Atlas Copco STB User Manual
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Atlas Copco STB User Manual

Atlas Copco STB User Manual

Static transducer bench
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User Guide
STB (Static Transducer Bench)
Atlas Copco Industrial Technique AB
9836 3078 01
Edition 2.11
2017-11

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  • Page 1 User Guide STB (Static Transducer Bench) Atlas Copco Industrial Technique AB 9836 3078 01 Edition 2.11 2017-11...
  • Page 3 STB (Static Transducer Bench) User Guide Revision history Revision history Reference Revision Date Author Description Minimum Software version 2007-01 14-02-2007 M. Grippa New Edition 2007-02 05-09-2007 M. Grippa Test Setup section updated 2008-01 12-02-2008 M. Grippa Introduction review Tool calibration function from Torque...

  • Page 4: Table Of Contents

    Copyright Atlas Copco Industrial Technique AB NOTE: This User Guide may be altered without further notice. For further information log on to the Atlas Copco website: www.atlascopco.com NOTE: In case of conflicts between translations of this User Guide, always refer to the official English version.
  • Page 5 STB (Static Transducer Bench) User Guide Table of Contents Ethernet Port ......................23 Serial Port RS232 ....................23 PC Reset Switch ....................24 3.10 Main Panel ......................24 3.10.1 Power supply / batteries ..................25 3.11 Hardware Protection Key: System Backup ............. 26 EXECUTING A FREE TEST .................

  • Page 6: Safety Information

    WARNING: PLEASE READ CAREFULLY THE SAFETY INFORMATION (No. 9836 5531 00) PRIOR TO USE THE PRODUCT AND PAY ATTENTION TO THE SAFETY INSTRUCTIONS PROVIDED. THE DOCUMENT IS APPLICABLE TO THE STB EXCEPT FOR THE HYDRAULIC COMPONENTS NOT PRESENT IN THIS BENCH. 6 (82)

  • Page 7: Batteries Information According To European Regulation 2006/66/Ec

    WARNING: All the service activities, including those related to maintenance of the batteries, must be executed only by Atlas Copco service personnel who has been properly trained. NOTE: Once removed, the wasted batteries must be dismissed according to local regulations.

  • Page 8: Introduction

    Introduction STB (Static Transducer Bench) User Guide INTRODUCTION About This Document This document is a User Guide for the STB and it is divided into the main following parts: Part Name Description Chapter 1 Introduction This part introduces this User Guide and details bench technical specifications.

  • Page 9: Reference Documents

    Reference Documents The following is a list of important documents useful for a complete view of the product in all its applications:  STB Safety Instructions (No. 9836 5531 00): Multilanguage safety instructions and declaration of conformity  BLM Torque Seminar ...
  • Page 10  Battery Fuses: 2 fuses 25A 500 VAC type gG  Industrial PC  Indication “Low battery”  Dimensions / Weight of the STB (Static Transducer Bench): 1.55m (h) x 1.15m (w) x 0.53m (d) for standard version, max 250 kg INTERFACES ...

  • Page 11: Ec Declaration Of Conformity

    Atlas Copco BLM is an ACCREDIA calibration center. EC Declaration of Conformity The STB Benches are in conformity with the requirements of the council Directives on 06/22/1998 on the approximation of the laws of the Member States relating:  2006/95/EC LVD - Low Voltage Directive ...

  • Page 12: Stb Overview

    Since it is powered by batteries, the test bench may be used at any point along the assembly line. Special PC software (Torque Supervisor) is available to allow the STB to be programmed with the tests to be carried out during the week, and to receive their results. This software has been specifically developed...
  • Page 13 The tests carried out are therefore fully traceable, including the X/R cards and the "history" of the tool, an indispensable requirement for compliance with the standard ISO 9000. Contact your Atlas Copco sales for any further information regarding this software.
  • Page 14 STB Overview STB (Static Transducer Bench) User Guide An additional box is delivered with the bench: This box contains safety instructions, manuals, certificates, passwords for software and other important documents. It should be removed and kept in a safe place by the bench administrator.
  • Page 15 STB (Static Transducer Bench) User Guide STB Overview USB Recovery Key, containing the backup of the bench factory configuration. This key must be kept in a safe place, and must be available for service personnel during bench maintenance activities. On the bench monitor desktop there are links to the main software(s) and some folders containing bench...

  • Page 16: Stb Versions

    STB Versions The STB bench family includes different options and versions. The software and functions are the same described in this manual. For customized bench with special software functions or additional components; refer to this user guide and also to the specific attachment describing the customized functions.

  • Page 17: Stb Ad Standard

    STB AD standard This is the standard bench version. The most typical customization is the number and capacity of transducers. 2.1.2 STB AD with custom keyboard and monitor Monitor This version features a smaller chassis, a monitor 12”, and a tiltable keyboard installed outside the drawer.

  • Page 18: User Interfaces

    STB (Static Transducer Bench) User Guide USER INTERFACES Static transducers The standard STB bench features a set of static transducer SRTT-B: Static transducers are designed to test:  Impulse power tools. When the impulse tool has a shut-off valve, a mechanical joint simulator is required.

  • Page 19: Mechanical Joint Simulators

    STB (Static Transducer Bench) User Guide User Interfaces NOTE: For old benches, a static cell was installed instead of the SRTT-B: The test philosophy on the static cell is the same of the one for SRTT-B. However, the static cells are threaded and require the specific mechanical joint simulator (when a joint simulator is needed).

  • Page 20: Lcd Monitor With Touch Screen

    STB (Static Transducer Bench) User Guide LCD Monitor with Touch Screen The STB is equipped with a LCD monitor with touch screen. To use all of the functions described in this manual, the touch screen can be used to manage all of the operation (the bench keyboard/mouse, or external keyboard/mouse can be used as well).

  • Page 21: Keyboard

    STB (Static Transducer Bench) User Guide User Interfaces Keyboard Keyboard Together with the touch screen, the keyboard can be used as well to input data and to manage the bench software. The keyboard includes also an embedded mouse. A virtual keyboard is also installed on the monitor:...

  • Page 22: External Transducers Connectors

    User Interfaces STB (Static Transducer Bench) User Guide External Transducers Connectors External transducers (Torque, Torque/Angle (encoder)) can be connected to the bench to execute a test. The number of external transducer connector varies according to the bench version. Description Description...

  • Page 23: Usb Ports

    STB (Static Transducer Bench) User Guide User Interfaces USB Ports The USB 2.0 ports can be used to connect external mouse, keyboard, or USB memory devices. Ethernet Port The Ethernet port can be used to connect the bench to the network. A typical application is to program or download data from benches using Torque Supervisor Client.

  • Page 24: Pc Reset Switch

    3.10 Main Panel Hereunder is the standard main panel of the STB (Static Transducer Bench): Press START switch for 5 seconds to start bench operations: the PC starts the software automatically. Press STOP to turn off the bench.

  • Page 25: Power Supply / Batteries

    STB (Static Transducer Bench) User Guide User Interfaces 3.10.1 Power supply / batteries The bench is powered by batteries characterized by an operative endurance equal to 16 hours (2 work shifts). Perform the following procedure in order to recharge the batteries: - Connect the bench with the AC Power socket (100 ÷...

  • Page 26: Hardware Protection Key: System Backup

    Battery is not charging Battery charger fault: fuse burnt 3.11 Hardware Protection Key: System Backup The STB (Static Transducer Bench) contains a hardware protection USB key; which provides the following features:  System backup: Test bench settings and calibration data.
  • Page 27 STB (Static Transducer Bench) User Guide User Interfaces NOTE: The user profile provided by hardware protection key does not have access to the bench calibration and advanced bench settings. This key performs different backups:  Daily backup  Weekly backup ...
  • Page 28 When a backup or a restore is executed, a password is required. The default passwords are provided with the test bench. Atlas Copco strongly recommends to change these passwords: The Admin and Operator passwords allow the same functions; the only difference is that the Admin password allows also to change the two passwords.

  • Page 29: Executing A Free Test

    Free Test Launches the test interface window. For the user this button opens the external transducers setup window (refer to the paragraph “External Transducers Setup”). For Atlas Copco service personnel this allows Setup bench settings and calibration. Opens the window for viewing traces. Refer to the paragraph “Traces Viewer” for further Traces details.
  • Page 30 Executing a Free Test STB (Static Transducer Bench) User Guide The following icon on the PC desktop can be use to restart the software if manually closed: Click Free Test to start a measurement: The following window is shown: Standard Click to execute a free test.
  • Page 31 STB (Static Transducer Bench) User Guide Executing a Free Test Click Standard. The following window is shown: Nom. Torque Torque value for the tool under test (select also the desired Measurement Unit). Transducer Number Transducer of the bench on which the test is run.
  • Page 32 Executing a Free Test STB (Static Transducer Bench) User Guide Click Start Test to start the tool testing. The tool test window is displayed, and a test bar is shown in the bottom area of the screen: Test results area (test n. 0 is...

  • Page 33: Testing Wrenches

    Testing Wrenches All type of wrenches can be test by the STB. Having the static cell mounted in a vertical position and the wrench tested always in the horizontal position, the prescriptions of the ISO regulations about wrench testing are satisfied.
  • Page 34 Executing a Free Test STB (Static Transducer Bench) User Guide This menu can be accessed by a proper bench administrator password, provided with the test bench documents delivered with the bench. Select Wrench tab (as shown in the above figure). The first peak function is used to detect the click point of the wrench (for click point adjustment or to measure the wrench Cm-Cmk).
  • Page 35 STB (Static Transducer Bench) User Guide Executing a Free Test The first peak is measured if there is a drop in torque (due to the cut-out of the clutch); the drop must be less than the “2 %” and over the percentage the “1 %”...
  • Page 36 Time out, the test ends. The Time out is given in milliseconds. Tout (msec) NmAng and Angle Computation Method These parameters are not used by the STB 36 (82) 9836 3078 01 Edition 2.11...

  • Page 37: Testing Impulse Tools

    STB (Static Transducer Bench) User Guide Executing a Free Test Testing Impulse Tools WARNING: Impact tools cannot be tested on the STB Benches. Pulse tools do not provide a continuous torque output but they generate single high energy pulse of very short duration ( 1ms). This series of pulses results in the tightening of a fastener.
  • Page 38 Executing a Free Test STB (Static Transducer Bench) User Guide For the impulse tools the test window shows an additional parameter: The Att. Coeff. Can be used to correct the difference between the torque measured on the bench and the residual torque measured on the real joint;...

  • Page 39: Impulse Tools Test Setup

    STB (Static Transducer Bench) User Guide Executing a Free Test 4.2.1 Impulse tools test setup The test parameters for Impulse tools can be customized in the Test Setup menu: This menu can be accessed by a proper bench administrator password, provided with the test bench documents delivered with the bench.

  • Page 40: Testing Power Tools

    The mechanical joint simulator on the static cell reproduces the behavior of a joint. Refer to the official Atlas Copco price list, published and updated every year, for the list of the available mechanical joint simulators from Atlas Copco.

  • Page 41: Power Tools Test Setup

    STB (Static Transducer Bench) User Guide Executing a Free Test 4.3.1 Power tools test setup The test parameters for power tools (divided into 1-Step and 2-Steps tools) can be customized in the Test Setup menu: This menu can be accessed by a proper bench administrator password, provided with the test bench documents delivered with the bench.
  • Page 42 Executing a Free Test STB (Static Transducer Bench) User Guide The first peak is detected if it occurs over the 1 % (measured on the maximum torque), and if the drop in the torque goes below the 2 % (measured on the first peak).

  • Page 43: External Transducers Setup

    External Transducers Setup EXTERNAL TRANSDUCERS SETUP Most of the tests on the STB are performed directly on the bench transducers. However, it is possible to connect an external transducer connected to one of the external transducer connectors. This can be used, for example, in the following cases: ...
  • Page 44 Encoder Impulse Number of pulses for encoder. Since the STB Benches measure the rising and falling edges of both the signals from the encoder, the number specified on the transducer must be multiplied by 4. Example for IRTT-B 75 Nm: 256 (specified on the transducer label) x 4 = 1024...
  • Page 45 For instance, in a standard STB bench you can define 11 external transducers, assigning each one to a different Cell. The Channel associated with the Cell defines to which external connector of the bench the transducer must be connected.
  • Page 46 External Transducers Setup STB (Static Transducer Bench) User Guide At the time of the test, connect the IRTT-B 25 Nm with connector XDUC 6 and select Transd. No. 5 (Cell 5): Transd. No. 5 selects Cell 5 To select the IRTT-B 75 Nm, Transd. No. 6 must be selected and IRTT-B 75 Nm is connected with connector XDUC 8 (Channel 8).

  • Page 47: Traces Viewer

    STB (Static Transducer Bench) User Guide Traces Viewer TRACES VIEWER After each test, by selecting Torque/Time Graph, the graph window appears: Sampling Frequency Zoom cursors Torque/time trace - Green: unfiltered trace Pointer - Black: filtered trace Pointer data The graph shows the torque versus the time.
  • Page 48 Traces Viewer STB (Static Transducer Bench) User Guide Filter Click to change the filter parameters: Click Edit to change the default cut frequency. In the box at the top of this window choose between a filter of the third or fifth order.
  • Page 49 Set to On Save Set to On the Debug Modeswitch and click Save. The traces can be viewed and edited by the Atlas Copco software Curve; ask to your Atlas Copco sales reference for more information. 9836 3078 01 Edition 2.11...

  • Page 50: Test Report

    Test Report STB (Static Transducer Bench) User Guide TEST REPORT After a set of minimum ten tests in the free test mode, it is possible to create a test report: Results Delete the selected result Create report In the results area, before generating the report it is possible to view the results. Click Delete Value to cancel the highlighted result in the list.
  • Page 51 Export results to file (.csv format) At the end of the report the statistic results are shown: Statistics If the STB is equipped with a dedicated printer for report printing, the report can be printed directly on the bench. 9836 3078 01 Edition 2.11...

  • Page 52: Working With Torque Supervisor

    Torque Supervisor software is the perfect solution for scheduling calibration and supervising your tool stock. Compatible with other Atlas Copco products, it manages the control routes for each shift at each test bench, keeps calibration expiry dates under control for each and every power tool and torque wrench, and collects quality control data (initial breakaway).
  • Page 53 STB (Static Transducer Bench) User Guide Working with Torque Supervisor When exchanging data with Torque Supervisor Full, the bench must be connected to the network (it can be disconnected then for test execution), and FTP Server Benchmust be always running on the bench: FTP Server icon Do not disable the application.
  • Page 54 Working with Torque Supervisor STB (Static Transducer Bench) User Guide For pulse tools, the Atten. Coeff. (Attenuation Coefficient, stored inside Torque Supervisor) is displayed. Click Start Test to start the test: Shown graph (refer to the paragraph “Traces Viewer” for further details) 54 (82) 9836 3078 01 Edition 2.11...
  • Page 55 STB (Static Transducer Bench) User Guide Working with Torque Supervisor When a statistic control test is run, the following window is shown: Test result Non-compliance message(s) Once the specified number of tests for the statistic control has been completed, the result is displayed.
  • Page 56 Working with Torque Supervisor STB (Static Transducer Bench) User Guide Below are the possible test results: IAGNOSIS URTHER ACTION USABILITY Can be The tool works properly. None used Can be The mean is higher than the nominal torque, Calibrate, reducing used but does not exceed the control limits.
  • Page 57 STB (Static Transducer Bench) User Guide Working with Torque Supervisor When a Cm-Cmk test is run and the double test option is enabled (typically this can be set by Torque Supervisor), the graph and the results area show the bench and tool readings at the same time: The Wirkungsgrad is calculated for every test as the ratio of Torque to Tool Torque;...

  • Page 58: Tool Calibration Function

    Working with Torque Supervisor STB (Static Transducer Bench) User Guide Tool Calibration Function The tool calibration is a function provided by Torque Supervisor to calibrate the tool controller. The minimum version for Torque Supervisor is 3.9r The test consists in a series of test on the tool in order to calculate the new calibration coefficient for the controller.
  • Page 59 STB (Static Transducer Bench) User Guide Working with Torque Supervisor After each test the following window appears: The torque value measured by the bench is shown; the torque value read by the tool controlled must be entered manually. Enter the torque measured by the tool controller value and click Enter to confirm.
  • Page 60 Working with Torque Supervisor STB (Static Transducer Bench) User Guide The Old Coefficient field shows the actual calibration value; if the actual calibration value is not stored in Torque Supervisor, the Edit Old button is shown and the value must be entered manually: After entering the old coefficient, the new one is shown.
  • Page 61 STB (Static Transducer Bench) User Guide Working with Torque Supervisor If the new calibration value is over the limit defined into Torque Supervisor (test marked as NOT PASSED) a warning message alerts the user asks to confirm or not the new value: If the new calibration value is almost the same of the previous one, the tool is considered as already calibrated.

  • Page 62: Power Focus / Powermacs Calibration

    The procedure described in the previous paragraph can be run in automatic mode when calibrating the Power Focus. It is possible to calibrate the only the Power Focus with Tensor ST or STB. The torque reading by Power Focus is automatically sent to the bench, and the bench automatically saves the new calibration coefficient inside Power Focus.
  • Page 63 STB (Static Transducer Bench) User Guide Working with Torque Supervisor PowerMACS calibration PowerMACS Classic: Cable 4145 New calibration 0973 03 or 4145 0974 03 + gender automatically sent changer F/F to PowerMACS PowerMACS 4000: ACTA serial cable (PowerMACS 4000 must be...
  • Page 64 Working with Torque Supervisor STB (Static Transducer Bench) User Guide During the test, the yellow LED indicates that the communication Bench - Power Focus is active: Power Focus connection LED Bench readings Power Focus readings If for any reason the communication gets lost, the procedure continues automatically in the manual mode as described in the previous paragraph of this manual.

  • Page 65: Maintenance

    STB (Static Transducer Bench) User Guide Maintenance MAINTENANCE WARNING: Maintenance operations must be executed by Atlas Copco Service personnel only. CALIBRATION: The bench transducers should be recalibrated once every year. Contact your customer center for this activity. Starting from one month before the calibration expiring of a transducer, the following message informs the...

  • Page 66: Transducers Test Procedure

    STB (Static Transducer Bench) User Guide TRANSDUCERS TEST PROCEDURE Atlas Copco strongly recommends calibrating the transducer monthly. This procedure is not intended to substitute the yearly calibration, but it is a straightforward and quick method for checking the transducers for correct operation and performing complete calibration, if needed.

  • Page 67: Appendix A - Tool Testing Guidelines

    Appendix A - Tool Testing Guidelines APPENDIX A – TOOL TESTING GUIDELINES This chapter gives an overview of the tool testing guidelines. The STB features 2 different type of test:  Statistic control test (when used with Torque Supervisor) ...

  • Page 68: Statistic Control Test

    Appendix A - Tool Testing Guidelines STB (Static Transducer Bench) User Guide 11.1 Statistic Control Test “Statistic control” is a statistical method for preventing errors and for controlling the productive process. The statistical calculation is based on checking the individual tests on each tool to verify that they are within the set tolerance limits, and on the sequence of periodic tests to define the tool’s repeatability and...
  • Page 69 STB (Static Transducer Bench) User Guide Appendix A - Tool Testing Guidelines  One average out of control limits:  Last N. averages above or below than the nominal value:  Range out of limits:  Last N. averages increasing or decreasing: 9836 3078 01 Edition 2.11...

  • Page 70: Cm-Cmk Test

    Appendix A - Tool Testing Guidelines STB (Static Transducer Bench) User Guide  Last 2 averages out of warning limits:  Last 4 averages over 1/3 of the upper control limit or under 1/3 of the lower control limit: 11.2...

  • Page 71: Appendix B - Processes And Statistics

    STB (Static Transducer Bench) User Guide Appendix B - Processes and Statistics APPENDIX B - PROCESSES AND STATISTICS BRIEF NOTES ON HOW THE PROCESS WORKS The functioning of a process is a measure of its reliability. A certain amount of variability can be found in...
  • Page 72 Appendix B - Processes and Statistics STB (Static Transducer Bench) User Guide Hereunder is the related diagram: 0,003 % 99,994 % 0,003 % 0,135 % 99,73 % 0,135 % 95,44 % 68,26 % -1 σ +1 σ +2 σ -2 σ...
  • Page 73 STB (Static Transducer Bench) User Guide Appendix B - Processes and Statistics The higher the value, the less the dispersion of the values and the better the Cp index. But the Cp value is only a measurement of dispersion; in other words, the amplitude of distribution of the values around the mean value, not their centering.
  • Page 74 Appendix B - Processes and Statistics STB (Static Transducer Bench) User Guide The following diagrams show the distribution patterns for the four different types of Cpk value. Cpk = 1,00 Cpk = 1,08 Cpk = 0,67 Cpk = 0,17 A low Cpk value means that either the process is not centered on the mean point of the specifications, or that it deviates from the specifications, or both.

  • Page 75: Troubleshooting Guide

    Troubleshooting Guide TROUBLESHOOTING GUIDE Below is a quick troubleshooting guide for the STB benches. If a problem occurs, before taking any action, or contacting customer support, be sure to check that the bench is being used properly; improper operation can cause defects even if the system is in good working order.
  • Page 76 Troubleshooting Guide STB (Static Transducer Bench) User Guide Problem Cause/Solution For Wrench T control strategy the Over Torque Too high torque has been applied to the Error message is shown on the monitor: transducer. - Torque overload between 120 % and 150 % of the transducer capacity →...
  • Page 77 The transducer is locked and must be inspected/repaired by the Customer Center. STB Bench has detected a torque overload error. Please contact the Customer Center for cell verification/maintenance. STB Bench has detected the following...
  • Page 78 Troubleshooting Guide STB (Static Transducer Bench) User Guide Problem Cause/Solution After starting a test, the following warning message Static zero computation is ongoing. is shown on the monitor: At the end of the static zero computation, the warning message disappears automatically.

  • Page 79: Abbreviations

    STB (Static Transducer Bench) User Guide Abbreviations ABBREVIATIONS Abbreviation Description Abbreviation Description Ampere Numbers (of values) Alternating current N.A. Not Applicable Ampere-hour Newton meter Counter clockwise Number Clockwise Approved (tightening) Decibel referred to milliwatt Not approved (tightening) Direct current Personal Computer...

  • Page 80: Index

    Index STB (Static Transducer Bench) User Guide INDEX Impulse tools test setup ........... 39 INTRODUCTION ..............8 ABBREVIATIONS ..............79 About This Document ............8 Accessories ............... 13 Keyboard................21 APPENDIX A – TOOL TESTING GUIDELINES ......67 APPENDIX B - PROCESSES AND STATISTICS ....... 71 Atlas Copco Remote Service ..........
  • Page 81 TRANSDUCERS TEST PROCEDURE ........66 STB..................8 TROUBLESHOOTING GUIDE ..........75 STB AD standard ..............17 STB AD with custom keyboard and monitor ..... 17 STB OVERVIEW ..............12 STB Versions ..............16 USB Ports ................23 USB Recovery Key.............. 15 USER INTERFACES ..............
  • Page 82 9836 3078 01 Edition 2.11 2017-11 www.atlascopco.com...

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