LinkNet 2 LinkNet 2
Pressroom Pressroom
Monitoring Monitoring
Software Software
Installation and Operating
Installation and Operating
Manual
Manual
LinkNet 2 inkNet 2
Link Electric & Safety Control Co.
444 McNally Drive
R
Nashville, TN 37211
Phone: (615) 833-4168
Fax: (615) 834-1984
© 2001
Table of Contents
Section 1 Introduction.......................................................................................................................... 1.1
1.1 Features.................................................................................................................................... 1.1
1.2 System Requirements............................................................................................................... 1.2
Section 2 Installation............................................................................................................................ 2.1
2.1 RS232-RS485 Converter Network Connections ..................................................................... 2.2
2.2 Drop Box Network Connections.............................................................................................. 2.2
2.3 OmniLink LCD Operator Terminal Network Connections..................................................... 2.4
2.4 OmniLink II LCD Operator Terminal Network Connections ................................................. 2.5
2.5 MicroLink Operator Terminal Network Connections ............................................................. 2.6
2.6 System 1100 Connections........................................................................................................ 2.7
2.7 Software Installation ................................................................................................................ 2.8
Section 3 Terminology......................................................................................................................... 3.1
Section 4 Configuration ....................................................................................................................... 4.1
4.1 LinkNet Security...................................................................................................................... 4.1
4.2 Operator Configuration............................................................................................................ 4.2
4.2.1 Adding an Operator.......................................................................................................... 4.2
4.2.2 Editing an Operator.......................................................................................................... 4.4
4.2.3 Deleting an Operator........................................................................................................ 4.4
4.3 Database Location Configuration (Standalone and Server Versions Only) ............................ 4.5
4.4 Database and Server IP Address Configuration (Client Version Only) .................................. 4.5
4.5 Communications Port Configuration ....................................................................................... 4.6
4.6 Configuring Shifts.................................................................................................................... 4.7
4.6.1 Adding a Shift.................................................................................................................. 4.7
4.6.2 Editing a Shift .................................................................................................................. 4.7
4.6.3 Deleting a Shift ................................................................................................................ 4.7
4.7 Configuring the Shift Schedule................................................................................................ 4.8
4.7.1 Adding a Shift Schedule Time....................................................................................... 4.10
4.7.2 Adding a Break Time..................................................................................................... 4.10
4.7.3 Adding a One-Time Schedule Entry.............................................................................. 4.11
4.7.4 Adding a One-Time Break............................................................................................. 4.11
4.8 Down Time Configuration..................................................................................................... 4.12
4.8.1 Down Time Category Configuration ............................................................................. 4.12
4.8.2 Down Time Code Configuration ................................................................................... 4.14
4.9 Machine Configuration .......................................................................................................... 4.16
4.9.1 Adding a Machine.......................................................................................................... 4.16
4.9.2 Editing a Machine.......................................................................................................... 4.20
4.9.3 Deleting a Machine ........................................................................................................ 4.20
4.10 Material Configuration........................................................................................................... 4.21
4.10.1 Adding Material............................................................................................................. 4.21
4.10.2 Editing Material ............................................................................................................. 4.23
4.10.3 Deleting Material ........................................................................................................... 4.23
4.11 Tooling Configuration ........................................................................................................... 4.24
4.11.1 Adding a Tool ................................................................................................................ 4.24
4.11.2 Editing Tooling .............................................................................................................. 4.26
4.11.3 Deleting Tooling ............................................................................................................ 4.26
4.12 Part Configuration.................................................................................................................. 4.27
4.12.1 Adding a Part ................................................................................................................. 4.27
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4.12.2 Editing Parts................................................................................................................... 4.29
4.12.3 Deleting Parts................................................................................................................. 4.29
4.13 Job Configuration................................................................................................................... 4.30
4.13.1 Adding a Job .................................................................................................................. 4.31
4.13.2 Editing Jobs.................................................................................................................... 4.35
4.13.3 Deleting Jobs.................................................................................................................. 4.35
4.14 Tonnage Wave Capture Configuration .................................................................................. 4.36
4.15 Preventive Maintenance Configuration ................................................................................. 4.37
4.15.1 Adding a Preventive Maintenance Item......................................................................... 4.38
4.15.2 Editing a Preventive Maintenance Item......................................................................... 4.39
4.15.3 Deleting a Preventive Maintenance Item....................................................................... 4.39
4.15.4 Resetting a Preventive Maintenance Item...................................................................... 4.40
Section 5 Using LinkNet...................................................................................................................... 5.1
5.1 The Overview Window............................................................................................................ 5.1
5.2 Detail Dialogs .......................................................................................................................... 5.2
5.2.1 Counter Detail.................................................................................................................. 5.2
5.2.2 Tonnage Detail................................................................................................................. 5.3
5.2.3 Average Tonnage Graph Detail ....................................................................................... 5.4
5.2.4 Stroking Rate Graph Detail.............................................................................................. 5.5
5.2.5 SPM Rates Detail............................................................................................................. 5.6
5.3 The “Window” Menu............................................................................................................... 5.6
5.4 The “Help” Menu..................................................................................................................... 5.6
Section 6 Reports ................................................................................................................................. 6.1
6.1 Report Parameter Selection...................................................................................................... 6.1
6.1.1 Report Time Selection ..................................................................................................... 6.1
6.1.2 Report Shifts Selection .................................................................................................... 6.2
6.1.3 Report Machine Selection................................................................................................ 6.3
6.1.4 Report Tool Selection ...................................................................................................... 6.4
6.1.5 Report Part Selection ....................................................................................................... 6.5
6.2 Machine Reports – Event Log ................................................................................................. 6.5
6.3 Machine Reports – DTC Summary.......................................................................................... 6.6
6.4 Machine Reports – Time Summary ......................................................................................... 6.6
6.5 Machine Reports – SPM Rate Summary ................................................................................. 6.6
6.6 Machine Reports – Stroke Productivity................................................................................... 6.7
6.7 Tool Reports – Usage Summary.............................................................................................. 6.7
6.8 Tool Reports – Machine Comparison...................................................................................... 6.7
6.9 Tool Reports – Tool Down Summary...................................................................................... 6.8
6.10 Tool Reports – Tool Down Detail ........................................................................................... 6.8
6.11 Tool Reports - Trend................................................................................................................ 6.8
6.12 Part Reports – Machine Comparison ....................................................................................... 6.8
6.13 Part Reports - Trend................................................................................................................. 6.9
6.14 Preventive Maintenance Reports – Tripped Items................................................................... 6.9
6.15 Preventive Maintenance Reports – All Items .......................................................................... 6.9
Section 7 Using the OmniLink 5000 with LinkNet (Monochrome OIT) ............................................ 7.1
7.1 Configuring the OmniLink 5000 for LinkNet (Monochrome OIT)......................................... 7.1
7.2 Using Down Time Codes on the OmniLink 5000 (Monochrome OIT) .................................. 7.3
7.3 Network Job Storage on the OmniLink 5000 (Monochrome OIT) ......................................... 7.4
7.4 Network Job Recall on the OmniLink 5000 (Monochrome OIT) ........................................... 7.4
7.5 Sending Tonnage Graphs from the OmniLink 5000 (Monochrome OIT)............................... 7.5
7.6 Viewing Machine and Job Notes on the OmniLink 5000 (Monochrome OIT)....................... 7.5
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Section 8 Using the OmniLink 5000 with LinkNet (Color OIT)......................................................... 8.1
8.1 Configuring the OmniLink 5000 for LinkNet (Color OIT)..................................................... 8.1
8.2 Using Down Time Codes on the OmniLink 5000 (Color OIT)............................................... 8.3
8.3 Network Job Storage on the OmniLink 5000 (Color OIT)...................................................... 8.4
8.4 Network Job Recall on the OmniLink 5000 (Color OIT)........................................................ 8.4
8.5 Sending Tonnage Graphs from the OmniLink 5000 (Color OIT) ........................................... 8.5
8.6 Viewing Machine and Job Notes on the OmniLink 5000 (Color OIT) ................................... 8.6
Section 9 Using the MicroLink OIT with LinkNet.............................................................................. 9.1
9.1 Configuring the MicroLink OIT for LinkNet .......................................................................... 9.1
9.2 Using Down Time Codes on the MicroLink OIT.................................................................... 9.1
9.3 Network Job Storage on the MicroLink OIT........................................................................... 9.2
9.4 Network Job Recall on the MicroLink OIT............................................................................. 9.2
9.5 Viewing Machine and Job Notes on the MicroLink OIT ........................................................ 9.3
Section 10 Using the System 1100 Tonnage Monitor with LinkNet............................................... 10.1
10.1 Configuring the System 1100 Tonnage Monitor for LinkNet ............................................... 10.1
10.2 Using Down Time Codes on the System 1100 Tonnage Monitor......................................... 10.1
10.3 Network Job Storage on the System 1100 ............................................................................. 10.2
10.4 Network Job Recall on the System 1100 ............................................................................... 10.3
10.5 Sending a Tonnage Graph from the System 1100 ................................................................. 10.4
10.6 The Network Clock on the System 1100 ............................................................................... 10.4
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Table of Figures
Figure 2.1: LinkNet Wiring Overview ............................................................................................... 2.1
Figure 2.2: Regular Drop Box Network Connections........................................................................ 2.3
Figure 2.3: Repeater Drop Box Network Connections ...................................................................... 2.3
Figure 2.4: OmniLink LCD Operator Terminal (Back Panel View) Network Connections.............. 2.4
Figure 2.5: OmniLink II LCD Operator Terminal (Front View) ....................................................... 2.5
Figure 2.6: OmniLink II LCD Operator Terminal (Back Panel View) Network Connections.......... 2.5
Figure 2.7: MicroLink Operator Terminal (Back View).................................................................... 2.6
Figure 2.8: System 1100 Network Connections................................................................................. 2.7
Figure 3.1: Off-Fall Example – Stamping a Circle Out of a Square .................................................. 3.1
Figure 3.2: Relationship Between Machines, Tools, Material, Parts, and Jobs ................................. 3.2
Figure 4.1: Operator Login................................................................................................................. 4.1
Figure 4.2: Operator Listing............................................................................................................... 4.2
Figure 4.3: Operator Configuration General Dialog .......................................................................... 4.2
Figure 4.4: Operator Configuration Computer Permissions Dialog................................................... 4.3
Figure 4.5: Operator Configuration Miscellaneous Settings Dialog.................................................. 4.3
Figure 4.6: Operator Configuration Notes Dialog Box ...................................................................... 4.4
Figure 4.7 Database Location Configuration Dialog ........................................................................ 4.5
Figure 4.8: Database Location and Server IP Address Configuration Dialog ................................... 4.5
Figure 4.9: Communication Port Configuration Dialog Box ............................................................. 4.6
Figure 4.10: Shift Listing Dialog Box.................................................................................................. 4.7
Figure 4.11: Shift Configuration Dialog Box....................................................................................... 4.7
Figure 4.12 Pressroom Schedule Listing Dialog Box ......................................................................... 4.8
Figure 4.13: Schedule Time Configuration Dialog Box .................................................................... 4.10
Figure 4.14: One-Time Schedule Entry Dialog Box.......................................................................... 4.11
Figure 4.15: Down Time Category Listing ........................................................................................ 4.12
Figure 4.16: Down Time Category Configuration Dialog Box.......................................................... 4.13
Figure 4.17: Down Time Code Listing............................................................................................... 4.14
Figure 4.18: Down Time Code Configuration Dialog Box................................................................ 4.14
Figure 4.19: Machine Listing ............................................................................................................. 4.16
Figure 4.20: Machine Configuration General Settings Dialog Box................................................... 4.16
Figure 4.21: Machine Configuration Physical Characteristics Dialog Box ....................................... 4.17
Figure 4.22: Machine Configuration Stroking Modes Dialog Box.................................................... 4.18
Figure 4.23: Machine Miscellaneous Settings Dialog Box................................................................ 4.19
Figure 4.24: Material Listing.............................................................................................................. 4.21
Figure 4.25: Material Configuration General Settings Dialog Box ................................................... 4.21
Figure 4.26: Material Configuration Physical Characteristics Dialog Box........................................ 4.22
Figure 4.27: Tool Listing.................................................................................................................... 4.24
Figure 4.28: Tool Configuration General Settings Dialog Box............................................................. 4.24
Figure 4.29: Tool Configuration Physical Characteristics Dialog Box.............................................. 4.25
Figure 4.30: Part Listing..................................................................................................................... 4.27
Figure 4.31: Part Configuration General Settings .............................................................................. 4.27
Figure 4.32: Part Configuration Physical Characteristics Settings .................................................... 4.28
Figure 4.33: Job Listing...................................................................................................................... 4.30
Figure 4.34: Job Configuration Machine Selection............................................................................ 4.31
Figure 4.35: Job Configuration General Settings Dialog Box ........................................................... 4.31
Figure 4.36: Job Configuration Physical Characteristics Dialog Box................................................ 4.33
Figure 4.37: Jog Configuration Tooling Dialog Box ......................................................................... 4.34
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Figure 4.38: Tonnage Waveform Configuration Dialog Box ............................................................ 4.36
Figure 4.39: Machine Configuration Preventive Maintenance Dialog Box....................................... 4.37
Figure 4.40: Tool Configuration Preventive Maintenance Dialog Box ............................................. 4.37
Figure 4.41: Preventive Maintenance Configuration Dialog Box...................................................... 4.38
Figure 5.1: Pressroom Overview Screen............................................................................................ 5.1
Figure 5.2: Machine Detail “Counters” Dialog Box .......................................................................... 5.2
Figure 5.3: Machine Detail “Tonnage” Dialog Box........................................................................... 5.3
Figure 5.4: Machine Detail “Average Tonnage Graph” Dialog Box ................................................. 5.4
Figure 5.5: Machine Detail “Stroking Rate Graph” Dialog Box........................................................ 5.5
Figure 5.6: Machine Detail “SPM Rates” Dialog Box....................................................................... 5.6
Figure 6.1: Report Time Selection Dialog Box.................................................................................. 6.1
Figure 6.2: Report Shift Selection Dialog Box .................................................................................. 6.2
Figure 6.3: Report Machine Selection Dialog Box ............................................................................ 6.3
Figure 6.4: Report Tool Selection Dialog Box................................................................................... 6.4
Figure 6.5: Report Part Selection Dialog Box.................................................................................... 6.5
Figure 7.1: OmniLink (Monochrome) Main Configuration Screen................................................... 7.1
Figure 7.2: OmniLink (Monochrome) Configuration Screen ............................................................ 7.1
Figure 7.3: OmniLink (Monochrome) Communications Configuration Screen................................ 7.2
Figure 7.4: OmniLink (Monochrome) Network Configuration Screen ............................................. 7.2
Figure 7.5: OmniLink (Monochrome) Down Time Code Screen ...................................................... 7.3
Figure 8.1: OmniLink Main Configuration Screen (Color Terminal)................................................ 8.1
Figure 8.2: OmniLink Operator Terminal Configuration Screen (Color OIT) .................................. 8.2
Figure 8.3: OmniLink Auxiliary Communications Configuration Screen (Color Terminal) ............ 8.2
Figure 8.4: OmniLink Down Time Code Screen (Color OIT)........................................................... 8.3
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Section 1 Introduction
The Link Systems Network Application (LinkNet 2) provides detailed monitoring of stamping
operations utilizing Link equipment. Supported equipment includes the OmniLink 5000 press control
and associated option modules, the System 1100 tonnage monitor, and MicroLink operator terminal
(both alone and when used with a MultiSet). By using a simple to wire “daisy chained” cable
arrangement to attach these units to an Intel based personal computer running Microsoft Windows, a
wealth of information can be gathered automatically.
1.1 Features
• Average tonnage, highest good tonnage, and lowest good tonnage are collected (from equipment
with tonnage monitors) in 10-minute intervals. This gives a good view of the consistency of the
production process.
• Production Rate is collected in 10-minute intervals. The production rate is also factored into
summary information for press utilization calculations versus standard rate. Production rate is
captured two ways:
• Actual Average - This is the actual average production rate over the scheduled time
the press is run.
• Production Average - This is the average production rate when the press is actually
running. This number indicates the typical stroking rate that the press is set to run.
• Down time codes and down time categories may be defined. A description for each down time
code can be typed in once at the computer and the descriptions are downloaded to all Link
equipment on the network. The user may choose from the descriptions, not just the numeric
code, at the press.
• “Events” are recorded. Events are automatically logged in the same databases as down time
codes. Examples of events include tonnage alarms, bypass changes to tonnage monitor and die
protection, die protection faults, part counter limits, etc.
• Some of the statistics available in reports include average SPM, production SPM, average PPM,
production PPM, OEE, average efficiency (versus user defined standard), production efficiency
(versus user defined standard), average setup time, down time, total hours, production hours, and
percent production time.
• The above statistics are associated with date and time, shift, machine number, job number, tool
number, and run.
• All data is stored in industry standard Microsoft Access 2000 database files. These files can be
read from many common spreadsheets, reporting tools, visual basic, etc.
• Jobs may be stored and recalled to and from the host computer giving Link equipment attached
to the network essentially unlimited job storage
• Standard reports are provided by LinkNet to make the information gathered by the system more
accessible and easier to interpret.
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• Reports are generated using Seagate Software Crystal Reports. This allows the end user to
customize (with separate purchase of Crystal Reports from any software vendor) LinkNet 2
reports for any special requirements, add a company logo, etc.
• Preventive Maintenance setpoints can be set by elapsed time, press running time, and strokes.
OmniLink 5000 controls additionally support setpoints by “Motor On” time, Total feed length,
and Clutch/Brake engagements.
• Tonnage signatures can be sent from OmniLink 5000 and System 1100 tonnage monitors to the
network for analysis, storage, or printing. Previous signatures can be overlaid for direct
comparison.
• Notes for each machine and die can be entered at the computer and viewed on OmniLink 5000
operator terminals.
1.2 System Requirements
LinkNet has been designed to run on Windows 98, Windows ME, Windows NT, or Windows 2000
operating systems.
Minimum Hardware Requirements:
• Pentium III or Celeron 500MHz CPU
• Windows 98 Operating System
• 64MB memory
• 10GB hard drive
• SVGA (800 by 600) display
• Mouse
• At least one free RS232 serial port
Recommended Hardware:
• Pentium III 800MHz CPU or better
• Windows 2000 Operating System
• 256MB memory
• 20GB or larger hard drive
• SVGA (1024 by 768) display or better
• Mouse
• At least one free RS232 serial port
1.2
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Section 2 Installation
LinkNet is connected to each piece of equipment in a bussed arrangement commonly called “daisy
chaining”. The means that the communications cable goes from the computer to the first machine, from
the first machine to the second, from the second to the third, and so on as shown in Figure 2.1.
The “Drop Boxes” shown in the figure are small boxes that contain plugable terminal strips. The
boxes mount on the press and serve as junctions for the network wire to come in to the machine, go out
to the next machine, and drop to Link equipment. In addition, the boxes can contain circuitry (called a
repeater) to enable the network to work with extremely long cable lengths or with more than 32
machines. At the computer, an RS232 to RS485 converter is necessary. This converts the standard
serial port on the host computer to a differential serial port suitable for electrically noisy industrial
environments. Link makes an RS232 to RS485 converter specifically for this purpose with termination
resistors built in that provide for reliable communications.
The computer that runs the network should be capable of running Windows 98, Windows ME,
Windows NT 4.0 (service pack 4 or higher), or Windows 2000.
Windows 2000 is the preferred platform for LinkNet 2. LinkNet 2 will run on the
other Windows version mentioned above, but Windows 2000 has proven to be far
more stable!
The network wiring should be Belden 8103 or equivalent (three twisted pairs and a shield) and
should not exceed 4000 ft (unless using a repeater).
Unit
Drop
Box
In
Out
Unit
Drop
Box
In
Out
Unit
Drop
Box
In
Out
Unit
Drop
Box
In
Out
Unit
Drop
Box
In
Out
Unit
Drop
Box
In
Out
Figure 2.1: LinkNet Wiring Overview
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Unit
Drop
Box
In
Out
Unit
Drop
Box
In
Out
Belden 8103 cable and many similar cables organized as twisted pairs use a special color code
scheme. Instead of each wire using a different color, each pair uses a color. One wire in the pair is
predominately white with a thin color stripe, and the other wire in the pair is predominately the color
with a thin white stripe. When referring to these wires a common convention names the predominate
color first. For example, a blue wire with a thin white stripe is called blue with white (shortened to
blue/white). A white wire with a thin blue stripe is called white with blue (shortened to white/blue).
This convention will be used in this document.
Other wire types can be used, but assuming Belden 8103 cable and the Link RS232 to RS485
converter, the network should be wired as shown in the following sections.
2.1 RS232-RS485 Converter Network Connections
The Link converter is labeled the same way as network drop boxes on the RS485 side. The RS232
side is equipped with a 6' cable that plugs into any standard 9-pin serial port connector on the host
computer. A power cord is also provided. The six terminal RS485 connector should be wired as
follows:
GND - Green/White and White/Green
RXD+ - Orange/White
RXD- - White/Orange
TXD+ - Blue/White
TXD- - White/Blue
SHLD - Shield (bare) Wire of Cable
Although not recommended, if another kind of RS-232 to RS-485 converter is used, it should be set
up in the following manner:
1) If configurable, transmit should always be on.
2) TX+ should connect to RXD+ on the drop box (Orange/White wire).
3) TX- should connect to RXD- on the drop box (White/Orange wire).
4) RX+ should connect to TXD+ on the drop box (Blue/White wire).
5) RX- should connect to TXD- on the drop box (White/Blue wire).
Note that “RX” and “TX” can be called different things depending on the manufacturer of the
converter, but will usually reflect some variation of “transmit” and “receive” (such as TXD and RXD).
2.2 Drop Box Network Connections
There are two kinds of drop boxes, regular and repeater. Regular drop boxes (Figure 2.2) simply
have connectors for field wiring to pass through the communication signals. Repeater drop boxes
(Figure 2.3) have active circuitry in addition to the terminals the regular drop box has. This circuitry
allows the network to extend over 4000ft and can allow more than 32 units to be attached to the line.
Drop boxes have three sets of plugable terminal strips labeled “DATA IN”, “DATA OUT”, and
“UNIT”. The terminal strip labeled “DATA IN” should be connected to the wire coming from the host
computer side, “DATA OUT” should go to the next drop box, and “UNIT” should go to the Link
equipment on the press.
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Figure 2.2: Regular Drop Box Network Connections
Figure 2.3: Repeater Drop Box Network Connections
All three connectors should be wired as follows:
GND Green/White and White/Green
RXD+ Orange/White
RXD- White/Orange
TXD+ Blue/White
TXD- White/Blue
SHLD Shield (bare) Wire of Cable
For Repeaters Only:
L1 “Hot” side of 110V AC
L2 “Neutral” side of 110V AC
M. GND Machine Ground
Some older versions of the drop box do not have the “SHLD” terminal. In this case, tie the shields of all
the cables together with a wire nut.
Whenever possible, the drop boxes should be mounted on the press in easy reach for troubleshooting
purposes. In addition, the length of the line from the drop box to the Link equipment should be kept as
short as reasonably possible. The drop boxes have knockouts sized for ½” conduit or cord grips.
2.3
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2.3 OmniLink LCD Operator Terminal Network Connections
There should be five connectors on the
back of the OmniLink 5000 operator
interface terminal as shown in Figure 2.4.
If only four connectors are present, then
an older communications board is
installed. If this is the case, contact Link
for pricing to upgrade the unit to the new
communications board with network
support. Port 5 is the network port and
should be wired as follows:
REF Green/White and White/Green
RXD+ Orange/White
RXD- White/Orange
TXD+ Blue/White
TXD- White/Blue
Figure 2.4: OmniLink LCD Operator Terminal (Back Panel
View) Network Connections
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2.4 OmniLink II LCD Operator Terminal Network Connections
Figure 2.5: OmniLink II LCD Operator Terminal (Front View)
There are eight connectors and a fuse on the back panel of the OmniLink II LCD operator terminal
as shown in Figure 2.6. Port 5 is the network port and should be wired as follows:
ISO GND Green/White and White/Green
+R Orange/White
-R White/Orange
+T Blue/White
-T White/Blue
Network Port
Figure 2.6: OmniLink II LCD Operator Terminal (Back Panel View) Network Connections
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2.5 MicroLink Operator Terminal Network Connections
The communications ports for the MicroLink operator terminal are internal to the unit. The back
cover must be removed to access the ports. Figure 2.7 shows a view of the inside of the MicroLink
terminal. Note that ports 4 and 5 reside on an optional (but usually present) “piggyback” circuit board.
If for some reason this card is not present, contact Link for upgrade information and pricing.
Port 5 is the network port and should be wired as follows:
REF Green/White and White/Green
RXD+ Orange/White
RXD- White/Orange
TXD+ Blue/White
TXD- White/Blue
Figure 2.7: MicroLink Operator Terminal (Back View)
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2.6 System 1100 Connections
System 1100 tonnage monitors with software versions older than version 3.2 in the operator
interface board (the circuit board that is mounted on the door of the 1100) will need to have a software
upgrade in order to function with LinkNet. Contact Link for the appropriate software. The System 1100
has three terminal strips on the circuit board mounted to the door of the unit, two of which should
already be wired. The “NETWORK” port (see Figure 2.8) should be wired as follows:
Terminal A Green/White and White/Green
Terminal B White/Blue
Terminal C Blue/White
Terminal D White/Orange
Terminal E Orange/White
Figure 2.8: System 1100 Network Connections
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2.7 Software Installation
Once the wiring is completed, the software on the host computer must be installed. Insert the
LinkNet compact disk (CD) in the computers CD-ROM drive. If “Auto Insert Notification” is enabled
for the drive (it is by default), then the LinkNet installation program will automatically start when the
CD is inserted. If for some reason “Auto Insert Notification” is not enabled, hit the “Start” button on the
desktop, select “Run...” and when prompted for the name of the program to run type “D:\SETUP”
(without the quotes) and hit the “OK” button. Note that the “D” in “D:\SETUP” should be the drive
letter of your CD-ROM drive.
The installation program will ask where to put the LinkNet files. It is strongly recommended that the
default directory be accepted. Program and data files will then be installed.
The installation program will create a new program group called “LinkNet” and will put a LinkNet
icon on the windows desktop. To start LinkNet, double click on the icon on the desktop, or select it
from the programs menu by hitting the Windows “Start” button, then “Programs”, then the “LinkNet”
group, and then the “LinkNet” selection in that group.
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Section 3 Terminology
In order to fully understand and get the best use of this manual, it is strongly
suggested that this section be read!
Throughout this manual, certain terms are used to describe measurements, statistics, and actions.
Since these terms may mean different things to different people, their meaning as used by LinkNet will
be explained in this section.
• Part - The part is the intended product of a manufacturing operation. For LinkNet this
will usually be a stamping operation. Note that this may not be the desired final
product, as more operations (even additional stamping operations) may need to be
performed on it. In other words, the part from one manufacturing process may
become the material for the next manufacturing process.
• Material - The input to a manufacturing operation from which parts are made. For stamping,
material is typically metal and may come in several forms.
• Sheet - A sheet is a rectangular (or square), flat portion of material.
• Strip - A strip is a long, narrow portion of material. It is sometimes referred to as a
“stick” of material.
• Coil - Material that has been rolled up to better facilitate automated production
processes. This type of material is typically fed to the press from a roll feeder.
• Blank - Material produced from a larger sheet, strip, or coil of material that will be
operated on to produce a part. It may be produced by cutting, shearing, or
from a previous stamping operation.
• Piece - Material usually produced by secondary operations on a blank. It is then fed
into further stamping operations.
• Off-Fall - The portion of the material that is trimmed, cut, or otherwise removed from the
material that becomes the desired part. Note that this is NOT the same thing as
scrap. For example, if feeding a die with square blanks produces a circle, the
portion of material outside the circle that is cut from the blank is the off-fall (see
Figure 3.1).
Off-Fall
Blank
Figure 3.1: Off-Fall Example – Stamping a Circle Out of a Square
Stamping
Operation
3.1
Part
Off-Fall
Manual Version 1.1 10/28/2001
Off-Fall
Off-Fall
• Scrap - The portion of material that ideally would have been a good part, but due to some
defect is not usable. For instance, if a punch in the die breaks, one or more parts
may be made missing a hole. These parts are scrap (unless they can be
reworked).
• Tool - A device used to shape or to perform work on material. For stamping, it is
usually called a die and consists of an upper portion attached to the slide of the
press and a lower portion attached to the bolster of the press. Note that in some
cases more than one tool may be used in a single stamping operation.
• Machine - A machine, as used in LinkNet, is the equipment (typically, but not always, a
stamping press) on which Link products with networking capability are used to
collect information.
• Job - A job, as used by LinkNet, represents a manufacturing process that brings
together a machine, one or more tools, and material to produce a part. Figure 3.2
demonstrates the relationship between these items.
Machine
Number
Capacity
Etc.
Tool 2 (If Applicable)
Tool 1
Job
Machine Number
Material Number
Tool Number
Part Number
Figure 3.2: Relationship Between Machines, Tools, Material, Parts, and Jobs
Press Control Settings
Tonnage Monitor Settings
Die Protection Settings
PLS Settings
Auto-Setup Settings
Etc.
Material
Part
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• Run - A run is the production of a certain number of parts from a job. While LinkNet
collects data by date, shift, etc., it also collects statistics by run. For example,
assume 20000 of part number PN-XYZ are made using job number 123 on press
number 456. The job starts on a Tuesday, runs for 36 hours, and ends on a
Thursday. The 20000 parts made would be one “run” of job 123 even though it
crossed multiple days and multiple shifts.
• Down Time Code - A code used to assign a “reason” that the machine is down (not
running production). Note that in LinkNet, the person entering the reason does
not actually have to remember a numeric code. LinkNet sends the actual
description of the code to each machine on the network. The operator selects
from a list of down time reasons rather than a numeric code.
• Down Time Category - Each down time code has a category to which it belongs. A
category groups related down time codes so they can be considered as a whole.
For instance, job setup may consist of mounting a coil of material, setting the tool
in the press, threading material through the die, and running the process until the
first good part is produced. Each of the previously mentioned individual actions
can be tracked with a down time code, but the total job setup will tracked by the
“Job Setup” down time category.
• Actual Average SPM - The average SPM the press made over all scheduled time. This
DOES count time when the press is on the schedule but down. This does NOT
count time when the press is off-schedule.
• Production Average SPM - May also be called “Average Production SPM”. The average
SPM the press made over all scheduled time when in production (NOT down).
This does NOT count time when the press was idle or down, and does NOT count
time when the press is off-schedule. The intention of this measurement is to show
the speed the press was running when it was running. In some dies, process
limitation (drawing, etc.) can limit the speed at which the process should be run
even if the machine can go faster. On the other hand, we generally want to run
the job as fast as we safely can in order to make money. This measurement
should closely track the stroking speed of the press.
• Job Standard Average SPM - Each Machine/Job combination can have a standard
average SPM. On many reports, the average actual SPM will be compared to this
value in order to generate a machine efficiency percentage.
• Job Standard Production SPM - Each Machine/Job combination can have a standard
production SPM. This is intended to be set to the stroking rate of the press when
running the job. On some reports, a production efficiency percentage will be
generated. This percentage is intended to show when the press is being run too
slow or too fast.
• Scheduled Time - The portion of time that is scheduled as part of a shift. In other words, this
is the time when the machine can be operating. See section 4.7 for details on
schedule configuration.
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• Break Time - Time during a shift when operators are on break. Data is collected but under a
break time code. See section 4.7 for details on schedule configuration.
• Off Schedule Time - Time when no shift should be active. For instance, if the plant is shut
down on Sunday, this is off-schedule time. Some, but not all, data is still logged,
but under the off-schedule time code. See section 4.7 for details on schedule
configuration.
• Shift Date - A shift date can be different from the calendar date. For instance, a shift
could start on Sunday at 10:00PM and end on Monday at 6:00AM. The shift
spans two calendar days. Whatever day of the week this shift is configured on
(see section 4.7 for details on schedule configuration) is the shift date for this
shift.
• OEE - Overall Equipment Effectiveness. This is a standard measurement use in
some circles to measure how effectively equipment is being used. To boil it
down, this is the percentage of parts produced versus the amount of parts that
could have been produced had everything run perfectly and at best speed.
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Section 4 Configuration
After the software is installed, it must be configured. This consists of the following steps:
• Configure LinkNet security.
• Select a communications port for LinkNet to use to “talk” to the machines.
• Configure the number of shifts, and shift times for each day.
• Enter any additional down time categories to the standard categories supplied.
• Enter down time codes and their descriptions.
• Enter material information.
• Enter tool information.
• Enter part information.
• Tell LinkNet what machines are present.
• Tell LinkNet what dies are present.
• Configure preventive maintenance.
4.1 LinkNet Security
LinkNet prevents unauthorized changes to its
configuration by allowing the configuration of
multiple operators, each with their own pass codes
and permissions. As shipped, there is only one
user, “Admin”, with a pass code of 444. The only
permission “Admin” has, as shipped, is to
configure other operators. After configuring
additional operators, the Admin pass code should
be changed to something other value. Pass codes
are four digit numeric values. The “Admin”
operator cannot be deleted.
NOTE: It is VERY important to
change the “Admin” pass code from its
default value. Failure to do so leaves
your system open to abuse since it is
likely that the default pass code can and
will be generally known.
When choosing a protected menu item in LinkNet
(any configuration item is protected), a login list
Figure 4.1: Operator Login
similar to Figure 4.1 will be displayed. Only
operators with the permission to change the item selected will be displayed in the list. Select the
appropriate operator name and the pass code will be requested. After the pass code is successfully
entered, LinkNet will allow changes to the configuration. The login will remain active as long as there
is activity by the user. When 1 minute passes with no activity by the user, the login will automatically
terminate.
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4.2 Operator Configuration
Before anything else can be
done in LinkNet, operators must be
configured. Any number of
operators can be configured, each
with separate pass codes and
permissions. To configure
operators, select “Configure” and
then “Operators” from the LinkNet
menu. The login list should appear
(See Figure 4.1 for an example).
After login, an operator list box
similar to Figure 4.2 should appear.
From the operator configuration
list, operators can be added, edited,
or deleted.
4.2.1 Adding an Operator
Figure 4.2: Operator Listing
To add an operator, hit the
“Add Operator” button at the
bottom of the operator list (see
Figure 4.2). A dialog box similar to
Figure 4.3 will appear. Clicking
the “Tabs” along the top of the
dialog box (labeled “General”,
“Comp. Perm.”, “Miscellaneous”,
and “Notes”) will show different
aspects of the operator
configuration.
4.2.1.1 Operator General
Information
The “General” tab (see Figure
4.3 for an example) contains, as
expected, some general information
about the operator. The first entry
needed is “Operator Name”. This
can be the name of a specific
Figure 4.3: Operator Configuration General Dialog
person, a job description, or
anything else meaningful and will show up in the login list as shown in Figure 4.1. “Employee ID” is an
optional field. At present, it is not used by LinkNet itself. The pass code can be up to four numeric
digits. “Operator Number”, at the bottom of the dialog box, is the unique number assigned to the
operator for internal database operations and is displayed for information only.
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4.2.1.2 Operator Computer Permissions
The “Comp. Perm.” (Computer
Permissions) tab is used to configure the
operations each LinkNet user is allowed
to do. Note that there is more than one
“Comp. Perm.” tab. Check each item
the user is allowed to do by clicking on
the item (clicking the item will toggle
the check mark). Make sure each item
the user is NOT allowed to do is
unchecked. Be sure to go to each
“Comp. Perm.” tab to select all the
user’s permissions.
Figure 4.4: Operator Configuration Computer Permissions Dialog
4.2.1.3 Operator Miscellaneous Settings
The “Miscellaneous” tab contains
three customer-defined fields, which are
50 character alphanumeric. These
settings are not used by LinkNet but can
be used to store any other information
desired. One use for these fields might
be as a way for external programs or
databases to find data in LinkNet
databases.
Figure 4.5: Operator Configuration Miscellaneous Settings Dialog
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4.2.1.4 Operator Notes
The “Notes” tab allows notes to be
entered for the operator. These notes
are for reference use and are completely
free form. The length of the notes is
essentially unlimited.
Figure 4.6: Operator Configuration Notes Dialog Box
4.2.2 Editing an Operator
To edit an operator, double click on the operator name in the operator configuration list (see Figure
4.2 for an example), or select an operator in the list by single clicking it, and hit the “Edit Operator”
button. This will bring up the same editing dialogs as used when adding an operator. See Section 4.2.1
for details.
4.2.3 Deleting an Operator
To delete an operator, select an operator from the list by single clicking it, and hit the “Delete
Operator” button. A box will appear asking for confirmation for the deletion. Note that the “Admin”
operator cannot be deleted.
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4.3 Database Location Configuration (Standalone and Server Versions Only)
By default, LinkNet stores its
database files in the directory where it is
installed. This can be changed,
however, so that the database files can
be stored on a network server for easier
backup. To change the database
location, select “Configure” and then
“Database Directory” from the LinkNet
menu. After logging in (refer to section
Figure 4.7 Database Location Configuration Dialog
4.1), a dialog similar to Figure 4.7
should appear. Type the new directory in the edit box. Alternatively, hit the “…” button at the right of
edit box to bring up a standard windows directory browsing dialog.
4.4 Database and Server IP Address Configuration (Client Version Only)
LinkNet client software needs to
know the location of the database files
the LinkNet server software is using as
well as the TCP/IP address of the
LinkNet server on the network. In
addition, the update rate must be
configured. The update rate determines
how often the pressroom overview
screen is updated with new information.
Typically, the update rate should be set
somewhere in the neighborhood of 10
seconds. It can be set as low as 1
second, if desired.
Figure 4.8: Database Location and Server IP Address
Configuration Dialog
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4.5 Communications Port Configuration
LinkNet uses a standard RS-232
serial port (commonly called a “comm
port”) to communicate with the
machines on the factory floor via an
external RS-232 to RS-485 converter.
No boards have to be installed or
configured on the host computer. There
are typically two comm ports installed in
most computers, “COM1" and “COM2",
although others may be present as well.
An unused comm port must be available
for LinkNet to use.
Select “Configure” and then “Comm
Figure 4.9: Communication Port Configuration Dialog Box
Port” from the menu in LinkNet and a dialog box similar to Figure 4.9 should appear. Note that only
comm ports that are not currently in use (by anything other than LinkNet itself) show up in the “Comm
Port” list. Pick the comm port that will be used by LinkNet from the list and click on the “OK” button.
NOTE: The various timeouts and delays in this menu are present for troubleshooting
only. Do not change these values unless instructed to do so by a Link representative.
Doing so could render communications unstable or unusable!
.
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4.6 Configuring Shifts
LinkNet collects most information only while in a shift. This keeps the system from needlessly
filling up the hard drive with information not related to production and lets many types of information
be tracked by shift. The relative performance of different shifts can then be compared and analyzed.
To configure the number and names
of shifts, select “Configure” and then
“Shifts” from the LinkNet menu. A
dialog similar to Figure 4.10 should
appear. Any number of shifts can be
configured, although three is typical.
The shift listing dialog box has buttons
to add, edit, or delete shifts.
4.6.1 Adding a Shift
To add a shift, click the “Add”
Figure 4.10: Shift Listing Dialog Box
button on the shift listing dialog box (see
Figure 4.10). A dialog box similar to
Figure 4.11 should appear. The shift
number, by default, will be the next
available shift number. If desired, a
different shift number can be entered, as
long it has not already been used. The
shift name can be anything, but by
default will be “Shift 1”, “Shift 2”, etc.
Note that the shift name could just as
well be made “Weekend Shift”,
“Overtime Shift”, etc. The customer
fields are not directly used by LinkNet
and can be anything you wish. A space
for notes is provided at the bottom of the
dialog box. Finally, note that the
“Enabled” check box will let you enable
of disable a shift by checking or unchecking the box respectively.
Figure 4.11: Shift Configuration Dialog Box
4.6.2 Editing a Shift
To edit a shift, highlight the shift you want to edit in the shift listing dialog box (see Figure 4.10) and
click the “Edit” button. Alternatively, the shift can be “double clicked” in the list. A dialog box similar
to Figure 4.11 will appear. The same options apply as in adding a shift (see previous section), with the
exception that the shift number cannot be changed.
4.6.3 Deleting a Shift
To delete a shift, highlight the shift you want to delete in the shift listing dialog box (see Figure
4.10) and click the “Delete” button. A message box will appear asking to verify the deletion. Hit the
“Yes” button to delete the shift or “No” to cancel the deletion.
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4.7 Configuring the Shift Schedule
To configure the shift schedule, select “Configure” and then “Schedule” from the LinkNet menu. A
dialog box similar to Figure 4.12 will appear. For each shift configured, a set of times for each day that
the shift is active needs to be entered. The starting and ending time of each shift can be configured in 10minute intervals. By default, when a shift is added (see Section 4.6) it gets a disabled time entry for
each day of the week. As shown in Figure 4.12, each day gets an independent schedule. That is, shift 1
(or any shift for that matter) can have different hours on each day of the week.
Figure 4.12 Pressroom Schedule Listing Dialog Box
Clicking any of the radio buttons (labeled Sunday, Monday, Tuesday, etc) will display the scheduled
times for that day. In addition, there is a separate radio button for one-time adjustments. Unlike the day
of week settings, which apply every day of that week (every Monday, for example), a one-time
adjustment overrides the schedule only from one day and time to another day and time.
Notice also that a “Set This Day The Same As Monday” button is available when viewing every day
except Monday and when viewing “One-Time Adjustments”.
Note: Since Monday thorough Friday typically uses the same schedule, Monday can be set up first, and
then the other days can be set the same as Monday by clicking the “Set This Day The Same As Monday”
button when viewing the other days.
The listing area in this dialog box has several headings for the schedule information:
Name: The name of the schedule entry for the day displayed.
Time Type: The type of time for the schedule entry. This can be one of the following types:
Normal Daily Schedule: A normal scheduled shift time that applies for the given day of the
week. For every configured shift, a schedule entry of this type is provided for each day.
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