KOMTRAX Instruction Manual

Transcription

1 KOMTRAX Instruction Manual (For North America and Southeast Asia, the 1 st edition) Issued on January 31, 2015 Komatsu Industries Corp

2 Contents 1.1. Formation of KOMTRAX Necessary device and environment Exemption clauses Basic Instructions Internet connection Login Logout Explanation of Screen and Operation Explanation of screen Definition of Time and Times on display Current Production Production History Machine Library Machine Running Status Specified Period Running Status Daily Report 1 (report output: part number control, list type) Daily Report 2 (report output: part number control, band graph type) Maintenance Inspection Information Event History Modify Machine Information Other Functions Search Criteria Sort CSV Download Modify user information Change Password Operator Administration Contents Added with Upgraded Software Version for Machine Current Production Machine Running Status Specified Period Running Status Daily Report 1 (report output: part number control, list type) Daily Report 2 (report output: part number control, band graph type)

3 Introduction The KOMTRAX is a system that operation status of the machine is automatically collected and can be seen and controlled through Internet Formation of KOMTRAX The KOMTRAX System consists as shown below: (1) The KOMTRAX terminal continuously watches and measures conditions of the machine on which it is incorporated. (2) The measured data are sent out to the KOMTRAX Server (at Komatsu Computer Center) via portable and wireless transmission channel every one hour. (3) The data are accumulated and aggregated on the KOMTRAX Server. (4) Operation conditions of the machine can be taken out in the form of tables and graphs through the Internet. Portable and wireless transmission KOMATSU Client's machine External antenna KOMTRAX Server Control panel Internet KOMTRAX Terminal Client's PC Client's company * The PC for WEB browsing and Internet environment have to be prepared by the clients

4 1.2. Necessary device and environment PC for Internet connection It is recommended to browse with the resolution of (XGA) or higher. Internet connection channel Internet Explorer (Version 7.0 or later is recommended.) Google Chrome (Version or later is recommended.) Software for PDF files (Adobe Reader etc.) The Adobe Reader can be downloaded free from the below link. Above articles are requested to prepare by the client Exemption clauses Following items are out of our obligation with this system: (1) We do not guarantee accuracy of the information provided by us. (2) The system may be interrupted for maintenance without prior notice. (3) Obtaining information may be impossible or unstable depending on the location of the machine since the portable and wireless transmission channel is used. (4) The KOMTRAX WEB screens and software shall be subject to change without prior notice for improvement. (5) The contents of this manual shall be subject to change without prior notice. No part of this manual shall be reproduced

5 2. Basic Instructions 2.1. Internet connection nection Start the WEB browser and enter the below URL to the address bar. (Enter all letters starting with Login By connecting to the address above, the scree as shown below shall be displayed. Enter user ID and password, and press the "System Starts" button. (Note that upper-and lowercase letters of user ID and password have to be distinguished.) Remarks: The user ID and initial password shall be written on a separate sheet. If you have lost, contact the "Address for inquiry" described in the section above. By checking the [Record User name and Environment.], entering the user ID and password can be omitted from the next time. Use [Language] and [Date format] as they are Logout The logout screen shall appear by clicking the [Exit] link on the left of any screen. And you shall be automatically logged out if you don't operate for 30 minutes. (* You are not logged out automatically on some screens because of automatic screen refreshment.) - 5 -

6 3. Explanation of Screen and Operation 3.1. Explanation of screen The typical KOMTRAX screen is divided into the following three areas. 2 Search Criteria area 3Shortcut Menu area 1Information Display area 1 Information Display area (bottom right of the screen) Information on various machine statuses shall display. Contents are different depending on each screen. See explanation of each screen for details. 2 Search Criteria area (top right of the screen) When too much information is displayed in the Information Display area to find objective information, it can be limited by using here. See "Retrieval of Information" for using this area. (No Search Criteria area is provided on some screens.) 3 Shortcut Menu area a (left of the screen) Links to an objective screen are located. Three categories of [Machine Overview], [Machine Monitoring] and [User Administration] are provided in addition to [Exit]. [Machine Overview]: function of displaying information of all belonging machines. Click "Machine Library" for moving to the machine list screen. [Machine Monitoring]: function of displaying information of a particular machine. Enter Machine Model and Serial Number (omissible) and click the link for the screen you want to see. [User Administration]: Your password can be changed here. [Exit]: to terminate KOMTRAX to move to the Logout screen

7 4. Definition of Time and Times on display Display of time or duration Power-on Duration: hours during which the control power of the machine is turned ON. Operation Time: hours during which the machine is operating Production Duration: hours during which the machine is operating in the production mode. Idle Time: hours during which the machine is not operating in the production mode. Set-up Duration: hours during which power is turned ON but not for production (hours during which the machine is either operating or stopping with power-on but not in the production mode) Summed Power-on Hours: total of power-on hours since KOMTRAX was installed Summed Operation Hours: total of operation hours since KOMTRAX was installed Display of Times Operation Times Type of machine PRESS MACHINE PRESS BRAKE TWISTER, LEASER PROCESSING MACHINE and FIBER LASER PROCESSING MACHINE GATLING PRESS CENTER Description Number of stroking Number of pressurizing Number of piercing Number of punching Number of Production Times: number of operation times with selecting the production mode Summed Operation Times: total of operation times since KOMTRAX was installed Summed Production Times: total of production times since KOMTRAX was installed - 7 -

8 5. Current Production Operation statuses and abnormalities of all the machines in the plant are integrated and displayed. The display can work as an operation bulletin to grasp current status of the machines in the plant (as below). Description of displayed information Inspection: Information only of the machine(s) checked here is displayed. <How to use> 1 Click to check the box on the left column of the list. 2 Click to check the box for "Display machines with check only" in the Search Criteria area. 3 Press the "Search" button. * Abnormal: Indication turns ON if an abnormality arises with the machine. Alarm: red indication; Caution: yellow indication Maintenance: Indication turns on if parts replacement is required with the machine. Replace now: red indication; Replace soon: yellow indication Installation Site: Enter location of the machine. (Any description to your convenience is allowed.) Machine Name: machine number, line name etc. (any description to your convenience) * Order No.: Upgrading your production machine is required to display. * Product Identification No. Name: Upgrading your production machine is required to display. * Operator: Upgrading your production machine is required to display. Running Status: Blue bands are displayed with production hours. Running Rate: percentage of "production hours" out of power-on hours Production Duration: hours when the machine produces * Real-time display: Screens are updated every 5 minutes

9 Production Count Type of machine PRESS MACHINE PRESS BRAKE TWISTER LEASER PROCESSING MACHINE FIBER LASER PROCESSING MACHINE GATLING PRESS CENTER * With selecting the production mode Description Number of stroking Number of pressurizing Number of piercing ON Number of punching Power-on Duration: Hours during which the control power of the machine is turned ON. Software Version: Software version of KOMTRAX terminal shall be displayed. Country: Country where the machine is operating shall be displayed

10 6. Production History The history of the operation bulletin can be displayed by selecting the date (as shown below). Description of displayed information Inspection: Information only of the machine(s) checked here is displayed. <How to use> 1 Put a check by clicking the check box on the left column of the list. 2 Check the box for "Display machines with check only" in the Search Criteria area. 3 Press the "Search" button. Installation Site: Enter location of the machine. (any description to your convenience) Machine Name: Serial number, line name etc. (any description to your convenience) Running Status: Blue bands are displayed with production hours. Running Rate: percentage of "production hours" out of power-on hours Production Duration: hours when the machine produces Production Count: Type of machine PRESS MACHINE PRESS BRAKE TWISTER LEASER PROCESSING MACHINE FIBER LASER PROCESSING MACHINE GATLING PRESS CENTER * with selecting the production mode Power-on Duration: hours during which the control power of the machine is turned ON Software Version: Software version of KOMTRAX terminal shall be displayed. Country: Country where the machine is operating shall be displayed. Description Number of stroking Number of pressurizing Number of piercing ON Number of punching

11 7. Machine Library The list of your machines that comply with the KOMTRAX is displayed (as shown below). Check: Information only of the machine(s) checked here is displayed. Check: Information only of the machine(s) checked here is displayed. <How to use> 1 Put a check by clicking the check box on the left column of the list. 2 Click to check the box for "Display machines with check only" in the Search Criteria area. 3 Press the "Search" button. * Abnormal: Indication turns on if an abnormality arises with the machine. Alarm: red indication; Caution: yellow indication Maintenance: Indication turns on if parts replacement is required with the machine. Replace now: red indication; Replace soon: yellow indication Machine Type: name of major grouping of the machine (press, laser etc.) Machine Model; Model Type: brand and model of the machine Serial Number: of the machine Installation Site: location of the machine (any description to your convenience) Machine Name: machine number, line name etc. (any description to your convenience) Cumulative Production Duration: total of operation hours since KOMTRAX was installed Cumulative Production Count: total of operation times since KOMTRAX was installed Last Communication Time: last time when the machine communicated with the Server Production Date: of the machine Maker: name of the machine manufacturer Country: country where the machine is located * Real-time display: screen updated every 5 minutes

12 8. Machine Running Status Operation status of a specified date for a specified machine can be seen (as shown below). Since initial display information will be of the day, enter the date and time you want to check into the "Appoint Period" columns. Graph 1 Numerical value 1 Numerical value 2 Graph 2 Description of displayed information Graph 1: Band graph Power-on: Green bands show the duration of power-on time. Production: Blue bands show the duration of production time. (Status that machine is operating with control power ON and production mode ON) Abnormal: Red bands show duration of abnormal time. Graph 2: bar graph and line graph SPM (strokes/min) (blue column graph): production times per one minute; average of production counts for 6 minutes Production Count for the Day (red line graph): total production times of the day Numerical value 1: percentage of each hours out of power-on hours Numerical value 2: operation rate and total production count Running Rate of the Day: percentage of "production hours" out of power-on hours Production Count for the Day: total production times during appointed period

13 9. Specified Period Running Status Operation status in a specified period is displayed in the unit of day. You can know production status of every day. 1Collection period and display time Description of displayed information 1 Period Appointment: Appoint collection period and display time. 2 Number of Days of Period: Number of days in the collection period is displayed. 3 Number of Days of Operation: Number of days when the power (to the KOMTRAX) was turned ON in the collection period is displayed. 4 Production Duration; 5 Production Count; 6 Power-on Duration Average calculation: Total value during the operation days is divided by the operation days. Total calculation: Total hours or times during the operation days are displayed. 7 Date: of the collected days. Days of no power-on are not displayed. 8 Running Status: Operation status of each day is displayed in one minute unit. Minutes when the machine is running are displayed in blue. Abnormal minutes are in red. 9 Running Rate: against specified hours of the day 10 Production Duration; 11 Production Times; 12Power-on Duration: Totals of specified hours and production times during the collected days

14 10. Daily Report 1 (report output: part number control, list type) Operation status of the appointed machine is output in a report form. A feature is that memorandums on the job can be input directly from the PC. The output can be stored as a PDF file, or be printed out (A4 size is recommended) Description of displayed information 1 Period Appointment: Enter dates for output. 2 Time Appointment: Enter start time and end time for the graph output. (It will be convenient to enter start time and end time of your working hour.) 3 Update: of the screen 4 Company Name, Department and Name: Enter person in charge for the report. (Omissible) 5 Operation Contents: Enter comments per every one hour. (Omissible) 6 Remarks: are displayed in the comment column on the bottom of the report. (Omissible) 7 PDF Output: Click for displaying the PDF output screen. 8 Data Updating: Click for updating the operation data. * Previous contents for 2 Time Appointment and 4 Company Name, Department and Name are displayed as initial values next time

15 11. Daily Report 2 (report output: part number control, band graph type) Operation status of the appointed machine is output as a report form. The output can be stored as a PDF file, or be printed out (A4 size is recommended) Description of displayed information 1 Period Appointment: Enter dates for output. 2 Time Appointment: Enter start time and end time for the graph output. (It will be convenient to enter start time and end time for the work.) 3 Update: of the screen 4 Company Name, Department and Name: Enter person in charge for the report. (Omissible) 5 Bar graph for number of production times: production times per one minute; average of for 6 minutes 6 Line graph for total production count: cumulative production count for the day 7 Operation rate of the day: percentage of "production hours" out of power-on hours 8 Sum of operation count of the day: aggregate production count during appointed period 9 Band graph of operation: Power-on hours, production hours and abnormal time are displayed. 10 Remarks: are displayed in the comment column on the bottom of the report. (Omissible) 11 PDF Output: Click for displaying the PDF output screen. 12 Date Updating: Click for updating the operation data. * Previous contents for 2 Time Appointment and 4 Company Name, Department and Name are displayed as initial values next time

16 12. Maintenance Inspection Information This is the screen for maintenance (inspection and replacement) of your machines. You can control the next maintenance on hours and times considering the previous date. Press the corresponding "reset" button after maintenance Description of displayed information 1 Maintenance Items: check points on the machine 2 Specify Interval: recommended maintenance intervals 3 Current Value: elapsed hours till now 4 Last Maintenance Date: previous date of pressing the reset button 5 Remaining Interval: hours or times before the next maintenance 6 Reset: Press this button after maintenance. 7 History: for displaying resetting history

17 8 Reset Time: Enter the date of maintenance. The maintenance information is processed based on this date. 9 User Original Maintenance Item: Items you want to check and control can be added and changed. You can handle them the same as other maintenance items. 10 Machine and Company Information: Location, Company, Person in charge, Telephone Number, Fax Number and for the machine are displayed. The location is linked with the Google map. Note) Figures in items 2, 3 and 5 above with the unit "H" are "residual intervals in hours and with "times" are "residual intervals in times." Note) See the maintenance manual of individual machine for concrete maintenance contents for each item

18 13. Event History Occurred and occurring alarms, warnings and interruptions are displayed By appointing the collection period and pressing the "Update" button, the alarms and errors in the period are displayed as a list. Description of displayed information 1 Code: See each machine manual for concrete contents. 2 Sort: "Warning " or "Alarm" is displayed. 3 Text: The message made with the alarm or error is displayed. 4 Time of Occurrence: The date and time when the error occurred are displayed. 5Times of Occurrence during the Period: Number of the same errors occurred in the collection period is displayed. 6 Machine and Company Information: Location, Company, Person in charge, Telephone Number, Fax Number and for the machine are displayed. (These items are registered on the "Modify Machine Information" screen.) The location is linked with the Google map. Note) Obtaining and displaying the Error Code are not possible with some machines

19 14. Modify Machine Information The name and information of the machine can be set. Use here for your convenience Modify Machine Information Enter information and press the "Modify" button. 1 Installation Site: Enter location and section of the machine. (Plant name, line name, section name etc.) 2 Machine Name: Enter a common name of the equipment. (Line number, product name etc.) 3 Representative: Enter person in charge for the machine. 4 Telephone Number: of the person in charge 5 Fax Number: of the person in charge 6 of the person in charge Modify Period/Times of Replacement Date (offset setting) Replacing intervals of the maintenance parts can be modified. Use here for your convenience. Enter offset values and press the "Modify" button

20 15. Other Functions Search Criteria Information to display can be limited by entering letters to narrow down into the "Search Criteria" columns and pressing the "Search" button. Only the information to comply with the entered letters is displayed. Search Criteria Machine Sort and Maker: Select from the pull-down menu. Installation Site and Machine Name: Enter a key word in the text box. (partial-match search) Machine Model, Model Type and Serial Number: Enter a key word in the text box. (complete-match search) * Wild card (*) search is also possible Sort By clicking the item description, the list is sorted in ascending order with the column of the item. The list order changes in the order of (ascending descending no sorting ascending) on each clicking CSV Download On the screen where [CSV Download] button is provided, the equivalent data with the displayed data can be downloaded as a CSV text file. Since the dialog box for saving the file shall be displayed by pressing the [CSV Download] button, save it at your appropriate location. The saved file can be used with miscellaneous spreadsheet and database programs. (See the manual of the software for using the file.)

21 15.4. Modify user information Your contact address and daily report in one-screen display can be changed. If your telephone and fax numbers are changed, please modify them since we use them for communications with you Change Password You can change your password Current Password: Input your password before modification. 2 New Password: Enter your new password. 3 Confirm Password: Enter the same New Password again. The password has to be in 6 through 20 characters. Note that upper-and lowercase letters are distinguished. Changing your password periodically is recommended

22 16. Operator Administration This is the setting screen for combining the "operator code" on the machine with the name displayed on the WEB. The name is displayed as the operator name on the daily reports. Note) Registration and modification are possible, but deletion is not possible

23 17. Contents Added with Upgraded Software Version for Machine Current Production Data 1 Graph 1 Graph 1 Data 1: Order No., Part No. and Operator have been added. * Order No.: Currently producing Order No. with the machine is displayed. * Product Identification No. and Name: Currently producing Part No. with the machine is displayed. * Operator: Currently working operator with the machine is displayed. Graph 1: Running statuses are expressed in different colors. Running Rate: Percentages of "Production hours, "Idle hours and "Set-up hours out of Power-on hours are graphically displayed. Production hours: blue; Idle hours: yellow; Set-up hours: orange * Real-time display: * Real-time display: screen updated every 5 minutes

24 17.2. Machine Running Status Graph ① Graph ② New feature Table ① Table ② Table ①: Production control table per each part number has been added. It will support your production control by contrasting the production plans with the production results. PRESS MACHINE and PRESS BRAKE

25 TWISTER, GATLING PRESS CENTER and LEASER PROCESSING MACHINE FIBER LASER PROCESSING MACHINE New feature Table 2: Consumables control table has been added. TWISTER By displaying the utilization rates on replacing, wrong usage can be avoided. And such machine troubles as an abnormal torch can be judged. Graph 1: Band graph for idle and set-up hours has been added. By adding the idle hours and set-up hours, more details of production status can be seen. Idle: Idle hours are displayed in yellow. (Status that machine is not producing with control power ON and production mode ON) Set-up: Set-up hours are displayed in orange. (Status that machine is operating with control power ON and production mode OFF) Graph 2: Graph for periodical monitoring has been added. FIBER LASER PROCESSING MACHINE Visualizing gas and power consumption helps save running costs. New feature

26 17.3. Specified Period Running Status Numerical value 1 Graph 1 Numerical value 1: Average/total values for idle time and set-up duration have been added. Average calculation: Total value during the operation days is divided by the operation days. Total calculation: Total hours or times during the operation days are displayed. Graph 1: Running statuses are expressed in different colors. Running Rate: Percentages of "Production" hours, "Idle" hours and "Set-up" hours out of "Power-on" hours are graphically displayed. Production hours: blue; Idle hours: yellow; Set-up hours: orange

27 17.4. Daily Report 1 (report output: part number control, list type) Graph 1 Graph 2 New feature Graph 3 Table 1 Table 2 Graph 1: Band graph for idle and set-up hours has been added. By adding the idle hours and set-up hours, more details of production status can be seen. Idle: Idle hours are displayed in yellow. (Status that machine is not producing with control power ON and production mode ON) Set-up: Set-up time is displayed in orange. (Status that machine is operating with control power ON and production mode OFF) Graph 2: Gas consumption has been added to the graph for periodical monitoring. FIBER LASER PROCESSING MACHINE Visualizing gas consumption helps save running costs

28 Graph 3: Power consumption has been added to the graph for periodical monitoring. FIBER LASER PROCESSING MACHINE Visualizing power consumption helps save running costs. Table 1: Production control table per each part number has been added. It will support you with your production control: You can check the machine, person, part number, times and hours of production. And you can contrast the production plans and the production results. Table 2: Consumables control table has been added. TWISTER By displaying the utilization rates on replacing, wrong usage can be avoided. And such machine troubles as an abnormal torch can be judged. See [17.2. Machine Running Status] section for details

29 17.5. Daily Report 2 (report output: part number control, band graph type) Graph 1 Graph 2 New feature Graph 3 Graph 4 Graph 1: Band graph for idle and set-up hours has been added. By adding the idle hours and set-up hours, more details of production status can be described on the daily report. Idle: Idle hours are displayed in yellow. (Status that machine is not producing with control power ON and production mode ON) Set-up: Set-up time is displayed in orange. (Status that machine is operating with control power ON and production mode OFF) Graph 2: Gas consumption has been added to the graph for periodical monitoring. FIBER LASER PROCESSING MACHINE Making gas consumption visualize can help save running costs. Graph 3: Power consumption has been added to the graph for periodical monitoring

30 FIBER LASER PROCESSING MACHINE Visualizing power consumption helps save running costs. Graph 4: Band graph of production control per each part number has been added. Since production hours for each part number are displayed with the band graph, you can see the machine, person, part number, times and hours at a glance