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BENEFITS • Enhanceddefectdetection
• Built-indiagnosticsforpressmachinery
• Quickersetupandeasiermaintenancethancompetitivesystems
• Lowestmonitoringcostperramintheindustry
• Multiplechannelsystemcanmonitorupto4rams
• Setupwizardallowsconfigurationwithinminutes
• Collect,graphicallyviewandanalyzedatafromupto4ramssimultaneouslyusingintuitive,operatorfriendlyinterfaces
• Integratedtouchscreenoptionwitheasymachinemountandpanelmount
FEATURES
Software• Industry’sbestsoftwareforassembly
andpress-fitmonitoring• Exceptionalcolordisplay,graphics,
menusystem,setupwizard
Packaging• Compactindustrialhardwarecanbe
installedinapanelcutout,DINrailmountedormachine/wall/desktopmounted
• NEMA12(IP67)modelsalsoavailable• Modularterminalconnectorplugsfor
AnalogandDigitalI/Oconnectionssimplifyinstallationandwiring
QuickandEasySetup• Out-of-the-boxfunctionalityin
standaloneornetworkedoperation• 32modeltypes• Setupwizardmakesiteasyto
configureinamatterofminutes• UnmatchedDataCollection• Upto8analogchannels,16bitA/D• Upto4encoderinputchannels
IntuitiveUserInterface• Simpleandintuitiveoperatordisplays• Touchscreennavigationoption• Operator,engineerandsupervisor
accountswithpasswordsecurity
MultipleDataViews• Status:seepartteststatus(passorfail)• Curves:viewdatacurves(e.g.Forcevs.
Distance)withoverlaidlimits• Histogram:seeStatisticalProcess
Control(SPC)datafortestcycle• Trend:viewtrendsfrommultipletests• History:reviewthousandsoftest
cyclesandparthistoryrecords• Limits:viewcurrentlimits
DetailedDataManagementandReporting• Local&remotestorageoftestresults
organizedbymodel,part,ram,etc.• SPCreporting• Widerangeofanalysisfeatures
available• Statisticallylearnedtestlimits
Connectivity• Communicationwithstation
controllerviadiscreteI/O• Optionalfieldbussupportfor
communicationthroughindustrystandardhardware(RS232,RS485,10/100BaseT)andprotocols(Devicenet1,Profibus1,Interbus1,EthernetI/P,ModbusTCP)
ApplicationsDesignedtobeusedwithanymechanicalpress:• Hydraulic• Servo• Airpressure• Airoveroil
Assembly Press-Fit mOnitOring system
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OVERVIEW
sigPODPressisdesignedtomonitorassemblypressoperationsandprovidereal-timeanalysisofthedatatoidentifydefectiveparts,faulty
pressmachinery,andoutofcontrolassemblyprocesses.Itmeasuresforcevs.timeorforcevs.distancesignaturesforeachpartcycle,and
thenanalyzesthecurve(s)inmillisecondstoprovideaninstantpass/failoutputforeachpressram.Compatiblewithalmostallloadcelland
distancesensors,sigPODPressisavailableinsingleramormultipleramconfigurations,andcanbenetworkedtogethertoprovidehigher
levelinsightintoassemblyprocessesbycollectingdataacrosstheentireassemblyline.ThestandardsigPODPresscansupporttraditional
hydraulicrampresssystems,servomotorbasedpresses,airpressureorair-over-oilsystems,crimpingmachines,andalmostanyother
mechanicaloperationthatexhibitsaforce-distancesignature.
sigPODPressprovidesextensivehardwareandsoftwarefunctionsforparttest,analysisanddataconnectivity:
1 to 8 Analog Inputs
1 to 4 Encoder Inputs
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UNMATCHED DEFECT DETECTION
AttheheartofsigPODPressisSciemetric’s
ProcessSignatureVerification(PSV),
themostadvancedyeteasiesttouse
signatureanalysistechnologyavailable
tomonitorandcontrolmanufacturing
processes.PSVisbasedonascientific
analysisofeachpresswaveform,which
dramaticallyimprovestheaccuracyof
defectdetectionresultinginreliablepass
orfaildecisionmaking.Thedatacollected
bysigPODPressalsoprovidesimportant
informationforreporting,analysisand
yieldimprovement.
EASE OF SETUP
Afterasimple15minutesetup,thesigPOD
Pressisreadytogo.Thefirsttimeyoustart
upthesigPODPress,thesystembeginsthe
SetupWizardwhichprovidesanautomated
step-by-stepwalkthroughtoquickly
configurethesystemtoyourneeds.Youcan
returntotheWizardatanytimetomake
changes.Foreachstep,theWizardprovides
bothatestingmodeandanadjustment
modetoensurethattheconfiguration
exactlymatchestheindividualram
characteristicsofthepressmachines.
sigPODPresssupportshandshakingwith
thepresscontrolleroverindustrystandard
networks(Fieldbus,Ethernet/IP).Press
type(presstoahardstoporpresstoa
presetdepth)andRappingoperation
areautomaticallymanagedduring
handshake.Handshakeisconfigurable
forbothinterlockandnon-interlock
mode,allowingsigPODPresstowork
inenvironmentswhereonlyminimal
handshakeinformationisavailablefrom
thepresscontroller.
MULTIPLE GRAPHICAL DATA VIEWS
ThesigPODPressscreensdisplaysystem
information,showtestresultsintables
andgraphs,andprovideicon-based
buttonstonavigatequicklyandeasily
fromonetestandassemblymonitoring
functiontoanother.Theuserlevel
determinestheinformationdisplayed
andthemenuchoicesavailable:sigPOD
Pressprovidesoperator,engineer,and
supervisoruseraccountstocontrol
accesstosystemcriticalfunctionssuchas
calibration,limitmanagement,andsystem
maintenance.
Multiplewaystoviewthepressdata
ensuresthatoperatorsandengineers
canimmediatelydetectanyproblems
andtakeaction.sigPODPressprovides
multiple‘features’thatcanbetoggled
asgraphicaloverlaysonthepressdata
tohighlightandtracktrends.Sample
featuresincludeInsertionForcelimits,
InsertionDepthlimitsandAlignment
Force.Featurescanbeoverlaidonto
livedataoronanypreviouslycollected
historicaldata.Duringpressoperation,the
operatorcanchoosetographicallyview
onlythecurrentpartbeingmanufactured
oracompositeofallpartsbuiltduringa
productioncycle.
Thefollowingscreensnapshotshighlight
thevariousviewsofsigPODPress:
DefectsDetectedIdentify product abnormalities:
• Wrongorientation(e.g.backwards)
• Crackedparts
• Overorundersizeparts
• Tolerancestack-up
• Notfullyinserted
Identify machining or process abnormalities:• Badmachinealignment
• Improperlubrication
• Wrongramspeed
(timebasedcollections)
• Loosefixtures
• Damagedseals
• Lowhydraulicpressure
• Binding
PARTS
A
A
B
B
C
C
D
D
E F
E
CORRECTASSEMBLY
Missing part
Excessive distance
Insufficient distance
Incorrect insertion
Incorrect part
F Incorrect orientation
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STATUS VIEW
Highlevelstatusscreenallowsoperatorandsupervisorstoquicklyassessthepartteststatus.Thetopbannerindicatestheoverallpartstatus,serialnumber,model,keysystemoutputs,andcyclestatisticsandisavailableonallscreens.Theoverallteststatusandthestatusforeachpressramareindicatedwithlargestatusindicators.Asystemfaultcanberesetfromthisscreenandwiththerightloginaccesstheusercanexittheapplication.
CURVES VIEW
Allowstheusertoreviewfeaturesandcurvedataforeachpressramandprovidesalistoffeatureswiththeirlimits,values,andunits.Thefeaturevalueandtheexceededlimitareindicatedinredifthefeaturefailedforeasyrecognitionofthefailurecondition.Thecurrentfeatureishighlightedinthefeaturelistandthegraphindicatestherangeandlimitsforthathighlightedfeature.Theusercanselectthedesiredpressramabovethefeaturetableandviewitsfeaturesandcurve.DatacanbeviewedasForcevs.displacement,Forcevs.TimeorDisplacementvs.Time.
HISTOGRAM VIEW
Reviewofindividualfeaturevaluedistributionsthroughahistogramview.Indicatorsforthenominalcurve,specificationlimits,andcontrollimitsareselectablebytheuser.HistogramtableindicatesfeatureswithStatisticalProcessControl(SPC)statisticsincludingtotalnumberofentries,numberoffailedparts,percentageoffailedparts,andCpkvalues.
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StatusView–Main
TREND VIEW
Reviewoftrenddataforeachfeature.Indicationofnominalcurve,specificationlimits,andcontrollimits.TrendtableindicatesfeatureswithSPCstatisticsincludingtotalnumberofentries,numberoffailedparts,percentageoffailedparts,andCpkvalues.
HISTORy VIEW
Eachtestcycleresultsinatestrecordthatincludesfeaturevalues,limitsandthecollectedcurves.sigPODPresscanstorethousandsoftheserecordslocallyforreviewpurposes.Whenatestrecordisselectedthecurvesscreenisloadedwiththeselectedtestrecorddataandplacedinpausemodeforreview.
SETTING LIMITS
Therearemultipleviewsforviewinglimits:curves,histogram,trend,properties,andmodels.
Featuresviewwithmultiplefeaturesdisplayed
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LOAD CELLS AND DISTANCE SENSORS sigPODpresscanworkwithalmostanytypeofloadcellanddistancesensoravailable.Itisrecommendedthatallpress-fitoperationsbecharacterizedbymeasuringthecompleteforce-distancesignaturesincethisresultsingreaterreliability,butifthisisnotpractical,sigPODPresscanalsomonitorforce-timesignatures.
LoadCells–sigPODsupportsbothunamplifiedandamplifiedstraingagesensors,normalDCvoltagesensors,mAsensors,piezoelectricsensors,andmore.Forstraingages,sigPODPresshasabuilt-ininstrumentationamplifierwithprecisionDCexcitationsowiringisverysimple:justconnectthe4wiresoftheloadcelldirectlytothePODandsettheamplifiergainandcalibrationinsoftware.
sigPODPressalsosupportstwotypesofpiezosensors:directchargeamplifiedloadcellsandICPsensors.Inbothpiezocases,acompactsignalconditionerisavailablewhichplugsintoeachsigPODanalogchannelandprovidesaBNCconnectorreadyforthesensor.
DistanceSensors–sigPODPresscanworkwithmostdisplacementsensorsincludingencodertype(linearorrotary),DCLVDTs,voltagepotentiometers,mAoutputsensors,andmore.IfACLVDTsaretobeused,anexternalsignalconditionerwillberequired.
• Theencoderinputscanbe
configuredtomonitorasinglephase
pulse(countermode),oratwo
phaseA-Bpulsetotrackdirection
(quadraturemode).Eachencoder
channelprovidesa5voltsource
topowerthesensor,andhasinput
overloadprotectiontoprotectthe
channelfromwiringfaultsorother
failures.Theencoderinputscanbe
usedtomeasurelineardisplacement
datasuchaswithaSONYDLprobe.
AUTOMATIC LIMIT MANAGEMENT & SPCDuringinstallation,theSetupWizardautomatically‘learns’theinitialpresscontrollimitsandallowstheoperatortomanuallyadjustthemasneeded.Asproductionpartsaremeasured,sigPODPresscontinuouslycapturesstatisticsandcalculatestheoptimaltestlimits.Whenreviewingproductiondetails,theoperatorcanthenchoosetoenabletheseproposedcontrollimits,ensuringthatoptimumyieldisachieved.Advancedlimitmanagementresultsinfewerfalsefailuresthananyotherpress-fitmonitoringsolution.
DATA COLLECTION, STORAGE AND TRANSFERInstandalonemode,sigPODPresswillreliablycapturetolocalstorageallparttestdataincludingmodel,partandpressprocesssignatures.Whenthelocalstoragereachesaconfigurablethresholdlimit,theoperatorisnotified(viascreenalertandemail)thatdataneedstobebackedup.Aone-buttonpressbackupwillcopytestdatatoUSBkeyandcleanthesystemforthenextpressoperation.
HANDSHAKING & COMMUNICATIONSigPODPressisequippedtocommunicateoversimplediscreteI/O,orasanoption,withoneoftoday’smostcommonindustrystandardprotocols.MultiplecommunicationhardwareoptionsincludeRS232serialand10/100BaseTEthernet,dependingonhardwaremodel.
Supportedcommunicationprotocolsinclude:
• Devicenet1
• Profibus1
• Interbus1
• EthernetI/P
Serialnumberscanbereceivedviatheseinterfacessothetestresultscanbemadetraceable.NumerictestresultscanalsobetransmittedviaEthernetI/PorserialoutputinsimpleASCIIformat,allowingdataintegrationwiththemostMESorERPsystems.
Compatible with three main types of load cells:• Straingage
• PiezoICP
• Piezochargeamplifier
1SelectedfieldbusavailableonsigPOD12xxsystemsonly.
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Power• SupplyVoltage:24VDC(18VDCminimum,36VDC
maximum)• PowerAdapterInput:100–240VACRMSat50Hz,1.5A• PowerConsumption:48Wmaximum,30Wtypical
Processor• SystemMemory:1GBRAM• DataMemory:40GBHDminimum• Ethernet:1or2(seechart)• USB:2• RS232:1• Monitor:SVGAConnector• Keyboard/Mouse:USB
General• OperatingTemperature:5to40˚C(41to104˚F)• OperatingHumidity:8%-90%• Environment:NEMA12(IP52)Model12xxonly• PaintFinish:Blackbackedpowder
PressConfiguration• Numberoframs:1to4simultaneous.Optionsavailable
formorerams(e.g.32simultaneous)• Numberofmodels:Upto32uniquepressconfigurations• Ramdisplacementtypes:Analogsensor,Digitalencoder,
Time• Forcesensor:Amplified(powered)orunamplified
(notpowered)• Models/recipes:32• Typicalanalysistime:<100ms(dependentupon
complexityofanalysis)• Responsetotrigger:<50ms
Learn Mode• AutomaticlearningofSetContactzone,
AlignmentZone,InsertionZone• GraphicallyAdjustzonesusingleft/rightbuttons• AutomaticlearningofLimits:MaxForce,InsertForce,
AlignForce,InsertionForce,InsertionDepth,InsertionWork
• AdjustLimitsasneededafterlearn
SetupCheck• Shuntcalibration:Ifenabled,set%FullScale,Rawvalue
(Volts)andTolerance(%FullScale)• Handshaking: Presstohardstop,Presstopresetdepth,IgnoreRapping
operation; Standardhandshake(interlockedtoPLC)orMinimized
handshake(non-interlockedtoPLC)• Handshakecheck• Fieldbusinterfaces:Profibus,DeviceNet,Interbus,Ethernet/IP
SSR Inputs• NumberofChannels:8• Characteristics:opticallyisolated,commonlead,
bi-directional• Powerstates:16VDCon,8VDCoff
SSR Outputs• NumberofChannels:8• Characteristics:SPST,opticallyisolated,normallyopen,
bi-directional• Powerstates:switch±60VDCor40VACat1A16VDCon,
8VDCoffAnalogInput• NumberofChannels:2,4• InputRanges:Seemodelchart• InputAccuracy: ±0.02%for±1Vrangeandgreater; ±0.05%forrangeslessthan1V• Resolution:16bitA/D,±32,768counts• MaximumSampleRate:10kHz• InputImpedance:10Gohmsinparallelwith100pF
(820Ohmsnopower)• CrossTalk:75dBadjacentchannels, 90dBnon-adjacentchannels• CMRR:(DCto60Hz) 75dB(Model12xx) 92dB(Models14xx,1302) 100dB(Model15xx)• OverloadProtection:±25Vforupto2channelspowered
and±15Vwhenoff
AnalogExcitation• ExcitationVoltage:+10VDC• MaximumCurrent:100mAperchannel• Accuracy:±0.1%• MaximumNoise:100μV• ShortCircuitProtection:Continuous
Encoder Input• NumberofChannels:Seemodelchart(2or4)• Sensors:Rotaryencodersandlinearscales• InputVoltage:5VTTL• SignalType:Quadratureorsinglephase• MaxInputFrequency:10MHzTTL,50kHzOpenCollector• Counter:32bit(±2x109counts)• InputProtection:+24Vor-18Vwithoutdamage• SensorPower:+5VDC@150mA,currentlimited
DigitalInputs• NumberofChannels:8withcommonreturnline• Polarity:Bidirectional• IsolationVoltage:±120V(Opticallyisolated)• Inputcurrent:lessthan2.3mA• Inputforlowstate:8VDCmaximum• Inputforhighstate:16VDCminimum• MaximuminputVoltage:±48V• Switchingspeed:2msec
DigitalOutputs• NumberofChannels:8withcommonreturnline• Polarity:Bidirectional• IsolationVoltage:120V(Opticallyisolated)• SwitchingCapability:±1A@±48VDCorVACpeak• ContactResistance:>100MOhmsoff;<0.5Ohmson• PowerOnState:AllOff
• Switchingspeed:8ms
TEChNICALSPECIFICATIONS
2 / 4±10, 2, 0.1, 0.033 V
2/48 In / 8 Out
650 MHz512 MB60 GB2 V1.0
1Ethernet I/PModbus TCP
ProfibusDeviceNet Interbus
XP Embedded7.5 x 9.66 x 4.2 (199 x 241 x 107)
3
1202/04
Analog InAnalog Range
Encoder InDigital I/OProcessor
MemoryHD
USBEthernet
Industrial Networks (optional)
Operating SystemSize Inch (mm)
NEMA 12 (IP 52)
8±10, 5, 2, 1, 0.5, 0.2, 0.1 V
28 In / 8 Out
1.6 GHz1 GB
120 GB4 V2.0
2Ethernet I/PModbus TCP
XP Embedded8 x 6.5 x 8 (203 x 165 x 203)
-
1508
4/8±10, 5, 1, 0.2 V
28 In / 8 Out
1.6 GHz1 GB
120 GB4 V2.0
2Ethernet I/PModbus TCP
XP Embedded8 x 6.5 x 8 (203 x 165 x 203)
-
2±10, 5, 1, 0.2 V
18 In / 8 Out
1.6 GHz1 GB
40 GB4 V2.0
1Ethernet I/PModbus TCP
XP Embedded8 x 4.5 x 8 (203 x 114 x 203)
-
1404/08NEW! 1302
SIGPODPRESSmODELS
sigPOD Press
8
10.4”TOUChSCREEN 12xxmODELS
11.5
8.3
2.14
CL
2.2
4.3
11.0
ADJUSTABLE STAND 0-90
3.50
3.50
4X .31
MACHINE MOUNT
2X PANEL MOUNTBRACKET
PANEL MOUNT
mOUNTINGOPTIONS
3
3
1202/04
MACHINE MOUNT
PANEL MOUNT
WALL MOUNT
DIN RAIL
3
3
3
3
1508 1608 Expander
3
3
3
3
3
1404/081302
sigPODoffersarangeofmountingoptions.Seethefollowingpagesformoreinformation.
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1302AND1608mODELS
9.4
8.0
8.4
4.9
2X PANEL MOUNT BRACKET
PANEL MOUNT (1302 with integrated monitor only)
4.5
9.40
.8
.7
3.77
8.90
2X .38
2X .27
4.5
8.0
.3DIN RAIL, DIN 3, 35 X 15MM (W x H)
WALL MOUNT
DIN RAIL MOUNT
mOUNTINGOPTIONS
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ABOUT SCIEMETRIC
Since1981,Sciemetric’sprocessmonitoringandqualitymanagementsystemsandsoftwarehaveenabledsomeoftheworld’sleadingautomotive,medicalandindustrialmanufacturerstogainvisibilityintoandcontrolovertheirmanufacturingprocesses.Ontheproductionfloor,ProcessSignatureVerification(PSV™)technologyprovidesthemostaccuratedeterminationofprocesshealthandpartqualitywhilecollectingalldata.ManufacturingmanagersuseSciemetric’sanalytictoolstotransformthedataintoactionableinformationtoreducecosts,managequality,andmaximizeyieldwhileprovidingproofofprocesscomplianceandcompleteline-widetraceability.
[email protected]©2010SciemetricInstruments,Inc.Allbrandandproductnamesaretrademarksorregisteredtrademarksoftheirrespectivecompanies.Productsandspecificationssubjecttochangewithoutnotice.
Rev1,March2010
6.5
8.0
.3
DIN RAIL, DIN 3, 35 X 15MM (W x H)
6.5
9.4
.8
.7
5.75
5.75
8.90
2X .38
2X .27
DIN RAIL MOUNT
WALL MOUNT
14xx-15xxmODELS
mOUNTINGOPTIONS
Recommended
