Torque Validation Module (TVM)

Transcription

1 Assembly Technologies Torque Validation Module (TVM) User Manual Important Safeguards For your protection, please read these instructions completely, and keep this manual for future reference. Carefully observe and comply with all warnings, cautions and instructions placed on the equipment or described in this manual THE STANLEY WORKS, ALL RIGHTS RESERVED

2 User Manual Contents Getting Started Warnings and Cautions Qualified Personnel Safe Use Introduction Electrical Safety Specifications...2 Installation and Use Easy Set-up and Maintenance Adjusting the Rate TVM-40 Assembly (Part No. TVM-40) TVM-180 Assembly (Part No. TVM-180) TVM-350 Assembly (Part No. TVM-350) TVM-1000 Assembly (Part No. TVM-800) TVM-2700 Assembly (Part No. TVM-2200) TVM Frequency Filters Service and Maintenance...11 ii

3 Torque Validation Module Getting Started 1.1 Warnings and Cautions The safety notices and warnings for protection against loss of life (the users or service personnel) or for the protection against damage to property are highlighted in this document by the terms and pictograms defined here. The terms used in this document and marked on the equipment itself have the following significance: Danger Warning Caution Indicates that death or severe personal injury will result if proper precautions are not taken. Indicates that death or severe personal injury may result if proper precautions are not taken. Indicates that property damage may result if proper precautions are not taken. Indicates an electrical hazard. This icon appears as a part of a Danger, Warning, or Caution notice. W A R N I N G Indicates a general hazard. This icon appears as a part of a Danger, Warning, or Caution notice. Indicates that eye protection should be worn. This icon appears as a part of a Danger, Warning, or Caution notice. Read and understand all the safety recommendations and all operating instructions before operating tools and controllers. Indicates an item of special interest. To Avoid Injury: Read and understand all the safety recommendations and all operating instructions before operating tools and controllers. Save these instructions for future reference. Train all operators in the safe and proper use of power tools. Operators should report any unsafe condition to their supervisor. Follow all safety recommendations in the manual that apply to the tools being used and the nature of the work being performed. Verify that all warning labels illustrated in this manual are readable. Replacement labels are available at no additional cost from STANLEY ASSEMBLY TECHNOLOGIES. 1.2 Qualified Personnel W A R N I N G To Avoid Injury: Only allow suitably qualified personnel to install, program, or maintain this equipment and or system. These persons must be knowledgeable of any potential sources of danger and maintenance measures as set out in the Installation, Operations, and Maintenance manual. This product must be transported, stored, and installed as intended, and maintained and operated with care to ensure that the product functions correctly and safely. Persons responsible for system planning and design must be familiar with the safety concepts of automation equipment. Getting Started 1

4 1.3 Safe Use User Manual This manual is intended to promote proper and safe use and give guidance to owners, employers, supervisors, and others responsible for training and safe use by operators and maintainers. Please contact your Stanley Sales Engineer for further information or assistance on Stanley training or assembly tool operations. 1.4 Introduction Designed for electronic torque testing, calibration and validation of power tools, the TVM is compatible with impact wrenches, pulse tools and all gear driven air and D/C electric tools. Industry needs a way to check and certify the torque output of all power tools, not just gear driven tools but ALL power tools, including pulse and impact wrenches. The TVM series of torque transducers is designed to hold up to the kind of pounding of today s impacts. The TVM is a torque transducer designed to handle the most rugged torque tools available. Extremely robust and employing an easily replaceable Grade 9 hex head cap screw the TVM is ready to take on any impact, pulse or direct drive tool within its range. Utilizing a 700ohm strain gauged Wheatstone bridge and industry standard A, B, C, D wiring, most instrumentation is compatible. NOTE: When testing pulse and impact tools, make certain the instrumentation can properly process the signals so that true torque is presented. Together with our PSI-A Transducer Indicator a TVM can be used to set-up, validate or test the torque output of any power tool. The TVM uses a series of Bellville washers that can be positioned to simulate a variety of joint conditions. With the integrated socket acting as a nut, torque readings are realistic and accurate. The TVM can also be used to set click type torque wrenches. Heavy duty design stands up to impact wrenches Easy to replace wear items Dead weight calibrated; N.I.S.T. Certificate of Calibration Adjustable joint rate. 1.5 Electrical Safety The issue of operator safety is of maximum importance from both the attitude of ergonomic comfort as well as electrical safety. W A R N I N G ELECTRICAL HAZARD To Avoid Injury: Plug power cord into a grounded outlet that conforms to National Electric Code standards. Do not defeat the grounding pin on plug or substitute a cable that does not conform to the power and safety requirements of system. 1.6 Specifications The range of TVMs available from Stanley covers torques from 2 Nm to 2700 Nm. Five models are available to suit your torque range and requirements. See Table 1 below. 2

5 Torque Validation Module Model Part Number Range in Nm. Range in ft/lbs. Angle range TVM 40 TVM Nm ft/lbs degrees TVM 180 TVM Nm ft/lbs degrees TVM 350 TVM Nm ft/lbs degrees TVM 1000 TVM Nm ft/lbs degrees TVM 2200 TVM Nm ft/lbs degrees Table 1: TVM Models The robust hardened steel sensor is a double gauged Wheatstone bridge that comes complete with a Certificate of Calibration, guaranteeing accuracy and traceability to an A2LA lab and N.I.S.T. standard. A standard 2Mv/V signal at 700 ohms insures compatibility with most torque meters and instrumentation. When used with our PSI-A Transducer Indicator, the TVM can be employed to test pulse, impact and all direct drive air or DC electric tools. The PSI-A Transducer Indicator has selectable filter settings specifically developed for pulse and impact tools including the standard ISO 5393 filter setting of 500 hertz as required for all direct drive air and DC electric tools. The filter in the unit can be adjusted from hertz in 50 hertz increments. NOTE: If using pulse and impact tools, it is very important to use the same extensions and adapters used on the tool s application. Otherwise, the applied torque on the application will be different than what was tested. All PSI tools should be equipped with EcoDrive sockets and extensions for the AH and AM tools or the Taper Lock sockets and extensions for all AP and AT tools. Performance and capability statements or claims are not ensured without these specialty sockets and attachments. WARNING To Avoid Injury: Always wear eye and foot protection when installing equipment. Keep the work area clean, well lit and uncluttered. Keep unauthorized personnel out of the work area. Do not install worn, damaged, or modified equipment that may be unsuitable for safe us. Train all operators in the safe and proper use of power tools. Operators should report any unsafe condition. Install tools in dry, indoor, non-flammable, and non-explosive environments only. Getting Started 3

6 User Manual Installation and Use 2.1 Easy Set-up and Maintenance Each TVM comes supplied with a set of Belleville spring washers that can be easily configured to cover the joint range at torque as rated. A simple O-ring retains the washers internally and is accessed from the front. Changes in joint rate and washer stack configuration are accomplished in seconds. The entire TVM range is designed to use a commonly available Grade 10.8 hardened bolt with the supplied socket, which acts like a nut as well. Both coarse and fine threads can be used to most accurately duplicate the desired torque rate and range. The threaded fastener is the wear item, can be sourced locally, and changed in less than a minute. There is no need to stock expensive replacement parts. The TVM has an industry standard electrical connector for transducers. The TVM can be used with most transducer torque indicators using the standard cable (part # 24C502002) except Crane Torque Star indicators. A special cable is needed (part # 24C504402) to connect to the Crane Torque Star. For all others see the TVM transducer connector schematic in Figure 1 below to learn how to make a compatible cable. 4 Figure 1: TVM Connector Schematic To use simply connect, via the appropriate transducer cable, the TVM to a torque indicator such as a PSI-A. Follow the instructions for the torque indicator and use the calibration number from the calibration sheet that came with the TVM when prompted. Use the filter frequencies, if necessary, as defined in section 2.7. Connect a tool with the provided socket and run the tool clockwise to perform a fastening cycle. Write down, or store, the information displayed on the connected TVM torque indicator and the tool s controller for comparison. Place the tool into reverse, or use another tool, and back the nut off to get ready for another rundown on the TVM. Repeat as necessary. 2.2 Adjusting the Rate Each TVM, except the TVM-2700, comes with cupped spring washers or Belleville washers that can be used to adjust the torque rate, or final angle, of the test fastening cycle. They have a slight conical shape which gives the washer a spring characteristic. Belleville washers are used as springs, or to apply a pre-load or flexible quality to a bolted joint such as the TVM. Multiple Belleville washers may be stacked to modify the spring constant or amount of deflection. Stacking in the same direction will add the spring constant in parallel, creating a stiffer, or harder, joint (with the same deflection). Stacking in an alternating direction is the same as adding springs in series, resulting in a lower spring constant and greater deflection creating a softer joint. Mixing and matching directions allow a specific spring constant and deflection capacity to be designed. Ideally, no more than 4 springs should be placed in parallel. The number of springs used in a series stack is not as much of an issue as in parallel stacks. The three diagrams below show how the serial and parallel stack-up of the Belleville washers will create hard, medium and soft joints.

7 Torque Validation Module Hard Joint All the Belleville washers are stacked in parallel to provide the most rapid torque rate. Medium Joint The Belleville washers are divided and each half stacked in parallel with the paralleled halves stacked in series. Soft Joint More sets of parallel Belleville washers are stacked in series rather than parallel. Diagram 1: Torque Rate Simply remove the rubber o-ring from the front of the TVM, remove the Belleville washers, stack them into the required parallel or serial configurations to get the desired torque rate. It might be helpful to write down, and keep for future reference, the torque rate provided by different configurations. Picture 1: TVM Assembly Installation and Use 5

8 User Manual 2.3 TVM-40 Assembly (Part No. TVM-40) 6

9 Torque Validation Module 2.4 TVM-180 Assembly (Part No. TVM-180) Installation and Use 7

10 User Manual 2.5 TVM-350 Assembly (Part No. TVM-350) 8

11 Torque Validation Module 2.6 TVM-1000 Assembly (Part No. TVM-800) Installation and Use 9

12 User Manual 2.7 TVM-2700 Assembly (Part No. TVM-2200) 10

13 Torque Validation Module 2.8 TVM Frequency Filters When using the TVM with the PSI-A for testing discontinuous drive impact and pulse tools, the following frequency filters are recommended for each model: TVM-40 = 2000 Hz TVM-180 = 2000 Hz TVM-350 = 2000 Hz TVM-800 = 1300 Hz TVM-2200 = 1300 Hz 2.9 Service and Maintenance Send the TVM back to Stanley for NIST traceable annual calibration. Lubricate the Belleville washers and the bolt in the TVM monthly. Use good quality molybdenum grease such as the Dow Corning BR2+. Should spare parts or service be required, contact your local distributor or Stanley Assembly Technologies sales person. Installation and Use 11

14 Contacts User Manual STANLEY ASSEMBLY TECHNOLOGIES: 5335 Avion Park Drive, Cleveland, Ohio , USA Tel: +1 (440) Fax: +1 (440) ; STANLEY ASSEMBLY TECHNOLOGIES: Outils Portatifs et Systemes d Assemblage, Zone Immoparc Route De Chartres, Bâtiment Loire 4, Trappes Cedex, France Tel: +33 (130) Fax: +33 (130) ; SATinfo@stanleyworks.com STANLEY ASSEMBLY TECHNOLOGIES: Divisione: SWK UTENSILERIE s.r.l., Via Parco 47, Biassono (MI), Italy Tel: +39 (039) Fax: +39 (039) ; SATinfo@stanleyworks.com 12