90781128880 1

LIST OF FIGURES


S.No. LIST OF FIGURES Page No.
1.1 Company Profile 3
2.1 Solution Business 5
2.2 Ergonomic Handling 6
2.3 Precision Fastening 7
2.4 Fluid Solutions 8
3.1 Electronics Lab 9
3.2 ICD/M Controllers 10
3.3 Siemens PLC 10
3.4 Control panel having Siemens PLC 12
3.5 Allen-Bradley PLC 12
3.6 QM series DC tool 20
3.7 QE series DC tool 21
3.8 Inputs 24
3.9 Outputs 25
3.10 Power head port 26
3.11 Terminal switch 26
4.1.a Actual design 27
4.1.b Layout 28
4.1.c Side view 28
4.1.d Upper view 29
4.2 Powerhead srtup mode 30
4.3 Config 1 assigned 31

90781128880 2

S.No. LIST OF FIGURES Page No.
4.4 Parameters 32
4.5 Program parameters 32
4.6 Program parameters 33
4.7 Config 2 assigned 34
4.8 Program parameters 34
4.9 Program parameters 35
4.10 General setup 35
4.11 Controller 1 I/Os 36
4.12 Controller 2 I/Os 36
4.13 Controller 3 I/Os 37
4.14 ETA 39
4.15 Sound level meter 39
5.1 Actual Design 40
5.2 Side view 41
5.3 Readings 43
5.4 RI Bracket tightening 43
5.5 Readings 44
5.6 Housing screw 44
5.7 Readings 45
5.8 RI shaft tightening 45
5.9 Readings 46
5.10 Cable anchoring 46
5.11 Readings 47
5.12 B Mount bracket 47

90781128880 3

S.No. LIST OF FIGURES Page No.
5.13 PC adapter 48
5.14 Profibus connector 48
5.15 Actual layout 49
5.16 I/O of controller 50
6.1 Appearance of ZEN PLC 52
7.1 Steps of program 60



















90781128880 4

TABLE OF CONTENTS


S.No. TABLE OF CONTENTS Page No.
1. COMPANY PROFILE 3
1.1 Overview 3
2. DEPARTMENT OF WORKING 5
2.1 Solution Business 5
2.2 Ergonomic Handling System 6
2.3 Precision Fastening 7
2.4 Fluid Solutions 8
3. EED 9
3.1 Electronics Lab 9
3.2 Research & Development 10
3.2.1 Application 10
3.3 Testing, Support, Training 11
3.3.1 Application 11
3.4 DC Tools 20
3.4.1 QM series DC tools 20
3.4.2 QE series DC tools 21
3.5 ICS software 22
3.6 Power head setup 25
4. PROJECT 1 30
4.1 Introduction 30

90781128880 5

S.No. TABLE OF CONTENTS Page No.
4.2 Customer and its requirements 33
4.3 Drawing 39
4.4 Problems faced 40
4.5 Quality check 40
5. PROJECT 2 42
5.1 Introduction 42
5.2 Customer and its requirements 43
5.3 Drawing 51
6. . PROJECT 3 52
6.1 Introduction 52
6.2 Applications/Projects 54
6.3 Other projects/applications 58
7. OTHER PROJECTS AND APPLICATIONS 59
7.1 Introduction 59
7.2 US Controller testing 59
7.3 NPD Lab/EB testing lab 62









90781128880 6

CHAPTER ONE
COMANY PROFILE

Ingersoll-Rand (India) Limited

Fig.1.1
1.1 Overview
INGERSOLL Rand India Private Limited was founded in Kolkata in 1921, one of the first
American investments in India. In 1958 the company opened a branch office in Ahmedabad and
in 1963 the head office was shifted to Mumbai. INGERSOLL Rand established its first
manufacturing plant in Naroda, Ahmedabad in 1965 and in 1977 became a public limited
company.
INGERSOLL RAND is a $14 billion global diversified industrial company, driven by employees
who are proud to offer products and solutions people use every day to create a positive impact in
their world. Driven by a 100- year-old tradition of technological innovation, we enable
companies and their customers to create progress.
With a major emphasis on Innovation to drive Productivity, the company has had many firsts
to its credit. INGERSOLL Rand is a pioneer in bringing centrifugal technology into India and
started when centrifugal technology was hardly known and accepted. In recent times, with the
focus shifting to energy efficient compressor technology, INGERSOLL Rand launched the
award-winning Nirvana energy saving rotary compressors. The company continues to bring
latest technologies to India and launch localized products keeping in mind the requirements of
the Indian market. Not just path-breaking technologies and products, INGERSOLL Rands key
strength is its world class service that it provides to its customers across the country.
Ingersoll Rand Industrial Products Pvt. Limited is a part of Ingersoll Rand's Industrial
Technologies Sector .Ingersoll Rand's experienced workforce is committed to produce high
quality assembly equipments and is provided with modern manufacturing & test facilities. All
critical operations are done in house. The company has been certified to comply with ISO 9001

90781128880 7

requirements. Ingersoll Rand Industrial Products Pvt. Limited lays great emphasis on pre & after
sales service to help customers select appropriate technology and products to exactly match their
applications and requirements as well as to ensure optimum utilization of equipments supplied.
Ingersoll Rand Industrial Products Pvt. Limited also manufactures and markets a complete range
of accessories.
Ingersoll Rand's portfolio of businesses are divided into four distinct sectors.
The Climate Solutions sector delivers energy efficient HVACR solutions for customers globally.
Its brands include Hussmann, a manufacturer of refrigeration and food merchandising
solutions, Thermo King, transport temperature controls, and Krack, warehouse refrigeration,
and Trane, a provider of energy efficient heating, ventilating and aire conditioning systems,
building contract services, world class parts support and advanced controls for homes and
commercial buildings.
The Industrial Technologies sector provides products, services and solutions that enhance energy
efficiency, productivity and operations. Ingersoll Rand branded products range from complete
compressed air systems, tools and pumps to material and fluid handling systems and
environmentally friendly microturbines. Also included in this sector is Club Car, the global
leader in golf carts and utility vehicles.
The Residential Solutions sector comprises brands such as Schlage, Schlage LiNK and Trane.
Products, services and solutions include mechanical and electronic locks, heating and air
conditioning systems, indoor air quality solutions, advanced controls, portable security systems
and remote home management.
Security Technologies sector products include electronic and biometric access control systems,
locks and locksets, door closers, floor closers, exit devices, steel doors and frames, portable
security devices, decorative hardware, cabinet hardware and time, attendance and personnel
scheduling systems from brands likeSchlage.
In 2007, the Security Technologies sector started to move the Falcon, Monarch and Dor-O-Matic
brands into a new single brand of Falcon Door Hardware. The individual brands will lose their
identity in 2008 and 2009.


Ingersoll Rand Industrial Products Pvt. Limited -
Factory and North/East Zone
Sales office: - 37-A, Site 4, Sahibabad
Industrial Area, Ghaziabad -201 010 U.P


90781128880 8

CHAPTER TWO
DEPARTMENT OF WORKING
(SOLUTIONS)

Ingersoll Rand Industrial Products Pvt. Limited- South Asia Solution Centre.
2.1 Solution Business
Fig.2.1


Solution
Business
Pneumatic
Tools,
Accessories
And Testing
Equipments
Fastener
Tightening
System And
Assembly
Automation
Ergonomic
Handling
System
Fluid
Dispensing
System

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2.2 Ergonomic Handling System















Fig.2.2




Ergonomic
Handling System
Articulating
Arm
Grippers
Seat Handling Tyre Handling
Body Handling Sack Handling
Miscellaneous

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2.3 Precision Fastening














Fig.2.3





Precision
Fastening
Low cost QMM
Fixtured units
Overhead
suspension
Universal joint
application
Single spindle
DC
Tool
accessories
Bail with
reaction bar
Torque Arm
Socket Tray

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2.4 Fluid Solutions















Fig.2.4




Fluid Solutions
Standard
Packages
Oil Pkg Grease Pkg
Spray Pkg
Customized
Packages
Oil Dispensing
System
Grease
Dispensing
System
Water Coolant
Dispensing
System
Sealant
Dispensing
System
Ink Dispensing
System

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CHAPTER THREE
EED LAB
(RESEARCH AND DEVELOPMENT)

3.1 Electronics Lab


Fig.3.1


Electronics Lab
Research and
Development
Integration Data Archive
Data Print
Testing &Trouble
Shooting
of DC Controllers
ICD/M DC
Contollers
capabilities
ICS Software
EOR Print PLC Program
ICD/M DC
Controller & Internet
Cards

90781128880 13

3.2 Research & Development
3.2.1 APPLICATIONS
ICD/M Controllers


ICD ICM
Fig.3.2
The IC12D Series of controllers give you full closed loop-control in an industry leading compact
size. With features like 1/4 VGA color display and intuitive programming interface, the IC12D
units provide unmatched performance and value. These controllers have full communication
capability using Ethernet, RS232, Field bus or standard I/O. Units may be programmed
either through the key pad or via a PC running ICS software. IC12D Controllers will self identify
and operate all QE and QM Series of tools making set-up and operation an easy task.
1/4 VGA 216 color display
Ethernet, RS232 and I/O communication
Device Net and Profibus available
Dual mode power supply: 90 - 120 VAC and 200 - 240 VAC
Operating range of 0 to 50 degrees C
Operates all QE and QM Series Tools
Multiple mounting options
The IC12M Series of controllers give you full closed loop-control in an industry leading
compact size. With standard features like multiple torque strategies, digital display and
Parameter Transfer Key, the IC1M units provide unmatched performance and value. These
controllers have full communication capability using Ethernet, RS232, Fieldbus or standard
I/O. Units may be programmed either with the Parameter transfer Key or via a PC running ICS
software. A 0 to 60 degree C (32 to 140 F) internal operating range allow these units to be used

90781128880 14

in the most demanding conditions without risk of overheating. IC12M Controllers will self
identify and operate all QE and QM Series of tools making set-up and operation an easy task.

One Line digital display
Ethernet, RS232 and I/O communication
DeviceNet and Profibus available
Dual mode power supply: 90 - 120 VAC and 200 - 240 VAC
Operating range of 0 to 60 degrees C
Operates all QE and QM Series Tools
Multiple mounting options

EOR PRINT
Following steps are there-
1. Controller should be in power head mode (CAN address should be 1).
2. EOR print settings should be as follows:-
















90781128880 15

3. The output screen looks like-


























4. Most required step-













90781128880 16
























SQL Queries

SQL sometimes referred to as Structured Query Language) is a programming
language designed for managing data in relational database management systems (RDBMS).
The most common operation in SQL is the query, which is performed with the
declarative SELECT statement. SELECT retrieves data from one or more tables, or expressions.
Standard SELECT statements have no persistent effects on the database. Some non-standard
implementations of SELECT can have persistent effects, such as the SELECT INTO syntax that
exists in some databases. Queries allow the user to describe desired data, leaving the database
management system (DBMS) responsible for planning, optimizing, and performing the physical
operations necessary to produce that result as it chooses.




90781128880 17

PLC










Fig.3.3
Fig.3.3 shows Siemens PLC
A programmable logic controller (PLC) or programmable controller is a digital
computer used for automation of electromechanical processes, such as control of machinery on
factory assembly lines, amusement rides, or light fixtures. PLCs are used in many industries and
machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output
arrangements, extended temperature ranges, immunity to electrical noise, and resistance to
vibration and impact. Programs to control machine operation are typically stored in battery-
backed-up or non-volatile memory. A PLC is an example of a hard real time system since output
results must be produced in response to input conditions within a bounded time, otherwise
unintended operation will result.
More recently, PLCs are programmed using application software on personal computers. The
computer is connected to the PLC through Ethernet, RS-232, RS-485or RS-422 cabling. The
programming software allows entry and editing of the ladder-style logic. Generally the software
provides functions for debugging and troubleshooting the PLC software, for example, by
highlighting portions of the logic to show current status during operation or via simulation. The
software will upload and download the PLC program, for backup and restoration purposes. In
some models of programmable controller, the program is transferred from a personal computer to
the PLC through a programming board which writes the program into a removable chip such as
an EEPROM or EPROM.
The functionality of the PLC has evolved over the years to include sequential relay control,
motion control, process control, distributed control systems and networking. The data handling,
storage, processing power and communication capabilities of some modern PLCs are
approximately equivalent to desktop computers. PLC-like programming combined with remote

90781128880 18

I/O hardware, allow a general-purpose desktop computer to overlap some PLCs in certain
applications.
Regarding the practicality of these desktop computer based logic controllers, it is important to
note that they have not been generally accepted in heavy industry because the desktop computers
run on less stable operating systems than do PLCs, and because the desktop computer hardware
is typically not designed to the same levels of tolerance to temperature, humidity, vibration, and
longevity as the processors used in PLCs. In addition to the hardware limitations of desktop
based logic, operating systems such as Windows do not lend themselves to deterministic logic
execution, with the result that the logic may not always respond to changes in logic state or input
status with the extreme consistency in timing as is expected from PLCs.
Still, such desktop logic applications find use in less critical situations, such as laboratory
automation and use in small facilities where the application is less demanding and critical,
because they are generally much less expensive than PLCs.


Fig .3.4

Fig .3.4 shows panel having Siemens PLC CPU.
The main difference from other computers is that PLCs are armored for severe conditions (such
as dust, moisture, heat, cold) and have the facility for extensive input/output (I/O) arrangements.
These connect the PLC to sensors and actuators. PLCs read limit switches, analog process

90781128880 19

variables (such as temperature and pressure), and the positions of complex positioning systems.
Some use machine vision. On the actuator side, PLCs operate motors,
pneumatic or hydraulic cylinders, magnetic relays, solenoids, or analog outputs. The input/output
arrangements may be built into a simple PLC, or the PLC may have external I/O modules
attached to a computer network that plugs into the PLC.
A PLC program is generally executed repeatedly as long as the controlled system is running. The
status of physical input points is copied to an area of memory accessible to the processor,
sometimes called the "I/O Image Table". The program is then run from its first instruction rung
down to the last rung. It takes some time for the processor of the PLC to evaluate all the rungs
and update the I/O image table with the status of outputs.. This scan time may be a few
milliseconds for a small program or on a fast processor, but older PLCs running very large
programs could take much longer (say, up to 100 ms) to execute the program. If the scan time
was too long, the response of the PLC to process conditions would be too slow to be useful.
As PLCs became more advanced, methods were developed to change the sequence of ladder
execution, and subroutines were implemented.
]
This simplified programming and could also be
used to save scan time for high-speed processes; for example, parts of the program used only for
setting up the machine could be segregated from those parts required to operate at higher speed.
Special-purpose I/O modules, such as timer modules or counter modules, could be used where
the scan time of the processor was too long to reliably pick up, for example, counting pulses
from a shaft encoder. The relatively slow PLC could still interpret the counted values to control a
machine, but the accumulation of pulses was done by a dedicated module that was unaffected by
the speed of the program execution.
PLCs may need to interact with people for the purpose of configuration, alarm reporting or
everyday control. A human-machine interface (HMI) is employed for this purpose. HMIs are
also referred to as man-machine interfaces (MMIs) and graphical user interface (GUIs). A simple
system may use buttons and lights to interact with the user. Text displays are available as well as
graphical touch screens. More complex systems use programming and monitoring software
installed on a computer, with the PLC connected via a communication interface.
PLCs have built in communications ports, usually 9-pin RS-232, but optionally EIA-
485 or Ethernet. Modbus, BAC net or DF1 is usually included as one of the communications
protocols. Other options include various field buses such as Device Net or Profibus. Other
communications protocols that may be used are listed in the List of automation protocols.
Most modern PLCs can communicate over a network to some other system, such as a computer
running a SCADA (Supervisory Control And Data Acquisition) system or web browser.
PLCs used in larger I/O systems may have peer-to-peer (P2P) communication between
processors. This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link. These communication links
are also often used for HMI devices such as keypads or PC-type workstations.

90781128880 20

PLC programs are typically written in a special application on a personal computer, then
downloaded by a direct-connection cable or over a network to the PLC. The program is stored in
the PLC either in battery-backed-up RAM or some other non-volatile flash memory. Often, a
single PLC can be programmed to replace thousands of relays.
Under the IEC 61131-3 standard, PLCs can be programmed using standards-based programming
languages. A graphical programming notation called Sequential Function Charts is available on
certain programmable controllers. Initially most PLCs utilized Ladder Logic Diagram
Programming, a model which emulated electromechanical control panel devices (such as the
contact and coils of relays) which PLCs replaced. This model remains common today.
IEC 61131-3 currently defines five programming languages for programmable control
systems: function block diagram (FBD), ladder diagram (LD), structured text(ST; similar to
the Pascal programming language), instruction list (IL; similar to assembly language)
and sequential function chart (SFC)
[8]
. These techniques emphasize logical organization of
operations.
While the fundamental concepts of PLC programming are common to all manufacturers,
differences in I/O addressing, memory organization and instruction sets mean that PLC programs
are never perfectly interchangeable between different makers. Even within the same product line
of a single manufacturer, different models may not be directly compatible.


Fig .3.5
Fig .3.5 shows Allen-Bradley PLC
PLCs are well-adapted to a range of automation tasks. These are typically industrial processes in
manufacturing where the cost of developing and maintaining the automation system is high
relative to the total cost of the automation, and where changes to the system would be expected
during its operational life. PLCs contain input and output devices compatible with industrial pilot
devices and controls; little electrical design is required, and the design problem centers on
expressing the desired sequence of operations. PLC applications are typically highly customized
systems so the cost of a packaged PLC is low compared to the cost of a specific custom-built
controller design. On the other hand, in the case of mass-produced goods, customized control
systems are economic due to the lower cost of the components, which can be optimally chosen

90781128880 21

instead of a "generic" solution, and where the non-recurring engineering charges are spread over
thousands or millions of units.
For high volume or very simple fixed automation tasks, different techniques are used. For
example, a consumer dishwasher would be controlled by an electromechanical cam timer costing
only a few dollars in production quantities.
A microcontroller-based design would be appropriate where hundreds or thousands of units will
be produced and so the development cost (design of power supplies, input/output hardware and
necessary testing and certification) can be spread over many sales, and where the end-user would
not need to alter the control. Automotive applications are an example; millions of units are built
each year, and very few end-users alter the programming of these controllers. However, some
specialty vehicles such as transit buses economically use PLCs instead of custom-designed
controls, because the volumes are low and the development cost would be uneconomic.
Very complex process control, such as used in the chemical industry, may require algorithms and
performance beyond the capability of even high-performance PLCs. Very high-speed or
precision controls may also require customized solutions; for example, aircraft flight
controls. Single-board computers using semi-customized or fully proprietary hardware may be
chosen for very demanding control applications where the high development and maintenance
cost can be supported. "Soft PLCs" running on desktop-type computers can interface with
industrial I/O hardware while executing programs within a version of commercial operating
systems adapted for process control needs.
Programmable controllers are widely used in motion control, positioning control and torque
control. Some manufacturers produce motion control units to be integrated with PLC so that G-
code (involving a CNC machine) can be used to instruct machine movements.
PLCs may include logic for single-variable feedback analog control loop, a "proportional,
integral, derivative" or "PID controller". A PID loop could be used to control the temperature of
a manufacturing process, for example. Historically PLCs were usually configured with only a
few analog control loops; where processes required hundreds or thousands of loops, a distributed
control system (DCS) would instead be used. As PLCs have become more powerful, the
boundary between DCS and PLC applications has become less distinct.
PLCs have similar functionality as Remote Terminal Units. An RTU, however, usually does not
support control algorithms or control loops. As hardware rapidly becomes more powerful and
cheaper, RTUs, PLCs and DCSs are increasingly beginning to overlap in responsibilities, and
many vendors sell RTUs with PLC-like features and vice versa. The industry has standardized on
the IEC 61131-3 functional block language for creating programs to run on RTUs and PLCs,
although nearly all vendors also offer proprietary alternatives and associated development
environments.

90781128880 22

In recent years "Safety" PLCs have started to become popular, either as standalone models (Pilz
PNOZ Multi, Sick etc.) or as functionality and safety-rated hardware added to existing controller
architectures (Allen Bradley Guard logix, Siemens F-series etc.). These differ from conventional
PLC types as being suitable for use in safety-critical applications for which PLCs have
traditionally been supplemented with hard-wired safety relays. For example, a Safety PLC might
be used to control access to a robot cell with trapped-key access, or perhaps to manage the
shutdown response to an emergency stop on a conveyor production line. Such PLCs typically
have a restricted regular instruction set augmented with safety-specific instructions designed to
interface with emergency stops, light screens and so forth. The flexibility that such systems offer
has resulted in rapid growth of demand for these controllers.
As an example, say a facility needs to store water in a tank. The water is drawn from the tank by
another system, as needed, and our example system must manage the water level in the tank.
Using only digital signals, the PLC has two digital inputs from float switches (Low Level and
High Level). When the water level is above the switch it closes a contact and passes a signal to
an input. The PLC uses a digital output to open and close the inlet valve into the tank.
When the water level drops enough so that the Low Level float switch is off (down), the PLC
will open the valve to let more water in. Once the water level rises enough so that the High Level
switch is on (up), the PLC will shut the inlet to stop the water from overflowing. This rung is an
example of seal-in (latching) logic. The output is sealed in until some condition breaks the
circuit.
| |
| Low Level High Level Fill Valve |
|------[/]------|------[/]----------------------(OUT)---------|
| | |
| | |
| | |
| Fill Valve | |
|------[ ]------| |
| |
| |

An analog system might use a water pressure sensor or a load cell, and an adjustable (throttled)
control (e.g. by a valve) of the fill of the tank.


90781128880 23

SCADA
Power heads
Integration
New Developments
Proving the new developments
Validating the Customer requirements

3.3 Testing, Support and Training
3.3.1 APPLICATION

Testing
New Software Release
Under development Hardware of Controller
Online EOR print Capabilities

Support
Guiding service persons at customer site by reproducing similar setup
Solving QMS issues by real setup
Training
Providing training and awareness sessions to new learners by practical work

3.4 DC tools

3.4.1 QM series DC tools

Fig. 3.6

90781128880 24

QM Series DC spindles are the workhorse of your multispindle application. With four platforms
that provide broad torque and speed coverage, Ingersoll Rand QM spindles deliver the highest
level of performance, durability, and reliability in the industry. The QM3, QM5, QM7, and QM9
platforms are so durable, in fact, that we stopped testing them after three million fault-free
cycles.With our QM spindles on your assembly line, youll be able to redefine the productivity
of your process.

The QM Series Fixtured spindles were developed to meet the high production and duty
cycles required in many of today's manufacturing facilities. Designed to work either alone or
in multiple, these spindles when teamed with an IC Controller, will deliver the quality and
performance your fastening application may require. The QM5 Series has a torque range up
to 90 Nm and speeds up to 590 RPM. With their compact 44 mm center to center distance,
optional spindle lengths and multiple mounting options, they will fit most any application.

The QM Series Fixtured spindles were developed to meet the high production and duty
cycles required in many of today's manufacturing facilities. Designed to work either alone or
in multiple, these spindles when teamed with an IC Controller, will deliver the quality and
performance your fastening application may require. The QM7 Series has a torque range up
to 220 Nm and speeds up to 273 RPM. With their 70 mm center to center distance, optional
spindle lengths and multiple mounting options, they will fit most any application.

The QM Series Fixtured spindles were developed to meet the high production and duty
cycles required in many of today's manufacturing facilities. Designed to work either alone or
in multiple, these spindles when teamed with an IC Controller, will deliver the quality and
performance your fastening application may require. The QM9 Series has a torque range up
to 2500 Nm and speeds up to 278 RPM. With their 89 mm center to center distance, optional
spindle lengths and multiple mounting options, they will fit most any application.


3.4.2 QE series DC tools

Fig. 3.7

90781128880 25

The Ingersoll Rand QE Series handheld tools take productivity, ergonomics, and reliability to
new levels. With angle, inline, push-to-start, offset and motor configurations, four motor
platforms, and torque coverage to 400 Nm, our QE Series tools are engineered for enhanced
productivity with impressive features.
The QE Series of fixtured angle wrenches when teamed with the IC Series Controllers provide
superior accuracy and durability to meet your fastening requirements where the tool needs to be
mounted to a fixture or reaction arm. This series offers a torque range from 2.6 Nm to 400 Nm
with speeds up to 1230 RPM. Models in the chart show units with an activation from the
controller or machine start. Other variations are available with trigger or lever start and there are
different angle head and spindle options. Please contact your local Ingersoll-Rand distributor or
Solution Center for additional information. The non-contacting switches, heavy duty gear train
and DC brushless motor create a durable package that will keep your maintenance cost down and
your production line running.
The QE Series of fixtured inline nutrunners, when teamed with the IC Series Controllers provide
superior accuracy and durability to meet your fastening requirements in situations where the tool
needs to be mounted to a fixture or reaction arm. The QE Fixtured Inline series offers a torque
range from 0.3 Nm to 230 Nm with speeds up to 3,000 RPM. Models in the chart show units
with an activation from the controller or machine start. Other variations with trigger or lever start
and additional spindle options are available. Please contact your local Ingersoll-Rand distributor
or Solution Center for additional information. For production applications requiring high or
extreme duty cycles, the QM Series provides additional options.

3.5 ICS Software
Paired with an Insight ICD or ICM controller and a computer, our groundbreaking ICS Software
Suite makes it possible to more precisely control and monitor your fastening process. Optimizing
your system is as simple as selecting the software package from the four available that best fits
your requirements.

ICS Connect
ICS Connect provides operators the ability to access and program basic fastening strategies, as
well as view cycle data with a single IC12D or IC12M controller via a one-to-one Ethernet
connection. ICS Connect is supplied standard with all IC12D and IC12M controllers.

ICS Network
ICS Network enables programming of multiple IC12D and IC12M controllers connected through

90781128880 26

a local area network (LAN) or direct connection. This option also allows operators to program
advanced fastening strategies including yield and prevailing torque control. Finally, ICS
Network unlocks the patented TactAlert feature of the QE Series tools that provides the operator
with tactile feedback of a tool fault or NOK signal through gentle mechanical oscillation in the
grip surface, reducing reliance on visual or audible signals.
ICS Enterprise
ICS Enterprise offers advanced programming and management of a network of up to 500 IC12D
or IC12M controllers using QE tools, QM spindles, or multispindle systems. This package
includes all elements of ICS Connect, Network, and MultiSync, and also enables ODBC-
compliant database archiving, searching, and statistics processing.
ICS MultiSync
The ICS MultiSync package facilitates set-up and control of multispindle systems consisting of
up to 100 spindles in groups of up to 40 spindles. This package also offers advanced multispindle
fastening strategies, remote monitoring, and data archiving.

3.5.1 ICS Operational modes
Working in Network (Live) Mode
This is the default mode of operation. When you are operating in this mode, you are viewing
(live) data from the controller to which you are connected. At the top of the work sub screen, the
Source indicator will display the text Network. In addition, the Controller ID drop box will be
populated with all detected controllers on the network. To connect with a controller and see the
current settings/data, frst select the desired controller from the Controller ID drop box. Next
select the desired spindle (always 1) and then (if appropriate) select the confguration. Once this
is complete, the appropriate data is read from the controller and displayed. The data, once
displayed, can either be saved to the local drive (via the save command) for later inspection or
edited and sent back to the controller (via the send button on the tool bar). The data can be
refreshed at any time via the refresh button.

Working in Database (Local) Mode
The database mode is used to view data fles that have previously been saved to the local PC hard
drive. Click on the Database button in the Main toolbar to switch to database mode. To view a
set, select the controller from the Controller ID drop box, the spindle from the Spindle drop box,
and the Data Set desired from the Date Time stamp.

Working in Archive Mode
The Archive Mode is used to view Data fles that have been previously saved automatically to the
SQL database. Click on the Archive button in the Main toolbar to switch to Archive Mode. At
the top of the work sub screen, the Source indicator displays the text Archived DB. To view a
Data Set, select the controller from the Controller ID drop box, the spindle from the Spindle drop
box, and the Data Set desired from the Date Time stamp.

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3.5.2 Assigning Inputs/Outputs to the controller
All the inputs/outputs are assigned to the controller through General setup in ICS software. The
Assign Inputs tab provides you with a method of assigning input behaviours to physical input
locations on the controller. The software detects and restricts multiple assignments of one
behaviour. To assign an input, frst click on the input for which you wish to assign a behaviour.
Then click on the behaviour that you wish to assign to the input and click on the assign (left
pointing arrow) button. To de-assign an input, frst click on the input to which you wish to de-
assign a behaviour. Then click on the de-assign (right pointing arrow) button. To deassign all
behaviours click on the de-assign all button.

Fig. 3.8 shows assign inputs in General setup
Note: For safety reasons, after the new input assignments are sent to the controller, they will not
take efect until the controller is rebooted.
The Assign Outputs tab provides you with a method of assigning output behaviours to physical
output locations on the controller. To assign an output, frst click on the output for which you
wish to assign a behaviour. Then click on the behaviour to which you wish to assign the output
and click on the assign (left pointing arrow) button. To de-assign an output, frst click on the

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output to which you wish to de-assign a behaviour. Then click on the de-assign (right pointing
arrow) button. To de-assign all behaviours, click on the de-assign all button. If the time for the
output is set to zero, the output will remain active until a new cycle is started. To set an
expiration time for the output, enter a time into the time column for the appropriate output (it will
remain on for that number of seconds once initially activated).


Fig, 3.9 shows assign outputs in General setup.

3.6 Powerhead setup mode
A group of Insight units synchronized together to perform a multiple bolt tightening task is
called a Power head. If you are arranging a series of Insight controllers together in this way, you
must link them in a daisy chain fashion to create a Power head Synchronization Bus. These
can comprise up to 40 Insight controllers. You must also set each controllers two rotary address
switches depending on its location in the chain.

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1. On the frst Insight controller in the powerhead, the top rotary switch must be set to 0, while
the bottom switch is set to 1.
2. Connect a powerhead synchronization cable to the bottom powerhead connector on the frst
controller.

Fig. 3.10
Fig. 3.10 shows port for powerhead connector
3. Connect the other end of the same cable to the top powerhead connector on the second unit in
the chain.
4. On the second controller, set the top rotary switch on the second unit to 0, with the bottom
switch set to 2.
5. Continue using this same pattern of cabling and rotary settings up to 40 units.
NOTE: The top rotary switch is set to 1 for units 10-19, 2 for units 20-29, 3 for units 30-39, and
4 for unit 40.
6. Set the terminal block for the frst and last units in the chain to 1 On and 2 Of,.as shown
below.


Fig. 3.11
Fig. 3.11 shows terminal switch
NOTE: All other units in the power head should be set to 1 Of and 2 Off.





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CHAPTER FOUR
PROJECT 1
THREE SPINDLE DC NUT RUNNER BOLT
TIGHTENING MACHINE

4.1 Introduction
Application- DOOR TOP HINGE BOLT TIGHTENING.
Three Spindle DC Nut Runner Bolt Tightening Machine includes three QM series Spindles in
Power head. All the three spindles are attached to three Controllers in power head mode through
tool cable. In power head mode, one controller is master and the other two controllers are slave.
They are synchronized to each other through power head connector.
Following figures shows the machine view and design-


Fig. 4.1.a.shows actual design

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Fig. 4.1.b shows layout
Fig. 4.1.c shows side view

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Fig. 4.1.d shows upper view
Fig. 4.1 a, b, c, d shows actual design of machine with details
All the Controllers are programmed through ICS software installed in a PC/Laptop. In ICS
software, program is done through Advance setup in powerhead mode. In Advance setup,
different strategies can assigned t the controller attached to the spindle.Basically, in Bolt
tightening case, the main strategy is Torque and other includes angle and backout.
The Advanced Setup screen is similar to the Quick Setup screen, but it provides access to all
confguration parameters, allowing programming of multistep strategies. Confgurations are
loaded, edited, and saved on an individual basis. Advanced Setup is available on the Network,
MultiSync, and Enterprise versions of ICS software. Navigating to Setup/Advanced displays the

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Advanced Setup screen, use the drop boxes to select a Controller, Spindle, and Confguration for
programming (for Data Base mode, select new or a previously saved Confguration).

4.2 Customer and its requirements
Customer- Whirlpool of India Ltd.- Faridabad
Requirements- Whirlpool of India Ltd, manufactures refrigerators. For tightening of door top
hinge of refrigerator which includes self- threaded bolts is done by this three spindle nut runner
bolt tightening machine.
Following are the strategies and requirements of the customer including program in powerhead
mode-
1. Firstly, the program is made in powerhead mode, in which Group 1 contains three spindles
attached to three controllers respectively as shown in Fig. 4.2.

Fig. 4.2

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2. Secondly, Spindle 1 attached to controller 1(master controller) is assigned config 1 made in
advance setup, which is automatically assigned to other two spindles attached to other two
controllers respectively according to the customer requirement as follows-
Requirements-
- All the three bolts should finally be tight at target torque of 8 Nm.

Fig. 4.3
Fig. 4.3 shows the config 1 asigned to spindle 1.
The config 1 includes following parameters as shown in Fig. 4.4 -
Engage parameter
Angle parameter
Torque parameter
Backout parameter
Torque parameter

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Fig. 4.4
- All the bolts should move 1000 angles with a free speed of 100%.
Fig. 4.5

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- Then, they should be attain a torque of 6 Nm.
Fig. 4.6
- If there is a bolt which gets damaged or there is a bolt which gets free, then the bolt is reopen
after 6 Nm totque step by backout step.
Fig. 4.7

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- At last, all the bolts are tightened at a torque of 8 Nm with a free speed of 50%.
Fig. 4.8
- Now, if customer has to do rework or customer rehit the tightened bolts at a torque of 8 Nm,
then all bolts are reopened at 4000 angles by a final back out action in congif 3
Fig. 4.8

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Fig. 4.9
Fig. 4.10 shows general setup of operation of spindles

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4.3 Drawing
4.3.1 Inputs and outputs of all three controllers
Fig. 4.11 shows i/os of master controller
Fig. 4.12 shows I/O of controller 2

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Fig. 4.13 shows I/O of controller 3

4.4 Problems faced
Following were the problems faced during installation and running the machine-
- One of the controllers got hanged.
Solution- Controller restarted.
- One or two spindles were not running showing calibration failed on the main screen of the
controllers.
Solution- The spindles were loosen and tightened using Allen key and checked using tool test in
diagnostic mode of controller (tested ok).
4.5 Quality Check
-Quality check is done using Expert torque analyzer (ETA).It is used for measurement of actual
torque at which the bolts are tightened.

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ETA is used to see how much variation is there in the target torque which is 8 Nm in this case
and the actual torque delivered. Transducer is attached with the ETA and to the socket.
When the bolt is tightened, the value is shown on ETA. For each spindle, it is measured
separately. Readings are noted separately for each spindle. Then, the target torque appearing on
the main screen of the controller and the actual torque delivered are compared. The readings are
copied in the tabular form and Cp and Cpk values are calculated using the formula. According
the values of Cp and Cpk, the range of sigma is calculated. For highest the range should be
between 5 and 6 sigma. The graph is also plotted against variation of torque.

Fig. 4.14
- Quality check is also done through Sound level meter. It is done to check the sound of the three
spindles attached to sockets during running time. The sound level should be between 50 db 80
db.

Fig. 4.15

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CHAPTER FIVE
PROJECT 2
DC TOOL SYSTEM

5.1 Introduction
Application- 05 NOS DC TOOLS
Five Spindle DC tool system includes five different QE series Spindles of different torque
capacity for five different applications. All the five spindles are attached to five Controllers
separately through tool cables. All the five machines are programmable through PLC using
Siemens PLC and profibus settings is done in PLC and the program is also based on profibus
settings. All the controllers have profibus port. All of them are attached to profibus connectors
through PLC.This is done to fetch the data to the PC/laptop. The machine is mainly used for
tightening of different bolts of different parts of TATA Nano engine.
.Following figures shows the machine view and design-

Fig. 5.1 shows actual design

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Fig. 5.2 shows side view

5.2 Customer and its requirements with different applications
Customer- TATA SANAND, LUCKNOW
The different Applications and Requirements according to the customer are as follows-
1. RI Bracket tightening
In this type of application, the requirement of customer is-
Target torque- 23 Nm
High limit- 25 Nm
Low limit- 21 Nm
Free speed- 50%
The program with torque strategy is made in the controller itself using Quick setup mode. The
readings noted are as follows-

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Fig. 5.3 shows readings

Fig. 5.4 shows RI Bracket tightening

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2. RI Shaft tightening
In this type of application, the requirement of customer is same as in RI Bracket tightening.
The program with torque strategy is made in the controller itself using Quick setup mode. The
readings noted are as follows-

Fig. 5.5 shows reading

Fig. 5.6 shows RI Shaft tightening

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3. Housing Screw tightening
In this type of application, the requirement of customer is same as in RI Bracket tightening.
The program with torque strategy is made in the controller itself using Quick setup mode. The
readings noted are as follows-

Fig. 5.7 shows reading

Fig. 5.8 shows Housing screw tightening

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4. Cable Anchoring Bracket tightening
In this type of application, the requirement of customer is same as in RI Bracket tightening.
The program with torque strategy is made in the controller itself using Quick setup mode. The
readings noted are as follows-

Fig. 5.9 shows reading

Fig. 5.10 shows cable Anchoring Bracket tightening

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5. B Mount Bracket tightening
In this type of application, the requirement of customer is-
Target torque- 40 Nm
High limit- 42 Nm
Low limit- 38 Nm
Free speed- 50%
The program with torque strategy is made in the controller itself using Quick setup mode. The
readings noted are as follows-

Fig. 5.11 shows reading


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Fig. 5.12 shows B Mount Bracket tightening
6. All the controllers are connected to each other only through Profibus cable connectors to the
input and output of profibus connector. The starting terminal is PLC with termination ON and
the ending terminal is fifth controller with termination ON in profibus connector. The controllers
are connected to the Ethernet hub in main panel and also to PC with the Ethernet cable. The PC
is connected to PLC with PC Adapter.

Fig. 5.13 shows PC Adapter

Fig. 5.14 shows Profibus connector

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7. The most important requirement of customer was the setup of SQL on its PC.SQL setup is
needed to see all the data including the cycle log, peak torque, peak current, peak angle, barcode,
shutdown code, and other parameters in the SQL database. For this, the ICS Connect should be
in database mode. The data can be seen in SQL management studio in ICS common EOR data
out option. The profibus addresses for five controllers are as follows-
22- Controller 1
23- Controller 2
24- Controller 3
25- Controller 4
26- Controller 5
The complete layout of the machine DC tool system can be shown as follows-
Fig. 5.15 shows actual layout

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8. The program using Siemens PLC is fed to the PLC for running the machine using profibus
settings.
5.3 Drawing
5.3.1 Inputs and Outputs of Controller

Fig 5.15 shows I/O of controller
The all five controllers have same I/Os except in place of sp1 reject and accept, it will be sp2,
sp3, sp4, and sp5 (sp denotes spindle).Instead of Cycle 1 complete, it will be cycle 2, cycle 3,
cycle 4, and cycle 5.The I/Os are given to the controller through ICS Enterprise software.
On connecting the Profibus cable to all the controllers, we can also see the data on PC in
SIMATIC Software inside profibus settings (data includes the target torque and target angle).


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CHAPTER SIX
PROJECT 3
OMRON ZEN PLC PROGRAMMING AND ITS APPLICATIONS

6.1 Introduction
Omron ZEN PLC programming is used for different auto mechanical processes or different
automotive applications or projects. The ZEN programmable logic module provides a total of 10
I/O points (6inputs and 4 outputs). It has two types of controllers:
LCD type: with display screen and keypad.
LED type: without display screen and without operating keypad.
The following are some of the most important features:
Capacity to carry out small scale automatic control at low cost.
Ladder diagram programming directly in the LCD type CPUs is possible.
Maximum program capacity of 96 lines.
Very small dimensions: 90 x 70 x 56 mm.
Easy to set up and reduced wiring time.
Upgradable up to 18 inputs and 16 outputs using 3 expansion modules.
Protection against power supply faults (battery optional).
Programs easily copied using optional memory cassette.
Programming and monitoring by computer.
Large switch capacity up to 8A /contact with 250 VAC.
Direct AC inputs between 110 and 240 VAC.
Equipped with 8 configurable timers in 4 operating modes and 3 timer
ranges.

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Also equipped with 8 counters this can work either inclined or declined.
Clock-calendar functions.
2 analog inputs in voltage mode (0 to 10 V).
Possibility of configuring input filters to avoid noise influence.
The program can be protected by a password.
Screen menus displayed in 6 languages



Fig. 6.1 shows external appearance of ZEN PLC


90781128880 54

6.2 Applications/Projects
A) 2SPINDLE BOLT TIGHTENING MACHINE



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This project includes tightening of 2 bolts of connecting rod by 2 spindles in power head mode.
This project includes various Inputs and Outputs. This project is programmable using ZEN PLC
as programmed above.
The outputs of above program mainly includes- power head down, power head up, Spindle 1
tightening over, gang advance, gang reset, and ok condition as shown by Q symbol.The inputs
mainly includes- start push button, emg stop, stop button, tightening start, free speed, config
select, forward, reverse.
.


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B) Traffic light/ Street light working with Traffic



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This project includes the working of three traffic lights- Green, yellow, and red along with the
movement of the traffic. This program shows the working of Whole Street light along with the
movement of traffic.
The inputs include- Red light, yellow light and green light. The outputs mainly include- traffic 1
start and traffic 2 start as shown by Q symbol.
6.3 Other projects/applications based on ZEN PLC
Other applications and projects I am working on includes- Automatic welding machine,
tightening machine, different types of movement of cylinder in different directions, lightening
control in offices and companies and some other big applications.








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CHAPTER SEVEN
OTHER PROJECTS AND APPLICATIONS

7.1 Introduction
This chapter mainly includes other projects and applications, which area in continuation are as
follows-
- US Controller testing
- NPD (New product development)
This includes EB development testing lab.
- 2 Spindle Connecting Rod Bolt Tightening Machine
7.2 US Controller testing
This includes testing of US DC Controllers arrived for testing. This testing is going on in all
parts of world in Ingersoll Rand..
US Controller arrived has some modifications as compared to previous ICD Controllers. These
Controllers are IC12D and have modified control board in the circuit and other version RISC
band control board. Testing of both the controllers 1 going on tightening of bolts by DC Tools
attached to the controllers. This DC tools includes QM series spindles. This testing includes-
1. Testing both the controllers in single mode. This is done by programming the controllers in
quick setup mode with a target torque of 15 Nm attached to the spindles of max. torque of 90
Nm.
2. Testing both the controllers in power head mode. This done by programming the controllers in
power head setup mode in the ICS Connect software through Ethernet cable attached to both the
controllers. Power head cable is also attached to each other, so that one is master controller and
other is slave controller by changing their CAN address.
The program includes two configurations as follows-
- Configuration 1-
Target torque- 15 Nm

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High limit- 18 Nm
Low limit- 12 Nm
Free speed- 50%
Gang Count- 3
Auto increment- 2
- Configuration 2-
Target torque-30 Nm, High limit- 36 Nm, Low limit- 24 Nm, Gang count- 0, Auto increment- 1
Connections-
1. Inputs to PLC are connected from O/P terminal of the controller (Master).
2. Outputs from PLC are connected at I/P terminal of the controller (Master).
3. Both controllers are connected to PC through Ethernet cable for view of Cycle log in ICS
Connect software.
4. Both controllers are connected to each other in power head mode through power head cable.
Three conditions for not ok-
1. Cycle stop in between when push button (stop) is pressed.
2. Bolts thread slipping.
3. Tool rehitting.
PLC Inputs-
X0- Push button (cycle start).
X4- Accept.
X6- Push button (stop)
PLC Outputs-
Y0- Forward.
Y1- Reverse.

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Y3- Free speed.
Master controller I/Ps-
2-I-1- Free speed.
2-I-3- Forward.
2-I-4- Reverse.
Master controller O/Ps-
1-O-1- In cycle.
1-O-2- Cycle complete.
1-O-3- Accept.
The tightening procedure is programmed and controlled by MITSUBISHI FX PLC, which
include following steps-

Fig. 7.1 shows steps of program

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7.3 NPD testing lab/EB lab
There is research study of development of new product in NPD department. After the research is
over and study over that product is over, it is developed and manufactured for testing in EB lab.
After the product is passed in EB testing lab, it goes for manufacturing.
Two types of testing is done in testing lab before manufacturing of product as follows-
1. Performance testing
In this type of testing, the performance of the product is tested based on certain parameters.
Instruments used for performance testing are as follows-
- Dynamometer Controller
Using this type of instrument, air motor of different torque capabilities are tested and in the
output of this testing, the torque, power (hp), current, and speed of the air motor is calculated as
shown in the controller. The dynamometers available in the lab are of 25 Nm, 3.25 Nm, and 1
Nm torque capabilities. Readings are noted and graph is plotted.
- Champion tester (ISU-5393 Tester up to 15 Nm)
In this, the capability test is performed. All the air tool including small screw tighteners air tools
are tested with champion testers. The Air tools are attached to the soft joints and hard joints, then
tested. This testing is also programmable using PLC. In the output of this testing, the torque is
calculated. Variations are calculated and then Cp, Cpk values are calculated to know the shift in
the torque. Graph is plotted by the software itself.
2. Endurance testing
In this type of testing, the life cycle of the tool is tested. The life cycle test is done inside the
grinder. All the tools are tested. This is programmable using OMRON PLC.
VFD (Variable frequency drive)
It is used for testing of angle head of the tool. This can be programmable and manual. This can
be run through software and all the parameters example- torque can be calculated. It is
programmable according to the motor capability and parameters which is used in this testing.



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REFERENCES


1. Websites

www.ingersollrandproducts.com
www.ingersollrand.co.i
www.omron.co.in
www.siemens.co.in
www.irtools.co.in
www.mitsubishielectric.co.in


2. Manuals

ICS Manual
DC tools Manual
PLC Manual
ZEN PLC Manual
ICD Controllers Manual
FX PLC Manual
SQL setup Manual

3. Assembly Catalogues
Cordless catalogues
IR tools catalogues
ETA Catalogue
Sound level meter Catalogue





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