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AST11-2

Deprag AST11-1, AST11-2-S, AST11-1-S, AST11-2 Operating Instruction Booklet

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Operating instruction booklet
- Translation of the original instruction -
Sequence controller
AST11-1 AST11-1-S AST11-2 AST11-2-S
390041 A 390041 B 390042 A 390042 B
NOTICE ALL DOCUMENTATIONS ! Before beginning work this operating instru ction booklet and the enclosed
safety instructions (no. 01 6000, pink-colored boo klet) have to be read through
carefully. Always follow the instructions during operation. Give this operating in­struction booklet and the ap propriate safety instructions to the operator.
Contents
1 DEFINITION OF SIGNAL WORDS AND SYMBOLS....................................................... 8
2 SAFETY INSTRUCTIONS................................................................................................ 9
3 INTENDED USE................................................................................................................ 9
4 SCOPE OF DELIVERY................................................................................................... 10
5 SHORT DESCRIPTION.................................................................................................. 10
6 HARDWARE DESCRIPTION ......................................................................................... 11
6.1 Views of the AST11......................................................................................................... 11
6.1.1 Front Panel...................................................................................................................... 11
6.1.2 Rear View........................................................................................................................ 12
6.1.3 Connection panel ............................................................................................................ 13
6.2 Interface Description ....................................................................................................... 14
6.2.1 Fuse ................................................................................................................................14
6.2.2 Voltage Supply ................................................................................................................ 14
6.2.3 Ethernet........................................................................................................................... 14
6.2.4 Screwdriver ..................................................................................................................... 14
6.2.5 I/O Interface..................................................................................................................... 14
6.2.6 Multifunctional Serial Interface ........................................................................................ 15
6.2.7 Feeder Port ..................................................................................................................... 16
6.2.8 Emergency-Stop 2 Channel ............................................................................................ 16
6.2.9 F-Controller Port.............................................................................................................. 17
7 COMMISSIONING .......................................................................................................... 18
7.1 Dimension Sheet............................................................................................................. 18
7.2 Assembly Instructions ..................................................................................................... 19
7.3 Example for screwdriving systems .................................................................................. 22
7.4 Minimum bending Radius of Screwdriver Cable ............................................................. 23
7.5 Information on programming the Sequence Controller ................................................... 23
7.6 Functioning of the Sequence Controller AST11 .............................................................. 23
7.6.1 Operation as Stand-Alone unit with a handheld Screwdriver .......................................... 23
7.6.2 Operation with a higher level controller ........................................................................... 23
7.6.2.1 Operation with a handheld Screwdriver .......................................................................... 23
7.6.2.2 Operation with a stationary Screwdriver.......................................................................... 24
7.6.2.3 Selection and Start of a Screwdriving Program via I/O interface .................................... 24
7.6.2.4 Standard Communication higher level controller – AST11.............................................. 24
7.6.2.5 Standard Communication higher level controller – Emergency Stop 2 Channel............. 25
7.6.3 Connection on a master controller via the Fieldbus (optional) ........................................ 26
7.6.3.1 Profibus DP / Profinet...................................................................................................... 26
7.6.3.2 General Information......................................................................................................... 26
7.7 Connection on a master controller via the Fieldbus (optional) ........................................ 27
7.7.1 Profibus DP / Profinet...................................................................................................... 27
7.7.1.1 General Information......................................................................................................... 27
7.7.1.2 Hardware configuration ................................................................................................... 27
7.7.1.3 Software .......................................................................................................................... 28
8 INSTRUCTIONS FOR THE SEQUENCE CONTROLLER ............................................. 36
8.1 General............................................................................................................................ 36
8.2 Operating Elements......................................................................................................... 36
8.2.1 Functional Display (LEDs)............................................................................................... 36
8.2.2 Keypad Layout ................................................................................................................ 37
8.2.2.1 Function Keys.................................................................................................................. 37
8.2.2.2 Numerical Keypad and ESC-key..................................................................................... 37
8.2.2.3 Menu and Cursor Keys.................................................................................................... 37
8.2.3 Menu Structure................................................................................................................ 38
8.2.4 Menu Functions............................................................................................................... 39
8.2.5 Description of the Menus................................................................................................. 39
8.2.5.1 Menu System Info ........................................................................................................... 39
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8.2.5.2 Menu Process Data......................................................................................................... 39
8.2.5.3 Menu Setup..................................................................................................................... 40
8.2.5.4 Menu Screwdriving Sequence......................................................................................... 45
8.2.5.5 Menu Test ....................................................................................................................... 46
8.3 Operation via the web interface....................................................................................... 50
8.3.1 Requirements .................................................................................................................. 50
8.3.1.1 Hardware......................................................................................................................... 50
8.3.1.2 Software .......................................................................................................................... 50
8.3.1.3 Connection to the sequence controller AST11................................................................ 50
8.3.2 Preparing to use the web interface.................................................................................. 50
8.3.2.1 Setting the sequence controller AST11........................................................................... 50
8.3.2.2 Setting the browsers/operating systems ......................................................................... 50
8.3.3 Menu Structure................................................................................................................ 51
8.3.4 Description of the menu .................................................................................................. 52
8.3.4.1 Start................................................................................................................................. 52
8.3.4.2 System Info Tool Data................................................................................................. 53
8.3.4.3 System Info System Data............................................................................................ 54
8.3.4.4 Process Data Screwdriving Sequences ...................................................................... 55
8.3.4.5 Process Data Statistics ............................................................................................... 56
8.3.4.6 Process Data Graphic................................................................................................. 57
8.3.4.7 Process Data Final Values.......................................................................................... 58
8.3.4.8 Setup General Settings ............................................................................................... 59
8.3.4.9 Setup Time.................................................................................................................. 60
8.3.4.10 Setup F-Control....................................................................................................... 60
8.3.4.11 Setup Password ...................................................................................................... 60
8.3.4.12 Setup Serial Device................................................................................................. 61
8.3.4.13 Setup Extensions .................................................................................................... 64
8.3.4.14 Screwdriving sequence ............................................................................................... 64
8.3.4.15 Tools Manuals......................................................................................................... 68
8.3.4.16 Tools Additional Programs ...................................................................................... 68
8.3.4.17 Tools Fieldbus......................................................................................................... 69
8.3.4.18 Tools Update........................................................................................................... 69
9 F-FUNCTION .................................................................................................................. 70
9.1 General............................................................................................................................ 70
9.2 Functionality .................................................................................................................... 70
9.2.1 General............................................................................................................................ 70
9.2.2 Operation with supervision of number of screw-joints per part ....................................... 71
9.2.3 Operation without the supervision of number of screw-joints per part ............................ 71
9.3 Menu Functions for the F-Function ................................................................................. 72
9.3.1 Settings ........................................................................................................................... 72
9.3.1.1 Activate............................................................................................................................ 72
9.3.1.2 Reset Button.................................................................................................................... 72
9.3.1.3 Part Clearance ................................................................................................................ 72
9.3.1.4 Programs......................................................................................................................... 72
9.3.2 Diagnostic Functions....................................................................................................... 73
9.4 Interfaces......................................................................................................................... 73
10 SETTINGS ......................................................................................................................74
10.1 Description of the adjustable parameters........................................................................ 74
10.1.1 Parameters of the System Settings................................................................................. 74
10.1.2 Special parameters for fieldbus systems (optional)......................................................... 76
10.1.2.1 Profibus ....................................................................................................................... 76
10.1.2.2 Profinet ........................................................................................................................ 76
10.1.2.3 Ethernet IP .................................................................................................................. 76
10.1.2.4 Ethercat ....................................................................................................................... 76
10.2 Default Values................................................................................................................. 77
10.2.1 System Settings .............................................................................................................. 77
10.2.2 Special parameters for fieldbus systems (optional)......................................................... 77
11 SCREWDRIVING STRATEGIES AND COMMANDS..................................................... 79
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11.1 Screwdriving Strategies................................................................................................... 79
11.1.1 Fasten / Loosen to Torque .............................................................................................. 79
11.1.2 Extended Fasten to Torque............................................................................................. 80
11.1.3 Fasten / Loosen to Angle ................................................................................................ 81
11.1.4 Fasten / Loosen to external Stop-Signal ......................................................................... 83
11.1.5 Friction value package (optional) .................................................................................... 84
11.1.5.1 Friction value measurement ........................................................................................ 84
11.1.5.2 Fasten to differential torque......................................................................................... 85
11.1.5.3 Fasten dependent on friction value ............................................................................. 87
11.2 Commands...................................................................................................................... 90
11.2.1 Display values ................................................................................................................. 90
11.2.2 Save values..................................................................................................................... 90
11.2.3 Statistic............................................................................................................................ 90
11.2.4 Print................................................................................................................................. 90
11.2.5 Waiting time..................................................................................................................... 90
11.2.6 Hold position.................................................................................................................... 90
11.2.7 Wait for input ................................................................................................................... 91
11.2.8 Set output........................................................................................................................ 91
11.2.9 Reset output.................................................................................................................... 91
12 DOCUMENTATION ........................................................................................................92
12.1 Final values ..................................................................................................................... 92
12.2 Curve Representation ..................................................................................................... 93
12.3 Statistic............................................................................................................................ 94
12.4 Print output...................................................................................................................... 94
13 MAINTENANCE AND SERVICING ................................................................................97
13.1 Updating the software ..................................................................................................... 98
13.1.1 Main control and touch display........................................................................................ 98
13.1.2 Power element ................................................................................................................ 98
13.2 Replace the filter mat of the sequence controller............................................................ 98
13.3 Spare parts.................................................................................................................... 100
14 ERROR DISPLAY AND TROUBLESHOOTING .......................................................... 101
14.1 System error.................................................................................................................. 101
14.1.1 MINIMAT–EC-Servo Screwdriver.................................................................................. 101
14.1.2 Power unit ..................................................................................................................... 101
14.1.3 Main controller............................................................................................................... 102
14.1.4 Communication ............................................................................................................. 103
14.2 Error in the screwing sequence..................................................................................... 103
15 TROUBLE SHOOTING ................................................................................................. 105
16 REQUIRED ACCESSORIES........................................................................................ 106
16.1 Power Cable.................................................................................................................. 106
17 OPTIONAL EQUIPMENT ............................................................................................. 106
17.1 Motor Cable for MICROMAT®-E................................................................................... 106
17.2 Extension for MICROMAT-E Motor Cable..................................................................... 106
17.3 Plug ............................................................................................................................... 106
17.4 Fieldbus modules .......................................................................................................... 107
17.4.1 Profibus ......................................................................................................................... 107
17.4.2 Profinet.......................................................................................................................... 107
17.4.3 EtherCAT....................................................................................................................... 107
17.4.4 EtherNet/IP.................................................................................................................... 107
17.5 Toolbox.......................................................................................................................... 108
17.6 Standfuß........................................................................................................................ 108
17.7 Barcode scanners ......................................................................................................... 108
17.8 Printer connector........................................................................................................... 108
17.9 Hardware-Module.......................................................................................................... 108
17.10 Optional software packages .......................................................................................... 110
17.10.1 Friction value software package................................................................................ 110
17.10.2 GRAPH10 – Superimposed graph display ................................................................ 111
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17.10.3 DataLogger................................................................................................................ 112
17.10.4 TC30-PC Statistics .................................................................................................... 113
17.10.5 DEPRAG ASTxx Serial Remote................................................................................ 114
18 TECHNICAL DATA....................................................................................................... 115
19 GLOSSARY.................................................................................................................. 116
20 EG-CONFORMITY DECLARATION............................................................................. 120
21 SERVICE LOCATIONS AND AUTHORIZED PARTNERS .......................................... 121
5
List of figures
Figure 1: Front view AST11........................................................................................................ 11
Figure 2: Rear view .................................................................................................................... 12
Figure 3: Connection panel AST11-1 ......................................................................................... 13
Figure 4: Connection of feeder port............................................................................................ 16
Figure 5: Dimension sheet.......................................................................................................... 18
Figure 6: Screwdriving system ................................................................................................... 22
Figure 7: Burst ............................................................................................................................ 25
Figure 8: Burst ............................................................................................................................ 26
Figure 9: Hardware configuration of Profibus DP ....................................................................... 27
Figure 10: Hardware configuration of Profinet.......................................................................... 28
Figure 11: Operating Elements................................................................................................. 36
Figure 12: Menu structure at the display .................................................................................. 38
Figure 13: Menu Structure Web interface................................................................................. 51
Figure 14: The home page ....................................................................................................... 52
Figure 15: Start page................................................................................................................ 52
Figure 16: Tool data ................................................................................................................. 53
Figure 17: System data ............................................................................................................ 54
Figure 18: System data, lower part of the page........................................................................ 55
Figure 19: Screwdriving program ............................................................................................. 56
Figure 20: Screwdriving program with displayed parameter values ......................................... 56
Figure 21: Statistics .................................................................................................................. 57
Figure 22: Downloading curve data.......................................................................................... 57
Figure 23: Screwdriver results.................................................................................................. 58
Figure 24: General settings ...................................................................................................... 59
Figure 25: General settings - lower part of the page ................................................................ 59
Figure 26: Date / Time.............................................................................................................. 60
Figure 27: Setup F-Control ....................................................................................................... 60
Figure 28: Change password ................................................................................................... 60
Figure 29: Printer settings ........................................................................................................ 61
Figure 30: Selection of fieldbus ................................................................................................ 61
Figure 31: Settings for fieldbus, EtherCAT example................................................................. 62
Figure 32: Settings for fieldbus, EtherNet/IP example.............................................................. 62
Figure 33: Settings for fieldbus, Profibus example ................................................................... 62
Figure 34: Settings for fieldbus, ProfiNet example ................................................................... 62
Figure 35: Settings for Program selection via barcode............................................................. 63
Figure 36: Activating options .................................................................................................... 64
Figure 37: Screwdriving sequence – empty program ............................................................... 65
Figure 38: Screwdriving sequence ........................................................................................... 66
Figure 39: Manuals................................................................................................................... 68
Figure 40: Additional programs ................................................................................................ 68
Figure 41: Fieldbus................................................................................................................... 69
Figure 42: Update..................................................................................................................... 69
Figure 43: Screwdriving Application to torque .......................................................................... 79
Figure 44: Expanded screwdriving to Torque........................................................................... 80
Figure 45: Screwdriving to Angle.............................................................................................. 81
Figure 46: Loosening on Angle................................................................................................. 82
Figure 47: Fasten / Loosen to external Stop-Signal ................................................................. 83
Figure 48: Friction value measurement .................................................................................... 84
Figure 49: Screwing on differential torque................................................................................ 85
Figure 50: Screwing applications depending on friction ........................................................... 87
Figure 51: Power unit on the rear housing wall ........................................................................ 99
Figure 52: Filter mat on the housing rear wall .......................................................................... 99
Figure 53: Fieldbus module, power supply and connection cable.......................................... 107
Figure 54: GRAPH10E ........................................................................................................... 111
Figure 55: DataLogger............................................................................................................ 112
Figure 56: TC30-PC Statistics ................................................................................................ 113
Figure 57: DEPRAG ASTxx Serial Remote ............................................................................ 114
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List of tables
Table 1: Pin assignment I/O interface ....................................................................................... 14
Table 2: Pin assignment multifunctional serial interface ........................................................... 15
Table 3: Pin assignment feeder port ......................................................................................... 16
Table 4: Pin assignment emergency-stop 2 channel ................................................................ 17
Table 5: Pin assignment F-controller......................................................................................... 17
Table 6: Program choice ........................................................................................................... 24
Table 7: Modules and UDT's for the control.............................................................................. 28
Table 8: Directory of the modules ............................................................................................. 29
Table 9: Description - Interface parameters (FB15) .................................................................. 29
Table 10: Description – Data structure of the control signals (UDT51) ....................................... 30
Table 11: Description – Data structure of the status signals (UDT52) ........................................ 31
Table 12: Description – Error Codes ........................................................................................... 32
Table 13: Description – Data structure of the screw data (UDT33)............................................. 34
Table 14: LEDs............................................................................................................................ 36
Table 15: Menu and Cursor Keys................................................................................................ 37
Table 16: Errors of F-function...................................................................................................... 71
Table 17: Adjustable parameters ................................................................................................ 76
Table 18: Configurable Profibus parameters............................................................................... 76
Table 19: Configurable Profinet parameters ............................................................................... 76
Table 20: Configurable Ethernet IP parameters.......................................................................... 76
Table 21: Default Values............................................................................................................. 77
Table 22: Default values for Profibus .......................................................................................... 77
Table 23: Default values for Profinet........................................................................................... 77
Table 24: Default values for Ethernet IP ..................................................................................... 78
Table 25: Structure of the data set.............................................................................................. 92
Table 26: Print parameters.......................................................................................................... 95
Table 27: System error MINIMAT–EC-Servo screwdriver......................................................... 101
Table 28: System error - power unit .......................................................................................... 102
Table 29: System error - Master control unit ............................................................................. 102
Table 30: System error – Communication................................................................................. 103
Table 31: Fault in the screwing sequence................................................................................. 104
Table 32: Troubleshooting......................................................................................................... 105
Table 33: .......................................................................................................... 115 Technical Data
7
y
1 Definition of signal words and symbols
The signal words and symbols used in the technical documentation (safety instructions, operat ing in struction b ooklet, et c.) have the follow ing meani ng:
DANGER Indicates an imm e diate danger which causes serious injuries or even
death if not avoided.
WARNING
Indicates a thr eat e ni ng da nge r which can cause serious injuries or even
death if not avoided.
CAUT ION
Indicates a dange r or uns a fe pr oc ed ur e which can cause injuries to a per-
son or material damages if not avoided.
NOTICE Indicates a potentially dangerous situation which can cause damage to
the product or its surroundings if not avoided.
IMPORTANT
Ind i cates ti ps an d o ther usef ul info rmat ion.
In each case t he symbol used does not replace t he safety text. The text must always be read full
. In some cases other symbols will be us ed with the signal words.
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2 Safety instructions
Reading the enclosed safety instruction booklet no. 016000 (pink-coloured booklet) is essential for working with the equipment.
WARNING
Fires, electric shocks and other injuries, or damages to components can be
caused if the safety guidelines are ignored.
WARNING Risk of fatal injury due to electrocution!
Disconnect the electric equipment from the power supply before starting any work on the tool (e.g. installation, changing of accessories or machine tools, removal of covers prior to longer downtimes, maintenance works, etc.).
Switch off the mains switch and pull out the mains plug!
3 Intended use
The sequence controller AST11 is designed exclusively for fittings in industrial use. And must only be operated with DEPRAG MICROMAT–EC screwdrivers and DEPRAG MINIMAT–EC screwdrivers (stationary and handheld) of the series 320Exx19, 320Exx22, 320Exx27 and 320Exx36. The system is especially suitable for application requiring the highest demand of quality, flexibility and documentation.
Use beyond its intended use is considered unauthorized and therefore improper. Further­more, DEPRAG is not liable for damage resulting from the misuse of the instrument; the user alone is liable.
The correct use of the instrument includes compliance with all operating, maintenance and repair instructions.
IMPORTANT
Please contact your DEPRAG Representative, our international service centers or contact DEPRAG SCHULZ GMBH u. CO. directly if you have any questions.
Visit our website at www.deprag.com
.
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4 Scope of Delivery
Check that the shipment is complete and that there have been no damages in transit.
Quantity Designation Part no.
AST11-1 Sequence controller
1
1 Patch cable (AST11 to PC connecting cable) 831902
1 Plug (Interface GX6) 385476 A
1 Quick-Start instructions for the Operation of… 014090xx
1 Safety Instruction 016000
AST11-1-S Sequence controller AST11-2 Sequence controller AST11-2-S Sequence controller
390041 A 390041 B 390042 A 390042 B
5 Short Description
The sequence controller AST11 is a sequence controller with integrated performance elec­tronics to operate DEPRAG MICROMAT-EC screwdriver or MINIMAT–EC screwdrivers (stationary and handheld). The AST11-1/-S can be operated with screwdrivers of the series 320Exx19 and 320Exx22 and 320Exx27. The AST11-2/-S can be operated with screwdrivers of the series 320Exx36.
The sequence controller already includes standard screwdriving programs for tightening to torque and loosening to angle. Parameters can be directly altered to suit screwdriving tasks using the sequence controller’s keypad. The AST11 allows free programming of your screwdriving sequences for hand-held or stationary screwdriving tools. If required, further screwdriving programs can quickly and easily be set-up using the already existing basic program.
Fast access to the 16 programmable screwdriving programs is enabled by the integrated display- and operating unit.
To set parameters and access additional control functions, simply use any common web browser or the integrated key pad. Additional software is not required. The web interface and the display are available in several languages to select from.
Several communication options, especially for stationary use, enable connection via ether­net, fieldbus, PLC input-outputs and RS232.
The AST11 displays the screwdriving results of the last 7 production days. The screwing applications can be analyzed and evaluated using the statistic and curve representations.
Extensive diagnostics possibilities help detect possible faults in the screw driving se­quence, at the screwdriver or at the sequence controller.
Combination with an automated DEPRAG screw feeder is also possible.
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6 Hardware Description
6.1 Views of the AST11
6.1.1 Front Panel
Display
Function display
Operating elements
Figure 1: Front view AST11
11
6.1.2 Rear View
Attachment points
Filter openings
Attachment points
Figure 2: Rear view
To ensure the air exchange, the filter openings must not be covered up. The inside filter can be replaced.
12
6.1.3 Connection panel
10
1
2
9
3
4
5
Figure 3: Connection panel AST11-1
1 multifunctional serial interface GX10 for connection of:
printer barcode scanner or
fieldbus 2 ethernet GX9 3 main switch 4 fuse 5 voltage supply GX2 6 F-Controller port GX7 7 feeder port GX8 8 emergency stop port GX11 (not shown, only by type AST11-1-S and AST11-2-S) 9 screwdriver port GX1 10 I/O interface GX6
8
7
6
13
6.2 Interface Description
6.2.1 Fuse
Description: Main Fuse Size: 2 A Type: M2/250E, 20x5 mm Glasrohr
6.2.2 Voltage Supply
Description: GX2 Connector: Hirschmann STASEI 200 Voltage: 230/115 V, 50/60 Hz
6.2.3 Ethernet
Description: GX9 Connector: female connector RJ45
6.2.4 Screwdriver
Description: GX1 Connector: SUB-D 15-pole (socket)
6.2.5 I/O Interface
Description: GX6 Connector: SUB-D 25-pole (socket)
Pin Description Used for: Pin Description Used for:
1 Input 1 Start 14 Output 3 Screw Joint NOT O.K. 2 Input 2 -- 15 Output 4 ready 3 Input 3 Program Selection 16 Output 7 Change Part 4 Input 4 Program Selection 17 Output 8 -­5 Input 5 Program Selection 18 Input GND external 6 Input 6 Program Selection 19 Input 24 V external 7 Input 7 Reload 20 Output GND internal 8 Input 8 Start Release 21 Output 24 V internal 9 Input 9 External Stop 22 -- --
10 Input 11 Reset Error 23 Input Release controller /
emergency stop 11 Input 12 Release Part 24 Input n.c. 12 Output 1 System O.K. 25 -- -­13 Output 2 Screw Joint O.K.
Table 1: Pin assignment I/O interface
To use the I/O-ports the integrated I/O module of the AST11 has to be supplied with 24 V DC. For this the following variants are permissible:
• Supply of the I/O module externally by pins 18 and 19
• Supply of the I/O module by the internal 24V of the AST11. To do this a contact has to
be built between pins 20 and 18, and between pins 21 and 19, respectively.
As a precondition to start a screwdriving program a 24 V signal has to be provided at input 'Release controller / emergency stop'. For this signal the internal voltage of the AST11 has to be used. This can be done by a direct contact or by a relay controlled e. g. by a PLC (pin 21 to pin 23, see drawing).
14
Pin 21 internal 24 V
24 V (Emergency stop)
Pin 23 Release controller/ emergency stop
0 V
If a relay is used, when the sequence controller is switched on the signal 'Release control­ler / emergency stop' must have a delay of at least 1 second after switching on the 115/230V supply. When an emergency-Stop has been activated, the signal has to be acti­vated with a delay of at least 4 seconds.
When using hardware-module 385521 A (Safe torque off, see 17.9 Hardware-Module), the internal voltage of the AST11 has to be provided permanently at input 'Release controller / emergency stop' (contact pins 21 and 23).
6.2.6 Multifunctional Serial Interface
Description: GX10 Connector: SUB-D 9-pole (socket)
This interface can be used in conjunction with a printer as a serial printer interface, in com­bination with an external fieldbus module as a fieldbus interface or in combination with a barcode scanner.
Pin Description
1 -­2 TX 3 RX 4 -­5 GND 6 -­7 -­8 -­9 --
Table 2: Pin assignment multifunctional serial interface
Port adjustment when used as printer port:
• 9600 – 115200 baud selectable
• 8 data bits
• 1 stop bit
• no parity
• no protocol
15
Port adjustment when used with barcode scanner:
• 9600 – 115200 baud selectable
• 5 – 8 data bits selectable
• 1 – 21 stop bits selectable
• parity selectable
• no protocol
6.2.7 Feeder Port
Description: GX8 Connector: Binder Round-Connector Series 763, M12-4pole Color: black
Pin Description Used for:
1 Output GND 2 Output 24 V 3 Output 5 Reload 4 --
Table 3: Pin assignment feeder port
Potential connected:
Output 5
Pin 3
Input
AST11 Feeder
GND GND
Pin 1
Potential free:
Output 5
Pin 3
A1
AST11 Feeder
GND GND
Pin 1
K1
A2
13
14
Input
Figure 4: Connection of feeder port
6.2.8 Emergency-Stop 2 Channel
The emergency stop 2 channel module is integrated as standard in the types 390041 B and 390042 B. The AST11 types 390041 A and 390042 A can be converted to include this module, see 17.9 Hardware-Module.
Description: GX11 Connector: Binder Round-Connector Series 763, M12-4pole (male) Color: black
16
Pin Description Used for:
1 Contact Relay A1 (+24 V) 2 Contact Relay A2 (GND) 3 Contact Normally Closed Contact terminal 2 4 Contact Normally Closed Contact terminal 1
Table 4: Pin assignment emergency-stop 2 channel
IMPORTANT
The relay must only be switched on without any load! Pay attention to the signal sequence (see 7.6.2.5 Standard Communica-
tion higher level controller – Emergency Stop 2 Channel) !
6.2.9 F-Controller Port
Description: GX7 Connector: Binder Round-Connector Series 763, M12-4pole Color: red
Pin Description Used for
1 Output GND 2 Output 24 V 3 Output 6 Magnetic Valve 4 Input 10 Part Presence Sensor
Table 5: Pin assignment F-controller
potential-free
contact
17
7 Commissioning
7.1 Dimension Sheet
Figure 5: Dimension sheet
18
7.2 Assembly Instructions
WARNING Risk of fatal injury due to electrocution!
Switch off the AST11 sequence controller at the main switch and remove the mains plug before connecting the screwdriver!
Commissioning should be done only by trained personnel.
For the initial start-up proceed as indicated in the brief instructions 014090 "Quick-Start Instructions for the Operation of the Sequence Controller AST11 with 320E... EC­screwdriver"
CAUTION Injuries from electricity or damages on the device
Prior to connecting to the power, compare the layout design of the sequence controller AST11 with the in-house power supply (also refer to 18 Technical
Data)
Connect the EC-screwdriver (to the GX1 inter­face) and screw on the retaining screw tightly.
Optional: Connect the screw feeder / start release signal, if there is a screw feeder. (Interface GX8)
Optional: Connect the F-control, if there is an F-control. (Interface GX7)
19
Optional: Connect the plug of I/O-interface and screw on the retaining screw tightly. (to the GX6 interface)
ATTENTION Sequence controller not function­ing!
The interface GX6 must always be occupied. When the I/O interface is not in use plug in the connector 385476 A.
Optional: Multifunctional serial printer to connect a printer, barcode scanner or fieldbus module, see 17
Optional Equipment
(Interface GX10)
20
Connect the sequence controller AST11 to the power supply (GX2 interface). Plug the power cable into the power socket.
Switch on the sequence controller AST11 using the main switch.
More information about the interface assignment can be found under 6.1.3 Connection
panel and 6.2 Interface Description
Read the Operating Instruction /Safety Guidelines.
Please read and heed the enclosed operating instructions for the individ­ual actuators and sensors.
21
7.3 Example for screwdriving systems
handheld screwdriver
power supply cable
Figure 6: Screwdriving system
AST11
22
7.4 Minimum bending Radius of Screwdriver Cable
ATTENTION
Non-observance will cause damage to the screwdriver cable!
Observe minimum bending radius of screwdriver cable.
At constant motion:
Minimum bending radius 90 mm
At singular motion:
Minimum bending radius 45 mm
Please make sure that there is no mechanical load on the cables during operation.
To assure best possible contact, the connections of the cable to the sequence controller and the screwdriver must be solid.
7.5 Information on programming the Sequence Controller
The sequence controller AST11 is already pre-configured upon delivery.
A functioning screw assembly program is already available for the enclosed EC screw­driver. The screw assembly programs and settings must however be adjusted to the pre­sent application case.
Default settings and parameter changes of the screw assembly programs can be done directly on the sequence controller AST11, refer to 8.2.5.4 Menu Screwdriving Sequence.
The web interface must be used to modify or create new screw assembly programs refer to 8.3.4.14 Screwdriving sequence.
7.6 Functioning of the Sequence Controller AST11
7.6.1 Operation as Stand-Alone unit with a handheld Screwdriver
When manually screwdriving, the start of a screwdriving application occurs depending on screw type via contact pressure or via the start button. The program indicated in the Set­up "Type of program choice" menu is started. Program 16 always starts if the program switching has been actuated either via key or switch lever.
7.6.2 Operation with a higher level controller
7.6.2.1 Operation with a handheld Screwdriver
When manually screwdriving, the start of a screwdriving application occurs depending on screw type via contact pressure or via the start button. The program indicated in the Set­up "Type of program choice" menu is started.
• If “Inputs” is selected and a program is entered via the inputs of the I/O interface then this program will be started (see 7.6.2.3 Selection and Start of a Screwdriving Pro-
gram via I/O interface).
• If “Fieldbus” is selected and a program is entered via the fieldbus then this program will be started.
Program 16 always starts if the program switching has been actuated either via key or switch lever.
23
7.6.2.2 Operation with a stationary Screwdriver
The start signal starts screw assembly on spindle screwdrivers. The program indicated in the Setup  "Type of program choice" menu is started.
• When “Inputs” is selected and a program is entered via the inputs of the I/O interface then this program will be started (see 7.6.2.3 Selection and Start of a Screwdriving
Program via I/O interface).
• When “Fieldbus” is selected and a program is entered via the fieldbus then this pro­gram will be started.
7.6.2.3 Selection and Start of a Screwdriving Program via I/O interface
Use the inputs 3 to 6 of the I/O interface to select programs in accordance with the follow­ing table:
Program Input 6 Input 5 Input 4 Input 3
1 0 0 0 1 2 0 0 1 0 3 0 0 1 1 4 0 1 0 0 5 0 1 0 1 6 0 1 1 0 7 0 1 1 1 8 1 0 0 0
9 1 0 0 1 10 1 0 1 0 11 1 0 1 1 12 1 1 0 0 13 1 1 0 1 14 1 1 1 0 15 1 1 1 1
Table 6: Program choice
7.6.2.4 Standard Communication higher level controller – AST11
Signal sequence of a screwdriving cycle:
Basic prerequisites:
• signal High to input ‘Release controller’ – pin 23
• presence of the program selection (may be present continuously, but it is evaluated only when the start signal is applied)
Communication:
1. Indicator on output Ready, signal on HIGH? Sequence controller is ready for screw assembly.
2. Enter signal HIGH on input program start
3. Indicator on output Ready, signal on LOW? Screw assembly has started.
4. Indicator on outputs OK and NOT OK, one of the signals on HIGH? Screw assembly has finished.
5. Signal LOW on input program start, if required alter bit pattern for program pre­selection
6. Wait for output Ready, signal on HIGH? Sequence controller is ready for screw assem­bly again.
7. Continue according to item 1 – new screwdriving cycle
24
With the program launch, the Ready signal and OK / not OK is set on low level. The follow­ing high-level of OK or not OK signals the end of screwdriving cycle.
IMPORTANT
The start signal must be at least 150 ms on LOW between two screw as­semblies.
ready
O:K: / NOT O.K.
program start
Figure 7: Burst
7.6.2.5 Standard Communication higher level controller – Emergency Stop 2
Channel
Basic requirements:
• AST11 type 390041 B or 390042 B or the controller has to be equipped with the hardware-module 385521 A (17.9 Hardware-Module)
• While the sequence controller is booting the relay must be energized (Emergency­Stop high) in order to enable the screwdriver to initialize itself
IMPORTANT
The relay must only be switched on without any load!
Only after 100 ms past switching on the relay the Program-Start must be set!
Communication:
Screwdriving cycle without Emergency-Stop-Situation:
1. Request a Ready-Signal – Pin 15 high and Normally Closed Contact low
2. Signal high to input Program-Start – Pin 1
3. Request a OK or NOT OK – Pins 13 und 14
4. Request a Ready-Signal – Pin 15 high
5. Set Signal low to input Program-Start
6. Continue according to point 1 – new screwdriving cycle
With the program launch, the Ready signal as well as OK / not OK is set on low level. The following high-level of OK or Not OK signals the end of screwdriving cycle.
Emergency STOP situations:
1. Set Emergency-Stop-Signal to low (as long as the Emergency-Stop is active the Nor­mally Closed Contact is on high-level )
2. Set Program-Start to low (can be set at the same time with point 1)
3. OK / NOT OK and Ready change from low to high
4. In order to reset the Emergency-Stop-Situation, set Emergency-Stop to high
5. Request a Ready-Signal high and Normally Closed Contact low
25
6. 100 ms after setting Emergency-Stop to high, the Program-Start can be set to high in order to start a new screwdriving cycle.
ready
O.K. / NOT O.K.
Program start
emergency stop
a b c d e f
Figure 8: Burst
Burst-explanation: a) Complete screwdriving cycle b) Waiting-time between two screwdriving cycles c) New screwdriving cycle d) Emergency-Stop-Situation (Set and Reset) e) Waiting time of 100 ms before the new screwdriving cycle f) New screwdriving cycle
normally closed contact
7.6.3 Connection on a master controller via the Fieldbus (optional)
7.6.3.1 Profibus DP / Profinet
The device files for the Profibus and Profinet can be downloaded through the AST40 se­quence controller's web interface (see 8.3.4.17 Tools Fieldbus)
7.6.3.2 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_AST40PNDP.zip.
IMPORTANT
The modules must only be used for S7 – control units with an integrated Profibus master or Profinet interface.
26
7.7 Connection on a master controller via the Fieldbus (optional)
7.7.1 Profibus DP / Profinet
The device files for Profibus and Profinet may be downloaded via the web interface of the AST11 (see 8.3.4.17 Tools Fieldbus).
7.7.1.1 General Information
All the program modules necessary for Profibus or Profinet connection to a Siemens S7 ­controller are available in the DEPRAG_AST11PNDP.zip software package.
IMPORTANT
The modules must be used only for S7 - controllers with integrated Profibus master or Profinet interface.
7.7.1.2 Hardware configuration
7.7.1.2.1 Profibus DP
Figure 9: Hardware configuration of Profibus DP
27
7.7.1.2.2 Profinet
Figure 10: Hardware configuration of Profinet
7.7.1.3 Software
The following modules or UDT's are required to control the AST11 via the Profibus or Pro­finet:
Module Name Description
Control module for the AST11 sequence controller
FB15 AST11
DB50 IDB_AST11DP DB51 AST11_Interface DB52 IDB_AST11PN UDT51 AST11_Control UDT52 AST11_State UDT53 AST11_Data
Table 7: Modules and UDT's for the control
This module must be loaded for each AST11 sequence controller (with each new instance data block respectively)
DB instance for FB15 (e.g. Profibus) Data module for the interface parameters of FB15 DB instance for FB15 (e.g. Profinet) Data structure of the control signals Data structure of the status signals Data structure of the screw data
28
Table 8: Directory of the modules
7.7.1.3.1 Description - Interface parameters (FB15)
Designation Type Data type Description
I_Addr1 INT
I_Addr2 INT
I_Addr3 INT
I_Addr4 INT
O_Addr1 INT
O_Addr2 INT
O_Addr3 INT
O_Addr4 INT
Control
State
Data
Table 9: Description - Interface parameters (FB15)
IN
OUT
Structure of UDT 51
Structure of UDT 52
Structure of UDT 53
Input address from the hardware configuration e.g. 256 Input address from the hardware configuration e.g. 320 Input address from the hardware configuration e.g. 384 Input address from the hardware configuration e.g. 448 Output address from the hardware configuration e.g. 256 Output address from the hardware configuration e.g. 320 Output address from the hardware configuration e.g. 384 Output address from the hardware configuration e.g. 448 Data structure of the control signals (see 7.7.1.3.2
Description - Data structure of the control signals (UDT51)
Data structure of the status signals (see 7.7.1.3.3
Description - Data structure of the status signals (UDT52))
Data structure of the screw data (see 7.7.1.3.5
Description - Data structure of the screw data (UDT53)
)
)
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7.7.1.3.2 Description - Data structure of the control signals (UDT51)
Designation
Data type
Description Start signal for the AST11
When the state of the start signal changes from "low" to "high", the
Start BOOL
pre-selected screwdriving program is started on the AST11 – se­quence controller The start signal must be present until the screw­driver operation has ended.
Stop signal for the AST11
When the status of the stop signal changes from “low” to “high”
Stop BOOL
then the screwdriving program in the AST11 – sequence controller is stopped. The stop signal must be set after each screwdriving operation unless the signal AutoStop is set.
AutoStop signal for the AST11
AutoStop BOOL
When the AutoStop signal is set, after each screwdriving operation the stop signal is automatically set for the AST11.
Reload signal for the AST11
Reload BOOL
When the status of the reload signal changes from “low” to “high” then a reload impulse is sent to the connected feeder.
Start release for the AST11
StartRelease BOOL
When the status of the start release changes from “low” to “high” then the AST11 – controller is approved for screw assemblies
(ready signal changes from “low” to “high”)
Input 2 for the screwdriver program
ProgIn2 BOOL
This input can be sensed in the screwdriver program of the AST11 – sequence controller in order to stop or continue the
screwdriver operation program.
FC_PART_ SENSOR
FC_RELEASE _PART
FC_ERROR_ RESET
BOOL
BOOL
BOOL
F-Function: Input part sensor
When the part sensor is connected the status of the signal FC_PART_SENSOR changes from “low” to “high”
F-Function: Input part release
When the status of the signal FC_RELEASE_PART changes from “low” to “high” then the part is released
F-Function: Input reset error
By altering the status of the signal FC_ERROR_RESET from “low” to “high” pending errors can be acknowledged
Data saved
With the help of this signal it is indicated to the AST11 – sequence
DataSaved BOOL
controller that the current screw data has been saved in the PLC. If this signal is set, the AST11 – sequence controller withdraws the
"Data available" signal.
ResetPower­unit
BOOL
Reset power unit
By altering the status of the signal ResetPowerunit from “low” to “high” the power unit will be rebooted
External stop
ExtStop BOOL
By altering the status of the signal ExtStop from “low” to “high” an external stop is transmitted to the AST11
ResetMainte­nance
BOOL
Reset Warnung Wartungszähler erreicht
By altering the status of the signal ResetMaintenance form „low“ to
„high“ the message„ next maintenance is due“ is reset
Screwdriver program
ProgramNo INT
The user must enter the desired screwdriver program of the AST11 sequence controller here.
Possible input values: 1 – 16
Table 10: Description – Data structure of the control signals (UDT51)
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7.7.1.3.3 Description - Data structure of the status signals (UDT52)
Designation Data type Description
System OK
SystemOk BOOL
Ready BOOL
Ok BOOL
NOk BOOL
FC_PART_ ACTIVE
FC_CHANGE _PART
ProgOut8 BOOL
DataAvailable BOOL
ComError BOOL
Heartbeat BOOL
ExtStop BOOL
SystemStatus INT
ErrorCode WORD
Table 11: Description – Data structure of the status signals (UDT52)
BOOL
BOOL
This signal indicates that the AST11 – screwdriver controller has started up and is ready.
Ready
This signal indicates that the AST11 – screwdriver controller is ready for screwdriver operation.
Connection Ok
After making proper connection, this signal has the "high" state
Connection NOk
After failing to make a proper connection, this signal has the "high" state
Status of the F-Function: Part active
This output is set on the AST11 when the F-Function is activated and a part is active
Status of the F-Function: Change part
This output is set by the AST11 when the F-Function is activated and the part should be changed
Output 8 on screwdriving program
In the screwdriving program of the AST11 sequence controller this output can be set or reset and read on the PLC.
Data available
This signal indicates that there is new screwdriving data available. It is restored by the AST11 when the signal “DataSaved” from the
PLC program is set or a new screwdriving sequence is started.
Error
This signal indicates that in the component FB15 an error has oc­curred. The detailed error code is found in the parameter “Error Code”.
Heartbeat signal
This signal is indicated during constant changes between the func­tions of the AST11 sequence controller
External stop
This signal mirrors the hardware input “External stop£
System status
This parameter indicates the system status of the AST11.
(for possible status values see 14.1 System error)
Error Code
This parameter indicates the internal errors in the module. ((for possible status values, see below 7.7.1.3.4
ror Codes)
Description – Er-
31
7.7.1.3.4 Description – Error Codes
Error Description
Error in the input address range
FF00
FF01
FF02
FF03
FF04
FF10
FF11
FF12
FF13
FF14
F100
Table 12: Description – Error Codes
Cause:
The interface parameter I_AddrX (X=1-4) does not have a value or has one that is
<= 0.
Error while reading the input module 1 (I_Addr1)
Possible causes:
- An incorrect input module has been entered in the hardware configuration. In-
put module 1 must be configured with "64 bytes in".
Incorrect start address of the input module 1 at the interface parameter I_Addr1
Error while reading the input module 2 (I_Addr2)
Possible causes:
- An incorrect input module has been entered in the hardware configuration. In-
put module 2 must be configured with "64 bytes in".
Incorrect start address of the input module 2 at the interface parameter I_Addr2
Error while reading the input module 3 (I_Addr3)
Possible causes:
- An incorrect input module has been entered in the hardware configuration. In-
put module 3 must be configured with "64 bytes in".
Incorrect start address of the input module 3 at the interface parameter I_Addr3
Error while reading the input module 4 (I_Addr4)
Possible causes:
- An incorrect input module has been entered in the hardware configuration. In-
put module 4 must be configured with "32 bytes in".
Incorrect start address of the input module 4 at the interface parameter I_Addr4
Error in the output address range
Cause:
The interface parameter O_AddrX (X=1-4) does not have a value or has one that is
<= 0.
Error while writing to the output module 1 (O_Addr1)
Possible causes:
- An incorrect output module has been entered in the hardware configuration.
Output module 1 must be configured with "64 bytes out".
Incorrect start address of the output module 1 at the interface parameter O_Addr1
Error while writing to the output module 2 (O_Addr2)
Possible causes:
- An incorrect output module has been entered in the hardware configuration.
Output module 2 must be configured with "64 bytes out".
Incorrect start address of the output module 2 at the interface parameter O_Addr2
Error while writing to the output module 3 (O_Addr3)
Possible causes:
- An incorrect output module has been entered in 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
Error while writing to the output module 4 (O_Addr4)
Possible causes:
- An incorrect output module has been entered in the hardware configuration.
Output module 4 must be configured with "32 bytes out".
Incorrect start address of the output module 4 at the interface parameter O_Addr4
Timeout error in the fieldbus communication
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7.7.1.3.5 Description - Data structure of the screw data (UDT53)
Designation Data type Description
Program number
fd_Prog INT
fd_Status INT
fd_Time REAL
fd_Step1 DINT
fd_Torque1 REAL
fd_Angle1 DINT
fd_Step2 DINT
fd_Torque2 REAL
fd_Angle2 DINT
fd_Step3 DINT
fd_Torque3 REAL
fd_Angle3 DINT
fd_StepNOk DINT
fd_TorqueNOk REAL
fd_AngleNOk DINT
fd_TorqueUnit INT
The program number of the screwdriver program started previ­ously is output here.
Screw status
The screwdriver status is output here in detail. (for possible values of the status, see 14.2 Error in the screwing
sequence)
Screw fixing time
The screw fixing time (in seconds) necessary of the program started previously is output here.
Step number of the Data backup (1)
The step number of the AST11 – program in which data backup (1) was done is output here
Torque value of the Data backup
The torque value of the data backup (1) is output here
Angle value of the Data backup (1)
The angle value of the data backup (1) is output here
Step number of the Data backup
The step number of the AST11 – program in which data backup (2) was done is output here
Torque value of the Data backup (2)
The torque value of the data backup (2) is output here
Angle value of the Data backup
The angle value of the data backup (2) is output here
Step number of the Data backup (3)
The step number of the AST11 – program in which data backup (3) was done is output here
Torque value of the Data backup
The torque value of the data backup (3) is output here
Angle value of the Data backup (3)
The angle value of the data backup (3) is output here
Step number of the Data backup screw joint
The step number of the AST11 – program in which data backup for an incorrect or improper screw joint was done is output here
Torque value for an incorrect or improper screw joint
The torque value of an incorrect or improper screw joint is output here
Angle value for an incorrect or improper screw joint
The angle value of an incorrect or improper screw joint is output here
Unit of torque
The unit of torque set in the AST11 is output here: Possible values are:
0 = N·m 3 = In·lb 1 = N·cm 4 = kg·m 2 = ft·lb 5 = kg·cm
(1)
(2)
(2)
(3)
for an incorrect or improper
33
F-Function: Status
Here the status of the last screw assembly of the AST11 started using F-Function is shown: Possible values:
FC_STATUS INT
FC_COUNTER _TARGET FC_COUNTER _CURRENT
Table 13: Description – Data structure of the screw data (UDT33)
INT
INT
0 = OK 1 = too short 2 = too long 3 = part missing 4 = change part
F-Function: Target screw assemblies
Number of OK-screw assemblies until the component is finished F-Function: Current screw assemblies Current number of OK-screw assemblies
34
7.7.1.3.6 Data backup
The 'Save values' command can be used as often as desired in the screwdriver operation, but however, only the last three values are saved. In case of an error or a failure, the val­ues are always saved.
The value last saved is always available 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 an error occurs during the screwdriver operation, the screw fixing values of the incorrect step are saved in the range fd_StepNOk / fd_TorqueNOk / fd_AngleNOk.
Example:
fd_Step3
fd_Step3 fd_Step2 fd_Step3
fd_StepNOk
fd_Step2 fd_Step1 fd_Step3 fd_Step2 fd_Step3
fd_Step2 fd_Step1 fd_Step3 fd_Step2 fd_Step3
35
8 Instructions for the Sequence Controller
8.1 General
The sequence controller can be programmed by using the WEB-Interface or by the inte­grated numeric keypad, whereby the programming choices on the keypad are more lim­ited.
The sequence controller can be operated as a stand-alone unit or it can be operated by a PLC.
8.2 Operating Elements
function keys
functional display
menu- and cursor keys
Figure 11: Operating Elements
numerical keys
8.2.1 Functional Display (LEDs)
The LED’s located below the display notify the user about the operating status of the se­quence controller:
Color Description Meaning
yellow Power all voltage are O.K.
blue ready the sequence controller is ready
green Status last screw assembly was O.K.
red Status last screw assembly was not O.K.
Table 14: LEDs
36
8.2.2 Keypad Layout
8.2.2.1 Function Keys
In automatic mode, the function keys have the following functions:
left function key: manual reloading of a screw when operated with feeder
right function key: part approval when using the F-Function, if this function has been en-
abled in the relevant menu.
In different menu items the function keys are assigned to different functions. The display shows which functions are assigned to function keys, e.g. in the menu item speed test to start and stop the test run and to enter the desired speed.
8.2.2.2 Numerical Keypad and ESC-key
Use the numerical keypad to input number values (such as nominal speed), to set a pa­rameter or to perform a test. Always confirm any numerical input with RETURN-key.
Use the ESC-key to interrupt your input; the original value remains intact.
8.2.2.3 Menu and Cursor Keys
The menu keys have the following functions:
m in automatic mode, the main menu can be called up with this key DEL use the DEL-key to remove incorrect numerical inputs. ESC use the ESC-key to change into the next higher menu-level, to exit the indi-
vidual menus or to cancel an input.
RESET use the RESET-key to reset an error, which occurred while operating in the F-
function, if the corresponding menu allows such a reset.
↑ ↓ navigation in the menu, the up- and down- keys move the cursor either up or
down
Enter use the ENTER-key to change to the selected menu item
Table 15: Menu and Cursor Keys
37
8.2.3 Menu Structure
System-Info Tool-Data System-Data Process-Data Screwdriver Programs Statistics Setup Date / Time Language Torque Unit Main Direction Startmode Handtool Opt. Parameters Password Device Addresses IP-Address Gateway Printer Options
Display Contrast Start Release Speed Reduction Beeper Default Values Maintenance Interval F-Control Settings Activate Resetbutton Part Clearance Programs
Diagnostics
PG-Setting Timeframe Screwdriving
Sequence Default Programs Test Tool-Test Speed-Test Angle-Test Torque-Test Tool-I/O-Test System-Test Ready-Criteria Process-Test Interface-Test I/O Interface Key-Test Display-Test Controller-LED-Test Special-Tests
Figure 12: Menu structure at the display
Torque Adjust-
ment
Program Choice Number
Modify
Screwjoints
38
8.2.4 Menu Functions
All sub-menus, where values can be changed or which causes the interruption of the au­tomatic operation, are protected by a password.
If the password is set to 0000, then all menus are freely accessible!
The password may be changed in the menu item SETUP.
Important
The following settings are implemented at delivery: Password: 0000
ATTENTION
Some menu points will interrupt the automatic cycle, which means the screw assembly cycle cannot be continued!
The following menus interrupt the automatic cycle:
• Setup
• Screwdriving Sequence
• Test Please assure by setting passwords that only authorized personnel can make changes.
8.2.5 Description of the Menus
8.2.5.1 Menu System Info
The menu system info displays general data of the sequence controller and the connected screwdriver. The data can be displayed during equipment operation, without interrupting the automatic sequence.
8.2.5.1.1 Tool Data
The tool data include all important information about the connected driver, such as screw­driver model, serial number, torque limits, etc.
8.2.5.1.2 System Data
The system data contain basic sequence controller settings, such as language, IP ad­dress, MAC address, main direction, etc.
8.2.5.2 Menu Process Data
The menu process data supplies data for the screwdriving process. The data can only be displayed, but not changed. The data can be displayed during equipment operation, with­out interrupting the automatic sequence.
8.2.5.2.1 Screwdriving Programs
The menu item Screwdriver Programs displays the parameters of the individual screwdriv­ing programs. After inputting the required program number, use the cursor keys to switch between the individual parameters within the programs.
Use the function keys to directly change from and to the individual programming steps.
39
8.2.5.2.2 Statistics
To use the statistics display, make sure to include the command STATISTICS in the screwdriver program. The data will not be saved permanently. When the AST11 is switched off, the data will be deleted.
8.2.5.2.2.1 Show
First, input the program number to display the statistics. Then you can select between dis­play of torque or angle.
The last 100 values are used to calculate the statistics.
The following values are shown:
• Number of Data Sets
• Average
• Standard Deviation Actual
• Standard Deviation in Percentage
• CP–Value
• CPK–Value
Use the cursor keys to switch between the individual display values.
The left function key allows the deletion of the statistics of an individual program.
The right function key allows the inputting of limit values for the CP- and CPK-Value calcu­lation.
If no limit values are entered +/- 15% of the average values are used for limits.
8.2.5.2.2.2 Delete
It is possible to either delete the complete statistics for all programs (left cursor key) or on­ly the statistics for individual programs (right cursor key).
8.2.5.3 Menu Setup
Use the setup menu to input general sequence controller adjustments.
8.2.5.3.1 Date / Time
The current system time as well as system date will be displayed. Use the left function key to change time and date. Proceed using the following steps:
• Press key CHANGE, a blinking cursor appears over the date
• Input the current day, confirm with ENTER key, the current day will be displayed and the blinking cursor appears over the month.
• Input current month, confirm with ENTER key, the current month will be displayed and the blinking cursor appears over the year.
• Input current year, confirm with ENTER key, the current year will be displayed and the blinking cursor appears over the hour area of the time.
• Input current time (hour), confirm with ENTER key, the current time (hour) will be dis­played and the blinking cursor appears over the minute area of the time
• Input current time (minute), confirm with ENTER key, the current time (minute) will be displayed and the blinking cursor appears over the seconds area of the time
• Input current time (seconds), confirm with ENTER key, the current time (minute) will be displayed
Use the left function key to accept the changes.
40
8.2.5.3.2 Language
The system allows the selection between different languages.
Use the cursor keys to select the required language and confirm your selection with the ENTER-key. To leave the menu without making any changes, use the ESC-key.
8.2.5.3.3 Unit
Several different measuring units are available.
Use the function keys for selection and the ENTER key to accept the selection. Use the ESC-key to exit the menu without making any changes.
8.2.5.3.4 Main Direction
Use this area and the cursor keys to select between “Right” or “Left” main direction. The basic setting is RIGHT. Use the ENTER key to accept the selection. Use the ESC-key to exit the menu without making any changes.
8.2.5.3.5 Startmode Handtool
It can be selected to use external start (start and program choice by e.g. PLC) with the handtool.
8.2.5.3.6 Optional Parameters
8.2.5.3.6.1 Password
The password can be changed using the left cursor key or even deleted, using the right cursor key.
ATTENTION
If a password is deleted, then all menus are freely available!
The following menus interrupt the automatic cycle:
• Setup
• Screwdriving Sequence
• Test Please assure by setting passwords that only authorized personnel can make changes to the corresponding menus.
To change the password, input a four-digit password and confirm entry with the ENTER­key. It is necessary to input the password twice and if both entries are identical, then the password will be accepted. The password may be any combination of digits between 0000 and 9999.
41
8.2.5.3.6.2 Device Addresses IP-Address:
When the IP-Address is changed, the system starts-up new!
To change the IP-Address:
• use the function key “Modify?”
• input the four numerical blocks individually
• confirm your entry with the ENTER-key
• input the four numerical blocks for the net mask
• confirm this entry with the ENTER-key
The right function key accepts the input.
Immediately thereafter, the system will be automatically rebooted and the display shows “AST11 Reboot System”.
Gateway:
When the gateway is changed, the system starts-up new!
To change the gateway:
• use the function key “Modify?”
• input the four numerical blocks individually
• confirm your entry with the ENTER-key
The right function key accepts the input.
Immediately thereafter, the system will be automatically rebooted and the display shows “AST11 Reboot System”.
8.2.5.3.6.3 Printer Options
There is a selection possibility for different print options. Use the cursor key to make the selection and the ENTER-key to confirm the selection. Use the ESC-key to exit the menu without making any changes.
42
8.2.5.3.6.4 Torque Correction Factor (TQ-Adjustment)
Use this area to input an individual value, which adapts the torque to an external meas­urement.
ATTENTION
When inputting a correction factor, the factory-made calibration will be changed. (The torque established by this factor is only valid for the torque, which was obtained by the input factor.)
To change the value, proceed as follows:
• Use the left function key “Modify?”
• input value
• confirm entry with ENTER-key.
Use the right function key “SET?” to save your entry.
8.2.5.3.6.5 Display Contrast
Use the two function keys to change the contrast of the display. Confirm changes with the ENTER-key.
8.2.5.3.6.6 Start Release
The enable start allows, if activated, that the screwdriving cycle only starts after the input Start Release (I/O interface GX6, Pin 8) has received a „high“ signal. If no signal was gi­ven then the sequence controller is not ready.
The enable start may be activated or deactivated. The basic setting is “deactivated”.
Make a selection with the cursor-keys and use the ENTER-key to confirm your selection. Use the ESC-key to exit the menu without making any changes.
8.2.5.3.6.7 Speed-Reduction
When driving a fastener to a preset torque, the option „speed reduction“ is activated at 80% of the maximum torque.
The „speed reduction“ option can be activated or deactivated.
At delivery, the „speed reduction“ is activated.
The deactivation of the automatic „speed reduction“ option may lead to higher imprecisions of the torque value!
Use the cursor keys for selection. The respective selection is activated with the Enter key. Use the ESC key to exit the menu without making any changes.
8.2.5.3.6.8 Beeper
The end of a tightening process can be indicated by an audible signal. Several options can be selected.
To select the between the signal options, use the cursor keys. Confirm your entry with the Enter key. Use the ESC-key to exit this menu without making any changes.
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8.2.5.3.6.9 Default Values
Use this menu area to reset the setup-adjustments of the sequence controller to the origi­nal values (see 10.2 Default Values).
8.2.5.3.6.10 Maintenance Interval
In this menu the maintenance intervals can be set (see also 10.1.1 Parameters of the Sys-
tem Settings). The maintenance intervals can only be entered in steps of thousands.
To change the value, proceed as follows:
• Use the left function key “Modify?”
• input value
• confirm entry with ENTER-key.
Use the right function key “SET?” to save your entry.
8.2.5.3.6.11 F-Function (only visible with handheld Screwdrivers)
see separate chapter 9 F-Function
8.2.5.3.6.12 Program Choice
Here you can set the mode for program choice (see also 10.1.1
Settings
).
Parameters of the System
If “fixed setting” is selected then in the following menu item (PG-Setting) a value for the program number can be entered.
To select the between the signal options, use the cursor keys. Confirm your entry with the Enter key. Use the ESC-key to exit this menu without making any changes.
8.2.5.3.6.13 PG-Setting (only visible with handheld Screwdrivers)
If “fixed setting” (previous menu item “Program Choice”) is selected then in this menu item a value for the program number can be entered.
To change the value, proceed as follows:
• Use the left function key “Modify?”
• input value
• confirm entry with ENTER-key.
Use the right function key “SET?” to save your entry.
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8.2.5.4 Menu Screwdriving Sequence
8.2.5.4.1 Modify
Use the menu item “Screwdriving Sequence Modify” to adjust the parameters of the in­dividual screwdriving program. At first, the system asks for the program number to be in­put. Thereafter, the cursor allows to select between the individual parameters within one program.
Use the function-key to switch from one to the next program step.
To input a numerical value, use the ENTER-key, then input the value and again press the ENTER-key. Only numbers, which are within an allowable range of the driver, are ac­cepted.
To change the selection values, use the ENTER-key, then use the cursor key to select the required value and again use the ENTER-key to confirm the change.
Use the ESC-key to interrupt an input; the previous valid values remain. Again, use the ESC-key to exit the menu.
Now, use the two function keys to save or not save the changes!
left function key: the changes will be saved, the values will be reconfirmed and if nec-
essary, the system will return to the menu to adjust the parameter
right function key: all changes will be disregarded, the program remains unchanged.
8.2.5.4.2 Default Programs
Use the menu item “Default Programs” to generate the programs 1 and 16 as standard programs.
The programs will be generated as follows:
Program 1: one-step tightening to torque with driver-dependent standard values
Program 16: one-step loosening to angle with driver-dependent standard values.
ATTENTION
Generating default programs will overwrite programs 1 and 16. All other programs will be invalid!
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8.2.5.5 Menu Test
8.2.5.5.1 Tool Test
8.2.5.5.1.1 Speed Test
The mode “speed test” allows the testing of the speed outside of the program sequence.
The two function keys can control the speed test.
Proceed as follows:
• input nominal speed:
• use left function key „Nominal Value“; a blinking Cursor occurs
• input nominal speed and confirm entry with the ENTER key
• To run driver, use right function key “START“; Driver rotates at specified speed
• To stop driver, use right function key “STOP“; Driver stops
Exit the menu item „Speed Test“ with the ESC-key.
8.2.5.5.1.2 Angle Test
To verify the angle measurement, simply rotate the screwdriver. The current angle is dis­played. Use the right function key “RESET” to reset the angle value to “0”. Exit the menu item „Angle Test“ with the ESC-key.
8.2.5.5.1.3 Torque Test
The menu item “Torque Test” allows the verification of the torque measurement, even out­side of program sequences. A one-step standard program will be created using the input torque value, which in turn can be verified through a tightening process on a measuring platform. The two function keys may control the torque test.
Proceed as follows:
• Insert the nominal torque:
• Press the left function key “Nominal Value”; a blinking Cursor occurs.
• Input nominal torque and confirm entry with the ENTER-key. To activate the driver, press the function key “START”; the driver starts the tightening pro­gram.
Press the STOP-key to turn the driver off.
To exit the torque-test menu at any time, simply press the ESC-key.
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8.2.5.5.1.4 Tool I/O Test (only visible with handheld Screwdrivers)
Use the menu item “Tool I/O Test” to test the LED’s and buttons on the screwdriver.
Use the cursor-keys to switch between the individual LED’s and buttons.
The status of the button will be displayed; the LED’s may be turned on or off by the EN­TER-key.
To exit the Driver I/O Test menu at any time, simply press the ESC-key
8.2.5.5.2 System Test
8.2.5.5.2.1 Ready-Criteria
The menu item „Ready-Criteria“ displays all parameters, which influence the ready status of the sequence controller.
The status of the parameters is updated only when calling the menu.
Use the cursor-keys to switch between the individual values.
8.2.5.5.3 Process Test
Use the „Sequence Test“ to check the function of each step in a Screwdriver Program.
To control this test, use the two function keys and proceed as follows:
• Input program number
• Press the Key „PROG“, a blinking Cursor occurs
• Input program number and confirm input with the ENTER-key
• Start the sequence with the key „START“, the first step of the program is processed
• Use the key „NEXT“ to start the next step
• Use the key „STOP“ to stop the process at any time
The current programming step is displayed on the upper right corner. To exit the process­test menu at any time, simply press the ESC-key.
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8.2.5.5.4 Interface Test
8.2.5.5.4.1 I/O-Port
Use the menu item I/O–Port to verify the I/O-conditions. Use the numerical keys 0 to 7 to activate or deactivate each individual output.
Exit the I/O–Test mode with the ESC-key.
Description of each step in the display:
Inputs:
000000000000
Input 1: Start Input 2: -­ Input 3: Program Selection Input 4: Program Selection Input 5: Program Selection Input 6: Program Selection Input 7: Reload Input 8: Start Release Input 9: External Stop Input 10: Part Sensor Input 11: Reset Error Input 12: Release Part
Outputs:
00000000
Output 1: System O.K. Output 2: Assembly O.K. Output 3: Assembly NOT O.K. Output 4: Ready Output 5: Reload Output 6: Magnetic Valve Output 7: Change Part Output 8: --
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8.2.5.5.5 Display-Test
In the menu item „Display-Test“, all test areas will be completely dark. This allows the op­erator to see whether all pixels of the displays are functional!
To exit the display-test menu at any time, simply press the ESC-key.
8.2.5.5.6 Key Test
The „Key Test“ displays the last actuated key. This menu item allows that all keys are te­sted in regard to their functionality.
To exit the key-test menu at any time, simply press the ESC-key.
8.2.5.5.7 LED-Test
Use this „LED-Test“ function to verify that all LED’s on the sequence controller are func­tional. Use the cursor keys to select between the individual LED's.
Use the ENTER-key to turn the individual LED’s on or off. To exit the LED-test menu at any time, simply press the ESC-key.
8.2.5.5.8 Special Tests
These test functions are exclusively for internal use and only accessible to DEPRAG ser­vice personnel.
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8.3 Operation via the web interface
8.3.1 Requirements
8.3.1.1 Hardware
The web interface operates on any common PC or Notebook with a network card or a WLAN card.
8.3.1.2 Software
The web interface can be used with any common operating system, such as MS Windows, Linux, OS X... and it functions with all common, current browsers.
8.3.1.3 Connection to the sequence controller AST11
The PC on which the web interface is operating can either be connected with the se­quence controller AST11 or via a common network.
Cross cables as well as uncrossed cables can be used for the direct connection; the se­quence controller AST11 recognizes them automatically and adjusts the connection re­spectively.
8.3.2 Preparing to use the web interface
In order to use the web interface, the sequence controller AST11 as well as the browser must be set in a manner that a TCP/IP connection between both can be established and the data exchange released.
8.3.2.1 Setting the sequence controller AST11
A set IP address must be set at the sequence controller AST11 (also refer to 8.2.5.3.6.2
Device Addresses and brief description "Quick-Start Instructions for the Operation of Se-
quence controller AST11"). They must be issued by the administrator of the local network. At the time of delivery the following values are preset:
IP Address: 10.10.25.100 Subnet mask 255.255.0.0 Gateway: 10.10.20.9
8.3.2.2 Setting the browsers/operating systems
The browser must have free access to the sequence controller AST11, meaning;
• the IP address of the sequence controller AST11 must be reachable.
• the HTTP protocol must not be deactivated
• a possible proxy for the IP address of the sequence controller AST11 (or local ad-
dresses general) must be deactivated.
Furthermore, the browser cookies must accept the sequence controller AST11 and JavaScript must be activated. In case of doubts contact your responsible EDV representa­tive.
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8.3.3 Menu Structure
The menu has the following structure:
Start Page System Info Tool Data System Data Process Data Screwdriving Sequence Statistics Graphic Final Values Setup General Settings Time F-Control New Password Serial Device Extensions Screwdriving Sequence Tools Manuals Additional Programs Fieldbus Update
Figure 13: Menu Structure Web interface
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8.3.4 Description of the menu
8.3.4.1 Start
To access the web interface, enter the IP address of the sequence controller AST11 (also refer to 8.2.5.3.6.2 Device Addresses) into the address bar of the browser and press the enter key (e.g. "http://10.10.25.108"). The browser connects to the sequence controller AST11 and loads the home page.
Figure 14: The home page
If you intend to perform changes, enter the password. The standard password at the time of delivery is "0000". If you only want to view data, without changing them, you will not need a password and leave the input fields empty.
Click the login button or press the enter key.
Subsequently the home page is displayed.
Figure 15: Start page
The start page shows the versions of the main control, the power element and the screw­driver logistics. On the left side is the main menu, which is used to access the individual pages of the web interface.
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If you enter a valid password then all pages are accessible. Otherwise, the pages on which changes can be made are hidden.
8.3.4.2 System Info  Tool Data
This page displays the most-important data of the connected Screwdriver. These data cannot be changed on this page.
Figure 16: Tool data
The following data is displayed:
• Software version: version of the screwdriver logic
• Screwdriver type: name of the screwdriver type
• Serial number: individual serial number of the screwdriver
• Torque settings: screwdriver specific value to adapt the torque calculation to special
cases
• Minimum torque: smallest possible torque
• Maximum torque: largest possible torque
• Minimum rotation speed: smallest possible rotation speed
• Maximum rotation speed: largest possible rotation speed
• Maximum torque hold time: longest possible time that the screwdriver can maintain a
constant torque
• Number of cycles: number of screwdriving procedures of the screwdriver
• Number of cycles at last maintenance: number of screwdriving procedures of the
screwdriver at the time of the last maintenance
• Maintenance interval: interval describes the number of screwdriving procedures until
the next maintenance is due
• Next maintenance: the next maintenance of the screwdriver is due when the speci-
fied number of screwdriving procedures has been reached
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8.3.4.3 System Info  System Data
This page shows the screwdriver independent adjustments of the sequence controller. These data cannot be changed on this page.
Figure 17: System data
The following data is displayed:
• Version of main unit: software version of the main unit
• Version of power unit: software version of the power unit
• Date: the date set in the sequence controller
• Time: the time set in the sequence controller
• IP-Address: IP address of the sequence controller
• Netmask: bitmask of the sequence controller network element
• Gateway: IP address of the gateway set in the sequence controller
• MAC Address: hardware address of the Ethernet port
• Torque unit: the set torque unit
• Main direction of rotation: set direction of rotation for a standard screwdriving applica-
tion
• Speed reduction: automatic decrease of the speed at 80% of the target torque
• Start release: control of the 'Ready'-state by a higher level controller
• Beeper: Setting for the signal sound at the end of the screwdriving application
o always o only O.K. o only NOT O.K. o never
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Figure 18: System data, lower part of the page
• Print options
o values of O.K. and NOT O.K. assemblies o only values of O.K. assemblies o only values of NOT O.K. assemblies
• Offset gear: If the screwdriver is equipped with an external ancillary transmission, this
area indicates the corresponding values for the offset gearing; otherwise, the stan­dard values are displayed.
o Gear ratio: the offset ratio of the eventual integrated offset gearing o Efficiency: the efficiency grade of the offset gear in reference to the torque o Direction change: this option indicates whether the offset gear reverses the
turn direction of the screwdriver
• Handheld with External Start: displays if handheld screwdriver will be started by a
higher level controller (only visible for handheld screwdrivers)
• Type of program choice: indicates via which interface program selection is controlled
• Delay interrupt: delay interrupt set for the handheld screwdriver
• Device for the serial interface: device into which the serial interface is connected
o printer o barcode scanner o fieldbus
• Additional data displayed according to the selected device
8.3.4.4 Process Data  Screwdriving Sequences
This page indicates the available screwdriving programs and their parameters.
55
Figure 19: Screwdriving program
This page does not allow generating or changing screwdriving sequences. There are ma­ximum 16 individual screwdriver sequences. Available programs are gray highlighted; the buttons for other programs remain white.
Figure 20: Screwdriving program with displayed parameter values
8.3.4.5 Process Data  Statistics
Here, the statistics for all programs are displayed. You can select the program for which the statistic should be displayed. This is done by clicking the respective button.
(Also refer to 12.3 Statistic)
Click on the delete button to delete the statistics for the selected program.
If you want to alter the limit values for the Cp- and Cpk-calculations enter the required val­ues into the fields “Cp-lower limit” and “Cp-upper limit” in the column torque or angle and then click on “Apply”. With one click on “Undo” the altered limit values will return to the standard values of +/- 15 %.
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Figure 21: Statistics
Click on “Refresh data”, if further screw assemblies have been carried out whilst the statis­tics page has been open.
In the lower half of the page the statistics data and the limit values of all programs can be deleted.
IMPORTANT
Statistic values are only saved and analyzed if the "statistic" command in the screwing sequence is open.
8.3.4.6 Process Data  Graphic
This page provides the possibility to load the data of the last screwing application as a da­ta from the sequence controller AST11. In principle, all screwing applications are recorded. The record will be available until the sequence controller AST11 is switched off or a new screw connection is established. It is furthermore possible to download, free of charge, the viewing program GRAPH10(E) for the binary curve data.
If you click the blue note on the "Viewer for the display of binary data" then you will first receive a detailed description of the installation of the GRAPH10 viewer. At the end of the description you will find information to load the program onto your PC.
(Also refer to 12.2 Curve Representation)
Figure 22: Downloading curve data
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The following data are recorded:
• speed
• torque
• angle
• program step
• current
• screwdriver temperature
8.3.4.7 Process Data  Final Values
This page offers the possibility to save the final values of all assemblies of the last seven days as csv-values (refer to 12.1 Final values).
Figure 23: Screwdriver results
The files have the same limits for CSV-data as described in 12.2 Curve Representation.
The final values, which are older than seven days, will be replaced by new final values.
Additionally the final data of the last screwdriving are saved into a file called “actual.csv”. This file can also be downloaded from this page.
IMPORTANT
This data are only available, if the screwdriving program contains the command „Save Values“ or if a sequence error has occurred.
58
8.3.4.8 Setup  General Settings
Here it is possible to perform most settings for the sequence controller AST11.
Figure 24: General settings
A description of the individual parameters can be found in Chapter 10 Settings.
Click "Submit" to transfer the settings to the sequence controller AST11. Click "Default Values" to restore the default values (delivery status).
In the lower part of the page you can save your settings in order to transfer them to other sequence controllers Type AST11, or to reload later.
Figure 25: General settings - lower part of the page
After clicking the "Create Backup" button, a dialog is opened in which you can set the na­me and location of the back up file.
In order to transfer back up copy to the sequence controller AST11 you must enter the file name and path in the lower input field and click "Load Backup". Alternatively you can se­lect the file by clicking the "Search…" button next to the input field.
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8.3.4.9 Setup  Time
Here, you can enter the date and time of the sequence controller AST11.
Figure 26: Date / Time
8.3.4.10 Setup  F-Control
If you use the F-control function, use this area to do the appropriate adjustments.
Figure 27: Setup F-Control
More information on the F-Control function you find in chapter 9 F-Function.
8.3.4.11 Setup  Password
On this page you can set the password for the access to the sequence controller AST11.
Figure 28: Change password
The password is only valid for changes to the settings of the sequence controller AST11, not for the complete access.
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8.3.4.12 Setup  Serial Device
On this page you can set which device is connected to the multi-functional serial interface. If there is no device connected, select “no device”.
8.3.4.12.1 Printer
Figure 29: Printer settings
The following settings can be altered:
• Baud rate: the baud rate which the printer receives data
• Printed text: variable text which should be printed after a screw assembly
Under printed text you can determine what should be printed if a screwdriving program uses the command “Print”. The printed text is printed as entered whereby the variables are replaced by the relevant values. Variables always begin with the '@' symbol and must end with a space character. A detailed description of the printouts and variables available can be found in 12.4 Print output.
8.3.4.12.2 Fieldbus module
On this page all general settings for the (optional) fieldbus module can be found. The spe­cific settings for the installed fieldbus module can also be carried out on this page, see also 10.1.2
Special parameters for fieldbus systems (optional).
Figure 30: Selection of fieldbus
First click on the button “Search for fieldbus module”, so that the AST11 establishes a con­nection with the fieldbus module connected.
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Figure 31: Settings for fieldbus, EtherCAT example
Figure 32: Settings for fieldbus, EtherNet/IP example
Figure 33: Settings for fieldbus, Profibus example
Figure 34: Settings for fieldbus, ProfiNet example
Click on “Submit”, to transfer the settings to the AST11.
62
8.3.4.12.3 Barcode-Scanner
If a barcode scanner is connected to the sequence controller via the serial interface then the relevant settings can be carried out here. Details can be found in the instruction man­ual of your barcode scanner.
Figure 35: Settings for Program selection via barcode
The following settings can be altered:
• Baud rate: the baud rate at which the barcode scanner works
• Data Bits: data bits selected can be 5, 6, 7 or 8
• Stop Bits: stop bits selected can be 1 or 2
• Parity: the parity can be selected from none, even or odd
• End marker for barcode: end marker which the barcode scanner sends once a bar-
code has been read. Any character within the range 0x0A – 0x0F.
• if a barcode is selected for Program Choice in the Basic Settings then the following
settings are available:
o Range mask: this determines which part of the scan code read for program
choice is used. Only one mask can be set which is valid for all programs.
o Scan code mapping: for each program from 1 to 15 a range of codes is se-
lected for each of the programs. The start and end of these ranges is en­tered. The ranges may not overlap. If only one code is required for the Pro­gram Choice then the same start and end code can be entered.
IMPORTANT
The length of the barcode must be a maximum of 30 characters.
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8.3.4.13 Setup  Extensions
On this page you are able to activate options of the AST11.
Figure 36: Activating options
Different options are available, at extra cost, for the sequence controller AST11 (also refer to 17.10 Optional software packages).
To activate these options please contact the DEPRAG sales department or your DEPRAG dealer.
In order to be able to perform the activation, some information is required which must be contained in your order:
◦ Activation key of the respective option ◦ Serial number of the sequence controller
The activation key can be found to the right, next to the respective option. The 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 activation key can be entered directly on the bottom of the page or by clicking the button "load key".
As an alternative, the license data can be also directly loaded. To do this, click on the but-
ton "search....." and select the respective file. Click "load license data".
Once the activation key is loaded, the option is displayed as released and can now be used.
8.3.4.14 Screwdriving sequence
You may display, create and edit screwdriver operations on this page. Making changes is possible only if the correct password has been entered at the time of login, otherwise the information is merely displayed.
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Figure 37: Screwdriving sequence – empty program
If there is no program a standard program can be created. Select the type of program and then it will be created by the sequence controller AST11.
For a detailed description of the screwdriving strategies and commands see 11 Screwdriving Strategies and Commands.
You are able to create up to 16 programs. It is easy to detect which programs already ex­ist; they are highlighted in Grey on the respective button.
If you would like to process a program or create a new program, click the button with the corresponding program number.
General parameters:
There are three parameters for each program, which affect the complete program:
• Program title: Any designation with a character length limit of 16 characters. The title
is intended for easier labelling of the program and has no effect on the screwdriving sequence. The program name must not contain any special characters.
• Direction change: Determines if another main rotational direction applies for this pro-
gram as in the general settings. If for example the rotational direction is set to the right, the program will screw to the left if the direction change is active.
• Screw feeder signal: Determines when the reload signal is given to the feed screw-
drivers.
◦ always: after each screwing application the reload signal is issued.
◦ only OK: the reload signal is only issued after an OK screwing application.
◦ never: the sequence controller provides no reload signal.
Adding steps to the program: Option 1:
Select a screwdriver pattern 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. Insert the screwdriver pattern or the command by releasing the mouse button.
Option 2:
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Select an available program step by clicking this step. Subsequently click the strategy or the command that you like to insert. If you click "insert before", the strategy or command should be inserted in front of the currently selected program step or click "insert after", if the strategy or the command should be inserted behind the currently selected program step.
IMPORTANT
If the screwing program is still empty, then the strategy or command is always inserted as first parameter step.
Figure 38: Screwdriving sequence
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 entered in the input field next to the parameter.
Save program:
Click the "Submit" button, which can be found below the last program step in order to save the program step and the parameters.
Copy program:
If you want to save an available program under another program number, select the new program number from the list field next to the "submit as" button. The "submit as" button can be found below the last program step. Subsequently click on "submit as" in order to save the program under a new number.
Printing a program:
If you would like to print out a program, click on the "Print Preview" button. To return to the normal view, press the "Normal View" button.
Deleting a program step or a program:
If you would like to delete individual program steps, click on the "Remove" button of the step that needs to be deleted. If you would like to delete the entire screwdriver program, click on the "Remove" button on the right next to the title of the screwdriver program. If you would like to delete all screwdriver programs, first click on the 'General' tab and then on the "Delete all programs" button.
66
IMPORTANT
A program step, a complete program or all programs are deleted immedi­ately without a confirmation prompt
Create / Load backup:
At the lower part of the page you may
• back up existing programs
• saved programs can be restored and
• all programs can be deleted.
After clicking the "Create Backup of all Programs" button, a window is opened in which you can set the name and location of the back up file.
In order to restore saved programs, enter the file name and path in the input field and click "Load Backup ". Alternatively you can select the file by clicking the "Search..." button next to the input field.
.
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8.3.4.15 Tools  Manuals
On this page you can transfer and read all available manuals for the sequence controller AST11.
If your browser has a pdf plug in, then you can read the manuals directly in the browser.
Figure 39: Manuals
8.3.4.16 Tools  Additional Programs
On this page you can download all programs which are available for the controller AST11. Usage of the software is partly liable to pay costs. Please consider the notes regarding the activation in the respective programs.
Figure 40: Additional programs
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8.3.4.17 Tools  Fieldbus
On this page, you may download all fieldbus drivers available for the AST11 sequence controller.
Figure 41: Fieldbus
8.3.4.18 Tools  Update
New software can be loaded onto the sequence controller in the Update menu (also see
13.1 Updating the software).
Figure 42: Update
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9 F-Function
9.1 General
The F-function of the AST11 offers – besides the supervised values of torque and angle – the following additional possibilities:
• Supervision of total duration of an assembly and with this option it is possible to de-
tect incorrect screw threads, missing washers or an indirect depth control.
• The number of screw joints per product. With this option it is possible to assure that
each product is completely assembled.
The adjustment for the F-function on the sequence controller is located in the menu Setup Optional Parameters F-Control Settings and at the web interface in the menu Setup F-Control.
IMPORTANT
The F-Functionality is only possible with handheld screwdrivers!
9.2 Functionality
9.2.1 General
If the F-function is activated and adjusted to the screw-joint, then the assembly can be started. Position the Screwdriver directly and perpendicular to the screw location. The screwing sequence starts according to the design of the screwdriver either with push-to­start or with button start.
Once the programmed shut-off condition is achieved, the screwdriver shuts off. However, the total cycle time of the screwdriver has to be within a pre-determined time-frame. If this is the case, then the screwdriver is ready for the next assembly.
Otherwise, an error message is shown on the display, the RED LED glows and the se­quence controller doesn't release the screwdriver (no Ready-Signal, i.e. no green LED). After resetting the error (either with the reset button on the sequence controller or through the PLC-port), the screwdriver is again ready for operation.
If additionally the number of screw joints per part has to be controlled, then the controller will give an acoustical signal – once the pre-programmed number of O.K. screw joints are reached – and the display indicates that the part has to be changed. The screwdriver is blocked by the AST11 sequence controller, until a new part is presented (loaded). Thereaf­ter, the assembly continues as before.
The screwdriver programs 1 through 15 can be extended to include an individual time­window, as well as the number of screw joints per part.
However, per product only one program can be used, which means that a program change is only possible with a corresponding part change.
The screwdriving program 16 can be used as well, but it is not supervised by the F­function, which means that errors do not have to be reset and O.K. Screw joints will not increase the number of O.K. screw joints per part. The program 16 may be used as a loo­sening program to correct errors. If this is not allowable, then deactivate program 16, or remove program 16 if it is already activated!
The error evaluation is identical to the error evaluation under normal operation of the AST11; however, the following additional supervisory criteria are evaluated:
• Time-Frame for the total-time of the screw-process
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• If a part-presence sensor is used: Presence of the part
The following additional errors or informational notes are shown:
Error
Displayed Text Meaning
Number
0 OK no error 1 TOO SHORT the predetermined minimum time of the screw-process was
not reached
2 TOO LONG the predetermined maximum time of the screw-process was
exceeded 3 PART MISSING no part is present 4 CHANGE PART the predetermined number of individual O.K. screw-joints
per part has been reached! Change part!
Table 16: Errors of F-function
9.2.2 Operation with supervision of number of screw-joints per part
This operational mode is activated if the amount of individual screw-joints per part is input into the screwdriving program with a number larger than ZERO.
With this operational mode, the time-frame in the menu item “Settings Programs Time Frame“ will be activated. The number of individual screw joints in the menu item “Settings Programs Number of screw joints“ will be controlled as well.
If the screwdriver does not shut-off within the predetermined time-frame, then an error message will be shown on the display and the RED status-light glows. If the part is re­moved prior to reaching the predetermined number of O.K. screw-joints per part, then an error „Part Missing“ is displayed.
If the correct number of O.K. screw-joints is reached, the controller will give an acoustical signal and the display indicates „Change Part”. If the screwdriver is used on the same, al­ready assembled part, the AST11 controller blocks the screwdriver, until a new part is pre­sented (loaded). Thereafter, the screwdriver is ready for the next screwing sequence.
This operational mode also allows to lock the part, e.g. with a locking-cylinder. For this op­tion use the output „Magnetic Valve“ on the Interface F-controller. The part will only be re­leased, when the correct amount of O.K. screw-joints per part are reached.
If the part has to be removed prior to reaching the predetermined number of O.K. Screw­screw joints (because of an error), then the output can be released through the higher le­vel controller or by using the right function key on the sequence controller (if activated).
9.2.3 Operation without the supervision of number of screw-joints per part
This operational mode is active, if the number of screw-assemblies per part is input into the screwdriving program with a ZERO.
Then the AST11 reacts to incorrect screw-joints as described in 9.2.2 Operation with su-
pervision of number of screw-joints per part. However, the monitoring of O.K. screw-
assemblies per part is inactive. If a part-sensor for part presence or a PLC is connected, then this operational mode will not be evaluated.
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9.3 Menu Functions for the F-Function
9.3.1 Settings
9.3.1.1 Activate
The system offers a choice between „Activate F-Function“ yes or no.
Make your selection with the cursor keys. Confirm your selection with the ENTER-key and exit this menu with the ESC-key.
9.3.1.2 Reset Button
The system offers a choice between „Reset by Button“ yes or no.
Make your selection with the cursor keys. Confirm your selection with the ENTER-key and exit this menu with the ESC-key.
If the reset button is active, then an error reset is possible on the sequence controller, oth­erwise a reset signal has to be given over the PLC-port.
9.3.1.3 Part Clearance
The system offers a choice between „Part Clearance by Button“ yes or no.
Make your selection with the cursor keys. Confirm your selection with the ENTER-key and exit this menu with the ESC-key.
If the part clearance by button is active, then the right function key on the sequence con­troller can make the part clearance, otherwise the part clearance signal has to be given over the PLC-port.
9.3.1.4 Programs
Use the menu item „Programs“ to change the parameter for the F-function of each individ­ual program.
First, input the program number, then change the number of screw-joints per part and the time frame.
9.3.1.4.1 Number of Screw-joints
You may input the number of the required O.K. screw-joints per part.
To change the value, proceed as follows:
• Use the left function key „Modify?“
• input value
• confirm your input with the ENTER-key
Use the right function-key „Set?“ to activate your setting.
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9.3.1.4.2 Time Frame
The time frame for the screw-joint may be changed.
To change the value, proceed as follows:
• Use the left function key „Modify?“
• input the value for the minimum cycle time and confirm the input with the ENTER-key
• then input the value for the maximal cycle time and confirm your input with the Enter­key
Use the right function-key „Set?“ to activate your setting.
9.3.2 Diagnostic Functions
The diagnostic functions allow the operator to analyze each screw-joint and to automati­cally establish values for the time-frame. These values are only estimates and have to be fine adjusted, if needed.
The analysis acquires values from 5 screw-joints.
Proceed as follows:
• First, input the program number, which is used for the analysis.
• Thereafter, process the first screw-joint; the actual screwdriving time is displayed.
• Now, process the next screw-joint, and so on.
After the fifth screw-joint, the minimum and maximum screwing time is displayed, with an added upper and lower 20% offset. Use the left function key to activate this setting.
Error screw-joints will be ignored!
You may leave the diagnostic function at any time by pressing the ESC-key, without sav­ing any of the adjustments.´
IMPORTANT
If a feeder is attached to the screwdriver, the screw has to be manually reloaded, so that this diagnostic analysis can be made.
9.4 Interfaces
A detailed description of the ports can be found in the section 6.2.5 I/O Interface.
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10 Settings
10.1 Description of the adjustable parameters
10.1.1 Parameters of the System Settings
Parameter Description
IP Address The IP address via which the AST11 can be reached
in the network.
Network mask It indicates the network segment in which the se-
quence controller AST11 is located.
Gateway The IP address of the gateway for the network seg-
ment in which the sequence controller AST11 is lo­cated.
Display contrast The display contrast can only be set on the sequence
controller.
Language The language that should be displayed in the web
interface as well as also the operating interface of the sequence controller AST11.
Torque unit The torque unit that is used for display and settings of
torque values. Available units are:
• N·m
• N·cm
• ft·lb.
• in·lb.
• kg·m
• kg·cm
Main direction of rotation The main direction of rotation indicates what direction
is defined as screwing application. The main direction right means that all screwing samples will operate rotating to the right, all screw samples to release with rotate to the left.
Speed reduction If the rotation speed decrease is active then the
torque screwing levels, that do not have torque trans­fer occurring, will automatically lower the rotation speeds when 80% of the target torque is reached. This provides a higher cut-out accuracy.
Start release If the clearance to start is active then a screwing ap-
plication can only be started, if 24 V are available at the start release input (also refer to 6.2.5
face). Otherwise the controller will not be ready for a
screwdriving cycle.
Beeper Determines under which conditions the signal sound
is released at the end of the screwing process.
Print options Determines what should be printed if a program uses
the command “Print” and a printer is connected to the serial interface.
Torque adjustment Adjustment factor for the torque calculation for special
screw joints
I/O Inter-
74
Maintenance interval The maintenance interval determines after how many
screwdriving procedures the screwdriver should be checked/undergo maintenance. If a maintenance interval is entered then the se­quence controller AST11 signals that the next main­tenance of the EC screwdriver is due. This message can be acknowledged by pressing the ESC key and work can continue as normal. The message will ap­pear at regular intervals i.e. if another hundredth of a maintenance interval has passed since the first sig­nal. If the maintenance interval is set to 0 no signal will
appear. Offset gear
Gear transmission ratio Transmission ratio for the adapter gear Efficiency Effectiveness of the adapter gear Direction change Specifies whether the adapter gear causes change of
direction. Handheld with external start Determines that a handheld screwdriver should be
started via external start signal (Fieldbus or I/O inter-
face). This setting only appears for handheld screw-
drivers. Type of program choice You can set the type of program choice:
• fixed setting: the program number set in the menu PG-Setting will always be started
• keys: the number keys on the keyboard are used to select program number. This function is not available if F-Function is activated.
• Barcode: selection of program depends on bar­code read
• Inputs ports: selection of program number via I/O interface
• Fieldbus: selection of program number via field­bus connected to serial interface
Program The number of screwdriving procedures which should
be carried out once screwdriver is started if the pro­gram choice is on “fixed setting”.
Delay interrupt The set abort delay prevents that a screwing process
is evaluated as aborted, if the start signal of the screwdriver separates, but is present again within the set time. This is especially important in connection with a screw feeder device to prevent errors during the pushing through of the screw through the mouth piece. This setting only appears for handheld screwdrivers.
Password The menus of the sequence controller in which
changes can be performed can be password pro­tected. The password can be in a range of 0000 to 9999 and must be four-digit. If 0000 is set as a password then all menus at the sequence controller are freely accessible. In delivery state the password is set to 0000.
Date / Time Setting for the internal real-time clock of the sequence
controller.
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F-Control
active Indicates whether F-control is active. Reset by Button If there is an error in screw assembly the reset button
can be pressed.
Release by Button Once screw assembly on a part is finished this button
releases the part. Number of Cycles Number of screw assemblies per component Minimum Time Minimum screw assembly time Maximum Time Maximum screw assembly time
Table 17: Adjustable parameters
10.1.2 Special parameters for fieldbus systems (optional)
10.1.2.1 Profibus Parameter Description
Profibus address Address under which the AST11 is accessible in the
Profibus.
Table 18: Configurable Profibus parameters
10.1.2.2 Profinet Parameter Description
IP address The IP address via which the AST11 is accessible in
the network via Profinet.
Net mask It designates the network segment in which the
AST11 sequence controller lies.
Gateway The IP address of the gateway for the network seg-
ment in which the AST11 sequence controller lies.
Station name Station name of the AST11 in the Profinet.
Table 19: Configurable Profinet parameters
10.1.2.3 Ethernet IP Parameter Description
IP address The IP address via which the AST11 is accessible in
the network via Ethernet IP.
Net mask It designates the network segment in which the
AST11 sequence controller lies.
Gateway The IP address of the gateway for the network seg-
ment in which the AST11 sequence controller lies.
DHCP If DHCP is active, the network addresses set / dis-
played are not valid. They are assigned via a DHCP
server.
BOOTP If BOOTP is active, the network addresses set / dis-
played are not valid. They are assigned via BOOTP.
Table 20: Configurable Ethernet IP parameters
10.1.2.4 Ethercat
No settings are necessary.
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10.2 Default Values
10.2.1 System Settings
The default values can be adjusted as follows:
• in the menu System Opt. Parameters  Default Values at the control, press the left function key
• click the "Default Values" button in the web interface in the Settings menu General Settings.
Parameter Value
Display contrast 195 Language english Unit for torque Nm Main direction of rotation right Speed reduction active Start release inactive Beeper never Print options always Offset gear
Type of program choice fixed setting Program 1 Password 0000 Delay interrupt 3 F-Control
Statistic: Limits for CP/CPK value +/- 15 %
Table 21: Default Values
10.2.2 Special parameters for fieldbus systems (optional) Profibus:
Parameter Value
Profibus address 64
Table 22: Default values for Profibus
Profinet:
Parameter Value
IP address 10.10.24.10 Net mask 255.255.00 Gateway 10.10.20.9 Station name nic 50 repns
Table 23: Default values for Profinet
Gear transmission ratio 1 Efficiency 100% Direction change no
active no Reset by Button inactive Release by Button inactive Number of Cycles 0 Minimum Time 0 Maximum Time 0
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Ethernet IP:
Parameter Value
IP address 10.10.24.11 Net mask 255.255.0.0 Gateway 10.10.20.9 DHCP inactive BOOTP inactive
Table 24: Default values for Ethernet IP
Ethercat:
No settings are necessary.
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11 Screwdriving Strategies and Commands
11.1 Screwdriving Strategies
11.1.1 Fasten / Loosen to Torque
The screwdriving strategy fasten / loosen to torque is a tightening / loosening process with stop control via parameter torque. Angle monitoring is possible as an option.
Strategy Description:
Figure 43: Screwdriving Application to torque
Strategy description:
At the start of the screwdriving sequence cycle time monitoring is started. Cyclic torque measurements are performed. If the angle measurement option is active then angle measurements are performed additionally starting at the pre-selected torque threshold.
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 monitoring)
Analysis:
OK evaluation:
The screwdriving sequence is considered OK (fault free), if the shut off is achieved via torque and the torque value is within the preset limits. With optional Angle monitoring active the angle value must also be within the preset lim­its.
Not OK analysis:
The screwdriving sequence is evaluated as Not OK (faulty) if the final torque value is outside the preset limits or the maximum screwdriving time has been exceeded.
If angle monitoring is active the screwdriving sequence is evaluated as Not OK, if the an­gle value is outside the preset upper and lower limits.
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Parameters:
The following parameters are used in the screwdriving Sequence:
• Supervision time: maximum time until the cut-out torque is reached
• Shut-off torque, shut-off torque upper/lower limits
• Speed
• Torque holding time
• Angle supervision: active / inactive if angle monitoring is active the following parameters are added:
◦ Threshold torque for angle measurement start ◦ Angle lower limit / angle upper limit
11.1.2 Extended Fasten to Torque
The screwdriving strategy extended fasten to torque is a tightening process with shut off at a preset torque value. Angle monitoring is possible as an option.
Strategy Description:
Figure 44: Expanded scre wdriving to Torque
Strategy description:
At the start of the first screwdriving sequence/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 is changed to RPM
2. Cyclic torque measurements are performed. If the angle monitoring option is active then angle measurements are performed in addition starting at the preset torque threshold value (sequence step 2).
Shut-off criteria:
The screwdriving process is ended once the
• target shut-off torque is achieved
• the maximum screwdriving time (time monitoring) is expired
• the maximum angle of rotation is reached (only when angle monitoring is active)
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Analysis:
OK evaluation:
The screwdriving sequence is considered OK (fault free), if the shut-off occurs via tor­que and the torque value is within the preset limits. If the Angle monitoring option is active the final angle value must be within the preset limits.
Not OK evaluation:
The screwdriving sequence is evaluated as Not OK (faulty) if the final torque value is outside the preset limits or the maximum screwdriving time has been exceeded. If angle monitoring is active the screwdriving sequence is evaluated as Not OK, if the angle value is outside the preset limits.
Parameters:
The following parameters are used in the screwdriving sequence:
• Supervision time: Maximum time until the shut-off torque is reached
• shut-off torque, shut-off torque lower / upper limits
• Speed 1
• Threshold torque for Speed 2 (step 2)
• Speed 2
• Torque holding time
• Angle of rotation supervision: active / inactive if angle monitoring is active the following parameters are added.
◦ Threshold torque for angle measurement ◦ Angle lower limit / angle upper limit
11.1.3 Fasten / Loosen to Angle
The screwdriving strategy fasten / loosen to angle of rotation is a tightening / loosening process with stop control via angular displacement (angle control).
Figure 45: Screwdriving to Angle
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Figure 46: Loosening on Angle
Strategy Description:
At the start of the screwdriving sequence time monitoring and angle measurement is started. Cyclic torque measurements are performed.
Shut-off criteria:
The screwdriving process is ended once the
• shut-off angle is achieved
• the maximum screwdriving time (time monitoring) is exceeded
• the max. torque is reached
Analysis:
OK evaluation:
The screwdriving level is considered OK (fault free), if the screwdriver shut-off occurs via the angle of rotation and the value of the angle measurement is in the preset limits. Furthermore, the torque 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 been exceeded. If angle monitoring is active the screwdriving sequence is evaluated as Not OK, if the angle value is outside the preset limits.
Parameters:
The following parameters are used in the screwdriving sequence:
• Supervision time: maximum time until the shut-off angle is achieved
• Shut-off angle, shut-off angle upper/lower limits
• Torque upper/lower limits at target angle
• Speed
• Result value generation: final torque / maximum torque The resulting torque can be displayed as final torque (torque at end of screwdriving) or the maximum torque (maximum torque achieved during the cycle) in the final val­ues.
82
11.1.4 Fasten / Loosen to external Stop-Signal
The screwdriving strategy Fasten/Loosen to External Stop-Signal is a screwdriving proc­ess with switch off to external signal.
Figure 47: Fasten / Loosen to external Stop-Signal
Sequence of the Screwdriving Strategy:
• at the start of the screwdriving start of the screwdriver with pre-selected speed and time monitoring
• cyclic torque and rotation angle measurement completed
• External stop signal monitored
Switching -Off Criteria:
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) has run out
Evaluation:
O.K. Evaluation
The screwdriving level is evaluated as OK, if:
• switching off occurs via the external stop signal.
• Torque and angle are within the permissible limits.
NOT O.K. Evaluation
The screwdriving level is evaluated as not OK, if:
• the torque and angle of rotation is outside the set limits.
• the screwdriving time is exceeded.
Parameters:
• Maximum allowable time to reach the shut-off angle (time supervision)
• Shut-Off Angle min / max
• Torque min/max
• Speed
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11.1.5 Friction value package (optional)
11.1.5.1 Friction value measurement
The function of the screwing sample is the tightening of a screw, while considering the fric­tion value prior to the head connecting to the surface.
Sequence of the screwing sample
Figure 48: Friction value measurement
Switching off criteria:
The measuring process is ended once the
• end of the measuring range is reached
• a monitoring criteria is reached
• the maximum screwing time (monitoring time) is expired
Analysis:
OK evaluation:
The screwing level is considered OK (fault free), if the friction value has been determined and the value of the torque is in the set limits.
Not OK analysis:
The screwing level is evaluated as Not OK (faulty), if the friction moment in the monitored window is outside the set limits or the determined friction value is out side the indicated limits. The screwing level is also evaluated as Not OK when the monitoring time is ex­ceeded.
84
Parameter:
The following parameters are used in the screwing sample:
• Supervision time Maximum time until the screwing level is aborted
• Angle friction measurement Input of the angle range in which the friction monitoring should be active.
• Friction value type: Mean value/maximum value selectively the maximum value or mean value of the friction value can be used to de­termine the friction torque.
• Friction torque lower limit Input of a minimum torque that must not be undershot by individual torque values during the friction monitoring.
• Friction torque upper limit Input of a maximum torque that must not be exceeded by individual torque values during the friction monitoring.
• Friction value lower limit Input of the minimum torque that must not be undershot by the friction torque.
• Friction value upper limit Input of the maximum torque that must not be exceeded by the friction torque. The limits of the friction torque can be recorded tighter then the limits of the individual fric­tion values.
• Speed Input of the rotation speed that should be used for the screwing application.
11.1.5.2 Fasten to differential torque
The function of the screwing sample is the adding of a torque to an occurring torque in the screwing application in a previous stage (e.g. friction measurement).
Sequence of the screwing sample:
Figure 49: Screwing on differential torque
85
Switching off criteria:
The screwing process is ended once the
• cut-out torque is reached
• a monitoring criteria is reached
• the maximum screwing time (monitoring time) is expired
Analysis:
OK evaluation:
The screwing level is considered OK (fault free), if the switching off occurs via the differential moment and the value of the torque is in the set limits. On the angle of rotation monitoring option the reached angle must be within the set limits.
Not OK analysis:
The screwing level is evaluated as Not OK (faulty) if the torque is outside the set limits. On an active angle of rotation the screwing level is evaluated as Not OK, if the angle of rotation is outside the indicated limits. The screwing level is also evaluated as Not OK when the monitoring time is ex­ceeded.
Parameter:
The following parameters are used in the screwing sample:
• Supervision time Maximum time until the screwing level is aborted
• Differential torque Input of the differential end moment The actual target moment/torque results from the sum of the torque of the previous level and the differential moment.
• Differential torque lower limit Lower limit of the differential end moment. The actual torque lower limit results from the sum of the torque of the previous level and the lower limit of the differential mo­ment.
• Differential torque upper limit Upper limit of the differential end moment. The actual torque upper limit results from the sum of the torque of the previous level and the upper limit of the differential mo­ment.
• Speed 1 Input of the rotation speed that should be used for the screwing application.
• Threshold torque Speed 2 Input of the differential torque at which the torque decrease on the second rotation speed occurs. The actual swell torque for the rotation speed decrease results from the sum of the torque of the previous level and the differential moment.
• Speed 2 Input of the rotation speed that should be used for the screwing application.
• Torque holding time A holding time can be defined to keep the torque for this time.
• Final values type: differential torque / total torque Selectively the end torque can be displayed as difference between the total torque and the torque of the previous level or as total torque in the end values.
86
• Angle supervision: active / inactive Monitoring of the angle with a window angle if the angle monitoring is switched on, the following parameters are added:
◦ Threshold torque
Input of the torque from when the angle monitoring should be started (compare point 1 in the previous figure).
◦ Angle upper limit
Upper limit of the end angle
◦ Angle lower limit
Lower limit of the end angle
11.1.5.3 Fasten dependent on friction value
The screwing sample friction dependent screwing connects the screwing sample friction measurement and the screwing to differential moment.
Sequence of the screwing sample:
Figure 50: Screwing applications depending on friction
Switching off criteria:
The screwing process is ended once the
• cut-out torque is reached
• a monitoring criteria is reached
• the maximum screwing time (monitoring time) is expired
87
Analysis:
OK evaluation:
The screwing level is considered OK (fault free), if the switching off occurs via the differential moment and the value of the torque is in the set limits. On the angle of rotation monitoring option the reached angle must be within the set limits.
Not OK analysis:
The screwing level is evaluated as Not OK (faulty) if the torque is outside the set limits or the determined friction value is outside the indicted limits. On an active angle of rotation the screwing level is evaluated as Not OK, if the angle of rotation is outside the indicated limits. The screwing level is also evaluated as Not OK when the monitoring time is ex­ceeded.
Parameter:
The following parameters are used in the screwing sample:
• Supervision time Maximum time until the screwing level is aborted
• Threshold torque angle measurement Input of the torque from when the angle counting should be started.
• Start angle friction measurement Input of an angle that should be turned after reaching the swell moment, prior to acti­vating the friction value monitoring.
• Speed 1 Input of the rotation speed that should be used for the screwing application.
• Angle friction measurement Input of the angle range in which the friction monitoring should be active. This range starts with the start angle of the friction measurement.
• Friction value type Selectively the maximum value or mean value of the friction value can be used to de­termine the friction torque.
• Friction torque lower limit Input of a minimum torque that must not be undershot by individual torque values during the friction monitoring.
• Friction torque upper limit Input of a maximum torque that must not be exceeded by individual torque values during the friction monitoring.
• Friction value lower limit Input of the minimum torque that must not be undershot by the friction torque.
• Friction value upper limit Input of the maximum torque that must not be exceeded by the friction torque. The limits of the friction torque can be recorded tighter then the limits of the individual fric­tion values.
• Threshold torque Speed 2 Input of the differential torque at which the rotation speed decrease on the second ro­tation speed occurs. The actual swell moment for the rotation speed decrease is de­rived from the detected friction torque and the differential torque.
• Speed 2 Input of the rotation speed that should be used for the screwing application.
• Differential torque Input of the differential end moment. The actual target moment/torque results from the sum of the determined torque and the differential moment.
88
• Differential torque lower limit Lower limit of the differential end moment. The actual torque lower limit results from the sum of the lower limit of the friction moment and the lower limit of the differential moment.
• Differential torque upper limit Upper limit of the differential end moment. The actual torque upper limit results from the sum of the upper limit of the friction moment and the upper limit of the differential moment.
• Torque hold time A holding time can be defined to keep the moment for this time.
• Final values type: Differential torque / total torque Selectively the end torque can be displayed as difference between the total torque and the torque of the previous level or as total torque in the end values.
• Angle supervision: active / inactive Monitoring of the angle with a window angle if the angle monitoring is switched on, the following parameters are added:
◦ Angle upper limit
Upper limit of the end angle. The value counts starting from the end of the friction measurement.
◦ Angle lower limit
Lower limit of the end angle. The value counts starting from the end of the friction measurement.
89
11.2 Commands
11.2.1 Display values
Displays the values of the previous screwing level at the touch display. The command can used as often as you like.
11.2.2 Save values
Saves the values of the previous screwing level into the end value data set. The command can be used as often as you like (also see 8.3.4.7 Process Data Final Values).
IMPORTANT
As a maximum the last three results are saved.
11.2.3 Statistic
Affects the calculation of the statistic of the previous screw level (also see 12.3 Statistic).
IMPORTANT
The statistic can only be calculated for a screwing level per program. If the 'statistic' command is entered more than once into the program then only the statistic for the last screwing level is calculated, for which the 'statistic' command has been indicated.
11.2.4 Print
Causes the output of the result of the preceding step on the serial printer interface.
IMPORTANT
One precondition is that a printer is connected to the multifunctional printer interface and the printer is configured as a device on the serial interface (see 8.3.4.12 Setup Serial Device).
Data is printed after OK or NOT OK screw assembly according to the system settings.
11.2.5 Waiting time
Inserts a waiting time into the program.
Parameter:
• Waiting time
11.2.6 Hold position
Hold the screwdriver tension position.
Parameter:
• Holding time
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11.2.7 Wait for input
Waits for an input signal. Only available for input number 2. Change to the next step will occur as soon as the input is set.
Parameters:
• maximum waiting time
• Input number
11.2.8 Set output
Sets an output. Only available for output number 8.
Parameters:
• output number
• time supervision: yes / no
o time until reset
11.2.9 Reset output
Resets an output. Only available for output number 8.
Parameters:
• output number
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12 Documentation
The sequence controller AST11 provides a wide variety of documentation possibilities.
12.1 Final values
If the command 'save value' is used on the screwing program, then the screwing results are stored in a CSV data and can be loaded by the sequence controller via the web inter­face (see also 8.3.4.7 Process Data Final ValuesProcess Data  ). The command "save values" can be used as often as you like within the screwing process, however, only the three last values are saved. In case of a fault these values are always saved.
IMPORTANT
The data is only available if the screwing program has received the com­mand "save final values" or if a faulty screwing application is present.
One CSV data per day is saved. The last data of the last seven days is always available. The final values of the screwing application that are older than seven days are overwritten by new final values.
The final value data of the last screwing application are also saved in the file "actual.csv".
The files are subject to the same limitations as described in chapter 12.2 Curve Represen-
tation for the curve data.
The CSV file is structured as follows:
• First line: Title bar with caption of the values
• Following line: results of a screwing application per line
Value Description
Date Date of screwing application Time Time of screwing application Program number Program used Status Status, also see 14.2 Error in the screwing sequence Total duration Total duration of the program Step1 Step number of the first saved step Moment1 Torque of the first saved step Angle1 Angle of tilt of the step of the first saved step Step2 Step number of the second saved step Moment2 Torque of the second saved step Angle2 Angle of tilt of the second saved step Step3 Step number of the third saved step Moment3 Torque of the step of the third saved step Angle3 Angle of tilt of the step of the third saved step Step not OK Step number of the faulty step MomentNotOK Torque of the faulty step AngleNotOK Angle of tilt of the faulty step FC Status Not available for AST11 FC counter Not available for AST11 Torque unit Unit torque Angle unit Angle of rotation unit
Table 25: Structure of the data set
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12.2 Curve Representation
A screwdriving curve is created for every screwdriving process with the AST sequence controller. This can be viewed or saved in different ways.
• Displayed directly on the control unit in the Process Data menu area Graphic
• Download via the web-based user interface in the Process Data menu area Graphic in following formats:
◦ As binary file: The file contains the recorded raw data. The GRAPH10 viewer
program is required for viewing or processing.
◦ As CSV file: The data is converted into a table separated by commas, meaning
the values are represented as text, with commas between the columns and line feed characters between the datasets. This format can be read or edited by spreadsheet programs such as Microsoft Excel or OpenOffice.org / LibreOf­fice.org Calc. It is also possible to analyze with scripts or own programs. There are two limitations for table processing:
1. Older versions of Microsoft Excel (up to and including Excel 2003) and OpenOffice.org Calc (Versions older than 3.3) cannot process more than 65536 rows; the curve data however frequently contain more data sets. Microsoft Excel Version 2007 and newer as well as OpenOf­fice.org/LibreOffice.org Calc Version 3.3 and newer can contain 1,048,576 rows.
2. Both table processes interpret the decimal number depending on lan­guage: German version expects a decimal comma, foreign languages a decimal point, the other format is wrongly represented. The curve data for the sequence controller always uses a decimal point because this is the usual format for computer data. For the analysis with the German version of the table processing the commas should therefore be replaced by semi­colons and the decimal point by commas.
◦ As shortened CSV file: The amount of datasets is shortened under the process
limit of the table processing (65536 lines). For this, several datasets are com­bined by using the highest value respectively. If the file is shortened to half the volume, the maximum rotating speed, the maximum torque, etc. will be assem­bled into one data set from every two data sets.
• In connection with the GRAPH10 (E) curve viewer as a direct download from the con­troller
The following data is recorded:
• Rotation speed
• Torque
• Angle
• Program step
• Current strength
• Temperature of the electronics
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12.3 Statistic
If the command "statistic" is used in the screwing program then in the sequence controller AST11 a statistic is kept about the last 100 values for the respective program.
The following values are calculated for moment and angle:
• Mean value
• Standard deviation absolute
• Standard deviation percentages, based on mean value
• CP value / CPK value
The limits for the Cp/CPK value calculation can be entered. If no limits are set then the calculation is done automatically with ±15 % of the mean value. The limits entered are maintained even after switching off the sequence controller AST11.
The statistic can be displayed via the sequence controller AST11 as well as via the web interface (also see 8.2.5.2.2 can be deleted for individual programs or completely for all programs.
The statistic is deleted when the sequence controller AST11 is switched off.
Statistics and 8.3.4.5 Process Data Statistics). The statistic
12.4 Print output
Data can be printed out in ASCII format via the serial data port of the AST40. The sum­mary of the required values employs a format string template.
A format string can be summarized using random text and specified commands, whereby texts can be output directly to the printer and commands can be replaced by the respective valid value (see following table).
A command consisting of @ characters and ending with a blank character are shown for this.
Changing the format string is only possible via the web-based user interface (see
8.3.4.12.1 Printer). The print output is activated by the command "Print" during the screw-
driving process. Results of NOK screwdriving processes are always printed out.
The following commands are available:
Command Output value Output format Example
date_euro Date in Euro-format Day.Month.Year 24.04.20013 date_usa Date in US format Month/Day/Year 04/24/20013 date_iso Date in ISO format Year-Month-Day 20013-04-24 time Time Hour:Minute:Second 7:13:37 AM step Step number Value 3
torque
angle
prog Program number Value 1 errornum Status / Error number Value 0 errortext Status / Error text Error message torque underrun runtime Running time Value unit 0.5 s torquetarget Torque target value Value unit 0.200 Nm torqueLL Torque lower limit Value unit 0,000 Nm torqueUL Torque upper limit Value unit 0,350 Nm angletarget Angle target value Value unit 1080 degrees angleLL Angle lower limit Value unit 1000 degrees angleUL Angle upper limit Value unit 1150 degrees
End torque Measuring system 1 Angle measuring sys­tem 1
Value unit 0,215 Nm
Value unit 1080 °
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screwdriver Screwdriver type Value 311E27-0020 calibration Calibration value Value 1,000
StatAngleAv
StatAngleStddev%
StatAngleStddevAbs
StatAngleCPK Statistics Angle CPK Value 2.16 StatAngleCP Statistics Angle CP Value 2.03
StatAngleCPKmin
StatAngleCPKmax
StatAngleNum
StatTorqueAv
StatTorqueStddev%
StatTorqueStddevAbs
StatTorqueCPK Statistics Torque CPK Value 1,77 StatTorqueCP Statistics Torque CP Value 2,12
StatTorqueCPKmin
StatTorqueCPKmax
StatTorqueNum
fcerrornum
fcerrortext
fcpartnum Counter F-Function Value 1/5
screwcounter
title Program Title Text Standard 1
Table 26: Print parameters
Statistics Angle Mean Value Statistics Angle Stan­dard Deviation % Statistics Angle Stan­dard Deviation Abso­lute
Statistics Angle CPK Lower Limit Statistics Angle CPK Upper Limit Statistics Angle Num­ber Values Statistics Torque Mean Value Statistics Torque Stan­dard Deviation % Statistics Torque Stan­dard Deviation abs.
Statistics Torque CMK Lower Limit Statistics Torque CMK Upper Limit Statistics Torque Num­ber Values Status / Error Number F-Function Status / Error Text F­Function
Number of cycles since sequence controller has started
Value unit 1081 °
Value unit 1.36 %
Value unit 14.70
Value unit 1000 °
Value unit 1150 °
Value 96
Value unit 0,213 Nm
Value 1,7 %
Value unit 0,020 Nm
Value unit 0,000 Nm
Value unit 0,350 Nm
Value 100
Value 1
Error text TOO SHORT
Value 1236
IMPORTANT
Statistical values can only be printed if the command "Statistics" is
inserted ahead of the print command in the screwdriving process.
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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 Nm AN: 1080 °OK
The amended format string @date_euro @time Program: @prog step: @step fault: @error runtime:@runtime torque: @torque angle: @angle delivers following output, e.g.:
24.01.2013 07:13:37 Program: Step 12: 3 faults 0 runtime: 0.5 s torque: 2.15 Nm angle: 1080 °
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13 Maintenance and servicing
Incorrect disassembly or assembly can lead to injury of an operator and damage of the ma­chine. Dis assemb ly a n d assemb ly work may only be c arr ied o ut by DEPRAG or qu alifi ed personnel.
Recommendations should help to uphold warranty claims. Keep the devi ce in a dry place. Preci pit atio n, da mpness and al l type s o f f luids or w et
conditions may con tai n min erals w hich corro de electri c circuitry.
Do not keep or use the device in dusty or dirty surroundings. The moveable parts and
electronic components could be damaged.
Do not keep the device in hot conditions. High temperatures can shorten the life of
electric devices and deform or melt certain plastics.
Do not keep the device in cold conditions. 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 instructions. Do not let the device fall, be hit or bumped and do not shake it. Rough handling can
damage electronic circuitry and mechanical parts.
Do not use any harsh chemicals, cleaning solvents or strong cleaning agents to clean
the device.
Do not paint the device. Paint could stick together moveable parts and prevent correct
operation of the device.
WARNING
To avoid damage to surface finish, avoid using chlorine bleach, chlorine based cleaners, abrasive substances, ammonia, rags or cleaning pads
containing metallic particles! Use ade qu ate cl eaning agent!
Unauthorised alterations or additions can damage the de vi ce an d vi olate specif ica tio ns.
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13.1 Updating the software
13.1.1 Main control and touch display
Updating can only be done via the web interface. Registration is done as described in sec­tion 8.3.4.1 Start.
Click on Tools >> and then Update. In order to update the main control, enter the file name and path in the input field and click "load". Alternatively you can select the file by clicking the "Search..." button next to the input field.
After you clicked the "load" button the inscription "the update is being transfer to the con­troller" appears. Wait until the update file is transferred and the AST11 is started anew. "Updating Main Unit" appears on the display of the sequence controller AST11.
The update is completed when the main screen with the process display is displayed on the display.
13.1.2 Power element
Updating can only be done via the web interface. Registration is done as described in sec­tion 8.3.4.1 Start.
Click on Tools >> and then Update. In order to update the power element, enter the file name and path in the input field and click "Load". Alternatively you can select the file by clicking the "Search..." button next to the input field.
After you clicked the "Load" button the inscription "the update is being uploaded to the controller" appears. Wait until the update file is transferred and the sequence controller is started anew. "Updating Power Unit" appears on the display of the AST11.
The update is completed when the main screen with the process display is displayed on the display.
13.2 Replace the filter mat of the sequence controller
Danger
Risk of fatal injury due to electrocution! The work must only be performed by a licensed electrician! The sequence of the work process must be adhered to! Prior to opening the housing, the sequence controller must be switched
off and the power plug must be disconnected and secured against unau­thorized plugging in!
Important
The filter at the sequence controller must be replaced in regular intervals depending on the degree of contamination. The material used must meet protective class IP54. Suitable filter mats are available under the order number 826057. All screwdriving connection described in the following work steps are
loosened or bolted using a hexagon socket wrench SW 2.5.
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This is how you replace the filter mat:
1. Prior to opening the housing, the sequence controller must be switched off and the power plug must be disconnected and secured against unauthorized plugging in.
2. Loosen the six screws (hexagon socket wrench SW 2.5) at the housing rear wall.
3. Open the housing.
4. Loosen the 4 bolts of the power unit.
power unit
screw with lock washer
Figure 51: Power unit on the rear housing wall
5. Remove the power unit at the rear housing wall.
6. Pull out the filter mat from the rear wall, in the direction marked in the illustration.
power unit
filter mat
Figure 52: Filter mat on the housing rear wall
7. Place the new filter mat (part no. see 13.3 Spare parts) in a manner that the finely structured, dense side of the filter mat lays against the housings rear wall.
8. Using the four screws and the lock washer mount the power unit to the housings rear wall.
9. Using the six screws attach the rear wall.
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Caution
Prior to the re-start perform the operating media test acc. to the valid regulations, e.g. BGV A3.
13.3 Spare parts
Designation Part no.
Filter mat 826057
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