process monitoring for press fit auloma apm-ba
TRANSCRIPT
AULOMAAPM-BA
PRESS CONTROL AND FORCE VS DISPLACEMENT MONITORING SYSTEM
Perfection in Press Fit Operations 2
APM-BA SERVO PRESS PROCESS MONITORING
PRESS CONTROL AND FORCE VS DISPLACEMENT MONITORING SYSTEM
BENEFITS
•Lonely environment to control servo press job
and process monitoring instal led in servo drive
memory
•Modular press programs unti l 5 steps for press
to force, press to position and press to relative
position
•Real time process monitoring
•Servo press diagnosis
•Enhance defect detection
•Reduce the scrap cost
•Operator friendly interface for press program
•Ethernet interface for data exchange
•Analysis data in CSV format for SPC
•PC tool kit compatible with wichever MS widows
Vista ® machine and later version
FEATURES
Software
•Best industrial software for press
program and process monitoring
•Two channels (x)(y) analisys for
real time Process Monitoring
•Multiple waveform control zones
•Envelope function for complete
waveform control
•CSV data trasnfert
Hardware
•Servo Drive with Built-In PLC ABB
•I/O terminals connector for easy
plug and wiring
•Two Ethernet/Ethercat interface
for PLC and PC connection
Quick Set Up
•Friendly wizard for set up the
servo press parameters
•Friendly wizard for set up the
wavform control zone
PC User Interface
•Simple and intuitive user display
•Supervisor account with password
security
Multiple Data Views
•Status: see part test status (pass
or fai l)
•Curves: view data curves (Force
vs. Distance) with overlaid l imits
•History: review last test cycles and
part history records
•Limits: view current l imits
Detailed Data Management and
Reporting
•Local & remote storage of test
results organized by model, part,
ram, etc.
•Process data available in CSV
format for Statistical Process
Control (SPC)
Servo Drive Connectivity
•Communication with station
control ler via discrete I /O in APM
slave configuration
•Ethernet TCP/IP for data transfert
•USB
Applcations
•Servo press control
•Press applications process
monitoring
3 Perfection in Press Fit Operations
APM-BA SERVO PRESS PROCESS MONITORING
OVERIEW
APM-BA is designed to control the servo press motion and in the same time monitoring the press operations, thus
the system provide real-time analysis of the data to identify defective parts, faulty press machinery, and out of
control assembly processes. I t measures force vs. distance signatures for each part cycle, and then analyzes the
curve(s) in mil l iseconds to provide an instant pass/fai l output for press ram. Compatible with piezoelectric force
sensor or strain gauge amplified with analog output of ±1 0V, APM-BA can be networked to provide higher level
insight into assembly processes by collecting data across the entire assembly l ine.
APM-BA provides extensive hardware and software functions for part test, analysis and data connectivity
APM-BA CONFIGURATION STANDARD TO CONTROL PRESS RAM
DIGITAL INPUT FORCESENSORCALIBR.
PRESSREADY
MOTORBRAKE
ANALYSIS
OK
ANALYSIS
NOK
CYCLERUNNING
FORCESENSORTARE
SERVODRIVE
WORKPIECEPRESENT
ETHERNET
HOMEPOSITIO
NCOMMAND
CYCLESTART
RESET
PROGRAM
WAIT
JOG
+
JOG
-
ETHERCAT
DIGITAL OUTPUT
ANALOG
INPUT0-10V
MOTORFREQUENCYCONTROL
ENCODERINTERFACE
DIGITAL
OUTPUT
DIGITAL INPUT
PRESSREADY
MOTORBRAKE
ANALYSIS
OK
ANALYSIS
NOK
CYCLERUN
USER'S
PLC
HOMEPOSITIO
NCOMMAND
CYCLESTART
RESET
PROGRAM
WAIT
JOG
+
JOG
-
DIGITAL OUTPUT
SERVO PRESS
FORCE SENSOR
MOTOR
ENCODER
PROXIMITY
SENSOR
OTPTICAL
MAGNETIC
CAPACITIVE
(OPTIONAL)
PC LAPTOP WITH
APM-PC TOOL
INSTALLED
PC SERVER WITH
APM-PC TOOL
INSTALLED
(OPTIONAL)
MASTER
SLAVE
ETHERNET
SWITCH
Perfection in Press Fit Operations 4
APM-BA SERVO PRESS PROCESS MONITORING
THREE DIFFERENT KIND OF SERVO PRESS CONTROL
APM-BA own three programs to control the press ram. The set up of each program is easy and friendly. In few
minutes is possible set up the press according your application. The three programs allow a ram control to press at
the right force, at the right position and at the right relative position from a force signal trigger. the ram program is
saved in the memory of the servo drive unti.
THE BEST HUNTER OF PARTS DEFECTS
The brain of the APM-BA is the powerful CPU that al low a faster analysis of the data gathered from the press
sensors. The APM software produce a faster analysis of al l data provided by the servo press. The press waveform
results are control led by multiple tolerance off set zones or by an envelope that wrapping the trajectory. Thanks to
this method if the process is repeatable the analysis results are repeatable also and by the comparison of a
masterpiece waveform the APM can decide in few mil l iseconds if the parts are correct or wrong.
MULTIPLE GRAPHICAL DATA VIEWS
The APM displays all informations about press program and test result on a Windows ® PC machine with APM -
BA tol l kit instal led. Thanks to the icons on the software interface is easy display tables and graphs. The navigation
inside the APM - BA Toll kit is protected by password and allow different set up level according the permission.
CSV DATA TRANSFERT
The APM-BA can provide the process signature data in CSV ( Comma Separated Value ) format to an external
data storage. The CSV data can be used for SPM ( Statistic Process Management ) or SPC ( Statistic Process
Control ) and can be processed by many ERP, MRP and spread sheet )
DEFECTS DETECTED
PARTS CORRECT
ASSEMBLY
EXCESSIVE
DISTANCE
INCORRECT
INSERTION
INCORRECT
ORIENTATION
INCORRECT
PART
INSUFFICENT
DISTANCE
MISSING
PART
APM-BA TOOL KIT FUNCTIONALITY
The best yield obtained by Auloma servo press is when all analysis data provided are saved and analysed in a PC
machine. Statitistical analysis of your data allow an awared knowledge of your quality trend. Through APM-BA Tool
Kit whichever PC machine can set up the press operations but can also save and see all analysis data. With a
good organizzation of the archive folders is possible research the data stored through a DB and then analysed by
Statistic Process Management instal led.
5 Perfection in Press Fit Operations
APM-BA SERVO PRESS PROCESS MONITORING
TOOL KIT STATUS VIEW
High level status screen allows operator and
supervisors to quickly assess the part test status. The
program diplays unti l four press in run. Each menu
displays the istantataneous value of force and posi-
tion of each ram. The central lower menu displays the
press cycle results .
TOOL KIT SETTING LIMITS
The APM-BA displays a menu to setting the force limits
on wafeform
TOOL KIT PRESS PROGRAM
APM-BA displays a templates where is possible edit
the parameters to control the servo press ram. The
templates propose three different execution of the
press cycle, one for press to the nominal force value,
another one to press to the nominal position and the
last one to press to the relative position.
Perfection in Press Fit Operations 6
APM-BA SERVO PRESS PROCESS MONITORING
TOOL KIT CURVES VIEW
The APM-BA provide each cycle the curves produced
by the data gathered. The curve is displayed on (x)
(y) graph, where in (x) there is the ram stroke scale
and in (y) the force. The view of the curve is aided by
a smart zoom function and pan function. The off set
force limit settled on the curves can be displayed
through the properly buttons on the screen.
TOOL KIT HISTORY VIEW
The APM save each cycle result in two diffrent CSV
files. The 1 st fi le provides the raw data to identify the
historical period, the 2nd fi le provides the raw data
about the analysis. Both fi les are saved on the re-
sperctive folder path. The analysis history is displayed
below the curve templates and is possible diplays ea-
ch historical curves through a flaggable field.
TOOL KIT HTML REPORT
The analysis results can be plot in HTML format to
generate useful documets.
7 Perfection in Press Fit Operations
APM-BA SERVO PRESS PROCESS MONITORING
For complex press operations or if breakpoints for the supply of material or tools are required, an extended se-
quence of press fit programs is available. The APM-BA has the capabil ity of 5 steps in sequence to provide
operational profi les with breakpoint and inversion of the direction of travel.
home positionapproach introduction end fit
0
1
2
3
position set 1 position set 2 position set 3 position set 0
home position idle stroke
( fast foward) unti l
workpiece
introduction
( slow forwad)
for few mil l imetres
to bear the correct
workpiece alignment
fitting to the target
value
( force or position )
back stroke
( fast backward)
unti l tool change
position
0
position set 0
home positionapproach flaringtool change 0
4
position set 4 position set 0
tool change position
idle time for tool
changing
idle stroke
( fast foward) unti l
workpiece
flaring stroke
( slow forward )
to the target
value
back stroke
( fast bakward) unti l
home position
5
position set 5
0
position set 0
PRESS PROGRAM
Perfection in Press Fit Operations 8
APM-BA SERVO PRESS PROCESS MONITORING
PRODUCTS OVERVIEW
SERVO DRIVE E1 50 FOR PRESSES WITH THRUST CAPACITY BELOW 20 KN
APM-BA SOFTWARE
SERVO DRIVE E1 80 FOR PRESSES WITH THRUST CAPACITY OVER 20 KN
9 Perfection in Press Fit Operations
APM-BA SERVO PRESS PROCESS MONITORING
TECHNICAL SPECIFICATIONS E1 50
SERVO DRIVE FEATURES
•Embedded Ethernet including EtherCAT®, Modbus/TCP and Ethernet/IP
•EtherCAT conformance certified by ETG
•Safe torque-off (STO) as standard - to IEC 61 800-5-2, SIL3 PLe
•2 / 4 wire RS485 with optional termination and Modbus RTU support
•APM-BA TOOLKIT provides configuration via USB or Ethernet TCP/IP
•AC servo drive 3, 6 or 9A with 200% overload
•Single or three phase 1 05 - 250 V AC operation (maximum limits)
•Encoder BiSS
•Dual encoder input for l ine shaft fol lowing or dual loop control (position / velocity and commutation)
•1 0 x digital inputs. Opto-isolated 24V.
•2 inputs can be programmed to capture axis position within 1 micro-second (feedback device dependant)
•7 x digital outputs. Opto-isolated 24V PNP. 50mA per channel.
•2x +/-1 0V analog inputs 1 x +/-1 0V analog output
•Notch fi lters to combat mechanical resonance
•7 segment LED status indicator for error and communications notification
TECHNICAL SPECIFICATIONS E1 80
SERVO DRIVE FEATURES
•Embedded Ethernet including EtherCAT®, Modbus TCP and Ethernet/IP
•EtherCAT conformance certified by ETG
•Safe torque off (STO) as standard - to IEC 61 800-5-2, SIL3 PLe
•APM-BA TOOLKIT provides configuration via Ethernet TCP/IP
•Three phase operation 230 -580 V AC
•Encoder BiSS
•Secondary encoder input for l ine shaft fol lowing or dual loop control (position / velocity and commutation)
•1 0 x digital inputs. Opto-isolated 24 V.
•2 inputs can be programmed to capture axis position within 1 micro-second (feedback device dependant)
•7 x digital outputs. Opto-isolated 24 V PNP. 50 mA per channel.
•2x +/-1 0 V analog inputs 1 x +/-1 0 V analog output
•Notch fi lters to combat mechanical resonance
•7 segment LED status indicator and LED communications status
Auloma Holding S.r.l.
Address:
Via Mussolina 1 074 - 4001 8 San Pietro in Casale ( BO)
ITALY
T. +39 051 81 82 85
www.auloma.com
201 5-05-1 5- Rev. 00 - APM-BA-MMXV
© Auloma Holding S.r. l . , al l rights are reserved. I t is prohibited to use text or immages from this
documentation, in whole or in part, without written permission. All products are subject to
technical change without notice. Liabil ity for printing errors in the technical data is excluded.