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Description of application
Electric Drivesand Controls Pneumatics Service
Linear Motion and Assembly TechnologiesHydraulics
Rexroth PS 6000PSQ-Analyse
1070087118Edition 05
The data indicated below is intended to describe the
product. Should information on its use be provided,
such information represents application examples
and suggestions only. Catalog specifications shall
not be deemed as warranted quality. This
information does not release the user from
performing his own assessments and verifications.
Our products are subject to natural wear and aging.
This manual is the exclusive property of Bosch
Rexroth AG, Germany, also in the case of
intellectual property right applications. Reproduction
or distribution by any means subject to our prior
written permission.
An example configuration is shown on the cover
page. The delivered product may therefore deviate
from the picture.
Original operating instructions
Language version of the document: EN
Original language of the document: DE
DOK-PS6000-ANALYSETOOL-AP05-EN-P
1070087118 | PSQ-Analyse Bosch Rexroth AG 3/40
Table of contents
GE
RM
A
N
EN
GL
ISC
H
fran
ça
is
Table of contents
1 Regarding this documentation .................................................................... 4
1.1 Validity of this documentation............................................................. 4
1.2 Necessary and supplementary documents ........................................ 4
1.3 Presentation of information ................................................................ 5
1.3.1 Safety instructions .............................................................. 5
1.3.2 Icons ................................................................................... 7
1.3.3 Designations ....................................................................... 7
1.3.4 Abbreviations ...................................................................... 7
2 Safety instructions ................................................................................... 10
3 General information on damage to property and products ......................... 10
4 Scope of delivery ..................................................................................... 10
5 PSQ-Analyse .......................................................................................... 11
5.1 Concept ............................................................................................ 12
6 System requirements ............................................................................... 13
7 Installation ............................................................................................... 14
7.1 Start setup assistant ......................................................................... 14
8 License ................................................................................................... 17
8.1 Order license .................................................................................... 17
9 Adjust memory for SQL server ................................................................. 19
10 Main window ........................................................................................... 20
10.1 Menu (1) ......................................................................................... 21
10.2 Filter (2) ......................................................................................... 21
10.3 Function selection tabs (3) ............................................................... 21
10.4 Measured values (4) ........................................................................ 21
10.5 Zoom of the y axis (5) ...................................................................... 22
10.6 Activate and deactivate measured quantities and information (6) .... 22
10.7 Graphs (7) ........................................................................................ 22
10.8 Action buttons (8) ............................................................................. 23
11 Expulsion and system analysis................................................................. 26
11.1 Line overview ................................................................................... 30
12 Reference curves .................................................................................... 31
13 Automatic calculation of tolerance band ................................................... 33
13.1 Calculate 35
14 Fault messages ....................................................................................... 36
15 Index ....................................................................................................... 38
4/40 Bosch Rexroth AG PSQ-Analyse | 1070087118
Regarding this documentation
1 Regarding this documentation
1.1 Validity of this documentation
The present documentation
applies to
the PSQ-ANALYSE software.
is designed for
Planning, assembly personnel, operators, start-up, service technicians, plant
operators.
provides information about
installation
functionality
operation
The present information is meant to supplement the respective „PSI 6000 manual
on control and I/O level“ and the "BOS 6000 online help“.
This documentation and particularly the operating instructions contain important
information on the safe and appropriate assembly, transportation, commissioning,
operation, use, maintenance, dismantling and simple trouble shooting of the
product.
Please read this documentation completely, and especially read the "Safety
instructions" section in the Operating instructions before working with the
product.
1.2 Necessary and supplementary documents
Do not operate the product until you have received the documents marked by
and you have understood and observed them.
Table 1: Necessary and supplementary documents
Title Document number Document type
PSI6xxx: Weld timer with medium-
frequency inverter
1070080028
Operating
instructions
PSI6xxx: Weld timer with medium-
frequency inverter - Type-specific
instructions
depending on type
Operating
instructions
(type-specific
supplement)
BOS6000 Online Help 1070086446
Reference
For which product?
Target group?
Topics dealt with?
1070087118 | PSQ-Analyse Bosch Rexroth AG 5/40
Regarding this documentation
1.3 Presentation of information
Uniform safety instructions, icons, terms and abbreviations are used in this
documentation to enable you to work with your product rapidly and safely. They
are described in the sections below for a better understanding.
1.3.1 Safety instructions
In this documentation, safety instructions are provided ahead of a sequence of
action involving danger of bodily injury or property damage. The action described
to avert the danger must be adhered to.
Safety instructions call your attention specifically to danger potentials or risks.
We distinguish among the following places where safety instructions may be
required:
Basic safety instructions:
They are related to general important matters and apply to the complete
documentation. These safety instructions are provided in Sections 2 and 3 of
operating instructions „PSI 6xxx: Weld timer with medium-frequency inverter“
(doc. no. 1070080028; also refer to page 4).
Preceding safety instructions:
They refer to topic-related matters and are provided at the beginning of a
chapter or at the beginning of a whole procedure.
Integrated safety instructions:
They are related exactly to a separate procedure step and are provided right
before the relevant step within the procedure.
A safety instruction is always structured as follows:
Warning sign (only in case of personal injury)
Signal word to indicate the danger level
Type and source of danger
Consequences of failure to observe
Action for averting danger.
Table 2: Example for the structure of a safety instruction
Integrated safety instructions may be embedded in the format of the
environment so that no ”visual” break in the action sequence is provoked.
Therefore they do not necessarily use the layout shown in the example but
they do use the indicated structure.
Where?
Structure?
SIGNAL WORD Type and source of danger
Consequences of failure to observe
Action for averting danger
Further actions for averting danger
6/40 Bosch Rexroth AG PSQ-Analyse | 1070087118
Regarding this documentation
The safety instructions are classified into danger levels (danger classes). The
signal word represents the danger level.
Table 3: Danger classes according to ANSI Z535.6-2006
Warning sign, signal word Description
DANGER characterizes a dangerous situation where death or
serious physical injuries will occur if it is not avoided
WARNING characterizes a dangerous situation where death or
serious physical injuries may occur if it is not avoided
CAUTION characterizes a dangerous situation where light to
moderate physical injuries may occur if it is not avoided
NOTICE indicates property damage. The product or the
environment may be damaged.
Table 4: Examples for classification of safety instructions
Danger levels?
G
DANGER SafetyInstrType
SafetyInstrConseq
SafetyInstrPrec
EFAHR
Type and source of danger
Consequences of failure to observe
Action for averting danger
Further actions for averting danger
Warnu
WARNING SafetyInstrType
SafetyInstrConseq
SafetyInstrPrec
NG
Type and source of danger
Consequences of failure to observe
Action for averting danger
Further actions for averting danger
VORSICH
CAUTION SafetyInstrType
SafetyInstrConseq
SafetyInstrPrec
T
Type and source of danger
Consequences of failure to observe
Action for averting danger
Further actions for averting danger
Hin
NOTICE SafetyInstrType
SafetyInstrConseq
SafetyInstrPrec
WEIS
Type and source of danger
Consequences of failure to observe
Action for averting danger
Further actions for averting danger
1070087118 | PSQ-Analyse Bosch Rexroth AG 7/40
Regarding this documentation
1.3.2 Icons
The following icons indicate instructions which are not safety-relevant but which
improve the comprehensibility of the documentation.
Table 5: Meaning of the icons
Icon Description
If this information is not observed, optimal use or operation
of the product is not possible.
individual, independent action step
1.
2.
3.
numbered instruction:
the numbers indicate that the action steps are performed
consecutively.
1.3.3 Designations
The following designations are used in this documentation:
Table 6: Designations
Designation Description
BOS Welding user interface
PE Protective Earth. PE conductor.
PG Programming terminal/welding computer
PLC Programmable Logic Controller
PSG PSG Transformer-rectifier unit
Medium-frequency welding transformer
PSI programmable weld timer
Timer Weld timer.
Also referred to as timer or resistance weld timer.
1.3.4 Abbreviations
The following abbreviations are used in this documentation:
Table 7: Abbreviations
Abbreviation Description
%I Scale divisions, represent an electrical heat value or pulse width
BOS Welding user interface
BQR User interface for U/I controller
CAN Controller Area Network; data bus
CCR (KSR) Constant-Current Regulation, i.e. the current in the secondary circuit
is kept at a constant level by this control mechanism
CT Cool time, time between the current impulses/blocks (1., 2., 3. CT)
DST Down slope time, current slope at the end of the MainWLD
ED Duty cycle: Ratio between weld time and time without current flow
8/40 Bosch Rexroth AG PSQ-Analyse | 1070087118
Regarding this documentation
Abbreviation Description
Ext External, e.g. +24V voltage for signal transmitters (switches) and
actuators (valves) outside the timer
FQF Force quality factor
I/O Input / Output
Ignition Ignition, firing pulses for triggering the power unit are switched on
and off
kA Kilo-Ampere (amount of current)
kN Kilo-Newton (force)
KUR Constant-Voltage Regulation, mains voltage fluctuations are
balanced
LAN Local Area Network: General network
LT Power unit (thyristor or inverter)
MainWLD 2nd weld time (MainWLD), main welding time, may consist of a block
comprising individual impulses; only the MainWLD can be
programmed with an upward and downward slope.
MSDE Microsoft Data Engine. (Freely available database with restrictions,
e.g. database size 2 GB)
PG Programming terminal/welding computer
PHA Heat value (Phase angle) or pulse width
PSF Process stability parameter
PSG Transformer-rectifier unit for the PSU/PSI inverter
PSI Medium-frequency power unit (1000 Hz)
PSL PS power unit
PSQ Quality assurance system
PSS PS timer unit
PST Thyristor power unit (50/60 Hz)
PSU Welding current inverter (medium-frequency)
Slope Current increase from an initial to a final %I (heat) value
Solenoid Solenoid valve, drives the cylinders for closing the electrodes
SQL Structured Query Language
SQL server Database server by Microsoft
SQL Server
2005 Express
Successor of MSDE
SQZ Squeeze time that runs before the weld time. The electrodes
squeeze the parts to be welded together.
Temp Temperature
Timer Weld timer, also referred to as resistance weld timer
UDM Ultrasonic data processing module (front-end)
UIP Spot quality parameter
UIR U/I controller
1070087118 | PSQ-Analyse Bosch Rexroth AG 9/40
Regarding this documentation
Abbreviation Description
ÜK Monitoring contact, e.g. for monitoring the pressure cylinder (that
closes the electrodes) or monitoring of the electrode position (e.g.
gun closed.).
US Ultrasonic
USE Ultrasonic sensors
USP Lower intersection
USR Ultrasonic controller
UST Up-slope time, current slope at the beginning of the MainWLD
Stepper Heat stepping in order to compensate for electrode wear
USW NEXUM operating data acquisition and statistics management
software
VB6 Visual Basic Version 6.0 (Microsoft)
WC Weld complete contact (WC)
WLD Weld time
XQR Controller module
10/40 Bosch Rexroth AG PSQ-Analyse | 1070087118
Safety instructions
2 Safety instructions
Please note the section with the identical name in the operating instructions for
the PSI 6xxx and PST 6xx0 product families (for information on document
numbers, refer to table 1, page 5).
3 General information on damage to property
and products
Please note the section with the identical name in the operating instructions for
the PSI 6xxx and PST 6xx0 product families (for information on document
numbers, refer to table 1, page 5).
4 Scope of delivery
Please observe the order number of the CD in the following table.
Table 8: Part numbers
Title Part number
PSQ-ANALYSE CD R911171930
1070087118 | PSQ-Analyse Bosch Rexroth AG 11/40
PSQ-Analyse
5 PSQ-Analyse
Fig. 1: PSQ-Analyse main window
The PSQ-Analyse software evaluates the weld current protocol of the BOS6000
for welding data analysis. A connection to the database of BOS6000 is required
for this purpose.
12/40 Bosch Rexroth AG PSQ-Analyse | 1070087118
PSQ-Analyse
5.1 Concept
Fig. 2: PSQ-Analyse for operating data recording
Thus there are two possible operating locations for PSQ-Analyse. The user can
employ it either directly at the line PC or at a central PC with access to the line
PCs.
The software simplifies the commissioning of the Q module in particular. The use
of PSQ-Analyse saves a tremendous amount of time in comparison with manual
commissioning.
Production level Office level
- Access to line PC through the network - Each line PC in the network is within reach - Analysis of entire production lines / series / factory possible from a central work place - Optional PSQ-Analyse
Production
line
Line PC
BOS6000
DB
DBMS
PC with BOS6000 and optional PSQ-
Analyse
SQL-Server
2000/2005
Network
Central
PC
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System requirements
It is possible to analyze entire systems during production within a very short time.
The purpose is to determine the system status. The analysis result allows the
user to determine whether there is need to optimize the system or whether it is
operating stably.
6 System requirements
2 GHz Intel1 Pentium1 M processor or equivalent type
1 GB RAM or more
Operating system
– Windows 1 2000 and Service Pack 4,
– Windows1 XP and Service Pack 2,
– or Windows1 Server 2003 and Service Pack 1
Microsoft Internet Explorer1 5.0 (or higher)
RS232/V24 link or field bus
Screen resolution at least 1024 x 768
1 All trademarks and names are the property of their respective
manufacturers.
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Installation
7 Installation
7.1 Start setup assistant
Conditions:
You must have administrator privileges for your operating system in order to
perform the installation!
First close all other Windows programs!
The CD contains the installation set and the documentation as PDF-file.
1. Start the installation by calling up the "Setup.exe" file.
2. Click on the ”Start” command button and select ”Run”.
The ”Run” dialog screen is displayed.
3. Enter E:\Setup.exe (where E: represents your CD-ROM drive) and click on
OK.
4. Afterwards, please follow the instructions of the setup assistant.
Fig. 3: Installation of PSQ-Analyse
1070087118 | PSQ-Analyse Bosch Rexroth AG 15/40
Installation
Fig. 4: Chose installation folder
Fig. 5: Starting the installation
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Installation
Fig. 6: Installation procedure
Fig. 7: Finish installation
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License
8 License
8.1 Order license
The PSQ-Analyse software can only be used with a license. The license term is
limited.
Fig. 8: Term of the license
Pressing the button „Order license“ takes you to the window shown below.
18/40 Bosch Rexroth AG PSQ-Analyse | 1070087118
License
The license has to be ordered from:
Bosch Rexroth AG
D-64711 Erbach
Berliner Straße 25
Tel.: +49 (0) 9352 / 405060
Fax: +49 (0) 6062 / 78-890
E-Mail: [email protected]
A 24-hour hotline is available.
To obtain a license, it is necessary to report the MAC address to Bosch Rexroth
because it serves as copy protection. The license is then valid on this PC only.
The license fee to be paid varies depending on the term of the license.
The license code received has to be copied into the respective line, and the
licensing procedure is completed by pressing the "Activate license" button. The
term of the license will be extended accordingly, and if activation is successful,
you will receive a corresponding acknowledgment. Otherwise, an error message
will be displayed.
The "MAC information" box lists all network adapters identified (also W-LAN
and VM-Ware). The MAC address of the primary connection has to be
provided (as a rule LAN connection).
Fig. 9: MAC address
MAC address
1070087118 | PSQ-Analyse Bosch Rexroth AG 19/40
Adjust memory for SQL server
9 Adjust memory for SQL server
The random access memory allocated to the SQL server is limited to 120 MByte
as a standard. The database of the BOS6000 usually has a size of 500 MByte
and more.
Whenever data are to be read from the database using PSQ-Analyse, the SQL
server is required to move data to the hard disk to be able to carry out the
process at all. Access to the hard disk is considerably slower than access to the
random access memory. This may lead to extremely long computing times.
To avoid this, the function
Functions Adjust memory for SQL-server
has been provided.
The following window is displayed:
Fig. 10: Adjust memory
This function allows the allocated memory for the SQL server to be set to a higher
value.
The upper field indicates the total size of the random access memory available to
the PC. The field below is used to adjust the random access memory to the
required value. The suggested value of 90% of the total random access memory
has been entered here. The value can be edited and set to any value less than or
equal to the total random access memory. It is recommended to use the
suggested value.
The new value is accepted by pressing OK.
Press Cancel to exit the window without accepting the new value.
Closing the software will automatically reset the value that was active prior to
the start of PSQ-Analyse. The value may already have been adjusted
previously by means of the configuration tool of BOS6000. This value will
become active again after PSQ-Analyse has been closed. Thus, the value
entered before is only valid during the operating period of the PSQ-Analyse
software. The procedure described above has to be repeated again at the
next software start.
20/40 Bosch Rexroth AG PSQ-Analyse | 1070087118
Main window
10 Main window
Fig. 11: Main window
The most important purpose of the main window is to analyze individual programs of a specific weld timer in greater detail. Numerous functions have been provided to support the user in performing the analysis.
The most important purpose of the main window is to analyze individual programs
of a specific weld timer in greater detail. Numerous functions have been provided
to support the user in performing the analysis.
After program start, the active SQL server is searched automatically via the
Registry. If MSDE 2000 and SQL server 2005 have been installed, it is possible to
change the SQL instance via the project loader. The PC may be the computer
executing PSQ-Analyse or e.g. a line PC which can be accessed through the
network.
The default value entered for “PC“ is local. If you keep this entry and click the
Connect button, a selection window will be displayed where MSDE 2000 or SQL
server 2005 can be selected. However, it is also possible to enter the name of the
line PC that you want to connect with through the network. As an extension of this
function, the option to read in a list of PC names is provided. This list is
maintained during the execution period.
This step has to be repeated after a restart of PSQ-Analyse. The list of PCs is
loaded via the button. A txt-file can be selected in which the required PC
names have been previously entered in list form.
2
7
5 6
8
1
3
4
1070087118 | PSQ-Analyse Bosch Rexroth AG 21/40
Main window
10.1 Menu (1)
The following functions are available here:
Adjust memory for SQL server.
The function is described in Section 9 of the present documentation.
Language change-over: German or English.
10.2 Filter (2)
This option can be used to filter the required data.
The available filter criteria are PC name, weld timer, program number and
date/time. These four criteria allow for the selection and limitation of all the data
available in the database.
Having connected to a PC, PSQ-Analyse automatically fills the filter boxes. All the
weld timers that have already generated an entry in the weld current protocol will
then be available in the filter box for the timers.
This also applies to the program number. Only the program numbers that appear
in the weld current protocol are available for selection.
In version 2.3.0 and later, PSQ-Analyse has been prepared for processing of
up to 1024 programs which are already supported by several weld timer types.
By activating the check mark
PSQ-Analyse automatically reads the date and time of generation of the
reference curve of the currently selected program.
PSQ-Analyse enters this information into the filter boxes
and .
The default values displayed in these boxes are the first and last spot that appear
in the weld current protocol in the relevant period.
10.3 Function selection tabs (3)
In addition to the analysis function, the functions reference curves, welding
parameters and automatic tolerance band calculation are available here. The
functions are described in separate chapters of the present documentation.
10.4 Measured values (4)
If the cursor is moved to a new spot weld, the measured values in the text boxes
above the graphs will be updated automatically.
The values measured for current (I), weld time (t), voltage (U), resistance (R),
UIP, PSF, FQF, pulse width (PHA), %I (power, P) and energy (E) can be read.
The value for wear at the selected time is indicated additionally if the respective
check mark has been set. In addition to the measured values, the number of
welding expulsions and the percentage share of welding expulsions in the filtered
data quantity are available.
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Main window
10.5 Zoom of the y axis (5)
The option to adjust both y axes is provided for each of the three graphs. Two
inputs fields for each measured quantity are available for this purpose.
Y min is used to define the minimum value of the y axis. Y span specifies the
displayed range of the y axis. As default setting, each y axis is displayed from 0 to
the maximum value that has occurred.
10.6 Activate and deactivate measured quantities and information (6)
Each of the values of current, weld time, voltage, resistance, UIP, PSF, FQF,
pulse width, %I (power) and energy can be activated and deactivated in the
respective graphs. This is done by activating or deactivating the corresponding
check marks.
In addition to these values, it is possible to display or suppress further information
in the graphs.
Count (wear):
If you activate this check mark, the characteristic of wear is shown in the graph
and the present wear is entered in the text box.
Tolerance bands
By activating the respective check mark, the set tolerance bands can be
displayed in the same manner.
10.7 Graphs (7)
By clicking on the
button, the filtered data are read from the data base and drawn in the graphs. It is
updated automatically when a new program or a new weld timer is selected.
Every spot weld in the graph can be selected via a cursor. The program number,
spot weld name and date / time of the respective selected spot weld are indicated
in the title bar of the graph.
Every measured quantity can be displayed in each of the 3 graphs. Limit values
can be displayed for each measured quantity. Any graphs which are not needed
can be simply suppressed so that there is more space and the remaining graphs
can be analyzed more easily. Only two sizes can be shown simultaneously for
each graph.
Moving within the data is possible by pulling the x and y axes of each graph. An
“E” in the data rows indicates a replacement of the electrode caps.
1070087118 | PSQ-Analyse Bosch Rexroth AG 23/40
Main window
10.8 Action buttons (8)
The entire display is updated taking into account the currently set filter.
This button permits the user to read in and display the previously calculated
tolerance limits. The txt-file containing the calculated tolerance bands is selected
through a dialog. Please refer to the section "Automatic calculation of tolerance
band” for information on calculation of the tolerance bands.
Then the tolerance limits read in for the displayed program are shown next to the
charts. The set tolerance limits can be transferred comfortably into the previously
read in txt-file using the “Apply tolerance band changes” button.
After the txt-file has been read in, the tolerance bands are displayed in the graph.
This is very helpful for verification of the calculated tolerance bands. The
adjustment of the tolerance bands is made by "pulling" the lines directly in the
chart. The current tolerance limit value is shown next to the chart.
The display of the tolerance bands is activated through, e.g. “Tolerance band
UIP”. Each graph can only display the tolerance bands of one parameter, e.g. UIP
or PSF or FQF. It is not possible to display both tolerance bands at the same
time.
The green area marks the range from the conditional tolerance band upwards.
The yellow area marks the zone between conditional tolerance band and absolute
lower tolerance band. The area below or above the absolute tolerance limit is
displayed in red.
In version 2.3 and later, an upper conditional tolerance band can be set for UIP
and FQF. The upper yellow area then shows the upper conditional tolerance
band.
24/40 Bosch Rexroth AG PSQ-Analyse | 1070087118
Main window
Fig. 12: Display tolerance bands
As a default, 100 measured values are shown in the three graphs. If you use
“Zoom -“, more spot welds will be displayed in the graphs. Every time you click on
“Zoom -“, the number of spot welds shown will be increased by factor 2.
Proceeding on the basis of 100, only 50 values will be displayed after the first
click, then 25, etc. The distance between two spot welds is thus increased.
As a default, 100 measured values are shown in the three graphs. If you use
“Zoom -“, more spot welds will be displayed in the graphs. Every time you click on
“Zoom -“, the number of spot welds shown will be increased by factor 2.
Proceeding on the basis of 100 values, 200 values will be displayed after the first
click, then 400, etc. The distance between two spot welds is thus reduced.
The “Export” button can be used to export the filtered data to a txt-file. The txt-file
can be opened and edited in Excel.
1070087118 | PSQ-Analyse Bosch Rexroth AG 25/40
Main window
This function helps the user to track parts and the possible correlation between
the data and the spot diameters resulting from destructive tests of the tracked
parts.
Fig. 13: Part identifier filter
In principle, there are two options to filter the required data from the database and
to export it.
Prerequisite for the use of this new functionality is the ability of the robot to report
this information to the weld timer. This functionality has to be available in the weld
timer as well. If this functionality is present, the respective part identifier for each
spot weld is stored in the weld current protocol. This is the most comfortable
option to track parts. The user has to note the part identifier of the removed part
and enter it into the “Part identifier” field shown above. By clicking OK the data of
the respective part is exported to a txt-file and can then be edited, e.g. in Excel.
The part identifier is not available in all areas of car body production of a series.
This information does not exist for smaller parts.
For this reason, there is a second filter and export option. Before the part that you
want to track or remove is welded, it is “marked” in the database. To do this, you
set the monitoring reference value of energy to 1. Then you copy this setting to all
programs used for the part. After that, the part is welded. After welding of the part,
the reference value of energy is reset to the original value and copied to all
programs used. Now you can use the filter option "Energy = 1" to export the data
of the selected part.
Filtering according to part identifier:
Filtering according “Energy = 1“:
26/40 Bosch Rexroth AG PSQ-Analyse | 1070087118
Expulsion and system analysis
11 Expulsion and system analysis
A click on
initiates the determination of numerous data which provide important information
about the system status to the user.
The status of the calculation is indicated by a progress bar. The calculation may
take longer or shorter depending on the equipment of the PC performing the
calculation. As a rule, the calculation time is 2-3 minutes. To achieve the best
possible performance, it is important to perform “Adjust memory for SQL-Server”.
Fig. 14: System analysis
After completion of the calculation, the resulting data are available to the user in a
table.
The system data determined in detail:
Table 9: System table
Parameter Description
Timer name Name of weld timer
Elec. no. Electrode/Stepper number
Prg. No. Program number
Spot name Spot name
1070087118 | PSQ-Analyse Bosch Rexroth AG 27/40
Expulsion and system analysis
Parameter Description
Current PreWLD Parameterized current of the first (pre-)weld time
Current MainWLD Parameterized current of the second (main) weld time
Current PostWELD Parameterized current of the third (post-)weld time
Current upslope Parameterized current of the slope
Time PreWLD Parameterized time of the first weld time
Time MainWLD Parameterized time of the second weld time
Time PstWLD Parameterized time of the third weld time
Time UST Parameterized time of the slope
Total time Total weld time
WLD min Minimum weld time
WLD av. Average weld time value
WLD max Maximum weld time
WLD prol. % Prolongation in percent, with reference to
parameterized time
Pulses Number of impulses of the 2. weld time (MainWLD)
Force Parameterized force value
Spots Number of welded spots of this program that are still
contained in the database.
Expulsion Number of expulsions of this program that are still
contained in the database.
Expulsion % Percentage share of expulsions of this program
UI measurement (P) Program-dependent parameter measurement on/off
UI regulation (P) Program-dependent regulation on/off
UI monitoring (P) Program-dependent monitoring on/off
Welding time prolongation Parameterized welding time prolongation
UI measurement (G) Global parameter measurement on/off
UI regulation (G) Global parameter regulation on/off
UI monitoring (G) Global parameter monitoring on/off
UIP min Minimum UIP
UIP medium Average UIP value
UIP max Maximum UIP
PSF min Minimum PSF
PSF medium Average PSF value
PSF max Maximum PSF
UIP reference Parameterized reference value of the UIP
UIP upper tol. Parameterized upper tolerance band for UIP
UIP U. cond. tol. Parameterized conditional upper tolerance band for
UIP
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Expulsion and system analysis
Parameter Description
UIP L. cond. tol. Parameterized conditional lower tolerance band for
UIP
UIP lower tol. Parameterized lower tolerance band for UIP
PSF cond. tol. Parameterized conditional tolerance band for PSF
PSF lower tol. Parameterized lower tolerance band for PSF
FQF min Minimum FQF that occurred
FQF mean Mean value of the FQFs that occurred
FQF max Maximum FQF that occurred
FQF upper tol. Parameterized upper tolerance band for FQF
FQF upper cond. tol. Parameterized upper conditional tolerance band for
FQF
FQF lower cond. tol. Parameterized lower conditional tolerance band for
FQF
FQF lower tol. Parameterized lower tolerance band for FQF
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SoftwareVersion timer Firmware version of the timer
Software version controller Firmware version of the UI controller
Using the
button, the user can export the data determined to a text file which, in turn, can be
opened in Excel for further processing.
The text file includes all the data indicated above.
Several columns of the results table are highlighted red and green. This is a
visual support for the user.
In addition, the column entries of
„UI measurement (P)“,
1070087118 | PSQ-Analyse Bosch Rexroth AG 29/40
Expulsion and system analysis
„UI regulation (P)“,
„UI monitoring (P)“,
„Weld time prolongation“,
„UI measurement (G)“,
„UI regulation (G)“ and
„UI monitoring (G)“
are displayed in red when the entry is “OFF”.
In PSQ-Analyse version 2.3 and later, the
button can be used to select the displayed parameters according to a specific
value, e.g.:
Only the values with SQZ 200 will then be displayed, for instance, as shown in the
figure below.
Fig. 15: Filter
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Expulsion and system analysis
11.1 Line overview
By pressing the ‚Line overview‘ button the user can call up the following screen:
Fig. 16: Line overview
The line overview displays diagrams for maximum value, average (mean) value
and minimum value UIP, FQF etc.
The display of the diagrams is related to the filter setting in the welding
parameters table. The X axis represents all programs of all filtered timers from the
welding parameters table. The Y axis indicates the respective measured value.
The input window
is used to hide dressing programs, e.g. program number 251 or certain welding
programs, which have no relevance for this display.
The evaluation can be performed by trained experts.
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Reference curves
12 Reference curves
Fig. 17: Reference curves
This window provides a lot of information to the user which is helpful to evaluate
the reference curve. The window is divided into three main sections.
The user can select the required reference curve using the text boxes. The timer
is entered in text box
and the corresponding program in
After selection of a timer and a program, the corresponding reference curve is
shown.
The graph displays the curves for voltage, current, resistance, heat value and
force. The current is scaled on the first y axis, and the resistance on the second y
axis. The remaining measured values are normalized to resistance.
A cursor is available for selection of every measured value. The corresponding
measured values are displayed above the graphs and updated automatically
when you move the cursor.
1
2
2
3
1
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Reference curves
By pressing the
button, the current page is transmitted to the standard printer.
Using the
button, it is possible to export the reference curve displayed to a txt-file which, in
turn, can be opened and processed in Excel.
In the 3 tables in the lower half of the window, the most important KSR (CCR) and
UIR parameters as well as parameters of force measurement are output.
3
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Automatic calculation of tolerance band
13 Automatic calculation of tolerance band
Fig. 18: Automatic tolerance band calculation with Q stop
Another representation is obtained by clicking on the “Automatic calculation of
tolerance band” tab. It is divided into five main components.
Definition of the tolerance bands to be calculated:
The option is provided to calculate the tolerance bands for all available measured
quantities.
It is possible to select freely which tolerance bands are to be calculated. The
selection is performed by activating the respective check marks. As a rule, it is
useful to calculate all tolerance bands and the reference value of a measured
quantity.
In version 2.3 and later, an additional upper conditional tolerance band can be
set for UIP, weld time and FQF.
1
1 2 3
5
4
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Automatic calculation of tolerance band
Activation of program-dependent monitoring.
To activate the monitoring, it is necessary to change a total of three parameters in
the BOS6000. Two of these parameters can be activated directly by PSQ-Analyse
for all programs used in a system.
To do this, it is necessary to first activate the check mark for the measured value
to be monitored and then the check mark for “Program”.
Having done this, it is only necessary to set the monitoring active by activating the
global monitoring using the BOS6000 at each timer.
Sensitiveness of tolerance band definition and calculation:
The sensitiveness of the tolerance band calculation can be influenced by a slide
control. When the window is called up, the slide control is set to Standard. This
setting may be moved to “More tolerant” or “More sensitive”, if necessary.
More tolerant: the calculated tolerance bands are generally reduced by the
value that is set.
More sensitive: the calculated tolerance bands are generally increased by the
value that is set.
The actual calculation of the tolerance bands is started by clicking the “Calculate”
button. This can take several minutes depending on the PC configuration. The
current calculation status is indicated by a progress bar.
After completion of the calculation, a table is provided to the user in the bottom
part of the window.
This table shows how many violations of the tolerance bands just calculated
would have occurred in relation to the values available in the database. It shows
how often a tolerance limit would have been violated by UIP and PSF.
If too many violations are shown, this indicates that the calculated tolerance
bands are too narrow.
In version 2.3 and later, an additional upper conditional tolerance band is
available in connection with the respective BOS6000 and XQR or timer firmware.
The user can adjust the calculation sensitivity using the two slide controls and
perform the calculation again. In order to know which programs were affected by
the violations, you have to click on the button
.
Q stop parameter
There is a possibility of setting Q stop parameters.
A difference is made between Q stop (program-related) and Q stop (all
programs), i.e. component-related parameters.
Only fixed values for the selected programs can be determined. An automatic
calculation as for the other monitored parameters is not possible.
2
3
4
5
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Automatic calculation of tolerance band
13.1 Calculate
Before activating the Calculate button, it is necessary to select the weld timers in
the ‘Timer name’ selection box and the programs in ‘Program filter’. Calculation of
the tolerances can generally be performed in two manners.
Either as fix value which is entered by the user
Or as calculation via history data.
In this case, the variations of the individual values of a parameter are regarded
relative to the respective reference value. Schedules without ignition (current = 0),
schedule faults (schedule status) and spot repetitions are not considered in the
calculation! These schedules are filtered by the corresponding criteria.
The calculation for the lower tolerance band is based on the standard deviation of
all values deviating downward from the reference value. This applies in analogy to
the upper tolerance value. The procedure for the conditional tolerance band will
result from experiments with different databases.
In this mode, the 3 parameters current, PSF and UIP are offered to the user as
default suggestion. In case of initial setup, it is useful to enter a fix value because
neither history data nor a sufficient quantity of data are available.
Serves as subsequent calculation once production has been running for a while
and sufficient values are available for an automatic calculation.
Monitoring of the resistance and the heat value are suggested for these cases.
Fix values are suggested. The suggestions for ‘First tip dress’ have been selected
in a more narrow range than for ‘Tip dress’ because a lower degree of variation is
expected.
The user has the option for each calculation mode to specify and modify the
values to be calculated and to decide freely to either use a fix value or the
automatic calculation option.
Saves the settings made in this window.
Initial setup
Calculation of tolerance band
(Calc. tolb.)
First tip dress / Tip dress
Save settings
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Fault messages
14 Fault messages
You are informed by the weld timer of all relevant events that might occur during
operation.
For more fault and status messages of PS 6000 weld timers and U/I
controllers in use, please refer to the notes on causes of faults and fault
correction in the “Error list PS5000/PS6000” (no. 1070 087 001).
For information on the external reset of faults, please refer to the relevant
timer manual.
Warnu
WARNING SafetyInstrType
SafetyInstrConseq
SafetyInstrPrec
NG
Damage to persons and to property due to immediate machine start after
fault reset!
If the start signal is present when a fault is reset (acknowledged), the weld timer
will start its program run immediately! Hazardous machine movements may be
the result!
Therefore, prior to fault reset, make sure that there is no-one in the hazard
area of the welding equipment!
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Fault messages
Notes:
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Index
15 Index
D Damage to property and products
10
F Fault messages 36
I Installation 14
L License 17
Order license 17
P PSQ-Analyse
Calculation of tolerance band 33
Concept 12
Fault messages 36
Installation 14
License 17
Main window 20
Overview 11
Reference curves 31
SQL server 19
S Safety instructions 5, 10
SQL server
Memory 19
Start
installation 14
System requirements 13
T Tolerance band 33
Calculate 35
DOK-PS6000-ANALYSETOOL-AP05-EN-P1070087118
Bosch Rexroth AG Electric Drives and Controls P.O. Box 13 57 97803 Lohr, Germany Bgm.-Dr.-Nebel-Str. 2 97816 Lohr, Germany Tel. +49 9352 18 0 Fax +49 9352 18 8400 www.boschrexroth.com/electrics