Burster ForceMaster 9110 Operating Manual Download

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Summary of Contents for ForceMaster 9110

Page 1: ...kg All rights reserved Manufacturer burster pr zisionsmesstechnik gmbh co kg Talstra e 1 5 76593 Gernsbach Germany P O Box 1432 76587 Gernsbach Germany Valid from 08 10 2013 Tel 49 07224 6450 Fax 49...

Page 2: ...ik hereinafter referred to as product are the results of targeted development and meticulous research As of the date of delivery burster provides a warranty for the proper condition and functioning of...

Page 3: ......

Page 4: ...4of 95...

Page 5: ...automation 13 3 8 Front view of the ForceMaster 9110 14 3 9 Rear view of the ForceMaster 9110 15 3 10 Menu structure of the ForceMaster 9110 16 3 10 1 Operating example extract from the menu 19 3 10...

Page 6: ...lacement measurement system DMS to the manual press 42 4 3 Setting up the measurement chain on the ForceMaster 9110 44 5 Measurement 46 6 Configuring the ForceMaster 9110 settings 49 6 1 Counter menu...

Page 7: ...cement curves 82 8 Technical data 89 9 Configuration notes 90 9 1 Choosing the right load cell 90 9 2 Choosing the right displacement sensor 91 9 3 Advice 91 10 Available accessories 92 11 Ordering ex...

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Page 9: ...tions are taken Caution Damage to property can occur if no appropriate precautions are taken Note It is important to heed these safety notices in order to ensure correct handling of the instrument Sym...

Page 10: ...erfaces The device is not a replacement for safety equipment such as for the emergency shutdown of a press if the pressing force exceeds a limit value 2 2 Ambient conditions 2 2 1 Storage conditions c...

Page 11: ...al 1 x mains cable PC software MasterCard 9110 Z001 2 5 Conversions and modifications If you open up the ForceMaster 9110 or dismantle it during the warranty period the warranty will be immediately vo...

Page 12: ...is also detected The measuring mode is set automatically Units such as newtons N kilonewtons kN or displacement mm are set automatically 3 4 Counter The ForceMaster 9110 counts the number of parts th...

Page 13: ...a that has been collected can then be saved on a PC or a server The large amount of storage available on a USB stick makes it possible to store the documentation over a longer period of time You shoul...

Page 14: ...Support for automation 3 8 Front view of the ForceMaster 9110 Key Explanation 1 Card reader 2 Two line display 3 Folding feet 4 Operating knob 5 Red indicator lamp NOK 6 Green indicator lamp OK 7 Loud...

Page 15: ...he ForceMaster 9110 Key Explanation 8 Mains connection 9 Mains switch 10 Fuse 11 Connection for USB stick optional 12 Connection for load cell 13 Connection for displacement sensor 14 RS232 interface...

Page 16: ...16of 95 Menu structure of the ForceMaster 9110 3 10 Menu structure of the ForceMaster 9110...

Page 17: ...17of 95 Device concept...

Page 18: ...18of 95 Menu structure of the ForceMaster 9110...

Page 19: ...Aids to orientation for operation Arrows that indicate the possible directions of rotation are provided on the lower right of the display immediately next to the rotary knob for better orientation in...

Page 20: ...mething press the operating knob This takes you to a sub menu By turning the operating knob you can navigate through the sub menu When you have found the function you want press the knob in order to s...

Page 21: ...n the operating knob in order to select the letter or the number that you want 4 Press the button again in order to confirm the selection 5 Repeat steps 1 4 for every location in the text that you wou...

Page 22: ...ameters Step 2 Setting the modes You can check which monitoring modes the ForceMaster 9110 suggests and are able to specify a different one Step 3 Setting the parameters You can check what monitoring...

Page 23: ...n the display shows waiting upwards 4 Move the punch back up When the pressing operation is complete the display shows Step 2 Set modes It may be necessary to correct the values learnt through the aut...

Page 24: ...ween the start and end of blocking There is no force monitoring in this region Monitor blocking force Means that between the start and end of blocking the curve must reach the lower blocking force thr...

Page 25: ...nt value at which the gateways evaluated T2 lo You can specify up to five gateways Set blocking Displacement low These values are to be set if you chose the Monitor blocking force item in Step 2 Displ...

Page 26: ...orce must not exceed Set the values for the force thresholds pure force monitoring or force displacement thresholds 1 Open the Set values menu 2 Press the operating knob in order to select the Set lev...

Page 27: ...b in order to select the menu item 4 Select the value that you want to set 5 Turn the operating knob in order to set the value 6 Press the operating knob to confirm the setting Set the values of the t...

Page 28: ...s at the device This is not possible without the MasterCard This prevents unauthorized users from changing important settings 3 12 2 ToolCard You can save the settings of the ForceMaster 9110 for a pa...

Page 29: ...em in order to specify the condition for the program step You will find a list of possible conditions in Section 6 3 1 Liste m glicher Bedingungen Entry command Select this sub menu item in order to s...

Page 30: ...e operating knob in order to select the condition that you want 7 Press the operating knob to confirm the condition 8 Press the operating knob in order to select the Entry command menu item 9 Turn the...

Page 31: ...enu item Enable PLC 1 Open the PLC I O menu 2 Turn the operating knob until the Enable PLC menu item appears 3 Press the operating knob in order to select the menu item Enable I O 1 Open the PLC I O m...

Page 32: ...Bottom dead centre not reached E1 Input 1 0 OK Part OK E2 Input 2 0 NOK Part not OK E3 Input 3 0 F1 Force smaller than force threshold below E4 Input 4 0 F1 Force greater than force threshold below E...

Page 33: ...1 0 1 9 9 sec Input 1 0 1 sec T2 Set timer 2 0 1 9 9 sec T1 Reset timer 1 T2 Reset timer 2 JMP Jump to target line BE Set beep BE Reset beep LO Switch OK LED on LN Switch NOK LED on L Switch LEDs off...

Page 34: ...ing knob in order to select the menu item 5 Turn the operating knob in order to set the start value that you want 6 Press the operating knob to confirm the value 7 Press the operating knob in order to...

Page 35: ...aulic power are used for pressing the ForceMaster 9110 can protect against excessive forces There are two force alarms for this purpose Both force alarms set output 8 and have a reaction time of about...

Page 36: ...60 The step chain controller operates according to the step chain principle If the condition at the beginning of a line is satisfied the command on that line is executed The step chain controller has...

Page 37: ...nwards movement of the press If the programmed value is negative then the reaction occurs during the upwards movement of the press Examples Cam start Cam end Function 20 2 mm 30 3 mm Press movement do...

Page 38: ...5 16 E8 Emergency off for International PLC operation 17 E7 Not evaluated by the ForceMaster 9110 18 E6 Not used 19 E5 Not used 20 E4 Not used 21 E3 Not used 22 E2 Not used 23 E1 Error acknowledgement...

Page 39: ...to small start of measurement not reached A2 A4 A5 End of measurement not reached A1 Measurement OK A6 Force between KSU and KSO even when measurement has not started A7 Ready for measurement A8 Forc...

Page 40: ...changed the device recognizes this and the message Sensors have been changed appears Perform an autoconfiguration if the sensors have been changed If the calibration interval of two years for one or m...

Page 41: ...2 If there is a pressing tool on the manual press remove it 3 Push the press head upwards by a distance equal to the height of the load cell depending on the measuring range 4 Insert the load cell in...

Page 42: ...plate for displacement measurement system DMS on the press 2 Push the displacement sensor with the probe tip downwards into the adapter typical application The probe tip must touch the catch that is a...

Page 43: ...is for the displacement sensor to be able to move freely between the upper and lower positions of the press without reaching either of its stops Since the system deliberately provides a large number...

Page 44: ...the MasterCard into the card reader and turn the operating knob to the right until AutoConfig appears on the display 3 Push the operating knob in order to open the next sub menu Step1 teach in 4 Pres...

Page 45: ...45of 95 Initial commissioning It may be necessary to correct the values learnt through the autoconfiguration If necessary these can be manually adjusted see Section 3 11 3...

Page 46: ...ndow you see how many parts have been checked altogether F1 F2 Fmes F1 Status of force threshold 1 Possible values are low or ok F2 Status of force threshold 2 Possible values are high or ok high forc...

Page 47: ...ion window appears again An attention signal sounds as soon as you produce a faulty part and deliberately or accidentally do not acknowledge this procedure Operating the press again immediately result...

Page 48: ...12 BSO exceeded Block threshold above exceeded The blocking force was larger than the block threshold above 13 BSU not reached Block threshold below not reached The blocking force has not reached the...

Page 49: ...n the card reader Opening one of the sub menus 1 Insert the MasterCard into the card reader with the contacts pointing towards the display 2 Turn the operating knob until the sub menu you want appears...

Page 50: ...sets the down counter to the value specified under sub menu item D set set Down counter Sets the initial value for the down counter The down counter allows you to have a freely editable message shown...

Page 51: ...ars 3 Press the operating knob in order to select the menu item 4 Press the operating knob in order to select the Down counter menu item 5 Turn the operating knob as long as necessary to see the numbe...

Page 52: ...carried out on the stick Caution Do not switch the device off or withdraw the USB stick while storage is taking place or the stick s operating lamp is flashing This will result in loss of data and to...

Page 53: ...rage is presently taking place in this case folder 23_03_08 as an example JOB001 CSV Indicates the current job file to which data is being written in this case JOB001 CSV as an example GRA011 CSV Indi...

Page 54: ...ollowing operations are stored on the stick as a curve file This function is useful if graphical evaluations of critical pressing operations on high value parts are to be carried out over a long perio...

Page 55: ...ick menu 2 Turn the operating knob until the Curve stick menu item appears 3 Press the operating knob in order to select the menu item Storing the next 100 measurement curves on the stick 1 Open the U...

Page 56: ...to the manual press Interrupting storage of all measurement curves on the stick 1 Open the USB stick menu 2 Turn the operating knob until the All C STOP menu item appears 8 Press the operating knob in...

Page 57: ...Peening displacement min peening displacement max 15 63 Trigger point displacement 29 86 0 0 106 7 1 Gateway position gateway min gateway max 32 28 50 9 157 6 2 Gateway position gateway min gateway m...

Page 58: ...in order to specify the condition for the program step You will find a list of possible conditions in Section 6 3 1 Liste m glicher Bedingungen Entry command Select this sub menu item in order to spe...

Page 59: ...ob in order to select the menu item 6 Turn the operating knob in order to select the condition that you want 7 Press the operating knob to confirm the condition 8 Press the operating knob in order to...

Page 60: ...knob in order to select the menu item Enable PLC 1 Open the PLC I O menu 2 Turn the operating knob until the Enable PLC menu item appears 3 Press the operating knob in order to select the menu item En...

Page 61: ...Input 8 1 BDC Bottom dead centre not reached E1 Input 1 0 OK Part OK E2 Input 2 0 NOK Part not OK E3 Input 3 0 F1 Force smaller than force threshold below E4 Input 4 0 F1 Force greater than force thr...

Page 62: ...0 1 9 9 sec Input 1 0 1 sec T2 Set timer 2 0 1 9 9 sec T1 Reset timer 1 T2 Reset timer 2 JMP Jump to target line BE Set beep BE Reset beep LO Switch OK LED on LN Switch NOK LED on L Switch LEDs off CN...

Page 63: ...rs 4 Press the operating knob in order to select the menu item 5 Turn the operating knob in order to set the start value that you want 6 Press the operating knob to confirm the value 7 Press the opera...

Page 64: ...settings of the ForceMaster 9110 with respect to present data onto a tool card You can label the card and can include it with the order documentation PLCCard Through this sub menu item you save the c...

Page 65: ...operating knob in order to select the menu item 4 Take the MasterCard out of the card reader and insert the ToolCard onto which you want to write the tool data 5 Press the operating knob in order to...

Page 66: ...The message CARD written appears 7 Press the operating knob to acknowledge the message Enable reading a ToolCard for workers without MasterCards 1 Open the CARD menu 2 Turn the operating knob until th...

Page 67: ...r the force alarm 1 through this sub menu item FO Alarm 1 You can move the threshold for the force alarm 2 through this sub menu item Setting the value of the force for the trigger point 1 Open the Ma...

Page 68: ...as long as necessary to see the value that you want to set 2 Press the operating knob to confirm the setting Setting force alarm 2 1 Open the Manual settings menu 2 Turn the operating knob until the F...

Page 69: ...dium loud very loud Error acknowledgement standard In this sub menu you can choose how the pressing error is acknowledged Error acknowledgement without MasterCard with MasterCard Errors can only be ac...

Page 70: ...cessary to see the volume that you want to set 5 Press the operating knob to confirm your selection Setting the type of error acknowledgement 1 Open the Error signal menu 2 Turn the operating knob unt...

Page 71: ...ing the ForceMaster 9110 settings Switching off the warning tone 1 Open the Error signal menu 2 Turn the operating knob until the Beep off menu item appears 3 Press the operating knob in order to sele...

Page 72: ...the text for the item designation here The text appears on printouts and in the Excel table of the job memory OrderNo You can enter the text for the order number here The text appears on printouts and...

Page 73: ...the order number 1 Open the Order data menu 2 Turn the operating knob until the OrderNo menu item appears 3 Press the operating knob in order to select the menu item 4 Enter the item number See Secti...

Page 74: ...ng menu is closed and stops when the measurement menu is closed You can retrieve the following information in this menu Statistics Parts per hour Parts per minute Time per part Time for ten parts Time...

Page 75: ...standard display direction auto Select this menu item in order to have the display direction depended automatically FS Autoconfig When you start an autoconfiguration the ForceMaster 9110 takes the fo...

Page 76: ...er 9110 two standard values This is useful when settings have been made in the various sub menus that are inappropriate After the standard settings have been restored the ForceMaster 9110 is again in...

Page 77: ...the operating knob until the RS232 USB menu item appears 3 Press the operating knob in order to select the menu item 4 Turn the operating knob until the USB menu item appears 5 Press the operating kno...

Page 78: ...the operating knob until the Display format menu item appears 3 Press the operating knob in order to select the menu item 4 Turn the operating knob until the Force menu item appears 5 Press the opera...

Page 79: ...t which the entire transit path of the press is continuously displayed 5 Press the operating knob in order to conclude the procedure 6 Execute the Train the UTK menu item Setting to standard settings...

Page 80: ...order to set it Setting the date 1 Open the Date time menu 2 Press the operating knob in order to select the Date menu item 3 Turn the operating knob in order to set the day 4 Press the operating knob...

Page 81: ...ate Version time 1 Select the Status menu 2 Turn the operating knob until the information you want appears 6 13 Languages menu Select this menu item in order to change the language settings Language G...

Page 82: ...on as a red square at its end The red bars symbolize the gateways Abbreviations WS displacement start TR trigger MS measurement start ME measurement end KSU force threshold below KSO force threshold a...

Page 83: ...in automatic presses the Alarm force 1 can be used for collision monitoring See Section 3 16 Kraft Alarme Abbreviations WS displacement start TR trigger MS measurement start ME measurement end KSU for...

Page 84: ...sed in cannot be fed cleanly into the lower part there are sharp edges or burrs on both parts play in the pressing tool makes an exact pressing position difficult The thread in force has two monitorin...

Page 85: ...SU must be exceeded since otherwise the pressing force is too small and the parts could come apart again The force threshold above KSO must not be exceeded as otherwise the workpiece will be damaged F...

Page 86: ...hy we call this force the blocking force There are reasons for monitoring this blocking region These reasons will be considered more closely below The blocking force occurs when 1 the part being press...

Page 87: ...Abbreviations WS displacement start TR trigger MS measurement start ME measurement end KSU force threshold below KSO force threshold above BS block start BE block end BSU block threshold below BSO bl...

Page 88: ...ion must at least have required Maximum peening displacement is the displacement that must not be exceeded since otherwise manufacturing tolerances will not be observed Abbreviations WS displacement s...

Page 89: ...ousing type Aluminum profile housing Protection class IP20 Connections coded special connector Sampling interval 10 kHz Number of I O 8 input 8 outputs Dimensions W x H x D 150 x 95 x 260 mm Weight ap...

Page 90: ...required for your production operation is about 200 N which will be done on a press that can deliver 5 kN and you buy a load cell capable of up to 5 kN it will not supply a useful measurement signal a...

Page 91: ...this example you would only be able to resolve 160 steps within the active measuring window For some applications this is inadequate A 10 mm sensor would be more suitable for the example above The res...

Page 92: ...ors on manual presses 8713 Displacement sensor 9900 K349 USB cable to PC 9900 K333 RS232 cable to PC 99221 591A 0090030 Connecting cable for potentiometric displacement sensors with plug in connection...

Page 93: ...potentiometric displacement sensors with plug in connection e g 8712 Type 99221 591A 0090030 RS232 cable to PC Type 9900 K333 USB cable to PC Type 9900 K349 MasterCard for full configuration access T...

Page 94: ...ment sensor 39 41 42 74 89 90 Displacement start 83 Down counter 27 31 49 50 60 E Error acknowledgement 37 39 46 68 69 Error message 27 34 39 45 52 Error signals 68 F Force alarms 34 Force channel 88...

Page 95: ...e tip 41 Profile 21 89 Protection class 10 88 R Readjustment 42 RS232 15 74 76 88 91 92 S Scope of supply 11 Sensing pin 74 75 Standard settings 75 Statistics 73 Status 80 Step chain 28 32 35 57 61 St...

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Burster ForceMaster 9110, Operating Manual

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