Sensing Systems for Manufacturing

Mechanical Components
Terminology

EMAP TorquePRO REMAP

Electro-Mechanical Assembly Press Rotational Electro-Mechanical Assembly Press

P.O. Box 748 • Brighton, MI 48116 • 810-229-9334 • promess@promessinc.com

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 System
Layout
EMAP with
UltraPRO
Controller

P.O. Box 748 • Brighton, MI 48116 • 810-229-9334 • promess@promessinc.com

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EMAP Press Mechanical Layout

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TorquePRO Mechanical Layout

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REMAP Mechanical Layout

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 X11 Service Port
24VDC Supply
X1
STO Input
X5 EtherCAT In

X6 EtherCAT Out
Motor Power
X2
Holding Brake X7 Inputs/Outputs

X8 Inputs/Outputs

DC-Bus X10 Feedback

X3
Brake Resistor

X4 Main Power DrivePRO Servo

Drive with
Connections
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 3 Phase power connections

X7A EtherCAT in

DrivePRO X7B EtherCAT out

(S700) X2 Motor resolver input

Servo Drive X1 Encoder input

with
Connections Drive control power
Drive control signals
X3 * P-Stop (E-Stop)
* Enable
* STO inputs

Motor power connector

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 X1 EtherCAT in

X2 EtherCAT out

Digital
X3 Analog input 1 Signal
X4 Analog input 2
Conditioner
X5 Encoder input 1
(DSC)
X6 Encoder input 2

X7 Proximity switch input

4 Digital outputs
X8
3 Digital inputs

X9 Power in

X10 Power out

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UltraPRO Controller

• IP65 rated enclosure

• Anchor and first node in the UltraPRO
EtherCAT network
• Connector based connections, can be
mounted outside an electrical enclosure

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Safety Drive Enclosure (SDE)

• IP65 rated enclosure

• Connector based
connections
• Can be mounted outside
of an electrical enclosure
• Contains drive and safety
relay

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HMI Screen
• Status Bar
• Readout Panel
• Command Bar
• Serial Number Readout
• Monitor Data Region
• Gauging Data Spreadsheet

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 Status Bar Readout Panel

Settings Menu
(Hamburger Menu)
Part Status

Gauging Data Table

Monitor Data

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Readout Panel

 Defaults to right side of HMI screen

 Ability to give live readout of:
 Axis positions

 Sensor readings

 Variable values

 Right click to:

 Show/Hide readouts

 Change decimal places

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Command Bar

Step:
Used to step through an UltraPRO program one line at a time
Cycle Start:
Will execute the entirety of the loaded UltraPRO program
Jog:
Opens the manual motion screen. Can also be accessed from the main menu
Soft Stop:
Used to stop the execution of the program through the software. When pressed, the system will stop
running the current program and wait for another command.
Home:
The home button is used to command the system to run a homing routine.
More information on homing is provided later in the presentation

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 Status Bar
• Shows Status of Controller
• Ready
• Running
• Faults Click here to find out more
information about controller's
• E-Stop Applied current state.
• Overload
Notifications
• OK/NOK

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Serial Numbers
Serial numbers can be entered manually or automatically from the PLC

Captured serial number

for that cycle

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Monitor Data Region

Visual Feedback
of different sensor
values along with
monitor strategy.

Zoom functions
Zoom
Pan
Max zoom out

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 Gauging data Spreadsheet
Information collected in cycle with gauging steps is viewed here.

Multiple data points can be stored depending on application

The last
part ran is Gauging Labels
always at
the top.

Failed parts will be indicated by red cells

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 Settings Menu (Hamburger menu)

• New Program • Manual Motion

• Load Program • Service Screen
• Save Program As • More Tools
• Edit Program
• Options
• Program Management
• Switch User
• Modify Variables
• Switch Controller
• Edit System
• Homing Program • About
• System Settings
• Axis Settings
• Global Resources
• User Management

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New Program
 Used to create new programs
 Name must only contain:
 Letters
 Numbers
 Underscores
 Name must begin with Letter.

 Program will not be stored until “Save to

Controller” is selected in editor tab

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Load Program

• Used to open an existing program

• Program must be stored on the
controller.
• The currently loaded program is listed
first in the list of programs.
• Current program name will be displayed
above the status bar on the main HMI

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Save Program As…

• Used to the save currently loaded

program as a different name.
• Creates a copy of the active program
and opens the Editor Tab
• You can save the new program to the
controller
• The original program will remain
intact with all its data.
• The new program will save with a
new name.
* note: the currently loaded program does not
change.

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Edit Program

• Used to open the editor for the

selected program.
• The top of the list shows the
currently selected program

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 Program Management

• Used to manually manage the

program files on the controller.
• Use this to set Binary numbers for the
programs
• Select program, Right side of HMI
will turn into settings for the
selected program
• Can set comments for each program
created.
• Import, Export, Rename, and Delete
Programs

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 Modify Variables

• Used to set values for variables in a live environment

• Changes made will not be saved until “Apply” is selected
• As soon as apply is selected the variable changes on the
controller
• Cancel will simply close the window and discard any
pending changes.

• PLEASE NOTE: use extreme caution when using this

tool. Variables can change during a cycle and applying
values will change them immediately.

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Edit System…

• Edit Homing Program

• Edit System Settings
• Edit Axis Settings
• Global Resources
• User Management
• Import/Export

Further discussion later in the training

P.O. Box 748 • Brighton, MI 48116 • 810-229-9334 • promess@promessinc.com

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 Manual Motion

The Manual Motion Screen is used to

manually jog the system. You can jog to a
position or force.

The ready output will go low when the

manual motion is open, and the system
must be homed after any manual
movement is performed.

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Manual Motion continued

• Position is in real-time
• Force is in real-time
• Incremental Extend/Retract
• These will extend and retract the system for as long as the button is pressed. The
system will go no further than the value in the Positon amount or Force
amount. If the position amount is met, the system will stop and if the increment
button is pressed again, it will then reset the increment counter to zeroThe System
will move at the speed entered into the JOG SPEED setting.
• The System will move until it reaches the max length of the system, overloads, or
reaches the amount specified.

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 Manual Motion continued
Overload
Jog Extend/Retract • This is a value that can be set to protect the system
• These buttons will extend and retract the during the manual Motion.
system for as long as the button is pressed. • Can be set to the max rating of the sensor being
• Not constrained by position amount used.
• Will move at the Jog Speed Setting • By Default, the starting overload value when the
• System will move until it reaches the max manual motion window is opened, is half of the
length of the system or reaches the overload sensors rated value.
value. Jog Speed
Position Amount • The speed at which the unit will move during its
• This is the limit on how far the system will manual motion.
extend or retract while using the • The speed can be changed at any time by typing in a
Incremental buttons new value
• The maximum speed allowed for manual motion is
set by Promess to prevent damage to the equipment.
Please contact Promess for any changes
needed to the default limits.
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More Tools…

• Part Statistics
• Reset Cycle Counter
• Step Pointer
• Set Serial Number
• Zero Absolute Encoder
• Calibration
• Event Viewer

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Event Viewer

The Event Viewer shows different

errors, program statistics and
system information.

If something isn’t behaving as

expected it should be one of the
first places to go for
troubleshooting.

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Settings Menu cont’d

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UltraPRO Editor
and Editing
Programs
UltraPRO Editor

• The editor is opened when selecting

• Edit Program
• New Program
• Edit System…

Note: Program changes cannot be saved if the system is running or

otherwise unable to receive a command.

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 Edit System…
This option contains a subsection of system settings

• Edit Homing Program

• Edit System Settings (Software attributes of Promess system)
• Edit Axis Settings (Physical attributes of Promess hardware)
• Global Resources (Macros, Live Variables, and Variables that are not
program specific)
• User Management (Setting up user rights for specific users)
• Import/Export (Importing of specific system settings, global resources,
programs and axis settings)

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 Editing the Homing Program
• This is the program that is run when
the HMI Home Command is
pressed.
• This program will also run when a
homing input is received from the
PLC
• No other motion steps can occur
before the homing step in the
homing program
• Programming process will be
covered later

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 System Settings…
• Hardware Tab
• Shows all the components connected to EtherCAT network.
• Setup of all sensors wired into the system
• Setup of I/O communication for the system

• Policies Tab
• Advanced software settings

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DrivePRO outputs

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Fieldbus
Selecting the Fieldbus option in the hardware
tab will show the Fieldbus settings.

Fieldbus Type:
• Ethernet IP
• Modbus TCP
• Profinet

If using Profinet, the networking settings are set

by the PLC

Mapping must match on the UltraPRO and the

PLC.

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 Inputs and Outputs
• Inputs
• To configure an input, select the input and
choose the function you wish to assign to
the input from the assigned functions
pulldown.
• Outputs
• To configure an output, select the output
and then choose the function you wish to
assign to the output from the assigned
functions pulldown.

• NOTE: Any changes made to the I/O mapping

will require you to Save to the Controller.

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Integer/Real Inputs and Outputs

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Digital Inputs

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Digital Outputs

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 DSC Sensors
• Label
• This will be the name used for the sensor throughout the
UltraPRO software
• Units
• Selects the units the sensor will show in the software
• Nominal Range
• This is the range of the sensor – typically Promess will set
this 20% higher from the factory
• Enable Overload Protection
• When this box is checked, whenever the value overload
value is exceeded in the software, the press will throw an
overload warning and the press will require a home.
• Promess enables this overload from the factory and should
be consulted before any changes are made to the sensor
settings. Failure to do so may VOID the Promess warranty.

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Policies

This tab gives a list of more advanced software

related settings including policies that ar

Changes made to policies will need to be saved

to the controller after editing.

These polices should not be enabled without

guidance from Promess

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Axis Settings

WARNING: Promess sets the axis settings for each system

before shipping. Changing any of these values or properties
without first consulting Promess can result in damage to the
equipment and void any Promess warranty.

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 Axis Settings

• Axis settings are the properties that tell

the software what type of actuator is
connected to an axis.

• These settings affect how the actuator

responds to a given command.

• There is no need for anyone other

than a Promess engineer to
change any of these settings.

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Homing Algorithm Options

• Home to proximity switch and index point (Default for all press systems)
• Ram will retract until the home switch is made
• Ram will extend until off of the home switch
• Motor will stop when the first index point from servo motor resolver or encoder is found
• Find home switch only
• Ram will retract until the home switch is made
• Ram will extend and stop when the home switch changes states
• Find index point only
• Homing routine will terminate at the first index point from the resolver or encoder
• Zero axis only
• Will zero the axis and the servo drive will be enabled
• Move to Zero (Absolute Encoder)
• This feature is only for when a servo motor has an absolute encoder

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Global Resources

• The global resources section is where anything global is done. Global means that
anything added in here will be accessible in any program, unlike program specific
things that are only accessible in program they are created. A globe icon will be added
to any global resource added, this will help identify it as either global or program
specific.

• There are the following global resources:

• Macros
• Variables
• Timers
• Live Variables

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 Live Variables
Live variables are continuously calculated in the
background and can be used wherever a signal
can be used.

Types:

• Maximum – Calculates the maximum for the

selected inputs and uses that value.
• Minimum – Calculates the minimum for the
selected inputs and uses that value.
• Sum – Adds or subtracts two or more values.
• Derivative – Calculates the derivative of two
input signals (X value and Y value) based on a
given time delta. The X input signal value
defaults to time.

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User Management

Assign different users' access to

various actions within the software.

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 Import/Export

Export your system configuration to a zip file.

Import specific or all settings in a system

configuration. A backup taken from the
Configuration Utility or a zip file from Export
may be used.

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Editing a Part Program
Editing Program Layout
Steps
Monitors and Monitoring Strategy

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 Part Program Layout
The programming editor contains a grid structure to support multi-axis functions. The more axes there are,
the more columns.

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Part Program Layout Continued

Configuration has changes

and needs to be saved to
the controller.

Selected cell

Saves changes over to the

controller.

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Evaluation Steps

Sets the sensor

value
Starts and stops
monitors created
under the
monitor tab.
Compares the
measurement
to preset
tolerances.
Sends Pass or
Fail output to the
Feature that allows for math PLC.
calculations, boolean
comparisons, and additional
commands.
Sets or resets the
part status
manually.

This step will take a

measure step’s input
formula result and store
it as the master value

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Set Sensor Value

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Gauging

Limits that
determine pass
or fail

Label is required
when storage
enabled.

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Monitor Trigger

List of the monitors created under

the monitor tab.

Stop and analyze should be used

to calculate the monitor strategy.

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Expression

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 Update Part Status
and Set Part Status

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Master

List of Measure
steps found This step will take a measure step’s
within the part input formula result and store it as the
program. master value.

The master value will then be used as

the target value for the specified
measure step.

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Program Flow Steps

Used in conjunction with any of

These steps evaluate the Jump steps to command the
conditions and if the flow of the program.
condition is true the program
moves to the Jump Location.

Sets outputs that have been

designated “User Output”
The program waits at this step
until all the axis of motion have
been completed.

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Program Flow Steps cont’d…
Exit the
subroutine

End the part

program

Runs the Macro

subroutine

Ends the cycle and

immediately starts Program waits at
another. this point until the
Pauses the condition of the
part input is met.
program.

Clears the
Overload status of Action step (start, stop, reset) for
a step overload. Timer created in Global Resources.

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Comment and

Delay

The Delay step holds the program for amount

of time set. The time is in milliseconds.

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 JumpJumpValue
on Status
Input
Step Step
Step Jump steps and Jump
location

Jumps
Jumps to
to the
Always the Jump
Jump
jumps Location
Location
to the when
Jumpwhen
based the
the
when
Location input
state
the conditionstatus
is met. is true.
is true.

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Set User Output and
Wait for Motion.

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 Macros

Macros are subroutines within a program. A macro can be used to simplify a program by grouping
a block of commands that are repeated several times in a program into one macro. That macro can
then be used inside the program as many times as necessary.

When first creating a program the default location of all steps will be in the Main macro.
To create a new macro, click on the New Macro button. You will then be prompted to give the new
macro a name, spaces are not allowed. Once a name is given, select OK to create the macro.
To delete a macro, select the macro you wish to view and then click the Delete Macro button, this
will delete all program steps within this currently opened macro.

Note: The main macro cannot be deleted.

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 Run Assign Macro
and Run Macro

The macro to be ran when

this step is executed.

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 Exit Macro,
End
Program and

Repeat
Cycle
These steps end a subroutine
or part program. Everything that normally occurs with the end
program step (Variable reset, data collection,
The repeat cycle step is used cycle counter iteration, etc.) will occur. ‘
to repeat the cycle. Effectively
the same as an end program The ready output remains low during the
step followed immediately by repeat, so no new PLC commands can come
another cycle start. in.

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Axis/Motion Steps

Runs the homing routine set up

in the axis settings. Should
only be used in the Homing
Program.
Move steps will move to the
programmed position Travel of
the system is reached. The Move To Signal step is used
to control the system to a
specified signal reading
The Constant Signal step is
used to control the system to a
specified signal reading and Commands the axis to run at a
maintain that reading. programed velocity until
commanded to stop.
Stops and disables the axis in
the column that is created in
and discards the move queue.
The Measure step is used for
applications where a component
must be pressed to a critical
dimension relative to a datum on
a part.

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Move Step

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Move to Signal Step

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 Constant
Signal
Step

This step uses

Stop Conditions
to exit the step.
These will be
discussed further
on in the
training.

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Apply Velocity Step

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Stop Conditions Stop conditions are found in the
Constant Signal and Apply
Velocity steps.

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Measure Step

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Monitors and Monitoring Strategy

UltraPRO has the ability to graph and set limits around the signature curve of a process.
Any sensor signal to the controller can be used to generate a curve.
The reference curve and strategy for the monitor is defined in the monitoring tab in the
program editor.

The data is store along with the gauging data in an 80Gb data buffer on the
controller. Once the data buffer is full the oldest data is replaced with the newest.

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Monitor Tab continued…

The monitor toolbox is used to

analyze the signals collected
during the monitor.

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 Toolbox and Monitor Strategy
 Each Monitor has a strategy.

 A strategy is a composition of functions that produce the

desired analysis of data.

 This strategy is visually represented as an outline style layout

called the “strategy tree”

 Some of these functions can have functions within them to

analyze the results produced.

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Monitor Strategy continued…

In this example, we want to acquire a graph while also

finding the following:
In window “A” we want to find the maximum force
In window “B” we want to find the minimum force
And in the overall process, we also want to find the
maximum force (Which may or may not be the same
value as window “A”
Using this method, we can use one set of data and while
breaking down and analyzing different subsets (The child
functions here)

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Window Functions
Windowing functions are used to slice out particular sections of data for
analysis.

Windows can only have curves for their parents (Acquire, or Transform
functions)

Settings:
Label: This is the desired name requested for this particular window. Keep in
mind, this name will be used when referencing this window in other parts of
the software.

Anchor: This is the point in which the window will be anchored, there are three
settings by default; origin (0,0), begin curve, and end curve. Any Maximum,
Minimum, or Y Crossing located on the same level or higher on the strategy
tree can also be used as anchor points.

Begin Offset: This is the X value where the window offset will start. This must
be an X value less than the End of Window point.

End Offset: This is the X value where the window offset will stop. This must be
an X value greater than the Begin of Window point.

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Transform Functions
The transform functions are used to take the current data acquired and then transform it into something else
for additional interpretation.

Delta Y Curve: The delta Y curve takes the current monitor that was acquired and transforms it to create a
new graph showing the delta/change in the y values
Settings:
• Label: the name of this Delta Y graph
• Number of intervals: this value is the amount of intervals in which you would like to break the delta
Y graph into. Example: 1 interval will produce 1 point on the graph. This point would be the
difference between the two Y values at the beginning and end of the window. 10 intervals will
produce 10 points on the graph, each one displaying the delta from the last point made.

Slice Average:
The Slice Average function takes the acquire curve and gives you the ability to “slice down” the data
points into a specified slice width.

Directional Filter:
The direction filter function gives the ability to only show the curve if it is moving in a specific
direction, increasing or decreasing. Typically, it is useful to use the slice average function before
specifying a direction filter to eliminate any small hysteresis in the curve. Any change, large or small in
the direction of the curve will result in the curve being cut off.

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Analytical Functions
Analytical functions are used to perform fine-detailed analysis of the input data.
These functions can be the children of both data and window functions.
These will return the computed value across their parent window.

Example:
A maximum function directly under an acquire function will return the maximum for all the
data acquired.
If the maximum function is under a window function, it will return the maximum inside that
window.

 Maximum: This function returns a single point representing the maximum Y value and
the X location of that value inside the parent window.
 Minimum: This function returns a single point representing the minimum Y value and the
X location of that value inside the parent window.
 Average: This function will compute the average value of the data from the parent window

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Markers
X Crossing: This function returns a single point representing the Y value at which the graph crosses
a specified X location inside the parent window.

Settings:
• Label: The name given to the specific function used to be able to reference inside of an expression.
• ‘X’ Location: The crossing point in which you would like to capture the Y value. This value can be
specified using a variable.
• Occurrence Number: Used to handle scenarios where the graph passes by the X location multiple
times, this setting determines which value you would like to capture.

Y Crossing: This function returns a single point representing the X value at which the graph crosses
a specified Y location inside the parent window.

Settings:
• Label: The name given to the specific function used to be able to reference inside of an expression.
• ‘Y’ Location: The crossing point in which you would like to capture the X value. This value can be
specified using a variable or function result.
• Occurrence Number: Used to handle scenarios where the graph passes by the X location multiple
times, this setting determines which value you would like to capture.

Begin Curve

End Curve

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Limits
Limits are functions that can be placed under any other functions (data, window, or
analytical) that will check the parent function against criteria specified in the limit’s
settings and generate a pass or fail signal.

Fixed Upper/Lower Limit: Fixed Limits are limits that are set to a specified
constant value. These straight-line limits are set so that if the value exceeds or falls
below the upper or lower limits, respectively, a fail signal is generated. If desired, an
output can be chosen from a drop-down list to go high if the specified limit fails. Fixed
Upper Limits and Fixed Lower Limits are separate functions.

Relative Upper/Lower Limit: Relative Limits are limits that are automatically
generated based on the reference curve of the monitor. The Relative Offset is used to
determine how far away from the reference curve the limit will be created. If the signal
exceeds or falls below the upper or lower limit, respectively, a Fail signal is generated.
If desired, an output can be chosen from a drop-down list to go high if the specified
limit fails. Relative Upper Limits and Relative Lower Limits are separate functions.

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Calibration

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Calibration

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Contacting Promess
Collect the Job Number information from the system
On Every Major Component
Say “I have an UltraPRO system, the job number is XXXXX-XX.X
Saves time in finding out what system we are working with
Know the Software Version currently on the system
Menu>> About
Call Promess @ 810.229.9334 - Support available 24/7/365
days a year

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 THANK YOU!

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