evolution controller - acradyne.comacradyne.com/manuals/manualevolution.pdf · the kdm and the...

1

EVOL

UTION

CON

TROL

LER Operations Manual

Version 2001 Revision 1.0

A SUBSIDIARY OF AiMCO D.C Nutrunners • Torque Measurement & Audit Equipment • Articulating Arms • Assembly Systems

2

This manual contains information critical to proper operation, set-up and operator/service personnel safety. Whenever Critical Safety items are addressed,

the type will be in Bold Italics.

Shock Hazard & Safety Circuits The EVOLUTION Controller is designed with the most advanced dual safety circuits in the industry. The incoming AC power is GFCI protected against any current leakage to ground. This is the only path for current that offers any safety hazard. However, the GFCI and the protection it provides WILL NOT FUNCTION PROPERLY unless the grounding circuit from the wall outlet or supply is present and installed according to the National Electric Code. The EVOLUTION Controller employs a unique redundant safety circuit that constantly monitors the integrity of the GFCI circuit loop from the tool body, cable and controller chassis. Should an open or even an intermittent break occur anywhere in the system, the computerized circuit will shut down the entire system immediately.

SERVICE PERSONNEL WARNING Due to the design efficiencies of the servo-amplifier and the high power output of this device, there exists a shock hazard whenever the cover is removed from the EVOLUTION Controller. IT IS IMPERATIVE THAT ONLY AUTHORIZED SERVICE PERSONNEL REMOVE THE COVER! Even when AC power has been disconnected, the highly charged capacitors in the servo-amplifier MAY contain a level of energy sufficient to represent a shock hazard when the cover is removed. While this hazard is a momentary and not a continuous current source, the possible shock could be dangerous. BEFORE ATTEMPTING ANY MAINTENANCE OR MODIFICATION, IT IS IMPORTANT THAT THE CHARGED CAPACITORS BE FULLY DISCHARGED. The design of the system provides for a (30) second bleed-off of the charge after disconnect of the AC power source.

INTRODUCTION

WARNING

I/INSTALLATION

Backplane dimensions for mounting. Enclosure shown in low mount position.

Enclosure shown in high mount position. Cable exits top for festooning, indicator lights and keypad angled down for easy access.

3

Mounting the Evolution controller is easily done by first mounting the backplane to a suitable surface. The controller is then latched onto the backplane and tightened with the supplied thumb- screw. The controller can be mounted in two different manners. As illustrated, the controller can be setup for either low or high mounting. The cable connection and the status light are interchangeable with the use of an allen key. The KDM and the torque display board must also be flipped. Changing the orientation of the enclosure should only be done by a certified service person. In order to function properly the following requirements must be met: 110VAC +/- 10% 220VAC +/- 10% *20 AMP Supply *10 AMP Supply * The controller will only draw these amounts of current at max draw for short times

KEYPAD (KDM)

TORQ

SECONDA

I/FRONT PANEL

INDICATOR LIGHTS RED = HIGH TORQUE / HIGH ANGLE YELLOW = LOW TORQUE / LOW ANGLE GREEN = ACCEPT BLUE = IN CYCLE

4

DISPLAY MODULE

UE DISPLAY

RY DISPLAY

5

I/BOTTOM PANEL

I/TOP PANEL

GFCI

SERIAL PORT (OPTIONAL)

HDD CAN EXPANSION

FUSES

DEDICATED CAN INTERFACE USED FOR: �ROTARY TRANSDUCER �SOCKET TRAY

POWER INLET

LOGIC I/O

PC WITH (2) SERIAL PORTS AND (1) PS2 PORT

ISA EXPANSION SLOTS

6

POWER key – Turns on and off the KDMODULE. (Needs to be held down for 2 or more seconds when turning off KDM). SHIFT key – Enables use of auxiliary key functions. When the Shift key is pressed a blue light illuminates ensuring that the alternate keys can be depressed. NUMBERED keys (1-9) – Enter and Modify Values per customer applications. HELP key - Aids operator to configure and trouble shoot system. MENU key – Moves one level up in the programming tree. ARROW keys – Dual functioned keys allow movement through the menu structure and are also

used to adjust torque in quick setup. (SHIFT + ARROW) YES key - Enables functions when available. (SHIFT + YES) NO key - Disables functions when available. (SHIFT + NO) F1 key – Displays current torque strategy within active parameter setting. (SHIFT + F1) F2 Key – Future use. (SHIFT + F2) RUN key – Accepts entered values writing data to both the Controller and the Nutrunner. Activates the run screen when pressed at the Main Menu screen. (SHIFT + RUN) OOPS key – Allows operator to reenter or reset a value that was entered by mistake. (SHIFT + OOPS)

I/KDM KEYPAD FUNCTIONS

7

T_TQ: 20.0 NM Final Torque

ANGLE: 30 Final Angle (Degrees)

CYCLE: ACCEPT Cycle Result

PS 1 / 8 Current Parameter Set The run screen on the keypad display module shows the results of a final tightening cycle. As indicated above the final torque and angle are displayed along with the cycle result. The engineering units used are also displayed in the torque row. The cycle result will either indicate accept or will show the control variable that was not satisfied. For example, low torque. The bottom row indicates the current parameter set being used along with the number of available parameter sets. To switch parameter sets, use the <2> and <8> to scroll through available parameter sets. Once the desired parameter set (for example 2 / 8) is displayed, press the <9> button to “lock” that parameter set in. If an external rotary transducer is plugged in, the display will replace the angle row with a row displaying the external rotary transducer torque. Also, the bottom of display will show the option to enter the AutoCal menu. By pressing <yes> (<Shift> + <9>), the controller will automatically enter the auto-calibration section. This is explained under the Calibration section of this manual.

T_TQ: 20.0 NM Final Torque

X_TQ: 20.4 NM External Xducer Torque

CYCLE: ACCEPT Cycle Result

AUTOCAL? PS 1 / 8 Current Parameter Set AutoCal Option

I/CONTROLLER RUN SCREEN

Shown above is the run screen on a keypad display module. The run screen is accessed through pressing run (<Shift> + <9>). The screen is updated after each rundown.

Shown above is the run screen on a keypad display module with an external transducer plugged into the system.

ANGLE TARGET

Target value for rot

CYCLE COMPLETE Torque level that detorque must be low

CYCLE START

Torque level at whithe torque needed

DOWNSHIFT TORQUE

Torque level where ERGO MODE

Ramps the releaseoperating environm

HI LIMIT

The upper control lAny torque/angle eTorque and/or Hi A

LO LIMIT

The lower control liAny torque/angle loTorque and/or Low

RPM DOWN

Spindle output speedownshift torque.

RPM FREE

Spindle output speeof a tightening cycle

SOFT START Allows slow rotation

TARGET TORQUE

Torque level where TORQUE CONTROL Control strategy in TORQUE CONTROL / ANG

Control strategy in monitored. A valuaand stripped fasten

TORQUE MONITOR / ANG

Control strategy in torque – turn applic
I/GLOSSARY OF TERMS
8

ational angle when measured from threshold torque.

termines the completion of a fastening cycle. The cycle complete er than the cycle start torque.

ch begins a tightening cycle. The torque level should correspond to to engage the bearing surface of the fastener to the work piece.

the motor speed is changed from initial speed to final speed.

of torque after reaching target torque to provide a more ergonomic ent when used in a hand held tightening operation.

imit for torque and/or angle. Must be set higher than target parameter. xceeding this value will be indicated by a red light and with a Hi ngle error on KDM.

mit for torque and/or angle. Must be set lower than target parameter. wer than this value will be indicated by a yellow light and with a Lo Angle error on KDM.

d (expressed as a percentage of maximum speed) after exceeding

d (expressed as a percentage of maximum speed) at the beginning .

of output spindle in order to engage the socket to the fastener.

system stops producing torque.

which torque is the only control parameter.

LE MONITOR which torque is the control parameter, but rotational angle is ble strategy for controlling torque, while checking for cross-threaded ers.

LE CONTROL which angle is the control parameter, but torque is monitored. Used in ations.

9

MAIN MENU

--- ACRADYNE---EVOLUTION

VERSION 2001

SETUP PSET CALIBRATION ADMIN VIEW STATS

The above menu tree illustrates the programming of the Evolution controller. The following sections will discuss the each of the four major divisions. Setup Pset Used to establish the operational parameters of the nutrunning system. The system is capable of maintaining (8) independent parameter sets. When editing parameter sets the operator can choose to edit an existing parameter set or the next available parameter set. When running or editing the current parameter set is displayed as PS x, where x is the number of the parameter set. As illustrated by the attached menu tree, there are two ways to program a parameter set. Quick Start Quick start only requires the user to select the desired parameter set and operating torque. All other values are set according to the system defaults (further explained in the ADMIN section). The torque is selected by using the arrow keys. If shift is held in then the arrow keys will increment torque by whole numbers. If the shift key is not held in torque will increment by tenths. Once the desired torque is set press Shift + Run to send the parameters to the controller. Configure Configure allows the operator to edit all programmable operating functions for the desired parameter set. The arrow keys are used to advance from screen to screen and to scroll up and down the options shown in the menu tree. All functions are fully described in the KEY TERMS section of this manual. Once the desired changes are made, press Shift + Run to send the parameters to the controller. Torque high and low limit can be entered in two different manners. The high and low limit can be entered as values by scrolling to the desired function and typing in the value. Alternatively, by scrolling to the bottom +/- % line, the high and low limits can be automatically calculated as a percentage of target torque. For example, if a target torque of 20Nm was set and 10 were entered for +/-%, values of 22 and 18 would automatically be entered for high and low limit.

I/PROGRAMMING

10

Setup Pset (Continued) The torque values for threshold, downshift, and cycle complete can also be programmed in two different manners. Scrolling to the desired function and typing in the value can enter actual torque values. Alternatively, by scrolling to Auto Set and entering YES (Shift + 1) the torque values are automatically set according to the Parameter Set Defaults (See ADMIN section for more info).

I/PROGRAMMING

11

EXPLANATION: The tool will begin a new fastening cycle once torque rises above the Tq Threshold (Torque Threshold) value. Once Tq Downshift (Torque Downshift) is reached, the tool will change speeds from RPM Free speed to RPM Downshift. These speeds are expressed as a percentage of maximum RPM. The tool will continue to run until it reaches target torque. Upon reaching target torque the tool will shut off. Once cycle complete is crossed, the maximum torque achieved is displayed. If this torque is between Tq Hi Limit and Tq Low Limit then cycle accept is displayed and the green led’s are illuminated.

CONTROL STRATEGIES – Torque Control

12

EXPLANATION: This strategy functions the same as Torque Control, with the exception that angular rotation is monitored. Angular rotation is measured from Tq Threshold. The limits for angular rotation are established by setting Angle Hi Limit and Angle Lo Limit. Angular monitoring is useful for detection of cross-threaded and stripped fasteners.

CONTROL STRATEGIES – Torque Control / Angle Monitor

13

EXPLANATION: When using angle as the control parameter, there are several differences. As in Torque Control, the tool will begin a new fastening cycle once torque rises above the Tq Threshold (Torque Threshold) value. Angular rotation is measured from Tq Threshold. Also, in torque monitor / angle control downshift always takes place at threshold torque. The user is required to program an angle target, angle high limit, torque high limit and torque low limit. The tool will continue to rotate until either the angle target is reached or torque high limit is reached. Shutting off on the torque high limit prevents the tool from running outside of its rated torque range. An accepted cycle must be within both the angle and torque windows. Angle control strategies are best used with fixtured tools.

CONTROL STRATEGIES – Torque Monitor / Angle Control

14

EXPLANATION: Torque Control / Angle Control uses both torque and angle to control the event. As in all configurations, the cycle begins when threshold is crossed and angle measurement begins. The tool will change to RPM Downshift once the Tq Downshift level is reached. During the rundown both torque and angle is monitored. Once either torque target or angle target is reached, the other variable is compared against its limits. If it is within those limits, the tool will shut off and display the result upon crossing Cycle Complete. If either Tq Hi Limit or Angle Hi Limit is reached, the cycle is immediately ended and the result displayed. If either torque target or angle target is reached but the other variable is not within limits, the event will continue until the low limit is reached. For example, in the above diagram once a torque of 15 Nm is reached the tool will change to the downshift speed. If the tool reached 25 Nm before 690 degrees of angular rotation from threshold, the angle value is then checked to see if it was between 500 and 800 degrees. If the angle were 505 degrees the tool would shut off. If the angle were less than 500 degrees the tool would continue to rotate in order to get inside of the angle limits. If a torque of 29.3 Nm was reached before 500 degrees of rotation the tool would shut off and display reject. This strategy is most effectively used with precision parts.

CONTROL STRATEGIES – Torque Control / Angle Control

Ergo Mode: YSStart: YES

Lo Limit: 18.0+/- %: 10.0

Tq Target: 20Hi Limit: 22.0

Rpm Free:100Rpm Down: 7

DwnShift: 14.Cycle Comp: 2Auto-Set?:

Thold: 5.0

Tq Contro

4) Con1 - 3)

-- QUI

-- QUI

4) Con1 - 3)

Se

Qu
I/SETUP PARAMETER SET MENU
15

Lo Limit: 10Hi Limit: 80Ang Target: 50

PS1

Lo Limit: 18.0

Auto-Set?: PS1

Rpm Free:100.0

Ergo Mode: YESSStart: YES PS1

Rpm Down: 75.0

+/- %: 10.0 PS1

Cycle Comp: 2.5DwnShift: 14.0Thold: 5.0

Hi Limit: 22.0Tq Target: 20.0

Tq Cont/Angcont

ES PS1

PS1

.0

.05.0

0.5

PS1


PS1

Hi Limit: 999Ang Target: NA

Lo Limit: 5

+/- %: 10.0 PS1Lo Limit: 18.0Hi Limit: 22.0Tq Target: 20.0

Auto-Set?: PS1

Rpm Down: 75.0Rpm Free:100.0

Cycle Comp: 2.5DwnShift: 14.0Thold: 5.0


PS1

Hi Limit: 80Lo Limit: 10

Ang Target: 50

+/- %: 10.0 PS1

Auto-Set?: PS1

DwnShift: 14.0Thold: 5.0

Cycle Comp: 2.5

Rpm Free:100.0Rpm Down: 75.0

Lo Limit: 18.0Hi Limit: 22.0Tq Target: 20.0

l

fig NextConfig Pset

CK START --

CK START --

fig NextConfig Pset

tup Pset

ick Start

3) TqMon/AngCont4) TqCont/AngCnt

2) TqCnt/AngMon1) Tq Control

4) Config Next1 - 3) Config Pset

-- CONFIG PSET --

Tq Cont/Angmon

Configure

Tq Mon/Angcont

SHIFT + RUN Sends Changes to Tool

ADMIN The administration section of tSetting up security password, Vtree for the ADMIN section is e PARAMETER SET DEFAULTParameter set defaults are theQuick Start or Auto Set. All va Tq Target: The default settingvalue entered is a percentage entered is 80 and the maximumentering quick programming w Tq +/-%: The default percentaof target torque. Tq Thold: The default setting torque. Tq Dshift: The default setting torque. CycComp: The default settingtarget torque. RPM Free: The default settingmaximum output spindle speed RPM Down: The default settinvalue entered is a percentage Units: The default engineeringengineering unit for all parameparameters sets new and old. SECURITY The system allows for securityand replaced with a blank paneunwanted tampering with the p The security password is estab<yes>. The user will then be pverify this password before it is TOOL INFO The tool information section alViewable information is as follo

Tool serial number Tool maximum torqueTool maximum output Tool calibration value

RESET DEFAULTS Allows the user to reset three vfollows:
I/ADMINISTRATION
16

he KDM has four functions: Setting up parameter set defaults, iewing tool information, and Resetting factory defaults. The menu

nclosed.

S values used to calculate control parameters when using either lues are described in full below:

for target torque shown when entering quick programming. The of the maximum torque of the tool. For example, if the value

torque of the tool is 30 Nm, the default target torque when ould be 27.0 Nm.

ge used for high and low limit. The value entered is a percentage

for threshold torque. The value entered is a percentage of target

for downshift torque. The value entered is a percentage of target

for cycle complete torque. The value entered is a percentage of

for RPM free speed. The value entered is a percentage of in rotations per minute (RPM).

g for spindle speed after crossing the downshift torque level. The of maximum output spindle speed in rotations per minute (RPM).

units for operation. The KDM is only capable of using one ter sets. Changing the units in this section will affect all

in two manners. The KDM can be removed from the enclosure l or the security password can be implemented. Both prevent rogramming of the Evolution controller.

lished by toggling to the enable password option and entering rompted to enter a (4) digit password. The user will be asked to implemented.

lows the user to view information stored on the Tool ID board. ws:

output in Nm speed in RPM

ariables to the factory default settings. The three variables are as

Reset Tool Cal V when it was initially built. This Reset Logic I/O: The logic I/O can I/O section of this Reset Parameterparameter set, wh ERROR CODE Allows the user tobinary message r

A C E

When an error is

example:

A C E

Shown above is the eEvolution controller.

alue: Resets the tool calibration value to the original value it had

I/ADMINISTRATION – ERROR CODES

17

Company: AcraDyne File Data: Current Parameter Sets Time: 4:05:29 PM Date: 10/6/00 Parameter Set Number: 1 Units: Nm Strategy: Tq Control Target: 30 Target Hi: 34 Target Lo: 28 Tq Threshold: 10 Tq Downshift: 20 Tq Cycle Complete: 3 Angle Target: 0 Angle Hi: 999 Angle Lo: 10 Rpm_Freespeed: 85 Rpm_Downshift: 40 Soft Start: No Ergo: No

value is permanently written to the tool when it is produced.

Resets the logic input/output portion of the controller back to default settings. be changed by using ToolWare. The relay settings are explained in the Logic manual.

Set: Erases all active parameter sets and replaces them with one generic ich is set as follows:

perform basic troubleshooting with the KDM. The user will be presented with a epresenting and error message.

-- ERROR CODE -- UTO: 00000 00000 YCLE: 00000 00000 XT: 00000 00000

present in the system a numeric value will be displayed on the screen. For

-- ERROR CODE -- UTO: 00169 00000 YCLE: 00000 00000 XT: 00000 00000

rror screen on the KDM. This screen can be used for basic troubleshooting of the

By using

For exam

find the e128, leavwould div8 and 1 in

Error Co

BbT Bbc F(d

Hath Inthcp Ls

Mth

Mth

ERR

I/ADMINISTRATION – ERROR CODES (Cont’d)

18

the table below the end user can determine which faults are present in the system.

ple, as shown on the previous page, there is an error of 169 in the AUTO column. To rror(s) divide 169 by the largest error code possible. In this case we would divide by ing a remainder of 41. Repeat this process until there is no remainder. Therefore we ide 41 by 32; divide 9 by 8; divide 1 by 1. This would tell us that we have errors 128, 32, the AUTO column.

de Definitions: Listed below are brief definitions for the most common errors.

utton State – The tool is not sending an operational direction to the system. This can e verified by using ToolWare - TechWare – Monitor Button State as explained above. he tool is prevented from operating until a direction is sent.

utton Timeout – The system has lost communication with one of the operational uttons. As a safety precaution the tool is prevented from running until it has full ommunication with all buttons.

ree Run Timeout – The tool ran under no load for longer than the set time period efault setting is five seconds).

all Error – The motor commutation hall sensors sent an invalid sequence to the control lgorithm. Commonly, this is due to the loss of a hall sensor, which can be verified via e test points on the spindle control card.

compatible Voltage – The operational voltage selected via either the tool eeprom or e dipswitches in the controller is not compatible with the tool connected. This situation

an be remedied by reviewing the dipswitch setting in the controller and/or verifying the roper voltage selection on the tool eeprom.

oad Run Timeout – The tool ran under load (above cycle threshold) for longer than the et time period (default setting is 15 seconds).

CU Param – The keypad display module is not communicating properly with the rest of e system.

CU Timeout – The keypad display module is no longer communicating with the rest of e system.

OR CODE AUTO CYCLE EXTERNAL1 TID Timeout Free Run Timeout PSET Value2 Future Use Load Run Timeout Future Use4 Future Use Hall Error Future Use8 XDCR Timeout Tool Offset TID Param Value16 Future Use XDCR Offset Future Use32 Tool GND Future Use TID Param Timeout64 Power On Throttle Tool Level Future Use128 Button Timeout XDCR Level XDCR Param256 Button State Future Use Future Use512 Undefined Voltage Locked Rotor XDCR Timeout1024 Incompatible Voltage Drive Fault Future Use2048 Tool Update Required Future Use Future Use4096 Future Use Future Use Target Value Fault

Ppre

Tth TPb

Tru Tom T Tnw

Udthto

Xlile X

FILTER F This featu

Evolutionsystems tis 500 Hz

ADAPTIV Adaptive

by adjustilower con

None: Tu

Thereforetorque to CPK.

Ten: Takmake theboth abov All: Simi

ten r

I/ADMINISTRATION – ERROR CODES (Cont’d)

19

ower on Throttle – The system detected the throttle in the run position when it was owered on. As a safety precaution the tool is prevented from running until the throttle is set.

ID Param – The tool identification board is not communicating properly with the rest of e system.

ID Timeout – The tool ID board is no longer communicating to the rest of the system. ossible causes are loss of power to the tool ID board or faulty wiring to the tool ID oard.

ool GND – The safety ground loop in the tool is open. The tool will be prevented from nning until the ground loop is restored.

ool Level Error – The transducer voltage level has gone outside the acceptable perating limits. These limits require a minimum voltage level of +0.5 VDC and a aximum voltage level of +4.0 VDC.

ool Offset – The no load transducer voltage is outside of acceptable operating limits.

ool Update Required – The digital signal processor version and the tool ID version are ot compatible. The tool must be updated in order to function. Updates are done via riting parameters to the tool eeprom.

ndefined Voltage – The operational voltage selected via either the tool eeprom or the ipswitches in the controller is undefined. This situation can be remedied by reviewing e dip switch setting in the controller and/or verifying the proper voltage selection on the ol eeprom.

DCR Level - The transducer voltage level has gone outside the acceptable operating mits. These limits require a minimum voltage level of +0.5 VDC and a maximum voltage vel of +4.0 VDC.

DCR Offset - The no load transducer voltage is outside of acceptable operating limits.

REQUENCY re is reserved for future development. The filter frequency option will allow the

controller to be used with continuous and non-continuous drive tools. In all DC electric he filter frequency is defaulted to direct. The filter frequency used for direct drive tools . This is the recommended frequency as published in ISO 5393.

E CONTROL control is a useful option when a high CPK is the most important variable. This is done ng the control to ensure the average applied torque is centered between the upper and trol limit. This feature has three options, which are explained below.

rns adaptive control off. The tool will produce torque until the target torque is achieved. , all results will be equal to or greater than the target. This will cause the average be greater than the target torque, thus making it extremely difficult to produce a high

es an average of the first ten readings in a new parameter set and adjusts the control to average torque correspond with the target torque. Therefore, there will be readings e and below the target torque, thus maximizing CPK.

lar to the above, but continually adjusts the control based on the average of the previous eadings in an attempt to maximize CPK.

20

Filte

r Fr

eq

Yes

) En

ter

N

o) C

lrRan

ge: (5

0 - 5

000)

3)

OTH

ER2)

PULS

E1)

DIR

ECT

F

ILT

ER

FREQ

: Rpm

Free

: 100

. 0

Tq

Tar

get:

75.0

PSet

Def

aults

Tq

+/-

%: 1

0.0

Tq

Tho

ld: 2

0.0

Tq

Ds h

ift: 6

5.0

Cyc

Com

p: 1

0.0

Cha

nge

Pwor

dEn

able

Pw

ord

Secu

ri ty

Tog

gles

bet

wee

n en

able

and

disa

ble

pass

wor

d

New

Pw

ord:

****

Adm

in

Res

et D

efau

lts

1)

Too

l Cal

Val

ueRES

ET--TO

OL

INFO

--

Too

l Inf

o

Max

_Spe

ed: 107

5

--TO

OL

INFO

--

ID:

420012

Tq:

30.0

N

M3)

Para

m S

e t2)

Logi

c I/

O

AD

MIN

ERRO

R

Erro

r C

ode

Ext:

00000 0

0000

Cyc

le:0

0000 0

0000

Aut

o:00000

00000

FILT

ER

Rpm

Dow

n: 7

5.0

Uni

ts: N

M

Ver

ify P

assw

o rd

Pass

wor

d: *

***

Pas s

wor

d C

orre

ctSt

orin

g Pa

ssw

ord

Pass

wor

d: *

***

Cal

: 128.0

AD

APT

IVE

CTRL

Ada

ptiv

e C

trl

3

) A

LL*

2)

10

1

) N

ON

E

I/ADMINISTRATION MENU

It is necessary to perioshowing the correct to Manual CalibrationInstalling an external rmanual calibration. Onwill display a torque vareading. If the values do not mascrolling to the new catransducer is entered fin the tool. It may be ncalibrated, the calibratoverwritten. Automatic CalibratAutomatic calibration irotary torque transducentering AutoCal the uused for averaging purnumber of rundowns evalue that is the avera The user can leave thethe run screen is enterthe screen. AutoCal c

X_Tq: 2

Man

T_Tq: 2

Yes) Ent

--MANU

I/CALIBRATION PROCEDURE

21

dically calibrate the nutrunning system to ensure that the display is rque. Performing either a manual or an automatic calibration can do this.

otary torque transducer in-line with the nutrunning system performs a ce the rotary transducer is installed, perform a fastening cycle. The KDM

lue that should correspond to the independent rotary torque transducer

tch, then a manual calibration value is entered by selecting manual cal and l portion of the display. At this point, the value for the external torque or new cal. After this is done select <yes> to update the calibration value ecessary to repeat this operation more than once. Once the tool is

ion value is stored on the tool ID board and will remain present until

ion s performed with an Evolution controller and with an AcraDyne external er plugged into the CAN interface port on the spindle control card. Upon ser will be prompted to enter the number of runs (between 1 and 9) to be poses. Once this information is entered, the user needs to perform the ntered. Upon completion, the user can either accept the new calibration ge of all rundowns or decline to accept the new calibration value.

AcraDyne transducer plugged in after the calibration procedure. When ed both the tool torque and the external rotary torque will be displayed on an be entered directly from the run screen by entering <yes>.

1.0

ual Cal

0.0

er No) Clr

AL CAL--

--AUTO CAL--T_Tq: 20.0X_Tq: 20.0001 / 009

Yes) Enter

# Of Runs (1 - 9)--AUTO CAL--

Auto Cal

Calibration

NewCal: 128.5OldCal: 128.0--AUTO CAL--

Yes) Enter No) Clr

22

The last option from the main menu of the KDM is stats. By selecting this option, the user can display statistical information for a particular parameter set. Up to 100 data points are stored per parameter set. These data points are used to calculate statistical information. If any change is made to a parameter set, then all data for that particular parameter set will be cleared. The statistical values displayed are: POP Population; The total number of observations used to calculate the statistical data CPK

Process capability, which takes both sigma and mean into account. The equation for CPK is the smaller of:

(Upper Limit – Mean) / 3 Sigma or (Mean – Lower Limit) / 3 Sigma

CP Overall capability, which is the ratio of 6 sigma to the tolerance. The equation for CP is:

(Upper Limit – Lower Limit) / 6 Sigma

6 Sigma The standard deviation multiplied by 6. A total range of 6 sigma will include 99.7% of all data. The equation for 6 sigma is as follows:

6 x

/X X-Bar; Mean; (Sum of All Readings) / (Number of Readings) R Range; The difference between the maximum and minimum reading.

1 - 8) PSET 1 - 8

POP: 50

CP: 2.05CPK: 1.66

-- VIEW STATS --

R: 2.32/X: 45.046SIG: 2.35-- VIEW STATS --

SELECT PSET

-- VIEW STATS --

View Stats

I/STATISTICAL INFORMATION

23

OUTPUTS INPUTS 1 +24 VDC COMMON 23 +24 VDC COMMON 45 INPUT #12 HIGH

2 +24 VDC 24 +24 VDC 46 INPUT #12 LOW

3 RELAY #6 NO 25 RELAY #7 NO 47 INPUT #11 HIGH

4 RELAY #6 COMMON 26 RELAY #7 COMMON 48 INPUT #11 LOW

5 RELAY #6 NC 27 RELAY #7 NC 49 INPUT #10 HIGH

6 RELAY #5 NO 28 RELAY #8 NO 50 INPUT #10 LOW

7 RELAY #5 COMMON 29 RELAY #8 COMMON 51 INPUT #9 HIGH

8 RELAY #5 NC 30 RELAY #8 NC 52 INPUT #9 LOW




12 +24 VDC COMMON 34 +24 VDC COMMON 56 INPUT #7 LOW

13 +24 VDC 35 +24 VDC 57 INPUT #6 HIGH










67 INPUT #1 HIGH

68 INPUT #1 LOW

OUTPUTS All outputs produce either a normally closed or normally open contact closure. If needed the end user can implement the supplied unregulated +24 VDC power supply. This power supply is isolated from the rest of the nutrunning system. The power supply is capable of producing up to 4 amps for use on external equipment (display lights, line interfacing, etc) INPUTS All inputs operate on a +24 VDC signal that requires less than 15mA for closure. DEFAULT SETTINGS The I/O is user programmable through the use of ToolWare, a software package produced by AcraDyne. Listed below is the default configuration for the I/O. OUTPUTS INPUTS RELAY 1 CYCLE ACCEPT RELAY 1 TOOL FORWARD RELAY 2 CYCLE REJECT RELAY 2 TOOL REVERSE RELAY 3 HIGH TORQUE RELAY 3 DISABLE TOOL RELAY 4 LOW TORQUE RELAY 5 ANGLE HIGH RELAY 6 LOW ANGLE

I/INPUTS & OUTPUTS

24

RELAY 7 IN CYCLE TOOL SHUTS OFF AT LOW TORQUE

IMPROPER PROGRAMMING Increase threshold torque value

TOTAL RUNDOWN LONGER THAN TIMEOUT VALUE The tool has a safety feature, which shuts the tool off after 10 seconds of continuos running. The timeout value can be increased via customer request.

TOOL REACHING HIGH ANGLE LIMIT Adjust angle limits so target torque can be reached within angle window

TORQUE ANGLE DISPLAY DOES NOT WORK

VERIFY RIBBON CABLE IS PLUGGED INTO KDM CORRECTLY VERIFY TORQUE ANGLE DRIVER BOARD IS SEATED PROPERLY

DISPLAY SHOWS WRONG ENGINEERING UNITS

Engineering units are changed under option <1> PSET Defaults in the Administration menu. Use the arrow keys to change units.

I/O DOES NOT FUNCTION PROPERLY IMPROPER WIRING ON I/O BAD I/O POWER SUPPLY

Verify presence of +24VDC on output of I/O supply IMPROPER PROGRAM – RESET DEFAULTS IF NECESSARY UNABLE TO GET TO RUN SCREEN – BLUE SHIFT LIGHT DOES NOT OPERATE

Press <Menu> button to refresh keypad UNABLE TO OPERATE – BLUE SHIFT LIGHT WILL NOT GO OUT

Cycle power to the KDM by powering off and then powering on

I/TROUBLESHOOTING - TOOL I/TROUBLESHOOTING

25

ANY TIME THE COVER IS REMOVED POWER MUST BE UNPLUGGED AFTER UNPLUGGING CONTROLLER LEAVE IDLE FOR ATLEAST (5) MINUTES TO ALLOW ALL CAPACITORS TO DISCHARGE. HIGH LEVELS OF POWER ARE STILL PRESENT EVEN WHEN MAIN POWER IS UNPLUGGED. MAKE SURE YOU ARE OPERATING IN THE CORRECT PARAMETER SET CHANGE ACTIVE PARAMETER SET BY USING THE ARROW KEYS AND THEN HITTING <9> TO LOCK INTO THAT PARAMETER SET IT IS EASIEST TO SWAP WITH KNOWN GOOD COMPONENTS TO FIND OUT WHICH COMPONENT IS FAULTY SERVICE BULLETINS ARE AVAILABLE TO HELP TROUBLESHOOTING TOOLWARE SOFTWARE ALLOWS FOR INCREASED DIAGNOSTIC CAPAPBLITY, DATA STORAGE AND PROGRAMMING OF UNIT VIA A PC

I/TROUBLESHOOTING –GENERAL KNOWLEDGE

evolution controller - acradyne.comacradyne.com/manuals/manualevolution.pdf · the kdm and the...

Documents