Fiat - Argentina - Wheel Aligner / Headlamp Aimer #16435

Transcription

1 2017 iat - Argentina - Wheel Aligner / Headlamp Aimer #16435 Wheel Aligner / Headlamp Aimer Operation & Maintenance Manual Calibration / Testing ori Automation Version 1.2 4/21/2017

2 iat - Argentina - Wheel Aligner / Headlamp Aimer #16435 TABLE O CONTENTS Section 1.0 Machine Operations Wheel Aligner Calibration Load Cell Calibration...4 Section 2.0 EV & Matrix Testing olling eference Unit Equipment Variability Tests (EV Tests) Machine Operations ori Automation Version 1.2 Page 1

3 iat - Argentina - Wheel Aligner / Headlamp Aimer #16435 SECTION 1.0 MACHINE OPEATIONS 1.1 Wheel Aligner Calibration Wheel Aligner Calibration Description Graphics 1. Place system in Auto Mode. 2. Select the Select Cal button on the Mode screen. Of the HMI 3. PC, selects the type 100- calibration automatically. The wheelbase will move into position. 4. Using a hoist, retrieve the master calibration fixture and slowly lower it onto the system. Use care when placing the fixture on the machine. Verify the fixture is on the contact pads. 5. Access the calibration screen on the PC by pressing the 5 function key, calibration pull down menu or clicking the Cal Hds icon. Machine Operations ori Automation Version 1.2 Page 2

4 iat - Argentina - Wheel Aligner / Headlamp Aimer #16435 Description Wheel Aligner Calibration 6. The Calibration screen will open. Press the STAT button. When the calibration data is displayed on the menu screen, press Accept Calibration. Press the Start Calibration button on the Calibration menu screen to run a calibration sequence a second time to verify that the deviation values stay below Graphics 7. Perform the Steering Wheel Leveler & Headlamp Aimer calibration. Note: ori Automation recommends calibrating the wheel aligner prior to each shift. If the plant chooses to calibrate the system less frequently ori has the following recommendation. Machine Operations ori Automation Version 1.2 Page 3

5 iat - Argentina - Wheel Aligner / Headlamp Aimer # Load Cell Calibration Load Cell Calibration Description 1. Open the load cell calibration screen. 2. Select the corner to calibrate. Graphics 3. Verify there is no weight on the corner that has been selected for calibration. Make sure the weight scale is unloaded and stable. 4. Unclamp floating plates and brakes. 5. Verify one set of shot pins is up. 6. Press Initiate Calibration 7. When the Continue Calibration button becomes enabled place the calibration weight onto the corner being calibrated. Machine Operations ori Automation Version 1.2 Page 4

6 iat - Argentina - Wheel Aligner / Headlamp Aimer #16435 Load Cell Calibration Description 8. Let the weight stabilize for a few seconds and press Continue Calibration. Graphics 9. When the Save Calibration button becomes enabled press it. 8. When the calibration active text indicator disapears, the calibration is now complete. 9. epeat this procedure for the remaining corners Machine Operations ori Automation Version 1.2 Page 5

7 iat - Argentina - Wheel Aligner / Headlamp Aimer # Steering Wheel Leveler Calibration Description Steering Wheel Leveler Calibration 1. After the Wheel Aligner calibration is complete, calibrate the steering wheel leveler. 2. Open the Steering Wheel Leveler screen. Graphics Verify Enabled is checked. 3. Place the steering wheel leveler in the Nominal position. Press the button to extend the pogo. 4. Click the At Nominal button. 5. Press the button on the steering wheel leveler to retract the pogo. Move the steering wheel leveler to the At (-) Low Limit position. Press the button to extend the pogo. Press the At (-) Low Limit button. 6. Press the button on the steering wheel leveler to retract the pogo. Move the steering wheel leveler to the At (+) High Limit position. Press the button to extend the pogo. Press the At (+) High Limit button. 7. Press the button on the steering wheel leveler to retract the pogo. Move the steering wheel leveler to the Nominal. Press the button to extend the pogo. Do not click the At Nominal button. If the readings are +/ click the Accept button. 8. If the readings are greater than +/-.10 click the Accept button and repeat the calibration procedure. 9. eplace the steering wheel leveler to the stand. Machine Operations ori Automation Version 1.2 Page 6

8 iat - Argentina - Wheel Aligner / Headlamp Aimer # Headlamp Aimer Calibration Description Headlamp Aimer Calibration 1. On the Headlamp Aim PC screen select vehicle type 100. Graphics 2. Press Calib button to open the calibration screen. 3. After the wheel alignment calibration is complete, set the calibration laser on the master calibration fixture. Plug in the laser and turn it on. Line up the beam with the center of the small hole on the laser platform and the slot on the front calibration fixture. Verify that the laser is shooting directly through the center of the slot and touching the scribed line on the front fixture. 4. Place the Headlamp aimer cover onto the aimer box. Click the Start Laser Calibration icon and the system will move into the calibration position. The laser s position relative to the cross hairs should be shown on the screen. Adjust the aimer so the laser dot is at the center of the cross hairs on the image screen of the computer. Machine Operations ori Automation Version 1.2 Page 7

9 iat - Argentina - Wheel Aligner / Headlamp Aimer #16435 Description Headlamp Aimer Calibration 5. To store a calibration value, press Accept Calibration. System will prompt you to return the aimer to home position, select yes. Graphics 6. emove the calibration cover and place on the second aimer box. 7. Unplug and remove the calibration laser. 8. Perform the mirror calibration procedure. 9. Once both procedures are complete, unplug the laser and remove / store it. emove the aimer box cover and store. Machine Operations ori Automation Version 1.2 Page 8

10 iat - Argentina - Wheel Aligner / Headlamp Aimer # Learn Target This procedure is for personnel that are very familiar and have experience with Headlamp Aiming. Proper training is recommended prior to performing. This procedure is intended as a guide for those individuals. Description Learn Target Graphics 1. The learn target option is used to teach the orivision system a new set of parameters from a known, (properly aimed) master headlamp to ensure that all headlamps of the same type as the master headlamp will be aimed to those new parameters. 2. Secure plant s master headlamps in the proper place. If a vehicle has been pre-adjusted with the aim board, position the vehicle onto the machine and center it. Make sure the same Electrical condition exists as when the vehicle was mastered, i.e. engine running / charger connected. 3. Click the Enable Learn icon from the HLA Main screen. 4. Press the Cycle Start button on the main screen. The aimer will position itself in front of the first headlamp. 5. Enter new vehicle type or select an existing vehicle type from the drop down list Machine Operations ori Automation Version 1.2 Page 9

11 iat - Argentina - Wheel Aligner / Headlamp Aimer #16435 Description Learn Target 6. Click the Learn target button. Graphics 7. Target mill move to 0,0 position. 8. Press Clear to Move on screen. epeat steps 2-7 for second headlamp. Machine Operations ori Automation Version 1.2 Page 10

12 iat - Argentina - Wheel Aligner / Headlamp Aimer #16435 SECTION 2.0 EV & MATIX TESTING 2.1 olling eference Unit The rolling reference unit is a reference unit and does not require certification. The camber and toe settings are purposely skewed for the purpose of testing the geometric aligner's measuring capability. The skewed settings are measured at each head of the machine both forward and backward as well as right side up and upside down during Matrix and EV Testing. This is done to confirm the machines capability of accurately measuring the rolling reference unit in all directions. The reason for using such a fixture is that the angles are fixed. Using a vehicle for testing is impractical due to variation in the suspension and steering gear and linkage play. Before using the rolling reference unit, it is very important to make sure that the tires are inflated to the proper inflation rate as specified on the tire itself. To flip the rolling reference unit it requires a forklift and a chain with hooks on each end. The proper way to flip the rolling reference unit is to lift the fixture with the chain and forklift, unclamp the lock, slowly flip the unit over and lock it, lower unit back to the ground. Maintaining the rolling reference unit is a matter of checking tire pressures, checking bolt torque and keeping the steering mechanism lubricated. 2.2 Equipment Variability Tests (EV Tests) To achieve the greatest degree of accuracy of the measurements on the geometric wheel aligner, the machine must be leveled, maintained and calibrated. To assure the accuracy of the machine readings and to correlate the machine with other alignment equipment, two types of measurement analysis tests have been developed. These tests are the EV Test (Equipment Variability Test) and the Matrix Test (Toe Matrix, Camber lip-over Matrix and Camber Non-lip Matrix). The EV Test checks the machine's ability to repeat its measurements over a period of twenty-eight cycles. The PC program for this test then calculates the percent of error based upon the range of data over four sets of seven cycles. Acceptable repeatability is achieved when the percent of error for each type of reading is ten percent or less. Percentage values above ten percent can indicate some mechanical or electrical problem in the machine's operating system or measuring heads. The Matrix Tests are tests designed to measure the accuracy of the measured toe and camber readings. Each wheel of the rolling reference unit is measured at each Measuring Head both forward and backward, and in the case of the Camber lip-over Matrix, both ight side up and upside down. The test measures the wheels at each position for three cycles, thus the need for accuracy in the EV Test. After running all the positions in the Matrix Test, the computer then calculates the actual rolling reference unit measurements and the percent of error at each of the axle positions. Acceptable accuracy exists when the percent of error at each axle position is ten percent or less. Percent values higher than ten percent can indicate machine leveling or electrical problems. Other causes of higher percent values could be differences in machine build. To compensate for the differences in build and/or set up, the computer has machine-offset capability. The offsets are minimal and help maintain machine correlation and accuracy. Large offset requirements can indicate worn out parts and/or electrical problems as well as Measuring Head Problems. On the next few pages are the long hand formulas used by the computer to calculate the percent of error and the actual measurements of the rolling reference unit. EV & Matrix Testing ori Automation Version 1.2 Page 11

13 iat - Argentina - Wheel Aligner / Headlamp Aimer # EV Test EV Test Individual Toe: E.V.%=[((range data set 1 + range data set 2 + range data set 3 + range data set 4) x.25) /.20] x 188 Total Toe: E.V.%=[((range data set 1 + range data set 2 + range data set 3 + range data set 4) x.25) /.40] x 188 Camber: E.V.%=[((range data set 1 + range data set 2 + range data set 3 + range data set 4) x.25) / 1.00] x 188 ange equals Absolute Value [ High - Low ] per set of seven cycles. NOTE: calculations shown above assume the following spec. tolerances: - individual toe = 0.20deg, - total toe = 0.40deg, - camber = 1.00deg, EV & Matrix Testing ori Automation Version 1.2 Page 12

14 iat - Argentina - Wheel Aligner / Headlamp Aimer # Toe Matrix test Position #1 Position #2 Position #3 Position #4 Position #5 Position #6 Ave = (1st+2nd+3rd)/3 : average of three readings per position ** SUM TOE olling reference unit Analysis ** M ront On Machine ear = (#1Ave - #7Ave)/2 M ront On Machine ront = (#3Ave - #5Ave)/2 M Calc'd Sum Toe = ( (#1Ave + #3Ave) - (#5Ave + #7Ave) ) / 4 M ear On Machine ear = (#2Ave - #8Ave)/2 M ear On Machine ront = (#4Ave - #6Ave)/2 M Calc'd Sum Toe = ( (#2Ave + #4Ave) - (#6Ave + #8Ave) ) / 4 ** SUM TOE Machine Analysis ** M ront On Machine ear = (#1Ave + #7Ave) M ront On Machine ront = (#3Ave + #5Ave) M ear On Machine ear = (#2Ave + #8Ave) M ear On Machine ront = (#4Ave + #6Ave) EV & Matrix Testing ori Automation Version 1.2 Page 13

15 iat - Argentina - Wheel Aligner / Headlamp Aimer # Position #1 Position #2 Position #3 Position #4 Position #5 Position #6 Ave = (1st+2nd+3rd)/3 : average of three readings per position ** SUM TOE ront to ear Comparison ** M ront oward = (#1Ave - #3Ave) M ront Backwards = (#5Ave - #7Ave) M ear oward = (#2Ave - #4Ave) M ear Backwards = (#6Ave - #8Ave) ** SUM TOE Machine Accuracy ** #1 Error = M Calc'c Sum Toe - #1Ave #2 Error = M Calc'c Sum Toe - #2Ave #3 Error = M Calc'c Sum Toe - #3Ave #4 Error = M Calc'c Sum Toe - #4Ave #5 Error = M Calc'c Sum Toe - #5Ave #6 Error = M Calc'c Sum Toe - #6Ave #7 Error = M Calc'c Sum Toe - #7Ave #8 Error = M Calc'c Sum Toe - #8Ave ** Percent Sum Toe Error At 0.40 degree Nominal Sum Toe Spec ange ** %Err = 100 * Error / Nominal Sum Tolerance(0.40 degrees) ** Suggested SUM TOE Correction actor ** ront Heads = (#3Ave + #4Ave + #5Ave + #6Ave) / 4 ear Heads = (#1Ave + #2Ave + #7Ave + #8Ave) / 4 Camber lip Over Matrix Test EV & Matrix Testing ori Automation Version 1.2 Page 14

16 iat - Argentina - Wheel Aligner / Headlamp Aimer # Position #1 Position #2 Position #3 Position #4 Position #5 Position # Top Side Up On #1-# Top Side Down On #5-# Ave = (1st+2nd+3rd)/3 : average of three readings per position ** olling reference unit Calcd Camber ** M Calc'd Camber: L = ( (#1LeftAve - #7LeftAve)/2) + (#3LeftAve - #5LeftAve)/2) ) / 2 = ( (#1ightAve - #7ightAve)/2) + (#3ightAve - #5ightAve)/2) ) / 2 L = ( (#2LeftAve - #8LeftAve)/2) + (#4LeftAve - #6LeftAve)/2) ) / 2 = ( (#2ightAve - #8ightAve)/2) + (#4ightAve - #6ightAve)/2) ) / 2 ** Camber Machine Error ** Camber Error: L = M Calc'd Camber L - #3LeftAve = M Calc'd Camber - #3ightAve L = M Calc'd Camber L - #2LeftAve = M Calc'd Camber - #2ightAve ** Percent Camber Error At 1.20 Degree Nominal Camber Spec ange ** %Err = 100 * Camber Error / 1.2 ** Suggested Camber Correction actor ** L = (#3LeftAve + #4LeftAve + #5LeftAve + #6LeftAve) / 4 = (#3ightAve + #4ightAve + #5ightAve + #6ightAve) / 4 L = (#1LeftAve + #2LeftAve + #7LeftAve + #8LeftAve) / 4 = (#1ightAve + #2ightAve + #7ightAve + #8ightAve) / 4 EV & Matrix Testing ori Automation Version 1.2 Page 15

17 iat - Argentina - Wheel Aligner / Headlamp Aimer # Camber Non-lip Over Matrix Test Position #1 Position #2 Position #3 Position #4 Position #5 Position #6 Ave = (1st+2nd+3rd)/3 : average of three readings per position ** olling reference unit X-Bar Camber ** Camber X-Bar: L = (#1LeftAve + #3LeftAve + #5LeftAve + #7LeftAve) / 4 = (#1ightAve + #3ightAve + #5ightAve + #7ightAve) / 4 L = (#2LeftAve + #4LeftAve + #6LeftAve + #8LeftAve) / 4 = (#2ightAve + #4ightAve + #6ightAve + #8ightAve) / 4 ** Camber ange ** Camber ange: L = MAX-MIN(#1LeftAve,#3LeftAve,#5LeftAve,#7LeftAve) = MAX-MIN(#1ightAve,#3ightAve,#5ightAve,#7ightAve) L = MAX-MIN(#2LeftAve,#4LeftAve,#6LeftAve,#8LeftAve) = MAX-MIN(#2ightAve,#4ightAve,#6ightAve,#8ightAve) Camber -Bar = (Camber ange L + + L + ) /4 ** Camber Machine Error ** Camber Error: L = Camber X-Bar L - #3LeftAve = Camber X-Bar - #3ightAve L = Camber X-Bar L - #3LeftAve = Camber X-Bar - #3ightAve EV & Matrix Testing ori Automation Version 1.2 Page 16

18 iat - Argentina - Wheel Aligner / Headlamp Aimer # Camber Non-lip Over Matrix Test Position #1 Position #2 Position #3 Position #4 Position #5 Position #6 ** Percent Camber Error At 1.20 Degree Nominal Camber Spec ange ** %Err = 100 * Camber Error / 1.2 ** Suggested Camber Correction actor ** L = ( (Camber X-Bar L - #3LeftAve) + (Camber X-Bar L - #4LeftAve) + (Camber X-Bar - #5LeftAve) + (Camber X-Bar - #6LeftAve) ) / 4 = ( (Camber X-Bar - #3ightAve) + (Camber X-Bar - #4ightAve) + (Camber X-Bar L - #5ightAve) + (Camber X-Bar L - #6ightAve) ) / 4 L = ( (Camber X-Bar L - #1LeftAve) + (Camber X-Bar L - #2LeftAve) + (Camber X-Bar - #7LeftAve) + (Camber X-Bar - #8LeftAve) ) / 4 = ( (Camber X-Bar - #1ightAve) + (Camber X-Bar - #2ightAve) + (Camber X-Bar L - #7ightAve) + (Camber X-Bar L - #8ightAve) ) / 4 EV & Matrix Testing ori Automation Version 1.2 Page 17

19 iat - Argentina - Wheel Aligner / Headlamp Aimer # Performing The EV Test The EV Test when selected automatically defaults as a type 99. The first step is to make sure that type 99 is set-up properly. In the vehicle parameters menu, select type 99, change description to "olling reference unit" for easy reference. If you would like to use the rolling reference unit to also test machine cycling, then parameters will have to be entered, such that the rolling reference unit will have passing values. Most rolling reference units will pass testing with the following specification values: Tolerances Description Nominal Lo Set Pt Hi Set Pt Lo Spec Hi Spec ront left toe ront right toe ront total toe ear left toe ear right toe ear total ront left camber ront right camber ront cross camber ear left camber ear right camber ear cross camber Thrust angle Symmetry Steering wheel angle NOTE: Specifications above are only suggestions and are not necessary for EV and Matrix Testing. Next in the options tab, the wheelbase must be entered. This measurement must be in millimeters. The tire rotation periods must be entered next. The best way to measure time rotation is to; A) Put the rolling reference unit on the machine; B) Place a piece of tape on the tire side wall; C) Manually center the fixture; D) Unclamp the floating plates; E) Start the drum rollers. With a stopwatch, time ten rotations of the tire. Divide the value in seconds by ten and enter the result as the rotation period. Steering gear ratio can be left as it is. Thrust angle compensation should be unchecked (off) and symmetry compensation should be checked (on). our wheel adjust should be unchecked or off as well as any machine specific functions such as static mode, etc. After type 99 is set up, click OK and click OK in the save parameters pop up window. Close the main screen and double click the ori Automation Icon. Before starting the EV Test, make sure the printer is on line and ready for printing. To perform the EV Test, click "Tests" at the top of the main screen, scroll down to EV Test and select by clicking. Now the EV Test window should pop up and the wheelbase should move to the selected wheelbase for type 99. oll the rolling reference unit on the machine with all four wheels on the floating plates. Click the start button on the EV Test pop up screen to initiate the twenty-eight-cycle test. Each seven-cycle data set may be viewed by selecting the appropriate tab. esults may be viewed after all cycles are complete. Clicking the print button will print results. (NOTE: Best print out is accomplished by setting font to 9). EV & Matrix Testing ori Automation Version 1.2 Page 18

20 iat - Argentina - Wheel Aligner / Headlamp Aimer # Performing The Matrix Test When selecting the Matrix Test the computer program defaults to Type 99. Make sure Type 99 is properly set up as described in "Performing the EV Test". To perform the Matrix Test, click "Tests" at the top on the main screen, scroll down to Matrix Test; scroll over to Toe Matrix or Camber lip Matrix. To save time the Toe and Camber lip Matrix can be done as one test when doing it as described here. The Matrix Test consists of three cycles (iterations) run on each of eight rolling reference unit positions. The eight rolling reference unit positions are set in six positions. Position 1 = ront axle on rear of machine, top side up, rolling reference unit position #1 Position 2 = ront axle on front of machine and rear axle on rear of machine, top side up, rolling reference unit positions #3 (front of machine) and #2, (rear of machine) Position 3 = ear axle on front of machine, top side up, rolling reference unit position #4 Position 4 = ront axle on front of machine, rolling reference unit turned around 180 degrees, top side down, rolling reference unit position #5 Position 5 = ront axle on rear of machine and rear axle on front of machine, top side down, rolling reference unit positions #6 (front of machine) and #7 (rear of machine) Position 6 = ear axle on rear of machine, top side down, rolling reference unit position #8 The best way to start is to put the olling reference unit in position #2, with all four wheels on the machine, (this will help center olling reference unit for optimum results). In the Matrix pop up window, select the #2 position, and then click the start button. The machine will run three cycles and stop. The results can be viewed as the cycles are running by clicking the results tab. After the three cycles are complete, roll the olling reference unit forward or back to Position one or three. Select the position that corresponds to the way the olling reference unit is set on the machine, (one or three). un three cycles at each position by clicking the start button. After running positions one, two, and three, roll the olling reference unit off the machine, raise the master with a forklift and chain, unlock the center tube and carefully flip over the olling reference unit and lock in position, lower the olling reference unit. Now, flip up the steering wheels and turn master around 180 degrees. oll the master back onto the machine with all four wheels on the floating plates. Select position five and start the cycles as previously described. Carefully roll the olling reference unit forward or back, select the position accordingly and start the cycles. After the last set of cycles are run, leave the olling reference unit at that position. Now, view the analysis, and print results by clicking the print button. If the Matrix Test that was just run was a Toe Matrix, close the pop-up screen. Go back up to "Tests" and scroll down and over until you can select Camber-lip Matrix Test, (if the test just run was a Camber-lip, select Toe Matrix). The Camber-lip Matrix pop-up screen should now appear. If you click the results tab, you will see values for the positions but no averages or calculations of errors. Go back to the position tab; select the position that the olling reference unit is sitting at now. Click the start button. After the machine runs three cycles, stop. Now click the analysis tab and all calculations should be configured, click the print button and print results. After all testing is complete observe the percent of error. All percentages should be ten percent or less. If the percentages are higher, inspect machine for problems. ix or repair any problems found. If no problems are found, call the equipment engineer to correct the offsets. e-run tests again and percentages should be OK. EV & Matrix Testing ori Automation Version 1.2 Page 19

21 iat - Argentina - Wheel Aligner / Headlamp Aimer # º Test Procedure Place the master calibration fixture onto machine. un a calibration sequence and accept the readings. ecord the toe and camber values displayed on the calibration dialog. otate the master calibration fixture 180 degrees, and place onto machine. ecord the toe and camber values displayed on the calibration dialog, but DO NOT ACCEPT THE VALUES. Perform the following calculations to determine machine deviation. If deviations of toe are greater than 0.01 degree or deviations of camber are greater than 0.02 degrees, machine leveling or calibration gage re-certification may be required. ront Left Gage Toe Deviation = (LT(Gage At 0 Degrees) + T(Gage At 180 Degrees))/2 ront ight Gage Toe Deviation = (T(Gage At 0 Degrees) + LT(Gage At 180 Degrees))/2 ear Left Gage Toe Deviation = (LT(Gage At 0 Degrees) + T(Gage At 180 Degrees))/2 ear ight Gage Toe Deviation = (T(Gage At 0 Degrees) + LT(Gage At 180 Degrees))/2 ront Left Gage Camber Deviation = (LCB(Gage At 0 Degrees) - CB(Gage At 180 Degrees))/2 ront ight Gage Camber Deviation = (CB (Gage At 0 Degrees) - LCB (Gage At 180 Degrees))/2 ear Left Gage Camber Deviation = (LCB (Gage At 0 Degrees) - CB (Gage At 180 Degrees))/2 ear ight Gage Camber Deviation = (CB (Gage At 0 Degrees) - LCB (Gage At 180 Degrees))/2 LT: ront Left Machine Toe eading T: ront ight Machine Toe eading LT: ear Left Machine Toe eading T: ear ight Machine Toe eading LCB: ront Left Machine Camber eading CB: ront ight Machine Camber eading LCB: ear Left Machine Camber eading CB: ear ight Machine Camber eading EV & Matrix Testing ori Automation Version 1.2 Page 20