Tightening automation. Only excellent solutions.

Transcription

1 Tightening automation. Only excellent solutions. Hightech automatic tightening solutions

2 Automatic tightening solution The best of Fiam for your prod They allow to control, monitor, analyze, diagnose and programme in realtime. They can be integrated perfectly with the network control systems of the production site. They guarantee a very high control of the productive process and consequently of the quality of the assembled products. These are the new Fiam solutions for industrial tightening: a concentration of innovation and reliability. 2

3 s. uction cycle. For any threaded element Semiautomatic solutions: a valuable help for operators Multispindle tightening units: they assemble several fasteners simultaneously Anthropomorphic robot, versatile and always convertible Brushless motor (with offset device) installed on fastening slide and anthropomorphic arm Electric axis to ease assembly on different surface Manual use on cartesian arm Pallets automatic line to fasten the screws on thermohydraulic collectors 3

4 Configurations High technology electric nutrunner motors with feed and control unit: perfect synergy for high quality assemblies This wide range of hightech DC electric nutrunner motors along with the controller guarantees extreme precision and accuracy of every industrial assembly. Several configurations with different modes of torque control and monitoring to solve any tightening need, even most difficult ones. Suitable for all industrial fields from motor vehicle to aerospace, from electric household appliances to electromechanical field. These solutions guarantee allover: high flexibility of tightening process, easy integration in the productive lines, traceability of all tightening data, costs reduction thanks to reduction of waste. RANGE: 0,5 90 Nm INDIRECT (current control) and DIRECT (torque/angle control with builtin transducer) brushless electric nutrunner motors RANGE: 0,5 90 Nm INDIRECT (current control) and DIRECT (torque/angle control with builtin transducer) brushless electric nutrunner motors 4

5 COPPIA / TORQUE Window OK CPMAX CP nominal CPMIN CPThreshold Different control modalities available: torque control with angle monitoring, angle control with torque monitoring, only torque control. DIA 3 ANG MIN ANG nominal ANG MAX Rotation angle Controller and feeding unit Driver Control unit 5

6 Controller and feeding unit the intelligent simplicity TCSB E (Tightening Control System Basic Evolution) are innovative and compact units that include electric feeding to the motors, programming and control of each stage of tightening cycle. They control both current control and torque/angle nutrunner motors. 5 strategies: it is possible to choose between screw driveengagement, torque, torque/angle, angle/torque, loosening. 5 programmable modalities, to guarantee reliability and working speed. Optical outcomes visualization for an immediate understanding through OK, NOK, RUN leds. Wide connectivity: 5 inputs and 5 outputs for connection to signal tower light or external devices; they control and assure working continuity. RS232 connection for programming, diagnostics and data collection Software is supplied with standard equipment, for a simple and intuitive programming, with clear and complete instructions to set and manage the tightening strategy Accessory release sequence: programmable instruction to be used when the accessory and/ or screw drive collapse preventing release of screw/accessory, thus stop the working cycle. Therefore it guarantees operating continuity and high productivity in the automatic working cycles. Plug&Play system: automatic adjustment of torque transducer signal (for torque/angle control systems) System Display Working test (inputs and outputs work, motor speed, motor connection control, feeding tension and temperature values) 6

7 TCSB E: TOUCH PANEL I/O FREELY SETTABLE (5 + 5) CONTROLLER AND FEEDING UNIT PLC LIGHT COLUMN WITH ALARM PC RS 232 PRINTER TCSB E SOCKET PROGRAM SELECTOR EXTERNAL STORAGE KIT CABLE MOTORS 15MCB 25MCB 50MCB PLC 7

8 Driver + control unit: for a perfect communication DRIVER TOD models supply correct electricity feed and tension parameters to different motors according to the parameters preset in the control unit to be connected. Failure signal through LED (TODH series) CONTROL UNIT For all electric nutrunner motors, TOC units ensure a complete monitoring of the tightening cycle thanks to visualization of the OK NOK cycles, torque/time values and different control strategies. All can be stored and elaborated statistically. Several programs and working steps are available, for and accurate cycle setting at all stages: start, speed, time, angle value, torque value, tightening time value, management of inputs to connect... Immediate display of fastening outcomes (angle, torque, working time) Visualization and printing of last rundown diagram Only one unit controlling two motors at the same time which can be also different, working synchronously (ideal for multispindles units) or asynchronously (independent assembly channels) Nutrunner rotation test (CW CCW) 8

9 ETHERNET (LAN)* FIELDBUS (DEVICENET, PROFIBUS)* * with dedicated interfaces, see page 14 TOUCH PANEL PLC I/O FREELY SETTABLE: ( ) CONTROL UNIT PC with software (optional) RS 232 PRINTER SOCKET PROGRAM SELECTOR TOC CABLE LIGHT COLUMN WITH ALARM FEEDING UNIT TODL TODH4 TODH3 15MCB 25MCB 47MCB 9

10 Technical features Generals Weight (Kg) Dimensions (mm) Output tension driver motor (dc link) Max power Display (lines/columns) Graphic display Programming keypad Display torque/time curve Italian English French German Spanish Automatic nutrunner configuration Led (OK NOK RUN) Number of Motors to manage (channels) Storage Results to be stored OK /NOT OK cycles Torque/angle/time values General statistics Basic functions Programs number Strategies number OK NOT OK results Error Tightening sequence programming Program instructions Advanced functions Number of screws for tightening sequence Chart Programming software Diagnostics Accessory release Tightening strategies Screw feeding function Torque Torque/time Torque /angle Angle/ torque Untightening Connectivity I/O (24 Vdc) RS 232 Ethernet output Fieldbus output BAR Code Accessories Programming software TCSB E TOC 9,5 10,6 4,4 390x155x x232x143 70/300 Volt Depending on motor 600VA 2kVA 40watt 4x20 128x128 (software) (software) 1 Max (+4) Up to Upon request with software RJ485 output Included Upon request 10

11 Controller and feeding unit TCSB E Dimensions (mm) Voltage: Volt, 5060 Hz Standard equipment (supplied with unit) 305 Programming software TCSB E Feed cable 2m. RS232 serial output 3 m. Quick guide Ecofriendly packaging Use and maintenance manual on CD Models available upon request Addition of 4 more programs. Code TCSB...E Driver TOD Dimensions (mm) Voltage: Vac 50 Hz ,5 9,5 Standard equipment (supplied with unit) Electric feeding cable lenght to 2 mt Ecofriendly packaging Use and maintenance manual TOD Tightening Operations Driver Functioning signal through led Generic led of functionality (mod. TOD) 381 Keyboard operations General switch Clockwise and counterclockwise rotation 9, FUSE POWER 10, Control unit TOC Dimensions (mm) , Voltage: Vac, 50 Hz Standard equipment (supplied with unit) Electric feeding cable lenght to 2 mt Ecofriendly packaging Use and maintenance manual Models available upon request Models with customized software (also with other languages) Models for field bus modules Models for Ethernet connection (exclusively through TOCNET R software) ,5 232 Accessories available upon request OK/KO torque signal light column cod (for 1channelversion, for 2channelversion). 9 pin connection cable for connecting the PC to the printer (5 mt long). Programmes manual selector RJ485 cable cod Cable for RS232 cod (serial) USB cable cod Cartesian arms for torques up to 500 Nm 11

12 Software FEEDING AND CONTROLLER TCSB E SUPPLIED WITH TCSB PROGRAMMER SIMPLE, INTUITIVE CONNECTIONS AND PROGRAMMING Simple, intuitive installation on a PC with the standard equipment supplied (RS232 cable) System configuration through the quick guide, document step by step to immediately start the system System calibration: the motors connected to this unit are on display; it is sufficient to select the motor connected and all parameters are automatically set OFF LINE programming: it is possible to create, modify and save the tightening programs without connection to TCSB E system ON LINE programming: management of tightening programs with PC directly connected to the unit; it is possible to upload and save the tightening data directly to the PC while the tightening program works FAST ARRANGEMENT OF CONTROL PROCESS Torque/angle/speed adjustment: easy change od parameters through preset grid Programs storage: programs can be saved in txt format, exported and printed Data printout: combined with view/print function available for stored programs, allows printing through serial port of a string including main information about last performed rundown. DIAGNOSTIC CONTROLS Diagnostics: window displaying the number and type of errors detected (temperature, feeding tension, diagnostic test, check of motor sensors, resolver, transducer and system). Effective way to control system inputs and outputs connected to PLC. 12

13 UPON REQUEST EXTERNAL STORAGE KIT Cod PROGRAM EXPANSION Cod Device able to collect serial data processed by the unit, couple them with date and hour and store them in digital storage card supplied with. The card has a 2GB capacity and can be used with PC for data storage and processing. Supplied with electric supply unit (IN100240Vac 5060Hz /OUT 12 Vdc), serial interface cable for unit, 2GB capacity digital storage card. Programming. Follows example of data stored. TCSB E units can be activated to further 4 tightening programs (for a max of 8 programs). It is sufficient to buy the activation code that will be supplied separately. Cod = Tightening date 2 = Tightening hour 3 = Character of start of printing string 4 = Tightening torque in Nm 5 = Tightening torque outcome (Y = yes, N = ) 6 = Space for angle values (detected in degrees but not present in this example) 7 = Tightening angle outcome (Y = yes, N = ) 8 = Overall outcome of tightening sequence (Y = yes, N = ) 9 = Parameter of motor temperature 10 = Temperature of feeding and control unit (in C degrees) 11 = Number of selected tightening sequence 12 = Selected program number 13

14 Software Control unit TOC UPON REQUEST UPON REQUEST Local Mode Ideal for production facilities without Ethernet networks Via TOCNET L software installed on PC placed nearby and serial ports (RS Null modem + USB adapter) Connection between PC and TOC unit through serial cable Software Cod. TOCNET L Remote Mode For production facilities with Ethernet networks Via TOCNET R software installed on PC in turn connected to Ethernet network via LAN cable distance limitations Ethernet network must be of industrial kind to allow higher transfer rate OUT OF PRODUCTION Software Cod. TOCNET R The software can be installed on a PC running Windows XP Programming data and acquired data are all displayed in realtime This software can be used to generate countless programs which can be stored in the PC, in addition to the 30 programs you can load into TOC Upload: exporting tightening outcomes from the TOC and storing them into PC, with results (7.000 for channel) The data exported from the TOC are opened automatically in Excel, ready to be processed The software is available in Italian and English Only one TOC control unit at a time can be connected to the PC in remote mode. 14

15 Fieldbus interfaces: to expand connectivity Dimensions HxPxL Weight Interface type Code For control unit type mm gr PROFIBUS DP TOC 1CH and TOC 2CH 120 x 75 x DEVICENET upon request TOC 1CH and TOC 2CH 120 x 75 x

16 Brushless solutions for ever Brushless electric nutrunner motors don t need maintenance and thanks to absence of coal dust eliminate pollution in the working area Builtin resolver/encoder: they guarantee an elevated resolution in the angle measurement and therefore it assures an excellent tightening process control Motor appropriate selection and accurate programming (angle, torque, time etc ) reduce the need of post process controls with remarkable production benefits Compact design, reduced dimensions and weights: ideal with multispindle tightening units and robots Wide torque range: from 0,5 up to 90 Nm CURRENT CONTROL The torque parameters are achieved by measuring the current absorbed by the brushless motor; the angle parameters are achieved by appropriate sensors. CURRENT CONTROL ELECTRIC NUTRUNNER MOTORS 15 MCB 05C1/2 15 MCB 10C1/ MCB 20C1/2 25 MCB 20C1/ MCB 35C1/ MCB 50C1/2 47 MCB 45C1/ MCB 65C1/ MCB 90C1/ MCB 45C1/ MCB 65C1/ MCB 90C1/ Torque range RPM

17 y need TORQUE AND ANGLE CONTROL Equipped with an electronic transducer to read the torque applied to the screw; while the angle is read directly by appropriate sensors. ELECTRIC NUTRUNNER MOTORS WITH TORQUE AND ANGLE CONTROL 15 MCB 05A1/2 15 MCB 10A1/2 15 MCB 20A1/2 25 MCB 20A1/2 0, MCB 35A1/ MCB 50A1/2 47 MCB 45A1/ MCB 65A1/ MCB 90A1/ MCB 45A1/ MCB 65A1/ MCB 90A1/ Torque range RPM

18 Current control Type of brushless electric motor Idle speed Reversibility Weight Accessories Axial stroke/load compensator bit: Model Code Recommended tightening torque Nm in lb rpm Type Kg lb Drive mm/n 15MCB05C , MCB05C /35 15MCB10C , MCB10C , /35 15MCB20C , MCB20C , /35 25MCB20C , MCB20C MCB35C , MCB35C MCB50C , MCB50C , MCB45C MCB45C , MCB65C MCB65C , MCB90C MCB90C , MCB45C MCB45C , MCB65C MCB65C , MCB90C MCB90C , Legend 15 = Power of the motor/10 MC = Nutrunner motor B = Electric brushless 05 = Maximum torque in Nm C = Current absorption control 1 = Output with square drive without axial compensator 2 = Output with square drive with axial compensator Legend Reversibility: All models are suitable for tightening and untightening operation Standard equipment (supplied with motor) Axial compensator (where indicated: see chart) Flange bracket to fix the motor Test certificate ise level has been measured in accordance with ISO 3744 and ISO standards (inf. to 72 dba). Accessory drive: male square drive in accordance with ISO The code number must be used when ordering. Use and maintenance manual Ecofriendly packaging Data shown in the table are indicative and can be changed without prior notice. Torque values are purely indicative and may be influenced by the softness of the type of joint, by the type and length of the screw, and by the type of accessory used. For all further details, please apply to Fiam Technical Consultancy Service. 15MCB models use Hall sensors to read the angle value. The 25, 47 and 50 MCB models are equipped with a builtin angle transducer (resolver) that guarantees an elevated resolution in the angle measurement. 18

19 Controller and feeding unit to use Cables Driver to use Control unit to use Cables Model Code Lenght Code Model Code Model Code Lenght Code TCSB 15E TCSB 15E TCSB 15E TCSB 15E TCSB 15E TCSB 15E TCSB 25E TCSB 25E TCSB 25E TCSB 25E TCSB 25E TCSB 25E TCSB 50E mt. 10 mt. 15 mt. 5 mt. 10 mt. 15 mt TOD L TOD L TOD L TOD L TOD L TOD L TOD H4 TOD H4 TOD H4 TOD H4 TOD H4 TOD H4 TOD H3 TOD H3 TOD H3 TOD H3 TOD H3 TOD H mt. 10 mt. 15 mt. 5 mt. 10 mt. 15 mt. 5 mt. 10 mt. 15 mt TCSB 50E mt TCSB 50E TCSB 50E mt TCSB 50E mt TCSB 50E Models available upon request Models with offset device (to be used for motors up to 8 Nm) (for narrow distances between the axis) Models with quick change chuck Models with modified flange and/or with customized body design Models with angle head Accessories available upon request Addition of 4 more programs for TCSB E. Code OFF SET DEVICE 19

20 Torque and angle control Type of brushless electric motor Recommended tightening torque Idle speed Reversibility Weight Accessories Axial compensator bit: stroke/load Model Code Nm in lb rpm Type Kg lb Drive mm/n 15MCB05A , , MCB05A , , /35 15MCB10A , MCB10A , /35 15MCB20A , MCB20A , /35 25MCB20A , MCB20A MCB35A , MCB35A MCB50A , MCB50A , MCB45A MCB45A , MCB65A MCB65A , MCB90A MCB90A , MCB45A MCB45A , MCB65A MCB65A , MCB90A MCB90A , Legend 15 = Power of the motor/10 MC = Nutrunner motor B = Electric brushless 05 = Maximum torque in Nm A = Torque and angle control 1 = Output with square drive without axial compensator 2 = Output with square drive with axial compensator Legend Reversibility: All models are suitable for tightening and untightening operation Standard equipment (supplied with motor) Axial compensator (where indicated: see chart) Flange bracket to fix the motor Test certificate ise level has been measured in accordance with ISO 3744 and ISO standards (inf. to 72 dba). Accessory drive: male square drive in accordance with ISO The code number must be used when ordering. Use and maintenance manual Ecofriendly packaging Data shown in the table are indicative and can be changed without prior notice. Torque values are purely indicative and may be influenced by the softness of the type of joint, by the type and length of the screw, and by the type of accessory used. For all further details, please apply to Fiam Technical Consultancy Service. 15MCB models use Hall sensors to read the angle value. The 25, 47 and 50 MCB models are equipped with a builtin angle transducer (resolver) that guarantees an elevated resolution in the angle measurement. 20

21 Controller and feeding unit to use Cables Driver to use Control unit to use Cables Model Code Lenght Code Model Code Model Code Lenght Code TCSB 15E TCSB 15E TCSB 15E TCSB 15E TCSB 15E TCSB 15E TCSB 25E TCSB 25E TCSB 25E TCSB 25E TCSB 25E TCSB 25E TCSB 50E mt. 10 mt. 15 mt. 5 mt. 10 mt. 15 mt TOD L TOD L TOD L TOD L TOD L TOD L TOD H4 TOD H4 TOD H4 TOD H4 TOD H4 TOD H4 TOD H3 TOD H3 TOD H3 TOD H3 TOD H3 TOD H TCSB 50E mt TCSB 50E TCSB 50E mt TCSB 50E mt TCSB 50E Models available upon request Models with offset device (to be used for motors up to 8 Nm) (for narrow distances between the axis) Models with quick change chuck Models with modified flange and/or with customized body design Models with angle head Accessories available upon request Addition of 4 more programs for TCSB E. Code OFF SET DEVICE 21

22 Overall dimensions (mm) of current cont Electric motors 15MCB... C1/C2 Model L Drive 15MCB05C MCB05C MCB10C MCB10C MCB20C1 15MCB20C Flange bracket to fix the motor to the support (included) (STROKE 20) Electric motors 25MCB...C1/C2 Model 25MCB20C1 25MCB20C2 25MCB35C1 25MCB35C2 25MCB50C1 25MCB50C2 L Drive 1/2 1/2 Flange bracket to fix the motor to the support (included) VERSION C1 FOR 25MCB (STROKE 50) VERSION C2 FOR 25MCB L FOR MODELS 25MCB...1 L FOR MODELS 25MCB

23 rol nutrunner motors Electric motors 47MCB...C1/C2 and 50MCB...C1/C2 Model 47/50MCB45C1 47/50MCB45C2 47/50MCB65C1 47/50MCB65C2 47/50MCB90C1 47/50MCB90C2 L Drive 1/2 1/2 1/2 1/2 1/2 1/2 Flange bracket to fix the motor to the support (included) VERSION C1 FOR 47MCB AND 50MCB (STROKE 50) L FOR MODELS 47MCB MCB...1 L FOR MODELS 47MCB MCB...2 VERSION C2 FOR 47MCB AND 50MCB 23

24 Overall dimensions (mm) of nutrunner m Electric motors 15MCB...A1/A2 Drive Model L AT 45 ONLY FOR 15MCB 15MCB05A1 15MCB05A2 15MCB10A1 15MCB10A2 15MCB20A1 15MCB20A Flange bracket to fix the motor to the support (included) AT 45 ONLY FOR 15MCB Other technical features Overall dimensions (mm) Electric motors 25MCB...A1/A2 Drive Model L L (STROKE 20mm) 25MCB20A MCB20A MCB35A MCB35A MCB50A1 25MCB50A VERSION C1 FOR 25MCB (STROKE 50) VERSION C2 FOR 25MCB L FOR MODEL 25MCB...1 L FOR MODEL 25MCB

25 otors with torque and angle control Electric motors 47MCB...A1/A2 and 50MCB...A1/A2 Model 47/50MCB45A1 47/50MCB45A2 47/50MCB65A1 47/50MCB65A2 47/50MCB90A1 47/50MCB90A2 L Drive 1/2 1/2 1/2 1/2 1/2 1/2 Other technical features Overall dimensions (mm) L FOR MODELS 47MCB MCB...1 L FOR MODELS 47MCB MCB...2 VERSION C1 FOR 47MCB AND 50MCB (STROKE 50) VERSION C2 FOR 47MCB AND 50MCB 25

26 Accessories FASTENING SLIDES Designed entirely by Fiam, they guarantee very high reliability and resistance over time, also in presence of high production rates. They ensure a perfect approach stroke of the motor (screw head) to the component to be tightened and are suitable also for applications with more tightening points with a very close distance to centre (min. 41 mm size 15, min 51 mm size 20). Offset devices to reach distance to centre of 20 mm are available upon request. Their compact dimensions and the extremely low weight make these components extremely versatile and usable with manipulators, electric axis and robots. Singlestroke fastening slide: the stroke ecompasses approaching fastening point and driving the screw. Dualstroke fastening slide: the first stroke brings the nozzle close to the workpiece, the second is used to run the screw. With antioverturning device: used to handle screws having a ratio total length/head diametre close to 1. This device allows the movement of the head avoiding screw incorrect positions during tightening and preventing screws from getting stuck with consequent production stop. Type of motor Singlestroke fastening slide Singlestroke fastening slide Singlestroke fastening slide Size Model Size Model Size Model SL 15D MCB C1/C2 15 MCB A1/A2 up to 10 Nm 15 SL 15D SL 15D SL 15D SL 15D SL 15D SL 15D SL 15D SL 15D SL 15D SL 15D SL 15 D AR SL 15 D AR SL 15D SL 20D ,5 15/25 MCB C1/C2 15/25 MCB A1/A2 from 10 to 50 Nm 20 SL 20D ,5 SL 20D ,5 20 SL 20D ,5 SL 20D ,5 SL 20D ,5 SL 20D ,5 Upon request 20 SL 20D ,5 SL 20D ,5 SL 20D ,5 47 MCB C1/C2 e A1/A2 up to 90 Nm Upon request Upon request Upon request 50 MCB C1/C2 e A1/A2 up to 90 Nm Upon request Upon request Upon request N.B. : Each motors can be builtin a fastening slide using appropriate brack Legend SL = Fastening slide 15 = Dimension of rail in mm D 20 = Ø cylinder in mm 050 = Tightening stroke in mm 50 = Approaching stroke in mm 36 = Ø brackets in mm For other accessories for automation see catalogue n

27 Screwdrivers powered by brushless electric motor with direct or indirect tightening cycle control A MANUAL Tightening system including: 1 15CB brushless electric screwdriver: available in 6 models up to 20 Nm; 3 models with current control and 3 models with torque/angle control. The straight grip screwdriver with lever start is hung to a cartesian arm. 2 BC40/7 cartesian arm to be positioned on the work bench: supports the screwdriver, helps maintaining tool vertical position, ensures the best ergonomics of the workplace by counterbalancing possible torque reaction on the operator s wrist. 3 Multifunction Panel: for programs selection (4 or 8 depending on which TCSB E model it is paired with), managing untightening operations and external connections (pallet lock/release / led signal tower / Socket Program Selector/Enable/On Off). Features 3 indicator LEDs to report OK NOK RUN, 2 memory statuses and 2 LEDs reporting output status. Includes bracket for fastening to the cartesian arm. 4 Cables Kit: 5mtlong to connect the screwdriver to the Multifunction Panel and TCSB E unit. 5 TCSB15 E: feeding and controller unit. For technical features see on pag. 6. FOR FURTHER INFORMATION READ CATALOGUE N. 101 AND CONTACT FIAM TECHNICAL CONSULTANCY SERVICE. 27

28 To choose your tightening solutions, read the following catalogues online EasyDriver: autofeed tightening module Components for tightening automation circular feeders, fastening slides, screw heads, etc. SPS: Socket Program Selector April Printed on recycled paper for the safeguard of the environment Copyright Fiam Spa. The unauthorised distribution and/or reproduction of all or part of this publication is strictly forbidden. Fiam Utensili Pneumatici Spa Viale Crispi Vicenza Italy Tel Fax Fiam France s.a.s.u. ZI Champ Dolin, 3 allée du Lazio, Bâtiment C Saint Priest France Tel Fax serviceclient@fiamfrance.fr Quality Management System Certificate Environmental Management System Certificate