WORKSHOP UFM - V5

(ELECTRO MECHANICAL ASSEMBLY UNITS)

WORKSHOP THEMES

1. SYSTEM DESIGN
2. MECHANICAL DESIGN
3. ELECTRICAL DESIGN
4. SOFTWARE DESIGN
5. PROCESS CONTROL
6. CREATION OF JOINING CYCLES
7. INTERPRETATION OF ERROR-MESSAGES
8. EXCHANGE OF COMPONENTS; CALIBRATION
1. SYSTEM DESIGN
Unit 1

PC NC Drive

Unit 2

NC Drive

Unit 3

NC Drive

Unit n
PLC-Control
NC Drive
2. MECHANICAL DESIGN

Principle „Transparent Technology“

Solid design
Designed for long life time
High forces, high speeds
Clean and smooth running
System without oil or air
Technology to solve complex requirements
2. MECHANICAL DESIGN

Ball Screw
Press Ram
Axial Bearing
External Pipe
Force Transducer
Tooth Wheel and Tooth Belt
AC-Servo-Motor
2. MECHANICAL DESIGN
Ball Screw
2. MECHANICAL DESIGN
Ball Screw with Press Ram
2. MECHANICAL DESIGN
Unit without Motor and Belt
2. MECHANICAL DESIGN
Complete Unit
2. MECHANICAL DESIGN
Lubrication advice
If Lubrication is insufficient, no
guarantee is offered by PROMESS

Lubrication chart and Lubricant

according to manual

Lubrication Points:
A und B for link-block guides
C for ball screw
D for axial bearing
2. MECHANICAL DESIGN
Lubrication advice

Lubrication for 3kN unit

Intervals:
5000 working hours or
250000 strokes
3. ELECTRICAL DESIGN

The UFM is connected to the PC

by the Ethernet Module

Several UFM’s can easily be

connected to the PC by a Switch

maximum 16 units can

communicate with 1 PC
3. ELECTRICAL DESIGN
Components: Drive
Slot 1 : SM-Resolver-Module;
SM-Universal-Encoder-Plus-Module

Slot 2: SM - Applications – Plus Module

Slot 3: Field bus - Module

e.g.: SM - Profibus DP
SM - ProfiNet
SM - Ethernet
3. ELECTRICAL DESIGN
Drive + Ethernet Module
RS485-Interface to
Applicationsmodule

Ethernet
connection to PC

Electrical Supply and Update Interface

3. ELECTRICAL DESIGN
analog strain gauge pre-amplifier

Sensor sensitivity: 0.3 – 3.0mV/V

Signal outputs:
+/- 10V; 4-20mA; 0-20mA

ZERO GAIN
Potentiometer Potentiometer
3. ELECTRICAL DESIGN
digital strain gauge pre-amplifier (PDM-S)

Force signal PROMESS-

Bus

Encoder Power supply

connector 24VDC

LED
function
3. ELECTRICAL DESIGN
digital strain gauge pre-amplifier (PDM-S)

LED functionality

LED state
24 VDC lights up green when the device is supplied with power
Indicates the status of the cycle or the assigned unit
OK / NOK
(lights up green or red)
COM Communication signal
permanent green lighting = communication OK
green flashing = communication NOK
1 time flashing, break = hardware initialisation fault
2 times flashing, break = duplicate address assignment
3 times flashing, break = not connected to the bus
4 times flashing, break = no bus token
4. SOFTWARE DESIGN
Basics of measurement and testing technology

PRESSING POSITIONING TORQUE

• Joining • Synchronic • Flange play

• Rivets movement measurement
• Shaping • Force and torque • Thread testing
• Stamping remain constant • Moment of
• Bending friction
• Molding measurement
4. SOFTWARE DESIGN
Advantages of Promess Software

Easy programming
Simple to adjust or to change over
Integrated force and position monitoring
Clearly represented graphic design
The envelope will be created on the display so that
the force curve is monitored
4. SOFTWARE DESIGN

+ =

High Force High Speed Low life time

4. SOFTWARE DESIGN
Software main screen
 4. SOFTWARE DESIGN
Software main screen Input signals

16 Gauging
Variables
Push Buttons
Start / homing
3 Part-ID’s

Programming
Area Signal curve
64 Variables
Curve status
Status Line Information
4. SOFTWARE DESIGN
Memory and Data Organization
The NC-Module has an ID-number, which
DRIVE defines a specific unit and will never be used
for another module.
When the PC and the Module is
NC-
MOD connected for the first time, the PC will create
ULE
a directory with this ID-number
The directory includes:
Parameter file ( .px5)
Configurations files (.ini)
P Programs (.prg)
C Program Preselection list (.txt)
Database (.mdb)
4. SOFTWARE DESIGN
Memory and Data Organization

Identification number
4. SOFTWARE DESIGN
Memory and Data Organization

Parameter File

Process Program

Configuration File
WORKSHOP UFM – V5
(ELECTRO MECHANICAL ASSEMBLY UNITS)

End of
Workshop part 1
WORKSHOP UFM – V5
(ELECTRO MECHANICAL ASSEMBLY UNITS)
WORKSHOP THEMES

1. SYSTEM DESIGN
2. MECHANICAL DESIGN
3. ELECTRICAL DESIGN
4. SOFTWARE DESIGN
5. PROCESS CONTROL
6. CREATION OF JOINING CYCLES
7. INTERPRETATION OF ERROR-MESSAGES
8. EXCHANGE OF COMPONENTS; CALIBRATION
 5. Process Control
Calculation of Position example: UFM 3kN

Screw pitch: Gear ratio: i = 1.56

s = 5 mm (tooth belt gear)

Gear ratio: i = 1
(bearing)

Encoder solution:
65536 inc./revolution

Stroke: 10mm = Mathematical Model:

203889.78inc
(1,56 * 65536 inc) / 5 mm = 20388.978 inc/mm
5. Process Control Homing
 5. Process Control Homing

When the motor or the belt has been replaced,

the position of the reference index also changes.
5. Process Control Homing

Each of the three positions corresponds to the

home index (reference-index) of the Resolver
6.CREATION OF JOINING CYCLES

Move
Press to signal
Motion control
Gauging, Variables
Tara,
Conditional jumps,
Inputs/Outputs
6.CREATION OF JOINING CYCLES
Move

s
start final
position position
Fügen auf Block
6.CREATION OF JOINING CYCLES
Move

Start position
Fügen auf Block
6.CREATION OF JOINING CYCLES
Move

Final position
6.CREATION OF JOINING CYCLES
Press to Signal

F/v

Pre-position max. press-in pos.

6.CREATION OF JOINING CYCLES
Press to Signal

Benchmark position: Pre-position

Speed: 50 km/h
Fügen auf Block
6.CREATION OF JOINING CYCLES
Press to Signal

Pre-position (behind the block)

Fügen auf Block
6.CREATION OF JOINING CYCLES
Press to Signal

Block position (the part is pressed against the shoulder)

6.CREATION OF JOINING CYCLES
Press to Signal

End gauge with

+/- tolerance
Work piece with
+/- tolerance
6.CREATION OF JOINING CYCLES
Press to Signal

End positions may

have different
tolerances
6.CREATION OF JOINING CYCLES
Press to Signal

Example:
Catalyst testing

Catalyst UFM
WORKSHOP UFM – V5
(ELECTRO MECHANICAL ASSEMBLY UNITS)

End of
Workshop part 2
WORKSHOP UFM – V5
(ELECTRO MECHANICAL ASSEMBLY UNITS)
WORKSHOP THEMES

1. SYSTEM DESIGN
2. MECHANICAL DESIGN
3. ELECTRICAL DESIGN
4. SOFTWARE DESIGN
5. PROCESS CONTROL
6. CREATION OF JOINING CYCLES
7. INTERPRETATION OF ERROR-MESSAGES
8. CALIBRATION; EXCHANGE OF COMPONENTS
7.INTERPRETATION ERROR-MESSAGES
cause of failure: force transducer

cable defect
supply voltage is broken or interrupted
measuring wire is broken

overload / destruction of the force transducer

permanent deformation of the force transducer
8. Calibration
Calibration of strain gauge sensors
The accuracy class of the PROMESS system is 1.0
The reference-sensor with display should be more accurate than 1.0

Procedure of calibration:
1. Check the zero point (in unloaded position)
2. Create a calibration program in the PROMESS software
3. Compare different values from reference and PROMESS
sensors
4. If the PROMESS values are out of tolerance, adjust
potentiometer within the pre-amplifier, up or down
8. Calibration
Promess digital pre-amplifier

• PDM-S 1 x force (strain gauge sensor) + 1 x stroke

• PDM-P 1 x force (piezo sensor) + 1 x stroke
• PDM-A 4 x analog inputs
• PDM-IO 16 digital inputs and outputs
8. Calibration
Promess digital pre-amplifier
Resolution A/D converter:
24bit

Save the calibration list

8. Calibration
PDM-S 2-point-calibration
For the 2-point calibration there is only one best fit line over the complete load
range. The linearity error of the force transducer cannot therefore be compensated.

25

20

15
Kraftaufnehmer
10 Ausgleichsgerade

0 Accuracy class 1 %
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
8. Calibration
PDM-S 2-point-calibration
Adjustment zero point without force:
1. Push the exclamation point to transfer the
current digit value
2. Enter 0.00 as reference value to define
the digit value as zero

Push the exclamation point to transfer the

current digit value

Adjustment amplification:
1. Approach a calibration force
2. Push the exclamation point to transfer the
current digit value
3. Enter the force value according to the
reference measurement
8. Calibration
PDM-S multipoint calibration
For the multipoint calibration there is not only one best fit line, but instead serveral
for each characteristic zone over the complete load range.
Promess software offers a maximum of 10 best fit lines. The non-linearity of the
force transducer can therefore better compensated.
25
Kraftaufnehmer
20 Ausgleichsgerade 1
Ausgleichsgerade 2
15
Ausgleichsgerade 3
10 Ausgleichsgerade 4
Ausgleichsgerade 5
5 Accuracy class less
Ausgleichsgerade 6 then
Ausgleichsgerade 7
<0,3 %
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
8. Calibration
PDM-S multipoint calibration
Adjustment zero point without force:
1. Push the exclamation point to transfer the
current digit value
2. Enter 0.00 as reference value to define
the digit value as zero

Push the exclamation point to transfer the

current digit value

Adjustment amplification:
1. Approach 1-10 diff. force calibrations
2. Push the exclamation point to transfer the
current digit value
3. Enter the force value according to the
reference measurement
8. Calibration
Program example
8. Calibration
Program example 2
8. EXCHANGE OF COMPONENTS
Preparation
Saving of following data:

note current software -version

save system parameters
save the directory of the station (Ident.-no.)
record the reference position of the motor:
1.) record location of the absolute zero point (resolver
position when the ram makes contact with proximity
switch)
2.) record position by using a master piece
8. EXCHANGE OF COMPONENTS
Finding out the master piece position

1. Put in the Master piece

(red)
2. Position the ram on that
piece with low force and
note the position
3. The difference between
the old and the new
value is entered as
reference offset
8. EXCHANGE OF COMPONENTS
changing mechanical unit

After changing the mechanics or the pre-amplifier, a

calibration is necessary
The difference of the position can be determined with
a master piece and entered as a offset in the software
(home offset)
Find out the resolver position by using a test program.
(The ram will drive up to the proximity switch.)
8. EXCHANGE OF COMPONENTS
Changing the drive (SP)

1. Switch off the main power

2. Take out all modules (resolver,applications,fieldbus)
3. Disconnect the drive
4. Mount the new drive of the same type
5. Connect the drive, check the sequence of the
modules !
6. Switch on the main power and start the software
7. Download the system parameters
8. EXCHANGE OF COMPONENTS
Changing the drive (SP)
Slot 1 : SM-Resolver-Module;
SM-Universal-Encoder-Plus-Module

Slot 2: SM - Applications – Plus Module

Slot 3: Field bus - Module

e.g.: SM - Profibus DP
SM - ProfiNet
internal braking
resistor SM - Ethernet
8. EXCHANGE OF COMPONENTS
Changing the drive (SP)

OPEN
Preselection of
the system
parameter file
„ “
Parameters will be
downloaded from
PC to the drive
8. EXCHANGE OF COMPONENTS
Changing the SM–Applications-Plus Module

1. Switch off the main power

2. Change the SM-Applications-Plus Module (Slot 2 !)
3. Switch on the main power and start the software
4. In case of different software version = Software update!
5. Download the system parameters
6. Download the assembly programs
WORKSHOP UFM – V5
(ELECTRO MECHANICAL ASSEMBLY UNITS)

End of
Workshop part 3