Summary of Contents for molex 63800-7950
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Page 1: Instruction Manual
Crimp Force Monitor 63800-7950 Crimp Force Monitor Instruction Manual Order No. 63800-7950 UNCONTROLLED COPY Doc. No: TM-638007950 Release Date: 03-21-13 Page 1 of 21 Revision: A Revision Date: 03-21-13... -
Page 2: Safety Warnings And Information
Keep this manual available when using this tool. Replacement manuals are available for download at no charge at www.molex.com. SAFETY ALERT SYMBOL This symbol is used to call your attention to hazards or unsafe practices which could result in an injury or property damage. -
Page 3: Application Tooling Technical Assistance
Call Toll Free 1-800-786-6539(US) 1-630-969-4550(Global). This assistance is limited to the operation and set-up of a customer’s Molex tool. Questions with regard to Molex connector products or how to identify the proper tooling and/ or tooling documentation should be directed to your local Molex personnel or Customer Service Representative. -
Page 4: Table Of Contents
Crimp Force Monitor Table of Contents Contents Safety Warnings and Information ..............................2 Application Tooling Technical Assistance .............................3 Section 1 .......................................5 General Description ..................................5 Features ..................................5 Technical Specification ..............................5 Description ..................................5 Delivery Check ................................6 Tools ....................................6 Section 2 .......................................7 Setup and Installation ................................7 Controls Overview of the Crimp Force Monitor ......................7 Set-Up ....................................8 Ram Sensor Installation ..............................8... -
Page 5: Section 1
Crimp Force Monitor Section 1 General Description 1.1 Features Accurate discrimination of crimp defects from normal production Simple operator function – easy to set up Graphics color changes for visual indication of crimp defect Audible alarm when defect is found Press can be inhibited when defect is found USB2.0 interface for PC software Password protected set up... -
Page 6: Delivery Check
Crimp Force Monitor 1.4 Delivery Check Carefully remove the crimp force monitor from its shipping carton and determine the following items are included in the package. Decription: Quantity Control Module Force Sensor with Ram Mount SMB sensor cable Mini-USB cable DC power supply Foot switch cable Press Mounting kit... -
Page 7: Section 2
Crimp Force Monitor Section 2 Setup and Installation 2.1 Controls Overview of the Crimp Force Monitor SUSPECT LIMIT (%) GROSS LIMIT (%) PEAK CRIMP FORCE TARGET 63800-7950 ANALYSIS REGION 24VDC INPUT BLACK BAR: PROCESS ERROR CRIMP SIGNATURE RS232 I/O PORT... -
Page 8: Set-Up
Crimp Force Monitor 2.2 Set-Up Read the following instructions before attempting to operate the crimp force monitor. This unit ships from the factory assembled, calibrated, and tested. For best results, users should familiarize themselves with the setup and operation of the unit before placing it in service. As a load sensing device, the unit should be handled with care. -
Page 9: Cable Connections
Crimp Force Monitor 2.5 Cable Connections With the control module and ram sensor installed, connect the cables as shown in Figure 3. The sensor cable should be looped behind the press to avoid interfering with the press guard door. NOTE: Use care when connecting the sensor cable. The SMA terminals are fragile and easily damaged. FOOT SWITCH POWER SUPPLY CABLE INTERFACE CABLE... -
Page 10: Section 3
Crimp Force Monitor Section 3 Operation 3.1 Learning a Process 1. From the main menu select the LEARN icon. 2. After the press has been set up and the crimp verified, press the ENTER key to start the learn process. NOTE: BE SURE THE CRIMP IS VERIFIED. -
Page 11: Run Screens
Crimp Force Monitor Peak Force of Reference Signature – Peak Force of Crimp with No Wire X 100 Peak Force of Reference Signature INITIAL POWER ON SCREEN HEADROOM PEAK FORCE REFERENCE SIGNATURE PEAK FORCE OF CRIMP WITH NO WIRE Performing the Headroom Calculation The Headroom is automatically calculated after every crimp using the peak force of the last machine cycle and the peak force of the reference signature. -
Page 12: Counter Screen
Crimp Force Monitor Suspect Fail -ve If the signature error exceeds either the outline box then the fail condition is annunciated in Red on the screen as shown below. Gross Fail -ve 3.4.2 Counter Screen The Counter Screen totals the number of “Pass”, “Suspect” and “Fail” parts while automatically calculating the scrap rate. - Page 13 Crimp Force Monitor 3.5.2 Press Inhibit The crimp force monitor can be programmed to inhibit the press immediately after a bad crimp. This functionality is associated with the operation of the FAIL or SUSPECT output. Several methods are available to reset the machine allowing the operator to continue production. With the reset method set to Keypad, the operator will be required to press a button on the keypad continue.
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Page 14: Section 4
Crimp Force Monitor Section 4 Process Setup 4.1 Signature Analysis and Tolerances The region of the force signature analyzed is represented by the box as shown below. This region can be adjusted from the RUN screen by pressing the key. If a password is enabled you will be required to enter it before proceeding. -
Page 15: Loading A Part Number
Crimp Force Monitor 4.2.1 Loading a Part Number 1. From the main menu, select the icon. 2. Scroll through the part number list with the keys. 3. Press the button to select the highlighted part number. 4. Confirm the selection. 5. -
Page 16: Run Screen
Crimp Force Monitor 4.2.4 Run Screen The part number selected is displayed at the bottom of the run screen only. When this part number appears, the part number shown has gone through the learn procedure and is currently running with all the correct parameters intact. If any of the parameters of this part number are changed. The part number will disappear. -
Page 17: Learn Parameters
Crimp Force Monitor 4.3.2 Learn Parameters At the start of the learning process, the crimp force monitor uses the GAIN setting configured in the Learn Gain parameter. Learn Gain For certain low force crimping applications where more sensor signal amplification is required, the GAIN can be increased to achieve more signal amplification to ensure the force signal is detected by the crimp force monitor. -
Page 18: Machine Interface
Crimp Force Monitor 4.3.3 Machine Interface Input functionality can be assigned to 1 of 4 options. None – Input is not used. This is the default setting of the crimp force monitor. External Trigger – The signature capture will only commence after the Input is Input Activated and sensor input trigger level reached. -
Page 19: Other Settings
Crimp Force Monitor 4.3.4 Other Settings Restores all of the Setup parameters to the factory settings Set Defaults – See Appendix A for factory settings The crimp force monitor provides support for two distinct user accounts. The user accounts are called Operator and Supervisor, to closely match the types of users typically working with the crimp force monitor. -
Page 20: Appendix A - Configuration Worksheet
Max Samples Machine Interface Output 1 Fail / NC / Keypad Output 2 None Input None Appendix B – Spare Parts Molex Part Number Description 638007951 Control Module For 638007950 638007952 Force Sensor, Ram Mounted 638007953 Sensor Cable 638007954 USB Cable... -
Page 21: Appendix C - Typical Force Signatures Of Crimp Defects
No Conductor Brush Warranty Molex warrants its products to the original purchaser to be free from defects in workmanship and material under normal use and proper maintenance for two years from original purchase. This warranty shall not be effective if the product has been subject to overload, shock load, misuse, negligence, accident, or repairs attempted by others than Molex.
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