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Crimp Force Monitor

Doc. No: TM-638007950

Release Date: 03-21-13

UNCONTROLLED COPY

Page 1 of 21

Revision: A

Revision Date: 03-21-13

63800-7950

Crimp Force Monitor

Instruction Manual

Order No. 63800-7950

Summary of Contents for 63800-7950

Page 1: ...Crimp Force Monitor Doc No TM 638007950 Release Date 03 21 13 UNCONTROLLED COPY Page 1 of 21 Revision A Revision Date 03 21 13 63800 7950 Crimp Force Monitor Instruction Manual Order No 63800 7950 ...

Page 2: ... to alert against unsafe practices associated with events that could lead to personal injury WARNING WARNING Always wear proper eye protection when operating or servicing a press Failure to wear eye protection could result in serious eye injury from flying debris during test Never install or service this unit while connected to any electrical power source Disconnect power by unplugging the AC adap...

Page 3: ...either of the two numbers listed below and asking for the Molex Tooling Group Call Toll Free 1 800 786 6539 US 1 630 969 4550 Global This assistance is limited to the operation and set up of a customer s Molex tool Questions with regard to Molex connector products or how to identify the proper tooling and or tooling documentation should be directed to your local Molex personnel or Customer Service...

Page 4: ...e 8 2 5 Cable Connections 9 2 6 Power Supply Connection 9 Section 3 10 Operation 10 3 1 Learning a Process 10 3 2 Auto Gain Feature 10 3 3 Information Screen 10 3 4 Run Screens 11 3 4 1 Main Screen 11 3 4 2 Counter Screen 12 3 5 Operator Interaction 12 Section 4 14 Process Setup 14 4 1 Signature Analysis and Tolerances 14 4 2 Part Number Database 14 4 2 1 Loading a Part Number 15 4 2 2 Creating a ...

Page 5: ... inverting selectable SMA connector Communication USB 2 0 Mini B connector Inputs and Outputs Input 1 24VDC discrete input Output 1 1A 30VDC 1A 240VAC Output 2 1A 30VDC 1A 240VAC Dimensions Height 147mm 5 6in Width 89mm 3 5in Depth 25mm 1 0in 1 3 Description The crimp force monitor measures the force signature of a crimped terminal and compares it to a reference crimp Depending on the limits progr...

Page 6: ...y Control Module 1 Force Sensor with Ram Mount 1 SMB sensor cable 1 Mini USB cable 1 DC power supply 1 Foot switch cable 1 Press Mounting kit 1 CD for PC software 1 CD for operating manual 1 Crimp Force Monitor Manual TM 638007950 1 FoceView Software Manual TM 638007958 1 1 5 Tools The following tools are recommended for installation of the crimp force monitor 1 3mm hex wrench to install ram senso...

Page 7: ... Force Monitor MENU KEY Return to previous screen or cancel DOWN KEY Move down to next menu item or screen UP KEY Move up to next menu item or screen ENTER KEY Move to selected screen or select current item BLACK BAR PROCESS ERROR 63800 7950 PEAK CRIMP FORCE ANALYSIS REGION CRIMP SIGNATURE SUSPECT LIMIT GROSS LIMIT TARGET SENSOR CABLE INPUT 24VDC INPUT MINI USB PORT RS232 I O PORT POWER SWITCH ...

Page 8: ...rash or by dropping the sensor assembly can cause irreparable damage to the sensor 2 3 Ram Sensor Installation The ram adapter in the press must be removed and replaced with the ram sensor furnished with crimp force monitor CAUTION Always disconnect power supply before installing or removing tooling 1 Using a 3mm hex wrench remove the M6 set screw from the right side of the press ram There is a se...

Page 9: ... used if the crimp force monitor is to inhibit the foot switch during a fault One end of the cable connects to the back of the press one end connects to the foot switch plug and the last end connects to the DB9 I O receptacle on the back of the control module The mini USB cable is used to connect the crimp force monitor to a PC for data logging See TM 638007958 for installing the ForceView softwar...

Page 10: ...ive to the peak crimp force Small gauge wire crimping for example will have a higher gain to optimize the analysis In some very low crimp force applications it may not be possible to detect the crimp force signal following the press cycle If no signal is detected while in the GAIN stage press the key to initialize the Auto Gain feature 1 After crimping a wire press the key 2 The crimp force monito...

Page 11: ...ly crimp a terminal without a wire 3 4 Run Screens 3 4 1 Main Screen The Main screen provides a snapshot signature of the last machine cycle relative to the learned signature The box displayed is the analysis region of the crimp force signature The error bar on the right side of the display indicates both the and signature error variation relative to the learned signature Two levels of failure Sus...

Page 12: ...enter while viewing password may need to be entered depending on settings 3 5 Operator Interaction The crimp force monitor includes several special features to help control access and limit uncontrolled adjustment 3 5 1 Password Access Passwords can be optionally activated to control access to the tolerances and analysis regions and setup menus The crimp force monitor utilizes 2 user accounts Oper...

Page 13: ...s associated with the operation of the FAIL or SUSPECT output Several methods are available to reset the machine allowing the operator to continue production With the reset method set to Keypad the operator will be required to press a button on the keypad continue Alternatively if more control is required the INPUT option requires that the digital input to be activated before production can contin...

Page 14: ... of curve to 100 end of curve FAIL Fail tolerance for positive variation FAIL Fail tolerance for negative variation SUSPECT Suspect tolerance for positive variation inside the FAIL tolerance SUSPECT Suspect tolerance for negative variation inside the FAIL tolerance 4 2 Part Number Database The part number database allows up to 50 different parameter configurations to be stored in the crimp force m...

Page 15: ...ameters Stored in a New Part Number The CFM will save the current configuration parameters under the entered name The parameters from the Signature Capture Signature Analysis Gross Tolerances and Learn Parameters are stored in the part number database Please refer to Appendix A for more information on the parameters stored for each mode of operation 3 Enter a name for the new part number using the...

Page 16: ...e sensor with a full scale value of 5000lbs would have a trigger point set at 250lbs Pre Trig ms Amount of time that data is captured prior to the trigger point Duration ms Amount of time that data is captured after the trigger point The CFM will automatically shorten the duration time to an optimal value if applicable Filter Sensor input must remain above the start level for the defined time befo...

Page 17: ... Learn Tolerance In Learn mode the first press cycle determines the gain level and is in addition to the minimum number of cycles required to complete the learn process Max Samples Maximum number of machine cycles permissible to learn a process If the crimp force monitor does not learn a process after the maximum press cycle limit is reached then the learn process has failed and will be restarted ...

Page 18: ...t Fail output active after fail part This option must be selected if the foot switch interface cable is used For both Suspect and Fail output there are 3 output reset options available Timed the output will turn ON for the time duration selected in milliseconds Not used Keypad the output will be reset by pressing any key Default setting Input the output will be reset following a digital input is a...

Page 19: ...password of each user account can be edited by the password holder Edit Limits Access to adjust the tolerances and analysis region is controlled by the assigned password Edit Setup Access to the setup menu is controlled by the assigned password Change Password Change the password for the selected user account Language Selects the displayed language Edit Contrast Adjusts the LCD screen contrast I O...

Page 20: ...erting Filter 5 Signature Analysis Cutoff 1 15 Cutoff 2 70 Gross Tolerances FAIL 12 FAIL 12 SUSPECT 10 SUSPECT 10 Signature Learn Parameters Learn Gain 2 Learn Tol 5 0 Min Samples 5 Max Samples 16 Machine Interface Output 1 Fail NC Keypad Output 2 None Input None Appendix B Spare Parts Molex Part Number Description 638007951 Control Module For 638007950 638007952 Force Sensor Ram Mounted 638007953...

Page 21: ...period we will at our option either repair or replace defective products Please call our customer service department for a return authorization number and return the defective product to us with freight prepaid The foregoing warranty constitutes the SOLE AND EXCLUSIVE WARRANTY and we hereby disclaim all other warranties express statutory or implied applicable to the products and or software includ...

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