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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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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www.sciemetric.cominquiries@sciemetric.com1-877-931-9200

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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