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Sturtevant Richmont Programmable Torque Verifier FM II Owner's Manual

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Sturtevant Richmont
Global Reach. Local Support.
Programmable Torque Verifier FM - Generation II
Owner's Manual
Sturtevant Richmont Div. Ryeson Corporation
3203 N. Wolf Road Franklin Park, IL 60131
P/N: 857234A
Phones: 847/455-8677 800/877-1347
Rev.: A
Fax: 847/455-0347
URL: www.srtorque.com
Date:May 30, 2003
E-mail: CustomerService@srtorque.com

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Summary of Contents for Sturtevant Richmont Programmable Torque Verifier FM II

  • Page 1 Sturtevant Richmont Global Reach. Local Support. Programmable Torque Verifier FM - Generation II Owner's Manual Sturtevant Richmont Div. Ryeson Corporation 3203 N. Wolf Road Franklin Park, IL 60131 P/N: 857234A Phones: 847/455-8677 800/877-1347 Rev.: A Fax: 847/455-0347 URL: www.srtorque.com Date:May 30, 2003...
  • Page 2 Thank you for choosing for your assembly solution! The Programmable Torque Verifier FM - Generation II is simple to operate once you have become familiar with it. We encourage you to read this manual carefully and use it when setting up and operating your new unit. Should you need any additional support, please contact us via e-mail, phone, or fax, or visit our website: www.srtorque.com.

  • Page 3: Table Of Contents

    Table of Contents Chapter Page Chapter 1 - Introduction to the PTVFM Generation II ......3 Chapter 2 - Principles of Operation .
  • Page 4 Page 2...

  • Page 5: Chapter 1 - Introduction To The Ptvfm Generation Ii

    Chapter 1 - Introduction to the PTVFM Generation II Photograph 1 Key to Photographs 1 through 4 1. Antenna Mount 2. Case 3. Front Panel Screws (4) 4. Faceplate 5. Key Lock 6. Beeper 7. Run LED 8. Setup LED 9.
  • Page 6 Photograph 2 Photograph 3 Page 4...
  • Page 7 Antenna Mount The antenna mount is where the antenna (20) is attached to the unit. The antenna receives the FM radio signal from the FM Switch Wrenches. Case The case houses all of the electronics components. It is made of steel and has a black crinkle finish.
  • Page 8 Reject LED The red reject LED lights when the FM Switch Wrench has been pulled for more than the maxi- mum specified period of time for the programmed requirements for the fastener. This almost always means the fastener has been overtorqued. When this LED is lit, the fastener must be loosened, then properly torqued.
  • Page 9 Parameter Select Switch The parameter select switch allows the user to select which set of parameters the PTV-FM is to use. A set of parameters includes: FM Switch Wrench (one only per parameter), FM channel (1 channel only per parameter) minimum pull time, maximum pull time, TBC (Time Between Clicks), TBB (Time Between Batches), and the number of fasteners in each batch.
  • Page 10 How to Distinguish First Generation PTV-FM Units from Generation II PTV-FM Units First Generation Generation II Attached Power Cord Separate Power Cord No Power Entry Module Power Entry Module on right side of unit. No Parameter Select Switch Parameter Select Switch on left side of unit. Delivered through 4/15/03.

  • Page 11: Chapter 2 - Principles Of Operation

    Chapter 2 - Principles of Operation Overview The PTV/Switch Wrench System is designed to assist the manufacturer in closing several loops in the quality system which have been, until now, gaps in their quality improvement efforts. The key capabilities this system enables: 1.
  • Page 12 quality-conscious assembler. The probability of occurrence rises with any lack of attention, train- ing, or experience - individually and in combination. On assemblies with multiple fasteners, the previously-listed failure modes that exist for each fas- tener are joined by a fourth failure mode: Failure to torque all fasteners.
  • Page 13 By determining the correct amount of time a wrench should spend in the “clicked” position on any given joint, we can rule out any shorter or longer peri- od in that position as unacceptable. Diagram 2 depicts the addition of mini- mum and maximum acceptable times for the wrench to be in the “clicked”...
  • Page 14 Diagram 5 shows the signal from a wrench that was pulled past the click, most likely overtorquing the fastener. The time the wrench spent in the clicked position exceeds the maximum allowable time for that joint. This fas- tener is rejected for overtorque. The PTV-FM works with the FM Switch Wrench to bring systematized control to the use of manu- al torque wrenches.
  • Page 15 The PTV-FM reduces the probability of missing a fastener in a multi-fastener assembly in two ways: 1. Displaying the count of properly-torqued fasteners (or quantity remaining to be torqued) in the batch at all times. 2. Sending a “Batch Accept” signal to the PLC and an audible signal to the operator when the correct number of fasteners on the assembly has been properly tightened.
  • Page 16 First Example In this drawing we see the product to be assembled, and the three fasteners to be tightened at this assem- bly station. The operator has been provided with an FM Switch Wrench preset to the proper torque for the three fasteners.
  • Page 17 The operator then tightens the third fastener in the series, but uses the torque wrench incorrectly by pulling past the click. This results in the red Reject LED lighting on the PTV, and the beeper going off. The count does not advance, since the wrench was not used properly.
  • Page 18 This requires the use of two different FM Switch Wrenches, each set to a different torque. It also uses the multiple parameter capability of the Generation II PTV-FM. This is not done just because of the two wrenches required, but also because the soft joint requires a different time to work properly.
  • Page 19 6. On Nut #5 the operator inadvertently jerks the wrench. Since there is no green Accept LED lit and the count did not advance, he knows he must retorque the fastener. He loosens the fastener, then properly retorques it. The green Accept LED lights and the count advances from 2 to 3 on the LED Panel.
  • Page 20 Page 18...

  • Page 21: Chapter 3 - Installation

    Chapter 3 - Installation Installation Considerations The PTV-FM and FM Switch Wrenches use FM radio to communicate with each other. The PTV-FM uses PLC cables to communicate with the rest of the facilitys' IT structure. The PTV- FM communicates with the operator via visual and audio devices, and requires electric power. The above, and the constraints they impose,must be taken into consideration when determining where and how to install the PTV-FM.
  • Page 22 4. Remove the Power Setting Notice from the case. 5. Check the voltage window on the Power Entry Module. It should display "110V". A. If the window does not display "110V", there are two options available. 1. Use a different power source that is 220 VAC. 2.
  • Page 23 Changing the Power Setting A. Obtain a flat tip screwdriver. B. Locate the Power Entry Module on the lower half of the right side of the PTV. C. Insert the tip of the screwdriver under the Tab of the Fuse/Voltage Selector Holder. D.
  • Page 24 Replacing the Fuse A. Obtain a flat tip screwdriver. B. Locate the Power Entry Module on the lower half of the right side of the PTV. C. Insert the tip of the screwdriver under the Tab of the Fuse/Voltage Selector Holder. D.

  • Page 25: Chapter 4 - Programming The Generation Ii

    Chapter 4 - Programming the PTV-FM Generation II Programming the PTV-FM is performed via the keyswitches on the faceplate of the unit. The keyswitches work individually and in conjunction with each other to set the various components of each parameter. There are noticeable changes in programming the Generation II over the first generation of the PTV-FM.
  • Page 26 1. The number of fasteners on the assembly 2. The minimum acceptable time (duration) of signal for the joint. 3. The maximum acceptable time (duration) of signal for the joint. 4. The minimum time required between wrench cycles (clicks). 5. The minimum time required between batches (groups of fasteners). 6.
  • Page 27 8. When the PTV receives a signal from the wrench, it will display first the channel on which it received the signal, then the strength of the signal ("GOOD"). 9. Press the UP keyswitch to get to the Time Between Batches. The LED Display will show: 10.
  • Page 28 UP keyswitch to move to the next element of the parameter. 17. The next element is the Time Minimum for the minimum time the wrench should be in the cycled or clicked position for each acceptable use of the wrench. This element of the param- eter is shown as TMIN on the LED Display.
  • Page 29 The ones column digit will begin flashing. Use the UP and DOWN keyswitches to display the desired selection, then press the SET keyswitch to lock in the last digit and return to the BATCH element. Press the UP keyswitch to go to the next element. 22.
  • Page 30 26. All elements of the selected parameter have been programmed. Turn the Key to the LOCK position to leave the Programming Mode and re-enter the Operating Mode. The display will then show the parameter and the number of fasteners tightened in the batch so far (0), in the format "A.

  • Page 31: Chapter 5 - Operating The Ptv-Fm Generation Ii

    Chapter 5 - Operating the PTV-FM Generation II The Generation II is much simpler to operate than the first generation of PTV-FM once program- ming and communications have been established. When the unit is first turned on it is in Operating Mode. The active parameter and the number of fasteners correctly tightened are displayed on the LED Display, and the green Accept LED is lit.
  • Page 32 1. If the second click occurs so rapidly after the first click that signal processing is still occur- ring, the result may be a TMAX rejection. The signal has been treated as one click that is longer than the allowed maximum time. Example: TMAX 2.

  • Page 33: Chapter 6 - Fm Communications

    Chapter 6 - FM Communications Principles The PTV-FM and FM Switch Wrench work together as a system using FM radio signals in the 900 MHz band as the medium of communication. There are several ramifications to this: 1. The FM Switch Wrench must have a useable battery in it. 2.
  • Page 34 Selecting the channel on the Generation II is covered in Step 23 of the programming procedure in Chapter 3 of this manual (Page 27). As an element of each parameter, it is readily accessible in the Program mode and can be changed in less than one minute. All FM Switch Wrenches are shipped from the factory with all three jumpers installed.

  • Page 35: Chapter 7 - Plc Communications

    Chapter 7 - PLC Communications The PTV-FM Generation II has a 19-pin female Amphenol Connector to facilitate communication with PLC’s used for line control and other functions in assembly operations. The location of the connector is shown on Page 4 of this manual. The schematic diagram below shows the proper use of each pin and the code for it.
  • Page 36 Page 34...

  • Page 37: Chapter 8 - Frequently Asked Questions

    Chapter 8 - Frequently Asked Questions Can multiple PTV-FM units be used in close proximity to each other without crosstalk? Yes. There are several built-in safeguards to preclude the problem of crosstalk. The first of these is the use of eight FM channels. Simply using different channels on units in close proximi- ty effectively eliminates the problem.