MP85 / MP85DP. Data sheet. Special features MP85 / MP85DP. B en

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1 MP85 / MP85DP Data sheet MP85 MP85DP Special features - 100% quality control of the production process - Universal twin-channel amplifier for many of the usual market sensors - Powerful algorithms for monitoring fitting, testing and press-fitting processes - Memory function for results, curves and device settings - Convenient integration into the automation system by means of standardized fieldbus interfaces - Compact industrial design Carrier-frequency excitation voltage 4.8 khz Supply for active transducers 5 or 24 Power supply electrically isolated 24 A D µp Control inputs and control outputs A D Intelligent signal conditioning and powerful algorithms for monitoring fitting CANopen interface 10 SSI transducer MP85 / MP85DP Keyboard and display MMC memory card Profibus DP interface (for MP85DP)

2 Description Integrated quality assurance With the MP85, quality assurance can be integrated into the production process. Operational reliability, economic efficiency and product liability are of paramount importance. Permanent monitoring is indispensable, especially when quality assurance is only possible during the actual manufacturing process. Typical examples include: press-fitting: fitting riveting flanging and roller-burnishing Solutions for mounting processes The MP85(DP) monitors two measured quantities, such as force and displacement or time. Production and machine status can be monitored using the mounting characteristic curve by means of freely adjustable evaluation criteria. This allows the operator to control the quality and the output of production. Monitoring is either continuous by means of a tolerance band or by max. 9 freely definable tolerance windows. The system monitors: thread-in force block force end position the full force vs displacement curve Performance features and advantages: Easy configuration and commissioning with free parameterization and visualization software (PME Assistant) Precise process analysis to meet requirements Flexible system for monitoring different workpieces, 31 different device settings and 31 different workpieces/processes Storage of results, curves and statistics, as well as the device settings in the device itself or on an external PC Continuous traceability thanks to integrated process control and the statistics functions of the stored processes Integration via digital inputs/outputs or integrated fieldbus interfaces to primary control systems Flexible application, tailored to use at manual workstations Expansion of existing machines, easy to install Possible press-fit situations no part available loose fitted wrong part not fitted fitted too deep Monitoring flanging processes Monitoring riveting processes Classification of force and displacement HBM 2

3 Process analysis with tolerance windows The following windows are used for evaluation: 1 alarm window Limits at which an alarm is triggered. This window is used to protect the machine. 1 range window Defines the range in which measured values are stored, within which all the other tolerance windows are positioned tolerance windows for analyzing the fitting process. In the case of tolerance windows, there is a free choice of incoming and outgoing sides; the windows can be evaluated in real time. Mean value windows are also possible. Force measuring range Displacement measuring range Systems of coordinates: Tolerance window coordinates can be defined absolutely or relatively (dynamically). Use the relative system of coordinates if the absolute position of the fitting pieces (e.g. bearing/shaft) is not always the same. It is possible to mix these two windows. Analysis with windows With relative x coordinates, all that is measured is the relative movement as from the start or end position, relative to the x axis of the two fitting pieces. F (force) End force End position Target value y (defines the start position) Absolute, displacement transducer (mm) relative to the start position relative to the end position Example: Pressing a bearing onto a shaft 40 mm Start position Relative displacement Start position -40 Target value x 0 Absolute displacement coordinates Relative displacement coordinates 3 HBM

4 Analyzing the courses of curves with relative force windows The curves below could arise, for example, when testing a steering column locking lever. With clamping processes of this type, it is important that the force increases evenly, reaches a maximum value (which is within a defined tolerance window) and then drops again (engaged position). To analyze this process, define tolerance windows 3 and 4 relative to F max or F min of tolerance window 2. The same curve run will then always be analyzed. F Tolerance window 2 A B NOK A B OK Tolerance window 3 Tolerance window 4 s A, B : relative reference to F max of tolerance window 2 Process analysis with a tolerance band When evaluating with a tolerance band, the full course of the curve is monitored continuously. It only takes one measured value outside the tolerance band for the test operation to be rated NOK. With this evaluation, one or more reference curves first have to be measured and then the tolerance band of max. 64 support points is adapted to it/them. This automatically generated tolerance band can be adapted manually later on. Force measuring range Displacement measuring range HBM 4

5 Start and stop conditions The start and stop conditions are used to synchronize measurement control to the production process. Start and stop conditions are available for a wide variety of applications, such as: external start and stop signal target value y and overshoot time target value x and overshoot time standstill recognition The following examples describe each method individually. External stop signal With this method, the end position is signaled by an external transducer (such as a proximity switch). Example: The required position is signaled by the proximity switch. Proximity switch F Target value x s External stop Target value y and overshoot time This method should be used when the end position is defined by a mechanical limit. The end position is detected when prescribed target value y is exceeded (e.g. block force). Example: Press-fitting a bearing at block position F Overshoot (displacement within the oversho End position Target value y (F Block) s Target value x and overshoot time With this method, the x channel signals that the end position has been reached. Example: Press-fitting a bearing with displacement monitoring Displacement transducer F Overshoo t Target value x s-target Target value x Standstill recognition This method is used if the process is to be stopped as soon as there is no longer any change in the x channel. Example: The bearing should be press-fitted up to the end position. F s End position Standstill s 5 HBM

6 Parameter set and window dependent statistics function Statistics graphics can be called to clearly display the OK and NOK processes. Global statistics with a process counter are grouped by parameter sets. The tolerance window result can be read at a glance for each parameter set. This allows - tool wear - component tolerances or - damage to a machine to be detected early. The graphic windows in Counting can be used to analyze the distribution of the OK and NOK processes individually for each window. Counting automatically calculates the distribution of the minima and maxima with accompanying standard deviation. Data management With the MP85 (DP), it is possible to store results, curves, statistics and the device settings. This allows processes to be analyzed later on and ensures 100% traceability. You can choose whether to store the data on your PC or on the multimedia card in the PME device. In both cases, curves and/or results can be stored in ASCII or Qdas format: - NOK processes only or - OK processes only or - all processes The data can also simply be exported and evaluated in EXCEL. HBM 6

7 Specifications Type MP85 / MP85 DP Accuracy class 0.1 Supply voltage DC 24; potential separation from the measuring system (typically 500 DC ) Permissible supply voltage range Power consumption MP85, typically MP85DP, typically MP85 / MP85DP, max. Behavior in the event of a supply voltage failure W W W automatic data retention after power failure Typical backup battery life (CR2032) for the realtime clock years 5 Modes of operation, independently adjustable for both channels Carrier-frequency amplifier Carrier frequency khz % Excitation voltage eff % Connectable transducers SGs, half and full bridges Inductive half and full bridges, LDTs Potentiometric transducers Input sensitivities Ω mh Ω Measuring range (m/) m/ Length of transducer cable, max. m 500 Scaling range, max. digits , at 10% of the input measuring range Scaling range, min. digits 100, at 100% of the input measuring range Permissible common-mode voltage, max. 5.5 Common-mode rejection db db db Linearity deviation % 0.03 Noise voltage, typically Measuring range (m/) Hz Hz µ/ pp µ/ pp Hz µ/ pp Hz µ/ pp Sampling rate, max. 1/s 2400 Measurement frequency range, adjustable Nominal -1-3 Phase Rise time Overshoot value fc db db delay 4th order low-pass with Bessel characteristic (ms) (%) (Hz) (Hz) (Hz) (ms) HBM

8 Shunt calibration m/ 1 3% Effect of operating voltage on zero point on sensitivity Effect of 10K change in ambient temperature on zero point full bridge on zero point half bridge on sensitivity Long term drift over 48 h (measuring range 4 m/; 0.5 h after activation) DC-voltage transducers Connectable transducers % f.s. % f.s. µ/ µ/ % Measuring range (m/) µ/ 2 DC-voltage transducers, voltage sources Nominal (rated) measuring range 10 Input signal range 10.5 Scaling range, max. digits , at 10% of the input measuring range Scaling range, min. digits 100, at 100% of the input measuring range Internal resistance of the signal source kω 1 Permissible common-mode voltage, max. 2 Measurement frequency range, adjustable (-1 db) Hz 0, Filter characteristics Bessel, 4th order Linearity deviation % 0.03 Sampling rate, max. 1/s 2400 Incremental transducers Connectable transducers oltage supply 2-channel mode Inputs (F1 ( ), F2 ( ), Ix ( )) Input levels Low level High level Each line to measurement ground, max Incremental transducers (up/down counter with zero index signal) 5, max. 150 ma or 24, max. 300mA Time-division multiplex method Differential inputs (RS422) Hysteresis Permissible common-mode voltage, max. -7 / +12 Input impedance, typically kω 12 Detection of direction of rotation via 90 o phase-shifted signal F2 Input range pulse counting Imp Maximum pulse rate Imp/s Gap between 2 consecutive edges ns 400 F1( ), F2( ) Scaling range, max. digits 20 at 1 pulse Scaling range, min. digits 1 at pulses Measurement frequency range, adjustable (-1 db) Hz Sampling rate, max. 1/s 2400 HBM 8

9 SSI transducers Connectable transducers oltage supply 2-channel mode Data input D( ) Input levels, data input D ( ) Low level High level Each line to measurement ground, max. Displacement and angle transducers with SSI interface 5, max. 150 ma or 24, max. 300 ma Time-division multiplex method Differential input (RS422) Hysteresis Permissible common-mode voltage, max Clock output Cl ( ) Differential output voltage Cl( ), without load, max. Differential output voltage Cl( ), RL = 50 ohms, min. Differential output (RS422) Common-mode voltage at Cl ( ), max. 3 Short-circuit current, clock output Cl ( ), typically ma 100 Resolution, single turn bits 12, 13 Resolution, multi-turn bits 24, 25 Scaling range, max. digits 20 at 1 pulse Scaling range, min. digits 1 at pulses Measurement frequency range, adjustable (-1 db) Hz Sampling rate, max. 1/s 1200 Baud rates kbaud 100, 200, 500, 1000 Coding Gray code 9 HBM

10 General specifications Limit value switches Number Reference level 4 per channel gross Hysteresis % Adjustment accuracy digit 1 Response time, typically (fc=1000 Hz) ms 2 Control outputs Number 4 (MP85DP) / 8 (MP85) Nominal (rated) voltage, external power supply DC 24 Permissible supply voltage range Maximum output current per output A 0.5 Short-circuit current, typically (U ext. = 24, R L 0.1 ohm) A 0.8 Short-circuit period unlimited Isolation voltage, typically DC 500 Control inputs Number 1 (MP85DP) / 5 (MP85) Input voltage range LOW Input voltage range HIGH Input current, typically, (High level = 24 ) ma 12 Isolation voltage, typically DC 500 CAN interface Sampling rate, max. 1/s 1200 Protocol CAN 2.0B; CANopen compatible Hardware bus link to ISO Baud rates Maximum line lengths Termination resistor Connection Parameter memory (Flash) Multi Media Card (memory card on Flash basis) kbits/s m connectable by switch terminals 31 plus factory setting Usable types MBytes 8, 16, 32, 64, 128, 256, 512 Data transmission rate, typically kbytes/ 1 s File system DOS Display Type 2-line, 8-character alphanumeric, LCD Keyboard Touch-sensitive keypad with three keys Temperature range Nominal temperature range o C Operating temperature range o C Storage temperature range o C Degree of protection IP20 Dimensions mm 55 x 146 x 156 Weight, approx. g 800 HBM 10

11 Profibus DP interface (MP85DP only) Protocol Profibus DP Slave, as per DIN Baud rate, max. MBaud 12 Slave address 3-123, set via the keyboard Profibus ID number Hex 699 Configuration data bytes 5 Parameter data, max. bytes 6 (+7DP standard) Parameterization (asynchronous) to DP1 standard Input data, max. bytes 142 Output data, max. bytes 40 Update rate, inputs ms 1 (for 4 measured values) Update rate, outputs ms 10, for zeroing, limit values Diagnostic data bytes 48 Profibus connection 9-pin sub-d (DIN ), potential separation from power supply and measurement ground Evaluation unit specifications Max. number of measured value triplets 4000 (auto. data reduction) (channel x), (channel y), (time) Sampling rate Hz 2400 Evaluation Max. number of evaluation windows 9 Type of window oblique or straight Evaluation methods per window Analyzing the course of the curve Analyzing the mean x or y value in the window x coordinates for the tolerance window absolute or relative to the start position, or relative to the end position y coordinates for the tolerance window absolute or relative to F min of tolerance window 2 or relative to F max of tolerance window 2 Stop conditions External stop signal Target value y + overshoot time Target value x + overshoot time Standstill recognition Start conditions External start signal Target value x Target value y Number of independent parameter sets 31 Switching between parameter sets, max. ms 500 Duration of offline evaluation end window ms 6 Duration of offline evaluation straight window ms /measurement pair in window Duration of offline evaluation oblique window ms /measurement pair in window Statistics (separately for each parameter set) Maximum number of fitting processes 4 x 10 9 Number of histogram classes for 2 values (x max, x min, y max, y min ) 9 per tolerance window 11 HBM

12 Modifications reserved. All details describe our products in general form only. They are not to be understood as express warranty and do not constitute any form of liability whatsoever. Hottinger Baldwin Messtechnik GmbH Postfach , D Darmstadt, Germany Im Tiefen See 45, D Darmstadt, Germany Tel.: / ; Fax: / support@hbm.com