Pressing Monitoring APM-SI

force vs displacement

Pressing Monitor Systems APM-SI

The Advanced Force Distance Process Monitoring System for Pressing Applications

How do you determine the quality of your parts? In contrast to conventional practices of inspecting the finished part for defects, our system can combine the Force and Distance measure provided by the sensors embedded in our servo press. The system in this way receives the necessary data to monitor the process and provides the capability to create a warning system. Our systems have the capability of measuring the process variation during production, thus detecting problems at the source before they become quality issues, thanks to the capability of combined control of two parameters Force vs Displacement. Comparisons can now be made with the waveforms generated by a masterpiece preloaded in the systems. This information is very important because it can be compared to a mathematical model of your quality standards. In other words if an acceptable process is known, our system can be calibrated to repeat the known process and produce parts that conform and the process is verifiable consistent and repeatable. A constant control of Force vs Distance indicates that the resulting part has been produced according to the previously verified acceptable part. By continuously monitoring the measurement parameters of the servo press, it is possible to detect variances that can mean the process is no longer quality capable. Catching defects at the source gives manufacturers the confidence that only good parts are shipped to the customers. Auloma is looking to find system integrators skilled in Siemens ® hardware installation to be affiliate in our network to expand our business in India.

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APM-SI MeMo

Video: Press Monitoring Software

Press fit applications and metal forming.

Pressing Monitor Systems APM-SI

Product Configuration

APM-SI is a process monitoring software developed to monitoring the pressing applications. The software is installed in the CPU of the intelligent servo drive SIEMENS ® and is possible set up the pressing parameters trough our APM-PC ToolKit. APM-SI is configured as slave machine and its flexibility allow several applications in different industries. Our System can be connected to a PLC (master) with Profinet or Ethernet interface. As soon as you install an Auloma servo press with APM, you can verify the simplicity of the hardware installation.

pressing monitoring for industrial process

SIEMENS ® Servo Drive with APM-SI installed, HEIDENHAIN ® Drive Cliq interface and APM-PC ToolKit CD-Room

 

Servo Drive D410-2 main features

Display and diagnostics

  • LEDs to display operating states and errors
  • 3 measuring sockets
  • Service switch and mode selector
  • Diagnostics button

Onboard I/Os

  • 5 digital inputs
  • 8 digital inputs/outputs (max. 8 as output cams or 8 as measuring inputs)
  • 3 fail-safe, two-channel inputs (F-DI); can also be used as 6 DI
  • 1 fail-safe output (F-DO); can also be used as 1 DO
  • 1 analog input (either ± 10 V or ± 20 mA)

Communication

  • 1 x DRIVE‑CLiQ
  • 1 x PROFINET IO (1 interface with 2 ports, D410‑2 DP/PN only))
  • 1 x PROFIBUS DP (D410‑2 DP: 2 × PROFIBUS DP)

Data backup

  • 1 x slot for SIMOTION CompactFlash card

Additional interfaces

  • Terminals for 24 V electronics power supply
  • 1 x encoder input for
  • SSI absolute encoder (without incremental signals)
  • 1 x temperature sensor input (KTY84‑130 or PTC)
  • PM IF interface (Power Module interface) on rear for direct operation with a SINAMICS S120 PM240-2 or PM340
  • Power Module in blocksize format
 
 

Pressing Monitor System APM-SI Benefit

  • Lonely environment to control servo press job and process monitoring installed in servo drive memory
  • Modular press programs with infinite steps for press to force, press to position and press to relative position
  • Real time process monitoring
  • Servo press diagnosis
  • Enhance defect detection
  • Reduce the scrap cost
  • Ethernet interface for data exchange
  • Analysis data in CSV format for SPC
  • PC tool kit compatible with wichever MS Windows 7 ® machine and later version

Pressing Monitor System APM-SI Features

Software

  • Best industrial software for press program and process monitoring
  • Two channels (x)(y) analysis for real time Process Monitoring
  • Multiple waveform control zones
  • Envelope function for complete waveform control
  • Eight additional force limits
  • Waveform trajectory recognition
  • CSV data transfer

Hardware

  • Memory capability to store 254 press recipes
  • Memory capability to store 254 envelopes force control

PC User Interface

  • Simple and intuitive user display
  • Supervisor account with password security

Multiple Data Views

  • Status: see part test status (pass or fail)
  • Curves: view data curves (Force vs. Distance) with overlaid limits
  • History: review last test cycles and part history records
  • Limits: view current limits

Detailed Data Management and Reporting

  • Local PC & remote storage of test results organized by model, part, ram, etc.
  • Process data available in CSV format for Statistical Process Control (SPC)

Servo Drive Connectivity

  • Communication with station controller via Profinet or Ethernet in APM slave configuration
  • Communication with station controller via discrete I/O in APM slave configuration
  • Ethernet TCP/IP for data transfert
  • USB
 
 

Pressing Monitor Systems APM-SI

THREE DIFFERENT KIND OF SERVO PRESS CONTROL

APM-SI own three mode to control the press ram. The set up of each program is easy and friendly. In few minutes is possible set up the press according your application. The three mode allow a ram control to press at the right force, at the right position or at the right relative position from a force signal trigger or by an external sensor. The press program is saved in the memory of the servo drive unit and within a maximum of 254 recipes

THE BEST HUNTER OF PARTS DEFECTS

The brain of the APM-SI is the powerful CPU that allow a faster analysis of the data gathered from the press sensors. The APM software produce a faster analysis of all data provided by the servo press. The press waveform results are controlled by multiple tolerance off set zones or by an envelope that wrapping the trajectory. Thanks to this method if the process is repeatable the analysis results are repeatable also and by the comparison of a masterpiece waveform the APM can decide in few milliseconds if the parts are correct or wrong.

MULTIPLE GRAPHICAL DATA VIEWS

The APM displays all informations about press program and test result on a Windows ® PC machine with APM-SI toll kit installed. Thanks to the icons on the software interface is easy display tables and graphs. The navigation inside the APM-SI Toll kit is protected by password and allow different set up level according the permission.

CSV DATA TRANSFERT

The APM-SI can provide the process signature data in CSV ( Comma Separated Value ) format to an external data storage. The CSV data can be used for SPM ( Statistic Process Management ) or SPC ( Statistic Process Control ) and can be processed by many ERP, MRP and spread sheet )

DEFECTS DETECTED

Parts
Correct Assembly
 
Crack Part
Excessive Distance
Incorrect Insertion
Incorrect Orientation
Incorrect Part
Insufficient Distance
Missing Parts
 
 

Software ToolKit APM-SI

Functionality

The best yield obtained by Auloma servo press is when all analysis data provided are saved and analysed in a PC machine. Statistical analysis of your data allow an awared knowledge of your quality trend. Through APM-SI Tool Kit whichever PC machine can set up the press operations but can also save and see all analysis data. With a good organization of the archive folders is possible research the data stored through a DB and then analysed by Statistic Process Management installed.

 
 

APM ToolKit Press Program

APM-SI displays a templates where is possible choose and edit the variables to control the servo press drive profile. Is possible create complex recipes with multifunction and manage different tools and applications. In the same recipes it will be possible execute and monitoring the process for press fit, forming, joining, clinching, bending, riveting and more applications.

 
 

APM ToolKit Press Monitoring Setting Limits

The APM-SI displays a menu to setting the force limits on waveform. APM has the possibility to load several waveforms (curves) and displays all together to aid the programmers in force limits set up.

 
 
Function to displays several masterpiece curves to determinate the force off set (Hi and Low) limits
 
 
Capability to set 8 control boxes of Hi and Low force off set values
 
 
Capability to set 8 consecutive control boxes (Envelop) of Hi and Low force off set values to wrapping the waveform
 
 
Capability to set 8 control zones composed by a mix of Envelop and control boxes
 
 
Capability to set 8 additional 8 force limits, displayed by horizontal red dashed lines
 
 

APM ToolKit Curves View

The APM-SI provide each cycle the curves produced by the data gathered. The curve is displayed on (x) (y) graph, where in (x) there is the ram stroke scale and in (y) the force. The view of the curve is aided by a smart zoom function and pan function. The off set force limit settled on the curves can be displayed through the properly buttons on the screen.

 
 
 

APM ToolKit History View

The APM save each cycle result in two different CSV files. The 1st file provides the raw data to identify the historical period, the 2nd file provides the raw data about the analysis. Both files are saved on the respective folder path. The analysis history is displayed below the curve templates and is possible displays each historical curves through a flaggable field.

 
 

APM ToolKit Waveform Analysis

Capability to recognize the waveform trajectory through the defined intersection with the control boxes. Wrong intersection is displayed in red and provide a warning signal to the master PLC

 
 
Capability to recognize the waveform trajectory out from the off set Hi and Low force value. Control boxes displayed in red. The system provide a warning signal to the master PLC
 
 
Capability to recognize the waveform trajectory inside the off set Hi and Low force value. Control boxes displayed in green. The system provide an ok signal to the master PLC