Portable intelligent tightening system scheme

1、 Preparation before use
1. Unpacking
First of all, thank you for using the portable intelligent tightening system. Before use, please confirm whether you have the following items
S/N Item Name Quantity
1 Electric screwdriver controller cabinet 1
2. Handheld intelligent electric screwdriver 1
3 Industrial control tablet 1
4 Multidimensional code scanning gun 1
5 Infrared sensor 1
6 MOT power line 1
7 Serial port line 1
2、 Wiring definition and installation
1. Connection diagram of each component
2. Code scanning gun configuration
This code scanning gun supports one-dimensional and two-dimensional code scanning, and uses RS232 and 115200 baud rates for communication; You can select one of two recognition modes.
Manual identification: sweep the trigger to identify when reading the product code.
Inductive identification: put the code scanning gun on the bracket, and put the product code in front of the code scanning gun for automatic reading, eliminating the operation of the code scanning gun.
Scan the code scanning gun to scan the one-dimensional code corresponding to the above figure for relevant settings.
3. Infrared sensor
  
Related parameters
Inductive object: any inductive object;
Response frequency: 2ms;
Sensing distance: 7~30cm sensing distance can be adjusted;
3、 Introduction to each functional module of the software
1. Public view of main interface
Click the execution file ScrewdriverSys.exe to start the software, as shown below:
The interface is mainly divided into four parts:
(1) Function menu at the upper left corner;
(2) Function tab page in the upper right corner;
(3) Display area of intermediate function module;
(4) The bottom status bar displays communication, task details and alarm conditions.
2. (1) Communication setting
Connection setting of the scanning gun: After connecting the scanning gun, please confirm that the power on of the scanning gun is normal, and determine the corresponding serial port number. The baud rate is 115200
Then click Connect.
Controller connection setting: the default device number of the system is 1, and the default communication baud rate is 115200. Select the correct serial port number and click Connect.
[Find] This function can find devices that are normally connected online.
After the controller is connected normally, it will automatically switch to the record display page and pop up system related information.
(2) . Record display
After successful connection, enter the main page;
The main page is the main working interface. This page displays all kinds of information related to the current workpiece QR code and the status of locking and tightening results. The table displays the tightening status of the completed screw of the current workpiece, and the lower status bar displays the working status of the completed last screw. Each lock screw will be displayed with pictures and texts. On the left is the execution status of the current task chain. You can choose to turn on the "Automatic Task Switching" function. When it is turned on, the system will automatically switch the execution of each tightening task in sequence according to the task execution sequence and the number of tightening screws set in the task chain; When the function is turned off, it can be switched manually.
Infrared detection: display whether the workpiece is in place; When the number of screws to be tightened is not completed and the workpiece is removed, the alarm of missing screw is displayed.
(3) Task planning
Task planning is an important function setting in the system, which determines the efficiency and success rate of intelligent electronic batch.
○ 1. [Load Task] Import the previously saved task file from the hard disk file;
○ 2. [Save] Save the task parameters as a hard disk file;
○ 3. [PC<<Device] Read task parameters from the controller to PC software;
○ 4. [PC>>Device] Issue the task parameters in PC software to the device;
○ 5. [Save] Save the task parameters in the current controller;
[Note: When saving the parameters, do not let the screwdriver stay on the tightened screws; wait for 5 seconds for subsequent operations.]
○ 6. [Restore factory] Restore the default task parameters of the controller when it leaves the factory;
[Note: When restoring the factory, do not let the screwdriver stay on the tightened screws; wait for 5 seconds before resuming the factory for subsequent operations.]
○ 7. Task selection: select the task number 00~15 to be set; At the same time, the number of tasks displayed is the maximum number of tasks that the controller has;
○ 8. Task step setting: set the planning and sequence of each task,
[Tightening] At present, STEP0~STEP4 can be supported. There are five STEPs in total. Each STEP can set the number of tightening turns and tightening speed when the screws are working; If the number of turns is set to be greater than 0, the STEP is valid; Setting the number of turns equal to 0 is an invalid STEP step.
The program will automatically skip the invalid STEP step and then execute the subsequent valid STEP step.
[Loosen] The setting can be divided into 2 steps at most. The method of parameter setting is similar to the tightening method;
[Free] Set the speed and direction of free rotation of the electric screwdriver, and start and stop are controlled by command input and disconnection;
[Add on] Select the torque unit used: mN. m/0.01Kg. m ^ 2;
Output effective optocoupler status: ON/OFF, default is OFF, and output low level is effective;
○ 9. Task parameter setting: set relevant parameters of each task;
Tightening mode: 2 modes are supported, namely
0 -- Automatic mode, speed range 30-1200rpm;
2 -- High speed mode (applicable to self tapping screws), speed range 30-1800rpm;
Tightening rotation direction: (with the screwdriver head upward as reference) 0-CW (clockwise); 1-CWW (counterclockwise);
Target torque: set the final target torque value of the locking screw;
Torque holding time: when the torque reaches the target value, the time to keep the target torque;
Torque compensation value: when there is a fixed deviation between the set target torque and the actual torque, set this parameter to add a value or subtract a value; When setting this parameter, first set a slightly larger value (such as 10 or - 10), and then look at the measured feedback effect of the torque meter before further fine tuning.
Standby adjustment time: the waiting time before the screwdriver head switches to the free state after the operation of the electric screwdriver stops
Floating height sliding tooth detection: 0=closed; 1=ON. (Closed by default for debugging; it is recommended to open it in actual use)
After this function is enabled, the two parameters "– Number of floating height defining turns" and "+Number of sliding tooth defining turns" are valid;
If it is not opened, the tightening results are only OK, NG and incomplete; Floating height and sliding teeth will not be checked.
– Number of floating height defining circles: used to set the floating height judgment value;
The number of motion cycles<the set number of cycles - the defined number of cycles of floating height If the torque has reached the target torque, the floating height is reported
+Number of slip defining cycles: used to set the slip judgment value;
The number of motion cycles=the number of set cycles+the number of defined cycles of sliding teeth. If the torque does not reach the target torque, the sliding teeth shall be reported
You can select to enable the infrared detection function in the additional item page. As shown below:
(4) . Debugging execution
The electric screwdriver tightening and loosening control command comes from two sources, namely "IO port" and "PC software".
If "IO port" is selected as the command source, the external IO command is valid and the "PC software" command is invalid;
If the command source is "PC software", the external IO port command is invalid, and the PC software command is valid. The following operations are valid.
Debug the actual operation of each task, and make corresponding adjustments to the task according to the actual operation;
Press the [Tighten] button with the left mouse button to start tightening, and the left mouse button pops up to stop tightening;
Press the [Loosen] button with the left mouse button to start loosening, and the left mouse button pops up to stop loosening;
Press the [Free Rotation] button with the left mouse button to start the free rotation, and the left mouse button pops up to stop the free rotation;
[Note: When the command source is switched to PC software, please first confirm whether the button of the electric screwdriver is released. If it is pressed, the switch is unsuccessful.
(5) . Operating waveform
The tightening waveform is the state feedback of the whole tightening process; Through the waveform of position, speed, current and torque, various problems in the tightening process can be analyzed.
Display detailed waveform data of the whole process when each screw is locked, with sampling accuracy of 3ms. Select part of the area to magnify the waveform, and right-click to return to the previous amplification display status of the waveform.
(6) . I/O status
I/O display current controller input/output, working status, alarm status; Grey indicates no signal, green indicates signal.
When the control output status is checked, the IO signal can be forcibly output
(7) . Alarm center
Alarm information includes number, alarm name and cause analysis, which can quickly locate the problem. 10 alarm records can be saved in the controller. First in first out mode is adopted to remove the alarm records in the lowest position.
Click "Clear Alarm" to clear all alarm records.
The alarm function selection can shield or open some alarms.
The specific alarm code table is as follows:
No. ERR0~3 lamp name Alarm reason
10000 floating height does not reach the specified lower limit of travel, reaching the target torque;
2 0001 The sliding tooth reaches the upper limit of the specified travel, but does not reach the target torque;
3 0010 Short circuit of overcurrent motor line or power line, or large fluctuation of power supply voltage;
4 0011 Overvoltage power supply voltage exceeds the normal voltage range of the controller;
5 0100 The undervoltage supply voltage is lower than the normal voltage range of the controller;
6 0101 When the flying car is powered on, the screwdriver head is not free hanging and there are obstacles on both sides; Or the target speed exceeds 1800rpm; Or when the task parameters are saved, the header is not free hanging and there are obstacles on both sides;
7 0110 The electric screwdriver encounters obstacles during overheating movement; Or when power on, the screwdriver head is not free hanging, and there are obstacles on both sides; Or when the task parameters are saved, the header is not free hanging and there are obstacles on both sides;
8 0111 Reverse is not in place. Obstacles are encountered during reverse movement; Encoder cable is not connected or has poor contact
9 The 1000 position deviation is too large and obstacles are encountered in the movement; Or when power on, the screwdriver head is not free hanging, and there are obstacles on both sides; Or when the task parameters are saved, the header is not free hanging and there are obstacles on both sides; Whether encoder cable is connected properly;
10 1001 Electric screwdriver disconnection Electric screwdriver disconnection
11 1010 The screw with excessive torque deviation does not match the screwdriver head;
Note: When an alarm occurs, the ERR port will output an indication. The specific alarm category can be found according to the output code of ERR0~ERR3.
(8) . Work records
The work record module records the working data statistics of the electric screwdriver in a period of time
Record the tightening process parameters and tightening results of each screw. A maximum of 21000 records can be maintained. If the records exceed 21000, the system automatically maintains the deletion of records.
(1) Click Query to query all records; You can set query criteria to achieve accurate query.
(2). [Clear Record] Clear all existing records.
During the query, the statistics display three statuses: "OK", "NG" and "Incomplete"; The total number of statistics is the sum of the three;
(3). Each piece product code will generate a record file, which records the screw tightening results of this work.
Please refer to the record file under the record saving path for relevant tightening results.
(9) Waveform comparison
Up to ten waveforms can be selected for comparison, and the waveform type must be the same.
(10) . System Additions
During networking of multiple controllers, different device numbers must be set for different controllers. When changing the device number, the software will automatically prompt whether to continue. It also prompts whether the modification of the equipment number is successful or not.
The saving time and path of work records can be set according to actual needs.
The number and saving path of waveform records can be set.
Note: The waveform record file can only be generated after switching to the waveform display page for waveform record saving; The save path of waveform record file cannot be the same as the save path of work record, so as to prevent the system from deleting the record file by mistake when managing the file.
(11) Task chain management
Task chain management can set one task or multiple tasks in a task chain according to the requirements of the types of screws on the workpiece. Set the number of screws to be tightened for the workpiece. The system will judge whether the workpiece is completed or not according to the set number of screws when working.
Manage task chain related information through "New", "Add", "Delete", and "Modify".
Each task chain can set 8 different or the same execution tasks. The task chain composed of multiple tasks is mainly used in situations where there are multiple screws to be tightened in a workpiece, and the feeder that needs to supply multiple different screws synchronously can give full play to its best performance. Usually, a screw is operated. One task chain only needs to set one task.
(12) . Product Management
Set the corresponding relationship between the product type code and the product, and select the corresponding task chain for work according to different products.
4、 Quick Use Guide
Step 1: Connect the components according to the diagram. The product is designed to be foolproof, and each interface is different, so it will not be inserted incorrectly. Pay attention to the connection between the serial port line and the industrial tablet computer; Remember the serial port number connected to the scanning gun and the serial port number connected to the control cabinet; And the control chassis end shall be switched to PC communication.
Step 2: Open the tightening system software and power on the intelligent electric screwdriver. Select different ports for communication according to the serial port number just connected between the scanning gun and the chassis. The communication baud rate of the scanning gun and the control cabinet is 115200. Click Connect to check whether the communication in the lower left corner is connected normally. If it is abnormal, please check whether the power is on, whether the serial port number is set correctly, and whether the control chassis is switched to PC communication mode. Check whether the products can be scanned correctly.
Step 3: Switch to the "Task Management" module, and set relevant parameters according to the number of screw turns, speed, target torque, etc.
Step 4: Switch to the "Task Chain" module and set the task chain according to the number and type of product screws. Generally, one task chain corresponds to one task.
Step 5: Switch to the "Product Management" module, take one of the products of a certain type and scan the code to register and manage the product QR code. Associate a product type with a task chain. When a product of this type is scanned, the related task chain is automatically executed.
Step 6: Switch to the "Record Display" module, and you can work
The above steps can be fine tuned according to various problems in the tightening process.