adaptive feed drill controller - apex power tools

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Parts & Operation ManualPL92-DMP-Q09/03/2010

DMP SeriesAdaptive Feed Drill Controller

PL92-DMP-Q09/03/2010

Statement of Use:This Controller is for use with the pneumatic Adaptive Drill System intended for producing holes with the drill mounted securely in a suitable fixture.

Do not modify the controller, any guard or accessory unless approved in writing by Apex Tool Group, LLC.

Personnel Training:Personnel must be trained in the correct handling of this equipment. The user must make this manual available to the operator and ensure that the operator has read and understands it’s contents. This equipment may be connected, operated, serviced and repaired by qualified personnel only.

Copyright Protection and Disclaimer:Copyright © 2010 Apex Tool Group, LLC

Apex Tool Group, LLC reserves the right to modify, supplement or improve the document or the product without prior notification. This document may not be reproduced in any way, shape or form, in full or parts thereof, or copied to another natural or machine readable language or to a data carrier, whether electronic, mechanical, optical or otherwise without the express written permission of Apex Tool Group, LLC.

Safety:Indicates a potentially hazardous situation which, if not avoided, could result in personnel death or serious injury.

Indicates a potentially hazardous electrical shock situation which, if not avoided or instructions not followed, could result in personnel death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate personnel injury or property and environmental damage.

Helpful information or application tips such as special assembly requirements. No hazardous conditions.

Always comply with Federal, State and Local regulations related to the installation and operation of electrical and pneumatic equipment.

Impact resistant eye protection must be worn while operating or working near this equipment.

Hearing protection is recommended in high noise areas, 85 dBA or greater.

The pneumatic section of this equipment is designed to operate at 90 psi minimum and 140 psi maximum air pressure. Excessive air pressure can increase the load and stress on parts and may result in breakage.

Before removing this equipment from service make sure the air supply is shut off and the air line pressure is released.

Basic safe working practices:Read all instructions provided with the equipment prior to installation and use. Failure to observe all safety instructions could result in personnel injury or equipment damage.

Ensure there is adequate space in the work area.•

Keep the work area clean.•

Shut off controller in case of unusual sound.•

Disconnect air and electrical supply.•

Have a qualified technician inspect and repair.•

Lubricant:Air tool oil reservoir: We recommend using a light air tool oil for air tool lubrication..

Controller Specifications:

IMPORTANT !

DO NOT ALLOW TOOL OPERATION WITHOUT FULLY READING AND

UNDERSTANDING THIS MANUAL.

Quackenbush®

General Information and Precautions

Controller Number 642003PT 633890PT

Model Number DMP-111-15 DMP-111-25

Electrical Supply115V 50/60Hz

2A

230V 50/60Hz

2A

Plug

ProtectionOne Fuse:

on line

Two Fuses:

on line &

on neutral

Pneumatic Supply

Overal Dimensions

Weight

Nema 5-15P

3/4" NPT 90-140 psi

Clean Dry Air

13"W x 15"D x 26"H

53 lbs.

PL92-DMP-Q09/03/2010

Quackenbush®

Dimensional Data

11.8”(300mm)

11.83”(300mm)

15.961”(405mm)

0.851”(21.6mm)

10.901”(277mm)

3/4-14NPT

11.405”(290mm)

12.811”(325mm)

10.00”(254mm)

0.562”(14.3mm)

26.077”(662mm)

21.061”(535mm)

1.562”(39.7mm)

9.656”(245mm)

6.131”(156mm)

13.727”(349mm)

“A”

PL92-DMP-Q09/03/2010

Connecting and Operating the System:Before connection and operation of the unit, ensure suitable air tool oil and required coolant are placed in the reservoirs. Regularly check oil and coolant levels – recommended before each set of drilled holes to ensure Tool is always lubricated and Cutter always has coolant when drilling.

Allowing air tool oil to run out can damage the tool and cause incorrect drilling operation.

Allowing coolant to run out can damage the cutter and the component being drilled.

Quackenbush®

System Operation and Use

Illustration “B”: Reservoirs

Illustration “C”: Connections

Air Tool Oil Reservoir

CoolantReservoir

Connect Main Power Cable

Connect Main Air Inlet

3/4” NPT

PL92-DMP-Q09/03/2010

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Connecting and Operating the System:Connect the Coolant Hose and main Air Supply Hose to the tool.

Illustration “D”: Hose Connections

Illustration “E”: Front Box Connections - Lights and On/Off Switch

Coolant Hose Connection (Connector Supplied) CoolantReservoir

Coolant Prime Button

Main On/Off Switch

Main Tool Air ((Connector Not Supplied - 1/2” NPT)

Red Status Indicator

Box to PC Ethernet Connection forData Collection

Green DC Power Light

Tool to DMP Communication

Connector

PL92-DMP-Q09/03/2010

Power up the system using the On/Off switch.

After tool memory is read, DMP will allow air flow to the main air inlet at the tool. The tool is now ready to drill. The tool operation is the same as a standard positive feed unit. Refer to the specific tool operating manual.

Before drilling, ensure coolant is primed to the cutter. Use the coolant prime button to activate coolant supply manually. Prime until coolant is seen exiting the cutter.

Note: Once the tools are programmed you can disconnect and reconnect the tools without turning off the control box.

Red status light will provide information about the operation.

The sequence is as follows:

Tool Not Running:

1 short blink = Box powered up but no tool connected

On = Ready to drill (box powered up and tool properly connected)

2 short blinks = Tool bit counter exceeded, bit must be changed and reset using DMP-Tool Management Software

3 short blinks = Tool programming issue, check parameters using DMP-Tool Management Software

Tool Running:

On = NOT under adaptive control

If this occurs after approximately 6 seconds of tool running, the system must be SHUT DOWN and restarted. Otherwise, the tool will drill at high speed only with potential damage to the cutter and component.

1 short blink = Tool under adaptive control. This should occur within 6 seconds of operation.

Quackenbush®


PL92-DMP-Q09/03/2010

Data Collection:

Data Collection:

Each time the tool is operated, using the DMP controller, the system will record information about the drill cycle and store the data on the controller memory. This data can be retrieved from the controller and transferred to a PC using the Ethernet connection on the side of the controller cabinet in conjunction with the “DrillData.exe” software. The files are stored in a comma separated variable (CSV) format and can be read using Microsoft Excel. To further enhance the user’s ability to understand the data it is preferable to convert the CSV files to standard Excel XLS format using the “Adaptive Air Chart Maker date.exe” software.

The Date will be the revision level of the software.

Retrieving CSV files:

A laptop or desktop PC must first be connected to the Air Adaptive control cabinet using a standard RJ45 Ethernet cord commonly used for connecting any PC to the intranet/internet. The DrillData.exe software will automatically connect to the Air Adaptive controller using Dynamic Host Configuration Protocol (DHCP). Connection of the PC to the controller will take approximately 40 seconds. Faster connection can be obtained using a fixed IP address on the PC. If using a laptop, the wireless LAN may need to be disabled in order to make the connection to the controller. Once the connection is made you can click on file list to bring up a list of files currently stored on the controller. The files are listed in order by date with the newest files will be located at the bottom of the list. You can select multiple files by placing a check mark in the box next to each file. You must specify a storage location on your PC by selection the Out Dir button. Now you can get all the selected files, the display window will show “Done” when all the files are retrieved. You can now close the window if you are finished retrieving files from the controller.

Quackenbush®


Illustration “F”: Drill Data Archiver

PL92-DMP-Q09/03/2010

Formatting Files:Once the files are retrieved from the controller they can be fchanged to Excel format for interpretation of the data. The Adaptive Air Chart Maker software will convert the CSV files to XLS format and make 3 graphs which are useful for interpreting the events that occurred during drilling. You must first specify the location of the CSV files retrieved in the previous step using the DrillData.exe software by clicking the first Browse button. You can select single files or multiple files using the shift or control buttons on your keyboard. Next, specify the location to store the XLS files by clicking the second Browse button. Now you can make the XLS files by clicking the Process Selected CSV Files button. When the software has converted the files you will see a confirmation in the Status window.

Quackenbush®


Illustration “G”: Adaptive Air Smart Tool Chart Maker

PL92-DMP-Q09/03/2010

Understanding the XLS files:The top part of the XLS file provides much of the same information that is stored on the memory on the drill motor showing operating details. The Event Times column is helpful in determining when process changed occurred on the graphs.

Quackenbush®


Illustration “H”: XLS Files

Refer to the following Glossary for definitions of key components shown on the XLS graph.

PL92-DMP-Q09/03/2010

Glossary:

RPM

Calculated by the encoder counts recorded during drilling.

TexAvg

Long running average of encoder error counts. Used for setting Base.

Base

Base is used as a reference to determine when to shift processes in the next material/layer. Base is captured once the major diameter has engaged the new material/layer. Once a trigger level is satisfied, the controller waits DelBaseC if at high speed or DelBaseT if at low speed before capturing a new Base.

Eav0

Short running average of encoder counts. Used as a reference in combination with Base to determine when to shift processes.

Vout

Voltage applied to the proportional valve to control motor speed. Vout changes in response to encoder counts. Rising Vout indicates increased load on the motor.

Trigger

Trigger indicates when the motor will shift processes based on eav0-base or base-eav0 or base-TexAvg depending on soft to hard or hard to soft transition.

Recommended values for CFRP/Ti are trigger1=2, trigger2=2, Ti/CFRP are trigger1=2, trigger2=2.

A small trigger value will shift processes as early as possible.

KP and KD

Gains for the PID loop used to control the motor RPM. KP controls frequency of how often the controller tries to correct RPM. KD controls how hard the controller tries to correct the RPM discrepancy. High KP values tend to suppress the level of error generation, while low KP values allow more error to be generated but can cause more variation in RPM. Setting either value too high can set up a resonant frequency with wild swings in RPM. Recommended values are: KP – Ti=60-80, Air=100-120, CFRP=120-170 and KD=40 for all materials.

Quackenbush®


PL92-DMP-Q09/03/2010

Trouble Shooting:

DMP will not power up:

1. Check power supply

2. Check On/Off Switch

3. Check Fuse

DMP powers up but no air supply to the tool:

1. Drill bit counter = Max Number of Cycles allowed, Change drill bit and reset drill bit counter

2. Incorrect layer combination chosen, accepted layer combinations are:

Two Layers CFRP/Ti Ti/CFRP Ti/AI

Three Layers Ti/CFRP/Ti AI/CFRP/Ti

DMP powers up, air supply to tool but tool stops after a few seconds:

1. Drill can not achieve high speed set. Check high speed setting is not at max speed setting.

2. Drill can not achieve high speed set. Check last service date, check air tool oil supply, tool needs servicing.

3. Drill can not achieve high speed set. Check input air pressure.

4. Incorrect programming e.g. drill point angle set to zero, check tool memory for errors in programming.

Early shift to low speed:

This is usually caused by one of two events, RPM is too high for diameter and material being drilled or trigger is set too low. A quick indicator the RPM is too high will be a constant rise in Vout. If Vout is constant the trigger level will have to be increased to maintain RPM in the material.

Lube does not shut off at exit:

This is typically caused by lubeoff trigger being set too low. If the change at exit is very small when exiting CFRP try increasing the high speed RPM slightly (25 RPM at a time) or decrease KPCF incrementally by 10 counts until enough delta between CFRP and Air is achieved.

Quackenbush®


PL92-DMP-Q09/03/2010

Page 12

“I”

2

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Frame Assembly

122

3

6

3

5

11

10

10

10

106

6

1

1

4

4

1

5

7

77

7

6

9

9

9

8

8

8

9 8

1

11

PL92-DMP-Q09/03/2010

EN

Description

1 93300034 8 8 Screw, 1/4-20 x 1/2" BHC

2 93310133 2 2 Screw, 1/4-20 x 1" SHCS

3 633635PT 2 8020 1010 Extrusion (24")

4 633636PT 2 8020 1010 Extrusion (10")

5 633637PT 2 8020 1010 Extrusion (9.8")

6 633638PT 2 Double Anchor Fastener

7 633639PT 4 Anchor Fastener

8 633640PT 4 4 Nut, Economy "T"

9 633641PT 4 Mesh Retainer

10 633642PT 4 4 Rubber Bumper Assembly

11 633644PT 1 Expanded Metal Assembly

12 633645PT 1 Handle

(#) Quantity

(X) Recommended Spare Parts

Illustration "I"

Ref Number # X

Quackenbush®

Frame Assembly

PL92-DMP-Q09/03/2010

“J”

1 See Service Notes

5

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Pneumatics

2

23 4

4

4

4

15

8

9

7

68

18

171

68

7

12

316

14

2

1

220

2

9811

10

19

21

20

13

2

5

22

1

2

PL92-DMP-Q09/03/2010

EN

Description

1 861069 2 Close Nipple

2 93300010 4 4 Screw, 1/4-20 x 3/8" BHC

3 93440007 1 Pipe Plug


5 633647PT 1 Enclosure Assembly (Pneumatics)

6 633650PT 2 Air Inlet Manifold

7 633651PT 2 2 Lock Washer, External Tooth

8 633652PT 4 4 Jam Nut, 1-1/4 - 12

9 633653PT 2 Washer

10 633658PT 1 90˚ Street Elbow

11 633663PT 1 Air Filter

12 633669PT 1 1 Adapter (Push to Connect)

13 633673PT 1 1 Quick Disconnect, 1/2"

14 633677PT 1 2 Speed Control Valve

15 633682PT 1 Label

16 633710PT 1 2 Compression Fitting, Machined

17 642025PT 1 Valve Assembly (Proportional) (includes Ref. 18)

18 633649PT 1 1 Silencer, 1/2 NPT

19 642026PT 1 Air Solenoid and Cable Assembly

20 F523PT 2 Close Nipple

21 F584 1 90˚ Street Elbow

22 633686PT 1 Lock (Key Insert)

23 633887PT 1 Label (Quackenbush)

(#) Quantity


Illustration "J"

Ref Number # X

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Pneumatics

PL92-DMP-Q09/03/2010

“K”

Quackenbush®

Pneumatics

3 See Service Notes4

27

29

2811

21

62

“J”

12

1623

14

26 47

4

14

1324

14

20

10

17

15

17

8

15

20“J”

3

52

69

5

322

1

7

18

1

1925 3

4

PL92-DMP-Q09/03/2010

EN

Description

1 382500 2 2 Elbow

2 382539 4 4 Screw, SHC (6-32 UNC)

3 844287 4 4 Lock Washer, Spring (1/4)

4 93210026 4 4 Hex Nut, #6-32

5 93300010 4 4 Screw, 1/4-20 x 3/8" BHC

6 W186 4 4 Flat Washer (Steel)

7 94140007 4 4 Lock Washer

8 633654PT 1 Coolant Injector

9 633655PT 1 1 Reducing Nipple

10 633656PT 1 Tool Oil Injector

11 633657PT 1 Tool Oil Reservoir

12 633664PT 1 Bulkhead Anchor Connector

13 633665PT 1 Connector (male/female/female)

14 633666PT 3 3 Elbow (push to connect)

15 633667PT 2 2 Elbow (push to connect)

16 633668PT 1 Bulkhead Connector

17 633669PT 2 2 Adapter (push to connect)

18 633670PT 1 Solenoid Base

19 633672PT 2 2 Hose Fitting (push to connect)

20 867801PT 2 Pipe Plug

21 633680PT 1 Coolant Reservoir

22 633681PT 1 Grommet, 3/4 I.D.

23 633683PT 1 1 Bulkhead Fitting Plug

24 633710PT 1 1 Compression Fitting, Machined

25 642027PT 2 Lube Solenoid

26 642028PT 1 Coolant Air Solenoid

27 633674PT 1 1 Tool Hose Assembly

28 PMN050700ZA0B2X Tubing, 1/8" O.D. Nylon (Qty = Per Foot)

29 633716PT 1 1 Check Valve

PMN050T004A0BZ Tubing, 1/4" O.D. x .170 I.D. (Not Shown) (Qty = Per Foot)

(#) Quantity


Illustration "K"

Ref Number # X

Quackenbush®

Pneumatics

PL92-DMP-Q09/03/2010

“L”

Quackenbush®

Electronics

13

14

4

17

11

15

129

5

5

2

8

11

5

18

3

10

165

8

6

67

6

6

5 See Service Notes6 7 8 9

5

6

7

8

9

PL92-DMP-Q09/03/2010

Quackenbush®

Electronics

EN

Description

1 541615 2 Ground Strap Label

2 541616 1 Warning Label

541795 1 3 Fuse: 250V 10A 1/4x1-1/4 Slowblow (Controller 642003PT)

541795 2 6 Fuse: 250V 10A 1/4x1-1/4 Slowblow (Controller 633890PT)

4 544035 1 Switch

5 93300010 4 4 Screw, 1/4-20 x 3/8" BHC


7 633681PT 1 Grommet, 3/4 I.D.

8 633879PT 1 Electronics Enclosure Assembly

9 633880PT 1 Label

633692PT 1 1 Fuse Holder (Controller 642003PT)

633692PT 2 2 Fuse Holder (Controller 633890PT)

11 633693PT 1 Ethernet Port

12 633694PT 1 Ethernet Port Cover

13 642030PT 1 Push Button and Wiring Assembly

14 642031PT 1 Green LED and Wiring Assembly

15 642032PT 1 Red LED and Wiring Assembly

16 642033PT 1 Power Cable Assembly

17 642034PT 1 Drill Connector and Wiring Assembly

18 633686PT 1 Lock (Key Insert)

633719PT 1 Namplate (Not Shown)

(#) Quantity


3

10

Illustration "L"

Ref Number # X

PL92-DMP-Q09/03/2010

“M”

Quackenbush®

Electronics

“L”

9

5

6

10

5

12

11

612

126

13

12

8

43

1

512

6

18

31617

4

15

19

2

2

2

2

7

1314

12

PL92-DMP-Q09/03/2010

Quackenbush®

Electronics

EN

Description

1 541615 1 Ground Strap Label

2 542940-1 4 4 Screw, #4-40 x 3/16 w/Washer

3 542940-4 3 3 Socket Head Cap Screw

4 542942-2 3 3 Starwasher, M4 Zinc

5 542943-13 4 Standoff, 1/2

6 542943-14 4 Standoff, 5/8

7 542943-15 3 Standoff, 3/16

8 543321-1 1 1 3-Way Grounding Tab

9 633681PT 1 Grommet, 3/4 I.D.

10 633685PT 1 Enclosure Mounting Plate

11 633695PT 1 Controller, GALIL

12 633696PT 10 10 Flat Washer, #4

13 633697PT 6 6 Machine Screw

14 633698PT 1 Rabbit Board

15 633699PT 1 DIN Rail

16 633700PT 1 Power Supply

17 633701PT 1 Ethernet Switch

18 633702PT 1 Mini SD Card

19 PCA2022 1 Interface Board

633703PT 3 Ethernet Patch Cable (Not Shown)

(#) Quantity


Illustration "M"

Ref Number # X

PL92-DMP-Q09/03/2010

Quackenbush®

Service Notes

1 Illustration “J”: 642025PT Proportional Valve Assembly

3 Illustration “K”: 642027PT Lube Solenoid

2 Illustration “J”: 642026PT Air Solenoid

17

18

Pin 2: Green (Ground)

Pin 4: Red (24v)

Pin 3: White (Ctrl)

Pin 1: Black (Ground)

19

Pin 2 Red Wire

Pin 3: Green Wire

Pin 1: Red Wire

Pin 1: Red Wire

Pin 2: Black Wire

25

PL92-DMP-Q09/03/2010

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Service Notes

4 Illustration “K”: 642028PT Coolant Air Valve

6 Illustration “L” 642031PT Green LED

5 Illustration “L”: 642030PT Push Button

Pin 1: Red Wire

Pin 2: Black Wire

Pin 2: White Wire

Pin 1: Red Wire

Pin 2: White Wire

Pin 1: Red Wire

26

13

14

Quackenbush®

Service Notes

7 Illustration “L”: 642032PT Red LED

9 Illustration “L”: 642034PT Drill Connector

8 Illustration “L”: 642033PT Power Cable

Pin 2: White Wire

Pin 1: Red Wire

15

16

Green / Yellow Wire

Blue Wire

Brown Wire

Pin 2: White Wire

Pin 4: Black Wire

Pin 3: Blue Wire

Pin 1: Brown Wire

Pin 6: Pink Wire

Pin 5: Gray Wire

17

Sales & Service CentersNote: All locations may not service all products. Please contact the nearest Sales & Service Center for the appropriate facility to handle your service requirements.

Dallas, TX Detroit, MI Houston, TX Lexington, SCApex Tool Group Apex Tool Group Apex Tool Group Apex Tool GroupSales & Service Center Sales & Service Center Sales & Service Center 670 Industrial Drive1470 Post & Paddock 2630 Superior Court 6550 West Sam Houston Lexington, SC 29072Grand Prairie, TX 75050 Auburn Hills, MI 48326 Parkway North, Suite 200 Tel: 800-845-5629Tel: 972-641-9563 Tel: 248-391-3700 Houston, TX 77041 Tel: 803-359-1200Fax: 972-641-9674 Fax: 248-391-7824 Tel: 713-849-2364 Fax: 803-358-7681 Fax: 713-849-2047

Los Angeles, CA Seattle, WA York, PA CanadaApex Tool Group Apex Tool Group Apex Tool Group Apex Tool GroupSales & Service Center Sales & Service Center Sales & Service Center Sales & Service Center15503 Blackburn Avenue 2865 152nd Avenue N.E. 3990 East Market Street 5925 McLaughlin RoadNorwalk, CA 90650 Redmond, WA 98052 York, PA 17402 Mississauga, Ont. L5R 1B8Tel: 562-926-0810 Tel: 425-497-0476 Tel: 717-755-2933 CanadaFax: 562-802-1718 Fax: 425-497-0496 Fax: 717-757-5063 Tel: 905-501-4785 Fax: 905-501-4786 Germany England France ChinaCooper Power Tools Cooper Power Tools Cooper Power Tools SAS Cooper (China) Co., Ltd.GmbH & Co. OHG GmbH & Co. OHG a company of a company ofa company of a company of Apex Tool Group, LLC Apex Tool Group, LLCApex Tool Group, LLC Apex Tool Group, LLC Zone Industrielle 955 Sheng Li Road,Postfach 30 Unit G Quinn Close BP 28 Heqing Pudong, ShanghaiD-73461 Westhausen Seven Stars Industrial Estate Avenue Maurice Chevalier China 201201Germany Whitlet 77831 Ozoir-la-Ferrière Cedex Tel: +86-21-28994176Tel: +49 (0) 73 63/ 81-0 Coventry CV3 4LH France Fax: +86-21-51118446Fax: +49 (0) 73 63/ 81-222 England Tel: (011) 33 1 64 43 22 00 Tel: +44-2476-3089 60 Fax: (011) 33 1 64 40 17 17 Fax: +44-2476-3089 69

Mexico Brazil Cooper Tools Cooper Tools Industrial Ltda. de México S.A. de C.V. a company of a company of Apex Tool Group, LLC Apex Tool Group, LLC Av. Liberdade, 4055 Vialidad El Pueblito #103 Zona Industrial - Iporanga Parque Industrial Querétaro 18087-170 Sorocaba, SP BrazilQuerétaro, QRO 76220 Tel: (011) 55 15 238 3929Tel: +52 (442) 211-3800 Fax: (011) 55 15 228 3260Fax: +52 (442) 103-0443

PL92-DMP-Q/Printed in USA 09/2010/Copyright © Apex Tool Group, LLC

Apex Tool Group, LLC1000 Lufkin RoadApex, NC 27539Phone: 919-387-0099Fax: 919-387-2614www.apextoolgroup.com

adaptive feed drill controller - apex power tools

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