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CRIMP DATA ANALYZER

CDA10

REV.01

GENERAL DESCRIPTION

The control unit detects and analyses the force profile obtained by 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:

Range

0 – 20 kN

Temperature

0 – 70 °C

3.1

LAYOUT

ITEM

DESCRIPTION

Adjustable support

Control unit

Force cell sensor

Encoder

Содержание CDA10

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

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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

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