Process Technologies SK 7 Manual de usuario
10/04
Technical details are subject to change without prior notice.© Schwer + Kopka GmbH
Operating Manual
Process Monitoring System
for Cold Forming Machines
SK 7SK 7
Process Technologies Group, Inc.
30W106 Butterfield Road
Warrenville, IL 60555
Phone: (630) 393-4777 Fax: (630) 393-4680
Contents
SK 7
SK7-01
Contents
Please note that some of the features described in this manual are optional
and/or may not be available for all models or applications.
Technical details are subject to change without prior notice.
V5.2 E 10/04
System layout................................................2 Part counters... ............................................21
- how to set the counter. ..............................21
Display Panel..................................................3 - order size counter...... ...............................21
- tool life counter..........................................21
Controls and connections (rear panel).............4 - AUTO2-counter.........................................22
- batching counter.......................................22
Start- up/basic functions.................................5
SKToolmaster (header set-up).......................24
Operation modes............................................6
Sorting control/idle stroke adjustment............26
- sorting function .........................................26
Envelope monitoring (force)............................7
- how to set the sorting parameters................27
- envelope display.........................................7
- idle stroke adjustment.................................27
- machine stop with envelope error.................8
- SKSinglemaster.........................................28
- restart after stop.........................................8
- sensitivity ..................................................9
Machine and process data analysis..............29
- tolerance....................................................9
- machine run time diagram.........................29
- error statistics...........................................29
- error memory (failure curves)....................30
Load distribution profile.................................31
Part data memory.........................................32
Machine Interface.............................................
Q-factor monitoring......................................18
SKAutomaster..............................................10
SKFuzzymaster............................................11
SKProfilemaster...........................................12
Trend Monitoring..........................................14
- trend display with stop/go............................15
- trend parameter settings..............................16
- setting of trend limits...................................16
- relative or absolute trend limits.....................16
SKQmaster..................................................20
System layout
Piezo electric
sensors
(up to 16 channels)
Timing
signal
(prox)
Rotary
angle
encoder
DB 37
female
DB 37
male
24 VDC
T
S-N
V/A
sc hw er k o pk a
+
CE
s c h w e r ko p k a
+
24 VDC / 4 A
SK 4 C
S1
DO/1
I1 24VDC
Abmasse:
200 B x 250 H x 160 T
Raster Befestigungslöcher:
160 B ; 272 H
Sensor Box
schw er k o p k a
+
Machine
Interface
By-Pass
key switch
schw er k o p k a
+
to machine
control cicuits
85 - 265 VAC
50/60 Hz
On/Off
SK 7
V5.2 E 10/04
SK7-02
schwer kopka
+
SK 7SK 7
10,4"
12,1"
SK7-15
Display Panel
Front Panel
1. 12,1”-LCD-colour-screen (TFT)
with Touch-Screen Surface
2. Function keys / Symbol keys
(touch elements)
12
SK 7
V5.2 E 10/04
SK7-03
Controls and connections
1. On/Off switch 5. Network socket
2. Power Supply connector 24VDC 6. Serial port (RS 232)
3. Connecting socket for Sensor Cable (S1 7. Serial number plate
4. Connecting socket for Interface Cable (I1) 8. Rear panel lock
T
S-N
V/A
sc hw e r ko pk a
+
s c h w e r k o p k a
+
24 VDC / 4 A
SK 4 C
654
32 1 7
T
S-N
V/A
s ch we r ko pk a
+
CE
24 VDC / 4 A
SK 4c
8
S1 O/1
I1 24VDC
SK 7
V5.2 E 10/04
SK7-04
Start (switching the system on)
The electronics of the SK unit are switched on via the On/Off push button located on the rear panel
(unit is tyically installed inside the main machine control box, see also page 4).The operating
screens for the process monitoring functions are called up by pressing the respective function key
(often F6) on the main PC control panel. The first screen will show the force curves.
Selecting the different functions
The SK system is designed to work with Touch-Screen controls as well as with regular push-button
operating panels. The decription in this manual concentrates mainly on touch-screen.
The touch-screen version has a row of function symbols at the bottom of the screen. The symbols
can change depending upon the selected functions. Just touch the respective symbol to call-up the
desired function. Where numerical entries are required, a numerical keyboard window will automati-
cally pop-up.
With push button controls, just press the function key (F1 - F10) belonging to the desired symbol in
order to start the respective function. For numerical entries please use the number keys on the front
panel.
Screen layout
Many features and operational steps are similar on the differents screens. These are briefly explained
below using the example of the multi-curve screen:
Start / basic functions
Upper right corner
always shows current
machine speed in
strokes/minute
Current date and time
Shows current
part number if unit
is equipped with
part data memory
The background color changes with the
selected operation mode:
- yellow: set-up (MAN)
- green: automatic mode (AUTO)
- red: machine is in STOP
The upper left corner describes the
currently selected function screen.
When in STOP, this line gives in red
the reason why the machine was
stopped.
If machine has more
than 5 channels press the
cursor key to advance
to other channels
Change to trending
screens
Pressing the channel
number on the keyboard
(or touching the curve)
will give an enlarged
view of that channel
The symbol boxes
indicate which
functions are
currently available
The symbol key labelled SPS or PLC (mostly F6)
will switch back to the main machine controls. SPS
SK 7
V5.2 E 10/04
SK7-05
Operation Modes
MAN mode (yellow)
The MAN mode is not actively monitoring the process. However, the unit registers and displays the force
signals to help the operator set up the machine. The MAN mode is normally selected after each STOP to
release the stop relays. In this case , the system will learn new envelope limits after it enters AUTO mode.
The time spent in MAN mode can be limited to an adjustable number of strokes after which the unit will
switch into AUTO mode by itself (adjustment is done within the set-up menu). If wanted, the system can
be set so that it re-uses the previous envelopes without relearning. In this case, after a stop condition, the
system should go directly into AUTO mode.
AUTO1 mode (green)
The green mode starts the automatic monitoring mode. The unit is immediately active after the green
mode commenced. The system either starts learning fresh limits or returns to the previous envelopes (de-
pending on the mode change). In the second case, the unit will wait for a few machine strokes before it re-
sumes the previous envelopes to allow the machine to reach consistant speed.The monitoring limits
(force and acoustic envelopes) are dynamically updated and matched with the process variation. Count-
ing of good parts made starts also. Every impermissible deviation of the process curve signal will cause
the unit to react.
AUTO2 mode
Automatic mode offers the same functions as in AUTO1, but is used when running unmanned shifts. In
addition, the AUTO2 parts counter provides a separate count for parts made during AUTO2 mode. When
stopping the machine during AUTO2, the unit fires the separate EMERGENCY-STOP relay that switches off
the machine entirely (AUTO1 mode will only fire the MOTOR-STOP relay).
STOP (red)
The STOP light comes on every time the unit has switched off the machine. In addition, a machine stop
can be initiated by pushing the STOP key manually. The unit always will prompt a stop
message on the display to identify the reason for switching the machine off.
Selecting operation modes
The different operation modes are selected via the mode buttons when touching the coloured display
beam on the top of any screen. They include functions such as set-up mode or automatic mode for regu-
lar or unmanned shifts. The colour of each display beam indicate which mode is currently running.
Touch the coloured display beam
on the top of any screen...
and the mode buttons will appear.
SK 7
V5.2 E 10/04
SK7-06
Envelope monitoring
The envelope monitoring technique scans the entire force wave form from start to finish (as
determined by the established timing window). Each point scanned is compared to a previously
memorized "good parts wave form" by using the upper and lower envelope threshold curves. These
are automatically established by the monitoring system each time it is put into AUTO-mode.
Envelope display
Pressing the Curve function key will display the force wave form together with the envelopes. The
display shows either multiple-curves (up to 5 sensors at a time) or single curves representing one
sensor only. Channel selection from one sensor to another is made by simply pressing the number
of the channel you wish to see.
Changing from multiple to single curve presentation and vice versa is initiated by pressing the Curve
function key, or by directly pressing the number key for the desired channel. If the monitor has more
than 5 channels, use the up and down cursor keys to change the channel displayed.
Envelope Monitoring (force)
Multiple curves
Single curve
Envelope
band (green)
Current force
(blue)
This number (in
millivolts) indicates
the peak reading
of the signal
for the last stroke
Shown while single
curve display is active:
S: Sensitivity
Tol.: Tolerance
Q: Q-Factor
QL: Q-Limit
To alter any of the
settings, press the C-key
once, then change the
numbers, and confirm
by pressing the E-key
SK 7
V5.2 E 10/04
SK7-07
Envelope Monitoring (force)
Machine stop with envelope error
If a channel’s force curve exceeds the upper envelope curve or drops below the lower envelope,
the monitoring system will immediately initiate an appropriate stop action. The LCD screen
automatically switches to the single curve display of the channel in question making it easy to
locate the error. The reason why the machine was stopped along with a date and time stamp for
the error are displayed in the red portion at the top of the screen.
Restart after Stop
After stopping the machine due to a force error, it is necessary to determine and to eliminate the
cause of that error before you restart production. This prevents the system from learning an
improper setup and establishing ineffective control limits. Once this has been done, one of the fol-
lowing procedures should be performed.
The system switches from adjusting mode (yellow beam/MAN-Mode) into AUTO Mode. Alterna-
tively, you can skip into the AUTO-Mode (if your unit is programmed to re-use the
previously established envelopes).
The monitoring mode (AUTO) is reached, when the display beam on the top of the screen appears
in green.
Or restart the machine after confirming that the cause of the error is eliminated. Then press the
AUTO-key to switch the unit back into monitoring mode. The SK bbx now calculates new envelope
limits, or returns to the previous envelopes if you already pressed the AUTO-key (please refer to
page SKbbx-06, selecting the MAN-mode).
Error curve (red
Envelope band (green)
Stop reason
Stop time
on the display beam
Shows error size
(here is 38 % of the force
curve above upper envelope)
SK 7
V5.2 E 10/04
SK7-08
Envelope Monitoring (force)
Adjusting monitoring accuracy
Sensitivity and Tolerance
The accuracy or precision of the enveloping technique typically is set automatically by the SK unit
to match the stability and repeatability of each curve segment. Thus, it is not necessary to fine tune
this any further through manual adjustments, however, the SK does provide the possibility to alter
within a certain range the settings for “Sensitivity” and “Tolerance” individually for each connected
channel.
Sensitivity (S) can be adjusted in steps from 1 - 9 (1=coarse, 9=fine). The sensitivity setting has
an effect on the basic width of the envelope which is the distance between upper and lower
envelope curve. A coarse setting (= low sensitivity numbers) widens the gap between upper and
lower threshold, while a fine setting (= high sensitivity numbers) narrows the gap down which
represents a more precise control. Setting the sensitivity to “0” switches the monitoring off for this
channel (no more envelope curves are being displayed).
The optional SKProfilemaster software (see page 27) provides a segmented envelope profile
around the force curves (tight where needed; loose where necessary).
The Tolerance (Tol) setting determines how many consecutive “bad” parts with force signals
outside the envelope are ignored or “tolerated” before the machine is stopped. Therefore, the
tolerance setting prevents undesired machine stoppages caused by random or erratic force errors.
Tolerance can be set to values from 0 - 9 with the following meanings:
0: No “bad” parts are tolerated. The first “out-of-limit” part will stop the machine.
1: One “bad” part is tolerated. If it is followed by another “bad” one, the machine stops..
9: 8 consecutive “out-of-limit” parts will be tolerated. The 9th “bad” part stops the machine.
NOTE: Use of tolerances should be scrutinized carefully. Remember, an input essentially bypasses
the machine for the number of tolerances entered. Serious damage to tooling could result if this
feature is improperly used.
How to alter S and Tol:
Select sensor chanel and touch the desired field S or Tol;
enter desired value and confirm by E
Example:
Adjusting of S (sensitivity)
Touch desired
sensitivity
Confirm
by E
SK 7
V5.2 E 10/04
SK7-09
Manuales populares de Instrumento de medición de otras marcas
Endress+Hauser
Endress+Hauser Proline Promag 50 Especificaciones técnicas
Siemens
Siemens SITRANS F Coriolis FCT030 Manual de lista de piezas
KLINGER
KLINGER CMF V Series Manual de usuario
EXFO
EXFO FTB-2 Manual de operación y mantenimiento
Keysight
Keysight M8290A Manual de usuario
ADTEK
ADTEK MW-5 Manual de usuario