forceview3tm crimp force monitor software user manual

CFM2100 User Manual Supports ForceView3ForceView3 User Manual 2 Revision 1.0 August 2014
ForceView3 User Manual 3 Revision 1.0 August 2014
Table of Contents 1.0 –OPERATION 4
1.1 IN PRODUCTION 4 1.2 TREND GRAPH 7 1.3 CPK 9 1.4 MENU OPTIONS 9 1.5 MENU INFORMATION & STATUS INDICATORS 10 1.6 LEARNING A PROCESS 10 1.7 PART MANAGER 11 1.8 CRIMP DATA LOG FILES 12 1.9 ADDING A COMMENT 13 1.10 COUNTER AND TREND RESET 14
2.0 – CONFIGURATION 15 2.1 NEW INSTALLATION 15 2.2 ADDING A NEW DEVICE 15 2.3 PASSWORD ACCESS 16 2.4 STEP 1 – LEARN PARAMETERS 16 2.5 STEP 2 – SENSOR CONFIGURATION 17 2.6 STEP 3 – SIGNATURE CAPTURE 18 2.7 STEP 4 – SIGNATURE ANALYSIS 19 2.8 STEP 5 – ADVANCED SETTINGS 21 2.9 STEP 6 - PART MANAGER 22 2.10 STEP 7 – MACHINE INTERFACE & CONTROL 22
Outputs 23 Inputs 24
2.11 STEP 8 - CONFIGURATION MANAGER 25
3.0 – HARDWARE TOOLS 25 3.1 HARDWARE STATUS 25 3.2 REALTIME MODE 25 3.3 HEADROOM 28 3.4 FACTORY DEFAULTS 29
4.0 - TOOLS 29 4.1 SECURITY 29 4.2 LANGUAGE OPTIONS 30 4.3 AUTOGEN PROGRAMMER 30 4.4 SCREEN CAPTURE 31 4.5 PROGRAM OPTIONS 31
1.0 –Operation 1.1 In Production The production screen (also referred as popup) displays the crimp signature following each crimp cycle with a PASS/FAIL indicator.
The CFM captures and analyzes the crimp force signature from all production crimps. The crimp signature from each production cycle is compared to the learned reference signature for process variation error. OES’s Cumulative Deviation Analysis (CDA) computes the process variation error relative to the reference signature. Three regions of the crimp force signature (R1, R2, & R3) are analyzed for process variation error relative to a tolerance limit for discrimination of good or defective crimps. The vertical bar on the right side of the screen represents the total crimp process variation error relative to the CDA tolerance limit (by default CDA-L is 125.0). This CDA tolerance limit (CDA-L) will discriminate between good and defective crimps.
Learn
Configuration
The CFM provides detailed view of the crimp signature and the trend of the process error relative to the CDA limit for the previous 20 crimps.
If the computed crimp process variation error exceeds the CDA limit, this is considered a crimp defect. The crimp defect condition is displayed on the production screen as shown and will inhibit the machine through the CFM electrical interface.
Sensor Connect/Disconnect
Menu Options
Pass/Fail Decision
The CFM also monitors for a characteristic change in the force signature. This enables the CFM to target crimp defects such as high insulation and other crimp errors that can only been seen in the shape change of the force signature. This example below shows a signature shape change that exceeds the CDA limit and is displayed as “Curve Mismatch”.
The Curve Mismatch is confirmed on the operator display. The crimp process variation error is displayed in orange.
Curve Mismatch
Click on the force signature for an expanded view.
1.2 Trend Graph The trend screen displays the crimp process variation error for all production crimps. Click on the trend screen icon for an expanded view. Each vertical bar represents the process variation error of each crimp. GREEN presents crimp that is within the tolerance limit, RED represents process variation error that exceeds the tolerance limit, and ORANGE represents process variation error that exceeds the tolerance limit combined with a shape change that is characteristic of a high insulation defect. The trend screen provides a view of the process stability relative to the CDA limit.
%TOLERANCE (default 125%)
The CDA tolerance limit can be adjusted from the Trend screen by clicking over the CDA value on the trend graph and entering a new value (value from 10 to 600). This feature may require a user with enough security privileges to log in.
The Advanced SPC summary displays the trend graph for each production part since the CFM last learned. It calculates a statistics performance of the minimum, maximum, mean, Standard deviation, CP and CPK for the CDA error and Peak force.
Current CDA Limit
Click on CDA Limit value to enter new CDA limit followed by Enter key
CDA-L (default 125%)
CDA Error Statistics
1.3 CPK
The CPK is calculated on the peak value of each cycle. This value is continuously updated in the main screen as the cycles occur based on the last 200 crimps. The Advanced SPC summary view will show a CPK based on all crimps since the last learn.
1.4 Menu Options
LEARN – Send CFMs to learn mode
SETUP & CONFIGURATION – Setup Parameters, Sensor Configuration, Curve
Capture, Analysis, Machine Interface
CRIMP DATA LOGGING – Enable/disable crimp data logging functions –replay
crimp log, export crimp log
CFM SETUP – Machine Interface, I/O configuration
CLEAR – Counters, Trends, All
MINIMIZE ForceView DISPLAY – Pop-up/Production Mode places small icon on the display
1.5 Menu Information & Status Indicators
COUNTER – Pass/Fail/Total counters. USER – Different user levels can be configured. LOGGING status icon displayed during crimp data logging. SENSOR STATUS indicates the sensor is connected or disconnected.
Blue for connected
Red for disconnected.
1.6 Learning a Process 1. From the main menu click the LEARN icon. Click the learn button to learn the CFM or
click All Channels to learn all CFM units connected. 2. Cycle the machine/Press and the CFM will learn automatically.
User logged in
A preconfigured minimum number of crimp samples are required to create a new LEARN reference signature from which all production signatures are compared.
To perform a new setup or changeover to a different crimp process there is normally no requirement to make changes to CFM configuration settings or tolerances. The default configuration settings will provide consistent high performance for most crimping processes and terminal/wire combinations. For certain crimp monitoring processes, there may be a requirement to adjust the configuration parameters to optimize the crimp monitor performance. For these applications, the configuration parameters set can be saved and recalled by a part number for efficient changeover. The CFM can store an unlimited number of configuration settings by part number.
1.7 Part Manager
Part numbers can be assigned to terminal/wire combinations that require a unique set of configuration parameters. These CFM configuration parameters are automatically recalled and applied by part number. The part number is displayed over the trend graph.
PRODUCTION MODE
The part manager stores the configuration of Learn parameters, Sensor Settings, Signature capture and Signature analysis. After loading a part profile, the unit will automatically enters, learn mode.
1.8 Crimp Data Log Files ForceView 3 provides data storage to log all production crimp data comprising the crimp signature, process trend, configuration settings. Log files can be optionally setup by file name and logged specifically to a data file. Click the Data Files icon, select the New or Append Log option and enter the Log file name followed by Save. The CFM will log the data from each crimp produced including the signature and all configuration parameters by time stamped by date and time. Click the Stop Logging button will end the log file. If Stop Log is not selected the file will continue to log. If the software is shutdown or connections is lost due to a power loss. When power is returned the ForceView 3 will automatically connect back up and continue to log.
1.9 Adding a Comment Type the comment in the space provided (once logging has started, comments can
only be added after the first machine cycle).
To save the comment to the log file press
In the File menu, select Open Log File button to recall crimp data log files. Select the file of interest and click Open.
The crimp log menu functions are as follows:
Log Replay
File and CFM unit information Exporter to CSV CFM configuration at
time of logging
Curve and analysis
Log files can be exported into CSV format for further analysis and reporting.
1.10 Counter and Trend Reset
Counters and trends are reset by clicking on the icon. This feature may be protected by user password, see User Manager Section.
Allows administrator to create CSV files to be exported or copy Log files to be reviewed on a desktop computer.
2.0 – Configuration 2.1 New Installation The CFM is designed for installation onto a wide range of automatic machines. It is assumed that the CFM has been installed, supplied with power, and the appropriate sensor is installed and connected by sensor cable to the CFM sensor input. The following steps are recommended for successful configuration of the CFM:
Step 1 - Sensor Configuration Step 2 - Force Signature Capture Step 3 - Force Signature Analysis Step 4 - Machine Interface & Control
To access the setup and configuration routines the user will first need to enter a correct password. When prompted the default user is ‘admin’ and the default password is ‘oes’. Additional users can be added as described in the “Security” section of this manual.
2.2 Adding a new device After installing and launching ForceView, Click on CFM Device and select Add device (or enter Ctrl + N). A window will come up with the available connections.
Select the connection going to the CFM. A new tab is created for the device
2.3 Password Access
Password entry may be required to access some configuration routines. By default the user “admin” has all privileges and the password “oes”.
Following successful password entry, the Configuration menu options are displayed and accessible.
2.4 Step 1 – Learn Parameters
Following a new setup and validation of crimp dimension, the CFM is placed into Learn mode. A minimum number of crimp samples are captured and averaged to compute the new learn reference signature from which all production signatures will then be compared. The Signature Learn configuration setting functions are as follows:
Max Learn Variation - The CFM captures and averages the selected minimum number of crimp signature samples to establish the learned signature from which all production crimp signatures will be compared. The Maximum Learn Variation is entered as a percent of the maximum variation between each learn signature. Signature samples within 3% variation relative to the previous signature are accepted as Learn samples, while signatures with variation greater than 3% of the previous sample average are excluded from the learn.
Minimum Samples– is the minimum number of learn samples to establish the learn reference signature. The selected minimum number of learned samples can be set between 2 and 10 samples.
Maximum Samples - Is the maximum number of Learn samples/machine cycles to establish the reference signature. If for example the signatures captured exceed the variation then the maximum samples may be reached resulting in a “LEARN FAILED” condition and the machine will be inhibited.
Target Recalculation This allows the crimp reference signature to adjust to normal changing process conditions. The value is the interval of good parts at which the recalculation is performed. For example, the default value of 16, means that a target recalculation is performed every 16 good cycles below the recalculation limit.
Recalculation Limit – Is the maximum CDA value a good part can have to be used for a target recalculation.
Process Deviation Is a maximum limit on the Target Recalculation to prevent excessive drifting of the process from original learn.
2.5 Step 2 – Sensor Configuration
The CFM is compatible with OES full series of piezo dynamic force sensor options – Piezo Strain, SenFit PBT, and Piezo Force sensors. Piezo strain sensors are physically mounted in-line with the compression force during the crimping process. The force sensor is mounted into the ram or baseplate of the press and have a calibrated maximum force range, which is entered as the Sensor Range. The sensor range must be manually adjusted based on the Sensor units required. Tension should be selected when using this sensor.
Piezo Strain sensors detect the micro deflection of the press frame during the crimping cycle. The strain sensor is bolted to the frame and provides a micro-strain output relative to the tension or compression exerted on the frame during the crimping process. The mounting location of the strain sensor will determine the selection of tension or compression. In most applications, the sensor is set to “tension”, monitoring the micro tension (deflection) of the press frame during the crimping process. PBT sensors are installed in the ram of the press, allowing it to be vertically aligned and in series with the crimp tooling. All of the force during the crimp process is sensed as compression mode. The tension or compression on the PBT and strain sensor output is scaled to engineering units to provide a force measurement relative to the crimp force applied. (**OES CAL5000 press analyzer is optionally used to scale the OES CFM with strain sensor to an accurate absolute force measurement. In many cases, calibration to absolute force measurement is not required since crimp force monitoring is relative measurement to detect the relative change in the process variation rather than absolute measurement).
2.6 Step 3 – Signature Capture
The force signature capture default settings will provide correct signature capture for most standard crimp presses. With the monitor in learn, cycle the press and confirm that the entire signature is captured and displayed. If the crimp signature is cutoff at the beginning or end of the cycle, then there will be requirement to adjust the force signature capture configuration settings. A detailed explanation of each of the Force Signature Capture setting is as follows: Start Level – the CFM is normally configured for automatic trigger referencing the input threshold level of the force sensor input to trigger the signature capture. The start level is set as a % of the sensor input range with a default setting of 5%. The start level is displayed as shown.
Filter – eliminates false trigger by ensuring that the force input is greater than the Start Level threshold for the filter time default ( 5 milliseconds). Signature capture will be initiated after the force input exceeds the start level and maintained for the filter time period.
The Pre-trigger is the time period in advance of the Start Level to capture the beginning of the force signature. This time period is entered in milliseconds. The default of 10ms will ensure capture of the complete force signature for typical crimp presses. Certain crimping presses with a slower press cycle rate may require a longer pre-trigger time to capture the complete crimp force signature. The Duration is the time period to capture the complete crimp force signature following the Start Level. This time period is entered in milliseconds. The default of 75ms will ensure complete capture of the force signature for typical crimping presses. Certain presses with a slower cycle rate may require a longer duration time to capture the complete crimp force signature. The Alignment aligns the reference learned force signature with the force signature of every production crimp. The default alignment is 20% of the falling edge of the force signature. The alignment slope is accessible by a user with “Advanced analysis settings” privilege to ensure authorized entries only.
2.7 Step 4 – Signature Analysis The force signature analysis has default settings that should ensure correct analysis for most standard crimping processes and applications. Cumulative Deviation Analysis (CDA) computes the crimp process variation error using 3 regions of the force signature when compared to the learn signature. The computed error from each region is weighted and accumulated for a total CDA-E. The CDA-E is normalized to a value relative to a maximum process variation limit of 125.0. If the CDA-E exceeds 125.0, this will be considered a crimp defect, and the output signal is sent to the machine for control of the crimp defect.
CDA-L - is the cumulative deviation analysis maximum limit. The CDA Error is compared to crimp deviation analysis limit (CDA-L) for determination of Pass or Fail. Curve Mismatch (CMM) – utilizes Cumulative Deviation Analysis and analyzes the signature for shape change that is characteristic of high insulation. The CMM is normalized to a value relative to a maximum process variation limit of 125.0. If the Curve Mismatch error exceeds 125.0 this will be considered a crimp defect, and the appropriate output signal is sent to the press or machine for control of the crimp defect. The greater of CDA-E or CMM-E is displayed and the crimp error is confirmed by color – RED = CDA-E, and ORANGE = CMM-E.
CDA-E
CDA-L
CDA-E
CMM-E
2.8 Step 5 – Advanced Settings The Advanced Settings are accessible by a user with “Advanced analysis settings” privilege to ensure controlled access only. This user then has access to the Signature Advanced tab.
cda-L E Region % – is the % error factor or “weight” for each region for calculation of total CDA Error. Compensation – is a factor that will increase the low force sensitivity for optimizing the detection of a missing strand condition, while not affecting sensitivity for normal crimp process variation. E Priority Limit % - Factory set to 115% E Priority Value – Factory set to 50% Curve Mismatch – algorithm for detection of certain high insulation defects can be enabled/disabled. CMM % Error – is the % error factor or “weight” for each region for calculation of total CMM Error. VR5 % – Advanced algorithm to improve detection of missing strand errors. When the crimp curve is less than the learn curve error from the falling edge of the curve is added to the VR3 region. The VR5 defines the location of this analysis zone. Note that the setting defaults have been established and optimized following extensive testing for a wide range of wire crimping processes and under typical crimping processes should not require any adjustment.
2.9 Step 6 - Part Manager Allows users to create/import and export preconfigured Part number profiles to be used by the operator in the future.
2.10 Step 7 – Machine Interface & Control
Following successful signature capture, signature analysis, and achieving a repeatable crimp monitoring process (producing good parts with minimum unnecessary scrap/good called bad), the 7th step is to connect the CFM with the machine. An electrical interface is determined following the electrical interface instructions from the press or machine supplier.
Allows user with privileges to import/export Part numbers from one wire processing machine to another.
I/O Settings: Outputs
There are 4 independent output relays that can be assigned to preset functions
Pass Output – output is enabled for PASS
Gross Output – output is enabled for FAIL
WireChop – output is enabled for control of WireChop
Learn Output – output is enabled when the channel is in Learn Mode
Data valid Output – output is enabled for PASS or FAIL
Ready – Output is disabled when the unit receives a force signature and enabled after a pass/fail decision has been made.
Each function can be assigned to an output relay. Refer to electrical specifications for output specification. Assign the function to the relay that best meets the electrical interface requirement for the automatic machine. The Output Pulse Delay and Duration are entered in milliseconds. The Relay State can be Normally open or Normally closed is the selected “standby state” of the relay. In the event of a crimp defect the output(s) is/are enabled to control the machine. The Gross Output Reset Method provides options to reset the CFM and output relays for continued production. The options are:
Input 1-3 – assignment of any of the 3 inputs, which must be enabled to release, output to standby state (example external machine control, external key switch, etc.)
The External Trigger Timeout is the maximum time after the input is received in which the crimp curve must occur. The Consecutive Gross Fail is the amount of consecutive fail cycles that must occur for the Gross Output to activate.
Wire Chop Control The Wire Chop output provides control of WireChop device to automatically cut the wire short following a crimp defect for error proofing the production operation.
Chop Stations – This is for wire transfer or conveyor applications where the WireChop device is mounted downstream from the crimp press. For these applications, the number of stations downstream is entered as the Chop Stations (determined by the number of press cycles). For most applications, this is set to 0.
Chop in Run automatically cycles the chopper following crimp defect in normal production mode
Chop in Learn automatically cycles the chopper following every crimp cycle in Learn Mode to destroy all Learned parts
Inputs
There are 3 independent inputs that can be assigned to the following functions:
Disabled – not used.
Firing Pulse – is an option to trigger signature capture with an external input signal. An input is assigned to Firing Pulse, which is a momentary input signal that triggers the press cycle. The trigger is configured to activate on the positive or negative going signal from the input. The timeout is the duration in milliseconds for the analysis to be completed.
Learn – input from an external device will automatically activate a re-learn.
Fail Reset – Assigns the input to reset the Gross output after a gross failure.
Disable Channel – While this input is held active. All force signatures are disregarded and no pass/fail decision will be made.
Data capture – while this input is held active. The CFM will capture and analyze all force signatures. When inactive it all signatures are disregarded and no pass/fail decision will be made.
Schaefer H/S – Enables advanced handshake with predetermined machines.
2.11 Step 8 - Configuration Manager Allows users to create/import and export preconfigured Part number profiles to be used by the operator in the future.
3.0 – Hardware Tools
The Tools menu provides menu options in support of process monitoring, maintenance and troubleshooting.
3.1 Hardware Status To review the CFM hardware status in real time. This is supportive of new installations and troubleshooting electrical interface issues.
3.2 Realtime Mode Real Time Mode is a tool that supports new system integration, setup, and troubleshooting. It aids the user to test sensor and inputs signature level and timeline. To enter Realtime mode, click on Tools and select Realtime Tool.
Allows user with privileges to import/export Part numbers from one wire processing machine to another.
Real time mode captures the sensor data within a selected time base. A sensor trigger level starts the sensor monitoring for the time period selected and then displays the sensor data similar to an oscilloscope. A zoom feature provides for detailed view of the force versus time input.
Select start and cycle the press, a preview screen will display the data as is being recorded. Once the data has been retrieved. It will be displayed in the zoom window. To zoom the signature, highlight an area in the Zoom window. Only the highlighted area is displayed in the zoomed data. To calculate the signature capture parameters manually, Point to the Start, End and trigger over the curve. Pulse is only required if there is a firing pulse enabled, in which case the Pulse is selected over the input signature (orange or red). Realtime mode will calculate the Signature capture parameters according to the selected signature capture pointers and the values can be sent to the CFM.
Add notes
Sensor Amplification
To calculate the signature capture parameters automatically, click on Auto-Calculate. Select the signatures to be used and click on Auto Calculate. An Average signature will be calculated and the Trigger level, Pre-trigger and Duration will be automatically computed. The Signature Capture parameters can be sent to the monitor by Clicking on Send to Monitor.
Start
Send signature capture to CFM
Right click on any signature to remove it from the calculation
Click on Auto Calculate to average all curves and compute the Trigger, Pre-Trigger, and Duration
Send Signature capture parameters to monitor
Computed the Trigger level, Pre-Trigger and Duration
Average Signature
3.3 Headroom
Headroom is a useful tool to determine the capability of the CPM to detect missing strands for various terminal wire combinations. The terminal hardness contributes to a lower headroom and reduced capability to detect missing strands, compared to a softer terminal crimping the equivalent wire. Another contributor to reduced headroom is high compression of the conductor core. Headroom is a calculation of the % difference of the peak force of a crimp with and without conductor. An example calculation is as follows:
% = Peak force with 100% of the conductor in the conductor core crimp
Peak force with 0% of the conductor in the conductor core crimp 100
A headroom > 30% can be effectively monitored using standard OES configuration settings. For headroom < 30% the configuration settings should be carefully reviewed and configured as required to confirm crimp defect detection capability. Optimized configuration settings can be assigned to a part number for recall of configuration parameters specific to those low head room crimping combinations.
To calculate the headroom of a process, start by learning the process. Once in production create a crimp with no wire. Go to Tools and select Headroom. The headroom is calculated by using the last production curve and learned curve.
4257N
2834N
66%
3.4 Factory Defaults Return the CFM to factory defaults by going to Tools and selecting Factory Defaults.
4.0 - Tools
4.1 Security
Under the Tools pull down menu Security Sign in as a user with administrative privileges. By default, the user name is “admin” and the password is “oes”. Use the change password to enter a new secured password and click on the User manager to create/edit users and privileges.
Privileges:
Learn – Allows user to send the CFM into learn mode by clicking the learn icon.
Configuration – Allows the user to edit the configuration screen.
Realtime – Allows user to run advanced configuration
Clear Counter – Allows user to clear counters by clicking in the clear icon.
Reset Defaults – Allows user to return the unit to factory defaults.
Allows administrator to create different levels of Users, each with an individual password and allowable functions.
Part Manager – Allows the user to load preconfigured part numbers.
Add/ Remove Devices – Allows user to connect-disconnect the CFM to ForceView and close ForceView
Move Popups – Allows the user to change the location in the screen where the production screen (popup) is located.
Access Autogen – Allows the user to load a new firmware into the CFM
Program options – Allows the user to modify ForceView screen view
Edit Tolerances Graphically – Allows the user to change the CDA limit from the SPC/Trend screen
Restore from System tray – Allows user to restore software that is minimized to system tray. Minimize to system tray option is enabled in the program options
4.2 Language Options
Go to the Tools menu, then language and select from the language options to automatically configure all text to the language of choice. For other languages, please contact OES sale representative.
4.3 Autogen Programmer
Autogen programmer is used to load new firmware revisions into the CFM.
Select the Firmware file supplied by OES, the communication method and port. Then click Start, the program will start downloading. Do not power off or disconnect the CFM at this time. The progress bar will notify when the program has been fully downloaded.
After downloading a new firmware, close the Autogen Programmer screen. All previously connected devices will reconnect. You must load Factory defaults to all devices with a new firmware, to properly initialize all parameters.
4.4 Screen Capture Screen capture will save the current screen as a picture in .jpg format for support purposes.
4.5 Program Options Program Options configures ForceView usage and viewing options.
Default Unit Name – Sets the default name displayed on the tab when a new device is added.
Profile Folder Location – Default location where profiles and part number files are saved
Log Folder Location – Default location where log files are saved
Auto Sign Out Interval (s) – Maximum time a user will remain signed in.
Graphic Gross Tolerance Limit (%) – This is the maximum amount that the CDA-L can be adjusted to; through the SPC chart. Allows for a supervisor to adjust the tolerances without having access to the full configuration settings. This option gives some control to ensure that parameters are not being set to a large value disabling the CFM.
Popup Opacity (%) – Production Display/Popup opacity level. Lower numbers make the display more see through.
Popup Fixed – Disables the option to move the Production Display/Popup location within the monitor
Hide Popup Tolerances – When enabled the CDA bar is not displayed in Production Display/ Popup mode
Start in Popup Mode – When the software is loaded starts in popup mode
Single Popup Window – When enabled it creates one Production Display/Popup window with all devices tiled. When disabled, it creates one per device.
Disable Popup – When enabled ForceView can only fun in full mode.
Permissions Required to Restore from System Tray - Authorized users can restore ForceView software from system tray
Minimize to System Tray - Minimizing ForceView will place software in system tray instead of Windows task bar
Start in System Tray - ForceView will start and automatically minimized to the system tray.
4056 Blakie Road London, Ontario, Canada N6L 1P7
519-652-5833 FAX: 519- 652-3795

forceview3tm crimp force monitor software user manual

Documents