综合拧紧技术（上）--翻译（肖凤）.doc

根据福特技术资料转化 KRAUSE综合拧紧机操作系统3.1手册 INTEGRATED TIGHTNING TECHNOLOGY综合拧紧技术Operating System 3.1操作系统 3.1Manual手册Edition:3.0 Date:01/91版本：3.0 日期：01/91TABLE OF CONTENTS 目录1. INTRODUCTION 绪论41.1. CONTROL SCHEME 控制体系图系统配置图51.2. FRONT PANEL OF WF 661 WF661的前端面板62. CONTROL PANEL 控制面板73. SWITCH ON SEQUENCE 启动步骤104. LOGIC OF OPERATOR PROMPTING 操作提示114.1 GENERAL 概要114.2 MODES OF OPERATION 操作方式115.PROGRAMMING OF THE NUTRUNNER 拧紧机的编程155.1 PASSWORD AND KEYSWITCH 密码和按键开关165.2 KEYBOARD 键盘165.3 PROGRAMMING OF PARAMETER SET 参数编程设置组编程175.3.1 GENERAL PARAMETER 一般参数225.3.2 TORQUE CONTROL DIAGRAM 3 WITH ANGLE MONITORING AND SAFETYANGLE SWITCH OFF 带有角度监测和安全角度切断的扭矩控制图3 255.3.3ANGLE CONTROL DIAGRAM 5 WITH TORQUE MONITORING AND SAFETY TORQUE SWITCH OFF带有扭矩监测安全扭矩切断功能的角度控制图5275.3.4YIELD POINT CONTROL DIAGRAMM 6 WITHTORQUE AND ANGLE MONITORING ANDSAFETY SWITCH OFF (OPTIONAL) 带有扭矩和角度监视与全切断的屈服点控制图6（可选择的）295.3.5 MISMATCH MONITORING 错配监控325.3.6 PRETORQUE MONITORING 初始扭矩监控335.3.7 SOCKET LOCATION WITH PULSING 脉冲槽位点动定位套筒345.3.8 REVERSING OF FASTENERS 拧紧件的回动365.3.9 SELFTAPPING 自攻385.3.10 2nd TIGHTNING 二次拧紧395.3.11 SOCKET RELEASE 槽套筒释放405.3.12 STOP AT T1 停在T1415.3.13 DATA OUTPUT VIA MFI 经MFI数据输出41 审核: 校对: 转化:肖凤3TABLE OF CONTENTS 目录 5.3.14 OUTPUT FORMATION 输出形式425.3.15 TORQUE RATING 额定扭矩445.3.16 DEVIATION MONITORING 监测偏差455.3.17 STICK SLIP MONITORING 爬行监控475.3.18 TEACH-IN 示教485.4 PARAMETER SET COPY 参数组设置复制495.5 PARAMETER SET APPOINT TO SPINDLE 轴参数设置组配置到轴设定505.5.1 SPINDLES IN DIFFERENT PRODUCTION GROUPS51轴在不同的生产种类5.5.2 TIGHTNING SEQUENCES 拧紧顺序步骤525.5.3 TEMPORARY CANCELLATION OF A SPINDLE轴的临时取消555.5.4 CANCELLATION OF A SPINDLE 轴的取消555.6 DATA OF SPINDLE TYPE/TEST DATA 轴类型型号数据/测试数据565.7 SOCKET LOCATION 槽位套筒定位586. MANUAL OPERATION 手动操作597. PARALLEL OPERATION 并行操作618. OUTPUT OF TIGHTNING DATA 拧紧数据输出648.1 TIGHTNING RESULTS ON MONITOR 在监控器上的拧紧结果648.2 PRINT OF TIGHTNING RESULTS 拧紧结果的打印668.3 TIGHTNING RESULTS OF PREVIOUS TIGHTNINGS ON MONITOR OR PRINTER 在监控或打印之前拧紧的拧紧结果678.4OUTPUT OF DATA VIA 20MA INTERFACE OF THE WF 661 WF 661经20MA接口输出数据708.4.1OUTPUT OF XY-PLOT FOR TORQUE/ANGLECURVE AND GRADIENT CURVE 70输出XY图的转矩/角曲线和梯度斜率曲线8.4.2OTHER OUTPUT FUNCTIONS 其它输出功能739.TEST OF THE NUTRUNNER 拧紧机的测试749.1 TEST RUN IN MANUAL AND AUTOMATIC OPERATION 74 手动测试运行和自动操作9.2 SPINDLE TEST IN MANUAL OPERATION 轴的手动测试759.3 SELF CHECK OF THE NUTRUNNER SYSTEM77 拧紧机系统的自检根据福特技术资料转化 KRAUSE综合拧紧机操作系统3.1手册 TABLE OF CONTENTS 目录 10. FAILURE CODES OF NUTRUNNER 拧紧机的故障编码7811. ALLOWED COMBINATION OF CONTROL AND MONITORING-METHODS 不同允许控制和监测方法的合并的组合7912. EXPLANATION OF SHORT FORMS 简易格式缩写说明801.INTRODUCTION 绪论The integrated Tightning Technology by Krause is based on the station control S5 115U or S5 150U by Siemens which will be expanded by nutrunner control modules WF 661 (one module per spindle).Krause综合拧紧技术基于西门子S5 115U或S5 150U，通过拧紧机控制模块WF 661 进行扩展(一个主轴配置一个WF661模块)。The tightning programme is stored in the WF 661. The tightning sequence is controlled by the S5 (sequence of start, selection of production groups).拧紧程序存储在WF 661中。拧紧顺序控制(如：起动步骤，生产组产品组别的选择)通过S5 PLC实现。An AC/EC- motor which is controlled by a servo amplifier is used as spindle drive. The output of the AC/EC-motor is reduced by a planetary gear.主轴驱动采用伺服放大器控制的无刷电机驱动，通过行星齿轮减速后输出。A combined torque-/angle sensor outputs the dynamically detected torque and angle to the WF 661.通过扭矩/角传感器把实时检测到的扭矩和角度传送到WF 661。The nutrunner control is integrated in the operation system 3.1 by Krause. With this operation system all fasteners can be tightened simultaneously or in a programmed sequence.Krause把拧紧机控制集成到操作系统3.1中。 通过这个操作系统，所有的拧紧件可以被同时或按程序设定的步骤拧紧。Programming and invocation of parameter setting are done by a keyboard in the operator panel. Input or modification of parameter setting are ensured by a key-operated switch and a password.通过操作面板上的一个键盘来编写和调用参数设置。 为了保证安全，输入或修改参数需要钥匙和密码。 审核: 校对: 转化:肖凤531.1 CONTROL SCHEME 控制体系系统配置图无刷电机行星齿轮主轴扩展扭矩传感器/角度编码器拧紧机控制模块可编程控制器模块伺服放大器电源操作员面板中央打印机接口CP524 （可选择的）SSU中央绘图仪接口 （可选择的）打印机XY-绘图仪XY-绘图仪打印机站控制打印机和XY-示波器是可选择的SCHEME 1INTEGRATED TIGHTNING TECHNOLOGY 图1综合拧紧技术1.2 FRONT PANEL OF WF 661 WF661的前端面板- Connection to the S5 bus (at the rear)- 与S5控制器通过总线连接（在后面）- Key:RESET 按键：复位按钮 - Indicator lamp:TROUBLE, CYCLE MONITORING (red LED) - 指示灯：故障，循环监测（红色发光二极管）- Indicator lamp: OPERATING/STOP (duo-LED) - 指示灯： 运行/停止（双二极管）- Switch: OPERATING/STOP - 开关： 运行/停止- Connection X1: X1电缆接口：Multifunction interface (MFI) for the output of fastening results: 拧紧输出结果的多功能输出接口（MFI） - 20 mA interface 20mA接口 - analogous output 模拟量输出 - Connection X2: X2电缆接口：output of fast critical signals for control of the servoamplifier控制伺服放大器的高速关键信号输出- Connection X3: X3电缆接口：Input of external power supply 外部电源输入- Connection X4: X4电缆接口：Input of signals from torque transducer and angle encoder 扭矩传感器和角度编码器的信号输入 GEBN0102.QEMSCHEME 2NUTRUNNER CONTROL MODULE WF661图2 拧紧控制模块WF6612.CONTROL PANEL 控制面板For the operating of the nutrunner the machine operating panel has to be used. 通过机床操作面板来操作拧紧机的操作必须使用机床操作面板。 For the explanation of the key functions see scheme 3. 有关关键主要功能的解释见图3。The keys for switch on of the power supply are in the bottom part of the control panel. 接通电源的开关在控制面板的底部。The programming of the nutrunner has to be done via the keyboard. 拧紧机编程必须通过键盘完成。The different matrixes for nutrunner programming can be selected via the softkeys right and left of the VDU.拧紧机编程中不同的程序组可以通过VDU的左右软按键来选择。SCHEME 3OPERATOR PANEL 图3 操作面板1 FUNCTION KEY PICTURE 功能键图2 FUNCTION KEY PICTURE 功能键图3- 10 SOFTKEYS 软键11 FUNCTION KEY F1 功能键F112 FUNCTION KEY F2 功能键F213 LAMP: CYCLE REJECT (RED) 灯：拒绝循环拧紧不合格（红色）14 LAMP: PC FAN FAULT (RED) 灯：PC故障（红色）15 LAMP: OVERHEATED CABINET (RED) 灯：柜子电柜过热（红色）16 LAMP: CONTROL VOLTAGE ON (WHITE) 灯：控制电压接通（白色）17 LAMP: NC VOLTAGE ON (WHITE) 灯：数控电压接通（白色）18 LAMP: NUTRUNNER VOLTAGE ON (WHITE) 灯：拧紧轴机电压接通（白色） 19 KEY OPERATED SWITCH: LIMIT SWITCH OVERRIDE ON操作钥匙开关键：限位开关接通20 KEY OPERATED SWITCH: NC TEST/HAND 钥匙开关操作开关键：无负载测试/手动22 PUSH BUTTON: SELECTION / MONITOR ON (BLACK) 按钮：选择/监控接通（黑色）23 PUSH BUTTON: LAMP TEST (BLUE) 按钮：灯检验（蓝色）24 EMERGENCY STOP 紧急停止运26PUSH BUTTON: CONTROL VOLTAGE OFF (RED) 按钮：控制电压断开（红色）27PUSH BUTTON: CONTROL VOLTAGE ON (BLACK) 按钮：接通控制电压（黑色）29 PUSH BUTTON: POWER SUPPLY NC OFF (RED) 按钮：数控电源断开（红色）30 PUSH BUTTON: POWER SUPPLY NC ON (BLACK) 按钮：数控电源接通（黑色）31 PUSH BUTTON: NUTRUNNER OFF (RED) 按钮：拧紧轴机断开关闭（红色）32 PUSH BUTTON: NUTRUNNER ON (BLACK) 按钮：拧紧轴机接通（黑色）35 115 V PLUG 115V插头36 PG CONNECTION PG-连接37 B/W MONITOR CONNECTION B/W监控监视器（显示器）连接38 PRINTER INTERFACE 打印机界面39 SELECTION SPINDLE OF NUTRUNNER 选择拧紧机轴40 ASCII KEYBOARD NUTRUNNER 拧紧机ASCII键盘3.SWITCH ON SEQUENCE 启动步骤- switch on the main switch 接通主开关- switch on power supply (key on operator panel) 接通电源（键在操作面板上的钥匙开关）The STARTING MENU appears 出现“开始菜单”SCHEME 4STARTING MENU SWITCH ON CONTROL 图4 开始菜单接通控制 控制接通控制器控制接通控制器/操作模式开启机械驱动装置开启/中心无急停安全门关闭机械机床无急停不可操作数控轴电源开启拧紧机电源开启故障：数控轴电源断开When all switch-on conditions are completed and no error is displayed, the machine is ready for start. 当具备所有的接通条件并且没有故障显示时，机床准备启动。Please note: 请注意：For commissioning, e.g. after the S5 programme by Siemens has been deleted, the parameter sets, the data of spindle type and test data have to be put in once more. The appointment of parameter sets to the spindles also has to be done once more (see item 5.5). During normal operation and also in case of a voltage drop down the tightning data are memorized in a battery buffered memory which lasts about 12 months. 试运转/调试，即，在删除西门子S5的程序之后，参数集、主轴数据和测试数据必须重新输入。 对轴指定配置的参数集组也必须再次输入(参见目录5.5)。在正常情况或者甚至同样假设电压下降的情况下, 拧紧数据通过电池缓冲存储器可以被保存约12个月。4.LOGIC OF OPERATOR PROMPTING 操作菜单提示With the operating menu different operation modes of the machine can be selected. When the modes of operation are selected, different menues are available for the operation of the nutrunner. 通过操作菜单，机床可以选择不同的操作模式。当选择好操作模式时，于是可以得到操作拧紧机的各种操作菜单。 4.1 GENERAL 概要From the starting menu MODE OF OPERATION via the softkeys (1-8) other menus can be selected. By operating the keys together the next higher menu can be selected. By operating only one of the keys, different pages of the menu will appear. The complete operating menu is displayed in the schemes 6a and 6b. 从开始菜单“操作方式 通过软键(1-8)可以选择其他菜单。通过操作键 可以选择更高一级的菜单。 通过操作（）中的一个键，可以访问菜单的相关页面。 完整的操作菜单见图6a和6b。4.2 MODES OF OPERATION 操作方式Following modes of operation are available 下面的操作方式是可运行的Manual operation: 手动操作：All function of a machine can be manually selected on the(Softkey 1)（软键 1）operator panel. 可以在操作员面板上手动选择机床的所有功能 Automatic operation: The PLC controls a cycle after cycle after the Start. Only (Softkey 2) （软键 2） Stop at initial position, and emergency stop are possible 确 commands. 启动“开始”后，在程序起动后，PLC控制下周而复始地控制程序运行的执行循环，“开始”后一个周期。仅仅 “停止在初始位置和“紧急停止”命令在程序起动后可用条件下有效。 Nutrunner: 拧紧机：The basic menu nutrunner will appear. Via further menus the nutrunner can be programmed. (Softkey 3) （软键 3）将出现拧紧机的主菜单。通过拧紧机下一级菜单可以对其编程。Parallel operation: 并行操作：During automatic operation the tightning results of up to 16 previous cycles can be displayed or printed. (Key menu selection) The programmed tightning data can be changed. （菜单选择键） The changed data will be valid for tightning after pressing the softkey transfer (see item 7.) 自动操作时，可以显示或打印最近16个周期循环的拧紧结果。已编好的拧紧数据可以被修改，。在按软键“传送”后，已经修改的数据可以为拧紧机所用 生效(参见目录7.)The operating modes can be selected via the softkeys. Parallel operation can be selected via the key monitor on / menu selection.可以通过软键选择操作方式。通过“监控/菜单选择monitor on / menu selection”键选择并行操作。手动操作自动操作拧紧机SCHEME 5STARTING MENU MODE OF OPERATION 图五 运行方式的开始 The starting menu MODE OF OPERATION can be selected from starting menu SWITCH ON CONTROL by pressing key 通过按键从起动菜单“打开控制”“接通控制SWITCH ON CONTROL”中选择 起动菜单“操作模式MODE OF OPERATION”。MANUAL OPERATION / AUTOMATIC开始菜单运行方式1手动操作2自动操作4拧紧机手动/自动操作参数设置编程程序。第4页参数设置编程程序。第5页参数设置编程程序。第3页参数设置编程程序。第2页轴检验测试1 零点2 放大器3 扭矩传感器5 数据传输数据6 角编码器7 轴速度 N18 速度轴 N2轴检测数据WF661输出拧紧顺序轴参数设置拷贝参数参数设置程序编程。第1页拧紧机开始主菜单1 程序 参数设置2 拷贝参数3 轴参数设置指定配置5 WF661输出7 额定值名义值/检测值值测试8 轴检验测试自动操作手动操作1 停止2 开始3 重新启动4 试验测试5 插口位定位6 回动7-8 选择生产组产品组开始菜单控制开关菜单选择SCHEME 6a STRUCTUR MANUAL OPERATION/AUTOMATIC 图6a 手动/自动操作结构拧紧并行菜单结果显示菜单程序参数设置并行菜单。第4页程序参数设置并行菜单。第3页程序参数设置并行菜单。第5页程序参数设置并行菜单。第2页程序参数设置并行菜单。第1页显示功能组选择1 站操作位4 拧紧机数据6 操作说明拧紧数据并行菜单1 程序参数设置2 传输参数传输设置3 存储器输出4 监控显示拧紧结果5 打印机拒绝不合格结果6 打印机上全部结果菜单选择菜单选择PARALLEL MENU 并行菜单-14-SCHEME 6b STRUCTUR PARALLELMENU 图 6b 并行菜单结构 I SEBN0403.GEM5.PROGRAMMING OF THE NUTRUNNER 拧紧机的编程Via the nutrunner starting menu all necessary menus for programming can be selected. 通过拧紧机的开始菜单，可以选择所有编程必需要的菜单用来编程。的菜单密码*复制程序参数设置指定配置轴数据参数设置从WF661输出拧紧数据轴标准值值测试运行轴测试SCHEME 7NUTRUNNER STARTING MENU 图7 拧紧机开始菜单For the operating of the nutrunner following has to be set: 使用拧紧机时，必须设置以下参数：Data of spindle type as size of torque transducer, gear factor, efficiency, data for test run for each individual spindle. 相关主轴数据有：扭矩传感器的型号，齿轮因素传动比，传动效率，单个主轴的测试运行数据。Nutrunner tightning data (parameter set) 拧紧机的拧紧数据(参数组集)Appointment of parameter sets to spindles 给指定主轴指定配置参数组集 5.1PASSWORD AND KEYSWITCH 密码和按键钥匙开关To protect the nutrunner against unauthorised programming the key-board is locked. Only after switching on the key switch and keying in the password programming of the nutrunner is possible. 为了保护拧紧机以防止未授权编程，必须锁定按键面板。只有在打开钥匙开关和输入编程密码后，才可以对拧紧机编程。When the nutrunner starting menu has been selected the password can be keyed in. 当选择拧紧机的开始菜单，可以输入密码。switch on the key switch 打开钥匙开关key in the password with the keys 0-9, (see 5.2) for each figure one * disappears. 通过键“0-9”进行密码输入，（参见5.2）每输入一个数字将显示一个*。If the correct password has been keyed in programming of the nutrunner can be started. If the wrong password has been keyed in, the stars will appear again and no programming is possible. 如果输入正确的密码，则可以启动拧紧机编程。 如果输入的密码错误，将再出现星号，并且不能运行编程。5.2KEYBOARD 键盘SCHEME 8KEYBOARD FOR NUTRUNNER PROGRAMMING 图8 拧紧机编程键盘The programming has to be done via the keyboard. The used keys are displayed. For detailed description see later sections of the manual. 编程必须通过键盘完成。可以显示使用过的健。 关于详细描写描述见手册的后面部分。5.3 PROGRAMMING OF PARAMETER SET 参数组编程设置When the display Parameterset: Programming is activated, the parameter set page 1 appears on the VDU. One parameterset consists of 5 pages. The page number will be shown under the title line and is marked by a cursor. The selection of other pages Is done by softkey forward and backward ( ). 当显示“参数组设置：编程”时，第1页的参数组设置页面第1页出现在视频显示装置显示器上。1个参数组设置包括5页，。页码将显示在标题行之下并且由指针光标指示。 其他页的选择由软键向前和向后完成( )。The parameter set no. appears at the bottom line. With function key F2 the next higher parameter set no. can be selected, with function key F1 the next lower parameter set no.can be selected. There are 10 parameter sets (no. 0-9) available. 参数设置组号在最下面一行。 通过功能键F2可以选择下个下一级一组的参数设置，功能键F1可以选择上一级参数组设置。，总共有10个参数设置集合组(第0-9) 。The line cursor appears in the first line. The selection of other lines is possible with keyor with key. 行游标指向第一行。 可以通过键和键来指向其他行。The set value has to be written with the keys on the position of the cursor. Zeros after the decimal point have to be written, but it is not necessary to write the zero before the decimal point. For end of input in on