 1 where N KS i 1 N XI population value X population mean N number of measurements of the population Process Capability LA CP lt where IT tolerance interval Max Tol min Tol O standard deviation Coefficient of position and dispersion X Tolmin CPK min CS X X Poi o 5 NF E 60 181 STANDARD Sie Estimator of the intrinsic standard deviation for each mode number where 2 lt e lt k and K is the number of samples n gt Die Xe j 1 n 1 44 where Di 6x Si IT Tolerance interval n gt ER d Le x x L Cpkz M d P int 35 3Sp
61. ed tightenings 10 2 6 FIFO settings The controller regularly sends results to CVINet and erases the same results from the controller memory as soon as they have been sent The purpose is to provide a full traceability Block if FIFO full when enabled the tool will get blocked when the result memory is full The data collection will not work any more and data may get lost To avoid such a blocking situation an alarm threshold can be set in number of tightenings before the FIFO is full 50 by default e Save and quit by pressing the Save icon 10 3 I O and accessories 10 3 1 1 0 management e Click on Configure to display the I O The goal is to associate I O events to the controller I O Click this icon to display the controller I O connector Userinterface Networks 1 0 and Accessories R5232 Date and Time Identfier Table Configure Add delete accessories 10 3 1 1 Inputs 1 0 Overview Input events Inputs D I Internal 1 0 General commands a E M input 1 direct Inputs Start Stop Tightening on state Pset selection bit 0 Reverse direction H input 2 direct Outputs Gp Pset selection bit 0 Pset selection bit 1 Pset selection bit 1 DB input 3 direct Pset selection bit 2 Pset selection bit 2 Pset selection bit 3 Input 4 Pset selection bit 4 Input 5 direct Pset selection bit 5 Acknowledge er
62. edure code no 228 Drive Software Error 1 Software failure 2 Restart the controller 3 If the problem occurs again contact your Desoutter representative for support Drive PWM watchdog error 1 Software failure 2 Restart the controller 3 If the problem occurs again contact your Desoutter representative for support 230 Drive DC bus voltage high 1 Max current exceeded DC bus voltage high 2 Contact your Desoutter representative for support 231 Drive DC bus voltage too low 1 Power failure DC bus voltage low 2 Contact your Desoutter representative for support 232 Fieldbus module not recognized 1 The Fieldbus module plugged in the CVI3 cannot be run it is not an authorized Desoutter module not a Desoutter one 2 Contact your Desoutter representative for more information CVINet FIFO full 1 The CVINet result FIFO is full the CVINet connection has been lost 2 Check the CVI3 Ethernet cable 3 Check CVI3 Ethernet configuration 4 Check if CVINet is running correctly 234 Fieldbus module mismatch 1 The Fieldbus module declared in configuration is not the same that the one present in controller e g Profibus declared but a Profinet module in CVI3 235 Warning max speed setting 1 Invalid speed setting speed is greater than tool characteristics 2 By default speed setting has been replaced with tool max speed Toolsnet FIFO full 1 The ToolsNet result FIFO is full the CVINet connection has been lost 2 Check the CVI3 Etherne
63. eed Control LA Torque Maxtorque 8 80 Target torque 8 00 Min torque 7 20 Angle threshold 4 00 Help lt Back Cancel e Fill in the values and click on Next A new Pset has been successfully created e Click on Exit again to finish the process A new Assembly Process has been successfully created e Click on Exit 28 If you select an existing Pset The process is shorter because the Pset parameters are already defined e Select the existing Pset e Click on Next to finish the process A new Assembly Process has been successfully created e Click on Exit 15 2 Advanced Assembly Process Create an assembly process amza Simple or advanced assembly process Simple assembly process Contains a single parameter set executed one or more times Q Advanced assembly process Contains more than one parameter set e Click on Next e Select the Assembly Process number e Validate by pressing OK The following screen is displayed Assembly line X Assembly line Singletool Assembly process 1 Assembly Process x ly Assembly line 2 Assembly process 1 Description Assembly Process Change S H Single tool Tightening unit E Assembly process ME Ir zen Process Actions Reset output Sense input Post processing Manage actions C Delete General OP Export to file Import from file
64. embly Process mode the process is aborted Ready output stays on Reset only status Resets only State Tightening OK NOK Spindle OK NOK Tightening Finished Tightening finished without timeout Batch OK NOK Finished The Assembly Process is not aborted Result values angle torque are still present in Fieldbus Tool and controller lights are not affected 50 6159930290_01 03 2012 Name Description Stats External stop abort Used with proximity detectors to end the running Pset Rising edge Pset The user can choose which state or transition will stop the Pset No Rising Falling or state Change High Low When a Pset is aborted the result is NOK External stop to next Used with proximity detectors to end the running step Rising edge step The user can choose which state or transition will stop the step No Rising Falling or state Change High Low The user can also choose the result of the step when the stop request occurs OK NOK Monitoring Restart Controller To reboot the controller Rising edge Acknowledge error message displayed on HMI Rising edge Keep alive To check that the controller is still alive State of this input is copied to Keep alive ack output This input can be used by PLC to inform the controller that Fieldbus communication is working Select next Pset To select the next existing Pset number Rising edge Select previous Pset To select the previous existing Pset number
65. en eees 44 20 5 NF E 60 181 standard 44 20 6 Normal distribution tests 44 20 7 Control charts x 2 46 21 APPENDIX CVI3 I O AND EVENTS 47 21 1 CVIS logical outputs EE 47 21 2 CVI3 logical Inputs uses sure 50 22 APPENDIX USER INFO CODES 52 6159930290 01 03 2012 23 APPENDIX FIELDBUS USER MANUAL sss seene e 56 23 1 General 56 23 2 Hardware installation 56 23 3 Configuration 56 23 4 General configuration 58 23 5 Hardware mapping 59 23 6 Data MAD DING nee 60 23 7 Modules detailed description 63 24 APPENDIX CVI3 CONNECTIONS 67 24 1 Tool connector 67 24 2 CVI II adaptor EE 67 24 3 RS232 SubD E E 68 24 4 Digital inputs 0 24V 68 24 5 Digital outputs 0 24V 68 24 6 eBUS for accessories 69 25 APPENDIX CVI3 SPARE PARTS 70 6 6159930290 01 03 2012 1 SAFETY AND STATEMENT OF USE This product is intended to program and configure CVI3 controllers No other use permitted For professional use only General safety instructions and installation of controllers and electric spindles are collected in the Quick start user manual part no 6159932290 O2 SAVE THESE INSTRUCTIONS CAREFULLY 2 INSTALLATION The PC minimum configuration is Windows 2
66. eneral Control Torque Monitor Current 2 7 Current monitoring Monitoring option Check at end e Target torque Max current 40 00 Min curent 35 00 Value to monitor Peak v Exit The Current check at end checks the torque value measured by the torque transducer and the current drawn by the motor for coherence It is a simple way to detect any torque drift or any drift of efficiency in the tool The monitored value can be Peak or Final e Fill in the values according to your selection e Tick the box on the top left to confirm your selection and click on Exit to quit the screen 14 3 3 Slip off Strategies Motor control General Control Torque Monitor Slip off 2 Slip off Threshold 4 00 Torque drop 50 00 Slip off angle 10 00 Lie 6159930290 01 03 2012 e Fill in the values e Tick the box on the top left to confirm your selection and click on Exit to quit the screen 14 3 4 Stick slip Strategies Motor control General Control Torque Monitor Stick slip 2 M Stick slip Threshold 4 00 Number of slips 3 e Fill in the values e Tick the box on the top left to confirm your selection and click on Exit to quit the screen 14 3 5 Time Min time 1 00 10 00 Max time e Fill in the values A step duration can last from 0 to 99 9 sec e Tick the box on the top left t
67. er is set in the Pset running mode and that the Pset selection source is Socket tray see chapter Tightening unit configuration e In the table assign a Pset to each socket Click this icon to delete your selection 6159930290_01 03 2012 10 3 3 2 Guided mode The operator s task is guided either by the Pset selection or by the Assembly action of the Assembly Process The color code remains the same when the Pset is selected the green LED of the corresponding socket is blinking Once the socket is lifted the red LED is on When the green LED is steady the tool is ready to operate Pset selection User interface Networks 1 0 and Accessories RS232 Date and Time Identifier Table Configure Add delete accessories 2 Overview B Internal 1 0 Inputs Outputs i 1 4 Socket tray i 4 4 Socket tray i 5 4 Socket tray d 1 7 Stack Light Inputs Outputs e Tick one socket position per Pset Click this icon to delete your selection Assembly action selection e Refer to chapter Assembly action page 30 10 3 3 3 External mode The socket tray is controlled by the customer protocol LEDs are flashing or lit according to that protocol e Save and quit by pressing the Save icon 10 3 4 I O expander configuration re Naw VO das 57 Da mrt i Configure Add delete accessories 2 1 0 Overview E Internal 1 0 Inputs Outputs
68. fier table 18 PAN a ne 12 10 6 1 Add Edit an identifier 18 5 4 Help a EE A 12 10 6 2 Result mask a 19 TOOLBAR as ei 12 OP 11 CONTROLLER AND TOOL INFORMATION sss sss sss seene 19 7 ASSEMBLY LINE BUILD AREA 13 11 1 Controller no sennennennenneenennennsrnsrnsrnsrnernsrrsrnenn 19 OR E 19 7 1 Assembly line eee ee ee eee 13 1 2 e He un LEE 13 12 TIGHTENING UNIT CONFIGURATION20 FE R IS e e E 13 eegene i 12 1 Running mode 20 7 3 2 Parameter set 13 Peres 20 Eege 13 15 TE E E EN 20 6159930290 01 03 2012 3 12 4 Reject report Options see eee 20 12 5 Tool accessories and triggers 21 13 PARAMETER SET PROGRAMMING 21 13 1 How to create a Deer 21 13 2 Pset general parameters 22 13 2 1 Cycle start torque 22 13 2 2 Remove torque fastener limit 22 13 2 3 Overall angle mode 22 13 2 4 Overall time mode 22 13 2 5 External stop abort Deet 22 13 2 6 Run reverse direction 22 13 3 Cycle SOIR aan 22 13 3 1 Torque Check uen ion 22 13 3 2 Jog enabled sse seen 22 13 3 3 Rehit enabled 23 13 4 Cycle stop 23 13 4 1 Socket release enabled 23 13 4 2 Ergostop enabled 23 13 4 3 Reject on trigger lost 23 13 5 Setting up the curves display
69. gh level 4 4 1 Abort the running AP when another AP during a duration longer than keep alive number is requested inactivity time out then the Fieldbus is considered as disconnected If this item is active then when PLC select a new AP number then the current AP is aborted and the requested one is KEEP ALIVE selected 4 4 2 Restart finished AP when same AP number is requested by PLC If this item is active then when the current AP is finished then the CVI3 will select the AP requested by PLC even if its value did not change since AP start Value change If the value of variable keep alive value does not change during a duration longer than keep alive inactivity time out then the Fieldbus is considered as disconnected 5 HARDWARE MAPPING KEEP_ALIVE_VALUE e Click on the icon Hardware mapping to display the following screen A Fieldbus Mapper sce Fieldbus is disconnected if Tvalue gt ors ra er a C ere T TE FREE Parameters 4 3 2 Actions te Select assembly to abort current AP and select AP given 0 process in argument Zr Set I O to set Input or Output given in argument to active state Reset I O to set Input or Output given in argument to inactive state l Delete Filaluih geed V 1 3 0 5 Save Exit Blink I O to blink Input or Output given in argument when state is offline blinking frequency is
70. gnificant characters positions thanks to your mouse Significant characters Significant characters and positions gt Positions Identifier 6159930290 01 03 2012 Note that 2 different codes with the same length will have the same action You can copy or delete any identifier Import export e Click on Import to get identifiers from an Excel file 10 6 2 Result mask The result mask gives the position of the characters to be stored in the result characters at the same place will have the same d Note that 2 different codes with the same significant action e Click on Edit and then on Result mask to set the significant characters positions identifier Result Mask 2 Mask data to be stored I Read code Significant characters Result Mask Set the result data mask positions thanks to your mouse Significant characters and positions e In the identifier mask grid enter the mask manually by clicking into the boxes e Use this mask to set the results data positions It is possible to memorise up 30 characters of a code with a result By default the 30 first characters are selected The next screen helps you to define the mask of the data to be stored e Note that it is possible to select several package of characters within the code e Save and quit by pressing the Save icon 6159930290 01 03 2012 11 CONTROLLER AND TOOL INFORMATION
71. he current assembly process is aborted CVI3 behavior can be adapted using Assembly process panel in general configuration Identifier Identifier e g VIN number can be used to start an assembly process Keep alive value Value that will be copied in Keep Alive Value Ack Value change can be used as heartbeat management User variable 1 A variable freely settable by user No treatment is made on this value This value that is copied in User Variable 1 Ack 6 7 Events in PLC output All input events described in CVI3 User Manual can be associated to PLC output in Fieldbus For each event you can choose to invert or not the signal Note that you can associate up to 4 input events to a unique bit in PLC output This allows you to set several events at the same time 6 8 Bypass between PLC and IO For some reasons you may want to directly control CVI3 inputs outputs by PLC without any treatment on it External input output bits are dedicated to this usage Example to read a CVI3 physical in PLC memory e First associate a CVI3 input to an External inputs PLC bit in I O and accessories panel 6159930290_01 03 2012 User interface Networks 1 0 and Accessories RS232 Date and Time identifier Table Configure Add delete accessories 2 1 0 Overview _ Input events Inputs 3 internal vo 7 0 General commands WER input 1 direct Start Stop Tightening on state Pset selection
72. he tool motor windings has exceeded the Motor temperature The signal turns temperature temperature security limits threshold exceeded off when the 100 C max for fixed tools temperature returns 60 C max for portable tools below the limits plus 10 C Angle Angle sensor fault detected by servo drive It can be a sensor Angle sensor fault Disconnecting tool measurement fault or tool electronic fault or both or new check without fault fault Offset failure detection Disconnecting tool or new check without fault Invalid spindle Tool characteristics do not match Pset parameters e g Pset selection or tool Tool disconnection or settings negative jog times or contradictions torque over the maximum connection new Pset selected tool torque range speed over the maximum tool speed Invalid Pset The selected Pset failed Pset selection failed Pset selection selected Pset number does not exist in the controller succeeded Lock on reject The tool is locked after a rejected tightening operation The Tightening finished Error acknowledge controller will not continue to operate the tool depending on with NOK result and input activated or run lock on reject option option lock on reject reverse operation or until the Error Acknowledge input is activated activated loosening operation until a run reverse operation until a loosening operation Tightening The tightening operation has actually started the tool
73. his event can be linked to a 24 V output Repeat When enabled this function will allow starting the AP again without waiting the source start When disabled a source start information is required to start this AP or another one O Click this icon to delete an action e Click on Save 15 6 Assembly Process import export e Click on Export to file to save the Assembly Process in a file named Assembly Process AP xml and located in the following path C Program Files Desoutter CVIPC Click on Import to file to import a file named Assembly Process AP xml from the following path C Program Files Desoutter CVIPC e Change the file location as you like 16 PC TO CONTROLLER DATA TRANSFER The transfer depends on how the PC is connected to the controller s The PC can be connected to the controller s via a Point to point OR a network connection In a Point to point communication mode data are transferred to the controller in real time You can start running the Assembly Process at once In a Network communication mode you will have to transfer data from the PC to the connected controllers one by one In both modes ensure that the Running mode in the controller s is correctly set Pset or Assembly Process Refer to the controller s user manual to know how to set the controller e To transfer data use the Transfer menu or the tool bar 16 1 Transfer menu e In the main menu click on T
74. idate 2 2 2 How to activate your CVIPC e Login to the website https licensing desouttertools com License Management e Click this icon to view the following screen Manage existing licenses License Number PC User Install name date XXXX XXXX XXAX XXAX AAAABBBBCCCCDDDD XXXX XXXX XXXX XXXX Type Serial number Installs remaining Add 1 x 6159276010 Delete 11 e Click on Add to get your registration code Industrial Software install r License card il License type Part number ZZZZZZZZZZZZZ Software designation CVIPC 1 user Installs 1 License Serial number License Number Date manufacturing 01 05 2012 02 44 38 Installs remaining 1 Features ZZZZZZZZZZZZZ r Software install Public key PC name www desouttertools com Copyright 2011 Desoutter Tools e Copy paste the public key you will get as follows e Launch CVIPC e In the Menu area click on Service and then Registration to display the following screen In order to register please follow the link below https Aicensing desouttertools com After registration you will be requested to enter your product license number and part Recistrati Your public key Registration code Register e Click on Submit to validate Install User Public key LZZLZLZLZLZLZLZLZLZLZLZLZZ ZZZZZZZZZZZZZZZZZ 2012 02 28 18 58 22 Registration code
75. ifier OK Tightening OK Identifier NOK Output 7 direct Keep alive ack User info present H O Extemal outputs Batch OK H O Tool status H O 10 Socket tray H O Miscellaneous Num Interval Sec 1 Nomal x e Refer to the previous chapter to know how to assign an event to an output e Click right on the output to select the logical operation or by default and nor nand e Click on the ouput number and select the type of interval Normal The output is maintained until one of the events changes The output is maintained during 10 s max Flashing The type of interval is the same as Normal and flashing 375 ms on 375 ms off For example normal TT imed from 1 to 10 s flashing TUUUPL e Click on Set defaults to restore the initial configuration Refer to APPENDIX CVI3 1 0 AND EVENTS to get more information about the I O and events e Save and quit by pressing the Save icon 10 3 2 Add delete accessories Accessories connected to the controllers can be added to the list of inputs events and assigned to physical inputs e Click on Add delete accessories to display the screen 16 Configure Add delete accessories al Add delete controller accessories Accessories Overview Internal I O Address 4 Change Ra 4 4 Socket tray e Select an available accessory by clicking on its name It will be immediately disp
76. in reverse direction when the operator presses the trigger Once the tool has run the tightening direction is automatically re activated Alternate The tool runs in the selected direction when the operator presses the trigger as long as the direction does not change Reverse The reverse direction is not possible disabled e Fill in the following values Speed This can be used for any loosening operation except for a Pset loosening step Min torque and These will allow to detect a real Min Angle loosening of the assembly Maximum time Maximum loosening duration Max number of Maximum loosening turns from trigger turns start 12 4 Reject report options e Select one of the options to lock the tool after a NOK tightening The tool can then be unlocked by actuating the Error Acknowledge input by pushing the run reverse button or by loosening 6159930290_01 03 2012 12 5 Tool accessories and triggers 1st step enter the Target torque Create a parameter set Click on Tool to display the model the max torque and the DEE EENS max speed The Parameter Set contains the fastening strategy and associated parameters for the operation Specify a name target value and control strategy Assembly line VW36 2 Tightening unit Tool Tool Tightening System Single ool Model Max torque Max speed 1 EAD50 900 50 300 Parameter set number 1 Parameter set name Parameter set e Click
77. ing normal operating conditions or higher temperatures i e in an industrial environment the specified max current for this output is 10mA 7 4 Profinet 1 port 6159930290 01 03 2012 65 Network Status LED A test sequence is performed on this LED during startup LED State Off Offline No power No connection PLC Green Online RUN Connection with PLC established PLC in RUN state Green Online STOP Connection with PLC established PLC in STOP state flashing Module Status LED A A test sequence is performed on this LED during startup Not Initialized No power or Module in SETUP or NW_INIT state Green Normal Module has shifted from Operation the NW NIT state Green 1 flash Diagnostic Diagnostic event s Event s present Green 2 Used by engineering tools flashes to identify the node on the network Exception Module in state Error EXCEPTION Red 1 flash Configuration Expected Identification Error differs from Real Identification Red 2 flashes IP Address IP address not set Error Red 3 flashes Station Name Station Name not set Error Red 4 flashes Internal Error Module has encountered a major internal error LINK Activity LED Off No Link No link no communication present Green Link Ethernet link established no communication present Green Activity Ethernet link established flickering comm
78. ink established no communication present Green Activity Ethernet link established flickering communication present Ethernet Interface The Ethernet interface operates at 100Mbit full duplex as required by PROFINET 6159930290 01 03 2012 APPENDIX CVI3 CONNECTIONS 1 TOOL CONNECTOR Legend A Connector 12 pts Male B Connector 12 pts Female a Ground shielded cable b WARNING Shielded insulate STA Twisted pairs 2x0 25 STB mm at 10 MHz 65 Q 2 CVI IT ADAPTOR LG TN Ze AM d EN La V L l Legend 1 CVI3 tool connector 2 CVIII tool adapter 3 CVIII cable 4 CVIII tool 6159930290 01 03 2012 sm Re 67 3 RS232 SubD 9pt 4 DIGITAL INPUTS 0 24V AGND 24V controller 0 24V controller Quick Stop Channel 1 Quick Stop Channel 2 Input 1 Input 2 Input 3 Input 4 IEEEEEEEEEEEEET Input 5 Input 6 Input 7 Input 8 Legend 1 Digital input connector Example of connections possibility to connect a 24V external supply in parallel of the 24V delivered by the controller 24V Controller 68 5 DIGITAL OUTPUTS 0 24V AGND 24V controller 1 14 0 24V controller Common 1 Output 1 Output 2 Output 3 Output 4 Output 5 EEE EEE Output 6 Output 7 Output 8 D Common 2 Legend 1 Digital o
79. is Torque reachs the The tightening running running and the torque is over the start torque threshold start torque threshold operation is finished Tightening The Pset report is available Result generation New start tool finished trigger or external start or reset input Pset selected Echoes the binary Pset selected bit 0 7 input if the New Pset selected New Pset selected bit 0 7 corresponding Pset exits Echoes 0 if the Pset does not exist Tightening OK The tightening operation for a specific tightening unit is Result generation New start tool successful and all tightening parameters are within their trigger external tolerances start or reset input Tightening NOK The tightening operation for a specific tightening unit has Result generation New start tool failed trigger or external start or reset input Spindle OK The tightening operation for a specific spindle is successful Result generation New start tool and all tightening parameters are within their tolerances trigger or external start or reset input Spindle NOK The tightening operation for a specific spindle has failed Result generation New start tool trigger or external start or reset input 6159930290_01 03 2012 Angle low The tightening angle report is below the minimum value The tightening angle report is above the maximum value The tightening angle report is correct The tightening torque report is below the minimum va
80. layed in the overview of accessories e If needed change the accessory address on the eBus between 0x0 and OxF e To remove an accessory select it in the Accessories Overview and press Delete e Once the accessories are selected return to the previous screen by clicking on Configure The new accessory is now listed in the I O Overview and can be assigned to an input e Click twice on the new accessory in the Accessory overview to set it up e Save and quit by pressing the Save icon 10 3 3 Socket tray configuration Userinterface Networks 1 0 and Accessories RS232 Date and Time identifier Table Configure Add delete accessories 2 1 0 Overview z D Internal 1 0 Inputs Outputs Sa 4 4 Socket tray ee LED Flash duration 400 gt msec Mode Selection v Sockets 4 4 4 g 3 e Change the socket tray direction according to the positioning of the LEDs Note that the LED no 1 is always the first left e Select the LED flash duration up to 1 s e Enter a comment for each socket e Select the socket tray mode according to your assembly configuration There are 3 modes 10 3 3 1 Selection mode The controller automatically selects the Pset associated to the lifted socket The red LED is on when the socket is lifted and the green LED is on when the tool is ready to operate e Ensure that the controll
81. ld 25 00 Maxtorque 20 00 Min torque 15 00 Parameters Loosening threshold Target angle Loosening angle expected Stop conditions IF Angle 2 Target angle OR IF Torque 2 Abort torque Start the angle measure IF Min torque lt Final torque lt Max torque AND IF Min angle lt Angle lt Max angle For each channel the 3 report controller LEDs will light according to the following diagram aye Nm Remove and replace fastener Abort torque Loosening threshold Max torque Target Min torque ange Start torque JER ee Min ges angle angle Result data Final torque Peak OR Final angle 6 JUMP This step allows continuing a Pset by jumping to another step within the same Pset Jump op 7 CURRENT CHECK AT END Adding a current monitoring makes the fastening operation even more reliable it acts as a second torque transducer monitoring Even if transducerised tools provide high reliability as the level of production is very high they still need to be checked regularly The current monitoring is a way to both reduce the checking and detect pro actively potential maintenance Issues The current check at end monitoring checks the torque value measured by the torque transducer and the current drawn by the motor for coherence It is a simple way to detect any torque drift or any drift of efficiency in the tool Target torgue Max curent
82. lect your own language and click on Change e Click on File Exit to close CVIPC and re start the program to display the new language 6159930290_01 03 2012 5 2 2 E mail configuration Email configuration You can configure your SMTP server to allow CVIPC sending report when bugs appear f you want to notify people of these bugs you can add them in the Cc field SMTP Max attachment size 10 M Company nar Person to contact Separate the addressees by a comma like cvi3 support Sdesouttertools com cvi3 supporEdesouttertools com You can test sending an email to the Uc addressees to see if your configuration is comect ox Jl Geet e Point your SMTP server to allow CVIPC sending report when bugs appear Max attachment size 10 M by default e If you want to notify people of these bugs add their e mails in the Cc field Separate the addresses by a comma e Click on Test to check that your configuration is correct e Save and quit by pressing OK 5 2 3 Preferences 5 2 3 1 General The general settings of CVIPC are displayed Preferences e General al Network connection Scan Ok Gei e Click on Default to restore the initial values 5 2 3 2 Network connection Network connection Scan Front Panel enabled 4 Scan at CVIPC startup Number of tries on network 3 Time To Live TTL Number of tries Send keep alive
83. led W Reject on trigger lost 13 3 1 Torque check If yes the torque offset value will be checked at each Pset start and a span test will be performed It is recommended to set this parameter to Yes to detect the torque offset and to span the drift 13 3 2 Jog enabled The jog function helps to fit the tool socket onto a bolt When enabled a spindle turns a given rotation angle in a specific direction forward reverse or alternate and repeatedly n times The jog function can be selected for each spindle General Cycle start stop Curves Start stop general Jog H v Jog enable E T 0 10 30 00 Repetition delay Rotation angle Repetitions 1 Rotation direction Forward v e Fill in the screen stop torque speed acceleration time repetition delay rotation angle 6159930290 01 03 2012 post jog delay 13 4 2 Ergostop enabled repetitions rotation direction This options allows for a smoother tool stop so as to reduce e When finished tick the box on the top left to valid your torque reaction on the operator selection and click on Exit to quit General Cycle start stop Curves Start d stop general Ergostop 13 3 3 Rehit enabled 2 Ergostop enable This function is used to detect that a joint has been re tightened The conditions for rehit are Rehit enabled AND Angle reached between Rehit threshold and Rehit torque lt Rehit angl
84. line one or more connections are established Flashing On line no connections established Green 1 Hz Red Critical link failure Flashing Red One or more connections timed out 1 Hz Alternating Self test Red Green Module Status Operating in normal condition Flashing Missing or incomplete configuration Green 1 Hz device needs commissioning Rd Unrecoverable Fault s Flashing Red Recoverable Fault s 1 Hz Alternating Self test Red Green DeviceNet Connector This connector provides DeviceNet connectivity Pin Signal Description v Negative bus supply voltage 3 smen caesa 5 v Positive bus supply votage DeviceNet bus power For more information refer to DeviceNet Technical Specification 7 2 Ethernet IP Network Status LED A test sequence is performed on this LED during startup LED State No power or no IP address Green On line one or more connections established CIP Class 1 or 3 Green flashing On line no connections established Rd Duplicate IP address FATAL error LED State Red flashing One or more connections timed out CIP Class 1 or 3 Module Status LED A A test sequence is performed on this LED during startup Major fault EXCEPTION state FATAL error etc Red flashing Recoverable fault s LINK Activity LED Ethernet Interface The Ethernet interface support
85. little bit and retightens it to the final conditions Un tightening after a rejected tightening operation Un tighten clamps used to maintain parts while machining The possible loosening strategies for the loosening control are Torque control Angle control 5 1 Torque control and angle monitoring Loosening with torque control and angle monitoring is used when you want to keep up a small constraint in the assembly The un tightening operation is not complete Abort torque 32 00 Breakaway torque 30 00 Loosening threshold 25 00 Maxtorque 20 00 Target torque 18 00 Min torque 15 00 Parameters Breakaway torque starts the torque measure Loosening threshold starts the angle measure IF Min torque lt Final torque lt Max torque AND IF Min angle lt Peak or Final Angle lt Max angle For each channel the 3 report controller LEDs will light according to the following diagram o XI SE Remove and replace fastener Max torque Min torque Start Or9ue tn Min Max angle angle Result data Final torque Peak OR Final angle 6159930290 01 03 2012 39 5 2 Angle control and torque monitoring Loosening with angle control is mainly used to release the constraints in the assembly completely When this Strategy is selected the torque and the angle are monitored automatically Abort torque 32 00 Loosening thresho
86. lj X A37 Upper limit ls X A30 where A3 1 427 2 Upper and lower check limits of the standard deviation Lower limit li B30 Upper limit ls B40 where B3 0 B4 2 089 O mean of the standard deviations for each sample 5 measurements For each sam ple the standard deviation is calculated as follows __ X x X PV N 1 6159930290_01 03 2012 APPENDIX CVI3 I O AND EVENTS 1 CVI3 LOGICAL OUTPUTS 1 1 Lockout Span failure When starting a tightening and before running the tool the Span failure detection Disconnecting tool controller checks the torque span This output is activated if or new check without the span drift is more than 3 causing a tool lockout This fault fault can be due to a torque transducer or a tool electronics failure Offset failure The offset 0 point drifts by 50 of full scale or more This error exists when at the beginning of the tightening operation the torque transducer is seen to have 50 or more of full scale torque prior to even starting the motor With an offset failure the controller cannot adequately compensate for this transducer error and therefore will not allow a tightening operation to occur Offset failures can come from a severely damaged torque transducer cable or controller No tool The controller is not detecting the tool No tool connected or Tool connected and connected tool not recognized recognized Motor over The temperature of t
87. lue The tightening torque report is above the maximum value The tightening torque report is correct Remove The tightening operation has exceeded the Remove fastener Fastener limit There is a risk that the tightening operation is not reliable disassemble the joint and check parts Overall time The maximum overall time has been reached reached Tight finished no timeout Tightening is finished without overall timeout Batch finished The batch count has been completed whatever the reports Batch OK The batch count is complete All tightenings are OK or forced as OK Batch NOK The batch count is complete Some tightenings are NOK or forced as NOK or the AP has been aborted Result generation Result generation Result generation Result generation Result generation Result generation Result generation Result generation Result generation The batch is finished The batch is finished and OK The batch is finished and NOK A new AP has been selected New start tool trigger or external start or reset input New start tool trigger or external start or reset input New start tool trigger or external start or reset input New start tool trigger or external start or reset input New start tool trigger or external start or reset input New start tool trigger or external start or reset input New start tool trigger or external start or reset input New start
88. n the left e Save and quit by pressing the Save icon 15 4 Process actions There are 4 types of Process actions Assembly The assembly action is associated to a Pset to run an assembly operation Set output During the assembly process the controller triggers an AP external output bit 0 9 output event This event can be linked to a 24 V output Reset output During the Assembly Process the controller resets an AP external output bit 0 9 output event This event can be linked to a 24 V output Sense input This input waits for the rising edge of a specific input Process actions can be sequential or parallel The logic operators are AND and OR x Click this icon to dock the bottom screen pt Click this icon to undock the bottom screen o Click this icon to delete an action 15 4 1 Assembly action e Click on Assembly to start building the tree of Process actions This first action is compulsory and it is not possible to delete it e Slide the mouse on the bottom screen to display the parameters Assembly line Singletool Assembly process 1 Assembly Process E 2 Assembly process 1 Description Assembly Process Change Process Actions Sequential actions mn Set output amp Reset output ERR S Sense input ren Parallel actions Post processinq z 4 ES Description Assembly Number 1 Comment Parameter set 1 Paramete
89. n your computer This application allows you to view and analyse the results that you have uploaded Tightening results VW36 2 Tightening unit MA lt gt x U SNE Date Time T Unit Sp RP Torque Angle 2011 03 31 12 28 32 Tightening unit 1 1044 OK 2011 03 31 12 28 41 Tightening unit 1 1044 OK Number of results 2 Last results only Fitters Start 11 al End C 15 L Spindle comment Filter on report Step number all C Only OK Spindle number e C Only NOK y Cycle number Aes Part number vs 17 2 1 Results display SK Click this icon to customize the display of results e Tick the elements to display and move the cursor to the right or left to view them all e Valid by pressing OK 17 2 2 Results filtering e Use the filter boxes to sort the results by date by type of report or by item number e Click the red arrow e Press the Search button to start the process You can also filter the results by spindle comment step number spindle number cycle number part number 6159930290_01 03 2012 17 2 3 Barcode reader connection 18 MAINTENANCE Us Click this icon to set up the connection with the O barcode reader and fill in the screen 18 1 CVIMONITOR software Desoutter has developped a specific software to monitor results maintenance and diagnostic data in real time In details CVIMONITOR offers 17 2 4 Printing re
90. nshift speed 42 6159930290_01 03 2012 APPENDIX STATISTIC COMPUTATION 1 LIST OF STANDARDS Process capability CAM z IT List of standards available for statistical calculations Di ISO 5393 proposed by default where IT Tolerance Interval Max tolerance Min CNOMO E41 32 110 N tolerance NF E 60 181 Means of production Method for assessing ability to make components Q544000 V6 0 measurements W must comply with Testing the homogeneity of the population each sample of IT 2 GLOSSARY a ew X CAM cdc Measurements Number of measurements selected Standard deviation for the computations Number of samples of 5 measurements Tolerance interval Result of maximum tolerance minus minimum tolerance lowest value of the population where Highest value Highest value of the population Values lt min tol Number of values below the N minimum tolerance y 1 Values gt max tol Number of values over the N population mean maximum tolerance N Naan Mean of population XI population value CAM Process capability according CNOMO standard N number of measurements of the population CPK Coefficient of position and Corrected standard deviation dispersion CP Process capability according ISO Oo Cxo standard where C is a function of the number of samples Number of samples Coefficient C huis Instantaneous standard deviation Oj _ 6 1 28 Estimated from the m
91. o confirm your selection and click on Exit to quit the screen 295 14 3 6 Rundown angle Strategies Motor control General Control Torque Monitor Rundown angle 2 Rundown angle Rundown max angle 3600 00 Rundown min angle 1800 00 Downshift torque 10 00 Rundown complete torque 7 00 Rundown angle threshold 1 00 e Fill in the values e Tick the box on the top left to confirm your selection and click on Exit to quit the screen 14 4 Options Refer to Appendix Tightening strategies to get more information about the options 14 4 1 Latch threshold When this option is ticked the controller starts measuring the angle when the torque crosses the angle threshold for the first time The measure then continues till the end even if the torque becomes below the threshold The measured angle is therefore closed to the real angle The angle is measured starting at a torque value called Angle threshold There are 2 possibilities Without latched threshold the controller stops counting the angle when the torque falls below Angle threshold With latched threshold the controller starts counting the angle as soon as the torque rises above the Angle threshold If the torque should fall below Angle threshold the controller proceeds counting Nm amp Deg Angle with latched threshold Target angle less cesse nues EE Z Angle without latched threshold
92. ommunication issues the software measures the memory fill in rate When the target threshold is reached the Reporting alarm output switches on Identifier OK Identifier received and identified e g barcode Identifier received and 0 5 s after rising identified Identifier NOK Identifier received but not identified e g barcode Identifier received but 0 5 s after rising not identified Keep alive ack This output is the copy of the Keep alive input It can be When Keep alive When Keep alive used by the PLC to check that the controller is still running input rises input falls User info 3 levels of user information Info Warning Error The user information The user information present is displayed is not displayed 1 3 External outputs PLC external The output is controlled by PLC via Fieldbus like a remote Managed by PLC Managed by PLC output 1 10 I O AP external The output can be set or reset within an Assembly Process Managed by AP Managed by AP output 1 10 OP external The output is dedicated to Open Protocol Managed by OP Managed by OP output 1 10 1 4 Tool status Name Description lt lt lt Rising condition Falling condition Tool direction The tool is running forward Tool direction in Tool direction in reverse forward direction direction Tool tightening The tool is running forward Start torque threshold is not taken Tool starts in forward Tool stops into account direction Tool not lo
93. on value Initial calibration value Unbalance reference manufacturer information Unbalance tolerance Max offset Min offset The characteristics of the second torque transducer are displayed if the tool is equipped with and if the second torque transducer is enabled e Click on Update to display the current parameters This function is useful to refresh the information for example if you have hot swapped the tool 12 TIGHTENING UNIT CONFIGURATION This screen will allow you to adjust the settings of each spindle the Running mode the Run reverse parameters the number of curves declared as OK or NOK the Reject report options the tool accessories and triggers Click on Single tool and then expand the tree by clicking on the on the left Click on the Tightening Unit icon Normal mode 2 Normal settings for tightening unit Total spindles 1 Comment Running mode Run reverse parameters Running mode PSet Z Reverse mode Altemate v PSet selection source CVI3 Front panel 4 Speed 50 z Store identifier in results enabled LL so Mi le 720 00 Execute identifier enabled pode deg Cl Store non tightening results BN Soc Abort running AP when another AP number is request Max number of tums 399 Curves stored per spindle Reject report options OK NOK Lock on reject option 10 10 Z Not used X Change the description of the tightening unit if required
94. or Pset selection bit 6 H input 6 direct d Pset selection bit 7 Start Stop Tightening on state Enable spindle forward S H input 7 direct i Enable spindle reverse Reverse direction Acknowledge eror oO Input 8 direct Reset Reset Reset only status Extemal stop to next Pset i Restart controller Click on Inputs in the I O Overview to display the input events and the physical inputs Some of the most frequently used events are already assigned Drag an event from the left and drop it to the right to assign an event Drag and drop to the left to remove an assignment In the list of I O events click right on the event to see its assignment In the list of I O click right on an input to select the signal direction Inputs and events follow the same direction Input is inverted compared to the event e Click on Set defaults to restore the initial configuration 6159930290_01 03 2012 15 10 3 1 2 Outputs E 1 0 Overview Output events Outputs Internal I O Lockout status o Output 1 direct bns H O PSet status Tightening OK gt Assembly process status o Output 2 direct Outputs B General status Ready Ready D Output 3 direct Yellow report Pset selection bit 2 Green report DI Output 4 direct Red report Ready Manual reverse in process o Output 5 direct Fastener loosened Tightening running Fieldbus faut O2 Output 6 direct Gp Ident
95. or 2 Tool Tool connection value 2 in TU unit disconnection Tool max speed Tool maximum speed in rpm Tool Tool connection disconnection Result type Type of the result 0 no result Tight start Result received 1 tightening 2 run reverse User info code Value of info error or warning New user info No more user info displayed displayed displayed Keep alive value Mirror of Keep Alive Value in PLC Controller start New value in ack output keep alive value User variable 1 Mirror of User Variable 1 in PLC Controller start New value in user ack output variable 1 Controller name Controller name Never CVI3 starts or new config Tightening unit Tightening unit name Never CVI3 starts or name new config Socket lifted Socket lifted CVI2 or CVI3 UP Socket lifted socket tray Identifier 1 2 3 4 Identifier stored in result Tight start Result received 62 6159930290_01 03 2012 6 5 Events in PLC input All output events described in CVI3 user Manual can be associated to PLC inputs in Fieldbus For each event you can choose to invert or not the signal Ke You can specify different parameters for this input output E Invert bit value Association with 6 6 Outputs variables Name Description gt CVI3 inputs State of the 8 CVI3 inputs that can be forced by PLC Pset selection Id of Pset expected by PLC AP selection Id of Assembly process expected by PLC If the assembly process 0 is requested then t
96. ou as soon as possible d Crash disk Forget uninstall Other reason Em Reason www desouttertools com e Tick Other reason and add a comment to explain why you want to uninstall your licence e Click on Submit to validate e Please wait for a message from Desoutter support confirming that your license has been unregistered You will then be able to reactivate the license on a new PC 6159930290 01 03 2012 2 3 Communication with controllers The PC must be connected to the controller s via a Point to point OR a network connection 2 3 1 Point to point Pre requisite The PC Ethernet card must be configured in DHCP The PC is directly connected to the controller on the dedicated Ethernet port on the front panel Communication parameters are automatically set Legend 1 Ethernet port dedicated to CVIPC only e Connect the PC on the port 2 3 2 Ethernet networks The PC and the controllers are connected to the Ethernet network gy HO IEH Legend 1 Embedded Ethernet switch 4 ports e Connect the PC according to the following description e To set up the parameters refer to the controller s manual operator or contact your Desoutter representative for support 1 network Plug your Ethernet cable into any port Ethernet network 1 2 networks Ethernet network 2 6159930290 01 03 2012 3 OVERVIEW
97. p 00049 0 0245 0 0386 et 00163 0 0814 er PP 00081 0 0244 22 PP 0 0000 0 0174 29 LL ll DEn 25 1 00035 Calculation of W b S There is a 5 probability of not having a normal distribution if W is lower than W95 given in table Normal distribution test population of more than 50 measurements CHI CARRE test 1 Distribute into classes of at least 4 or 5 measurements 2 Calculate the mean and standard deviation 6159930290_01 03 2012 45 mean gt N standard deviation B S xi X PV N 1 3 Calculate for each class limit _ lj X oO A i 4 Calculate ni nj Hr x where n number of measurements in class i n theoretical number of measurements for a normal distribution n N F u F uj 1 F ui reduced table of normal distribution there is a 5 probability of not having a normal distribution if X is higher than X given in table below 7 CONTROL CHARTS Mean Range control chart 1 Upper and lower check limits of the mean Lower limit li X A2W Upper limit ls X A2W where A2 0 577 for samples of 5 measurements W mean range for each sample 46 2 Upper and lower check limits of the range Lower limit li D3W Upper limit I DAW where D3 lt 0 Dd 2 114 Mean Standard deviation control chart 1 Upper and lower check limits of the mean Lower limit
98. p WT Tight start Result received Min current in Amps last step A Tight start Result received Max current in Amps last step BR Tight start Result received Current trend Current trend last step 0 no result Tight start Result received 1 min 2 max 3 accepted Tightening result Tightening result A accepted 0 no result Tight start Result received R rejected 1 accepted 2 rejected 6159930290_01 03 2012 value Final current Final current in last step MG Tight start Result received Min current in last step ee ee Tight start Result received Max current in last step A Tight start Result received Tool serial Tool serial number Tight start Result received number Rundown speed Rundown speed in rpm BR Tight start Result received Downshift speed Downshift speed in rpm n Tight start Result received Downshift Downshift torque threshold Tight start Result received torque Angle threshold Threshold in Nm used to start Tight start Result received angle measure Spindle Comment written in tool memory Tool Tool connection comment disconnection Tool model Model of tool connected e g Tool Tool connection EAD50 900 disconnection Tool max torque Maximum torque of tool Tool Tool connection connected in TU unit disconnection Tool calibration Calibration value for tool sensor 1 Tool Tool connection value 1 in TU unit disconnection Tool calibration Calibration value for tool sens
99. peed 750 833 Downshift speed Downshift t pere res 150 167 K Final speed Cycle start S 44 torque os Sec 0 40 Acceleration time Rotation direction AN o G REN 3 speed ergospeed motor control is a good compromise between Pset time and accuracy and it improves the operator comfort 6159930290_01 03 2012 Fill in the values e Select the Rotation direction Clockwise Counterclockwise e Select External stop to stop the current phase and shifts to the next one as soon as one of the following signals shifts to 1 onrising edge on falling edge onchange on high level on low level 14 6 General parameters e Click on General to display the following screen Strategies Motor control General 2 Step general parameters Comment Post step delay 0 00 dN 10 00 Maximum time Reject on timeout V Continue on NOK Note These parameters are common to all spindles Store results The step general parameters are common to all Spindles e Add a comment up to 100 characters e Fill in the values Post step delay This is the time between 2 steps Max time This is the maximum step duration before proceeding to the next one 10 s by default Reject on timeout e Tick the box to declare the phase NOK in case of a step timeout If not the result is measured against the setpoints of tightening Continue on NOK e Tick the box
100. peration If this input becomes inactive at any time during the tightening the tool will stop running At the end of tightening a new tightening begins only if the signal falls and then rises Start stop tightening This input is only enabled for fixed tools without trigger Rising edge on edge Initiates or ends a tightening operation A rising edge initiates a tightening A falling edge has no effect during tightening If a tightening is in execution a rising edge will stop it Reverse direction When this input is activated the tool green amp red lights are flashing to indicate that reverse State direction is selected This signal status is not controlled during a tightening but only when the tool is not running Pset selected bit 0 7 Used to select Parameter sets up to 250 Binary coded Spindle validation Enables the tool forward direction State forward Spindle validation Enables the tool reverse direction State reverse Error acknowledge Enables the Reject Lockout function Once locked a tool cannot work until this input is Rising edge activated Reset When Reset input rises State tool and controller reports lights are set off the last result values on display are readable tightening is immediately stopped no reports are generated tool is locked defaults are acknowledged batch counter of the current Assembly Process is reset in Pset mode the selected Pset remains unchanged In Ass
101. peration starts immediately the PLC may have too little time to read result values Result management allows to select how to manage results for the PLC 8 Fieldbus Mapper Fieldbus general configuration Results Management Fieldbus Status management Assembly Processes Options Result management No management Holding duration 0 Several modes are available No management there is special behavior about result management Holding time management result remains in memory during a certain amount of time 4 3 Connection disconnection management KA Gees File View Fieldbus general configuration Results Management Fieldbus Status management Assembly Processes Options Keep Alive Control Keep Alive activity on Unused X l Keep Alive inactivity Timeout 0 Ms re connection actions list disconnection actions list Execute re connection actions after 0 gt Ms Execute disconnection actions after Blinking I O frequency 1 3 V 1 3 0 5 l pat This panel is dedicated to set the behavior expected from CVI3 when connection and disconnection events are occurring 4 3 1 Connection disconnection detection Connection disconnection is always detected using detecting missing data from PLC In addition a keep alive signal coming from the PLC input KEEP_ALIVE or KEEP_ALIVE_VALUE can be supervised by CVI3
102. que out of range 1 The target torque value is above the tool max torque 2 Check Pset settings with tool characteristics Tool communication error 1 Tool communication error 2 Check tool and cable connections If the problem occurs again contact your Desoutter representative for support N Tool over current 1 Tool leds are not corrrectly supplied 2 Disconnect and reconnect the tool If the problem occurs again contact your Desoutter representative for support N Number of retries reached 1 The number of retries max has been reached 2 The tool is locked 3 The running Assembly Process has to be aborted Tool locked lift correct socket 1 The tool is locked the CVI3 is waiting for the correct socket to be lifted Unsupported tool 1 The tool connected to the CVI3 is not supported 2 Contact your Desoutter representative for more information Tool loosening prohibited by VW 1 Loosening is disabled by VWXML protocol XML 22 23 4 2 LE 5 Tool tightening prohibited by VW 1 Tightening is prohibited by VWXML protocol XML 100 Cable invalid parameters 1 Problem detected with the cable memory cannot be read 2 Change the cable If the problem occurs again contact your Desoutter representative for support 101 Cable not detected 1 Tool communication error Check cable connection 2 If problem occured again Contact your Desoutter representative for support 199 Serial console activated 1 The serial console i
103. r set X PSet selection source CVI Auto PSet v Socket Socket Tray control Socket Tray Socket position Not used v Batch Batch size 1 H Batch count type Count OK x Retries Unlimited v Allow loosening Always m Decrement after loosening Never v Undo Save e Enter a description up to 40 characters e Enter a comment up to 100 characters This comment is displayed on the controller Pset You have to select the Pset which will control the tightening operation e Select one of the Psets already programmed 30 Pset selection source e Select the source which is allowed to select the Pset or the current Pset by selecting CVI Auto Pset Socket Socket tray control not used The tightening operation is allowed lift The Assembly Process is expecting the operator lifts the socket put all back and lift The Assembly Process is expecting the operator lifts the socket In case the socket is already lifted the operator has to put it back and lift it again Socket tray 0 IO socket tray CVI II socket tray on the I O 1 F IO socket tray 1 F is the address number of the CVI3 socket tray on the eBUS Note that the address is unique per accessory Socket position from 1 to 32 according to the socket tray model Batch e Enter the batch size 1 99 e Select the number of retries 1 99 unlimited The last Pset will
104. ransfer File View Transfer Options Serice About Ga D Transfer PC gt Controller 18 Transfer Controller gt PC E Compare Controller lt gt PC The transfer menu is active only when a single tool is selected e Select the transfer direction You can also compare PC data with controller data and then decide to upload data pr e Click on All to transfer all parameters including Psets and Assembly processes An alternative is to transfer part of the data click on Selective tab and select the data to be transferred as shown below Transfer PC gt Controller Tightening system Sindle ool All Selective This operation transfers all parameters of a controller including all tightening unit parameters all PSets and all steps mm a Connecting 16 2 Tool bar e Before transferring data from the PC you need to identify the controller where to send the data by clicking on it Use this icon to transfer data from the PC tothe controller BD 17 RESULTS 17 1 How to get the last results curves e Select a Tightening unit and click the following icon CVIPC will automatically get the last results from the controller and the Viewercvipc application will be launched CVIPC will automatically get the last curves from the controller and the Viewercvipc application will be launched 17 2 Viewercvipc application MP This new icon will appear o
105. rt by identifier Comment Selected by Identifier Selection source Open Protocol hd gente ldentfer 0 JI Estus Store in results Undo Save e Enter a description up to 40 characters and a comment up to 100 characters e Choose the Selection source e In the Identifier box select the required identifier name Click on Edit list to view all identifiers and modify them if necessary e Tick on Store in results to to ensure traceability e g to save the operator ID at the beginning of a shift e Save and quit by pressing the Save icon 15 3 4 Start by input event OR 77 By identifier ra By assembly number By input event Pe 3 Start by input event Start by input event Description Start by input event Comment Input event Extemal inputs AP Extemal Input 1 Output event s External outputs Extemal outputs AP Etemal Output 1 AP Extemal Output 1 AP Extemal Output 3 AP Extemal Output 4 AP Extemal Output 5 AP Extemal Output 6 AP Extemal Output 7 AP Extemal Output 8 AP Extemal Output 9 AP Extemal Output 10 CE Undo Save e Enter a description up to 40 characters e Enter a comment up to 100 characters e Select an Input event e Click below on one of the output events to select it or click on External outputs to select them all e Use the arrows to add them on the right or remove them o
106. s each step describing a function The tool will execute the steps one after the other in the given order Content of the steps and their order can be changed at any time The minimum to run the tool is 1 Pset containing 1 step There are up to 250 Psets per Tightening unit 7 3 3 Step A step is shown by this icon A Parameter set is composed of one or several steps up to 15 steps per Pset Generally for the tightening steps Strategies covers control of target values safety values tolerance values monitoring and options Motor control deals with the way the target is reached acceleration rundown speed speed strategy etc General parameters cover the general parameters for each step The default values are generally convenient 7 4 Management Management Use Copy and Paste to duplicate items Use Delete to suppress one or more items 7 5 Yellow and red messages The value is out of the recommended values The value is out of mandatory values 8 ASSEMBLY LINE PROGRAMMING 10 SINGLE TOOL CONFIGURATION The first action to do is create an Assembly line This screen will allow you to adjust the settings of your work 2 eua x Assembiy ine Es environment Ra Assembly line Es ser ine 2 Description Assembly ine user interface Gs networks H DS BEE O and accessories Py RS232 and USB ports P een EE date and time
107. s 10 100Mbit full or half duplex operation CVI3 Ethernet IP module characteristics 10 and 100Mbits s supported Half and full supported WebServer Internal webserver in module allowing setting connection parameters IP address 7 3 Profibus Operation Mode PROFIBUS Connector Operation Mode Not online No power On line data exchange Flashing On line clear Green 6159930290_01 03 2012 Flashing Red Parametrization error 1 flash Flashing Red PROFIBUS Configuration error 2 flashes Status State Jindication Comments No power or not Anybus state SETUP initialized or NW INIT Green Initialized Anybus module has left the NW INIT state Initialized Extended diagnostic bit Flashing Green diagnostic is set event s present Exception error Anybus state EXCEPTION PROFIBUS Connector DB9F Pin Signal Description CS CE PE E 5V Bus 5V termination power isolated Output short circuit protected SE CE 8 ALine Negative RxD TxD RS485 level Housing Cable Shield Internally connected to the Anybus protective earth via cable shield filters according to the PROFIBUS standard The current drawn from this pin will affect the total power consumption To simplify development the output supplies up to 60mA when operated in room temperature 20 22 degrees Celsius which is sufficient to power e g master simulators etc Dur
108. s activated 2 Warning this console is dedicated to debug purposes only and should not be used in production 52 6159930290_01 03 2012 Error Description Resolution procedure code no 200 Quick stop activated 1 The quick stop has been activated 2 Check your Phoenix contact 01 Replace backup battery 1 The real time clock backup battery needs to be replaced 202 Fieldbus connection lost 1 Fieldbus connection with PLC is lost 5 no heartbeat is received from PLC the cable is broken or disconnected the PLC is off line or not powered 2 Check the Fieldbus configuration 204 Spindle not validated by IO 1 Spindle locked by I O 2 Check the I O settings the Spindle validation must be active to unlock the tool 05 Torque settings and tool mismatch 1 Invalid Torque setting torque is greater than tool characteristics 2 Check Pset settings with the current tool characteristics 0 Speed settings and tool mismatch 1 Invalid speed setting speed is greater than tool characteristics 2 Check Pset settings with the tool max speed Assembly process done 1 Assembly Process is done the tool is locked 2 Select new Assembly Process to unlock the tool Invalid run reverse parameters 1 Invalid Run reverse setting torque or speed are greater than tool characteristics or reverse strategy is not supported 2 Check Pset settings with the current tool characteristics 2 NO N O 07 208
109. s not readable the backup starts by number select source I O AND The process starts if all conditions are fulfilled forced in the correct order order For example VIN number then part number are scanned to start the process AND free The process starts if all conditions are fulfilled order whatever the order For example the operator has to scan VIN and part number but the order is not forced e Save and quit by pressing the Save icon 15 3 2 Start by number Click on Start by number This first condition is compulsory and it is not possible to delete it e Slide the mouse on the bottom screen to display the Start step parameters e Customize the Start step description up to 40 characters e Enter a comment up to 100 characters e Select the source I O HMI Open Protocol Fieldbus x Click this icon to dock the bottom screen pt Click this icon to undock the bottom screen O Click this icon to delete an action 6159930290 01 03 2012 20 15 3 3 Start by identifier Start conditions Start conditions OR vil By identifier ET By assembly number 2 Start 3 Start by input 4 By input event ES 1 Start by number be pavers 4a iat TF AND forced order 2 By identifier ES By assembly number By input event AND free order Ni By identifier Fig By assembly number By input event i ost ess Delete qe Start step 2 Description Sta
110. sensor 2 The tool needs maintenance Contact your Desoutter representative for support Tool invalid parameters 1 The tool memory cannot be read or is invalid 2 The tool needs maintenance 0 Tool calibration alarm date 1 The tool calibration date expired expired 2 A tool calibration procedure needs to be done to ensure the measurement accuracy Tool EEPROM could not be read 1 The tool memory cannot be read or is invalid 2 The tool needs maintenance If the problem occurs again contact your Desoutter representative for support Tool motor bad ground connection 1 Phase phase or phase to ground shortcircuit 2 Disconnect the tool Contact your Desoutter representative for support Tool torque power default 1 The torque sensor is not corrrectly supplied N D gt IN O O N R N Q D 2 The tool needs maintenance If the problem occurs again contact your Desoutter representative for support 15 Tool locked on reject 1 The tool is locked forward after a NOK 2 Unlock the tool by according to lock on reject option i e by reversing loosening or digital input O Tool locked by Open Protocol 1 Tool has been locked by Open Protocol 2 Unlock the tool by sending an Enable tool message via Open Protocol Loosening prohibited 1 Loosening is prohibited 2 The loosening is disabled in the Assembly operation 3 The batch count type OK NOK is used 8 Tool tor
111. ssories panel 1 Pset Id of Pset currently UINT8 1 selected selected byte 2 Final Final torque in Nm FLOAT 4 torque last step bytes UINT8 1 byte 7 Torque Torque trend last trend step 0 no result 1 min 2 max 3 accepted Final angle in degrees FLOAT 4 last step bytes Angle trend last step UINT8 1 0 no result byte 1 min 2 max 3 accepted There are also data coming from PLC to CVI3 Start Stop PSet on State Start Stop PSet on Edge Reverse Direction PSet Selection Bi PSet Selection Bi PSet Selection Bi PSet Selection Bi PSet Selection Bi PSet Selection Bi PSet Selection Bi PSet Selection Bi Spindle Validation Forward Spindle Validation Reverse Error Acknowledge Reset Reset only status External stop abort pset Address Name Description Format Size CVI3 State of the 8 CVI3 UINT8 8 bits inputs inputs that can be forced by PLC By default CVI3 inputs are Input 1 Pset selection bit 0 Input 2 Pset selection bit 1 Input 2 Pset selection bit 2 Input 4 Input 5 Acknowledge error Input 6 Start stop tightening on state Input 7 Reverse direction 1 Pset Id of Pset expected UINT8 1 selection by PLC byte 4 GENERAL CONFIGURATION In CVIPC software click on this icon to launch the
112. sults gt Click this icon to print the results Real time process monitoring with results curves amp A statistics Real time maintenance monitoring with I O status counters 17 2 5 Curves display controller tool cable Trouble shooting with alarms history logs problem solving guidance DA Click this icon to view the curves User information history Select a controller and click this icon to launch the 17 2 6 Exporting files CVIMONITOR software e Refer to the CVIMONITOR s user manual supplied on the K l CDROM gt Click this icon to export data to a text file SC 18 2 Database back up 17 2 7 Statistics computing e Click on File in the Menu area alle Click this icon to start computing statistics G CVIPC for CVI 3 Service About 3 View Transfer Options Refer to APPENDIX Statistic computation to get more information about the Statistics computation Save copy as Load Assembly line Infos to save your work in the database to save your work in the database Use an unique name The path is by default C Program Files Desoutter CVIPC Save a to copy an existing database and rename it copy as to upload an existing database to display the database file location Be careful when naming the databases Do not overwrite them We recommend to create as many folders as assembly lines 6159930290_01 03 2012 33 34 61
113. t cable 3 Check CVI3 Ethernet configuration 4 Check if ToolsNet is running correctly Fieldbus invalid process data 1 The Fieldbus mapping has too many items Fieldbus invalid device address 1 The device address affected to Fieldbus is invalid Fieldbus invalid communication 1 Fieldbus communication settings are invalid settings VW XML protocol not authorized 1 The selected XML protocol is not authorized check the ePOD characteristics Save log started 1 Saving the CVI3 logs to USB key has started Save log done 1 Saving the CVI3 logs to USB key has ended Identifier accepted 1 An identifier has been received and accepted 2 The identifier is matching an Assembly process start condition 311 Identifier rejected 1 An identifier has been received 2 The identifier does not match any Assembly process start condition Access rights expired 1 The access rights on the USB key could not be read 2 Try unplugg the key and insert it again 3 If the issue is persistent the access right file is probably corrupt 4 Contact your CVI Key administrator 23 23 30 2 7 8 9 40 0 oO O Access rights not readable 1 The access rights on the USB key could not be read 2 Try unplugg the key and insert it again 3 If the issue is persistent the access right file is probably corrupt 4 Contact your CVI Key administrator 400 Default network configuration set 1 Network configuration has been set to default Network configuration f
114. t loosens the joint a little bit and retightens it to the final targets to condition a joint Un tightening after a rejected tightening operation Un tighten clamps used to maintain parts while machining 1 1 3 Jump 1 4 Motor control The jump function can be used to execute endurance tests rework 1 2 Control and Monitor types A control type defines the way to stop the step A monitoring type defines the way to get the result of the step Auto speed This type of control is appropriate for simple tightening steps with high joint variance mix of hard medium soft joints or one joint with variable behaviour It automatically amp dynamically adapts the tool speed and power within each step to optimize process capability cycle time and ergonomics for that particular step 2 speed This type of control is the most popular and easiest to use for simple to advanced tightening steps with low joint variance It runs high speed up to the downshift torque and finishes the tightening operation at lower speed to optimize process capability cycle time and ergonomics for that particular step 3 speed This type of control is appropriate and easiest to use for simple to advanced tightening steps with hard to very hard joints It runs high speed up to the downshift torque then slow down in 2nd shift to break inertia and finishes the tightening operation at lower speed to optimize process capability cycle time an
115. ter your licenses e Go to the website https licensing desouttertools com 2 r H Industrial Desoutter License Manager My account The brand new Desoutter License Manager is your privileged interface to manage 7Days 24h your license numbers Login The online application enables you to Fe e Install CVIC software i Lost password e Uninstall CVIC software cs geg d e Follow up your current serial numbers Re e Create your own login and password as you like e Click on Submit Your account has been created You will receive your login and password by e mail Industrial Desoutter License Manager The brand new Desouter Licence Manager is your privileged interface to manage 7Days 24h your license num bers The online application enables you to e Install CVIC software e Uninstall CVIC software e Follow up your current serial numbers e Click this icon to view the following screen License management Add a new license Serial number License number Submit e Enter the serial number e Enter the key or license number You will find them on the label of the CDrom REF 6159276010 CVIPC 1 user Serial N zzzzzzzzzzz Key ZZZZ ZZZZ ZZZZ ZZZZ ZZZZ ZZZZ ZZZZ 05 01 2012 or on the back page of the cover REF 6159276010 CVIPC 1 user Serial N zzzzzzzzzzz Key ZZZZ ZZZZ ZZZZ ZZZZ ZZZZ ZZZZ ZZZZ ZZZZ 05 01 2012 e Click on Submit to val
116. to continue the tightening even if the step result is NOK This function is not activated on the last step Store results e Tick the box to record the step in the tightening results e Save and quit by pressing the Save icon 14 7 How to add copy paste delete a step e In the Build area click on Step then select the step type for the new step e To copy paste or delete a step select first the step and use the tools in the Buid area 15 ASSEMBLY PROCESS PROGRAMMING CVIPC will guide you to create a new Assembly Process e Click on Assembly Process in the Build area e Select Simple or Advanced 15 1 Simple Assembly Process ae Create an assembly process So Simple or advanced assembly process A Simple assembly process Contains a single parameter set executed one or more times Advanced assembly process Contains more than one parameter set e Click on Next e Customize the description up to 40 characters e Select the source I O HMI Open Protocol Fieldbus e Enter the batch size 1 99 If you select a new Pset e Enter the Pset name up to 40 characters e Select the Control strategy e Enter the Target torque e Click on Next The following screen is displayed Q Simple Setup E ES Torque control parameters The following parameters are used for the torque control strategies Change any values as needed and press Next when ready to proc
117. unication present Ethernet Interface The Ethernet interface operates at 100Mbit full duplex with auto negotiation enabled as default 7 5 Profinet 2 ports KO CIO me C AL H Ki l A Ethernet port 2 Link Activity LED port 1 6 Link Activity LED port 2 Network Status LED A test sequence is performed on this LED during startup LED State Off Offline No power No connection with PLC Green Online RUN Connection with PLC established PLC in RUN state Green Online STOP Connection with PLC flashing established PLC in STOP state Module Status LED A test sequence is performed on this LED during startup Off Not Initialized No power or Module in SETUP or NW_INIT state Green Normal Module has shifted from Operation the NW INIT state Green 1 flash Diagnostic Diagnostic event s Event s present Green 2 Used by engineering tools flashes to identify the node on the network Exception Module in state Error EXCEPTION Error differs from Real Identification Red 1 flash Configuration Expected Identification IP address not set Red 2 flashes IP Address Error Red 3 flashes Station Name Station Name not set Error LED State Red 4 flashes Internal Error Module has encountered a major internal error LINK Activity LED Off No Link No link no communication present Green Link Ethernet l
118. utput connector Example of connections Possibility to connect a 24V external supply in parallel of the 24V delivered by the controller 24V Controller Output 8 k 0 24V Controller 6159930290 01 03 2012 6 EBUS FOR ACCESSORIES 6 1 Port description 24V EXT D 600606060000 6159930290 01 03 2012 69 APPENDIX CVI3 SPARE PARTS NE a FR W D s LS RX sz C Ce gt SS TVA d Aan S VA E K N VA SE KH AECH d ki Co EJ jem Ref Designation 1 Interface board including screws Drepp T a TRR board comecion Dr pse 10 11 12 5 EE ne En En En EE EE KA En En gt En d 6159930290 01 03 2012 More Than Productivity www desouttertools com Copyright 2012
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