PSQ-Analyse | 1070087118

Description of application

Electric Drivesand Controls Pneumatics Service

Linear Motion and Assembly TechnologiesHydraulics

Rexroth PS 6000PSQ-Analyse

1070087118Edition 05

The data indicated below is intended to describe the

product. Should information on its use be provided,

such information represents application examples

and suggestions only. Catalog specifications shall

not be deemed as warranted quality. This

information does not release the user from

performing his own assessments and verifications.

Our products are subject to natural wear and aging.

This manual is the exclusive property of Bosch

Rexroth AG, Germany, also in the case of

intellectual property right applications. Reproduction

or distribution by any means subject to our prior

written permission.

An example configuration is shown on the cover

page. The delivered product may therefore deviate

from the picture.

Original operating instructions

Language version of the document: EN

Original language of the document: DE

DOK-PS6000-ANALYSETOOL-AP05-EN-P

1070087118 | PSQ-Analyse Bosch Rexroth AG 3/40

Table of contents

GE

RM

A

N

EN

GL

ISC

H

fran

ça

is

Table of contents

1 Regarding this documentation .................................................................... 4

1.1 Validity of this documentation............................................................. 4

1.2 Necessary and supplementary documents ........................................ 4

1.3 Presentation of information ................................................................ 5

1.3.1 Safety instructions .............................................................. 5

1.3.2 Icons ................................................................................... 7

1.3.3 Designations ....................................................................... 7

1.3.4 Abbreviations ...................................................................... 7

2 Safety instructions ................................................................................... 10

3 General information on damage to property and products ......................... 10

4 Scope of delivery ..................................................................................... 10

5 PSQ-Analyse .......................................................................................... 11

5.1 Concept ............................................................................................ 12

6 System requirements ............................................................................... 13

7 Installation ............................................................................................... 14

7.1 Start setup assistant ......................................................................... 14

8 License ................................................................................................... 17

8.1 Order license .................................................................................... 17

9 Adjust memory for SQL server ................................................................. 19

10 Main window ........................................................................................... 20

10.1 Menu (1) ......................................................................................... 21

10.2 Filter (2) ......................................................................................... 21

10.3 Function selection tabs (3) ............................................................... 21

10.4 Measured values (4) ........................................................................ 21

10.5 Zoom of the y axis (5) ...................................................................... 22

10.6 Activate and deactivate measured quantities and information (6) .... 22

10.7 Graphs (7) ........................................................................................ 22

10.8 Action buttons (8) ............................................................................. 23

11 Expulsion and system analysis................................................................. 26

11.1 Line overview ................................................................................... 30

12 Reference curves .................................................................................... 31

13 Automatic calculation of tolerance band ................................................... 33

13.1 Calculate 35

14 Fault messages ....................................................................................... 36

15 Index ....................................................................................................... 38

4/40 Bosch Rexroth AG PSQ-Analyse | 1070087118

Regarding this documentation

1 Regarding this documentation

1.1 Validity of this documentation

The present documentation

applies to

the PSQ-ANALYSE software.

is designed for

Planning, assembly personnel, operators, start-up, service technicians, plant

operators.

provides information about

installation

functionality

operation

The present information is meant to supplement the respective „PSI 6000 manual

on control and I/O level“ and the "BOS 6000 online help“.

This documentation and particularly the operating instructions contain important

information on the safe and appropriate assembly, transportation, commissioning,

operation, use, maintenance, dismantling and simple trouble shooting of the

product.

Please read this documentation completely, and especially read the "Safety

instructions" section in the Operating instructions before working with the

product.

1.2 Necessary and supplementary documents

Do not operate the product until you have received the documents marked by

and you have understood and observed them.

Table 1: Necessary and supplementary documents

Title Document number Document type

PSI6xxx: Weld timer with medium-

frequency inverter

1070080028

Operating

instructions

PSI6xxx: Weld timer with medium-

frequency inverter - Type-specific

instructions

depending on type

Operating

instructions

(type-specific

supplement)

BOS6000 Online Help 1070086446

Reference

For which product?

Target group?

Topics dealt with?



1.3 Presentation of information

Uniform safety instructions, icons, terms and abbreviations are used in this

documentation to enable you to work with your product rapidly and safely. They

are described in the sections below for a better understanding.

1.3.1 Safety instructions

In this documentation, safety instructions are provided ahead of a sequence of

action involving danger of bodily injury or property damage. The action described

to avert the danger must be adhered to.

Safety instructions call your attention specifically to danger potentials or risks.

We distinguish among the following places where safety instructions may be

required:

Basic safety instructions:

They are related to general important matters and apply to the complete

documentation. These safety instructions are provided in Sections 2 and 3 of

operating instructions „PSI 6xxx: Weld timer with medium-frequency inverter“

(doc. no. 1070080028; also refer to page 4).

Preceding safety instructions:

They refer to topic-related matters and are provided at the beginning of a

chapter or at the beginning of a whole procedure.

Integrated safety instructions:

They are related exactly to a separate procedure step and are provided right

before the relevant step within the procedure.

A safety instruction is always structured as follows:

Warning sign (only in case of personal injury)

Signal word to indicate the danger level

Type and source of danger

Consequences of failure to observe

Action for averting danger.

Table 2: Example for the structure of a safety instruction

Integrated safety instructions may be embedded in the format of the

environment so that no ”visual” break in the action sequence is provoked.

Therefore they do not necessarily use the layout shown in the example but

they do use the indicated structure.

Where?

Structure?

SIGNAL WORD Type and source of danger


Action for averting danger

Further actions for averting danger



The safety instructions are classified into danger levels (danger classes). The

signal word represents the danger level.

Table 3: Danger classes according to ANSI Z535.6-2006

Warning sign, signal word Description

DANGER characterizes a dangerous situation where death or

serious physical injuries will occur if it is not avoided

WARNING characterizes a dangerous situation where death or

serious physical injuries may occur if it is not avoided

CAUTION characterizes a dangerous situation where light to

moderate physical injuries may occur if it is not avoided

NOTICE indicates property damage. The product or the

environment may be damaged.

Table 4: Examples for classification of safety instructions

Danger levels?

G

DANGER SafetyInstrType

SafetyInstrConseq

SafetyInstrPrec

EFAHR





Warnu

WARNING SafetyInstrType

SafetyInstrConseq

SafetyInstrPrec

NG





VORSICH

CAUTION SafetyInstrType

SafetyInstrConseq

SafetyInstrPrec

T





Hin

NOTICE SafetyInstrType

SafetyInstrConseq

SafetyInstrPrec

WEIS







1.3.2 Icons

The following icons indicate instructions which are not safety-relevant but which

improve the comprehensibility of the documentation.

Table 5: Meaning of the icons

Icon Description

If this information is not observed, optimal use or operation

of the product is not possible.

individual, independent action step

1.

2.

3.

numbered instruction:

the numbers indicate that the action steps are performed

consecutively.

1.3.3 Designations

The following designations are used in this documentation:

Table 6: Designations

Designation Description

BOS Welding user interface

PE Protective Earth. PE conductor.

PG Programming terminal/welding computer

PLC Programmable Logic Controller

PSG PSG Transformer-rectifier unit

Medium-frequency welding transformer

PSI programmable weld timer

Timer Weld timer.

Also referred to as timer or resistance weld timer.

1.3.4 Abbreviations

The following abbreviations are used in this documentation:

Table 7: Abbreviations

Abbreviation Description

%I Scale divisions, represent an electrical heat value or pulse width

BOS Welding user interface

BQR User interface for U/I controller

CAN Controller Area Network; data bus

CCR (KSR) Constant-Current Regulation, i.e. the current in the secondary circuit

is kept at a constant level by this control mechanism

CT Cool time, time between the current impulses/blocks (1., 2., 3. CT)

DST Down slope time, current slope at the end of the MainWLD

ED Duty cycle: Ratio between weld time and time without current flow




Ext External, e.g. +24V voltage for signal transmitters (switches) and

actuators (valves) outside the timer

FQF Force quality factor

I/O Input / Output

Ignition Ignition, firing pulses for triggering the power unit are switched on

and off

kA Kilo-Ampere (amount of current)

kN Kilo-Newton (force)

KUR Constant-Voltage Regulation, mains voltage fluctuations are

balanced

LAN Local Area Network: General network

LT Power unit (thyristor or inverter)

MainWLD 2nd weld time (MainWLD), main welding time, may consist of a block

comprising individual impulses; only the MainWLD can be

programmed with an upward and downward slope.

MSDE Microsoft Data Engine. (Freely available database with restrictions,

e.g. database size 2 GB)

PG Programming terminal/welding computer

PHA Heat value (Phase angle) or pulse width

PSF Process stability parameter

PSG Transformer-rectifier unit for the PSU/PSI inverter

PSI Medium-frequency power unit (1000 Hz)

PSL PS power unit

PSQ Quality assurance system

PSS PS timer unit

PST Thyristor power unit (50/60 Hz)

PSU Welding current inverter (medium-frequency)

Slope Current increase from an initial to a final %I (heat) value

Solenoid Solenoid valve, drives the cylinders for closing the electrodes

SQL Structured Query Language

SQL server Database server by Microsoft

SQL Server

2005 Express

Successor of MSDE

SQZ Squeeze time that runs before the weld time. The electrodes

squeeze the parts to be welded together.

Temp Temperature

Timer Weld timer, also referred to as resistance weld timer

UDM Ultrasonic data processing module (front-end)

UIP Spot quality parameter

UIR U/I controller




ÜK Monitoring contact, e.g. for monitoring the pressure cylinder (that

closes the electrodes) or monitoring of the electrode position (e.g.

gun closed.).

US Ultrasonic

USE Ultrasonic sensors

USP Lower intersection

USR Ultrasonic controller

UST Up-slope time, current slope at the beginning of the MainWLD

Stepper Heat stepping in order to compensate for electrode wear

USW NEXUM operating data acquisition and statistics management

software

VB6 Visual Basic Version 6.0 (Microsoft)

WC Weld complete contact (WC)

WLD Weld time

XQR Controller module


Safety instructions

2 Safety instructions

Please note the section with the identical name in the operating instructions for

the PSI 6xxx and PST 6xx0 product families (for information on document

numbers, refer to table 1, page 5).

3 General information on damage to property

and products

Please note the section with the identical name in the operating instructions for

the PSI 6xxx and PST 6xx0 product families (for information on document

numbers, refer to table 1, page 5).

4 Scope of delivery

Please observe the order number of the CD in the following table.

Table 8: Part numbers

Title Part number

PSQ-ANALYSE CD R911171930


PSQ-Analyse

5 PSQ-Analyse

Fig. 1: PSQ-Analyse main window

The PSQ-Analyse software evaluates the weld current protocol of the BOS6000

for welding data analysis. A connection to the database of BOS6000 is required

for this purpose.


PSQ-Analyse

5.1 Concept

Fig. 2: PSQ-Analyse for operating data recording

Thus there are two possible operating locations for PSQ-Analyse. The user can

employ it either directly at the line PC or at a central PC with access to the line

PCs.

The software simplifies the commissioning of the Q module in particular. The use

of PSQ-Analyse saves a tremendous amount of time in comparison with manual

commissioning.

Production level Office level

- Access to line PC through the network - Each line PC in the network is within reach - Analysis of entire production lines / series / factory possible from a central work place - Optional PSQ-Analyse

Production

line

Line PC

BOS6000

DB

DBMS

PC with BOS6000 and optional PSQ-

Analyse

SQL-Server

2000/2005

Network

Central

PC


System requirements

It is possible to analyze entire systems during production within a very short time.

The purpose is to determine the system status. The analysis result allows the

user to determine whether there is need to optimize the system or whether it is

operating stably.

6 System requirements

2 GHz Intel1 Pentium1 M processor or equivalent type

1 GB RAM or more

Operating system

– Windows 1 2000 and Service Pack 4,

– Windows1 XP and Service Pack 2,

– or Windows1 Server 2003 and Service Pack 1

Microsoft Internet Explorer1 5.0 (or higher)

RS232/V24 link or field bus

Screen resolution at least 1024 x 768

1 All trademarks and names are the property of their respective

manufacturers.


Installation

7 Installation

7.1 Start setup assistant

Conditions:

You must have administrator privileges for your operating system in order to

perform the installation!

First close all other Windows programs!

The CD contains the installation set and the documentation as PDF-file.

1. Start the installation by calling up the "Setup.exe" file.

2. Click on the ”Start” command button and select ”Run”.

The ”Run” dialog screen is displayed.

3. Enter E:\Setup.exe (where E: represents your CD-ROM drive) and click on

OK.

4. Afterwards, please follow the instructions of the setup assistant.

Fig. 3: Installation of PSQ-Analyse


Installation

Fig. 4: Chose installation folder

Fig. 5: Starting the installation


Installation

Fig. 6: Installation procedure

Fig. 7: Finish installation


License

8 License

8.1 Order license

The PSQ-Analyse software can only be used with a license. The license term is

limited.

Fig. 8: Term of the license

Pressing the button „Order license“ takes you to the window shown below.


License

The license has to be ordered from:

Bosch Rexroth AG

D-64711 Erbach

Berliner Straße 25

Tel.: +49 (0) 9352 / 405060

Fax: +49 (0) 6062 / 78-890

E-Mail: [email protected]

A 24-hour hotline is available.

To obtain a license, it is necessary to report the MAC address to Bosch Rexroth

because it serves as copy protection. The license is then valid on this PC only.

The license fee to be paid varies depending on the term of the license.

The license code received has to be copied into the respective line, and the

licensing procedure is completed by pressing the "Activate license" button. The

term of the license will be extended accordingly, and if activation is successful,

you will receive a corresponding acknowledgment. Otherwise, an error message

will be displayed.

The "MAC information" box lists all network adapters identified (also W-LAN

and VM-Ware). The MAC address of the primary connection has to be

provided (as a rule LAN connection).

Fig. 9: MAC address

MAC address


Adjust memory for SQL server

9 Adjust memory for SQL server

The random access memory allocated to the SQL server is limited to 120 MByte

as a standard. The database of the BOS6000 usually has a size of 500 MByte

and more.

Whenever data are to be read from the database using PSQ-Analyse, the SQL

server is required to move data to the hard disk to be able to carry out the

process at all. Access to the hard disk is considerably slower than access to the

random access memory. This may lead to extremely long computing times.

To avoid this, the function

Functions Adjust memory for SQL-server

has been provided.

The following window is displayed:

Fig. 10: Adjust memory

This function allows the allocated memory for the SQL server to be set to a higher

value.

The upper field indicates the total size of the random access memory available to

the PC. The field below is used to adjust the random access memory to the

required value. The suggested value of 90% of the total random access memory

has been entered here. The value can be edited and set to any value less than or

equal to the total random access memory. It is recommended to use the

suggested value.

The new value is accepted by pressing OK.

Press Cancel to exit the window without accepting the new value.

Closing the software will automatically reset the value that was active prior to

the start of PSQ-Analyse. The value may already have been adjusted

previously by means of the configuration tool of BOS6000. This value will

become active again after PSQ-Analyse has been closed. Thus, the value

entered before is only valid during the operating period of the PSQ-Analyse

software. The procedure described above has to be repeated again at the

next software start.


Main window

10 Main window

Fig. 11: Main window

The most important purpose of the main window is to analyze individual programs of a specific weld timer in greater detail. Numerous functions have been provided to support the user in performing the analysis.

The most important purpose of the main window is to analyze individual programs

of a specific weld timer in greater detail. Numerous functions have been provided

to support the user in performing the analysis.

After program start, the active SQL server is searched automatically via the

Registry. If MSDE 2000 and SQL server 2005 have been installed, it is possible to

change the SQL instance via the project loader. The PC may be the computer

executing PSQ-Analyse or e.g. a line PC which can be accessed through the

network.

The default value entered for “PC“ is local. If you keep this entry and click the

Connect button, a selection window will be displayed where MSDE 2000 or SQL

server 2005 can be selected. However, it is also possible to enter the name of the

line PC that you want to connect with through the network. As an extension of this

function, the option to read in a list of PC names is provided. This list is

maintained during the execution period.

This step has to be repeated after a restart of PSQ-Analyse. The list of PCs is

loaded via the button. A txt-file can be selected in which the required PC

names have been previously entered in list form.

2

7

5 6

8

1

3

4


Main window

10.1 Menu (1)

The following functions are available here:

Adjust memory for SQL server.

The function is described in Section 9 of the present documentation.

Language change-over: German or English.

10.2 Filter (2)

This option can be used to filter the required data.

The available filter criteria are PC name, weld timer, program number and

date/time. These four criteria allow for the selection and limitation of all the data

available in the database.

Having connected to a PC, PSQ-Analyse automatically fills the filter boxes. All the

weld timers that have already generated an entry in the weld current protocol will

then be available in the filter box for the timers.

This also applies to the program number. Only the program numbers that appear

in the weld current protocol are available for selection.

In version 2.3.0 and later, PSQ-Analyse has been prepared for processing of

up to 1024 programs which are already supported by several weld timer types.

By activating the check mark

PSQ-Analyse automatically reads the date and time of generation of the

reference curve of the currently selected program.

PSQ-Analyse enters this information into the filter boxes

and .

The default values displayed in these boxes are the first and last spot that appear

in the weld current protocol in the relevant period.

10.3 Function selection tabs (3)

In addition to the analysis function, the functions reference curves, welding

parameters and automatic tolerance band calculation are available here. The

functions are described in separate chapters of the present documentation.

10.4 Measured values (4)

If the cursor is moved to a new spot weld, the measured values in the text boxes

above the graphs will be updated automatically.

The values measured for current (I), weld time (t), voltage (U), resistance (R),

UIP, PSF, FQF, pulse width (PHA), %I (power, P) and energy (E) can be read.

The value for wear at the selected time is indicated additionally if the respective

check mark has been set. In addition to the measured values, the number of

welding expulsions and the percentage share of welding expulsions in the filtered

data quantity are available.


Main window

10.5 Zoom of the y axis (5)

The option to adjust both y axes is provided for each of the three graphs. Two

inputs fields for each measured quantity are available for this purpose.

Y min is used to define the minimum value of the y axis. Y span specifies the

displayed range of the y axis. As default setting, each y axis is displayed from 0 to

the maximum value that has occurred.

10.6 Activate and deactivate measured quantities and information (6)

Each of the values of current, weld time, voltage, resistance, UIP, PSF, FQF,

pulse width, %I (power) and energy can be activated and deactivated in the

respective graphs. This is done by activating or deactivating the corresponding

check marks.

In addition to these values, it is possible to display or suppress further information

in the graphs.

Count (wear):

If you activate this check mark, the characteristic of wear is shown in the graph

and the present wear is entered in the text box.

Tolerance bands

By activating the respective check mark, the set tolerance bands can be

displayed in the same manner.

10.7 Graphs (7)

By clicking on the

button, the filtered data are read from the data base and drawn in the graphs. It is

updated automatically when a new program or a new weld timer is selected.

Every spot weld in the graph can be selected via a cursor. The program number,

spot weld name and date / time of the respective selected spot weld are indicated

in the title bar of the graph.

Every measured quantity can be displayed in each of the 3 graphs. Limit values

can be displayed for each measured quantity. Any graphs which are not needed

can be simply suppressed so that there is more space and the remaining graphs

can be analyzed more easily. Only two sizes can be shown simultaneously for

each graph.

Moving within the data is possible by pulling the x and y axes of each graph. An

“E” in the data rows indicates a replacement of the electrode caps.


Main window

10.8 Action buttons (8)

The entire display is updated taking into account the currently set filter.

This button permits the user to read in and display the previously calculated

tolerance limits. The txt-file containing the calculated tolerance bands is selected

through a dialog. Please refer to the section "Automatic calculation of tolerance

band” for information on calculation of the tolerance bands.

Then the tolerance limits read in for the displayed program are shown next to the

charts. The set tolerance limits can be transferred comfortably into the previously

read in txt-file using the “Apply tolerance band changes” button.

After the txt-file has been read in, the tolerance bands are displayed in the graph.

This is very helpful for verification of the calculated tolerance bands. The

adjustment of the tolerance bands is made by "pulling" the lines directly in the

chart. The current tolerance limit value is shown next to the chart.

The display of the tolerance bands is activated through, e.g. “Tolerance band

UIP”. Each graph can only display the tolerance bands of one parameter, e.g. UIP

or PSF or FQF. It is not possible to display both tolerance bands at the same

time.

The green area marks the range from the conditional tolerance band upwards.

The yellow area marks the zone between conditional tolerance band and absolute

lower tolerance band. The area below or above the absolute tolerance limit is

displayed in red.

In version 2.3 and later, an upper conditional tolerance band can be set for UIP

and FQF. The upper yellow area then shows the upper conditional tolerance

band.


Main window

Fig. 12: Display tolerance bands

As a default, 100 measured values are shown in the three graphs. If you use

“Zoom -“, more spot welds will be displayed in the graphs. Every time you click on

“Zoom -“, the number of spot welds shown will be increased by factor 2.

Proceeding on the basis of 100, only 50 values will be displayed after the first

click, then 25, etc. The distance between two spot welds is thus increased.

As a default, 100 measured values are shown in the three graphs. If you use

“Zoom -“, more spot welds will be displayed in the graphs. Every time you click on

“Zoom -“, the number of spot welds shown will be increased by factor 2.

Proceeding on the basis of 100 values, 200 values will be displayed after the first

click, then 400, etc. The distance between two spot welds is thus reduced.

The “Export” button can be used to export the filtered data to a txt-file. The txt-file

can be opened and edited in Excel.


Main window

This function helps the user to track parts and the possible correlation between

the data and the spot diameters resulting from destructive tests of the tracked

parts.

Fig. 13: Part identifier filter

In principle, there are two options to filter the required data from the database and

to export it.

Prerequisite for the use of this new functionality is the ability of the robot to report

this information to the weld timer. This functionality has to be available in the weld

timer as well. If this functionality is present, the respective part identifier for each

spot weld is stored in the weld current protocol. This is the most comfortable

option to track parts. The user has to note the part identifier of the removed part

and enter it into the “Part identifier” field shown above. By clicking OK the data of

the respective part is exported to a txt-file and can then be edited, e.g. in Excel.

The part identifier is not available in all areas of car body production of a series.

This information does not exist for smaller parts.

For this reason, there is a second filter and export option. Before the part that you

want to track or remove is welded, it is “marked” in the database. To do this, you

set the monitoring reference value of energy to 1. Then you copy this setting to all

programs used for the part. After that, the part is welded. After welding of the part,

the reference value of energy is reset to the original value and copied to all

programs used. Now you can use the filter option "Energy = 1" to export the data

of the selected part.

Filtering according to part identifier:

Filtering according “Energy = 1“:


Expulsion and system analysis

11 Expulsion and system analysis

A click on

initiates the determination of numerous data which provide important information

about the system status to the user.

The status of the calculation is indicated by a progress bar. The calculation may

take longer or shorter depending on the equipment of the PC performing the

calculation. As a rule, the calculation time is 2-3 minutes. To achieve the best

possible performance, it is important to perform “Adjust memory for SQL-Server”.

Fig. 14: System analysis

After completion of the calculation, the resulting data are available to the user in a

table.

The system data determined in detail:

Table 9: System table

Parameter Description

Timer name Name of weld timer

Elec. no. Electrode/Stepper number

Prg. No. Program number

Spot name Spot name




Current PreWLD Parameterized current of the first (pre-)weld time

Current MainWLD Parameterized current of the second (main) weld time

Current PostWELD Parameterized current of the third (post-)weld time

Current upslope Parameterized current of the slope

Time PreWLD Parameterized time of the first weld time

Time MainWLD Parameterized time of the second weld time

Time PstWLD Parameterized time of the third weld time

Time UST Parameterized time of the slope

Total time Total weld time

WLD min Minimum weld time

WLD av. Average weld time value

WLD max Maximum weld time

WLD prol. % Prolongation in percent, with reference to

parameterized time

Pulses Number of impulses of the 2. weld time (MainWLD)

Force Parameterized force value

Spots Number of welded spots of this program that are still

contained in the database.

Expulsion Number of expulsions of this program that are still

contained in the database.

Expulsion % Percentage share of expulsions of this program

UI measurement (P) Program-dependent parameter measurement on/off

UI regulation (P) Program-dependent regulation on/off

UI monitoring (P) Program-dependent monitoring on/off

Welding time prolongation Parameterized welding time prolongation

UI measurement (G) Global parameter measurement on/off

UI regulation (G) Global parameter regulation on/off

UI monitoring (G) Global parameter monitoring on/off

UIP min Minimum UIP

UIP medium Average UIP value

UIP max Maximum UIP

PSF min Minimum PSF

PSF medium Average PSF value

PSF max Maximum PSF

UIP reference Parameterized reference value of the UIP

UIP upper tol. Parameterized upper tolerance band for UIP

UIP U. cond. tol. Parameterized conditional upper tolerance band for

UIP




UIP L. cond. tol. Parameterized conditional lower tolerance band for

UIP

UIP lower tol. Parameterized lower tolerance band for UIP

PSF cond. tol. Parameterized conditional tolerance band for PSF

PSF lower tol. Parameterized lower tolerance band for PSF

FQF min Minimum FQF that occurred

FQF mean Mean value of the FQFs that occurred

FQF max Maximum FQF that occurred

FQF upper tol. Parameterized upper tolerance band for FQF

FQF upper cond. tol. Parameterized upper conditional tolerance band for

FQF

FQF lower cond. tol. Parameterized lower conditional tolerance band for

FQF

FQF lower tol. Parameterized lower tolerance band for FQF

Comment 1 Text of comment field 1














SoftwareVersion timer Firmware version of the timer

Software version controller Firmware version of the UI controller

Using the

button, the user can export the data determined to a text file which, in turn, can be

opened in Excel for further processing.

The text file includes all the data indicated above.

Several columns of the results table are highlighted red and green. This is a

visual support for the user.

In addition, the column entries of

„UI measurement (P)“,



„UI regulation (P)“,

„UI monitoring (P)“,

„Weld time prolongation“,

„UI measurement (G)“,

„UI regulation (G)“ and

„UI monitoring (G)“

are displayed in red when the entry is “OFF”.

In PSQ-Analyse version 2.3 and later, the

button can be used to select the displayed parameters according to a specific

value, e.g.:

Only the values with SQZ 200 will then be displayed, for instance, as shown in the

figure below.

Fig. 15: Filter



11.1 Line overview

By pressing the ‚Line overview‘ button the user can call up the following screen:

Fig. 16: Line overview

The line overview displays diagrams for maximum value, average (mean) value

and minimum value UIP, FQF etc.

The display of the diagrams is related to the filter setting in the welding

parameters table. The X axis represents all programs of all filtered timers from the

welding parameters table. The Y axis indicates the respective measured value.

The input window

is used to hide dressing programs, e.g. program number 251 or certain welding

programs, which have no relevance for this display.

The evaluation can be performed by trained experts.


Reference curves

12 Reference curves

Fig. 17: Reference curves

This window provides a lot of information to the user which is helpful to evaluate

the reference curve. The window is divided into three main sections.

The user can select the required reference curve using the text boxes. The timer

is entered in text box

and the corresponding program in

After selection of a timer and a program, the corresponding reference curve is

shown.

The graph displays the curves for voltage, current, resistance, heat value and

force. The current is scaled on the first y axis, and the resistance on the second y

axis. The remaining measured values are normalized to resistance.

A cursor is available for selection of every measured value. The corresponding

measured values are displayed above the graphs and updated automatically

when you move the cursor.

1

2

2

3

1


Reference curves

By pressing the

button, the current page is transmitted to the standard printer.

Using the

button, it is possible to export the reference curve displayed to a txt-file which, in

turn, can be opened and processed in Excel.

In the 3 tables in the lower half of the window, the most important KSR (CCR) and

UIR parameters as well as parameters of force measurement are output.

3


Automatic calculation of tolerance band

13 Automatic calculation of tolerance band

Fig. 18: Automatic tolerance band calculation with Q stop

Another representation is obtained by clicking on the “Automatic calculation of

tolerance band” tab. It is divided into five main components.

Definition of the tolerance bands to be calculated:

The option is provided to calculate the tolerance bands for all available measured

quantities.

It is possible to select freely which tolerance bands are to be calculated. The

selection is performed by activating the respective check marks. As a rule, it is

useful to calculate all tolerance bands and the reference value of a measured

quantity.

In version 2.3 and later, an additional upper conditional tolerance band can be

set for UIP, weld time and FQF.

1

1 2 3

5

4



Activation of program-dependent monitoring.

To activate the monitoring, it is necessary to change a total of three parameters in

the BOS6000. Two of these parameters can be activated directly by PSQ-Analyse

for all programs used in a system.

To do this, it is necessary to first activate the check mark for the measured value

to be monitored and then the check mark for “Program”.

Having done this, it is only necessary to set the monitoring active by activating the

global monitoring using the BOS6000 at each timer.

Sensitiveness of tolerance band definition and calculation:

The sensitiveness of the tolerance band calculation can be influenced by a slide

control. When the window is called up, the slide control is set to Standard. This

setting may be moved to “More tolerant” or “More sensitive”, if necessary.

More tolerant: the calculated tolerance bands are generally reduced by the

value that is set.

More sensitive: the calculated tolerance bands are generally increased by the

value that is set.

The actual calculation of the tolerance bands is started by clicking the “Calculate”

button. This can take several minutes depending on the PC configuration. The

current calculation status is indicated by a progress bar.

After completion of the calculation, a table is provided to the user in the bottom

part of the window.

This table shows how many violations of the tolerance bands just calculated

would have occurred in relation to the values available in the database. It shows

how often a tolerance limit would have been violated by UIP and PSF.

If too many violations are shown, this indicates that the calculated tolerance

bands are too narrow.

In version 2.3 and later, an additional upper conditional tolerance band is

available in connection with the respective BOS6000 and XQR or timer firmware.

The user can adjust the calculation sensitivity using the two slide controls and

perform the calculation again. In order to know which programs were affected by

the violations, you have to click on the button

.

Q stop parameter

There is a possibility of setting Q stop parameters.

A difference is made between Q stop (program-related) and Q stop (all

programs), i.e. component-related parameters.

Only fixed values for the selected programs can be determined. An automatic

calculation as for the other monitored parameters is not possible.

2

3

4

5



13.1 Calculate

Before activating the Calculate button, it is necessary to select the weld timers in

the ‘Timer name’ selection box and the programs in ‘Program filter’. Calculation of

the tolerances can generally be performed in two manners.

Either as fix value which is entered by the user

Or as calculation via history data.

In this case, the variations of the individual values of a parameter are regarded

relative to the respective reference value. Schedules without ignition (current = 0),

schedule faults (schedule status) and spot repetitions are not considered in the

calculation! These schedules are filtered by the corresponding criteria.

The calculation for the lower tolerance band is based on the standard deviation of

all values deviating downward from the reference value. This applies in analogy to

the upper tolerance value. The procedure for the conditional tolerance band will

result from experiments with different databases.

In this mode, the 3 parameters current, PSF and UIP are offered to the user as

default suggestion. In case of initial setup, it is useful to enter a fix value because

neither history data nor a sufficient quantity of data are available.

Serves as subsequent calculation once production has been running for a while

and sufficient values are available for an automatic calculation.

Monitoring of the resistance and the heat value are suggested for these cases.

Fix values are suggested. The suggestions for ‘First tip dress’ have been selected

in a more narrow range than for ‘Tip dress’ because a lower degree of variation is

expected.

The user has the option for each calculation mode to specify and modify the

values to be calculated and to decide freely to either use a fix value or the

automatic calculation option.

Saves the settings made in this window.

Initial setup

Calculation of tolerance band

(Calc. tolb.)

First tip dress / Tip dress

Save settings


Fault messages

14 Fault messages

You are informed by the weld timer of all relevant events that might occur during

operation.

For more fault and status messages of PS 6000 weld timers and U/I

controllers in use, please refer to the notes on causes of faults and fault

correction in the “Error list PS5000/PS6000” (no. 1070 087 001).

For information on the external reset of faults, please refer to the relevant

timer manual.

Warnu

WARNING SafetyInstrType

SafetyInstrConseq

SafetyInstrPrec

NG

Damage to persons and to property due to immediate machine start after

fault reset!

If the start signal is present when a fault is reset (acknowledged), the weld timer

will start its program run immediately! Hazardous machine movements may be

the result!

Therefore, prior to fault reset, make sure that there is no-one in the hazard

area of the welding equipment!


Fault messages

Notes:


Index

15 Index

D Damage to property and products

10

F Fault messages 36

I Installation 14

L License 17

Order license 17

P PSQ-Analyse

Calculation of tolerance band 33

Concept 12

Fault messages 36

Installation 14

License 17

Main window 20

Overview 11

Reference curves 31

SQL server 19

S Safety instructions 5, 10

SQL server

Memory 19

Start

installation 14

System requirements 13

T Tolerance band 33

Calculate 35

DOK-PS6000-ANALYSETOOL-AP05-EN-P1070087118

Bosch Rexroth AG Electric Drives and Controls P.O. Box 13 57 97803 Lohr, Germany Bgm.-Dr.-Nebel-Str. 2 97816 Lohr, Germany Tel. +49 9352 18 0 Fax +49 9352 18 8400 www.boschrexroth.com/electrics

Documents

PSQ-Analyse | 1070087118