Project Book for. Tightening System. Document Name.: FGA_ET_PROJECT_BOOK_V2_4.DOCX. Version 2.4. Release Date: Nov2014

Transcription

1 Project Book for Tightening System Document Name.: FGA_ET_PROJECT_BOOK_V2_4.DOCX Version 2.4 Release Date: Nov2014 This is a common document valid within Fiat Group Automobiles SpA - Engine & Trasmission Revised Date:04/12/2014 Page No.: 1 of 65

2 DOCUMENT MANAGEMENT INFORMATION The controlled version of this document is stored on the Bosch Rexroth website. with automatical re-link to Web address reference is available on the following Fiat Powertrain web site: Any printed copy is an uncontrolled copy. The user shall verify with the web site that he/she is in fact using the appropriate version of the specification for the specific project he/she is working on. Any questions or comments with respect to this specification should be directed to the project engineer for the specific project in question. Revised Date:04/12/2014 Page No.: 2 of 65

3 Revision History Revision Date Version No. Description Section Affected Revised By 10/10/ Issue of documents by Mr. M. Rust ( BRC/PAT12 ) DC-IA/SFA12 Rust M. 12/06/ FPT Version C635 PROJECT - DCIT/SFT Cattaneo F. 03/03/ FPT Version C635 PROJECT DCIT/SFT (HW configuration) Crespi D. 07/04/ Index adjustment Crespi D. 26/05/ Elimination Racks IP20 and reintroduction BG2 & BG5 Crespi D. 02/04/ Changed generation components from 300 to system 350 Crespi D. 02/04/ Introduction of pneumatics, linear guides and transfer systems. Crespi D. 07/05/ New Bosch Rexroth 'FIAT AUTOMOTIVE homepage URL Page 4 Crespi D. 07/05/ Contacts P / C 2 Crespi D. 07/05/ New LT modules and Overview Components P / C 3.5 Crespi D. 30/05/ Elimination pneumatics, linear guides and transfer systems. Chapters Crespi D. 30/05/ Improvement of the Controls planning chapter C 4.5 Crespi D. 30/05/ Part List Added C 5.2 Crespi D. 19/09/ New FCA EMEA POWERTRAIN logo All DCIT/SPF Crespi D 19/09/ Document renamed Page. 1 Crespi D. 19/09/ Chapters numeration compliant to the new master form All Crespi D. 26/11/ New FGA E&T Logos All Crespi D. Revised Date:04/12/2014 Page No.: 3 of 65

4 CONTENTS 1. INTRODUCTION ACCEPTANCE PROCEDURE CONTACT & SUPPORT PRODUCT OVERVIEW - TIGHTENING SYSTEM STATIONARY TOOL SELECTION Size 2: Spindle Bearing ( Nm ) Size 2: Offset Output Drive ( Nm ) Size 2: Angle Head ( Nm ) Size 2: Feed Outpud Drive ( Nm ) Size 3: Spindle Bearing ( Nm ) Size 3: Offset Output Drive ( Nm ) Size 3: Offset Output Drive with Integrated Measurement Transducer ( Nm ) Size 3: Angle Head ( Nm ) Size 3: Feed Output Drive ( Nm ) Size 4: Spindle Bearing ( Nm ) Size 4: Offset Output Drive ( Nm ) Size 4: Offset Output Drive with Integrated Measurement Trasducer ( Nm ) Size 4: Angle Head ( Nm ) Size 4: Feed Output Drive ( Nm ) Size 5: Spindle Bearing ( Nm ) Size 5: Offset Output Drive ( Nm ) SELECT CABLING FOR STATIONARY SPINDLES ERGOSPIN TOOL SELECTION Right Angle Tooling Inline and Custom Output Tooling Pistol Grip Tooling SELECT CABLING FOR HAND TOOLS CONTROLS PLANNING SB356: 5/6 Channel System Box Tightening Controllers and Servo Amplifiers Basic System Architecture (SB356) Control And Power Electronics - Components Overview VM350 Power Supply Module Revised Date:04/12/2014 Page No.: 4 of 65

5 3.5.6 SE352 and SE352M Control Units LTS350D and LTE350D Servo Amplifiers KE350 and KE350G IL Communication Units Interface Modules IM24V IMpdp IMpnio BS350 Software for ErgoSpin and Stationary spindles (version from 2.300) Extension accessories Suspension accessories Socket trays ADDITIONAL INFORMATION WORLD WIDE CONTACT & SUPPORT PART LIST DATA AND I/O SIGNALS INTERFACE Revised Date:04/12/2014 Page No.: 5 of 65

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7 1. INTRODUCTION This document contains product information to be used for the selection of components for FCA EMEA POWERTRAIN programs. This document provides a basic guide to selecting the correct type of tightening system for the correct application. It also provides the necessary contact information to assist in application engineering, program management review, and stocking locations for ease of purchasing. All information contained in this document is super ceded by the requirements of the FCA EMEA POWERTRAIN Global Specification. A current, and accurate, copy of the specification can be downloaded from the following web addresses: Revised Date:04/12/2014 Page No.: 7 of 65

8 1.1 ACCEPTANCE PROCEDURE Scalone Biagio Revised Date:04/12/2014 Page No.: 8 of 65

9 2. CONTACT & SUPPORT FGA E&T EUROPE - ITALY Address Corso Settembrini, Turin (Italy) Website Project Contact Mauro Falletti Company FGA SpA Engine & Trasmission Office Mobile Fax mauro.falletti@fcagroup.com Bosch Rexroth S.p.A. COMMERCIAL EUROPE - ITALY TECHNICAL Address Strada Statale Padana Superiore 11, Cernusco sul Naviglio (MI) Italy Via Olanda Gallarate (VA) Italy Website Project Contact Biagio Scalone Machinery Tools & Automotive Sales Cluster Manager & FIAT Group Global Account Manager Fabrizio Cattaneo Project Leader and Engineering Application Manager Company Bosch Rexroth S.p.A. Bosch Rexroth S.p.A. Office Mobile Fax biagio.scalone@boschrexroth.it fabrizio.cattaneo@boschrexroth.it Revised Date:04/12/2014 Page No.: 9 of 65

10 3. PRODUCT OVERVIEW - TIGHTENING SYSTEM 350 A fast market demands flexible production systems. The new Bosch Tightening System 350 has been developed for a market that is fast moving and flexible. Shorter product cycles and changing tasks require a flexible technology with straightforward controls. Controllers and tightening spindles are modular to ensure optimal construction using standard components. Whether you are using automated tools or hand tools the modular design concept allows for common components that are interchangeable, limiting the amount of spares required. A communication unit (KE) coordinates this system, for up to 40 tightening channels. The interface oriented PC software BS350 makes programming clear and easy. Servo amplifiers (LT), controller (SE) and communication unit (KE) form a powerful unit in the system card rack (BT) with compact slide-in modules. As alternatives to the system card rack (BT), the CS351 system box is available for the inclusion of a single tightening channel and the SB356 system box for the inclusion of up to six tightening channels. This modularity ensures easy system installation. A single connector cable suffices to connect the tightening controller with the servo amplifier. This cable provides both power supply and communications. Revised Date:04/12/2014 Page No.: 10 of 65

11 3.1 STATIONARY TOOL SELECTION Tools should selected such that they are loaded to approximately 80% of Max torque. This allows ample ability for removal of tightened fasteners or detection of process irregularities. Example, 10Nm target torque should have a tool with at least 12Nm of torque Select the proper tool configuration to meet the application: First choose the output type. Sliding, Offset or Right Angle Second, choose the motor-transducer-gearbox combination to achieve the desired torque/speed. o o In the 10Nm target example, we would recommend: EC303-3GE27-3DMC017-G2A152 (motor - gearbox - transducer - output drive) In general, sliding spindles are the preferred choice for fixtured applications. Offsets can be used as an alternate if the bolt pattern is too tight for sliding spindles. If there is no room above the part for an inline tool, a right angle attachment can be used to orient the tool perpendicularly to the applications. Transverse gearboxes can also be used to reduce the overall length of the tool. Special Notes: Some offsets and angle heads include an extra gear ratio that increases the torque capacity of the spindle. Gearbox selection affects torque and RPM. Motor torque/speed characteristics can be found inside our catalog. Revised Date:04/12/2014 Page No.: 11 of 65

12 Size 2: Spindle Bearing ( Nm ) Use only with FCA EMEA POWERTRAIN permission Revised Date:04/12/2014 Page No.: 12 of 65

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14 Size 2: Offset Output Drive ( Nm ) Use only with FGA E&T permission Revised Date:04/12/2014 Page No.: 14 of 65

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16 Size 2: Angle Head ( Nm ) Use only with FGA E&T permission Revised Date:04/12/2014 Page No.: 16 of 65

17 Revised Date:04/12/2014 Page No.: 17 of 65

18 Size 2: Feed Outpud Drive ( Nm ) Use only with FGA E&T permission Revised Date:04/12/2014 Page No.: 18 of 65

19 Revised Date:04/12/2014 Page No.: 19 of 65

20 Size 3: Spindle Bearing ( Nm ) Revised Date:04/12/2014 Page No.: 20 of 65

21 Revised Date:04/12/2014 Page No.: 21 of 65

22 Size 3: Offset Output Drive ( Nm ) Revised Date:04/12/2014 Page No.: 22 of 65

23 Revised Date:04/12/2014 Page No.: 23 of 65

24 Size 3: Offset Output Drive with Integrated Measurement Transducer ( Nm ) Revised Date:04/12/2014 Page No.: 24 of 65

25 Revised Date:04/12/2014 Page No.: 25 of 65

26 Size 3: Angle Head ( Nm ) Revised Date:04/12/2014 Page No.: 26 of 65

27 Revised Date:04/12/2014 Page No.: 27 of 65

28 Size 3: Feed Output Drive ( Nm ) Revised Date:04/12/2014 Page No.: 28 of 65

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30 Size 4: Spindle Bearing ( Nm ) Revised Date:04/12/2014 Page No.: 30 of 65

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32 Size 4: Offset Output Drive ( Nm ) Revised Date:04/12/2014 Page No.: 32 of 65

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34 Size 4: Offset Output Drive with Integrated Measurement Trasducer ( Nm ) Revised Date:04/12/2014 Page No.: 34 of 65

35 Revised Date:04/12/2014 Page No.: 35 of 65

36 Size 4: Angle Head ( Nm ) Revised Date:04/12/2014 Page No.: 36 of 65

37 Revised Date:04/12/2014 Page No.: 37 of 65

38 Size 4: Feed Output Drive ( Nm ) Revised Date:04/12/2014 Page No.: 38 of 65

39 Revised Date:04/12/2014 Page No.: 39 of 65

40 Size 5: Spindle Bearing ( Nm ) Use only with FGA E&T permission Revised Date:04/12/2014 Page No.: 40 of 65

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42 Size 5: Offset Output Drive ( Nm ) Use only with FGA E&T permission Revised Date:04/12/2014 Page No.: 42 of 65

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44 3.2 SELECT CABLING FOR STATIONARY SPINDLES Revised Date:04/12/2014 Page No.: 44 of 65

45 Revised Date:04/12/2014 Page No.: 45 of 65

46 3.3 ERGOSPIN TOOL SELECTION Right Angle Tooling First determine the type of output required (GripLine or SlimLine) GripLine has a protective rubberized head and socket cover to protect the operator. SlimLine does not have cover, but has a larger range of torques. Second, select the tool based on torque / speed required based on the chart below Tools should selected such that they are loaded to approximately 80% of max torque. This allows ample ability for removal of tightened fasteners or detection of process irregularities. Example, 10Nm target torque should have a tool with at least 12Nm of torque. Special outputs for Crow Feet and Tube Nut applications can be found in Inline and Custom Tooling. ErgoSpin VarioLine models interface with Spindle Outputs for Inline applications using interface below. Revised Date:04/12/2014 Page No.: 46 of 65

47 3.3.2 Inline and Custom Output Tooling Tools based on torque / speed required based on the chart below Tools should selected such that they are loaded to approximately 80% of max torque. This allows ample ability for removal of tightened fasteners or detection of process irregularities. Example, 10Nm target torque should have a tool with at least 12Nm of torque. ErgoSpin VarioLine models interface with Spindle Outputs for Inline applications using interface below. Below are Special Interfaces for Custom Applications. Revised Date:04/12/2014 Page No.: 47 of 65

48 3.3.3 Pistol Grip Tooling Tools based on torque / speed required based on the chart below Tools should selected such that they are loaded to approximately 80% of max torque. This allows ample ability for removal of tightened fasteners or detection of process irregularities. Example, 10Nm target torque should have a tool with at least 12Nm of torque. Availible upon request are Special gearbox attachments for the ESM025HT for Custom Applications. Revised Date:04/12/2014 Page No.: 48 of 65

49 3.4 SELECT CABLING FOR HAND TOOLS Standard cabling is AL005 (5 meters in length). Revised Date:04/12/2014 Page No.: 49 of 65

50 3.5 CONTROLS PLANNING SB356: 5/6 Channel System Box The SB356 has the capability of up to five (5) spindles (Stationary or ErgoSpin) plus a KE350 communication module. Additional system boxes support up to six (6) spindles (stationary or ErgoSpin). For multiple System Boxes, a NKS350 is needed for the first System Box and NK350 s are needed for subsequent System Boxes for communication between all channels. NKL002 s are the cables necessary for linking the System Boxes. For systems supporting up to 40 spindles, configurations up to 16 boxes can be connected with a maximum network length of 150m. The voltage requirements are 380~500 VAC 3 phase, 2.5KVA per system box. Nema 12 / IP54 protection (SB356) An external disconnect and thermal protection to 45C are integrated directly within the SB356 box. Enclosures can be mounted on a table or hung vertically by an included DIN rail Tightening Controllers and Servo Amplifiers Each Tool needs a Servo Amplifier: - ErgoSpin Tools use the LTE350D - Size Spindles use LTS350D Up to two (2) controllers can be controlled by the Tightening Controller, SE352. Below is a guide for setting up Servo Amplifiers (LT s) to System Boxes. Dummy Plates, BP352 s cover unfilled (SE and LT) slots. Dummy Plates, BP351 s cover unfilled (LT s) slots. Revised Date:04/12/2014 Page No.: 50 of 65

51 The SB356 can accommodate the following tools, based on a maximum output current of 140A to the servo system: Total power consumption (tightening spindles + Ergospins) 140A Basic System Architecture (SB356) Revised Date:04/12/2014 Page No.: 51 of 65

52 3.5.4 Control And Power Electronics - Components Overview DO NOT USE THESE Use only with FGA E&T permission DO NOT USE IT DO NOT USE THESE Use only with FGA E&T permission DO NOT USE IT DO NOT USE IT DO NOT USE IT Revised Date:04/12/2014 Page No.: 52 of 65

53 DO NOT USE THESE Revised Date:04/12/2014 Page No.: 53 of 65

54 3.5.5 VM350 Power Supply Module The VM350 power supply module is used to supply power to all the slots in the BT356 card rack or in the SB356 system box. One VM350 is required for each system box. There is a 24 V interface (X1S1) on the front side of the VM350. This interface offers an external 24 V supply, with which the control power supplies of KE, SE and LT may be maintained when, under certain motor stop conditions, the main power supply is disconnected. Additionally the VM350 incorporates a motor stop interface and a 24 V supply for external consumers SE352 and SE352M Control Units The control unit controls and monitors the tightening process of up to two independent tightening channels per control unit. It also carries out the system diagnosis and monitors all individual components of a tightening channel. Tightening processes and rework strategies are simply and flexibly programmed via the BS350 operating program. Automatic recognition of individual components enables fast and secure start-up. Use in multi-channel tightening systems requires a KE350/KE350G IL communication unit. The SE352M control unit has one free slot. An IM24V interface module can be inserted in this slot for communication with superior controllers. On delivery, the SE352M control unit slot is sealed with a cover. Revised Date:04/12/2014 Page No.: 54 of 65

55 3.5.7 LTS350D and LTE350D Servo Amplifiers The digital servo amplifier controls the EC motor. The control parameters are transmitted digitally from the SE control unit to the LT servo amplifier. The integrated motor contactor is an important component for the motor stop function Servo Amplifiers for all the Tightening Spindle sizes Servo Amplifiers for all the ErgoSpin KE350 and KE350G IL Communication Units. The KE350 and KE350G IL communication units coordinate the individual control units and organize the interfaces with external systems (e.g. PLC or central computer). The internal system communication with the control units occurs via a standard bus system. One serial interface and three free slots are available to connect external systems. Via these, the tightening system can be controlled and, if necessary, data can be exchanged. Various interface modules available for controlling and data communication. On delivery, the slots in the KE350 and KE350G IL communication units are closed off with covers. Integrated logic: Logic is already integrated into the KE350G IL. It can be flexibly programmed in compliance with IEC and gives the user countless automation options for the entire tightening process. Revised Date:04/12/2014 Page No.: 55 of 65

56 3.5.9 Interface Modules IM24V The IM24V interface module makes it possible to control the tightening system via a 24 V interface or to output 24 V status signals from the tightening system. The IM24V interface module is inserted in a slot on the KE350 or KE350G IL communication unit, the SE352M control unit or the CS351 Compact System. The module provides 10 inputs and 13 outputs. The outputs are short circuit-proof and protected against reverse polarity. The IM24V complies with DIN IMpdp The IMpdp interface module connects the tightening system to the PROFIBUS DP field bus. The tightening system is then controlled by the superior control system, e.g. the PLC function. Data can simply be transferred via the I/O level. The IMpdp is inserted into the A slot of the KE350 communication unit or the CS351 Compact System. The module has a 400 byte address space on the field bus. Depending on the requirements of the tightening system, this address space can be adjusted from 16 I / 16 O points (2 bytes) to 512 I / 512 O points (128 bytes) as well as a 0-64-bit ID code and bytes of data. The logical configuration of the control signals is set using the BS350 operating system IMpnio The IMpnio is a complete PROFINET IO interface with IO device function (slave). It includes all the analog and digital components of a powerful PROFINET IO interface connection. Data can simply be transferred via the I/O level. The module complies with the real-time classification (RT) of the PROFIBUS user organization. Thanks to the standardized hardware and software interface to the KE350, KE350G IL and the CS351 Compact System, it can be easily exchanged with other field bus modules of the same type. Revised Date:04/12/2014 Page No.: 56 of 65

57 BS350 Software for ErgoSpin and Stationary spindles (version from 2.300) Convenient programming and analyzing: with the PC via the network or with the laptop directly on-site. This provides users with a flexible working environment. The BS350 operating system can be installed using the System Stick on any PC via USB. This allows users to generate tightening programs as well as analyze tightening cases and conduct system tests. The user interface with menus and clear icons can be operated intuitively. System requirements - Pentium or compatible microprocessors with at least 500 MHz, a minimum of 128 MB RAM and at least 100 MB of free hard drive memory; x 768 graphics resolution. - Connection to tightening system: USB or Ethernet. - OS: Windows XP; Windows Vista; Windows 7; Windows 764bit. Revised Date:04/12/2014 Page No.: 57 of 65

58 Extension accessories These ergonomic accessories are used to decrease the resultance reaction force on the operator arm Suspension accessories To hang the ErgoSpin from a spring balancer a Swivel Suspension Bail, ESMH1 or ESMH2 provide a clamp in the center of the ErgoSpin to allow the operate to still maintain a range of motion. If a vertical orientation is better suited for an application, a Vertical Bail that attaches to the the end of the ErgoSpin just prior to the cable connection Socket trays The System 350 offers socket trays for use with hand tools. These trays are offered in either four (4) or eight (8) position configurations. Each position includes a removable insert which can be machined to the unique properties of the socket to be used. It also includes two indicators per socket for the operator. One indicates socket presence, and the other can be used by a PLC host to indicate which socket to select (worker guidance). Each position is terminated in a 12mm micro din connector. This provides a standard interface which can be coupled to a remote I/O block quickly and cost effectively. Revised Date:04/12/2014 Page No.: 58 of 65

59 4. ADDITIONAL INFORMATION 4.1. WORLD WIDE CONTACT & SUPPORT NAFTA Global Contact Commercial TECHNICAL Title Rodney Rusk, NAFTA Referent Daniel Cejka Applications Engineering Mgr Company Bosch Rexroth Corporation Bosch Rexroth Corporation Address 2730 Research Drive Rochester Hills, MI USA 2730 Research Drive Rochester Hills, MI USA Phone +1(248) (248) Website Fax +1(248) (248) address FGA E&T Local Contact Leads for CHINA (DC Tightening Controls, DCC) Commercial TECHNICAL Title Pan Yujun Chen Guoping Company Address Shanghai Bosch Rexroth Hydraulics & Automation Ltd. 333 Fuquan (N.) Road Shanghai P.R. Shanghai Bosch Rexroth Hydraulics & Automation Ltd. 333 Fuquan (N.) Road Shanghai P.R. Phone +86 (021) (021) Website Fax address Revised Date:04/12/2014 Page No.: 59 of 65

60 FGA E&T Local Contact Leads for INDIA (DC Tightening Controls, DCC) Commercial TECHNICAL Title Parag Mahaddalkar Adinath More Company Bosch Rexroth (India) Limited Bosch Rexroth (India) Limited Address 18/4-19/4 - Hadapsar Industrial Estate Pune Maharashtra India 18/4-19/4 - Hadapsar Industrial Estate Pune Maharashtra India Phone +91 (20) (20) Website Fax address Parag.M@boschrexroth.co.in Adinath.More@boschrexroth.co.in FGA E&T Local Contact Leads for BRAZIL (DC Tightening Controls, DCC) Commercial TECHNICAL Title Alessandro Gaiotto, LATAM Referent Rogerio Anraku Company Bosch Rexroth AG Bosch Rexroth AG Address Av. Tégula Unidades 13/14 Bairro Ponte Alta Atibaia SP Av. Tégula Unidades 13/14 Bairro Ponte Alta Atibaia SP Phone +55(11) (11) Website Fax +55(11) (11) address alessandro.gaiotto@boschrexroth.com.br rogerio.anraku@boschrexroth.com.br Revised Date:04/12/2014 Page No.: 60 of 65

61 FGA E&T Local Contact Leads for POLAND (DC Tightening Controls, DCC) Commercial TECHNICAL Title Marek Gaj Marek Gaj Company Bosch Rexroth AG Bosch Rexroth AG Address Jutrzenki 102/ Warszawa Jutrzenki 102/ Warszawa Phone Website Fax +48 (22) (22) address FGA E&T Contact Leads for SERBIA (DC Tightening Controls, DCC) Commercial TECHNICAL Title Company Bosch Rexroth AG Bosch Rexroth AG Address Mihajla Pupina 10Z/I, PP Novi Beograd Mihajla Pupina 10Z/I, PP Novi Beograd Phone Website Fax address Revised Date:04/12/2014 Page No.: 61 of 65

62 Technical Support - Afterhours NORTH AMERICA EUROPE ASIA PACIFIC Phone 800-REX-ROTH +49 (9352) Eaven Wang Company Bosch Rexroth Corporation Bosch Rexroth AG Shanghai Bosch Rexroth Hydraulics & Automation Ltd. Address 2730 Research Drive Rochester Hills, MI Fornsbacher Strasse 92 Murrhardt, Germany 333 Fuquan (N.) Road Shanghai P.R. Website Fax +1(248) (711) (021) Project and Sales Coordination Bosch Rexroth (DC Tightening Controls) NORTH AMERICA EUROPE ASIA PACIFIC Contact Jeff Buehler Goetz Kemmler Michael Rust Company Bosch Rexroth Corporation Bosch Rexroth AG Bosch Rexroth AG Address 2730 Research Drive Rochester Hills, MI USA Fornsbacher Strasse 92 Murrhardt, Germany Fornsbacher Strasse 92 Murrhardt, Germany Phone +1(248) (7192) (7192) Website Fax +1(248) address jeff.buehler@boschrexroth-us.com goetz.kemmler@boschrexroth.de michael.rust@boschrexroth.de Revised Date:04/12/2014 Page No.: 62 of 65

63 4.2. PART LIST Refer to attached excel file FGA_ET _Part List _v x.x Revised Date:04/12/2014 Page No.: 63 of 65

64 4.3. DATA AND I/O SIGNALS INTERFACE Refer to attached excel file FGA_ET_Data IO Signals Interface _v x.x Revised Date:04/12/2014 Page No.: 64 of 65

65 Revised Date:04/12/2014 Page No.: 65 of 65