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Configuration Guide
(How to configure a system)
Evaluate your needs for installation, number and type of
sensors, PC requirements. Click on the links for pictures and details
about each product mentioned. If you just want to get a
complete turnkey system suitable for most metalforming applications you can just
go to the PIP page and almost everything you
need and the price is listed there. IF
you are an engineer and want the details you can continue and see all
the components that can be configured for a system by continuing to the next
step:
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The system starts with a
signatureACE® SA2000 Processor Card (called the 'SAM"), Part /SA2
and /P. |
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Next, select the type of position device interface board,
resolver or encoder. (More on slave /SLV later)
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Best is the resolver /RSV for
reliability. See the installation
guide to make sure that you know the requirements for
installation. Short cuts will cost in resolution of your
system. Existing resolvers may be used with the /CNV
resolver converter if the resolver is installed per our guide. |
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Encoders require special attention and we recommend you
coordinate this with our applications engineers. |
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Next, select the type of I/O board you plan to add to the
SA2, Part /A08, /A6D, /D16, or /A+D
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/A08 is our most commonly used
interface and provides for 8 high or low level analog signals.
Strain gauge signal conditioning and isolated inputs are standard.
Use this card if you plan to do mostly in-die or press frame analog
sensors. Check the data sheet for details. You can get 4
die-protection channels without ordering a die-protection enabled
interface card by using OPTO22 modules on the termination board.
These must be DC clean sensor signals if the OPTO22 is used. The
are also high speed OPTO22 modules available. |
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/A6D is our second most commonly
used interface card since it incorporates all the signal conditioning
for any type of conventional device or wire used for 4 channels of
die-protection as well as the 6 analog inputs which have the same specs
as the /A08. By using this card you can monitor the force in the
connections on the press with two channels, have 4 spare channels for
in-die analog sensors, have 4 conventional die-protection channels
(buckle, feed, eject and spare). Also, if you have some digital
on-off sensors being used for die-protection, you can add 4 OPTO22
modules to accommodate these. |
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/D16 accommodates 16 conventional
die-protection channels. This is available on custom order.
Most users that need this many points are using multiple SAMs and have
plenty of die-protection points. |
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/A+D is the older version of the /A6D. It has 8
conventional die-protection channels and 4 analog channels. These
channels have the same specifications as those above. |
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If your input needs are not met with these options then
contact us. If you need more channels you will need to add another
SA2000 processor using a /SLV interface. This interface synchronizes
the processors on all SA2000s so equipped (up to 6 in parallel).
Our most common form of multi-SA2000 system has two /A6D interfaces
cards. Advantages to multi-SA2000 systems are:
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One SA2000 is allocated to the press with force
sensors on the frame and connections providing press condition
monitoring and protection. This provides a monitoring window
for the full 360 degree rotation with conventional signature
analysis being applied to the entire process. |
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The second SA2000 is allocated for in-die sensors
with a much narrower monitoring window in order to maximize
resolution. |
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Next, you need to determine what kind of computer you plan
to install the signatureACE cards into or if you plan to remote the computer
from the cards. The PC will have the SAMnet card
installed in it.
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Most automotive or dirty environments use the /PPB
Industrial Workstation mounted in the Press Control Panel. The
field terminations are brought to the Press Control Panel and terminated
on a /TEB termination board connected to the SA2000 board(s) using /T04
cables.
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The decision to use the /TEB
or /TEC depends on total installed cost of
wiring. |
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The /PPA modular system is used in
most other applications. It provides a nice industrial enclosure
for the SA2000 and industrial PC with a remote display of your
choice. This product is also suitable for dirty environments if
the enclosure is mounted inside another enclosure such as a press
control cabinet. |
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The last option, not recommended, is to use your own PC
and connect via the network to the /BOX which
contains the SA2000s. This method is not recommended since with
the advent of the windows version of the software, ST limits it's
responsibility for trouble shooting "strange" computers,
especially "clones". |
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Many options exist for the PC, packaging, installation,
and user interfaces. We have probably experienced most versions. |
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Next, you need to decide on what software you want.
All our software falls into the SAMview™
family.
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Currently, but soon to be changed with the windows
release, all systems must have the following foundation software:
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/CCM press critical curve and tonnage monitoring
software. This provides conventional peak and angle tonnage
monitoring with protection of the press through the entire load
curve provided by the manufacturer...the only real form of press
load protection. Peak tonnage does not really protect most
presses! Press curves are easily installed by the user without
any charges typical for this service using any text processor. |
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/DIE die setup facility. This provides a
complete data base for tools, sensors, additional presses on the
same network, and alarm event logging. Each tool has a unique
die setup signature and tool note file which is used to assure
consistent setups by providing the setup information and then
confirmation by comparison of the setup with the master signature. |
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/SAM is the signature-based process control software
which assure consistent parts by comparing each part made with the
master signature or prior selected run signature. It has event
logging, save signatures by fault type, provides user comments on
each saved signature for later use or for assistance in using the
optional software products. |
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Our most powerful tool, usually purchased in addition to
the above by all existing users, is SPCview, part /SPC.
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SPCview, as a minimum established a complete SPC
system for tracking specific features of the signature which
represent critical process data. |
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The most powerful part of this package is it's
ability to provide the process engineer with a tool to apply to
existing bad signatures in order to look for the same bad features
in the future and then when discovered to display the actual problem
to the operator with a text message instead of requiring the
operator to understand the signature. It is a knowledge base
tool that stores information about problems and then automatically
displays this information when the system see the same problem. |
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Our most advanced process software is FeatureView, part
number /FEX.
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This product provides sophisticated process analysis
tools for measuring work done tools or sections of tools. |
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It provides tool condition monitoring. |
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It provides the ability to implement solution of
formulas in real-time while the process is running. |
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It has been applied to a Ford patent, solely
licensed by ST, which monitors the thickness, hardness and work
hardening coefficient during deep draw operations. |
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This product is never purchased without ST
involvement in the application. |
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Next you need to determine what firmware options, if any,
you desire
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There are many firmware options. They include
remote pushbutton operator support, part-tracking through the die,
automatic limit setting based upon process trending (usually used on
high speed presses), servo output control, light stack interfacing, and
many more. |
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Next you need to determine the position transducer you plan
to use.
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This matches your selection of the interface card above. |
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ST sells a resolver which connects using a cable or we
can supply the connector. See /RSV. |
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ST does not stock any encoders but can assist in
selection. Most encoders are only applied in linear applications
such as hydraulic presses or assembly systems. |
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If you have an existing resolver you can use a /CNV
converter as noted above. |
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Next you need to select the cable lengths required for your
installation.
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The SAMnet cable length needs to be specified...the
distance from the PC to the SA2000 card(s). This can be any
distance but we supply standard lengths of 1 foot (/S01), 30 foot
(/S30), and custom (/SXX). |
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The termination cable from the SA2000 to the /TEC or
/TEB. The /T04 is four feet and is used internal to
enclosures. Other sizes are 10 foot (/T10), 30 foot (/T30), 50
foot (/T50), and custom (/TXX) |
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You now need to select the length of cable needed for
your position transducer.
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For resolvers we supply 30 foot (/R30), 50 foot
(/R50), 75 foot (/R75), custom (/RXX), and we provide just the
connector (/RSC) |
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For the /CNV converter we supply a 2 foot cable for
the input side with the /CNV. This must not be changed.
We also supply the output cables in 30 foot (/C30), 50 foot (/C50),
75 foot (/C75), custom (/CXX) |
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We do not supply cables for encoders except under
custom order. |
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Next you need to select the sensors you plan to use.
This is usually known by the customer. The variety is so larger that
we do not stock in-die traditional sensors. We do stock special in-die
and press force sensors. Do not attempt to use force sensors for in
the die that do not have at least 500% over-range protection or you will
incur high sensor replacement and downtime costs.
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Our sensors for the press frame or connections are the /400
Insitu sensors. They come with cable lengths of 1 foot
(/400-01), 35 foot (/400-35), 50 foot (/400-50), 75 foot (/400-75), and,
custom (/400-XX) |
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Our in-die sensors come in many sizes and types.
We custom make many sensors to suit the specific application. Some
stock sensors:
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In-die rugged zed /CSL
featuring high over-range protection and sealed. |
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Ball-lock sensors /BL |
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Finally you need to determine if you need our assistance in
installation or training. We offer both services either at our factory
or on site. Please contact us for specifics. |
Hopefully this guide give one the overview of all the
components in a typical system.
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