Pl12en com 1 tm com v2 5 2 0108 by Joinmax

Programming Manual PL12EN-COM-1

01/08

Electric Tool Control TM-COM TM-COM1 TM-COM1M Version 2.5.2

For additional product information visit our website at http://www.coopertools.com N O R T H A M E R I C A (N A)

E U R O P E (E U)

Cooper Power Tools P.O. Box 1410 Lexington, SC 29071-1410

Cooper Power Tools GmbH & Co. OHG Postfach 30 D-73461 Westhausen, Germany

TM-COM TM-COM1 TM-COM1M

Disclaimer: The information and data in this document has been prepared to the best of our ability. Nonetheless, differences between the information and the actual product cannot be excluded with absolute certainty. Cooper Power Tools does not assume any liability for consequential errors and damages. We likewise do not assume liability for damages resulting from defective circuitry inside the devices supplied. Cooper Power Tools reserves the right, to amend, supplement or improve this document or the product without serving prior notice. Without the express approval of Cooper Power Tools this document must not be reproduced in its entirety or in part by any means; it must not be converted to any type of natural or machine readable language or be saved on data storage media of electronic, mechanic, optical or other type.

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Contents

Page

Installation

1.1 1.2 1.3 1.4

TM-COM and TM-COM1 Installation Instructions ................................ TM-COM1M Installation Instructions .................................................... Setup Types ......................................................................................... Installation TroubleShooting .................................................................

7 7 7 7

Overview Help

2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 2.1.8 2.1.9 2.1.10 2.1.11 2.1.12 2.1.13 2.1.14 2.1.15 2.2 2.2.1 2.2.2 2.2.3 2.3 2.4

About the TM-COM Network Overview Program ................................. 9 Groups.................................................................................................. 9 Adding a group ................................................................................... 10 Loading a group ................................................................................. 10 Deleting a group ................................................................................. 10 Deleting all groups.............................................................................. 10 Renaming a Group ............................................................................. 10 Adding Units to a Group ..................................................................... 10 Deleting Units From a Group.............................................................. 10 Opening Units..................................................................................... 10 Monitoring Units................................................................................... 11 Sorting Units ........................................................................................ 11 Demonstration Mode ........................................................................... 11 Language ............................................................................................ 11 Used Timeouts .................................................................................... 11 TM-COM Network Overview Troubleshooting .................................... 12 About the TM-COM1 and TM-COM1M Connection Programs........... 13 Connecting to a Unit ........................................................................... 13 Demonstration Mode .......................................................................... 13 Language ........................................................................................... 13 TM-COM1 and TM-COM1M Connection Troubleshooting ................. 14 Licensing ............................................................................................ 14

Feature Access

Connecting to a Unit

4.1 4.1.1 4.1.2 4.2 4.2.1 4.2.2 4.2.3 4.2.4

Serial Connections (TMEM Only) ....................................................... Serial Connections to TMEM with null-modem cable ......................... Serial Connections to TMEM with USB-Serial Adapter ...................... Ethernet Connections ......................................................................... Determining Host IP Settings ............................................................. Determining Controller IP Settings ..................................................... Ethernet Connections Using a Private LAN........................................ Ethernet Connections Using a Company LAN ...................................

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Programming

5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5

Navigator Menu................................................................................... Basic Navigation Instructions .............................................................. Work Cell............................................................................................. Password Function.............................................................................. Print Screen ........................................................................................ Two Channel Features: General Description (2-Channel V2.xx.xx C2 only) ............................................................. Navigator Menu................................................................................... Administration ..................................................................................... Basic Application Builder..................................................................... Basic Parameters for Torque Control / Angle Monitor......................... Basic Parameters for Angle Control / Torque Monitor......................... Basic Application Builder Parameters ................................................. Advanced Parameter Default Values .................................................. Backoff using Reverse Switch (Sequence 41 or Sequence 46).......... Basic Application Builder / Auto Program ........................................... Basic Application Builder / Copy ......................................................... Standard Application Builder ............................................................... Standard Application Builder / View Stages ........................................ Standard Application Builder / View Stages / Copy ............................. Standard Application Builder / Select Sequence................................. Standard Application Builder / Parameters ......................................... Standard Application Builder / Advanced Parameters ........................ Advanced ............................................................................................ Advanced Application Builder / Application Matrix .............................. Advanced Application Builder / Inputs................................................. Advanced Application Builder / Outputs.............................................. Advanced Application Builder / Fieldbus............................................. Advanced / Linking.............................................................................. Advanced Application Builder / Signals............................................... Advanced Application Builder / System Settings ................................ RUN Screen ........................................................................................ Run Screen / Tool 2............................................................................. Run Screen / Split Screen ................................................................... Run Screen / TMEI.............................................................................. Run Screen / Configure....................................................................... Oscilloscope........................................................................................ Communication ................................................................................... Communications / Data Transmission................................................. Communication / Part ID ..................................................................... Communications / Printer.................................................................... Communications / Work Cell............................................................... Tool Setup ........................................................................................... Tool Library.......................................................................................... Tool Library..........................................................................................

21 21 21 22 22

5.1.6 5.1.7 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.4.7 5.5 5.5.1 5.5.2 5.5.3 5.5.4 5.6 5.7 5.7.1 5.7.2 5.7.3 5.7.4 5.8 5.9 5.9.1

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5.10 Statistics ............................................................................................. 5.10.1 Statistics / Chronological History ........................................................ 5.10.2 Statistics / Graphs............................................................................... 5.10.3 Statistic / Parameter ........................................................................... 5.11 Diagnostics ......................................................................................... 5.11.1 Inputs / Outputs .................................................................................. 5.11.2 Diagnostic / Fieldbus .......................................................................... 5.11.3 Tool / Calibration................................................................................. 5.11.4 Tool / Angle Encoder .......................................................................... 5.11.5 Tool / Voltages .................................................................................... 5.11.6 Tool / TQ Measurement ...................................................................... 5.11.7 Tool / Speed........................................................................................ 5.11.8 Tool / Tool Memory ............................................................................. 5.11.9 Arcnet / Map ....................................................................................... 5.11.10 Arcnet / Statistic.................................................................................. 5.11.11 Serial .................................................................................................. 5.11.12 Event Log ........................................................................................... 5.12 Utilities ................................................................................................ 5.12.1 Utilities / Installed Versions................................................................. 5.12.2 Utilities / Update Software .................................................................. 5.12.3 Utilities / System Settings ................................................................... 5.13 Administration..................................................................................... 5.13.1 Administration / Load/Save................................................................. 5.13.2 Administration / Print .......................................................................... 5.13.3 Administration / Password .................................................................. 5.13.4 Administration / Date & Time.............................................................. 5.13.5 Administration / Language.................................................................. 5.13.6 Administration / Counter .....................................................................

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Statistics

6.1 6.1.1 6.1.2 6.1.3 6.1.4 6.2

Understanding Statistics ..................................................................... 97 The Nature of Variation....................................................................... 97 The Normal Curve .............................................................................. 97 The Procedure.................................................................................... 98 System Improvement........................................................................ 101 Statistic Symbols .............................................................................. 102

Glossary

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Installation

1.1

TM-COM and TM-COM1 Installation Instructions Note: The installation software is currently only available in English. 1. Insert the Cooper Power Tools USB flash drive into an unoccupied USB slot on your computer. 2. Navigate to the CooperPowerTools folder and double-click the installation file. 3. Once the installation begins follow the on-screen instructions to install the program. 4. Once the installation is complete, double-click the icon on your desktop to begin the program.

1.2

TM-COM1M Installation Instructions Note: The installation software is currently only available in English. 1. Insert the CD into the CD-ROM drive of your computer. The installation program will automatically begin. 2. Once the installation begins follow the on-screen instructions to install the program. 3. Once the installation is complete, double-click the icon on your desktop to begin the TMCOM1M program.

1.3

Setup Types •

• •

1.4

Typical - Installs the current version and previous versions. You will be able to connect to TM-units that have the current version installed, as well as, TM-units that have previous versions installed. Minimal - Installs the current version only. You will only be able to connect to TM-units that have the current version installed. Custom - Choose Custom to select the versions you wish to install.

Installation TroubleShooting TM-COM1M Installation does not start automatically On many computers, the installation program is launched automatically. If your computer does not automatically launch the program, locate the CD-ROM drive using Windows Explorer and double-click the TMCOM1M.msi file.

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Overview Help

2.1

About the TM-COM Network Overview Program The TM-Network Overview application allows access to multiple groups of controllers directly from your desktop or laptop computer.

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Fig. 2-1: TM-COM Network Overview

2.1.1

Groups Each time the TM-COM Network Overview program is launched a group must be loaded. If there are no groups in the list, a group must be added. See 2.1.2 Adding a group. Once a group is added to the list, load the group to begin using the TM-COM Network Overview program. See 2.1.3 Loading a group. Then add units to the group. See 2.1.7 Adding Units to a Group.

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Fig. 2-2: TM-COM Groups

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2.1.2

Adding a group ➔ ➔ ➔

2.1.3

Loading a group ➔ ➔

2.1.4

➔ ➔

➔ ➔ ➔ ➔

To add a unit, go to the main menu of TM-Network and click TM Unit with your mouse pointer, then click Add. For a serial connection select the COM1 or COM2 radio buttons. For an Ethernet connection select the Ethernet radio button and enter the IP Address of the TM-unit. Click OK to add the TM-unit to the list of units. A new entry should then appear in your list of stations. Click Cancel to abort the operation.

Deleting Units From a Group ➔ ➔ ➔

2.1.9

To rename a group, go to the main menu and click File with your mouse pointer; then click Groups. In the Groups dialog, click on the name of the group you want to rename; then click on the Rename button. In the Rename dialog, change the name on the group; then click OK.

Adding Units to a Group ➔

2.1.8

To delete all groups, in the Groups dialog, go to the main menu and click Edit; then click Delete All. In the Delete dialog, click Yes to delete all groups or click No to cancel.

Renaming a Group ➔

2.1.7

To delete a group, go to the main menu and click File with your mouse pointer; then click Groups. In the Groups dialog, click on the name of the group you want to delete; then click on the Delete button. In the Delete dialog, verify the correct group was selected; then click OK.

Deleting all groups ➔

2.1.6

To load a group, go to the main menu and click File with your mouse pointer. Then click Groups. In the Groups dialog, click on the name of the group you want to load; then click on the Load button.

Deleting a group ➔

2.1.5

To add a group, go to the main menu and click File. Then click Groups. In the Groups dialog, go to the main menu and click Edit; then click Add new group. In the Add new group dialog enter the name on the new group; then click OK.

To delete a unit, click the button displaying that unit's IP Address or port it is connected to. A dialog box will appear with the IP address or port number, station name and station number. Confirm that you have selected the correct unit and click the Delete TM Unit button. Click OK to delete the unit. The unit will be removed from your list. Click Cancel to abort the operation.

Opening Units To open a unit, it must first be active in your list of units; see also 2.1.7 Adding Units to a Group. ➔ ➔

To open an active unit, click the button displaying that unit's IP Address or port it is connected to. A dialog box will appear with the IP address or port, station name and station number. Confirm that you have selected the correct unit and click the Open TM Unit button.

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➔

2.1.10

Click OK to monitor the unit or click Cancel to abort the operation. Up to four TM-unit windows can be opened for each unit.

Monitoring Units To monitor a unit, it must first be active in your list of units; see also 2.1.7 Adding Units to a Group. ➔

2.1.11

To monitor a unit, click the check box next to that unit's IP Address or port it is connected to. A check in the check box indicates the TM unit is currently being monitored.

Sorting Units The units can be sorted by the last three digits in the IP address or comm port, station number, or station name. ➔ To sort by the last three digits in the IP address or comm port, click the TM Unit heading. ➔ To sort by the station number, click the Station Number heading. ➔ To sort by the station name, click the Station Name heading.

2.1.12

Demonstration Mode TM-Network provides the ability to work in Demonstration Mode. In this mode, a TM-Unit window is opened without establishing a network connection to a TM-unit. ➔ To open a demonstration unit window go to the main menu of TM-Network and click TM Unit with your mouse pointer; then click Add. ➔ Click the DEMO radio button, then click OK. The Demonstration "unit" can be opened or deleted in the same manner as other TM-Units in the list.

2.1.13

Language ➔

2.1.14

To change the language of TM-Network, go to the main menu and click Language with your mouse pointer; then click the language you wish to change to. The available languages are English, German, Italian, Spanish, Czech, Portuguese, French, Polish, Dutch, and Chinese.

Used Timeouts After a station has been active for more than thirty minutes, a dialog box will appear asking if you wish to continue monitoring that station. ➔ Click Yes to continue monitoring the unit. The TM-Unit window will remain open for monitoring for another 30 minutes. ➔ Click No to stop monitoring the unit. The TM-Unit window will be closed. ➔ To open the TM-Unit window for this unit again see 2.1.9 Opening Units. If the dialog box does not receive a response within a minute it will automatically close the TM-Unit window.

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2.1.15

TM-COM Network Overview Troubleshooting Error message

Measures and remedies

ERROR READING REGISTRY: Confirm that the application was installed properly.

The software does not detect the application's registry keys. You must be logged on as a user with rights to the registry.

TM-COM V2.xx.xx is not installed in Station Number column

The TM-COM version 2.xx.xx is not installed on your computer. TM-COM is trying to connect to a TM-unit that has the version 2.xx.xx but this is not installed on your computer. To connect to this unit, upgrade the TM-unit to the version installed. If TM-COM was installed using a Minimal or Custom type installation, you may be able to modify the installation to get all previous versions. To modify the installation, select Add/Remove Programs in the Control Panel. Select TM-COM, and then select the Change button. Follow the instructions to modify the program. This option displays the Custom Selection dialog in which you can change the features that are installed.

Connecting in Station Number column

TM-COM is currently trying to establish communication with the TM-unit specified.

Failed to Connect in Station Number column

TM-COM cannot connect to the TM-Unit specified. This may be due to Serial or Ethernet connection problems. Please see section Connecting to a Unit in this document. TM-COM will attempt to connect to the unit again in approximately five seconds.

GETTMVER is missing in Station Number column

The application used to connect to a unit is missing. To repair the installation, select Add/Remove Programs in the Control Panel. Select TM-COM, and then select the Repair button. This option fixes missing or corrupt files, shortcuts and registry entries.

This address is already added

The IP address or port you entered is already listed in the unit list and can only be added once.

TMREMOTE cannot start

The application used to communicate to a unit is missing. To repair the installation, select Add/ Remove Programs in the Control Panel. Select TM-COM, and then select the Repair button. This option fixes missing or corrupt files, shortcuts and registry entries.

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2.2

About the TM-COM1 and TM-COM1M Connection Programs The TM-COM1 and TM-COM1M applications allow access to a single controller directly from your desktop or laptop computer.

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Fig. 2-3: TM-COM1, TM-COM1M

2.2.1

Connecting to a Unit To use a Serial connection to connect to a unit click the Serial button with your mouse pointer. ➔ Click the radio button for the port you would like to use, COM1 or COM2. Then click OK. ➔ To use an Ethernet connection to connect to a unit click the Ethernet button with your mouse pointer. Then enter the IP address of the controller and click OK.

2.2.2

Demonstration Mode The TM-COM1 and TM-COM1M applications provide the ability to work in Demonstration Mode. In this mode, a TM-Unit window is opened without establishing a network connection to a TM-unit. ➔ To open a demonstration unit, click on the Ethernet button and enter the IP address 127.0.0.1. Then click OK.

2.2.3

Language ➔

➔

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To change the language, go to the main menu and click Language with your mouse pointer; then click the language you wish to change to. The available languages are English, German, Italian, Spanish, Czech, Portuguese, French, Polish, Chinese and Dutch. Changing the language in the TM-COM1 and TM-COM1M programs does not change the language of open TM-unit windows. To change the language in a TM-unit window see Administration/Language in the Programming section of this document.

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2.3

TM-COM1 and TM-COM1M Connection Troubleshooting Error message

Measures and remedies

Cannot get version

The TM-unit that TM-COM1 or TM-COM1M is connected to is running a version that is not installed on your computer. To connect to this unit, upgrade the TM-unit to the version installed. If the program was installed using a Minimal or Custom type installation, you may be able to modify the installation to get all previous versions. To modify the installation, select Add/Remove Programs in the Control Panel. Select TM-COM and then select the Change button. Follow the instructions to modify the program. This option displays the Custom Selection dialog in which you can change the features that are installed.

TM module needs update

2.4

TM-COM1M connection program will connect to controllers with version 2.02.00 or greater.

Licensing Several licenses are included with the provided Cooper Power Tools USB flash drive. At least one available license is needed to install TM-COM or TM-COM1. You may only install as many instances of the software as licenses you have available. TM-COM1M does not require a license. When uninstalling TM-COM or TM-COM1, the license is restored to the Cooper Power Tools USB flash drive.

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Feature Access Each product supports a different level of functionality for managing your TM controllers. Table 1 below lists each feature and indicates which programs allow access to that feature with an 'X'. TM-COM

TM-COM1

Serial connections

TM-COM1M X

Ethernet connections

Multiple connections

Multiple windows

Demonstration Mode

Basic

Tool Setup

Standard

Statistics – Chrono History

Statistics – Graphs

Statistics – Parameter

Advanced – Matrix

Advanced – Inputs

Advanced – Outputs

Advanced – FieldBus

Advanced – Linking

Advanced – Signals

Advanced – System Settings

Diagnostics – Inputs/Outputs

Diagnostics – FieldBus

Diagnostics – Tool

Diagnostics – Arcnet

Diagnostics – Serial

Diagnostics – EventLog

RunScreen

Run Screen - Oscilloscope

Run Screen - Configure

Utilities – Installed Versions

Utilities – Software Update

Utilities – System Settings

Communications – Data Transmission

Communications – Part ID

Communications – Printer

Communications – Work Cell

Administration – Load/Save

Administration – Print

Administration – Password

Administration – Date/Time

Administration – Language

Administration – Counter

Fig. 3-1: Feature Access

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Connecting to a Unit In the context of this document TM-COM also refers to TM-COM1 or TM-COM1M. The PC or laptop, which is running TM-COM or other communications software, is referred to as the host. The controller being connected to is referred to as the target. It is assumed that the host PC is running Windows 2000. Some procedures may differ for Windows NT or XP host systems.

4.1

Serial Connections (TMEM Only)

4.1.1

Serial Connections to TMEM with null-modem cable The Cooper part number for the 10-foot serial DB-9 null-modem cable is: 543490. A 9-pin null-modem cable is wired as follows:

Host system serial port connector

Target controller serial port connector

Signal

Transmit data

Receive data

Request to send

Clear to send

6, 1

Data set ready and carrier detect

Signal ground

6, 1

Data terminal ready

Connect one end to the COM1 or COM2 serial port on your host PC or laptop. Connect the other end to COM1 on the target TMEM (front of the unit below the display screen). Start TM-COM and select the COM port where the cable is connected on the host. If a connection is not established within one minute, follow this procedure to verify the serial port and cable: Verify serial port on the TM-COM (host) PC: 1. 2. 3. 4. 5. 6.

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Exit from TM-COM. On the host PC, open Hyperterminal: Start->Programs->Accessories->Communications->HyperTerminal In the New Connection window, type any name and click OK. In the Connect To window, under Connect Using, select COM1 or COM2 depending upon the COM port where the null modem cable is connected to the host, and click OK. In the COM1 (or COM2) Properties window click OK. Hypterminal should connect to the COM port, and there should be a â&#x20AC;&#x153;Connectedâ&#x20AC;? status in the lower left corner of the window. If the port is not available, the following message appears: Unable to open COM1. Please check your port settings. In this case, another program is using the COM port. Terminate that program to free the COM port, or select a different COM port. Terminate the HyperTerminal program on the host, then try TM-COM again.

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Verify the cable: 1.

Remove the cable from the TMEM, and plug it into a PC or laptop with an available serial port. The target port may be on the host PC if it has more than one COM port available. On the target PC, open Hyperterminal: Start->Programs->Accessories->Communications->HyperTerminal In the Connection Description window, type any name and click OK. In the Connect To window, under Connect Using, select COM1 or COM2 depending upon the target port, and click OK. In the COM1 (or COM2) Properties window select the following, then click OK:

2. 3. 4. 5.

6. 7.

4.1.2

Bits per second: 57600

Data bits: 8

Parity: None

Stop bits: 1

Flow control: None On the host PC, start TM-COM and select a connection using the host COM port. On the target PC, the Hyperterminal window should display output. There is a repeating series of symbols and characters. Within the symbols, the characters “PrEaMbL” should be seen. If something else, or nothing is seen, then there is a problem with the serial port/cable combination on the host PC.

Serial Connections to TMEM with USB-Serial Adapter The procedure is identical to connecting with a null-modem cable, with the addition that the USB-Serial Adapter must be properly configured on the host PC. The Cooper part number for the USB-Serial adapter cable is: 543486. 1. 2. 3. 4. 5. 6.

Plug the adapter cable into a USB port on the host PC, and complete the connection to the target TMEM COM1 port with a null modem cable. On the host PC click Start->Settings->Control Panel. Double-click System to bring up the System Properties window. Click the Hardware tab. Click Device Manager Expand the “Ports (COM & LPT)” folder. You should see an entry “Prolific USB-to-Serial Comm Port (COMx)”. If this entry is not present, ensure the driver is loaded. The driver can be downloaded from http://www.cablestogo.com/help/ctg_drivers.asp. TM-COM can connect to COM1 or COM2. If the “COMx” shown on the Prolific entry is different, right click on the entry and select Properties. Click the Port Settings tab, then click Advanced. In the COM Port Number pulldown, select COM1 or COM2, then click OK. When starting TM-COM, select the port (COM1 or COM2) that was specified in step 7.

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4.2

Ethernet Connections For proper communications across Ethernet, the host and target IP addresses must be properly configured.

4.2.1

Determining Host IP Settings A host PC or laptop can be configured to either “Obtain an IP address automatically” (DHCP or dynamic configuration) or “Use the following IP address” (static configuration). With DHCP configuration, the IP settings are automatically obtained from a network DHCP server if available. To select DHCP or static IP settings on the host, use the following procedure: 1.

Click Start->Settings->Network and Dial-up Connections->Local Area Connection. 2. In the Local Area Connection Status window, click Properties. 3. In the Local Area Connection Properties window, Components… box, locate and highlight Internet Protocol (TCP/IP), then click Properties. 4. Click the desired method to assign IP addresses, and enter the addresses manually for a static configuration. Close all of the windows to allow the new settings to take effect. On some PCs it is necessary to reboot (a message may not be given!) for the new settings to take effect. An easy way to verify host network settings and target connectivity is the use the commands IPConfig and Ping respectively. These commands are entered from the Command Prompt window. Open this window by clicking Start->Programs->Accessories-> Command Prompt. Type IPConfig and <ENTER> to view the IP Address, Subnet Mask, and Default Gateway of the host PC. Type Ping <IPADDR> and <ENTER> to check connectivity with target at <IPADDR> e.g. Ping 10.120.99.205. If an Ethernet connection with the target is possible the command responds with e.g. Reply from 10.120.99.205. Otherwise there is an Ethernet link problem and the host is not able to communication with the target.

4.2.2

Determining Controller IP Settings The TMEM controller is capable of dynamic (DHCP) address configuration. DHCP is enabled when the controller’s IP address, as configured in the “Communications / Data Transmission” screen, is set to 0.0.0.0 (factory default). Any other address configured in “Communications / Data Transmission” is assigned to the controller statically. The IP address of the controller is assigned as follows: • •

•

If a static IP address has been programmed in “Communications / Data Transmission”, that address is used. If DHCP is enabled and a DHCP server can be contacted, the IP settings are assigned by the DHCP server.

If DHCP is enabled and a DHCP server cannot be contacted, default IP settings are assigned: Address 169.254.xxx.yyy, Subnet 255.255.0.0. (xxx and yyy are determined by the controller).

The Ethernet address of a TMEM unit is displayed on the front LCD panel in 2 cases: •

Immediately after the unit completes start-up, if there is a physical connection. If a static IP address was programmed and there is no physical connection, the message “Ethernet Address failed” is displayed. If DHCP is enabled and there is no physical connection, there is no IP information displayed.

•

Whenever a physical Ethernet connection is established or re-established (cable plugged in at both ends). If you are uncertain of the IP address of the controller, un-plug and re-plug the Ethernet cable and watch the LCD display for IP information. Note: it may take up to 10 seconds before the IP address is displayed.

It is not necessary to have the cable connected when the controller is started. However, the IP settings are not configured until a physical connection is established (the cable is plugged in). At this time the IP address is shown on the LCD display.

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4.2.3

Ethernet Connections Using a Private LAN With a private LAN, the host and target(s) are connected via a network-coupling device, typically a hub. The network is private because it contains no “uplink” to a larger network containing DHCP or DNS servers or gateways. An Ethernet crossover cable creates a two-node private LAN between the host and target without the need for a network-coupling device. The Cooper part number for the 7-foot Ethernet crossover cable is: 543446-7. An Ethernet crossover cable is wired as follows: Pin 1 of the RJ-45 plug on one end of the cable is connected to pin 3 of the RJ-45 connector on the other end. Pin 2 is connected to pin 6, pin 3 is connected to pin 1, and pin 6 is connected to pin 2 For proper communications using a private LAN, the host and target must be configured for the same subnet. The subnet is the portion of the IP address corresponding to the subnet mask in hexadecimal e.g. if the IP address is 169.254.103.160 and the subnet mask is 255.255.0.0, then the subnet is 169.254. With a private LAN, the Gateway address is not used. When a host PC is connected to a private LAN the IP settings are as follows (verify using IPConfig): •

DHCP configuration: Since no DHCP server is available, default settings are used. On most PCs this is IP address 169.254.xxx.yyy, Subnet mask 255.255.0.0.

•

Static configuration: As set in Internet Protocol (TCP/IP) Properties. To connect to a controller, use the methods above to ensure that the host and target have the same subnet, but different IP addresses. Verify the setup using the Ping command. If successful, then start TM-COM on the host, and select an Ethernet connection using the target IP address.

4.2.4

Ethernet Connections Using a Company LAN In a company LAN a large number of devices are interconnected, usually on several different subnets with, routing handled by gateways. In such environments, the IP settings for each device are typically assigned by a network administrator. In this case it is necessary to program the controllers with the assigned static IP addresses before Ethernet connections can be established. Use the methods described above to determine the IP settings. Use the Ping command to verify that a controller can be reached, then start TM-COM on the host, and select an Ethernet connection using the target IP address. When connected to a company LAN it is possible for a TMEM controller to have its IP settings automatically assigned by a DHCP server, e.g. if a network administrator has not yet made assignments. However a TME-100 controller must be programmed with static IP settings that are within the same subnet. Care must be taken to ensure that a controller’s IP address is not in conflict with any other device.

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Programming

5.1

Navigator Menu

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Fig. 5-1: Navigator Menu nav.txtS

5.1.1

Basic Navigation Instructions Each field in a screen is selectable with an orange highlight using the 4 arrow keys and Enter. Upon entering a screen the top left most field is always highlighted. The Navigator key (ship's wheel) will always return the user to the Navigator Menu. At the bottom of the screen 4 soft keys are available. These functions will change from screen to screen. In some cases the screen label will contain the (>>) character to indicate more functions are available when the key is pressed. To edit a textbox the user can use 0-9 or the DEL keys. To exit the edit mode the user can press the arrow keys to move the highlight or press the ESC key. The ESC key will return the original value. In order to describe the soft key functions the left soft key is referred to as F1, center left soft key F2, center right soft key F3 and right soft key F4. They are located in the orange display border. F4 is always functions as Help for that screen. Applications are selectable 1-255. When entering an application number of 1 or 2 digits (1-99), a cursor blinks in the edit box. The number is accepted when the <ENTER> key is pressed, or after 3 seconds. A 3 digit application number (100-255) is accepted as soon as the third character is typed. Stages are selectable 1-6.

5.1.2

Work Cell To connect to a remote unit configured in the work cell, press the <F3> "Work Cell" button from the Navigator menu. From the "Work Cell List" dialog box, press the <ENTER> key do display the droplist of configured units. Use the up or down arrow keys to select the desired unit, then press the <ENTER> key again. Press the down arrow key to highlight the "OK" button and press

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the <ENTER> key again. The user interface switches control to the selected unit. When a remote unit is selected the IP address, station name, and station number of that unit are displayed in the title bar of all screens. To return control to the local unit, return to the Navigator menu and use the above procedure, this time selecting "Local TM Unit" in the Work Cell List dialog. To add units to the Work Cell List, use the Work Cell screen in Communications.

5.1.3

Password Function Passwords can be configured to operate in one of two modes: Read Protected or not Read Protected. Refer to Administration / Password for configuration details Read Protected: A password is required when selecting a section from the Navigator menu. It is only required to enter the password once. If the user exits a section with programmable data (Basic, Standard, Advanced, Communications, Tool Setup) that has been changed, then only the confirm entry in the password dialog is displayed. Not Read Protected: No password is required when selecting a section from the Navigator menu. If the user exits a section with programmable data (Basic, Standard, Advanced, Communications, Tool Setup) that has been changed, then the password entry dialog will be displayed. If no password is activated, then only the confirm entry in the password dialog is displayed. Once the password has been entered, it must be entered each time an appropriate screen is exited.

5.1.4

Print Screen A Print Screen function is available on all screens. In some cases a Print Screen soft key has been added that will allow the bitmap to be saved to the floppy disk, disk, or print directly to a printer (Laser, Inkjet). On screens that do not have this soft key, the user can reach this function by pressing the "0" key. A dialog box allowing the user to assign a filename will be displayed. Using the arrow keys, highlight the filename and enter up to 8 characters, then activate Accept to save to the floppy.

5.1.5

Two Channel Features: General Description (2-Channel V2.xx.xx C2 only) The user interface is identical to the single-channel configuration. On all screens, the data for the currently selected tool is displayed. The current tool is selected by entering a 1 or 2 in the "Tool" edit box. The Tool may be selected from the Run Screen, Basic Application Builder, Standard Application Builder, or Statistics screens. On screens where there is no Tool edit box, the currently selected tool is displayed in the blue title bar at the top of the screen. Both tools are always operable regardless of which tool is currently selected by the user interface. All editable parameters are set and saved individually for each tool, with the following exceptions: • Language • Date/Time • Passwords • Field Bus Parameters • Torque Units • Run Screen 2-Tool Display Configuration (Auto-select) • Ethernet protocol, IP addresses and port number

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•

System Settings/General "Same for both tools" option (See 5.4.7 Advanced Application Builder / System Settings, page 52) The 2-channel model has the following limitations: • Field Bus (DeviceNet/Profibus): When active, all inputs and outputs are only applicable to the operation of Tool 1. • The PFCS communications protocol uses a single Machine ID (MID) for both tools. • The auto-select feature does not apply to the Oscilloscope screen.

5.1.6

Navigator Menu Basic Application Builder Basic Application Builder allows the user to graphically select and program a two-stage rundown for Torque Control/Angle Monitor (Seq11+Seq30) or Angle Control/Torque Monitor (Seq11+Seq50) for any of the 255 Applications. The user only enters Torque, Angle, and Speed Setpoints in one screen. Other parameters such as timers, etc are automatically defaulted to pre-determined values. Standard Application Builder Standard Application Builder allows the user to program up to a 6-stage rundown for any of the 255 Applications. Once the fastening sequences are selected for each stage, the associated Torque, Angle, Speed, and Advanced parameters can be programmed. Advanced Application Builder Advanced Application Builder allows the user to View all Application setups at once, and perform I/O Mapping. The Application Matrix shows an overview of Application and Stage programming by displaying the selected Fastening Sequence for each stage. I/O Mapping lets the user select from a list of functions and assign that function to a given input or output. RUN Screen The Run Screen button takes the user directly to the display for Torque, Angle, and Status Indicator Labels. The Oscilloscope function used for diagnosing torque traces is also located in the Run Screen. Communications The Communications Setup allows the user to configure all communications for the Printer and Serial Data Transmission. Appropriate communications settings for protocol, port, baud rate, etc can be set in this screen. Tool Setup The Tool Setup displays the Tool Memory Data and allows the user to modify this information by changing it directly or selecting from the Tool Library. Statistics Chronological History and associated statistics are viewable from this screen. Data can be erased and printed as well. Diagnostics The System Diagnostics contains screens to determine if the system is functioning properly. There are diagnostics for I/O, Arcnet, Tool and Tightening Module, Serial Communications, and Transducer Calibration.

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Utilities Utilities contains functions for upgrading or changing the system software. From the Utilities screen the user can update the TME application software, or install a new firmware version in the Tightening Module.

5.1.7

Administration From the Administration screen the user can load, save and configure system information. Administration functions include loading and saving the system configuration to a diskette, setting date and time, setting password protection, and printing the system configuration, and selecting the application software language (English, German, Italian, Spanish, Czech, Portuguese, French, Polish, Dutch). From the Administration / Counter screen, the user may view, enable, disable, or reset any of the available counters.

nav.txtE

Basic Application Builder

c00278en.bmp

5.2

Fig. 5-2: Torque Control / Angle Monitor

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Fig. 5-3: Angle Control / Torque Monitor basic.txtS

The Basic Application Builder allows the user to select a typical two-stage rundown where the first stage is a high speed rundown and the second stage is a lower speed rundown that controls on either torque or angle. Fastening Strategies Torque Control/Angle Monitoring (Sequence 11/Sequence 30) or Angle Control/Torque Monitoring (Sequence 11/Sequence 50) are selectable from the dropdown listbox in the upper right hand corner of the screen. Once a strategy is selected, the appropriate parameters will be displayed for programming. From the Basic Application Builder, the Auto Program feature is available by pressing the <F1> soft key only when a tool is connected to the controller. The <F1> “Auto Program” button should look disabled if there is no tool and <F1> should do nothing if there is no tool. The <F1> soft key should be disabled if Angle Control/Torque Monitoring is selected. You can input the Stage 2 target torque and select the units on this dialog. Pressing the <Cancel> button exits the auto program screen without saving changes. Pressing the <OK> button causes the auto calculations to be done and the results are displayed on the basic screen. From the Basic Application Builder, the user can copy the parameters of an application to one or more other applications by pressing the “Copy” <F3> soft key. From this dialog box, the user can specify the source and target tool and application. When using “Copy” function from the Basic Application Builder, all stages of the selected application are copied. Multiple target applications may be specified by separating the application numbers with a period as shown. Backoff using Reverse switch (Sequence 41 or Sequence 46) The Backoff stage is automatically set to Sequence 46 for a tubenut tool and Sequence 41 for all others. The automatic selection of a tube nut tool depends on a ‘T’ in the tool model number. That means, if a ‘T’ appears in the model number a tube nut tool is expected. This fastening sequence is selected when the tool runs in the reverse (untighten) direction. It is also used to return a tubenut tool to the home position on every other trigger pull. The resolver integrated into the nutrunner measures the angle during the untightening. The value is processed by the control

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system. When the Turnoff angle is reached the nutrunner is shut off. For a tubenut tool, the Turnoff angle is programmed so that the attachment will always turn far enough to reach the home position and stop based on the torque reaction against the pawl.

5.2.1

Basic Parameters for Torque Control / Angle Monitor • • • • • • • •

5.2.2

Trigger Torque [Nm] - Torque to start collecting oscilloscope data. Turnoff Torque Stage 1 [Nm] - Torque to change from stage 1 to stage 2. Threshold Torque [Nm] - Torque to begin counting angle in stage 2. Torque Low Limit [Nm] - Minimum acceptable torque. Turnoff Torque Stage 2 [Nm] - Torque to turnoff the tool. Torque High Limit [Nm] - Maximum acceptable torque. Angle Low Limit [Deg] - Minimum acceptable angle. Angle High Limit [Deg] - Maximum acceptable angle.

Basic Parameters for Angle Control / Torque Monitor •

Turnoff Angle [Deg] - Angle to turnoff the tool.

•

The rest of the Parameters are the same as Torque Control/Angle Monitor except Turnoff Torque Stage 2 is eliminated.

Below are the acceptable ranges for each Parameter and its default value. For initial programming, the Parameters automatically use the default values.

5.2.3

Basic Application Builder Parameters Parameter Name

Range

Typical

Fastening Strategy

Torque Control/Angle Monitor Angle Control/Torque Monitor

Torque Control/Angle Monitor

Trigger Torque [Nm]

0 to Tool Max

10% of Turnoff Torque

Turnoff Torque Stage 1 [Nm]

0 to Tool Max

As appropriate

Threshold Torque [Nm]

0 to Tool Max

50% of Turnoff Torque

Torque Low Limit [Nm]

-Tool Max* to Tool Max

90% of Turnoff Torque

Turnoff Torque Stage 2 [Nm]

Low Limit to Tool Max

As appropriate

Torque High Limit [Nm]

Turnoff to 1.2 TQ-Cal. value

110% of Turnoff Torque

Angle Low Limit [Deg]

0 to 9999

90% of Turnoff Angle

Turnoff Angle [Deg]

Low Limit to 9999

As appropriate

Angle High Limit

Turnoff to 9999

110% of Turnoff Angle

Speed Stage 1 [RPM]

0 to Tool Max

80% of Tool Max

Speed Stage 2 [RPM]

0 to Tool Max

Backoff Speed

0 to Tool Max

50% of Tool Max

* Note: negative values may be entered by preceeding the value with two dots ".." In the Basic Application Builder some parameters are not programmable and are also set to default values. These values are located in the Standard Application Builder under Advanced Parameters. However, if the parameters are changed using the Standard Application Builder, then the Basic Application Builder does not reset them back to the default values.

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5.2.4

Advanced Parameter Default Values Parameter Name

Stage 1

Stage 2

Start delay time [mS]

Start spike time [mS]

Max. Fastening time [mS]

10000

End delay time [mS]

Torque Filter Factor

If NOK go to stage

Stop

None

If an Application with more than two stages is required, or if a different Fastening Strategy has previously been selected for the Application than described above, the Standard Application Builder must be used.

5.2.5

Backoff using Reverse Switch (Sequence 41 or Sequence 46) The Backoff stage is automatically set to Sequence 46 for a tubenut tool and Sequence 41 for all others. The automatic selection of a tube nut tool depends on a ‘T’ in the tool model number. That means, if a ‘T’ appears in the model number a tube nut tool is expected. This fastening sequence is selected when the tool runs in the reverse (untighten) direction. It is also used to return a tubenut tool to the home position on every other trigger pull. The resolver integrated into the nutrunner measures the angle during the untightening. The value is processed by the control system. When the Turnoff angle is reached the nutrunner is shut off. For a tubenut tool, the Turnoff angle is programmed so that the attachment will always turn far enough to reach the home position and stop based on the torque reaction against the pawl.

Basic Application Builder / Auto Program

c00393en.bmp

5.2.6

Fig. 5-4: Basic Application Builder / Auto Program

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From the Basic Application Builder, the Auto Program feature is available by pressing the <F1> soft key only when a tool is connected to the controller and if the application is not already programmed. The <F1> "Auto Program" button should look disabled if there is no tool or if the application is programmed or if Angle Control/Torque Monitoring is selected. The Auto Program feature accepts the Stage 2 target torque and the torque units. Pressing the cancel button exits the auto program screen without saving changes. Pressing the <OK> button causes the auto calculations to be done and the results are displayed on the basic screen.

Basic Application Builder / Copy

c00362en.bmp

5.2.7

Fig. 5-5: Torque Control / Angle Monitor / Copy

From the Basic Application Builder, the user can copy the parameters of an application to one or more other applications by pressing the Copy <F3> soft key. From this dialog box, the user can specify the source and target tool and application. When using Copy function from the Basic Application Builder, all stages of the selected application are copied. Multiple target applications may be specified by separating the application numbers with a period as shown. basic.txtE

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Standard Application Builder

5.3.1

Standard Application Builder / View Stages

c00280en.bmp

5.3

Fig. 5-6: View Stages viewstag.txtS

From View Stages, Stages 1-6 and a Backoff Stage are programmable for a given tool and application. When the tool is started, each Stage having a programmed Fastening Sequence will be run in succession based on the results from the previous stage. The Backoff Stage is used when the tool is run in the reverse or untighten direction. When the Counter Clockwise box is checked, each stage is run with the tool tightening in a counter-clockwise direction. Sequence 41 (angle controlled backout) and the Backoff Stage are run in the clockwise direction. WARNING: When the Counter-Clockwise box is checked, the normal direction of rotation is opposite from what is indicated by the label of the Reverse switch on the tool. If a sequence has not been selected for a stage, then N/A is displayed for that stage. Otherwise the Sequence number, description and icon are displayed. Sequences can be selected using the Select Seq <F1> soft key. This key is only valid when stages 1-6 are highlighted. The Fastening Sequence for the Backoff Stage is selected automatically. The parameters for any stage can be programmed using the Parameters <F3> soft key. This key is only valid when a Sequence has been selected for a given Stage.

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Standard Application Builder / View Stages / Copy

c00366en.bmp

5.3.2

Fig. 5-7: View Stages / Copy

From the Standard Application Builder, the user can copy the parameters of an application or stage to one or more other applications or stages by pressing the Copy <F2> soft key. From this dialog box, the user can specify the source and target tool, application, and one or all stages. A single stage can be copied to multiple applications and/or stages. Multiple target applications and stages may be specified by separating the numbers with a period. viewstag.txtE

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Standard Application Builder / Select Sequence

c00281en.bmp

5.3.3

Fig. 5-8: Select Sequence selectse.txtS

Fastening Sequences are selectable for a given Tool, Application and Stage by using the Control and Monitor check boxes or selecting a Fastening Sequence directly from the drop down listbox. The following Fastening Sequences or Fastening Strategies are available: Sequence 41 or Sequence 46

Backoff using Reverse switch/Relax

Sequence 11

High Speed Rundown

Sequence 30

Torque Control/Angle Monitor

Sequence 50

Angle Control/Torque Monitor

Sequence 41

Angle Controlled Backoff

When a Sequence is selected the Control and Monitor check boxes and Fastening Sequence listbox will both display the appropriate settings for the selected Sequence. An icon portraying the selected Sequence is also displayed in the bottom right-hand corner. The following table shows a matrix of the Control and Monitor schemes for each Sequence: Sequence 11

Sequence 30

Sequence 50

Sequence 41

Control Torque Control Angle Control

Angle Control Reverse

Monitor Torque Monitor

Angle Monitor

The Parameters <F3> soft key allows the user to program all associated control parameters for the selected Sequence. It is only valid when a Sequence has been selected.

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The following is a detailed description of each Fastening Sequence: Sequence 11 High Speed Rundown This tightening method is generally used as a fast pre-tightening stage. The torque transducer integrated into the nutrunner measures the torque during the tightening. The value is processed by the control system. When the defined Turnoff Torque is reached the nutrunner is shut off. Thereafter the peak torque is measured during a dwell time and is then processed as the tightening torque of the bolt in the control system. This value is displayed on the Run Screen and can be output to a printer or transmitted to other system components by data communication. When the trigger torque is reached the torque curve is recorded and can be viewed and evaluated using the oscilloscope function. Sequence 30 Torque Control with Torque and Angle Monitoring This tightening stage is normally preceded by a fast pre-tightening stage. The transducer integrated into the nutrunner measures the torque and the resolver measures the angle during the tightening. The values are processed by the control system. When the threshold torque is reached the angle count starts. When the Turnoff Torque is reached the nutrunner is shut off. Thereafter the peak torque is measured during a dwell time and is then processed as the tightening torque of the bolt together with the evaluation of the rundown in the control system. This value is displayed on the Run Screen and can be output to a printer or transmitted to other system components by data communication. When the trigger torque is reached the torque curve is recorded and can be viewed and evaluated using the oscilloscope function. Sequence 50 Angle Controlled Tightening with Angle and Torque Monitoring This tightening sequence is generally preceded by a fast pre-tightening cycle. The transducer integrated into the nutrunner measures the torque and the resolver measures the angle during the rundown. The values are processed by the control system. When the Turnoff angle is reached the nutrunner is shut off. Thereafter the final angle and the peak torque are measured during a dwell time, and these tightening values for the bolt are then processed together with the evaluation of the rundown in the control system. These values are displayed on the Run Screen and can be output to a printer or transmitted to other system components by data communication. When the trigger torque is reached the torque curve is recorded and can be viewed and evaluated using the oscilloscope function. Sequence 41 Angle Controlled Back-off with Angle Monitoring This fastening sequence is generally used to loosen a bolt a specified number of degrees. The resolver integrated into the nutrunner measures the angle during the untightening. The value is processed by the control system. When the Turnoff angle is reached the nutrunner is shut off. Thereafter the final angle is measured during a dwell time and is then processed as the back-off angle of the bolt together with the evaluation of the untightening in the control system. This value is displayed on the Run Screen and can be output to a printer or transmitted to other system components by data communication. In this stage the oscilloscope function is not supported. Sequence 41 or Sequence 46 Backoff using Reverse switch/Relax The Backoff stage is automatically set to Sequence 46 for a tubenut tool and Sequence 41 for all others. The automatic selection of a tube nut tool depends on a 'T' in the tool model number. That means, if a 'T' appears in the model number a tube nut tool is expected. This fastening sequence is selected when the tool is run in the reverse or untighten direction. It is also used to

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return a tubenut tool to the home position on every other trigger pull. The resolver integrated into the nutrunner measures the angle during the untightening. The value is processed by the control system. When the Turnoff angle is reached the nutrunner is shut off. For a tubenut tool, the Turnoff angle is programmed so that the attachment will always turn far enough to reach the home position and stop based on the torque reaction against the pawl. selectse.txtE

Standard Application Builder / Parameters

c00282en.bmp

5.3.4

Fig. 5-9: Parameters paramete.txtS

Parameters are programmable for a given Tool, Application and Stage based on the selected Fastening Sequence and only the appropriate parameters are displayed for the selected Fastening Sequence. The Next Stage <F2> key will increment to the next stage until it reaches the last stage having a selected Sequence. It will then rollover to the first stage. In order to add a stage without a selected Sequence the user must highlight the stage field and enter a number 1-6. The following is a detailed description of each Fastening Sequence and associated Parameters: Sequence 11 High Speed Rundown This tightening method is generally used as a fast pre-tightening stage. The torque transducer integrated into the nutrunner measures the torque during the tightening. The value is processed by the control system. When the defined Turnoff Torque is reached the nutrunner is shut off. Thereafter the peak torque is measured during a dwell time and is then processed as the tightening torque of the bolt in the control system. This value is displayed on the Run Screen and can be output to a printer or transmitted to other system components by data communication. When the trigger torque is reached the torque curve is recorded and can be viewed and evaluated using the oscilloscope function.

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The following parameters are programmable from the Standard Application Builder: • Fastening Sequence = 11 • Trigger Torque (Nm) = trigger torque, beginning of measurement for the graphic display. • Turnoff Torque (Nm) = turnoff torque for the pre-tightening stage. • Speed = max speed of the nutrunner during the pre-tightening stage. Parameter Name

Range

Typical

Fastening Strategy

Sequence 11

High Speed Rundown

Trigger Torque [Nm]

0 to Tool Max

10% of Turnoff Torque

Turnoff Torque [Nm]

Trigger to Tool Max

As appropriate

Speed Stage 1 [RPM]

0 to Tool Max

80% of Tool Max

Sequence 30 Torque Control with Torque and Angle Monitoring This tightening stage is normally preceded by a fast pre-tightening stage. The transducer integrated into the nutrunner measures the torque and the resolver measures the angle during the tightening. The values are processed by the control system. When the threshold torque is reached the angle count starts. When the Turnoff Torque is reached the nutrunner is shut off. Thereafter the peak torque is measured during a dwell time and is then processed as the tightening torque of the bolt together with the evaluation of the rundown in the control system. This value is displayed on the Run Screen and can be output to a printer or transmitted to other system components by data communication. When the trigger torque is reached the torque curve is recorded and can be viewed and evaluated using the oscilloscope function. The following parameters are programmable in the Standard Application Builder: • Sequence input value = 30 • Trigger Torque (Nm) = trigger torque, beginning of measurement for the graphic display. • Threshold Torque (Nm) = threshold torque, beginning of angle counting • Turnoff Torque (Nm) = shut-off torque for the stage. • Torque High Limit (Nm) = max torque, high limit for torque reached. • Torque Low Limit (Nm) = min torque, low limit for torque reached. • Angle High Limit (deg) = maximum angle, high limit for angle reached. The nutrunner will stop if this value is exceeded • Angle Low Limit (deg) = minimum angle, low limit for angle reached. • Speed = max speed of the nutrunner during the tightening stage. Parameter Name

Range

Typical

Fastening Strategy

Sequence 30

Torque Control/ Angle Monitor

Trigger Torque [Nm]

0 to Tool Max

10% of Turnoff Torque

Threshold Torque [Nm]

0 to Tool Max

50% of Turnoff Torque

Torque Low Limit [Nm]

-Tool Max* to Tool Max

90% of Turnoff Torque

Turnoff Torque [Nm]

Low Limit to Tool Max

As appropriate

Torque High Limit [Nm]

Turnoff to 9999

110% of Turnoff Torque

Angle Low Limit [Deg]

0 to 9999

70% of Final Angle

Angle High Limit

Low Limit to 9999

130% of Final Angle

Speed [RPM]

0 to Tool Max

* Note: negative values may be entered by preceeding the value with two dots ".."

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Sequence 50 Angle Controlled Tightening with Angle and Torque Monitoring This tightening sequence is generally preceded by a fast pre-tightening cycle. The transducer integrated into the nutrunner measures the torque and the resolver measures the angle during the rundown. The values are processed by the control system. When the Turnoff angle is reached the nutrunner is shut off. Thereafter the final angle and the peak torque are measured during a dwell time, and these tightening values for the bolt are then processed together with the evaluation of the rundown in the control system. These values are displayed on the Run Screen and can be output to a printer or transmitted to other system components by data communication. When the trigger torque is reached the torque curve is recorded and can be viewed and evaluated using the oscilloscope function. The following parameters are programmable in the Standard Application Builder: • Sequence input value = 50 • Trigger Torque (Nm) = trigger torque, beginning of measurement for the graphic display • Threshold Torque (Nm) = threshold torque, beginning of angle counting • Turnoff Angle (deg) = shut-off angle for the stage • Angle High Limit (deg) = maximum angle, high limit for angle reached • Angle Low Limit (deg) = minimum angle, low limit for angle reached • Torque High Limit (Nm) = max torque, high limit for torque reached and safety shut-off • Torque Low Limit (Nm) = min torque, low limit for torque reached • Speed = max speed of the nutrunner during the tightening stage Parameter Name

Range

Typical

Fastening Strategy

Sequence 50

Angle Control/ Torque Monitor

Trigger Torque [Nm]

0 to Tool Max

10% of Turnoff Torque

Threshold Torque [Nm]

0 to Tool Max

As appropriate

Torque Low Limit [Nm]

-Tool Max* to Tool Max

70% of Final Torque

Torque High Limit [Nm]

Low Limit to Tool Max.

130% of Final Torque

Angle Low Limit [Deg]

0 to 9999

90% of Turnoff Angle

Turnoff Angle [Deg]

Low Limit to 9999

As appropriate

Angle High Limit

Turnoff angle to 9999

110% of Turnoff Angle

Speed Stage [RPM]

0 to Tool Max

* Note: negative values may be entered by preceeding the value with two dots ".."

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Sequence 41 Angle Controlled Back-off with Angle Monitoring This fastening sequence is generally used to loosen a bolt a specified number of degrees. The resolver integrated into the nutrunner measures the angle during the untightening. The value is processed by the control system. When the Turnoff angle is reached the nutrunner is shut off. Thereafter the final angle is measured during a dwell time and is then processed as the back-off angle of the bolt together with the evaluation of the untightening in the control system. This value is displayed on the Run Screen and can be output to a printer or transmitted to other system components by data communication. In this stage the oscilloscope function is not supported. The following parameters are programmable in the Standard Application Builder: • Sequence input value = 41 • Turnoff Angle (deg) = shut-off angle, back-off angle • Angle High Limit (deg) = maximum angle, high limit for angle reached. • Angle Low Limit (deg) = minimum angle, low limit for angle reached. • Speed = max speed of the nutrunner during the back-off stage. Parameter Name

Range

Typical

Fastening Strategy

Sequence 41

Angle Control in Reverse

Angle Low Limit [Deg]

0 to 9999

90% of Turnoff Angle

Turnoff Angle [Deg]

Low Limit to 9999

As appropriate

Angle High Limit

Turnoff angle to 9999

110% of Turnoff Torque

Speed [RPM]

0 to Tool Max

80% of Tool Max

Backoff Using Reverse Switch (Sequence 41 or Sequence 46) The Backoff stage is automatically set to Sequence 46 for a tubenut tool and Sequence 41 for all others. The automatic selection of a tube nut tool depends on a "T" in the tool model number. That means, if a "T" appears in the model number a tube nut tool is expected. This fastening sequence is selected when the tool is run in the reverse or untighten direction. It is also automatically used to return a tubenut tool to the home position on every other trigger pull. The resolver integrated into the nutrunner measures the angle during the untightening. The measured angle value is processed by the control system. When the Turnoff angle is reached the nutrunner is shut off. For a tubenut tool, the Turnoff angle is programmed so that the attachment will always turn far enough to reach the home position and stop based on the torque reaction against the pawl. The following parameters are programmable in the Standard Application Builder: • Speed [rpm] = Max speed of the nutrunner during the backoff stage

Parameter Name

Range

Default

Speed [RPM]

0 to Tool Max

500 or 30% of Tool Max (tubenut)

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The backoff parameters that are not displayed are set to values as in the table below. Parameter Name

Sequence 41

Sequence 46

Start delay time [mS]

Start spike time [mS]

Max. Fastening time [mS]

10000

End delay time [mS]

Torque Filter Factor

Torque Target

---

3,5% of Tool max. Torque

Torque High Limit

---

10% of Tool max. Torque

Angle Low Limit

Angle Target

9999

370

Angle High Limit

9999

380

For at tube nut tool the maximum speed for backoff is 30% of Tool Max Speed. It is not possible to enter a higher value. Relax This sequence is generally used at the end of a rundown to prevent mechanical locking of the tool without loosening the joint. The relax parameters are set to values as in the table below. These parameters cannot be programmed. Parameter Name

Value

Fastening strategy

Sequence 46

Start delay time [ms]

Start spike time [ms]

Max. fastening time [ms]

3000

End delay time [ms]

Torque filter factor

Used from preceding stage

Torque target

1/6 of Torque low limit from preceding stage

Torque high limit

1/3 of Torque low limit from preceding stage

Angle low limit

Angle target

Angle high limit

Speed stage [RPM]

Used from preceding stage

The results are not displayed on the Run Screen unless the relax stage was NOK. paramete.txtE

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PL12EN-COM-1 01/08

TM-COM TM-COM1 TM-COM1M

Standard Application Builder / Advanced Parameters

c00283en.bmp

5.3.5

Fig. 5-10: Advanced Parameters advparam.txtS

The user can enter the Advanced Parameters using the Advanced <F3> soft key from the Parameter screen. These parameters are identical regardless of the selected Fastening Sequence. The Next Stage <F2> key will increment to the next stage until it reaches the last stage with a selected Sequence. It will then rollover to the first stage. In order to add a stage without a selected Sequence the user must highlight the stage field and enter a number 1-6. Timers Start delay time [mS]

time delay before the stage will start

Start spike time [mS]

time delay for the control system to start measuring torque after the stage starts

Max. Fastening time [mS]

max time for the tool to run during the stage.

End delay time [mS]

time delay from tool turn off until shut-off of measured value recording.

Other Torque Filter Factor

used for torque averaging

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Speed Ramp-up, Beginning of Stage Ramp-up time [ms]:

Time to accelerate to tool max speed.

Speed Ramp-down, End of Stage Deactivate Ramp-down:

Allows the user to deactivate the ramp-down.

Begin Ramp-down [%]:

Percentage of turn off torque (seq 11, 30) or high limit torque (seq 50), where speed ramp-down begins.

Use Default for Target Speed:

Default value for target speed is used. The default value depends on parameter of the next stage. Refer to the programming manual for more information.

Target Speed [RPM]:

Target speed after ramp-down at turn off. From beginning of ramp down, speed is reduced in 30 steps to target speed.

Flex-Stop, After Turn-off Deactivate Flex-Stop:

Allows the user to deactivate the flex-stop.

Flex-Stop [%]:

Percentage of duration of flex-stop. The higher the percentage the longer it takes to relieve torque after shut-off. The absolute time depends on the rundown parameter and the joint.

Max Flex-Time [ms]:

Max time for flex-stop to relieve torque after shut off

. Advanced Parameters

Default

Range of Values

Start delay time [mS]

0 - 60000

Start spike time [mS]

0 - 999

Max. Fastening time [mS]

10000

1 - 60000

End delay time [mS]

0 - 999

Torque Filter Factor

1, 2, 4, 8, 16, 32

Ramp-up time [ms]

1000

100 - 2000

Begin Ramp-down [%]

1 - 100

Target Speed [RPM]

(*)

1 - speed of stage

Flex-Stop [%]

10 - 100

Max Flex-Time [ms]

1000

1 - 2000

(*) The default value depends on parameter of the next stage. Refer to manual for more information. advparam.txtE

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PL12EN-COM-1 01/08

TM-COM TM-COM1 TM-COM1M

Advanced

5.4.1

Advanced Application Builder / Application Matrix

c00284en.bmp

5.4

Fig. 5-11: Application Matrix appmatri.txtS

The Application Matrix is a display matrix of 255 Applications vs. 6 Stages showing the selected Sequence number for each stage. It gives the user an overview of controller programming in a single screen. The arrow following the sequence number for a stage indicates the direction of rotation (> for clockwise; < for counter-clockwise).

appmatri.txtE

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TM-COM TM-COM1 TM-COM1M

Advanced Application Builder / Inputs

c00285en.bmp

5.4.2

Fig. 5-12: Inputs

T ool Start

T ool S top in Final Stage

T ool Start

Start Stage2

Inputs I0. Application Select 0 I1. Application Select 1 I2. Application Select 2 I3. T ool Start I4. R eject R elease I5. T ool R everse I6. T ool Enable W ith Linking: I7. R eset Linking / Synchronization In W ith Too l S ynch ronization : I7. R eset Linking / Synchronization In

c00288en.bmp

Fig. 5-13: Input Timing Diagram inputs.txtS

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PL12EN-COM-1 01/08

TM-COM TM-COM1 TM-COM1M

Eight optically isolated, +24 V inputs are available at the Phoenix input connector under the right side door and are defined as follows: PIN 1

+24 VDC

PIN 2

Input 0

PIN 3

Input 1

PIN 4

Input 2

PIN 5

Input 3

PIN 6

Input 4

PIN 7

Input 5

Pin 8

Input 6

PIN 9

Input 7

PIN 10

Input Common

Pin 11

Signal Ground

Pin 12

Spare

Each of the physical inputs 0 - 7 can be programmed to have one of the following definitions: Not Used

Unused

Tool Enable

When active, allows the tool to run in conjunction with Tool Start

Tool Start

Starts the tool. Works in parallel with the start switch on the tool.

Tool Reverse

When active, causes the tool to run in the counter-clockwise direction using the Backoff strategy. Works in parallel with the reverse actuator on the tool

Tool Ready

Prepares the controller for a new rundown. When active, the previous outputs are cleared, and the yellow LEDs flash

Appl. Select 0

Application Selects 0-7 are used to select Applications 1-255 using a binary count of 0-254 where Appl. Select 0 is the least significant bit. This feature overrides application changes from the keypad. When Linking is activated, the Tightening Group is selected with these inputs.

Appl. Select 1 Appl. Select 2 Appl. Select 3 Appl. Select 4 Appl. Select 5 Appl. Select 6 Appl. Select 7

Synchronization Input

If enabled from Advanced / System Settings, the tool is prevented from continuing to the next stage until this input is active

Reset Linking

When active, Linking (batch counting) is reset to position one

Reject Release

Used when Reject Release is enabled from System Settings, and the Release Method is "Release Input Toggle". When the tool is disabled due to the reject limit being reached, it is re-enabled after this input is toggled

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Socket Tray Enable Socket Tray Sel 0

Socket Tray Enable is used along with Socket Tray Sel 0-2 to indicate to the worker which socket to use.

Socket Tray Sel 1 Socket Tray Sel 2 Acknowledge

When this signal is ON, the "results" output signals should be cleared and the tool cannot be started; however, the tool LEDs should still indicate the status of the previous rundown until cleared by another tool start or the tool ready signal.

All inputs are active high. They are referenced to an isolated Input Common (pin 10). When using the internal +24 V (pin 1) to activate these inputs, you must connect Input Common (pin 10) and GND (pin 11). Note:

When active, the Fieldbus has the priority. Refer to help page for Advanced / Fieldbus.

inputs.txtE

Advanced Application Builder / Outputs

c00286en.bmp

5.4.3

Fig. 5-14: Outputs

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TM-COM TM-COM1 TM-COM1M

T ool Start

T ool Stop in F inal S tage E nd S tage1

T ool S tart

Start Stage2

O utputs O 0. C ycle O K

As appropriate

O 1. C ycle N O K

As appropriate

O 2. T orque H igh

As appropriate

O 3. T orque Low

As appropriate

O 4. Linking O K

As appropriate

O 5. Linking N O K

As appropriate

O 6. C ycle C om plete W ith Linking: O 7. Linking C om plete / S ynchronization O ut

As appropriate

W ith Tool S ynchronization : O 7. Linking C om plete / S ynchronization O ut

c00287en.bmp

Fig. 5-15: Output Timing Diagram outputs.txtS

Eight relay outputs are available at the Phoenix output connector under the right side door and are defined as follows: PIN 1

+24 VDC

PIN 2

Output Common

PIN 3

Output 0

PIN 4

Output 1

PIN 5

Output 2

PIN 6

Output 3

PIN 7

Output 4

PIN 8

Output 5

PIN 9

Output 6

PIN 10

Output 7

PIN 11

Signal Ground

PIN 12

Spare

Each of the physical outputs 0-7 can be programmed to have one of the following definitions:

Not Used

Unused

Active if Torque / Angle / Yield are within programmed limits

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NOK

Active if Torque / Angle / Yield are outside limits or some other error has occurred

Torque Low

Active if Peak Torque < Torque Low Limit

Torque High

Active of Peak Torque > Torque High Limit

Angle Low

Active if Angle < Angle Low Limit

Angle High

Active of Angle > Angle High Limit

Torque OK

Active if Peak Torque is within limits

Angle OK

Active if Angle is within limits

Tool Running

Active when the tool is running

Cycle Complete

Active when a rundown has ended in the last stage

Linking Complete

Active when rundowns of all positions of the selected batch group are complete

Linking OK

Active if all positions of Linking were OK

Linking NOK

Active if one or more positions of Linking were NOK

Confirm App. Sel 0

Confirm application Selects 0-7 are used to indicate the currently selected applications 1-255 using a binary count of 0-254 where Appl. Select 0 is the least significant bit

Confirm App. Sel 1 Confirm App. Sel 2 Confirm App. Sel 3 Confirm App. Sel 4 Confirm App. Sel 5 Confirm App. Sel 6 Confirm App. Sel 7 Sync Output

If enabled from Advanced / System Settings it is active at the end of each stage to allow for synchronization with other controllers

Tool In Reverse

Indicates that a tool reverse input or actuator is set

Socket Tray Enable

Pass-through of Socket Tray Enable input signal

Socket Tray Sel 0

Pass-through of Socket Tray select 0-2 input signals

Socket Tray Sel 1 Socket Tray Sel 2 Fault (Active Low)

Indicates the servo module has detected an error (transducer, resolver etc)

All relay outputs are active high. One side of all of the relay contacts is tied to a common point called Output Common (pin 2). When using the internal +24 V (pin 1) as a source for these outputs, you must connect Output Common (pin 2) and +24 V (pin 1). The outputs will then be referenced to GND (pin 11). For hardware pin location please see page 19. Note:

When active, the Fieldbus inputs have priority. Refer to help page for Advanced / Fieldbus.

outputs.txtE

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PL12EN-COM-1 01/08

TM-COM TM-COM1 TM-COM1M

Advanced Application Builder / Fieldbus

c00400en.bmp

5.4.4

Fig. 5-16: FieldBus fieldbus.txtS

From the FieldBus Screen the user is allowed to choose from four options for fieldbus connections: None, DeviceNet, Profibus, or Ethernet/IP. For selection of DeviceNet or Profibus additional hardware is required.

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Field Bus Configuration Node Address

Defines the address of the TME controller. DeviceNet (1-63), Profibus (2-125), Ethernet/IP uses the controller IP address configured in Communications / Data Transmission.

Baud Rate

Defines the rate at which information is sent/received from the TME controller. For DeviceNet three choices are available: 500KBits, 250 KBits, or 125 KBits. The rate should be set to match the fieldbus system available. For Profibus and Ethernet/IP, this option is not available. The Baud Rate is automatically set to the master settings.

Part ID

A checked box enables the Part ID function.

Disable on disconnect

A checked box that disables further rundowns and displays a "Check Cable" Message on Run Screen as long as the fieldbus doesn't work.

Format

Determines how the 32-bit Part ID is converted into readable characters. When "Decimal" is selected, the resulting Part ID is 10 characters in length. When "Hexadecimal" is selected, the resulting Part ID is 8 characters in length.

Tool 2 Control

A checked box enables an alternate format for word 1 byte 0 of the fieldbus outputs that replaces the standard Torque/Angle results outputs with Cycle OK, Cycle NOK, and "yellow light" outputs that originate from tool 2.

Dwell Time

This is the number of milliseconds that each fieldbus output bit will stay on or off immediately after a state change. The standard range is 50 to 999 milliseconds.

Enable I/O Configuration This section allows the user to control the information sent/received in the data stream. Inputs and Outputs can be individually enabled. Inputs Appl. Select (1-8)

Allows the fieldbus to control the Application selected from 1 to 8

Reset Linking

Allows the fieldbus to reset the linking to the first position

Remote Tool Start

Allows the fieldbus to start the tool

Remote Tool Reverse

Allows the fieldbus to control the rotation direction

Tool Ready

Allows the fieldbus to blink the yellow LED on the tool

Tool Enable

Allows the fieldbus to enable/disable the tool

Appl. Select (9-255)

Allows the fieldbus to control the Application selected 1 to 255. This can only be enabled if Appl. Select (1-8) is set

Socket Tray Lamp Select (1-8)

Allows the fieldbus to control the Socket Tray Lamp Select, and enables the "Socket Tray Lamps Enable" input.

Outputs Linking Outputs

Output data will include linking OK, NOK, and Complete

Appl. Select (1-8)

Output data will include current Application selection 1-8

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Tool Enable from Socket Tray

Output data will include the tool enable signal from socket tray

Tool Running

Output data will indicate when tool is in a rundown cycle

Tool Reverse

Output data will indicate when tool is in reverse

Cycle Complete

Output data will indicate when rundown cycle is complete

Tool Ready Input PassThrough

Output data will include the tool ready signal from the input

Green Tool Light (Cycle OK)

Output data will indicate when cycle is within programmed limits

Cycle NOK

Output data will indicate when cycle is outside of programmed limits

Yellow Tool Light

Output data will indicate when cycle met the yellow light conditions

Torque/Angle Results

Output data will indicate results for the torque and angle specifically

Appl. Select (9-255)

Output data will include current Application selection 1 to 255. This can only be enabled if Application Select (1-8) is set

Socket Tray Appl. Select (1-8)

Output data will indicate the socket tray appl. select

Fault

Indicates the servo module has detected an error (transducer, resolver etc)

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Signal Descriptions Inputs If DeviceNet configuration is selected, the input packet is 4 Words long (8 bytes) including Part ID Number (4 bytes) if enabled, or 2 words long (4 bytes) if Part ID is not enabled. If Profibus configuration is selected, the input packet is 4 words long (8 bytes). WORD 0

BYTE 0

BIT 0-3:

Spare

BIT 4-6:

Application/Link. Select Code 1-8(Bit 4=LSB)

BIT 7:

Reset Linking

BIT 0:

Remote Tool Start

BIT1:

Remote Tool Reverse

BIT 2:

Tool Ready (Flashing Yellow Light)

BIT 3:

Tool Enable

BIT 4:

Socket Tray Lamps Enable

BIT 5:

Socket Tray Lamps Appl. Sel. 0

BIT 6:

Socket Tray Lamps Appl. Sel. 1

BIT 7:

Socket Tray Lamps Appl. Sel. 2

BIT 0-4:

Application/Link. Select Code 9-255 (Bit 0=LSB)

BIT 5-7:

Spare

BYTE 1

ALL:

Spare

BYTE 0

ALL:

Part ID

BYTE 1

ALL:

Part ID

BYTE 0

ALL:

Part ID

BYTE 1

ALL:

Part ID

BYTE 1:

WORD 1

WORD 2 WORD 3

BYTE 0

Example of Part ID (BCD - HEX Format) WORD 3 WORD 2

BYTE 1

00000000 - 00

BYTE 0

00000010 - 02

BYTE 1

11111111 - FF

BYTE 0

00000001 - 01

The HEX-Format (0002FF01) will be displayed on the Run Screen, Chrono History, and Printout.

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TM-COM TM-COM1 TM-COM1M

Outputs The output packet will be 2 Words long (4 bytes). When Ethernet/IP is the selected field bus, and the "Torque / Angle Values" box is checked, the output packet is 5 words (10 bytes). The status of all fieldbus outputs is viewable from a diagnostics screen on the TME. All outputs are updated continuously. WORD 0

BYTE 0

BIT 0:

Spare

BIT 1:

Linking OK

BIT 2:

Linking NOK

BIT 3:

Linking Complete

BIT 4-6:

Application/Link Select Code 1-8 (Mirror)

BIT 7:

Tool-Enable from Socket Tray

BIT 0:

Tool In-Cycle

BIT 1:

Tool Reverse Switch

BIT 2:

Fault

BIT 3:

Cycle Complete

BIT 4:

Tool Ready pass-through from Input

BIT 5:

Socket Tray Application Select

BIT 6:

Socket Tray Application Select

BIT 7:

Socket Tray Application Select

BIT 0:

Green Tool Light (Cycle OK)

BIT 1:

Cycle NOK

BIT 2:

Yellow Tool Light

BIT 3:

Torque Low

BIT 4:

Torque High

BIT 5:

Angle Low

BIT 6:

Angle High

BIT 7:

Spare

BIT 0-4:

Application/Link Select Code 9-255 (Mirror)

BIT 5-7:

Spare

BYTE 0

ALL:

Torque

BYTE 1

ALL:

Torque

BYTE 0

ALL:

Torque

BYTE 1

ALL:

Torque

BYTE 0

ALL:

Angle

BYTE 1

ALL:

Angle

BYTE 1

WORD 1

BYTE 0

BYTE 1 WORD 2 WORD 3 WORD 4 fieldbus.txtS

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TM-COM TM-COM1 TM-COM1M

Advanced / Linking

c00315en.bmp

5.4.5

Fig. 5-17: Linking linking.txtS

Linking allows the user to automatically change from application to application for a predefined number of positions (up to 96). Each application is run when the start switch on the tool is activated in the order specified by its position. Upon completion of the cycle, the application will then automatically change to the next position. Up to eight different linking strategies called Tightening Groups can be programmed and are remotely selectable from the Application Inputs (0-2). This feature can also be used for Batch Counting by entering the same application in the desired number of positions. To setup a linking strategy, a Tightening Group 1-8 should be selected and given a name. This will designate which linking strategy is being used. The user can also program if the linking strategy should reset to position 1 after an NOK or set the number of times a fastener can be retightened after an NOK before advancing to the next position. To configure linking, an Application 1-255 must be associated with a position in the linking strategy. To do this, the user must enter App (1-255), and can also provide a Fastener ID and Position Name. Pressing Add <F1> will place the selected application in the user-specified position of the linking strategy. Pressing Delete <F2> will remove the user-specified position from the linking strategy. Once Linking is enabled, the controller will automatically run from position 1 to the last programmed position. Note that the tool start switch or remote start input will have to be toggled between positions. The Tightening Group and Position will also be displayed on the Run Screen. The following inputs and outputs will also be active when Linking is enabled: Linking OK, Linking NOK, Linking Complete, and Reset Linking. Please refer to the Inputs and Outputs section for more information on these signals.

linking.txtE

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TM-COM TM-COM1 TM-COM1M

Advanced Application Builder / Signals

c00416en.bmp

5.4.6

Fig. 5-18: Signals signlset.txtS

From the Signals screen the user can configure set conditions that control the activation of signals. The fault signal for a tool may be activated by a servo warning event, total cycles exceeding a desired number, cycles since service exceeding a desired number, or any combination of these three choices. The fault signal becomes active when any of the selected conditions are satisfied. These settings are stored together with the system settings.

signlset.txtE

Advanced Application Builder / System Settings

c00313en.bmp

5.4.7

Fig. 5-19: System Settings

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TM-COM TM-COM1 TM-COM1M

sysset.txtS

From the System Settings Screen the user can configure parameters pertaining to the system. General Allows the user to assign an identifying name and number to the TME controller. This information will be used when sending and printing data. Station Name

(10 characters - alphanumeric)

Station Number

(10 characters - alphanumeric)

Work Cell Name

(25 characters - alphanumeric)

Work Cell Number

(3 characters - alphanumeric)

FILE NAME PREFIX

(15 characters - alphanumeric) This string is appended to the front of default file names so that multiple controller files can be saved to the same disk media.

Same for both tools

(2-Channel only) When this box is checked, the most recently entered Station Name and Station Number are automatically synchronized and used for both tools. When not checked, the Station Name and Station Number may be programmed differently for each tool. The use of this check box also affects the serial communication protocols Standard, Standard2, and 3964R. If "Same for both tools" is not checked, then the 2-digit ASCII tool number transmitted is taken from the Station Number field. If "Same for both tools" is checked, then the 2-digit ASCII tool number transmitted is hard-coded to be "01" or "02" depending on which tool the results data is from.

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Reject Release Max Number of Rejects

Allows the user to enter the maximum number of rejects that will be permitted before a release signal is required. If 0 is entered, the function is disabled.

Release Method

Release on Backoff Allows the user to release the tool by running the tool in reverse. Release Input Toggle Allows the user to set a low-high-low pulse of the Reject Release input as a release signal

Others Torque Units

Allows the user to select which units the controller uses for presenting torque. Available choices: Nm, FtLbs, InLbs, KgCm, KgM and dNm. When the units are changed, all new torque values are immediately changed to the new units and all rundown data is cleared.

Tool Sync/Disable Linking

Allows the user to enable Tool Synchronization and disable the linking function.

NOK if Start Switch Release

Causes NOK status after any rundown with Early Trigger Release (ETR). ETR is any case in which the rundown did not end progamatically, i.e. if the tool did not reach Turn Off or High Limit torque or angle, or reach Max Fastening time. In this case an NOK result is generated and the yellow LEDs on the TME and tool will be illuminated.

Archive only if Torque > Trigger

Allows the user to specify that only rundown cycles where the torque is greater than the trigger torque of the last tightening stage will be saved in Chrono History.

External Application Select

Allows the user to enable the requirement for an external signal into the inputs Appl. Select 0-7 (Appl. Select 0-2 with a socket tray) for selecting the application. In the absence of a signal, the TME controller defaults to application 1.

External Tool Enable

Allows the user to enable the requirement for an external signal Input before the rundown cycle can begin.

Latched Remote Start

Allows the user to enable the requirement for an external pulse signal input to start the rundown cycle. If unchecked the remote start signal must be maintained for the tool to continue running.

Blinking Lights in Reverse

(TME only) Allows the user to select the option of blinking lights on TME controller and tool when the tool is in reverse. If the box is unchecked, there is no visible indication that the tool is in reverse.

sysset.txtE

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TM-COM TM-COM1 TM-COM1M

RUN Screen

c00289en.bmp

5.5

Fig. 5-20: Run Screen runscrn.txtS

From the Run Screen the user sees rundown data as it occurs. The Torque and Angle readings are displayed with a background color corresponding to the status of each. The background is red if the value is too high, yellow if it is too low, and green if it is within limits. The current tool model number, station name, and indicator labels are also displayed. The desired Application (1-255), Tightening Group (1-8, if enabled), and Part ID (if enabled) are selectable using the keypad. When enabled, the Part ID and Part ID Status boxes are displayed below the Tool and Application. When allowed, the Part ID edit box may be used to manually enter a Part ID using the keypad or an attached keyboard. NOTE: when manually entering a Part ID, the <ENTER> key must be pressed to validate the entry. During manual entry, the <ESC> key may be pressed to return to the previous Part ID and state of validity. The Part ID Status box contains three indicators: 1. Valid: Indicates whether or not the part ID is valid, and when not valid, whether or not the tool is enabled: -

“Part ID Valid” (green LED): Part ID is valid. The tool is always enabled.

“Part ID Invalid; Tool Disabled” (red LED): When configured in INTERLOCK mode, an invalid Part ID causes the tool to be disabled. A new, valid Part ID must be entered to enable the tool.

“Part ID Invalid; Tool Enabled” (yellow LED): When configured without INTERLOCK mode, the tool may be run without entering a valid Part ID.

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Function: Indicates the status of Part ID Data Function: -

“Data function: not configured” (clear LED): Part ID “Data Function” is configured to "None".

“Function: None” (yellow LED): Part ID “Configure Data” is enabled, but the Part ID is invalid or does not match any Configure Data entries.

“Function: XYZ” (green LED): Part ID “Configure Data” is enabled, and the current Part ID has engaged function XYZ (see Communications - Part ID help screen for function definitions).

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Input status: Indicates whether or not a new Part ID can be entered. -

“Accepting Part ID input” (green LED): A new Part ID may be entered.

“Not Accepting Part ID input” (red LED): A new Part ID may not be entered.

A new Part ID may not be entered when the tool trigger is active.

“NEW INPUT IGNORED!” (red LED): This status is displayed if a new Part ID is entered while “Not Accepting Part ID input” is true.

Below the Torque and Angle display is the “Status” window. This window displays various messages related to the tool, rundown status, or errors. The <F1> “Print” soft key causes any rundown data that has not previously been printed to be sent to the parallel port printer interface. If the Part ID is configured to “Print Interlock”, the Part ID is invalidated, and the tool is disabled. The <F2> “Oscilloscope” soft key displays the Oscilloscope function for evaluating Torque and Angle curves. It is automatically updated after each cycle. The Run Screen may be optionally configured to display Rundown Details or Counter information as shown. These options are available by pressing the Configure <F3> soft key. See "Run Screen / Configure". Counter information is available for individual applications and tightening groups (linking). See "Administration / Counter". The rundown details include the application number, the stage number of the Torque/Angle results currently displayed, the total number of stages in the application, and the rundown status summary (Good, A High, T Low, etc). (2-Channel only) Tool display options are Manual Select, Auto Select, and Split Screen. See "Run Screen / Configure". In the single tool display, when tool 2 is selected, the run screen display has the labels for the result LEDs on the right side. When navigating to other screens, the "active" tool for other functions is the tool selected in the "Tool" edit box. When Split Screen is selected, the side of the display containing the focus (red highlight) determines the "active" tool. Split Screen limitations: • • • •

With Linking enabled, the total number of tightening positions is not displayed. With Linking enabled, the display of the tightening group name is limited to 5 characters. If the group name is longer than 5 characters, only "Group" is displayed. With Part ID enabled, the Part ID status box is not displayed. A long Part ID may not be completely displayed.

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Run Screen / Tool 2

c00363en.bmp

5.5.1

Fig. 5-21: Run Screen / Tool 2

(2-Channel V2.xx.xx C2 only) When tool 2 is selected, the run screen display has the labels for the result LEDs on the right side.

Run Screen / Split Screen

c00386en.bmp

5.5.2

Fig. 5-22: Run Screen / Split Screen

(2-Channel V2.xx.xx C2 only) When "Split screen" is selected, the run screen simultaneously displays the results and status from both tools.

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Run Screen / TMEI

c00413en.bmp

5.5.3

Fig. 5-23: Run Screen / Configure

The TMEI Run Screen displays an OK or NOK result. It does not display a numeric torque value or units. The TMEI Run Screen does not provide access to the Oscilloscope screen. runscrn.txtE

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Run Screen / Configure

c00364en.bmp

5.5.4

Fig. 5-24: Run Screen / Configure runcfg.txtS

Run Screen / Configure allows customization of the Run Screen display. The user may select the display of counter information and/or rundown details. The counters are activated and reset using the "Administration / Counter" screen. When the "Station Name" box is checked, and Linking is disabled, the Station Name programmed in "Advanced / System Settings" is displayed next to the application number. (2-Channel V2.xx.xx C2 only) The user has the option of having the Run Screen display automatically switch to the tool which has most recently reported results, or simultaneously displaying the results from both tools. This is done by checking the Auto Select box, or Split Screen respectively.

runcfg.txtE

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Oscilloscope

c00290en.bmp

5.6

Fig. 5-25: Oscilloscope Operation oscope.txtS

The Oscilloscope function displays a Torque vs. Angle curve after each complete rundown in the tightening direction. The curve is colored in alternating red and black lines to indicate the different stages. A green box is also displayed on the trace to indicate the torque and angle limits. There is a data point for each degree of angle rotation. Archive The Archive allows the user to display the last rundown with automatic update after each new rundown, or to display the last five rundowns with an OK result and the last five rundowns with an NOK result without automatic update. Zoom Using the Zoom indicators on the left side of the display, a specific area of the torque trace can be enlarged. Using the up/down arrow keys, highlight the "Left" zoom indicator. Using the left/ right arrow keys set the orange vertical line to the left extent of the desired zoom window. Then highlight the "Right" zoom indicator and set the right extent to the desired zoom window. Once the window extents are set, pressing "Enter" will enlarge the trace to the desired zoom window. Highlight the "Full" zoom indicator and press "Enter" to return the trace to the original unzoomed size. Cursor The cursor (red cross-hatch) can be moved along the torque trace using the left and right arrow keys. The actual torque and angle values of the cursor position are shown at the top to the display. Stage The Stage softkey allows to select the corresponding stage by input of a stage number (0 to 6). If you enter "0", the entire rundown is shown.

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Rundown Indicator At the bottom left of the display is the rundown indicator. The final torque and angle values are displayed on either a green (OK) background or red (NOK) background. Parameters At the bottom of the display is a summary of the parameter settings for the rundown. The Save softkey <F2> lets you print a hardcopy. Note:

The TMEI does not provide access to the Oscilloscope screen.

oscope.txtE

Communication

5.7.1

Communications / Data Transmission

c00404en.bmp

5.7

Fig. 5-26: Data Transmission commdata.txtS

From the Data Transmission Screen the Serial and Ethernet connections can be configured. Serial Protocol

None, Standard, Standard2, PFCS, CT01 3964R, Appolo 3.1, FEP

Port

COM 1, COM 2

Baud Rate

2400, 4800, 9600, 14400, 19200, 38400, 57600, 115200

Data Bits

4, 5, 6, 7, 8

Parity

None, Odd, Even, Mark, Space

Stop Bits

1, 1.5, 2

Flow Control

None, Hardware, Xon/Xoff

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Protocol allows the user to select between different data transmissions. If Appolo 3.1 is selected, then after linking is OK, a special protocol for a label printer is sent to the programmed COM port. With each other selection, the serial data transmission is sent after each cycle. The basic settings are Port, Baud rate, Data bits, Stop bits, Parity, and Protocol. (2-Channel V2.xx.xx C2 only) The Standard, Standard2, and CT01 3964R serial communications protocols can be configured as a unique serial port (COM1 or COM2) for each tool, or such that a single serial port is shared between the tools. The transmitted "Tool Number" is a two-digit ASCII field as programmed in Advanced / System Settings "Station Number". When the option Advanced / System Settings: "Same for both tools" is checked, the Tool Number field is hardcoded as "01" or "02" as appropriate. The following table details the transmission data for Standard:

Start

End

Length or Value

Description

42 hex

2 Digit ASCII

Tool Number

2 Digit ASCII

Parameter Set

12 Char ASCII

Date and Time (YYMMDDHHMMSS)

7 Digit ASCII

Peak Torque

7 Digit ASCII

Low Torque Limit

7 Digit ASCII

High Torque Limit

1 Char ASCII Status

Torque Status Flag L = low A = accept H = high

7 Digit ASCII

Final Angle

7 Digit ASCII

Low Angle Limit

7 Digit ASCII

High Angle Limit

1 Char ASCII Status

Angle Status Flag L = low A = accept H = high

1 Char ASCII Status

Overall Status Flag A = accept R = reject

2 Digit ASCII

Link/Position (Only for Linking)

2 Digit ASCII

Number of linked positions (Only for Linking)

0D hex

CR (carriage return)

0A hex

LF (line feed)

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The following table details the transmission data for Standard2: Start

End

Length or Value

Description

42 hex

2 Digit ASCII

Tool Number

3 Digit ASCII

Parameter Set

12 Char ASCII

Date and Time (YYMMDDHHMMSS)

7 Digit ASCII

Peak Torque

7 Digit ASCII

Low Torque Limit

7 Digit ASCII

High Torque Limit

1 Char ASCII Status

Torque Status Flag L = low A = accept H = high

7 Digit ASCII

Final Angle

7 Digit ASCII

Low Angle Limit

7 Digit ASCII

High Angle Limit

1 Char ASCII Status

Angle Status Flag L = low A = accept H = high

1 Char ASCII Status

Overall Status Flag A = accept R = reject

2 Digit ASCII

Link/Position (Only for Linking)

2 Digit ASCII

Number of linked positions (Only for Linking)

0D hex

CR (carriage return)

0A hex

LF (line feed)

If Part ID is ENABLED, then a 25 character ASCII part ID is transmitted prior to CR/LF. TM-COM via COM1 When this feature is enabled the COM1 serial port is reserved solely to listen for an incoming TM-COM connection. The COM2 port remains available for other functions; however, on the TME-200 product COM2 is used to support the fieldbus interface and is not available if fieldbus is activated. Activating this feature requires restarting the controller. Once activated, this feature allows another PC running TM-COM to connect via the COM1 serial port so that parameters may be saved/loaded, etc.

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Ethernet Protocol

None, Standard, PFCS, FEP

The ethernet settings include: • Server IP Address • Gateway • Host • Subnet Mask •

Port Address

The MAC address of the ethernet interface is displayed for informational purposes only and is not configurable. See your network administrator for proper settings. To enable communications with TM-COM, the IP address of for TM Unit, Gateway, and Subnet must be entered. For further protocol descriptions contact a Technical Service Representative in Customer Satisfaction. (2-Channel V2.xx.xx C2 only). When the ethernet "Standard" protocol is selected, there is one connection made per controller. For all messages containing a "Station Number", the station number for tool 1 is used. For the Rundown packet (#4), the "Spindle Number" field is 1 or 2 depending on the associated tool. Refer to Engineering Specification 543027 "Network Software Specification" for more information. commdata.txtE

Communication / Part ID

c00405en.bmp

5.7.2

Fig. 5-27: Part ID comprtid.txtS

The Part ID configuration screens allow the user to specify the interface and functionality of the Part ID used on the Run Screen and archived with the rundown data. Changes to the Part ID and Configuration Data edit screens are saved when the “Communications” screen is exited (Run Screen or Navigator button pressed). At this time the request to save the configuration is confirmed with a password dialog box. The Part ID may be entered manually from the run screen, input using a barcode reader attached to a serial port, or transmitted through a FieldBus. A Part ID may consist of any sequence of Alphanumeric characters, including spaces.

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(2-Channel V2.xx.xx C2 only) The Part ID configuration settings are unique for each tool. The Barcode Serial Interface can be configured as a unique serial port (COM1 or COM2) for each tool, or such that a single serial port, and therefore each Part ID, is shared between the tools. When the tools share a common Part ID source and serial port, the "Number of Characters" must be identical for both tools. Settings Enable

Defines the level of functionality of the Part ID Disable

The Part ID interface is completely disabled. No Part ID information is present on the Run Screen, and a part ID string of “(Disabled)” is archived with each rundown. The part ID is not transmitted with the standard serial protocol output data.

Enable

The Part ID interface is enabled, and is present on the Run Screen. A valid part ID is NOT REQUIRED to run the tool. Following a rundown, the Part ID or the string “(Not Valid)” is archived with the rundown data. The Part ID is transmitted with the standard serial protocol output data.

Enable Interlocked

The Part ID interface is enabled, and is present on the run screen. A valid Part ID is REQUIRED to run the tool. Following a rundown, the Part ID is archived with the rundown data. The Part ID is transmitted with the standard serial protocol output data. Following either a good rundown (linking disabled) or good linking sequence (linking enabled) the Part ID is invalidated and the tool is disabled.

Print Interlocked

The Part ID interface is enabled, and is present on the Run Screen. A valid Part ID is REQUIRED to run the tool. Following a rundown, the Part ID is archived with the rundown data. The Part ID is transmitted with the standard serial protocol output data. The Part ID is valid and the tool is enabled until the operator presses the <F1> “Print” key on the Run Screen. At this time, the Part ID is invalidated, the tool is disabled, and any rundowns which have not previously been printed are sent to the parallel port printer interface.

Part ID Source

Defines a source of the Part ID (i.e. Barcode reader through the serial port or fieldbus). Fieldbus is only available if the Part ID option is enabled in the Advanced\Fieldbus screen.

Number of Characters

Defines the length of the Part ID, not including any termination characters which may be sent by the barcode reader. • Valid values are 1 to 25

Keypad Entry

Defines whether or not a Part ID can be entered manually

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Allowed

A Part ID can be entered manually by highlighting the Part ID box on the Run Screen and typing from the keypad or an attached keyboard.

Disallowed

The Part ID can not be entered manually from the run screen.

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Data Function

Batch interrupt.

Allows the tool functionality to be automatically controlled based on the Part ID. See “Configure Data” below. None

The Part ID characters have no control over the tool functionality. The <F3> “Configure Data” soft key on the Part ID configuration screen is disabled. NOTE: setting this option to “None” does NOT cause Configure Data table entries to be lost.

Configure Data

The Position/Value pairs on the Configure Data screen may be used to control the tool functionality. When selected, the <F3> “Configure Data” key is enabled. From the Configure Data screen, the user may enter Position/Character pairs with associated functions to control the tool based on the part ID.

Defines the way a new scanned ID number should be handled during batching. Activated when "Enable" is set to "Enable Interlocked". Reset

Running batching will be interrupted and the scanned PartID number will be used for the next batching. NOK will be reported for any batch operation that is terminated prior to completion. NOK will be held for 1.5 s after the batch is aborted, and then the new batch will start.

Ask

The user will be asked how to proceed with new scanned number. (e.g. finish current batching or interrupt batching and start with new one.)

Barcode Serial Interface Defines the serial port used to interface to the barcode reader. Note:

The default port for the serial barcode interface is COM2. Port

COM1, COM2

Baud Rate

2400, 4800, 9600, 14400, 19200, 38400, 57600, 115200

Data Bits

4, 5, 6, 7, 8

Parity

None, Odd, Even, Mark, Space

Stop Bits

1, 1.5, 2

Flow Control

None, Hardware, Xon/Xoff

Termination

Defines what (if any) characters the barcode reader appends to the barcode when transmitting to the serial interface (None, CR/LF, LF, CR)

Configure Data The Part ID: Configure Data screen is entered by pressing <F3> “Configure Data” from the Part ID edit screen. Up to 12 position/value pairs may be entered, along with corresponding functions. When a new Part ID is received by the controller, the table of entries is scanned. An entry which matches a Part ID character “Value” in the corresponding “Position” causes the associated "Function" to be engaged. The entries are displayed in a table at the top of the screen. The “Position”, “Value”, “Function” and “App/Group” edit boxes are at the bottom of the screen. Pressing the <F1> “Add” key causes the current values in the edit boxes to be added to the table. All values are validated

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prior to insertion in the table. New entries are always inserted at the END of the table. Pressing the <F2> “Delete” key brings up a dialog box in which the user types the table entry number to be deleted. The delete function may be aborted by selecting “Cancel”. Pressing the <F3> “Part ID” key returns the user to the Part ID configuration screen. Note:

When the table is scanned for a Part ID Position/Value pair match, the scanning is terminated after the first match in the table has been found. The Part ID character positions are numbered from left to right. Position

1-<Number of Characters>

Value

Any Alphanumeric character

Function

Use Application X, Use Tightening Group X, Tool Enable, Tool Disable

App/Group

1-255 when function "Use Application X" is selected 1-8 when function "Use Tightening Group X" is selected Ignored when function "Tool Enable" or "Tool Disable" is selected

comprtid.txtE

Communications / Printer

c00291en.bmp

5.7.3

Fig. 5-28: Printer commprin.txtS

Note:

From this screen the user can configure the setup for the Parameter/Rundown Printer. When Parallel Enable is checked, rundown data is automatically sent to the parallel port whenever a full page has been queued. Unprinted rundowns are sent to the printer whenever any other print request is made (typically by pressing Print <F1> from the Run Screen). The Filter parameter allows the user to select whether All, OK, or NOK rundowns are printed. This filter applies to both the automated printing of rundowns (Parallel Enable), and the manual printing of rundowns (pressing Print <F1> from the run screen). Only the Centronics printer interface is supported. The Font Size selection can be used to adjust the size of the printed output. The Printer must be on before you switch on your TME. This will guarantee correct initialization of the printer.

commprin.txtE

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Communications / Work Cell

c00389en.bmp

5.7.4

Fig. 5-29: Work Cell workcell.txtS

From this screen, the user can add IP addresses to the list of remote units. To add a remote unit, enter the IP address and select Add <F1>. To delete a remote unit, select Delete <F2> and enter the position number of the IP address. To get the status of the remote unit select Verify <F3>.

workcell.txtE

Tool Setup

c00293en.bmp

5.8

Fig. 5-30: Tool Memory toollist.txtS

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The Tool memory data is displayed for the selected tool and redundancy. Only the Field Torque Calibration (Âą20% of nominal) and the static current factor are editable, in order to correct the torque calibration of the selected tool. If no Tool memory is available, then all data is programmable. In case a tool with memory is changed to another tool with memory of the same type the tool will continue to work without any necessary changes. In case the tool is changed to a tool without memory or to a different type, then after power on or when pressing the start switch a message is displayed which prompts the user to verify the Tool Setup. If tool memory is not available, <F1> and <F2> will change to Standard Tools and Fixtured Tools, respectively. Pressing the Standard Tools <F1> key will allow the user to select from a library of predefined hand tools. This library can be used to program the tool parameters when tool memory is not available or to change the existing tool memory values. Pressing the Fixtured Tools <F2> key will allow the user to select from a library of predefined fixtured tools. This library can be used to program the tool parameters when tool memory is not available or to change the existing tool memory values. The Safety Shutoff mechanism uses current monitoring to turn off the tool in the event of a transducer failure during a rundown, thereby preventing unexpected high torque. If an application experiences undesired shutoffs due to current spikes, this feature can be disabled at the discretion of the user. When disabled, the tool will still be shut off if the measured current exceeds what is allowable for that tool. Note:

Calibration with an external (master) transducer and torque monitor traceable to a third party standard is only required for the following circumstances: Before putting a new tool in service, after the tool has been repaired; continuous reading errors; periodic basis of 6 months or 100,000 cycles (whichever occurs first), or as mandated by Quality Assurance. Each transducer's calibration values should be documented for future reference.

c00394en.bmp

TMEI Only

Fig. 5-31: Tool Setup

The Tool Setup screen for the TMEI does not display a Transducer type, and no Redundancy information.

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toollist.txtE

5.9

Tool Library

5.9.1

Tool Library

c00294en.bmp

Fig. 5-32: Tool Library toollib.txtS

Using the arrow keys, move the orange highlight to the desired tool. Press ENTER to select that model or ESC to exit. If a model is selected these new parameters will be used as the tool parameters. Note that it is extremely important that the correct model is chosen to avoid damage to the tool or injury to the worker. Use Page Up <F2> and Page Down <F3> when appropriate to view more tool models.

toollib.txtE

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Statistics

5.10.1

Statistics / Chronological History

c00297en.bmp

5.10

Fig. 5-33: Chronological History chrono.txtS

The user can view the Chronological History of rundowns for any or all applications, filtered using the criteria from Statistics / Parameters. This history includes time, date, application, status, torque, angle, and Part ID. Use Prev Page <F1> and Next Page <F2> in order to go through the Chronological History. At the top right the Entries: XXXX / YYYY display indicates the number of Chrono entries matching the filter criteria / the total number of chrono entries stored in the database. The Page XXXX / YYYY indicates the current page being displayed / the total number of pages of entries matching the filter criteria. The Clear Chrono <F3> soft key allows the user to delete all rundowns. To view additional details on a particular rundown, use the up or down arrow keys to highlight the desired rundown, then press the <ENTER> key.

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c00417en.bmp

TM-COM TM-COM1 TM-COM1M

Fig. 5-34: Chronological History / Rundown Information

c00414en.bmp

Additional rundown information can be viewed for a rundown by using the up and down arrows to highlight the rundown, then press <Enter>.

Fig. 5-35: Chronological History TMEI

The TMEI Statistics screen does not display the Peak TQ column. chrono.txtE

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Statistics / Graphs

c00357en.bmp

5.10.2

c00361en.bmp

Fig. 5-36: Statistical Histogram

Fig. 5-37: Range

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Fig. 5-38: X-Bar graphs.txtS

The Statistics / Graphs screens are used to view the statistics from the selected rundowns in summary and in graphical form. Refer to Chapter 4 Statistics, page 91 for a description of the meaning of the statistics values. The rundowns are selected by the "Application" on the Graphs screen, and are further filtered using the criteria in the Statistics / Parameters screen. The user may also select the Subgroup Size (2-25) or switch between calculations for Torque and Angle. The <F3> soft key is used to toggle the view between the Histogram, Range, and Xbar charts. The <F1> soft key is used to toggle between Manual and Automatic update. In Automatic mode, the statistics are recalculated, and the graph redrawn, whenever a new rundown is entered into the Chronological History. In Manual mode, the recalculation is done only when the user presses the <F2> "Refresh" key. With large data sets, it may be desirable to set Manual update mode for performance reasons. The left side of the screen contains a textual summary of the statistical calculations. The table at the bottom of the screen displays the relevant programmed parameters for the currently selected application. The TMEI does not provide access to the Graphs screen.

Note:

If any of these programmed parameters (Min / Max / Turnoff Torque / Angle) is changed, any previous rundowns for this application are no longer valid for statistical calculation purposes. When a Min / Max / Turnoff value is changed, an entry is made in the Chronological History indicating the end of valid rundowns for statistical calculations:

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c00359en.bmp

graphs.txtE

Fig. 5-39: Chronological History

Statistic / Parameter

c00401en.bmp

5.10.3

Fig. 5-40: Statistical Parameter statpara.txtS

From the Parameter Screen the user is able to apply a filter to the chrono data. Filter 1.

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Select from the pull down menu: "All, OK, or NOK" rundowns.

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2. 3.

Enter a number for the "Count (Last n)" field. A value of 0 disables this filter criteria. Enter the Start date/time and the End date/time. The parameters are verified and updated whenever the selected field is changed, or when the Parameter screen is exited. The parameters selected from this screen apply to both the Chrono History and Graphs displays.

Export Chrono This softkey <F3> allows the user to send the filtered data to the available disk media or the printer. statpara.txtE

Diagnostics

5.11.1

Inputs / Outputs

c00298en.bmp

5.11

Fig. 5-41: Inputs / Outputs opaldiag.txtS

A light box for each available input and output is displayed to show the current status. In case an input or output is active, the light will be green. You will find a detailed description of these signals under 5.4.2 Advanced Application Builder / Inputs, page 41, 5.4.3 Advanced Application Builder / Outputs, page 43. (2-Channel only) The Diagnostics Inputs / Outputs screen displays the status of the +24V digital inputs and outputs for both tools simultaneously. Debug I/O Debugging I/O is inherently dangerous as toggling on any input or output can trigger another response. The outputs can be connected to other devices causing movement of the tooling.

Note:

Use extreme caution when activating this feature!

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When the Debug I/O is activated, you may select input and output channels to be activated manually by selecting the check box that is located to the left of the desired signal. The On button <F1> key, Off button <F2> key and Restore button <F3> key may be pressed to change the state of the signal. Manually turning on/off signals overrides the system signal on the selected channels simultaneously. The system signal is restored on all channels when the restore button is pressed and when the diagnostics menu is exited. The state of all signals will remain intact when other menu tabs are selected. Note that fieldbus inputs that are activated will override inputs from the 24v digital I/O in some cases; thus, activating a digital input under this scenario may not produce a system response. This feature may not be activated from TM-COM except for TMEM. opaldiag.txtE

Diagnostic / Fieldbus

c00403en.bmp

5.11.2

Fig. 5-42: Fieldbus diafield.txtS

Note:

Debugging I/O is inherently dangerous as toggling on any input or output can trigger another response. The outputs can be connected to other devices causing movement of the tooling. Use extreme caution when activating this feature! When the Debug I/O is activated, you may select input and output channels to be activated manually by selecting the check box that is located to the left of the desired signal. The On button <F1> key, Off button <F2> key and Restore button <F3> key may be pressed to change the state of the signal. Manually turning on/off signals overrides the system signal on the selected channels simultaneously. The system signal is restored on all channels when the restore button

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is pressed and when the diagnostics menu is exited. The state of all signals will remain intact when other menu tabs are selected. This feature may not be activated from TM-COM except for TMEM. diafield.txtE

Tool / Calibration

c00299en.bmp

5.11.3

Fig. 5-43: Tool / Calibration testcali.txtS

Note:

This test function cyclically recalibrates the system with the values used immediately before the start of a rundown. The spindle must be released for this function! The values "Offset Voltage" and "Full Scale Voltage" of the torque transducer are displayed. If redundancy is activated, the values of the second transducer are displayed. If a value is out of tolerance, it is shown in red. Rated values and tolerances: Value

Rated value

Tolerance

Calibration offset:

+/-200 mV

Calibration voltage:

+/-150 mV

Entering a password and viewing of a warning is required prior to running any "active" tool diagnostics. Not available on the TMEI.

testcali.txtE

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Tool / Angle Encoder

c00301en.bmp

5.11.4

Fig. 5-44: Tool / Angle Encoder testangl.txtS

The tool start switch starts the spindle with a speed of 30% of the maximum. After one revolution of the output shaft (set angle 360 deg), measured with the tool resolver, it is stopped. During a permanently adjusted dwell time of 200 ms any further angle pulses occurring are traced. The total result is shown as "Actual Angle". The "Shut-off Torque" displayed is the torque prevailing at shut-off or the maximum value reached during the dwell time if that value is higher than the torque at shut-off. If the test run is not terminated by a monitoring criterion, the total result equals or is higher than 360 degrees and is evaluated as okay ("OK"). Monitoring criteria are the torque of transducer 1 and a monitoring time. If the torque of transducer 1 exceeds 15% of its calibration value (even during the dwell time), or if the monitoring time of 5 seconds is elapsed, the test run is terminated with "NOK". The user must check himself, if the output shaft has actually turned by the value indicated (e. g. put mark on the spindle). If the angle reached by the output shaft does not agree with the value displayed, either the angle factor is or the resolver is defective.

testangl.txtE

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Tool / Voltages

c00300en.bmp

5.11.5

Fig. 5-45: Tool / Voltages testvolt.txtS

The table displays the measured voltages of a channel. These are the most important supply voltages on the measuring board, required for proper torque and angle measurement. Therefore, these must be monitored continuously. If a voltage is out of tolerance, it is shown in red. Designation voltage

Rated value

Tolerance

Logic voltage:

+5 V

+250 mV/-400 mV

Pos. analog Positive analog voltage

+12 V

Âą600 mV

Neg. analog Negative analog voltage

-12 V

Âą900 mV

testvolt.txtE

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Tool / TQ Measurement

c00302en.bmp

5.11.6

Fig. 5-46: Tool / TQ Measurement testmeas.txtS

Note:

This test function recalibrates the system with the values used immediately before the start of a rundown. The spindle must therefore be released still when this function is called up! Then the tool is started at zero speed and the torque is continuously measured and displayed. The field "Current torque" displays the current torque, "Peak torque" displays the highest value measured since the start of the function. If "Redundancy" is activated, the values of the second transducer are also displayed. Not available on the TMEI.

testmeas.txtE

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Tool / Speed

c00314en.bmp

5.11.7

Fig. 5-47: Tool - Speed testtach.txtS

When you press the tool start switch, the spindle starts with maximum speed. The current output shaft speed is displayed. To achieve this, the angle factor must have been entered correctly, since the integrated speed measurement is derived from the resolver signals. When you release the start switch the spindle stops. As a safety function the torque is monitored by the tool transducer. If it exceeds 15% of its calibrated value, the tachometer function is terminated.

testtach.txtE

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Tool / Tool Memory

c00316en.bmp

5.11.8

Fig. 5-48: Tool / Tool Memory testiden.txtS

Provides a constant update of the tool memory data in the attached tool.

testiden.txtE

Arcnet / Map

c00303en.bmp

5.11.9

Fig. 5-49: Arcnet / Map arcmap.txtS

The ARCNET map displays information on the current number of participants in the network, their ARCNET-ID, status, serial and software number and identification. The display is continuously updated, e. g. if the connection with a participant is interrupted, it is removed from the table, or if a new participant is added, it is added to the ARCNET table.

arcmap.txtE

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Arcnet / Statistic

c00304en.bmp

5.11.10

Fig. 5-50: Arcnet / Statistic arcstat.txtS

arcstat.txtE

The ARCNET statistics allow to check the stability of the field bus system. There are two different statistics: â&#x20AC;˘

For all external hardware components (bridges, TMs)

â&#x20AC;˘

For the station controller

The following is a description of the parameters required for stable operation. TM Bridge Description

Reconfigurations

Change upon each reset of a participant

Own reconfigurations

Change upon each reset or severe failure

Excessive NAK

Should be stable

New next ID

Change upon switch-off/on of downstream participant

CRC error

Should be stable

Lost Token

Should be stable

Send repetitions

Should be stable

Send termination

Should be stable

Receive terminations

Should be stable

Command errors

Should be stable

Unassignable ACKs

Should be stable

ACKs with Bit 14/15-Packets without CPT protocol

Should be stable

Input queue overflow

Should be stable

Packet not assigned by node

Should be stable

Discarded input packets

Should be stable

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Host Driver Statistics Reconfiguration

Change upon each reset of a participant

Host reconfiguration

Change upon each reset or severe failure

CRC error

Should be stable

Outbound packets - Inbound packets - Next ID

Change upon switch-off/on of downstream participant

Excessive NAK

Should be stable

Lost Token

Should be stable

Statistics of ARCNET Manager Broadcasts received Synchronous starts Stopped synchronous starts CRC error

Should be stable

Timeout A

Should be stable

Timeout B

Should be stable

Wrong ARCNET ID received

Should be stable

Packets not for host

Should be stable

ACKs in READY status ACKs in ERROR status

Should be stable

Unassignable ACK

Should be stable

ACKs with Bit 14/15 Should be stable

Input queue overflow

Should be stable

Packet not assigned by node

Should be stable

Discarded input packets

Should be stable

Serial

c00305en.bmp

5.11.11

Packets without CPT protocol

Fig. 5-51: Serial Port Diagnostics

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serial.txtS

The serial diagnostics allows the user to test the selected COM port by displaying sent (black text) and received data (red text). The <F1> “Start Hardware Test” transmits 10 characters. It reads back a byte based on the CTS signal. For this test an external Adapter with shorted pins is necessary. Note that serial data display is only available with serial data transmission configured as “Standard” or “CT01 3964R”. The Clear Screen <F2> soft key will clear the displayed bytes The <F3> soft key toggles the transmission record display between ASCII and hexadecimal.

serial.txtE

Event Log

c00387en.bmp

5.11.12

Fig. 5-52: Event Log eventlog.txtS

The Event Log allows viewing of errors and events that aid in diagnosing controller or operational problems. The log displays system startup action, abnormalities detected by the STMH servo, and field bus communications problems. The <F1> Prev Page and <F2> Next Page function keys are used to navigate through the list. Up to 999 events are stored. The <F3> "Clear Event Log" key is used to delete the archive of events

eventlog.txtE

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Utilities

5.12.1

Utilities / Installed Versions

c00395en.bmp

5.12

c00396en.bmp

Fig. 5-53: Installed Versions TME-100

Fig. 5-54: Installed Versions TME-200

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Fig. 5-55: Installed Versions TMEI SWInfo.txtS

The software and firmware revisions active on the controller are listed on this screen.

SWInfo.txtE

Utilities / Update Software

c00398en.bmp

5.12.2

Fig. 5-56: Update Software TME-100

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Fig. 5-57: Update Software TME-200 updateso.txtS

One or more upgrade/update packages may be installed from this screen. A single â&#x20AC;&#x153;packageâ&#x20AC;? may contain system software, servo firmware, help file updates, or a combination of these and/ or others. The active software package indicates which package the running software was loaded from when the controller was started. After an update or upgrade of the system software, the active package will not change until the controller is restarted. Package date/time information indicates when the package was created and its contents were collected and stored. The <F3> soft key reads the storage device and displays the contents. The storage device may contain many packages for different products, but only valid packages intended to be installed on the targeted unit (e.g. TME-200, TMEM) are listed. The UP and DOWN arrow buttons may be used to navigate to a listed package and select it for installation by pressing the <ENTER> button. Multiple packages may be selected for installation at one time. The <F2> soft key loads all selected packages to the targeted unit, unpacks and installs them. A single firmware update package is installed on each tool in the controller, eliminating the need to install twice. If installing to a remote unit from a Cell Manager unit, you should first install to all remote controllers prior to installing to the Cell Manager unit. All units of a cell must be running the identical version of software in order remote access to be possible.

CAUTION!

During ANY update the system power must not be switched off!

updateso.txtE

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Utilities / System Settings

c00408en.bmp

5.12.3

c00409en.bmp

Fig. 5-58: System Settings TME-100

Fig. 5-59: System Settings TME-200 utilsysset.txtS

System Settings displays the total memory and the available memory of the controller. On TME-200 units, the screen off timer can be set to the number of minutes the screen backlight will remain activated while the controller is idle. The backlight is turned off when the timer expires. The backlight is reactivated whenever a keypad key is pressed, an external input signal is changed, or when the tool is started.

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Setting the screen off timer to 0 minutes will keep the backlight activated indefinitely. It is recommended that the timer be activated so that the backlight lifetime can be extended. Uncheck the Activate screen when tool I/O changes box if the screen backlight should be turned on only when a keypad button is pressed or a keyboard key is pressed. Otherwise, any change in external I/O (e.g. tool enable, tool start) will turn on the screen and reset the screen off timer. The screen off timer setting is not available for TME-100 or TMEM units, and therefore is not displayed when connected to either via TM-COM or the Cell Manager. utilsysset.txtE

Administration

5.13.1

Administration / Load/Save

c00307en.bmp

5.13

Fig. 5-60: Load / Save loadsave.txtS

Using the check boxes, the user can select the parameters to load or save. The Load <F2> soft key searches the disk media for previously-saved files and presents a dialog so that the desired file can be selected. The Save <F3> soft key saves the selected items to the disk media in one file. A dialog is presented that requests a file name to be specified, and this name can be modified if desired. Unchecking the Load IP Settings box will preserve the active TCP/IP Ethernet settings whenever communications settings are loaded.

loadsave.txtE

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Administration / Print

c00308en.bmp

5.13.2

Fig. 5-61: Print setuppri.txtS

Using the check boxes, the user can select the items to print. These will be sent to the printer or to a file on the disk media if selected. If print to file is checked, then the file name is activated to the right and may be edited. Default names are provided using the file name prefix and the checked item to print. The Print <F3> soft key will start printing.

setuppri.txtE

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Administration / Password

c00309en.bmp

5.13.3

Fig. 5-62: Password password.txtS

The Password displays the active users and corresponding rights. There are different rights available for Programming, Statistics, Diagnostics and Administration. The date and time of the last entry changes automatically when parameters are changed. The Password function supports up to ten different users plus a master password. Pressing Add User <F1> it is possible to add a new user. If the first user does not activate the “Administration” rights he will get them automatically. Pressing Delete User <F2> it is possible to delete a user. If the last user does not have the “Administration” rights he will get them automatically. By checking the "Read Protected" box, a password is required when entering a screen from the Navigator menu, rather than after programming changes have been made.

password.txtE

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Administration / Date & Time

c00310en.bmp

5.13.4

Fig. 5-63: Date & Time datetime.txtS

Using the radio buttons the user can select European or US format for time and date. The Checkbox for Winter/Summer will account for Daylight Savings Time. The System Time and date will be updated when the Accept <F3> soft key is pressed.

datetime.txtE

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Administration / Language

c00360en.bmp

5.13.5

Fig. 5-64: Language language.txtS

The Administration / Language screen is used to select the language for the user interface. Use the up and down arrow keys to highlight the desired language, then press <ENTER> to confirm.

language.txtE

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Administration / Counter

c00365en.bmp

5.13.6

Fig. 5-65: Counter counters.txtS

From the Administration / Counter screen, the user may view, enable, disable, or reset any of the available counters. Counters are provided for each application (1-255) and for each linking group (1-8). The view is toggled between Application and Linking view by selecting either Application or Linking in the pull-down menu. Each counter may be enabled by highlighting the desired type of operation in the "Status" pulldown menu, then pressing the Enter key. When "- Backoff" is selected, the counter is enabled, and the current count is decremented each time the tool is started in the backoff direction. The "Backoff" mode is not available for Linking counters. The "Auto Reset Mode" allows the counter to operate like a batch counter. In this mode, the counter is automatically reset to zero after the total number of rundowns (OK + NOK = Size) or number of OK rundowns (OK = Size) equals the value programmed in the "Size" edit box. Each counter may be reset manually by highlighting the "Reset" checkbox and pressing <ENTER>.

Note:

The counters are not enabled, disabled, or reset until the Accept <F3> soft key is pressed, and the correct password (if enabled) and confirmation are provided.

counters.txtE

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Statistics

6.1

Understanding Statistics Your unit provides a wide array of statistical and data reports (charts) for the control of manufacturing processes. The following provides a description of the control chart for variables and an outline of the procedure for its use. Known as the -R chart (pronounced X-bar-R), the chart for variables can be used whenever a quality characteristic can be measured and expressed by a numerical value. When properly used, it can bring substantial improvement in product quality and a reduction of scrap and rework. When we control a process, we monitor the variation of the characteristics that are important to the product. During production, samples from the process are measured. By plotting the results of these measurements on the control chart, we are able to see if the process is operating in a stable manner (in a state of statistical control), or if the pattern has been disturbed by an event that drives the process out of control. In other words, the control chart tells us what the process is doing - when to take action and when to leave it alone. Although it is a powerful tool, the -R Control Chart is easy to use. Only an understanding of a few basic statistical concepts and the use of simple arithmetic is needed.

6.1.1

The Nature of Variation Variations in measured product are always present because of random fluctuations and inconsistencies in machines, material, and operator performance. No two items produced are exactly alike. When variation is random and stable, the process is in a state of statistical control (see graph 4-1a). The process has an identity, and its performance is predictable. The stable pattern of variation is caused by conditions that are inherent to the manufacturing system, such as spindle run out, bearing clearances, differences in material properties, accuracy of measuring equipment, and operator performance. We call this "common cause" variation. When variation is sporadic and unstable, the process is out of statistical control (see graph 4-1b). The process loses its identity and is no longer predictable. The unstable pattern is caused by such events as tool breakage, tool wear, bad material, and operator error. This is called "special cause" variation.

Fig. 6-1: a) Common Cause Variation

6.1.2

Fig. 4-1: b) Special Cause Variation

The Normal Curve Most processes in statistical control have a fixed pattern of variation. The mathematical curve that describes this pattern is known as the normal curve (see graph 4-2a). The normal curve is symmetrical about the average. It is high in the middle and becomes smaller as the distance from the average increases. Since the shape resembles a bell, it is sometimes referred to as a bell curve. The normal curve is defined by two conditions - the average of all items produced, and the amount of variation from the average. We can think of these as the center and width of the bell, respectively. The center is the arithmetic average of all items produced. The width is expressed in terms of the standard deviation which is a statistical calculation for the amount of variation from the average. The standard deviation, represented by the Greek letter sigma (Ď&#x192;), holds a fixed relationship to the normal curve, as follows (see graph 4-2b):

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• •

68% of all items produced will be within +1σ of the average (two sigma spread). 95% will be within +2σ of the average (four sigma spread).

•

99.7% will be within +3σ of the average (six sigma spread).

These two characteristics - the average and the standard deviation - provide the foundation for statistical process control. By taking sample measurements during production, we can predict the average value and the amount of variation for all items produced.

3σ 2σ

Avg.

1σ

Avg. 1σ

2σ

3σ

68% 95% 99.7%

Fig. 6-2: a) The Normal Curve

6.1.3

Fig. 4-2: b) Areas Under The Normal Curve

The Procedure The procedure for establishing a statistical process control program consists of three phases. The first is to obtain statistical control - a state of random and stable variation. The second is to establish process capability. A state of statistical control in itself does not assure that the process is capable of meeting the specification. The limits of variation must be equal to or less than the total specification tolerance. The third is to monitor the process throughout production using the control chart, to detect and correct conditions that upset the stable pattern of variation. Use of the -R Control Chart includes the following steps:

Select the Characteristic

Since a separate chart is required for each characteristic, practical considerations limit use to selected requirements. A good candidate is a characteristic that is important to the function of the item. Others include those that are causing a high cost loss because of scrap or rework, and those that require evaluation by destructive testing.

Designate the Sample Size

It is usually desirable to keep the sample size small so that variation within the sample is at a minimum, but not so small that statistical validity is lost. The control chart described in this document is structured for a sample size of five units. If a sample other than five is selected, the manufacturing or quality engineer can provide alternate factors for use in calculating the control limits and standard deviation (Steps 8 and 10).

Designate the Sample Frequency

Selection of the sample frequency should be based on economic considerations for the cost of measurements and the potential loss that may occur if samples are not taken often enough. Early in the production run, samples should be taken more frequently and then extended after satisfactory control is verified. The frequency may be expressed as a time interval or as a portion of quantities produced.

Assure Measurement Accuracy

Measurement accuracy is mandatory for successful statistical control. Measuring and test equipment must be of a type suitable for the characteristic being evaluated, and must be calibrated and properly used. Decisions resulting from the analysis of a control chart will be no better than the measurement data.

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Complete the Data Sheet Headings

It is important that all heading entries on the data sheet be completed. They include the part number and description, the operation performed, the name of the operator, the machine or equipment used, and the specification limits. The data sheet and control chart can provide evidence of quality for use by the Quality Assurance organization if the information is properly recorded and traceable to the products manufactured.

Start Production

Average

Take samples of five units (preferably consecutive units produced) at the designated frequency, and record each measurement (X) on the data sheet. For each sample of five calculate the average ( ) and range (R), and plot the results on the chart (see graph 4-3). - Add the five measurements and divide the sum by five. For a sample of five, it is often easier to multiply the sum by two and move the decimal one place to the left. R - Substract the smallest measurement from the largest. (Note that the range can never be negative.)

20 X

16 12

Range

8 4

Fig. 6-3: Entries for Range and Average

Calculate Process Center Lines

After data for 20 samples of five have been plotted, calculate the center lines for both the average and range plottings. The center line for the average chart is known as the grand average ( ) and is the average of all of the sample averages. This is the value that best represents the size of all measurements:

ÎŁX n

where ÎŁ is used to indicate the sum of the sample averages, ( ), (be careful to observe the + and - signs), and n the number of samples, in this case 20. Similarly, the center line for the range chart ( ) is the average of the ranges for all samples.

ÎŁR n

Average

Draw solid lines on the control chart for values representing

UCL X

LCL X

Range

and

(see graph 4-4).

UCL R

LCL R

Fig. 6-4: Drawing The Center Lines And Control Limits

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Calculate Control Limits

Calculate the upper and lower control limits (UCL and LCL) using the following formulas and the values previously calculated for the grand average ( ) and the average range ( ). (Factors are for samples of five units only.)

Average

UCL LCL

Range

UCL

x x

LCL R

X +0.577(R) X

0.577(R)

X +2.114(R) 0

Note: For a sample size of six or less, the lower control limit for the range is zero. Plot the limits on the control chart as broken lines.

Evaluate for Statistical Control

Analyze the control chart to see if the process is in a state of statistical control. Variation should be random about the center lines for both averages and ranges, with all points within the control limits. If these conditions are not satisfied, special cause variation may be present. Sometimes a process takes time to stabilize after start-up. If the indication of special cause variation occurs only in the first few samples, continue to take several more samples and recalculate the limits by omitting the special cause values. However, if the indications of special cause variation occur other than at start-up, action should be taken to identify and correct the cause, and the process re-started.

10. Evaluate for Process Capability When the process is in a state of statistical control, estimate the standard deviation (σ) using the value for the average range ( ) previously calculated. (The factor is for samples of five units only.)

Estimate of σ

R 2.326

If the 6σ spread is equal to or less than the total specification tolerance, the process is capable. It will produce at least 99.7% of all items to specification.

Avg. 6σ Spec. Tolerance Fig. 6-5: Capable Process If the 6σ spread is greater than the specification tolerance, three options are available: • Improve the system - reduce variability • Increase the specification tolerance • Continue production and sort by 100% inspection

100

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11. Center the Process After the 6σ capability requirement is satisfied, it may be desirable to center the process so that the process average is close to the middle of the specification tolerance. This can usually be accomplished by a simple machine or tooling adjustment. If the magnitude of the adjustment is known, the center line and the control limit lines for the average plotting may be moved a distance equal to the adjustment, and re-verified after 20 additional samples are plotted. Centering the process does not affect the center line or control limits for the range, so no adjustment should be made to them.

12. Realign the Inspection Activity When properly controlled, production can usually continue without the need for 100% inspection. More attention can be placed on process surveillance and audits of operator performance. However, certain safety critical requirements will justify an independent verification.

13. Maintain Control The operator shall continue to take sample measurements and plot the results on the control chart. As long as the pattern of variation remains random and within the control limits, no action is taken. However, if an indication of special cause variation is detected, the trouble should be identified and corrected (see graph 4-6). An indication of special cause variation can result from conditions such as tool wear, tool breakage, defective material, measurement error, a mistake in calculating the average or range for a sample, and plotting a point on the control chart incorrectly. Special cause variation may be indicated by one of the following situations: • A point outside a control limit. • A shift, with several consecutive points inside a control limit but on the same side of the center line.

•

A trend of consecutive points that moves steadily toward a control limit.

Outside of Limit

Shift

Trend

Fig. 6-6: Indications of Special Cause Variation Since we are controlling by evaluating only small sample sizes from the process, the criteria for continuing production must be the control limits. For this reason, we do not place the specification limits (which are recorded on the data sheet) on the control chart.

6.1.4

System Improvement There are always two risks associated with statistical control. The first is the risk of accepting bad product, and the second is the risk of rejecting good product. Both are undesirable, but our primary concern is usually the first since it has a direct impact on customer satisfaction. The six sigma spread of the process described in this procedure is in general use throughout American industry. When properly applied, it assures us that at least 99.7% of all units produced will meet specification. This relates to a risk of delivering three substandard units for each thousand produced. While this provides much better quality than can be obtained with an uncontrolled process and 100% inspection, it may not be good enough in the future as competition becomes stronger in the world market. So it's important that we continue to improve the manufacturing system - to reduce the influence of conditions that affect variations in the performance of people, machines, and materials (see graph 4-7). There

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will be practical and economic limitations to this effort, but to the extent that we can further reduce process variation we will increase the probability that all delivered product meets the specification.

Variation

Spec. Toler.

Fig. 6-7: Improving The System By Reducing Variation

6.2

Statistic Symbols σ

• • • • • • • •

R Cp Cpk n Sub Sz Y

•

=standard deviation (or sigma) =mean (or average) =range =Capability of Process =Capability index =number of runs =Subgroup size =Torque summary run data

Angle summary run data

(Note: See glossary for definitions)

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Glossary accepted data

data that fall within the acceptable limits in a fastening strategy

accepted rundown

a run cycle within limits

angle capability indexes

a measure of acceptable variation of final angle values in a fastening process

angle control

a fastening strategy by which you are controlling a tool by predetermined angle limits

angle encoder

a device that measures the angle of rotation

angle high

active if final angle > angle high limit

angle high limit (AHL)

the maximum acceptable angle for a run cycle

angle limits

the range between the maximum and minimum acceptable angle for one cycle

angle low

active if final angle < angle low limit

angle low limit (ALL)

the minimum acceptable angle for a run cycle

angle monitor

a fastening strategy by which you are monitoring a tool by predetermined angle limits

angle reject

a cycle rejected when the acceptable angle is not achieved

application

a programmed setting of the unit for a given application; TME 100 has eight application settings. Often referred to as product group

application select 0-2

application selects 0-2 are used to select applications 1-8 using a binary count of 0-7 where app. sel. 0 is the least significant bit

baud rate

the frequency at which the unit communicates

capability of process (Cp)

The ratio of the process tolerance to 6 standard deviations. Ranges from 0.0 to infinity with larger values indicating a more capable process. (Often referred to as Process Potential Index or Inherent Capability Index.)

capability index (Cpk)

An index combining the process potential and the measure of the difference between process and the specification mean. CPK will equal Cp if the process mean is centered on the target (nominal) specification value; if CPK is negative, the process mean (X-Bar) is outside the specification limits; if CPK is between 0 and 1, then some of the 6 sigma spread will fall outside of the specifications; if CPK is larger than 1 then the 6 sigma spread is completely within the specification tolerance.

control parameters

the parameters that define the fastening strategy sequence for a given tool

cycle complete

active whenever tool is not running

cycle NOK

active if torque/angle/yield are outside limits or some other error has occurred

cycle OK

active if torque/angle/yield are within programmed limits

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cycle start switch

the switch on a tool that initiates a run cycle

default parameters

parameters automatically selected by the unit

desired final torque

the final torque desired in a fastening process (referred to as torque setpoint)

end delay time [ms]

time delay from the tool turnoff until the torque measurement ends

engineering units

units of torque measurement

external transducer

a transducer physically located on the outside of a tool

fastener rotation

direction in which a fastener rotates

fastening strategy

a strategy used to control or monitor a fastening process

final angle

the final angle desired in a fastening process

histogram

a printout generated from statistical data output

if NOK go to stage

gives the control system direction if the stage is NOK

internal transducer

a transducer physically located inside the tool

LCD screen

the screen on the unit that provides directions to programming the unit

LED flashing in reverse

if yes, the tool LED's will blink when the tool is in reverse

LED screen

the screen on the unit that provides the readout data from a run cycle

linking

Allows the user to automatically change from application to application for a predefined number of positions (up to 32). Up to eight different linking strategies called Tightening Groups can be programmed and are remotely selectable from the Application Inputs (0-2). This feature can also be used for Batch Counting by entering the same application in the desired number of positions.

load

refers to the amount of torque applied to a device or tool

main menu

the first menu that appears on LCD screen

marking output

output from paint marker solenoid after each cycle

master transducer

a transducer used as a benchmark to calibrate another transducer

max. fastening time [mS]

max time for the tool to run during the stage

mean (Xbar)

the average of all readings taken in a sample

number of Repeats NOK (linking)

Selects the number of time a fastener can be retightened after an NOK before going to the linking position.

NOK after reverse

if yes, the controller will report an NOK if the tool is run in reverse

peak torque

the maximum torque achieved in a run cycle

port

the socket used for connecting a cable or peripheral equipment

position (linking)

A number 1 to 32 that determines the order in which applications will be run during linking.

power supply

a unit used to supply power to an electrical device

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pulses per degree

number of encoder pulses generated by the tool when rotating the head exactly 1 degree or 1/360 of a revolution

range (R)

a statistical measurement of the difference between the lowest and highest reading taken in a sample

redundant transducer

secondary transducer used to read torque

redundant transducer calibration

the calibration process of the secondary transducer

reject interlock

the stopping of further operation of the system after a predetermined number of rejected cycles has occurred

rejected data

the data generated by unacceptable rundowns

rejected rundown

a rundown that has not met the criteria of a fastening strategy

remote parameter select

a remote device that bypasses the parameter select button on your unit

reset after NOK (linking)

Determines whether the controller will reset to linking position 1 after an NOK.

rundown printout

gives the control system direction for when to print

run number

number of accepted and rejected rundowns

second transducer

frequently referred to as the redundant transducer

sequence 11

high speed rundown

sequence 30

torque control/angle monitor

sequence 50

angle control/torque monitor

sequence 41

angle controlled backoff

speed

max speed of the nutrunner during the tightening stage

standard deviation (Ď&#x192;)

the measurement of the scatter of the population around a mean

start delay time [ms]

time delay before the stage will start

start spike time [ms]

time delay for the control system to start measuring torque after the stage starts

statistical data

data used to measure the performance and accuracy of the unit and tool

status light

lights located either on the unit or tool that represent accepted and rejected cycles

sub group size (Sub Sz)

the sub group size of data used for statistical analysis; the smallest sub group size = 5

synchronization input

when active allows the tool to start from stage to stage in conjunction with tool start

synchronization output

active at the end of each stage to signal a stage is complete

threshold torque [Nm]

torque to begin counting angle

tightening group (linking)

Contains a specific linking strategy of up to 32 positions. It is remotely selectable from the Application Inputs (0-2).

tool enable

when active allows the tool to start in conjunction with tool start

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tool rpm capability

maximum allowable speed of the tool

tool reverse

when active prior to tool start, the tool will run counterclockwise using the backoff strategy

tool start (LCD and outputs also clear)

starts the tool

tool stop

stops the tool

torque capability indexes

a measure of acceptable variation of final torque values in a fastening process

torque control

a fastening strategy by which you are controlling a tool by predetermined torque limits

torque filter factor

used for torque averaging

torque high

active of peak torque > torque high limit

torque high limit (THL)

the maximum acceptable torque value for one cycle

torque low

active if peak torque < torque low limit

torque low limit (TLL)

the minimum acceptable torque value for one cycle

torque monitoring

a fastening strategy by which a tool is monitored based on predetermined torque limits

torque reject

a cycle rejected when the acceptable torque is not achieved

torque threshold (TTH)

the point at which the angle counting starts

transducer

a device used to read torque

transducer span (torque cal.)

full load reading of transducer

trigger torque [Nm]

torque to start collecting oscilloscope data

turn off angle

the angle at which a tool is shutoff

turn off torque

the torque at which a tool is shutoff

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Sales & Service Centers Note: All locations may not service all products. Please contact the nearest Sales & Service Center for the appropriate facility to handle your service requirements. Dallas, TX Cooper Power Tools Sales & Service Center 1470 Post & Paddock Grand Prairie, TX 75050 Tel: (972) 641-9563 Fax: (972) 641-9674 Detroit, MI Cooper Power Tools Sales & Service Center 4121 North Atlantic Blvd. Auburn Hills, MI 48326 Tel: (248) 391-3700 Fax: (248) 391-6295

Cooper Power Tools P.O. Box 1410 Lexington, SC 29071-1410 USA Phone: 800-845-5629 803-359-1200 Fax: 803-359-0822 Cooper Power Tools 4121 North Atlantic Blvd. Auburn Hills, MI 48326 USA Phone: (248) 391-3700 Fax: (248) 391-6295

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Cooper Power Tools de México S.A. de C.V. Libramiento La Joya No. 1 Bodega No. 2 Esq. Politécnico Barrio San José Cuautitlán, Edo de México C.P. 54870 Phone: +52-55-5899-9510 Fax: +52-55-5870-5012 Cooper Tools Industrial Ltda. Av. Liberdade, 4055 Zona Industrial - Iporanga 18087-170 Sorocaba, SP Brazil Tel: +55-15-3238-3929 Fax: +55-15-228-3260

Seattle, WA Cooper Power Tools Sales & Service Center 2865 152nd Ave N.E. Redman, WA 98052 Tel: (425) 497-0476 Fax: (425) 497-0496 York, PA Cooper Power Tools Sales & Service Center 3990 East Market Street York, PA 17402 Tel: (717) 755-2933 Fax: (717) 757-5063

Canada Cooper Power Tools Sales & Service Center 5925 McLaughlin Road Mississauga, Ont. L5R 1B8 Canada Tel: (905) 501-4785 Fax: (905) 501-4786

Cooper Power Tools SAS Zone industrielle – B.P. 28 77831 Ozoir-la-Ferrière Cedex France Téléphone: +33-1-6443-2200 Téléfax: +33-1-6440-1717

Cooper Tools Hungária Kft. Berkenyefa sor 7 H-9027 Györ Hungary Tel: +36-96-505 300 Fax: +36-96-505 301

Cooper Power Tools GmbH & Co. OHG Postfach 30 D-73461 Westhausen Germany Phone: +49 (0) 73 63/ 81-0 Fax: +49 (0) 73 63/ 81-222 E-Mail: sales-de@coopertools.com

Cooper (China) Co., Ltd. 955 Sheng Li Road, Heqing Pudong, Shanghai China 201201 Tel: +86-21-28994176 +86-21-28994177 Fax: + 86-21-51118446

www.cooperpowertools.com

Cooper Industries, Ltd. 600 Travis, Ste. 5800 Houston, TX 77002-1001 P: 713-209-8400 www.cooperindustries.com