welcome!

© Haller + Erne GmbH 2014

PresentationWorker guidance

Holger Erne, Haller + Erne GmbH

Welcome!


Contents

Introduction TKSE-Project Software for worker guidance

Applications User interface Features Limitations News for the upcoming version

Other Projects

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IntroductionOverview

Haller + Erne GmbH Soft- and hardware development since 1987 6 employees ISO9001 certified since 2012

Data acquisition software for Rexroth tightening systems Standard products for data conversion:

Q-Das QS-Stat (QTrans V1.1 certified 2005, V2.0 certified 2010 as AQDEF V3.0 Category C)

For Sciemetric QualityWorX (graphs + data) Worldwide use in the automobile industry, e.g. GM, Ford

Software for worker guidance Recaro, Benteler Worker guidance Porsche/Daimler, Valve assembly Rexroth Lohr

Website www.haller-erne.de

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© Haller + Erne GmbH 2014 4

IntroductionAreas of activity

Automation

Sensors, control, accessories and

software

Bolting

Socket trays, software, data

connection, worker guidance

Communication

Fieldbus systems, data connection (protocols and

databases)

Soft- and hardware for industrial control and communication

Standard solutions and customer-specific solutions

Development: project-related solutions and engineering

Software for collecting process data, converting and archiving

Accessories for Rexroth tightening systems• Hardware (e. g. socket trays)• Software PC/KG‘s (data-,

protocol converter, process control)

• Internal firmware (VxWorks) for tightening systems (IPM, PLUS)

• IndraLogic applications and modules (e. g. Modbus-master for tightening systems)


TKSE-projectOverview

Small scale series of AMG bodys Two Nexo‘s per operator Two operator at one assembly station

are working on the same vehicle (left and right side)

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approx. 20 tasks per side approx. 100 bolts per side Requirements:

Ensuring quality (worker guidance, socket tray, tightening and loosening bolts)

Visualization (which steps are up next, what‘s still missing) Recording and storing data (scanning, Q-data, traceability) Optimizing the process time


Worker guidance - softwareApplications

Prototypes and lab Standalone-operation (without network) Frequent changes of procedures Documentation as pdf/printout (w. graph)

Production Small scale series with multiple stations Data interface with network, ident systems Central definition of tasks and tightening specs

Standby workstations Use as temporary replacement in case of breakdown

of station on the line Usable at multiple stations

Post-treatment Similar to standby, but initial part status is provided by

network

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© Haller + Erne GmbH 2014 7

Worker guidance - softwareTopology and data management

Splitting into different components…

• Two databases – configuration and data

• “Monitor“ – runtime for the workplace

• “Configurator“ – editor for configuration

…makes different topologies possible

• Standalone

• Offline-configuration

• Central configuration

• Online/server-operation

Simple data management

• Versioning of the configuration

• Single-file copy/transfer


Worker guidance - softwareApplication interface – “Monitor“

Also works for small screens with low resolution Touch-screen operation Minimalistic & simple Only three pages:

Sign-in Part list Tightening job

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Job selection

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Job status

Job selection by clicking (touch)

Visualization of job state

Input: barcode scanner or keyboard

Actions

Current job



Tightening Job

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tightening results

Job

Current toolactions

Pre-tightening (dark green), final tightening (light green)

Tightening status(green: OK, red: NOK, yellow: next position)

result of last rundown

click/touch: loosen, delete, skip


Worker guidance - softwareApplication interface – “Configurator“

Hierarchy of parts and jobs (job groups) Reusable jobs in different parts Color coding for jobs (yellow) and job groups (blue) Separate definition of bolts and process steps / tool actions

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production series

list of barcodes for parts

Jobs/Groups for selected part

list of all jobs/groups (catalog)

list of barcodes for parts/assembly groups

Add job to currently selected part

menu and tabs

Configure parts and barcodes



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additional functions (pictures/clipboard)

properties of the currently selected item

picture selection

actions

create new parts by drag & drop

menu and interfaces (tabs)

Creating new jobs

navigation similar to Windows Explorer

Jobs and job groups



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Active page shown is “bolts”

Filtering the displayed bolts: all, pre tightening, final tightening

properties of the selected bolt

Bolts (double click: add new ; ctrl/shift-click: change size ;right click: menu)

Edit bolts

list of bolts (with name, number)



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operation properties (tool, program-number, bit-type, …)

actions

assigning tightening operations to steps: right click / add operation

Edit tightening sequence

Bolts (double click: new ; ctrl/shift-click: change size ;right click: menu)

drag & drop for changing sequence

Active page shown is “tightening sequence”


Worker guidance - softwareFeatures – Overview

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Available functions Multiple tools per station:

Ergospins Tightening aggregates Electronic wrenches/GWK

Single tool active per station Manual confirmation and notes Part-hierarchy: part, job groups,

jobs Pre-tightening, final tightening,

post-process Tightening positions in fixed

sequence or free selection Barcode or manual selection of

jobs and parts

Not supported Multiple workers working

simultaneously at one station Working on one tightening

position with different tools/bits (two tools can be used by using the post-processing feature)

Reloading or editing tightening programs


Worker guidance - softwareFeatures – interfaces and expandability

I/O with USB, Profibus, OpenProtocol/IM24V, Modbus-TCP/UDP

Driver interface for bolting systems CS/KE (Profibus) and OpenProtocol (Nexo) Electronic wrenches GWK, Saltus

Socket trays (by USB or CS/KE IM24V) Recognizes location of tightening positions (by Profibus) Worker-identification (e.g. Euchner-Key) Data output interfaces

XML-file (“Motis“), text file (“csv“) Exporting/archiving from local database

Lua-scripting for several application areas

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Worker guidance - softwareSpecial Features

“low cost“ standalone-solution: Nexo + PC + MSTKN Standard-PC (all-in-one touch) with integrated WLAN-AP Nexo with direct-WLAN-connection (without CS351) Socket trays connected over USB

Plausibility check against drawing params/plausibility values Pre-tightening, final tightening and post-process interrupting/resuming operation on a part 3 access levels (operator, supervisor (can loosen/delete),

admin (can input/change settings)) Core data versioning

Changing a job will create a new version of the job/part Historical part result data will stay consistent

Report-designer Report-generator can also generate configuration/master

data reports (e.g. list of tools) and customer specific reports

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Worker guidance – softwareStartup and configuration

Initial startup Setup by using installation program Configuration of stations Tool interface setup I/O-interfaces (configure BMS table and evt.

Profibus/OpenProtocol) Texts/headers (engine, vehicle type, …) Editing ini-files

Defining tightening processes Customer can do that himself Use “Configurator“ GUI application

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Worker guidance - softwareOn the agenda…

Changes planned for current version Improved error messages Per tool diagnostics (currently only by tool type/driver) Text-display on Nexo (if timing gets fixed with V1100)

Changes planned for next version Enhanced (per job/bolt) loosening operations Splitting station and process definition, definition of

tightening process not depending on tool used (use a „operation name“ instead of tightening program number, so each stations can use different programs numbers)

Improve ease-of-use for configurator Improved handling of part variants Improved station/ hardware configuration Better modularity Additional scripting areas

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PresentationWorker guidance

Holger Erne, Haller + Erne GmbH

Thank you for your attention

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