MP85A/ MP85ADP. FASTpress. Data Sheet. Special features MP85A / MP85ADP. B en

Transcription

1 MP85A/ MP85ADP FASTpress Data Sheet Special features 100% quality control of the production process Powerful algorithms for monitoring fitting, testing and press fitting processes Universal twin channel amplifier for many of the usual market sensors with TEDS sensor detection Memory function for results, curves and device settings Convenient integration into the automation system by means of standardized fieldbus interfaces Carrier frequency excitation voltage 4.8 khz Power supply for active transducers 5 or 24 oltage supply, electrically isolated EEPROM 24 A D μp Control inputs and control outputs A D Intelligent signal conditioning and powerful algorithms for monitoring fitting CANopen interface Ethernet interface 10 SSI transdu cer MP85A / MP85ADP Keyboard and display MMC memory card Profibus DP interface (for MP85ADP)

2 Description Integrated quality assurance in production and laboratory With the MP85A, quality assurance can be integrated into the production process. Operational reliability, economic efficiency and product liability are of paramount importance. Permanent monitoring is indispensable, especially when quality assurance is only possible during the actual manufacturing process. Typical examples include: press-fitting fitting riveting and clinching flanging and roller-burnishing MP85A provides all the functions required for full monitoring together with user-friendly, flexible software that enables users to configure variable test sequences without extensive programming knowledge. Performance features and advantages: Easy configuration and commissioning with free parameterization and visualization software (PME Assistant) Download from Support Software Precise process analysis to meet requirements Flexible system for monitoring different workpieces, 31 different device settings and 31 different workpieces/processes Storage of results, curves and statistics, as well as the device settings in the device itself, on a memory card or on an external PC Continuous traceability thanks to integrated process control and the statistics functions of the stored processes Integration via digital inputs/outputs or integrated fieldbus interfaces to primary control systems, such as a PLC control or process control systems Flexible application, tailored for use at manual workstations Expansion of existing machines, easy to install Possible fitting situations Press fitting no part available loose fitted fitted too deep wrong part not fitted Monitoring flanging processes Monitoring riveting processes Clinch monitoring HBM 2

3 Twin channel fitting monitoring Solutions for mounting processes The MP85A(DP) monitors two measured quantities, such as force and displacement or time. Production and machine status can be monitored using the mounting characteristic curve by means of freely adjustable evaluation criteria. This allows the operator to control the quality and the output of production. Monitoring is either continuous by means of a tolerance band or by max. 9 freely definable tolerance windows. The system monitors: thread-in force block force end position limit values the full force vs displacement curve partial process sequences OK / NOK testing controls production and helps to minimize downtime. Warning limits monitor the production process and make it possible to protect the machines. Control signals control start/stop and limit value cutoff either via digital inputs, the Ethernet interface or the Profibus-DP1 interface (optional). All the individual and cumulative results, switching curve curves and switching events (break/make function) are stored. MP85A(DP) function blocks TEDS transducer and amplifier Setting Evaluation criteria Measuring Loading/ Storing Data storage Special functions Measuring/ isualization Immediate utilization of evaluation criteria Sensor data does not need to be set manually when using sensors with TEDS technology The TEDS data is read via the sense leads from the sensor (instead of an additional cable). The cable and the connector can be deployed as usual. The MP85A is ready for use in a matter of seconds 3 HBM

4 Process analysis with tolerance windows / measurement and visualization The following windows are used to evaluate the production process: 1 alarm window Limits at which an alarm is triggered. This window is used to protect the machine. 1 range window Defines the range in which measured values are stored, within which all the other tolerance windows are positioned tolerance windows for analyzing the fitting process. In the case of tolerance windows, there is a free choice of incoming and outgoing sides; the windows can be evaluated in real time. Mean value windows are also possible. Force measuring range Thread in window: Start window operates online (machine protection) Process window: The fitting window monitors the fitting process Mean value window: Monitors the averaged curve within the window. Block window: The end window monitors the block force Thresholds: Thresholds monitor the process curve in real time through a range (threshold). Displacement measuring range Systems of coordinates: Tolerance window coordinates can be defined absolutely or relatively (dynamically). Use the relative system of coordinates if the absolute position of the fitting pieces (e.g. bearing/shaft) is not always the same. It is possible to mix these two windows. Application: Analysis with tolerance windows press-fitting bushes With relative x coordinates, all that is measured is the relative movement as from the start or end position, relative to the x axis of the two fitting pieces. Window relative to the start position Window relative to the block position HBM 4

5 Application: Process analysis with a tolerance band or envelope curve These analyses enable the curve to be partially or consistently monitored. If a single value is outside the range, the test cycle is rated as NOK. With envelope curve analysis, a maximum of 4 segments with different tolerance limits can be selected. First, one or several reference curve(s) are measured (teach in) to which the tolerance band or envelope curve comprising 64 interpolation points is then adapted. The automatic generation of tolerance band or envelope curve based on previously measured process curves can be manually adapted by mouse click later. Force measuring range Displacement measuring range Start and stop conditions The start and stop conditions are used to synchronize measurement control to the production process. The signaling options are via: CANopen, PROFIBUS-DP1, digital input or internal trigger. Start and stop conditions are available for a wide variety of applications, such as: external start and stop signal target value y and overshoot time target value x and overshoot time target value x and target value y standstill recognition stop on reverse motion of channel x Standard IPCs can be used to visualize the process in situ. The device can also be subsequently integrated into existing systems. Connection is made through the CAN or Ethernet interface of the MP85A devices. Connection is made via the CAN, Profibus-DP1 or Ethernet interface of the MP85A devices. 5 HBM

6 Quality control / statistics Quality and tool wear for the fitting process are assessed using statistics functions. Statistics graphics can be called to clearly display the OK and NOK processes. Global statistics with a process counter are grouped by parameter sets. The tolerance window result can be read at a glance for each parameter set. This allows tool wear component tolerances or damage to a machine to be detected early. The graphic windows in Counting can be used to analyze the distribution of the OK and NOK processes individually for each window. Counting automatically calculates the distribution of the minima and maxima with accompanying standard deviation. Statistics data are stored in the device. Data management / loading and storing With the MP8A(DP), it is possible to store and clearly visualize results, curves, statistics and the device settings. This allows processes to be analyzed later on and ensures 100% traceability. You can choose whether to store the data on your PC or on the multimedia card in the device. Storage on an MMC card can be set up as a circular buffer for the last 1000 curves. In both cases, curves and/or results can be stored in ASCII or Qdas format: NOK processes only or OK processes only or all processes The data on the MMC card can then be transcribed to the PC. A protocol providing all information in detail can be printed out for every process, if needed. HBM 6

7 Management of production data Index / component no. MP85ADP production monitoring Internal MMC Ethernet Index / component no. The curve and result data can be stored with a component part number. This allows easy and unambiguous archiving. Utilizing the existing infrastructure Specifications Using the standard Ethernet interface enables networked systems with remote maintenance to be built up. Basic device MP85A / MP85A DP Accuracy class 0,1 Supply voltage DC 24; potential separation from the measuring system (typically 500 DC ) Permissible supply voltage range Power consumption MP85A, typically MP85ADP, typically MP85A / MP85ADP, max. Behavior in the event of a supply voltage failure W W W Automatic data retention after power failure Typical backup battery life (CR2032) for the realtime clock years 5 Evaluation unit specifications Max. number of measured value triplets 4000 (automatic data reduction) (channel x), (channel y), (time) Sampling rate Hz 2400 Start conditions Internal start signal External start signal Target value x Target value y Target value y + Target value y Stop conditions Internal stop signal External stop signal Target value y + overshoot time Target value x + overshoot time Target value x + target value y + overshoot time Standstill recognition Return channel x Process-end conditions External signal Simultaneous with end of start condition Target value x Target value y Target value x and target value y Number of parameter sets / Measurement programs 31 plus factory settings Number of parameter sets on the optional MMC 31 in XML format 1000 in binary format Switching between parameter sets, typ. ms HBM

8 Evaluation Tolerance band Envelope curve Evaluation 64 supporting points, can be adjusted in Calibration mode 4 tolerance ranges, 64 interpolation points, adjusted as required after end of process Max. number of evaluation windows 9 Type of window oblique or straight Evaluation methods per window Real time evaluation (online) Analyzing the course of the curve in the window (min/max) Analyzing the mean x or y value in the window Analyzing vertical and horizontal thresholds (online) x coordinates for the tolerance window absolute or relative to the start position, or relative to the end position y coordinates for the tolerance window absolute or relative to F min of tolerance window 2, relative to F max of tolerance window 2 or relative to F mean of tolerance window 2 Duration of offline evaluation end window, typ. ms 6 Duration of offline evaluation straight window, typ. ms /measurement pair in window Duration of offline evaluation oblique window, typ. ms /measurement pair in window Statistics (separately for each parameter set) Maximum number of fitting processes 4 x 10 9 Number of histogram classes for 2 values 9 per tolerance window (x max, x min, y max, y min ) Transducer and amplifier Carrier frequency khz 4,8 1 % Excitation voltage eff 2,5 5 % Connectable transducers SGs, half and full bridges Inductive half and full bridges, LDTs Potentiometric transducers Input sensitivities Ω mh Ω Measuring range (m/) m/ 0, , Length of transducer cable, max. m 500 Scaling range, max. digits , at 10% of the input measuring range Scaling range, min. digits 100, at 100% of the input measuring range Permissible common mode voltage, max. 5,5 Common mode rejection Hz Hz Hz db db db Linearity deviation % 0.03 Noise voltage, typically Measuring range (m/) Hz Hz Hz Hz μ/ pp μ/ pp μ/ pp μ/ pp 0,1 0, , Sampling rate, max. 1/s HBM 8

9 Measurement frequency range, adjustable 4th order low pass with Bessel characteristic Nominal value fc (Hz) 1 db (Hz) 3 db (Hz) Phase delay (ms) Rise time (ms) Overshoot (%) ,550 0, ,860 0,510 1, ,6 1,11 1, ,9 2,13 1, ,6 4, ,2 8, ,5 16, ,1 10,3 30,2 33, ,1 5, ,6 2, ,5 0,79 1, ,2 0,19 0, ,1 0,09 0, ,05 0,049 0, Shunt calibration m/ 1 3% Effect of operating voltage on zero point on sensitivity % f.s. % f.s Effect of 10K change in ambient temperature on zero point full bridge on zero point half bridge on sensitivity Long-term drift over 48 h (measuring range 4 m/; 0.5 h after activation) μ/ μ/ % Measuring range (m/) , ,05 μ/ 2 DC-voltage transducers Connectable transducers DC voltage transducers, voltage sources Nominal (rated) measuring range 10 Input signal range 10,5 Scaling range, max. digits , at 10% of the input measuring range Scaling range, min. digits 100, at 100% of the input measuring range Internal resistance of the signal source kω 1 Permissible common-mode voltage, max. 2 Measurement frequency range, adjustable ( 1 db) Hz 0, Filter characteristics Bessel, 4th order Linearity deviation % 0.03 Sampling rate, max. 1/s 2400 Incremental transducers Connectable transducers oltage supply 2-channel mode Inputs (F1 ( ), F2 ( ), Ix ( )) Input levels Low level High level Each line to measurement ground, max ,05 Incremental transd. (up/down counter with zero index signal) 5, max. 150 ma or 24, max. 300mA Time division multiplex method Differential inputs (RS422) HBM

10 Hysteresis 0,07 Permissible common mode voltage, max. 7 / +12 Input impedance, typically kω 12 Detection of direction of rotation via 90 o phase shifted signal F2 Input range pulse counting pulses Maximum pulse rate pulses/ s Interval between 2 successive edges F1( ), F2( ) ns 400 Scaling range, max. digits 20 at 1 pulse Scaling range, min. digits 1 at pulses Measurement frequency range, adjustable ( 1 db) Hz 0, Sampling rate, max. 1/s 2400 SSI transducers Connectable transducers oltage supply 2 channel mode Data input D( ) Input levels, data input D ( ) Low level High level Each line to measurement ground, max. Displacement and angle transducers with SSI interface 5, max. 150 ma or 24, max. 300 ma Time division multiplex method Differential input (RS422) Hysteresis 0, Permissible common mode voltage, max Clock output Cl ( ) Differential output voltage Cl( ), without load, max. Differential output voltage Cl( ), RL = 50 ohms, min. Differential output (RS422) 5,8 2 Common mode voltage at Cl ( ), max. 3 Short circuit current, clock output Cl ( ), typically ma 100 Resolution, single turn bits 12, 13 Resolution, multi turn bits 24, 25 Scaling range, max. digits 20 at 1 pulse Scaling range, min. digits 1 at pulses Measurement frequency range, adjustable ( 1 db) Hz 0, Sampling rate, max. 1/s 1200 Baud rates kbaud 100, 200, 500, 1000 Coding Potentiometric displacement transducer Gray code see transducer carrier frequency General specifications Limit value switches Number Reference level 4 per channel Gross Hysteresis % Adjustment accuracy digit 1 Response time, typically (fc=1000 Hz) ms 2 Control outputs Number 4 (MP85ADP) / 8 (MP85A) Function Process OK / NOK, process started/running, process terminated/valid, limit values 1 4, transducer test result, result tolerance window, status MMC, status channel x/y Nominal (rated) voltage, external power supply DC 24 Permissible supply voltage range Maximum output current per output A 0,5 Short circuit current, typically (U ext. = 24, R L 0.1 ohm) A 0,8 Short circuit period unlimited Isolation voltage, typ. DC 500 HBM 10

11 Control inputs Number 1 (MP85ADP) / 5 (MP85A), electrically isolated Function Zero balance, shunt calibration, parameter set selection, start/stop process, transducer test, store/clear statistics Input voltage range LOW Input voltage range HIGH Input current, typically, (High level = 24 ) ma 12 Isolation voltage, typ. DC 500 Ethernet interface Transfer MBit/s TCP/IP, networkable per IEEE802 Transfer rate, max. MBit/s 10 and 100 (automatic selection) Topology (twisted pairs) 2 LED display for revivers Transmitter (RxD/TxD) and link 2 Line lengths, maximum m 100 Cable type UPT category 5 or shielded twisted pair (STP) Connection socket RJ 45 CAN interface Protocol CAN 2.0B; CANopen compatible Hardware bus link to ISO Baud rates Maximum line lengths Termination resistor Connection Multi Media Card (memory card on Flash basis) kbits/s m connectable by switch terminals Function Storage of: parameter sets, curves and results, statistics, circular buffer of last 1000 curves, file transfer to PC Usable types MBytes 8, 16, 32, 64, 128, 256, 512, 1024 Data transmission rate, typically kbytes/ s 2 8 File system Display Type Keyboard Temperature range DOS, FAT format 2 line, 8 character alphanumeric, LCD Touch sensitive keypad with three keys, pressure sensitive Nominal (rated) temperature range o C Operating temperature range o C Storage temperature range o C Degree of protection Dimensions (W x H x D) mm 55 x 146 x 156 Weight, approx. g 800 IP20 Profibus DP interface (MP85ADP only) Protocol Profibus DP Slave, as per DIN Baud rate, max. MBaud 12 Slave address 3 123, set via the keyboard Profibus ID number Hex 699 Configuration data bytes 5 Parameter data, max. bytes 6 (+7DP standard) Function Access to and parameterization of all MP85A functions (remote control) Parameterization (asynchronous) to DP1 standard Input data, max. bytes 142 Output data, max. bytes 40 Update rate, inputs ms 1 (for 4 measured values) Update rate, outputs ms 10, for zeroing, limit values Diagnostic data bytes 48 Profibus connection 9 pin sub-d (DIN ), electrically isolated from power supply and measurement ground 11 HBM

12 Dimensions of the PME modules: Scope of supply 4 plug-in screw terminals, coded Phoenix order number: 1x voltage supply and CAN, 6 pin M STBW 2.5/6 ST 5.08 GY 2 x transducer, 8 pin MCW 1.5/8 ST 3.81 GY 1x In/Out digital, 8 pin MC 1.5/8 ST 3.5 GY FASTpress Suite System CD with: free PME Assistant setup software Online Help with Tricks&Tips Quick Reference Guide for beginners PME Assistant PLUS (demo version of the PME Assistant) including EASYsetup for user administration and EASYteach for statistical process analysis MP85A Toolkit: Function module kit for creating separate interfaces on operator panels via Ethernet under Windows XP, Windows CE and WindowsMobile MULTImonitor (demo version of the production software for simultaneous display of up to 4 checking processes) EASYmonitor CE (demo version of the production software for operation at a terminal with Windows CE operating system) EASYmonitor Mobil (application for operation with a PDA or pocket PC) Accessories (not included among the items supplied): DT85: 1/4 GA b/w display for visualization and parameterization of several MP85As via the CAN interface Multimedia card (MMC), e.g. Sandisk ( Standard flat ribbon cable, 10-pin, 1.27mm grid Modifications reserved. All details describe our products in general form only. They are not to be understood as express warranty and do not constitute any liability whatsoever. Hottinger Baldwin Messtechnik GmbH Im Tiefen See 45, D Darmstadt, Germany Tel.: Fax: support@hbm.com Internet: