9307 EN. Universal Process-Controller

Transcription

1 Uiversal Process-Cotroller For moitorig press-fit ad joiig operatios, torque ad process curves, plus sprig ad switch testig, icludig resistace measuremet, sigal testig ad leak detectio DIGIFORCE Series 9307 Poti Code: Delivery: ex stock/2 weeks Warraty: 24 moths ±10 V Piezo SSI EDat Ω Applicatio The DIGIFORCE 9307 moitors processes i which precisely defied fuctioal relatioships betwee two or more measured quatities eed to be demostrated. These measured quatities are recorded sychroously durig the maufacturig process or subsequet fuctioal testig to produce a measuremet curve, which is the assessed usig graphical ad mathematical evaluatio techiques. After iteral evaluatio, the measuremet curve ad computed evaluatio results are visualized o the color display ad are also output at the exteral cotrol iterfaces. The processes i the cotroller are optimized by a powerful real-time operatig system to achieve a extremely fast evaluatio cycle: it typically takes just 15 ms to deliver the global OK or NOK evaluatio result, which ca the be aalyzed by the higher-level cotroller. I additio to the traditioal evaluatio widows with defied etry ad exit sides, the DIGIFORCE 9307 also offers thresholds, trapeziums of type X or Y ad evelopes as graphical evaluatio elemets. Idividual evaluatio results from the graphical tools ca the be combied by mathematical operatios to provide eve more aalysis flexibility for a huge rage of sigal curves. DIGIFORCE has a wide rage of process cotrol applicatios, icludig moitorig processes such as joiig, rivetig or caulkig, or checkig torque curves, for istace for higes or high-quality rotary cotrols. Eve complex sigal/time curves (e.g. pressure curves, leaks etc.) ca be moitored usig the large choice of evaluatio techiques. Simultaeous recordig of up to two Y variables (Y1 ad Y2) with respect to a commo X variable allows may applicatios to Techical chages reserved. All data sheets at Comprehesive process moitorig delivered by iovative evaluatio elemets widow, thresholds, trapeziums, evelopes ad mathematical operatios High measuremet accuracy 0.05 % possible at 10 KHz samplig rate Flexible process itegratio thaks to a rage of Fieldbus iterfaces Simultaeous moitorig of two sychroous processes Ultra-fast evaluatio ad data trasfer for dyamic measuremets Etheret, USB, RS232 as stadard Up to 128 measuremet programs for a large variety of parts Trasfer of process, compoet ad worker data Itelliget sigal samplig usig a combiatio of t, X, Y Automatic sesor recogitio from burster TEDS DigiCotrol PC software with powerful data-loggig fuctio for process data use oe DIGIFORCE cotroller to moitor two sychroous processes. Alteratively, this feature ca be used to evaluate a applicatio with three process variables, for istace the force/ displacemet curve ad associated curret cosumptio of a liftig electromaget. While DIGIFORCE is used i may automated productio areas, it is equally at home i the maual workstatio, for istace to moitor force/displacemet whe usig had presses for assembly or for radom spot-checkig i goods iwards. burster praezisiosmesstechik gmbh & co kg Germay Talstr Gersbach Phoe ifo@burster.com INCR

2 - 2 Block diagram Poti ±10V Piezo INCR SSI EDat Sesor Iterfaces Sesor excitatio: Strai gauge, Poti, Trasmitter X Y1 Y2 A A A D D D 32 Bit µp Embedded Real-time operatig system Ultra-fast measuremet recordig ad evaluatio Measuremet data memory X,Y1,Y2 (Rig buffer) DIGIFORCE 9307 Fieldbus µp Numerical keyboard 5,7 LCD color graphic RS232 Etheret USB SPS E/A 23 iput 31 output (cofigurable) Fieldbus PROFIBUS DP, DP-V1 PROFINET, EtherNet/IP, EtherCAT PC or PLC commuicatio Frot pael set up ad services iterface 230 VAC supply Measuremet data acquisitio With a active measuremet, which ca be triggered by differet evets, the sychroously measured quatities X,Y 1 ad optioally Y 2 are saved i the measuremet data memory. Real-time sigals ca idicate whether measuremets are exceedig set sigal levels while the measuremet is still i progress. The evaluatio phase follows immediately after the measuremet. I this phase, DIGIFORCE checks whether the recorded measuremet curve(s) satisfy the stored graphical ad mathematical evaluatio criteria. If ay of these criteria has bee ifriged, the measuremet is classified as BAD (NOK), otherwise it is rated as GOOD (OK). Oce this evaluatio is complete, the measuremet curve, the global OK or NOK result ad umerous process-related values are displayed i a suite of measuremet widows ad updated at the Fieldbus iterface. The processig steps of the evaluatio phase, which fiishes whe the equipmet is ready for the ext measuremet, have bee optimized so that eve dyamic maufacturig processes ca be moitored. Evaluatio of a measuremet curve As a uiversal evaluatio tool for a vast rage of curve shapes, the DIGIFORCE 9307 provides cofigurable evaluatio elemets, which ca be used to classify a measuremet curve as OK or NOK. I additio to the traditioal evaluatio widows with defied etry ad exit sides, the DIGIFORCE 9307 also uses thresholds, trapeziums of type X or Y ad evelopes as graphical evaluatio elemets. Idividual evaluatio results from the graphical tools ca the be combied by mathematical operatios to provide eve more aalysis flexibility for a rage of sigal curves. The graphical evaluatio elemets ca be cofigured both umerically ad graphically i setup mode usig oe or more recorded measuremet curves. They ca be used i ay combiatio, eve overlappig i a X/Y graph. Widow evaluatio Max. umber: 10 The Widow evaluatio elemet tests whether the curve has passed through the defied etry side ad exit side i the widow area. The user ca cofigure these etry/exit sides as required, ad ca eve set multiple iput/output sides. A live sigal ca be assiged to up to two widows, which is eabled immediately durig recordig if ay ifrigemet occurs. It is also possible to defie widows of type NOT (o etry/exit) or BLOCK (curve eds iside the widow) by suitable cofiguratio of the etry/exit sides. This evaluatio elemet also calculates the values listed below, which ca optioally be displayed ad also iput to user-defiable mathematical fuctios for further processig ad evaluatio: Figure: Measuremet widow M1-1 cotais a graph of the measuremet curve. Shows a curve cotaiig a forward ad retur sectio ad detailed evaluatio usig widows, evelopes, thresholds ad mathematical operatios. Etry ad exit coordiates (measuremet pairs) Local miimum/maximum Absolute miimum/maximum Mea value Y Mea Itegral (area below curve to Y MIN limit iside widow) Curve gradiet Iflexio poit Techical chages reserved. All data sheets at burster praezisiosmesstechik gmbh & co kg Germay Talstr Gersbach Phoe ifo@burster.com EN

3 Trapezium evaluatio elemet Mathematical operatio - 3 Max. umber: 4 The DIGIFORCE 9307 offers two differet types of trapezium: the type-x trapezium widow with fixed X MIN, X MAX limits ad type-y trapezium with fixed Y MIN, Y MAX limits. The trapezium evaluatio elemet tests whether the curve has passed through the defied etry ad exit sides; oly oe etry side ca be cofigured for this elemet. The etry/exit values are calculated. Threshold evaluatio elemet Max. umber: 4 The threshold evaluatio elemet ca be used to calculate ad moitor where the measuremet curve passes through a defied X-value or Y-value. The user ca choose betwee threshold type X or Y. Threshold type Y provides the followig extra results: Local miimum/maximum Absolute miimum/maximum Mea value Y Mea Itegral (area betwee curve ad X-axis i the threshold regio X MIN to X MAX ) Curve gradiet Iflexio poit Evelope evaluatio elemet Max. umber: 2 The DIGIFORCE 9307 ca use oe or more measuremet curves to geerate up to two evelopes. The user ca the customize a geerated evelope i the X-domai, ad also set toleraces for the Y-domai. For a measuremet curve comprisig a forward ad retur curve sectio, the evelope caot lie over the turig poit. Whe subsequetly moitorig a measuremet i measuremet mode, DIGIFORCE tests whether the measuremet curve lies withi the defied evelope bad i.e. is classified OK, or whether the curve passes outside the valid evelope ad hece must be classified NOK. Rotary switch evaluatio elemet Max. umber: 2 The Rotary switch evaluatio elemet eables haptic testig of rotary switches ad rotary or rotatig cotrols comprisig up to 32 cotrol positios. This evaluatio tests whether the umber ad level of force maxima ad miima satisfy the saved criteria. I additio, the agular distace ad Y-mea value of the extreme values will be moitored. A + B/2 Max. umber: 10 of which 6 ca be evaluatio Specific measuremet curve variables ad results from the graphical evaluatio elemets ca be combied usig basic mathematical operators (+, -, x, ) ad evaluated. A result ca be processed further i a subsequet operatio. The evaluatio is fed ito the global evaluatio result. The results of a mathematical operatio ca be displayed i a measuremet widow ad retrieved via the Fieldbus ad/or commuicatio iterfaces. Flexible process itegratio The DIGIFORCE 9307 has the versatility to itegrate ito practically all process eviromets. A huge umber of detailed requiremets ca be implemeted usig the umerous I/Os (23 iputs / 31 outputs), some of which ca be assiged user-defied fuctios. A measuremet ca be started ad termiated at variable times by differet iteral ad exteral evets. Samplig ad recordig measuremet sigals Sigals ca be sampled as a combiatio of time iterval (Δt), X-iterval ad Y-iterval (ΔX, ΔY) to provide a flexible yet also compressed measuremet recordig. Curve areas cotaiig a costat or steadily chagig sigal ca be reproduced with just a few stored measuremet poits, while steep sigal slopes or alteratig waveforms require may poits. Start/Stop coditios for measuremet recordig The DIGIFORCE 9307 lets the user defie idepedet start/stop logic. Start coditios: Ext. cotrol sigal, measuremet above or below a defiable X-value or Y-value. Stop coditios: Ext. cotrol sigal, measuremet above or below a defiable X-value or Y-value, timeout, defiable umber of recorded measuremets reached. Recordig ad evaluatig two sychroous processes Two sigal curves Y 1 ad Y 2 ca be recorded with respect to a commo X-chael ad evaluated i oe measuremet phase. For the evaluatio, the user assigs the required graphical evaluatio elemets to each graph, ad the evaluatio is performed idepedetly usig separate process sigals (OK-Y 1/2 ). Alteratively, it is possible to moitor a applicatio that has three process variables. Limit moitorig i real time S1... S4 The user is able to assig the switchig sigals S1... S4 to the three measuremet chaels X, Y 1/2 as required, ad ca set their polarity. The associated PLC I/Os ad Fieldbus sigals are updated both i stadby mode ad also i real time durig the measuremet cycle (respose time < 10 ms). NOK... ONLINE 1/2 Up to two live sigals (NOK-ONLINE 1/2 ) ca be used if the curve does ot pass through the permitted regio of the widow evaluatio elemet. This allows preemptive termiatio of a joiig process i ultra-quick time if the two compoets get itertwied, protectig parts, tools or eve the etire system from damage. Techical chages reserved. All data sheets at burster praezisiosmesstechik gmbh & co kg Germay Talstr Gersbach Phoe ifo@burster.com

4 - 4 Process data The DIGIFORCE 9307 visualizes a comprehesive set of process data durig measuremet mode ad automatic productio mode. All relevat process data ca be trasferred to the cotroller or PC eviromet immediately after a measuremet. The user ca switch betwee the followig process widows: M1-1/2 Graph of Y1(X) or Y2(X) measuremet curve M1-3 Shared display of Y1/2(X) curves M2-1/2 Geeral display of Y1(X) or Y2(X) curves M3 Full-scree PASS/FAIL or smiley M4 Etry/exit data for evaluatio elemets M5 List of user-specific process values (up to 24 values) M6 Statistics o all graphical evaluatio elemets (tred/histogram) M7 Job sheet cotaiig process, worker ad parts data for trasfer to process-data acquisitio Each process widow displays the global header cotaiig iformatio o the selected measuremet program, the associated part quatities ad NOK figures, ad the global OK/NOK evaluatio. The status field o the right shows the evaluatio elemets that are active i the measuremet program ad their idividual results. Figure: A full-scree PASS/FAIL idicator gives operatig persoel a clear picture of the global OK/NOK evaluatio (OK/NOK smiley also possible). Figure: Process dialog showig sesor live values ad process values from the last measuremet. Sesor cofiguratio ad adjustmet Figure: Display showig the two measuremet curves Y1(X) ad Y2(X) The user ca choose which physical chaels A...F to assig to the measuremet graphs (X, Y1/2 coordiates) ad set the graph scale. This gives the user the freedom, for istace, to use a preferred moutig for a displacemet sesor, ad the set the scale to display/evaluate a decreasig or icreasig, positive or egative displacemet. There are several optios for adjustmet: adoptig the sesor specificatio from the burster TEDS electroic data sheet, maual iput from the sesor certificate data, or usig the teach-i process. Techical chages reserved. All data sheets at burster praezisiosmesstechik gmbh & co kg Germay Talstr Gersbach Phoe ifo@burster.com EN Figure: Statistics showig the frequecy ad distributio of NOK evaluatios. It is also possible to display a tred diagram ad histogram for the etry/exit data for each active graphical evaluatio elemet.

5 Fieldbus iterface A idepedet commuicatio processor provides the Fieldbus iterface via PROFIBUS, PROFINET, EtherCAT or EtherNet/IP. Cyclical realtime process data Process cotrol Retrieval of specific measuremet results Live values of the active sesors No cyclical parameter/admin/result data Trasfer of compoet/worker/job data for loggig Complete device cofiguratio Retrieval of large amouts of process ad curve data 32/128 measuremet programs The DIGIFORCE 9307 comes with the capability to maage up to 32 measuremet programs, which ca be rapidly selected via I/O, Fieldbus or keypad. Each measuremet program cotais the full cofiguratio of sesors, measuremet procedure ad evaluatios. The PC software DigiCotrol ca be used to dowload alterative DIGIFORCE 9307 firmware, which has the capability to hadle up to 128 measuremet programs. This firmware re-allocates the iteral memory so that up to 400 measuremet pairs/triplets ca be recorded. The itelliget samplig tool, with its facility to combie variables (Δt, ΔX ad ΔY), esures that these 400 value pairs are ormally sufficiet to reproduce ad evaluate a measuremet curve. - 5 Iteral measuremet curve memory I graphical setup mode, oe or more imported measuremet curves ca be used to cofigure the evaluatio elemets. This is still possible eve if the process requires a chage i measuremet program back at the setup stage. Up to te measuremet curves ca be saved i each measuremet program as a curve array, which the provides the basis for the evaluatios to be defied. I measuremet mode, this memory acts as a rig buffer, where the remaiig 50 measuremet curves are stored. The DigiCotrol PC software ca be used to retrieve ad aalyze these measuremets. User-defiable fuctio keys The fuctio keys F1...F4 below the display ca be assiged to various fuctios as required. The followig fuctios are available for selectio for example: browse measuremet screes, tare, start/stop measuremet, chage program, cofirm OK/ NOK evaluatios, sesor test. burster TEDS* DIGIFORCE 9307 uses burster TEDS (Trasducer Electroic Data Sheet) for automatic idetificatio of sesors coected to chaels A ad B. The istrumet reads the relevat sesor data from a EEPROM chip i the sesor coector ad uses this data to perform the ecessary chael cofiguratio automatically. The memory chip i the sesor coector is programmed as part of a service provided whe the sesor is first ordered or subsequetly calibrated. The burster TEDS feature is oly available for sesors that have a permaetly fitted coectig lead. * available for SN owards (Q2/2018) DigiCotrol PC software for DIGIFORCE 9307, 9310 ad 9311 The basic versio of this software, available free of charge, offers full device cofiguratio, data backups, ad export ad display of measuremet curves icludig all evaluatio results. A especially coveiet feature is the facility to defie graphical evaluatio elemets such as evelopes, widows, trapeziums ad thresholds from a set of curves measured for master or referece parts. Alteratively, pre-archived measuremets ca also be aalyzed to create ew evaluatios. I additio to these basic fuctios, the Plus versio (9307-P100) of the DigiCotrol PC software provides a automatic productio mode, allowig log measuremet data durig productio with clear parts referecig, for example. The resultat measuremet reports are ot oly available i the iteral program format, but ca also be ported ito the followig formats: ASCII raw data, EXCEL, PDF Prit ad SQL. Eve for sychroous processes ivolvig large amouts of data, loggig of measuremet data is optimized to achieve a ultra-short cycle time. For more complex tasks, the software also supports a additioal remote iterface, for istace for loadig a ew device cofiguratio or trasferrig compoet ames for measuremet-data loggig. Portig DIGIFORCE 9306 to DIGIFORCE 9307 DigiCotrol ca be used to create a DIGIFORCE 9307 device cofiguratio from a DIGIFORCE 9306 backup file. This is doe by importig the sesor ad evaluatio settigs ad selectig as close a cofiguratio as possible for the DIGIFORCE The just a few mior fial adjustmets ad settigs are eeded to resume productio uder process cotrol. Figure: The measuremet mode fuctio displays the curve ad status iformatio of the most recet measuremet. A multi-chael view is also possible. The correspodig log is automatically saved i the backgroud. Figure: A Data-log wizard provides filters for selectig ad displayig stored measuremet logs. A log pritout cotaiig compoet data, curve iformatio ad all evaluatio results ca be geerated for each idividual measuremet log. Techical chages reserved. All data sheets at burster praezisiosmesstechik gmbh & co kg Germay Talstr Gersbach Phoe ifo@burster.com

6 - 6 Geeral Techical Data Samplig rate: 10 khz Sigal samplig: X, Y, t i ay combiatio Measuremet curves: Y 1 (X) ad Y 2 (X) Digitalizatio: 16 bit Evaluatio time: 15 ms Measuremet programs: 32 (5,000 value pairs)* / 128 (400 value pairs) Power supply: VAC / Hz / typically 30 VA Delay i real-time limit sigals S1... S4: < 10 ms Operatig temperature rage: C Protectio class: IP30 / IP65 pael-mouted Display: 5,7 TFT LCD (640 x 480) Keypad: umerical, cofigurable fuctio keys * Factory-istalled device firmware. Firmware ca be chaged via PC software DigiCotrol. Compatible Sesors Flexible assigmet of physical chaels A... F to measuremet graphs (X/Y 1/2 coordiates) Chael A, B (strai gauge, potetiometer, process sigals) Strai gauge sesors Measuremet rages: ± mv/v Bridge resistace: 120 Ω... 5 kω Excitatio voltage: 2.5 V, 5 V, 10 V Excitatio curret: 35 ma or V Cut-off frequecy: ,000 Hz i discrete bads < 0.05 % 1 mv/v < 0.1 % < 1 mv/v Potetiometer, process sigals Excitatio voltage: 5 V / 10 V Trasmitter excitatio: 24 V, 150 ma Measuremet rages: ± 5 V, ± 10 V Excitatio curret: 100 ma max. Cut-off frequecy: ,000 Hz i discrete bads < 0,05 % F.S. Chaels A ad B support burster TEDS (SN owards) Chael C icremetal sesors, EDat 2.2, SSI Sigal: TTL / RS422, siusoidal voltage 1 V pp, siusoidal curret 11 µa Couter depth: 32 bit, ± 2EXP31 Cut-off frequecy: 1 MHz Referece mark: sigle, multipoit, distace-coded Absolute value: EDat 2.2, SSI, referece travel for distace ecodig Trasmitter excitatio: 5 V, 300 ma Chael D combied chael aalog/icremetal (optio) Strai gauge or process sigal: ± mv/v, ± 5 V, ± 10 V accordig to chaels A, B Icremetal iterface: TTL/RS422, Sius 1 V pp, Sius 11 µa Trasmitter excitatio: 5 V, 300 ma / 15 V, 200 ma Commuicatio Iterfaces Device parameterizatio, data backup (up/dowload), high-speed measuremet data loggig USB Slave port (model B) frot pael Data rate ~ 1 Mbaud RS232 D-SUB9 (PC coectig usig 1 : 1 cable 9900-K333) Format 8.1 Data rate 9600 baud Kbaud Etheret 10/100 Mbit, Wester socket (RJ45) Housig Combied desktop/pael-mouted housig (W x H x D): 205 x 160 x 240 [mm] Desktop versio: Frot pael (W x H): Frot pael cut-out (W x H): Weight: 4 rubberized feet (fitted as stadard) 220 x 175 [mm] 206 x 161 [mm] approx. 5 kg Accessories Fixig kit for pael moutig Model 9300-Z003 PC-Software DigiCotrol PC software for coveiet device cofiguratio icludig backup fuctio (upload/dowload), laboratory mode for maual readig ad aalysis of measuremet curves, ad data-log wizard with prit ad export fuctios. Supplied with the istrumet ad available free of charge from DigiCotrol PC software icludig USB data cable 9900-K349 Model 9307-P101 PC software DigiCotrol: PLUS versio icludig high-speed, i process loggig of measuremet data, Data-log wizard, ASCII raw data, EXCEL, PDF ad SQL export Model 9307-P100 Cables ad coectors Coectig cable for burster displacemet sesors series, legth 3 m Model A Coectig cable for torque sesor model 8651/8661 icl. agular measuremet to optio chael D, legth 3 m Model A Adapter cable (Y-type) for torque sesor model 8661 icl. agular measuremet to stadard chaels A/B ad C (oly to use together with model A-015xxxx) Model A Coectig plug for A, B ad E chael, D-SUB-9 (pack of 2 icluded with device) Model 9900-V209 Coectig plug for C ad D chael, D-SUB-15 Model 9900-V163 burster TEDS Coectig plug 9-pi, Mi-D icludig memory chip for the trasducer electroic data sheet Model 9900-V229 Fittig the coector icludig programmig of the electroic data sheet Chael E resistace measuremet (optio) Measuremet rages: 200 mω, 2 kω, 100 kω < 0.5 % 200 mω, 2 kω < 1 % 100 kω Chael F Piezoelectric (optio) Measuremet rages: 1 C... 1 µc i discrete bads Cut-off frequecy: ,000 Hz i discrete bads < 1 % F.S. Fieldbus Iterfaces I/O iterface Two parallel PLC ports to EN , 24 VDC, opto-isolated 23 iputs D-SUB-37 (male) 31 outputs, of which 23 cofigurable, maximum load I MAX 200 ma, D-SUB-37 (female) PROFIBUS (optio) D-SUB9 Bau drate Commuicatio protocol max. 12 MBaud cyclic service DP-V0 acyclic service DP-V1 Adjustmet of a complete measurig chai Adjustmet ad scalig of up to 3 sesors icludig test certificate 93ABG Order Code DIGIFORCE V Aalog optio Stadard Piezo iterface X 1 X X Combied chael aalog / INCR (D) ad resistace measuremet (E) X 2 X X Fieldbus optio EtherCAT X X X 1 PROFIBUS (DP-V0/DP-V1) X X X 2 PROFINET X X X 3 EtherNet/IP X X X 4 PROFINET, EtherNet/IP, EtherCAT (optio) 2 port wester-socket (RJ45) Commuicatio protocol cyclical realtime process data o cyclical parameter data Techical chages reserved. All data sheets at burster praezisiosmesstechik gmbh & co kg Germay Talstr Gersbach Phoe ifo@burster.com EN