Professional Documents
Culture Documents
Volume
ii
T able of Contents
SAFETY .............................................4
Definitions..............................................................4 SAFETY notices ....................................................5 Electrical Safety Warnings...................................7 Field Defaults................................................. 34 Directory/Files ............................................... 35 Graph ............................................................. 35 pring rate vs displacement ............................. 35 Force vs Displacement................................... 36 Raw Force vs Displacement .......................... 37 test.................................................................. 38 Create test ...................................................... 38 Delete test ...................................................... 39 Create Step test .............................................. 39 Step test.......................................................... 39 Math syntax ................................................... 40 Functions ....................................................... 40 Syntax ............................................................ 42
WARRANTY .................................... 52
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Chapter
Safety
WARNING The style shown here is used within these manuals to indicate that a WARNING has been given. A Warning relates to any sequence of events, procedure, drill, or situation that could lead to either injury, illness, or death to personnel.
DEFINITIONS WARNING Any comments regarding the threat of injury, illness or death to personnel, due to a particular sequence of events, procedures, drill or situation arising from a particular test configuration will be shown within this manual as a WARNING. The format of such a WARNING paragraph is shown below: CAUTION Any procedure that could lead to damage to equipment BUT NOT injury to personnel will be indicated as a Caution. Shown below is an example of the Caution paragraph style:
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SAFETY NOTICES THE TEST EQUIPMENT DESCRIBED AND WRITTEN ABOUT WITHIN THIS SUITE OF MANUALS MUST BE OPERATED USING PROCEDURES THAT PROVIDE THE MAXIMUM LEVELS OF SAFETY TO PERSONNEL AND TO THE EQUIPMENT ITSELF. All local and National Safety Standards, together with company-specific safety procedures MUST be observed at all times. It is essential that a detailed study of the information contained within Safety Considerations within this manual is made before operating the test equipment. The following guidelines are laid down as MINIMUM recommendations. Ensure that safety interlocks are fully, functional at all times. Only operate the test equipment after ensuring that no personnel are present in any areas that may be regarded as potentially hazardous. This includes the area around the test equipment and its component parts. All potential work area hazards must be properly guarded and all guards correctly closed BEFORE the test equipment is operated. Only trained personnel should operate the test equipment or be allowed to
Caution This is an example of a Caution notice. It is similar to the WARNING style, but has a differerent border. A Caution is given whenever a situation or procedure may cause damage to equipment but WILL NOT cause injury to personnel.
conduct tests using this equipment. The operators MUST be fully conversant with the Safety Considerations, Technical Descriptions and Operating Instructions contained within this manual, before operating the test system. Always ensure that the test equipment is operated within its design limitations.
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The test equipment should only be operated when regular maintenance schedules have been carried out and when it is known that the test equipment is in good working order. If the test equipment is producing unusual or excessive noise and/or vibration, stop the operation of the test equipment until such a time as the systems have been checked for possible faults. Maintenance procedures must only be carried out AFTER ensuring that all pneumatic and power has been dissipated and that the electrical power has been disconnected from the main supply.
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WARNING
The electrical power used in this equipment is at a voltage high enough to endanger life. Before carrying out maintenance or repairs, persons concerned must ensure that the equipment is isolated from the electrical supply and tests made to verify that the isolation is complete. When the supply cannot be disconnected, functional testing, maintenance and repair of the electrical components within the equipment is to be undertaken only by qualified electrical or electronic technicians who are fully aware of the dangers involved and who have taken adequate safety precautions. Lethal currents may result with voltages as low as 30 Volts RMS AC, or 50 Volts DC.
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Chapter
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INTRODUCTION Thank you for purchasing the REI Advance Spring Rater Program. This manual explains the operation of the Advance Spring 6 software package that is part of your spring checker system. The advance Spring 6 software runs under the Microsoft WINDOWS XP/Vista operating systems. If you are new to these operating systems, refer to the Microsoft manuals that were included with your computer. Go through the tutorial and become familiar with window and mouse operations.
GETTING STARTED This manual is written as a supplement to enhance your factory training, not replace it. It is recommended that you read the entire manual before attempting to operate the spring checker. Some things that may not be clear when first encountered in the manual will be more fully explained later. As an aid, all computer commands and options will appear as a different font: Computer
Command.
ICONS Certain commands can be accomplished by clicking the icon on the tool bar below the menu Bar. Most commands can also be executed using hot key listed on the hot key list or from the pull down menus
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Chapter
CREATING A TEST The create test wizard will walk you through creating a new test. Create test can be launched through the TEST pull down menu, with the ctl + M hotkey combination or the create test icon on the tool bar.
There are three areas that define a test. Pre stroke, test , and test points. Each area can be edited after a test is created.
PRE STROKE The pre stroke option will allow the operator to run the test specimen for a pre selected number of cycles to a defined force.
WARNING : the return position is a gap measurement, entering 0 would be the platens touching.
The number entered in the RETURN POSITION box Figure 1 will determine where the ram will return to between each cycle
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Figure 1
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Figure 2
The following window will set the force number that will be used to calculate the free length of the test piece. If zero is entered the program will use the first non zero force measurement as a free height.
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Figure 3
TEST POINTS The test point window figure 4 is used to set the parameters that will determine the area of the collection the program will use to calculate the spring rate. All data points within the start and end points will be averaged to calculate rate.
Figure 4
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If you select the point validation figure 5 the program will report a pass/fail of the returned data based on the validation points entered. You can select if the validation should applied to the compression, extension, average, or both compression and extension.
Figure 5
The final window will prompt you to name the test. Each test must have a unique name. You can create as many test as you require.
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Chapter
Collecting data
To start a test click on the Test Icon menu or the F11 hotkey. The Spring Test window displays the test parameters for all created test. To create a test, use the Create test wizard. A standard spring test will record data collected dynamically at the interval selected for the complete test range. Click on the arrow to the right of the select test window to view all created test. The three areas of a test description can be edited form the tabs on this page. Pre stroke and test points can be enabled or disabled using the check boxes on those pages. Select Configuration Defines the data card configuration that will be used for this test. Unless you have created a new configuration this will always be Default. Select the spring test to run The pull down arrow to the right of this window allows you to select a test from a list of test you have created. You can have as many spring test created as you need. The parameters for the selected test are displayed in the boxes below this window. Peak force the peak force that this test will compress the spring to, this is the force
that the machine will reverse from compression to extension.
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Test speed velocity in in/sec of the test. Pause time dwell time at peak force. Measurement interval displacement interval between data points. Spring height force The force the machine will use to define spring free height. Start/End point These define the range the program will use to calculate spring
rate. These numbers may be changed after the test.
figure 6
does not have a gap measurement recorded (red light displayed). You will need to measure the gap each time you start the program. You will be prompted to enter a block height number if you are using a block between the platens when measuring the stroke Once the gap has been measured and your tool height entered set click Next.
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Insert a tool height number in the Tool Retainer Height box if you are testing the spring with anything that adds to the free height of the spring. If a spring only is being tested this will be set to zero.
Figure 6
1. The next window is a final warning that the test is about to start. The machine will compress the spring to the peak force setting and return to home.
After the test is complete the following window will give you a snapshot of the collected data. The force, displacement, and rate data at the bottom of the results page is calculated based on the start and end points entered at the top of the page, this is the test range. The rate number is a average of all rate data points in the test range. Your start and end point numbers may be changed to view data from
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different areas of the spring. This will not affect the saved data and this point data may be viewed after the data is saved by using the point report. The start point is the distance between the platforms the end point number is also a distance between the platform unless you check Relative to start point. If you enter a number not in the spring range (ie: 3 displacement on a 2 spring) the program will not complete the results section. From this window you can click Finish to save the data file or save and repeat if you wish to run the same test again or Batch test if this is the first of a batch of springs to be tested..
Batch Test The batch test button is designed to give the user the ability to run a number of different springs and save the data as one data file. After running the first spring replace the spring in the machine and use the Batch Test Repeat button to re run the same test. After all the springs have been run use the Finish button to save and name the data file. The individual runs will be saves together in one data file and identified by which number run it was in the batch.
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Step Test
Unlike the standard dynamic collection test, the step test will collect data at user defined displacement points. The machine will stop and hold at each point while the software makes the collection. This is a static collection unlike the dynamic collect in other test types.
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force reading at a given displacement point. The Gap Move will move to the gap number entered in the move target box (gap is the distance between the spring platforms. Absolute move will move the lower platform the distance entered in the target box. Force move will compress the spring to the force entered in the Force Target window. Relative move will move the lower platform the distance entered in the Move size window. You can click on the up or down buttons to move the entered distance a number of times.
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Chapter
the file in the program, the file is still saved in the original file location. To aid the operator in analyzing the graph a movable curser and zoom window are available. Click on the trace to place the curser.. use the right and left arrow keys to move the curser along the trace. The data from each data point will read out on the status bar at the bottom of the screen. To zoom in on a section of the graph place your curser at a point on the graph hold down the left mouse button and drag a box around the area you wish to zoom, or use the zoom tool bar items
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To return to full view use the reset zoom button toolbar, then click paste in a document.
on the tool
bar. You can copy the graph to a document by clicking on the camera icon on the
Legend
Figure 7
By right clicking on the word Graph at the bottom of the legend you can insert more graphs. This is basically another sheet to open data files on. Your data can also be viewed in numeric form by selecting the Report, Point Report, and statistical Report tab at the top of the graph (figure:5).
Report page
- the program will display the data for the file name that is
highlighted in the legend. The up and down arrows can be used to move between file with the data window open. By using the Report box on the right of the screen you can define how the data is displayed. The numeric report can be
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exported to a file or the clipboard in three different formats using the Export box located under the Report box.
Point Report
The point repot can be used to find the force, displacement or rate
at any requested point or as a point referenced from the full length point of the spring (if you enter 1 with the R box checked this point would be 1 from the full length position). By default the full length point will automatically be the first point in the report. If the R box is empty that row will display data at that point in force or displacement depending on the units you select.
Statistical Report
On This page you are able to compare all open data files.
Use the start and end point boxes to define the report area. Data for each spring will be displayed as well as minimum, maximums, average, and standard deviation in compression, extension, and average data.
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figure:6
The scaling tab can be used to define the scaling and orientation of the data on the graph page. Auto scale will size the graph to fit the data trace. The span box will define the minimum scaling of the graph when you are on auto scale. To use span enter a scaling number in the span box (you must have auto scale checked) the program will now keep your scaling at that span and place the trace on the middle of the graph, if the trace is larger than the span the program will auto scale. Using span on the rate axis will keep the trace in the middle of the graph no matter what the rate. To set the scaling remove the check from auto scale and fill in your scaling numbers. From this page you can also define the number of lines per axis, and invert the sign or axis for both the x
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Chapter
MENUS
Each menu displays options and various tasks that can be done in the program. The following is a description of each menu, and what can be found under each menu heading. Please be aware that some sections are for advanced users only and should not be used unless you are familiar with function of the option and how it might affect the data. Main menus are displayed in blue in the following section.
FILE
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New Template
Templates will save all open data files in one file. To make a new template, click on New Template.
Save Template
allows the user to name the template when the save window appears. Templates are saved to a separate directory and named by the user. This option can also be used to save multiple traces on one graph.
Open Template
This menu opens to the directory that stores all templates allowing the user to select a preferred template.
Save Template
Selecting this option will open the save template window. template, give a name to your new template and click Save. To save a new
Printer Setup
Displays the windows print setup screen
Print
All user defined print options are on this screen. The graph layout function allows the user to size his graph, legend, and notes on the paper to fit his needs. The numbers that are entered in the divider box are the percent of the page from top or left that each item will start at. If the notes were positioned at the bottom of the page and set on 90% the note box would start at 90% of the page, measuring from the top of the page. The legend and notes can
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be located on the left, right, top, and bottom of the page or hidden. Moving an item will require a change in the page percent number to keep the graph area the same. In most cases selecting the same print settings on different machines will produce the same size graph on the paper, if you attempt to match graph sizing on different printers it may be necessary to set the size number different to create the same size graphs. Show Logo- Check this box to include a logo on your printed graph. To select a new logo click the small button to the right of the status bar under the show logo box. Select the bit map file you wish to use. The loaded logo file name will appear in the status box. If you select the stretch to fit box, the program will fit the logo to the page without changing the graph size. If this box is not checked the program will display the logo as the saved bitmap size.
Report options
This page defines all parameters for the numeric reports that are printed. To print only the graphs with no report remove all check marks on the Data Report section of this page. To print only the reports without the graphs uncheck the print graph box at the top of the page. The graph and data can be printed on the same page by checking the Graph Size box and adjusting the graph size to fit the data on the graph page, when printing data and graph on the same page the lay out works best on portrait mode.
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Export
from this menu the user can export the raw collected data. Exporting the file will export the data used to display the data on the open graph. (if force vs displacement graph was open the force and displacement channels would be exported). To export selected traces open the signal vs time graph and highlight the traces to export in the legend.
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Preferences (F12)
In this window the user can define default settings that control how a test will be run and graphed. Many of these settings can be changed in other parts of the program without affecting the default settings selected on this page. After changing a setting you must hit the enter key before OK or Apply to hold your change on all preferences pages.
Display
. Default graph will define the graph type that the program will open. The legend items will define how the legend id displayed. (figure:7)
figure:7
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Test
The enter Test Description box is used to control when the test description page will be displayed for user to fill in test information
Units
Use this page to set English or metric measurements in displayed data, Custom option allows user to mix systems. To change to a different metric unit click on the unit, use the pull down menu that opens to select a new unit. The CTL-F12 hot key or the unit hotkey can also be used to switch between units.
Color
This window lets the operator select the colors and order of colors that the program will use for displaying data files graph traces. Click on each box to select the color.
Graph
Grid, Cursor Styles, fonts and Trace Width can be modified from the graph page. Trace Width will define the thickness of the data traces as shown on the monitor and printed graph. (figure;8)
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figure:8
Smoothing
Smoothing on this page only affects the look of the graph to aid in comparing graphs, it does not affect the recorded spring rate number. REI recommends a 25 smoothing on the rate channel. In most cases all other channels should have the smoothing set to zero.
Math Signals
Math signals are channels that are not collected but are created with a mathematical operation using constants, math functions and channels. Math channels are treated the same as collected channels and may be graphed and used
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in other math channels. The math syntax for creating math signals is listed at the end of this manual.
Field Defaults
Fields are the pages that have areas for the operator to fill in test and spring information. The fields will be held with the test and displayed on the report tab. The default page allows you to customize the fields to contain the information you need. Clicking on the edit test Defaults will open the window displayed below. By clicking on a cell you can change the name of a field or the number of lines that will be reserved for that field. By using the INSERT key new lines may be added to expand the field page. To delete a line highlight the name by clicking on it and use the delete key. The default boxes can be used for descriptions that you want to appear with each saved data file as a default. Constants are numbers that would be used with math channels. This window allows the use to completely customize the data displayed on the report page.
Click on cell to Highlight that cell, when a cell is highlighted you can modify the contents of that cell
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Directory/Files
From this page the user can define the default file name and default location the data files. By default the program will always return to the last used directory when saving a data file. A user may select there own default location by clicking Use a predefined directory. The button to the right of the file name allows the operator to select another file for the default directory. This page can also be used to define the default file name (Spring Data by default) or have the program us the last entered file name followed by a number that is automatically inserted as a default.
Graph
This window allows you to select what graph format the program uses to display the open data files. Select the graph type you wish to use by clicking on the appropriate graph type or use the hot keys. The following is a short description of each graph type. Options to aid the user in viewing the data are explained in detail in the analyzing your data section starting on page nine. Use the properties page in the Edit menu to find options to change the layout of the graph.
depicts the spring rate by calculating the change in force divided by the change in displacement between each recorded data point and plotting these points against spring displacement. The complete trace displays the compression and extension data, the average is the average of the compression and extension. Spring rate vs force is the same graph except the X-axis is force.
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figure:10
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figure:11
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figure:12
test
This screen is used to perform a spring test as outlined on page five in collecting data
Create test
Standard test profiles are preset from the factory and can be selected in the test box, or modified with the edit button. To create a new test use the create test button. The create test wizard will walk you through the options to create a new test. After you name the new test the program will save that test in the pull down menu on the test page.
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Delete test
Using the delete test button will permanently remove the selected test profile from the from the test profile list.
Step test
Test window to execute a step test.
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Chapter
7
All
Math syntax
Functions
The following functions are supported by the Roehrig Math system. functions, unless specifically noted operate on all types of signals.
ABS ( expression )
Returns the sign of the expression. If expression is greater then 0, SGN returns 1. If expression is equal then 0, SGN returns 0. If expression is less then 0, SGN returns -1.
SIN ( expression )
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ATAN returns the tan-1 of expression. EXP returns the values of e to the expression power, or eexpression.
LOG ( expression )
SQRT returns the square root of expression DIFF differentiates expression with respect to time. expression.
INTG ( expression )
INTG integrates expression with respect to time. The sample rate of expression is assumed to be that same of the data being used to evaluate expression.
POSITIVE ( expression )
POSITIVE returns the value of expression if it is greater then zero, otherwise POSITIVE returns zero.
NEGATIVE ( expression )
NEGATIVE returns the value of expression if it is less then zero, otherwise NEGATIVE returns zero.
RAD ( expression )
MIN evaluates each individual expression and then returns the minimum of all of the expressions.
MAX (expression1, expression2, expression3, )
MAX evaluates each individual expression and then returns the maximum of all of the expressions.
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AVE evaluates each individual expression and then returns the average of all of the expressions.
UNITS ( symbol , measurement )
UNITS ensures that symbol is returned in measurement units. For example, if Displacement may be in inches or millimeters, UNITS(Displacement, {Mm}) would ensure the Displacement is in millimeters.
TOUNITS ( expression , measurement , targetmeasurement )
TOUNITS assumes expression is in measurement units and forces it to convert to targetmeasurement units.
SMOOTH ( expression , NUMBER )
SMOOTH evaluates expression and averages the values of expression for each of the NUMBER data points before and after the each data point. For example SMOOTH(Displacement, 5) would for each point of displacement it would average the eleven data points to generate the value at that data point. (It uses eleven because it takes 5 points from left, 5 points from the right and the data point itself.)
CYCLE ( expression , opendirection , closedirection )
CYCLE evaluates expression and then clips the data to contains only the opendirection and closedirection portions of the dyno cycle. opendirection and closedirection can be qith ~Rebound, ~Compression, or ~Ignore.
Syntax
expression: binaryop | simpleexpression | ( expression ) simpleexpression: | | | | | | number symbol function unaryoperation conditional smooth cycle
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number: | symbol
function: | | | | | | | | | | | | | | | | | | | |
ABS ( expression ) SGN ( expression ) SIN ( expression ) COS ( expression ) TAN ( expression ) ASIN ( expression ) ACOS ( expression ) ATAN ( expression ) EXP ( expression ) LOG ( expression )| SQRT ( expression )| DIFF ( expression ) INTG ( expression ) POSITIVE ( expression ) NEGATIVE ( expression ) RAD ( expression ) DEG ( expression ) MIN ( argumentlist ) MAX ( argumentlist ) AVE ( argumentlist ) UNITS ( symbol , measurement ) TOUNITS ( expression , measurement , measurement ) expression , argumentlist expression
argumentlist: |
unaryoperation: | binaryop: | | | | | | | | | | | | | |
- expression NOT expression + expression - expression * expression / expression % expression ^ expression > expression >= expression = expression != expression <= expression < expression AND expression OR expression XOR expression
expression expression expression expression expression expression expression expression expression expression expression expression expression expression expression
conditional: |
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IF ( expression , expression ) IF expression THEN expression IF expression THEN expression ELSE expression SMOOTH ( expression , NUMBER ) ~COMPRESSION ~REBOUND ~IGNORE CYCLE ( expression , direction , direction ) {UNKNOWNUNIT} {} {INCH} {M} {CM} {MM} {IPS} {INCH/SEC} {M/SEC} {CM/SEC} {MM/SEC} {LBS} {NEWTONS} {KGF} {F} {C} {RPM} {HZ} {FT} {MI} {KM} {SEC} {MIN} {HR} {FT/SEC} {MPH} {MI/HR} {KPH} {K/HR} {G} {FT/SEC^2} {MP/SEC^2} {IN*LBS} {FT*LBS} {N*M} {PSI} {BAR} {P} {V} {LBS/IN} {N/MM} {N/CM}
measurement:
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{N/M} {KGF/MM} {KGF/CM} {KGF/M} {OZ} {LBS} {GM} {KG} {FLOZ} {GAL} {L} {DEG} {RAD} {IN*LBS/DEG} {FT*LBS/DEG} {KGF*MM/DEG} {KGF*CM/DEG} {N*MM/DEG} {N*CM/DEG} {N*M/DEG} {NEWTON*CM} {NEWTON*MM} {KGF*MM}{KGF*CM} {KGF*M} {KGF*M/DEG} {%}
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7
Maintenance Procedures
Chapter
47
48
Crosshead
On some models the crosshead itself has clamp/unclamp bolts built into it as well as a clamp/unclamp actuator. The crosshead also has an acme motor screw drive assembly, which may require periodic maintenance. Lock/Unlock The crosshead is locked (clamped) in place through the use of two threaded bolts on lever arms, which are attached to the electric actuator, which is free to move. As one bolt has right-hand threads, and the other has left-hand threads, the actuator clamps the crosshead into position when the electric actuator is fully RETRACTED. The crosshead is in the UNCLAMP position when the electric actuator is in the fully EXTENDED position. NOTE that all motion of the Lock Unlock is accomplished through the PLC Manual Screen, under Crosshead Control. Crosshead assembly driven by a reversing electric motor. Raise/Lower The motor drives both acme screws The Crosshead Raise/Lower motion is accomplished through the use of an acme screw synchronously through the use of a timing belt, which will eventually require replacement if worn or aged. Please note that all motion control for the Crosshead Raise/Lower is also accomplished through the PLC Manual Screen, under Crosshead Control.
Recommended Spare Parts
Recommended spares have been broken down in distinct categories: Transducers, REI Custom Parts/Assemblies, Fuse Chart, and Purchased Parts. Roehrig Engineering adheres to the policy that it is not our intention to profit from spare parts, and provides this service to support previous sales. Items such as Transducers, Fuses, and Purchased Parts can be obtained either through REI, with cost markups to cover order processing charges, or can
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be obtained directly from the appropriate manufacturer. In the event purchased items are obtained from REI, REI standard warranties apply. If spare parts are purchased directly from manufacturers, warranty claims must be coordinated directly with the component manufacturer. Recommended Spare Parts is not intended to be an entire list of all potentially replaceable items, but rather includes items which REI has identified as either a component required for routing maintenance, a critical component which deems the machine inoperable, or items which may have unusually long lead items.
Transducers/Sensors
Description Load Cell Draw Sensor (String Potentiometer) Encoder Requires REI service for removal/install Part Number 1010ALD-5K-B Wire P510-40 Qty Used 1 1 Interface, Inc., UniMeasure, Replacement recalibration Only reqd for crosshead adjust/control requires Supplier Comments
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Volume
Warranty
SERVICE POLICY Roehrig Hardware Under Warranty A one-year warranty comes with the purchase of new Roehrig Engineering manufactured hardware products. Supplemental service plans are also available at additional cost.
1. 2. 3. 4. 5. 6. 7.
The following is a summary of what service can be obtained under the Standard warranty: Factory repairs on hardware product defects; Factory repairs are usually completed within 3 working days of Roehrig Engineerings receipt of the defective item. The customer is responsible for returning the hardware to Roehrig Engineering; Roehrig Engineering will return the hardware via UPS 2 day air service (USA only). If the customer is outside the continental USA, the customer is responsible for all shipping expenses. Expedited service can be arranged at the customers expense; Free technical support, for technical problems and applications, for all trained users; Warranties can be renewed annually on Roehrig Engineering products; A warranty cannot be purchased if the original or renewed warranty has expired. Warranties are transferable to subsequent owners under certain conditions: