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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 2.4
2014-12

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  • Page 1 User Guide STB (Static Transducer Bench) Atlas Copco Industrial Technique AB 9836 3078 01 Edition 2.4 2014-12...
  • Page 3 Copyright Atlas Copco Industrial Technique AB NOTE: This manual may be altered without further notice. For further information log on to Atlas Copco www.atlascopco.com NOTE: In the event of conflicts between translations of this user guide, always refer to the official English version.

  • Page 4: Table Of Contents

    STB Overview ...................... 12 STB Versions ......................17 2.1.1 STB AD standard ....................17 2.1.2 STB AD with custom keyboard and monitor ............18 User Interfaces ....................19 Static transducers ....................19 3.1.1 Mechanical joint simulators ..................21 LCD Monitor with Touch Screen ................21 Keyboard ........................
  • Page 5 STB User Guide Revision history Test report ......................55 Working with Torque Supervisor ............... 57 Tool Calibration Function ..................63 8.1.1 Power Focus / PowerMACS calibration ..............67 Scheduled Maintenance ..................70 Transducers Test Procedure ................71 APPENDIX A: Tool Testing Guidelines ............. 72 11.1 Statistic Control Test ....................

  • Page 6: Safety Information

    WARNING: PLEASE READ THE SAFETY INFORMATION No. 9836 5531 00 CAREFULLY PRIOR TO USING THE PRODUCT AND STRICTLY FOLLOW THE SAFETY INSTRUCTIONS PROVIDED. THE DOCUMENT IS APPLICABLE TO THE STB EXCEPT FOR THE HYDRAULIC COMPONENTS NOT PRESENT IN THIS BENCH. 6 (86)

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

    WEIGHT: 5 g 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. ONCE REMOVED, THE WASTED BATTERIES MUST BE DISMISSED ACCORDING LOCAL REGULATIONS 9836 3078 01 Edition 2.4...

  • Page 8: Introduction

    Introduction STB User Guide Introduction About This Document This document is a user manual for the STB and it is divided into the main following parts: Part Name Description Chapter 1 Introduction This part introduces this user manual 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: Specifications

    Introduction STB User Guide Specifications MAIN FUNCTIONS • Testing in Statistic Control, Cm and Cmk measurements and tool calibration. • Extremely simple for the user, providing immediate results with colored lamps: Green: OK, Red: NOT OK • Storage of test traces and reports with date and time.

  • Page 11: Standard Conformity

    • Atmospheric humidity: 95%, non-condensing • Altitude: Up to 2000m Standard Conformity The STB 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 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 STB User Guide STB Overview the standard ISO 9000. Contact your Atlas Copco sales for any further information regarding this software. The drawers contain a set of accessories: Set of adapters. Number and size of adapters depend from the bench transducers configuration.
  • Page 14 User Interfaces STB 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 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 JSB software(s) and some folders containing bench...
  • Page 16 This application, started automatically, executes system backup. QAT Bench Backup See the chapter Hardware Protection Key: System Backup for more information. This application can be used by the Atlas Copco service personnel Atlas Copco Remote Service for maintenance activities. 16 (86)

  • Page 17: Stb Versions

    STB Overview 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 18: Stb Ad With Custom Keyboard And Monitor

    User Interfaces STB User Guide 2.1.2 STB AD with custom keyboard and monitor Monitor Keyboard This version features a smaller chassis, a monitor 12”, and a tiltable keyboard installed outside the drawer. The lamps are installed on the top of the monitor, and the panel with the bench interfaces is installed on the back side of the monitor.

  • Page 19: User Interfaces

    STB User Guide User Interfaces User Interfaces Static transducers The standard STB bench features a set of static transducer SRTT-B: Transducers 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 20 User Interfaces STB User Guide Tighten the lever, before starting the test. NOTE: Tighten the lever before entering the test window; the zero alignment will be not performed properly otherwise. 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.

  • Page 21: Mechanical Joint Simulators

    For SRTT-B 1000 Nm, only one joint simulator is provided. Refer to the TJ SRTT-B User Guide for more information about the joint simulators. LCD Monitor with Touch Screen The STB is equipped with a LCD monitor with touch screen. 9836 3078 01 Edition 2.4 21 (86)

  • Page 22: Keyboard

    User Interfaces STB User Guide 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). To edit a value in the bench software, proceed as following:...

  • Page 23: Test Result Leds

    STB User Guide User Interfaces A virtual keyboard is also installed on the monitor: Virtual keyboard Virtual keyboard Test Result LEDs LEDs The monitor houses three lamps: Test completed with OK result GREEN (OK) RED (NOK) Test completed with Not OK result...

  • Page 24: External Transducers Connectors

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

  • Page 25: Usb Ports

    STB 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 26: Pc Reset Switch

    User Interfaces STB User Guide The serial port RS232 of the PC can be used for various functions including serial printers (when installed), Power Focus calibration and other custom features. PC Reset Switch A further switch is located inside the bench under the main panel. Activating this switch causes the PC to reset;...

  • Page 27: Main Panel

    STB User Guide User Interfaces 3.10 Main Panel The main panel is like the one shown in the following picture: Press the START switch for 5 seconds to start bench operations. The PC launches the software automatically. Press STOP to turn off the bench.

  • Page 28: Hardware Protection Key: System Backup

    Battery voltage < 20V and battery charger turned off 3.11 Hardware Protection Key: System Backup The STB bench contains a hardware protection USB key; which provides the following features: • System backup: Test bench settings and calibration data. 28 (86)
  • Page 29 STB User Guide User Interfaces NOTE: Personal documents are not saved in the backup! Traces saved during tests on the bench are included in the backup only if saved in the default C:\BLM 3860\3860Front folder • Hardware protection function (if the key is not present the bench software is not started) •...
  • Page 30 (from the Windows Task Manager) 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: 30 (86) 9836 3078 01 Edition 2.4...
  • Page 31 STB User Guide User Interfaces The Admin and Operator passwords allow the same functions; the only difference is that the Admin password allows also to change the two passwords. If the USB key is not present an error message is shown to indicate to connect the USB key: The hardware protection key is located on the HUB inside the bench and it must be always connected.

  • Page 32: Executing A Free Test

    Launches the test interface window. Free Test For the user this button opens the external transducers setup window (see par. External Transducers Setup). For Atlas Copco service personnel this allows bench settings and Setup calibration. Opens the window for viewing traces. See the chapter Traces Viewer for more Traces information.
  • Page 33 The following icon on the PC desktop can be use to restart the software if manually closed: Click on Free Test to start a measurement: The following window is shown: Standard Click to execute a free test. Not used for STB. Trace Simulation 9836 3078 01 Edition 2.4 33 (86)
  • Page 34 Executing a Free Test STB User Guide Click on Standard. The following window is shown: Torque value for the tool under test (select also the desired Measurement Unit). Nom. Torque Transducer of the bench on which the test is run.
  • Page 35 STB User Guide Executing a Free Test Test results Statistics area (test n. 0 is not considered) Abort test Delete last test result Display graph The results of the tests run on the tool are displayed in the Results area; the statistics are calculated in real time and updated every time a test is completed.

  • Page 36: Testing Wrenches

    STB User Guide 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 37 STB User Guide Executing a Free Test 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). The First Peak switch should be set to On. See the figure on the left...
  • Page 38 Executing a Free Test STB User Guide 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 “2nd %” and over the percentage the “1 %”...
  • Page 39 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 9836 3078 01 Edition 2.4...

  • Page 40: Testing Impulse Tools

    STB User Guide Testing Impulse Tools WARNING: Impact tools cannot be tested on the STB. 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. Due to the physics of the tool the final torque reached cannot be measured directly as with real torque tools.
  • Page 41 STB User Guide Executing a Free Test Set a low torque Check the residual torque Too low Slightly increase torque 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 42 Executing a Free Test STB User Guide Impulse tool without shut off SRTT-B static transducer without shut off  Also, pulse tools with shut off should be tested in static conditions. Only tools which shut off immediately after the first or second pulse cannot be tested correctly. In such a case, a joint...

  • Page 43: Impulse Tools Test Setup

    STB 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 44: 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 45: Power Tools Test Setup

    STB 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 46: Force Versus Torque Test

    Time out, the test ends. The Time out is given in milliseconds. The default value is 200 ms. Not used for STB. Force Versus Torque Test This test is typically run on TP Transducers or torque wrench with a force washer. The torque measurement is multiplied by the Att.
  • Page 47 STB User Guide Executing a Free Test Select the external transducers on which the force and torque transducers are connected. The external transducer must be properly before starting the test. See the External Transducers Setup chapter for more information. The Ctrl. Mode (control mode) select if the statistics must be calculated on the torque or on the force;...

  • Page 48: External Transducers Setup

    JSB Benches User Guide 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 49 Example for IRTT: 180 (specified on the transducer label) x 4 = 720 The number of Channels and Cells available depend from your bench configuration. For a standard STB the 4 transducers (the first 4 cells), associated to the first 4 channels, are reserved for the bench transducers;...
  • Page 50 In this External Transducers Setup menu, it is possible to setup the external channels. Having many Cells available allows to store several different external transducers. For instance, in a standard STB bench you can define 11 external transducers, assigning each one to a different Cell. The Channel associated to the Cell defines to which external connector of the bench you must connect the transducer for the test.
  • Page 51 JSB Benches User Guide External Transducers Setup At the time of the test, connect the IRTT-B 25 Nm to connector XDUC 6 and select Transd. No. 5 (Cell Transd. No. 5 selects Cell 5 To select the IRTT-B 75 Nm, Transd. No. 6 must be selected and IRTT-B 75 Nm will be connected to connector XDUC 8 (Channel 8).

  • Page 52: Traces Viewer

    Save Save the trace on the PC (.crv and a .k39 file are created). View Speed Not used for STB. Zoom The Zoom functions allow the operator to zoom in on the area selected with the two zoom cursors. Before activating the zoom, select the zoom function between Torque and Speed in order to zoom in properly on the trace of interest.
  • Page 53 STB User Guide Traces Viewer Restore Reset the zoom function and display the whole trace. Filter Click to change the filter parameters: Click on 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 54 Set to On Save Set to On the Debug Mode switch and click on Save. The traces can be viewed and edited by the Atlas Copco software Curve; ask to your Atlas Copco sales reference for more information. 54 (86)

  • Page 55: Test Report

    STB User Guide Test Report 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 on Delete Value to cancel the highlighted result in the list.
  • Page 56 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. 56 (86)

  • Page 57: 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 58 Working with Torque Supervisor STB User Guide 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 Bench must be always running on the bench: FTP Server icon Do not disable the application.
  • Page 59 STB User Guide Working with Torque Supervisor Control mode is set from Torque Supervisor. It is possible anyway to change its setting before clicking on Start Test: For pulse tools, the Atten. Coeff. (Attenuation Coefficient, stored inside Torque Supervisor) is displayed.
  • Page 60 Working with Torque Supervisor STB User Guide 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 61 STB User Guide Working with Torque Supervisor The possible test results are: 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 62 Working with Torque Supervisor STB User Guide 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 63: Tool Calibration Function

    STB User Guide Working with Torque Supervisor 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 64 Working with Torque Supervisor STB User Guide After each test the following window is shown: 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 on Enter to confirm.
  • Page 65 STB User Guide Working with Torque Supervisor After entering the old coefficient, the new one is shown. The New Coefficient field shows the new value, which must be entered manually into the tool controller. This value can be even edited manually, by clicking on Edit New.
  • Page 66 Working with Torque Supervisor STB User Guide 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 67: 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 68 Working with Torque Supervisor STB User Guide 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 set for RS485...
  • Page 69 STB User Guide Working with Torque Supervisor 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 70: Scheduled Maintenance

    Transducer Test Procedure STB User Guide Scheduled Maintenance WARNING: Maintenance operations must be executed by Atlas Copco 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 71: Transducers Test Procedure

    Scheduled Maintenance 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 72: Appendix A: Tool Testing Guidelines

    Appendix A: Tool Testing Guidelines STB User Guide 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 73: Statistic Control Test

    STB User Guide Appendix A: Tool Testing Guidelines 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 74 Appendix A: Tool Testing Guidelines STB User Guide • One average out of control limits: • Last N. averages above or below than the nominal value: • Range out of limits: 74 (86) 9836 3078 01 Edition 2.4...
  • Page 75 STB User Guide Appendix A: Tool Testing Guidelines • Last N. averages increasing or decreasing: • 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 9836 3078 01 Edition 2.4...

  • Page 76: Cm-Cmk Test

    Appendix A: Tool Testing Guidelines STB User Guide 11.2 Cm-Cmk Test The Cm-Cmk test is used to test the accuracy and repeatability of a power tool or a torque wrench at a specific calibration. The result is a value that summarizes the dispersion of a specific number of values measured (Cm) and the position with respect to the control limits (Cmk).

  • Page 77: Appendix B: Processes And Statistics

    STB 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 78 Appendix B: Processes and Statistics STB User Guide 0,003 % 99,994 % 0,003 % 0,135 % 99,73 % 0,135 % 95,44 % 68,26 % -1 σ +1 σ -2 σ +2 σ -3 σ +3 σ -4 σ +4 σ...
  • Page 79 STB User Guide Appendix B: Processes and Statistics 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. In the specific case of a power tool, the Cp index may be of acceptable size (greater than 1), meaning that there is limited dispersion around the mean value, but this mean value could differ considerably from the expected value.
  • Page 80 Appendix B: Processes and Statistics STB User Guide 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 81: Troubleshooting Guide

    Troubleshooting Guide Troubleshooting Guide Here 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 82 Troubleshooting Guide STB User Guide The Over Torque Error message is shown on the - Too high torque has been applied to the transducer. monitor: Torque overload between 110 % and 120 % of the transducer capacity → Torque overload message is...

  • Page 83: Abbreviations

    STB User Guide Abbreviations Abbreviations Abbreviation Description Abbreviation Description Ampere Volt Waste Electrical and Electronic Alternating current WEEE Equipment Ampere-hour Counter clockwise Clockwise Decibel referred to milliwatt Direct current Electromagnetic Compatibility Electromagnetic Interference Hertz (measurement unit of frequency) Light-Emitting Diode...

  • Page 84: Index

    Index STB User Guide Index 1-Step tools; 43 Hardware protection key; 28 Abbreviations; 81 Impulse tools; 39 Accredia; 11 Accuracy; 10 Joint simulator mechanical; 21 JSB Bench Backup; 28 overview; 12 Batteries; 27 Battery information; 7 Keyboard; 22 Calibration; 61 Power Focus;...
  • Page 85 STB User Guide Index Settings Touch screen; 21 1-Step tools; 44 Traces; 50 Impulse tools; 42 Transducers Wrenches; 35 test procedure; 69 Shut off valve; 40 Specifications; 10 standard conformity; 11 SRTT-B; 19 USB port; 24; 25 Standard conformity; 11 User interfaces;...
  • Page 86 9836 3039 01 Edition 2.4 2014-12 www.atlascopco.com...

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