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3.7.1 New reporter .........................................................................................33 3.7.2 Remove reporter...................................................................................35 3.7.3 Edit reporter ..........................................................................................36 3.7.3.1 Layout of Cycle Data ...............................................................37 3.7.3.2 Cycle Data layout example......................................................39 3.7.3.3 Work piece Merge ...................................................................41 3.7.3.4 Advanced Event settings.........................................................41 3.7.3.5 Advanced CD settings.............................................................42 3.8 Security ..............................................................................................................43 3.8.1 Registering users..................................................................................43 3.8.2 Access Levels for Menu Items..............................................................44 3.8.3 Login and Logout ..................................................................................44 3.8.4 Running the system without any security system.................................45 3.9 Printing ...............................................................................................................46

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4.17.7.3 Download software 1.2.6 or older to a TC running 2.0.4 or later....................................................................................................104 4.17.7.4 Change Net Data.................................................................104 4.17.7.5 Reset Net Data....................................................................104 4.17.7.6 Configure a TC as Primary TC............................................105 4.17.8 Clear data .........................................................................................106

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6.7.5.3 Torque Profile check..............................................................154 6.7.5.4 Torque – Current check.........................................................155 6.7.6 Step – Check ......................................................................................156 6.7.6.1 Check peak torque ................................................................156 6.7.6.2 Check torque in angle window ..............................................157 6.7.6.3 Check torque in time window ................................................157 6.7.6.4 Check mean torque ...............................................................157 6.7.6.5 Check angle...........................................................................158 6.7.6.6 Check time.............................................................................159 6.7.6.7 Check current ........................................................................159 6.7.6.8 Check torque/current.............................................................159 6.7.6.9 Check Post view Torque........................................................159 6.7.6.10 Check shut off torque ..........................................................160 6.7.7 Step – Reject ......................................................................................161 6.7.7.1 Checking the bolt status ........................................................161 6.7.7.2 Deciding what to do...............................................................162 6.7.7.3 Configuring Reject Management...........................................164 6.7.7.4 Advanced RM Actions ...........................................................166 6.7.7.5 Reject management states....................................................167 6.7.7.6 A reject management example..............................................170 6.7.8 Step – Speed ......................................................................................171 6.7.9 Step – Other........................................................................................173 6.8 Bolt Monitoring .................................................................................................174 6.8.1 Monitoring of Torque and Angle at Cycle End....................................176 6.8.2 Monitoring of Torque Rate and Deviation...........................................178 6.8.3 Monitoring Yield point torque and angle .............................................179 6.9 Result variables................................................................................................181 6.9.1 Statuses ..............................................................................................181 6.9.2 Station level result variables...............................................................182 6.9.3 Bolt level result variables ....................................................................183 6.9.3.1 Errors.....................................................................................185 6.9.3.2 Warnings ...............................................................................187 6.9.4 Step level result variables...................................................................188

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8.10.3 Fieldbus specific Information ............................................................226 8.10.3.1 Profibus ...............................................................................226 8.10.3.2 InterBus-S............................................................................227 8.10.3.3 DeviceNet ............................................................................229 8.10.3.4 Modbus Plus........................................................................230 8.11 External Communication................................................................................232 8.11.1 Accesses from External communication device ...............................233 8.11.2 Access to PLC data ..........................................................................234 8.11.3 Access to Process data ....................................................................235 8.11.4 External Communication Protocol Information .................................236 8.11.4.1 JBUS....................................................................................236 8.11.4.2 Siemens 3964R...................................................................237 8.11.4.3 Telemechanique UNI-TE.....................................................238 8.11.4.4 SATT Comli .........................................................................240 8.11.4.5 Allen-Bradley Data Highway (Plus) .....................................241 8.12 API, Application Programmers Interface........................................................242 8.12.1 Object model.....................................................................................245 8.12.2 Enumerators exported by the API.....................................................245 8.12.3 Api object ..........................................................................................246 8.12.3.1 Properties ............................................................................246 8.12.3.2 GetPLCBool.........................................................................246 8.12.3.3 SetPLCBool .........................................................................247 8.12.3.4 GetPLCInt............................................................................247 8.12.3.5 SetPLCInt ............................................................................247 8.12.3.6 GetPLCReal ........................................................................248 8.12.3.7 SetPLCReal.........................................................................248 8.12.3.8 GetPLCString ......................................................................249 8.12.3.9 SetPLCString.......................................................................249 8.12.3.10 GetCycleData ....................................................................250 8.12.3.11 GetCycleDataBin...............................................................250 8.12.3.12 GetEvent............................................................................251 8.12.3.13 GetEventEx .......................................................................252 8.12.3.14 GetTrace............................................................................252 8.12.3.15 GetTraceEx .......................................................................253 8.12.3.16 GetSetup ...........................................................................253 8.12.3.17 SetSetup............................................................................253 8.12.3.18 GetSetupItem ....................................................................254 8.12.3.19 SetSetupItem.....................................................................254 8.12.3.20 GetSystemDesc.................................................................254 8.12.3.21 GetStationDesc .................................................................255 8.12.4 System object ...................................................................................256 8.12.4.1 Properties ............................................................................256 8.12.5 Stations object (collection)................................................................257 8.12.5.1 Properties ............................................................................257 8.12.5.2 Item......................................................................................257 8.12.5.3 Exists ...................................................................................258 8.12.6 Station object ....................................................................................259 8.12.6.1 Properties ............................................................................259 8.12.7 Bolts object (collection).....................................................................260 8.12.7.1 Properties ............................................................................260 8.12.7.2 Item......................................................................................260 8.12.7.3 Exists ...................................................................................261 8.12.8 Bolt object .........................................................................................262 8.12.8.1 Properties ............................................................................262 8.12.9 TraceData object...............................................................................263 8.12.9.1 Properties ............................................................................263 8.12.10 Channels object (collection)............................................................264 8.12.10.1 Properties ..........................................................................264 8.12.10.2 Item....................................................................................264 8.12.10.3 Exists .................................................................................265

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8.12.11 Channel object................................................................................266 8.12.11.1 Properties ..........................................................................266 8.12.11.2 GetSampleValueNo...........................................................266 8.12.11.3 GetSampleValueTime .......................................................266 8.12.11.4 GetSampleValues..............................................................267 8.12.12 StepBounds object (collection) .......................................................268 8.12.12.1 Properties ..........................................................................268 8.12.12.2 Item....................................................................................268 8.12.12.3 Exists .................................................................................268 8.12.13 StepBound object ...........................................................................269 8.12.13.1 Properties ..........................................................................269 8.12.14 How to use the API .........................................................................270 8.13 Process data ..................................................................................................272 8.13.1 Data types.........................................................................................274 8.13.2 Layout of Cycle data in Process data ...............................................274 8.13.3 Layout of Events in Process data .....................................................274 8.13.4 Layout of Traces in Process data .....................................................276 8.13.5 Layout of Setup Item Descriptions....................................................277 8.13.5.1 Bolt.......................................................................................278 8.13.5.2 Spindle, Parameters............................................................279 8.13.5.3 Spindle, Channel data .........................................................280 8.13.5.4 Sequence and Program, Monitoring data ...........................280 8.13.5.5 Sequence and Program, Monitoring data, Torque rate data281 8.13.5.6 Sequence and Program, Step, Control data .......................281 8.13.5.7 Sequence and Program, Step, Restriction data..................282 8.13.5.8 Sequence and Program, Step, Check data.........................282 8.13.5.9 Sequence and Program, Step, Speed data ........................283 8.13.5.10 Sequence and Program, Step, Speed, Ramp down data .283 8.13.5.11 Sequence and Program, Step, Other data........................284 8.13.6 Layout of Setups...............................................................................285

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The PowerMACS system is the sixth generation of tightening systems from Atlas Copco Assembly Systems. It is the perfect solution for all tightening applications in your assembly plant, however complex.

Comprising WinTC software, highly intelligent Tightening Controllers and new, powerful OMX Nut runners, PowerMACS offers the highest level of intelligence and performance ever provided by a tightening system.

PowerMACS supports all known tightening and process monitoring methods. Its simple-to-program Windows user interface with on-line support, offers an exciting new level of user-friendliness. New technology in the Tightening Controllers and OMX Nut runners gives 50% higher motor output to speed up your production.

The PowerMACS is designed to interface smoothly and easily with all networks installed in your plant. It can be set up as stand-alone systems or as advanced automatic tightening multiples, connected to higher communications systems, if and when desired.

PowerMACS is not only the most productive, cost-effective and user-friendly tightening system on the market today, it also offers an impressive new level of installation flexibility.

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PowerMACS’ powerful WinTC software makes it simple for the user to program all tightening parameters, configure reporters and all supported communications networks.

)XOOUHSRUWLQJ WinTC offers full reporting of tightening results, set values and limits. An easily adapted annunciator shows the tightening results in read-at-a-glance graphics. The Hardware Overview MAP shows the system’s hardware status and the System Overview MAP shows the tightening status of the bolts. The system provides reports for any chosen parameters, trace curves, and advanced SPC and log files.

8VHUJXLGHV Accessible via Hyperlinks, the software includes SetUp Wizards, Tutorials, Tightening Templates which guide you through the most common tightening sequences, Spare Parts Lists with drawings and article numbers, service, fault-finding and FAQ functions, and a complete on-line manual.

If you need to configure the system for Ethernet or Fieldbus communication, the PowerMACS’ Set Up Wizards make the task simple.

$3,IRUHDV\DFFHVV WinTC includes an Application Program Interface (API) enabling the engineer to access data from the Tightening Controller. For example: read and write PLC, cycle and trace data and store cycle data to media. All internal and external communications are via Ethernet TCP/IP thin wire 100 Mbit/s.

PowerMACS can be tailored to any assembly process. A built-in PLC (IEC 61131-3), fully programmable using the WinTC interface, supports various in-station control requirements.

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PowerMACS is modular in concept, utilizing the new intelligent Tightening Controller (TC) with state-of- the-art software and a wide range of peripheral support and communication possibilities. The TC is easy to integrate into a production line as a stand-alone unit, with industrial protection class IP 54, or mounted in to a panel.

([SDQGHGFDSDFLW\ An attractive piece of industrial design, the PowerMACS TC is equipped with an impressive amount of memory, more than enough to handle the Real- Time Operative System, Application Programs and the PLC program.

Each TC contains identical hardware and software. In a system, one TC is configured as the primary unit and the rest as secondary units. In a system all secondary TCs can be replaced without needing to download the setup once again. One system can include a maximum of 15 stations. Up to 100 TC’s can be connected in one system, controlling 100 nut runners.

Full interchangeability means fewer spare parts are required, maintenance time is reduced and availability is increased.

$OOFRPPRQLQWHUIDFHV All TC’s are designed to interface with Ethernet, the most common Fieldbuses, and industrial PLCs. The Application Program Interface (API) ensures easy external access to the system.

3HULSKHUDOVVLPSO\DGGHG A wide range of peripherals can be connected to the PowerMACS TC including printers, bar code readers, operator table, operator annunciators, etc.

)OH[LEOHLQVWDOODWLRQ The plug-and-play modular design of the TC means maximum installation flexibility. Series communication in line control and data collection enables the PowerMACS TC’s to be discreetly integrated into the production line by the connection of two cables. The appropriate reporting system and suitable operator interface can be mounted next to the work area.

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This section describes the architecture of the PowerMACS system. It includes the descriptions of the hardware components, including computers and devices, the structures of the system, station and spindles.

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A PowerMACS System consists of one or more stations where each station may control one or more bolts.

A one station PowerMACS System

A three station PowerMACS System

Station

Station

Station

Station

Bolt

Bolt

Bolt

Bolt

Spindle

Spindle Spindle Spindle

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A V\VWHP comprises one or more Tightening Controllers linked together. A system works autonomously, performing the programmed tightening task(s).

The WinTC can only connect to one PowerMACS system at the time. This means that the user cannot edit or display data from two or more systems simultaneously while using one WinTC. If you need to display data from two or more stations at the same time you must design them in one system.

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Within a system you can have up to 15 VWDWLRQV and 100 %ROWV totally  One station can control up to 100 bolts but there must be no more than 100 Bolts in a system. The Station has a PLC to control the tightening cycles and interface with automation controllers. Cycle data is generated for each Station consisting of the result of all bolts controlled by the Station. The result from different Stations in a System can only be grouped together by a Work piece merge.

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A %ROW is the object that will be tightened by the system. A spindle does the actual tightening.

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A 6SLQGOH performs the actual tightening task. One Spindle can be used to tighten several Bolts and it normally comprises of:

• Motor

• Torque sensor

• Angle sensor

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The PowerMACS WinTC is a Windows NT application used to set up a PowerMACS system. It is not needed for automatic running, but it can optionally be used to monitor the system and to collect and display various data.

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The figure below describes the KDUGZDUHVWUXFWXUH of a PowerMACS system, i.e. how hardware components are used.

Peripheral

Factory Network Ethernet

Router

Console with WinTC

Hub

Peripheral

Serial bus

Field bus

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

I/O bus

TC 1 (primary) TC 2 (secondary) ...... TC n (secondary)

I/O-module

Digital I/O Sp 1 Sp 2.. ..Sp n

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$7LJKWHQLQJ&RQWUROOHU (TC)  takes care of various tasks around tightening: driving and controlling a spindle, measuring and storing angle and torque, running PLC, etc. Each TC contains all functions necessary to monitor and control one (1) spindle.

TCs are divided into primary and secondary units. The first TC in a System is called a primary TC and all the others are referred to as secondary TCs.

The primary TC is the TC that communicates directly with the WinTC. It is on this TC that the setup, downloaded from the WinTC, is stored and is responsible for starting the system when powered on, or after downloading a new setup.

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If the primary TC is nonfunctional and must be replaced then the setup must be downloaded from a backup media using the WinTC or the PowerMACS API. You should therefore always keep backups of your setups in a safe place.

The secondary TCs can be replaced while the system is operational, without requiring the setup to be downloaded to the new TC before starting it again. They will fetch its part of the setup from the primary unit when activated.

Internally a TC consist of the following parts:

Ethernet

TC controller board

A/D

TC Servo

Ethernet

Encoder

CPU

DI

RAM

DO

Flash-PROM

CAN

Batt. RAM

Serial

LED + SW

AnyBus TM

Connector board

board

Fieldbus Serial buses I/O unit (DeviceNet) Transducer Encoder

Power supply 3 x 400 VAC 20 VAC or 24 VDC

Spindle

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Ethernet Ethernet interface For communication with other TCs and the WinTC. 100 Mbit/s full duplex auto sensing.

CPU Central Processing Unit Motorola PowerPC 860T

RAM Random Access Memory For storage of program and data when executing, 8 Mbytes

Flash-PROM Programmable Read Only Memory of Flash type For storage of boot and program, 2 Mbytes

Batt RAM RAM with battery backup For storage of setups, traces, cycle data etc. 1 Mbytes. Up to 100 cycle data and 100 trace can be stored.

LED+SW LEDs and Switches Local indicators for errors etc, switches for configuration and network address

A/D Analog to digital converter For torque input, 2 channels torque bridge and 3 channels +-10V, 12 bit signed bias

Encoder Encoder interface For angle input, 2 channels TTL

DI Digital input For controlling servos, 5/24 V DC, not isolated

DO Digital output For controlling servos, 5/24 V DC, not isolated

Serial Serial interface Interface to serial devices, 3 channels RS232, 1 channel RS422, 2 channels RS485

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CAN CAN bus interface Interface to servos and I/O units, 1 Mbit/s, 2 channels, 1 channel optically isolated

AnyBus TM Fieldbus interfaces Interface to superior devices

Servo Controls the power to the spindle motor Holds the power stage and controls the speed and current of the spindle motor. Can be of different types (QPM or QMM)

All connectors are positioned directly on the TC. There are no external connection boards.

Depending on model the connectors are placed differently. This is thoroughly described in the document “Functional and Technical Description PowerMACS TCs” [1].

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All indicators are located on the front of the TC (QPM based):

Indicators on the TC controller board

Indicators on the TC servo board

Red = Other faults

Red = Over current

Red = Error

Red = VDC-bus

Green = Power

Red = Temp. high motor or servo

Yellow = Com .

Numbers - A

Yellow = Running

TC version and product no.

Numbers - B

Yellow = Start

Yellow = Internal comm. Servo OK

Green=ControllerOK

Green = CPU OK

Gold or silver colored cover plate

Green = +5V OK

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The number displays and the LEDs on the left hand side belongs to the TC controller board. At control Voltage power ON (20 VAC or 24 VDC), the following will be displayed:

• *UHHQ32:(5 indicates control voltage on

• 1XPEHUV$DQG% will display the following: In a system with a set-up downloaded, then the two displays will first show a dash and after a couple of seconds the node number selected using the rotary HEX-switches, SW1 and SW2, located behind the golden or silver cover. Note that the node number is displayed using hexadecimal notation. In a system without a set-up, then the node number is only shown on the primary TC and the other ones will show a dash in each display. After the set-up is downloaded, the individual TCs will show their node number.

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• 5HDG(5525 indicates an internal error in the TC 6\VWHP6RIWZDUH or the setup. Should an error occur then restart the system by powering the control voltage off and on. If the error still occurs then reset the system by closing dipswitch SW3.4 and restart it again. Since this clears the TC program memory you must download the setup from the WinTC after this. Should the error still occur then contact Atlas Copco Assembly Systems. In most cases when an error occur the number displays, A and B, will display an error code.

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01, 02, 03, 11,

Out of memory. This might be cause by running to many, memory consuming, devices on the failing TC.

Try to move one or more of the devices from the failing TC to another TC in the system. Especially devices used for reporting of Trace and Cycle data may consume much memory.

Any other combination Internal error. Write down the displayed numbers and contact Atlas Copco Assembly Systems

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The LEDs on the right hand side belongs to the servo drive. The function is as follows starting from the bottom (QPM servo drive).

• *UHHQ/(' indicates +5VDC CPU voltage on (internal)

• *UHHQ/(' flashing means CPU OK. A Firmware and software are downloaded and running in the servo.

• *UHHQ/(' indicates Controller OK. Valid application parameters are downloaded from the TC controller.

• 5HG´!7´ indicates over temperature in the motor or in the servo. A more detailed alarm is displayed in the Event Log. The” >T” LED will also indicate a broken or disconnected resolver cable in combination with the “triangle” LED.

• 5HG³!8´ Indicates high voltage meaning that the internal balast resistors did not manage to reduce the high voltage. This fault is very rare and high supply voltage shall be taken care of externally.

• 5HG´!,´ Indicates over current. There are three different protective functions for over current.

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o &XUUHQWOLPLW;DQG!<VHF . Default parameters are X = 90% and Y = 2 seconds. When the current to the motor exceeds 90% of the set current (Iref), the LED “>I” will light and if the 90% limit is exceeded for more than 2seconds, the servo will shut off and indicate with the LEDs “>I” and the "triangle".

o 2YHUORDGFXUUHQW . If the actual current to the motor exceeds Iref/10 during more than 300 sec., the servo will shut off and indicate with the LEDs “>I” and “triangle”. This function is to prevent that the duty cycle of the drive system doesn’t exceed the systems rating. The fault can be reset after 300 sec. in order to let the motor cool off (similar to I 2 t protection).

• 5HGWULDQJOH Indicate other faults and is sometimes shown together with one of the other LEDs. A "triangle" displayed together with the “>I” indicates a resolver signal fault.

To understand when an over current situation can occur you must understand how the servos current reference, Iref, is calculated by the TC at the start of each step. There are two cases:

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• Transducer control: Max set current for a specific motor and servo combination is limited in the spindle set-up. The max torque and the T/C-factor together will give the necessary current (Iref) to achieve the max torque. A safety margin of 20 % is added and this value is sent to the servo. If a torque restriction is programmed for the step then this value used instead of the max torque.

• Current control: Iref is calculated as for transducer control but based on the target torque and without any safety margin.

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A number of switches are Located under the TCs cover plate (gold or silver colored). They are used as follows:

SW4 Type: Dip switch 4 pole SW4.1 End termination resistor S1 bus (121 ohm if closed). SW4.1 End termination resistor S3 bus (121 ohm if closed). SW4.1 End termination resistor local I/O bus (121 ohm if closed). SW4.1 AI3 connected to 0 V if closed.

SW2 Type: Rotary Hex switch Low nibble (4bit) of last byte of the TC IP-address.

SW3 Type: Dip switch 8 pole SW3.1 Primary TC SW3.4 Program reset SW3.6 IP-address reset Switches are active if closed at power on. All other switches are reserved for test functions

SW1 Type: Rotary Hex switch High nibble (4bit) of last byte of the TC IP-address.

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When spindles are running during a cycle they are continuously monitored for other hardware failures than indicated by the above described LED’s

If a failure occurs the step is immediately terminated and an error event is generated. The table below lists the hardware checks done:

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Double torque transducers If double transducers are used the system checks that the torque values do not differ in magnitude or duration. See chapter: Double transducer checks.

Double angle encoders If double encoders are used the system checks that the angle values do not differ in magnitude or duration. See chapter: Double transducer checks.

External + 5 VDC Checks the + 5 VDC power supply to the transducers and encoders

External – 5 VDC Checks the – 5 VDC power supply to the transducers

AI reference Checks the reference voltage used as reference for the analog

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inputs.

Battery voltage Checks the voltage of the battery used for backing up non-volatile data.

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The &RQVROH&RPSXWHU is used for set up of the system and for monitoring and controlling using the WinTC program. It is optional for normal running.

The console computer comprises a standard IBM PC-compatible computer with Microsoft Windows NT operating system and is not location dependent.

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Communication between the &RQVROH&RPSXWHU and the 7LJKWHQLQJ&RQWUROOHUV or between two Tightening Controllers are done with use of an Ethernet network. This runs with 100 Mbit/s and uses TCP/IP as protocol. Physical media is 10Base-TX, i.e. twisted pair, max length 100 m. By use of commercially available products it is possible to build a network with optically isolated components.

Via a router other computers in the factory can access the Console Computer. To isolate the PowerMACS system from the rest of the factory (and vice versa) communication is done through a router. This is set up to allow communications between specific nodes.

If the Console Computer has a 100 Mbit/s Ethernet card you can connect it directly to the standard HUB/switch supplied by Atlas Copco Assembly Systems. However, should the PC only have a 10 Mbit/s card then try to connect it directly to a TC using a null modem.

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The following peripheral devices can be connected to the TC or Console Computer:

• I/O device

• Printer on CC

• Printer on TC

• ID device

• Communication via serial protocols

• Communication via fieldbus interface

• Communication from an external PC based application using the PowerMACS API, Application Programmers Interface.

Except for the devices that are to be connected to the Console Computer, most devices can be connected to any tightening controller within the system. For a more complete description of peripheral devices see chapter:: Peripheral Devices.

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This part covers the basic functions, like how to handle windows and screen, security, help, etc.

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This chapter gives a general presentation of the parts of the WinTC and how to operate them.

7LWOHEDU

On top of the screen there is a WLWOHEDU . In this you can see the name of the application (PowerMACS) and the name of the System object of the setup that you currently are working with. If no specific setup is active is displayed instead of the system name.

[JB1]

0HQXEDU

On top of the screen, just below the title bar, there is a PHQXEDU .

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When selecting one of the menus it drops down and you can see a set of PHQXLWHPV or PHQXFKRLFHV .

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Below the menu bar you have a WRROEDU . This contains buttons to reach the most frequently used functions of the system.

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On the bottom of the screen you have a status bar.

This is used by the system to show (from left to right):

• Status field (information from the system, errors, problems etc.)

• Current user logged in (”Anonymous” if no one has logged in)

• CAPS if the Caps Lock key has been pressed (capitalizes letters)

• NUM if the Num. Lock key has been pressed (the right part of the keyboard will then act as a numerical keyboard)

• INS if the Insert key has been pressed (text input will be inserted where the cursor is positioned instead of overwriting characters)

• Current date and time

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The following Windows controls are commonly referred to in this document:

• 7H[WER[ – Holds text that you can either enter or change

• )UDPH – Groups a number of controls that belongs together

• %XWWRQ – Carries out a command when pressed

• &KHFNER[ – Represents parameters of Boolean type, that is that either are True or False

• 5DGLREXWWRQ – Represents multiple choices from which you can choose only one

• &RPERER[ – Another way to represent multiple choices from which you can choose only one

• 6SUHDG – An Excel style control used to display table oriented data

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With the menu View you can show or hide the Toolbar and the Status Bar.

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If you have a number of windows on the screen at the same time you can get these rearranged in a structured way. Use the menu choices :LQGRZ&DVFDGH etc.

[JB5]

The layout of most windows are saved when the WinTC is closed and will be restored when the WinTC is started again.

Use menu choice :LQGRZ%DFNJURXQG to select a background picture.

[JB6]

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+HOS

)XQFWLRQNH\)

When running the PowerMACS WinTC application you can get all information you need, by a press of a button.

Whenever in trouble, press the function key F1.

F1 activates the help system and displays information relevant the topic you are just using. This is called context sensitive help.

+\SHUOLQNVLQ2QOLQH+HOS

In the displayed help text you can find K\SHUOLQNV . These are texts with a different color, green or blue. When moving the cursor over a hyper link the cursor changes from an arrow to a hand. If you then press your left mouse button you will directly get information on that topic. Either as a pop-up window or that you are transferred to that chapter of the help text.

+HOSPHQX

It is also possible to get help by use of the +HOS menu. &RQWHQWV brings up a list of topics with hyper links.

6HDUFKIRUKHOSRQ« brings up a dialog box where you can enter a keyword to the topic you want help on.

7URXEOHVKRRWLQJ will present a guide that can assist you in case of trouble. 0DLQWHQDQFH contains information on preventive maintenance, spare part lists etc.

6LWH6SHFLILF+HOS presents information that is specific for the current site.

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7KH)LOHPHQX

On the )LOH menu you can find basic functions for PowerMACS.

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The items 1HZ , 2SHQ , &ORVH , 6DYH , and 6DYHDV are for handling setups. ,PSRUW and ([SRUW are also used in connection with setups. Handling setups are described in chapter: Set Up and Maintenance.

3DJHVHWXS and 3ULQW is used for printing of setups. See chapter: Printing.

6HFXULW\ , /RJLQ , and /RJRXW is described in detail in chapter: Security.

*R2Q/LQH indicates if your WinTC is in contact with a running system. If you want to work off-line, even though you have a connection, select this item to switch it off. See also chapter: How to Start up.

The items above the ([LW item are a list of setups you have been working with recently. Select one of these to get an instant opening of it, instead of using the 2SHQ item.

Use ([LW to shut down the PowerMACS application. If you have modified the current setup you will be asked to save it first.

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+RZWR6WDUWXS

Depending on what you want to do you start the WinTC in either On line or Off line mode.

By default the WinTC will try go On line if it was on line when it was closed. If so it will try to connect to the system most recently connected.

7RHGLWDVHWXSLQ2IIOLQHPRGH

This is how you start up when you want to check or edit a setup, without connecting to a running system:

1. Press the 6WDUW button on your computer

1. Select 3URJUDP and then the PowerMACS application

1. From the )LOH menu, select 2SHQ

1. In presented file list, select an existing setup

If you want to create a completely new setup, select 1HZ from the )LOH menu instead of 2SHQ .

7RFRQQHFWWRDV\VWHPLQ2QOLQHPRGH

This is how you start up the WinTC when you want to check or edit a setup that already is running in a system.

1. Connect your console computer via Ethernet cable to the system

1. Press the 6WDUW button on your computer

1. Select 3URJUDP and then the PowerMACS application

1. From the 0DLQWHQDQFH menu, chose 6HOHFW7DUJHW6\VWHP and choose the system you want to connect to.

1. From the )LOH menu, select *R2Q/LQH

PowerMACS will try to connect to the system over the network. If it manages to contact the system it will retrieve the setup currently stored in it. You can then start checking and editing the setup as if you had read it from your console computer.

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9LHZLQJ

If you have your console PC connected to the tightening controllers (on-line), you can view several items in the system. You can start View displays by use of the menu 9LHZ or by pressing one of the corresponding buttons on the tool bar. 



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$VVHPEO\2YHUYLHZ

The Assembly Overview displays current status of the system, its stations and bolts using a descriptive picture of the object being assembled. You can easily add pictures as background for the system and the respective station. See chapter: Assembly Overview Set Up form for instructions.

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The color of the items indicates the current status of the item.

&RORU 6WDWXV

Green Idle after OK cycle

Red Idle after NOK cycle

Yellow Running cycle

If you want more information on the stations or bolts, expand the box by clicking on the box of interest.

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The information that is displayed in the different boxes and the size and position of them is set up using the Assembly Overview Set Up form.

If you have several stations in your PowerMACS system they can all be displayed in expanded mode over a common system background picture. The below shows an example of a two station layout where the bolt status of both stations are displayed on a, in this case white, background picture.

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6\VWHP0DS

The System Map gives an overview of all functional parts in the system. It can be used both as an indicator of current status for all parts, but also as a navigation tool within the system.

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When first started the System Map displays a page with the system shown in a tree structure. You can expand and collapse the tree structure by pressing the small squares with  or  , or clicking on items.

The color of the items indicates the current status of the item.

&RORU 6WDWXV

Green Idle after OK cycle

Red Idle after NOK cycle

Yellow Running cycle

If you want more information on the parts, press 0RUH!! . Then the page expands.

[JB11]

The page to the right reflects the item selected in the left page.

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Problems with equipment are indicated with a red cross over the icon. The Last error event field can also give information for troubleshooting.

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The data cannot be changed when you enter the form for viewing. The same form can be opened from menu 6HWXS . Then values can be changed.

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9LHZ&\FOH'DWD

The Cycle Data window is used to display data from the tightening cycles.

[JB13]

The display shows the last cycle. When new cycles are added older cycles are scrolled upwards. By use of the scrollbar you can go back to earlier cycles. The list of cycle data covers in total about 100 cycles.

If you press +ROG the display is temporarily stopped. Cycle data are still recorded and when you press the

+ROG button again (now with the text &RQWLQXH ) the presentation will continue. Press &OHDU to clear the list.

Press /D\RXW to enter a form where you can set up the layout of data as presented on screen.

If you want to present just specific cycles, press 0RUH!! to open a new page.

[JB14]

Here you can specify if you want to present OK and/or NOK cycles, for specific stations and/or tightening programs, or cycles with specific errors.

In the ID field write as many characters you like. All cycles that have an ID that contains the string of characters will be displayed.

You can also present cycles between certain times, e.g. 99-12-31, 23:59..00-01-01, 00:01. Enter date and time in the format your computer is set up for. Use “..” as separator between start and stop times. If you do not enter any date, today is assumed. If you do not enter any time, start time is assumed to be 00:00 and stop time 23:59.

1RWH To be able to filter out the results for a specific program you must have included the bolt level result variable “Program” in the reporter named “Screen”. The result will include all cycles where at least one bolt has executed the selected program.

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9LHZ6WDWLVWLFV

The Statistics window displays the statistical curves generated by the function "SPC, Statistical Process Control".

First select with 6WDWLRQ , %ROWRU6SLQGOH , 3URJUDP , 9DULDEOH , and 6WHS what variable you want to study the statistics for. Only values earlier configured for SPC using the SPC set up form can be displayed.

Then use the radio buttons in the upper right corner of the form to select which type of display you want. The following types are available:

• Average and Standard Deviation/Range curves for SPC and TDA

• Average and Standard Deviation/Range curves for Short Term Trend

• Histogram

[JB15]

With the cursor you can mark a specific part of the trace to zoom in. Place the mouse pointer on the upper left corner of the area you want to enlarge. Press the left mouse button and drag the mouse pointer to the lower right corner of the area to zoom in and release the mouse button. This will cause the graph to be redrawn displaying only the selected area. Click on the right mouse button to zoom out.

When the mouse pointer is located over the graph area a box under it will display the value of the x and y coordinates pointed at.

If you select $OO%ROWV or $OOVSLQGOHV the SPC diagram will show you SPC statistics based on data from all bolts or spindles in a station weighed together to a measure of the station as a whole. Only variables already set up for collection from this station are used when calculating the resulting values.

If there is a subgroup, which has possible corrupt data, you can delete it. Click in the diagram on the subgroup you want to delete. Press 'HOHWH6XEJURXS . This is possible only when the selection SPC and TDA is active.

To the left current capability values are displayed. The window is automatically updated whenever a new cycle is completed. Values displayed are calculated over same data as shown in the curve, for subgroups or for short-term trend.

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If you select +LVWRJUDP you will be presented the following view:

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This form displays the frequency distribution of the selected variable. The X-axis, displayed in the unit of the variable, is divided in 20 classes scaled so that 25% of the screen is left of LTL, and 25% is right of UTL.

The boundaries of each class are marked using dashed vertical lines where green indicates classes in between LTL and UTL.

On Y-axis is shown the count of values with in each of the classes.

If you want to have the current view on paper, press 3ULQW .

The viewed statistics is updated cyclically when online.

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9LHZ7UDFH

[JB17]

For each individual bolt’s tightening cycle a trace can be generated and recorded.The maximum length of a trace is 20 seconds. If a trace is recorded for longer time than 20 seconds the oldest values will be overwritten with new samples.

Using the Bolt Set Up form you can modify the condition for when a trace is started.

The Trace viewing window is used to present the traces of current and prior cycles.

Select the bolt you are interested in by use of the 6WDWLRQ and %ROW fields. Select type of trace you want to display by use of the 3 fields on the upper right of the window. You can study two curves at the same by using both colored fields. 

If you press one of the radio buttons /DWHVW or /DWHVW12. the latest OK or NOK trace for the selected bolt is shown. It will be automatically updated as new cycles are run with the same status.

Pressing the 6HOHFW radio button will enable the possibility to select specific traces either stored on one of the TC or as disk files on your PC.

• To read a trace from a TC press the 6HOHFW button in the frame labeled 7& . This will invoke the Select Trace form with which you can select not only one but several traces, and from one or multiple bolts.

• To read a trace earlier saved on disk press the 6HOHFW button in the frame labeled )LOH . This will invoke a file selection dialogue in which you can select the file to display.

If you see a trace that is interesting in some respect you can choose to save it, either in the TC or to a disk file on your PC.

• To save it in the TC press the 6DYH button the frame labeled 7& . This will cause the currently displayed trace to be tagged for save which protects it.

• To save it as a disk file press the 6DYH button in the frame labeled )LOH This will display a 6DYH

$V dialogue where you specify the name and the format of your file. Chose extension *.trc ("Trace Files"), to save it in PowerMACS internal format, or extension *.txt ("Text Files"), to save the trace as a text file. A trace saved in PowerMACS internal format includes all data of the trace and can later be opened using the )LOH6HOHFW« alternative. A trace file stored as text only includes the curves, the step boundaries (as a curve), the cycle data printed as text and the program printed in Quick View format. The curves are written as columns, separated by a tab character, with each sample on an own row. This makes the text file easy to import to, for example, Excel.

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With the cursor you can mark a specific part of the trace to zoom in. Place the mouse pointer on the upper left corner of the area you want to enlarge. Press the left mouse button and drag the mouse pointer to the lower right corner of the area to zoom in and release the mouse button. This will cause the graph to be redrawn displaying only the selected area. Click on the right mouse button to zoom out.

When the mouse pointer is located over the graph area a box under it will display the value of the x and y coordinates pointed at.

At the bottom you can see the first line of corresponding cycle data. If you press the 'DWD!! button the lower part of the window is expanded and displays more data. Press the /D\RXW button to set up the layout of the cycle data. This will invoke the Trace Reporter, see chapter: Edit reporter.

If you want to see the Tightening Program that was used for the cycle, press 3URJUDP . This will display the program in Quick View format (described in chapter: Quick View syntax).

If you press the 6KRZ!! button the form is expanded and displays controls that are used to specify additional data to be displayed in the diagram.

[JB18]

The following additional data may be added to the diagram:

• Fail Safe limits

• Restrictions

• Checks

• Control Parameters

• Step Starts and Stops

• Monitor Limits

To include any of the groups above in the trace check the corresponding checkbox. The respective limits or parameters are displayed only if they are relevant with respect to the trace currently displayed. The following control parameters may be displayed:

• Target torque for steps of type T - Run until Torque, DT - Run until DynaTork TM , and TC - Run until Torque with Current Control

• Target angle for steps of type A - Run until Angle and AO - Run until Angle with overshoot compensation

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Press the 3ULQW button to print the trace currently displayed. The printout will include the corresponding program in Quick View format.

When displaying several traces at the same time there are many reasons for the traces to differ on the x axis. Since this makes them difficult to compare it is possible to match the traces to each other. Press the

0DWFK!! button to display a frame where you can set up the match conditions.

[JB19]

If you select 7RUTXH matching will be done where the traces have reached the same level of torque. The level is specified in % in the field next to the alternative. If you e.g. specify 50% the traces will be matched to where the individual traces have reached 50% of their maximum torque (for the first time).

For 7LPH and $QJOH it is probably more interesting to set 100%, i.e. where they have reached their final angle or time.

The scale of the X-axis will be set for the latest trace.

Use the sliders for minor positioning sideways.

With the buttons next to the sliders you can change color of the traces.

6HOHFW7UDFH

This dialogue is invoked from the View Trace form by pressing the 6HOHFW button and is used for selecting one or several traces to display.

[JB20]

The list shows traces stored. By use of the 6KRZWUDFHVIRU« frame you can select which traces to show. In the ID field write as many characters you like. All traces that have an ID that contains the string of characters will be displayed.

Hold down the CTRL key and select with the mouse the traces you are interested in. When you return to the view window all the traces are presented in the same diagram, with different colors.

Normally traces are from the most recent cycles. Traces which are tagged for save will be saved indefinitely. The save tag can be switched on and off by use of the 6DYH8QVDYH button for any trace.

Due to the fact that traces consume quite a lot of memory only a limited number of traces can be saved. A new cycle will overwrite the oldest one not marked for save.

1RWH All traces, also the ones marked for “Save”, are deleted if the battery backed up memory is cleared, for example when new System Software is loaded.

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9LHZ(YHQW/RJ

In the PowerMACS system events could happen that the operator should be informed of. These can be of following types:

(YHQWW\SH 1XP,G ([DPSOH

General 0 Events that do not belong to any of the specific categories below.

Access 1 Operator log-in and log-out, failed log-in attempts

Power up 2 Restart of system

Emergency stop 3 Emergency or Machine stop of station

Checks 4 Tightening application errors, ”Torque high”, ”Angle low” etc.

System error 5 Abnormal situation, hardware breakdown etc.

Modifications 6 Changed parameter. Event contains additional information, like parameter, station, spindle, program etc.

Hardware error 7 Zero offset, calibration and angle count error

Software error 8 Internal communication errors, etc.

Ext. com. error 9 No response, to many retransmissions, etc., when communicating with external equipment.

SPC 10 SPC events, "7 up", "7 down", etc.

Setup 11 Erroneous configuration detected during run mode, e.g. missing parameters, etc.

All events are also classified by their Severity. Severity is one of the following:

6HYHULW\ 1XP,G ([DPSOH

Info 0 Events that only informs the user of some activity, for example "Power on".

Error 2 Severe errors in the system or events that indicate that cycle failed, the error might be repairable.

1XP,G above is the numerical identity of the respective Event Type. This value is used when events are reported to binary devices. See Layout of Events for a complete description of the binary format of events.

All events are stored in an Event Log, which can be viewed on the WinTC.

For each event is displayed (from left to right):

• If the event is observed or not (a check mark if observed)

• The severity of the event

• The date and time when the event occurred

• The number of the station to which the event belongs (zero (0) if not connected to a particular station).

• The number of the bolt (the user specified bolt number) to which the event belongs zero (0) if not connected to a particular bolt).

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• The name of the program to which the event belongs (blank if not connected to a particular program).

• The type of the event

• A textual description of the event

[JB21]

If you press the 0RUH!! button an extra area is expanded where you can specify which event types and/or Severities to display. You can also include just events connected to a certain station, bolt, or program.

Events that have been dealt with can be marked as “Observed”. Select one or more events in the list and press the 2EVHUYHG button. A single event can be marked by just double clicking it. An observed event shows a red check mark in the leftmost column.

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(DV\9LHZ

The (DV\9LHZ form can be presented either from a button on the Toolbar or via menu choice 9LHZ(DV\

9LHZ . This form is used for easy access to a small number of parameters. It is intended for users with limited knowledge or who should not be able to alter sensitive information.

[JB22]

The information presented on this form is configurable via menu choice 6HWXS(DV\9LHZ

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5HSRUWHU

The reporter is a very flexible and powerful tool that is used to configure which data to display and output from a PowerMACS system.

It can be seen as a function that helps you select various data from the system. It controls what data to send to a particular device and how this data is formatted. The reporter itself is not able to output any data, this is done by the device that the reporter is connected to.

Some devices, such as the WinTC Screen, the WinTC Printer, the WinTC File, and the Trace are considered to be logical devices that always exist, meaning that you do not need to create reporters for these.

To output data via any other type of device, the device must first be added to the PowerMACS system. See Add a device for how to this. When the device exists you may create a new reporter, connect it to the device and finally use the reporter to set up what data to report.

1HZUHSRUWHU

To create a new reporter use menu item 5HSRUWHU1HZ« This will display a wizard that guides you through the creation of the reporter.

[JB23]

From the list select which type of reporter you want to create:

7\SH 8VHGIRUFRQILJXUDWLRQRIGDWD«

WinTC Printer to be printed on a printer using the WinTC (requires the WinTC to be on-line)

File sent to a file via the WinTC (requires the WinTC to be on-line)

Excel File sent to an Excel file via the WinTC (requires the WinTC to be on-line).

Printer to be printed on a (line) printer directly connected to a TC

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PLC sent to inputs of PowerMACS internal PLC (defined on the CycleData_Var worksheet)

ID device sent to ID devices of type escort memory that are connected to the TC

Ext. Comm. Device available using external communication devices

Fieldbus available using fieldbus devices

API available using the PowerMACS API (Application Programmer Interface) for access by other PC based computer applications via the network

ToolsNet sent to a Atlas Copco ToolsNet server

You cannot create (or delete) reporters for the Screen, that is the WinTC Cycle Data window, or the Trace, that is the cycle data display in the Trace window. On the other hand, these reporters are always available in the system.

If wanted, specify an additional name of the reporter. If you create a reporter of type Printer and you add the name HP6P you can later find a menu item 5HSRUWHU3ULQWHU+33 that corresponds to this reporter.

The additional name specified for a )LOH or ([FHO)LOH reporter is used as the name of the result file. For each File reporter two files are created. The first have the character “1” appended to its name and the second, which is created when the first file is full, the character “2”. When the second file is full then the first will be overwritten. All files are created in the directory /RJ located in the directory where you to install the WinTC.

The ([FHO)LOH reporter can only be used if Microsoft Excel is installed on the PC that the WinTC executes on. If Excel cannot be started the data is written to a text file with extension *.txt instead. This text file is formatted in a format suitable for Excel. To import the text file from Excel follow do as follows:

• From inside Excel choose File/Open.

• In the Open dialogue box select "Text files (*prn; *.txt; *.csv)" as "Files of types". Then select your file and press Open.

• In the Text Import Wizard - Step 1: Select "Delimited" in the frame marked "Original dat type" and press Next.

• In the Text Import Wizard - Step 2: Check "Tab" in the frame "Delimiters" and press "Finish".

Name_DataWhenFileWasLocked_YYYYMMDD-HHMMSS".xls

where "Name" is the original name assigned to file and "YYYYMMDD-HHMMSS" is the current date and time (example: "Excel1_DataWhenFileWasLocked_20020514-125932.xls"). The temporary file will be used until the next time the you go off-line.

When ready with the first page then press 1H[W!! to display the next page of the wizard. If needed, depending on the type of reporter, you will be asked for some additional information.

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For a printer it looks like this:

[JB24]

For most of the types you must select which device this reporter should connected to. The Device list box displays all devices, of the relevant type, existing in the system. See $GGDGHYLFH for how to add new devices if you need to that.

When ready, press )LQLVK . A new window is displayed as if you had used the menu item 5HSRUWHU

2SHQ« In this specify what data to collect and the layout.

5HPRYHUHSRUWHU

You can remove a reporter by menu item Reporter-Remove…

[JB25]

Select a reporter and press 5HPRYH .

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(GLWUHSRUWHU

The reporter is used to specify what data to collect for a device and the layout of the data when presented on the device. All devices that should handle process data; Cycle Data, Events and Traces, must have a reporter set up for it in order for any data to be output.

To edit a reporter select its name in the Reporter menu, e.g. 5HSRUWHU±3ULQWHU This will open the following form:

[JB26]

Specify in the 6WDWLRQ field, which specific station you want data from, or $OO stations if data generated by all stations should go to the device.

The controls in the &ROOHFWHGGDWD frame are used to configure what type of Process Data that should be accessible for the device. Use them as follows:

• Check 2.&\FOHV if to include all cycle data with status OK

• Check 12.&\FOHV if to include all cycle data with status NOK

• Check (YHQWV to include events. More specific filtering may be defined using the $GYDQFHG(YHQW

VHWWLQJV form.

• Check 7UDFHV to include all traces (regardless of status)

• Check 'LVFRQQHFWHGEROWLQFOXGHG if you want such bolts to be included in the output.

For presentation on devices that can handle colors (the Screen and WinTC Printer), you can also specify the color you want the data to have. You may for example have events and NOK cycles shown in red. (Traces can only be output in binary form therefore color is not relevant.)

In the 'DWD frame you can specify if you want data in printable or binary form. Binary data may be sent to devices like a fieldbus but not to for example the screen or a printer which requires printable data.

Reports of results from several stations can be synchronized. This is done using the controls in the :RUN

SLHFH0HUJH frame.

For reporters of type )LOH or ([FHO)LOH the size, in kByte, of the resulting file is configured with the parameter )LOHV / 6L]H .

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/D\RXWRI&\FOH'DWD

Use the controls in the /D\RXWRI&\FOH'DWD frame to specify how the cycle data results should be presented.

The variables that can be included in the result are divided in three sections, 6WDWLRQGDWD , %ROWGDWD and

6WHSGDWD . Each section includes the variables that can be reported once for the respective item. That is, Station data variables are reported once for each cycle, Bolt Data variables once for each bolt and Step data variables one for each step.

The result is always laid out in a hierarchically manner, with the Station data at the top and the Step data at the bottom, as below:

Station data Bolt data for bolt 1 Step data for bolt 1, step 1 Step data for bolt 1, step 2 : Step data for bolt 1, step n Bolt data for bolt 2 Step data for bolt 2, step 1 Step data for bolt 2, step 2 : Step data for bolt 2, step n etc.

The variables possible to include for each of sections are listed on a tab labeled with the same name.

On each of the tabs the leftmost column lists all available variables. The other columns are used for selecting and formatting the respective variable as described in the below table:

&ROXPQ 8VDJH

Order Set a non-zero value to include the variable. The variable with lowest number is displayed first.

Width Defines the width of the field, in number of characters, in which the YDOXH of the variable is printed. (left adjusted).

When using table layout (Header text frequency > 0) then the width must be big enough to cover the variable name since it is used as column header.

When format is binary (Data/Binary selected) then Width normally should be left blank for all numerical values variables. This will cause the selection in the Type column to control the width of the field. However, specifying a value that is larger than the number of bytes implicated by the Type selection will make the variable occupy the specified number of bytes. Data is then left adjusted (the field is padded with NULL (0) characters).

Dec Specifies the number of decimals to print. Only valid for variables of numerical type and when format is Printable (Data/Printable selected).

Type Controls the data type of the variable when printed. Valid only when format is binary (Data/Binary selected). Takes the following values

• I1 - Value is formatted as a one-byte integer. Any fractional part is truncated.

• I2 - Data is formatted as a two-byte integer. Any fractional part is truncated.

• I4 - Data is formatted as a four-byte integer. Any fractional part is truncated.

• I8 and I12 - Data is formatted as 8 or 12-byte error/warning information. Only valid for the bolt level result variables "Error", "RM Error" and "Warning". See also chapter: Errors and Warnings.

• F - Data is formatted as a four-byte Float (either as IEEE754 or as "Fixed 2I2D")

• Str - Data is formatted as a string. The setting of Width controls the number of bytes occupied Text Check this checkbox to include the variable name as a leading, or prompter, text. When using table layout (Header text frequency > 0) then the variable name is always used as column header regardless of the selection in this column.

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Lines Specifies the number of new lines to be printed after printing the value of this variable. Not valid when the result is formatted as a table (Header text frequency > 0).

Each new line is printed as a Carriage Return plus a Line Feed character (occupies two bytes).

Step Specifies for which steps a variable will be printed. Only valid for Step data variables.

Enter the step number of the step(s) for which the variables should be included. Leaving the column blank will print the variable for all steps. See Tightening Sequence for how steps inside a sequence are numbered.

See chapter: Data types for a description of the different values for 7\SH above.

1RWH Selecting a variable in the reporter will cause the variable to be included in the result. However, this does not automatically mean that the variable will be measured. Most of the variables correspond to values measured by bolt monitoring and step checks. Whether these checks are performed or not is controlled by the Tightening program being executed. See Bolt Monitoring and Step – Check for how to set up these.

Variables that do not have a valid value, for example due to that the check that produces the value is not executed or data from disconnected bolts, are presented as “blank” (all spaces) when 'DWD is set to

3ULQWDEOH . With 'DWD set to %LQDU\ all undefined numerical variables are set to the value –32768 while text variables are set to an empty string, that is “”.

For a description of all variables see chapter: Result.

The parameter +HDGHUIUHTXHQF\ controls whether cycle data is printed as a table or not. Enter a non- zero value to have the result formatted as a table, that is the variables are printed in columns with their respective prompter texts as column headers. The value 10 of Header frequency will generate a header for every 10 th cycle data. Leave the parameter empty if you do not want the result to be formatted as a table. See Cycle Data layout example for examples.

Enter in the $GGLWLRQDOQHZOLQHV field the number of empty lines to print after that all cycle data has been printed.

Using the 7RUTXHXQLW field you can specify the unit in which all torque results are to be presented. The system will recalculate values before presentation. Set Standard if you want to keep the basic torque unit set using 2SWLRQV in the 6HW8S menu.

For reporters configured to format the result binary (Data/Binary selected) you can also:

• Control byte order of all numerical variables. Set %\WH2UGHU to 1RUPDO to have the most significant byte printed first, or at the lowest address. This is also known as Big Endian or Motorola format. Select ,QWHO to have the least significant byte printed first (Little Endian).

• Control how real values are formatted. Set )ORDWIRUPDW to ,((( to print them as standard 32 bit floating point values according to IEEE 754. Chose ,' to have them printed as a fixed-point value where the two most significant bytes contains the integer part and the two least significant bytes the decimal part multiplied with 1000.

For all TC based devices you can control the order in which the step results are printed. This is done using the 2UGHUVWHSVE\ combo box on the Step data tab. Select ([HFXWLRQRUGHU to print the steps in the order that they are executed and 6WHSQXPEHU to have them ordered in ascending step number order.

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&\FOH'DWDOD\RXWH[DPSOH

Configuring a reporter of type Printer with +HDGHUWH[WIUHTXHQF\ set to blank, $GGLWLRQDOQHZOLQHV to 1 and the following result variables:

Station variables:

9DULDEOH 2UGHU :LGWK 'HF 7H[W /LQHV

Station 1 8 yes

Time 2 24 yes

Bolt variables:

9DULDEOH 2UGHU :LGWK 'HF 7H[W /LQHV

Bolt No 1 8 yes

Bolt T 2 7 1 yes

Bolt A 3 7 yes

Step variables:

9DULDEOH 2UGHU :LGWK 'HF 7H[W /LQHV 6WHS

Step No 1 8 yes

Peak T 2 7 1 yes

Will produce the following print out:

Station: Stn 01 Time: 011030 09:40:58 Status: OK Bolt No: 1 Bolt T: 15.1 Bolt A: 435 Status: OK Step No: 1 Peak T: 2.4 A: 125 Step No: 2 Peak T: 15.2 A: 310 Bolt No: 2 Bolt T: 2.5 Bolt A: 436 Status: OK Step No: 1 Peak T: 2.5 A: 124 Step No: 2 Peak T: 15.2 A: 312 Station: Stn 01 Time: 011030 09:41:10 Status: OK Bolt No: 1 Bolt T: 15.1 Bolt A: 435 Status: OK Step No: 1 Peak T: 2.4 A: 125 Step No: 2 Peak T: 15.2 A: 310 Bolt No: 2 Bolt T: 2.5 Bolt A: 436 Status: OK Step No: 1 Peak T: 2.5 A: 124 Step No: 2 Peak T: 15.2 A: 312 Station: Stn 01 Time: 011030 09:40:22 Status: OK Bolt No: 1 Bolt T: 15.1 Bolt A: 435 Status: OK Step No: 1 Peak T: 2.4 A: 125 Step No: 2 Peak T: 15.2 A: 310 Bolt No: 2 Bolt T: 2.5 Bolt A: 436 Status: OK Step No: 1 Peak T: 2.5 A: 124 Step No: 2 Peak T: 15.2 A: 312 Station: Stn 01 Time: 011030 09:41:44 Status: OK Bolt No: 1 Bolt T: 15.1 Bolt A: 435 Status: OK Step No: 1 Peak T: 2.4 A: 125 Step No: 2 Peak T: 15.2 A: 310 Bolt No: 2 Bolt T: 2.5 Bolt A: 436 Status: OK Step No: 1 Peak T: 2.5 A: 124 Step No: 2 Peak T: 15.2 A: 312

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To have the result formatted as a table just change +HDGHUIUHTXHQF\ to for example 2. This gives the below printout:

Station Time Status Bolt No Bolt T Bolt A Status Step No Peak T A ---------------------------------------------------------------------------------------- Stn 01 011030 09:40:58 OK 1 15.1 435 OK 1 2.4 125 2 15.1 310 2 15.2 436 OK 1 2.5 124 2 15.2 312 Stn 01 011030 09:41:10 OK 1 15.1 435 OK 1 2.4 125 2 15.1 310 2 15.2 436 OK 1 2.5 124 2 15.2 312 Station Time Status Bolt No Bolt T Bolt A Status Step No Peak T A ---------------------------------------------------------------------------------------- Stn 01 011030 09:40:22 OK 1 15.1 435 OK 1 2.4 125 2 15.1 310 2 15.2 436 OK 1 2.5 124 2 15.2 312 Stn 01 011030 09:41:44 OK 1 15.1 435 OK 1 2.4 125 2 15.1 310 2 15.2 436 OK 1 2.5 124 2 15.2 312

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:RUNSLHFH0HUJH

In some cases a work piece goes through several stations controlled by the same PowerMACS system. In such cases you may want data from all the stations presented together at the same time. In such cases enable the :RUNSLHFH0HUJH function by checking the (QDEOH checkbox. Specify which is the /DVW

VWDWLRQ the work piece will be handled in. When the work piece is ready in the last station then the results from all stations for this work piece will be output. If you want you can have the 1RUPDOUHSRUWGLVDEOHG .

To be able to identify the work piece each station must have an identification device, that is a bar code reader, an escort memory etc.

$GYDQFHG(YHQWVHWWLQJV

Using the Advanced Event settings form you can configure a filter for which events that should be sent to the device and, for reporters configured to report data in binary format, how they should be formatted.

Events can be filtered on their type and their severity.

In the (YHQWW\SHVLQFOXGHG frame, check the event types you want to pass to the device controlled by this reporter.

In the 6HYHULW\LQFOXGHG frame, check the severities you want to pass to the device controlled by this reporter.

In the 'DWDLQFOXGHGIRUHYHQWZKHQSULQWHGELQDU\ frame, check the fields you want to include for each event reported.

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$GYDQFHG&'VHWWLQJV

Given that you have specified a +HDGHUIUHTXHQF\ in the Reporter form you can use this form to add a header and a footer to all pages of your cycle data.

[JB27]

Enter the text to be printed at the top of the document in the field +HDGHURQWRSRISDJH7H[W . For the WinTC Printer you may also use the %LWPDS combo box to select a bitmap to be displayed as header.

Enter the text to be printed at the bottom of the document in the field )RRWHUDWERWWRPRISDJH7H[W . For the WinTC Printer you may also use the %LWPDS combo box to select a bitmap to be displayed as footer.

To be able to include your own bitmap you must first place the bitmap in the directory named %PS located in the directory where you to install the WinTC.

Using the fields &KDUDFWHUVWREHVHQWWRWKH5HSRUWHU%()25(WKHPDLQGDWD and &KDUDFWHUVWREH

VHQWWRWKH5HSRUWHU$)7(5WKHPDLQGDWD you can specify character strings that will surround each cycle data result printed.

Here you may also include non-printable characters. Typing their ASCII code in hexadecimal format enclosed by a "<" and a ">" does this.



([DPSOH : To frame each cycle data with a start-of-text character (STX), before the data, and an end-of- text character (ETX), after the cycle data then enter:

• "<02>" in &KDUDFWHUVWREHVHQWWRWKH5HSRUWHU%()25(WKHPDLQGDWD

• "<03>" in &KDUDFWHUVWREHVHQWWRWKH5HSRUWHU$)7(5WKHPDLQGDWD

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6HFXULW\

PowerMACS contains a security system that prevents unauthorized access. All personnel must then be registered as users with password and access level.

The access level makes it possible to allow personnel as a group or individuals to have access at these levels:

• No access at all

• Read access

• Read and write access

5HJLVWHULQJXVHUV

Use menu item )LOH6HFXULW\8VHUV to register a new user, or to check or change data for an existing user.

[JB28]

The list contains current users.

Press 1HZ« to add a new user. A dialog box is shown.

[JB29]

Enter 1DPH , 3DVVZRUG , and $FFHVV /HYHO . Press 2. to register the user. $FFHVV/HYHO should be a number from 1 to 10. Access level 1 gives lowest access possibility, 10 the highest.

To change data for an existing user, select the name from the list and press &KDQJH« The same dialog box appears as for a new user. Change the data and press 2. .

To remove a user, select the name from the list and press 5HPRYH .

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$FFHVV/HYHOVIRU0HQX,WHPV

[JB30]

For all forms you can set up which access level a user must have to be allowed access. Use the menu item )LOH6HFXULW\$FFHVV /HYHO .

Enter access level for all forms. Access level should be a number from 0 to 10. Set to low value for presentation forms, and higher for forms, which need more protection. A user, which has not logged in yet (and therefore runs as user “Anonymous”), has an access level of 10. A registered user who has logged in has an access level of 1 to 10.

Access levels can be set for Read or Write access.

Recommendation: put highest possible access level for menu items )LOH6HFXULW\8VHUV« and $FFHVV

WR)RUPV . This way it will not be possible for a user to change his access level, or the access level for a form.

/RJLQDQG/RJRXW

[JB31]

When a new user is about to start to work with the system he should log in. This can be done in either of the following ways:

• Pressing button on the toolbar (if shown)

• Using the menu item )LOH/RJLQ

At log in the following dialog box is displayed:

[JB32]

If the name and password is correct the user will be let in. The name of current user is presented on the status bar, down to the right.

When the user is finished with his work he should log out to prevent other users from making any unwanted changes. This can be done in the same way as for log in.

If no actions are made on the Console for ten minutes the system will make an automatic log out.

8VHU0DQXDO3RZHU0$&6 %DVLF)XQFWLRQV x 



If you have made changes to the system and you log out you will automatically be asked to enter a message in the Service Log. You will also be asked to save changes in the setup file.

5XQQLQJWKHV\VWHPZLWKRXWDQ\VHFXULW\V\VWHP

When a setup is created it just has one registered user, ”Anonymous”. ”Anonymous” is the name of the user when no one specific has logged in. "Anonymous” has an access level of 10.

The security system is always enabled. When a new setup is created all forms are assigned a default access level for reading and writing. See chapter: Default Access Rights for a list of values.

This means that without logging in it is possible to use the system right away, as user ”Anonymous” (this user has no password). If acceptable, this way the system can be used indefinitely.

However, if any form of security is required the access level of ”Anonymous” should be lowered and the access levels of the forms should be adjusted so that “Anonymous” still can be left for tasks considered “safe”, e.g. displaying the assembly overview, reading the event log, etc..

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3ULQWLQJ

Use the menu item )LOH3ULQW« to print tables in a setup.

[JB33]

First select the type of table you want to print in the combo labeled 7DEOH . This will display all tables of the selected type in the 6RXUFH frame.

Select one table by clicking on it.

If you want to print several consecutive tables, point on the first one, press left mouse button and hold down. Drag the cursor over the table you want to print, and release the mouse button when on the last one.

You can select several non-consecutive tables by clicking on these while holding down the CTRL key on the keyboard.

Press 6HOHFWDOO to select all tables of the selected type. Press 6HOHFWFKDQJHG to print all tables that have been changed since last time they were printed.

When printing more than one table each table is formatted and printed on an own page.

Press 3DJH6HWXS« to enter a dialog box where you can set up which printer to use, number of copies etc.

If you press 3UHYLHZ« a window will be presented where you can see how the printout will look like on the printer.

1RWH You can only print tables on a printer that is accessible from the console computer. Either directly connected or via the network. It is not possible to reach a printer that is connected directly to the tightening controllers in the PowerMACS system.

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6HW8SDQG0DLQWHQDQFH2YHUYLHZ

This part handles how to set up and maintain the system.

1RWH Be careful when changing data in setups. If you are connected on-line, and your system is running,

a change will affect the system immediately when you press the $SSO\ button in the current form. Even though the change is activated in a controlled fashion between two cycles it might effect your system in a way you did not intend.

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6HWXSVDQG+RZWRKDQGOHWKHP

A VHWXS is a group of data that completely describes how a system should work. The PowerMACS system uses the information in the VHWXS to know what to do. A VHWXS can also be called a FRQILJXUDWLRQ . A VHWXS can be stored on the console computer in a file on a hard disk or on a floppy. It can be downloaded to the system, or uploaded for storing or modification.

Most items on the )LOH menu handle setups.

Use the 1HZ item to create a completely new setup. This is described in chapter: 6HWXSRIDQHZ

V\VWHP .

With the 2SHQ item you open an existing setup, to alter or just to check. When you are ready with a setup you can use &ORVH to close the setup.

If you have opened a setup and made modifications to it you can save these to disk by selecting 6DYH . You can also rename it by using 6DYHDV . Then the original setup will be kept. This is a also a fast way of creating new setups by starting from a similar one.

If you want to copy separate tables from one setup to another you can use the ([SRUW and ,PSRUW choices. This is described in chapter: Table Export and Import.

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



From the 6HW8S menu you can make very basic changes to the setup.

[JB34]

Use the 6\VWHP« item to make changes to the logical structure of the system. Here you can add or delete stations and bolts, or change their properties. You can also add or delete KDUGZDUH devices to the system, such as servos, printers, barcode readers. You can change properties of devices like the baud rate for a printer or the symbolic name for a device. See chapter: 6\VWHP6HW8S for details.

The %ROW« choice is used to set up things that concern the bolt, see %ROW6HW8S .

The 6SLQGOH« choice is used to set up all parameters concerning a spindle: channels, filtering, calibration etc., see 6SLQGOH6HW8S .

The 6HUYR item opens the 6HUYR6HW8S form in which you can configure the characteristics of a servo.

The ,'GHYLFH« item is used to set up parameters for ID device units, like bar code readers, and to program decoding of the read information. See chapter: ,'GHYLFH6HW8S for details.

Use the (DV\9LHZ« item to display the (DV\9LHZ6HW8S form in which you configure the parameters that should be possible to modify from the Easy View form.

The $VVHPEO\2YHUYLHZ« item is used to define which result parameters that will be displayed in the Assembly Overview form. See chapter: Assembly Overview Set Up for details.

Use the 3/&3DUDPHWHUV« item to display the PLC Parameters Set Up form in which you configure parameters that that are accessible from inside the PowerMACS PLC.

Use the 2SWLRQV« item to display the 2SWLRQV form in which you can set up certain options for the system, like which unit you are using for torque.

Selecting the $XWR7XQH alternative will display the $XWRWXQH form that can help you fine-tune your system.

Finally, the menu item &KHFNLI5HDVRQDEOH enables you to check if your setup is reasonable correct. This will check that target values in programs are possible to reach with respect to max values defined for the spindles and servos used.

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6HWXSRIDQHZV\VWHP

After you have decided what physical hardware you will have in your new system you should make a

VHWXS . A setup is a file, which contains all information that is needed for the system to execute its task properly.

You can create a new setup RIIOLQH on any PC computer. Off-line means that you are not connected to the actual hardware. When you are ready to run you connect your PC to the hardware and go RQOLQH . Your PC gets in contact with the hardware and downloads the setup.

1RWH You should take as a rule to always create a new setup using the Wizard since it automatically generates a setup that not only is valid but also contains a PLC program.

&UHDWLQJDQHZV\VWHPXVLQJWKH6HW8S:L]DUG

A ZL]DUG will guide you through the creation of a completely new setup. Select menu item )LOH1HZ«

[JB35]

A wizard is a set of dialog boxes that will lead you through the creation process. If you change your mind you can always go back with use of the 3UHYLRXV button.

Enter a name for the system, and the number of stations you will have in it.

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



Press 1H[W!! A new dialog box is presented.

[JB36]

Enter the number of bolts and spindles you want to have in the first station using the fields 1RRI%ROWVLQ

WKH6WDWLRQ and 1RRI6SLQGOHVLQWKH6WDWLRQ .

Enter in 'HIDXOW6SLQGOH W\SH and 'HIDXOW7&7\SH the type of spindles and TCs that you have in your system. If you have more than one type select the alternative you have most of. You can later individually change these values.

Press 1H[W!! . This will display the following dialog:

[JB37]

Here you may change the names of the bolts.

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Press 1H[W!! to be displayed the dialog where you may alter the names given to the spindles:

[JB38]

Here you may also change the type of the spindle and the servo corresponding to it.

Press 1H[W!! . If you specified fewer spindles than bolts in the second wizard dialog you will be displayed the following dialog:

[JB39]

Use the combo boxes in the Spindle column to select the spindle to be used to control each of the bolts.

Press 1H[W!! to display the next wizard dialog.

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



[JB40]

Enter the number of modes you want to have in the Mode table for the station (max is 50) and press

1H[W!! . This will present the following dialog:

[JB41]

Now specify the program to use when tighten the bolts in the given mode. You can choose between using an already existing program by selecting it in the 8VH3URJUDP combo box, or to create a new one. If you chose the latter alternative you must specify the main characteristics of the program using the controls to the right of the radio button 1HZ .

Checking the *HQHUDWH63&6HWXS check box will configure the SPC function to calculate SPC data for the variables Bolt T and Bolt A.

When done press 1H[W!! . This will cause this dialog to be repeated once for each mode you specified in the previous wizard dialog.

If you specified more than one station in the system the wizard will repeat the sequence above from dialog two for each station.

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When you have specified all data for all stations included in your system the following dialog is displayed:

[JB42]

Pressing )LQLVK will make the wizard create the new setup based on the information you have specified. The following items will be included in the setup created:

• Servo, spindle and bolt setup’s, one for each item specified.

• As many tightening programs as you have chosen to create. All programs created will have checks and fail safe limits setup for each step included as well as monitoring limits.

• A mode table for each station specifying the programs you have selected.

• SPC configured for measuring the final torque and angle for each of the bolts.

• A reporter for the CC screen and a printer connected to the CC.

• A PLC project containing one POU (Program Organization Unit) and one resource, with one task, for each station defined in the system. All POU's are copies of a predefined POU template.

The setup is complete in the sense that it will be possible to execute. It will therefore be a good starting point for your own application.

To lead you on the right way the System Set Up and The Tightening Program/Sequence forms will appear on the screen. With these you can finalize the set up.

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6\VWHP6HW8S

Using System Set Up form, invoked using the menu item 6HW8S6\VWHP , you can check and alter the system configuration. This is the same form as presented when pressing the System Map button on the toolbar, but here you can make changes.

You can expand or collapse the tree structure by clicking on an item or clicking in the small squares with + and -. When first shown you see the left part of the form. Press 0RUH!! to see the expanded view.

When you select an item in the tree to the left the most relevant data for the item is shown to the right. For some items, like System and Stations, all data will fit on the page to the right. For other, more complicated items, an $GYDQFHG« button is displayed. Pressing it will show you all parameters of the item.

Data in fields with white background can be changed. Press $SSO\ to save changes into the setup. 1RWH that if you are on-line the changes will affect the running system.

The items that make up a system are divided into two parts, the logical structure and the hardware structure. These are displayed on separate tabs on the System Set Up form. The systems logical structure is displayed on the 6\VWHP tab while the hardware layout is shown on the +DUGZDUH tab.

The $GG« and 5HPRYH« buttons are used to add and remove items to/from your setup. However, even though it is possible to add/remove logical items, such a station and bolts, displayed on the System tab it is recommended that you use the File-New Wizard (see Creating a new system using the Set Up Wizard) when doing major structural changes to your system.

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7KH6\VWHPWDE

The 6\VWHP tab on the System Set Up form displays your systems logical configuration.

The System is displayed in a tree structure with the system node as the root element. The next level contains all the Stations as well as the Program and Sequence folders.

Each Station contains the Mode table and all Bolts controlled by the Station.

The Programs and Sequences folders contain all programs and sequences that are defined in the setup, these are available to all Stations within the system.

7KH6\VWHPQRGH

Select the System node by clicking on it using the mouse. This will make all properties of the System to be displayed to the right of the tree view.

Use the 1DPH field to change the name of the System. It identifies the system, and setup, and may be up to 20 characters long. The name will be displayed as caption of the WinTC main form when the setup is loaded and will be displayed when you scan for TC and/or primary TC on a PowerMACS network (see Select Target System and Configure Target System).

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



7KH6WDWLRQQRGH

When selecting a Station node all its properties are listed to the right of the tree view.

[JB43]

The name entered in the 1DPH field defines the name of the Station. It will identify the Station in cycle data reports, etc. The name may be up to 20 characters long.

In the ,'GHYLFH combo box you may chose which ID device that the Station should read an ID string from, if so is requested. The combo box will only list the devices that are configured for the system. See ID Device for how to add and configure an ID device.

Normally no cycle data is generated if an Emergency Stop interrupts a cycle (caused be setting the PLC variables EMERGSTOP or MACHINESTOP, or if the station loses communication with one or more of its TCs). To generate a result also under these conditions check the 5HSRUW&\FOH'DWDDWHPHUJVWRS checkbox. The Cycle Data generated will include all result variables specified by the used Reporter but the value of all bolt and step level variables, except for the following will be empty ("Not Defined"):

• Bolt (name)

• Bolt No

• Spindle No

• Op Mode

• Status (always NOK)

The $GYDQFHG5HMHFW0DQDJHPHQWLI« settings are described in the functional description for Tightening, see chapter: Advanced RM Actions.

Press the $GYDQFHG« button to access the Advanced Station Settings form.

This form enables you to configure which type of Events that should be possible mark as observed from the PowerMACS PLC. Check all types that you want the PLC to have access to. See View Event Log for a description of the different Event types and Station variables for how to access them from inside the station PLC.

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7KH%ROWQRGH

Select a Bolt node to display the most common properties of the Bolt.

Use the 1DPH field to change the name of the Bolt. This name will identify the Bolt in cycle data reports, etc. and may be up to 20 characters long.

The number entered in the %ROWQXPEHU field may be used as a more compact identifier of bolt (in addition to its name). This number may be included in the reports as the variable "Bolt No" (see Bolt level result variables). The number must be unique within the station and within the range [1..127].

With %ROW6WDWXV combo box you can control whether or not the bolt is connected, i.e. used by the system, or disconnected. In the latter case you can also chose if it should be reported as OK or NOK.

%ROWW\SH is a free text that identifies the type of the bolt. This information is used for the result variables Total Type, Total Type OK and Total Type NOK, see chapter: Bolt level result variables.

Select in the 6SLQGOH combo box the spindle to use to tighten the bolt.

Should you be interested in all spindle parameters press the 2SHQ« button. This will open the Spindle Set Up form.

Specify to which reject management group, or groups, the bolt belongs using the 50*URXS field. Enter comma separated numbers (1, 3, 5), or intervals (1-5). See Group for a definition and Step – Reject for how it is used.

If you need to check or change any other parameter of the Bolt press the $GYDQFHG« button. This will open the Bolt Set Up form that gives you access to all parameters of a Bolt.

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



7KH3URJUDPV6HTXHQFHVQRGH

Double clicking on the Programs or Sequences node will in fold the respective folder and list all programs/sequences defined in the system.

Selecting a single program or sequence will display its Properties parameter to the right. You may use it to save a comment together program/sequence.

Also, to give you a preview of the selected program/sequence, it is displayed using the Quick View syntax in the 4XLFN9LHZ window.

To open The Tightening Program/Sequence form for a full listing of the program press the 2SHQ« button.

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7KH+DUGZDUHWDE

Using the +DUGZDUH tab of the System Set Up form you can check and alter your hardware configuration.

The hardware is displayed in a tree structure with the system node as the root element. The next level contains all the TC included in the system.

Under each TC all devices connected to it are displayed as leafs. Normally all TCs have a Spindle and a Servo device. While spindle is very obvious, the Servo is built into the TC and is always there.

In addition to these two devices you may add other devices, as you need them. The PowerMACS system supports numerous types of devices. To add a device to TC first select the TC to which you want to add a device and then press the $GG« button. This will bring up the Add Unit form in which you select the type of device to add.

[JB44]

1RWH All hardware devices but the I/O device requires a Reporter to function properly. The Reporter controls what data that should be reported over the device, and how it should be formatted. See chapter: New reporter and Edit reporter for how the reporter is added and set up.

To view the major settings for a device mark it in the Hardware tree and press the 0RUH!! button.

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



7KH6SLQGOHQRGH

Select a Spindle node to display the most common properties of the Spindle.

[JB45]

Use the 1DPH field to change the name of the Spindle. This name will identify the Spindle in cycle data reports, etc. and may be up to 20 characters long.

Use the 6SLQGOHW\SH combo box to change the type of the used spindle.

1RWH Changing spindle type will reset all spindle parameters to their default values. Any changes done compared to the previous types default values are lost.

Press the $GYDQFHG« button to access the Spindle Set Up form that enables full access to all the spindle parameters.

If the cycle counting function is enabled for the spindle (see Spindle Set Up, General) you can modify the current value of the cycle counter for by entering the new value in the text field to the right of the 6HW

&\FOH&QW button and press the button.

7KH6HUYRQRGH

Select a Servo node to display the most common properties of the Servo.

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



Use the 1DPH field to change the name of the Servo. This name will identify the Servo and may be up to 20 characters long.

Use the 6HUYR7&W\SH combo box to set the type of the used TC/servo.

1RWH Changing Servo/TC type will reset all servo parameters to their default values. Any changes done compared to the previous types default values are lost.

Press the $GYDQFHG« button to access the Servo Set Up form that enables full access to all the servo parameters.

2WKHUGHYLFHQRGHV

Selecting any node of any other device type will display the parameters of the selected device type.

For most devices all parameters are displayed to the right of the tree view.

Devices that have very many parameters make use of a specific form to access these. For such devices an $GYDQFHG« button is displayed on the System Set Up form. Press this button to open the device specific form.

The basics of these devices are described in the Peripheral Devices chapter.

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%ROW6HW8S

This form is invoked from the 6HWXS%ROW menu and is used to set up all bolt specific information.

This configuration will be used for all tightenings made on the specific bolt regardless of which tightening program that is used.

[JB46]

Use the 6WDWLRQ and %ROW combo boxes to select the bolt to view or edit.

The number entered in the %ROWQXPEHU field may be used as a more compact identifier of bolt (in addition to its name). This number may be included in the reports as the variable "Bolt No" (see Bolt level result variables). The number must be unique within the station and within the range [1..127].

Using the 6WDWXV combo In the *HQHUDO frame you control whether or not the bolt is connected, that is, used by the system, or disconnected. If disconnected you can specify if it should be reported as OK or NOK in the cycle data.

7\SH is a free text that identifies the type of the bolt. This information is used for the result variables Total Type, Total Type OK and Total Type NOK, see chapter: Bolt level result variables.

Select in the 8VHV6SLQGOH combo box the spindle to use to tighten the bolt.

Specify to which reject management group, or groups, the bolt belongs using the 50*URXS field. Enter comma separated numbers (1, 3, 5), or intervals (1-5). See Group for a definition and Step – Reject for how it is used.

The parameters in the 1RRIDQJOHLQFUHPHQWSHUEXIIHUHOHPHQWV frame controls the resolution of the buffer used for monitoring (see Bolt Monitoring). The buffer consists of 8192 elements, in units of [angle increments/buffer position].

If $XWRVFDOH is checked then the buffer is automatically rescaled if the traveled angle exceeds the maximum angle of the buffer. When started every element covers 1 encoder increment and whenever the buffer limit is reached this value is doubled causing a lower resolution. Already recorded data is kept (compressed) when the buffer is rescaled. If you leave $XWRVFDOH unchecked you must manually enter the resolution of the buffer in the edit field to the right of it. In this case the oldest recorded data will be overwritten when buffer limit is reached resulting in that the last part of the cycle is kept in the buffer.

When using a fix buffer resolution the check box $OORZPRQLWRULQJEXIIHURYHUUXQ controls whether or not a buffer overrun should be regarded as an error or not. If checked then an overrun will generate an event and cause the cycle to end NOK. If not checked then only a warning is generated.

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See Bolt Monitoring for a full description of the monitoring functions.

In the 7UDFH6WDUW frame you can set up how traces should be recorded. In many cases you are not interested in the first part of the tightening, but want more details in the latter parts. You can specify that trace should be recorded from &\FOHVWDUW , or from start of a certain 6WHS (click the radio button labeled Step and enter the step number in the field to the right of the radio button). You can also specify an optional additional condition, that the torque (or angle or current) is higher than a certain value.

In the 0RQLWRU6WDUW and (QG frames you can set up when the monitoring function should start and End. If you specify 3/&6LJQDO the monitoring starts and ends when the PLC program activates special outputs (MONSTART and MONEND), see chapter: Station variables.

If 6WHS is selected as Monitoring Start condition monitoring will be started when the first step having the Start/restart monitoring flag set is started (see Step – Control).

Selecting 7RUTXH as Monitoring Start, or End, condition and specifying a torque level will cause monitoring to be started, or stopped, when the respective torque is reached.

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6SLQGOH6HW8S

There are many parameters that control the running of a spindle. During set up these parameters are given default values. Most frequently changed parameters, like Gear Ratio, can be changed in the

6\VWHP6HW8S form.

In some cases this is not enough. Therefore it is possible to change all parameters with the 6SLQGOH item in the 6HW8S menu. At all times it is possible to return to default values for the spindle type specified in the 6SLQGOH7\SH combo by pressing the 'HIDXOW button.

The parameters are grouped into a number of frames.

[JB47]

*HQHUDO

In the General frame you find parameters of more general functions.

[JB48]

If you run a JOG - Run until digital input goes high / low step, the spindle runs until a specified input goes high or low. Specify in 'LJLQSXWIRU-2*VWHSV which digital input to supervise. Enter as

7&QR!FKDQQHO! e.g. 1.4. Leave blank if you do not have any input for this. See also the description of I/O Device in chapter: Peripheral Devices.

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Specify in 'LJRXWSXWIRU*HDU6KLIW the digital output that is connected to the spindles gearshift unit. This can be controlled using the GS - Run Gear Shift step. Enter as 7&QR!FKDQQHO! , e.g. 1.4. Leave blank if you do not have any output for this.

Enter in *HDU5DWLR the reduction of the gearshift. Enter number of turns on input shaft divided with number of turns on output shaft. If 2.5 turns on the input results in 1 turn on the output the gear ratio is 2.5.

The 6DPSOLQJIUHTXHQF\ controls how often measuring of torque and angle are done. A higher value may give a better tightening result but will lead to a higher load on the tightening controller, which will lead to slower execution of the PLC, presentation on screen etc. Default value is 1000 Hz for most spindles types.

Use the 'LUHFWLRQ field to select the basic direction for the spindle, normally )RUZDUG (or clockwise). If the spindle is equipped with a gearbox that reverses the direction select %DFNZDUG (or counter clockwise). You can also control the direction from the station PLC by selecting 33 , i.e. the PLCs Station variables GENOUT_1..5. If the selected PLC output is set to 1 then the spindle will go forward, otherwise backwards.

Specify in =HUR6SHHG how fast the spindle can rotate, in revolutions per minute, and still be considered having zero speed.

Use 7&IDFWRU to specify the relation between torque and current for the motor. Defined as the ratio Torque Motor /Current Motor , where Torque Motor is the torque generated by the motor when the current Current Motor is applied to it. Unit [/A].

0D[7RUTXH and 0D[6SHHG specify the maximum torque and speed allowed for the spindle. These parameters are used by the Check if Reasonable function when checking the torque and speed parameters of the used tightening programs.

Using the field :LQG8S&RHIILFLHQW you can compensate for the torsion in the gears and the shaft caused by the applied torque. Expressed in the unit [degrees/].

Use the field 1R&\FOHV0DLQ to specify the service interval, in number of cycles, for the spindle. Check the &\FOH&RXQW check box to enable counting of cycles for the spindle. If you want an alarm to be sent to the event log when the service interval is reached then check the &\FOH&RXQW$ODUP check box. The current value of the cycle counter can be viewed and modified in the System Set Up form.

&KDQQHOV

In the &KDQQHOV frame you find all parameters that has to do with measuring of tightening values.

[JB49]

Activate the measuring channels you want to use for the spindle by check the corresponding 8VHG check box.

Use the 7\SH combos to select the appropriate type of transducer for the torque signals. You may select between the bridge type (normal transducer) and voltage type.

Check 1HJ if you have negative polarity on your transducer. This will invert the signal polarity.

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6FDOHIDFWRU specifies the gain of the measured quantity. Depending on channel enter values as below:

&KDQQHO 7\SH (QWHUDV6FDOHIDFWRU

Torque 1 Torque 2 Bridge The nominal load of the transducer (normally printed on transducer). See also note 1.

Torque 1 Torque 2 Voltage The torque, in , that corresponds to an input voltage of 10 [V]

Current The current in [A] that corresponds to an input voltage of 10 [V]



1RWH : Depending on selected the voltage gain of the transducer is assumed to be:

V\VWHPWRUTXHXQLW! 9ROWDJHJDLQ

Nm 0.59 [mV/V]

kNm 0.59 [ µ V/V]

ftlbs 0.80 [mV/V]

inchlbs 66.7 [ µ V/V]

The torque channel inputs have the following principal design:

K Gain A

D

Where K is 42.2 if the input type is set to Bridge and 0.2 if set to Voltage. Gain is the value selected in the

*DLQ combo box. You can use Gain to increase the resolution of the torque measurement if you are not using the full swing of your transducer. However, if you do so you must make sure that the AD (Analogue to Digital) converter do not saturate. Max allowed input to the AD is ± 2.048 [V].

If you have double transducers for torque measuring you should specify values for both 7RUTXH and

7RUTXH .

Use the 7RUTXH8VDJH combo to specify which channel to use for Control and Monitoring. Choose between:

&RQWURO 0RQLWRULQJ 9DOXH

In addition to the alternatives above you can also control how the channels are used from the PLC. To do so, select one of the alternatives *(1287B3 , which correspond to the PLCs Station variables

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GENOUT_1..5, and use it to control which channel to use for what by assigning it an integer value according to the Value column in the table above.

Specify in the $QJOH8VDJH combo, which channel to use for Control and Monitoring. Possible combinations are:

&RQWURO 0RQLWRULQJ 9DOXH

The Angle Usage can also be controlled by the PLC the same way as for the Torque Usage.

&DOLEUDWLRQFKHFN

To check your torque transducers you can include a Diagnostic step (see ''LDJQRVWLF6WHS ) in your tightening program. In the &DOLEUDWLRQ frame you find all parameters used by all steps of this type.

[JB50]

In the &DOLEUDWLRQWHVW a resistor is connected over the torque measurement bridge to emulate a known torque load. There are two resistor values to choose between, 45 or 400 [kOhm], and which one to use depends on the transducer type. However, for all standard spindles (which have 700 [Ohm] transducers) the 400 [kOhm] resistor should be used. Under normal conditions this gives an expected torque of 74% of the entered Scale factor value.

If the measured value differs from programmed ([SHFWHGWRUTXHDWFDOLEUDWLRQWHVW more than the programmed value for $FFHSWHGGLIIHUHQFHDWFDOLEUDWLRQWHVW the check fails. A failing test will give

)DWDO as step status and set the error flag CALIBDIAG.

To verify that there really is a calibration problem, and not just a glitch, you can set up 1RRIVDPSOHV

WUDQVGXFHUVPD\GLIIHUEHIRUHDODUP

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 





=HURRIIVHW

To a large extent you can eliminate torque-measuring errors by performing zero offset check and compensation.

When such an operation should be done is controlled by the execution of a step named ''LDJQRVWLF

6WHS . The step also controls which type of tests to perform but how the respective test is executed is controlled by the parameters in the =HUR2IIVHW frames below.

[JB51]

6WDWLF]HURRIIVHW is measured without turning the spindle. The static zero offset is the average torque measured during 0HDVXULQJWLPH . The absolute value of the static zero offset must be below 0D[LPXP

6WDWLF=HUR2IIVHW . If not, step status is set to )DWDO and the error flag STZODIAG is set.

'\QDPLF]HURRIIVHW is measured as the average torque while the spindle first runs in the forward direction during half the specified 0HDVXULQJWLPH and then in the reverse direction during the second half of the specified time. 6SHHGIRU$QJOH&KHFN controls the speed in both directions. If the absolute value of the measured offset is greater then 0D[LPXP'\QDPLF=HUR2IIVHW then step status is set to )DWDO and the error flag DYNZODIAG is set.

)O\LQJ]HURRIIVHW is measured as the average torque while the spindle runs forward. The measurement is not started immediately when the diagnostic step is started but after 7LPHIURPF\FOHVWDUWWR

PHDVXULQJ . The average value is calculated during 0HDVXULQJWLPH . The absolute value of the measured offset should be below 0D[LPXP)O\LQJ=HUR2IIVHW . Whether the step is stopped or not when the offset exceeds this value depends on the value of &RQWLQXHWRUXQDIWHUIDLOHGVWHS . If checked then a too high value just generates a warning (FLYZODIAG) and the bolt is not stopped. If not checked, then the occasion is considered to be an error (FLYZODIAG) and step status is set to Fatal. Since measuring does not necessarily start immediately when the diagnostic step does, both measuring and evaluation may be done while during the execution of another step. If the cycle ends before measuring is started, that is before 7LPHIURPF\FOHVWDUWWRPHDVXULQJ has elapsed, then the measuring is cancelled and neither an error nor a warning is generated.

If an $QJOHFRXQWWHVW is specified  the  motor will run exactly as when performing a Dynamic zero offset test. The angle is measured separately in the forward and the backward direction. Both measured angles must be greater than the specified 0LQLPXPDQJOH and less then the specified 0D[LPXPDQJOH . If not then step status is set to )DWDO and the error flag ANGDIAG is set. If Dynamic zero offset is selected as well then it is measured at the same time as the Angle count test.

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The following text describes the sequence of actions that can occur:

IF (Static Zero Offset test OR Calibration test) THEN Measure the Static Zero Offset; IF (Static Zero Offset) THEN Save as Zero Offset compensation value if within limits; ENDIF IF (Calibration test) THEN Perform the calibration test (compensates with measured zero offset); ENDIF ENDIF IF (Dynamic Zero Offset test OR Angle test) THEN First run in the forward direction and then in the backward direction; Measure average torque and angle pulses in both directions; IF (Dynamic Zero Offset test) THEN Check the measured Dynamic Zero Offset; Save as Zero Offset compensation value if within limits; ENDIF IF (Angle test) THEN Check that both the measured angles are within specified limits; ENDIF ENDIF IF (Flying Zero Offset test) THEN Run forward a programmable time from the start of the diagnostic step (do not measure); Start measuring the torque and run another programmable time; Save as Zero Offset compensation value if within limits; ENDIF

'RXEOHWUDQVGXFHUFKHFNV

If you use double transducers or angle encoders the spindle will execute UHVWULFWLRQWHVWV to ensure that the transducers and/or encoders give similar values.

[JB52]

Use 0D[WRUTXHGLII and 0D[DQJOHGLII to specify how much the values from the two transducers and the two angle encoders may differ while still considered to be correct.

1RGLIIVDPSOHVEHIRUHDODUP specifies how many consecutive samples the respective difference may be over the respective limit before it is considered an error.

If error the step is immediately stopped with status )DWDO and one or both of the error flags TDIFF (torque transducer) or ADIFF (angle encoder) are set.

7UDQVGXFHUUHDGLQJVDWXUDWLRQ

This is a non-configurable restriction that monitors if the A/D converter used for reading the transducer saturates. If the signal level after the A/D converter is greater than 90% of the full reading the input is considered saturated. An event is generated and the error bit SAT is set in the bolt level result variables Error/RM Error. The error is always considered )DWDO .

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6HUYR6HW8S

In the Servo Set Up on the Set Up menu you can check and alter a number parameters that controls the servo. These parameters are downloaded to the servo at start up. If you make any changes you must restart the system before it takes effect.

1RWH Changes in the servo setup may be hazardous. Do not make any changes if you are not absolutely certain of their effects.

[JB53]

The 6HUYR7&7\SH identifies the servo as a specific type. The type determines what properties the servo setup can have and the default values are given in accordance with the servo and spindle type choices.

Which parameters that are available depend on the type of servo used.

By pressing the 'HIDXOW button you can always return to the default values defined for the servo and the selected QMX spindle type.

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,'GHYLFH6HW8S

The ID device form is invoked using menu item 6HWXS±,'GHYLFH« .

ID devices are equipment that can read (and write) identification information on the work piece. The information read for the ID device will be added to the tightening data, as the station level result variable "Wp. ID", but since the information also is available to the PowerMACS PLC it can also be used to control, for example how a tightening is performed.

[JB54]

Select the ID device to view or configure using the ,'GHYLFH combo box. (You can create new ones using the 6\VWHP6HW8S form invoked with the 6HWXS±6\VWHP« menu choice).

Depending on the type of the ID device the frame 7\SHVSHFLILFSDUDPHWHUV will display different controls.

For a %DUFRGHVFDQQHU (Barcode) you may freely choose which characters that are used to frame the ID string. The character entered as 6WDUWFKDUDFWHU , if any, must be the first character returned from the device. If not the device is marked erroneous until a correct string is scanned. Enter as (QGFKDUDFWHU the character that marks the end of returned string. Non-printable characters are entered using their hexadecimal code enclosed between a pair of "<" and ">", for example "<09>" for a horizontal tab.

If you use a 3HSSHUO)XFKVHVFRUWPHPRU\ (Escort P+F) you must specify where in the data tag to read

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



the ID string from and where to write cycle data to. Use the two pairs of 6WDUWDGGUHVV and 6WRSDGGUHVV to do this. The first address in the tag has address zero (0). For reading you can specify up to 40 cells and for writing up to 500.

For the $OOHQ%UDGOH\HVFRUWPHPRU\ you specify where to read the ID string from using 6WDUWDGGUHVV and 6WRSDGGUHVV .

5)ILHOGVWUHQJWK controls the power of the signal transmitted by the antenna and may need to be adjusted depending on the distance between the antenna and data tags.

The parameters 'HOD\EHIRUHUHVS , 'HOD\EHWZHHQFKDU and 6HQVRUWLPHRXW should normally be kept at their default values.

For more information on these parameters see Allen Bradley’s User Manual for the Intelligent Antenna.

The 0DVN and the &RQYHUVLRQ table are common for all ID device types and are used for decoding of the information. In the 0DVN , mark all characters relevant for the decoding. Only characters in the marked positions will be filtered through to the conversion table.

The Conversion table contains 20 rows, and on each of them you may enter a character string and a corresponding code.

You may use regular expressions to match general patterns. The following special expressions may be used as part of the string:

::= ::= ::= | NOTHING ::= See table below. ::= ’;’ | NOTHING ::= ’\’N where N is a number from 1 to 9. Represents the value of the Nth "tagged expression" found in from the left. See the below table for a definition of a "tagged expression". ::= ’<’ | ’>’ | ’=’ | ’<=’ | ’>=’ ::= A sequence of decimal digits representing an integer number in the range [0..999 999 999]

([SUHVVLRQ 6\QWD[ 'HVFULSWLRQ

Any one character ? Matches any one character.

Zero or more characters * Matches zero or more occurrences of any alphanumerical character.

1RWH Currently no special characters, that is, the ones listed in this table, may be used after a ’’ * ’.

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



One alphabetic character :c Matches one alphabetic character [a-zA-Z].

One decimal digit :d Matches one decimal digit [0-9].

One hexadecimal digit :h Matches one hexadecimal digit [0-9A-F].

Tagged expression {} Tags the text matched by the enclosed expression. The enclosed expression must either be a sequence of decimal digits or a sequence of hexadecimal digits. The value of the enclosed expression can be referred to in a subsequent range check (see ).

Example: {ddd} or {hhhh}

Escape \ Matches the character following the backslash (\). This allows you to find characters used in the regular expression notation, such as { and :.

Set of characters [] Matches any one of the characters enclosed within the [].

Example: [abc] matches any single occurrence of the characters ’a’ ’b’ or ’c’.

Range check start ; Marks the start of a range check (see )

The code will be available in the PowerMACS PLC as the input PLC input IDCODE and can there be used for selection of mode etc. If a match cannot be found then code is set to the value –32768.

1RWH The rows in the Conversion table is tested one by one, beginning at the top, until a match is found or until all rows have been tested.

([DPSOH Using a Mask where character positions 1-10 & 24 are checked and a conversion table as below:

&RQYHUVLRQURZ &RGH

[AB]{ddd}?{ddd}???; \1 < 300; \2 < 700 1

[AB]{ddd}?{ddd}???; \1 >= 300; \2 >= 700 2

will give the following results when an ID string is read:

5HDG,'VWULQJ ,'&2'(

L1234567892 -32768

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



(DV\9LHZ6HW8S

The (DV\9LHZ form can be presented either from a button on the Toolbar or via menu choice 9LHZ(DV\

9LHZ . This form is used for easy access to a small number of parameters. It is intended for users with limited knowledge or who should not be able to alter sensitive information.

[JB55]

This form, the (DV\9LHZ 6HW8S form, is used to configure the (DV\9LHZ form.

Enter in the 7LWOH column the titles you want to display for each of the parameters.

Use the 0LQ YDOXH and 0D[YDOXH fields to restrict the possibility to change values.

The 2EMHFWGHVFULSWLRQ should contain a description of the object that is connected to the parameter. See chapter: /D\RXWRI6HWXS,WHP'HVFULSWLRQV for a description of the syntax for this description.

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



$VVHPEO\2YHUYLHZ6HW8S

The $VVHPEO\2YHUYLHZ displays the current status of the system, its stations and bolts. Which data to display in the different boxes, and their layout, are controlled by the $VVHPEO\2YHUYLHZ6HW8S form. It is invoked using the 6HW8S$VVHPEO\2YHUYLHZ« menu item.

[JB56]

When selecting the 6HW8S$VVHPEO\2YHUYLHZ« item on the Maintenance menu two forms are displayed. First the Assembly Overview Set Up form and secondly the Assembly Overview form, now running in Set Up mode.

The first form is used to configure the basic settings for the Assembly Overview, that is which data and pictures to display in the Assembly Overview window.

The second form is used to define the position and size of the different station and bolt boxes.

7KH$VVHPEO\2YHUYLHZ6HW8SIRUP

Use the 6\VWHP%DFNJURXQG3LFWXUH combo to select the JPG file to display as System View background.

To include your own JPG files you must copy the files to the directory %PS located in the directory you installed the PowerMACS WinTC application in. All files with extension JPG in this directory are listed in the picture combo boxes when the form is opened the next time.

1RWH The selected JPG files are not included as a part of the setup. In order to display the same pictures on another computer then the one you created the setup with you must copy the files manually.

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



For each station you may select which station and bolt level variables to display in the corresponding boxes. For a description of the variables see chapter: Result variables.

Use the combo boxes on the 6WDWLRQ%R[ tab to define which result variables to display in the Station box.

The combo boxes on the %ROW%R[ tab controls which of the result variables that are displayed in the Bolt boxes.

Use the combo boxes on the %ROW tab to define which result variables to display in the Bolt detailed view.

The variables selected are displayed in the same order as entered in the grid. Use the columns )RQW

6L]H , 7H[W (whether to include the prompter text) and 'HF to control the format of the each variable.

Check ([SDQGHGE\GHIDXOWLQV\VWHPYLHZ if the Station box should be expanded, that is show its Bolt boxes on top of the stations background picture (“Station detail view”), when the Assembly Overview form is opened. If not checked, then the Station box is displayed in its collapsed form which means that it only show the variables selected on the Station Box tab, that is no background and no Bolt boxes.

Check 0D[LPL]HGZKHQVHOHFWHG if the “Station detail view” should occupy the whole Assembly Overview picture when displayed (that is when the Station Box is clicked on in the System view).

The above listed configurations are common for a given station regardless of which mode the station is running (see The Mode Table form for a description of modes) . However, there are a number of aspects that can be displayed differently depending on the currently selected mode: These are defined as a so called 6WDWLRQ9LHZ . Each station can have up to ten Station Views and for each of them you may specify the following:

• Which %DFNJURXQGSLFWXUH to use for the Station detail view.

• The size and position of the Bolt boxes in the Station detail view (this is edited directly in the Assembly Overview form).

• For which 0RGHV the Station View should be used. These are entered as a comma separated list of mode numbers.

7KH$VVHPEO\2YHUYLHZIRUPLQ6HW8SPRGH

This form is used to define the position and size of the different station and bolt boxes. The layout is modified directly in the displayed picture by using the mouse.

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



To change the positions of a box move the mouse pointer to the upper left corner of the box. When the mouse pointer changes to a vertical arrow pointing upwards, press the left mouse button and reposition the box.

To change the sizes of a box move the mouse pointer to the lower right corner of the box. When the mouse pointer changes to a diagonal arrow, press the left mouse button and resize the box.

All boxes of a given type will have the same size and display the same variables.

When you are satisfied with the settings press the $SSO\ button in the Assembly Overview Set Up form to save the settings of the current Station View.

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



3/&3DUDPHWHUV6HW8S

This form is invoked using the menu item 6HW8S3/&3DUDPHWHUV .

The PLC Parameters Set Up form is used to define parameters that are available from inside the PowerMACS PLC (see PLC - Overview).

Defining parameters for the PLC here is an alternative to defining them as a part of the PLC application directly (using the Multiprog editor). This is useful if it is likely that the end user will need to adjust them after delivery, or where one want to make a PLC application that is generic to some extent.

The parameters defined here can be modified by the end user using the PLC Parameters form.

The form contains 190 rows on which either a parameter or label can be defined. Labels are used only to make the layout of the form easier to read, they are not accessible from the PLC.

For each row you must define the following:

• A 3URPSWHU : Used to describe the parameter. Max 20 characters long.

• Data 7\SH of the PLC variable: One of the following ,17 (16 bit signed integer), 5($/ (32 bit floating point value), 675,1* (max 40 character long strings), /DEHO , or blank.

• 9DOXH . The default value of the parameters. Not valid if 7\SH is blank or /DEHO .

• 0LQ and 0D[ : The min and max value of the parameter. Valid only if 7\SH is ,17 or 5($/ .

• 3/&9DULDEOH : Defines to which variable in the PowerMACS PLC this parameter is connected. See also chapter: Station variables).

The maximum numbers of parameters that can be used are:

• 130 of Type ,17

• 20 of Type 5($/

• 10 of Type 675,1*

• 30 Labels.

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2SWLRQV

In the Options choice of the 6HW8S menu you can set up your main preferences.

[JB57]

Choose /DQJXDJH for presentation on screen. Change will take place when windows are closed and reopened.

1RWH All texts displayed by the WinTC are defined in a so-called Language file. To add support for a new language you just have to copy a file supporting the language in the same directory as your WinTC is installed in. The file should have a name expressing the language it supports and the extension “.LNG”, for example “English.LNG”.

Use the 7RUTXHXQLW combo box to select the unit you want all torque values expressed in. Possible choices are Nm, kNm, FtLbs and InchLbs.

Specify in 6WHSDQJOHVWDUW at which point the angle measurements used for UHVWULFWLRQ supervision is started for a step.

Possible values are:

6WHSDQJOHVWDUW 'HVFULSWLRQ

AS1 Angle measuring is started at the current position when the step is started.

AS2 Angle measuring is started at the shut of position of the previous step.

1RWH All steps of angle type but the AO - Run until Angle with overshoot compensation step starts the angle measurement at AS1 for its control function. The AO step starts at AS3, which is the point where the previous steps reached its maximum angle overshoot.

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Torque

shut off point

shut off point previous step

Angle

F

AS1

SOP

AS2

AS3

SO

P

• A - Run until AngleAO - Run until Angle with overshoot compensation

• DT - Run until DynaTork

• JOG - Run until digital input goes high / low

• T - Run until Torque

• TA – Run Torque-Angle with no stop

• TA – Run Torque-Angle with no stop

• TI - Run until Time

• PA - Run until Projected angle

• PLC - Run PLC step

• SR – Socket Release

• Y1 - Run until Yield point, method 1

• Y2 - Run until Yield point, method 2

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$XWRWXQH

It is possible to let the system automatically adjust the following parameters of a tightening program. See chapter: The Tightening Program for a detailed description of the programs being tuned.

The target parameter for the following step types:

• Run until torque - parameter T

• Run until angle - parameter A

The limit parameters for the following checks:

• Check peak torque - parameters TL and TH

• Check angle - parameters AL and AH

The limit parameters for the following monitoring checks:

• Final Torque and cycle end - parameters FTL and FTH

• Angle from threshold to Cycle End - parameters AL and AH

You can tune any program that you can run in your system and it does not matter whether you have created it using the Set Up Wizard or built it your self.

To do this, select the $XWR7XQH item in the 6HW8S menu. This will invoke the $XWR7XQH form.

[JB58]

First select the program to tune, and which bolt you want it to be tuned on, using the 6WDWLRQ , %ROW and

3URJUDP combos.

The tuning is based on the cycle data collected from the last 25 OK cycles executed for the bolt and program. It means that it does not matter if you trigger the program to be run using the PLC or the Program tab in Test Bolt. However, you must ensure that the Screen Reporter includes the variables you want to tune. If the program is generated using the Set Up Wizard this is already taken care of.

If you just want to see what the system suggests, press the &KHFN button. New values will then be calculated and presented together with the current value. Parameters for which enough samples are not

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



available are marked with the text "cannot be calculated, as there are to few samples". You can press the

&KHFN button as many times as you like without modifying any data in your setup.

Press $SSO\ to update the parameters of your program with the tuned values. This will cause new values to be calculated and downloaded to the target. Only parameters for which enough samples are available are modified. After the change the form is updated with changes made.

New target parameters are calculated with the goal to make the result become closer to the current target value, if the result tend be 0.2 under the target value the target value is increased by 0.2.

1RWH,I\RXFDOO$XWRWXQHRQFHDJDLQWKHLQFUHDVHGWDUJHWYDOXHZLOOEHXVHGDVWKHZDQWHGUHVXOW

7KLVLVSUREDEO\QRWDGHVLUHGHIIHFW

The calculation is made as follows.

• The peak torque and angle are measured using checks of the respective types.

• A mean value, Result Mean , is calculated based on the 25 most recent measured values.

• The new target value is calculates as Target New = 2 * Target Current - Result Mean . The new value is only used if ABS(Target New - Target Current ) / Target Current < 0.25.

New check and monitor limits are calculated as follows:

• The values are measured using the variables reported for the respective check and monitoring evaluation.

• For each check and monitoring, a mean value, Result Mean , and a Range, Result Range , are calculated based on the 25 most recent measured values.

• The new value for the high limit is calculates as HighLimit New = Result Mean + Result Range / 2.

• The new value for the low limit is calculates as LowLimit New = Result Mean - Result Range / 2

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&KHFNLI5HDVRQDEOH

The Check if Reasonable function performs a number of tests on your setup. It will test all combinations of programs against the bolt/spindles that you have setup using The Mode Table form. All target values will be tested with respect to max values defined for the spindles and servos used.

Any errors found will be reported in the following window:

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7DEOH([SRUWDQG,PSRUW

A VHWXS is a group of data that completely describes a PowerMACS system, how it looks and how it should work. It can be handled and reused as a complete unit as described in the chapter: “Setups and How to handle them”.

However, it is also possible re-use smaller parts of the setup. These parts are called tables and a table normally represents one particular object in the setup, for example a bolt, a reporter, etc.

A table can be moved from one setup to another by using the Table Export and Import functions by first exporting it from the first setup and then importing it into the second one.

The following tables are available for Export and Import:

• Program

• Sequence

• Station

• Reporter

• Misc (Easy View and SPC configurations)

• Bolt

• Spindle

• Servo

• Device

The ([SRUW7DEOH form is invoked using the )LOH([SRUW menu item 

[JB59]

First select which type of table to export using the 7DEOH combo.

Depending on Table type you specify exactly which instance to export using the displayed controls ( 6WDWLRQ , 3URJUDP , 6SLQGOH etc.) in the Source frame.

Use the Destination frame to specify to which file the table should be stored.

Finally press the ([SRUW!! button.

Repeat this for all tables you want to export.

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Use the )LOH([SRUW menu item to display the ,PSRUW7DEOH form.

[JB60]

First select the type of table to import using the 7DEOH combo.

Use the 6RXUFH frame to specify which table file to import.

Specify in the 'HVWLQDWLRQIUDPH exactly to which instance you want to import the data. For some table types you may also create a new instance using the imported data. In these cases the 1HZ field is enabled.

Finally press the ,PSRUW!! button.

Repeat this for all tables you want to import.

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7DEOH&RS\

This form is opened using the menu item (GLW0XOWL&RS\ . 

It enables easy copying of a table instance to one or more other instances of the same type.

[JB61]

Use the 7DEOH combo box to select which type of table to copy. Depending on type of table you can then in the 6RXUFH frame specify which table you want to copy.

Use the fields in the 'HVWLQDWLRQ frame to specify where to copy the table data. For most table types you may select multiple destinations (if displayed in the list). To do this, hold down the CTRL key and then click on all items you want, or if they are contiguous, mark the first one, press the SHIFT key, and then mark the last one

.

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0DLQWHQDQFH

The 0DLQWHQDQFH menu contains functions for maintenance, like checking the status of the system:

[JB62]

Use 6HOHFW7DUJHW6\VWHP« to choose which PowerMACS system to connect to.

7HVW%ROWV« opens a form from where you can run test passes for one or more bolts of a station. This is an alternative to the PowerMACS PLC when it comes to start tightening cycles. It is also useful for calibration of the torque, current, and angle measuring, see &DOLEUDWLRQ .

(YHQW6WDWLVWLFV« gives you an overview of the most frequent alarms.

'HEXJ« is currently only for Atlas Copco internal supervision. Do not use this function.

6HUYLFH/RJ« opens a logbook. Use it to log all your service actions.

5HSODFH,'6WULQJ« displays a form from which you manually can enter ID strings. Useful if your ID device does not work or just for testing.

&RQILJXUH7DUJHW6\VWHP« opens a form from where you can configure the TCs of your PowerMACS system. This involves function for upgrading the System Software, changing IP-address settings, etc.

&OHDUGDWD … is used for clearing data stored in the non volatile RAM of the TCs.

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6HOHFW7DUJHW6\VWHP

Selecting the 0DLQWHQDQFH6HOHFW7DUJHW6\VWHP menu item opens this form that is used to select which target system the WinTC should connect to when going online.

Click %URZVH to select the PowerMACS Network Configuration file that best describes the network to connect to.

A PowerMACS Network Configuration file describes the expected layout of a PowerMACS Network in the sense that it lists a number of PowerMACS system nodes (primary TCs), that for some reason are logically grouped together. Each PowerMACS system in the network is identified with the IP-address of its primary TC and free textual description. The main purpose of this file is to document a configuration where several PowerMACS systems are used, for example a complete assembly line.

The selected file will be opened automatically the next time you open this form, even between WinTC sessions. If no file has been selected, a default configuration is displayed.

How to create a Network Configuration file is described later in this chapter.

The network can also be scanned in order to automatically find all PowerMACS systems physically connected to it. Click the 6FDQIRU3ULPDU\7&V button to bring up a list of all primary TCs on the network.

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All primary TCs found during scan are compared to the contents of the currently selected Network Configuration file. Depending on the differences the rows in the list is marked with a color.

• Not scanned (Blue) – The TC in the list was not found on the net. When a network configuration file is opened, all rows are marked blue.

• New (Green) – A TC that was not in the list was found on the net.

• Changed (Red) – The attributes of the found TC are different compared to the previously known. Note that the 'HVFULSWLRQ field is not compared since it is not present in the TC it self.

• Not changed (Black) – The attributes of the found TC is the same as the previously known.

Select the PowerMACS system to connect to by clicking one of the radio buttons in the 6HOHFW column. The WinTC does only communicate with the primary TC (first TC in a system) so therefore only one selection need to be made.

Choose 7&6LPXODWRU if you do not have a real target system to connect to but still want to demonstrate the on-line functions of the WinTC.

To create, or edit, a PowerMACS Network Configuration file use the $GG , (GLW and 5HPRYH buttons to insert, change and remove entries in the list. When done editing, save the current configuration to file using the 6DYH$V button. Since the file name is used to identify the network you should give the file a descriptive name. Editing the file can be done without being connected to the network.

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7HVW%ROWV

The Test Bolt function gives you an alternative way to the execution of a tightening cycle, running all or only one selected bolt for a station.

[JB63]

First chose which station to test using the 6WDWLRQ combo box.

Depending on the status of the selected station the Test Bolt form may be disabled. The form is disabled for this reason if:

• The hardware Emergency input is inactive for the TC that executes the station (PLC station input EMERGSTOPIN True).

• The selected stations PLC output DISABLE_TESTBOLT is set True. See also the description of the Station variables in the PLC section.

In either case an explanation of why the Test Bolt form is disabled is displayed at the top of the form.

Should the Test Bolt form be closed, or the WinTC be disconnected from the TCs, while a cycle is executing then the cycle is terminated using Machine stop.



1RWH When running a station from the Test Bolt form the PowerMACS PLC outputs MODE and BOLTCONTROL are overridden. This means that PLC inputs that depends on these, for example BOLTSTATE, may have values that do not correspond to the values of MODE and/or BOLTCONTROL. To detect these situations in the PLC use the input CURRMODE and TESTBOLT_ACTIVE. The first one always reflects the mode currently known by the station and the second one is set True whenever the Test Bolt form is opened against the station in questions. Also, when the Test Bolt form is closed, or you switch to another station, the station is updated with the value of the PLC outputs MODE and BOLTCONTROL.

You can run the test in 6LQJOH5XQ mode, in 3URJUDP mode or in 0RGH table mode. You select which by activating the corresponding tab.

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6LQJOH5XQPRGH

In 6LQJOH5XQ the bolts are run once to a specified 7DUJHW defined either by 7RUTXH , $QJOH or &XUUHQW . Use the controls in the 5XQFRQGLWLRQV frame to define the direction and speed to use when executing the step.

6SHHG can also be specified as target. If so, then the bolt(s) will run continuously with speed and direction as set by the Run conditions.

When target is reached, or once a second if running speed, a number of measured values are displayed in the 5HVXOW frame. Except for the peak torque value all values are sampled at the switched off occasion.

1RWH See chapter: Calibration for how to use Test Bolt to calibrate your system.

3URJUDPPRGH

In Program mode you run the bolts by using one of the existing tightening programs.

[JB64]

Here you can specify how many cycles you want to run, or for how long. If you want to run more than one cycle you will probably need to specify a program to use for loosening. How to create a new program is described in chapter: Create a new Tightening Program.

Press the 6WDUW button to start executing the cycle. Press 6WRS to stop any on-going execution. 

Running a program produces Cycle Data and Statistics just as if the bolts where executed by the PowerMACS PLC. This means that data is reported over the normal channels, SPC is calculated, and so on. However, none of the variables that depend on outputs from the PowerMACS PLC are updated.

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This includes the following variables:

6WDWLRQOHYHOYDULDEOHV %ROWOHYHOYDULDEOHV

Wp ID

Total

Mode

Total OK

Mode No

Total NOK

Free Str

Total Type

Total Type OK

Total Type NOK

Total

Total OK

Total NOK

0RGH7DEOHPRGH

In Mode Table mode you run the bolts by ordering the station to run a particular mode.

This means that which bolts that will run and which programs they will execute is decided by the current Mode Table (see The Mode Table form).

Use the 0RGH and /RRVHQLQJPRGH combo boxes to select which Modes to run. If specifying more than once cycle the station will alter between the 0RGH and /RRVHQLQJPRGH , starting with the first. Please note that the two combo boxes are filled with the modes that are relevant with respect to the currently selected Bolt. If $OO is selected they will include all modes of the station. If a specific bolt is selected they will only include the modes for which the bolt has non-empty entries.

All other functions are the same as for the Program mode.

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&DOLEUDWLRQ

It is recommended to perform a calibration of the spindles after the system has been installed at the production site. It is also recommended to make a new calibration periodically (e.g. one time a year, every 6 months etc.) and this is normally specified in the customer quality control system.

The tests should preferably be run on the actual joint, but as this not always is possible a test joint can be used.

The test joint should have similar characteristics as the actual joint but acceptable results can also be achieved on a dummy joint that always is pre-tightened.

The easiest way to perform a calibration is to use the Test Bolts function. Use the “Single Run” function where you automatically will get some statistics.

1RWH You should only run one bolt (spindle) at a time when calibrating.

1RWH When you use the “single run” function, there is no “zero-offset check and compensation” made. This must be done manually by first running a tightening set that has a D - Diagnostic Step as a first step. The “zero-offset” measured by it will automatically be stored and used until you either run a new Diagnostic step or until you make a change in the Spindle Set Up form. Use the run “Program” alternative to do this.

7RUTXH

All Atlas Copco ASY torque transducers (e.g. QXT, QRT..) are factory calibrated to a sensitivity within +/- 0.3% of the nominal torque. Due to component tolerances in the TC electronics as well as different cable lengths used in the system, a fine tune of the torque sensor is recommended. Exchange of a torque transducer to an identical unit does not require a new calibration, but for quality control reasons it is anyway normally done.

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An inline slip-ring torque transducer and a peak hold monitoring amplifier shall be used for the torque measurement.

• Make at least 10 tightenings to the desired final torque and record the results.

• Calculate the mean torque and the difference from the set value in percent.

• Adjust the spindle parameter 6FDOHIDFWRU for channel Torque 1 (see Spindle Set Up, Channels) with the calculated percentage. Increase the 6FDOHIDFWRU in order to decrease the true torque and vice verse.

• Run a program with a D - Diagnostic Step.

• Run a new test series in order to confirm the correction.

• If a torque scatter test is required (Standard deviation, Cp, Cpk, Cmk, CAM……) a minimum of 20 tightenings is needed.

40;«77 spindles (with an additional torque transducer) are calibrated as follows:

• Read the result from both transducers in the “Single run” window. The monitoring transducer is the one that the torque results to the reporter(s) come from.

• The control transducer is calibrated in the same way as a single transducer (described above)

• The monitoring transducer can be calibrated at the same time by adjusting the scale factor for transducer 2

• Set the maximum allowed difference between the two transducers to 1% of the transducer capacity.

$QJOH

The angle measurement is performed with the resolver signal and is normally not necessary to calibrate (see “wind up” below). The Angle Scale factor is decided from the number of pulses/rev. of the resolver (default 32/(motor shaft rev.)) times the nut runner spindle gear ratio.

A check of the tightening angle is difficult but not impossible to make in a controlled way. The most reliable results are achieved with an inline Torque/Angle transducer and a Torque/Angle amplifier with trace capability.

Make a tightening on a joint and compare the trace curves, Torque vs. angle, from the two systems.

Results from tests made with an external Torque/Angle recording unit where the angle from a torque level to final torque is presented and then compared with the from PowerMACS reported value are normally not giving an acceptable result.

The main reasons for the discrepancy in measured angles are:

• The start point (torque level) does not occur simultaneously

• The stop point is not defined in the same way in the control and the monitoring systems.

There is a spindle parameter, named :LQG8S&RHIILFLHQW (see Spindle Set Up, General), which is used to compensate for the torsion in the mechanical parts (gears and shafts) between the electric motor shaft and the square drive. The coefficient can be modified in order to fine tune systems where external mechanics (like long thin extension shafts) affects the angle control.

The default value of the :LQG8S&RHIILFLHQW is 3 degrees at max spindle torque (i.e. parameter 0D[

7RUTXH ).



40;«$ spindles (with an additional optical angle encoder) are handled in the same way as the single angle encoder one.

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The angle results used in the reporters are from the monitoring encoder.

The max allowed angle difference could be set to 5 deg. or less depending on customer requirement.

&XUUHQWWRUTXH

The spindle parameter 7&IDFWRU (Torque/Current) (see Spindle Set Up, General) is the scale factor for current control. The unit of the 7&IDFWRU is [/A] and a theoretical value based on the motor data is used as default setting.

The T/C factor shall be calibrated in systems using current control and/or the DT - Run until DynaTork step (TC software versions later than 1.2.0) since the correct value differs from the theoretical one due to tolerances in motor data as well as components in the TC.

One way to calibrate the 7&IDFWRU is to select “Current” as control parameter under “Torque usage” in the Spindle Set Up form (see General).

Use the “Single Run” function located of the Test Bolts form.

Run 10 cycles and register the torque values from an inline torque transducer. Calculate a mean torque value and adjust the 7&IDFWRU if necessary. Increased TC-factor decreases the true torque.

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(YHQW6WDWLVWLFV

The Event Statistics form, invoked using the menu choice 0DLQWHQDQFH - (YHQW6WDWLVWLFV« , can give you a good view on which events that are most frequent.

It displays a so-called pareto diagram in which the most frequent event type is displayed to the far left. In the diagram you can see both the percentage and the number of times each event has occurred.

[JB65]

One bar is displayed for each event code of which there is at least one error. For a list of possible event codes see chapter: List of events.

Use the 6WDWLRQ combo box to select which station to study.

The event statistics are stored in the system in accumulators. You can reset these by pressing the 5HVHW button. The last time this was done is shown to the right of this button.

Press the 5HORDG button to first clear the accumulators and then reloaded them with all events currently stored in the Event Log (see View Event Log).

To study only certain event types press the 6HOHFWLRQ button to expand the (YHQW7\SHVIUDPH . Check each event type you want to include in the display.

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6HUYLFH/RJ

The Service Log is a useful tool to keep track of changes made to a system. It is invoked from the menu

0DLQWHQDQFH6HUYLFH/RJ«

[JB66]

The log can contain up to 100 messages and is a part of your setup and will therefore be stored both on disk and in the target system.

When you open the Service Log the titles of all existing logs are listed in the top list box labeled 7LWOH while the text box labeled 0HVVDJH displays contents of the currently selected title.

To create a new log entry press 1HZ . To change an existing message select its title and then press (GLW . In both cases a form is displayed in which you can enter a proper title and message texts.

To remove a log entry: select its title and press 5HPRYH .

If you have made changes to the system you will automatically be asked to enter a message in the Service Log when you log out, closes the current setup, or exit the WinTC.

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5HSODFH,'6WULQJ

Using the Replace ID String form, opened from the menu 0DLQWHQDQFH5HSODFH,'6WULQJ« , you can manually enter an ID string instead of actually input it using one of the ID-device devices in your system. This is useful if when a barcode label is damaged, or when the ID device for some reason is not working.

The form is accessible only when on-line.

First select the device to operate on using the &KRRVH,'GHYLFH combo box. It is filled with all ID devices defined in the system.

Depending on the type of the selected device the function is as follows:

• For type %DUFRGH : Enter the new string in the 5HSODFHZLWK field and press the $SSO\ button. The new string is treated by the system just as if it was scanned using the barcode scanner. This means that it is automatically sent to the Station and its PLC (visible as CURRIDSTRING, see Station variables) and is stored in the device.

• For type (VFRUW$% or (VFRUW3 ) : Enter the new string in the 5HSODFHZLWK edit field and specify how many times the string should be valid in the 1RRIUHDGV edit field. Press $SSO\ to send the string to the escort memory device. The next time the PLC orders reading of the device (by generating a positive edge on the PLC output IDREAD) the replacement string will be returned to the Station and PLC instead of actually trying to read data from the escort memory. This will be repeated as many times as set by the 1RRIUHDGV parameter.

Any manually entered ID string sent to the device (by pressing $SSO\ ) can be cleared by pressing the

&OHDU button.

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



&RQILJXUH7DUJHW6\VWHP

Selecting the 0DLQWHQDQFH&RQILJXUH7DUJHW6\VWHP menu item opens the Configure Target System form.

This form is used for configuration of your PowerMACS TCs. This includes function for upgrading their System Software and changing the IP-address data of them.

Press the 6FDQ)RU7&V button to bring up a list of all available Tightening Controllers connected to the same physically network as the WinTC. The scanning procedure uses network broadcast since this gives the best possibility to find all connected TCs regardless of their IP-address and net mask settings.

The scan takes approximately 10 seconds and results in a list of TCs that where reached by the WinTC. For each TC the following information is displayed:

• The current ,3DGGUHVV .

• If the TC is configured as a 3ULPDU\ . The primary TC is the TC that controls all other TCs included in a PowerMACS system. It is it that the WinTC is connected to and that holds the setup of the system

• The TC 7\SH

• The current 1HWPDVN

• The IP address of the current *DWHZD\

• The 9HUVLRQ of the TC System Software

• %RRWYHU , that is, the version of the TC Boot loader

• The current 6WDWXV of the TC boot loader. Can be one of the following:

• 1RDSSOLFDWLRQ – Means that the boot loader (the very first code executed by a TC when it is powered on) did not find a valid TC System Software when it started. This indicates that the System Software is either missing or is corrupt. To correct this try to download System Software to the TC.

• $SSOLFDWLRQ5XQQLQJ – Means that the boot loader did find a valid System Software which it started. It does not indicate that the TC has a setup loaded.

• :DLWLQJIRUGRZQORDG – Means that the TC is set up to start download of new System Software when it is restarted.

• 'RZQORDGLQJQQ – Indicates that download of System Software is progress.

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



• 'RZQORDG2N – Means that the boot loader has successfully downloaded System Software to the TC. The TC must be restarted for the new software to take effect.

• 'RZQORDGIDLOHG or 'RZQORDG$ERUWHG – Means that the boot loader failed to download System Software to the TC. The cause of this may be network problems. Try to download again.

For a primary TC, more data may be displayed in the field labeled 0RUHLQIRDERXWWKHVHOHFWHG7& under the list, when selected. This additional data includes the name of the System, the number of stations, the total number of bolts, and the number of TCs used by the system. It is always the actually used values of the parameters that are displayed in the list, this is important to understand when changing net data parameters.

1RWH Since the scan procedure uses broadcasts it will detect all TCs that are connected to your network regardless of their IP address configuration. However, this does not mean that you can connect to, or send configuration commands, to all TCs displayed in the list. The reason for this is that the normal communication between the WinTC and a TC is done using TCP that requires the communicating nodes to be on the same IP network, or that a route between the networks is known. Therefore whether or not you can connect to a TC depends on its IP-address, net mask, and default gateway.

To modify the network settings press the &KDQJH1HW'DWD« button. This will open the Change Net Data form.

Press the /RDG7&6:« button to prepare download of System Software using the form Prepare TC for download of System Software.

If your TCs are running version 1.2.6, or earlier, you must use another method for the download, see Download to TCs running version . This older method only supports loading of one TC at the time and is invoked by using the /RDG7&6:WRXQLWVZLWK6:ROGHUWKDQ« button.

When changing net data, or preparing TCs for download of System Software, commands are sent to the selected TCs. The results of these commands are displayed with small symbols in the leftmost column of the list.

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



A green checkmark indicates that the TC has accepted the command while a red cross indicates a communication error. To view more information of the latter, select one of the rows marked with a red cross.

For new net data, or a download to be effective, the TC must be restarted. Turning the power off and on again is the normal way to do this. But if at least one TC accepts the request you will be offered the possibility to restart those TCs remotely. You should only restart the TCs remotely if you are absolutely sure that it is safe for the system to do so.

If you choose to restart the TCs remotely the result of this new command to the TCs is displayed in the list.

3UHSDUH7&IRUGRZQORDGRI6\VWHP6RIWZDUH

This form is used to select which System Software file to load to TCs selected for the operation.

Follow these steps to download new System Software:

1. Press %URZVH« to locate the file to load. To reduce the risk for non-repairable errors caused by failures during System Software download the application is divided in two parts, the ERRWORDGHU and the DSSOLFDWLRQ . The boot loader contains only the functions needed for starting and upgrading the application part while the application contains the tightening functionality etc. Therefore, from release 2.1.0 the TC System Software module is always delivered in two files, named as follows: - BOOT_x_y_z.MX : This file contains the boot loader image - APP_x_y_z.MX : This file contains the application image x_y_z above is the version number of the respective file. Example: " APP_2_1_0.MX ".

1RWH8QOHVVH[SOLFLWO\VWDWHGLQWKHUHOHDVHQRWHDFFRPSDQ\LQJDQHZUHOHDVHRQO\WKH

DSSOLFDWLRQSDUWVKRXOGEHGRZQORDGHGZKHQXSJUDGLQJD7& If boot must be downloaded, click on the $GYDQFHG!! button and check the (QDEOH

GRZQORDGLQJERRWVRIWZDUH check box that is displayed. Select the file named BOOT_x_y_z.MX . Please note the warning.

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



1. Click 2. to SUHSDUH the selected TCs to download the specified file. This will cause a "Prepare TC for download" command to be sent to the TCs. The success or failure of this command is displayed in the Configure Target System dialog.

1. To start the actual download, you must restart the TCs. When restarted, each TC will request the new file from the WinTCs built in TFTP server.

1. During download, the display on the TCs will toggle between letters " G/ " and black while the WinTC indicates the progress for each TC in the 6WDWXV column of the Configure Target System form.

1. When the download is finished the result of the download is displayed both by the TCs and the WinTC. If successful the TC displays “  ” and if it failed “  ”. See chapter: Configure Target System for how the WinTC indicates the result.

Restart the TCs after download to make the new software effective.

'RZQORDGWR7&VUXQQLQJYHUVLRQRUROGHU

This form is used for download of System Software to TCs running version 1.2.6, or earlier. These TCs are not found when scanning the network.

You can only download to one TC at the time and this TC must have the last digit in the IP-address set to 1, 101, or 201. Assuming that the TC has node number 1 follow these steps to download the system program:

1. Ensure that only one TC with IP-address 192.168.0.1 is connected to the TC network.

1. Select the correct IP-address by pressing one of the 6\VWHPWRGRZQORDGWR radio buttons. (The IP address of the selected target in the WinTC is changed temporarily during the download. When download is finished, the previous selected IP address is restored).

1. Press 2. to open a file selection dialog. Use this to select the file containing the new TC system program file. Here you must always load the boot loader. Therefore select the file named " BOOT_x_y_z.MX ".

1. Press 2. in the file selection dialog to start the download. The progress of the download is displayed in the WinTC main windows status bar.

1. Wait for the download to finish (indicated by that the text in the status bar is cleared).

1. Restart the TC by switching the power off and on again.

1. Since you now only have loaded the boot loader you next step is to download the application software. This is done following the steps outlined in chapter: "Prepare TC for download of System Software".

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



'RZQORDGVRIWZDUHRUROGHUWRD7&UXQQLQJRUODWHU

Normally the only reason to download TC System Software version prior to 2.0.0 to a TC that already runs version 2.0.0 (or later) is when a new TC is used as spare part for an old system.

To download do follow the steps outlined in chapter: Prepare TC for download of System Software with the following in mind:

You should locate the file containing the old System Software version. This is normally named TC_HW.MX, TC_HW_1.2.0.MX, or similar.

Download should be done as if this file contains the application and the boot loader linked together, i.e. you have to press the Advanced >> button and check the (QDEOHGRZQORDGLQJERRWVRIWZDUH check box.

1RWH7RGRZQORDG6\VWHP6RIWZDUHWRD7&UXQQLQJ\RXPXVWXVHD:LQ7&WKDWLVRIYHUVLRQ

RUODWHU

&KDQJH1HW'DWD

This form is used for changing the network settings for one or more TCs.

Enter the new values in the field displayed

The 0DLQ1HW$GGUHVV determines the first three numbers in the IP address for the TC. Hex switches SW1 and SW2 on the TC always give the value of the last number.

If you set a network mask with a nonzero value as the last number you must manually ensure that the

'HIDXOW*DWHZD\ belongs to same network as all the TCs.

Click 2. to send the new values to the TCs. The result of this request is displayed in the Configure Target System form (see chapter: Configure Target System).

Keep in mind that the new values will not be displayed in the list until the TCs are restarted. The reason for this is that the list always shows the currently used data and the TC will not use the new values until it is restarted.

5HVHW1HW'DWD

A hardware switch can reset the net data configuration of a TC. This is very useful if you for some reason have a TC that your WinTC cannot connect to.

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



Do the following to reset the current net data configuration:

• Set switch SW3.6 “On” (located under the gold, or silver, colored cover plate on the front of the TC). See chapter: LEDs, Indicators and switches.

• Power on the TC. The TC will then display the letters “F” and “b” on the seven segment displays on the left side of the front.

• Set switch SW3.6 “Off”

• Power off and on the TC.

The above procedure will reset the net data configuration of the TC to the following values

• IP-address: 192.168.0.NN where NN is given by the hex switches SW1 and SW2.

• Net mask: 255.255.255.0

• Gateway: 192.168.0.254

&RQILJXUHD7&DV3ULPDU\7&

Whether or not a TC is a Primary TC is controlled by dip-switch SW3.1 (SW3 is located under the gold, or silver, colored cover plate on the front of the TC. It has the eight switches). See chapter: LEDs, Indicators and switches.

Set switch SW3.1 “On” to configure the TC as Primary TC. The TC will read the information the next time it is powered on.

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



&OHDUGDWD

The Clear data form is invoked using the menu item 0DLQWHQDQFH±&OHDUGDWD« .

The Clear Data form is accessible only when on-line and is used to clear process data stored in the non volatile memory on the TCs. This includes the following:

• SPC data, on all TCs or on a individual TC. The SPC data for a bolt is stored on the TC that controls the spindle used to tighten the bolt.

• Trace data, on all TCs or on a individual TC. The Trace data for a given bolt is stored on the TC that controls the spindle used to tighten the bolt.

• The Cycle data of the system. Only stored on the Primary TC, that is, the first TC in the system.

• The Event log of the system. Only stored on the Primary TC.

To clear any of the above listen items first select the wanted TC, or TCs, and then press the &OHDU button.

8VHU0DQXDO3RZHU0$&6 6HW8SDQG0DLQWHQDQFH x 



3/&2YHUYLHZ

In every PowerMACS station there is a PLC (Programmable Logical Controller), called PowerMACS PLC. This is programmed in a standardized, graphical, way according to the standard IEC 61131-3.

[JB67]

This part describes how to set up and use the PLC. A general description of the PLCs role in, and interface to, the PowerMACS system is given in the next two chapters: General and System Globals.

The basics on how to write a program are given in the Programming the PLC chapter while a small, but still powerful, user interface for the PLC is described in the PLC Console chapter.

How to access parameters inside the PLC using the WinTC interface is described in the chapter: PLC Parameters.

8VHU0DQXDO3RZHU0$&6 3/& x 



*HQHUDO

The PLC is used as ”glue” between various functions within the system as for example:

• Start of tightening from digital inputs

• Output of status to digital outputs

• Controlling flow of data

• Analyzing ID codes

The PLC has interfaces to several other units in the PowerMACS system.

Interfaces PLC-program

Interfaces

System Globals

API and external serial comm. devices PLC Console

AND

Cycle Data

OR

Digital I/O

AND

Fieldbus interface

The 6\VWHP*OREDOV are inputs that represent the state of, and outputs that are used to control the tightening process within PowerMACS. All these signals are described in chapter: System Globals.

The 3/&&RQVROH interface is a simple, but still powerful, interface between the PLC program and the WinTC application running on the Console Computer. See chapter: PLC Console for a detailed description of it.

From 'LJLWDO,2 the PLC can read digital inputs (push buttons, switches etc.) and write digital outputs (lamps, relays etc.) that have been configured in PowerMACS using an I/O device. See chapter: I/O Device for how this is done.

The )LHOGEXVLQWHUIDFH makes it possible to access signals in the PowerMACS PLC from a fieldbus master. From the master it is then possible to write and read data in order to control the system and check its status. See chapter: Fieldbus Interface for a description of this interfaces and how it is configured.

The $3, DQGH[WHUQDOVHULDOFRPPXQLFDWLRQ interface makes it possible to access signals in PLC from external application from an external PC program or via some serial communication protocols. This is handled much in the same way as the fieldbus interface. See chapter: API, Application Programmers Interface and External Communication for a description of these interfaces and how they are configured.

The &\FOH'DWD interface makes it possible to read data produced as cycle data result. See the description of PLC in chapter: Peripheral Devices, for how to enable this function.

8VHU0DQXDO3RZHU0$&6 3/& x 



6\VWHP*OREDOV

The 6\VWHP*OREDOV is the interface between the PLC and the tightening controller part of the system. By setting global outputs from the PLC you can order ID devices to be read, start a tightening cycle and so on. By reading inputs you can check the state of the system, for example if a cycle is ready.

These variables are all declared in the 6\VWHPB*OREDOV worksheet found in the project tree of the PowerMACS PLC.

6WDWLRQYDULDEOHV

The following inputs reflects the status of the station, and to some extent, the system:

9DULDEOH 7\SH 8VH

EMERGSTOPIN BOOL This signal is True if the TC hardware Emergency input is inactive.

STATIONSTATUS BYTE Indicates the status of the station. Takes one of the following values:

• 0: Idle OK

• 1: Idle OK after RM (OKR)

• 2: Idle Not OK (NOK)

• 3: Idle Stop and Terminate Not OK (TERMNOK)

• 4: Running

• 5: Evaluating

• 6: Waiting for PLC step CURRSYNCH INT Reflects the number of synchronization points that have been passed. Initialized to 0 at cycle start.

CYCLEDATASTORED BOOL This input is set False when START is set True and is set to TRUE when the Cycle Data result has been stored in the PowerMACS internal cycle data queue. That is, when True an external device can read the cycle data without delay.

This might be useful for external devices that need to know when they can expect the result of the last cycle is available.

SYSTEMSTATUS INT Indicates system errors. The respective bits have the following meaning (bit 0 is the least significant):

• 0: (value 1) Servo errors

• 1-31: Reserved TESTBOLT_ACTIVE BOOL This signal is True when the WinTC Test Bolt form is open and connected to this station. See also chapter: Test Bolts.

CD_OVERRUN_W1 BOOL This input is set True when there is room for less than 10 more cycle data in the cycle data queue for any device. If set, it is automatically reset when all devices have space for at least 10 more data, that is when the failing device has read its queue

CD_OVERRUN_W2 BOOL Same function as CD_OVERRUN_W1 with the difference that it indicates that at least one queue is full but not yet overrun. That is, the next cycle data will be lost.

8VHU0DQXDO3RZHU0$&6 3/& x 



CD_OVERRUN_E1 BOOL This input is set True when a new a cycle data caused the queue for at least one device to be overrun. If set, it remains set until a new cycle can be added to the queue without causing it to be overrun.

This means the flag is not reset immediately when the failing device read a cycle data from the queue (which frees one position in the queue). The status is not checked with less than that a new cycle data is generated.

CURRMODE INT This input always reflects the MODE value currently known by the station.

EVENT BOOL System events. Is True when there are unobserved events of any type (see View Event Log).

SPCEVENT BOOL This input is True when there are unobserved "SPC" evenst in the event log (see View Event Log).

ACCESSEVENT BOOL This input is True when there are unobserved "Access" events in the event log (see View Event Log).

POWERUPEVENT BOOL This input is True when there are unobserved "Power up" events in the event log (see View Event Log).

CHKEVENT BOOL This input is True when there are unobserved "Check" events in the event log (see View Event Log).

SWEVENT BOOL This input is True when there are unobserved "Software" events in the event log (see View Event Log).

SYSERREVENT BOOL This input is True when there are unobserved "System error" events in the event log (see View Event Log).

MODEVENT BOOL This input is True when there is unobserved "Modification" events in the event log (see View Event Log).

HWEVENT BOOL This input is True when there are unobserved "Hardware" events in the event log (see View Event Log).

EMERGEVENT BOOL This input is True when there are unobserved "Emergency stop" events in the event log (see View Event Log).

GENERALEVENT BOOL This input is True when there are unobserved "General" events in the event log (see View Event Log).

XCOMEVENT BOOL This input is True when there are unobserved "External communication" events in the event log (see View Event Log).

SETUPEVENT BOOL This input is True when there are unobserved "Setup" events in the event log (see View Event Log).

CONS_IN_1 BOOL Input connected to the WinTC form PLC Console.

CONS_IN_2 BOOL Input connected to the WinTC form PLC Console.

CONS_IN_3 BOOL Input connected to the WinTC form PLC Console.

CONS_IN_4 STRING(40) Input connected to the WinTC form PLC Console.

CONS_IN_5 STRING(40) Input connected to the WinTC form PLC Console.

8VHU0DQXDO3RZHU0$&6 3/& x 



Outputs used for controlling the station:

9DULDEOH 7\SH 8VH

MODE INT Set to number of mode to use in next cycle. Sampled on the positive edge of START.

RESET BOOL Reset servo errors on a positive edge. Should only be set True if the station is idle.

Have in mind that whether a bolt is "Connected normally" or not can be controlled from three locations

• Using the PLC output BOLTCONTROL

• From WinTC for the Bolt Set Up, see e.g. chapter: The Bolt node

• From The Mode Table form (depending of the value of MODE) For a bolt to be "Connected normally" it must be defined so in all the above locations.

START BOOL Starts cycle. A positive edge will start the first step in the cycle. This signal is ignored if the station is not idle, or if STEPSTOP, EMERGSTOP or MACHINESTOP is True.

STEPSTOP BOOL Step stop. Set to True to stop current step with status OK. Next START will continue with next step in the cycle.

EMERGSTOP BOOL Emergency stop. Set to True to stop the cycle with status NOK. Next START will start cycle from beginning.

MACHINESTOP BOOL Machine stop. Set to True to stop the cycle with status NOK. Next positive edge on START will start a new cycle.

MONSTART BOOL Start monitoring. Set to True to start monitoring of the spindles. This signal is ignored if the station is not idle.

MONEND BOOL End monitoring. Set to True to end monitoring of the spindles.

DATAHOLD BOOL Data hold. Set to True, before starting a cycle, to hold the transmission of cycle data. The data is released when the input is set to False if the station is idle (status < 4) and DATADROP is False.

DATADROP BOOL Data drop. If True when a cycle data is to be reported then the data is dropped, without any distribution.

Cycle data is normally reported when the cycle ends but if HOLDDATA is active it is reported when DATAHOLD is set to False.

TRACEDROP BOOL Trace drop. If True when the cycle end the traces will not be distributed to any device.

GENEVENT INT Set to a code 1-10 to generate an event. The code used will be displayed together with the event.

STEPTYPE INT Control data used for the PLC - Run PLC step used in the tightening program. Defines which control function the step should execute. See the step description for valid values.

STEPVAL REAL Control data for the PLC - Run PLC step. Used as target value.

GENOUT_1 GENOUT_2 :

INT General output. Can be used for selection of double encoders or change of spindle direction. See chapter: Spindle Set Up.

GENOUT_5

8VHU0DQXDO3RZHU0$&6 3/& x 



FREESTRING STRING(40) The value of this output can be included in the cycle data result as the station level result variable "Free Str". Sampled on the positive edge of START.

FREESTRING2 STRING(40) The value of this output can be included in the cycle data result as the station level result variable "Free Str 2". Sampled on the positive edge of START.

FREESTRING3 STRING(40) The value of this output can be included in the cycle data result as the station level result variable "Free Str 3". Sampled on the positive edge of START.

FREENUM1 DINT The value of this output can be included in the cycle data result as the station level result variable "Free No 1". Sampled on the positive edge of START.

FREENUM2 DINT The value of this output can be included in the cycle data result as the station level result variable "Free No 2". Sampled on the positive edge of START.

DISABLE_TESTBOLT BOOL Set this output TRUE to disable the usage of the WinTC Test Bolt form for this station. See also chapter: Test Bolts.

ACKACCESSEVENTS BOOL Set this output True to mark all events of type "Access" as observed (see View Event Log).

ACKPOWERUPEVENT BOOL Set this output True to mark all events of type "Power up" as observed (see View Event Log).

ACKCHKEVENT BOOL Set this output True to mark all events of type "Check" as observed (see View Event Log).

ACKSWEVENT BOOL Set this output True to mark all events of type "Software" as observed (see View Event Log).

ACKSYSERREVENT BOOL Set this output True to mark all events of type "System error" as observed (see View Event Log).

ACKMODEVENT BOOL Set this output True to mark all events of type "Modification" as observed (see View Event Log).

ACKHWEVENT BOOL Set this output True to mark all events of type "Hardware" as observed (see View Event Log).

ACKEMERGEVENT BOOL Set this output True to mark all events of type "Emergency stop" as observed (see View Event Log).

ACKGENERALEVENT BOOL Set this output True to mark all events of type "General" as observed (see View Event Log).

ACKXCOMEVENT BOOL Set this output True to mark all events of type "External communication" as observed (see View Event Log).

ACKSETUPEVENT BOOL Set this output True to mark all events of type "Set up" as observed (see View Event Log).

ACKSPCEVENT BOOL Set this output True to mark all events of type "SPC" as observed (see View Event Log).

CONS_OUT_1 STRING(40) Output connected to the WinTC form PLC Console.

CONS_OUT_2 STRING(40) Output connected to the WinTC form PLC Console.

CONS_OUT_3 STRING(40) Output connected to the WinTC form PLC Console.

CONS_OUT_4 STRING(40) Output connected to the WinTC form PLC Console.

CONS_OUT_5 STRING(40) Output connected to the WinTC form PLC Console.

1RWH The function of the respective ACKxxxEVENTS outputs can be disabled using the Advanced Event settings form.

8VHU0DQXDO3RZHU0$&6 3/& x 



The following shared memory variable also reflects the configuration and status of the station and system. Even though they are defined as shared memory variables, which means that the PLC application can be write to them, they should be used as inputs only.

9DULDEOH 7\SH 8VH

NO_OF_BOLTS INT Indicates the number of bolts defined for this station.

NO_OF_SPINDLES INT Indicates the number of spindles (and TCs) defined for this station.

IO_INCLUDED BOOL If True an I/O device is configured to be located on the same TC as this station runs on.

FB_INCLUDED BOOL If True a Fieldbus device is configured to be located on the same TC as this station runs on.

INT_PARAMS INT_PARAM_ARR This is an array of 130 parameters of type INT (16 bit signed integer) defined and modified using the WinTC forms PLC Parameters Set Up and PLC Parameters.

They can be used to make the PLC more generic in the sense that minor parameter changes that earlier must be done using the Multiprog wt editor now can be done by the end user using the normal WinTC interface.

REAL_PARAMS REAL_PARAM_ARR This is an array of 20 parameters of type REAL (32 bit floating point) defined and modified using the WinTC forms PLC Parameters Set Up and PLC Parameters.

See also the description of INT_PARAMS.

STRING_PARAM_1

STRING40 These parameters of type STRING40 (max 40 character long strings) are defined and modified using the WinTC forms PLC Parameters Set Up and PLC Parameters.

STRING_PARAM_2

:

See also the description of INT_PARAMS.

STRING_PARAM_10

STATIONSTATUS_EXT STATION_STATUS_ EXT_TYPE This variable indicates the station status of the last tightening.

It is a structure containing the following BOOL flags:

• OK True if result is OK or OK after RM (OKR).

• OKRM True if result is OK after RM.

• NOK True if result is NOK or Stop and Terminate Not OK (TERMNOK).

• TERMNOK True if result is Stop and Terminate Not OK (TERMNOK).

The value of this variable is only changed a result of starting a cycle. When the station is started all flags are reset and when the cycle is ready the relevant flags are set.

Use this variable together with STATIONSTATE as an alternative to the STATIONSTATUS input.

8VHU0DQXDO3RZHU0$&6 3/& x 



STATIONSTATE STATION_STATE_ TYPE This variable indicates the current state of the station.

It is a structure containing the following BOOL flags:

• IDLE True if the station is idle, that is, it is not executing a cycle.

• RUNNING True if the station is running a cycle, that is, it is not idle. This includes evaluating and waiting for PLC as well.

• EVALUATING True if the station is evaluating the results from the bolts.

• WAITING_FOR_PLC True if the station is waiting for a new START signal due to that some bolt is executing a step that requires a this to continue.

Use this variable together with STATIONSTATUS_EXT as an alternative to the earlier STATIONSTATUS input.

SYS_DEVTYPE_ERR DEVTYPE_ERR_ TYPE This variable indicates erroneous devices in the system per device type category.

The DEVTYPE_ERR_TYPE is a structure containing a BOOL flag for each type of device, plus TC and Servo, that can be included in PowerMACS system:

• ANYTYPE : True if a device of any type is erroneous in the system.

• TC : True if not all TCs have communication contact with all the other TCs in the system.

• SERVO : True if any servo in the system is erroneous.

• PLC : True if any PLC reporter device in the system is erroneous.

• FIELDBUS : True if any fieldbus device in the system is erroneous.

• IO : True if any I/O device in the system is erroneous.

• EXTCOM : True if any external communication device in the system is erroneous.

• API : True if any API device in the system is erroneous.

• IDDEV : True if any ID device device in the system is erroneous.

• PRINTER : True if any TC printer device in the system is erroneous.

• TOOLSNET : True if any ToolsNet device in the system is erroneous.

STN_DEVTYPE_ERR DEVTYPE_ERR_ TYPE This variable indicates erroneous devices related to the station per device type category.

It functions the same ways as the SYS_DEVTYPE_ERR variable with the differences that only the devices connected to a TC that belongs to this station are checked.

1RWH There is one exception to the above rule. The flag TC is set True also if this station has lost communication contact with the primary TC (TC1).

8VHU0DQXDO3RZHU0$&6 3/& x 



DEVICE_ERR DEVICENO_ERR_ ARR This variable indicates erroneous devices in the system per device number.

The variable is an array of 20 BOOL where each element represents the device with the number equal to the array index number.

That is, if DEVICE_ERR[10] is True then the device with device number 10 is erroneous.

The following shared memory variable can be used to indicate when process data has been written to a fieldbus device:

9DULDEOH 7\SH 8VH

FB_PROCDATA_STORED BYTE The PowerMACS system will write True to it when it has written anything to the Process Data output area of the fieldbus.

The System will never write False to it. In order to detect when it is set you must clear it from inside the PLC.

That it is a shared memory variable means that it can be written to from the PowerMACS system as well as from the PowerMACS PLC.

FB_PROCDATA_STORED may be used in many different ways depending on type of application. Example:

In a system where cycle data is generated after each cycle (also at emergency stop) and this data is automatically loaded to the fieldbus device one way of using it is as follows:

1. Have the powerMACS PLC write FALSE to the variable FB_PROCDATA_STORED just before, or simultaneously with, the start signal.

1. Wait for the powerMACS system to write TRUE to the variable FB_PROCDATA_STORED before indicating that the cycle is finished to the fieldbus master.

8VHU0DQXDO3RZHU0$&6 3/& x 



%ROWYDULDEOHV

The following inputs can be used to monitor the status of each individual bolt:

9DULDEOH 7\SH 8VH

BOLTSTATUS ARRAY[1..100] OF BYTE Status for bolt:

• 0: Idle OK

• 1: Idle OK after Reject Management (OKR)

• 2: Idle Not OK (NOK OR NOKRM)

• 3: Idle Stop and Terminate Not OK (TERMNOK)

• 4: Running

• 5: Running Reject Management

• 6: Evaluating

• 7: Waiting for PLC step COMPERRORS ARRAY[1..100] OF BYTE Reports the most commonly reported bolt errors for each of the bolts.

The respective bits have the following meaning (bit 0 is the least significant):

• 0: (value 1) THM (Torque High Monitoring)

• 1: (value 2) TLM (Torque Low Monitoring)

• 2: (value 4) AHM (Angle High Monitoring)

• 3: (value 8) ALM (Angle Low Monitoring)

• 4: (value 16) Reserved

• 5: (value 32) Reserved

• 6: (value 64) Reserved

• 7: (value 128) Reserved BOLTSERVOSTATUS ARRAY[1..100] OF BYTE Reports the current status of the servo used to tighten each of the bolts. While the bolt executes, i.e. BOLTSTATUS has a value greater than 3, this input is always zero (0).

The respective bits have the following meaning (bit 0 is the least significant):

• 0: (value 1) Controller OK

• 1: (value 2) Communication OK

• 2: (value 4) Any fault

• 3: (value 8) Over temperature

• 4: (value 16) Voltage fault

• 5: (value 32) Current fault

• 6: (value 64) Reserved

• 7: (value 128) Reserved See also the description of the PLC input RESET in chapter: Station variables.

8VHU0DQXDO3RZHU0$&6 3/& x 



Use the below output signals to control the behavior of the bolts:

9DULDEOH 7\SH 8VH

BOLTCONTROL ARRAY[1..100] OF BYTE This output controls which bolts to run when the station is started.

Takes one of the following values:

• 0: Connect normally. The bolt will run when station is started.

• 1: Disconnected with OK status

• 2: Disconnected with NOK status

• 3: Do not run during next cycle

The difference between "Disconnected" and "Do not Run" is that in the first case the bolt will be reported with the given status and in the latter nothing is reported for the bolt. In neither case will the bolt start when the station is started.

The outputs BOLTCONTROL and DATAHOLD are useful when running a stitching application, i.e. when a single spindle is used to tighten more than one bolt. To generate one cycle data result, including only one station header, even though several starts are done follow the below scheme:

1. Set DATAHOLD = True

1. Set BOLTCONTROL = 0 for all bolts to run in this cycle and BOLTCONTROL = 3 for all bolts that should not.

1. Generate a START. This will start only the selected bolts.

1. Wait for the cycle to end (monitor for example STATIONSTATUS)

1. If not all bolts are tightened yet go to step 2

1. Set DATAHOLD = False to release the cycle data, complete with one record for the station and one for each bolt tightened

The following shared memory variable also reflects the state and status of the bolts. Even though they are defined as shared memory variables, which means that the PLC application can be write to them, they should be used as inputs only.

9DULDEOH 7\SH 8VH

BOLTGROUPS BOLT_GROUPS_ARR This is an array of 100 WORDS (16 bit unsigned integers) where each element represents the groups that a particular bolt belongs to.

The respective bits in BOLTGROUPS[x] have the following meaning (bit 0 is the least significant):

• 0: (value 1) Bolt x belongs to group 1

• 1: (value 2) Bolt x belongs to group 2

• 2: (value 4) Bolt x belongs to group 3

• 3: (value 8) Bolt x belongs to group 4

:

• 8: (value 256) Bolt x belongs to group 9

• 9: (value 512) Bolt x belongs to group 10

• 10 -15: Reserved

8VHU0DQXDO3RZHU0$&6 3/& x 



BOLTSTATUS_EXT BOLT_STATUS_EXT_ ARR This variable is an array of 100 elements of type BOLT_STATUS_EXT_TYPE. Each element indicates the status of the last tightening for a bolt.

The BOLT_STATUS_EXT_TYPE is a structure containing the following BOOL flags:

• OK True if result is OK or OK after RM (OKR).

• OKRM True if result is OK after RM.

• NOK True if result is Not OK (NOK), Not OK due to RM (NOKRM) or Stop and Terminate Not OK (TERMNOK).

• NOKRM True if result is Not OK due to RM (NOKRM).

• TERMNOK True if result is Stop and Terminate Not OK (TERMNOK).

The value of this variable is only changed a result of starting a cycle as follows:

• When the station is started all bolts that are set to be Disconnected OK/NOK, either using the PLC output BOLTCONTROL or the WinTC forms "Mode Table" or "Bolt Set Up", the corresponding OK or NOK flag is set immediately. For all other bolts all status flags are cleared.

• When the cycle is ready the relevant flags are set.

Use this variable together with BOLTSTATE as an alternative to the earlier BOLTSTATUS input.

8VHU0DQXDO3RZHU0$&6 3/& x 



BOLTSTATE BOLT_STATE_ARR This variable is an array of 100 elements of type BOLT_STATE_TYPE. Each element indicates the current state of a bolt.

The BOLT_STATE_TYPE is a structure containing the following BOOL flags:

• DONOTRUN True if the bolt is ordered not to run, either using the PLC output BOLTCONTROL or the WinTC "Mode Table" form.

• DISCON_OK True if the bolt is disconnected with OK status, either using the PLC output BOLTCONTROL or the WinTC forms "Mode Table" or "Bolt Set Up".

• DISCON_OK True if the bolt is disconnected with NOK status, either using the PLC output BOLTCONTROL or the WinTC forms "Mode Table" or "Bolt Set Up".

• IDLE True if the bolt is connected normally and is idle, that is, it is not disconnected or ordered not to run and is not executing a cycle.

• RUNNING True if the bolt is running a cycle, that is, it is not idle. This includes running reject management, evaluating and waiting for PLC as well.

• RUNNING_RM True if the bolt is running reject management.

• EVALUATING True if the bolt is evaluating its monitoring results.

• WAITING_FOR_PLC True if the bolt is waiting for a new START signal due to that it is executing a step that requires a this to continue.

1RWH Since the connect state (Do not run, Disconnected OK, Disconnected NOK) of a bolt may depend on the MODE (the Mode Table form), changing the value of the MODE input may affect this variable.

This means that BOLTSTATE[x] always will reflect whether or not bolt x is disconnected or not, regardless from where it is disconnected.

Use this variable together with BOLTSTATUS_EXT as an alternative to the earlier BOLTSTATUS input.

8VHU0DQXDO3RZHU0$&6 3/& x 



,''HYLFHYDULDEOHV

The following inputs can be used for supervision of the IDSTRING handling:

9DULDEOH 7\SH 8VH

IDSTATUS INT Status for ID device read or write operation:

• 0: Idle and OK

• 1: Idle and NOK

• 2: Busy

CURRIDSTRING STRING(40) This input always reflects the ID string known by the station. Will be included in the cycle data as the station level variable "Wp. ID".

IDCODE INT Code from conversion of read ID string. See chapter: ID device Set Up for how the conversion is defined.

The following outputs are available for setting the IDSTRING:

9DULDEOH 7\SH 8VH

IDREAD BOOL Set to True to order reading of ID device connected to the station.

See System Set Up for to connect an ID device to a station.

IDWRITE BOOL Set to True to replace the ID string currently known by the station with the value of IDSTRING.

If the station is connected to an ID device this device will be used to generate a corresponding IDCODE. The written value will be echoed back to CURRIDSTRING.

IDSTRING STRING(40) String to replace the ID string currently known by the station. Sampled on the positive edge of IDWRITE.

The station will only use an ID string once. When it starts a cycle it will clear its internal ID string, and therefore also CURRIDSTRING, and then set the value of IDCODE to –32768.

Depending on which type of ID device that is used a read operation may take differently long time. For a barcode reader the last string scanned by the operator is stored internally by PowerMACS system so completing a read is done within less a few milliseconds. However, for devices of Escort memory, where the external data tag is read using a communication protocol, a read operation may take much longer time. You should therefore always check the input IDSTATUS to make sure that a read string is available to the station before you issue a start order.

([DPSOH : The below code issues an IDREAD order when the signal "Customer_Start_Signal" is set True, waits for the string to be returned, and then starts the tightening cycle.

8VHU0DQXDO3RZHU0$&6 3/& x 



*OREDOV

These variables are used to transfer information from one station PLC to another station PLC. All stations can reach these global variables.

9DULDEOH 7\SH 8VH

SYSTEMGLOBAL INT For communication between PLCs on different stations.

The variables are declared as a shared memory and can therefore both be read and written to both by the PowerMACS System and the PowerMACS PLC.

You should see to that only one station write to a given variable but any number of stations can read it.

8VHU0DQXDO3RZHU0$&6 3/& x 



3URJUDPPLQJWKH3/&

To edit the PLC program select the item 3URJUDP from the 3/& menu.

For every PowerMACS setup there is a PLC project. This project is created by the setup wizard, see

&UHDWLQJDQHZV\VWHPXVLQJWKH6HW8S:L]DUG , and is stored on disk together with the PowerMACS setup file. It has the same name as the setup file but the extension ".ZWT" instead of "STP".

For a two station system the PLC project tree displayed when the PowerMACS PLC editor is opened will look as follows:

[JB68]

Each station in the system is represented in the PLC project as a Resource. A Resource corresponds to a physical unit that can execute a PLC program; in our case this is a station TC. They are named Stn01 for the first station in the system, Stn02 for the second, and so on.

To execute a program the Resource uses one or more tasks. A task controls the time scheduling of a program. Tasks are typically cyclic which means that they are executed periodically with a given time interval. The Setup Wizard creates one task named T10MS, which is executed every 100th millisecond, for each of the resources.

The program that is executed by a task is called POU, or Program Organization Unit. The Setup Wizard creates one POU for each station in the system. They are named Pou01 for the first station, Pou02 for the

8VHU0DQXDO3RZHU0$&6 3/& x 



second, etc. When created all POUs looks the same since they are copied from the PowerMACS standard template. Normally you must adopt the program for each individual station. You do that by double clicking on the icon representing the variable worksheet (PouNNV) and/or the icon representing the logic worksheet (PouNN) of the POU of interest.

Each resource has a number of variables that are global within the resource. These can be used in all your programs (POUs) executed by the resource. The variables are divided in the following groups, all represented by an own worksheet in the project tree:

• &\FOH'DWDB9DU : - This sheet contains variables that are mapped to the optional cycle data interface. See the description of PLC in chapter: Peripheral Devices, for how this is done.

• )LHOG%XVB9DU : - This sheet contains variables that are mapped to the optional fieldbus interface. See chapter: )LHOGEXV,QWHUIDFH for how this is done.

• ([W&RPB$3,B9DU : - This sheet contains variables that are mapped to the optional external communication and/or API devices. See ([WHUQDO&RPPXQLFDWLRQ and $3,$SSOLFDWLRQ

3URJUDPPHUV,QWHUIDFH for how this is configured and used.

• 'LJLWDOB,QB2XW :- This sheet holds all variables that are mapped to the digital I/O interface. See ,2

'HYLFH for a detailed description.

• 6\VWHPB*OREDOV : - This sheet contains all variables interfacing the PLC with the tightening controller part of the PowerMACS system. See 6\VWHP*OREDOV for details.

• *OREDOB9DULDEOHV : - This sheet declares a number of PLC internal variables that can be used for advanced debugging of your PLC program.

The programming of the PLC logic can be done in two ways: - using functional blocks or ladder logic. In both cases you use a graphical editor. Below is given two examples of this.

[JB69]

[JB70]

8VHU0DQXDO3RZHU0$&6 3/& x 



After editing the program you must compile it before it can be downloaded. This is done using the item Make in the menu Build. If your program contains any errors you will be informed about them.

When the program is successfully compiled it is possible to download to the target system. This is normally done as follows:

1. First close the PowerMACS PLC.

1. If the WinTC already is on-line download the PLC project by selecting the menu item 3/&±

6\QFKURQL]H .

1. If the WinTC is not on-line then just go on-line

Downloading the PLC project this way ensures that the PLC program and the rest of the setup is kept synchronized.

However, during the development phase, when you have to change the program often, and quickly want to study the effect of your modifications you can download the program from inside the PLC. This is done using the following sequence:

• Open the 5HVRXUFH&RQWURO dialog from the 2QOLQH menu.

[JB71]

• Stop the execution of the PLC by pressing the 6WRS button.

• Reset the PLC by pressing the 5HVHW button.

• Open the 'RZQORDG dialog by pressing the button 'RZQORDG .

[JB72]

• Press the 'RZQORDG button in the %RRWSURMHFW frame

• Open the 'RZQORDG dialog again by pressing the 'RZQORDG button in the 5HVRXUFH&RQWURO dialog.

• Activate the Boot project by pressing the $FWLYDWH button.

• Start the execution of the PLC by pressing the button &ROG in the 5HVRXUFH&RQWURO dialog.

When your program is downloaded you can study current status of all signals in the program by using the

'HEXJ alternative in the PLC 2QOLQH menu. If the program has not been compiled yet the PLC will

8VHU0DQXDO3RZHU0$&6 3/& x 



complain by saying, "Cannot switch to online mode because the project is not successfully compiled!" In these cases just compile the program, and if there are errors, fix these. Then try to go on-line again.

1RWH : Saving the project from inside the PowerMACS PLC do QRW implicate cause the PLC project to be saved together with your setup on disk. To do that you must you choose 6DYH , or 6DYH$V , from the WinTC )LOH menu.

1RWH : It is the ZWT file that is regarded to be the source of the PLC project. It contains the project in compressed form. Whenever you open a PowerMACS setup the PLC project is expanded to the folder named &XUUHQW6HWXS , which is located below the folder you installed PowerMACS in. Keep in mind that this folder only is used as a temporary working folder. Whenever you save the setup the PLC project is also compressed and saved to disk. When you go on-line and download a setup to a system the ZWT is also downloaded.

8VHU0DQXDO3RZHU0$&6 3/& x 



3/&&RQVROH

The 3/&&RQVROH interface can be used as a simple operator’s interface to your PLC application. It is invoked using the 3/&±&RQVROH« item.

Use this form to display internal data of your PLC program that you want the operator to be able to see or modify.

[JB73]

Each of the controls in the frames PLC In and PLC Out are mapped to specific inputs and outputs in the PLC as described in the tables below. See also the Station variables chapter.

3/&,Q 7\SH &RQQHFWHGWR3/&,QSXW

Cons In 1 BOOL CONS_IN_1

Cons In 2 BOOL CONS_IN_2

Cons In 3 BOOL CONS_IN_3

Cons In 4 STRING(40) CONS_IN_4

Cons In 5 STRING(40) CONS_IN_5



3/&2XW 7\SH &RQQHFWHGWR3/&RXWSXW

Cons Out 1 STRING(40) CONS_OUT_1

Cons Out 2 STRING(40) CONS_OUT_2

Cons Out 3 STRING(40) CONS_OUT_3

Cons Out 4 STRING(40) CONS_OUT_4

Cons Out 5 STRING(40) CONS_OUT_5

The outputs will be displayed automatically for the selected station (given by the 6WDWLRQ combo box).

8VHU0DQXDO3RZHU0$&6 3/& x 



To set inputs do the following:

1. Enter the new values for one or more of the inputs. A checked check box corresponds to True, an unchecked to False.

1. Press the button Set. This cause the new values to be sent to the PLC.

1RWH The set values will remain in the PLC until next time they are changed, or the PLC is restarted. Closing the PLC Console window will QRW clear any values.

If you, as an example, connect "Cons In 1" to the PLC output START then you can simulate the external start signal that normally is input via some external device. Below the currently selected mode, which is set using digital inputs in this case, is also displayed as the "Cons Out 1" variable.

8VHU0DQXDO3RZHU0$&6 3/& x 



3/&3DUDPHWHUV

The PLC Parameters form, invoked using the 3/&±&RQVROH« menu item, is similar to PLC Console interface in the sense that they both can be used as a simple operator’s interface to your PLC application.

The difference is that the PLC Parameters are stored in non-volatile memory, and therefore will survive a restart of the PLC while all changes made using the PLC Console will vanish.

The parameters that are accessible using this form must first have been defined using the PLC Parameters Set Up form.

To change the value of a parameter just enter the new value in the Value column and press the $SSO\ button.

8VHU0DQXDO3RZHU0$&6 3/& x 



7LJKWHQLQJ2YHUYLHZ

Most functions needed for to create and edit tightening programs are found in the 7LJKWHQLQJ menu

Select 1HZ3URJUDP« to Create a new Tightening Program.

To edit an existing program or sequence select 2SHQ3URJUDP« or 2SHQ6HTXHQFH« . Both open The Tightening Program/Sequence form

Select 0RGH« to configure the mode table using The Mode Table form.

0RQLWRULQJ« opens The Monitoring form.

Select 4XLFN9LHZ« to edit a program using The Quick View form.

This chapter describes most things about the tightening process, for example

• How it works

• How to create a new program

• How to edit an existing program

To understand how the tightening process is actually performed within a PowerMACS system you should be familiar with all parts that make up the tightening process.

1. The PLC starts the tightening by setting outputs for start of tightening, for selection of which bolts to execute, and which tightening mode to run.

1. The Mode Table, set up using The Mode Table form, is used by the system to figure out which tightening program each bolt should run for the chosen mode.

1. The Tightening Program chapter describes how the tightening should be done for each bolt. A program is built using steps and sequences.

1. The spindles perform the actual tightening according to the information in the tightening program.

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



&UHDWHDQHZ7LJKWHQLQJ3URJUDP

There are numerous ways of configuring a tightening program, but if you use this wizard you will get a first version that will be a good starting point. The New Program wizard is opened using the 7LJKWHQLQJ - 1HZ

3URJUDP menu.

[JB74]

Start by entering a proper name for the new program in the 3URJUDPQDPH field.

From the lists to left you can pick one or more 6HTXHQFHV or ([LVWLQJSURJUDPV . Select one of the items in the lists and press $GG! , or just double click on it. This will insert it in the 1HZSURJUDP list to the right.

From the lists to left you can pick one or more ([LVWLQJSURJUDPV . Select one of the items in the lists and press $GG! , or just double click on it. This will insert it in the 1HZSURJUDP list to the right.

. If you want to rearrange the order, select an item and press the up

To remove an item from the 1HZSURJUDP list, select it and press the remove button

or down

buttons to move it upwards or downwards in the list.

The new program will consist of all steps that each of the selected items consists of, inserted in the same order as they occur in the 1HZSURJUDP list. Each step is added as it is, meaning that they already contain all necessary values, but you must yourself check that you have got what you want. 1RWH The program will not contain references to the selected sequences; all their steps will be inserted.

When you are ready press 2. to create the program. This will open The Tightening Program displaying your new program.

[JB75]

This program is ready to run but consider it a first attempt. You should check all parameters to confirm that they are acceptable and all end steps to confirm that they are in the correct positions.

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



7KH7LJKWHQLQJ3URJUDP6HTXHQFHIRUP

This form is opened using the 7LJKWHQLQJ2SHQ3URJUDP« or 7LJKWHQLQJ2SHQ6HTXHQFH« menu items.

The Tightening Program/Sequence form is used for creation and editing of programs or sequences. A detailed description of programs is given in the Tightening Program chapter.

[JB76]

Chose program (or sequence) to display or edit by selecting its name in the 3URJUDP combo box.

Even though a program always is identified as by its name you may optionally specify numerical identifier for it using the 3JP1R field. This number may be used as an alternative identifier of the used program in cycle data.

The program is made up of steps which you insert and remove using the ,QVHUWVWHS,QVHUWVHT« , and remove

buttons.

The steps that make up the program are displayed in the spread located in the middle of the form. They are presented in execution order from left to right. For each steps you can see the:

• The step number

• A schematic figure

• The step type

• The main value for the step (dependent on step type)

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



• The step references used for reject managements. Formatted as

The reject management function is configured on the Reject tab (see Step – Reject). An example:

Use the 6DYHDV« button, which opens the 6DYH3URJUDP6HTXHQFH$V dialog,

Pressing the 0RUH!! button expands a tab register that displays all parameters of the currently selected step. The information is divided in the following groups, each displayed on a separate tab:

7DE 8VH

Control What task the step performs. See Step – Control.

Restriction What restriction to run during the step. See Step – Restriction.

Check What checks to execute after the step. See Step – Check.

Reject Reject management in case anything goes wrong. See Step – Reject.

Speed What speed to use during the step. See Step – Speed.

Other Other configuration parameters for the step. See Step – Other.

You can choose if the execution of each step should be synchronized between different bolts or not using the 6\QF button. To toggle synchronization for one or more steps, mark them and then press the 6\QF button. Synchronized steps are indicated with a red right border. See General for a description of synchronization.

7KH0RQLWRU« button opens The Monitoring form used for configuration of the Bolt Monitoring function.

If you are a skilled operator you can study the program in a very compressed format using The Quick View form. Press the 4XLFNYLHZ« button to open it.

If your program contains a Sequence step (SE) double-click on it to open a new window displaying its contents.

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



Steps may be copied and pasted within the program but also between different programs. To copy one or more steps:

• Mark the step or steps

• Press the right mouse button. This will display the Copy and Paste pop up menu.

• Choose Copy.

To paste the copied step or steps into another location :

• Mark the step that the copied step(s) should be inserted EHIRUH .

• Press the right mouse button. This will display the Copy and Paste pop up menu.

• Choose Paste.

When a step is copied the copy will contain the full contents of the step, that is, the control part, restrictions, checks and so on.

Also checks can be copied using the Copy and Paste pop up menu.

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



7KH0RGH7DEOHIRUP

This form is opened using the 7LJKWHQLQJ0RGH« menu item.

The Mode Table is used to set up which tightening program each bolt in a station should execute for a given mode.

[JB77]

Each station has its own Mode Table. Use the 6WDWLRQ combo box to select the station for which the mode table should be edited.

The Mode Table has one column for each mode (up to 50) and a row for each bolt in the station. On the top row, labeled 1DPH , you can specify a symbolic name for each mode. This name may be included in the cycle data as the station level result variable Mode.

The remaining rows are labeled with the names of the respective bolts. On these you should specify the tightening program to use for each mode.

The lists labeled 7LJKWHQLQJ3URJUDP to the left lists all programs available in the system. In addition to these it also include the following entries which have special meaning:

• “Disconnected OK”

• “Disconnected NOK”

• “” (empty)

Bolts marked with Disconnected OK/NOK will be treated as disconnected for the corresponding mode. That is, they will not be executed but return a result, either OK or NOK depending on the selection. Disconnecting bolts here is equivalent to disconnecting them using the Bolt Status parameter of the Bolt with the difference that the selecting is only valid for specific modes.

Leaving a cell empty will have the effect that the bolt is not run when the station is started in the given mode. This corresponds to setting the PLC out BOLTCONTROL to the value 3, that is "Do not run", for the bolt. This may be very useful for so called stitching applications where the same spindle is used to tighten several bolts. See also the description of the PLC Bolt variables.

You may type the program name directly in the cells, but it is probably easier to use the copy function to the right. It is used as follows:

1. Mark the program you want to copy in the 7LJKWHQLQJ3URJUDP list.

1. Mark the cells in the mode table you want the name copied to.

button.

1. Press the

To clear a number of cells mark them and press the &OHDU button

If you want to Create a new Tightening Program, press 1HZ« .to open the New Program wizard.

To edit or view a program, mark it in the 7LJKWHQLQJSURJUDP list and press 2SHQ« . This will open The Tightening Program.

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



Press 3ULQW to print the current Mode Table configuration. The document printed on your systems default printer includes the settings for all used modes, that is, all modes for which a name is specified.

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



7KH0RQLWRULQJIRUP

This form is opened using the 7LJKWHQLQJ0RQLWRULQJ« menu item or from the 7LJKWHQLQJ3URJUDP

IRUP .

The Monitoring form is used to define the Bolt Monitoring, which is a part of the tightening program.

If the form is opened from the menu then use the 3URJUDP combo box to select the program to display the monitoring functions for.

[JB78]

There are three monitoring functions available each displayed on a separate tab:

7DE 8VH

Torque + Angle Checks Monitoring of Torque and Angle at Cycle End.

Torque Rate Checks Monitoring of Torque Rate and Deviation..

Yield point Checks Monitoring Yield point torque and angle.

If any of the monitoring checks on the respective tabs are active this is indicated at the top of the tab with the word " $FWLYH ".

See the corresponding items in the Bolt Monitoring chapter for a description on their respective functions and how to use them.

Press OK to save you changes. If the form was opened from the menu the changes are saved to the program directly, causing the changes be sent to the target system directly. If it was opened from the Tightening program form the changes will not be sent to the target until you press the $SSO\ button in it.

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



7KH4XLFN9LHZIRUP

The Quick View form can be opened from the 7LJKWHQLQJ±4XLFN9LHZ« menu item or from 7KH

7LJKWHQLQJ3URJUDP .

It allows you to display and edit a tightening program using the so-called Quick View syntax.

Select the program to view or modify using the program name combo box.

If the form was opened from the menu you may modify program using the Quick View syntax. If it was opened from anywhere else you can only view the program.

Press OK to save your changes and close the form.

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



7LJKWHQLQJ3URJUDP

The Tightening Program defines the algorithm to use for tightening a bolt. This includes evaluating the result of the tightening, during execution as well as the final result, and fault handling.

A Tightening Program consists of the following parts:

• General settings like name, program number, etc.

• Steps, the basic blocks for to build a program with. The parameters of each step is divided in the following parts:

• Control – Defines function of the step, i.e. when to switch off, in what direction to run, etc.

• Restrictions – Used for supervision of the control function. All the restriction tests are executed in parallel with control function and if any limit is exceeded it will interrupt the execution of the step.

• Checks – Defines variables that are measured during the execution of the step but are not evaluated until the step has finished. Checks never interrupt the execution of the step.

• Reject Management – Defines how to do an automatic repair in case of that the step fails

• Speed – Defines which speed to use during the step

• Other – Used for setting up start delays, stop conditions, etc.

• Bolt monitoring. Defines how the complete tightening cycle should be evaluated.

7LJKWHQLQJ6HTXHQFH

Commonly used combination of steps can be saved as a Tightening Sequence. A sequence is a number of steps that are saved as an entity with an own name and which can be used, as any ordinary step, in a tightening program.

Sequences are stored in parallel to programs. You can make up a library of general-purpose sequences that make it easy to build new programs.

When a sequence is used in a program the sequence is represented as one step, the SE step, which has as its only parameter the name of the sequence. However, when a program that contains a sequence is executed then the steps of the sequence will be executed just as if they all where inserted in the program. This means e.g. that eventually used synchronization points will be respected.

1RWH A sequence cannot consist of other sequences.

In reports where the step number is included then steps within a sequence are given the step number :

P * 100 + S

where P is the step number of the SE step that calls the sequence and S is the number of a step within the sequence.

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



*HQHUDOSURJUDPVHWWLQJV

A tightening program is identified by its name. However, you may optionally specify a number, called the Program number, as an alternative identifier. This number can only be used for reporting and not for selection of program, for example in The Mode Table form.

A program or sequence is divided in basically two different parts:

• The main part – Consists of the steps in front of the first Cycle End step. Normally these are the only steps that are executed.

• The repair and/or terminate parts – These are optional. Consists of all steps after the first Cycle End step. The repair and terminate parts defines actions to be taken only in order to either repair or terminate a bolt when fault occurs in one of the steps in the main part. See Step – Reject for a detailed description.

6\QFKURQL]DWLRQ

You can choose if the execution of the steps should be synchronized between different spindles or not.

When a station starts a tightening cycle the individual bolts may run freely as long as the steps are not synchronized. When the spindle encounters a synchronized step it will wait for all other spindles to reach their synchronization steps. Spindles may run different number of steps between the synchronization points.

This function is best used in in-homogenous stations with spindles that do individual jobs, e.g. a marriage point in a car assembly.

4XLFN9LHZV\QWD[

The tightening program or sequence is in some places presented in a Quick View comprehensive syntax. Each step is described with a statement:

[CO:] [RS:] [CH:] _

[RM:] [SP:] [X:]

An optional monitoring statement could be added last after all steps:

[MO:]

Some basics of the syntax:

,WHP 0HDQLQJ

<…> Should be substituted with real values

[…] Part is optional

_ Underscore. For continuation of statement over more than one line

: Heading for part

/ Separator between parameters

; Separator between elements



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$QH[DPSOH

01 CO: D=1/0/0/1/0/0/1 RM: Ra=/;Fb=1;Fg=1;Fo=3;Sb=1;Sg=1;So=3;Afb=1;Afg=1;Afo=3;Asb=1;Asg=1;Aso=3 SP: Sru=4000,00;Rt=1 X: Sm=1 03 CO: T=30,00/0/0/1 RS: Ft=45,00;Fa=100,00;Fti=5,00 CH: PT=0/33,00/27,00;A=0/100,00/10,00//3;Psct=0,03 RM: Ra=/;Fb=1;Fg=1;Fo=3;Sb=1;Sg=1;So=3;Afb=1;Afg=1;Afo=3;Asb=1;Asg=1;Aso=3 SP: S=6,00;Sru=4000,00;Rt=1 X: Sm=1 04 CO: End MO: Fta=1;Ftu=34,50;Ftl=25,50;Ata=1;Atu=500,00;Atl=10,00;Tt=3,00

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6WHS±&RQWURO

The FRQWUROSDUW describes what main task to perform during the step.

[JB79]

To the left you can set up the step type and all parameters connected to this. Possible step types are described later in this chapter.

All controls are done on data collected for control. Data collected for monitoring is not used.

The parameter for the main value for each step type is written in bold in the parameter list.

Many step types need the direction to run in as a parameter. This is controlled by selecting one of the radio-buttons %DFNZDUG or )RUZDUG .

The check box 6WDUWUHVWDUWPRQLWRULQJ can be used in conjunction with the settings for the bolt (see Bolt Set Up) in order to start or restart the recording into the monitor buffer. If restarted everything recorded before this step is erased. See also the description of Bolt Monitoring.

The following sub chapters list all available step types.



'75XQXQWLO'\QD7RUN



3DUDPHWHUV : 7 (Torque), TI1 (Time1), TI2 (Time2) , PERC (Current), DIR (Direction).

)XQFWLRQ : Run spindle, in DIR direction, until torque is T using current control. When the target is reached a new torque, DT, is calculated as DT = T * PERC / 100 This torque, i.e. DT, will then be retained during the next TI1 + TI2 seconds. The PERC parameter makes it is possible to DynaTork TM at a lower or higher level than the target.

5HVXOWYDU .: This step produces the step level result variables "DT Mean T" and "Relax A". "DT Mean T" is the mean torque measured during the second time interval (TI2). "Relax A" (relaxation angle) is the angle that the bolt moves during the time interval TI1 + TI2.

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75XQXQWLO7RUTXH

3DUDPHWHUV : 7 (Torque), DIR (Direction).

)XQFWLRQ : Run spindle, in DIR direction, until torque is T.

7&5XQXQWLO7RUTXHZLWK&XUUHQW&RQWURO

3DUDPHWHUV : 7 (Torque), DIR (Direction).

)XQFWLRQ : Run spindle, in DIR direction, until torque is T. The target T is converted into a current target with use of the spindle parameter 7&IDFWRU .

$25XQXQWLO$QJOHZLWKRYHUVKRRWFRPSHQVDWLRQ

3DUDPHWHUV : $ (Angle), DIR (Direction).

)XQFWLRQ : Run spindle, in DIR direction, an angle of A degrees. The angle is measured from where the previous step was stopped, that is from its shut off. Any overshoot will be included in this step. If the overshoot is greater than A the step will be signaled ready immediately. Overshoot is defined as the angle measured between shut off point in the previous step and the current angle when this step starts.

$5XQXQWLO$QJOH

3DUDPHWHUV : $ (Angle), DIR (Direction).

)XQFWLRQ : Run spindle, in DIR direction, to the position of A. Angle is zero at start of step.

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<5XQXQWLO

3DUDPHWHUV 7& (Torque TC), INC (Increment), NOS (No degrees), TDIFF (Torque difference), DIR (Direction).

)XQFWLRQ : Run spindle, in DIR direction, until yield point. Search for yield point starts when the torque has reached TC. The average of the torque (T n ) over NOS angle degrees is calculated. This procedure is repeated after INC angle degrees. The difference in average torque values (T n - T n-2 ) are continuously calculated and the max difference is stored. The yield point is considered reached when the calculated difference is less than TDIFF % of the current max difference.

Torque

DIFF4

DIFF3

DIFF2

DIFF1

TC

NOS INC NOS INC NOS INC NOS INC NOS INC NOS INC

Angle

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<5XQXQWLO

3DUDPHWHUV 7& (Torque TC), NOS (No degrees), NNOS, TDIFF (Torque difference), DIR (Direction), RNOS.

)XQFWLRQ : Run spindle, in DIR direction, until the yield point. Search for the yield point starts when the torque has reached TC. The average of the torque over NOS angle degrees is calculated. This procedure is repeated RNOS times. A reference slope is calculated with linear regression over the RNOS points. After that, new average values are continuously calculated over NOS degrees. The actual slope is calculated with linear regression over the last NNOS average points. The yield point is reached when the actual slope is less than TDIFF % of the reference slope.

que

Actual slope

Reference slope

TC

A l

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



3$5XQXQWLO3URMHFWHGDQJOH

3DUDPHWHUV $ (Angle), TC (Torque, TC), INC (Increment), NOS (No degrees), DIR (Direction).

)XQFWLRQ : Run spindle, in DIR direction, until projected angle A. Search starts when torque has reached TC. The average of the torque over NOS angle degrees is calculated. This procedure is repeated after INC angle degrees. A straight line is calculated through the two calculated torque average values and down to the x-axis. The projected angle starts from this intersection.

Torque

TC

NOS INCNOS

Angle

Projected angle

7'5XQXQWLO7RUTXHKDVGHFUHDVHG

3DUDPHWHUV 7 (Torque), A (Angle), DIR (Direction)

)XQFWLRQ : Run spindle, in DIR direction, until angle A is reached. From that point the torque is measured. The step stops when the measured torque is less than, or equal to, T. Torque

A

shut off point

T

Angle

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



/7/RRVHQXQWLOWRUTXH

3DUDPHWHUV 7RUTXH , Mask1, Mask2, DIR (Direction).

)XQFWLRQ : Run until torque decreases below the threshold level T. First run for Mask1 seconds in the DIR direction then measure the torque. Should the measured torque be less the Torque then the step is stopped with status OK since the bolt then is considered already loosened. Continue to run for Mask2 seconds in the DIR direction. During this time the step is not shut off regardless of the measured torque. From this point continue to run in the DIR direction until the measured torque is less than the parameter Torque.

Torque

Peak torque

Mask1

Mask2

(time)

(time)

shut off point

Torque

Angle

Release angle

The Release angle can be reported from this step. It is measured from the point where the torque reaches its highest value to the point where the projected torque vs. angle curve should have crossed the angle axis if not shut off. Please note that the peak torque is not checked for during Mask1.

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5$5HOHDVHDQJOH

3DUDPHWHUV 7RUTXH , Mask1, Mask2, DIR (Direction).

)XQFWLRQ : Run until torque decreases below 0.3 * peak torque (measured during the step). First run for Mask1 seconds in the DIR direction then measure the torque. Should the measured torque be less the Torque then the step is stopped with status OK since the bolt then is considered already loosened. Start monitoring of peak torque and continue to run for Mask2 seconds in the DIR direction. During this time the step is not shut off regardless of the measured torque. From this point continue to run in the DIR direction until the measured torque is less than 0.3 * the peak torque (measured from that the timer Mask2 was started).

Torque

Peak torque

Mask1

Mask2

(time)

(time)

shut off point

0.3 * Peak torque

Toque

Angle

Release angle

The Release angle can be reported from this step. It is measured from the point where the torque reaches its highest value to the point where the projected torque vs. angle curve should have crossed the angle axis if not shut off. Please note that the peak torque is not checked for during Mask1.

7,5XQXQWLO7LPH

3DUDPHWHUV 7, (Time), DIR (Direction).

)XQFWLRQ : Run spindle, in DIR direction, for TI seconds.

(5XQ(QJDJHPHWKRG

3DUDPHWHUV 7, (Time), T (Torque), C (Current).

)XQFWLRQ : Engage spindle, method 1. Run spindle reverse for TI seconds and then forward for TI seconds or until torque T or current C is reached.

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(5XQ(QJDJHPHWKRG

3DUDPHWHUV & (Current), TI (Time), DIR (Direction).

)XQFWLRQ : Engage spindle, method 2. Run spindle, in DIR direction, with maximum C current, until no increase in angle for TI seconds

*65XQ*HDU6KLIW

3DUDPHWHUV *6 (Gear Shift), TI1 (Time1), TI2 (Time2).

)XQFWLRQ : Controls the digital output used for shifting the gear for the currently executed spindle. GS equal to 1 (one) will cause gearshift output go high when this step is executed. GS equal to 0 (zero) will make the gearshift output go low. When changing speed from high to low (normal tightening), the spindle will first run reverse for TI1 seconds, then wait for TI2 seconds before the gear is changed. When changing speed from low to high the spindle will first run forward for TI1 seconds, and then wait for TI2 seconds before the gear is changed.

165XQXQWLOQH[WVWHS

3DUDPHWHUV ',5 (Direction).

3DUDPHWHUV Run spindle, in DIR direction, until next step starts. Next step starts when all the other spindles reach their next synchronization point. That is, this step is meaningful only if there are other spindles executing normal steps at the same time.

3/&5XQ3/&VWHS

3DUDPHWHUV ',5 , PLC output STEPTYPE, PLC output STEPVAL

)XQFWLRQ : This step is configurable during run-time using the PLC. When the PLC sets the start signal high the PLC Station variables STEPTYPE and STEPVAL are sampled. The first output, STEPTYPE, controls the type of step that will be executed and the STEPVAL is used as target value. DIR is the only parameter that is defined in the tightening program and it controls the direction of the step. STEPTYPE can take the following values:

67(37<3( 7\SHRI6WHS

1 Torque

2 Angle

3 Time

STEPVAL should be set to a target value of corresponding type, i.e. a torque, angle, or time.

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-2*5XQXQWLOGLJLWDOLQSXWJRHVKLJKORZ

3DUDPHWHUV : +/ (High/Low), DIR (Direction).

)XQFWLRQ : This step runs the current spindle, in the direction defined by parameter DIR, until the spindles digital input used for JOG goes high or low depending on the value of the H/L parameter.

::DLW

3DUDPHWHUV : 7LPH .

)XQFWLRQ : Wait for Time seconds. Does not run the spindle while waiting.

:3/&:DLWXQWLOVLJQDOIURP3/&WRFRQWLQXH

3DUDPHWHUV None.

)XQFWLRQ : This step waits until a positive edge of the PLC Station variables START is detected. Does not run the spindle while waiting.

7$±5XQ7RUTXH$QJOHZLWKQRVWRS

3DUDPHWHUV : $ (Angle), TC (Torque TC), DIR (Direction).

)XQFWLRQ : Run spindle, in DIR direction, until the torque-threshold TC is reached. Measured from this point, run until angle A is reached. The switch from torque to angle control is done "On-The- Fly", i.e. without stopping in-between.

Torque A

TC

Angle

The TA program is considered to be one step, as there is no step change where the spindles can be synchronized. The angle $ may be reported using an angle check. See Check angle for how to configure such a check.

The two parts can be programmed with different speeds and if so is done, then the speed will be changed on the fly with out stopping. See chapter: Step – Speed for how to program the speeds.

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65±6RFNHW5HOHDVH

3DUDPHWHUV $ (Angle), DIR (Direction).

)XQFWLRQ : Run spindle, in DIR direction, to the position of A. Angle is zero at start of step. This step performs the same function as a “A - Run until Angle” step except from that nothing that this step does is recorded by the %ROW Monitoring  function.

$'7$QJOH'HOWD7RUTXH

3DUDPHWHUV : 'HOWD7RUTXH , Angle, DIR (Direction).

)XQFWLRQ : 1. Run Angle with in the reverse direction. 2. Measure the torque when the angle Angle is reached and store this value as Tl ast . 3. Stop the spindle and wait until zero speed is reached. 4. Run in the forward direction until the torque T last + Delta Torque is reach. 5. Shut off the step. The same speed and speed ramps is used both when running in the backward and the forward directions. If Check angle is used it will report report the total angle without compensation of the lash. The step is intended to be used in an injector pump setting application and the proposed tightening sequence is: Step 1: T = 25 [Nm]; Direction = Forward Step 2: T = 3 [Nm]; Direction = Backward (to deal with the lash in the transmission). Step 3: ADT = 5 [Nm] / 60 [deg] Step 4: A = 30 [deg]; Direction = Backward Step 5: CE

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6*6QXJ*UDGLHQW

3DUDPHWHUV : '(/7$B$ (Delta Angle), TcMIN (Min Torque), TcMAX (Max Torque), TSLOPE (Torque Slope), ASG (Angle run), DIR (Direction).

)XQFWLRQ : 1. The spindle is started with the programmed speed in direction DIR. 2. The search for the Snug-point is started as soon as the torque passes TcMIN. 3. The average slope over DELTA_A deg is calculated. 4. This is repeated for every DELTA_A deg. 5. As soon as two slopes after each other are larger than TSLOPE the Snug-point is found. 6. From this point, the Snug-point, the spindle runs another ASG deg. 7. If the torque level TcMAX is passed without finding the Snug-point the step is aborted and an event is generated.

5HVXOWYDU .: After the step has finished the angle from the Snug-point to the end of the step can be checked using the normal angle check (see Check angle) if using the special start condition "SGP" (Snug Point). If so, the result is reported as the step level result variable "A".

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''LDJQRVWLF6WHS

3DUDPHWHUV 

[JB80]

)XQFWLRQ Defines the diagnostic checks to perform in a tightening program. Normally the diagnostic step is the first step in a program but it can be a later step in the program (e.g. when Flying Zero Offset is used). The diagnostic step can also be performed in a special program, which can be run between normal cycle programs. The normal programs will hence be faster. How the respective test should be executed, including limits, are configured individually for each spindle using the 6SLQGOH6HW8S form. Select =HUR2IIVHW7HVWDQG&RPSHQVDWLRQ if you want to include this function. Select which type of zero offset you want to measure by selecting pressing one of the radio buttons 6WDWLF , '\QDPLF , or )O\LQJ =HUR 2IIVHW . If the torque value measured as zero offset exceeds the programmed limit the test fails and the step reports status )DWDO . If the value is OK then the zero offset is remembered and is used to compensate all torque values in all programs, also programs that do not include a diagnostic step themselves. The measured offset is remembered until the next time a diagnostic step, set up to measure zero offset, is executed. For definition of the different types of zero offset compensation tests see the =HURRIIVHW chapter. Check &DOLEUDWLRQWHVW to have the torque bridge tested. See chapter: &DOLEUDWLRQ for how the test is performed. Check $QJOHFRXQWWHVW to execute a test of the angle measurement channels. Chapter:

=HURRIIVHW describes how this is done. Errors detected in a diagnostic step are reported as )DWDO errors except for one case. If “Continue to run” is checked (in the =HURRIIVHW form), then a flying zero offset error is reported as a warning.

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6WHS±5HVWULFWLRQ

You can set up restrictions that decide when a step shall be interrupted. A restriction stops a running step immediately and a restriction can be considered repairable or fatal.

All restriction tests are done on data collected for monitoring.

All restriction checks except for the Fail Safe Torque limit starts when torque spike elimination has ended and stops at shut off. The Fail Safe Torque check runs also during the torque spike elimination phase.

Restrictions comprise of:

• Fail Safe limits for Torque, Angle and Time

• Cross Thread and Gradient check

• Torque Profile check

• Torque – Current check

[JB81]

)DLO6DIH/LPLWV

3DUDPHWHUV : Torque, Angle and Time

$ODUPV : Torque restriction (TR), angle restriction (AR), time restriction (TIR)

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&URVV7KUHDGDQG*UDGLHQWFKHFN

3DUDPHWHUV : Torque level T1, T2 Torque level T2, Min angle, Max angle

)XQFWLRQ : Starts measuring the angle when the torque passes Torque level T1. Stops the angle measurement when the torque passes Torque level T2. Checks that the measured angle, A, is greater then Min angle and less then Max angle.

Torque

A A

T2

T1

Angle

$ODUPV : Cross thread restriction (CROSSTR) if A > Max angle. Cross gradient too high restriction (CROSSGR) if A < Min angle



7RUTXH3URILOHFKHFN

3DUDPHWHUV : AnStart, AnStop, TnHigh, TnLow. where n is in the range [1..3].

)XQFWLRQ : Checks that the torque in the three angle windows defined by the pairs AnStart to AnStop, is within the unique limits TnHigh and TnLow. The angles are measured from the start point according to the step angle definition.

Torque

T3Low T3High

T2High

T2Low

T1High

T1Low

Angle

A1Start

A3Start

A2Start

A1Stop

A3Stop

A2Stop

5HVXOWYDU This restriction produces the step level result variables "Tp1 Peak T", "Tp2 Peak T" and "Tp3 Peak T" which is the highest torque measured in the respective interval.

$ODUPV : Torque in window n too high (TnHR) and/or Torque in window n too low (TnLR).

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7RUTXH±&XUUHQWFKHFN

3DUDPHWHUV No of samples, Max. diff.

)XQFWLRQ This restriction detects a transducer cable failure by monitoring the difference of the read torque and the read current converted to a torque. The mean value of the torque measured using the transducer and the mean value of the torque calculated from the current are compared and if they differ more than "Max. diff." then the restriction is considered erroneous. Both mean values are calculated over the last "No. of samples" samples.

1RWH The restriction operates only from that Torque Spike Elimination phase is done until the step is shut-off.

$ODUPV "TCR"

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



6WHS±&KHFN

Checks are used to define which step level variables to measure and test against programmable limits.

1RWH Unless a check of a specific variable is defined then the variable will not be measured and therefore not available for reporting. This also goes for the corresponding SPC values.

The 3RVW6WHS&KHFN7LPH is set once for all checks in the step. The entered parameter decides for how long the measuring should continue after that the control function has shut off. This is important for measuring of overshoot, etc.

[JB82]

All checks can be set to repairable (R, default) or fatal (F). If repairable the Reject Management can try to re-tighten the joint (see 6WHS± Reject). Select the )DWDO box if you want the fault to be considered fatal. Fatal faults terminate the running cycle for the faulty bolt and for all bolts belonging to the same group as the faulty bolt.

A step can only have one check of the same type. Select what type of check you want. Relevant parameters are presented. Parameters between parentheses are optional. Fill in proper values.

All found check errors in a step are reported when the step has finished. Checks do not interrupt a running step.

When you have set up all conditions, press

 The check will be added to the list to the right. To remove an item from the checklist, select it and press the remove button

.

All checks are done on data measured on the monitoring channel. Data from the control channel is not used, unless no separate data is collected for monitoring. In that case the control data is used in all places where measurement values are needed.

In the following sub chapters all checks are described in detail together with all their parameters.

&KHFNSHDNWRUTXH

3DUDPHWHUV TH (Torque high), TL (Torque low)

)XQFWLRQ The peak torque is checked. PTH is the high limit and PTL is the low limit. Both or only one of the limits can be programmed.

5HVXOWYDU "Peak T" (peak torque).

$ODUPV Step peak torque high (PTH) and step peak torque low (PTL).

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&KHFNWRUTXHLQDQJOHZLQGRZ

3DUDPHWHUV TH (Torque high), TL (Torque low), Astart, Astop

)XQFWLRQ Astart and Astop define a window. All torque values within the angle window are checked. THAWIN is the high limit and TLAWIN is the low limit. Both or only one of the limits can be programmed.

5HVXOWYDU "A Win Hi T" (angle window high torque) and "A Win Lo T" (angle window low torque)

$ODUPV Step torque high in angle window (THAWIN) and step torque low in angle window (TLAWIN).

&KHFNWRUTXHLQWLPHZLQGRZ

3DUDPHWHUV TH (Torque high), TL (Torque low), Start time, Stop time

)XQFWLRQ Start time and Stop time define a window. All torque values within this time window are checked. TH is the high limit and TL is the low limit. Both or only one of the limits can be programmed.

5HVXOWYDU "A Win Hi T" (time window high torque) and "A Win Lo T" (time window low torque)

$ODUPV Step torque high in time window (THTIWIN) and step torque low in time window (TLTIWIN).

&KHFNPHDQWRUTXH

3DUDPHWHUV MTH (Mean torque high), MTL (Mean torque Low), TI (Time)

)XQFWLRQ The average torque during the last TI sec. of the step is checked. MTH is the high limit and MTL is the low limit. Both or only one of the limits can be programmed.

5HVXOWYDU "Mean T" (mean torque).

$ODUPV Step mean torque high (MTH) and Step mean torque low (MTL).

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&KHFNDQJOH

3DUDPHWHUV AH (Angle high), AL (Angle low), Start condition, Tstart (Torque start), Stop condition.

)XQFWLRQ Measures and checks the angle movement made during a step. The start and stop conditions for the measurement are controlled using parameters 6WDUWFRQGLWLRQ and 6WRS

FRQGLWLRQ as follows:

6WDUWFRQGLWLRQ 9DOXHXVHGDVVWDUWDQJOH

T The angle, A_Tstart, measured when torque reaches the value 7VWDUW .

AS1 The angle of the current position when the step is started.

AS2 The angle measured at shut of the previous step.

AS3 The peak angle reached during the execution of the previous step.

SGP The "Snug Point "of a SG step. See SG - Snug Gradient for a description.

6WRSFRQGLWLRQ 9DOXHXVHGDVHQGDQJOH

F - "Final" The final angle (AE1, measured when the "Post step check time" has passed after shut off).

SO - "Shut Off" The angle measured at the shut of point (AE2).

P - "Peak" The largest angle measured from shut off until the "Post step check time" has passed (AE3).

SOP - "Shut Off Previous" The angle measured when the torque falls under the shut off torque measured during the previous step (AE4).

1RWH The "Post step check time" (which is measured from that the step is shut off, see chapter: Step – Check) has to be programmed long enough to monitor the requested end condition.

Torque

shut off point

Tstart

shut off point previous step

Angle

F

AS1

A_Tstart

SOP

AS2

AS3

SO

P

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



5HVXOWYDU "A" (step angle)

$ODUPV Step angle high (AH) and Step angle low (AL).The measured value is compared against the parameters AH (Angle High limit) and AL (Angle Low limit). One of the limits can be omitted.

&KHFNWLPH

3DUDPHWHUV TIH (Time high), TIL (Time low)

)XQFWLRQ The time from when the step starts until it ends is checked. TIH is the high limit and TIL is the low limit. Both or only one of the limits can be programmed.

5HVXOWYDU "Time" (step time).

$ODUPV Step time high (TIH) and Step time low (TIL).

&KHFNFXUUHQW

3DUDPHWHUV CH (Current high), CL (Current low)

)XQFWLRQ The peak current for the step is checked. CH is the high limit and CL is the low limit. Both or only one of the limits can be programmed.

5HVXOWYDU "Peak C" (peak current).

$ODUPV Step current high (CH) and Step current low (CL).

&KHFNWRUTXHFXUUHQW

3DUDPHWHUV T/IH (Torque/current high), T/IL (Torque/current high), TI (Time)

)XQFWLRQ The average torque Vs average current during the last TI sec. of the step is checked. T/IH is the high limit and T/IL is the low limit. Both or only one of the limits can be programmed.

5HVXOWYDU "T/I" (torque vs. current).

$ODUPV Step torque vs. current high (T/IH) and Step torque vs. current low (T/IL).

&KHFN3RVWYLHZ7RUTXH

3DUDPHWHUV TC (Torque check level), TL (Torque low), AdistL (Low angle distance), AwinL (Low angle window), AdistH (High angle distance), AwinH (High angle window), TH (Torque high)

)XQFWLRQ This function checks that the torque in the angle window AwinL, located AdistL before the torque reaches TC, is above the torque limit TL. It also checks that the torque in the angle window AwinH, located AdistH before the torque reaches TC, is below the torque limit TH. It is possible to specify only one of the windows.

5HVXOWYDU None.

$ODUPV Post view torque too high (PVTH) and post view torque too low (PVTL).

Torque

TC

AdistH

AwinH

TL TH

Angle

AwinL AdistL

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&KHFNVKXWRIIWRUTXH

3DUDPHWHUV SOTH (Shut off torque high), SOTL (Shut off torque low)

)XQFWLRQ The torque measured at the shut off point of the step is checked. SOTH is the high limit and SOTL is the low limit. Both or only one of the limits can be programmed.

5HVXOWYDU "SO T" (shut off torque).

$ODUPV Step shut off torque high (SOTH) if and step shut off torque low (SOTL).

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



6WHS±5HMHFW

The 5HMHFW0DQDJHPHQW (RM) function is used for automatic repair of failed steps. Most of the RM settings are defined on the 5HMHFW tab

[JB83]

When a failed step is detected the RM performs the following:

1. Checks bolt status

1. Decides what to do

1. Starts repair

1. If problem was correctable, continues

1. If not correctable, generate error event

&KHFNLQJWKHEROWVWDWXV

The first thing that the Reject Management function does when a step fails is to figure out whether or not the step can be repaired. This is decided by the current bolt status.

At each synchronized step all bolts will be assigned a status. This status is the result of all checks made in the step, comprising the restriction tests, the step checks, hardware checks, etc. The resulting overall status for a bolt will be one of the following:

6WDWXVRIDOOUHVWULFWLRQVFKHFNVHWFRIWKHVWHS %ROWVWDWXV

All checks are Acceptable Acceptable

At least one check is Repairable and none is Fatal Repairable

At least one check is Fatal Fatal

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'HFLGLQJZKDWWRGR

%ROW&DWHJRULHV

All bolts executing are divided into one of three groups

• 5HMHFWEROWV : All Bolts that have other status than Acceptable, that is have failed hem self (Repairable or Fatal).

• 5HMHFWJURXS : All Bolts that have status Acceptable but belong to a group in which at least one bolt is not Acceptable.

• 2WKHUV : All Bolts that have status Acceptable and do not belong to a group where one or more bolts are not Acceptable.

3RVVLEOH50$FWLRQV

There are four different 50$FWLRQV to choose between:

• 7HUPLQDWH : The bolts should execute their Terminate sequence.

• &RQWLQXH : The bolts should continue with the next step. The bolt will first wait for any Terminate sequence to finish.

• 5HWU\ : The bolts should execute their Retry action(s).

• :DLW : The bolts should wait at the step they currently are at while other bolts are being repaired.

6HOHFWLQJ50$FWLRQ

You can specify different action for each bolt category depending on what kind of error that is at hand, and when it occurred. This is configured using the )LUVWWU\ , 6HFRQG7U\ and )DWDO7U\ settings specified for the steps.

• The )LUVWWU\ alternatives are used when the station is in its Running Normal state and offers the following alternatives:

• The 6HFRQGWU\ alternatives are used when the station is in its Running Repair state, that is when an error occurs during the repair, and offers the following alternatives (please note that the Retry alternative is QRW available for the steps located in the repair part of the program since this part is only intended for preparation of a repair):

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



• The )DWDOWU\ alternatives are used when a fatal error occurs for the bolt. It offers the following alternatives:

Depending on the overall status of all bolts that have executed the station will choose Reject Management will actions as follows:

6WDWXVRIDOO%ROWV 5HMHFW0DQDJHPHQW$FWLRQ

All bolts are Acceptable Continue with next step

At least one bolt is Repairable and none is Fatal Depends on the state of the station:

• If it is Running Normal (that is not currently repairing) then the First try settings of all bolts in the Reject bolts category are evaluated in order to decide the next action.

• If it is already Running Repair then the Second try settings of all bolts in the Reject bolts category are evaluated in order to decide the next action. At least one bolt is Fatal First the actions according to the )DWDOWU\ settings of all bolts with status Fatal are executed.

If there are any bolts remaining with Repairable errors after running the terminate sequence they will be executed according to the )LUVW or 6HFRQGWU\ settings as above.

Since the First, Second and Fatal try settings are defined per bolt the station can meet contradictory actions . Should this happen the ambiguity it is resolved by choosing the action in the following order: Terminate, Retry, Wait, and Continue.

When the station has decided what action each bolt should take it will order the bolts to either run the Terminate sequence, the Retry sequence, to continue with next step, or do nothing (wait).

The Retry and Terminate sequences are defined individually for each step and bolt.

See also chapter: Reject management states for a description of the states of the station and its bolts with respect to reject management.

6\QFKURQL]DWLRQPDUNV

In addition to the explicit synchronization marks there are also a number implicit ones, namely:

• All &\FOH(QG steps (CE).

• The end of the automatic loosening if defined using the parameters in the 5XQUHYHUVHEHIRUH

UHSDLU frame on the 5HMHFW tab.

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&RQILJXULQJ5HMHFW0DQDJHPHQW

Most reject management settings are defined per step using the 5HMHFW tab.

The parameters in the frame 5XQUHYHUVHEHIRUHUHSDLU controls if, and how, the bolt should be loosened before it starts any Retry action (see ,QLWLDWHUHSDLUZLWKVWHS and 5HSDLUZLWKVWHS below). The following parameters controls the loosening:

• 7RWRUTXH and 7RDQJOH . These radio buttons are used to control how loosening is done. The target value is specified in the corresponding textbox to the right.

• 6SHHG . The speed used when running reverse. If left empty then the speed defined on the 6SHHG tab is used.

• 0D[WLPH . The maximum allowed time to reach the target. Same function as the )DLOVDIH7LPH restriction. If left empty then the )DLOVDIH7LPH defined on the 5HVWULFWLRQ tab is used.

• 0D[WRUTXH . The maximum allowed torque while running reverse. Same function as the )DLOVDIH

7RUTXH restriction. If left empty then the )DLOVDIH7RUTXH defined on the 5HVWULFWLRQ tab is used. Only enabled when 7RDQJOH is selected.

• 0LQDQJOH . When loosening 7RWRUTXH the controller does not read the torque value until this angle has passed. Only enabled when 7RWRUTXH is selected.

Any failure, due to a restriction, a servo error, etc., during this automatic loosening is considered to be a

)DWDO error.

The parameters in the frame 5HWU\ controls how this bolt should be repaired when ordered so by the station:

• 0D[QRRIUHWULHV . Defines how many times this step may be repaired. When this number is exceeded the error is considered )DWDO . Max number of retries is 9.

• ,QLWLDWHUHSDLUZLWKVWHS . The number of the step to jump to in order to prepare the repair action. Any step in the repair part of the program (that is any of the steps after the first CE step) is allowed as target. Typically this sequence is used to loosen the bolt before the repair is started when the

5XQUHYHUVHEHIRUHUHSDLU options are insufficient. If left blank then no initial repair is done.

• 5HSDLUZLWKVWHS . Points to the step in the main program where the repair should be started when the optional initial repair is finished. Any step in the main part of the program up to, and including, the current step is allowed. If left blank no repair action is done.

• 7HUPLQDWHZLWKVWHS . The number of the step to jump to when ordered by the station to Terminate. Any step in the repair part of the program is allowed as target.

If both ,QLWLDWHUHSDLUZLWKVWHS and 5HSDLUZLWKVWHS are specified then ,QLWLDWHUHSDLUZLWKVWHS sequence is executed first. If non of them are specified the repair is considered finished and OK immediately.

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



On the )LUVWWU\ tab the following combinations are allowed:

5HMHFW%ROWV 5HMHFW*URXS 2WKHU

Terminate Terminate Terminate

Terminate Terminate Continue

Terminate Continue Continue

Continue Continue Continue

Retry Retry Retry

Retry Retry Wait

Retry Wait Wait

On the 6HFRQGWU\ tab the following combinations are allowed:

5HMHFW%ROWV 5HMHFW*URXS 2WKHU

Terminate Terminate Terminate

Terminate Terminate Continue

Terminate Continue Continue

Continue Continue Continue

Retry Retry Wait

On the )DWDOWU\ tab the following combinations are allowed:

5HMHFW%ROWV 5HMHFW*URXS 2WKHU

Terminate Terminate Terminate

Terminate Terminate Continue

Terminate Continue Continue

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



$GYDQFHG50$FWLRQV

The RM actions specified above do not take into consideration any ”history” of the cycle. Decisions are made for each sequence separately, without looking back on what has happened earlier in the cycle.

With the Advanced RM you can have an alternative RM dependent on what has happened earlier, in terms of number of sequences, spindles, and groups that has failed.

The conditions for when to start Advanced RM are set up for a Station object using the System Set Up form.

You may choose one or more of the following alternatives (with step is here meant all steps between two synchronization points):

• When more than 1RRIUHMHFWVWHSVLQF\FOH erroneous steps have been detected during the cycle. This test actually counts the number of times your station returns to the main program part after a Retry.

• When more than 1RRIUHMHFWJURXSVLQVWHS erroneous groups have been detected in one step.

• When more than 1RRIUHMHFWEROWVLQJURXS erroneous bolts have been detected in one step.

The Advanced RM will be used if any of the selected conditions has been met. The conditions are common to all steps in the cycle, independent of which is the current step.

[JB84]

The )LUVW6HFRQGWU\ grid for Advanced Reject Management is reached by clicking on the $GYDQFHG« button on the 5HMHFWWDE .

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5HMHFWPDQDJHPHQWVWDWHV

7KHVWDWHVRIWKH6WDWLRQ

With respect to reject management the station is always in one of the following states:

6WDWH 'HVFULSWLRQ

5XQQLQJ1RUPDO All bolts are running steps in the main part of their programs. No error has occurred. When all bolts have stopped, either because they reached a synchronization mark or that they failed, the station decides what reject action to take by evaluating the

• Fatal try settings for all bolts with Fatal errors

• First try settings for all bolts with Repairable errors

Should the settings lead to different actions for a given bolt the “hardest” action is taken

5XQQLQJ5HSDLU Some bolts are running their repair sequence. When all bolts have stopped, either because they reached a synchronization mark or that they failed, the station decides what reject action to take by evaluating the following conditions for all bolts that is not yet ready with their repair:

• Fatal try settings for all bolts with Fatal errors

• Second try settings for all bolts with Repairable errors

1RWH Only the bolts that currently are running repair are involved here. Bolts that never entered the repair sequence, for example due to that they had Wait or Continue as reject action, and bolts that are already ready with the repair sequence are not involved.

Should the settings lead to different actions for a given bolt the “hardest” action is taken

5HSDLU5HDG\ All bolts that once started their repair sequence have finished it. In this state the station do not execute any steps, it only evaluate the outcome of the repair in order to decide the next action.

The station evaluates the reject settings of all bolts that started repair and was not terminated while executing it using the

• Fatal try settings for all bolts with Fatal errors

• First try settings for all bolts with Repairable errors

The action decided is taken for all bolts that are not terminated, this means that not only the bolts that have done repair but also all bolts that had Wait or Continue as reject action when the station entered the Running Repair state may have new actions ordered here.

5XQQLQJ7HUPLQDWH One or more bolts are running a their terminate action. Synchronization is maintained for these bolts as long as the steps end OK. Should a step fail then the bolt is considered ready with status STNOK (Stopped and Terminated NOK) while the remaining bolts continue the terminate sequences.

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



An error has occurred and there is at least one bolt to terminate RUNNING NORMAL

An error has occurred and there is no bolt to terminate but at least one bolt to repair

A new error occurred and the Second try settings says there is at least one bolt to terminate

A new error occurred and the Second try settings says there is no bolt to terminate but at least one to repair

RUNNING REPAIR

RUNNING TERMINATE

The terminate action is ready and there is at least one bolt to repair

All bolts ready with repair

Evaluation of all bolts using First try gives that there is no bolt to terminate but at least one bolt to repair

Evaluation of all bolts using First try gives that next step in the main program should be started

REPAIR READY

Evaluation of all bolts using First try gives that there is at least one bolt to terminate

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



7KHVWDWHVRIWKH%ROW

With respect to reject management a bolt is always in one of the following states:

6WDWH 'HVFULSWLRQ

,GOH The bolt is done with any previous cycle and is just waiting for a new cycle to start.

5XQQLQJ1RUPDO The bolt is executing steps in the main part of its program. When it receives a “Start Step” command from the station it executes all steps until the next synchronization mark or that a step fails.

5XQQLQJ5HSDLU The bolt is running its repair sequence. The bolt enters this state when it is ordered to start repair.

It will then remember the synchronization interval from which it entered this state as the "Failing synchronization interval" (see the picture of the below example). This information is used when the bolt determines if it is ready with the repair

The bolt will stay in this state until it again stops in this interval, either due to that it failed to execute one of the steps in the interval or due to that it reached the ending synchronization mark of the interval.

Should the bolt be ordered to enter repair again while already in this state it will remain in this state, without changing the "Failing synchronization interval".

5XQQLQJ7HUPLQDWH The bolt is running steps in its terminate sequence.

IDLE

The terminate sequence is done The is no more to execute and the station order the bolt to finish

The cycle is started

The bolt is ordered to terminate

RUNNING NORMAL

RUNNING TERMINATE

The bolt is ordered to start repair

The bolt is ready with repair

RUNNING REPAIR

The bolt is ordered to terminate

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$UHMHFWPDQDJHPHQWH[DPSOH

Failing synchronization

interval Synch

Mark Synch

Mark

1 2 3 4 5 6 7 8 9 10 11 12

&( &(

-/-/- -/-/- 9/1/- -/-/- -/-/- -/-/- -/-/- -/-/- -/-/- -/-/-

Here the bolt transfer from

Here the bolt transfer from state RUNNING NORMAL

state RUNNING REPAIR to RUNNING NORMAL

to RUNNING REPAIR

When the bolt fails the first time in step 3 the station will use the First try settings of this step when computing the reject management action.

In this case an "Initiate repair sequence" is defined (step 9 to 11) so when the station orders the bolt to start repair the bolt will

• Enter the Running Repair state

• And jump to step 9

It will continue to execute without interaction with the station until it reaches a synchronization mark. Here the bolt will stop after step 11 since step 12 is a Cycle End (which is an implicit synchronization mark). This ends the "Initial repair sequence".

Since "Repair with step" is set to 1 for the step 3 the bolt will jump to step 1 when it receives the next start order from the station. Since step 1 has a synchronization mark the bolt will stop here and wait for a new order from the station.

When the station sends the next start order the bolt will run until step 5 is finished. Since the bolt now have reached its "Failing synchronization interval" it transfers from state Running Repair to the Running Normal. The station will not order the bolt to start the next step until all other bolts that also are running repair are finished.

When the next start order is received from the station the bolt will run until it reaches step 7 and at this point report to the station that has finished the program.

$OWHUQDWLYHVHTXHQFHV

Should the bolt fail while executing step 1 the second time (that is, while Running Repair) it would cause a new reject management action according to the Second try settings of step 1. This since it then have not reached its "Failing synchronization interval".

Should the bolt fail to execute one of the steps 2, 3, 4 or 5 the second time it will immediately return to the Running Normal state since it reached its "Failing synchronization interval". The station would then wait until all bolts is in the Running Normal state and then compute a new reject action according to the First try settings of the failing step (2, 3, 4 or 5).

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6WHS±6SHHG

The 6SHHG tab is used for to control the speed on the socket end during the different parts of the step. You can:

• Set the target speed

• Define how to ramp the torque at the start

• Define an acceleration for the start

• Define points where to change speed

• Enable zero speed detection

[JB85]

If you do not have any specific requirements just enter the wanted speed in [rpm] in 6SHHG field.

If you neglect to specify a speed the bolt will run with 1% of the spindles maximum speed and an event will be generated at every time the step is started.

For steps of type DT - Run until DynaTork, the =HURVSHHGGHWHFWLRQ check box is enabled. Check this to have the system to verify that the speed is less then the zero speed level, defined in the Spindle Set Up form, when the step has finished. If not, the warning flag NZS is set in the bolt level result variable "Warnings".

By entering a value for 7RUTXHUDPSXS [/s] you can control how the torque is built up when the step is started. If a non-zero value is entered the servo will start in torque control mode, ramping up the torque as specified. During this process it will monitor the error of the speed controller with respect to the programmed values of 6SHHG and 6SHHGUDPSXS . When the speed error becomes small enough the servo will automatically switch to speed control mode, picking up the current speed reference.

If needed, you can control every aspect of the speed curve by use of the 6SHHGUDPSXS , and 6SHHG

UDPSGRZQDW parameters.

Down ramp start point

Speed

Target Speed

Down ramp

Speed ramp up

New target speed

Smoothened

ramps

Time

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



The speed ramps can be smoothened or straight. Straight ramps are defined by a linear equation while smooth follows an S-function.

Up to five speed changes can be made during a step. These are defined in the 6SHHGUDPSGRZQDW spread. When to change speed can be triggered by one of the following conditions

• Angle reaches a specified value

• Torque reaches a specified value

• Current reaches a specified value

• A specified time from step start

Chose type by selecting the wanted type in the 6WDUW column and specify the trig value in the /HYHO column. Enter the new target speed in column 6SHHG and the acceleration/deceleration to use in 5DPS [rpm/s].

Only one of the start conditions is monitored at the time. The second condition will not be checked until the first condition has been met, and so on. However, there is no check done that the speed has reached the final value of the first condition before the second is activated.

Speed

Time

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6WHS±2WKHU

The 2WKHU tab holds the parameters that do not belong to the earlier parts.

[JB86]

Specify in 6WDUWGHOD\IRUVWHS if you want a delay first in the step, before the main function starts.

In 7RUTXH6SLNH(OLPLQDWLRQ specify the angle for which all torque readings should be disregarded for control.

In the +RZWRVWRS frame you can set up how you want to stop the spindle when the target for the step has been reached:

• ,QHUWLDEUDNH . Choose this alternative if you want to stop as quickly as possible. This is the recommended stop alternative for fastening.

• 5DPSGRZQWKHFXUUHQW . First lower the current to X % of the current value at target ( ,QLWLDO

YDOXH ), and after that ramp down the current with the 6ORSH [A/s]. Use this alternative to relax any torsion built up in a controlled manner.

• +ROGWRUTXH . This alternative does not stop any ongoing motion. The servo will maintain the torque it has when the step is stopped. Note! This means that if there is not contradicting force the spindle will continue to run. This stop condition is used for the DT - Run until DynaTork step.

By checking +ROGSRVLWLRQZKHQVWRSSHG the bolt will be held in the position it has when zero speed is detected. Cannot be used together with the Hold torque stop condition.

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



%ROW0RQLWRULQJ

The Monitoring function is used to examine the result of a whole tightening cycle.

This is done using a buffer, called the Monitoring buffer, in which each element represents a given angle interval measured from when monitoring is started. The buffer has a fix length of 8192 elements but its resolution, i.e. the length that each element represents, can be configured using the Bolt Set Up form.

The monitoring function can be started and stopped at any point during the cycle. When to start and stop monitoring is set up on the Bolt Set Up form. The following alternatives are available as start conditions:

• At cycle start (default)

• When a specific step is started

• When torque reaches a specified level

• PLC Station variables MONSTART is set high

The following stop conditions are available:

• At cycle end (default)

• When torque reaches a specified level

• PLC Station variables MONEND is set high

Monitoring can also be stopped when a step fails. To enable this check the 6WRSPRQLWRULQJLIVWHSHQGV

1. check box on the Monitoring form. This, together with the use of the Start/restart monitoring parameter for the steps (see Step – Control) can be useful if you want to report the result from the failing tightening.

The torque and angle values recorded in the monitoring buffer are taken from the channels set up for monitoring (see the description of Channels in the Spindle Set Up form).

When monitoring is running and the bolt is run in its forward direction, then the maximum torque value measured in each angle interval will be stored in the corresponding buffer position.

When the bolt is run in its backward direction (and monitoring is running) then the buffer is backed to the position that corresponds to the angle where the step stops. All values that correspond to the backed distance are erased. Should you pass the point (i.e. angle) where monitoring was started then the monitoring buffer will be restarted the next time the bolt is run its forward direction. This means that you cannot measure a negative angle using the monitoring buffer. (Should you need to measure a negative cycle angle there is an alternative method that does not use the monitoring buffer. See the Angle from threshold to Cycle End check in chapter: Monitoring of Torque and Angle at Cycle End for a description).

If the bolt runs forward again the recording is started from the current position.

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



Steps of the following types are handled specially:

• D - Diagnostic Step. Is always considered running backward.

• E1 - Run Engage method 1. Is always considered running backward.

• GS - Run Gear Shift. Is always considered running backward.

• SR – Socket Release. Nothing is recorded for this step, neither in the forward, or backward direction.

When monitoring ends two things are done. First, the last stored torque value is saved as the "Cycle End Torque". This value is used by the Monitoring Yield point torque and angle check. Secondly, the complete buffer is filtered for maximum torque for increasing angle. I.e. the following algorithm is applied on the buffer

Torque(k) = MAX(Torque(k), Torque(k – 1)), where k = [2..8192]

It is the filtered buffer that is used for all monitoring checks.

The monitoring checks are set up on tabs, each covering one type of monitoring check. These checks are described in detail in the following sub chapters.

When a monitoring error is found the error is reported in cycle data and the bolt is considered NOK. No other action is taken, as there is no reject management or handling of fatal errors detected during monitoring.

1RWH Monitoring can also be used in a station that has the spindles controlled by some other system. In these cases you should use the PLC Station variables outputs MONSTART and MONEND.

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



0RQLWRULQJRI7RUTXHDQG$QJOHDW&\FOH(QG

)LQDO7RUTXHDW&\FOH(QG

3DUDPHWHUV Active, FTH (High level), FTL (Low level)

)XQFWLRQ If Active is checked then this function checks that the Final Torque is within limits FTH and FTL. The final torque is the highest torque value found in the monitor buffer.

Torque

FTH

FTL

Angle

5HVXOWYDU "Bolt T".

$ODUPV Final torque too high (FTHM) and Final torque too low (FTLM).

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



$QJOHIURPWKUHVKROGWR&\FOH(QG

3DUDPHWHUV Active, AH (High level), AL (Low level), T1 (Torque Level) 

)XQFWLRQ This function checks that the angle A, measured from the point where the torque has reached T1 until the maximum angle, is within the specified limits AH and AL.

Torque

AH

A

AL

T1

Angle

5HVXOWYDU "Bolt A".

$ODUPV Angle too high (AHM) and Angle too low (ALM)

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0RQLWRULQJRI7RUTXH5DWHDQG'HYLDWLRQ

[JB87]

3DUDPHWHUV Active, T Start, T Stop, TRL, TRH, Dev 

)XQFWLRQ This function checks the Torque Rate (TR), i.e. the ratio of torque vs. angle. The torque rate is measured from the point where the torque reaches 76WDUW until it reaches 76WRS or the final torque, if it is reached before. The Torque Rate is calculated as: TR = (T STOP - T START ) / (A STOP – A START ) Leaving 76WRS blank will cause measuring to be stopped at the final torque. The measured TR is checked to be within the limits 75+ and 75/ . It also checks that the torque does not deviate more than 'HY from a straight line between

76WDUW and 76WRS (or the final torque). The Deviation in sample k, DEV(k), is calculated as: DEV(k) = ABS[T(k) – (A(k) * TR + m)] where m = T START – TR * A START You may specify one or two intervals, which may overlap.

Torque

Torque

T Stop 2 or Final Torque

T Stop 2 or Final Torque

T Start1

Angle

Angle

5HVXOWYDU "Bolt TR 1", "Bolt TR 2", "Bolt TR Dev 1", and "Bolt TR Dev2".

$ODUPV Torque rate in interval 1 too high (TR1HM), Torque rate in interval 1 too low (TR1LM) Torque rate in interval 2 too high (TR2HM) Torque rate in interval 2 too low (TR2LM) Too big deviation in interval 1 (DEV1M) Too big deviation in interval 2 (DEV2M)

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



0RQLWRULQJ

[JB88]

3DUDPHWHUV TC, NOS, INC, DIFF, Torque check Active, YTH, YTL, Angle check Active, YAH, YAL 

)XQFWLRQ Search for Yield point starts when the torque value has reached the trig level TC. From this point the average torque is measured over NOS degrees (T NOS ). This procedure is repeated after each INC degrees.

Torque

TDIFF

YTH

YTL YP

T3

YAL T2

NOS

T1

TC

INC

Angle

When three or more T NOS values have been measure (that is after 3 NOS + 2 INC) the difference in average torque, T DIFF (k), is calculated as T DIFF (k) = T NOS (k) - T NOS (k – 2 ) This value corresponds to the current torque rate. Also, every time T DIFF is calculated then its maximum value, MaxT DIFF , is updated MaxT DIFF (k) = MAX(T NOS (k), MaxT DIFF (k – 1)) The yield point is considered reached when T DIFF (k) < MaxT DIFF (k). Two result variables are produced. "Bolt YP T", which is how much the torque increases after the yield point, is calculated as "Bolt YP T" = T Cycle End , – T YP , where T Cycle End , is the Cycle End Torque (as described by Bolt Monitoring). The second variable, "Bolt YP A" represents how much the angle is increased from the yield point to the cycle end. It is calculated as: "Bolt YP A" = A Cycle End , – A YP ,

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



The function checks that "Bolt YP T" is within the limits YTH and YTL and that "Bolt YP A" is within the limits YAH and YAL. Note that YTH and YTL can be negative.

5HVXOWYDU "Bolt YP T" and "Bolt YP A".

$ODUPV Yield torque high (YTHM). If "Bolt YP T" > YTH Yield torque low (YTLM). If "Bolt YP T" < YTL Yield angle high (YAHM). If "Bolt YP A" > YAH Yield angle low (YALM). If "Bolt YP A" < YAL

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



5HVXOWYDULDEOHV

This chapter describes which system data and tightening results that are available for reporting to the different devices in the system.

What data to report to a particular device is configured using a Reporter. How to create and configure reporters is described in the chapter: 5HSRUWHU .

The result data is divided in the following sections

• Station level data

• Bolt level data

• Step level data

If a result variable for some reason does not have a value, e.g. due to that the check that produces the value is not included in the program, then the value NOT_DEFINED is reported for it.

A NOT_DEFINED value is printed as blanks (spaces) when reported as text and the value –32768 when reported in binary format.

6WDWXVHV

Stations and bolts have a variable named "Status" that indicates their resulting status.

The Station Status variable can take one of the following values:

0QHPRQLF 1XP,G 'HVFULSWLRQ

OK 0 Successful. No repairs have been made.

OKR 1 Successful. Errors have occurred but have been repaired

NOK 2 Not successful. Either a fatal error has occurred or a bolt failed to repair a repairable error.

TERMNOK 3 Not successful. An error occurred while running a terminate sequence (i.e. the steps specified using “Terminate with step” on the Reject tab for a step). The execution of steps was terminated when the error was found

Bolt Status variables can take one of the following values:

0QHPRQLF 1XP,G 'HVFULSWLRQ

OK 0 Successful. No repairs have been made.

OKR 1 Successful. Errors have occurred but have been repaired

NOK 2 Not successful. This bolt failed to execute a step either due to a restriction, a check or that any other fatal error occurred.

TERMNOK 3 Not successful. An error occurred while running a terminate sequence (i.e. the steps specified using “Terminate with step” on the Reject tab for a step). The execution of steps was terminated when the error was found

NOKRM 4 Not successful RQO\GXHWRUHMHFWPDQDJHPHQW . The bolt did not fail to execute a step but was ordered to terminate, or not to finish the program, as a reject management action.



1RWH For backward compatibility reasons the value NOKRM is reported to the PowerMACS PLC input as NOK. The NOKRM information is available in the PLC using the variable BOLSTATUS_EXT.

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6WDWLRQOHYHOUHVXOWYDULDEOHV

The Station level contain information concerning the station that run the tightening.

9DULDEOHQDPH 1XP,G 'HVFULSWLRQ

Data No 1 A device unique sequence number. This number is incremented by one for each cycle data reported over the device in question. This number can be used to detect missing cycles.

Station 2 The name of the station. See System Set Up for how to set or change the name of a station. Max. 20 ASCII characters.

Station No 3 The number of the station. The first station in the system is 1.

Time 4 The date and time when the cycle was started.

Wp. ID 5 Work piece Identity. Supplied to station from an ID device (see ID device Set Up) or set by the PLC using the IDSTRING output (Station variables). Max. 40 ASCII characters.

Mode 6 The name of the mode that was executed. Set using The Mode Table form. Max. 20 ASCII characters.

Mode No 7 The number of the mode that was executed.

Status 8 Total status for the station: See chapter: Statuses for possible values.

Total 9 Total number of cycles executed during the current shift. See Shift Reports and Shift Set Up for a description of shifts.

Total OK 10 Total number of cycles that ended OK or OKR during the current shift. See Shift Reports and Shift Set Up for a description of shifts.

Total NOK 11 Total number of cycles that ended NOK or TERMNOK during the current shift. See Shift Reports and Shift Set Up for a description of shifts.

Free Str 12 The value of the PLC output FREESTRING when the cycle was started (see Station variables).

Free No 1 13 The value of the PLC output FREENUM1 when the cycle was started (see Station variables).

Free No 2 14 The value of the PLC output FREENUM2 when the cycle was started (see Station variables).

Free Str 2 15 The value of the PLC output FREESTRING2 when the cycle was started (see Station variables).

Free Str 3 16 The value of the PLC output FREESTRING3 when the cycle was started (see Station variables).

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



%ROWOHYHOUHVXOWYDULDEOHV

Bolt level data is divided in two parts, Common data and Monitoring data where the latter consists of all variables that are produced by the Bolt Monitoring functions.

&RPPRQGDWD

The Common data consists of the following variables:

9DULDEOHQDPH 1XP,G 'HVFULSWLRQ

Bolt 31 The name of the bolt. Set System Set Up for how to set or change the name of a bolt. Max. 20 ASCII characters.

Bolt No 32 The number of the bolt as set using the Bolt Set Up form.

Spindle No 33 The number of the spindle used to tighten the bolt as set using the Bolt Set Up form.

Program 34 The name of the program used to tighten the bolt. Max. 20 ASCII characters.

OP mode 35 Operational mode of the bolt. Takes one of the following values:

• 0: Connect normally. The bolt was executed during the cycle.

• 1: Disconnected with OK status. The bolt was not executed during the cycle.

• 2: Disconnected with NOK status. The bolt was not executed during the cycle. Status 36 Overall status for the bolt including monitoring. See chapter: Statuses for possible values.

Total 37 Total number of cycles that this bolt has run during the current shift. See Shift Reports and Shift Set Up for a description of shifts.

Total OK 38 Total number of OK and OKR cycles that this bolt has run during the current shift. See Shift Reports and Shift Set Up for a description of shifts..

Total NOK 39 Total number of NOK and TERMNOK cycles that this bolt has run during the current shift. See Shift Reports and Shift Set Up for a description of shifts.

Total Type 40 The total number of cycles that all bolts, which is of the same type as this bolt, have run during the current shift. The bolt type is defined using the Bolt Set Up form. See Shift Reports and Shift Set Up for a description of shifts.

Total Type OK 41 The total number of OK and OKR cycles that all bolts, which is of the same type as this bolt, have run during the current shift. The bolt type is defined using the Bolt Set Up form. See Shift Reports and Shift Set Up for a description of shifts.

Total Type NOK 42 The total number of NOK and TERMNOK cycles that all bolts, which is of the same type as this bolt, have run during the current shift. The bolt type is defined using the Bolt Set Up form. See Shift Reports and Shift Set Up for a description of shifts.

Errors 43 Lists all errors that have occurred during the cycle and is not repaired. See Errors for possible values.

RM Errors 44 Lists all errors that have occurred during the cycle including all that have been repaired. See Errors for possible values.

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



Compact Errors 46 This is a compact version of the "Errors" result variable It may list the following errors:

• THM -Torque High Monitoring (bit 0, value 1)

• TLM -Torque Low Monitoring (bit 1, value 2)

• AHM -Angle High Monitoring (bit 2, value 4)

• ALM -Angle Low Monitoring (bit 3, value 8)

When reported binary, each error is represented by the bit written within parentheses above (bit 0 is the least significant).

Failing Step No 47 The number of the last step that failed in the main part of a program. Only valid if bolt status is OKRM, NOK, NOKRM or TERMNOK.

Pgm No 48 The optional number assigned to the program that was used to tighten the bolt. Set using The Tightening Program.

0RQLWRULQJGDWD

The Monitoring data contains variables that correspond to the result of the Bolt Monitoring functions.

In addition to the variables listed below the high and low limit set up for it, as well as the Cp, Cpk, and Cam SPC values calculated for them, are also available as result variables.

When including the limits of a variable both the high and the low limit will be included in the report.

If you choose to include the SPC values all three values are reported together.

9DULDEOHQDPH 1XP,G 'HVFULSWLRQ

Bolt T 57 Peak Torque for the cycle. See Monitoring of Torque and Angle at Cycle End.

Bolt A 58 Cycle Angle. Either measured from monitoring start or from when the threshold level T1 is reached. See Monitoring of Torque and Angle at Cycle End.

Bolt TR1 59 Torque Rate in interval 1. See Monitoring of Torque Rate and Deviation for how it is defined.

Bolt TR2 60 Torque Rate in interval 2. See Monitoring of Torque Rate and Deviation for how it is defined.

Bolt TR Dev 1 61 Maximum torque rate deviation in interval 1. See Monitoring of Torque Rate and Deviation for how it is defined.

Bolt TR Dev 2 62 Maximum torque rate deviation in interval 2. See Monitoring of Torque Rate and Deviation for how it is defined.

Bolt YP T 63 Yield Point Torque. See Monitoring Yield point torque and angle for how it is defined.

Bolt YP A 64 Yield Point Angle. See Monitoring Yield point torque and angle for how it is defined.

The numerical variable identity for the Limit and SPC variables that corresponds to the above listed basic variables are given by the following formulas:

• Num. Id. of the Limits for variable X = Num. Id. of variable X + 18

• Num. Id. of the SPC data for variable X = Num. Id. of variable X + 36

When including the limits of a variable both the high and the low limit will be included in the report. If you choose to include the SPC values all three values are reported together.

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



(UURUV

The Bolt result variables (UURUV and 50(UURUV can hold the errors listed below.

When reported in binary format the respective error variable occupy 12 bytes (96 bits) where each bit represent an error. The bits are numbered 0 to 95 and are laid out as below:

(UURUELWQR 31 24 23 16 15 8 7 0

(UURUELWQR 63 56 55 48 47 40 39 32

(UURUELWQR 95 88 87 80 79 72 71 64

1RWH If Type, see Layout of Cycle Data, is set to "I8" then only first 8 bytes are included, that is errors 0 to 63.

3RVVLEOHHUURUV

0QHPRQLF %LWQR 'HVFULSWLRQ

$1*',$* 0 Angle count test failed during a diagnostic step

&$/,%',$* 1 Calibration test failed during a diagnostic step

67=2',$* 2 Static zero offset failed during a diagnostic step

'<1=2',$* 3 Dynamic zero offset failed during a diagnostic step

)/<=2',$* 4 Flying zero offset failed during a diagnostic step

75 5 Fail safe Torque restriction exceeded

$5 6 Fail safe Angle restriction exceeded

7,5 7 Fail safe Time restriction exceeded

7&5 8 Torque – Current restriction exceeded

&526675 9 Cross thread restriction exceeded

&5266*5 10 Cross gradient restriction exceeded

7+5 11 Torque in window 1 too high from check

7+5 12 Torque in window 2 too high from check

7+5 13 Torque in window 3 too high from check

7/5 14 Torque in window 1 too low from check

7/5 15 Torque in window 2 too low from check

7/5 16 Torque in window 3 too low from check

37+ 17 Peak torque high alarm from check

37/ 18 Peak torque low alarm from check

$:,17+ 19 Torque high in angle window alarm from check

$:,17/ 20 Torque low in angle window alarm from check

7,:,17+ 21 Torque high in time window alarm from check

7,:,17/ 22 Torque low in time window alarm from check

07+ 23 Mean torque high alarm from check

07/ 24 Mean torque low alarm from check

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



$+ 25 Angle high alarm from check

$/ 26 Angle low alarm from check

7,+ 27 Time high alarm from check

7,/ 28 Time low alarm from check

&+ 29 Current high alarm from check

&/ 30 Current low alarm from check

627+ 31 Shut off torque high from check

627/ 32 Shut off torque high from check

7,+ 33 Torque/Current too high from check

7,/ 34 Torque/Current too low from check

397+ 35 Post view torque too high from check

397/ 36 Post view torque too low from check

7+0 37 Final torque too high during monitoring

7/0 38 Final torque too low during monitoring

$+0 39 Angle too high during monitoring

$/0 40 Angle too low during monitoring

75+0 41 Torque rate in interval 1 too high during monitoring

75/0 42 Torque rate in interval 1 too low during monitoring

75+0 43 Torque rate in interval 2 too high during monitoring

75/0 44 Torque rate in interval 2 too low during monitoring

'(90 45 Deviation in interval 1 too big during monitoring

'(90 46 Deviation in interval 2 too big during monitoring

<7+0 47 Yield point torque high during monitoring

<7/0 48 Yield point torque low during monitoring

<$+0 49 Yield point angle high during monitoring

<$/0 50 Yield point angle low during monitoring

7',)) 51 Double Torque transducer error

$',)) 52 Double Angle encoder error

%8)29)/0 53 Monitoring: Overflow in recording buffer. See description of parameter "Allow monitoring buffer overrun" in Bolt Set Up.

± 54 – 61 Reserved

6$7 62 A/D converter used for torque measurement saturated

27+(5 63 This is bit is set if any error bit(s) in the range 64 . 95 are set and only the first 8 bytes are included. That is, Type in the reporter is set to "I8".

/226(1 64 The automatic loosening, defined using the "Run reverse before retry" parameters on the Step – Reject tab, failed.

± 65 – 95 Reserved

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



:DUQLQJV

When reported in binary format the respective error variable occupy 8 bytes (64 bits) where each bit represent a warning. The bits are numbered 0 to 63 and are laid out as below:

(UURUELWQR 31 24 23 16 15 8 7 0

(UURUELWQR 63 56 55 48 47 40 39 32

3RVVLEOHZDUQLQJV

:DUQLQJ %LWQR 'HVFULSWLRQ

NZS 0 Not zero speed

FLYZODIAG 1 Flying zero offset failed during a diagnostic step

BUFOVFLM 2 Monitoring: Overflow in recording buffer. See description of parameter "Allow monitoring buffer overrun" in Bolt Set Up.

• 3 - 63 Reserved.

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



6WHSOHYHOUHVXOWYDULDEOHV

The Step level data is the data that can be reported for each individual step in a tightening cycle. It is divided in two parts, Common data and Check data, where the first covers all variables that available for all steps and the latter all variables produced by checks executed for the step.

&RPPRQGDWD

This section lists all variables that are available for all steps without any specific configuration.

9DULDEOHQDPH 1XP,G 'HVFULSWLRQ

Step No 178 The step number. This is the order of the step within the program. First step is one (1).

Steps within a sequence are given the step number P * 100 + S where P is the step number of the SE step that calls the sequence and S is the step number within the sequence.

Step Type 179 The numerical representation of the type of step. See the definition of the respective step for valid values (Step – Control).

Par 180 The parameters of the steps control part. See the definition of the respective step type (Step – Control) for which parameters that are printed, and in which order.

Speed 181 The target Speed for the step.

&KHFNGDWD

The check data consists of the variables that are produced as a result of running a check, a restriction or produced by the steps control function.

In addition to the variables listed below the high and how limit set up for it, as well as the Cp, Cpk, and Cam SPC values calculated for them, are also available as result variables.

9DULDEOHQDPH 1XP,G 'HVFULSWLRQ

Peak T 151 The highest torque reached during the step. Produced by the "Check peak torque" check.

Mean T 152 Mean torque during end of step. Produced by the "Check mean torque" check.

DT Mean T 153 The mean torque measured during the time interval TI2 of the DT - Run until DynaTork step.

A Win Hi T 154 The highest torque measured in the angle window. Produced by the "Check torque in angle window" check.

A Win Lo T 155 The lowest torque measured in the angle window. Produced by the "Check torque in angle window" check.

Ti Win Hi T 156 The highest torque measured in the time window. Produced by the "Check torque in time window" check.

Ti Win Lo T 157 The lowest torque measured during time window. Measured by “Check torque in time window”.

A 158 The step angle. Produced by the "Check angle" check.

Time 159 The time that the step was run. Measured from that the servo is started until it is stopped. Produced by the "Check time" check.

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



Peak C 160 The highest current reached during the step. Produced by the "Check current" check.

T/I 162 The mean value of torque vs. the mean value of current both measured during the last T s of the step. Produced by the "Check torque/current" check.

Relax A 163 The angle measured from that target is reached until the step is shut off. Only produced by the "DT - Run until DynaTork" step.

Release A 164 The release angle measured from the negative peak torque until the point where the line, trough the peak torque point and the shut off point, cuts the angle axis.

Is produced by the “LT - Loosen until torque” and the “”RA - Release angle steps.

Tp1 Peak T 165 The peak torque measured in angle window 1 of the restriction Torque Profile check.

Tp2 Peak T 166 The peak torque measured in angle window 2 of the restriction Torque Profile check.

Tp3 Peak T 167 The peak torque measured in angle window 3 of the restriction Torque Profile check.

SO T 172 The torque measured at the shut off point of the step. Produced by the "Check shut off torque" check.

The numerical variable identity for the Limit and SPC variables that corresponds to the above listed basic variables are given by the following formulas:

• Num. Id. of the Limits for variable X = Num. Id. of variable X + 41

• Num. Id. of the SPC data for variable X = Num. Id. of variable X + 65

When including the limits of a variable both the high and the low limit will be included in the report. If you choose to include the SPC values all three values are reported together.

8VHU0DQXDO3RZHU0$&6 7LJKWHQLQJ x 



63&2YHUYLHZ

This part describes how to set up the SPC, Statistical Process Control, and other statistics.

A first introduction to SPC is given in the next chapter:, SPC, Statistical Process Control.

!



63&6HW8S« opens the SPC set up form with which the SPC is configured.

6KLIW6HW8S« opens Shift Set Up form. Use it to configure shifts.

The other alternatives on the SPC menu are used for printing so-called shift reports. See Shift Reports and Shift Set Up for a description of these.

8VHU0DQXDO3RZHU0$&6 63&DQG6WDWLVWLFV x 



63&6WDWLVWLFDO3URFHVV&RQWURO

The purpose of the built-in SPC function is to provide the operator or quality control staff with data that will enable them to judge the stability and capability of the assembly process according to standard SPC rules. By automating the SPC function within the PowerMACS the work will be simplified and carried out without the necessity of external SPC charts.

Since any assembly parameter within PowerMACS can be used as a SPC variable, it is necessary to understand that only variables controlled by the PowerMACS reflects the performance of the PowerMACS system. Other variables will mainly reflect results from other processes. If e.g. a torque value is applied to a joint, then obviously SPC of the final torque value, and conclusions from that, such as Cp and Cpk will reflect the performance of the tool and the controller. A SPC study of the angle from some torque level will in the same case reflect mainly other aspects outside the PowerMACS sphere of influence, such as friction of the threaded surfaces, machining of thread and mating surfaces etc. even though it is reported by PowerMACS.

The built-in SPC is very flexible and it is possible to tailor data collection, calculations, and checks to suit most needs.

'DWD&ROOHFWLRQ

Data is collected only for those variables that have been set up for collection. Data are collected in two main ways:

• As subgroups for the SPC and TDA

• As latest results, or Short Term Trend

For the 63&DQG7'$IXQFWLRQ data is collected into subgroups. Only data with bolt status OK are calculated on, results from NOK cycles are ignored. The 6XEJURXSVL]H defines how many samples a subgroup is calculated from.

When 6XEJURXSVL]H values have been collected they are used to calculate the Average value and the Range or Standard deviation. These values are saved for the subgroup while the original values are lost.

This is repeated with a selectable frequency, either specified in number of samples ( 6DPSOHV ), or in time between start of subgroups ( 0LQXWHV ). Note that the selected frequency only controls when collection of data for a subgroup should be started. When started, the result of each OK cycle is taken until the subgroup is filled.

If frequency is specified as 6DPSOHV , say N, then the collection of a new subgroup is started N samples after that the previous subgroup was started. When started, the result of each OK cycle is taken until the subgroup is filled.

If frequency is specified as 0LQXWHV , say T, then the collection of a new subgroup is started T minutes after that the collection of the previous subgroup was started. Also, if a subgroup is not complete within 30 minutes it is discarded.

The SPC and TDA function will store and calculate data on 1RRIVXEJURXSVWRVDYH subgroups. It will not display any values until at least 1RRIVXEJURXSVWRFDOFXODWH has been collected. However, from that point it will use all subgroups stored in memory in the calculations.

The short 7HUP7UHQGIXQFWLRQ is used to give a detailed view of the latest recorded samples. It uses a buffer where the last ( 6XEJURXSVL]H * 1RRIVXEJURXSVWRVDYH samples are stored. Here are values from both OK and NOK cycles collected.

When the Short Term Trend is to be displayed then average and the range or deviation values are calculated for subgroups built from the data in the short Term trend buffer, starting with most resent value.

Which variables to collect are set up uniquely for each bolt/spindle and program.

8VHU0DQXDO3RZHU0$&6 63&DQG6WDWLVWLFV x 



&DOFXODWLRQVIRUVXEJURXSV

Data in a subgroup is calculated as:

;

$YHUDJH ;

L Q

Q

= = − = max( ) min( ) ; .. 1

5DQJH 5 ; ; L Q

; ;

Q L Q

WDQ

;

= −

;

Q



6 LV DSSUR[LPDWHG ZLWK

Q L Q

where n = size of subgroup

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When specified number of subgroups to use for calculations has been collected, the SPC function will start calculations to determine the statistical stability. This will be repeated every time a new subgroup is ready.

Calculations are performed in following steps: (m = number of subgroups)

Calculation of Average of Average values:

;

 1

;

L P

P

Calculation of Average of Range or Standard deviation:

= =

P L P



DQG

= =

L P



P

8VHU0DQXDO3RZHU0$&6 63&DQG6WDWLVWLFV x 



Calculation of Control levels (if enabled):

= +

= −

=

=

RU

= +

= −

=

=

$ ' ' DQG $ % % VHH WDEOH

   

Check and alarm (if enabled) if following happens with Average or Range or Standard deviation:

• one value outside control levels (One out)

• points consecutively increasing (Seven up)

• 7 points consecutively decreasing (Seven down)

• 7 points consecutively above average (Seven above)

• 7 points consecutively below average (Seven below)

• >90% in mid third (Mid gather)

• <40 in mid third (End gather)

8VHU0DQXDO3RZHU0$&6 63&DQG6WDWLVWLFV x 



Calculation of the process capabilities Cp and Cpk:

=

σ

G

• 5

864 ,0 645 ,1

⋅ − =

G G

N

5 V

’

) : ( .. 1 ;

= =

WDEOH VHH G P L

G

RU

6 V

’

) : ( .. 1 ;

= =

WDEOH VHH F P L

F

+ − =

/7/ 87/ &S

’

*

V VO VX



 − − =

/7/ ;

; 87/ &SN

• , * min

  

  

’ ’

V VO

V VX

+ − =

/7/ 87/ &DP

*

σ

VO VX

where

• for a normal distribution su = sl = 3

• d5 = 2.326 for subgroup size = 5

• k = no of subgroups to calculate

Cam is only calculated for subgroup size = 5, and requires range to be collected. Cam is not applicable to standard deviation.

An error event is generated if the value of Cam, Cp or Cpk is out of limit.

When SPC is wanted for a station, not for its individual bolts, the calculations are made on those variables that happen to be set up for data collection on that station.

Station, Program, Step and Variable are still defined, so only variables matching those criteria are used.

It is not possible to specify alarm limits or control limits for SPC calculated on a station.

8VHU0DQXDO3RZHU0$&6 63&DQG6WDWLVWLFV x 



The weighing together of values for the separate bolts are done for each subgroup according to the following rules:

up. set is collection - SPC for which station in this bolts of number The

=

1R%ROW

• bolt for j subgroup for mean value The X

=

ij

i bolt for j subgroup for varians The j subgroup for station for the average The

= =

;6WQ

9DU

j subgroup for station for the varians The

=

9DU6WQ

j subgroup for station for the deviation standard The

=

6WG'HY6WQ



;

=

=

;6WQ

1R%ROWV



⋅ − =

9DU ;6WQ ; 9DU6WQ

=

=

9DU6WQ 6WG'HY6WQ

8VHU0DQXDO3RZHU0$&6 63&DQG6WDWLVWLFV x 



63&FRQVWDQWV

The table below gives the constants to use in the mathematical formulas.

6XE

'LYLVRUVIRU

)DFWRUVIRU&RQWURO/LPLWV

JURXS

HVWLPDWHRI

VL]H

VWDQGDUGGHY

Q G F $ ' ' $ % %

2 1.13 0.798 1.88 - 3.27 2.66 - 3.27

3 1.69 0.886 1.02 - 2.57 1.95 - 2.57

4 2.06 0.921 0.73 - 2.28 1.63 - 2.27

5 2.33 0.940 0.58 - 2.11 1.43 - 2.09

6 2.53 0.952 0.48 - 2.00 1.29 0.03 1.97

7 2.70 0.959 0.42 0.08 1.92 1.18 0.12 1.88

8 2.85 0.965 0.37 0.14 1.86 1.10 0.19 1.82

9 2.97 0.969 0.34 0.18 1.82 1.03 0.24 1.76

10 3.08 0.973 0.31 0.22 1.78 0.98 0.28 1.72

11 3.17 0.975 0.29 0.26 1.74 0.93 0.32 1.68

12 3.26 0.978 0.27 0.28 1.72 0.89 0.35 1.65

13 3.34 0.979 0.25 0.31 1.69 0.85 0.38 1.62

14 3.41 0.981 0.24 0.33 1.67 0.82 0.41 1.59

15 3.47 0.982 0.22 0.35 1.65 0.79 0.43 1.57

16 3.53 0.984 0.21 0.36 1.63 0.76 0.45 1.55

17 3.59 0.985 0.20 0.38 1.62 0.74 0.47 1.53

18 3.64 0.985 0.19 0.39 1.61 0.72 0.48 1.52

19 3.69 0.986 0.19 0.40 1.60 0.69 0.50 1.50

20 3.74 0.987 0.18 0.42 1.59 0.68 0.51 1.49

21 3.78 0.988 0.17 0.42 1.58 0.66 0.52 1.48

22 3.82 0.988 0.17 0.43 1.57 0.65 0.53 1.47

23 3.86 0.989 0.16 0.44 1.56 0.63 0.55 1.46

24 3.90 0.989 0.16 0.45 1.55 0.62 0.56 1.45

25 3.93 0.990 0.15 0.46 1.54 0.61 0.57 1.44

8VHU0DQXDO3RZHU0$&6 63&DQG6WDWLVWLFV x 



63&VHWXS

This form is used for configuration of the SPC, Statistical Process Control function. It is opened using the

63&6HW8S menu item.

[JB89]

Specify 6XEJURXSVL]H and if you want to use 5DQJH or 6WDQGDUG'HYLDWLRQ .

In the 63&DQG7'$ frame, set up values for normal SPC and Trend Deviation Alarms.

Do the same for the 6KRUW7HUP7UHQG frame. These values will be used for calculations of all variables you choose to calculate on. See chapter: Data Collection for a description of the parameters.

In the 9DULDEOHVWRFROOHFW frame, add those variables you want to check. Select 6WDWLRQ , %ROWRU

6SLQGOH , 3URJUDP , 9DULDEOH , and 6WHS . For %ROWRU 6SLQGOH you may specify $OO , this will add the

variable for all bolts in the station. Press

. The variable shows up in the list box.

A PowerMACS system may contain up to 200 SPC variables and max 20 per TC/spindle.

To remove a variable from the list, select it and press the remove button

.

If you press the Information button

a dialog box is presented where you can enter various check values for the selected variable.

8VHU0DQXDO3RZHU0$&6 63&DQG6WDWLVWLFV x 



[JB90]

If you have marked $XWRUHFDOFXODWLRQRIOLPLWV on the first page, the 8FO/FO8FO[ and /FO[ fields will show current value of the control limits. If you disable automatic recalculation you can manually enter control limits in these fields.

Cam limit is only applicable if cam can be calculated.

8VHU0DQXDO3RZHU0$&6 63&DQG6WDWLVWLFV x 



6KLIW5HSRUWVDQG6KLIW6HW8S

It is possible to define automatic end of shift reports summarizing deviations and exceptions during the last shift. To use this function you must first define the shifts. This is done using the Shift Set Up form.

The report is produced automatically after each shift but can also be printed ”so far” during the current shift. The report can be previewed on the WinTC screen or sent to a printer connected to it. Preview and print are invoked from the 63& menu.

The report contains the following information per station:

• Total No. of cycles executed, No. of OK and No. of NOK.

• Total No. of cycles executed for each mode, No. of OK and No. of NOK.

• For each combination of program and bolt the following SPC data are listed for the bolt level result variables "Bolt T" and "Bolt A": Mean value, +3*Sdev, -3*Sdev, Cp, Cpk and Cam. To be included in the report the variables must first have been included using the SPC set up form.

A typical report looks as follows:

Print Date: 1999-05-01 15:00 Shift Start: 1999-05-01 06:00 Shift End: 1999-05-01 14:00 Station: NameOfStation01 Mode No. of cycles No. of OK cycles No. of NOK cyckles ------------------------------------------------------------------ All modes 2345 2300 45 NameOfMode01 1000 1000 0 NameOfMode02 1000 970 30 NameOfMode03 345 30 15 Program Bolt Variable Mean +3*Sdev -3*Sdev Cp Cpk Cam -------------------------------------------------------------------- Pgm01 Bolt01 Bolt T 10.35 0.45 0.45 0.10 0.10 0.10 Pgm01 Bolt01 Bolt A 367.35 0.80 0.80 2.20 2.20 2.20 Pgm01 Bolt02 Bolt T 10.68 0.45 0.45 0.10 0.10 0.10 Pgm01 Bolt02 Bolt A 368.90 0.80 0.80 2.20 2.20 2.20 Pgm02 Bolt01 Bolt T 8.80 0.21 0.21 0.20 0.20 0.20 Pgm02 Bolt01 Bolt A 98.50 0.80 0.80 2.20 2.20 2.20 Pgm02 Bolt02 Bolt T 8.80 0.21 0.21 0.20 0.20 0.20 Pgm02 Bolt02 Bolt A 98.50 0.80 0.80 2.20 2.20 2.20 Station: NameOfStation02 Mode No. of cycles No. of OK cycles No. of NOK cyckles ------------------------------------------------------------------ All modes 800 790 10 NameOfMode01 400 400 0 NameOfMode02 400 390 10 NameOfMode03 0 0 0 NameOfMode04 0 0 0 Program Bolt Variable Mean +3*Sdev -3*Sdev Cp Cpk Cam -------------------------------------------------------------------- Pgm01 Bolt01 Bolt T 10.35 0.45 0.45 0.10 0.10 0.10 Pgm01 Bolt01 Bolt A 367.35 0.80 0.80 2.20 2.20 2.20 Pgm02 Bolt01 Bolt T 8.80 0.21 0.21 0.20 0.20 0.20 Pgm02 Bolt01 Bolt A 98.50 0.80 0.80 2.20 2.20 2.20 Pgm03 Bolt01 Bolt T 0.00 0.00 0.00 0.00 0.00 0.00 Pgm03 Bolt01 Bolt A 0.00 0.00 0.00 0.00 0.00 0.00

Some statistics can be automatically reported on a shift base.

8VHU0DQXDO3RZHU0$&6 63&DQG6WDWLVWLFV x 



6KLIW6HW8S

The Shift Set Up form is used for to define shifts. It is invoked using the 63&6KLIWV6HW8S« menu item.

[JB91]

Each row in the above form represents a shift. Enter the day and time for when the shift starts and when it stops.

The days are expressed as numbers where 1 corresponds to Monday and 7 to Sunday. A shift may have different start and stop days.

The start and stop times must be entered using 24 h notation, i.e. as 00:00 to 23:59.

Check $XWRPDWLFFOHDUDWVKLIWVWDUW to have all shift statistics variables erased when a new shift starts. Clearing the shift statistics will reset the following:

• All counters (No. of cycles, No. of OK cycles, No. of NOK cycles) for each combination of station and mode used for the Shift Report.

• The Station level result variables "Total", "Total OK", and "Total NOK"

• The Bolt level result variables "Total", "Total OK", "Total NOK", "Total Type", "Total Type OK", and "Total Type NOK"

Check $XWRPDWLFSULQWRXWDWVKLIWHQG to automatically have the shift report printed when the shift ends.

8VHU0DQXDO3RZHU0$&6 63&DQG6WDWLVWLFV x 



3HULSKHUDO'HYLFHV2YHUYLHZ

Peripheral devices are used to get information in and out of a PowerMACS system. The devices can be both of simple type, like printers, and of more complex type like a fieldbus, a serial communication protocol and the PowerMACS API interface.

CC Printer

PC

CC, Console Computer

Application

Fieldbus Master

API

Ethernet

TC, Tightening Controller

Ext. Com. Device

I/O

Printer ID Device

Digital inputs and outputs

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PowerMACS can handle the following devices:

'HYLFH 8VDJH 6LJQDO,QWHUIDFH

Printer or File on CC Printout of cycle data, events, traces, SPC, etc. Printer port on CC.

File on CC Storage of cycle data end events in file. File system on CC.

Printer on TC Printout of cycle data and events. Serial port on TC.

I/O Device Binary data to/from the PLC. Internal fieldbus port on TC.

ID Device Input for identification data and/or output of cycle data and events. Serial port on TC.

External Communication using a serial Protocol Data to/from PLC, output of cycle data, events and traces, read/write Setups. Serial port on TC.

Fieldbus Interface Data to/from PLC, output of cycle data, events and traces, read/write Setups. Fieldbus interface board.

ToolsNet Reporting cycle data and traces to Atlas Copco’s ToolsNet server. Ethernet, TCP/IP.

PLC Reporting cycle data to the PowerMACS PLC (see chapter: PLC). Internal

API, Application Programmers Interface Data to/from PLC, output of cycle data, events and traces, read/write Setups, read/write Setup items. Software package on a PC computer.

The following chapters will describe how these devices are added and used.

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$GGDGHYLFH

You can have a total of 20 devices in a in a PowerMACS system and up to 6 can be connected to each TC.

To add a device, select menu choice 6HWXS6HWXS6\VWHP . Click on the +DUGZDUH tag to get the hardware view of the system. Select a TC and press $GG . From the presented list select a device to add.

[JB92]

You will be asked to give the new device a name. This name will later be referred to when you create a Reporter, which will be used to select and format the data sent to the device.

When you have added a device you should configure it. Which parameters that is available depends on the type of device. Example for an ID device:

[JB93]

For it you must specify Type, which is one of Barcode, Escort P&F and Escort AB.

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Select a suitable port. There are several ports on a Tightening Controller that can be used for in and output of data.

3RUW 8VDJH 6LJQDO,QWHUIDFH

Serial port 1, 2 and 6 General serial communication RS-232

Serial port 3 and 5 General serial communication RS-485

Serial port 4 General serial communication RS-232 or RS-422

CAN I/O port I/O Device communication CAN with DeviceNet

For the selected port you must also specify its characteristics: Baud Rate (300-115 200), Parity (None, Even or Odd) and Data Bits (7 or 8). Number of Stop Bits is always 1.

1RWH Due to technical reasons you can only use four different baud rates on each TC.

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6WDWXVIRUDGHYLFH

During performing its task each device checks for errors or malfunction. The result is shown in the

6\VWHP0DS , the +DUGZDUH tag. Press the 0RUH button to expand the box.

[JB94]

Devices working OK are shown in green, devices with some sort of problem are shown in red. Below the configuration fields there could be shown information connected to the device. As an example, for an ID device last input or output string of characters is shown.

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,2'HYLFH

An I/O device is used to communicate with hardware modules for digital input and output signals. This can be connected to all TCs that run a station. The TC communicates with the I/O using a local fieldbus (of DeviceNet type) over its CAN channel.

Station TC

Digital input module 1 (8 chan)

Digital input module max 8 (8 chan)

Digital output module 1 (8 chan)

Digital output module max 8 (8 chan)





The maximum configuration on the local I/O bus is three nodes. Each node can have a maximum of 64 inputs and 64 outputs. This gives a total number of 192 inputs and 192 outputs per TC

Currently the following I/O types are supported:

• VIPA DeviceNet slave IM253DN

• Allen-Bradley CompactBlock I/O Modules Series B (1791D)

• Beckhoff BK5210

An I/O device can be added on each TC that has a PLC, i.e. the first TC in each station.

Add an I/O device as described in previous chapter.

[JB95]

Specify for each node how many input inputs and how many outputs you have.

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The digital inputs and outputs are accessible from the PLC. They are declared in the 'LJLWDOB,QB2XW worksheet for the station resource to which the I/O is connected.

[JB96]

In this worksheet the maximum number of inputs and outputs are already declared. The signals are mapped as follows:

Your are free to change the name of the variables, and to remove the variables you do not use, but be careful to QRW change the logical address or type of any variable.

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When the WinTC is on-line you can have a look at the current status of all digital inputs and output connected to a particular TC. To do this select the I/O device in question on the Hardware tab in either the System Map o the System Set Up form. Press More>> to expand the area of the form and press the

$GYDQFHG« button. This will display the following form:



All I/O points that are active are indicated with a yellow dot.

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3ULQWHURQ7&

A Printer device connected to a TC can be used to print cycle data and events via a serial port.

Most printers will work as long as they are made for printout of normal ASCII characters. There is no handshake protocol or modem signaling needed.

Add a Printer device as described in previous chapter. Set up which port to use and the port characteristics.

Now you have added a printer device. To get data on it you must also create a 3ULQWHU Reporter. How to do this, and connect it to your Printer device, is described in the New reporter chapter. How to make the Reporter format the result as you wish is described in chapter: Edit reporter

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3ULQWHURU)LOHRQ&&

A Printer device connected to a CC can be used to print cycle data and events, but also for printout of graphical traces and SPC charts. Connect the printer to the CC’s printer port. Install it using Windows NT’s normal installation procedures for printers.

To get data to the printer it you must create a :LQ7&3ULQWHU Reporter. How to do this is described in the New reporter chapter. How to make the Reporter format the result as you wish is described in chapter: Edit reporter

1RWH The WinTC program must be running if order to be able to print on a printer connected to the CC.

8VHU0DQXDO3RZHU0$&6 3HULSKHUDO'HYLFHV x 



3/&

Using the PLC device it is possible to read cycle data from inside the PowerMACS PLC (see chapter: PLC).

To enable this function you must first add a PLC device, as described in chapter: Add a device, to TC that runs the PLC, i.e. the first TC in a station. Note that the PLC device is only a logical device, it requires no additional hardware to be connected to the system.

[JB97]

Secondly you must create New reporter and connect it to the PLC device.

Use the reporter to select what result variables to include in the cycle data, see Edit reporter for how to do that.

Finally you must declare variables within the PLC that corresponds to the layout of the Reporter.

Configuring a reporter with +HDGHUWH[WIUHTXHQF\ set to blank, $GGLWLRQDOQHZOLQHV to 0, %\WHRUGHU to Normal, )ORDWIRUPDW to IEEE754, and the following result variables:

6WDWLRQYDULDEOHV

9DULDEOH 2UGHU :LGWK 'HF 7\SH 7H[W /LQHV

Data No 1 I2

Station No 2 I2

Time 3 I4

Mode No 4 I2

%ROWYDULDEOHV :

9DULDEOH 2UGHU :LGWK 'HF 7\SH 7H[W /LQHV

Bolt No 1 I2

Status 2 I2

Bolt T 3 F

Bolt A 4 F

8VHU0DQXDO3RZHU0$&6 3HULSKHUDO'HYLFHV x 



The above setup corresponds to the declaration of the following PLC variables (for a station containing one bolt) on the &\FOH'DWDB9DU worksheet for the Station resource:

Then you must also enable and configure the drivers used for accessing the PLC data. This is done using the ,2B&RQILJXUDWLRQ worksheet for station in question.

By default the CYCLE_in driver is commented out so you must first remove the start-of-comment, "(*", and end-of-comment, "*)", marks surrounding the driver declarations.

The addresses, VAR_ADR and END_VAR_ADR, above are logical, meaning that a PLC variable later mapped to the logical address 4000 will correspond to the first byte of the cycle data. Use END_VAR_ADR to set the size of the area equal to the size of your cycle data.

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,''HYLFH

ID Devices comes in two forms: input only and both input and output. An input device could be used to get identification of a work piece. The read data could include information on how the tightening should be performed. The identification could also be used to identify output data.

An ID device, which can be written, can be used to store crucial data (status, final torque etc.) along with the work piece. This can then later be read in e.g. a repair station.

Currently the following ID device types are supported:

• Barcode scanner, any brand that uses a serial input.

• Escort memory of type Pepperl+Fuchs, MVI-D2-2HRX

• Escort memory of type Allen Bradley, Intelligent Antenna 2750-ASP* together with code tag 2750- TAU40

A Barcode scanner is an input only device. It can be used to read bar codes attached to a work piece. An Escort Memory is an ID device that can be used both for input and output.

Add an ID device as described in the Add a device chapter. Set up which 7\SH it is ( %DUFRGH , (VFRUW

3) , or (VFRUW$% ), port to use and port characteristics.

Press the $GYDQFHG« button to open the ID device Set Up form where you can specify decoding of the read ID string and which addresses to read and write from/to in case you use an escort memory.

Reading of input data is controlled from the PowerMACS PLC. This is described in chapter: ID Device variables.

For the Station to know which ID device to use the properties for the station in the System Set Up form to specify which ID device to use. It is also possible for several stations to read from the same ID device.

If you want to use your escort memory for output of data, add an ,'GHYLFH5HSRUWHU and specify that it should be using your ID device (see chapter: New reporter). Configure the Reporter to format the output data (see chapter: Edit reporter).

Remember to specify if data should be written as readable characters or in binary format. The writing of the escort memory is done as soon as the cycle is ready. The cells written are those specified in the ID device Set Up form.

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7RROV1HW

Using a ToolsNet device you may report cycle data and/or traces to an Atlas Copco ToolsNet server over the Ethernet.

To enable this function you must first add a ToolsNet device, as described in chapter: Add a device.

[JB98]

Select the created device and adjust its parameters if necessary.

Use 1DPH to specify the name of the device. This name should be referred to when you create a reporter for the new ToolsNet device using the New reporter form.

6HUYHU,3DGGUHVV should be set to IP-address of the computer on which the ToolsNet server is installed.

The parameter 6WDWXV77/ defines the Time-To-Live time for the status telegrams that are sent as multicasts. Routers and similar network devices use this value in order to filter out "old" data grams. Increase the value of this parameter if you experience that the status telegrams often are lost.

The remaining parameters depend on the ToolsNet configuration and should only be changed after consultation with your network manager.

The ToolsNet device does not require any additional hardware to be connected to the TC since it uses the TCs standard Ethernet connector. However, you must make sure that the network between your

8VHU0DQXDO3RZHU0$&6 3HULSKHUDO'HYLFHV x 



PowerMACS system and the ToolsNet server is correctly configured. See PowerMACS Ethernet Manual [3] for how to do this.

Create a new Reporter for the ToolsNet device and use it to set up what data to report to ToolsNet. The ToolsNet reporter is somewhat different from reporters used for other devices since you can only select what variables to include, not format them.

8VHU0DQXDO3RZHU0$&6 3HULSKHUDO'HYLFHV x 



)LHOGEXV,QWHUIDFH

On a tightening controller it is possible to have a fieldbus slave interface board mounted. This makes it possible to interact with your PowerMACS system from a fieldbus master. A fieldbus device handles access via fieldbus.

Currently the following fieldbuses are supported:

• InterBus-S

• ControlNet

• Profibus-DP

• CANopen

• DeviceNet

• Modbus Plus

Using a fieldbus device you can access the following PowerMACS functions:

• Read and write PLC signals

• Read cycle data

• Read events

• Read traces

• Read and write complete setups

From PowerMACS point of view most fieldbus types looks the same.

To access the PowerMACS system via a fieldbus you first have to add a fieldbus device, as described in chapter: Add a device, to TC that has a PLC, i.e. the first TC in a station.

A PowerMACS PLC can only access a fieldbus interface that is mounted on the same TC as the PLC is running on.

8VHU0DQXDO3RZHU0$&6 3HULSKHUDO'HYLFHV x 



Regardless of which type of fieldbus interface you use the following model describes how it is interfaced with the PowerMACS system.

Fieldbus Master

Write Read

Fieldbus device

PLC Process area data

PLC Process area data

OUT IN

3000 ...

3300 ...

PLC

Process Data

Reporter

Queues

Cycle

Events Traces Setup Tightening Controller

data

On the fieldbus interface there is a memory area that is accessible from the fieldbus master as well as the PowerMACS.

This area is split up in an IN and OUT area. Each of these areas is in turn split up in one part used by the PowerMACS PLC and one part used for transferring Process Data, that is cycle data, events, traces and setups.

The maximum available size of the IN and OUT areas varies with the type of fieldbus as listed in the comparison table below:

)LHOGEXV7\SH 0D[VL]HRIWKHUHVSHFWLYHLQSXWDQGRXWSXWDUHD>%\WHV@

,QWHU%XV 20 (2048 if PCP is used)

0RGEXV3OXV 64 (2048 if point-to-point transactions are used)

Because the size of the areas is limited you must specify the size of each area individually using the parameters 3/&E\WHV,Q , 3/&E\WHV2XW , 'DWDE\WHV,Q , and 'DWDE\WHV2XW of the fieldbus device.

8VHU0DQXDO3RZHU0$&6 3HULSKHUDO'HYLFHV x 



[JB99]

The below picture shows how the input and output areas are divided using the parameters:

,QSXWDUHD 

2XWSXWDUHD 

Inputs to the PowerMACS PLC

Outputs from the PowerMACS PLC

Size = PLC bytes In

Size = PLC bytes Out

: : :

: : :

Filedbus side

Filedbus side

8 : :

: : :

Used as Process

Data input, e.g. to request next cycle data. Size = Data bytes In

Used as Process Data output, e.g. the requested cycle data. Size = Data bytes Out

: : :

: : :

: : :

1RWH You should not configure the respective input and output areas bigger then what really needed. The reason for this is that all bytes you set up here will be transferred over the fieldbus, regardless if they are used by the application or not.

If you want to transfer Process data over the fieldbus then you must create a )LHOGEXV -Reporter. How to do this, and connect it to your fieldbus device, is described in the New reporter chapter. How to make the Reporter format the result as you wish is described in chapter: Edit reporter.

8VHU0DQXDO3RZHU0$&6 3HULSKHUDO'HYLFHV x 



$FFHVVWR3/&GDWD

There is no fix mapping of the tightening process control signals like START, MACHINESTOP, etc., to specific address in the PLC input and output areas. Instead the mapping is configured using the PowerMACS PLC by defining variables and connecting them using e.g. function block logic. This way the PLC programmer can set up exactly which signals to transfer over the fieldbus.

Access to the fieldbus PLC data area from the PowerMACS PLC is configured in two steps. First you must activate and configure the ANYBUS driver (ANYBUS is a generic fieldbus interface) to correctly map the size of the PLC input and output data areas. Secondly you must configure how the areas should be used.

The first step is done using the ,2B&RQILJXUDWLRQ worksheet for the Station resource that has the fieldbus interface mounted.

[JB100]

The first step is done using the ,2B&RQILJXUDWLRQ worksheet for the Station resource that has the fieldbus interface mounted.

By default the ANYBUS_in and ANYBUS_out drivers are commented out so you must first remove the start-of-comment, "(*", and end-of-comment, "*)", marks surrounding the driver declarations to enable it.

The addresses, VAR_ADR and END_VAR_ADR, above are logical, meaning that a PLC variable later mapped to the logical address 3000 will correspond to address 0 (i.e. the first byte) in the fieldbus PLC input area while the logical address 3300 correspond to address 0 of the fieldbus PLC output area. Use END_VAR_ADR to set the size of the areas to the sizes you defined for the fieldbus device.

1RWH All numerical values are written and read as Big Endian values (commonly referred to as Motorola format.

When the drivers are correctly configured you must set up how the input and output areas should be used. Declaring resource global variables that refer, or "point", to specific parts of the areas, does this. You do this in the )LHOGEXVB9DU worksheet for the Station resource.

8VHU0DQXDO3RZHU0$&6 3HULSKHUDO'HYLFHV x 



[JB101]

When the variables are declared you are free to refer them from any POU (Program Organization Unit) you have, or will, declare in the project.

$FFHVVWR3URFHVVGDWD

Accesses to the Process data, i.e. Cycle data, events, trace and setup, by the fieldbus master are done by read and write accesses to the Process data areas.

Because Process data normally is bigger than would fit into the areas available they are read by use of a special handshake sequence. This is described in chapter: Process data.

Also, since the same area (address) is used for accesses to all kinds of process data the input and output areas are prefixed with a command and a status word respectively. These are used to specify what to do, and with what kind of data. The Process data areas are therefore used as follows:

3URFHVVGDWD

3URFHVVGDWD

Byte

,1DUHD  Byte

287DUHD

0 CMD (Most Significant Byte) 0 STS (Most Significant Byte)

1 CMD (Least Significant Byte) 1 STS (Least Significant Byte)

3 Data : Data

: TO FROM

PowerMACS PowerMACS

: :

Data bytes In – 1 Data bytes Out – 1

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The first word in the IN area is used as Command (CMD). The fieldbus master writes commands in this to request PowerMACS perform a task.

The first word in the OUT area is used as Status (STS) in which PowerMACS writes information to indicate the result of the command issued.

The CMD word is laid out as follows:

%LW 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

1DPH R W F S X d2 d1 d0 - - - - - - - -

The respective bits have the following meaning:

1DPH 0HDQLQJ 8VDJH

R Read Set one (1) to read the process data selected with DataType.

W Write Set one (1) to write the process data selected with DataType.

F Flush Set one (1) to flush the data queue selected with DataType. Flushing will delete all items in the specified process data queue. However, a data item currently being read will not be deleted. It can safely be read also after that this command has been issued.

S Skip Set one (1) to skip reading of the current data item in the data queue selected with DataType. Next reading will return next data item (or the first part of it) in the queue.

X Extended format This bit is normally 0.

If this bit is set then which process data queue to read is QRW specified using the d2..d0. Instead the queue is specified using an address following the CMD byte. See Using the extended format for a detailed description. This can be used for to access more data to the PLC then the particular fieldbus allows.

d2..d0 DataType Specifies which process data queue the command is issued for. DataType = 4 d2 + 2 d1 + 1 d0 d. Allowed values of DataType are:

• 1: Cycle data queue

• 2: Event queue

• 3: Trace queue

• 4: Setup

The STS word is used as follows:

%LW 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

1DPH R W F S X d2 d1 d0 s7 s6 s5 s4 s3 s2 s1 s0

Bit 15 to 8 just mirrors the corresponding bits in the CMD word.

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The bits named s7 to s0 represents the status code that PowerMACS returns after executing the command. They should be interpreted as a signed 8 bit value where a value greater or equal to zero indicates a positive result, and negative values a failure. Currently the following status codes are defined:

6WDWXVFRGH 'HVFULSWLRQ

0 Success

-1 Illegal process data specified

-2 Illegal size of the process data area

-3 Device is not properly connected

-4 Error in sequence number

-5 Received setup is to big

-15 Unknown error

-16 Size of Data bytes In to small for the requested service

-17 Size of Data bytes Out to small for the requested service

-18 The specified Process Data type cannot be flushed/skipped

-19 Ambiguous Command (more than one of the R, W, F & S bits are set)

-20 Invalid Extended format

-21 Invalid Address

-22 Fieldbus read error

-23 Fieldbus write error

When the Fieldbus master wants to read or write anything via the PowerMACS process data interface it has to follow the following basic rules:

1. Read the STS word to ensure that it is zero.

1. If not zero then write zero to the CMD word to acknowledge that the previous data/result has been read.

1. Wait for the STS word to become zero. This is PowerMACS way to indicate that it is ready to receive a new command.

1. Write the wanted command to the CMD word.

1. Wait for the high byte (bit 15...8) of the STS word to become equal to the written in the CMD word. This is PowerMACS way to acknowledge that the command is received and executed.

1. Check that the low byte (bit 7...0) of the STS word is zero. This indicates that the command was executed successfully. If reading, the output data is now valid.

1. When finished, with reading of data and/or the STS word, write zero to the CMD word to acknowledge that the result is read.

8VHU0DQXDO3RZHU0$&6 3HULSKHUDO'HYLFHV x 



([DPSOHRQKRZWRUHDGSURFHVVGDWD

To read Process data the fieldbus master should use the following handshake sequence:

 )LHOGEXVPDVWHU 3RZHU0$&6

1 Sets CMD = R + DataType

2 Loads data in the OUT area

Sets STS = R + DataType + Status

3 Reads data from the OUT area

([DPSOHRQKRZWRZULWHSURFHVVGDWD

To write Process data the fieldbus master should use the following handshake sequence:

 )LHOGEXVPDVWHU 3RZHU0$&6

1 Writes data in the IN area

Sets CMD = W + DataType

2 Reads data from the IN area

Sets STS = W + DataType + Status

Whenever one of these sequences is executed a new package of data is transferred to, or from, the PowerMACS system.

Since most types of Process data are too big to fit into the available area it is split up into packages. Each access will transfer a new package. The data part of the IN and the OUT areas are therefore further dived into several fields in order to handle transferring sequence of packages.

See chapter: Process data for a detailed description of this. There is also described how the respective Process data is formatted.

Normally no data is written to the Process Data out area unless the client first has requested so. However, by checking the /RDG&\FOH'DWDDXWRPDWLFDOO\ check box for the fieldbus device (see System Set Up) the PowerMACS system will automatically load the first package of a cycle data when the cycle is finished.

The data will only be written if the Process Data out area is free for PowerMACS to write to. The area is considered free as long as the fieldbus master do not already have a read or write transaction ongoing (i.e. it have issued a command but not yet written zero (0) to the CMD word to indicate that it has read the response). If a Cycle Data is generated when the output area is not free then it will be lost. It will QRW be written automatically when the area becomes free again.

An automatically written cycle data is formatted exactly the same way as if the fieldbus master had used the CMD to request it. That is, in addition to the result data, the STS, SEQ, and LEN fields are also properly assigned.

After reading automatically loaded data the fieldbus master GRQRW need to indicate that he is done reading by writing zero (0) to the CMD word.

All normal Process Data functions over the fieldbus are supported in parallel. This means that the fieldbus master may request Events, Traces as well as Cycle Data’s (from the FIFO queue) if so wanted. However, the master must be aware of that doing so may interfere with the automatic loading of Cycle Data.

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Typically the master should issue such commands only in-between cycles and after the last generated Cycle Data have been read.

1RWH It is only the first package of a cycle data that is written automatically to the board. This means that if the cycle data is bigger then the Process data output area, i.e. Data bytes Out, then the client must request the remaining packages by using normal read request. See chapter: Process data for a description detailed description of how a cycle data is divided in packages. 

1RWH When using /RDG&\FOH'DWDDXWRPDWLFDOO\ the fieldbus master must ensure that it is done reading data before starting a new cycle.

8VLQJWKHH[WHQGHGIRUPDW

The Extended format gives you an alternative method of specifying the targeted type of process data.

When using this method you specify what to read or write to using an address instead of the bits d2..d0 in the command word. The address is the same as used for the External Communication (see its sub chapter: Accesses from External communication device).

An advantage of using this method is that you in addition of accessing the traditional process data, i.e. cycle data, trace, and events, also can read and write to the PLC input/output area normally used for the External communication devices and the API.

The address is specified in the first word of the Process data, i.e. the word following next after the command word. I.e. Process data should be laid out as below:

 3URFHVV'DWD

0 Target Addr (MSB)

1 Target Addr (LSB)

3 Message

Data

: (m bytes)

The layout of Message Data depends on whether the targeted data is of type "Process Data" (i.e. Cycle Data, Event Data, Trace Data and Setup Data) or "PLC Data".

 0HVVDJH'DWD

 0HVVDJH'DWDDV

WRIURPWKH3/&

3URFHVV'DWD

0 LEN (MSB)

0 SEQ (MSB)

1 LEN (LSB)

1 SEQ (LSB)

2 LEN (MSB)

3 LEN (LSB)

LEN LEN

:

n + 1 Data byte n

:

n + 3 Data byte n

The format of Process Data is the very same as used the External communication devices, but the format of PLC Data is slightly different. For the fieldbus device the first word of the Message Data specifies the

8VHU0DQXDO3RZHU0$&6 3HULSKHUDO'HYLFHV x 



length of data to be read or written. If writing, this is then followed with as many bytes of PLC data that is specified.

See chapter: Process data for a description of how the Process Data is laid out and how SEQ and LEN is used.

([DPSOH To write the ten characters ID code "ABCDEFGHIJ" to the PLC input starting at address 2010 the following should be written to the fieldbus process data input:

0 0x48 CMD (MSB)

1 0x00 CMD (LSB)

2 0x00 Target Addr. (MSB)

3 0x0A Target Addr. (LSB)

4 0x00 LEN (MSB)

5 0x0A LEN (LSB)

6 0x41 A

7 0x42 B

8 0x43 C

9 0x44 D

10 0x45 E

11 0x46 F

12 0x47 G

13 0x48 H

14 0x49 I

15 0x4A J

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)LHOGEXVVSHFLILF,QIRUPDWLRQ

Most field buses are handled the same way by the PowerMACS system but some of them have a number of extra parameters. These are described in the following sub chapters.

3URILEXV

The System Set Up form looks as below for a Profibus fieldbus device:

Use 1DPH to specify the name of the device. This name should be referred to when you create a reporter for the fieldbus using the New reporter form.

)LHOGEXV7\SH should be set to Profibus.

You can specify the node address of the PowerMACS system either by entering it in the 1RGHDGGU field, or using the two address selector switches mounted on the AnyBus TM board. Allowed values are [1..125] if you use the 1RGHDGGU field. and [1..99] for the hardware selectors.

1RWH If you specify the address using the 1RGHDGGU field then you must ensure that the address selector is set to "00".

PowerMACS will automatically detect the baud rate set by the master if it is in the range from 9.6 kBit/s to 12 Mbit/s.

How to configure the parameters 3/&E\WHV,Q , 3/&E\WHV2XW , 'DWDE\WHV,Q , and 'DWDE\WHV2XW is described in chapter: Fieldbus Interface.

See the previous chapter: Access to Process data for a description of /RDG&\FOH'DWDDXWRPDWLFDOO\ .

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,QWHU%XV6

The System Set Up form looks as below for an InterBus-S fieldbus device:

Use 1DPH to specify the name of the device. This name should be referred to when you create a reporter for the fieldbus using the New reporter form.

)LHOGEXV7\SH should be set to InterBus.

The node address for InterBus is given by its location in the ring so there is no node address to configure.

For InterBus-S the baud rate is fixed to 500 kBit/s.

How to configure the parameters 3/&E\WHV,Q , 3/&E\WHV2XW , 'DWDE\WHV,Q , and 'DWDE\WHV2XW is described in chapter: Fieldbus Interface.

InterBus-S can transfer two types of data over the fieldbus, I/O data and parameter data. The I/O data is transferred very fast and cyclically while the parameter data are using a lower data rate using a mechanism named PCP. The maximum size of the I/O data is 20 bytes in each direction. Using parameter data makes it possible to access up to 2048 bytes totally.

To enable transferring of parameter data you must first specify how many of the 20 bytes that should be set-aside for the parameter channel. This is done by entering the number of bytes to use for PCP divided by two in the field 1RRI3&3ZRUGV . The bigger value you specify, the faster the parameters are transferred.

If PCP is QRW enabled then all data is transferred as I/O data.

If PCP is enabled then )DVWE\WHV,Q and )DVWE\WHV2XW specify how many bytes that should be transferred as I/O data in the respective direction. The areas transferred as I/O data on the bus starts at the offset zero (0). The remaining bytes are transferred as parameter data over the PCP channel. Leaving the parameters "blank" will make the PLC bytes In/Out be transferred as I/O data.

On the fieldbus master the parameter data is mapped as a number of PCP objects. All objects are of the same type and contain an array of 58 bytes (unsigned 8). This means that each PCP object represent a 58 byte "piece" of the area set up as parameter data. The objects have no password or group protection and their index will range from 0x6000 to 0x603F (max) for inputs to the PowerMACS and 0x6040 to 0x607F (max) for outputs from the PowerMACS.

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With parameters set as in the above example the input and output areas will be mapped as below:

12! 3/ "$ %/"

! #"$%!"

+!8

"!0/

% 09

Fieldbus side

+8

"!0!

%!0:1;!

: : :

: : :

Fieldbus side

7 PLC byte AT 3007 7 &#'(&*)#+-,

%/. 

: : :

0 Data byte In 1 8 0

9 PLC byte AT 3309 9 &#'4&*)+5,

1 Data byte In 2 9 0x6000 1

%6. 

2 Data byte In 3 10 30 bytes 2

0 Data byte Out 1 10 0

: Data byte In 4 11 3

1 Data byte Out 2 11 0x6040 1

: : : :

2 Data byte Out 3 12 58 bytes 2

29 Data byte In 30 37 29

: : : :

: : :

56 Data byte Out 57 66 :

57 Data byte Out 58 67 57

59 Data byte Out 60 69 0

: : : :

99 Data byte Out 100 109 :

The parameter /RDG&\FOH'DWDDXWRPDWLFDOO\ is described in the previous chapter: Access to Process data.

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'HYLFH1HW

The System Set Up form looks as below for a DeviceNet fieldbus device:

Use 1DPH to specify the name of the device. This name should be referred to when you create a reporter for the fieldbus using the New reporter form.

)LHOGEXV7\SH should be set to DeviceNet.

Both the node address of the PowerMACS system on the bus and the baud rate can be set either by entering their values in the 1RGHDGGU field and %DXG5DWH fields, or by using the DIP switch mounted on the AnyBus TM board. Node address can be set to [0..63] and baud rate to 125, 250 or 500 kBit/s.

1RWH You must either specify both the node address and the baud rate by entering their values in the respective fields of the form, or set them both using the DIP switches on the board. If you enter them on the form then you must ensure that the address DIP switch is all set on ("0xFF").

How to configure the parameters 3/&E\WHV,Q , 3/&E\WHV2XW , 'DWDE\WHV,Q , and 'DWDE\WHV2XW is described in chapter: Fieldbus Interface.

See the previous chapter: Access to Process data for a description of /RDG&\FOH'DWDDXWRPDWLFDOO\ .

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0RGEXV3OXV

The Modbus Plus device supports Point-to-Point message and Global Data transactions with the following limitations:

• Point-to-Point message transactions: The PowerMACS node does only support Slave Data Paths which means that it only responds to read or write requests issued by other nodes. It will never initiate a point-to-point communication to any other node on the network.

• Global Data transactions: The PowerMACS node will only receive Global Data sent by RQH node on the network. However, which node that Global Data is read from, and what part of it to read (offset and size within the broadcasted message), is configurable.

The System Set Up form looks as below for a Modbus Plus fieldbus device:

Use 1DPH to specify the name of the device. This name should be referred to when you create a reporter for the fieldbus using the New reporter form.

)LHOGEXV7\SH should be set to Modbus.

For Modbus Plus the baud rate is fixed to 1 MBit/s.

You can specify the node address of the PowerMACS system either by entering it in the 1RGHDGGU field, or using DIP switch S1 mounted on the AnyBus TM board. Allowed values are [1..63].

How to configure the parameters 3/&E\WHV,Q , 3/&E\WHV2XW , 'DWDE\WHV,Q , and 'DWDE\WHV2XW is described in chapter: Fieldbus Interface.

In order to be able to configure how much of the input/output data that is transferred as Global Data on the network the following parameters are added:

The parameter )DVWE\WHV,Q defines the size (in bytes) of the input data read as Global Data from the Modbus Plus network to the powerMACS system. Max value is 64 (i.e. 32 words).

)DVWE\WHV2XW defines the size (in bytes) of the output data written by PowerMACS as Global Data to the network. Max value is 64 (i.e. 32 words).

The "fast" areas always start at offset zero (0) of the respective input or output area. The remaining part of the respective areas is only accessible from other nodes via point-to-point message transactions.

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Modbus reg. no Modbus reg. no

=>?!@#AB C/A

D2?/@E>?!@#AB C/A

Registers extracted from the Global Data sent by node

0 PLC word AT 3000 0 41025

0 PLC word AT 3300 0 40001

Registers sent as Global Data

1 PLC word AT 3002 1 41026

1 PLC word AT 3302 1 40002

2 PLC word AT 3004 2 41027

2 PLC word AT 3304 2 40003

broadcasts

3 PLC word AT 3006 3 41028

3 PLC word AT 3306 3 40004

4 PLC word AT 3308 4 40005

0 Data word In 1 4 41029

Registers that can be set using point-to-point

1 Data word In 2 5 41030

0 Data word Out 1 5 40006

2 Data word In 3 6 41031

1 Data word Out 2 6 40007

: : : :

2 Data word Out 3 7 40008

transaction from other nodes

Registers that can be read using point-to-point

: : : :

: : : :

14 Data word In 15 18 41043

: : : :

: : : :

transaction from other nodes

: : : :

: : : :

: : : :

: : : :

49 Data word Out 50 54 40055

Use 6RXUFH1RGHDGGU to configure which node to extract Global Data from.

6RXUFH2IIVHWZRUGV defines the offset within the Source Node’s Global Data to start reading from (will be mapped to offset zero (0) of the input area).

6RXUFHQRRIZRUGV defines the number of words to read from the Source Node’s Global Data, starting at the offset given by 6RXUFH2IIVHWZRUGV .

See the previous chapter: Access to Process data for a description of /RDG&\FOH'DWDDXWRPDWLFDOO\ .

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([WHUQDO&RPPXQLFDWLRQ

The external communication devices supports the following serial communication protocols:

• Siemens 3964R

• Telemechanique UNI-TE

• SATT Comli

• Allen-Bradley Data Highway (Plus)

• JBUS

Via an external communication device you can access the following PowerMACS functions:

• Read and write PLC signals

• Read cycle data

• Read events

• Read traces

• Read and write complete setups

External Communication Device

Write Read

Ext. comm. device

(1000-4000) (1000-4000)

OUT IN

PLC

Process Data

Reporter

Queues

Cycle

Events Traces Setup Tightening Controller

data

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To enable access to PowerMACS via a serial protocol add an external communication device as described in previous chapter. Add it to a TC that has a PLC, i.e. the first TC in a station. Set up which

7\SH of protocol to use, which port to use and port characteristics.

If you want to transfer Process data over the external communication device then you must first create a – Reporter for it. How this is done is described in the chapter: New reporter and Edit reporter.

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To access data in PowerMACS external devices should perform normal read and write operations. Depending on address different data is available:

$GGUHVV 'DWD /HQJWK 5HDG:ULWH

0..999 PLC-variables Length of variable R/W

1000 Cycle data 2..Max R/W

2000 Events 2..Max R/W

3000 Traces 2..Max R/W

4000 Setup 2..Max R/W

Max depends on which serial protocol that is used.

A read or write to an address between 0 and 999 will access a memory that the PLC on that TC can access, thereby providing a way to communicate with the PLC. See the following chapter: Access to PLC data for this is enabled.

By accessing address 1000-4000 the external device can get access to Process data.

It might seem odd to write to the Cycle Data, Event and Trace queues but by writing a two-byte integer to one of the corresponding address you can control the queues as follows:

9DOXH $FWLRQ

-2 Skips reading of the current data item in the data queue. Next read will return next data item (or the first part of it) in the queue.

-1 Flush the data queue. All items in the specified process data queue are deleted. However, the data item currently being read will not be deleted. It can safely be read also after that this command has been issued. To remove the current data item you have to issue a skip command.

0 Rewind the data queue to the oldest value data item available in the central SRAM storage.

1..32767 Here value is interpreted as an earlier received device specific sequence number (DataNo) to which the queue should be re-winded.

When the queue is read the next time the item that corresponds to DataNo = Value + 1 will be returned, if it exists in the queue.

If it no longer exists in the queue then the item returned will have DataNo set to Value + 2 to indicate this.

For Event and Trace the DataNo is always included in the item read. For Cycle data you must include it manual using the reporter for this device (see Layout of Cycle Data and Station level result variables).

1RWH If the external communication device is added to the first TC in a system, that is TC 1, the PLC data area will be shared with corresponding area used by the API, Application Programmers Interface. If you use these simultaneously you must co-ordinate the use of the cells to avoid unwanted collisions.

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$FFHVVWR3/&GDWD

The external device accesses the PLC data by simple read and write accesses to address 0..999. How this area is mapped is configured using the PowerMACS PLC by defining variables and connecting them using e.g. function block logic. This way the PLC programmer can set up exactly which signals to transfer via the serial protocol.

Access to the PLC data area from the PowerMACS PLC is configured in two steps. First you must activate and configure the EXTCOM driver to correctly map the size of the PLC input and output data areas. Secondly you must configure how the areas should be used.

The first step is done using the ,2B&RQILJXUDWLRQ worksheet for the Station resource that has the communication interface mounted.

[JB102]

By default the EXTCOM_in and EXTCOM_out drivers are commented out so you must first remove the start-of-comment, "(*", and end-of-comment, "*)", marks surrounding the driver declarations to enable it.

The addresses, VAR_ADR and END_VAR_ADR, above are logical, meaning that a PLC variable later mapped to the logical address 2000 will correspond to address 0 (i.e. the first byte) in the external communication PLC input area while the logical address 2500 correspond to address 0 of the PLC output area. Use END_VAR_ADR to configure the used size of the areas. For best performance you should not define a bigger area than you will use.

1RWH All numerical values are written and read as Big Endian values (commonly referred to as Motorola format).

When the drivers are correctly configured you must set up how the input and output areas should be used. Declaring resource global variables that refer, or "point", to specific parts of the areas, does this. You do this is in the ([W&RPB$3,B9DU worksheet for the resource.

8VHU0DQXDO3RZHU0$&6 3HULSKHUDO'HYLFHV x 



[JB103]

When the variables are declared you are free to refer them from any POU (Program Organisation Unit) you have, or will, declare in the project.

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The external device accesses the Process Data areas by normal read and writes accesses.

Since Process Data quite often is bigger than what can be transferred using a single read or write operation all process data handling are done by splitting up each process data item into smaller parts called packages. Each access will transfer a new package. The external device must then put the packages together to recreate the original data. How to do this is described in the chapter: Process data.

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([WHUQDO&RPPXQLFDWLRQ3URWRFRO,QIRUPDWLRQ

External communication devices use serial protocols to communicate with PowerMACS. Chapters below do not describe the protocols in full detail but gives a brief description of major characteristics and how they are used with PowerMACS.

The communication is for all protocols based on simple read and write operations. Examples of character flow is included for two types of communication:

• Read five integers at address 500..509, i.e. PLC outputs area, address 2500..2509

• Write five integers at address 0..9, i.e. PLC input area, address 2000..2009

External device is indicated with XD, PowerMACS with PM. Data that are irrelevant for PowerMACS are indicated with ‘*’.

-%86

Two types of commands are used:

• Word read (function 3) to read data from PowerMACS

• Multiple word write (function 16) to write data in PowerMACS

Checksum is calculated as CRC-16 for all bytes from the first byte (slave no) up until the checksum.

PowerMACS will respond to all telegrams independent of Slave no from XD.

5HDGLQJLQWHJHUVDWDGGUHVV  :ULWLQJLQWHJHUVDWDGGUHVV

;' 30 &RPPHQW  ;' 30 &RPPHQW

0x00 * Slave no 0x00 * Slave no

0x03 Read command 0x10 Write command

0x01 Address, MSB 0x00 Address, MSB

0xF4 Address, LSB 0x00 Address, LSB

0x00 Size in words, MSB 0x00 Size in words, MSB

0x05 Size in words, LSB 0x05 Size in words, LSB

0xC4 Checksum, LSB 0x0A Size in bytes

0x16 Checksum, MSB xx Data

: 5 x (MSB-LSB)

0x00 Slave no xx Checksum, LSB

0x03 Read command xx Checksum, MSB

0x0A Number of bytes

xx Data 0x00 Slave no

: 5 x (MSB-LSB) 0x10 Write command

xx Checksum, LSB 0x00 Address, MSB

xx Checksum, MSB 0x00 Address, LSB

0x00 Size in words, MSB

0x05 Size in words, LSB

0x01 Checksum, LSB

0xDB Checksum, MSB

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6LHPHQV5

Two types of commands are used:

• A-telegram for writing data to PowerMACS

• E-telegram for reading data from PowerMACS

Checksum is calculated as XOR for all bytes from the first byte after STX up until and including ETX.

5HDGLQJLQWHJHUVDWDGGUHVV  :ULWLQJLQWHJHUVDWDGGUHVV

;' 30 &RPPHQW  ;' 30 &RPPHQW

0x02 STX 0x02 STX

0x10 DLE 0x10 DLE

0x00 * 0x00 *

0x00 * 0x00 *

0x45 ‘E’ 0x41 ‘A’

0x44 ‘D’ 0x44 ‘D’

0x01 Address, MSB 0x00 Address, MSB

0xF4 Address, LSB 0x00 Address, LSB

0x00 Size in words, MSB 0x00 Size in words, MSB

0x05 Size in words, LSB 0x05 Size in words, LSB

0x00 * 0x00 *

0x00 * 0x00 *

0x10 DLE xx Data,

0x03 ETX  5 x (MSB+LSB)

0xE2 Checksum 0x10 DLE

0x10 DLE 0x03 ETX

xx Checksum

0x02 STX 0x10 DLE

0x10 DLE

0x00 0x02 STX

0x00 0x10 DLE

0x00 0x00

0x00 Error number 0x00

xx Data 0x00

 5 x (MSB-LSB) 0x00 Error number

0x10 DLE 0x10 DLE

0x03 ETX 0x03 ETX

xx Checksum 0x13 Checksum

0x10 DLE 0x10 DLE

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7HOHPHFKDQLTXH81,7(

Two types of commands are used:

• Read object (command 36) reading data from PowerMACS

• Write objects (command 37) for writing data to PowerMACS

Checksum is calculated as the modulo-256 sum of all bytes from and including DLE-STX up until and including the last character before the checksum.

If PowerMACS is configured with slave number = 1..255 it will respond only if Slave no from XD is the correct one. If slave number = 0 PowerMACS will respond to any Slave no from XD.

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5HDGLQJLQWHJHUVDWDGGUHVV  :ULWLQJLQWHJHUVDWDGGUHVV

;' 30 &RPPHQW  ;' 30 &RPPHQW

0x02 STX 0x02 STX

0x00 Slave no 0x00 Slave no

0x0E Length of rest of data 0x18 Length of rest of data

0x14 * Type of addressing 0x14 * Type of addressing

0x01 * Network 0x01 * Network

0x02 * Station 0x02 * Station

0x03 * Gate 0x03 * Gate

0x04 * Module 0x04 * Module

0x05 * Channel 0x05 * Channel

0x36 Read command 0x37 Write command

0x00 * Category 0x00 * Category

0x00 * Segment 0x00 * Segment

0x07 * Spec byte 0x07 * Spec byte

0xF4 Address LSB 0x00 Address LSB

0x01 Address MSB 0x00 Address MSB

0x0A Length LSB 0x0A Length LSB

0x00 Length MSB 0x00 Length MSB

0x7F Checksum xx Data,

0x06 ACK : 5 x (MSB+LSB)

xx Checksum

0x10 DLE 0x06 ACK

0x05 ENQ

0x00 Slave no 0x10 DLE

0x10 DLE 0x05 ENQ

0x02 STX 0x00 Slave no

0x00 Slave no 0x10 DLE

0x0A Length 0x02 STX

0x14 Type of address 0x00 Slave no

0x01 * Network 0x07 Length

0x02 * Station 0x14 Type of address

0x03 * Gate 0x01 * Network

0x04 * Module 0x02 * Station

0x05 * Channel 0x03 * Gate

0x66 Confirm 0x04 * Module

0x07 * (Spec byte) 0x05 * Channel

xx Data, 0xFE Confirm

: 5 x (MSB+LSB) 0x3A Checksum

xx Checksum 0x06 ACK

0x06 ACK

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6$77&RPOL

Checksum is calculated as XOR for all bytes from the first byte after STX up until and including ETX.

Data bytes have reverse bit order, i.e. bit7 = bit0, bit6 = bit1 etc. PowerMACS will respond to all telegrams independent of Destination from XD.

5HDGLQJLQWHJHUVDWDGGUHVV  :ULWLQJLQWHJHUVDWDGGUHVV

;' 30 &RPPHQW  ;' 30 &RPPHQW

0x02 STX 0x02 STX

0x30 * Destination, MSB, ‘0’ 0x30 * Destination, MSB, ‘0’

0x31 * Destination, MSB, ‘1’ 0x31 * Destination, MSB, ‘1’

0x31 Stamp, ‘1’ 0x31 Stamp, ‘1’

0x32 Read command, ‘2’ 0x30 Write command, ‘0’

0x30 Address, digit 1, ‘0’ 0x30 Address, digit 1, ‘0’

0x31 Address, digit 2, ‘1’ 0x30 Address, digit 2, ‘0’

0x46 Address, digit 3, ‘F’ 0x30 Address, digit 3, ‘0’

0x34 Address, digit 4, ‘4’ 0x30 Address, digit 4, ‘0’

0x30 Size, digit 1, ‘0’ 0x30 Size, digit 1, ‘0’

0x41 Size, digit 2, ‘A’ 0x41 Size, digit 2, ‘A’

0x03 ETX xx Data,

0x03 Checksum : 5 x (MSB+LSB)

0x03 ETX

0x02 STX xx Checksum

0x30 Destination, MSB, ‘0’

0x30 Destination, MSB, ‘0’ 0x02 STX

0x31 Stamp, ‘1’ 0x30 Destination, MSB, ‘0’

0x30 ‘Write’ command 0x30 Destination, MSB, ‘0’

0x30 Address, digit 1, ‘0’ 0x31 Stamp, ‘1’

0x31 Address, digit 2, ‘1’ 0x31 Write confirm, ‘1’

0x46 Address, digit 3, ‘F’ 0x06 ACK

0x34 Address, digit 4, ‘4’ 0x03 ETX

0x30 Size, digit 1, ‘0’ 0x06 Checksum

0x41 Size, digit 2, ‘A’

xx Data,

: 5 x (MSB+LSB)

0x03 ETX

xx Checksum

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$OOHQ%UDGOH\'DWD+LJKZD\3OXV

Two types of commands are used:

• Unprotected read for reading data from PowerMACS

• Unprotected write for writing data to PowerMACS

Checksum is calculated as the 2’s complement of the modulo-256 sum of all bytes from the first byte after DLE-STX up until but not including DLE-ETX. PowerMACS will respond to all telegrams independent of destination DST from XD.

5HDGLQJLQWHJHUVDWDGGUHVV  :ULWLQJLQWHJHUVDWDGGUHVV

;' 30 &RPPHQW  ;' 30 &RPPHQW

0x10 DLE 0x10 DLE

0x02 STX 0x02 STX

0x02 * DST 0x02 * DST

0x01 * SRC 0x01 * SRC

0x01 CMD 0x08 CMD

0x00 * STS 0x00 * STS

0x05 * TNS, LSB 0x05 * TNS, LSB

0x00 * TNS, MSB 0x00 * TNS, MSB

0xF4 Address, LSB 0x00 Address, LSB

0x01 Address, MSB 0x00 Address, MSB

0x0A Size in bytes 0x0A Size in bytes

0x10 DLE xx Data,

0x03 ETX : 5 x (LSB+MSB)

0xF8 Checksum 0x10 DLE

0x10 DLE 0x03 ETX

0x06 ACK xx Checksum

0x10 DLE

0x10 DLE 0x06 ACK

0x02 STX

0x01 DST 0x10 DLE

0x02 SRC 0x02 STX

0x41 CMD 0x01 DST

0x00 STS 0x02 SRC

0x05 TNS, LSB 0x48 CMD

0x00 TNS, MSB 0x00 STS

xx Data, 0x05 TNS, LSB

: 5 x (LSB+MSB) 0x00 TNS, MSB

0x10 DLE 0x10 DLE

0x03 ETX 0x03 ETX

xx Checksum 0xB0 Checksum

0x10 DLE 0x10 DLE

0x06 ACK 0x06 ACK

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$3,$SSOLFDWLRQ3URJUDPPHUV,QWHUIDFH

The $3,$SSOLFDWLRQ3URJUDPPHUV,QWHUIDFH is an interface to the PowerMACS TC system that makes it possible to access data in the PowerMACS TC from, externally written, custom applications.

The PowerMACS API is a software library that serves as the interface between the custom application and the PowerMACS TC. This means that it exports a number of functions that the custom application can call in order to access the PowerMACS target system without needing to know the details on how they are performed. Today the PowerMACS API exports functions for performing the following tasks:

• Read and write PLC signals from/to the PowerMACS station PLC

• Read cycle data from the PowerMACS system

• Read events PowerMACS system

• Read traces PowerMACS system

• Read and write complete setups from/to PowerMACS system

• Read or write individual parameters in a setup stored in a PowerMACS system

Any PC

Custom Application

File System This is an application written by you using e.g. Visual Basic, Visual C++, Excel (VB macros), or any other environment supporting ActiveX.

powerMACS API GetCycleData

Oracle Database

GetEvent

Excel

GetTrace

MS Access

TCP/IP Stack

Ethernet

TC1 (System Node)

TC2 TCn



The PowerMACS API handles all communication needed between the PC, on which the custom application resides, and the PowerMACS TC targets involved. The developer of the custom application needs only to know which function(s) to call, and in some cases how the returned data is formatted.

When the custom application invokes one of the API functions the API first translates the request to commands understood by the target TC. These are then sent to the target TC via the TCP/IP connection. Thereafter the API waits for the answer to be returned. When the answer is received it is interpreted and in some cases translated to a more easily understood format before the API returns the answer to the custom application.

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Custom applications using the API can be run on any PC that is connected to a PowerMACS TC via TCP/IP. It need not be the Console Computer, that is the PC running WinTC. However, only one custom application may use the API of a specific TC system at the time. The only information needed in order to establish a connection between the API and the specific target system is the IP-address of the first TC in the system.

Technically the PowerMACS API is implemented as a Microsoft ActiveX component. The main advantage with having the API implemented as an ActiveX component is that it provides a standardized way of describing its public interface. This makes it possible for a developer to use more or less any of the existing development environments that runs on a Windows NT machine when creating applications.

Before using the PowerMACS API you must install the component on the PC you are going to use it from. Executing the PowerMACS API install kit distributed on the same CD as the PowerMACS WinTC install kit does this.

The install kit will copy the component to the computer in question and make all necessary registrations. It also installs two small custom application examples, one written in Visual Basic and one written as a VBA macro in Excel, which shows you how to use the API. Given that you have access to a running PowerMACS TC you can also use it to verify that the component was correctly installed.

After installing the PowerMACS API you can start to develop applications performing tasks not covered by the standard PowerMACS system. Typical cases are:

• Storing cycle data on disk, or in a data base, in any customer specific format

• Sending cycle data to an external SPC program

• Sending or receiving data via any serial protocol

• Backing up setups on a central server

• Etc.

To access a PowerMACS system via the API the target system in question must be set up to allow access via the API. Adding an API device to the first TC in the system enables this access. See chapter: Add a device for how to do this.

Before being able to access signals in one of the PowerMACS station PLCs via the API you must enable the input and output areas in the PLC. How this is done is described in the chapter: Access to PLC data.

1RWH The PLC input and output data areas are shared with the areas used by the external communication devices. This means that if an external communication devices is located on TC 1 then the PLC data areas that this device accesses is the same as the area accessed via the API interface. If you use these simultaneously you must co-ordinate the use of the cells to avoid unwanted collisions.

If you want to fetch Process data, that is cycle data, events, traces, etc., then you must also add a Reporter that refers to the API device. Use the Reporter to configure if you want cycle data, events and/or traces to be accessible from the API. Also, define how cycle data should be formatted, if data is sent in readable format, i.e. as characters, or in binary format. It is important to understand that it is the configuration of this reporter that controls the layout and format of the cycle data returned by the API methods GetCycleData and GetCycleDataBin.

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Consol Computer

External

SPC Package

Remote Client

Application Storing

data

IF

QSRUT

QSRUT

Write Read

Ethernet

API device (server)

(1000-4000) (1000-4000)

OUT IN

PLC

Process Data

Reporter

Queues

Cycle

Events Traces Setup Tightening Controller

data

.

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2EMHFWPRGHO

The below picture describes how the objects of the PowerMACS API are related to each other:

Api

System

Stations Station

Bolts Bolt

TraceData

Channels Channel

StepBounds StepBound

(QXPHUDWRUVH[SRUWHGE\WKH$3,

The PowerMACS API exports a number of enumerated types representing return values, possible control strategies and statuses.

5HW&RGH(QXP

This enumerator lists the codes being returned by the functions of the API

&RQVWDQW 'HVFULSWLRQ

H5HW2N = 0 Function executed OK

H5HW1RW2N = -51 Function did not execute OK for reasons other then listed below

H5HW7LPHRXW = -52 No answer was received from the TC within 4 seconds

H5HW%XIIHU7R6PDOO = -53 The buffer supplied is not big enough for the returned data

H5HW,S$GGUHVV = -54 IP–address is invalid

H5HW&RQQHFW(UURU = -55 A TCP/IP connection cannot be established to the specified IP-address

H5HW:URQJ3OF$GGUHVV = -56 Incorrect PLC address (check parameters Address and/or Bit)

H5HW1R'DWD = -57 The data requested (Cycle data, Event, Trace or Setup) is not available.

6HYHULW\(QXP

This enumerator lists the possible Severities of an event (see View Event Log for a description of Severity).

&RQVWDQW 'HVFULSWLRQ

H6HY,QIR = 0 The event is classified as information only.

H6HY(UURU = 2 The event is classified as an error.

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$SLREMHFW

The $SL object represents the root of the PowerMACS API and is the only object in the interface that can be created, or instantiated, by your client application.

Using the $SL object your application get a description of the PowerMACS system that the $SL currently is connected to, read and write PLC data and access Process data, such as Cycle data, Trace and Events.

For any method of the $SL object to function you must be connected to a PowerMACS target system. Which TC to connect to is controlled using the property ,S$GGUHVV . Normally you connect to the system node, i.e. the primary TC of your system. However, in order to access the PLC of another station but the first (which always executes on the primary TC) you must connect to the TC on which the station in question runs.

The following methods does only function if connected to the primary TC:

• GetSetup

• SetSetup

• GetSetupItem

• SetSetupItem

3URSHUWLHV

The following table lists all properties on the $SL object:

3URSHUW\1DPH 5HWXUQ7\SH 'HVFULSWLRQ

,S$GGUHVV 6WULQJ This is the IP-address of the target that the Api will communicate to. It should be the IP-address of the primary TC of the system or a TC on which a Station is running.

Must be set prior to any other call to an API-method.

The syntax for accessing the properties of the $SL object is as follows:

REMHFW . 3URSHUW\1DPH

where REMHFW is an expression that evaluates to an object of type $SL .

*HW3/&%RRO

'HVFULSWLRQ This method reads a Boolean value from the PLC output data area for ExtCom_API (see Access to PLC data).

5HWXUQW\SH : A 5HW&RGH(QXP value.

6\QWD[ REMHFW . *HW3/&%RRO ( $GGUHVV%LW9DOXH )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW $SL The Api object to operate on.

$GGUHVV Integer In Specifies the offset in the PLC area of the Byte to read. Range 0 – 999.

%LW Integer In Specifies which bit to read within the byte. Range 0 – 7 where 0 is the Least significant bit and 7 is the Most significant bit.

9DOXH Boolean Out Returns the result. True if the read bit is 1, False otherwise.

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6HW3/&%RRO

'HVFULSWLRQ This method writes a Boolean value to the PLC input data area for ExtCom_API (see Access to PLC data). Can e.g. be used to start a station.

5HWXUQW\SH : A 5HW&RGH(QXP value.

6\QWD[ REMHFW . 6HW3/&%RRO ( $GGUHVV%LW9DOXH )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW $SL The Api object to operate on.

$GGUHVV Integer In Specifies the offset in the PLC area of the Byte to write. Range 0 – 999.

%LW Integer In Specifies which bit to write within the byte. Range 0 – 7 where 0 is the Least significant bit and 7 is the Most significant bit.

9DOXH Boolean In If True then the bit is set to 1. If False then it is set to 0.

*HW3/&,QW

'HVFULSWLRQ This method reads an Integer value from the PLC output data area for ExtCom_API (see Access to PLC data).

5HWXUQW\SH : A 5HW&RGH(QXP value.

6\QWD[ REMHFW . *HW3/&,QW ( $GGUHVV9DOXH )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW $SL The Api object to operate on.

$GGUHVV Integer In Specifies the offset in the PLC area of the first byte of the Integer to read. Range 0 – 999.

9DOXH Integer Out The read data interpreted as an Integer. Range –32768 to 32767.

6HW3/&,QW

'HVFULSWLRQ This method writes an Integer value to the PLC input data area for ExtCom_API (see Access to PLC data).

5HWXUQW\SH : A 5HW&RGH(QXP value.

6\QWD[ REMHFW . 6HW3/&,QW ( $GGUHVV9DOXH )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW $SL The Api object to operate on.

$GGUHVV Integer In Specifies the offset in the PLC area of the first byte of the Integer to write. Range 0 – 999.

9DOXH Integer In The data to write. Range –32768 to 32767.

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*HW3/&5HDO

'HVFULSWLRQ This method reads a Real value from the PLC output data area for ExtCom_API (see Access to PLC data).

5HWXUQW\SH : A 5HW&RGH(QXP value.

6\QWD[ REMHFW . *HW3/&5HDO ( $GGUHVV9DOXH )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW $SL The Api object to operate on.

$GGUHVV Integer In Specifies the offset in the PLC area of the first byte of the Real to read. Range 0 – 999.

9DOXH Single Out The read data interpreted as a Real. Range +/- 1.18 * 10 38 .

6HW3/&5HDO

'HVFULSWLRQ This method writes a Real value to the PLC input data area for ExtCom_API (see Access to PLC data).

5HWXUQW\SH : A 5HW&RGH(QXP value.

6\QWD[ REMHFW . 6HW3/&5HDO ( $GGUHVV9DOXH )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW $SL The Api object to operate on.

$GGUHVV Integer In Specifies the offset in the PLC area of the first byte of the Real to write. Range 0 – 999.

9DOXH Single In The data to write. Range +/- 1.18 * 10 38 .

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*HW3/&6WULQJ

'HVFULSWLRQ This method reads 40 consecutive bytes from the PLC output data area for ExtCom_API (see Access to PLC data). The read data is returned as an ASCII string.

1RWH Variables declared as STRING in the PLC are prefixed by two Short integers (four bytes) where the first short specifies max possible length of the string calculated as Max length – 80. The second short defines the strings current length. That is, the first character of the string is located at offset 4 (fourth byte). All PLC strings are also terminated with a NULL (0) character. This method GRHVQRW handle the four leading bytes.

([DPSOH To read a string declared as MyString AT %QB 2600 : STRING40; you should use MyApi.GetPLCReal(2604, Value)

5HWXUQW\SH : A 5HW&RGH(QXP value.

6\QWD[ REMHFW . *HW3/&6WULQJ ( $GGUHVV9DOXH )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW $SL The Api object to operate on.

$GGUHVV Integer In Specifies the offset in the PLC area of the first byte to read. Range 0 – 999.

9DOXH String Out The read data interpreted as a string.

6HW3/&6WULQJ

'HVFULSWLRQ This method writes the specified string to the PLC input data area for ExtCom_API (see Access to PLC data) as 40 consecutive bytes. Each byte will be set to the ASCII value of the respective character. See also the note for SetPLCString.

5HWXUQW\SH : A 5HW&RGH(QXP value.

6\QWD[ REMHFW . 6HW3/&6WULQJ ( $GGUHVV9DOXH )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW $SL The Api object to operate on.

$GGUHVV Integer In Specifies the offset in the PLC area of the first byte to write to. Range 0 – 999.

9DOXH String In The data to write.



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*HW&\FOH'DWD

'HVFULSWLRQ Call this method to read the next Cycle data from the FIFO queue for the API device. The data returned is interpreted as a string. Therefore this method should be used together with a Reporter configured to format data Printable. See Layout of Cycle Data for how to set up the reporter to format the data as wanted. Note that the reporter executes on the TC and that it can only be configured using the WinTC. The FIFO queue can hold max 100 cycle data. If overflowed then the oldest data is overwritten. Once a cycle data has been read by a call to this method it cannot be read again. If the queue is empty when called then %XI is set to an empty string and

H5HW1R'DWD is returned. If %XI is to small to receive the read cycle data then Size is set to 0 and H5HW%XIIHU7R6PDOO is returned.

5HWXUQW\SH : A 5HW&RGH(QXP value.

6\QWD[ REMHFW . *HW&\FOH'DWD ( %XI6L]H )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW $SL The Api object to operate on.

%XI String Out The string to receive the read cycle data.

6L]H Long In/Out At call: Max length of %XI , At return: The length of the returned string in %XI .

*HW&\FOH'DWD%LQ

'HVFULSWLRQ Call this method to read the next Cycle data from the FIFO queue for the API device. The data returned is the raw binary data received from the TC. It is QRW interpreted in any way. Therefore this method should be used together with a Reporter configured to format data Binary. See Layout of Cycle Data for how to set up the reporter to format the data as wanted. Note that the reporter executes on the TC and that it can only be configured using the WinTC. The FIFO queue can hold max 100 cycle data. If overflowed then the oldest data is overwritten. Once a cycle data has been read by a call to this method it cannot be read again. If the queue is empty when called then %XI is set to an empty string and

H5HW1R'DWD is returned. If %XI is to small to receive the read cycle data then Size is set to 0 and H5HW%XIIHU7R6PDOO is returned.

5HWXUQW\SH : A 5HW&RGH(QXP value.

6\QWD[ REMHFW . *HW&\FOH'DWD%LQ ( %XI6L]H )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW $SL The Api object to operate on.

%XI Byte array Out The byte array to receive the read cycle data.

6L]H Long In/Out At call: Max length of %XI , At return: The length of the returned data in %XI .

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*HW(YHQW

'HVFULSWLRQ This method is replaced with the GetEventEx method and should not be used in new applications. It is here only for backward compatibility reasons. GetEvent performs the same function as GetEventEx with the difference that it GRHVQRW return the Severity of the event.

5HWXUQW\SH : A 5HW&RGH(QXP value.

6\QWD[ REMHFW . *HW(YHQW ( 'DWD1R6HT1R7V&RGH7\S6WQ%OW3JP6WU )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW $SL The Api object to operate on.

'DWD1R Integer Out A device unique sequence number. This number is incremented by one for each event reported over this device.

6HT1R Long Out A global sequence number. This number is incremented by one for each event generated by the system.

7V Long Out Date and time for event. Expressed as no of seconds since 1970-01-01 00:00:00

&RGH Integer Out Event code, see List of events for possible values.

7\S Integer Out Event type, see View Event Log.

6WQ Integer Out Station on which the event occurred, 0 if not relevant

%OW Integer Out Bolt for which the event occurred, 0 if not relevant

3JP String Out Tightening program connected to the event, 0 if not relevant

6WU String Out Event string in the language configured using the WinTC.

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*HW(YHQW([

'HVFULSWLRQ Call this method to read the next Event from the FIFO queue for the API device. The FIFO queue can hold max 100 events. If overflowed then the oldest event is overwritten. Once an event has been read by a call to this method it cannot be read again. If the queue is empty when called then H5HW1R'DWD is returned..

5HWXUQW\SH : A 5HW&RGH(QXP value.

6\QWD[ REMHFW . *HW(YHQW ( 'DWD1R6HT1R7V&RGH7\S6WQ%OW3JP6WU )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW $SL The Api object to operate on.

'DWD1R Integer Out A device unique sequence number. This number is incremented by one for each event reported over this device.

6HT1R Long Out A global sequence number. This number is incremented by one for each event generated by the system.

7V Long Out Date and time for event. Expressed as no of seconds since 1970-01-01 00:00:00

&RGH Integer Out Event code, see List of events for possible values.

7\S Integer Out Event type, see View Event Log.

6WQ Integer Out Station on which the event occurred, 0 if not relevant

%OW Integer Out Bolt for which the event occurred, 0 if not relevant

3JP String Out Tightening program connected to the event, 0 if not relevant

6WU String Out Event string in the language configured using the WinTC.

6HY SeverityEnum Out The Severity of the event.

*HW7UDFH

'HVFULSWLRQ Call this method to read the next Trace from the FIFO queue for the API device. See chapter: Layout of Traces for the returned data is formatted. The FIFO queue can hold max 20 traces. If overflowed then the oldest trace is overwritten. Once a trace has been read by a call to this method it cannot be read again. If the queue is empty when called then H5HW1R'DWD is returned.

5HWXUQW\SH : A 5HW&RGH(QXP value.

6\QWD[ REMHFW . *HW7UDFH ( %XI6L]H )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW $SL The Api object to operate on.

%XI Byte array Out The byte array to receive the read trace.

6L]H Long In/Out At call: Max length of %XI , At return: The length of the returned data in %XI .

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*HW7UDFH([

'HVFULSWLRQ Call this method to read the next Trace from the FIFO queue for the API device. The data is returned as a TraceData object. The FIFO queue can hold max 20 traces. If overflowed then the oldest trace is overwritten. Once a trace has been read by a call to this method it cannot be read again. If the queue is empty when called then H5HW1R'DWD is returned.

5HWXUQW\SH : A 5HW&RGH(QXP value.

6\QWD[ REMHFW . *HW7UDFH([ ( 7UDFH'DWD )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW $SL The Api object to operate on.

7UDFH'DWD 6\VWHP Out A reference that can hold the returned TraceData object. Is set to Nothing (null) if error.

*HW6HWXS

'HVFULSWLRQ This method uploads the setup from the PowerMACS system in binary form. Such a setup can be used by the SetSetup method. If there is no setup to read when called then

H5HW1R'DWD is returned.

5HWXUQW\SH : A 5HW&RGH(QXP value.

6\QWD[ REMHFW . *HW6HWXS ( %XI6L]H )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW $SL The Api object to operate on.

%XI Byte array Out The byte array to receive the uploaded setup.

6L]H Long In/Out At call: Max length of %XI , At return: The length of the returned data in %XI .

6HW6HWXS

'HVFULSWLRQ This method downloads a setup in binary form to the PowerMACS system. The setup must have been created by an earlier call to GetSetup. The setup must have been uploaded from a system with the same version as the one it is downloaded to.

5HWXUQW\SH : A 5HW&RGH(QXP value.

6\QWD[ REMHFW . 6HW6HWXS ( %XI6L]H )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW $SL The Api object to operate on.

%XI Byte array In The byte array containing the setup to download.

6L]H Long In The size of the setup to download.

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*HW6HWXS,WHP

'HVFULSWLRQ This method returns the value of the setup item specified by the ,WHP string. The ,WHP string uses a specific syntax (see Layout of Setup Item Descriptions for a description) to point out which parameter to read the value of. The value is always returned as a floating-point number. Boolean parameters are converted to a Single such that zero (0) represents False and non-zero True.

5HWXUQW\SH : A 5HW&RGH(QXP value, or if in the interval [-40..-1] syntax errors in the ,WHP string. In case of syntax error then the absolute value of the returned value is equal to the position in the string of the first error.

6\QWD[ REMHFW . *HW6HWXS,WHP ( ,WHP9DOXH )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW $SL The Api object to operate on.

,WHP String In The string specifying which parameter to read, see Layout of Setup Item Descriptions.

9DOXH Single Out The value of the read parameter.

6HW6HWXS,WHP

'HVFULSWLRQ This method sets the value of the setup item specified by the ,WHP string. The ,WHP string uses a specific syntax (see Layout of Setup Item Descriptions for a description) to point out which parameter to write to. The value must be a floating-point number. For Boolean parameters - set zero (0) if False and non-zero if True.

5HWXUQW\SH : A 5HW&RGH(QXP value, or if in the interval [-40..-1] syntax errors in the ,WHP string. In case of syntax error then the absolute value of the returned value is equal to the position in the string of the first error.

6\QWD[ REMHFW . 6HW6HWXS,WHP ( ,WHP9DOXH )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW $SL The Api object to operate on.

,WHP String In The string specifying which parameter to write, see Layout of Setup Item Descriptions.

9DOXH Single In The value to write.

*HW6\VWHP'HVF

'HVFULSWLRQ This method returns a System object that describes the PowerMACS system currently connected to.

5HWXUQW\SH : A 5HW&RGH(QXP value.

6\QWD[ REMHFW . *HW6\VWHP'HVF ( 6\V'HVF )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW $SL The Api object to operate on.

6\V'HVF 6\VWHP Out A reference that can hold the returned System object. Is set to Nothing (null) if error.

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*HW6WDWLRQ'HVF

'HVFULSWLRQ This method returns a Station object that describes the PowerMACS station currently connected to.

5HWXUQW\SH : A 5HW&RGH(QXP value.

6\QWD[ REMHFW . *HW6WDWLRQ'HVF ( 6WQ'HVF )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW $SL The Api object to operate on.

6WQ'HVF 6WDWLRQ Out A reference that can hold the returned Station object. Is set to Nothing (null) if error.

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6\VWHPREMHFW

The 6\VWHP object represents the PowerMACS system currently connected to.

3URSHUWLHV

The following table lists all properties on the 6\VWHP object:

3URSHUW\1DPH 5HWXUQ7\SH 'HVFULSWLRQ

1DPH 6WULQJ The name of the system as entered for the System object using the System Set Up form.

6WDWLRQV 6WDWLRQV The collection of all Station objects that exists in the PowerMACS system.

The syntax for accessing the properties of the 6\VWHP object is as follows:

REMHFW . 3URSHUW\1DPH

where REMHFW is an expression that evaluates to an object of type 6\VWHP .

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6WDWLRQVREMHFWFROOHFWLRQ

The 6WDWLRQV object is a collection of Station object. It represents all station included in the PowerMACS system connect to.

3URSHUWLHV

The following table lists all properties on the 6WDWLRQV object:

3URSHUW\1DPH 5HWXUQ7\SH 'HVFULSWLRQ

&RXQW /RQJ Returns the number of objects in the collection. Read only.

The syntax for accessing the properties of the 6WDWLRQV object is as follows:

REMHFW . 3URSHUW\1DPH



,WHP

'HVFULSWLRQ : Returns a specific Station object in the collection either by position or by the Name property of the Station object. If the value provided as ,QGH[.H\ does not match any existing member of the collection, then Nothing (null) is returned.

5HWXUQW\SH : A Station object.

6\QWD[ REMHFW . ,WHP ( ,QGH[.H\ )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW 6WDWLRQV  The Stations object to operate on.

,QGH[.H\ 9DULDQW In An expression that specifies the position of a member of the collection.

If a numeric expression, ,QGH[.H\ must be a number from 1 to the value of the collection’s &RXQW property.

If a string expression, ,QGH[.H\ must correspond to the 1DPH property of a Station object.



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([LVWV

'HVFULSWLRQ : Checks if a specific Station object exists in the collection either by position or by the Name property of a Station object.

5HWXUQW\SH : A %RROHDQ value. True if the object exists, else False.

6\QWD[ : REMHFW . ([LVWV ( ,QGH[.H\ )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW 6WDWLRQV  The Stations object to operate on.

,QGH[.H\ 9DULDQW In An expression that specifies the position of a member of the collection.

If a numeric expression, ,QGH[.H\ must be a number from 1 to the value of the collection’s &RXQW property.

If a string expression, ,QGH[.H\ must correspond to the 1DPH property of a Station object.



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6WDWLRQREMHFW

The 6WDWLRQ object represents a PowerMACS station.

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The following table lists all properties on the 6WDWLRQ object:

3URSHUW\1DPH 5HWXUQ7\SH 'HVFULSWLRQ

1DPH 6WULQJ The name of the Station as entered for the Station object using the System Set Up form.

1XPEHU ,QWHJHU The number of the station within the system [1..15].

,S$GGUHVV 6WULQJ The IP-address of the station (as dotted decimal).

%ROWV %ROWV The collection of all Bolt objects that exists within the station.

The syntax for accessing the properties of the 6WDWLRQ object is as follows:

REMHFW . 3URSHUW\1DPH

where REMHFW is an expression that evaluates to an object of type 6WDWLRQ .

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%ROWVREMHFWFROOHFWLRQ

The %ROWV object is a collection of Bolt objects. It represents all bolts in a particular station.

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The following table lists all properties on the %ROWV object:

3URSHUW\1DPH 5HWXUQ7\SH 'HVFULSWLRQ

&RXQW /RQJ Returns the number of objects in the collection. Read only.

The syntax for accessing the properties of the %ROWV object is as follows:

REMHFW . 3URSHUW\1DPH

where REMHFW is an expression that evaluates to an object of type %ROWV .



,WHP

'HVFULSWLRQ : Returns a specific Bolt object in the collection either by position or by the Name property of the Station object. If the value provided as ,QGH[.H\ does not match any existing member of the collection, then Nothing (null) is returned.

5HWXUQW\SH : A Bolt object.

6\QWD[ REMHFW . ,WHP ( ,QGH[.H\ )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW %ROWV  The Stations object to operate on.

,QGH[.H\ 9DULDQW In An expression that specifies the position of a member of the collection.

If a numeric expression, ,QGH[.H\ must be a number from 1 to the value of the collection’s &RXQW property.

If a string expression, ,QGH[.H\ must correspond to the 1DPH property of a Station object.



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([LVWV

'HVFULSWLRQ : Checks if a specific Bolt object exists in the collection either by position or by the Name property of a Bolt object.

5HWXUQW\SH : A %RROHDQ value. True if the object exists, else False.

6\QWD[ : REMHFW . ([LVWV ( ,QGH[.H\ )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW %ROWV  The Bolts object to operate on.

,QGH[.H\ 9DULDQW In An expression that specifies the position of a member of the collection.

If a numeric expression, ,QGH[.H\ must be a number from 1 to the value of the collection’s &RXQW property.

If a string expression, ,QGH[.H\ must correspond to the 1DPH property of a Bolt object.



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%ROWREMHFW

The %ROW object represents a bolt within a Station.

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The following table lists all properties on the %ROW object:

3URSHUW\1DPH 5HWXUQ7\SH 'HVFULSWLRQ

1DPH 6WULQJ The name of the Bolt as entered using the Bolt Set Up form.

1XPEHU ,QWHJHU The number of the bolt within the station [1..100]. First bolt is always 1.

8VHU%ROW1R ,QWHJHU The bolt number assigned to the bolt using parameter %ROW1XPEHU on the Bolt Set Up form. [1..127].

The syntax for accessing the properties of the %ROW object is as follows:

REMHFW . 3URSHUW\1DPH

where REMHFW is an expression that evaluates to an object of type %ROW .

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7UDFH'DWDREMHFW

The 7UDFH'DWD object contains a requested trace.

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The following table lists all properties on the 7UDFH'DWD object:

3URSHUW\1DPH 5HWXUQ7\SH 'HVFULSWLRQ

%ROW,G /RQJ Bolt

&KDQQHOV &KDQQHOV The collection of all Channel objects that exists in the trace.

'DWD1R ,QWHJHU A device unique sequence number. This number is incremented by one for each trace reported over the device.

'DWH$QG7LPH 'DWD Timestamp of trace in Data format

3JP1DPH 6WULQJ Name of program used at the occasion

6WDWLRQ,G /RQJ Station

6WHS%RXQGV 6WHS%RXQGV The collection of all StepBound objects that exists in the trace.

7V /RQJ Timestamp of trace

The syntax for accessing the properties of the 7UDFH'DWD object is as follows:

REMHFW . 3URSHUW\1DPH

where REMHFW is an expression that evaluates to an object of type 7UDFH'DWD .

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&KDQQHOVREMHFWFROOHFWLRQ

The &KDQQHOV object is a collection of  Channel object. It represents all channels included in the requested trace.

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The following table lists all properties on the &KDQQHOV object:

3URSHUW\1DPH 5HWXUQ7\SH 'HVFULSWLRQ

&RXQW /RQJ Returns the number of objects in the collection. Read only.

The syntax for accessing the properties of the &KDQQHOV object is as follows:

REMHFW . 3URSHUW\1DPH



,WHP

'HVFULSWLRQ : Returns a specific Channel object  in the collection either by position or by the Name property of the Channel object. If the value provided as ,QGH[.H\ does not match any existing member of the collection, then Nothing (null) is returned.

5HWXUQW\SH : A Channel object.

6\QWD[ REMHFW . ,WHP ( ,QGH[.H\ )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW &KDQQHOV The Channels object to operate on.

,QGH[.H\ 9DULDQW In An expression that specifies the position of a member of the collection.

If a numeric expression, ,QGH[.H\ must be a number from 1 to the value of the collection’s &RXQW property.

If a string expression, ,QGH[.H\ must correspond to the 1DPH property of a Channel object.



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([LVWV

'HVFULSWLRQ : Checks if a specific Channel object exists in the collection either by position or by the Name property of a Channel object.

5HWXUQW\SH : A %RROHDQ value. True if the object exists, else False.

6\QWD[ : REMHFW . ([LVWV ( ,QGH[.H\ )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW &KDQQHOV The Channels object to operate on.

,QGH[.H\ 9DULDQW In An expression that specifies the position of a member of the collection.

If a numeric expression, ,QGH[.H\ must be a number from 1 to the value of the collection’s &RXQW property.

If a string expression, ,QGH[.H\ must correspond to the 1DPH property of a Station object.



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&KDQQHOREMHFW

The &KDQQHO object represents a channel in the trace.

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The following table lists all properties on the 6WDWLRQ object:

3URSHUW\1DPH 5HWXUQ7\SH 'HVFULSWLRQ

1DPH 6WULQJ The name of the Channel.

1R2I6DPSOHV /RQJ The number of stored samples.

6DPSOH7LPH 6LQJOH The Sample time at which the stored samples were collected.

7LPH2IIVHW 6LQJOH The time offset for the first stored sample, where Ts is 0.

The syntax for accessing the properties of the 6WDWLRQ object is as follows:

REMHFW . 3URSHUW\1DPH

where REMHFW is an expression that evaluates to an object of type &KDQQHO .

*HW6DPSOH9DOXH1R

'HVFULSWLRQ : Give sample time as parameter and get sample number as reply.

5HWXUQW\SH : A /RQJ value. Sample number possible values are 1 to 6000.

6\QWD[ : REMHFW . *HW6DPSOH9DOXH1R ( 6DPSOH9DOXH7LPH )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW &KDQQHO The Channel object to operate on.

6DPSOH9DOXH7LPH 6LQJOH In Time from Ts to when the current sample was taken.

*HW6DPSOH9DOXH7LPH

'HVFULSWLRQ : Give sample number as parameter and get sample time as reply.

5HWXUQW\SH : A 6LQJOH value. Time from Ts to when current sample was taken.

6\QWD[ : REMHFW . *HW6DPSOH9DOXH7LPH ( 6DPSOH9DOXH1R )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW &KDQQHO The Channel object to operate on.

6DPSOH9DOXH1R /RQJ In Sample number that corresponds to entered sample time.

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*HW6DPSOH9DOXHV

'HVFULSWLRQ : Get buffer with all sample values collected for the channel.

5HWXUQW\SH : A 5HW&RGH(QXP value.

6\QWD[ : REMHFW . *HW6DPSOH9DOXHV (Buf(), Size)

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW &KDQQHO The Channel object to operate on.

%XI 6LQJOH Out Array of Single, contains all sample values.

6L]H /RQJ In/Out Available array size in and stored number of samples out.

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6WHS%RXQGVREMHFWFROOHFWLRQ

The 6WHS%RXQGV object is a collection of  StepBound object. It represents all StepBounds included in the requested trace.

3URSHUWLHV

The following table lists all properties on the 6WHS%RXQGV object:

3URSHUW\1DPH 5HWXUQ7\SH 'HVFULSWLRQ

&RXQW /RQJ Returns the number of objects in the collection. Read only.

The syntax for accessing the properties of the 6WHS%RXQGV object is as follows:

REMHFW . 3URSHUW\1DPH



,WHP

'HVFULSWLRQ : Returns a specific StepBound object  in the collection by position. If the value provided as

,QGH[.H\ does not match any existing member of the collection, then Nothing (null) is returned.

5HWXUQW\SH : A StepBound object.

6\QWD[ REMHFW . ,WHP ( ,QGH[.H\ )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW 6WHS%RXQGV  The StepBounds object to operate on.

,QGH[.H\ 9DULDQW In An expression that specifies the position of a member of the collection.

If a numeric expression, ,QGH[.H\ must be a number from 1 to the value of the collection’s &RXQW property.



([LVWV

'HVFULSWLRQ : Checks if a specific StepBound object exists in the collection by position.

5HWXUQW\SH : A %RROHDQ value. True if the object exists, else False.

6\QWD[ : REMHFW . ([LVWV ( ,QGH[.H\ )

2EM$UJ 7\SH 'LU 'HVFULSWLRQ

REMHFW 6WHS%RXQGV  The StepBounds object to operate on.

,QGH[.H\ 9DULDQW In An expression that specifies the position of a member of the collection.

If a numeric expression, ,QGH[.H\ must be a number from 1 to the value of the collection’s &RXQW property.



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6WHS%RXQGREMHFW

The 6WHS%RXQG object contains start and stop times for one step or zone in the trace.

3URSHUWLHV

The following table lists all properties on the 6WHS%RXQG object:

3URSHUW\1DPH 5HWXUQ7\SH 'HVFULSWLRQ

6WHS1R /RQJ The step number that the start and stop times apply to.

6WDUW7LPH 6LQJOH The time difference from Ts to when the step started.

6WRS7LPH 6LQJOH The time difference from Ts to when the step started.

The syntax for accessing the properties of the 6WHS%RQG object is as follows:

REMHFW . 3URSHUW\1DPH

where REMHFW is an expression that evaluates to an object of type 6WHS%RXQG .

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+RZWRXVHWKH$3,

The API is developed in Visual Basic 6 as an ActiveX object and is as such callable from other languages as well. Below are some examples on how to call the API from Visual basic.

(QYLURQPHQW

Set up your Visual Basic environment according to the following

• PowerMACSAPI must be installed on the computer

• PowerMACSAPI must be checked in the project references dialog.

• Do not create more than instance of the PowerMACSAPI.Api object in your application.

'HFODUHDYDULDEOHDWPRGXOHOHYHO

Private mPowApi As PowerMACSApi.Api

3XWVRPHLQLWLDWLQJFRGHLQWKHIRUPORDGHYHQW

Set mPowAPi = New PowerMACSApi.APi mPowApi.IpAddress = ”192.168.0.1”

5HDGLQJF\FOHGDWDIURPWKHWDUJHWV\VWHP

This example assumes that there is a label where you can put the cycle data result if there is one. Normally you would loop and save the cycle data to disc or showing them continuously. Here we just do one call to see if there are any cycle data waiting for us.

Private Sub cmdGetCd_Click()

' ' Abstract: Get cycle data from API-server and display it ' On Error GoTo ErrorHandler Dim Size As Long Dim Ret As RetCodeEnum Dim Buf As String Size = 10000 Ret = mPowApi.GetCycleData(Buf, Size) If Ret = eRetOk Then lblResult = Buf ElseIf Ret <> eRetNoData Then MsgBox "GetCycleData returned: " & Ret End if Exit Sub ErrorHandler: libCleanTerminate "cmdGetCd_Click" Stop Resume End Sub

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6HWWLQJD%RROHDQYDOXHLQWKHWDUJHWV\VWHP

This example assumes that there are textboxes for address and value, and a dropdown list for the bit value.

Private Sub cmdSetBool_Click() ’ ’ Abstract: Set PLC Bool from API-server and display it ’ On Error GoTo ErrorHandler Dim Ret As RetCodeEnum Dim Address As Integer Dim Value As Boolean If Val(txtAddress) < 1 Or Val(txtAddress) > 999 Then MsgBox "Address must be between 1 and 999" txtAddress.SetFocus Exit Sub End If Address = CInt(txtAddress) Value = CBool(txtValue) Ret = mPowApi.SetPLCBool(Address, Val(cboBit), Value) if Ret <> eRetOk then msgBox "SetPLCBool returned: " & Ret Exit Sub ErrorHandler: If Err.Number = 13 Then MsgBox "Value must be a valid boolean" txtAddress.SetFocus Exit Sub End If MsgBox err.description exit sub End Sub

5HDGLQJDQ,QWHJHU3/&YDOXHIURPWKHWDUJHWV\VWHP

This example assumes that there are textboxes for address and value.

Private Sub cmdSetBool_Click() ’ ’ Abstract: Get PLC Integer from API-server and display it ’ On Error GoTo ErrorHandler Dim Ret As RetCodeEnum Dim Address As Integer Dim Value As Boolean If Val(txtAddress) < 1 Or Val(txtAddress) > 999 Then MsgBox "Address must be between 1 and 999" txtAddress.SetFocus Exit Sub End If Address = CInt(txtAddress) Ret = mPowApi.GetPLCInt(Address, Value) if Ret <> eRetOk Then msgBox "GetPLCInt returned: " & Ret else txtValue = CStr(Value) end if Exit Sub ErrorHandler: MsgBox err.description exit sub End Sub

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3URFHVVGDWD

Process data comprises following types of data:

• Cycle data

• Traces

• Events

• Setup

Process data is accessed from external devices using fieldbus, external communication protocols, the API, etc.

Cycle data, Events, and Traces generated by PowerMACS are put into a number of FIFO queues. Each device has their own queues, one for cycle data (100 cycles), one for traces (20 traces), and one for events (100 events). This means that they can read data at their own speed without interfering with each other.

All access to Process data is done on the client’s request. When requested for, the PowerMACS system will return the next data from the queue in question. Should the queue be empty then the client will receive an empty data package. It is the client’s responsibility to request new data. PowerMACS will not spontaneously indicate to him that new data is available.

Since a process data item, e.g. one cycle data, often are bigger than what can be handled by a single read or write access, it is accessed through successive reads or writes where each access returns a part of the complete data item. These parts are called packages. In other words, one data item consists of one or more data packages.

A Process data package has the following format:

Byte

0 SEQ (Most Significant Byte)

1 SEQ (Least Significant Byte)

2 LEN (Most Significant Byte)

3 LEN (Least Significant Byte)

: :

N + 4 Data byte N

First in the package there is a sequence number named 6(4 and a length field named /(1 . Both are Short Integers, which means that they occupy two bytes each (see Data types).

6(4 is the sequence number of the package within a particular data item (e.g. a cycle data). The first package has 6(4 = 1, the second has 6(4 = 2, and so on. To indicate the last package of a data item

6(4 is negated. This means that a data item that is divided in three packages will have the following values of 6(4 : 1, 2, -3.

/(1 is the length of the complete package, including both 6(4 and /(1 . /(1 is therefore always equal to N + 4 where N is the number of data bytes contained in the package.

To reconstruct the Data item being read you just have to concatenate the Data part (Data byte 1, …) of each package, from first package ( 6(4 = 1) to the last package ( 6(4 = -K).

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([DPSOH Assuming that a complete cycle data consists of the 10-character string "ABCEDFGHIJ" should be read using an 8-byte buffer then the below data transfer will occur when the cycle data is requested (all data is written in Hexadecimal notation):

VXWZY![\ ]:^_ `_

_6[bc_6d]fe ]!`3geEh6]/^ji Y2`3k/]mlEn o/`Ue ]/_6^*e ]6pg/]!o/`

0 0x41 (‘A’) 0 0x00

1 0x42 (‘B’) 1 0x01 SEQ = 1

2 0x43 (‘C’) 2 0x00 3 0x44 (‘D’) 3 0x08 LEN = 8

4 0x45 (‘E’) 4 0x41 (‘A’) Item data byte 0

5 0x46 (‘F’) 5 0x42 (‘B’) Item data byte 1

6 0x47 (‘G’) 6 0x43 (‘C’) Item data byte 2

7 0x48 (‘H’) 7 0x44 (‘D’) Item data byte 3

8 0x49 (‘I’)

9 0x50 (‘J’)

_6[bc_6d]fe ]!`3geEh6]/^ji Y2`3k/]mo6]/[/q#h^*e ]/_6^*e ]6p#g6]!o!`

0 0x00

2 0x00 3 0x08 LEN = 8

4 0x45 (‘E’) Item data byte 4

5 0x46 (‘F’) Item data byte 5

6 0x47 (‘G’) Item data byte 6

7 0x48 (‘H’) Item data byte 7

_6[bc_6d]fe ]!`3geEh6]/^ji Y2`3k/]m`Ekn e^*e ]/_6^*e ]6p#g6]o/`

0 0xFF

1 0xFD SEQ = --3

2 0x00 3 0x06 LEN = 6

4 0x49 (‘I’) Item data byte 8

5 0x50 (‘J’) Item data byte 9

6 xx not set

7 xx not set

If this was the last available cycle data in the queue then another read would give the following result (indicating that the queue is empty):

rs9t/u v:t6w6x6yzw6{|~} |!uE}E€/|6:‚ƒ €6x!|:„#6|6|~ƒ ‚:|s9t/u

0 0xFF

1 0xFF SEQ = --1

2 0x00 3 0x04 LEN = 4

4 xx not set

5 xx not set

6 xx not set

7 xx not set

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'DWDW\SHV

The following data types are used in the following sections:

'DWDW\SH 'HVFULSWLRQ 9DOXHV

Boolean 2 bytes, 16 bit unsigned binary Zero (0) represent False and non-zero True

Short integer 2 bytes, 16 bit, 2-complement signed binary -32768, …, +32767

Long integer 4 bytes, 32 bit, 2-complement signed binary -2 147 483 648, …, +2 147 483 647

Time 4 bytes, 32 bit long integer Number of seconds since January 1, 1970

Float or Real 4 bytes, 32 bit, IEEE-754 standard +/- 1.18 * 10 38

char[] Array of bytes containing ASCII- character Null-terminated i.e. the byte after last relevant character contains null, 0.

For data occupying more than one byte the order is that most significant byte comes first, at the lowest address. This is also known as Big Endian or Motorola format.

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The layout of Cycle data is set up by use of a Reporter. Chapter: Layout of Cycle Data describes in detail how it is used to configure the layout of a cycle data.

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An Event contains data as described in the table below.

2IIVHW ,WHP 'DWDW\SH 'HVFULSWLRQ

0 DataNo Short integer A device unique sequence number. This number is incremented by one for each event reported over the device.

2 SeqNo Long integer A global sequence number. This number is incremented by one for each event generated by the system.

6 Time Time Date and time for event.

10 Code Short integer Event code, see List of events for possible values.

12 Type Short integer Event type, see below.

14 Station Short integer Station on which the event occurred, 0 if not relevant

16 Bolt Short integer Bolt for which the event occurred, 0 if not relevant

18 Observed Short integer <> 0 if event is observed

20 Pgm char[21] Tightening program connected to the event, 0 if not relevant

41 EventStr char[81] Event string in the language configured using the WinTC.

122 Severity Short integer The severity of the event, see below.

Which items that are included for an event when it is read by a particular device is controlled by the Advanced Event settings of the Reporter connected to the device.

If all items are included then the size of an event is 124 bytes.

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The events are divided in a number of categories, called Event types, and are assigned a Severity. See View Event Log for definition of possible values.

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/D\RXWRI7UDFHVLQ3URFHVVGDWD

A Trace contains data as described in the table below.

2IIVHW ,WHP 'DWDW\SH 'HVFULSWLRQ

0 DataNo Short integer A device unique sequence number. This number is incremented by one for each trace reported over the device.

2 FmtVer Long integer Format version on the TC when the trace was created

6 Station Long integer Station

10 Bolt Long integer Bolt

14 Time Time Timestamp of trace

18 Freq Float Sampling frequency in Hz

22 TimeOffset Long integer Offset to first sample in milliseconds

26 NoTsamples Long integer Number of torque samples [0..2000]

30 NoAsamples Long integer Number of angle samples [0..2000]

34 NoCsamples Long integer Number of current samples [0..2000]

38 Not used Long integer Always zero (0)

42 PgmName char[21] Name of program used at the occasion

63 1 st T sample Float The first Torque sample

63 + 4 * ( NoTsamples – 1) Last T sample Float The last Torque Sample (sample NoTsamples)

63 + 4 * ( NoTsamples) 1 st A sample Float The first Angle sample

63 + 4 * ( NoTsamples + NoAsamples – 1)

Last A sample Float The last Angle Sample (sample NoAsamples)

1 st C sample Float The first Current sample

63 + 4 * ( NoTsamples + NoAsamples)

63 + 4 * ( NoTsamples + NoAsamples + NoCsamples – 1)

Last C sample Float The last Current Sample (sample NoCsamples)

The trace will only contain the samples that are recorded. This means that only data for used channels are recorded. The number of samples included for each channel is given by the variable NoTsamples, NoAsamples, and NoCsamples respectively.

Max size of trace is 24 063 bytes.

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/D\RXWRI6HWXS,WHP'HVFULSWLRQV

Using the API interface it is possible to read or write individual items within a setup. Items that can be accessed are parameters for which alteration would be meaningful and which can be handled by the system.

The following parts of a setup may be modified individually:

• Bolt

• Spindle – Parameters

• Spindle – Channel data

• Sequences and programs – Monitoring data

• Sequences and programs – Monitoring data, Torque rate data

• Sequences and programs – Step Control data

• Sequences and programs – Step Restriction data

• Sequences and programs – Step Check data

• Sequences and programs – Step Speed data

• Sequences and programs – Step Speed ramp down data

To access an individual item a description must be provided which points to the item. This description should be according to the syntax described in the following.

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%ROW

6\QWD[ %ROW>  @ = 1..Max station no = 1..Max bolt no in that station = See table below (and Bolt Set Up for a description)

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OpMode Short integer Operation mode:

• 0: Connected

• 1: Disconnected OK

• 2: Disconnected NOK TraceStart Short integer The main condition for when to start recording a Trace. Takes the following values:

• 1: At cycle start

• 3: When the step with number is started. TraceStartStep Short integer The number of the step where trace will start

TraceStartQty Short integer Specifies an addition condition for when to start recording a trace. Takes one of the following values:

• 0: None

• 1: When the measured angle reaches the value

• 2: When the measured torque reaches the value

• 3: When the measured current reaches the value TraceStartMin Float The minimum value to reach before trace starts. Valid only if has the value 1, 2 or 3.

MonStart Short integer Defines when to start monitoring. Takes the following values:

• 0: Disabled

• 1: At cycle start

• 2: When the PLC output MONSTART (Station variables) is set True (see Station variables)

• 3: When a step that has the Start/restart monitoring flag set is started (see Step – Control).

• 4: When the measured torque reaches the value . MonEnd Short integer Defines when to end monitoring. Takes the following values:

• 1: At cycle end

• 2: When the PLC output MONEND (Station variables) is set True (see Station variables)

• 3: When the measured torque reaches the value . MonStartTorqueVal Float The torque value to reach before starting monitoring. Only valid if is 4.

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MonEndTorqueVal Float The torque value to reach before ending monitoring. Only valid if is 3.

MonBufAutoScale Boolean If True then the resolution of the monitoring buffer is auto scaled.

MonResolution Short integer No of angle increment per buffer element in the monitoring buffer. Valid only if is False.

MonBufOverrunAllowed Boolean If True then monitoring buffer overrun is not regarded as an error. Valid only if is False.

ExternalBoltNo Short integer The bolt number used in cycle data reports.

([DPSOH Bolt[1,1].OpMode

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6\QWD[ 6SLQGOH> @ < spindle no > = 1..Max spindle no = See table below (and Spindle Set Up for a description)

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GearRatio Float Gear Ratio of Spindle

NoCyclMaint Long integer Service interval in no. of cycles (>= 0)

CycleCountOn Boolean If True then all cycles will be counted.

CycleCountAlarmOn Boolean Spindle generates an alarm when no. of cycles counted exceeds the value of

Direction Short integer Direction in which the spindle should rotate. Allowed values are:

1. Forward (CW)

1. Backward (CCW)

AngleWindUpCoef Float The Wind up coefficient.

ExpTorq1Calib Float Expected Torque at calibration test for transducer 1

AccTDiff1Calib Float Accepted Torque difference at calibration test for transducer 1

ExpTorq2Calib Float Expected Torque at calibration test for transducer 2

AccTDiff2Calib Float Accepted Torque difference at calibration test for transducer 2

SzoTime Float Measuring time, static zero offset.

SzoMax1 Float Max allowed static zero offset for transducer 1.

SzoMax2 Float Max allowed static zero offset for transducer 2.

DzoTime Float Measuring time, dynamic zero offset.

AcSpeed Float Speed for angle check.

DzoMax1 Float Max allowed dynamic zero offset for Torque 1.

DzoAMin1 Float Min allowed angle, in either direction, for Angle 1.

DzoAMax1 Float Max allowed angle, in either direction, for Angle 1.

DzoMax2 Float Max allowed dynamic zero offset for Torque 2.

DzoAMin2 Float Min allowed angle, in either direction, for Angle 2.

DzoAMax2 Float Max allowed angle, in either direction, for Angle 2.

FzoTime Float Measuring time, Flying zero offset.

FzoMeasTime Float Measuring time

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FzoMax1 Float Max allowed flying zero offset for Torque 1.

FzoMax2 Float Max allowed flying zero offset for Torque 2.

FzoContFailed Boolean True if spindle should continue to run after failed check.

MaxTDiff Float Max torque diff between double transducers

MaxAdiff Float Max angle diff between double transducers

NoDiffSamples Short integer Number samples transducers may differ before alarm in double transducer check.

ZeroSpeed Float The maximum speed that counts as zero speed

T_CFactor Float The relation between torque and current (T=C*T_C)

([DPSOH Spindle[1].GearRatio

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6\QWD[ 6SLQGOH> @&KDQ> @ < spindle no > = 1..Max spindle no < channel no > = Channel number, 1..6 (number is given by the order in the form) = See table below (and Spindle Set Up, Channels for a description)

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Scalefact Float Scale factor of Torque transducer

Gain Short integer Gain of Torque transducer. Allowed values are 1, 2, 4, 8 and 16.

Filter Short integer Filter frequency

([DPSOH Spindle[1].Chan[1].Scalefact

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6\QWD[ 3URJUDP> @0RQ

6HTXHQFH> @0RQ < pgm name > = The name of the program < seq name > = The name of the sequence = See table below (and Bolt Monitoring for a description)

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StopMonAtNokStep Boolean If True then monitoring is stopped when a step have a NOK status when it ends.

FinTorqAct Boolean If True perform Final torque monitoring

FinTorqHL Float Final torque high limit

FinTorqLL Float Final torque low limit

AngThreshAct Boolean If True perform Angle from threshold monitoring

AngThreshHL Float Angle from threshold high limit

AngThreshLL Float Angle from threshold low limit

ThreshTorque Float Threshold torque

MeasMaxAngle Boolean If True measure max angle

Ytc Float Yield point: Trig level TC

Ynos Float Yield point : NOS

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Yinc Float Yield point : INC

YtDiff Float Yield point: DIFF

YtorqueAct Boolean If True measure Final torque from yield point monitoring

Yth Float Yield point: YTH

Ytl Float Yield point: YTL

YangleAct Boolean If True perform Final angle from yield point monitoring

Yah Float Yield point: YAH

Yal Float Yield point: YAL

([DPSOH Program[Pgm01].Mon.FinTorqAct

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6\QWD[ 3URJUDP> @0RQ75> @

6HTXHQFH> @0RQ75> @ = The name of the program = The name of the sequence = Torque rate no., [1..2] = See table below (and Monitoring of Torque Rate and Deviation for a description)

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Act Boolean If True perform Torque rate monitoring

Tstart Float Start torque

Tstop Float Stop torque

TRlow Float TR low

TRhigh Float TR high

Dev Float Deviation

([DPSOH Program[Pgm01].Mon.TR[1].Act

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6\QWD[ 3URJUDP> < pgm name > @6WHS> < step no > @&RQWURO < parameter >

6HTXHQFH> < seq name > @6WHS> < step no > @&RQWURO < parameter > < pgm name > = The name of the program < seq name > = The name of the sequence < step no > = Step number, 1..50 = See table below (and Step – Control for a description)

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Sync Boolean If True then the step is synchronized.

StartMon Boolean If True then monitoring will be cleared and restarted when the step is started.

Par[ ] Float The control function parameter (allowed values are 1..7). The number of each parameter is given by the order they are listed in chapter: Step – Control.

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([DPSOH Program[Pgm01].Step[1].Control.Sync Program[Pgm01].Step[1].Control.Par[1 ]

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6HTXHQFH> @6WHS> @5HVWULFWLRQ = The name of the program = The name of the sequence = Step number, 1..50 = See table below (and Step – Restriction for a description)

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FsTorque Float Fail Safe Torque

FsTime Float Fail safe time

FsAngle Float Fail Safe Angle

CtgStatus Short integer Cross Thread and Gradient Status. Allowed values:

1. Not active

1. Repairable

1. Fatal

CtgTorque1 Float Cross Thread and Gradient Torque 1

CtgTorque2 Float Cross Thread and Gradient Torque 2

CtgMaxAngle Float Cross Thread and Gradient Max angle

CtgMinAngle Float Cross Thread and Gradient Min angle

Example: Program[Pgm01].Step[1].Restriction.FsTorqueStatus

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6\QWD[ 3URJUDP> @6WHS> @&KHFN> @3DU> @

6HTXHQFH> @6WHS> @&KHFN> @3DU> @ = The name of the program = The name of the sequence = Step number, 1..50 = Check number, 1..´5, as listed on the Step – Check tab. = Parameter number, 1..7, as listed in the description of each check, see chapter: Step – Check.

([DPSOH Program[Pgm01].Step[1].Check[1].Par[1]

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6HTXHQFHDQG3URJUDP6WHS6SHHGGDWD

6\QWD[ 3URJUDP> < pgm name > @6WHS> < step no > @6SHHG < parameter >

6HTXHQFH> < seq name > @6WHS> < step no > @6SHHG < parameter > < pgm name > = The name of the program < seq name > = The name of the sequence < step no > = Step number, 1..50 = See table below (and Step – Speed for a description)

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Speed Float Target Speed

Zsd Boolean If True then Zero Speed detection is active

Sru Float Speed ramp up

Tru Float Torque ramp up

RampType Short integer Ramp type. Possible values: Straight / Smoothened

1. Straight

1. Smoothened

NoSrds Short integer No of Speed ramp downs case used, [0..5]. See Sequence and Program, Step, Speed, Ramp down data.

([DPSOH Program[Pgm01].Step[1].Speed.Speed

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6\QWD[ 3URJUDP> < pgm name > @6WHS> < step no > @6SHHG5DPS'RZQ> < ramp > @ < parameter >

6HTXHQFH> < seq name > @6WHS> < step no > @6SHHG5DPS'RZQ> < ramp > @ < parameter > < pgm name > = The name of the program < seq name > = The name of the sequence < step no > = Step number, 1..50 < ramp > = Ramp number, 1..5 = See table below (and Step – Speed for a description)

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Start Short integer Defines the quantity to monitor as start condition. Allowed values:

1. Torque

1. Angle

1. Current

1. Time

Level Float The trig level of the measured quantity.

Speed Float The new target speed.

Ramp Float The ramp to use when changing the speed.

([DPSOH Program[Pgm01].Step[1].Speed.RampDown[1].Start

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6\QWD[ 3URJUDP> @6WHS> @2WKHU

6HTXHQFH> @6WHS> @2WKHU = The name of the program = The name of the sequence = Step number, 1..50 = See table below (see Step – Other for a description)

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StartDelay Float Start delay of step

TorqueSpikeAngle Float Torque spike elimination angle

StopMethod Short integer How to stop. Allowed values:

1. Inertia break

1. Ramp down current

1. Hold Torque

InitialStopValue Float The start level of the amperage ramp expressed in % of the amperage at shut off. Used only if is "Ramp down current".

DownRamp Float The amperage down ramp. Used only if is "Ramp down current".

HoldWhenStopped Boolean If True then the position should be maintained when stopped. Can only be used if is "Inertia break" or "Ramp down current".

([DPSOH Program[Pgm01].Step[1].Other.StartDelay

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A Setup is a complete package of data containing all information necessary to configure a complete PowerMACS system. It is stored in a proprietary compressed format, safeguarded by Checkums to keep its integrity. The main purpose for handling setups this way is for storage of backup copies, or for exchange of setups between systems. It is not possible with normal software tools to read or write information within a setup.

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This part is the specification of the system. It describes general performances of a complete system:

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Max. time from start signal until all spindles are running 50 msec..

Max. time from last spindle stops a step until all are running in the next step: 50 msec. + monitoring time.

Max. time from last spindle stops last step until OK/NOK status on digital output, per spindle and total: 0.1 sec. + monitoring time.

Max. time between cycles 0.5 sec at limited data reporting.

Position accuracy 0.5 degrees.

Sampling frequency 50 - 1000 Hz

Delays in set values to servo 2 x sampling time

Maximum time for a loop in the PLC program 5

Traces per spindle. Each trace with 2000 values for angle and torque. Current included but all 0. 100

Traces per spindle. Each trace with 2000 values for angle, torque and current. 50

Max time to change a device 3 min

The Performance values can be seen as a realistic estimate of performance for the finalized system, but the design of the system is focused on reaching the Target values.

Traces will be stored in two circular buffers with equal size, one for OK cycles, the other for NOK cycles. A new trace will overwrite the oldest stored trace, independent of tightening program.

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When a new setup is created the default user access rights are set as follows:

)RUP 5HDG :ULWH

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Reporter - Advanced Cycle Data Settings 2 4

Reporter - Advanced Event Settings 2 4

Service Log - New/Edit Message 2 4

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The below table lists the Code, Type, Severity and Event string for most events that can be generated by the system:

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1 Ext.com.Error Error Unexpected signal: %d %d %d

2 System Error Error DB Get error %d, Proc %d, Case %d

3 Hardware Error Error Spurious interrupt %d, %d, %d

4 System Error Error Internal error on line %d in class base no %d, ret %d

101 Power up Info Power on

102 Hardware Error Error System: TC %d is out of order

103 Hardware Error Info System: TC %d has restarted

104 Hardware Error Error System: TC %d is of wrong type

105 Hardware Error Error System: Slave TC %d is configured as primary

201 Setup Error EasyView parameter %d fails in pos %d

202 System Error Error Error when reading/writing ODB image (err=%d)

203 System Error Error Error when reading ODB image (ODB seq.=%d, my seq.=%d)

603 System Error Error Bolt %d is connected to invalid spindle %d

604 System Error Error Bolt %d is connected to invalid spindle %d

605 System Error Error ST: signal from undefined spindle

606 System Error Error ST: signal from undefined bolt

607 System Error Error ST: Datastructures inconsistent

608 System Error Error ST: Telegram %d received in wrong state %d from proc %d

609 System Error Error Station has no contact with spindle %d

610 System Error Error Station has no contact with PLC

611 System Error Error Station has no contact with TstBolt

612 System Error Error Unexpected Cycle End when running RM

613 System Error Error Invalid Bolt number from spindle

614 System Error Error ST: DB read error %d for bolt %d

617 System Error Error No contact with syinit after ipcHunt

618 Setup Error Cycle data too big, bolt %d not stored

700 System Error Error SP: DB read error %d, object %d

701 Setup Error No current channel configured

702 Setup Error Step %d, No clampload channel configured

703 System Error Error SP: Internal error line %d, file %d

704 Setup Error Step %d, Spindle %d has incorrect TC-factor

705 Setup Error Incorrect Mode number from PLC

706 Setup Error Incorrect Sampling frequency

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707 Hardware Error Error UF: Communication error

708 System Error Error Spindle initialization failed

709 System Error Error SP: Hunt for ipc process %d failed

710 Setup Error Step number %d not in program

711 Setup Error Incorrect Direction

712 Setup Error Step %d, Incorrect Torque spike elimination setup

713 Setup Error Step %d, Incorrect Pre step time

714 Setup Error Step %d, Incorrect Post step time

715 Setup Error Incorrect Torque usage

716 Setup Error Incorrect Angle usage

717 Setup Error Incorrect Torque channel

718 Setup Error Incorrect Angle channel

719 Setup Error Incorrect Current channel

720 Check Error Monitoring: Final torque. %f %c %f

721 Check Error Monitoring: Threshold angle. %f %c %f

722 Check Error Monitoring: Torque rate in interval %d. %f > %f

723 Check Error Monitoring: Torque rate in interval %d. %f < %f

724 Check Error Monitoring: Deviation in interval %d. %f > %f

725 Check Error Monitoring: Yield point torque diff. %f %c %f

726 Check Error Monitoring: Yield point angle diff. %f %c %f

727 Setup Error Monitoring: Incorrect configuration

728 Setup Error Monitoring: Incorrect Final torque

730 Setup Error Monitoring: Incorrect Torque rate

731 Setup Error Monitoring: Incorrect Yield point torque

732 Setup Error Monitoring: Incorrect Yield point angle

733 Setup Error Trace: Incorrect configuration

734 Setup Error Step %d, Control: Incorrect Torque

735 Setup Error Step %d, Control: Incorrect Angle

736 Setup Error Step %d, Control: Incorrect Time

737 Setup Error Step %d, Control: Incorrect Current

738 Setup Error Step %d, Control: Incorrect Clamp

739 Setup Error Step %d, Control: Incorrect Percent

740 Setup Error Step %d, Control: Incorrect NOS

741 Setup Error Step %d, Control: Incorrect NNOS or RNOS

742 Setup Error Step %d, Control: Incorrect INC

743 Setup Error Step %d, Control: Incorrect Direction

744 Setup Error Step %d, Control: Incorrect I/O

745 Setup Error Step %d, Control: Incorrect Digital Input

746 Setup Error Step %d, Control: Incorrect Digital Output

747 Setup Error Step %d, Control: Incorrect Steptype from PLC

748 Setup Error Step %d, Restriction: Incorrect FS Angle

749 Setup Error Step %d, Restriction: Incorrect FS Torque

750 Setup Error Step %d, Restriction: Incorrect FS Time

752 Setup Error Step %d, Restriction: Incorrect Cross thread and gradient

753 Setup Error Step %d, Restriction: Incorrect Torque profile

754 Check Error Step %d, Check: Peak torque. %f > %f

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755 Check Error Step %d, Check: Torque in angle window. %f > %f

756 Check Error Step %d, Check: Torque in time window. %f > %f

757 Check Error Step %d, Check: Mean torque. %f > %f

758 Check Error Step %d, Check: Angle. %f > %f

759 Check Error Step %d, Check: Time. %f > %f

760 Check Error Step %d, Check: Current. %f > %f

761 Check Error Step %d, Check: Clamp Load. %f > %f

762 Check Error Step %d, Check: Torque/Current. %f > %f

763 Check Error Step %d, Check: Post view torque high.

764 Check Error Step %d, Check: Post view torque low.

765 Check Error Step %d, Diagnostic: Static Zero Offset high. %f > %f

766 Check Error Step %d, Diagnostic: Dynamic Zero Offset high. %f > %f

767 Check Error Step %d, Diagnostic: Flying Zero Offset high. %f > %f

769 Check Error Step %d, Diagnostic: Angle count high on control ch. %f > %f

770 Check Error Step %d, Diagnostic: Calib. failed. Meas. %f, expected %f, max diff %f

771 Setup Error Step %d, Diagnostic: Incorrect configuration

772 Setup Error Step %d, Check: Incorrect Peak torque

773 Setup Error Step %d, Check: Incorrect Torque in angle window

774 Check Error Step %d, Check: Torque in angle window failed

775 Setup Error Step %d, Check: Incorrect Torque in time window

776 Check Error Step %d, Check: Torque in time window failed

777 Setup Error Step %d, Check: Incorrect Mean torque

778 Check Error Step %d, Check: Mean torque failed

779 Setup Error Step %d, Check: Incorrect Torque/Current

780 Check Error Step %d, Check: Torque/Current failed

781 Setup Error Step %d, Check: Incorrect Angle

782 Check Error Step %d, Check: Angle failed

783 Setup Error Step %d, Check: Incorrect Current

784 Setup Error Step %d, Check: Incorrect Clamp Load

785 Setup Error Step %d, Check: Incorrect Time

786 Setup Error Step %d, Check: Incorrect Post view

787 Check Error Step %d, Check: Post view Torque failed

789 Setup Error Spindle: Incorrect Torque scale

790 Setup Error Spindle: Incorrect Current scale

791 Setup Error Spindle: Incorrect Angle scale

792 Setup Error Spindle: Incorrect configuration

794 Setup Error Spindle: No program for mode %d

795 Setup Error Cycle data too big, step %d not stored

796 Check Error Monitoring: Final torque could not be evaluated

797 Check Error Monitoring: Threshold angle could not be evaluated

798 Check Error Monitoring: Torque rate could not be evaluated

799 Check Error Monitoring: Yield point torque could not be evaluated

800 Check Error Monitoring: Yield point angle could not be evaluated

801 Check Error Step %d, Check: Peak torque. %f < %f

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802 Check Error Step %d, Check: Torque in angle window. %f < %f

803 Check Error Step %d, Check: Torque in time window. %f < %f

804 Check Error Step %d, Check: Mean torque. %f < %f

805 Check Error Step %d, Check: Angle. %f < %f

806 Check Error Step %d, Check: Time. %f < %f

807 Check Error Step %d, Check: Current. %f < %f

808 Check Error Step %d, Check: Clamp Load. %f < %f

809 Check Error Step %d, Check: Torque/Current. %f < %f

810 Check Error Step %d, Diagnostic: Angle count low on control ch. %f < %f

811 Check Error Step %d, Diagnostic: Angle count high on monitoring ch. %f > %f

812 Check Error Step %d, Diagnostic: Angle count low on monitoring ch. %f < %f

813 Setup Error Step %d, Speed is not defined

814 Setup Error Step %d, Control: Slope has bad configuration

815 Setup Error Step %d, Check: Wrong steptype for Check

816 Check Error Step %d, Check: Angle at the corner failed

817 Check Error Step %d, Check: Angle at the corner %f < %f

818 Check Error Step %d, Check: Angle at the corner %f > %f

819 Setup Error Step %d, Check: Torque has bad configuration

820 Check Error Step %d, Check: Torque at the corner failed

821 Check Error Step %d, Check: Torque at the corner %f < %f

822 Check Error Step %d, Check: Torque at the corner %f > %f

823 Check Error Step %d, Check: Clamp Angle failed

824 Check Error Step %d, Check: Clamp Angle %f < %f

825 Check Error Step %d, Check: Clamp Angle %f > %f

826 Check Error Step %d, Check: Clamp Torque failed

827 Check Error Step %d, Check: Clamp Torque %f < %f

828 Check Error Step %d, Check: Clamp Torque %f > %f

829 Setup Error Step %d, Check: Shut Off Torque has bad configuration

830 Check Error Step %d, Check: Shut Off Torque %f < %f

831 Check Error Step %d, Check: Shut Off Torque %f > %f

832 Check Error Step %d, Check: Shut Off Torque failed

833 Setup Error Step %d, Restriction: Torque-Current has bad configuration

834 System Error Error Step %d, Received unexpected SP_RUN_STEPS from station.

835 General Error Step %d, Run reverse before retry failed (max time was exceeded)

836 General Error Step %d, Run reverse before retry failed (max torque was exceeded)

837 General Error Step %d, Run reverse before retry failed

838 Setup Error Step %d, Spindle %d has incorrect Gear ratio

901 Check Error Step %d, Restriction: Fail-safe torque

902 Check Error Step %d, Restriction: Fail-safe angle

903 Check Error Step %d, Restriction: Fail-safe time

904 Check Error Step %d, Restriction: Fail-safe clamp load

905 Check Error Step %d, Restriction: Cross thread and gradient

906 Check Error Step %d, Restriction: Torque profile

907 Check Error Double transducer: torque diff high

908 Check Error Double transducer: angle diff high

909 System Error Error / Info Monitoring: Overflow in recording buffer

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910 Hardware Error Error Step %d, Servo hardware failure, Id %d

911 Setup Error Incorrect Servo configuration

912 System Error Error Clamp load mesuring failed, status %d

913 Check Error Step %d, Torque channel 1 saturated

914 Check Error Step %d, Torque channel 2 saturated

916 Check Error Step %d, Restriction: Torque/Current

917 System Error Error No Snug point was found

1102 Hardware Error Error Low battery voltage on TC %d

1103 Hardware Error Error Low -5V external voltage on TC %d

1104 Hardware Error Error Low +5V external voltage on TC %d

1105 Hardware Error Error Low AI reference voltage on TC %d

1106 System Error Error Primary on addr 0x%x received setup from other primary with addr 0x%x

1107 System Error Error TC %d received setup from 2 primaries: 0x%x and 0x%x

1500 Ext.com.Error Error ID write error %d on TC %d, port %d

1501 Ext.com.Error Error ID read error %d on TC %d, port %d

1502 Ext.com.Error Error ID read error on TC %d, port %d. Invalid start char. ASCII = 0x%x

1503 Ext.com.Error Error ID read error on TC %d, port %d. Unable to read tag, Data = %d

1504 Ext.com.Error Error ID write error on TC %d, port %d. Unable to write tag, Data = %d

1601 System Error Error Device init. error (TC %d, device %d, info %d)

1602 Ext.com.Error Error Illegal link message received (TC %d, device %d, info %d)

1603 Ext.com.Error Error Device is not on a PLC TC (TC %d, device %d)

1604 Ext.com.Error Error Missing sequence number (TC %d, device %d, expected seq. no %d)

1605 Ext.com.Error Error Receivied setup is to big (TC %d, device %d)

1701 System Error Error Fieldbus on TC %d has no contact with PLC

1702 System Error Error Fieldbus on TC %d can not read process data (err %d)

1703 System Error Error Fieldbus on TC %d can not write process data (err %d)

1704 Ext.com.Error Error Fieldbus on TC %d can not read from board (err %d)

1705 Ext.com.Error Error Fieldbus on TC %d can not write to board (err %d)

1706 Ext.com.Error Error Fieldbus on TC %d rec. a req. (0x%x) that requires Data bytes In >= %d

1707 Ext.com.Error Error Fieldbus on TC %d rec. a req. (0x%x) that requires Data bytes Out >= %d

1708 Setup Error Fieldbus on TC %d requires Data bytes Out > %d to auto load cycle data

1709 Ext.com.Error Error Fieldbus on TC %d rec. a Flush/Skip req. (0x%x) for an invalid address %d

1710 Ext.com.Error Error Fieldbus on TC %d rec. an ambig. req. (0x%x) (>1 of R, W, F & S are set)

1711 Ext.com.Error Error Fieldbus on TC %d rec. a req. (0x%x) having an invalid extended format

1712 Ext.com.Error Error Fieldbus on TC %d rec. a req. (0x%x) having an invalid address (%d)

1713 System Error Error Fieldbus on TC %d is not licensed

1901 System Error Error API on TC %d rec. an illegal message (err %d, info %d)

1902 System Error Error API on TC %d rec. a Read Setup req. Only allowed on TC 1

1903 System Error Error API on TC %d rec. a Write Setup req. Only allowed on TC 1

1904 System Error Error API on TC %d rec. a Read Setup Item req. Only allowed on TC 1

1905 System Error Error API on TC %d rec. a Write Setup Item req. Only allowed on TC 1

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2001 System Error Error CCH: Error when receiving (type=%d, d1=%d, d2=%d)

2002 System Error Error CCH: Error when sending (type=%d, d1=%d, d2=%d)

2003 Hardware Error Error CCH: System Software in FLASH has wrong Checkum

2004 System Error Error CCH: PLC ZIP file access error (access=%d, info=%d)

2005 System Error Error CCH: Unable to delete trace (first failing TC=%d)

2006 System Error Error CCH: Unable to delete events (first failing TC=%d)

2007 System Error Error CCH: Unable to delete cycle data (first failing TC=%d)

2008 System Error Error CCH: Unable to delete SPC data (first failing TC=%d)

2009 System Error Error CCH: Link message is to big (sock=%d, size=%d)

2010 System Error Error CCH: Link message has no header (sock=%d)

2100 System Error Error REP: Calculated size wrong

2201 System Error Error IO: two units with same address

2202 System Error Error IO: Illegal channel

2203 System Error Error IO: No CAN driver found

2204 Hardware Error Error IO: TC %d, chan %d. Subscriber not found

2205 Ext.com.Error Error IO: Error communicating with I/O device (TC %d, device %d)

2400 System Error Error Zip expand failed. Error %d, size in %d, size out: %d

2401 System Error Error Zip compress failed. Error %d, size in %d, size out: %d

2701 System Error Error Hunt for spif process failed

2702 System Error Error Timeout when waiting for answer from SPIF process

2704 System Error Error No contact with the CAN process

2705 System Error Error Servo parameters in TC %d are not OK

2706 System Error Error Servo parameters Checkum changed for TC %

2707 Hardware Error Error Servo status TC %d: Servo did not respond to command

2710 Hardware Error Error Servo status TC %d: RD1 (resolver) error

2711 Hardware Error Error Servo status TC %d: Drive overheated

2712 Hardware Error Error Servo status TC %d: Motor overheated

2713 Hardware Error Error Servo status TC %d: Any Fault

2714 Hardware Error Error Servo status TC %d: Position error

2715 Hardware Error Error Servo status TC %d: Bleed error

2716 Hardware Error Error Servo status TC %d: RD2 error

2717 Hardware Error Error Servo status TC %d: Current limit error

2718 Hardware Error Error Servo status TC %d: DC bus overvoltage trip

2719 Hardware Error Error Servo status TC %d: Current regulator trip

2720 Hardware Error Error Servo status TC %d: Current trip

2721 Hardware Error Error Servo status TC %d: Bit 11 set

2722 Hardware Error Error Servo status TC %d: Bit 12 set

2723 Hardware Error Error Servo status TC %d: Over current - 300s

2724 Hardware Error Error Servo status TC %d: DC bus voltage too low

2725 Hardware Error Error Servo status TC %d: Firmware insuffucient for this PL application

2726 Hardware Error Error Servo status TC %d: Run down allowed

2727 Hardware Error Error Servo status TC %d: Run down in progress

2728 Hardware Error Error Servo status TC %d: Current control mode

2729 Hardware Error Error Servo status TC %d: Target reached

2730 Hardware Error Error Servo status TC %d: Target reached sent

2731 Hardware Error Error Servo status TC %d: Bit 21 set

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2732 Hardware Error Error Servo status TC %d: Bit 22 set

2733 Hardware Error Error Servo status TC %d: Bit 23 set

2734 Hardware Error Error Servo status TC %d: Bit 24 set

2735 Hardware Error Error Servo status TC %d: Bit 25 set

2736 Hardware Error Error Servo status TC %d: Bit 26 set

2737 Hardware Error Error Servo status TC %d: Bit 27 set

2738 Hardware Error Error Servo status TC %d: Bit 28 set

2739 Hardware Error Error Servo status TC %d: Bit 29 set

2730 Hardware Error Error Servo status TC %d: Bit 30 set

2741 Hardware Error Error Servo status TC %d: Bit 31 set

2742 Hardware Error Error Servo status TC %d: Bit 32 set

2743 Hardware Error Error Servo status TC %d: Bit 33 set

2744 Hardware Error Error Servo status TC %d: Bit 34 set

2745 Hardware Error Error Servo status TC %d: Servo detected lost communication

2774 Hardware Error Error Servo on TC %d does not support Hold Torque as stop condition

2802 System Error Error Invalid communication port for device %d

3100 System Error Error Hunt for station failed

3101 System Error Error TestBolt: DB read error, code %d

3102 Setup Error TestBolt: No station defined in the setup

3103 General Error TestBolt: Disabled by PLC for station %d

3201 System Error Error PLC: Run time system error (code 0x%x, info 0x%x)

3202 System Error Error PLC: Bootfile access error (error %d)

3203 System Error Error PLC: Only one input and one output ’EXTCOM’ driver allowed (now %d and %d)

3204 System Error Error PLC: ’EXTCOM’ area (input %d + output %d) is to big (max %d bytes)

3205 Setup Error PLC: ’ANYBUS’ variables defined but no Fieldbus device exists

3206 Setup Error PLC: Only one ’ANYBUS’ input/output driver is allowed (now %d and %d)

3207 Setup Error PLC: ’ANYBUS’ input area (%d) is to big. Fieldbus declares only %d bytes

3208 General Error PLC: User event %d generated

3209 Setup Error PLC: ’ANYBUS’ output area (%d) is to big. Fieldbus declares only %d bytes

3303 Setup Error Fieldbus on TC %d: Config. error. Max output size=%d, max input size=%d

3305 Setup Error Fieldbus on TC %d: Board type mismatch, type connected=%d, type configured=%d

3306 System Error Error Fieldbus on TC %d: Hardware access error (err %d)

3307 Setup Error Fieldbus on TC %d: Configured Node addr.(%d) is out of range

3308 Setup Error Fieldbus on TC %d: Setting Node addr. by SW is not supported

3309 Setup Error Fieldbus on TC %d: Setting Baude Rate by SW is not supported

3310 Setup Error Fieldbus on TC %d: Configured Baude Rate (%d) is not supported

3311 Setup Error Fieldbus on TC %d: Configured Source Node addr. (%d) is out of range

3312 Setup Error Fieldbus on TC %d: Source no. of words (%d) is > Fast bytes In / 2 (%d)

3313 Setup Error Fieldbus on TC %d: Source Offset + Source no. of words (=%d) must be <= 32

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3314 Setup Error Fieldbus on TC %d: Unsuppported param used (Modbus specific)

3402 System Error Error ToolsNet handler: Illegal message received (error type %d, info %d)

3403 Ext.com.Error Info Toolsnet handler: Connection to server established

3404 Ext.com.Error Error Toolsnet handler: Connection to server lost

3405 Setup Error ToolsNet handler: Bad Data IP address (%d)

3406 Setup Error ToolsNet handler: Bad Status IP address (%d)

3500 System Error Error SPC: DB read error (%d)

3501 System Error Error SPC: Out of memory

3503 System Error Error SPC: Variable does not exist (Bolt: %d, StepNo: %d, Var: %d)

3504 SPC Error SPC: One out check failed

3505 SPC Error SPC: End gather check failed

3506 SPC Error SPC: Mid gather check failed

3507 SPC Error SPC: Seven above check failed

3508 SPC Error SPC: Seven below check failed

3509 SPC Error SPC: Seven up check failed

3510 SPC Error SPC: Seven down check failed

3511 SPC Error SPC: Cp limit check failed

3512 SPC Error SPC: Cpk limit check failed

3513 SPC Error SPC: Cam limit check failed

3514 System Error Error SPC: Subgroup size must be > 0 (NoSttSgSave=%d Sgsize=%d NoSubSgSave=%d)

3515 System Error Error SPC: Ref. to free area is corrupt (FreeMem=%d SubgrpBase=%d NoSubSgSave=%d)

3516 SPC Error SPC: SPC data structure corrupt, pos %d, idx: %d, %d

3517 Setup Error SPC: Too many variables for spindle %d

3601 Ext.com.Error Error Illegal link message rec. (device %d, type %d, info %d)

3700 Ext.com.Error Error Send failed. Not possible to correct with retransm. (port %d, info %d)

3701 Ext.com.Error Error Received failed (port %d, info %d)

3702 Ext.com.Error Error Statemachine error for send (port %d, state %d)

3703 Ext.com.Error Error Statemachine error for receive (port %d, state %d)

3704 Ext.com.Error Error Status from sio not OK (port %d, retcode %d)

3705 Ext.com.Error Error Unknown protocol selected (port %d, protocol type %d)

3706 Ext.com.Error Error Bad Checkum received (port %d, Checkum in tgm %d, calc. Checkum %d)

3707 Ext.com.Error Error Read telegram failed (TELWAY protocol, info %d)

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5HIHUHQFHVWRH[WHUQDOGRFXPHQWV

1. “Functional and Technical Description PowerMACS TCs”

1. "PowerMACS PLC Manual"

1. "PowerMACS Ethernet Manual"

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,QWURGXFWLRQ

This part describes some basic concepts that are used throughout the complete document and have very specific meanings.

6\VWHP

A V\VWHP comprises one or more Tightening Controllers linked together. A system works autonomously, performing a tightening task.

6WDWLRQ

Within a system there is one or more VWDWLRQV . A station controls the tightening of one or more bolts. It has a PLC to control the tightening cycles.

%ROW

A EROW is the object that will be tightened by the system.

6SLQGOH A VSLQGOH performs the actual tightening of a bolt. It normally comprises:

• Motor

• Torque sensor

• Angle sensor

Often one bolt is tightened with one spindle, but it is possible to configure the system so several bolts are tightened with one spindle.

3URJUDPVWHSVDQGVHTXHQFHV

How the tightening of the bolt should be done is described in a tightening SURJUDP . The program comprises VWHSV , each describing how a part of the tightening cycle should be performed.

A number of steps can be saved as a VHTXHQFH . When building a new tightening program, or altering an existing one, it is possible to insert sequences.

0RGH

When a tightening cycle is started, the choice of tightening program is done using the 0RGH signal in the PLC. With use of a mode table it is defined which tightening program that should be used for each of the specific bolts in each mode. Each station in a system has its own unique 0RGH table.

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&\FOH

A tightening F\FOH is all operations from a start signal until ready to start next cycle.

5HMHFW0DQDJHPHQW

5HMHFWPDQDJHPHQW is an alternative sequence to be followed, in the event of a NOK situation with the purpose to achieve an OK condition by doing a second try.

6KLIW

A shift is a time period. It is programmable when shifts starts and stops during a day (weekends may be different). Some results/reports are related to shifts.

&RQVROH&RPSXWHU

The FRQVROH or FRQVROHFRPSXWHU is the PC computer used to set up a PowerMACS system. It is not needed for automatic running, but it can optionally be used to monitor the system and to collect and present various data using the WinTC program.

One console computer can be used for several systems, if these are hooked up on the same computer network, but only one system at a time.

:LQ7&

The WinTC is the graphical user interface of the PowerMACS system. It is a Windows based program that executes on the console computer. It is used to set up a PowerMACS system and can be used to monitor the system and to collect and present various data.

2IIOLQHDQGRQOLQH

The WinTC program can be run in off-line or on-line mode.

In off-line mode it does not have to be connected to the system, and can therefore be run anywhere. In off-line mode it is possible to set up a new configuration or alter existing ones. When ready connect the console computer and go on-line. The setup can then be downloaded and stored in the system.

When in on-line mode it is possible to monitor the system in real time. Cycle data can be presented, traces investigated, events checked etc.

6HWXSDQG7DEOHV

A VHWXS is a group of data that completely describes the system. The system uses the information in the

VHWXS to know what to do. A VHWXS could also be called a FRQILJXUDWLRQ . A VHWXS can be stored on the console computer in a file on a hard disk or on a floppy. It can be downloaded to the system, or uploaded for storing or alteration.

A VHWXS is made up of WDEOHV , each containing data for a specific topic, e.g. tightening program, SPC VHWXS etc.

Setups are manipulated with the WinTC application program on the console computer. It is possible to export and import certain tables, but the setup itself is a complete package.

V\VWHPWRUTXHXQLW!

is the torque unit selected for the system, or setup. This is selected using the Options form.

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3/&

In every PowerMACS station there is a 3/& (Programmable Logic Controller). The PLC is used as ”glue” between various functions within the system like:

• Start of tightening from digital inputs

• Output of status to digital outputs

• Controlling flow of data

• Analyzing ID codes

*URXS

In many cases, when there is a problem with one bolt, reject actions must be performed not only on this bolt but with others within the station. In PowerMACS it is therefore possible to put bolts together in

JURXSV .

A group is a set of bolts, which are run completely separate from each other, but have some form of relationship. In case of reject management, they are considered to belong to the same group, and special actions can be specified for bolts within the group.

The bolts in a station can be divided into groups of bolts as in following figure:

station groups

St 1

Gr 1

Gr 2

Gr 3

bolt

All bolts belong to the station St 1.

Bolts 1 and 2 belongs to group Gr 1, bolt 3 and 4 to group Gr 2, bolt 5 and 6 to group Gr 3.

A special case is bolt 3 and 5, which both belongs to two groups at the same time.

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