Process Monitoring for press fit Auloma APM-BA

AULOMAAPM-BA

PRESS CONTROL AND FORCE VS DISPLACEMENT MONITORING SYSTEM

Perfection in Press Fit Operations 2

APM-BA SERVO PRESS PROCESS MONITORING

PRESS CONTROL AND FORCE VS DISPLACEMENT MONITORING SYSTEM

BENEFITS

•Lonely environment to control servo press job

and process monitoring instal led in servo drive

memory

•Modular press programs unti l 5 steps for press

to force, press to position and press to relative

position

•Real time process monitoring

•Servo press diagnosis

•Enhance defect detection

•Reduce the scrap cost

•Operator friendly interface for press program

•Ethernet interface for data exchange

•Analysis data in CSV format for SPC

•PC tool kit compatible with wichever MS widows

Vista ® machine and later version

FEATURES

Software

•Best industrial software for press

program and process monitoring

•Two channels (x)(y) analisys for

real time Process Monitoring

•Multiple waveform control zones

•Envelope function for complete

waveform control

•CSV data trasnfert

Hardware

•Servo Drive with Built-In PLC ABB

•I/O terminals connector for easy

plug and wiring

•Two Ethernet/Ethercat interface

for PLC and PC connection

Quick Set Up

•Friendly wizard for set up the

servo press parameters

•Friendly wizard for set up the

wavform control zone

PC User Interface

•Simple and intuitive user display

•Supervisor account with password

security

Multiple Data Views

•Status: see part test status (pass

or fai l)

•Curves: view data curves (Force

vs. Distance) with overlaid l imits

•History: review last test cycles and

part history records

•Limits: view current l imits

Detailed Data Management and

Reporting

•Local & remote storage of test

results organized by model, part,

ram, etc.

•Process data available in CSV

format for Statistical Process

Control (SPC)

Servo Drive Connectivity

•Communication with station

control ler via discrete I /O in APM

slave configuration

•Ethernet TCP/IP for data transfert

•USB

Applcations

•Servo press control

•Press applications process

monitoring

3 Perfection in Press Fit Operations


OVERIEW

APM-BA is designed to control the servo press motion and in the same time monitoring the press operations, thus

the system provide real-time analysis of the data to identify defective parts, faulty press machinery, and out of

control assembly processes. I t measures force vs. distance signatures for each part cycle, and then analyzes the

curve(s) in mil l iseconds to provide an instant pass/fai l output for press ram. Compatible with piezoelectric force

sensor or strain gauge amplified with analog output of ±1 0V, APM-BA can be networked to provide higher level

insight into assembly processes by collecting data across the entire assembly l ine.

APM-BA provides extensive hardware and software functions for part test, analysis and data connectivity

APM-BA CONFIGURATION STANDARD TO CONTROL PRESS RAM

DIGITAL INPUT FORCESENSORCALIBR.

PRESSREADY

MOTORBRAKE

ANALYSIS

OK

ANALYSIS

NOK

CYCLERUNNING

FORCESENSORTARE

SERVODRIVE

WORKPIECEPRESENT

ETHERNET

HOMEPOSITIO

NCOMMAND

CYCLESTART

RESET

PROGRAM

WAIT

JOG

+

JOG

-

ETHERCAT

DIGITAL OUTPUT

ANALOG

INPUT0-10V

MOTORFREQUENCYCONTROL

ENCODERINTERFACE

DIGITAL

OUTPUT

DIGITAL INPUT

PRESSREADY

MOTORBRAKE

ANALYSIS

OK

ANALYSIS

NOK

CYCLERUN

USER'S

PLC

HOMEPOSITIO

NCOMMAND

CYCLESTART

RESET

PROGRAM

WAIT

JOG

+

JOG

-

DIGITAL OUTPUT

SERVO PRESS

FORCE SENSOR

MOTOR

ENCODER

PROXIMITY

SENSOR

OTPTICAL

MAGNETIC

CAPACITIVE

(OPTIONAL)

PC LAPTOP WITH

APM-PC TOOL

INSTALLED

PC SERVER WITH

APM-PC TOOL

INSTALLED

(OPTIONAL)

MASTER

SLAVE

ETHERNET

SWITCH



THREE DIFFERENT KIND OF SERVO PRESS CONTROL

APM-BA own three programs to control the press ram. The set up of each program is easy and friendly. In few

minutes is possible set up the press according your application. The three programs allow a ram control to press at

the right force, at the right position and at the right relative position from a force signal trigger. the ram program is

saved in the memory of the servo drive unti.

THE BEST HUNTER OF PARTS DEFECTS

The brain of the APM-BA is the powerful CPU that al low a faster analysis of the data gathered from the press

sensors. The APM software produce a faster analysis of al l data provided by the servo press. The press waveform

results are control led by multiple tolerance off set zones or by an envelope that wrapping the trajectory. Thanks to

this method if the process is repeatable the analysis results are repeatable also and by the comparison of a

masterpiece waveform the APM can decide in few mil l iseconds if the parts are correct or wrong.

MULTIPLE GRAPHICAL DATA VIEWS

The APM displays all informations about press program and test result on a Windows ® PC machine with APM -

BA tol l kit instal led. Thanks to the icons on the software interface is easy display tables and graphs. The navigation

inside the APM - BA Toll kit is protected by password and allow different set up level according the permission.

CSV DATA TRANSFERT

The APM-BA can provide the process signature data in CSV ( Comma Separated Value ) format to an external

data storage. The CSV data can be used for SPM ( Statistic Process Management ) or SPC ( Statistic Process

Control ) and can be processed by many ERP, MRP and spread sheet )

DEFECTS DETECTED

PARTS CORRECT

ASSEMBLY

EXCESSIVE

DISTANCE

INCORRECT

INSERTION

INCORRECT

ORIENTATION

INCORRECT

PART

INSUFFICENT

DISTANCE

MISSING

PART

APM-BA TOOL KIT FUNCTIONALITY

The best yield obtained by Auloma servo press is when all analysis data provided are saved and analysed in a PC

machine. Statitistical analysis of your data allow an awared knowledge of your quality trend. Through APM-BA Tool

Kit whichever PC machine can set up the press operations but can also save and see all analysis data. With a

good organizzation of the archive folders is possible research the data stored through a DB and then analysed by

Statistic Process Management instal led.



TOOL KIT STATUS VIEW

High level status screen allows operator and

supervisors to quickly assess the part test status. The

program diplays unti l four press in run. Each menu

displays the istantataneous value of force and posi-

tion of each ram. The central lower menu displays the

press cycle results .

TOOL KIT SETTING LIMITS

The APM-BA displays a menu to setting the force limits

on wafeform

TOOL KIT PRESS PROGRAM

APM-BA displays a templates where is possible edit

the parameters to control the servo press ram. The

templates propose three different execution of the

press cycle, one for press to the nominal force value,

another one to press to the nominal position and the

last one to press to the relative position.



TOOL KIT CURVES VIEW

The APM-BA provide each cycle the curves produced

by the data gathered. The curve is displayed on (x)

(y) graph, where in (x) there is the ram stroke scale

and in (y) the force. The view of the curve is aided by

a smart zoom function and pan function. The off set

force limit settled on the curves can be displayed

through the properly buttons on the screen.

TOOL KIT HISTORY VIEW

The APM save each cycle result in two diffrent CSV

files. The 1 st fi le provides the raw data to identify the

historical period, the 2nd fi le provides the raw data

about the analysis. Both fi les are saved on the re-

sperctive folder path. The analysis history is displayed

below the curve templates and is possible diplays ea-

ch historical curves through a flaggable field.

TOOL KIT HTML REPORT

The analysis results can be plot in HTML format to

generate useful documets.



For complex press operations or if breakpoints for the supply of material or tools are required, an extended se-

quence of press fit programs is available. The APM-BA has the capabil ity of 5 steps in sequence to provide

operational profi les with breakpoint and inversion of the direction of travel.

home positionapproach introduction end fit

0

1

2

3

position set 1 position set 2 position set 3 position set 0

home position idle stroke

( fast foward) unti l

workpiece

introduction

( slow forwad)

for few mil l imetres

to bear the correct

workpiece alignment

fitting to the target

value

( force or position )

back stroke

( fast backward)

unti l tool change

position

0

position set 0

home positionapproach flaringtool change 0

4

position set 4 position set 0

tool change position

idle time for tool

changing

idle stroke

( fast foward) unti l

workpiece

flaring stroke

( slow forward )

to the target

value

back stroke

( fast bakward) unti l

home position

5

position set 5

0

position set 0

PRESS PROGRAM



PRODUCTS OVERVIEW

SERVO DRIVE E1 50 FOR PRESSES WITH THRUST CAPACITY BELOW 20 KN

APM-BA SOFTWARE

SERVO DRIVE E1 80 FOR PRESSES WITH THRUST CAPACITY OVER 20 KN



TECHNICAL SPECIFICATIONS E1 50

SERVO DRIVE FEATURES

•Embedded Ethernet including EtherCAT®, Modbus/TCP and Ethernet/IP

•EtherCAT conformance certified by ETG

•Safe torque-off (STO) as standard - to IEC 61 800-5-2, SIL3 PLe

•2 / 4 wire RS485 with optional termination and Modbus RTU support

•APM-BA TOOLKIT provides configuration via USB or Ethernet TCP/IP

•AC servo drive 3, 6 or 9A with 200% overload

•Single or three phase 1 05 - 250 V AC operation (maximum limits)

•Encoder BiSS

•Dual encoder input for l ine shaft fol lowing or dual loop control (position / velocity and commutation)

•1 0 x digital inputs. Opto-isolated 24V.

•2 inputs can be programmed to capture axis position within 1 micro-second (feedback device dependant)

•7 x digital outputs. Opto-isolated 24V PNP. 50mA per channel.

•2x +/-1 0V analog inputs 1 x +/-1 0V analog output

•Notch fi lters to combat mechanical resonance

•7 segment LED status indicator for error and communications notification

TECHNICAL SPECIFICATIONS E1 80

SERVO DRIVE FEATURES

•Embedded Ethernet including EtherCAT®, Modbus TCP and Ethernet/IP

•EtherCAT conformance certified by ETG

•Safe torque off (STO) as standard - to IEC 61 800-5-2, SIL3 PLe

•APM-BA TOOLKIT provides configuration via Ethernet TCP/IP

•Three phase operation 230 -580 V AC

•Encoder BiSS

•Secondary encoder input for l ine shaft fol lowing or dual loop control (position / velocity and commutation)

•1 0 x digital inputs. Opto-isolated 24 V.

•2 inputs can be programmed to capture axis position within 1 micro-second (feedback device dependant)

•7 x digital outputs. Opto-isolated 24 V PNP. 50 mA per channel.

•2x +/-1 0 V analog inputs 1 x +/-1 0 V analog output

•Notch fi lters to combat mechanical resonance

•7 segment LED status indicator and LED communications status

Auloma Holding S.r.l.

Address:

Via Mussolina 1 074 - 4001 8 San Pietro in Casale ( BO)

ITALY

T. +39 051 81 82 85

[email protected]

www.auloma.com

201 5-05-1 5- Rev. 00 - APM-BA-MMXV

© Auloma Holding S.r. l . , al l rights are reserved. I t is prohibited to use text or immages from this

documentation, in whole or in part, without written permission. All products are subject to

technical change without notice. Liabil ity for printing errors in the technical data is excluded.

Technology

Process Monitoring for press fit Auloma APM-BA