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"product") are the results of targeted development and meticulous research. As of the date of delivery, burster provides a warranty for the proper condition and functioning of these products covering material and production defects for the period specified in the warranty document accompanying the product.
Counter .............................. 12 Documentation of measuring operations ..................12 Languages ............................13 Support for automation ........................13 Front view of the ForceMaster 9110 ....................14 Rear view of the ForceMaster 9110 ....................15 3.10 Menu structure of the ForceMaster 9110 ..................16 3.10.1...
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Fitting the load cell to the manual press .................... 41 Fitting the displacement measurement system (DMS) to the manual press ........42 Setting up the measurement chain on the ForceMaster 9110 ............44 Measurement ..............................46 Configuring the ForceMaster 9110 settings ....................49 "Counter"...
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Force-displacement curves ..........................82 Technical data ..............................89 Configuration notes ............................90 Choosing the right load cell ....................... 90 Choosing the right displacement sensor ................... 91 Advice ..............................91 10. Available accessories ............................92 11. Ordering example ............................93 12. Index .................................. 94 of 95...
For your safety The following symbols on the device and in this manual warn of hazards: Symbols in the manual Warning Death or serious injury can occur if no appropriate precautions are taken. Caution Damage to property can occur if no appropriate precautions are taken. Note It is important to heed these safety notices in order to ensure correct handling of the instrument.
Introduction Intended use The ForceMaster 9110 is a device for monitoring repetitive production processes. Its particular purpose is the recording and evaluation of process signals, where the curve of the force has a defined relationship with displacement or time. The result of the analysis is classified as either ACCEPTABLE (OK) or is NOT acceptable (NOK).
• MasterCard 9110-Z001 Conversions and modifications If you open up the ForceMaster 9110 or dismantle it during the warranty period, the warranty will be immediately voided. The ForceMaster 9110 may only be opened by our technical personnel. It is forbidden to make any modification to the ForceMaster 9110 without our written permission.
Bedienknopf, der genügt, um durch das Menü zu navigieren. Autoconfiguration The work required to set up the ForceMaster 9110 has been simplified through the introduction of an autoconfiguration system. You carry out the pressing of a part as an example, and the ForceMaster 9110 records the pressing forces and the distance.
You should, however, evaluate the data regularly, so that anything learnt from it can promptly be used to modify the production process. Languages The ForceMaster 9110 can be set for operation in a number of languages. See Section 6.15 for the available languages. Support for automation The ForceMaster 9110 has a simple, freely programmable step chain controller, is supported in addition by a cam switching mechanism.
Front view of the ForceMaster 9110 Explanation Card reader Two-line display Folding feet Operating knob Red indicator lamp NOK Green indicator lamp OK Loudspeaker of 95...
Rear view of the ForceMaster 9110 Explanation Mains connection Mains switch Fuse Connection for USB stick (optional) Connection for load cell Connection for displacement sensor RS232 interface I/O interface USB connection for PC of 95...
Beep VST ^^^^^ Extract from the setting menu The menu structure of the ForceMaster 9110 has been kept simple. Like PC applications, there is a main menu. When you select a menu item, you are taken to a sub-menu. 3.10.2 Aids to orientation for operation Arrows that indicate the possible directions of rotation are provided on the lower right of the display, immediately next to the rotary knob, for better orientation in the menu.
Note There are menu functions that can be switched on or off. An asterisk (*) appears at the end of the line if the function is switched on, so that you can see the status straightaway. 3.10.3 Display and operating concept A single knob, which you can turn and press, serves as the operating element.
3.10.4 Entering text and numbers Text and numbers are input in order to make the settings in some of the menu items. Turn the operating knob to move the cursor to the location in the text that you want to change. Press the knob in order to select the text location.
3.11 Autoconfiguration Autoconfiguration allows two aspects of the ForceMaster 9110 to be dealt with quickly and easily. The ForceMaster 9110 detects the sensors that have been connected, and a teaching process takes place in order to find the optimum monitoring values for the parts to be checked.
3.11.2 "Step 1: teach-in" Always start the settings for a new part with a Teaching. Open the "Autoconfiguration" menu. Press the operating knob in order to select "Step 1 teach-in". The display now shows: "waiting: downwards". Carry out a pressing operation. After you have pressed a part, but before you move the punch upwards again, the display shows "waiting: upwards".
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Step 2 Set modes Force-displacement Means that force-displacement thresholds are thresholds monitored. Gateways Means that gateways specified in the force profile are monitored. No thread in force Means that there is no thread in force. Thread in force Means that there is an thread in force. No blocking force Means that no monitoring takes place in the blocking force region.
3.11.4 "Step 3: Set values" Set level Displacement low These values are to be set if you chose the "Force-displacement thresholds" item in Step 2. "Displacement low" is the beginning of the pressing phase. Displacement high The end of the pressing phase. Force low The force threshold, that the pressing force must at least reach.
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Set thread in force FIdisp high These values are to be set if you chose the "Thread in force" item in Step 2. "FIdisp" high is the final position, up to which the thread in force is monitored. FIforce high The threshold that the thread in force must not exceed.
Set the values of the blocking force monitoring Open the "Set values" menu. Turn the operating knob until the "Set blocking" menu item appears. Press the operating knob in order to select the menu item. Select the value that you want to set. Turn the operating knob in order to set the value.
There are three different memory cards, known as the MasterCard, ToolCard and PLCCard. If you want to write data to a card, the ForceMaster 9110 checks whether it is the correct card. You cannot, for example, store tool data to a MasterCard. In that case, an error message would appear on the display.
3.13 "PLC & IO" menu This menu is only present on the ForceMaster 9110 with the step chain option. The step chain is a very good way of automating small workstations economically. See Section 3.17 Schrittkettensteuerung for more information. You can make the following selections in the sub-menus: Reset PLC This sub-menu item resets the PLC.
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Reset PLC Open the "PLC & I/O" menu. Press the operating knob in order to select the "Reset PLC" menu item. See program Open the "PLC & I/O" menu. Turn the operating knob until the "See program" menu item appears. Press the operating knob in order to select the menu item.
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Delete program Open the "PLC & I/O" menu. Turn the operating knob until the "Delete program" menu item appears. Press the operating knob in order to select the menu item. Turn the operating knob until the "Yes" menu item appears. Press the operating knob in order to select the menu item.
Acknowledge error 3.14 "Cam" menu This menu is only present on the ForceMaster 9110 with the step chain option. The cams are an extension to the PLC. The PLC can query the electronic cams, and in that way control automation procedures.
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You can make the following selections in the sub-menus: Programming Next cam Select this sub-menu item in order to edit the next cam. Cam start Select this sub-menu item to set the beginning of the cam. Cam end Select this sub-menu item to set the end of the cam.
1 millisecond. The occurrence of the alarm is indicated by an error message. 3.16.1 Force alarm 1 Force alarm 1 is effective from top dead centre of the press onwards until the ForceMaster 9110 detects the trigger. Once the trigger point has been reached, this alarm can no longer be activated.
3.17 Step chain controller (option) The integrated step chain controller provides a good way of making even simple workstations more productive. The range of functions has been kept simple. The number of programming steps is limited to 60. The step chain controller operates according to the step chain principle. If the condition at the beginning of a line is satisfied, the command on that line is executed.
Press movement downwards: cam deactivation at 12.2 mm If the electrical power supply to the ForceMaster 9110 is to be used for switching, pins 1 and 2 must be bridged together, as must pins 25 and 24. An input is activated through an electrical contact from p 2 to the input pin.
Common contact for all inputs Supply voltage If the electrical power supply to the ForceMaster 9110 is to be used for external signals, pins 1 and 2 must be bridged together, as must pins 25 and 24. The procedure for setting the cams will be found in Section 6.4 Fehler! Verweisquelle konnte nicht gefunden werden..
3.19.2 I/O signal combinations "Force-displacement" measuring mode with gateways Signals Meaning A2 + A3 Force-displacement gateway error Measurement OK Force 1 or 2 has been exceeded (even if measurement has not started) Ready for measurement "Force-displacement" measuring mode with force thresholds, or "Force-time" Signals Meaning A2 + A3...
Otherwise it cannot be guaranteed that the measured values are correct. The sensors are only detected when switching on. Once the ForceMaster 9110 has been switched on, it is ready for use after about 10 seconds. • The welcome text "HELLO" appears on the display.
Initial commissioning Fitting the load cell to the manual press Push the supplied catch from the 5501-Z004 assembly kit from the peg side, over the load cell. Clamp the catch carefully (max. tightening torque 3 Nm) to the upper edge of the load cell.
Fitting the displacement measurement system (DMS) to the manual press Fit the adapter for the displacement sensor on the side of the press. Use the 5501-Z004 adapter from the assembly kit supplied. Adapter plate for displacement measurement system (DMS) on the press Push the displacement sensor with the probe tip downwards into the adapter (typical application).
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. The sensors are now mounted on the manual press and are mechanically adjusted for the parts that are to be pressed. Connect the sensors to the ForceMaster 9110. Switch the ForceMaster 9110 on. of 95...
When the pressing operation is complete, the numeric display shows "Step2 >set mode“. Turn the operating knob until you reach the following display. The ForceMaster 9110 has saved the values it has learned, and is ready for measuring. You can start production, with supervision. of 95...
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It may be necessary to correct the values learnt through the autoconfiguration. If necessary, these can be manually adjusted – see Section 3.11.3. of 95...
Measurement In measuring mode you can choose between various information windows. Press the operating knob to move from one window to the next. After the "Max. values" window, the current values appear again. You can choose between the following information windows: Measuring mode Current values In this window you see the current values for force...
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In measuring mode, an error that occurs during the pressing operation is shown immediately as a message on the display. You must acknowledge this error message (with or without MasterCard, depending on the setting). After acknowledging the error the selected information window appears again.
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Error messages and their meaning Internal Displayed Full text Meaning fault text number Pdisp too Peening The relative peening displacement was small displacement too smaller than specified. small Pdisp too Peening The relative peening displacement was large displacement too larger than specified. large Thread in threshold The thread in force was larger than...
Configuring the ForceMaster 9110 settings You can only reach the settings menu if the MasterCard is inserted in the card reader. Opening one of the sub-menus Insert the MasterCard into the card reader with the contacts pointing towards the display.
"Counter" menu You can make the following settings in the Counter sub-menu: display OK parts Number of good parts NOK parts Number of bad parts Total parts Total of all parts Down counter Status of the down counter D-set Initial status of the down counter Tot.
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Clearing the parts counter Open the "Counters" menu. Turn the operating knob until the "Clear" menu item appears. Press the operating knob in order to select the menu item. Press the operating knob in order to select "Parts count". The message "Parts counter cleared" appears. Press the operating knob to acknowledge the message.
Note The USB stick must be formatted as FAT. This permits a maximum storage capacity of 2 If a large quantity of data is already stored on the stick, the ForceMaster 9110 takes longer to establish its data structure. For fast working, the stick should contain is little data as possible. Existing data is basically of no concern.
6.2.2 "USB stick" menu You can make the following settings in the "USB stick" menu: USB status USB module "OK" means that a USB module is present, and is working properly. "NOK" means that either no USB module is present, or that it is faulty. USB stick "OK"...
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Note that the ForceMaster 9110 is not able to measure during the recording time. The graphic files also take up a great deal of space on the stick.
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Setting that measurements are also possible without a USB stick Open the "USB stick" menu. Turn the operating knob until the "Without stick: OK" menu item appears. Press the operating knob in order to select the menu item. Setting that measurements are only possible with a USB stick Open the "USB stick"...
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Interrupting storage of all measurement curves on the stick Open the "USB stick" menu. Turn the operating knob until the "All C -> STOP" menu item appears. Press the operating knob in order to select the menu item. of 95...
6.2.3 Data storage example Text in the data store Meaning 15:36:27 11_02_10 10334455 9.014 Time, date, Snr.FM, Vers.SW. FM Order data PART.NO Part number ORDER.NO Order number ORDER.REF Order reference CUSTOMER Customer name Limits Recording time[1], IO marker[2], error number[3] 52 1000 Sensor displacement max., sensor force max.
"PLC & IO" menu This menu is only present on the ForceMaster 9110 with the step chain option. The step chain is a very good way of automating small workstations economically. See Section 3.17 Schrittkettensteuerung for more information. You can make the following selections in the sub-menus: Reset PLC This sub-menu item resets the PLC.
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Reset PLC Open the "PLC & I/O" menu. Press the operating knob in order to select the "Reset PLC" menu item. See program Open the "PLC & I/O" menu. Turn the operating knob until the "See program" menu item appears. Press the operating knob in order to select the menu item.
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Press the operating knob in order to select the menu item. Delete program Open the "PLC & I/O" menu. Turn the operating knob until the "Delete program" menu item appears. Press the operating knob in order to select the menu item. Turn the operating knob until the "Yes"...
Acknowledge error "Cam" menu This menu is only present on the ForceMaster 9110 with the step chain option. The cams are an extension to the PLC. The PLC can query the electronic cams, and in that way control automation procedures.
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You can make the following selections in the sub-menus: Programming Next cam Select this sub-menu item in order to edit the next cam. Cam start Select this sub-menu item to set the beginning of the cam. Cam end Select this sub-menu item to set the end of the cam.
You read a PLC card with this sub-menu item. The data saved on this card is then used in the ForceMaster 9110 as the PLC program. At the same time the cam data saved on this card is written to the device memory.
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Reading the ToolCard Open the "CARD" menu. Press the operating knob in order to select the "Read" menu item. Take the MasterCard out of the card reader, and insert the ToolCard that you want to read. Press the operating knob in order to select the "Tool C" menu item. The message "CARD read"...
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Writing to the PLCCard Open the "CARD" menu. Turn the operating knob until the "Write" menu item appears. Press the operating knob in order to select the menu item. Take the MasterCard out of the card reader, and insert the PLCCard onto which you want to write the current PLC program.
"Manual settings"" menu. You can make the following selections in the sub-menus: TR FO You can set the trigger point for the value of the force through this sub-menu item. You should, however, have enough experience of monitoring the pressing force to make this setting sensibly.
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Setting force alarm 1 Open the "Manual settings" menu. Turn the operating knob until the "FO alarm 1" menu item appears. Press the operating knob in order to select the menu item. Turn the operating knob as long as necessary to see the value that you want to set.
"Error signals" menu Warning Only use the highest volume level in a working environment where hearing protection is obligatory. There is a risk of hearing damage. You can make the following selections in the sub-menus: Error signal single beep In this sub-menu you can choose the sound with which the device reacts to a pressing error.
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The large number of error signals makes it possible to detect quickly the device that is signaling an error in an environment with several ForceMaster 9110s. Setting the type of error signal Open the "Error signal" menu. Press the operating knob in order to select the "Error signal" menu item. Turn the operating knob as long as necessary to see the type of error signal that you want to set.
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Switching off the warning tone Open the "Error signal" menu. Turn the operating knob until the "Beep off" menu item appears. Press the operating knob in order to select the menu item. of 95...
"Order data" menu This data appears in the printout, and is written into the USB stick. It is also available in measuring mode. You can make the following selections in the sub-menus: ItemNo You can enter the text for the item number here. The text appears on printouts, and in the Excel table of the job memory.
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Entering the item designation Open the "Order data" menu. Turn the operating knob until the "ItemDes" menu item appears. Press the operating knob in order to select the menu item. Enter the item number. See Section 3.10.4, Fehler! Verweisquelle konnte nicht gefunden werden..
"Statistics" menu This menu is purely an information window. The time for the statistical information begins when the setting menu is closed, and stops when the measurement menu is closed. You can retrieve the following information in this menu: Statistics Parts per hour Parts per minute Time per part...
FS. Autoconfig When you start an autoconfiguration, the ForceMaster 9110 takes the force as a trigger in order to detect when the pressing process starts. This standard figure is for this force to be 5% of the sensor's rated value.
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This is useful when settings have been made in the various sub-menus that are inappropriate. After the standard settings have been restored, the ForceMaster 9110 is again in the state in which it was shipped. Setting the displacement measurement for the sensing pin in compression Open the "Internal settings"...
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Triggerkraft einstellen Open the "Internal settings" menu. Turn the operating knob until the "FS autoconfig" menu item appears. Press the operating knob in order to select the menu item. Press the operating knob in order to select the "Force level" menu item. Turn the operating knob in order to set the value that you want.
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Changing the displacement unit Open the "Internal settings" menu. Turn the operating knob until the "Display format" menu item appears. Press the operating knob in order to select the menu item. Turn the operating knob until the "Displacement" menu item appears. Press the operating knob in order to select the menu item.
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Adjusting the UTK Open the "Internal settings" menu. Turn the operating knob until the "Adjust the UTK" menu item appears. Press the operating knob in order to select the menu item. Bring the UTK sensor with the shaft to a position at which the entire transit path of the press is continuously displayed.
6.11 "Date & time" menu You can make the following selections in the sub-menus: Date The date is needed by the ForceMaster 9110 for printouts, for the job memory, and for monitoring the calibration intervals. Choose this menu item in order to set it.
6.12 "Status" menu This menu is purely an information window. You can retrieve the following information in this menu: Status Firmware version Software version Version date Version time Select the "Status" menu. Turn the operating knob until the information you want appears. 6.13 "Languages"...
Force-displacement curves Example of a pressing curve: The thread in region is represented as a red rectangle at the start of the curve, and the blocking region as a red square at its end. The red bars symbolize the gateways. Abbreviations: = displacement start = trigger...
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The press moves in the direction of the workpiece, without any force being developed. It is not necessary to monitor the force in this region. If the ForceMaster 9110 is being used in automatic presses, the Alarm force 1 can be used for collision monitoring. (See Section 3.16 Kraft-Alarme).
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Region 2 The press meets the workpiece. This is a critical moment. In many cases an increased force occurs here, since the part that is to be pressed in must be fed into the lower part of the workpiece. That is why we refer to this force as the thread in force. It is sometimes useful to monitor the thread in force.
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Region 3 The thread in operation is complete. The force will rise, since the frictional forces of the parts being pressed gets greater and greater. The force can vary both upwards and downwards. This is a result of surface roughness and the effects of lubricating media such as cooling agent from the machining, or even skin grease from touching the parts.
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Abbreviations: = displacement start = trigger = measurement start = measurement end KSU = force threshold below KSO = force threshold above = block start = block end BSU = block threshold below BSO = block threshold above = end thread in ESO = thread in threshold above Key: Region...
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The block threshold above (BSO) must not be exceeded, since otherwise manufacturing tolerances will be violated. Monitoring parameters for case 2: In this case there are no force thresholds, since the tool finishes the insertion displacement. The displacement is, however, must be monitored, in order to detect exceeding the manufacturing tolerances.
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Block window Gateway Special case: Force monitoring only If no displacement sensor is attached to ForceMaster 9110, none of the monitoring regions can be used, since the ForceMaster 9110 cannot establish a relationship between force and displacement. There is only, therefore, a force threshold below (KSU) and a force threshold above (KSO).
Technical data General device data • Display: 2-line illuminated LCD display • Warding and acknowledgement tones: adjustable signal type • Warning tone volume: up to 75 dB Measurement channels: Force/displacement or force/time • • Interface: USB, RS232 Mains connection 90 ... 240 V AC / 50 ... 60 Hz •...
The press has force and displacement sensors mounted on it for this purpose. These sensors supply a measurement signal to the ForceMaster 9110. It evaluates the profile of the force in relation to displacement. If the values exceed or fall below specified limits, the pressing operation is reported as faulty.
Choosing the right displacement sensor The stroke of your press is crucial for the choice of displacement sensor. If the press has a stroke and 50 mm, you can get a 50 mm displacement sensor from us. Note, however, that the smallest resolution step for a 50 mm displacement sensor is 0.0125 mm (measured displacement/4000).
Available accessories • 9110-Z001 MasterCard for full configuration access • 9110-Z002 (PLC card, storage of PLC step chain procedures) • 9110-Z003 (Tool card for storing the tool data and measuring programs) • 8552 Load cell • 5501-Z004 Assembly kit for displacement sensors on manual presses •...
Ordering example • ForceMaster with PLC function and USB logging, setting up and evaluation software (under preparation) Type 9110-V0101 Order code ForceMaster 9110 V Standard Options Step chain function USB stick logging Accessories • Assembly kit for easy assembly of the displacement sensor to the manual press Type 5501-Z004 •...
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