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Deprag AST40-1, Operating Instruction Booklet

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Deprag AST40-1 Operating Instruction Booklet Download Page 2

 

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Table of contents 

1

 

DEFINITION OF SIGNAL WORDS AND SYMBOLS............................................................... 10

 

2

 

SAFETY INSTRUCTIONS ........................................................................................................ 11

 

3

 

INTENDED USE ....................................................................................................................... 11

 

4

 

SCOPE OF DELIVERY............................................................................................................. 12

 

5

 

BRIEF DESCRIPTION.............................................................................................................. 12

 

6

 

HARDWARE DESCRIPTION ................................................................................................... 13

 

6.1

 

AST40 Views ......................................................................................................................... 13

 

6.1.1

 

Front view........................................................................................................................ 13

 

6.1.2

 

Connection side .............................................................................................................. 13

 

6.2

 

Interface description............................................................................................................... 14

 

6.2.1

 

MINIMAT–EC-Servo Screwdriver ................................................................................... 14

 

6.2.2

 

Power Supply .................................................................................................................. 14

 

6.2.3

 

Ethernet........................................................................................................................... 14

 

6.2.4

 

USB................................................................................................................................. 14

 

6.2.5

 

Emergency Stop.............................................................................................................. 14

 

6.2.6

 

Printer (optional).............................................................................................................. 14

 

6.2.7

 

I/O interfaces................................................................................................................... 15

 

6.2.7.1

 

Voltage supply for I/O interfaces .................................................................................. 15

 

6.2.7.2

 

Interface SPS 1 ............................................................................................................ 15

 

6.2.7.3

 

Interface SPS 2 ............................................................................................................ 16

 

6.2.7.4

 

Interface 3 .................................................................................................................... 16

 

6.2.8

 

Fieldbus interface (optional)............................................................................................ 17

 

6.2.8.1

 

Profibus ........................................................................................................................ 17

 

6.2.8.2

 

Profinet......................................................................................................................... 17

 

6.2.8.3

 

EtherNet/IP................................................................................................................... 17

 

6.2.8.4

 

EtherCAT ..................................................................................................................... 17

 

7

 

START-UP ................................................................................................................................ 18

 

7.1

 

Dimension sheet .................................................................................................................... 18

 

7.2

 

Assembly ............................................................................................................................... 19

 

7.3

 

Method of operation of the sequence controller AST40......................................................... 21

 

7.4

 

Instructions on programming the sequence controller ........................................................... 21

 

7.5

 

Connection to a higher level controller................................................................................... 21

 

7.6

 

Connection on a master controller via the Fieldbus (optional) ............................................... 22

 

7.6.1

 

Profibus DP / Profinet...................................................................................................... 22

 

7.6.1.1

 

General Information ..................................................................................................... 22

 

7.6.1.2

 

Hardware configuration ................................................................................................ 22

 

7.6.1.3

 

Software ....................................................................................................................... 23

 

7.6.2

 

EtherNet/IP...................................................................................................................... 35

 

7.6.2.1

 

General Information ..................................................................................................... 35

 

7.6.2.2

 

Bus configuration ......................................................................................................... 35

 

7.6.2.3

 

Software - Import.......................................................................................................... 39

 

7.6.2.4

 

Software - description of data types............................................................................. 49

 

7.6.2.5

 

Ethercat........................................................................................................................ 56

 

8

 

USERS...................................................................................................................................... 57

 

9

 

OPERATION USING THE INTEGRATED TOUCH DISPLAY ................................................. 58

 

9.1

 

Control elements.................................................................................................................... 58

 

9.1.1

 

Buttons ............................................................................................................................ 58

 

9.1.2

 

Selecting between two options........................................................................................ 58

 

9.1.3

 

Selecting between several options.................................................................................. 59

 

9.1.4

 

Text and numerical input................................................................................................. 59

 

9.2

 

Description of the menu structure .......................................................................................... 60

 

9.2.1

 

Overview ......................................................................................................................... 60

 

Summary of Contents for AST40-1

Page 1: ...ALL DOCUMENTATIONS Before beginning work this operating instruction booklet and the enclosed safety instructions no 016000 pink colored booklet have to be read through carefully Always follow the inst...

Page 2: ...4 EtherCAT 17 7 START UP 18 7 1 Dimension sheet 18 7 2 Assembly 19 7 3 Method of operation of the sequence controller AST40 21 7 4 Instructions on programming the sequence controller 21 7 5 Connection...

Page 3: ...eparing to use the web interface 86 10 2 1 1 Setting up the AST40 sequence controller 86 10 2 1 2 Setting the browsers operating systems 86 10 3 Description of the menus 87 10 3 1 Start 87 10 3 2 The...

Page 4: ...depending on friction 122 12 2 Commands 125 12 2 1 Waiting for input 125 12 2 2 Setting the output 125 12 2 3 Resetting the output 125 12 2 4 Display values 125 12 2 5 Save values 125 12 2 6 Statistic...

Page 5: ...Pen 143 17 8 Optional software packages 143 17 8 1 Friction value software package 143 17 8 2 DataLogger 144 17 8 3 GRAPH10 curve overlapping 145 17 8 4 TC30 PC Statistics 146 18 GLOSSARY 147 19 DECO...

Page 6: ...Import AST40_Control L5X Change Final Name and Description 46 Figure 25 Import AST40_Control L5X Menu tree 46 Figure 26 Import AST40_Control L5X Description of the module 47 Figure 27 Import AST40_Co...

Page 7: ...System setup 90 Figure 82 System setup 91 Figure 83 System setup Fieldbus example without fieldbus 92 Figure 84 System setup Fieldbus EtherCAT example 92 Figure 85 System setup Fieldbus EtherNet IP e...

Page 8: ...8 Figure 114 Screw assemblies depending on friction 122 Figure 115 DataLogger 144 Figure 116 GRAPH10E 145 Figure 117 TC30 PC Statistics program 146...

Page 9: ...ice Page 2 78 Table 25 Diagnosis I O Port Outputs Page 3 79 Table 26 Diagnosis I O Port I O interface Page 4 79 Table 27 Fieldbus Inputs Diagnosis Page 2 81 Table 28 Diagnosis Fieldbus Program Selecti...

Page 10: ...er which can cause serious injuries or even death if not avoided CAUTION Indicates a danger or unsafe procedure which can cause injuries to a per son or material damages if not avoided NOTICE Indicate...

Page 11: ...Intended use The sequence controller AST40 is designed exclusively for fittings in industrial use And must only be operated with DEPRAG MINIMAT EC Servo screwdrivers of the series 311E The system is...

Page 12: ...ons as well as programming controller and documentation interfaces provide maximum flexibility during integration into existing process environments The diversified communication possibilities involve...

Page 13: ...interface SPS2 GX4 I O interface 3 GX5 Printer optional GX6 USB GX7 Ethernet GX8 Power Supply GX9 Emergency Stop GX10 Fieldbus optional GS1 Main switch LEDs LED 1 System OK MC PU LED 2 Ready LED 3 OK...

Page 14: ...Plug connector Binder plug connector 4 pin round and straight Pin Designation 1 STO1 2 STO2 3 GND 4 24V Table 2 Configuration Interface Emergency stop IMPORTANT The integrated I O module of the AST40...

Page 15: ...selection 4 Input 6 Program selection 2 Input 25 Program selection 5 Input 7 Program selection 3 Input 26 Program selection 6 Input 8 external stop digital Input 27 Start Input 9 external stop analog...

Page 16: ...quence 12 Output 13 n c Table 6 Configuration I O interface SPS2 CAUTION Maximum load per output of 50 mA The total current for all the interfaces must not exceed 600 mA 6 2 7 4 Interface 3 Designatio...

Page 17: ...GND Mass Ground 6 PB 5V Voltage supply 5V 7 8 RX TX N Send Receive data Data line A 9 Table 8 Configuration Interface Profibus 6 2 8 2 Profinet Designation GX10 Plug connector 2x Female connector RJ45...

Page 18: ...18 7 Start up 7 1 Dimension sheet Figure 3 Dimension sheet...

Page 19: ...ical supply compare the rating of the AST40 s sequence control system with the building s internal power supply also see 20 Technical Data Plug in the EC Servo screwdriver using the motor cable interf...

Page 20: ...vice More details on the interfaces can be found in Section 6 1 2 Connection side and 6 2 Interface description CAUTION Observe the minimum bending radii for motor cable Non observance can lead to dam...

Page 21: ...programs are to be changed or new ones are to be created then this must be done via the web user interface see 10 3 4 Menu Area Screwdriving sequence Standard programs like Torque Screwdriving Rotati...

Page 22: ...face see 10 3 6 3 Fieldbus 7 6 1 1 General Information All the required program modules to connect the Profibus and Profinet to a Siemens S7 control unit can be found in the software package DEPRAG_AS...

Page 23: ...le must be loaded for every AST40 sequence controller with each new instance data block respectively DB20 IDB_AST40DP Instance data block for FB12 e g Profibus DB21 AST40_Interface Data block for the...

Page 24: ...g 256 O_Addr2 INT Output address from the hardware configuration e g 320 O_Addr3 INT Output address from the hardware configuration e g 384 O_Addr4 INT Output address from the hardware configuration e...

Page 25: ...r the screwdriver program This input can be scanned in the screwdriving program of the AST40 sequence control to stop or continue the screwdriving program ProgIn5 BOOL Input 5 for the screwdriver prog...

Page 26: ...set then the AST40 sequence controller withdraws the signal Data available Program no INT Screwdriver program Enter the required screwdriving program for the AST40 sequence controller here Possible i...

Page 27: ...of the AST40 sequence controller ProgOut6 BOOL Output 6 from the screwdriver program This output can be set or reset and queries in the SPS in the screwdriving program of the AST40 sequence controlle...

Page 28: ...are interface This signal indicates the status of the Part release signal at the hardware interface see 6 2 7 I O interfaces HW_ReleaseStart BOOL Clearance to start hardware interface This signal indi...

Page 29: ...tered in the hardware configuration Input module 2 must be configured with 64 bytes in Incorrect start address of the input module 2 at the interface parameter I_Addr2 FF03 Error while reading the inp...

Page 30: ...n the hardware configuration Output module 3 must be configured with 64 bytes out Incorrect start address of the output module 3 at the interface parameter O_Addr3 FF14 Error while writing to the outp...

Page 31: ...re fd_Torque1 REAL Data backup torque setpoint 1 The torque value of the data backup 1 is output here fd_minAngle1 DINT Lower angle of rotation limit of the Data backup 1 The set lower limit of the an...

Page 32: ...r torque limit of the data backup 3 is output here fd_Torque3 REAL Torque value of the Data backup 3 The torque value of the data backup 3 is output here fd_minAngle3 DINT Lower angle of rotation limi...

Page 33: ...ngle of rotation setpoint of the faulty screw assembly 1 is output here fd_maxAngleNOk DINT Upper angle of rotation limit for a faulty screw assembly The set upper angle of rotation limit for a faulty...

Page 34: ...e in the range fd_Step3 fd_Torque3 fd_Angle3 When using the Save values command multiple times in the screwdriver program the previous values are shifted upwards fd_Step3 fd_Step2 fd_Step1 If a fault...

Page 35: ...es are only to be used for the control of the Logix series that can be programmed with the RSLogix 5000 The sample programs were created with the version 20 00 7 6 2 2 Bus configuration 7 6 2 2 1 Summ...

Page 36: ...te any EtherNet IP Module use the following method 1 In the I O configuration right click on Ethernet and select New Module Figure 7 Creating Ethernet IP new module When using an ENET module e g 1768...

Page 37: ...elect the module ETHERNET MODULE Generic Ethernet and confirm with Create Figure 8 Creating Ethernet IP select module 3 Enter the settings and confirm with OK Figure 9 Creating Ethernet IP confirm set...

Page 38: ...description of the of the fieldbus node Comm Format Data SINT Data format IP address IP address that is set on the AST40 fieldbus setting Input Assembly Instance 101 Input Size 228 Output Assembly Ins...

Page 39: ...IN_Signals and AST40_OUT_Signals AST40_Cntr L5X Data type Contains the data types AST40_IN_FinalValues AST40_IN_Signals and AST40_OUT_Signals Controller Tags csv Tags CSV file with controller tags AST...

Page 40: ...Import Figure 11 Import AST40 L5X Confirm Import 3 In the following dialog window user specific changes can be made to the name Final Name and the description Description it is recommended to keep the...

Page 41: ...Cntrl L5X 1 In the menu tree right click on Data Types User Defined and select Import Data Type Figure 14 Import AST40_Cntrl L5X Data Types User Defined and Import Data Type 2 Search for the file AST4...

Page 42: ...o the name Final Name and the description Description it is recommended to keep the name and the description Then confirm with OK Figure 16 Import AST40_Cntrl L5X Final Name 4 The added elements are n...

Page 43: ...under Tools Import Tags and Logic Comments Figure 18 Import Controller Tags csv Tags and Logic Comments 2 Search for the file Controller Tags csv contained in DEPRAG_AST40EIP zip and confirm with Imp...

Page 44: ...isplay the controller tags Figure 21 Import Controller Tags csv Display controller tags IMPORTANT If several AST40 controllers are operated the number of array elements has to be increased The array e...

Page 45: ...sk in the menu tree e g main program and select Import Routine Figure 22 Import AST40_Control L5X Import Routine 2 Search for the file AST40_Control L5X contained in DEPRAG_AST40EIP zip and confirm wi...

Page 46: ...nal Name and the description Description it is recommended to keep the name and the description Then confirm with OK Figure 24 Import AST40_Control L5X Change Final Name and Description 4 The added el...

Page 47: ...of the module Current path 0 GSV Used to determine the status on the EtherNet IP slave AST40 Call the AST40 Add On Instruction IMPORTANT When several AST40 controllers are operated this current path...

Page 48: ...NT 228 EtherNet IP module input data DataOut SINT 224 EtherNet IP module output data Inputs AST40_IN_Signals AST40 inputs FinalValues AST40_IN_FinalValues AST40 end value Outputs InOut AST40_OUT_Signa...

Page 49: ...is active This signal has the status high when the Emergency Stop circuit is functioning properly Sto2_active BOOL Emergency stop signal 2 is active This signal has the status high when the Emergency...

Page 50: ...ts sensor for F function hardware interface This signal indicates the status of the Parts sensor signal at the hardware interface see 6 2 7 I O interfaces MI_Change_Part BOOL Part release for F Functi...

Page 51: ...r program Hardware interface This signal indicates the status of input 4 at the hardware interface see 6 2 7 I O interfaces Analogue_Sensor INT Condition of the analog sensor This signal is currently...

Page 52: ...up 1 The set torque upper limit of the data backup 1 is output here Torque_1 REAL Torque value of the Data backup 1 The achieved torque value of the data backup 1 is output here Angle_1_min DINT Angle...

Page 53: ...he set torque lower limit of the data backup 3 is output here Torque_3_target REAL Torque set point of the Data backup 3 The set lower torque set point of the data backup 3 is output here Torque_3_max...

Page 54: ...ation lower limit for a faulty screwdriving operation The set angle of rotation lower limit for a faulty screwdriving operation is output here AngleNOK_target DINT Angle of rotation set point for a fa...

Page 55: ...driver program of the AST40 controller in order to stop or continue the screwdriver operation program ScrPRG_3 BOOL Input 3 for the screwdriver program This input can be sensed in the screwdriver prog...

Page 56: ...ue_3 Angle_3 When using the Save values command multiple times in the screwdriver program the previous values are shifted upwards Step_3 Step_2 Step_1 If an error occurs during the screwdriver operati...

Page 57: ...Table 22 Rights of the various user types The menus opened last in the list of the open modules are stored for every user and is saved when he logs off After logging in the user immediately has acces...

Page 58: ...n be used to access and control the menu for example Switches Switches are used for example in the interface tests to switch the outputs on and off The keys for the menu as well as the open modules ar...

Page 59: ...ype of input required numbers with decimals and internal decimal places are also a possibility Text inputting is required e g for the program name Tap the text input field and a keyboard will be displ...

Page 60: ...nus leads to an interrupt of the automatic operation Diagnostic I O interface Diagnostic tool test Diagnostic fieldbus if fieldbus is available Please ensure by means of the User facility that only au...

Page 61: ...soon as a user logs in 9 2 3 Registration User registration can be reached at any time using the list of open modules on the right below the display Figure 34 User log in To log in select your User ID...

Page 62: ...ctive program is displayed on the upper line In the second line the date time and duration of the last screw assembly is displayed The status of the last screw assembly is displayed in the status area...

Page 63: ...press on the entry field with the error message or on the key The torque and angle results of the last screw assemblies are displayed in the areas Measuring System 1 Motor and Measuring System 2 depe...

Page 64: ...nter the program number or use the keys and Press the key or to switch between the statistics for the torque and the statistics for the angle Press the key to delete the statistics for the current pro...

Page 65: ...ettings of the AST40 sequence controller Figure 41 System data Press the key or to reach the next system data page 9 2 5 2 System setup The basic settings also see 11 Settings for the AST40 sequence c...

Page 66: ...change the network settings press on the individual input fields Enter the addresses using the numeric keypad Figure 43 System setup Network Press the key to get to the next settings page or to go th...

Page 67: ...ure for the torque by pressing on the required unit Adjust the main direction of rotation Select whether the reduction in the rotational speed should be active or inactive Figure 45 System setup Gener...

Page 68: ...settings on the optional fieldbus module are located on the next page of the System Setups The specific settings for the built in fieldbus module see 11 1 1 2 Fieldbus system parameters optional can...

Page 69: ...igure 50 System setup Fieldbus Profibus example Figure 51 System setup Fieldbus ProfiNet example Press the key to get to the next settings page or to go the previous settings page The alternatives of...

Page 70: ...standard values Press on to accept the settings Press on the key to exit the Settings without a save 9 2 5 3 User Administration The User Administration is only accessible to the administrator Log in...

Page 71: ...ive Figure 55 Change user data You can set the selected user to active or inactive in the screen Change user data Select active if you want to create a new user or change user data Enter a user name a...

Page 72: ...11 Settings can be performed in this menu if a user is logged in If no user is logged in only the set values are displayed Changes are not possible Figure 57 Screwdriver settings Press on to accept th...

Page 73: ...be done via the web user interface also see 10 3 4 Menu Area Screwdriving sequence The prerequisite for this is that a user is logged in If no user is logged in only the set values are displayed No m...

Page 74: ...ht beside Program The superimposed keyboard can then be used to alter the name To modify the parameters press on the number that is to be changed The superimposed keypad can then be used to set the re...

Page 75: ...nosis 9 2 7 1 Tool status You can view the status of the connected MINIMAT EC Servo Screwdriver here Figure 63 Tool status Page 1 The number of screwdriving cycles is shown on the left side The total...

Page 76: ...MINIMAT EC Servo screwdriver can be checked Figure 65 Tooltest Press the button to start the angle test Turn the drive of the MINIMAT EC Servo screwdriver The real value of the current measurement sys...

Page 77: ...here there is a signal are shown in yellow all the other switches are shown in grey Figure 66 Diagnosis I O Port Inputs Page 1 All the inputs are located on the SPS1 GX2 interface Designation Pin Desc...

Page 78: ...able 24 Diagnosis I O Port Program choice Page 2 Press the key to get to the next diagnosis page or to go the previous diagnosis page Figure 68 Diagnosis I O Port Outputs Page 3 All the outputs are lo...

Page 79: ...5 4 Input 5 in the command Wait for input Sequence 6 5 Input 6 in the command Wait for input Sequence 7 6 Input 7 in the command Wait for input Sequence 8 7 Input 8 in the command Wait for input Sequ...

Page 80: ...l All the inputs and outputs as well as the communication flags of the fieldbus interface can be examined in the Fieldbus menu also see 6 2 8 Fieldbus interface optional The fieldbus menu can be opene...

Page 81: ...2 Description of the data structure of the control signals UDT21 and for EtherNet IP in section 7 6 2 4 4 Description data structure AST40_OUT_Signals Designation AST40 Profibus Profinet EtherNet IP...

Page 82: ...e control signals UDT21 and for EtherNet IP in section 7 6 2 4 4 Description data structure AST40_OUT_Signals Designation AST40 Profibus Profinet EtherNet IP Program ProgramNo PROG_NR Table 28 Diagnos...

Page 83: ...mergency stop 2 active Sto2active Sto2_active Sequence 1 ProgOut1 OUT_ScrPrg_1 Sequence 2 ProgOut2 OUT_ScrPrg_2 Sequence 3 ProgOut3 OUT_ScrPrg_3 Sequence 4 ProgOut4 OUT_ScrPrg_4 Reload Reload Reload T...

Page 84: ...Out5 OUT_Signals uni_IO 0 Sequence 6 ProgOut6 OUT_Signals uni_IO 1 Sequence 7 ProgOut7 OUT_Signals uni_IO 2 Sequence 8 ProgOut8 OUT_Signals uni_IO 3 Sequence 9 ProgOut9 OUT_Signals uni_IO 4 Sequence 1...

Page 85: ...IMPORTANT It is urgently recommended that all available data be included in the system mapping System mapping procedure 1 Plug in an USB stick 2 Press on Generate 3 Wait until you see that the system...

Page 86: ...d the browser must be installed in such a way that a TCP IP connection between both of these can be established and the exchange of data is enabled 10 2 1 1 Setting up the AST40 sequence controller A...

Page 87: ...data The browser now establishes a connection with the AST40 sequence controller and loads the home page Figure 77 The home page If you plan to change any settings enter user name and password The st...

Page 88: ...lay and the I O interface as well as the type of fieldbus module that is installed The IP addresses and MAC addresses of the master control unit and the display are also displayed The main menu that i...

Page 89: ...Time Users Screwdriver Data Screwdriver Settings Tool Status Maintenance Log in Screwdriving Sequence Program 1 10 Program 111 120 Process Data Final Values Statistics Program 1 10 Program 111 120 Gr...

Page 90: ...C Servo Screwdriver 10 3 3 1 System data This page displays the unchangeable data as well as the network settings of the AST40 sequence controller It is identical with the home page Figure 80 System d...

Page 91: ...and Print Printed text is printed as it is entered although the variables are replaced by the corresponding values Variables always begin with the character and must end with a space character An exac...

Page 92: ...ldbus module are found on this page The specific settings for the built in fieldbus module see 11 1 1 2 Fieldbus system parameters optional can also be entered on this page Figure 83 System setup Fiel...

Page 93: ...93 Figure 85 System setup Fieldbus EtherNet IP example Figure 86 System settings Fieldbus Profibus example...

Page 94: ...set for the AST40 sequence controller here The current time for the AST40 sequence controller is displayed in the uppermost row You have the possibility of assuming the current PC time or of setting...

Page 95: ...assword in the field repeat Select the User type see 8 Users and then click on Set 10 3 3 2 5 Create Load Backup Go to page System Setup General You can save your settings in the lower part of the pag...

Page 96: ...wdriver settings The settings for the connected MINIMAT EC Servo Screwdriver also see 11 Settings can be performed in this menu if a user is logged in If no user is logged in only the set values are d...

Page 97: ...d on this page see 14 3 Calibrating the touch display Figure 93 Adjustment of the touch display 10 3 3 7 Log in You can log in again on this page if the AST40 sequence controller had to be re started...

Page 98: ...rams Making changes is possible only if the password has been entered at the time of login otherwise the information is merely displayed Figure 95 Screwdriving sequence empty program It is possible fo...

Page 99: ...a screwdriver sample or a command by clicking on it Keep the mouse button pressed and drag the screwdriver pattern or the command to the desired position in the screwdriver program Add the screwdrive...

Page 100: ...mmediately without a confirmation prompt View process a program step Select an available program step by clicking this step The parameters of this step are displayed A new value can be directly entere...

Page 101: ...wdriving samples and commands Subsequently click on Submit as in order to save the program under a new number 10 3 4 2 Create Load Backup You can save your screwdriving programs in the lower part of t...

Page 102: ...es of the latest screwdriving process Click on a file to load it onto your PC Click on Delete all Final Values if you want to delete all the screwdriving result files The final values cannot be delete...

Page 103: ...ing the data for the last screwdriving process as a file from the AST40 sequence controller also see 13 2 Curve display In principle all screw assemblies are recorded The image continues to be availab...

Page 104: ...tion booklet Quick Start instructions as a PDF file and other multi language documents If your browser has a pdf plug in then you can read the manuals directly in the browser Figure 101 Manuals 10 3 6...

Page 105: ...ntroller can be downloaded on this page Figure 103 Fieldbus 10 3 6 4 Updates New software can be loaded onto the control unit in the Updates menu also see 14 2 Updating the software Figure 104 Update...

Page 106: ...e key can either be directly copied and inserted in an email or saved by clicking the file You will receive a license file for the activation which contains the respective activation key The activatio...

Page 107: ...e added all the screwdriving programs screwdriving results Curve displays on the latest screw assemblies IMPORTANT It is strongly recommended that all available data be included in the system image Af...

Page 108: ...n If the speed reduction feature is active in the torque screwdriving stages in which there is no speed transition the speed is reduced automatically when 80 of the target torque is reached This provi...

Page 109: ...hich the AST40 sequence controller is located Gateway The IP address of the gateway for the network segment in which the AST40 sequence controller is located Station name Station name of the AST40 seq...

Page 110: ...System Settings Select System Setup to set the general parameters to standard values Select User Data to delete the user data Only the user admin remains with the standard password 0000 Select Fieldb...

Page 111: ...OTP inactive Table 40 Standard values EtherNet IP EtherCAT No settings are necessary 11 2 2 MINIMAT EC Servo Screwdriver The standard values for the MINIMAT EC Servo screwdriver can be set in the web...

Page 112: ...Shut off criteria The screwdriving process is ended once the Target torque is achieved the maximum screwdriving time monitoring time is exceeded the maximum angle of rotation is reached only for angle...

Page 113: ...e step time monitoring is started and the screwdriving process is started with RPM setting 1 Once the torque threshold for step one has been achieved Sequence step 2 is started and the speed setting i...

Page 114: ...quence Maximum time until the shut off torque is reached monitoring time shut off target torque shut off torque min max RPM 1 Threshold torque for RPM 2 step 2 RPM 2 Torque holding time Angle of rotat...

Page 115: ...value must be within the preset limits Not OK evaluation The screwdriving sequence is evaluated as Not OK faulty if the angle of rotation is outside the preset limits or the screwdriving time has bee...

Page 116: ...ia The screwdriving sequence is completed when an external Stop Signal is received the maximum angle is exceeded the maximum torque is exceeded the maximum allowable screwdriving time time supervision...

Page 117: ...screwdriving level is considered OK fault free if the switching off occurs via the angle of rotation or the torque Not OK evaluation The screwdriving level is evaluated as Not OK faulty if the torque...

Page 118: ...ed variable shut off torque value is determined based upon the friction value the maximum screwdriving time time monitoring is exceeded Analysis OK evaluation The screwdriving sequence is considered O...

Page 119: ...aximum friction torque Input of a maximum torque that must not be exceeded by individual torque values during the friction monitoring Minimum friction value Input of the minimum torque that must not b...

Page 120: ...of the torque of the friction sequence step and the differential torque value Minimum differential torque Lower limit of the differential end torque The actual torque lower limit results from the sum...

Page 121: ...lower limit Lower limit of the end angle 12 1 6 3 Screw assemblies depending on friction The screwdriving sequence friction dependent screwdriving connects the screwdriving sample friction measuremen...

Page 122: ...ment Input of an angle value that should be realized after reaching the threshold torque value prior to activating the friction value monitoring Screwdriver RPM 1 Input of the rotation speed that shou...

Page 123: ...r limit of the differential torque Torque hold time A holding time can be defined to keep tension applied to the screw joint for a preset time to allow for material elasticity End value creation Diffe...

Page 124: ...preceding screwdriving stage in the end value data set The command can be used as often as you like The end value data can be loaded by means of the web based user interface from the AST40 sequence c...

Page 125: ...8 Printing Outputs the results of the preceding screwdriving stage to the serial printer interface also see 13 4 Print output 12 2 9 Hold position Hold the screwdriver tension position Parameter Hold...

Page 126: ...bject to the same limitations as described in chapter 13 2 Curve display for the curve data The CSV file is structured as follows First line Title bar with caption of the values in files 1 7 csv only...

Page 127: ...ation of the second saved step Max Angle 2 Angle of rotation upper limit of the second saved step Angle 2 Angle of rotation of the step of the second saved step Step3 Step number of the third saved st...

Page 128: ...s the curve data however frequently contain more data sets Microsoft Excel after Version 2007 as well as OpenOffice org LibreOffice org Calc after Version 3 3 can contain 1 048 576 rows 2 Both table p...

Page 129: ...letely for all programs The statistic is deleted when the sequence controller AST40 is switched off 13 4 Print output Data can be printed out in ASCII format via the serial data port of the AST40 The...

Page 130: ...StatAngleAv Statistics Angle Mean Value Value unit 1081 StatAngleStddev Statistics Angle Standard Deviation Value unit 1 36 StatAngleStddevAbs Statistics Angle Standard Deviation Absolute Value unit 1...

Page 131: ...of the print command in the screwdriving process At the time of delivery the standard format is date_iso time PG prog ST step TQ torque AN angle errortext Issue 2013 04 24 07 13 37 PG 12 ST 3 TQ 2 15...

Page 132: ...nditions Internal dampness can build up and damage the electric circuitry when the device then is moved to normal temperature conditions Do not try to open the device in any other way than in the inst...

Page 133: ...file by clicking the Search button next to the input field After clicking the Load button the message The update is being uploaded to the controller appears Wait until the update file is transferred...

Page 134: ...ried using the following steps 1 Start calibration either directly in the display see 9 2 5 6 Maintenance or through the web based user interface see 10 3 3 6 Maintenance using the Maintenance menu sy...

Page 135: ...e 010 5V supply outside of range 011 Value outside of limits 012 Incorrect number of available measuring systems Troubleshooting not possible Table 45 System error MINIMAT EC Servo screwdriver 15 1 2...

Page 136: ...s well as the screwdriving logic is faulty 135 Initial stage of the motor controller is defective 136 Intermediate circuit voltage outside of tolerance 137 Network supply frequency or voltage outside...

Page 137: ...m error Master control unit 15 1 4 Communication Number Meaning Trouble shooting 301 No connection 302 General error 303 Checksum error 304 Module not found 305 Unknown command 306 Timeout 307 Access...

Page 138: ...433 Output System OK used as input 434 Output Ready used as input 435 Output OK used as input 436 Output NOK used as input 437 Output Status HS Reserve used as input 438 Output Emergency stop 2 active...

Page 139: ...he screwdriver operation 11 Over current Current exceeds maximum permissible value Check the screw assembly process and adjust the program if required If necessary please contact DEPRAG Service 12 Err...

Page 140: ...controller possible Check whether the IP address set for the AST40 sequence controller is correct Display does not react to touch Press a bit harder onto the touch display Ensure that the touch displa...

Page 141: ...controller via the web based user interface Designation Product Code Patch cable 831902 17 4 Fieldbus modules Only one module can be used per control unit The fieldbus module cannot be used in conjunc...

Page 142: ...7 8 1 Friction value software package The software package friction values contain the following additional screwdriving Sequences Friction value measurement Screwdriving with differential torque Scre...

Page 143: ...the end value data sets from up to 10 sequence controllers AST and to archive them The DataLogger program can be downloaded free of charge via the web interface of the sequence controller AST40 Howeve...

Page 144: ...116 GRAPH10E The GRAPH10 E program can be downloaded free of charge via the web interface of the sequence controller AST40 However the use of the curve overlapping is subject to cost Designation Part...

Page 145: ...calculation of average value standard deviation and cmk value For the graphic display several alternatives may be selected The TC30 PC Statistics program can be downloaded free of charge via the web...

Page 146: ...for the control and data exchange with sequence control resp the base station developed by the company Allen Bradley EtherCAT Ethernet based fieldbus for the control and data exchange with sequence c...

Page 147: ...cess capability index is then no longer possible Process capability examination Prior to using a processing device for the series production it is possible to check if the requirements are met with su...

Page 148: ...all data of the screwdriver is stored If the screwdriver is connected to the controller then it recognizes all data of the screwdriver No settings have to be performed manually Screwdriving program Se...

Page 149: ...ions storage and disposal see page 37 For shut down perform the following steps No Action 1 Disconnect the electric equipment of the machine device from power supply switch off main switch and pull ou...

Page 150: ...45 Dimensions cm B x H x T 23 2 x 31 5 x 20 5 Weight kg 7 5 Voltage V 100 240 Network frequency Hz 50 60 Maximum input power W 2300 Maximum load per output mA Total current max mA 50 600 Display and o...

Page 151: ...ion Name SEQUENCE CONTROLLER Machine Type _________________________________________________________ Serial Number _________________________________________________________ Year of Manufacture ________...

Page 152: ...eb site www deprag com If you need any further information then please either contact your representative or us directly at DEPRAG SCHULZ GMBH u CO During business hours our Service Hotline 49 0 700 0...

Page 153: ...92203 Amberg Germany Carl Schulz Platz 1 92224 Amberg Germany Service Hotline 49 0 0700 00 371 371 49 0 9621 371 0 Fax 49 0 9621 371 120 Internet http www deprag com e mail info deprag de Mar 14 Techn...

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