Toolinspect. Operating Instructions of the Tool Monitoring System. via 3 - functionkeys

Transcription

1 Operating Instructions of the Tool Monitoring System Toolinspect via 3 - functionkeys Maierhöfen, This document is for information purposes only. Technical modifications reserved. Version:

2 Table of contents: 1.) Features ) System description ) Operating instructions Operation and visualisation Operation and visualisation Displays Types of monitoring Status displays: Operation number Offset number / program number Additional functions Data export functions ) Adaptive control (optional) Interface of the AC control: ACR relearn: ACR evaluation: ) Tool wear monitoring (optional) Alarms Operating instructions and visualisation tool wear Operating instructions and visualisation tool wear ) Machine data acquisition MDA (optional) MDA Activated via Toolinspect program: Graphical representation: Functional description of the main MDA screen Selecting the time period (main MDA screen): Schematic representation: Filtering machine data: Functional description of MDA (second menu page): MDA export functions: ) Notes on alarm messages and recommended courses of action Visualisation message: No connection possible Diagnosis of hardware malfunctions ) Safecard (optional) Exchanging a Toolinspect box with Safecard ) M-functions and programming notes for Machinery manufacturer ) Technical Data Environmental conditions Features Connection to CNC control Visualisation Warranty ) Sales ) Appendix

3 1.) Features The Toolinspect device is used to monitor tools on metal-cutting machines. The data necessary for this task are normally transmitted to the device by a CNC control via a Profibus-DP interface. The monitoring strategy is automatically selected by the integrated software, according to the tool or machining process. The necessary parameters are determined and entered individually for one machine type by the machine tool manufacturer. No changes or adjustments are then necessary in the NC program or via the visualisation interface. 2.) System description Overview: Siemens 840D with Toolinspect TI-DP1 The hardware communicates with the CNC control via Profibus-DP or also via analogue signals. The software of the visualisation in the control panel of the control is connected to the hardware via a TCP/IP interface. On each channel* (max. of 4 channels per module) 3 torque values or force values and the path of a feed axis can be monitored. For example: Path = Torque 1 = Torque 2 = Torque 3 = Z-axis Spindle torque Feed force of the Z-axis Feed force of the X-axis *Channel means that with a single box, four simultaneous processes can be monitored. For example, a four-spindle machining centre or four stations of a rotary indexing machine. 2

4 3.) Operating instructions The system adapts fully automatically to various operating states of the machine and automatically selects the appropriate monitoring strategy. It is operated using a visualisation interface, which is usually activated by means of a soft key in the CNC control. This visualisation interface closes automatically when it is hidden by another software program and loses the focus, e.g. it is overlaid by the HMI interface of the CNC control. The tool inspection functionality is implemented in the Toolinspect hardware box, which means that the visualisation is offered on an optional basis only. Alternatively, the system can also be operated, with minor limitations, using the function buttons of the CNC control. This variant is for control systems which have no Windows operating system. Before an operation is actually triggered, a message box appears with a short description of the function: Example: Operation is usually channel-specific. That is, a function can only be triggered in the currentlyselected channel. However, it is also possible to merge channels via an entry in the Toolinspect.ini file (MultiChannel=0). In this case, a single function button on a multi-spindle machining centre can act on all channels. Program-specific data and ascertained limits are stored on the CF card in the hardware box. If a new program number is specified (mostly via an H-function in the NC program), either the system learns the new program or loads the data record, if one exists, from the CF card. Note Monitoring is deactivated while the status of the system is Learning. To switch to the Monitoring status, an NC program run must be performed without interruption and without reducing the feed velocity with the override switch (which must be on 100%). Attention In the first cycles after "Relearn" or Reset limits or after long machine standstill periods, the limits readjust. Monitoring of very small tools is only 100 % reliable after approx. 5 machine cycles. If the override switch is not on 100%, then monitoring is not active! 3

5 3.1 Operation and visualisation 1 Reset limits button This button resets the system for the active program (the program which is displayed in the interface under Prog. no.:) to the original values and relearn is carried out. Machining operations which have been increased via the Increase limits button are reset. Relearn button This button is used to carry out relearn. The program-specific data (increased limits) are not reset. The limits readjust to the actual values in the following machine cycles. This function is required when changes have been made in the CNC program or for other reasons all monitoring limits should be recalculated. Increase limits button If Toolinspect repeatedly generates an incorrect message during the same operation, the Increase limits function can be used to permanently raise the switching threshold that generates the fault message. Increasing the limit value only affects the limit value for this specific cut and not for the tool as a whole. The increase is indicated graphically by a yellow marking of the limit or in the tool table. If the alarm is still generated in spite of the increase, the button can be activated again. In the case of limits 1-3, this leads to deactivation (orange colour). The breaking limit can be increased any number of times and will not be deactivated. Help button This button is used to call the Help function. A second menu page is activated. It is described in section "Extra Functions". 4

6 3.2 Operation and visualisation 2 << Channel button This button is used to switch over (decrement) the active channel, e.g. from channel 2 to channel 1. Channel >> button This button is used to switch over (increment) the active channel, e.g. from channel 1 to channel 2. Wear button This button is used to visualise wear monitoring. This is an option. If the option is not activated, a demo screen appears here. End button This button ends the visualisation. Monitoring remains active. Displays In the left-hand section of the screen, displays show the increased and deactivated limits in yellow or orange. In the middle of this display, an alarm of the relevant limit is shown in red. (Also see the section Displays and status messages ) 5

7 3.3 Displays Breakage monitoring is always active and cannot be deactivated. The limit monitors (limits 1 to 3) can be deactivated using the M-functions in the NC program. Limits deactivated by the CNC program are displayed in blue. In the active state, the limit display can assume the colour bright-grey (internally deactivated by system) or dark-grey (active). Note With an active time axis, Limit 2 is always displayed in bright-grey. RED: An alarm has occurred. YELLOW: The limit has been permanently raised following and alarm. ORANGE: The limit has been deactivated (automatically or by repeated manual increasing). This status is only possible with Limits Types of monitoring a.) Breakage monitoring: A red line over the machining curve is the breaking limit. If the break line is coloured purple then the dynamic range of the limit calculation has been exhausted. This state occurs with heavily fluctuating machining curves. 6

8 Alarm example, screen 1 Break alarm (torque is too high) The blue line describes the last actual value that caused the alarm. (A machine stop has been triggered, which also interrupted recording of the actual curve.) The green line describes the course of the reference torque (good machining curve) Alarm example, screen 1 Break alarm with limit alarm (torque is too high, though the break line is not exceeded) V onwards The blue line describes the last actual value that caused the alarm. The green line describes the course of the reference torque (good machining curve) b.) Monitoring of Limit 1, Limit 2 and Limit 3: Limits 1-3 complement the breaking limit. A message in these areas can also be interpreted as Tool missing or Insufficient torque. In some machining processes, depending on the size of the spindle, the material of the work piece and above all the size of the tool, no torque increase is visible because the machining curve runs horizontally. In this case, it is physically impossible to monitor the relevant processes for Insufficient torque using Limits 1-3. Limit 3 is automatically deactivated and coloured orange as a reminder. Monitoring for tool breakage remains active. 7

9 Alarm example, screen 2 Limit 2 alarm (torque is too low) The blue line describes the last actual value that caused the alarm. (A machine stop has been triggered, which also interrupted recording of the actual curve.) The green line describes the course of the reference torque (good machining curve) c.) Curve monitoring Limit 1 (optional) (software version V onwards) This monitoring technique monitors the curve. This is especially useful for turning and milling processes. Alarm example screen 3 Limit 1 alarm, Curve monitoring (the curve has changed shape) The blue line describes the last actual value that caused the alarm. The green line describes the course of the reference torque (good machining curve) d.) Automatic wear monitoring: (optional) (software version V onwards) If significant wear is detected automatically by the system, an alarm is output, the yellow line is shown and the alarm is indicated by the wear status. This type of monitoring is independent of the wear monitoring option and does not have to be activated manually. If false alarms occur in relation to wear, the sensitivity can be reduced here too by pressing the Increase limit button. 8

10 Note This alarm sets the Alarm Limit 2 bit and the Wear pre-alarm bit. This type of monitoring can be switched off by deactivating Limit 1 monitoring. Alarm example, screen 4 Automatic wear alarm If the torque rises significantly during three consecutive machining operations, the following alarm is triggered. e.) NC program monitoring: (software version V onwards) If the NC program has been changed during the process and the Relearn key has not been pressed, the change is detected automatically during the machine s running time and this alarm is generated. In this case, an alarm Limit 1, 2, 3 is also triggered, which stops the machine. Alarm example, screen 5 NC program has been changed 9

11 3.5 Status displays: The status line shows the current state of the tool monitoring system. Learning Adjusting limits Monitoring Reworking Synchronisation Discard learning No connection The system is taking in the active NC program; monitoring is not active. (1 machine cycle at 100%) If the override potentiometer is changed (not equal to 100%) during the learning process, the learning process is triggered again for the next machine cycle. The monitoring limits are adapted to the current process. Monitoring is active. The monitoring limits have been adjusted to the optimal values. The machine is not running at 100% (override potentiometer). Monitoring is not active. Monitoring has been deactivated due to reworking or a program interruption. With the next tool change, monitoring will be reactivated and the status changed to monitoring. The NC program sequence has changed compared to the sequence learned. (The number or sequence of cuts has changed.) Also see section 3.4 part e.) The network connection to the Toolinspect module is disconnected. 10

12 3.6 Operation number Toolinspect only monitors definite feed movements of the machine. Accordingly, rapid movements (G0) of the machine are not monitored. The operation number is required so that all operations can be allocated their own limit values. Every individual operation receives an operation number. The operation number is generated automatically and is shown on the main page of the monitoring software for the current machining operation. All monitored tools are entered in the tool table (see section on opening the table) along with their associated cuts (S1, S2, S3, ). The first cut of the first tool activated receives the operation number 101. If the same tool has another cut, the operation number is incremented to 102. When the tool is changed, the operation number is set to 201 (2 nd monitored tool, first cut). When a tool is activated again, no new line is created in the table. (E.g.: T112, operation number 301) Operations with permanently-increased limit values are highlighted yellow in the tool table (e.g. operation no. 201). The active cut is always displayed on the main page of the Toolinspect software. Should the current operation exhibit increased limit values, the range which has thus been increased (break, limit 1, limit 2 or limit 3) is marked in yellow. Example: 3.7 Offset number / program number With the offset number, which is typically transferred to the Toolinspect system using an H- function, it is possible to differentiate between NC programs which alternate continually during operation, e.g., clamping table A and clamping table B. Following an offset switch, the operation number starts at 101 again. Note The program number describes a work piece and may not change during an automatic production run. At every program change the monitoring limits are temporarily increased. In this case, the monitoring limits would not be properly adjusted. 11

13 3.8 Additional functions The F1 (help) button in the Toolinspect program opens the second menu page. F1 <Alarms Alarms and status displays are shown here. Other data export functions are displayed. See section Data export functions F2 Tool Table Example: This table lists all monitored tools in the order in which the tools were activated. You can navigate in the table using the arrow keys. In the columns, Increase limits temp. and Relearn tool, you can select a tool using the Select or Space button. Increasing limits in tool table The increase limits function temporarily increases the limit values of the selected tool. Afterwards the limits adjust themselves again to the active process. This function is used to recalculate the limits for a specific tool. 12

14 Relearn tool in tool table (version V onwards) In the Relearn tool column, it is possible to select individual tools for which the machining operations should be relearned. For the selected tools, there is no monitoring for the duration of one machine cycle. In the subsequent machine cycles the limits are adjusted once more to the actual values. This function should be used in case of false alarms (limit1, limit2 or limit3) after a tool change. Note "Increasing the limits in the tool table," Activation of the function and learn new tool in the tool table will be made on a hook in the corresponding table field graphically indicated. This status message will remain pending until the S1 (section1) in this row of the table was processed by the machine. It should be noted that before the signal "the beginning of the program" must be detected. I.e. if this function during the course of the machine is triggered, possibly the function until the next machine cycle will run finished. in the table are several offset values with the same tool listed, the hook is deleted only in the row that has already been processed. 13

15 Resetting limits in the tool table (software version V onwards) Available with version or later, limits which have been permanently increased can be reset for specific cuts. A precondition is that the limit has either been increased (coloured yellow) or deactivated due to repeated increases (coloured orange). When you select by clicking or using the arrow keys and then press the Select or the Space key, the following message is generated: Confirm your input by pressing the Input or Enter key, and the function is activated. If the selected limit has not been increased the following message appears: 14

16 Tool table grouping (software version V onwards) A channel grouping can be configured in the Toolinspect.ini file, which is located in the installation directory of the Toolinspect software. The default setting is tool table=0000 In the section [mode] Tooltable=1100 (Channels 1 and 2 are grouped) When a tool table grouping has been activated via the Toolinspect.ini file, this is indicated in the area highlighted in orange. All control options (Increase limits temp., Relearn tool) are then performed simultaneously in the grouped channels, and there is no need to change channels. Export XLS (software version V onwards) With the Export XLS button, the current tool table for a specific channel can be exported to an Excel file. This file is stored in the relevant folder among Toolinspect\Data1 to 4. Example: T- No. Offset Siemens- Designation Duplo Increase limits temp. Relearn tool Relearn ACR Evaluation ACR S1 S2 S3 S4 S5 S6 S7 S

17 F3 Increase all This button causes all limits of all tools to be recalculated (increased temporarily). This function is used, for example, to readjust machining forces which have been altered during a batch change for castings. This function should be given preference over relearning, because a somewhat restricted monitoring is still carried out. F4 Increase tool This button causes the limits for the current tool to be recalculated (increased temporarily). It is comparable to the Increase all function, with the difference that it only applies to the current tool. This function is equivalent to the Increase limits temp. function in the tool table. 16

18 F6 Language This button is used to select the various languages of the interface. The language is selected via the arrow buttons and with the Enter button. 3.9 Data export functions F1 <Alarms opens the Data export screen from the Help screen In version V and later, it is possible, for diagnostic purposes, to export data directly from Toolinspect to a USB stick or drive. These data can also be used for process optimisation. MCU offers an Excel-based software program for these evaluations. If a drive (e.g. USB stick) is connected by USB it is selected automatically. Press the ENTER key to export the data to a Toolinspect folder (in this case F:\Toolinspect\). You can create a new folder using the Create new folder button (select by clicking or with arrow keys). Use the Tab key to switch to the graphic window, and you can select a sub-folder using the arrow keys. 17

19 F2 Export data This button exports the data in the original file format. This function can be performed while the machine is still running. F3 Export Zip This button first compresses the data in a ZIP file and then copies it to the drive. This is the standard export function. This function can be performed while the machine is still running. F4 CF card Zip With this button, you can export the current parameter settings, which are stored on the CF card in the Toolinspect box. This function should only be performed when the machine is at standstill. When you press the CF card Zip soft key, the following message box appears. Expert note: A machine-specific name can be preset in the Toolinspect.ini file, which is located in the installation directory of the Toolinspect software. The default setting is Toolinspect. In the section [Debug] ExportFolder=Toolinspect In this way, it is possible to store the data for several machines in different folders on the USB stick, without having to create new folders manually. 18

20 4.) Adaptive control (optional) Adaptive control was developed from the same point of view as the monitoring of tool breakage and wear. The optimum control values are determined and optimised automatically, without parameterisation by the operator. Monitoring of tool breakage and wear is still possible for controlled tools. 4.1 Interface of the AC control: The Toolinspect main page always shows the current cut and the process time saving or increase in %. 100% (YELLOW) means no change or control not active for this cut. 110% (RED) means machining is slowed by 10%. 95% (GREEN) means a reduction in machining time of 5%. 19

21 When the option Adaptive control is activated, there are 2 additional columns in the tool table. 4.2 ACR relearn: The AC control for the selected tool is reset by clicking on the panel. This function is used shortly before the end of the service life of a tool to reassess and optimise machining. (In this way, the torque can be measured with a blunt tool, as a result of which it may be possible to achieve an even greater reduction in cycle time with a new tool). 4.3 ACR evaluation: An evaluation is carried out here for a specific tool. The display refers to all cuts which are AC controlled with the relevant tool. The colour is displayed in this panel with a reduction in machining time (GREEN) and with an increase (RED). The font colour of the individual cuts indicates whether the machining time for a cut has decreased (GREEN) or increased (RED). 20

22 5.) Tool wear monitoring (optional) The NC program currently running in the machine is scanned by Toolinspect and the torque values or axis forces of all the tools it contains are stored internally. The tools in the NC program are displayed in grey in bar form after approx. 10 machine cycles with a value of 100 %. 5.1 Alarms Pre-alarm: is issued 10% before the wear limit is reached. This is shown in the graph with an orange pre-alarm LED. The tool number is shown in the display below it. Alarm: is issued when the wear limit is reached. This is shown in the graph with a red alarm LED. The tool number is shown in the display below it. The relevant tool column is coloured red. 21

23 5.2 Operating instructions and visualisation tool wear 1 Limit + button The Limit + button is used to increase the wear limit, i.e. the actual value decreases graphically (colour of tool bar light green for actual value / dark green for wear range) Tool page >> button This button is used to select a further tool page, if available. Tool >> button This button is used to select a tool for operation within the page displayed. The selected tool is highlighted in colour. Help button This button is used to call the Help function. Monitoring remains active. 22

24 5.3 Operating instructions and visualisation tool wear 2 Limit button The "Limit -" button is used to reduce the wear limit, i.e. the actual value increases graphically (colour of tool bar light green for actual value / dark green for wear range). If the actual value exceeds the limit value, this is displayed graphically in red and a wear alarm is generated. Activate button Tool changes are carried out in the machine as normal. Toolinspect analyses the differences between worn and new tools and displays this in light and dark grey. A light and dark grey bar can be activated with the Activate button. (colour of tool bar light green for actual value / dark green for wear range) When the actual value reaches the wear value last reached, an alarm is triggered. Deactivate button Wear monitoring can be deactivated for a selected tool with the Deactivate button. All limits are deleted and the bar is displayed 100% in light grey. Back button This button is used to return to the breakage visualisation. 23

25 6.) Machine data acquisition MDA (optional) The NC-integrated interface of the Toolinspect system enables the presentation and evaluation of every type of production data, machine reports and error codes in graphical or schematic form. The evaluation of operating states, error codes and downtimes increases the transparency of your production processes and thus helps to increase the productivity of your production system. 6.1 MDA Activated via Toolinspect program: The MDA option is opened from the Toolinspect program. Press Help (F1) on the main screen of the Toolinspect program and you reach the second menu page (see screenshot). The MDA interface is loaded via the relevant soft key. Note: If the MDA option is not activated, the MDA soft key will not be shown. 24

26 6.2 Graphical representation: The three main machine states (production, downtime and malfunction) are represented in a bar graph as percentages of the selected period of time. Production Downtime Malfunction 25

27 6.3 Functional description of the main MDA screen The order of the list can be changed with the keys Chronological and Number (see below for a detailed description). The soft keys Today, 24h, 48h and 96h are used to select the time period to be displayed in the bar graph and in the table (see below for a detailed description). Help This button opens the second menu bar and the help function. All the functions which can be activated on the second menu page are described briefly here. 26

28 6.4 Selecting the time period (main MDA screen): The soft keys Today, 24h, 48h and 96h (F2 F5) are used to select the time to be displayed in the bar graph and in the table. The button for the selected time period is highlighted in blue. Today - Time period: today s date, 00:00 until now. 24 h - Time period: yesterday, 00:00-24:00, (not including today) 48 H Time period: yesterday & day before yesterday, 2x 00:00-24:00, (not including today) 96 h Time period: the last four days, 4x 00:00-24:00, (not including today) Changing the order of the list (main MDA screen): The order of the list can be changed with the soft keys F6 (chronolog.) and F7 (number). The criterion according to which the machine messages are sorted can be seen from the blue highlighting of key F6 (chronolog.) or key F7 (number). If chronological is selected, all machine messages are sorted and displayed in chronological order. The Number key sorts the machine messages by frequency. The machine message which occurs most frequently is displayed in the first line. Second menu page MDA: 27

29 6.5 Schematic representation: The MDA table is shown to the right of the bar graph. It lists all relevant messages, alarms and fault texts output by the machine. The MDA table is divided into 5 columns: Event Shows what type of machine message has occurred. Channel Number Tool no. Tool name Note: MDA table: Shows the number of the monitoring channel. Shows how often this message has occurred in the selected time period. The tool number is shown here (with Siemens controls this is the internal Siemens T-number). This column gives the tool name from the tool management system (only available with Siemens controls). In order for this name to be read from the tool management system, the option DDEActive=true must be configured in the Toolinspect.ini file. The machine messages are sorted by frequency. List order Number is selected. If the list order is changed to chronological, additional columns are shown in the MDA table (date, time, type and program number). 28

30 6.6 Filtering machine data: It is possible to search for specific machine messages within a selected time period. Example: To filter the machine data, a search term must be entered in the first line of the MDA table. (In this example the search term is limit.) All machine messages containing the search term are displayed. 29

31 6.7 Functional description of MDA (second menu page): Delete database This soft key deletes all machine messages in the database. When the next machine message is output, the database starts to fill up again. (Max. size of database: 4 days.) Export function These soft keys activate various export functions. The machine message database can be saved in Excel and CSV files. (See below for a detailed description of the individual functions.) Help Displays the help text and moves the cursor to the text field. You can scroll through the short descriptions of individual soft keys using the arrow keys (Up / Down). The export functions and deletion of the database require a password. The password is visa. The Excel worksheet function is only available in later versions of Toolinspect. On the second MDA menu page, the F7 soft key has not been allocated a function. 30

32 6.8 MDA export functions: The export functions can be used to output all machine messages of the selected time period from the machine message database into Excel or CSV (.txt) files. The maximum time period is 96 hours (4 days). Machine messages older than 96 hours are deleted from the database and cannot be exported. There are three different data export options: Export CSV Export Excel Export Expert (F4) (F3) (F2) If the Export CSV or Export Excel function is selected, a window appears in which the storage location for the Excel or txt file can be specified. The Export folder in Toolinspect is proposed as standard. The file name of the Excel or txt file indicates the sort order (chronological or number), the selected time period, and the date and time. 31

33 Export CSV: Export Excel: 32

34 Export Expert: The export Expert function also lists all the start and end pulses of the individual machine messages. As with the other export functions the sort order and the relevant time period are also displayed. The Expert mode can be confusing for normal users. They are therefore advised to use the Excel or CSV export function. 33

35 7.) Notes on alarm messages and recommended courses of action Alarm message Possible cause Course of action Tool breakage alarm Though the tool is not broken - Fluctuating stock allowance - Built-up edge on the tool's cutting edge - Hard foreign matter, e.g. in cast parts - Interruption to cooling or greasing of tool One-off alarm message Press Delete fault button and continue processing or restart NC program. Continue operation with NC start and temporarily reduced override. Repeated alarm message Press the Increase limits button. Press Delete fault button and continue processing or restart NC program. Continue operation with NC start and temporarily reduced override. Several consecutive alarm messages Press the Relearn button. Press Delete fault button and continue processing or restart NC program. Continue operation with NC start and temporarily reduced override. Limit 1-3 message (missing) - Double operation - Pre-machining too big - Material fluctuations - Less material allowance with cast parts - New tool One-off alarm message Press Delete fault button and continue processing or restart NC program. Continue operation with NC start and temporarily reduced override. Repeated alarm message Press the Increase limits button. Press Delete fault button and continue processing or restart NC program. Continue operation with NC start and temporarily reduced override. Several consecutive alarm messages Press the Relearn button. Press Delete fault button and continue processing or restart NC program. Continue operation with NC start and temporarily reduced override. 34

36 7.1 Visualisation message: No connection possible: The following window appears automatically when the Toolinspect program is started, if the workstation cannot establish a connection to the Toolinspect module. Possible causes: No crossed network cable IP addresses have been changed. No 24V power supply to the Toolinspect module See also the MCU installation manual. 7.2 Diagnosis of hardware malfunctions The status of the green LEDs provides information for diagnosing hardware malfunctions. LED Power If this LED is illuminated, it means a 24V power supply is applied to the green plug. LED DP1 This LED is illuminated for about 15 seconds during boot-up. This LED blinks when the Profibus connection to the bus master (PLC control) is established. LED TCP/IP This LED is illuminated for about 15 seconds during boot-up after the DP1 LED has gone out. This LED blinks when the visualisation software communicates with the box. Note Permanent illumination of the DP1 LED or the TCP/IP LED indicates a hardware malfunction in the box. If the DP1 and TCP/IP LEDs are not illuminated for about 15 seconds after the 24V power supply is switched on or after the green supply plug is temporarily connected and disconnected, this also indicates a hardware malfunction. 35

37 8. ) Safecard (optional) All the current parameters (Profibus addresses, limits, etc.) are always stored on the Safecard (CF card inserted in the left side of the housing of the Toolinspect box). When the system is booted up, the data is transferred from the Safecard to the internal flash memory of the Toolinspect CPU. When the flash card is empty, the data in the Toolinspect box is automatically copied to the flash card. The CF card must be formatted with FAT Exchanging a Toolinspect box with Safecard Remove the Safecard from the defective Toolinspect box Insert the Safecard in the new box Connect the 24V power supply to the new box Allow about 30 seconds for the boot-up (LED DP1 blinks) Disconnect the power supply again for about 5 seconds Connect the power supply again. Expert note It is not necessary for the box to be disconnected again, if the IP address of the replacement box is already configured correctly. (The standard address of MCU is ) 36

38 9.) M-functions and programming notes for Machinery manufacturer. Please see the documentation on your machine! 37

39 10.) Technical Data 10.1 Environmental conditions Power supply 20-30V DC (optional 6-60V DC) Temperature range 0-60 C No condensation water and humidity up to 50% Power consumption approx.15w 10.2 Features Unlimited number of tools Automatic, self-teaching monitoring system with intelligent monitoring strategy. Tool monitoring standard (breakage / missing) Optional extension for tool wear monitoring Optional extension for AC control (adaptive feed control) Optional extension for MDA (machine data acquisition) Integrated data backup via Safecard (CF card) 4 channels with the option of analysing three torque or force values on each channel Path or position analysis for feed axes Scanning rate< 5ms 10.3 Connection to CNC control Standard communication via Profibus DP up to 12 Mbaud Extendable up to 6 Toolinspect modules on a Profibus DP interface. As an alternative to the Profibus DP interface, analog torque signals 0-10V, +/-10V, 0-20mA and digital 24V I/O can be analysed Visualisation 10.5 Warranty Visualisation can be carried out on the control panel or on an external PC/notebook. Minimum system requirements: 200MHz ; 256MB RAM; 50MB free hard disk memory; operating systems: Windows 98, Windows NT4.0,Windows 2000, WindowsXP, Windows Vista, Windows 7 Connection via a network interface protocol: TCP/IP 24 months warranty on hardware after delivery WARNING The place of performance is the place of manufacture If the hardware is operated in environmental conditions other than those specified, all warranty claims for damage to the equipment are null and void! 38

40 11.) Sales Should you have any questions please contact: MCU GmbH & Co. KG Global sales office Max-Eyth-Str. 51 D Winnenden Germany Telephone +49 (0) Fax. +49 (0) Internet : The images of the controls and drive modules provided are protected by copyright of the individual control manufacturers. All information provided is without guarantee of correctness. Subject to change! Date of issue: Updated: Version: MCU GmbH & Co. KG, Maierhöfen 39

41 12.) Appendix 40