Soltec CFM-SOL mini Instruction Manual
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Soltec CFM-SOL mini Instruction Manual

Crimp force monitor
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CFM-SOL mini General instruction manual
General instruction manual
CRIMP FORCE MONITOR
CFM-SOL mini
Ver 1.2
1 / 54

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Summary of Contents for Soltec CFM-SOL mini

  • Page 1 CFM-SOL mini General instruction manual General instruction manual CRIMP FORCE MONITOR CFM-SOL mini Ver 1.2 1 / 54...
  • Page 2 CFM-SOL mini General instruction manual Update history Version number Date Updated by Detail Version 1.0 Oct. 24, 2017 Mr. Masato Sato Version 1.1 Nov. 13, 2017 Mr. Masato Sato Edited 1. Overview Version 1.2 Dec. 14, 2018 Mr. Masato Sato 1.2 description for...

  • Page 3: Table Of Contents

    CFM-SOL mini General instruction manual CONTENTS Overview ......................... 5 1.1. In the beginning ....................5 1.2. The main unit, standard accessories and optional accessories ......5 1.3. Main specifications of the unit ................7 1.4. I/O pin assignment ....................7 1.5.
  • Page 4 CFM-SOL mini General instruction manual 3.2.15. Description of other screen ................. 39 Technical description ..................... 41 4.1. Good / Bad judgement (T1/T2/T3/TD) ............... 41 4.2. Maintenance for Applicator and crimping tools..........44 Troubleshooting ......................46 5.1. The major defect which must be detected is not detected ........ 46 5.2.

  • Page 5: Overview

    1. Overview 1.1. In the beginning This product, called CFM-SOL mini, works with manual crimping machine or semi- automatic crimping machine, as a crimp force monitor. All operation on the main unit is done by LCD touch panel. The main unit function is simplified, designed to operate only with crimp force curve display and some buttons on the touch panel.
  • Page 6 CFM-SOL mini General instruction manual Bottom USB-A type port for USB USB-B type port for Dongle key port memory USB-AB cable Sensor input Serial No. seal D-sub 9 pin port AC adaptor Power switch Power LED for I/O cable port FG (Frame Ground) must be connected firmly to the earth via e.g.

  • Page 7: Main Specifications Of The Unit

    CFM-SOL mini General instruction manual 1.3. Main specifications of the unit Outer dimensions W 137mm x H 84mm x D 50mm Analog sensor Resolution 12bit signal Max sampling rate 20kHz Sensor FTW series (ring type force sensor, cable output, 0.1 to 10 ton)

  • Page 8: Scope Of Detectable Defect

    CFM-SOL mini General instruction manual 1.5. Scope of detectable defect This article describes the scope of detectable and non-detectable defect by CFM- SOL mini, based on a good condition of crimping machine, applicator, and tools. Crimped terminal Wire barrel Fitting part...
  • Page 9 CFM-SOL mini General instruction manual Deep feed (Wire barrel pinches the insulation) Example of deep feed (detectable Insulation Wire barrel Fitting part Insulation barrel Wire This is the case of the deep feed defect, where wire barrel pinches insulation. The total force applied onto wire barrel changes. It generates change on crimp force curve, and CFM can detect it.
  • Page 10 CFM-SOL mini General instruction manual Deep feed (The insulation is under the bell mouth, but not pinched by the wire barrel) Example of deep feed (hard-to-detect) Wire barrel Fitting part Insulation Insulation barrel Wire This is the case of deeper feed than the usual. The insulation looks like being under the bell mouth.
  • Page 11 CFM-SOL mini General instruction manual Deformation of the insulation barrel Unlike the wire barrel, so small force is applied onto the insulation barrel. Any wire barrel deformation does not make enough change to the force curve. Wire strands out and laid on the terminal This is the defect that the wire strands go out of the wire barrel but crimp on the wire barrel from outside.

  • Page 12: Minimum Wire Size

    Crimped terminal sample (Deep feed) Low feed Like strands cut or out, the force curve is lower. Crimped terminal sample (Deep feed) 1.6. Minimum wire size The minimum wire size available with CFM-SOL mini is AWG28. 12 / 54...

  • Page 13: Tolerance

    CFM-SOL mini General instruction manual 2. Tolerance CFM-SOL mini has 5 tolerance index. No. 1 is the smallest, No. 5 is the biggest. If the result value % exceeds the +/- limit, CFM-SOL mini judges this is error. Tolerance index (initial value) 25.0...

  • Page 14: How To Use

    CFM-SOL mini General instruction manual 3. How to use 3.1. Main unit 3.1.1. Start screen Shown when the main unit is turned on. It automatically goes to TEACH screen after 3 seconds. 3.1.2. TEACH screen A screen for TEACH. It goes to OPE screen when TEACH is finished or canceled.
  • Page 15 TEACH button to go to TEACH mode to capture the reference curve. CFM is already in TEACH mode so it can’t be tapped. TEACH mode is a function that CFM-SOL mini leans the reference force curve with 2 good crimps. This good crimp number can be changed 2 to 5 by PC software (see 3.2.4..

  • Page 16: Ope Screen

    CFM-SOL mini General instruction manual Can be Judgement result of T3 is shown. switched with When error occurs, it is shown in red. small one by Judgement result of TD is shown. tapping it. When error occurs, it is shown in red.
  • Page 17 CFM-SOL mini General instruction manual Numerical Meas: Measurement time of the force curve is shown in display upper mSec. right corner Judgement result of T1 is shown. (detail): When error occurs, it is shown in red. Can be Judgement result of T2 is shown.

  • Page 18: Error Screen

    CFM-SOL mini General instruction manual 3.1.4. Error screen A screen for error judgement. This can be reset by “X” button at the lower right. Count ？ Good xxxxxx xxxxxx Peak xxxxmV Meas xxxms xx.x% 3.1.5. Sensor error screen A screen for sensor error, which appears when the sensor is not connected to the main unit.

  • Page 19: Tolerance Setting Screen

    CFM-SOL mini General instruction manual 3.1.7. Tolerance setting screen A screen for setting tolerance. xx.x% xx.x% xx.x% xx.x% xx.x% xx.x% xx.x% xx.x% Graph in the middle -xx.x% -xx.x% -xx.x% -xx.x% -xx.x% -xx.x% Tolerance number button (not chosen) By tapping it, it turns to chosen status.

  • Page 20: Parameter Screen

    CFM-SOL mini General instruction manual 3.1.8. Parameter screen A screen when parameter screen is opened in PC software. This can’t be shown manually. This is closed automatically when the parameter screen in PC is closed. 3.1.9. Other icon Fluctuation icon ！...

  • Page 21: Pc Software（Pro-Lite

    Description for the PC software Pro-Lite. Pro-Lite is a specially designed PC software for CFM-SOL mini, which supports users to work with CFM-SOL mini. See the different document “CFM-SOL mini installation manual” how to set up on 3.2.1. Start screen (main screen)
  • Page 22 CFM-SOL mini General instruction manual Tolerance screen Parameter screen for setting parameter in the main unit. Configuration screen for changing setting PC software. Utility screen is opened. Force curve data can be saved or loaded. Pro-Lite is closed. 22 / 54...

  • Page 23: Example Of Force Curve Display

    CFM-SOL mini General instruction manual 3.2.2. Example of force curve display 1) These numbers shows the same values as the main unit. 2) Showing the force curve captured date and time. The date and time is taken from the time in the main unit.

  • Page 24: Parameter Screen (Logged On)

    Preload screen is opened. This is used for preloading the base plate to fix the base plate type sensor, FTW series, when PSS sensor is not used. See the different document “CFM-SOL mini installation manual” for more information. Auto Trigger Check Auto Trigger Check screen is opened.
  • Page 25 CFM-SOL mini General instruction manual Head room Head room software is opened, This can check how accurate the production with CFM works, like detecting error and how stable it is. See “3.2.13 Head room software” for detail. Download All parameter value is sent to PC to be saved in it as a file.
  • Page 26 CFM-SOL mini General instruction manual Trigger Delay This is effective when Switch (Fall) or Switch (Rise) is chosen for Trigger. It delays the timing of starting capturing the force curve by the number set in mSec. This is used if there is delay between fall of machine ram and start of crimping start.
  • Page 27 CFM-SOL mini General instruction manual Area This sets the dividing point for each judgement area. T1 Start The start point of T1 area is set by %. CFM searches from the peak to the left and the first point which becomes the set % is decided as T1 start.
  • Page 28 CFM-SOL mini General instruction manual Dongle This is a function for interlocking CFM-SOL mini mode or function of TEACH, Tol (Tolerance set), and Reset for error. For example, only supervisor can touch Reset button to start production again. Operator can’t do this.

  • Page 29: Parameter Screen (Logged Off)

    CFM-SOL mini General instruction manual 3.2.6. Parameter screen (Logged off) The parameter saved in PC is shown or edited. Description of buttons Save Current settings in the parameter screen is saved in PC as a file. Load The saved file in PC is loaded and shown.

  • Page 30: Configuration Screen

    CFM-SOL mini General instruction manual 3.2.7. Configuration screen The configuration of PC software is set. Path to Head room Executable file The executable file path in the folder where Head room software is installed is set. Normally this is fixed.

  • Page 31: Utility Screen

    CFM-SOL mini General instruction manual 3.2.8. Utility screen Save Data File The force curve data collected by Pro-Lite is saved as a file. Load Data File The force curve data file saved in PC is opened in different window. Exit Menu Utility screen is closed.

  • Page 32: Preload Screen

    CFM-SOL mini General instruction manual 3.2.10. Preload screen This is used for sensor preload. When the screen is opened, it is ready to preload. Preload % on the screen increase when preload is applied to the sensor. When the % reaches to 10 - 20%, preloading is finished.

  • Page 33: Auto Trigger Check Screen

    CFM-SOL mini General instruction manual 3.2.11. Auto Trigger Check screen This is used for checking Auto Trigger by capturing raw force data when it is not working correctly. Description of buttons. All settings are saved to Parameter screen and the screen is closed.

  • Page 34: Capture Of The Raw Force Data : Example

    CFM-SOL mini General instruction manual 3.2.12. Capture of the raw force data : example Signal line of the external trigger Trigger level The raw force data from the sensor Sky blue This shows the status of the external trigger sensor.
  • Page 35 CFM-SOL mini General instruction manual How to use it (2) : with Auto Trigger The Yellow force curve line peak force has to exceed the White thin line at crimp to activate Auto Trigger to start capturing the force curve. Set appropriate Trigger Level by referring to the screen.

  • Page 36: Head Room Software

    CFM-SOL mini General instruction manual 3.2.13. Head room software The accuracy of detection depends on combination of terminal and wire, or status of the crimping machine or the applicator. There are 2 reference numbers to know how accurate CFM can work as “monitor”. One is Head room, the other is Normal dispersion %.

  • Page 37: How To Use Hear Room Software

    CFM-SOL mini General instruction manual Normal dispersion % This is a number showing how much the peak force is fluctuating, by collecting 30 good crimps. The standard deviation of the 30 good crimps peak force is calculated and divided by the average of the peak force of the 30 crimps and showed in percentage.
  • Page 38 CFM-SOL mini General instruction manual A. Setting Threshold Drag the red horizontal line to set it between the graph of good crimp and the crimp without wire. Then, as shown in below picture, the peak graphs over the red line are shown in blue, the peak graphs below the red line are shown in red.

  • Page 39: Description Of Other Screen

    CFM-SOL mini General instruction manual 3.2.15. Description of other screen Description of buttons Language The language of the screen is chosen. Help Software version is shown. Back Head room screen is closed. Clear All data on the screen is cleared.
  • Page 40 CFM-SOL mini General instruction manual Normal crimping Count of the good crimp which has the bigger peak force count than the threshold between the good crimp and the crimp without wire is shown. Terminal only Count of the bad crimp which has the lower peak force...

  • Page 41: Technical Description

    CFM-SOL mini General instruction manual 4. Technical description In this article, more details of the function has been already described, how to maintain the system, or how to upgrade the program, are described. 4.1. Good / Bad judgement (T1/T2/T3/TD) The force curve is, after captured, divided into 3 areas, T1/T3/T3. In each area, the...
  • Page 42 CFM-SOL mini General instruction manual T1 area T1 Start T2 Start T1 area corresponds to the start of crimping the terminal. The crimping tool start touching the terminal, the wire barrel is pushed down, and the force increases, then the force curve goes up.
  • Page 43 CFM-SOL mini General instruction manual T3 area Peak force (lower dead point of the machine ram) T3 Start T3 End T3 area corresponds to the end of pushing the wire barrel down, lower dead point of the machine ram, and from the lower dead point to the home position of the ram.

  • Page 44: Maintenance For Applicator And Crimping Tools

    CFM-SOL mini General instruction manual 4.2. Maintenance for Applicator and crimping tools. The role of CFM-SOL mini in crimping production is to capture the crimp force and judge it. Therefore, if the crimp force is unstable, it can’t judge it correctly. Here you can see the standard daily maintenance work for crimping equipment.
  • Page 45 CFM-SOL mini General instruction manual B) Base plate The maintenance for the base plate is so important, independent of where the sensor is installed, in case PSS sensor to get the strain of machine body, base plate type sensor, or machine ram type sensor.

  • Page 46: Troubleshooting

    CFM-SOL mini General instruction manual 5. Troubleshooting When facing problem with using CFM-SOL mini, refer to troubleshooting to help to solve problem. 5.1. The major defect which must be detected is not detected Detecting the major defect, such as crimp without wire (terminal only), no strip crimp, or double terminal crimp are absolutely essential.

  • Page 47: Small Defects Are Not Detected

    CFM-SOL mini General instruction manual Possible cause 3 : Incorrect area setting of T1,T2, and T3 to make wrong judgement If the division lines of each judgement area are incorrect as shown below, it possibly makes wrong judgement. The initial value of each division lines are T1 Start : 5%, T2 Start : 30%, T3 Start : 70%, and T3 End : 90%.

  • Page 48: Defect Of Large Wire Is Not Detected

    To know if the size of the terminal and wire is suitable to detecting defect with CFM-SOL mini, use Hear Room software.

  • Page 49: There Are Many Force Alarm Which Stops Production So Often

    PSS sensor series is detecting the strain of the machine. If the machine expansion is unstable to have fluctuating force curve, use the base plate type FTW series. See the different document “CFM-SOL mini installation manual” for detail.
  • Page 50 In such case, set an appropriate Trigger Level by Auto Trigger Check screen, or use external trigger with proximity sensor. See the different document “CFM-SOL mini installation manual” how to install the external trigger.

  • Page 51: No Force Curve Is Captured When The Terminal Is Crimped

    After checking with Auto Trigger Check screen, if there is no force peak, check the position of the sensor, or if the sensor set screw is fixed rigidly. See the different document “CFM-SOL mini installation manual” for more information. 51 / 54...

  • Page 52: The Power Of The Main Unit Does Not Turn On When The Power Switch Is On

    5.10. The no terminal crimp can’t be detected If the no terminal crimp (wire only) can’t be detected by CFM-SOL mini, the force is too small to reach the Trigger Level, the force is not recognized as the force curve.

  • Page 53: Index

    CFM-SOL mini General instruction manual 6. Index Minimum wire size ..........9 Ａ Ｏ Adaptive ............22 Alignment ............22 OPE ..............12 Ｄ Ｐ Dongle ............24 Parameter ............20 Pro-Lite ............18 Ｅ Ｓ EJECT ............24 Sensor error ............ 15 Ｆ...

  • Page 54: Warranty

    However, if the failure was caused by the reason attributable to the users such as improper operation, or to something other than True Soltec, this is not covered by the warranty even if within warranty period. True Soltec shall make this judgement.

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