Pressing Monitoring APM-BA

Industrial processes monitoring

Pressing Monitor Systems APM-BA

The Smart Force Distance Process Monitoring System

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. With our advanced signature analysis technology force vs distance, we provide the most accurate defect detection, parts traceability and data analysis transformed in actionable information to reduce scrap cost and maximize yield

Interface with application name configurable capable of manage 4 presses or more simultaneously

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Pressing Monitor Systems APM-BA

Product Configuration

APM-BA is a process monitoring software developed to monitoring the pressing applications. The software is installed in the CPU of the intelligent servo drive Bosch Rexroth® and is possible set up the pressing parameters trough our APM-PC ToolKit. APM-BA is configured as slave machine and its flexibility allow several applications in different industries. Our System can be connected to all kind of PLC (master) because the dialogue with the APM station is trough discrete digital Inputs/Outputs. As soon as you install an Auloma servo press with APM, you can verify the simplicity of the hardware installation and the few time spent for configuring and set up.

pressing monitoring hardware

Bosch Rexroth® Servo Drive with APM-BA installed and APM-PC ToolKit CD-Room

 

Servo Drive IndraDrive main features

  • Embedded MultiEthernet
  • Safe torque-off (STO) as standard - to IEC 61 800-5-2, SIL3 PLe
  • RS232 serial interface
  • APM-BA TOOLKIT provides configuration via Ethernet TCP/IP
  • AC servo drive from 4.5 to 145 A with 150 or 200% overload
  • Single phase 200 - 250 V AC or three phase 200 - 500 V AC operation (maximum limits)
  • Encoder EnDat
  • Encoder SSI input for close ring (optional)
  • 7 x digital inputs. Opto-isolated 24V fully occupied for press communications.
  • 4 x digital inputs Opto-isolated 24V fully occupied for press communications.
  • +/-10V analog inputs occupied for force monitoring
  • 2 x +/-10V analog output
  • Operation panel
 
 

Pressing Monitor System APM-BA Benefit

  • Lonely environment to control servo press job and process monitoring installed in servo drive memory
  • Modular press programs until 16 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 widows Vista ® machine and later version

Pressing Monitor System APM-BA 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
  • APM-BA TOOLKIT provides configuration via USB or Ethernet TCP/IP
  • Envelope function for complete waveform control
  • CSV data transfer

Quick Set Up

  • Friendly wizard for set up the servo press parameters
  • Friendly wizard for set up the waveform control zone

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 & 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 discrete I /O in APM slave configuration
  • Ethernet TCP/IP for data transfert
  • USB
 
 

Pressing Monitor Systems APM-BA

THREE DIFFERENT KIND OF PRESSING CONTROL

APM-BA own three modalities 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 modalities allow a ram control to press at the right force, at the right position and at the right relative position from a force signal trigger. the ram program is saved in the memory of the servo drive unit.

THE BEST HUNTER OF PARTS DEFECTS

The brain of the APM-BA 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-BA toll kit installed. Thanks to the icons on the software interface is easy display tables and graphs. The navigation inside the APM-BA Toll kit is protected by password and allow different set up level according the permission.

CSV DATA TRANSFERT

The APM-BA 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-BA

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 aware knowledge of your quality trend. Through APM-BA ToolKit 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-BA displays a templates where is possible edit the parameters to control the servo press ram. The templates propose an editor where is possible load the single functions from the default library to program a recipe with a maximum of 16 breakpoint. The program developed can execute three different kind of press control:

  • Press to force
  • Press to position
  • Press to relative Position

This flexibility allow toll changing and execute two or more kind of controls in the same cycle.

 
 

APM ToolKit Press Monitoring Setting Limits

The APM-BA displays a menu to setting the force limits on wafeform

 
 

APM ToolKit Status View

High level status screen allows operator and supervisors to quickly assess the part test status. The program displays until four presses in run. Each menu displays the instantaneous value of force and position of each ram. The central lower menu displays the press cycle results.

 
 

APM ToolKit Curves View

The APM-BA 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 1 st 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 HTML Report

The analysis results can be plot in HTML format to generate useful documents