qtrans - haller + erne

QTrans

System 300 data conversion to Q-Das data format

V1.27.12

© 2008-2010 Haller + Erne GmbH

Document revisions

Document revisions 2008-09-29 HE Added description for QTrans V1.27.7:

- added description for AMT-XML output driver (5.2.5)

- added description for new global option for switching between

different Q-Das ID-Code behavior (4.4.2, 3.3.4.1)

2009-04-14 HE Added mapping information for AMT-XML output driver

2009-07-21 HE Added V1.27.9 information:

- new QTrans.ini [Global] parameter FTPBufSize

- new dynamic report GUI

- KEScanner Wizard for system auto-configuration

2010-08-02 HE Added V1.27.12 information:

- added description for Siemens HMI interoperability (chapter

2.2.2)

Table of contents

Table of contents

1 INTRODUCTION ......................................................................................... 1

1.1 System overview ..................................................................................................... 1

1.2 Terms and Definitions ........................................................................................... 2

2 INSTALLATION AND CONFIGURATION .................................................. 4

2.1 Installation .............................................................................................................. 4 2.1.1 Manual installation ........................................................................................... 4 2.1.2 Automatic installation ....................................................................................... 4

2.2 Post installation tasks ............................................................................................ 4 2.2.1 Configuration .................................................................................................... 4

2.2.2 Siemens Software and HMI compatibility ....................................................... 4

2.3 Startup .................................................................................................................... 5

2.4 Data protection, security and backup .................................................................. 6

3 USER INTERFACE AND OPERATING PROCEDURES ........................... 7

3.1 Introduction to fundamental grid details ............................................................ 7 3.1.1 Column Layout ................................................................................................. 8

3.1.2 Filtering results ............................................................................................... 10

3.2 QTrans Status Monitor ....................................................................................... 12 3.2.1 Station operation modes ................................................................................. 15

3.2.2 GUI ................................................................................................................. 16 3.2.3 Configuration .................................................................................................. 19

3.2.4 Reports ............................................................................................................ 20

3.3 DBEditor ............................................................................................................... 28 3.3.1 Workflow ........................................................................................................ 28

3.3.2 General usage ................................................................................................. 29 3.3.3 Main GUI Window ......................................................................................... 30 3.3.4 Editors ............................................................................................................. 31 3.3.5 Tools ............................................................................................................... 48

4 REFERENCE ............................................................................................ 51

4.1 Detecting part changes ........................................................................................ 51

4.2 Part definition and bolt mapping ....................................................................... 52

Table of contents

4.2.1 Overview ........................................................................................................ 52 4.2.2 Tool studies (tool verification) ....................................................................... 52 4.2.3 Stitching and batching .................................................................................... 53 4.2.4 Sample part definitions ................................................................................... 55

4.3 Configuration – QTrans.ini ................................................................................. 56 4.3.1 Description of Sections and Keys ................................................................... 56 4.3.2 Example: Data processing on a local computer in „verify mode” ................. 59 4.3.3 Example: Distributed data processing ............................................................ 60 4.3.4 Example: Data processing on a local computer in „report mode” ................. 62

4.3.5 QTRANS - Command line parameters ........................................................... 63

4.4 Additional notes ................................................................................................... 64 4.4.1 General notes .................................................................................................. 64 4.4.2 Special K-Field handling ................................................................................ 64

4.5 Tool Verification field mappings ........................................................................ 66

5 REFERENCE AND OUTPUT DRIVERS ................................................... 68

5.1 Reference meter drivers ...................................................................................... 68 5.1.1 RS Technologies Model 960 Transient Recorder ........................................... 68

5.1.2 Burster DigiForce ........................................................................................... 68

5.2 Output drivers ...................................................................................................... 68 5.2.1 Q-Das QS-Stat ................................................................................................ 68 5.2.2 Excel ............................................................................................................... 68

5.2.3 XML-CAQ ...................................................................................................... 69 5.2.4 CSV ................................................................................................................ 69 5.2.5 AMT-XML ..................................................................................................... 72

6 REQUIREMENTS AND RESTRICTIONS ................................................. 75

6.1 System 300 Configuration ................................................................................... 75 6.1.1 ID-Code (VIN or other identification number) .............................................. 75 6.1.2 Data output settings ........................................................................................ 75

6.2 Tightening programs ........................................................................................... 75 6.2.1 Application number selection ......................................................................... 75

6.2.2 Rework ............................................................................................................ 75

7 TROUBLESHOOTING .............................................................................. 78

7.1 Data converter does not receive data ................................................................. 78

7.2 Verification Study ................................................................................................ 78

Table of contents

7.3 Production Studies ............................................................................................... 78

8 SAMPLE WALKTHROUGHS ................................................................... 80

8.1 Sample setup walkthrough .................................................................................. 80 8.1.1 Setting the KE FTP communication with the BS300: .................................... 80

8.1.2 Setup the Tool program/application ............................................................... 81 8.1.3 Configuring the Q-trans file: .......................................................................... 83

8.2 Sample Q-DAS review reports walkthrough ..................................................... 87 8.2.1 Choose Module ............................................................................................... 87

8.2.2 General Use .................................................................................................... 87 8.2.3 Sample Analysis Module ................................................................................ 88 8.2.4 Measurement System Analysis Module ......................................................... 89

9 REFERENCED DOCUMENTATION ......................................................... 91

1 Introduction

1

1 Introduction

1.1 System overview

The main purpose of the Q-Trans application is to provide a real time conversion utility to

translate Bosch Rexroth Tightening System 300 information into a file format compatible

with Q-DAS ME 5.0 GMPT edition.

The following graphic shows an overview of the system:

SE/KE300

cell and tightening

controllersSpindles

SE/KE300

cell and tightening

controllers

PC running

QTrans

conversion

software

Spindles

RS-Tech

torque meter

Trans-

ducer

TCP/IP

RS232

To provide superior ergonomics QTrans features a real time monitor (Dynamic Report

Window) for actual data received from the tightening tools with a history of up to 2400

Cycles per KE. QTrans also delivers report functionality with predefined filters. See the

program process chart below for principal reference.

1 Introduction

2

QTrans

Dynamic Report

Window

311-tght.res.

312-tght.res

313-tght.res

314-tght.res

SE/KE300

cell and tightening

controllers

SE/KE300

cell and tightening

controllers

Applications /

Programs

Database

DBEdit

Editing

Cell, Line

information

…, (316), (315)tightening results:

Q-Das (dfx, dfd)

XML-CAQ

Logs

Output-Data

plausibility + line/ cell info

ma

x.

24

00

cycle

s /K

E

311 – tightening result



Dynamic Report Image

DataView.dat

(311), (312),

(313), (314)

1.2 Terms and Definitions

The following illustration shows an overview of a generic tightening system and defines the

terms used in this manual:

Powerhead 1

Powerhead 2

Po

werh

ea

d 3

KE2KE1

KE-Cell KE-Cell

GM-Operation = KE-Station

GM-Station = KE-Application

1 Introduction

3

Typically there is only one KE per station, so most tightening systems will be configured in

the following manner:

Powerhead 1

Powerhead 2

KE

GM Operation = KE Station

KE-Applications

1.2.1.1 Bosch System 300 terms and definitions

Cell System 300 tightening cell (KE)

Master System 300 communication controller (KE)

Channel System 300 tightening controller for a single spindle (SE)

Step System 300 tightening step (within a program)

Program System 300 tightening program (defined per spindle)

Application System 300 tightening application (FO, defines group of spindles)

For additional information on the System 300, please refer to the full System 300 reference

manuals.

1.2.1.2 Production line definitions

Line Typical production line consisting of multiple stations

Station Group of spindles, physically connected to the same machine

Spindle Physical tightening tool. Spindles are integrated within a station. Each

spindle maps to a Bosch System 300 channel (SE)

1.2.1.3 GM definitions

Loop Defines a section of the production line

Operation Number or description used to define a station’s function

Powerhead Group of spindles started by a common run signal

= Bosch Rexroth terminology: KE application (group of spindles)

= GM terminology: Station (group of coordinated spindles)

See also: GM specifications

1.2.1.4 Q-Das definitions

Characteristic type type of measurement, i.e. “Angle” or “Torque”

Characteristic normally defines an instance of a characteristic type, which is

uniquely assigned to a measurement source (i.e. Torque

measurement of channel x, program y, step z)

Value measured value of a given characteristic

Attribute additional attributes for a given value or measurement

K-Field many different meanings, see Q-Das documentation

See also: Q-Das specifications.

2 Installation and configuration

4


2.1 Installation

2.1.1 Manual installation

To install the software manually, copy all files from the installation media to a directory of

your choice. Make sure to remove the “read only” attribute if you have copied the files from a

read only media.

After you have copied all the files, you may create shortcuts for the start menu and the

autostart group.

2.1.2 Automatic installation

To install the software, run setup.exe from the installation media.

2.2 Post installation tasks

2.2.1 Configuration

Before starting the software, you should check user and password settings in QTrans.ini (see

4.3).

2.2.2 Siemens Software and HMI compatibility

On PCs with installed Siemens software, there might be issues with QTrans and Siemens

software interoperability in the following areas:

- FTP server: Some Siemens software configurations activate a FTP server to provide

firmware and parameter downloads to networked Siemens controllers. As QTrans also

contains an embedded FTP server, in this case care must be taken, that both services

can work as expected.

- HMI integrations: If Siemens HMI or visualization software is used, then QTrans can

use the Siemens PLC/NC security infrastructure to automatically synchronize to the

HMI user levels. In this setup, special configuration of the HMI software (or Transline

2000) is required to ensure smooth interoperability and to allow easy view switching

by HMI softkeys.

The following sections describe the required manual configuration steps.

2.2.2.1 FTP-Server configuration

To ensure Siemens FTP server (Win_BetaFTPD.exe) and QTrans FTP server work together

correctly, each server must be bound to a distinct IP address. This requires either two network

interface cards (which is normal for Siemens Hardware) or two IP addresses set up for the

PCs network interface card (in case the PC has only one network interface card). In general

the QTrans FTP server should be bound to the “public network interface” and the Siemens

FTP server should be bound to the Siemens “Internal Interface” (so called “System

Network”). Please also make sure, that all tightening controllers (KE3xx/CS3xx) are withing

the address range of the “public network interface”.

Setup QTrans and Siemens as follows:

- QTrans: During installation, enter the IP address of the “public network interface” on

the installer screen. The setting defined during the installation phase can viewed/edited

by opening the QTrans.ini file (see 4.3.1.1).


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- Siemens: Open the Siemens Win_BetaFTPD configuration file betaFTPd.conf from

<SiemensInstallDir>\services\betaftpd\etc and change (or add) the interface line to

read:

interface <ip addr of internal interface>

e.g.

Please make sure to reboot the PC after any manual change to the configuration files!

2.2.2.2 HMI integration

QTrans contains special code for integration into the Siemens standard HMI software. This

provides two benefits:

- Security integration: QTrans is able to recognize the HMI/NC/PLC user level set in

the HMI. This enables single sign on for both HMI and QTrans, therefore minimizing

username and password management and providing additional integration into all

Siemens HMI security services (e.g. logon using hardware tokens).

- Application view integration and active GUI switching using HMI soft/hardkeys. By

starting QTRans using the HMIs external software integration functions, the QTrans

main window gets managed by the HMI, therefore switching between the HMI

standard views and the QTrans main application can easily be managed using standard

HMI functionality (e.g. activate QTrans window using HMI function keys and

switching back to the HMI standard views).

To integrate QTrans into the HMIs window management, do the following:

- Delete the QTrans Autostart link from the window explorer (Start Programs

Autostart QTrans) to prevent automatic startup of QTrans during user logon (this

must be handled by Simatic HMI to fully integrate QTrans into the HMI).

- Add the following softkey/function key configuration:

o Path/File: Full path to QTrans.exe

o Window class name: TfrmMain

o Window name: (empty)

o Preload: Active

o Timeout: > 60sec

- Add the following to the HMI configuration file (exe.ini): PRELOADMINIMIZE=0

To integrate QTrans into the HMI security, do the following:

- Open QTrans.ini and add/modify the QTrans.ini file as described in section 4.3.1.7)

2.3 Startup

If you have installed Q-Trans using the automatic method, the software will register itself

within the windows common startup group and will start automatically after a user logs on to

Windows. If a fully automatic startup process is desired without user intervention, the

Windows system administrator must enable automatic login within Windows.


6

If you have installed the software manually, you may start it by running QTrans.exe (either

directly from the installation directory or from any shortcut).

2.4 Data protection, security and backup

All QTrans files are placed inside its installation directory. QTrans does not create or updated

any files during runtime, so the administrator might put security on the installation directory.

All configuration information is stored inside the following two files (inside the installation

directory):

- config.ib: system configuration and data processing configuration

- users.ib: users, groups and passwords

These files are accessed by the database engine, normally running under <localsystem>

security context. To backup/restore all configuration information simply copy these files

to/from a backup media (make sure, that DBEdit.exe/QTrans.exe are not running). The user

database (users.ib) does not contain any system specific information and may be copied from

PC to PC (to globally update users/passwords).

In addition, the registry is used to store intermediate state information (e.g. name of last

generated dfd-files).

3 User Interface and Operating Procedures

7


3.1 Introduction to fundamental grid details

QTrans’ tables offer many possibilities in customizing views tailored to the user’s

requirements. In the following figure we introduce some basic features and terms.

1] By left clicking on the visibility box (in this case the one next to the columns) a dropdown

list shows all columns that are visible at present and can be made visible by ticking. This box

is also available on band level if reasonable.

2] Band: a band subsumes columns with one similarity (here on the left side: all columns can

be subsumed in one operation) to one set of columns. The banded table view provides a

detailed and concise overview without stretching the limits of the table providing superior

ergonomics for the user.

3] Cell Merging: neighboring columns cells with identical values within the same cycle result

are merged into a single cell for clarity of Display. The image shows this highlighted in a red

circle.

4] Cell: a cell represents one value determined by line and column

Consecutive rows are displayed in different background colors (white / light green) for better

ergonomics.

1 2 3 4


8

3.1.1 Column Layout

To alter column layout right click into a header cell and choose from one of the possibilities:

Sort Ascending: all lines are sorted ascending by the chosen column

Sort Descending: all lines are sorted descending by the chosen column

Clear Sorting: the sorting can be canceled by clicking this field

Group By This Field: Grouping by the selected column header will be activated. The Group

by box will show with the header shown within the box.

Group by Box: clicking on this line opens or closes the Group by box.

Footer: the footer is actively shown for two reports: EOCR and Root cause analysis. It is

possible to activate and deactivate the footer for all other reports by clicking this line, too but

it not used by QTrans. Leave untouched.

Group footers: unused by Qtrans. Leave untouched.

Remove This Column: by clicking the column will be made invisible for this view

Best Fit: is used for a certain column to adapt the cell to an optimal size fitting the largest

content (see image below)

Best Fit (all columns): does the same for all columns in this view, but for visible fields only.

Field Chooser: field chooser is a panel that shows currently hidden column headers. From the

panel all visible headers can be dragged into the header level of the Reports window in order

to add a new column to an already existing view. In the following image the Part cell is

dragged from the panel into the header level of the Operation band (see image).


9

Please note: the customization panel shows all Band headers and Column headers currently

invisible in the view. The headers must be dragged to their corresponding band (here:

Operation or Params). Possible positions to leave the header are indicated by green arrows. If

dragged to the wrong band the header simply cannot be dropped and a prohibiting sign is

shown. If the tick box for all bands is marked the next action made will be true for all bands.


10

3.1.2 Filtering results

There are several ways to filter the results that are showed in the reports view. The simplest

way to do so is to click the filter button that starts the filter builder. The filter builder globally

filters all cycles. See image below. Filtering rules follow the hierarchy of the reports (see

3.2.4). Filters defined in the lower hierarchy don’t alter the datasets on the upper levels.

By default there is no filter selected. Any rule must be defined by left clicking into the

respective field and adding or altering the rule. Several rules can be defined on the same level

and logical connections between the rules can be made by clicking into the connecting

operator.

In the next image a simple filter is defined for EUN with the condition L 000000003929. The

dataset is shown filtered (upper arrow). In the footer the filter bar is shown allowing to choose

filter conditions from a dropdown list or to open the Filter builder by pressing the Customize

button.


11

Filters with local conditions valid for a single column can be defined via clicking the filter

button in the header cell (upside down black triangle on the right side o the column’s header).

A list of all predefined filters for this column opens. In this list there opens also a custom filter

by clicking Custom... By choosing (All) the column’s filter is deleted.

The custom filter window opens when clicking on (Custom…).


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3.2 QTrans Status Monitor

After starting QTrans, the following window is displayed:

This window displays the following information:

[1] Operations tab: open on default. Shows the ongoing operation of all stations defined

(active in the view above)

[2] Reports tab: generates and shows current and static reports with active and stored data

Left side of status bar: Connectivity and diagnostic information:

[3] Number of transferred records and its volume in kb

[4] Number of sockets in use

3 4

1

2


13

Central Window: lists configured stations and their state, as well as the current operation

mode for each station.

The following station states are possible:

─ Idle: no data has been received for this station yet (since start of QTrans or since last

change of operation mode). Station is waiting for data.

─ Running: normal operation state, changes to this state after data has been (correctly)

received from any of the spindles attached to this station.

─ Stopping: station has received a stop signal. Until restarted, it will not accept any more

data from SE/KEs . For additional info, see chapter 4.1

─ Stopped: station has been stopped. It will not accept any more data.

The following operation modes are possible (see also 3.2.1):

─ Normal production: stations are running normally, tightening result data is converted

into dfd/dfx files and put into the “standard production” folder.

─ Production studies: stations are running normally, but tightening result data is

alternately converted into dfq files and put into a special study folder. Once the preset

number of cycles have completed, the station will automatically switch back to standard

mode and display an operator notification. While a station is currently in production

study mode, the background color changes to light blue

─ Tool studies: station is switched to tool verification mode and controls operation of all

spindles of this station using the BMS sequence test mode. In addition a reference

transducer must be attached to the PC’s serial port (as defined in global configuration).

While a tool study is active, the station mode of the other stations cannot be changed.

Lower right region: Contains user buttons and settings.

At system startup, all users have access to a limited number of functions. The basic options

are defined as follows (see also screenshot):

1. Ignore invalid data from KE [1] – This control allows the user to determine how to handle

invalid data received from the KE. This data could be misconfigured, unexpected,

misformatted, or a combination of all. This is not a transmission problem, but a situation

where a packet is not properly defined within the QTrans setup parameters.

─ If “ignore invalid data” is enabled, (default) such data is discarded and only the error

diagnostic counters increment.

─ If “ignore invalid data” is disabled, invalid data from SE/KE will not be accepted by the

Q-trans internal FTP-server so it’s “stuck” trying to transmit out from the KE. Since the

KE uses a FIFO buffer, no additional information will transfer from the KE until the

1 2 3


14

problem is identified and resolved. The KE will continue to attempt to retransmit until

the data packet is accepted.

2. Trace all SE [2] – all data received from SE/KE is written/appended to the global log file

(defined in global configuration). Use to debug invalid data.

3. Logon [3]: Allows a user to logon to the system. After clicking this button, the logon

windows appears:

The user should enter his or her user name, enter the password and click “Logon”.

At present there are four user levels:

─ No user logged on

─ Logged on engineer

─ Logged on maintenance

─ Logged on operator

Most operations (including exit program) require a logged on user. For additional details,

see also chapter 3.3.4.5.

After a user has successfully logged on, the main window shows additional items and allows

additional actions (depending on current user’s rights):

The button “Logon” now has changed to “Logoff” to allow the logged on user to logoff. The

button “configuration” is now enabled. Clicking this button starts DBEdit (see 3.3) for

accessing the system configuration. The button “show – edit” in the rightmost column in the

center area allows to look at the stations operation mode or change station operation mode

(see below).


15

If any of the stations is in production study mode, the lists row background color for this

station changes to light blue:

3.2.1 Station operation modes

3.2.1.1 Overview

Each of the stations defined in the configuration may be in one of the following operation

modes:

Normal Production Mode: Stations are running normally (controlled by PLC), tightening

result data is converted into dfd/dfx files and put into the “standard production” folder. Part

type and bolt (characteristic) is detected by looking at the tightening result program

number and application number. Part identification (engine-id) is used to determine which

tightening results belong to a distinct part.

Production Study Mode: Similar to normal production mode, the study mode is intended

to monitor production programs and parts. The main difference is that the result data is

converted into dfq-files and saved to a special folder defined at the beginning of each

study. The study mode is typically active until the user aborts it or the predefined number

of cycles has been run. While enabled, the entire station goes into study mode and will

process all incoming parts until complete. This means that if different part types enter the

station during a study, simultaneous studies will be run at the same time creating separate

DFQ files. To handle this multi-tasking, the number of runs is counted per part type within

the station. If all counters for all parts are either zero (not started) or equal to the preset

number of runs (study completed for the given part type), the station will automatically

notify the operator and switch back to normal production.

If desired, production studies may also be paused. If paused, the stations operation mode is

temporarily switched back to “normal production”, but may be switched back to

“production study mode” later. During pause, data received will be written to the “normal

production” dfd/dfx files. Data received after resuming “production study mode” will be

appended to the already existing production study file until the given number of runs is

done (if no parameters were changed in the meantime).

Tool Study Mode (tool verification mode). If this mode is selected, no normal operation of

the station is possible because the PC overrides the station’s automation controller using

the tool’s sequence test mode. After starting the “tool study mode” and selecting the

operation parameters, the user is guided through the steps required to run the study. This


16

includes connecting the validation torque meter and installing the torque sensor. Once the

tool study mode has completed (or aborted), the system writes a single dfq-file containing

the study results.

At system startup all spindles are automatically set to run “normal production mode”. In tool

study mode, the operator is allowed to work on the station configured at the beginning of the

test. While testing, He/She will not able to make any modifications to any other configured

station, however data processing functions for the other stations will continue normally.

3.2.2 GUI

3.2.2.1 Station Operation

Depending on the current station operation mode, clicking the “show – edit” button displays

one of the following dialogs:

If the station is in standard operation mode, you will be shown the study dialog:

This dialog box shows the part id (engine-id) of the last part processed by the station (“last

part ID”) and allows the user to switch the station into either “tool study” or “production

study” modes.

If the station is in production study mode the GUI displays the status of studies in process:

The status window lists all parts defined for the station and their current production study

state (current run number, destination path, filename, study started, and study finished).

The buttons in the lower area may be used to:

─ Stop all studies: terminate study mode for this station (will close all “.dfq”-files)

─ Pause/continue study: switch pause mode (see above)


17

If the station is in production study mode and the study has been paused, the window is

similar to the following screenshot:

3.2.2.2 Starting a production study

Once the “Production study” button has been pressed, the operator must configure the study

as shown on the following dialog box:

The dialog box lists the preconfigured GM studies in a dropdown box. After selecting a study,

the defaults for the selected study are copied to the edit fields and may be overridden at the

operator’s option. Additionally, the user may enter a filename prefix, which is used for

generating the “.dfq” filename.

Clicking the “start”-button will switch the station into production study mode.

3.2.2.3 Tool study (guided sequence interface)

After the system has been placed into tool study mode by pressing the corresponding button,

the “Studies & Verification” dialog is shown to configure the tool study:


18

To start a tool study the user, should first select a “verification part”. A verification part is not

an actual part run during normal production, but just a list of spindles and programs used

specifically for tool verification. This allows for maximum flexibility in defining tool

verification procedures and collection of relevant information.

The list shows all available channels and tightening programs for use by tool verification. The

user can then select which spindles to run by checking the “Enabled” column in the list. Note

that more than one spindle can be run, and more than one program per tool. All tools and

programs that are He also must select one of the preconfigured studies and update its

parameters (if necessary) using the edit-fields. Depending on the transducer used, it may be

necessary to check “automatically loosen after each run”. The study will then start by clicking

the “start” button.

After actually starting the tool verification, the user interface guides through the required

operations. The system will start with the first enabled spindle from the list and will present

the user the following message box:

The user should follow these instructions and confirm by pressing “OK”. “Cancel” will abort

the verification process. After the user has acknowledged, the system starts running the

spindles and displays the following dialog to show its progress and the result data:


19

After the given number of cycles (+1) are completed, the “OK” button is enabled and awaits

user confirmation to start the next stage of the test. Once pressed, the guided sequence

automatically continues with the next spindle on the list. Once all spindles are complete, the

list of available spindles and programs is updated to show the tool study result state (all

enabled spindles should show “done” in the rightmost column “status”).

After closing the “Studies & Verification” dialog, the station returns to normal operation

mode automatically.

3.2.3 Configuration

If a user with sufficient rights has logged on, the “Configuration” button in the main window

is active. By clicking this button, QTrans enters configuration mode and starts DBEdit (see

3.3). While in this mode, QTrans will not accept any input. To indicate this, the background

color of the QTrans main window changes to dark grey:


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After editing is done and DBEdit is closed, the system will inform the user processing will be

halted to update the runtime engine.

This notification is required as the QTrans software does not know if a part processing in

station is completed until it receives data for the new (next) part. The user should verify all

parts are complete within all stations prior to clicking “OK”.

If some of the stations are currently active, it issues one last warning:

This warning tells the user, that all currently active systems have been switched to “stopping”

state, i.e. all stations will only continue to accept data with the current part-id. If any data with

a different part-id is received (“next part”), it will not be accepted and the station will go into

“stop” state. This warning will close automatically, if all stations are in either “idle” or in

“stop” state, i.e. when it is safe to update the configuration.

The user may also manually start the update process by clicking the “stop now” button. In

either case, he/she should visually check that all stations have finished processing, so that data

is not lost. This is mainly a concern for stations with independent processes running

simultaneously.

3.2.4 Reports

The reports window offers a straightforward way to monitor ongoing tightening processes and

to search for errors in past results. From the dynamic window there can be derived up to 4

static reports (see report chart below).

The End of Cycle Report (EOCR) is created from the dynamic report by selecting the station

and the cycles wanted and by pressing the create report for button. From the EOCR there can

be derived the FTQ Summary Report, the Reject Report and the Root Cause Analysis by

clicking their tab. The report is created only the moment the tab is selected.

Static reports can be filtered for any parameter and tailored to any requirement by using the

editing and filtering functionality.


21

Dynamic Report

End of Cycle Report

Create Report:

derivation filter

Option:

- Station

- # Cycles

derivation filter

Option:

- period

- application

….

FTQ Summary Report

Reject Report

Root Cause Analysis


22

The following figure shows the global icons and tabs for the reports view.

1] Reports tab: on clicking here the window changes from operations to reports

2] Export button: on pressing the button the current data set is exported to an Excel- or XML

file

3] Print button: the actual data set can be previewed and printed

4] Full collapse button: closes all open record views

5] Full expand button: expands all records for detailed views

6] Report button: changes from dynamic (default) to static reports and vice versa.

7] Show last step only: when ticked, only the last step will show results

8] Navigation icons: start of data set, end of data set, page scroll, last/next record

9] Best Fit (for all columns): the borders for all cells are fit to their maximum content

10] Cancel grouping: all data grouping is reset

11] Filter data: the filter builder window opens on pressing the icon

8

9

10

11

6 5

1

4

3

2

7


23

3.2.4.1 Dynamic Report

The reports window is opened by clicking into the reports tab [6] on the upper left side of the

Q-Das transfer window. By default the dynamic report window is shown (see image below).

Reports can be created from all stations that are ticked in the dropdown list [7]. By default

only the first entry from the list is marked. Only stations that were previously defined and

deliver data can be checked. Stations that are defined only but did not send data yet display in

grey.

If any filters and sorting act, the dynamic report window always shows the most recent result

in the bottom row. Earlier results scroll up.

1] Create report for: when clicked a static report will be created with the choices made in [2]

+ [3]. The EOCR report window opens showing the created result.

2] Station choice: stations to create a report for can be selected in the dropdown list

3] Cycles input box: the number of cycles can be entered here up to which the report is

created for. Maximum is 2400 cycles.

4] Delete all: when pressed all cycles showed in the dynamic report window are deleted

Tooltips are showed for all window items when the mouse cursor is set over an object.

3.2.4.2 Static Reports

As seen in the figure above all static reports are derived from the dynamic view reports

window by clicking the button “Create report for” [1] after selecting the desired Station [2]

and the number of cycles [3]. By default the End of Cycle Report window is opened. The

2 1 3 4


24

choice for the available static reports follows the most useful standard reports used for

analyzing data in the industry.

3.2.4.3 End of Cycle Report (EOCR)

By default the EOCR shows all results listed by EUN (lines) and on the right side of the

separator all results grouped by spindle. In the footer the EOCR sums up FTQ results and

Number of cycles for certain spindles.


25

3.2.4.4 FTQ Summary Report

The second tab on the bottom of the Q-Das window shows the First Time Quality (FTQ)

Summary Report. On the upper right side of the window the user can select from a dropdown

list to show the report from the spindle- or application level.


26

[1] Cell’s FTQs are sorted ascending

[2] Application’s FTQs are sorted descending

3.2.4.5 Reject Report

The reject report shows all cycles that ended with the Quality code NOK.

View with

grouping

RightMouseClick on

Group Row

Group Rows

1

1

1 2

2

2

1 2


27

3.2.4.6 Root Cause Analysis

The Root Cause Analysis offers a straight approach to learn more about the reason for errors.

On the upper right side of the window the user can select from a dropdown list to show the

report from the step, program, application or station level point of view. The footer shows

summaries for certain columns to improve data analysis.


28

3.2.4.7 Navigating from one report to the other by sticking to the same

record

The same record can be analyzed with different reports by right clicking into one cell of the

record to be navigated through and by choosing the desired report from the dropdown list.

Please note: the static reports FTQ Summary Report, Reject Report and the Root Cause

Analysis can only be navigated to if they had been started earlier by clicking on the tab. If a

Record is chosen that does not exist in the selected report, an error message will be displayed.

If filters were used this can occur also when switching to another report.

3.3 DBEditor

DBEdit is a standalone configuration program which is normally called by clicking the

“Configuration” button from within the QTrans main window (see 3.2).

It provides the following tools:

Cell editor: define/ edit tightening cells and their parameters (channels, programs,

applications, steps, …) and default characteristic parameters. All information in the cell

editor is redundant to the parameters already present in the KE. Therefore QEdit provides

the import and comparison tool KE300Scan (except for step information).

Line editor: define/edit line and station parameters as well as mapping between tightening

result data and Q-Das data

Global parameter editor: edit global parameters

K-Field editor: define/edit list of available K-Fields and their values

In addition it provides some expert tools for diagnostics:

SQL browser: run special commands against the database or query for special data

Table editor: low level editor to edit configuration data

Log viewer: shows internal logging

3.3.1 Workflow

DBEdit keeps a rather strict separation between information which is provided by the

tightening controller and information for converting tightening result data to Q-Das format –


29

this way parts of the required information can be derived from the tightening controller. The

minimum effort for configuration therefore depends on the order of entering required

information i.e.:

1. Enter information derived from tightening controllers (SE/KE) configuration. This can

either be automatic via KE300Scan or manual by editing each setup in the respective field

facilitated by drag and drop functionality. Step information is not yet provided

automatically.

2. Setup defaults for characteristics (“step template characteristics”, should also be provided

automatically in the future)

3. Configure line and station parameters

4. Define the mapping between tightening system and parts/bolts/characteristics

Of course, this sequence is not mandatory, but is the fastest and safest way to setup the

system!

3.3.2 General usage

DBedit uses many data spreadsheets for viewing, entering and editing data. These sheets share

some common functions:

pressing the “ins” key inserts a new record or line in the database. The same can be

achieved by right clicking into a cell and selecting “add new record” from the dropdown

menu.

scrolling to the last row and pressing the “down” arrow key appends a new record (if

enabled in the grid)

right-clicking into the column headers shows a popup menu showing customization

options for the selected grid (if enabled)

right-clicking into the cell area shows a popup menu with additional options/actions (if

available)

changes to an edited record are normally posted (saved) only, when the active record focus

changes, i.e. when moving to the next/previous record

columns may be sized horizontally by dragging column header separators (if enabled)

columns may be reordered by dragging column headers (if enabled)

columns may be sorted by clicking the column header (if enabled)

columns may be filtered by clicking the dropdown in the column header (if enabled)

column headers provide tool tips

color convention:

─ cells with white background are used in K-Fields

─ cells with blue background are not used in K-Fields

─ cells with grey background are either information only (read only) or are not used


30

3.3.3 Main GUI Window

After starting DBEdit the following window will open:

The following menus are available:

File

Open Unused at the moment

Close Close window

Save Save the current settings. Similar to closing and reopening dbedit

(database commit)

Exit Exit DBEdit

Edit

Global parameters Open the global parameter editor

Cells Open the cells editor

Lines Open the lines editor

K-Fields Open the K-Fields editor

Users and Groups Open the Users and Groups Editor

DFD Parameters Open DFD Parameters Editor

Tools

SQL Browser Open the SQL browser window

Show Log Open the log window

Table Editor Open the table editor window

Window

Cascade Cascade all windows

Tile Horizontally Tile all windows horizontally

Tile Vertically Tile all windows vertically

Minimize All Minimize all windows

Arrange All Arrange all windows

Help

About Display the about box with version information


31

3.3.4 Editors

3.3.4.1 Global parameters editor

The global parameter screen is similar to the following screenshot:

There are four areas for configuration parameters:

1. Drivers:

a. Output Driver defines the output of QTrans: this can be either Q-Das QS-Stat, Excel,

XML-CAQ, … (see chapter 5.2 for a detailed description of available output drivers and

their parameters).

b. Std-prod output base directory: enter the full path to the base directory used for saving

Q-Das standard production data here

c. Std-production directory mode: to actually save dfd/dfx files, QTrans appends either

part name or station and part name to the Q-Das base directory. Setting this

configuration value to zero (default) only appends part name, setting it to one append

station name and part name

d. Reference meter driver: definition of predefined reference measuring equipment

e. Serial port for reference measurement device: specify the serial ports COM-number

here to which the meter is connected

f. Reference meter absolute angle: if set to 0, the angle value received from the reference

torque meter is used as is, else angle value sign is ignored

2. Q-Das standard production DFD file generation:

These settings define the policy for automatically generating new “.dfd” files. This may be

either by time or by number of cycles. If set to “generate by number of runs”, a new

“.dfd”-file is generated after the given number of cycles. If set to “generate by time”, the

time entry fields are used to build a number (1-3) of time ranges, which are checked

against the current time of day. If new result data arrives and falls into a new time range, a

new file is generated.


32

Additionally you can define the behavior for serial and part numbers. If the checkbox “Use

K0006/K0014…” is checked, then K0006 is used for the serial number and K0014 is used

for the part number (new behavior introduced in the 2008 version of the Q-Das

specification). If unchecked, K0009/K1001 are used instead (“old behavior”).

3. System parameters:

The path for the SE-Log data is defined here.

4. Study parameters:

This list is used to predefine studies and their parameters. Items entered here will be

available in the studies dropdowns in QTrans (tool studies (verification) and production

studies) and will provide defaults for those studies.

3.3.4.2 Cell editor

The cell editor is used to edit all data related to the tightening system e.g. which tightening

cells are available, what channels are connected, the programs, applications and steps. After

opening the cell editor it looks similar to the following screenshot:

The figure above also shows a minimum manual configuration within the cell editor. Right

click on the KE cell line opens the context dialog: from which the automatic import/

comparison function can be executed. The only additional manual input must be made for step

information. (For further information on automatic parameterization see title 3.3.4.7)

The editor consists of two panes: left pane with hierarchical tightening cell information and

right pane with additional properties tabs. The panes are separated by a splitter to allow

changing the width of both panes (use click and drag to move the splitter).

The buttons in the lower area provide the following functions:

disconnect program subtree: disconnects the program subtree from the main tree and

displays the hierarchy below channels in its own view (see also below)

Show additional parameters and templates: show/hide the right pane

After expanding the hierarchy levels, the cell editor looks similar to the following (expanded

Cells Channels Programs Steps):


33

If the tab “Application” is selected, the cell editor looks similar to the following (expanded

Cells Applications):

The following parameters are available:

Cells:

─ Name: name of the tightening cell/KE

─ Connection parameters: TCP/IP-Address of the KE controlling this cell

Applications:

─ FO: application number as defined in BS300

─ Name: application name

─ Description: user defined description

Channels:

─ Enabled: if not checked, then data from this channel is ignored

─ Rack: hardware rack number of this channel

─ Slot: hardware slot number of this channel


34

─ K2043: Q-Das K-Field data for K2043

─ K2281: Q-Das K-Field data for K2281

Programs:

─ Enabled: if not checked, data from this program is ignored

─ Program#: program number as defined in BS300. Note, that program 99 (loosen) should

never be defined here. In fact it will always be ignored by QTrans.

─ Name: program name


Steps:

─ Step#: sequential step number (1…n)

─ SE-Step: step number as used in BS300 program definition (e. g. “3A”)

─ Enabled: if not checked, data from this step is ignored

─ Verification: if checked, this step is used for tool studies (verification) to be compared

against the reference transducers values. This is required, as a tool verification program

might have to run additional steps after the actual measurement value (e. g. loosen)

─ Repeatcycle: repeatcycle count to be used in K2001 (should normally be 0, else should

be the number of runs, this step will run (retried))

To ease the process of creating programs and steps, programs and/or steps may be copied by a

drag & drop operation using one of the following procedures:

a. Copying steps:

1. expand source and destination programs, so the list of steps is visible

2. select one or more steps in the list of steps in the source program (multiple select: ctrl-

click, shift-click)

3. click one of the selected steps and drag over the destination step list (expanded

destination program)

4. release mouse button to copy steps

b. Copying programs (will recursively copy steps, too):

1. expand source and destination channels, so the list of programs is visible

2. select one or more programs in the list of programs in the source channel (multiple

select: ctrl-click, shift-click)

3. click one of the selected programs and drag over the destination program list (expanded

destination channel)

4. release mouse button to copy programs and steps to destination channel

Depending on the currently focused cell, the right pane will display additional properties for

either channel or step. If a channel or program is currently selected in the left pane, the right

pane shows additional channel properties (the tab “channel” will be activated):


35

The right pane now allows for configuring the resolution parameters for this channel. As Q-

Das requires resolution information for each characteristics type, there is a list showing all

available characteristic types. In the rightmost column the resolution value sent to Q-Das may

be entered (if 0, the K-Field used for resolution will be empty).

If a step is currently selected in the left pane, the right pane shows additional step properties

(the tab “step” will be activated):

Like in the additional channels’ properties list, there is a row for each characteristic type. In

contrast to the channels properties, these properties do not map directly to any Q-Das K-Field.

However, they define a template (“template step characteristics”) of default values to be

applied when a new bolt is created, which uses this step. This is necessary, as Q-Das does

only know of bolts and their characteristics, but not of steps (which may be reused among

different bolts!). These template characteristics therefore provide a way of having defaults for

all the bolt characteristics.

The editable values are:

Enabled: default value of the enabled property for bolt characteristics based on this

tightening step

Class: sets the default value of the characteristic class value for bolts based on this

tightening step. Any step which will produce an acceptable part should have its target

characteristic type set to a class value of “2”. All other characteristic types for all

remaining steps must be set to “1”.

Note: these settings are only templates used when adding a new bolt, so changing a value here

will not change anything in the Q-Das data output!

If the checkbox “disconnect program subtree” is activated, the view changes as shown in the

following screenshot:


36

The right pane now shows all programs and steps of the selected channel in the left pane. The

left pane now does not show programs and steps any more. The view may be switched back

by unchecking “disconnect program subtree”.

3.3.4.3 Line editor

The line editor is used to edit all data related to the station setup, like lines, stations, spindles

as well as parts and bolts and their mapping to the tightening channels. After opening the line

editor it looks similar to the following screenshot:

The editor consists of two panes: left pane with hierarchical line/station information and right

pane with additional properties.

After expanding the hierarchy levels, the line editor looks similar to the following (expanded

Lines Stations Spindles):


37

If the tab “Parts” is selected:

After the additional levels are expanded, the line editor looks similar to the following

(expanded Lines Stations Parts Bolts):

The following parameters are available:

Lines:

─ Line/Loop: Line/Loop number as used in K0008


38

─ Name: Line/Loop name


─ Plant: plant name (K1303)

Stations:

─ Station#: station number (K2001, K0053)

─ Short: short station name

─ Name: station name


─ Department: department (K1101)

─ Options : stitching = yes/no [and/or FO=Number]

Spindles:

─ Spindle#: spindle number (relative to this station, 1…n)

─ Short: short spindle name

─ Name: spindle name

─ Channel-ID: 1:1 mapping to a System 300 tightening channel (defined in the cells

editor)

─ Type: type of data output used (normally data format standard+)


Parts:

─ Type: part type number (either standard production or verification). Verification means,

this part (and its bolts) are available for tool studies (verification)

─ Short: short part name

─ Name: part name


─ Options : stitching = yes/no [and/or FO=Number]

Bolts:

─ Bolt#: bolt number

─ Short: short bolt name

─ Name: bolt name

─ Application: one of the applications available for this stations (applications are defined

in the cell editor. Application -1 means single spindle (no application used), see also

section 4.4). Use application -1 for a single spindle start (like in tool studies

(verification)).

─ Program: one of the programs available for this station (programs are defined in the cell

editor). Note, that program 99 (loosen) should never be mapped to a bolt (it should not

even be defined in the cell editor).

Note: a bolt is uniquely identified by cell, channel number, application number and

program number. So a unique combination of cell, channel, application and program does

only exist once (except for verification parts). See also the discussion on stitching (chapter

4.2.2).

If a bolt has been selected in the left pane, the right pane displays its characteristic parameters.

In general, this is a list of all characteristic types for all steps used for the selected bolt (see

screenshot above). When adding a bolt, these characteristics are created by copying the

“template step characteristics” from the steps defined in the cell editor. Each characteristic

enabled here will create output (data column) in the Q-Das data file. Editable values are:

Enabled: if checked, each time data for this bolt is processed, this characteristic will send

data to the Q-Das data file

Class: sets the characteristics class value for K2005

To ease the process of creating bolts, there is a auto-bolt-generation facility. It is based on a

template bolt, which will then be copied for each spindle defined in the station. To use it,

follow these steps:


39

If there is no bolt yet, add a bolt and set it up normally. This bolt will be used as a template

(program and application will be copied).

Right click the template bolt row and select “Add next bolts for unassigned spindles” from

the popup context menu.

DBEdit will now walk the list bolts for this part and spindles defined for this station and

will create a copy of the template bolt for each unassigned spindle.

When creating a new bolt from the template bolt, the following fields will be assigned:

Bolt#: sequentially incremented, starting at the bolt number given by the template bolt (so

you normally should right-click the last bolt)

Short: automatically constructed from the bolt number: “B” + bolt#, i.e. “B2”, “B3”, ...

Name: automatically constructed from the bolt number: “Bolt ” + bolt#, i.e. “Bolt 2”, “Bolt

3”, …

Application: equal to template bolt application

Program: equal to template bolt program

3.3.4.4 K-Field editor

The K-Field editor is used to edit the global list of K-Fields as well as to create user defined

overrides for K-Fields. If all data processing is finished for all data received from the

tightening controllers (but before actually writing this data to a Q-Das data file) data defined

in the K-Field editor is checked and applied, effectively overriding any data received from the

process or adding data not available from the process.

Actually there are three editors available:

K-Field overrides for part level: allows adding overrides for part level K-Fields

K-Field overrides for characteristic level: allows adding overrides for characteristic level

K-Fields

Global list of K-Fields: allows editing the global list of K-Fields

The different editors may be selected by clicking on the tabs in the upper area of the screen.

After opening the editor, the part level K-Field editor is active by default. It looks similar to

the following screenshot:

To override/add any part-level value, press the “ins” key and enter data into the following

cells:

Station: select station from the dropdown list

Part: select a part from the dropdown list to apply this override (the dropdown list will only

show parts from the selected station)

K-Field: select one of the available part-level K-Fields from the list

Value: enter the new override value here

By clicking on the “Characteristic level” tab, the display is switched to the characteristic level

K-Field editor. It looks similar to the following screenshot:


40

To override/add any characteristic-level value, press the “ins” key and enter data into the

following cells:

Station: select station from the dropdown list

Part: select a part from the dropdown list to apply this override (the dropdown list will only

show parts from the selected station)

Bolt: select a bolt from the dropdown list (the dropdown will only show bolts from the

selected part)

Characteristic: select a characteristic from the dropdown list (the dropdown list will only

show available characteristics, as defined by the selected station/part/bolt)

K-Field: select one of the available characteristic-level K-Fields from the list

Value: enter the new override value here

By clicking on the “K-Fields (global)” tab, the display is switched to the global K-Field list

editor. It looks similar to the following screenshot:

The following fields are available (see Q-Das documentation for additional information):

FLDNUM: numerical K-Field number

FLDKEY: string K-Field name

FLDLEN: field length

FLDTYPE: field type

KTYPE: type of K-Field, any allowed combination of DFD-Part (part level specification),

DFD-Characteristic (value-level specification), DFX-Characteristic (value-level value)

KDEST: where to write data to, any allowed combination of DFD, DFX, DFQ

Verification: bool, 1 = value used in verification mode

Required: bool, 1 = K-Field required

Enabled: bool, 1 = K-Field enabled

Editable: bool, 1 = K-Field editable (unused at the moment)

Lookup: 0 = no lookup, else reference id for K-Field lookup table

Default value: default value used, if there is no data from the process

Remarks: comments.

Description: comments.

Source: comments.


41

3.3.4.5 User and Group editor

The embedded security system for authentication and authorization uses the following model:

Rights: There are several predefined rights, which correspond to actions in the software. At

the moment, the following rights are available:

─ Exit application

─ Open station state dialog

─ Run production studies

─ Run tool verification studies

─ Run configuration editor

The following table shows the rights assignment to the user group Right Action Usergroup

Exit application

Open Station State dialog

Run production studies

Run tool verification studies

Run configuration editor

Operator X

Maintenance X X X

Engineer X X X X X

Groups: Each user must belong to exactly one group. Rights are assigned to groups, so

each group has a list of rights. A user’s right is therefore defined by the group the user

belongs to.

User names, group, enabled and full name can be edited directly in the grid. To delete a user

simply press <ctrl>-delete. To add a user or to change its password, use the buttons in the

lower area.


42

This dialog box shows what is behind the Add User button. All fields must be filled in before

OK can be pressed

To change a password the current password must be entered first. If a password is lost, you

may delete the corresponding user and recreate the account by clicking the “Add User”

button.

Note: DBEditor can also be started standalone (by running DBEdit.exe from explorer). In that

case, there will be no security check, so everybody will be able to change parameters. In case

of a lost password or accidentally deleted engineer, this can be used to regain access to user

and group settings.

3.3.4.6 DFD Parameters editor (runtime tightening limits)

Within the DFD Parameters editor all threshold values are shown concisely in a spreadsheet

and are editable in multiple ways.

For a convenient overview the columns shown in the editor can be reduced to the essential

ones by selecting “Characteristic Types: enabled only”


43

All values of the Charcteristic Types (Torque, Gradient, Time, Angle, etc…) can be edited

directly by selecting a cell (ex. Torque min in the image below) and typing in the designated

parameter value.

Parameters can also be edited within the status line on the bottom of the spreadsheet.

Choosing this way of modification is advisable if many cells have to be changed to the same

value (e.g. parameter Time in the image below)

All cell parameters are sortable by column (Cell, Channel, Program and SE-Step). Sorting

order can be ascending or descending and the sorting of the columns can be interconnected to

each other. The priority of the sorting order follows the order of choice of column to be

sorted. Using SHIFT-key and clicking into a Column header allows for multiple selection.

Using CTRL-key and clicking deselects the sorting by the selected column (The triangle in

the column headers Program and SE-Steps in the image below indicates the sorting type

within the selected column).


44


45

3.3.4.7 Automatic import and comparison of data from SE/KE

From Qtrans version 1.1.26 on it is possible to copy existing SE/KE data into DBEdit’s cell

editor or to compare existing data. This feature highly facilitates the parameterization of the

existing station and to keep it up to date. The function is started by right clicking on the KE

cell in question (see image below). From the context menu chose “Compare to KE”.

The program window “KE300Scan” shows an overview of all info from the database and

from the SE/KE (actual data). For exact automatic comparison the identical box on the lower

right of the window can be checked. This also compares the program names and CRC codes.

(Note: DBEdit’s CRC and SE/KE’s CRC are usually different, because DBEdit’s CRC

doesn’t include a timestamp therefore by default exact comparison is unchecked).

The checkbox “P99 ignore” toggles a filter in order to hide P99 which is by default used for

loosening. Records that are not shown in the overview remain unchanged.

The image above shows the exemplary data of KE OP2100. Each line represents a program.

Step information is not available within the KE300Scan window for SE/KE doesn’t provide

it. To edit or copy step information please refer to the title 3.2.4.8 “Update all steps” below.

On the left side of the window the data stored in DBEdit’s database is listed. The right side


46

shows the information stored in the loaded KE. The data is separated by a column containing

indicating symbols (see caption table below) and the Adopt column showing a tick-box for

each line of data to load from the SE/KE to DBEdit’s database. To load the shown data from

the SE/KE into DBEdit’s database the button “Apply changes” on the bottom of the window

must be pressed.

By default all boxes of those lines are ticked containing SE/KE data. However for data safety

it is not possible to tick the box if there is no data in the SE/KE fields. It is not possible to edit

data in the KE300Scan Window.

The data overview of KE300Scan can be passed on to a spreadsheet via the Export button. As

an output media Excel and XML-Files can be created for further reference.

Available for debugging reasons is the Log Tab on the lower left of the window. This enables

to show SE/KE error information for the experienced user.

Caption table: KE300Scan Symbols Symbol Meaning

No data stored in SE/KE for this record

Channel name is unequal DBEdit <> SE/KE

New program. Program is only stored in SE/KE

Program (CRC) was changed in SE/KE

All information is equal (Date is not compared)

3.3.4.8 Copying and Editing Programs and Step data

Programs and Steps can be copied from within the cell editor by opening the channels list and

right-clicking on the “master” channel to copy the programs or steps from.


47

Choosing “Copy programs” opens the program copy window. On the left side all channels

connected to the chosen KE are listed with their programs. There is also an indication whether

the channel is configured in the respective column. On the right side of the window all

program- and step information from the selected channel is shown.

To copy the programs from the master channel (marked grey, bold chars) to other channels

their tick-box in the column Overwrite must be marked and the button overwrite be pressed.

All existing programs of the marked channels are erased and replaced by the master’s

programs. Else all lines data (spindle and parts information) is also erased and must afterward

be added manually.

Channels marked with an asterisk include already the same program set as the master channel.

Empty channels are marked by default to be overwritten by the master information.

Be aware, on copying programs into a channel all line editor information of this channel is

lost due to data consistency and must later be added manually. Therefore it is advisable

mainly to use this functionality when building up the database from scratch.

While showing the channel and program overview within the cell editor data in the tree

window to the right can not be altered.


48

Choosing “Update all steps” opens the update steps window. The window shows the same

information as the copy program window. The usage is alike. By default all the same program

sets as their master channel are ticked for update.

If the master channel includes steps for the programs 1, 2, 40, 41 as in this example and the

update button is pressed all marked channels’ programs (1, 2, 40, 41) will get updated with

the same step information from the master. All other programs’ step information remains

untouched. Steps can only be updated as a whole set. A single step can not be selected for

update.

3.3.5 Tools

3.3.5.1 SQL browser

The SQL browser allows sending commands to the database, like inserting or updating data,

querying data or changing parameters. After opening the SQL-Browser window, it looks

similar to the following screenshot:


49

SQL commands should be entered in the edit field in the upper area of the windows. The

command then can be executed by clicking the “Execute” button. If the command returns a

result set, this will be visible in the lower area (grid view). Result sets may be filtered and

grouped using the grids header and footer area or the column filters.

3.3.5.2 Log

The log window displays internal processing information. After opening the log window, it

looks similar to the following screenshot:

In general, there is no logging. However, when the log view window is open, then internal

commands are logged. To additionally log database access, check the “Log SQL” checkbox.


50

3.3.5.3 Table editor

The table editor allows editing the internal database tables, i.e. to look at default values or

change some of the system parameters. After opening the table editor window, it looks similar

to the following screenshot:

After selecting the database table from the dropdown list, the editor reads the table and

displays its data in the editor grid:

By default the grid is set to readonly mode, i.e. editing is disabled. To enable editing, press

<Alt>-w. All changes are then posted. immediately to the database.

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4 Reference

4.1 Detecting part changes

In some cases, a part can require more than one tightening operation to construct a given part.

This process may be completed by a group of spindles in different positions, or by one spindle

tightening multiple bolts. (for more information on this topic, see stitching section 4.2.3). To

collect this information properly, Q-Das defines a unique bolt for each spindle location, thus

allowing a single spindle to report data multiple times within the framework of a single part.

For this reason, the data converter must know when a part changes, as the tightening system

may run more than once before the part is complete. To determine when a part change has

occurred, the QTrans monitors the part ID code (engine-ID) with each data packet from the

KE. When it detects a new ID for a given part, it writes the previous part data to the Q-Das

file and begins data collection for a new part.

However, this solution has one drawback: The system only detects, that a part is finished

when the station has already started processing a new part. This generally, does not cause

problems if running in normal sequential operation; but it is important to note that if the user

needs to shutdown the system or change operation modes (see 3.2.2.1), it will only be safe to

do so if the systems state is “idle” (time between “last part finished” and “new part started”).

As this state is not detected within QTrans due to the fact the system only detects the part

changing with the start of a new ID code, the user is prompted to make sure that the current

part is not still in process. Failure to visually check the system prior to shutdown could cause

data loss if the last part is still in process when QTrans is shut down!

This situation may occur during the following operations:

1. initiating a shutdown of QTrans

2. switching station operation modes

3. updating configuration data

The system takes some precautions to prevent problems with this:

Case 2, only a single station is affected. The assumption is, the user knows what he is

doing, so switching operation modes in this case means, that the current part is finished

immediately and data collected so far is written to the Q-Das file

Cases 1 and 3, all stations are affected. The system checks, if there is any pending part data

(station state is not idle nor stopped) and switches the affected stations into “stopping”

state. In that case the user is notified by the following dialog box:

If in “stopping” state, only data with the current id-code is accepted by a station. If data with a

different id-code is received, the part is considered finished, the station state is switched to

“stopped” and no more data is accepted by this station (also the data block, which has been

received with the new id-code is rejected). As the SE/KE saves the data internally and

retransmits it later, no data will be lost.

However, this is no bulletproof solution, as the KE does not keep track of data transmission

per channel, but only per KE and always transmits data in a fifo sequence. So if a single KE

hosts more than one station, the first station switched from “stopping” state into “stopped”

state will reject the data packet which triggered this state transition, which causes the KE data

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52

output to repeat only this data packet, which then results in stalling the data output

completely. In that case, there is no other solution than having the user press the “stop now”

button to terminate data processing.

4.2 Part definition and bolt mapping

4.2.1 Overview

One of the central points in converting tightening result data from System 300 to Q-Das is the

mapping tightening results to the various Q-Das characteristics. There are basically three

points required to realize this conversion:

1. determining part type from given tightening result data

2. mapping result data to bolts

3. mapping result data to Q-Das characteristics

As the only information available to the QTrans conversion software is a SE/KE300 result

data packet, only the following information is available to determine the part type, and to map

result data to bolt and characteristic:

TCP/IP-address of the KE that sent the result data packet (KE/Cell number)

Channel number

Program and application number (application number is implicitly = -1, for single channel

starts)

Result data step number(s)

The part/bolt relationship is defined by mapping a unique combination of channel, program

and application to a bolt. As a station may or may not run all bolts of a part, it is required that

a single tightening instance uniquely define the part type in process. For this reason, it is not

allowed to define different parts which use the same combination of channel, program and

application for any given bolt (except for verification parts, see below, chapter 0).

Characteristic mapping further adds step and characteristic information at the

channel/program level to be converted to Q-Das.

4.2.2 Tool studies (tool verification)

For tool studies, special program parameters and speeds are typically used which are close to

actual process limits, but typically slower to accommodate the verification transducer. The

QTrans software also takes control of the spindles in tool verification mode by BMS sequence

test, so it also requires additional information to determine which program number to run for

the test.

To accommodate this need, the user must create a “verification part” for use by a tool study.

This part cannot be used in standard production, but may have programs/applications assigned

which are also used by a standard production part (for cases where it is required that tool

verification uses the same program as standard production).

Note: this is an exception to the rule defined in chapter 4.2.1. Normally a single part

containing each spindle of the station with a verification program will be sufficient.

Sometimes it is additionally required to have multiple verification parts or run multiple

programs for a single spindle during verification – all these setups are possible using the

“verification part” model.

When starting a tool study, the user will normally select only a subset of the spindles defined

in the “verification part” (e.g. only the spindle which has been replaced). The system will

internally create a “virtual part” consisting only of the selected spindles under test and will

run each spindle the given number of cycles. The result is then saved into a single Q-Das

“.dfq”-file. However, in contrast to standard production, measurement results are saved in the

following organization:

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MeasurementSpindle 1 Spindle 2 Spindle m

Tool Ref Tool Ref Tool Ref

1

2

3

4

n

...

4.2.3 Stitching and batching

At the moment only stitching is supported. To make stitching work correctly, there are the

following requirements:

a. correct selection of KE application numbers

b. correct sequencing of the line controller

4.2.3.1 Selection of KE application numbers

As the KE application number defines stitching position as well as part type, it is required that

each application number uniquely defines bolt position and part type. Meaning it is not

allowed to use a single application for different part types (even if the tightening

spindles/programs run are actually the same)

Example (single operation shown):

Part type 1 (“I4”) Part type 2 (“I5”)

Powerhead 1 KE-application 11 KE-application 21

Powerhead 2 KE-application 12 KE-application 22

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4.2.3.2 Line controller stitching flowchart

Transmit ID-Code to

KE

Start (part enters

operation)

move to position 1 move to position 1

Type 1Part/engine

type

set KE-application

number to position 1,

part type 2 (e.g.

application 21)

run KE application

(run powerhead)

Stitching position 1

set KE-application


part type 1 (e.g.

application 11)

run KE application

(run powerhead)

move to position 2 move to position 2

set KE-application


part type 2 (e.g.

application 22)

run KE application

(run powerhead)

Stitching position 2

set KE-application


part type 1 (e.g.

application 12)

run KE application

(run powerhead)

abort? abort?

no no

sum up all results,

build total

read and store

position 1

OK/NOK results

read and store

position 1

OK/NOK results

read and store

position 2

OK/NOK results

read and store

position 2

OK/NOK results

done with part (part

leaves station)

application

31

application

PP

application

32

application

QQ

Type 2 Type 3 Type X

yes

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4.2.4 Sample part definitions

P1 P1 P1 P1

Symbols used:

P1

Powerhead (group of spindles), defined by single KE-

application

Spindle

Spindle running program shown (e.g. P1)

1 Powerhead position (for stitching)

4.2.4.1 Full automatic stitching (one spindle per bolt)

P2

P1 P1 P1 P1

P1 P1 P1 P1

Part type 1 - e. g. "I-4" Part type 2 - e. g. "I-5"

KE1-App1 KE1-App21

KE1-App2 KE1-App22

KE2-App23KE2-App1

P2

P1

P1

P1 P1 P1 P1

P1 P1 P1 P1

P1

Notes:

a single powerhead/application run should be sufficient to define part type (to ensure the

part type can be detected correctly even if just a single group of spindles is running)

applications should be uniquely defined even if the spindles run the same programs for

different parts (compare part type 1 and 2 above)

KE1-App1

KE1-App2

KE2-App1

KE1-App31

KE1-App42

KE2-App1

error: mix of existing part definitionserror: some application already

defined for another part type

Part type 3 Part type 4

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4.2.4.2 Automatic stitching

Part type 1 - e. g. "I-4" Part type 2 - e. g. "I-5"

KE1-App1

P1

P1

P1

P1

P1

P1

1 2 3

KE1-App2

KE1-App3

KE1-App11

P2

P2

P1

P1

P3

P3

1 2 3

KE1-App12

KE1-App13

Notes:

position and part type are defined by application number

a single powerhead/application run should be sufficient to define part type (to ensure the

part type can be detected correctly even if just a single group of spindles is running or if

process is aborted after first position)

applications should be uniquely defined even if the spindles run the same programs for

different parts (compare part type 1 and 2 above)

Part type 3 Part type 4

KE1-App21

P2

P2

P1

P1

P1

P1

1 2 3

KE1-App22

KE1-App21

KE1-App17

P5

P5

P7

P7

P3

P3

1 2 3

KE1-App15

KE1-App13

error: cannot identify bolt positionerror: application already used in another

part type

4.3 Configuration – QTrans.ini

QTrans.ini is used to define global parameters for the QTrans software. The QTrans.ini file

has to reside in the same directory as QTrans.exe.

4.3.1 Description of Sections and Keys

4.3.1.1 Section [Global]

Key Value Default value Description

Autologon 0 0 Ask user about user name and password

for logon

1 0 Use parameters from section [USERS] for

auto logon

FTPBindAddr 0.0.0.0 Ethernet address the FTP server should

bind to. If set to 0.0.0.0, the FTP server

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57

listens at all interfaces. May be used if

multiple FTP-Servers must co-exist on one

machine (use multiple IP-addresses or

network cards in that case and bind each

server to a different IP address)

FTPBufSize 65536 Size of FTP receive buffer used (in bytes).

Can be increased if used with tightening

application with many channels and/or

steps.

4.3.1.2 Section [Database]


CheckServer 0 1 Qtrans doesn’t check if InterBase Server is

running. Saves time by not having to wait

for InterBase response. Server must be

started manually if not already running

1 1 Qtrans checks whether InterBase Server is

running and starts it (if necessary)

NAME config.ib in

start-up

directory of

program

“QTRANS”

Full name of the database file including:

- IP address for remote database (if used);

- directory containing also database

“user.ib”;

- database name

Example:

120.0.0.10:c:\programs\Qtrans\config.ib

4.3.1.3 Section [USERS]


User name Password Qtrans uses these parameters for auto logon,

if key “Autologon” is set

4.3.1.4 Section [TCP_SERVER]

This Section is available for QTRANS SERVICE only!


STACK_SIZE integer 100 Stack size for tightening results

(number of cycles). In case TCP

Client is slow and some results are

lost, increase value

TCP_HOST_PORT integer 2055 Port number. If default number is

already occupied in system, use

another available number for both

programs (TCP Server and TCP

Client)

4.3.1.5 Section [TCP_CLIENT]

If this section is absent in INI-file or empty, the program “QTRANS” runs in “verify mode”,

else in “report mode”!


TCP_HOST_PORT integer

_

Port number. If QTRANS is supposed to

run in “report mode”, set this number

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according to the TCP Server’s port

number. In “verify mode” this key must

be absent

TCP_HOST_IP

_

IP address of TCP Server. If QTRANS

is supposed to run in “report mode”, set

this value according to the address of

the TCP Server. In “verify mode” this

key must be absent.

4.3.1.6 Section [Logging]


LogLevel 0xFFFF0000

4.3.1.7 Section [HMIUserLevels]

This section is for Siemens HMI interoperability. Each entry maps a Siemens user level (key)

to one of the QTrans builtin user names/roles (value). If a key is missing or if a value is

empty, this corresponds to “not logged on”. However, this should be used with care, as this

might trigger a message dialog during shutdown – possibly preventing correct QTrans process

exit and therefore blocking HMI shutdown. A better solution would be to always use the

“Operator” role and disable the switching softkey if the HMI security level is too high.

Key Value Default

value

Description

0

1

2

3

4

5

6

7

8

9

One of the

allowed user

levels:

Operator

Engineer

If left empty,

then this means

“not logged

on”.

Empty,

i.e. not

logged

on

Map Siemens HMI user levels (normally 0 =

Siemens HMI Superuser, 1 = Administrator,

higher levels are Operator levels) to QTrans

user names/roles.

Example setup:

[HMIUserLevels]

; map Simatic HMI user levels (0...9) to our builtin user names

; notes:

; - empty entries mean no rights, i.e. no logged on user!

; - this uses DDE: Service='ncdde', Topic="'machineswitch',

Item='MMCAccessLevel'

0=Engineer ; Siemens HMI SuperUser

1=Engineer ; User allowed to modify configuration parameters

2=Operator ; (normally unused)







9=Operator ; default user level

; note: in the normal Siemens HMI setup there is always

; at least an "Operator" logon active!

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4.3.2 Example: Data processing on a local computer in „verify mode”

QTRANS.INI

[Global]

Autologon=1

[Database]

CheckServer=0

NAME=C:\Programs\QTrans\config.ib

[USERS]

gm=gm

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4.3.3 Example: Distributed data processing

4.3.3.1 INI – file for PC1.QTRANS SERVICE (IP Address:

120.234.156.10)

QTRANSSERVICE.INI: [Global]

;

[Database]

; default CheckServer=1

NAME=C:\Programs\QTRANS\

;

[USERS]

Bosch=Robert

;

[TCP_SERVER]

STACK_SIZE=300;

TCP_HOST_PORT=2055

[Logging]

;

; LogLevel: Bitmask of:

; 0x00000001 = DIAG1

; 0x00000002 = DIAG2

; 0x00000004 = ENTER

; 0x00000008 = LEAVE

; 0x20000000 = WARN

; 0x40000000 = ERROR

;

LogLevel=0xFFFF0000

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4.3.3.2 INI –file for PC2.QTRANS (remote Database)

QTRANS.INI:

[Global]

Autologon=1

[Database]

CheckServer=0

NAME=120.234.156.10:C:\programs\QTRANS\config.ib

[USERS]

gm=gm

[TCP_CLIENT]

;

TCP_HOST_PORT=2055

TCP_HOST_IP=120.234.156.10

4.3.3.3 INI –file for PC2.QTRANS (local Database)

QTRANS.INI:

[Global]

Autologon=1

[Database]

CheckServer=0

NAME=C:\programs\QTRANS\config.ib

[USERS]

gm=gm

[TCP_CLIENT]

;

TCP_HOST_PORT=2055

TCP_HOST_IP=120.234.156.10

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4.3.4 Example: Data processing on a local computer in „report mode”

WARNING!!! QTRANSSERVICE and QTRANS in “verify” mode cannot be started on one

computer simultaneously!!!

4.3.4.1 INI –file for QTRANS

QTRANS.INI:

[Global]

Autologon=1

[Database]

CheckServer=0

NAME =C:\programs\QTRANS\config.ib

[USERS]

gm=gm

[TCP_CLIENT]

TCP_HOST_PORT=2055

TCP_HOST_IP=120.234.156.10

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4.3.5 QTRANS - Command line parameters

QTRANS [mode=verify/mode=report] [ip=IP_Address] [db=PATH]

4.3.5.1 mode= verify

Suppresses INI-file definitions and starts QTRANS in “verify” mode; Example:

C:\programs\QTRANS>QTRANS.exe mode=verify

4.3.5.2 mode=report

Suppresses INI-file definitions and starts QTRANS in “report mode” Example:

C:\programs\QTRANS>QTRANS.exe mode=report

4.3.5.3 ip= IP_Address

Overwrites TCP_HOST_IP value from INI-file. Is meaningful only after “mode=report”, else

to be ignored

WARNING!!! In case after “mode=report” any IP_ADDRESS is pointed, INI-file must

contain some TCP_HOST_IP value, else CONNECT ERROR occurs.

Example:

C:\programs\QTRANS>QTRANS.exe mode=report ip=120.234.156.10

TCP_HOST_PORT cannot be changed by this program call and is always set to “2055”!

4.3.5.4 db= NAME

Overwrites NAME value from INI-file and represents full path to the database including (in

order of appearance):

IP address for remote database (if used);

full directory path;

file name of the database

WARNING!!! Pointed directory must also contain database “user.ib”

If directory name contains blanks, fully delimit all NAME-string by the quote character:

“directory name\FileName”

Examples:

C:\programs\QTRANS>QTRANS.exe db=C:\DB\config.ib

C:\programs\QTRANS>QTRANS.exe db=”120.234.156.10:C:\DB\Front Cover.ib”

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4.4 Additional notes

4.4.1 General notes

Program 99 will always be silently dropped (cannot be mapped to any Q-Das data!)

Due to some restrictions in the KE data output, sometimes there may be application results

without channel results. In case of Application quality code 129 therefore data will be

dropped silently (same for data with sb=18 (system error))

If an ID-Code contains "_" at position length-3 and the last three characters define a

number in the range 001 to 999, then the 4 rightmost characters will be automatically

removed (strip tightening sequence counter)

When using single spindle start, a application number of -1 is used internally, i.e. when

configuring a part/bolt with single spindle start application -1 should be used (required also

for tool studies (verification))

The system is completely offline capable, as only information from FTP-data output of KE

is used

4.4.2 Special K-Field handling

4.4.2.1 K0002

Special handling for K-Field K0002 (empty value attribute):

Normally K-Field values are generated in this order:

- read default from K-Field list (database table KFIELDS, "global default")

- update with value from configuration (if configured/available)

- update with value from process (if available)

- overwrite with value from K-Field user override (if defined)

For K0002 this is different: The value given in 1. and 4. is used only, if there is no data

available, i.e. if there is data K0002 = 0. If there is no data, it will use the data processing

pipeline described above.

4.4.2.2 K0006, K0009, K0014 and K1001

Depending on the new global parameter (available from QTrans V1.27.7) different K-fields

are used for serial number and part number (see chapter 3.3.4.1):

- “new mode”: K0006 is used for the serial number and K0014 is used for the part number

- “old mode”: K0009 is used for the serial number and K1001 is used as the part number

Please note, there is also a special configuration option for K0006. If the default value of this

field is set to “CopyK0009” then K0006 will receive a copy of the K0009 value, i.e. it will

receive the current part identification value (Part-ID).

To set this value, open DBEdit (or click the “Configuration” button in QTrans), then use the

main menu Edit K-Fields (see also chapter 3.3.4.4). select the tab “K-Fields (global)” and

modify the default value of K0006 to read “CopyK0009” (this is case-sensitive). See the

following screenshot for an example:

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4 Reference

66

4.5 Tool Verification field mappings

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67

OP1020_Verify Torque

Spindle 1 Torq_S3A_T

5 Reference and output drivers

68

5 Reference and output drivers Starting with Version 1.27 the QTrans system uses drivers for handling reference meters and

providing flexible data output formatting. Reference and output driver are selected and

configured using the configuration software (in Edit Global parameters).

5.1 Reference meter drivers

At the moment two reference meters are supported. Both meters are connected to the PC

running QTrans using a serial connection.

5.1.1 RS Technologies Model 960 Transient Recorder

The RS Technologies Model 960 Transient Recorder measures torque and

angle and sends its data to the serial port. The QTrans configuration used

for this reference meter is activated by selecting “RS Technologies” as

reference meter driver.

This driver has the following configuration properties:

Serial port: Enter the serial port number for the COM-port the RS meter

is connected to (e.g. COM1 enter “1” here).

Use absolute Angle: This is a flag to define whether the angle reported

by the meter should be used with sign (Use absolute angle = 1) or the

absolute value of negative angle values should be used (User absolute

angle = 0).

5.1.2 Burster DigiForce

The Burster DigiForce measures torque and angle and sends its data to

the serial port. The QTrans configuration used for this reference meter is

activated by selecting “Burster DigiForce” as reference meter driver.

This driver has the following configuration properties:

Serial port: Enter the serial port number for the COM-port the RS

meter is connected to (e.g. COM1 enter “1” here).

Use absolute Angle: This is a flag to define whether the angle reported by the meter should

be used with sign (Use absolute angle = 1) or the absolute value of negative angle values

should be used (User absolute angle = 0).

5.2 Output drivers

At the moment four output drivers and data output formats are supported. See the following

sections for more details.

5.2.1 Q-Das QS-Stat

This is the default driver and is described in detail in this manual. Please see chapter 4 for

additional details.

5.2.2 Excel

This output driver is for reference measurement only and is should only used in verify mode

(see chapter 4.3 and 4.3.1.7). It generates XML files for use with Microsoft Excel (Version

2002 and above). Those XML data files can be linked into a standard Excel-Worksheet (using

data external data XML) which in turn can provide customized reports and formatting

for the data. Please see the sample XML/XLS files and templates for more information.


69

The driver allows to define additional data to be entered, recorded and exported to Excel. This

can be defined by creating a XML template (QTrans.xml, located in the same directory as

QTrans.exe) file. Each “StudyParameter” defined in this file is displayed in the guided

sequence operators interface and a value for the current measurement can be entered by the

operator. Parameters are stored in a recently used list for easy access and for easy reentry of

unchanged values between measurements.

5.2.3 XML-CAQ

This is a special XML data format for use with the Audi-CAQ software. Note, that this format

does not support tool verification or production studies. If XML-CAQ is selected as output

driver, tool verification and production studies will generate Q-Das QS-Stat data. Standard

production data is generated as XML-CAQ files.

5.2.4 CSV

The CSV driver creates comma separated output files with a fixed layout for use with either

Excel or automated processing. It behaves similar to the standard Q-Das QS-Stat driver in

terms of creating new files (rollover) by time or by number of runs (see 3.3.4.1).

Note that for using the CSV output driver it is not necessary to define steps in Edit Cells!

However, if using multiple column sets (see below) you might want to define the final step.

This driver creates csv-files in directories based on the part name. Each csv-file has a regular

layout (fixed column layout) with one or more column sets per bolt. Normally one column set

per bolt is created as follows:

Column x: “T-“ lower torque limit

Column x+1: “T” actual torque

Column x+2: “T+” upper torque limit

Column x+3: “A-“ lower angle limit

Column x+4: “A” actual angle

Column x+5: “A+” upper angle limit

Column x+6: Step: BS300 Step number

Column x+7: Result: OK/NOK result.


70

In this case the resulting data is the data generated in the last step ran for the bolt. However,

sometimes it is required to report more than one step per bolt. This is also supported by

adding an option to the bolt (see the following screenshot):

If the parameter is is set to a value > 1 (a value of one is default if the option is missing), then

the assigned number of column sets is generated for the bolt (maximum number of four is

allowed). If multiple column sets are used, one can additionally define the final step (see

screenshot below) for the bolt. This allows to correctly map the final step to the last column

set of the bolt (even in NOK case). If the final step is not defined, result step data is mapped

from right to left (see samples below).

Note, that if more than one step has the category “final torque” defined, only the first one is

actually used to determine the column set used for output.


71

To understand how this works, here is a sample:

Example 1: Spindle 1 (Ch 1.1) settings: Spindle 2 (Ch 1.2) settings:

CSVSteps=1 CSVSteps=1

Step 7A (Prg. 5) – final torque (final torque not set) ID Spindle 1 : last docu-buffer Spindle 2 : last docu-buffer

T- T T+ A- A A+ Step Res. T- T T+ A- A A+ Step Res.

CSV_TEST1 x x x x x x 7A OK x x x x x x 7A OK

CSV_TEST2 x x x x x x 5A NOK x x x x x x 5A NOK

CSV_TEST2 x x x x x x 3A NOK x x x x x x 3A NOK

Example 2: Spindle 1 (Ch 1.1) settings: Spindle 2 (Ch 1.2) settings:

CSVSteps=2 CSVSteps=3

Step 7A (Prg. 5) – final torque (final toque not set) ID Spindle 1 : (last docu-buffer) -1 Spindle 1 : ( last docu-buffer)


CSV_TEST1 x x x x x x 5A OK x x x x x x 7A OK

CSV_TEST2 x x x x x x 5A NOK

CSV_TEST2 x x x x x x 3A NOK

Spindle 2 : ( last docu-buffer)

T- T T+ A- A A+ Step Res.

x x x x x x 7A OK

x x x x x x 5A NOK

x x x x x x 3A NOK

Spindle 2 : (last docu-buffer) -2 Spindle 2 : ( last docu-buffer)-1


x x x x x x 3A OK x x x x x x 5A OK

x x x x x x 3A NOK


72

5.2.5 AMT-XML

The AMT-XML driver creates formatted XML output files for use with the “Koncept

Management Information Services” MMS (Machine Management System) application.

Unlike the standard Q-Das output driver, it generates a single new output file for each part

run.

The following screenshot shows the global configuration parameters for the AMT-XML

output driver:

The only available options are:

- Output base directory: Specify a directory, where QTrans should store the result files.

QTrans will normally generate subdirectories for each part type defined here and put

the corresponding result files into them.

- Filename prefix: You may specify a filename prefix for the generated files here.

Note that for using the AMT-XML output driver it is not necessary to define steps in Edit

Cells. However, you must define parts and bolts in Edit Lines. Note also, that the bolts

only define the allowed values for use with the XML output driver, so if you want to add a

new tightening program to a part, add a new program in Edit Cells and add a new bolt in

Edit Lines.

The AMT-XML output driver supports passing parameters from the ID-Code received from

the tool directly to the output file. It uses the station level option field for this configuration as

follows (see the screenshot from Edit Lines Stations below):


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To display the option value list editor, click the dropdown arrow on the right hand side of the

options column. Two options are supported here:

- IDCodeMask: This is a text string which defines which characters from the ID-Code

of the tool should be extracted and used as part serial number (<PartID />) in the XML

data output. If the character “I” is found at a given position in the IDCodeMask string,

then the corresponding character from the ID-Code is extracted and copied. If there is

a “_” character, nothing is copied.

- IDCodeKeys: This is a text string, which defines which characters should be extracted

to be used as the <TighteningPoint /> value for the XML output. If the character “P” is

found at a given position in the IDCodeKeys string, then the corresponding character

from the ID-Code is extracted and copied.

Example for IDCodeKeys:

6 8 H M 3 2 0 8 1 2 0 3 2 6 A FID-Code from tool:

- - I I I I - - - - - - - - I IConfigured IDCodeMask:

H M 3 2 A FResulting code:

The following mapping is used to create XML output:

XML-Tag QTrans configuration

<Location /> LineStation: Field “Name” (Station name)

<PartID /> Part ID received from tool after filtering according to IDCodeMask

and IDCodeKeys (see above)

<TighteningGroup /> Line Station: Field “Station#” (Station number)

<TighteningPoint /> TighteningPoint received from tool after filtering according to


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IDCodeMask and IDCodeKeys (see above). This is a bolt number

(numeric!).

<Spindle /> Line Station Spindles: Field “Spindle#” (Spindle number).

6 Requirements and restrictions

75


6.1 System 300 Configuration

6.1.1 ID-Code (VIN or other identification number)

For the Q-trans system to detect part changes automatically the use of an ID code by the

tightening system is required. Within the System 300, the ID code can be transmitted into the

KE through a number of interfaces such as RS-232, Ethernet, Profibus, etc. This code is then

transferred with the cycle data to the Q-trans system.

If no ID-code is available, the system should be configured such that the KE sequence counter

is used. Without an ID-code, stitching is not possible.

For proper operation, the System 300 ID-Codes should be configured to:

NOT delete ID-Code after start

Increment ID-Code automatically (if an option exists)

Add at least an underscore and 4 digits to the ID-Code mask. This creates a unique ID code

for each cycle. This can be done by enabling the “extend ID code with cycle counter” on

some interfaces. This is very important, as the files within the KE mass storage are defined

by ID code. Without a unique ID-Code per cycle, multiple runs will be overwritten. The Q-

Das converter will automatically remove the last 4 digits. Prior to stripping the last four

characters it checks:

─ Id-Code length > 4?

─ Id-Code[len-3] == '_'? (KE attached extension)

─ Last three digits of Id-Code is numeric and > 0?

─ If all requirements are met, the Q-trans understands this is a KE extended cycle, and the

last four characters will be removed. In all other cases, the id-code is not modified.

Note, that in the current SE/KE300 firmware (<= V1.400), only ID-Codes sent by FTP have

the option to append sequence numbers automatically. If any other interface is used, the PLC

is required to add four digits to the actual ID-Code to be sent to the controller. The additional

four digits must follow the rules defined above, i.e. “_001” … “_999”.

6.1.2 Data output settings

It is mandatory to set the System 300 data output format to (BS300: System tightening cell

data):

data output = enabled, send all results, send after sequence end

data output format = standard+

FTP setup: send all data to the PC where the QTrans software is installed (use PC’s

TCP/IP-address; username, password and directory settings are irrelevant).

6.2 Tightening programs

6.2.1 Application number selection

It is required for each application number to uniquely define a part type. In case of stitching it

additionally has to uniquely define a stitching position (see 4.2.2).

6.2.2 Rework

In general all rework is done inside the controller, i.e. there is no second start signal to the

same spindle/spindle group to do rework.

Automatic one-time rework without data Automatic one-time rework with data output


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output for 1st try. Only data for the last step run

and for the last run of step 3A are reported. for 1

st try (maximum 4 steps documented:

- 1st try pre-torque

- 2nd

try pre-torque - 1

st try final

- 2nd

try final (if there is an abort in one of the loosen or find steps, this will also be documented)

Notes:

For steps running in columns >= “B” there is a jump back to column “A”’s end-step

(6A in this example) required for the total tightening result to be reported as “OK”

Last step result data is always reported in data output, so there is no docu-buffer

assigned to step 8B in second example.

To make rework work as expected for tightening process and Q-Das data output, the

tightening programs must be programmed with the following points in mind:

Steps running multiple times will only report a single result even if they have a docu-buffer

assigned (result of the last time this step has been run).

To ensure data output for 1st try and for 2nd try (in case of rework) the steps to be

documented should not be executed twice. A solution to this problem is not to use “jump

back to start on NOK”, but to switch to another column and duplicate the step to be

documented (and assign a second docu-buffer, see example below).


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End-steps in columns >= “B” will always report total tightening result NOK even if the last

step run reported OK. To report the total tightening result OK, there should be a jump back

to column “A”.

Last step result data is always reported in data output, so there is no need to assign docu-

buffers to steps which always run last (like 8B in second example above).

Limitations:

There is a maximum of four docu-buffers available (three of them may be assigned freely,

one is always the last step run)

Each step will only report a single result data block, even if run twice (in that case, only the

result of the last run of this step will be reported)

7 Troubleshooting

78

7 Troubleshooting The following sections describe some common problems and their solutions.

7.1 Data converter does not receive data

Is FTP enabled on BS300?

Are datablocks received by Q-trans? Are the number of stored files increasing within the

KE mass storage card (see BS300)?

─ If yes, KE may not be able to transmit to Q-trans via FTP. Check cable and KE settings

via BS300.

─ If No, check if data output and settings for FTP. The number of un-transmitted files

should increase each cycle if the Ethernet cable is disconnected. If it does not increase,

the system is not configured to transmit results via FTP.

Are dropped packets increasing at regular intervals?

─ KE is trying to broadcast an invalid packet not accepted by Q-trans:

- Check the log file to review contents of packet sent by the tightening system

- Correct configuration in Q-trans for all application and program possibilities.

- Check “ignore invalid data” option on main screen. This will allow the Q-trans to

accept unexpected programs or applications.

- If all else fails, go to BS300 system test KE mass storage. Choose format card

to erase all invalid data within KE. NOTE, THIS WILL ERASE ANY

UNTRANSMITTED DATA WITHIN THE KE!

7.2 Verification Study

1. No parts appear for the given station.

a) Check configuration with DBEditor tool.

─ Verification programs must be configured as “enabled” and “verification” for each

spindle with the cell editor.

─ A verification part must also be created under the lines editor which uses this program.

2. Started study can’t connect to KE. KE/BMS error.

a) Check cable between KE and Q-Trans. Q-Trans must have proper IP address for the

configured KE to control the tools and start the study.

3. No data from verification transducer after first part cycle. C

a) Check that external transducer is:

─ ON and calibrated

─ Connected to PC’s serial port

─ Configured for “GM” communication

─ Check that proper COM port is chosen from DBEditor, global settings

7.3 Production Studies

1. File is not written for a given study after completion.

a) Files will not be generated if a program does not receive any recordable data. For

example:

─ If a tool is run without a bolt and fails in the first step, a rundown will be transmitted but

the first step may not be documented within Q-Trans as a reporting step. In this case the

rundown is counted, but no data will be saved for the part. If all cycles terminate in this

way, no part file will be generated as there is no useful data.

2. I get multiple files when running a test.

a) If the application, part, or limits change a new file will be generated to reflect the

changes within the study.

7 Troubleshooting

79

b) ID-Code digits 3-5 are used for Q-Das data definition. Changes in these digits will also

lead to multiple files.

8 Sample walkthroughs

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8.1 Sample setup walkthrough

This guide is meant to provide a step by step approach to set up a simple 3 spindle system. It

follows the recommended workflow, and assumes the user has already familiarized himself

with the Q-Trans editor and the Bosch Rexroth BS300 software package.

8.1.1 Setting the KE FTP communication with the BS300:

1. From the toolbar select System tightening cell data FTP

Set to “All Results”

Set to

Standard plus

Set to IP of PC running

Q-TRANS

Set large enough to

accommodate ID-code + 4

digits, all should be masked


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8.1.2 Setup the Tool program/application

8.1.2.1 SE Program (same for all tools)

Tightening Steps

2A – high speed rundown – stored in buffer (1)

4A – final stage, torque target – stored in buffer (2) so that data is preserved IF the tool

fails this step and retries through the “B” path. If this is not stored within a buffer, the tool

would not transmit data from this step UNLESS it completed here with on “OK” result

4C – reverse

6B – reverse – reverse tool and jump back to retry 4A

7B – final stage, rework second try – torque target, alternate final step if 4A fails


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8.1.2.2 KE Application

This application defines (3) spindles running the same program as a single group. There is

only one application in this example.


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8.1.3 Configuring the Q-trans file:

8.1.3.1 Set up channels and programs

Start by choosing the edit cells option from the DB editor menu

Define the IP address of the KE the tools are connected to.

If the KE and SEs in the system were previously fully set up using BS300, channel and

program data can be automatically retrieved from the KE by the compare function (see

3.2.4.7). Steps’ and applications’ data must still be added manually though. Go on by

defining the Line editor information (7.1.3.3). Else go on with the next line.

Define the channels (tools) that are connected to this KE. To add a new channel, press the

“insert” key after selecting the channels area or right-click.

Define the programs that will be monitored within each tool.

1) The program # must match the number defined on the tool controller.

2) The name is not critical, but it should be set to match the name entered on the tool

controller.

3) Select the tool you would like to edit and press the “ins” key or right-click to add a new

program. Programs that are not entered will not be monitored by Q-trans and thus not

produce Q-DAS records.

4) Program 99 should NOT be entered on this list.

Define the Steps you would like to collect from the program.

1) Select the area you would like to edit and press the “insert” key to add a new step.

2) Only these steps will be reported to Q-DAS if they are transmitted from the KE

controller. Other steps will be ignored. Steps to be documented in our example:

- 2A – high speed rundown


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- 4A – final stage, torque target

- 7B – final stage (rework), torque target

Configure the “Class” attribute which represent the final “target(s)” per step

1) Any step which will produce a good part (4A or 7B) must be configured such that the

target characteristic class = 2. In our example, torque is the target, so Torque class (on

right window pane) for steps 4A and 7B should be set to 2

2) All other characteristics should be set to the default characteristic class = 1

3) This can be overridden on a part/bolt basis later in the setup

4) If this is not done properly, studies will not show the “final characteristics” properly on

the report

Repeat to setup all desired programs

Copy all programs and steps to the other channels using drag and drop functions within the

program tree

Important Programming Notes:

The System 300 currently only allows the data from up to 4 steps to be transmitted for any

given program. Three of these steps can be freely defined within the program structure

(shown by a small # in the upper right hand corner of the step symbol, currently 2A and

4A). This number represents one of the four “buffers” within the tool controller. Additional

information on tool buffers:

1) The number of the buffer is not significant to Q-DAS, but the fact is it will always be

reported to Q-DAS

2) The last step completed by the controller will ALWAYS be transmitted, so it does not

need to be identified by a buffer

For data to be reported to Q-DAS, it must meet all of the following requirements:

1) it must be a defined step within the Q-trans application

2) it must be the last step the tool completed OR defined as a “buffer” step

When defining the steps in Q-trans, only define the steps that need to be collected.

Examples:

1) If you want to collect data from any step which may terminate, you can define all steps

within the Q-trans application. Keep in mind the file will be larger and that there will

only be data from the buffers and last step completed characteristics for a given

rundown

2) In the above program 6B and 4C are reverse programs. This data is not necessary, so

they typically should not be defined within Q-trans

3) If the tool would finish on 6B or 4C, this data would be discarded since it is not defined

in the Q-trans configuration. Only data that is defined in Q-trans will be reported to Q-

DAS

4) If you do not define the first step of a program, such as a find step, failures on that step

will not be documented and no valid data will be generated


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8.1.3.2 Define Applications

Choose the “Applications” tab

Press the “insert” key to add all applications or right-click.

1) The number MUST match the number used on the KE

2) The name should match for clarity, but is not required

3) Do not configure application 99


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8.1.3.3 Configuring Spindles

Start by choosing “lines” from the editor

─ The system can monitor multiple production lines or line segments, so the different lines

can be configured here

Next, configure each station defined within the KE

─ Up to 8 different applications can run at the same time by using the “fastening

operation” signals F01 – Fo8. Each desired fastening operation should be defined

separately within the Q-trans editor so that it can be collected and displayed as a unique

station

─ In our example, there is only one station. So it is entered as shown here

Assign spindles used on the station

─ Press the “insert” key to add each spindle


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8.1.3.4 Configuring Parts

Choose the “parts” tab after selecting edit lines from the menu bar

Choose parts, then enter a new part by pressing the “insert” key

Add bolts for the part by again pressing the “insert” key

Note that as you choose the applications and programs, the pane to the right updates to

show the steps and class for each attribute as configured earlier. You can filter your view

by pressing the customize button to filter for the target of torque as shown on the

screenshot

8.2 Sample Q-DAS review reports walkthrough

This guide is meant to provide a quick overview of the basic Q-DAS functions required to

review some of the data generated by Q-Trans. The user will need to have a GM Powertrain

specific copy of Q-DAS, and a set of files generated by Q-Trans to follow this tutorial.

8.2.1 Choose Module

You must begin by choosing a module. Choose edit from the menu.

Available choices:

Sample analysis – Used to review 5, 10 and 50 piece studies

Process Capability – Used to review normal production files

Measurement system analysis – used for tool verification studies

8.2.2 General Use

1. After opening a file the screen will display the following “characteristics mask” screen.

Here you can double click entries to enable/disable particular characteristics, but normally

you can just click OK to continue leaving all enabled. You can return to this screen back

by choosing “characteristics mask” from the toolbar


88

2. In some modules, you can see additional information about a specific characteristic by

selecting it on the chart or graph then selecting either parts mask or characteristics mask.

3. The values mask button shows a spreadsheet view of all characteristics and their respective

values.

4. If you enable/disable characteristics, you must press the execute evaluation button to

update charts/graphs

5. When reviewing statistics or plots, you can select the “advance characteristic” icons to

cycle through the various characteristics within each reported rundown. Different

characteristics could be step 1 torque, step 2 angle, etc.

6. Once you select OK from the values mask screen, a different set of screens will open

depending on the module you have selected prior to opening the file.

Q-DAS toolbar:

8.2.3 Sample Analysis Module

This module is used to review files generated with the production study tools of Q-trans.

1. First choose module sample analysis

2. Open the file created by Q-trans, typically found in c:\QSDATA\ARO\5 PIECE\ Partname\

3. Choose file report preview ARO/MRO 5 piece to look at report data

3) These tools allow you to cycle through

the different characteristics of a file.

1) characteristics mask

2) Parts mask

3) Values mask

4) Execute evaluation


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8.2.4 Measurement System Analysis Module

This module is used to review files generated after a tool verification study (Type 1-A)

1. First choose module measurement system analysis

2. Open the file created by Q-trans, typically found in c:\QSDATA\EMS\Type1A\

3. Use the characteristic advance icon to cycle through the different characteristics. The

charts and graphs will update accordingly

4. Choose file report preview to look at report data


90

9 Referenced Documentation

91

9 Referenced Documentation The system is modeled and defined based on the following specification documents written by

both General Motors and Q-DAS. These documents describe the procedures and requirements

in further details:

2002-06-01, E-PD 04 E, Q-Das ASCII Transfer Format,

2005-04-27, Q-DAS Inc., Final Flint Engine South Catalog, Process Data Network

Database Catalog, Jason Kohl

2005-05-04, Q-DAS Inc., GMPT K-fields 40511, “GMPT K-Fields_20040511.pdf”

(Support Department, Certification Integration, Data Certification Package, GMPT

Supplier Certification package, supporting documents + GMPT K-field list, GMPT-

Kfields_and_history_20040511.xls)

GM Powertrain, Machinery and Equipment Specification Document, Fastening

Specification for Single Spindle and Multiple Spindle Fixtured Tools, Document No.: SP-

M-Fastening_ Multiple Spindle Tools, Version 2.1, Original Date: 2000-08-10, Revised

Date: 2004-06-25

GM Powertrain, Machinery and Equipment Specification Document, Fastening

Specification for Single Spindle and Clustered Spindle Hand Tools, Document No.: SP-M-

Fastening Hand Tools, Version 1.0, Original Date: 2004-03-01

GM Powertrain, Global Machinery and Equipment Specification Document, Fastening

Specification for Single and Multiple Spindle Fixtured Tools, Document No.: SP-M-

Fastening_ Multiple Spindle Tools, Version 2.0, Original Date: 2000-08-10, Revised Date:

2004-03-01

GM Powertrain, Global Machinery and Equipment Specification Document, Assembly

Run Off and Acceptance Specifications (ARO), Document No.: SP-Q-ARO-GLOBAL,

Version 10.6, Original Date: 27-Oct-2000, Revised Date: 01-Jul-2004

GM Powertrain, Global Machinery and Equipment Specification Document, Evaluation of

Measurement Systems Specification (EMS), Document No.: SP-Q-EMS-GLOBAL, Draft

10.3, Original Date: 17-Dec-1999, Revised Date: 01-Mar-2004

GM Powertrain, Global Machinery and Equipment Specification Document, Evaluation of

Measurement Systems Specification (EMS), Document No.: SP-Q-EMS-GLOBAL,

Version 10.6, Original Date: 17-Dec-1999, Revised Date: 01-Jul-2004, Specification

GM Powertrain, Global Machinery and Equipment Specification Document, Gage

Computer Requirements For Measurement, Test, and Assembly Systems (GCR),

Document No.: SP-Q-GCR-Global, Draft 10.0, Original Date: 01-Mar-2004, Revised Date:

01-Mar-2004

GM Powertrain, Global Machinery and Equipment Specification Document, Gage Design

Specifications (GDS), Document No.: SP-Q-GDS-GLOBAL, Draft 10.1, Original Date:

17-Dec-1999, Revised Date: 01-Mar-2004

GM Powertrain, GMPT Machinery and Equipment Specification Document, Gage

Computer Requirements For Measurement, Test, and Assembly Systems, Document No.:

SP-Q-GCR, Version 4.0, Original Date: 01-Mar-2004, Revised Date: 29-September-2004

GM Powertrain, Global Machinery and Equipment Specification Document, Global

Machinery and Equipment Specification Document Machine Run Off And Acceptance

Specifications (MRO), Document No.: SP-Q-MRO-GLOBAL, Draft 10.5, Original Date:

17-Dec-1999, Revised Date: 1-Mar-2004

GM Powertrain, Global Machinery and Equipment Specification Document, Assembly

Run Off and Acceptance Specifications (ARO), Document No.: SP-Q-ARO-GLOBAL,

Draft 10.3, Original Date: 27-Oct-2000, Revised Date: 01-Mar-2004

9 Referenced Documentation

92

Please note: some documents listed above provide conflicting information, in that case,

information in newer documents supersedes older and local documents seem to supersede

global documents.

qtrans - haller + erne

Documents