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Mecal CDA10, Use And Maintenance Manual

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Mecal CDA10 Use And Maintenance Manual Download Page 9

 

 

CRIMP DATA ANALYZER

 

CDA10 

 

REV.01 

 

 

7 

8.3 SAFETY CONTROL PLAN ........................................................................................................................... 107 

8.3.1 Functional checks and tests on safety devices ................................................................................ 107 

8.4 MACHINE STOP PROCEDURE .................................................................................................................. 108 
8.5 MAINTENANCE SHEETS ........................................................................................................................... 109 
8.6 SPARE PARTS ........................................................................................................................................... 111 

8.6.1 Mechanical spare parts .................................................................................................................... 111 
8.6.2 Electrical spare parts ........................................................................................................................ 111 

9. ATTACHED DOCUMENTATION

 ..................................................................................................................... 

115 

9.1 LAYOUT .................................................................................................................................................... 116 

 

 

Summary of Contents for CDA10

Page 1: ...TRASLATION OF ORIGINAL INSTRUCTIONS CRIMP DATA ANALYZER CDA10 USE AND MAINTENANCE MANUAL Model CDA10 Serial number Revision 01 Customer Year of manufacturer 2019...

Page 2: ......

Page 3: ......

Page 4: ...to modify the characteristics of the product described in this manual without notice In case of doubts or difficulties in understanding or interpreting this manual the original official version indica...

Page 5: ...transport and unloading at the user facility CHAPTER 5 INSTALLATION This chapter contains instructions for correctly carrying out installation at the user facility connections to the facility s power...

Page 6: ...AL INFORMATION 21 2 1 1 Machine certification 22 2 1 2 Intended and improper uses 23 2 2 ENVIRONMENTAL OPERATING CONDITIONS 24 2 2 1 Fire protection installation 24 2 2 2 Explosive atmosphere 24 2 2 3...

Page 7: ...the equipment 50 5 1 4 Positioning and assembling the force cell sensor on TT and P107 presses 51 5 1 5 Positioning and assembling the force cell sensor on P040 and P080 presses 52 5 1 6 Positioning a...

Page 8: ...cting power 80 6 5 3 Operating mode 80 6 5 4 Switching off the machine 80 6 6 USE 81 6 6 1 Learning 81 6 6 2 Production 83 6 6 3 How crimp force curve mismatch is calculated 84 6 6 4 Crimp fail 86 6 6...

Page 9: ...PLAN 107 8 3 1 Functional checks and tests on safety devices 107 8 4 MACHINE STOP PROCEDURE 108 8 5 MAINTENANCE SHEETS 109 8 6 SPARE PARTS 111 8 6 1 Mechanical spare parts 111 8 6 2 Electrical spare...

Page 10: ...CRIMP DATA ANALYZER CDA10 REV 01 8 GENERAL INFORMATION 1 SAFETY 2 GENERAL DESCRIPTION 3 PACKAGING AND TRANSPORT 4 INSTALLATION 5 USE 6 DISMANTLING 7 MAINTENANCE 8 ATTACHMENTS 9...

Page 11: ...CRIMP DATA ANALYZER CDA10 REV 01 9...

Page 12: ...machine after final installation 1 2 SUPPORT For technical support contact MECAL S r l Registered and production office Strada per Felizzano 18 15043 Fubine AL Italy Tel 39 0 131 792792 Fax 0 131 7927...

Page 13: ...sisting of communication links for example text words signs signals symbols diagrams used separately or in combination to convey information to the user Intended use the use of machinery in accordance...

Page 14: ...and the severity of that harm Safe operating procedure a work method that reduces risks Safety measure means that eliminates or reduces a hazard Safety protections guard or protective device used as a...

Page 15: ...e machine and or equipment Pay attention to the text blocks indicated by this symbol WARNING NOTE Indicates a warning or a note of key features or of useful information Pay attention to the text block...

Page 16: ...always indicating the data shown on the identification plate of the machine in question Any requests for support at the Customer s site or for clarification regarding the technical aspects of this doc...

Page 17: ...ling 1 7 MANUFACTURER S RESPONSIBILITIES The Manufacturer declines all responsibility deriving from incorrect or improper use of the machine in question and from any damage caused by the use of non pr...

Page 18: ...ad this manual carefully Be familiar with which protections and emergency stop devices are present on the machine where they are located and how they work Removing or even partially removing the prote...

Page 19: ...hine downtime will be recognised The warranty does not cover damages due to use that does not comply with the contents of this Use and Maintenance Manual which is an integral part of the machine inclu...

Page 20: ...CRIMP DATA ANALYZER CDA10 REV 01 18...

Page 21: ...CRIMP DATA ANALYZER CDA10 REV 01 19 GENERAL INFORMATION 1 SAFETY 2 GENERAL DESCRIPTION 3 PACKAGING AND TRANSPORT 4 INSTALLATION 5 USE 6 DISMANTLING 7 MAINTENANCE 8 ATTACHMENTS 9...

Page 22: ...CRIMP DATA ANALYZER CDA10 REV 01 20...

Page 23: ...operation of all machine controls and their characteristics Tampering with or unauthorised replacement of one or more machine components and the use of accessories or spare parts other than those rec...

Page 24: ...1 MACHINE CERTIFICATION The machine is supplied with an EC Declaration of Conformity with the essential safety requirements in accordance with Machinery Directive 2006 42 EC Annex II A and Electromagn...

Page 25: ...responsibility for any damage caused to property and or persons and deems all forms and types of machine warranty to be forfeited The Manufacturer declines all responsibility in the event of tamperin...

Page 26: ...The machine must be positioned and adjusted to meet the physical and cognitive ergonomics criteria considering Easy human machine interfacing Preventing a prolonged concentration and rhythm conditione...

Page 27: ...of components complying with the Electromagnetic Compatibility Directive suitable connections and the installation of filters where necessary The equipment is therefore compliant with the Electromagn...

Page 28: ...See the machine use and maintenance manual to outline the danger zones of the press 2 5PERSONAL PROTECTIVE EQUIPMENT PPE Persons working on the machine must use personal protective equipment such as t...

Page 29: ...ine all the solutions necessary have been adopted to eliminate the risks and limit the dangers for exposed persons NOTE Periodically check the functionality of all safety devices Do not remove the pro...

Page 30: ...isible position on the machine Maintenance service must immediately replace any plates which have become illegible due to wear CAUTION Removing the monitoring plates from the machine is strictly prohi...

Page 31: ...CRIMP DATA ANALYZER CDA10 REV 01 29...

Page 32: ...CRIMP DATA ANALYZER CDA10 REV 01 30 GENERAL INFORMATION 1 SAFETY 2 GENERAL DESCRIPTION 3 PACKAGING AND TRANSPORT 4 INSTALLATION 5 USE 6 DISMANTLING 7 MAINTENANCE 8 ATTACHMENTS 9...

Page 33: ...CRIMP DATA ANALYZER CDA10 REV 01 31...

Page 34: ...y crimping The profile is compared with a previously learned one and in the event of defective crimping the unit emits a signal to the press that disables the operating mode Operating specifications R...

Page 35: ...CRIMP DATA ANALYZER CDA10 REV 01 33 Installation on TT and P107 presses Installation on P040 and P080 presses...

Page 36: ...CRIMP DATA ANALYZER CDA10 REV 01 34...

Page 37: ...lity 0 1 Sensor type Piezo ceramic Power supply from the press 9 24 Vdc Evaluation time 20 ms Communication protocol TCPIP HTTP UDP Dimensioni unit di controllo 85 x 103 x 35 mm Protection degree IP40...

Page 38: ...ller inclination can be regulated using the knob 3 3 2 CONTROL UNIT Equipped with a display to show the force curve of the crimping and four front buttons for choosing the settings and for performing...

Page 39: ...sor C and the spacer plate B are placed between the support A screwed to the press slide and the T connector E The sensor cable D is fixed with clips to the slide and to the press frame On model P040...

Page 40: ...detect machine activity and cannot report a malfunction To overcome this problem the control unit checks the signal from the encoder trigger at start up and periodically thereafter If the encoder sta...

Page 41: ...CRIMP DATA ANALYZER CDA10 REV 01 39...

Page 42: ...CRIMP DATA ANALYZER CDA10 REV 01 40 GENERAL INFORMATION 1 SAFETY 2 GENERAL DESCRIPTION 3 PACKAGING AND TRANSPORT 4 INSTALLATION 5 USE 6 DISMANTLING 7 MAINTENANCE 8 ATTACHMENTS 9...

Page 43: ...CRIMP DATA ANALYZER CDA10 REV 01 41...

Page 44: ...elements it is essential that they remain in closed containers until they are finally stored All external parts subject to oxidation machined surfaces unpainted parts etc are protected by a layer of p...

Page 45: ...ith tie rods on the loading surface of the articulated vehicle Carefully follow the instructions printed on the outside of the packaging to lift the crates Packaging can be recovered for possible re u...

Page 46: ...full compliance with them CAUTION Use a suitable lifting device adequate for the weight and the encumbrance of the load to be handled CAUTION Always ensure correct balancing of the load If it is unbal...

Page 47: ...CRIMP DATA ANALYZER CDA10 REV 01 45 4 3 1 WEIGHT OF PACKAGES Description Weight Complete equipment Adjustable support Controller Force cell sensor Encoder...

Page 48: ...CRIMP DATA ANALYZER CDA10 REV 01 46...

Page 49: ...CRIMP DATA ANALYZER CDA10 REV 01 47 GENERAL INFORMATION 1 SAFETY 2 GENERAL DESCRIPTION 3 PACKAGING AND TRANSPORT 4 INSTALLATION 5 USE 6 DISMANTLING 7 MAINTENANCE 8 ATTACHMENTS 9...

Page 50: ...CRIMP DATA ANALYZER CDA10 REV 01 48...

Page 51: ...formed by authorised personnel Unauthorised personnel must remain outside the installation area HAZARD Make sure there is nothing around during installation of the various parts that make up the machi...

Page 52: ...sit routes Escape routes Flooring capable of supporting the weight of the machine A general power supply including the earthing conductor according to the characteristics and tolerances required 5 1 3...

Page 53: ...cell on press models TT and P107 Fit the T connector support A with the two hex socket head cap screws N on the press slide Insert the load cell sensor C interposing the plate B and locking it with t...

Page 54: ...de and the shank connection Q Insert the hex socket head cap screw P and tighten it with a torque wrench setting a tightening torque of 40 Nm Position the collar R of the shank connector Q and secure...

Page 55: ...e of the press and secure them Install the encoder X on the encoder support plate W using three cylindrical head screws with Phillips head Position the hub U on the encoder shaft X leaving it free Tak...

Page 56: ...n Connect the brown cable to the pos 4 input 18V on the terminal board combined with the cable present Connect the white cable to the pos 5 input on the terminal board combined with the cable present...

Page 57: ...ned with the cable present Connect the white cable to the pos 5 input on the terminal board combined with the cable present Connect the grey cable to the pos 10 input on the terminal board combined wi...

Page 58: ...the compartment for housing the electrical components of the machine Intercept the cables from the load cell white and brown Connect the white cable to the pos 9 input on the terminal board located o...

Page 59: ...h 5 2 3 CONNECTING TO THE ELECTRICAL MAINS ON P080 P120 PRESSES The operations to be carried out to connect the load cell electrically are Check that the switch located on the press or in the electric...

Page 60: ...e press or in the electrical cabinet panel is in the OFF O position Disconnect the press from the electrical mains Disassemble cell TT1000 to be replaced disconnecting it from all connectors The load...

Page 61: ...ve some operations managed by the relays present on the electronic circuit Follow the connection and installation instructions present in the manual of the equipment to be connected to the CDA10 If th...

Page 62: ...s have been properly anchored Verify that the handling parts are properly lubricated if they need to be CAUTION Before making any movement make sure that there are no faults in order to avoid damage t...

Page 63: ...at all the cables inside the electronic boards are correctly connected see the relative electrical diagrams 2 Check that the connector interfacing with the machine is correctly connected to the sensin...

Page 64: ...NG CODES FOLLOWING INSTALLATION Following the removal of machine packaging and its installation remove the packaging from the area surrounding the machine and dispose of it in accordance with the regu...

Page 65: ...CRIMP DATA ANALYZER CDA10 REV 01 63...

Page 66: ...CRIMP DATA ANALYZER CDA10 REV 01 64...

Page 67: ...CRIMP DATA ANALYZER CDA10 REV 01 65...

Page 68: ...CRIMP DATA ANALYZER CDA10 REV 01 66 GENERAL INFORMATION 1 SAFETY 2 GENERAL DESCRIPTION 3 PACKAGING AND TRANSPORT 4 INSTALLATION 5 USE 6 DISMANTLING 7 MAINTENANCE 8 ATTACHMENTS 9...

Page 69: ...CRIMP DATA ANALYZER CDA10 REV 01 67...

Page 70: ...conjunction with the press machine The sensing unit contains the circuit that detects and analyses the crimping force and processes its profile The unit is connected directly to the press control unit...

Page 71: ...e of the crimping and four front buttons for choosing the settings and performing configuration The unit disables the press if it detects failed crimping Load cell sensor The sensor is chosen based on...

Page 72: ...a button on the unit The same signal is emitted when the press is in the stand by position P M S and the encoder is in position 0 To avoid this disturbance it must be adjusted a few degrees Perform t...

Page 73: ...aragraph 5 1 6 Activate the press three times and observe the results obtained at the end of each cycle Values must be stable 5 otherwise repeat the sequence making sure that all screws are correctly...

Page 74: ...rther information If the network has a DHCP server the controller will try to get an IP address from the server unless it is disabled on the Network Settings page otherwise it will choose a default IP...

Page 75: ...as the PC and or server Also check if your PC or server functions as a DHCP server To set the DHCP IP address and Subnet Mask go to the network menu Menu Setup Installation Network Settings After sett...

Page 76: ...scribed in paragraph 6 4 3 In addition it is possible to change the Host name and set a password for the control unit Admin Password The password allows you to protect the configuration pages from una...

Page 77: ...system information menu Menu Information System Information Software installation is performed via network connection without needing to directly access the control unit uploading the new software fi...

Page 78: ...smit the file and restart the device to install the new software During this time the backlight on the controller screen flashes When the operation is complete the controller will run the new software...

Page 79: ...this procedure 1 Click on CFA Settings on the sidebar of the main web page to enter the CFA Settings menu and click on the Sensor Calibration link 2 Enter the data in the table and send it to the con...

Page 80: ...edit the calibration notes To save changes made to the data on this page press the Submit button 6 4 7 CRIMP FORCE DETECTION HISTORY The Force History Table page shows the count of the forces detected...

Page 81: ...requests and or to establish a service program dedicated to the machine The counters can be reset or adjusted but an authorisation code must be provided Furthermore the data can be displayed graphica...

Page 82: ...tware update are disabled by default Follow these steps to set the password 1 Click on Network on the sidebar of the main web page to enter the CFA Settings menu and click on the Operating Password li...

Page 83: ...sure that the switch is in the ON position I Verify that the press ready status light is on Make sure that the load cell is correctly configured with the settings for use with equipment 6 5 2 CONNECT...

Page 84: ...ping and pull out height measurements The learning phase is carried out once the quality of crimping has been ascertained Enter the menu to start the learning procedure 1 Menu Start Learning and confi...

Page 85: ...CRIMP DATA ANALYZER CDA10 REV 01 83 3 Sequence of learning steps three crimpings See paragraph 6 6 5 to set the parameters for evaluating the force curves...

Page 86: ...force measured and result OK NO 51 100 PASS Non corresponding result 51 and tolerance limit 100 Press the right More button to display the additional information Count 5 Total performed crimping coun...

Page 87: ...the blue curve could be typically associated with a crimping error on insulation The figure below shows the area that is non corresponding which is given by the difference between the two curves The c...

Page 88: ...is always positive that has no unit of measure and the multiplication of the area by thousand is used to resize the value obtained to make it easily manageable as an integer A result that coincides wi...

Page 89: ...87 6 6 4 CRIMP FAIL The main screen on the control unit display shows the crimping error 1 Press any button to return to the production screen 2 Press the right More button to display additional infor...

Page 90: ...lue is 100 the default value is 77 for TCM software Noise Floor This parameter lets the operator set a threshold relative to the reference curve peak Any position of the curve below the set threshold...

Page 91: ...erage value of the adjacent group of original sample points This suppresses the high frequency components of the signal As the number of averaged samples increases the signal becomes more uniform The...

Page 92: ...rispetto alla curva di forza di riferimento Verificare la coerenza del processo di aggraffatura e risolvere le eventuali cause di scarsa ripetibilit del processo Aumentare la tolleranza della corrispo...

Page 93: ...G PROCEDURE There are no procedures required for unloading the equipment Any unloading procedures must be carried out according to the machine manual CAUTION Before making any movement be sure to swit...

Page 94: ...trical connections between the load cell and the equipment Check the signal connections between the load cell and the equipment The equipment does not stop the machine in case of Fail Cables disconnec...

Page 95: ...CRIMP DATA ANALYZER CDA10 REV 01 93...

Page 96: ...CRIMP DATA ANALYZER CDA10 REV 01 94 GENERAL INFORMATION 1 SAFETY 2 GENERAL DESCRIPTION 3 PACKAGING AND TRANSPORT 4 INSTALLATION 5 USE 6 DISMANTLING 7 MAINTENANCE 8 ATTACHMENTS 9...

Page 97: ...agraph 5 Remove the moving parts and as much as possible separate the various components by type of materials plastic metal etc to be disposed of through separate collection Remove and move the machin...

Page 98: ...owever the press machine produced used waste material for example lubricants Some specific regulations for environmental protection apply for the disposal of some of these materials See the machine ma...

Page 99: ...CRIMP DATA ANALYZER CDA10 REV 01 97...

Page 100: ...CRIMP DATA ANALYZER CDA10 REV 01 98 GENERAL INFORMATION 1 SAFETY 2 GENERAL DESCRIPTION 3 PACKAGING AND TRANSPORT 4 INSTALLATION 5 USE 6 DISMANTLING 7 MAINTENANCE 8 ATTACHMENTS 9...

Page 101: ...CRIMP DATA ANALYZER CDA10 REV 01 99...

Page 102: ...s contained in this paragraph must always be strictly observed during machine operation and maintenance in order to avoid harm to personnel and equipment These precautions will be referred to and furt...

Page 103: ...ake sure that the tools to be used are in perfect condition and have insulated handles where required Make sure that the insulation of the cables and conductors on test equipment does not show the sli...

Page 104: ...lously followed throughout its entire life Strictly comply with the established maintenance time intervals and the frequency of interventions according to specific needs in relation to the machine pro...

Page 105: ...he lubricants used when filling for the first time Upon completion of the traditional maintenance activities shown on the sheets technical maintenance personnel must also perform instrumental predicti...

Page 106: ...regarding work on fully automatic manufacturing systems Be willing to adapt to technological changes on the machines Note irregularities in the production process and take the necessary measures if n...

Page 107: ...e state of wear of protective devices Check of the state of wear of cables and flexible hoses Checks for the absence of oil leaks visible around the hydraulic systems where present Checks for the abse...

Page 108: ...ions Ability to work independently according to pre defined lubrication plans Knowledge of the correct methods of eliminating used lubricants in the context of environmental protection Required qualif...

Page 109: ...maintenance overhaul and if necessary repair of electrical and electronic units in particular Analysis of microprocessor equipment failure Analysis of electronic circuit failure Required technical kno...

Page 110: ...he various openings of the movable guards Check their correct fixing ASSEMBLY FASTENERS Check that nuts and bolts have not become deteriorated In particular check the adjustable handles that support t...

Page 111: ...ate and padlock the power sources of the machine if maintenance operations require it In other cases make no changes Check for the presence of residual energy and discharge it before operating on the...

Page 112: ...e you need to ensure regular and effective maintenance and constant control of indicator instrument parameters Maintenance troubleshooting and repair operations are only allowed to be performed by aut...

Page 113: ...CRIMP DATA ANALYZER CDA10 REV 01 111 MAINTENANCE LOG DATE OPERATOR DESCRIPTION OF INTERVENTION...

Page 114: ...ARE PARTS There are not mechanical parts subject to wear and or recommended 8 6 2 ELECTRICAL SPARE PARTS There are not electrical parts subject to wear and or recommended CAUTION Use original spare pa...

Page 115: ...CRIMP DATA ANALYZER CDA10 REV 01 113...

Page 116: ...CRIMP DATA ANALYZER CDA10 REV 01 114 GENERAL INFORMATION 1 SAFETY 2 GENERAL DESCRIPTION 3 PACKAGING AND TRANSPORT 4 INSTALLATION 5 USE 6 DISMANTLING 7 MAINTENANCE 8 ATTACHMENTS 9...

Page 117: ...CRIMP DATA ANALYZER CDA10 REV 01 115...

Page 118: ...ALYZER CDA10 REV 01 116 9 ATTACHED DOCUMENTATION The following documents will be inserted at the end of this manual N ALLEGATO DESCRIZIONE 9 1 Machine layout 9 2 Exploded diagram of the machine 9 3 Wi...

Page 119: ...CRIMP DATA ANALYZER CDA10 REV 01 117 9 1 MACHINE LAYOUT...

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