HIGHLIGHTS • Breakthroughcombinationofprice,performanceandfunctionality: Sciemetric’strademarkprocesssignatureverificationtechnologyinindustry’s lowestcost,2-channelprocessmonitor
• Featureshighresolution,fullcolortouch-screendisplaycombinedwith easy-to-usegraphicalinterface(alsoavailablewithoutdisplay)
• Flexiblesystemcanbequicklyconfiguredtomonitorvirtuallyanymanufacturingprocess: press,torque,weld,crimp,dispense,soundandvibration,profiling,functionaltesting
BENEFITS • Everyunitcomespre-loadedwithSciemetric’sindustry-leadingPSVTMtechnologyforprocesssignatureanalysis,providingthe mostaccuratedefectdetectionandmonitoringpossible
• Intuitive,point-and-clickinterfaceenablesrapidsetupwithstandardtemplatesforcommonapplications
• sigPODversatilityallowsconsolidationofmonitoringinfrastructuretoasingleproductfamilyacrossallapplications— simplifiestraining,commissioningandmanagement(i.e.:spares,repairs,maintenance)
• Multipleconnectivityoptionssimplifyintegrationwithstationcontrollersanddatanetworks
• ConnectiontomanufacturingexecutionsoftwareandanalyticaldatabasessuchasSciemetric’sQualityWorXsoftwareenables remotemonitoringofqualitydata
1 3 0 2
FEATURES
QuickandEasySetup• Universallyapplicablesoftware
pre-loadedwithstandardtemplates• Customapplicationsquickly
configuredusingmenu-driveninterface—noprogrammingrequired!
PowerfulAnalysisSoftware• Detailedwaveformanalysiswith
extensivelibraryofprocessingoptions• Comprehensivestatisticaltoolsetfor
SPCmonitoringandcontrol
IntuitiveUserInterface• Large8”,highresolution,fullcolor
touch-screendisplay
WELDTORQUETO TURN
FUNCTIONALTESTING
SOUND &VIBRATION
PROFILINGCRIMPING PRESSFITTING
DISPENSEMONITORING
• Easy-to-usegraphicalinterfacefeaturessimpleandintuitiveoperatordisplays
• Commonsoftwareandhardwareplatformprovidesunifiedlook&feelacrossentiresigPODfamily
UnmatchedDataCollection• 2highspeed16bitanalogchannels• Built-inprecisionsensorexcitation• Encoderinputforlinearorrotaryscales
EasyMountingOptions• Compactindustrialformfactoriseasily
installedinapanelcut-out,DINrailormachine/wall/desktopmounted
• Modularterminalconnectorplugsfor
analoganddigitalI/Oconnectionssimplifyinstallationandwiring
DetailedDataManagement• Extensivegraphingcapabilities:
waveforms,histograms,trendcharts• SPCanalysisandreporting• Statisticallylearnedtestlimits• Localandremotestorageofresults
SimpleConnectivity• Communicationwithstation
controllerviadiscreteI/O,Ethernet/IPorModbusTCP
• Ethernet10/100Base-T
AFFORDABLE PROCESS SIGNATURE VERIFICATION
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1302
ThesigPOD1302isalowcost,compact2-channelmonitoringsolutionsuitableforawiderangeofmanufacturingprocesses,suchastorque,press,weld,vibration,dispense,etc.FeaturingSciemetric’s
advancedPSVTMsoftwarefordatacollectionandanalysis,thesigPOD1302measuresandanalysesthedatafromanexternalsensor,determinespass/fail,provideslocalstorage,andreportsontheresults.
HARDWARE
AblockdiagramofhowthesigPOD1302integratesintoaproductionmonitoringapplicationisshowninfigure1below.ThesigPOD1302collectsdatafromsensorsthatareintegratedintothemanufacturing
sigPOD 1302Sensors
strain, temperature, pressure, displacement
Generic Analog Signals
voltage, current, resistance
Quadrature Encoderlinear or rotary displacement
Digital Control Signals
PLC, prox switch, push buttons
Digital OutputsPLC, lights, solenoids
Analog Inputs
Encoder Input
Digital Input
Digital Output
PLC Network
USB Port
RS232 Serial
Ethernet
Manufacturing Equipment
Station ControllerRemote Storage &
Analysis
Peripherals
Digital Signalsmachine data
Remote Display
Barcode scanner
Ethernet/IP, Modbus TCP
QWX Server
QWX EWA
Mouse
VGA
Keyboard
station,monitoringparameterssuchasposition,temperature,pressure,force,acceleration,etc.Itcanalsomonitorsignalsdirectlygeneratedbythemanufacturingequipmentitself,suchasvoltageorcurrent.Bothanalogchannelsoffertheflexibilityofacceptingdifferentialinputsignalsandindependentlycontrolledmeasurementranges,andfeatureaprecisionexcitationsourcetopowerthesensorifnecessary.Anencoderinputisprovidedtosimultaneouslymeasureangularorlinearposition,suchastherotarypositionofacrankshaftorlineardisplacementofapressram.8digitalI/Osaresupplied,someofwhicharededicatedtohandshakingcommunicationswiththestationcontroller,withtheremainderavailableformonitoringdigitalsignalsprovidedbythemanufacturinghardwareorothertestequipment.
SOFTWARE
Oncetheprocessdatahasbeencollected,itcanbestored,manipulatedandanalyzed
bythepowerfulPSVTMsoftwarethatcomeswiththe1302.Thisversatilesoftwarecomeswithtemplatesforsomecommonapplications,suchasPress,TorqueandNVH(Noise,VibrationandHarshness)andcanbequicklycustomizedtosuitvirtuallyanyprocess.Resultscanbeinstantlycommunicatedtothestationcontrollertoprovidego/nogofeedbackinafullyautomatedenvironment.Datacanbeviewedandmanipulateddirectlyatthestandonthehighresolutiontouch-screendisplay,oruploadedviaEthernettoadatanetworkforstorageandanalysisinananalyticaldatabase,suchasSciemetric’sQualityWorX.Thismakesitpossibletoremotelymonitormanufacturingandqualitydatafromthedesktop.
APPLICATION OVERVIEW
Figure 1: Schematic block diagram of system implementation
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PSV — UnmATcHED DEFEcT DETEcTiOn
Sciemetric’sPSVTMsoftwareprovidesthemostpowerful,flexible,easy-to-usetechnologyformonitoringandcontrollingmanufacturingprocesses.Basedonascientificanalysisoftheprocesswaveform,itdramaticallyimprovestheaccuracyofdefectdetection,resultinginreliablepassorfaildecisionmaking.Inaddition,thedetaileddataprovidesvaluableinformationforreporting,defectanalysis,andyieldimprovement.
inTUiTiVE inTERFAcE
ThesigPOD1302offersanintuitive,simpleinterfacetoallowtheusertoanalyseandviewtestinformation.Highleveloperatorstatusscreensallowoperatorstoquicklyassessthestatusofthemanufacturingprocess,whilemoredetailedresultsandgraphsareavailableforengineersto‘drilldown’rightattheteststation.Graphscanbemadetofullscreen,pannedandzoomedformorethoroughanalysisoftheresults.Asimplebackupandrestoreinterfaceallowsuserstocreatesystemordatabackupsinseconds.
FlExiblE TEST SETUP
EachsigPOD1302comeswithpre-programmedtemplatescorrespondingtosomeofthemostcommonmanufacturingapplications,makingsetupquickandeasy.
ThePSVTMsoftwarealsooffersanunmatchedflexibilitythatcanbetailoredtovirtuallyanyprocess.Ithastheabilitytostoresetupsforupto16differentmodelsofthemanufacturedpart,eachofwhichcanbecustomizedtomatchthespecificprocessparametersparticulartothatvariant.Foreachmodel,upto10differentoperations
orstepscanbemonitored.Forinstance,apresssystemmayrequirethatthepartsaremeasuredbefore,duringandafter
insertioninthepress.PSVTMsoftwarecouldaccommodatethisbysimplyassigningaseparateoperationtoeachofthethreemeasurements,actingasifitwerethreeindependentmonitoringdevices.Within
eachoperation,PSVTMcansupportupto10waveformdefinitions,wheresensordataisevaluatedagainsttime,position,oranyotherdatathatwascapturedduringtheprocess(eg:forcevs.displacementorvoltagevs.time).
POWERFUl PROcESSing AnD AnAlyTicS
Pre-processingcanbeappliedtothecollectedsensordatatoexploitorisolatepertinentfeaturesinthedata.Inallthereare18analyticalprocessesavailable,rangingfromsimpleremovalofaDCcomponentortheapplicationofhighorlow-passfilters,toderivatives,integrals,andFFTanalysis.Upto10processescanbecascadedandappliedtogenerateeachwaveformfromsensordatasets,permittingisolationofthedefectsignatureeveninthemostcomplexofcircumstances.Specificfeaturescanthenbeextractedfromtheprocesseddataforevaluatingthequalityofthemanufacturing
process.Forinstance,simpleparameterssuchasmin,maxormeanvalues,ormorecomplexparameterssuchascuspvalue/locationortotalharmonicdistortion,canallbeautomaticallyextractedfromthewaveformandtestedagainstuser-definedlimits.Inallthereare27powerfulfeaturechecksavailabletoevaluatetheprocessdata.Inaddition,envelopescanbegeneratedfromproductioncurvestocreateastatisticaltemplate,againstwhichacomplexwaveformcanbeevaluatedquicklyandeasily.Finally,auniquefeatureallowstheusertoinstantlyviewtheresultsofneworupdatedalgorithmsusingpreviouslysaveddata.Thisstreamlinesthesetupandcommissioningprocessbyeliminatingtheneedforre-testingproductionpartstoevaluatetheoutcomeofprocessorlimitchanges.
DATA mAnAgEmEnT AnD REPORTing
ComprehensiveSPCreportingandplottingcapabilitiesenableausertoeasilytracktestresultsandmakeinformeddecisions.Auniquefeatureallowstestlimitstobederivedfromthestatisticalcontrollimits,allowingtestlimitstobelearnedstatistically.Thousandsofproductioncyclescanbestoredlocally,providingtraceabilityofrecentproductiondirectlyattheteststation.Datacanbereviewedevenwhilecontinuingtomonitorproduction.Alldata,includingwaveforms,canbeuploadedtoaremotestorageandtraceabilitysolutionsuchasSciemetric’sQualityWorX,whichalsoprovidesdetailedsignatureanalysisinadditiontoextensivereportingandcompleteparttraceability.
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TECHNICAL SPECIFICATIONS
©2010SciemetricInstruments,Inc.Allbrandandproductnamesaretrademarksorregisteredtrademarksoftheirrespectivecompanies.Productsandspecificationssubjecttochangewithoutnotice.
PrintedinCanada
Power
• SupplyVoltage:24VDC(22to28VDC)
• PowerConsumption:30Wmaximum,20Wtypical
Processor
• SystemMemory:1GBRAM
• DataMemory:Min40GBHD
• Ethernet:1
• USB:4Ports(V2.0)
• RS232:1
• Monitor:SVGAConnector
• Keyboard/Mouse:PS2
General
• OperatingTemperature:5to45˚C
• Environment:
Model1302panelmounted:IP65(NEMA12)
Model1302or1302Tnotpanelmounted:IP30
• PaintFinish:Blackbackedpowder
• IndustrialNetworks:Ethernet/IP,ModbusTCP
Digital Inputs
• NumberofChannels:8withcommonreturnline
• Polarity:Bidirectional
• IsolationVoltage:±120V(Opticallyisolated)
• Inputcurrent:Lessthan2.3mA
• Inputforlowstate:8VDCmaximum
• Inputforhighstate:16VDCminimum
• MaximuminputVoltage:±48VDC
• Switchingspeed:2msec
Analog Input• NumberofChannels:2• InputRanges:±10V,±5V,±1V,±200mV• InputAccuracy: 0.02%for1Vrangeandhigher,0.05%for200mV
range• Resolution:16bitA/D,±32,768counts• MaximumSampleRate:250kS/s• InputImpedance:10GΩinparallelwith100pF
(820Ωnopower)• SmallSignalBandwidth:
700kHz(noanti-aliasingfilters)• CrossTalk:75dBadjacentchannels• CMRR:92dB• Maximumworkingvoltage:±11VDC• OverloadProtection:±25Vforonechannel
poweredand±15Vwhenoff
Analog Excitation
• ExcitationVoltage:+10VDC
• MaximumCurrent:100mAperchannel
• Accuracy:±0.02%
• MaximumNoise:100μV
• ShortCircuitProtection:Continuous
Digital Outputs
• NumberofChannels:8withcommonreturnline
• Polarity:Bidirectional
• IsolationVoltage:±120V(Opticallyisolated)
• SwitchingCapability:±1A@±48VACpeakorDC
• ContactResistance:>100MΩoff,<0.5Ωon
• PowerOnState:AllOff
• Switchingspeed:8msec
Encoder Input• NumberofChannels:1• Sensors:Rotaryencodersandlinearscales• InputVoltage:5VTTLorOC(OpenCollector)• SignalType:QuadratureorSinglePhase• MaxFrequency:
10MHzTTL,50kHzOpenCollector• Counter:32bit(±2x109counts)• InputProtection:+24VDCor-18VDCwithout
damage
• SensorPower:+5VDC@150mA,currentlimited
Test • Models/Recipes:16• Operationspermodel:10• Waveformsperoperation:10• ProcessesperWaveform:10• Featuresperwaveform:10• Signalprocesses:Bandpassfilter,clipper,
derivative,extract,FFT,highpassfilter,integral,knockdetection,linear,lowpassfilter,min&maxtrack,notchfilter,popnoisefilter,removeDC,removeidledata,removereverseddata,runningRMS,smoother,Synchronousaverageandwaveformmath
• Features:area,envelope,mean,median,minimumvalueandlocation,peakvalue/location,peaktopeak,peak/RMS,powersum,RMS,slope,totalharmonicdistortion,kneevalue/location,cuspvalue/location,numberofpoints,rise/falltime,standarddeviation,thresholdcountorcrossing,waveformlength,getYatX
1302 mODElS
ModelNumber 1302 1302TPartNumber 10500-1302-0H00 10500-1302-TH00Display Externaloptional 8”TFT,800x600pixelsDimensions(HxWxD) 8”x4.5”x8” 8”x9.4”x5.2”
AbOUT SciEmETRic inSTRUmEnTS
Since1981,Sciemetric’sprocessmonitoringandqualitymanagementsystemsandsoftwarehaveenabledsomeoftheworld’sleadingautomotive,medicalandindustrialmanufacturerstogainvisibilityintoandcontrolovertheirmanufacturingprocesses.Ontheproductionfloor,ProcessSignatureVerification(PSV™)technologyprovidesthemostaccuratedeterminationofprocesshealthandpartqualitywhilecollectingalldata.ManufacturingmanagersuseSciemetric’sanalytictoolstotransformthedataintoactionableinformationtoreducecosts,managequality,andmaximizeyieldwhileprovidingproofofprocesscomplianceandcompleteline-widetraceability.
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