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C-TEC PAL 3001 Operation Manual

Electronic measuring device for determining the machine capability of crimping presses
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PAL 3001 – Operation Manual – Version 2.1.11
for determining the machine capability
Created:
Changed:
File:
BA_PAL3001_EN_2022
PAL 3001
Electronic measuring device
of crimping presses
Operation Manual
Version 2.1.11
09/2008 Windorfer
05/2022 L. Schreiner
English
Version:
Checked:
2.1.11
M. Egginger
1

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  • Page 1 PAL 3001 – Operation Manual – Version 2.1.11 PAL 3001 Electronic measuring device for determining the machine capability of crimping presses Operation Manual English Version 2.1.11 Created: 09/2008 Windorfer Version: 2.1.11 Changed: 05/2022 L. Schreiner Checked: M. Egginger File: BA_PAL3001_EN_2022...

  • Page 2: Table Of Contents

    Testing external crimp monitors Impress © 05/2022 C-tec Cable technologies GmbH & Co. KG, Ilztalstrasse 11, DE- 94513 Schönberg, Germany Copies and prints only allowed under authorisation from C-tec. All rights reserved. No liability for errors and omissions in contents and printing. This manual is not exhaustive.

  • Page 3: Safety Regulations For Electrical Machines In Industrial Use

    PAL 3001 – Operation Manual – Version 2.1.11 Please study this handbook carefully before initial use of the equipment. Keep this handbook at the working place, where you can easily find it and hand it over with the equipment to other persons.

  • Page 4: Function Of The Equipment

    During the measurement, the crimping press is loaded by the PAL 3001 with a constant counterforce of 8kN. The precisely measured values are transmitted to a PC (laptop) during the press test and processed there by the PAL PC software.

  • Page 5: Intended Use

    PAL 3001 – Operation Manual – Version 2.1.11 Intended use The PAL 3001 has been developed for examining crimp presses of “mini applicator type”. Usually, such a press has a maximum press force of approx. 25kN. The PAL 4000 can be loaded up to this force level without any risk of damages.

  • Page 6: Scope Of Delivery

    Storing The PAL 3001 has to be stored in a dry and well-tempered room. The optimum storage temperature is at 20°C. Too high humidity can cause corrosion on important precision parts.

  • Page 7: Maintenance

    PAL 3001 – Operation Manual – Version 2.1.11 10 Maintenance The PAL 3001 requires no maintenance from the user. After the maintenance cycles have expired (can be read in the PAL PC programme) or after one year of operation, the Press Analyser should be sent back to C-tec for inspection and re-calibration.

  • Page 8: Preparation Works

    Note: If the pressure piece is damaged too heavily, it must be replaced. Now set up the PAL 3001 in the press and fix it there. Attention: Both of the firm prisms must equally enter the PAL body.

  • Page 9: Perform A Press Capability Test

    PC programme) it switches off automatically. Push the slide feed inwards as far as it will go (position 0). The PAL 3001 is now set to forceless and thus does not transmit any counterforce to the press.
  • Page 10 PAL 3001 – Operation Manual – Version 2.1.11 After the slide feed has been set to 0 N, the top red LED starts to light up continuously, signalling that the PAL 3001 is now switched to "Slow Motion" mode. This operating mode allows a rough pre-setting of the shut height of the crimping press.
  • Page 11 PAL 3001 – Operation Manual – Version 2.1.11 The LED display now provides information about the BDC to which the press is currently set. As in this example the yellow and the red LED light up at the same time, the BDC is set between 40 and 100 µm too low.
  • Page 12 PAL 3001 – Operation Manual – Version 2.1.11 Press is set too high (only the upper red LED lights up). If the press is set too high, there is a possibility that too little force is applied to the PAL when it is loaded and the unit will no longer complete the "learning operation".

  • Page 13: Fine Tuning Of The Press With 8 Kn Load

    PAL 3001 – Operation Manual – Version 2.1.11 12.2 Fine tuning of the press with 8 kN load Set the slide feed to 8 kN. Each force position is visually indicated by the labelling on the force adjuster and haptically indicated by a clear latching position.
  • Page 14 PAL 3001 – Operation Manual – Version 2.1.11 The green LED now starts flashing every second, indicating that the PAL 3001 is ready to measure under load conditions. Start/trigger the press by motor via the foot switch or the automatic start system. At least 3 press runs are necessary to "adjust"...
  • Page 15 PAL 3001 – Operation Manual – Version 2.1.11 Adjust the press ram downwards and secure the adjusting screw again! After each adjustment, start the press and read the height deviation on the PAL LED display. Start/release the press again and read the LED display.
  • Page 16 PAL 3001 – Operation Manual – Version 2.1.11 Adjust the press ram only slightly downwards and secure the adjusting screw again! The press is now set with a tolerance of +/- 9 µm to the closed component 135.78 mm.

  • Page 17: Preparation Of A Press Analysis

    Connect the RS232 interface cable to the PAL 3001. Connect the USB end of the adapter cable (USB 2.0 to 2 x RS232) to the laptop or PC and connect the RS232 cable from the PAL 3001 to one of the serial plugs.

  • Page 18: Press Is Not Yet In The Memory Of The Pal

    PAL 3001 – Operation Manual – Version 2.1.11 Start the PAL-PC software. The first display window shows all press numbers that have already been checked. In this example, a new installation is shown. No press check has been recorded and saved yet.
  • Page 19 In case of disturbed communication between the PC and PAL 3001, this information is missing. In this case, first check whether the PAL 3001 is switched on. If this is the case, click on the "Find COM" button and wait until the PAL PC software has selected the correct interface.

  • Page 20: Press Is Already In The Memory Of The Pal

    PAL 3001 – Operation Manual – Version 2.1.11 In the drop-down menu that opens, one of the available interfaces can be selected. Select the appropriate interface and confirm with OK. Now check whether the battery charge status is displayed. If this is not the case, select another available interface and repeat the test.
  • Page 21 PAL 3001 – Operation Manual – Version 2.1.11 The result of the last test on the selected press is now displayed. If the press is started, the display is cleared and a new measurement begins.

  • Page 22: Saving Of A Completed Measurement

    PAL 3001 – Operation Manual – Version 2.1.11 12.3.3 Saving of a completed measurement 125 measured values were recorded. Click on “Save” The name of the measurement is designated as a session and supplemented with the date and time. The name of the tester must be entered in the field "Test done by" or, if already available, the name can be selected from the drop-down menu.

  • Page 23: Performing Another Test On The Same Press (Retest)

    PAL 3001 – Operation Manual – Version 2.1.11 12.3.4 Performing another test on the same press (retest) To start a new measurement, click on the "new measurement" field. If "Teach in" is displayed in the PAL status field, a new measurement recording is started.
  • Page 24 PAL 3001 – Operation Manual – Version 2.1.11 The "Relay Cycle Time" slider can be used to set the period duration for a measurement recording. The number of measuring cycles for a press examination is entered in the "Relay Cycles" input field.

  • Page 25: The Pal Pc Software

    PAL 3001 – Operation Manual – Version 2.1.11 13 The PAL PC software 13.1 Explanation of the pictograms (mouse click areas) 13.1.1 Left side of the toolbar (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16 ) (17)
  • Page 26 PAL 3001 – Operation Manual – Version 2.1.11 (2) Open project: this button is only active on the start screen and allows you to open the project tree (overview of all presses) or to create a new project. Clicking on the icon opens...
  • Page 27 PAL 3001 – Operation Manual – Version 2.1.11 (4) Print: the currently opened measurement is printed. Click OK to print a histogram (bar chart). Click on Cancel to exit and not to print. Various templates for the PDF document can be selected via the drop-down menu.
  • Page 28 PAL 3001 – Operation Manual – Version 2.1.11 (6) New measurement: Clicking on the pictogram starts a new measurement recording. The message "Teach in" in the PAL 3001 status field indicates that a new measurement recording has been started. (7) Crimp monitor: if the PAL PC software is also connected to a crimp monitor, the calibrated peak force value can be transferred from the PAL to the crimp monitor.
  • Page 29 "Teach in" in the status field and the display of the battery charge level. (13) Stop COM: as soon as the PAL 3001 is successfully connected to the PAL PC software, the search function should be stopped by clicking on the Stop COM icon. Otherwise, the PAL will start the interface search again and again (e.g.
  • Page 30 PAL 3001 – Operation Manual – Version 2.1.11 (15) Logbook: the logbook displays the current firmware version of the unit and the counter reading (countdown) of the service counter. The values are updated as soon as the first measurement curve has been transferred from the PAL 3001 unit.
  • Page 31 PAL 3001 – Operation Manual – Version 2.1.11 (18) The slider can be used to view each currently recorded trace. You can move the slider by left-clicking + holding on the dark slider area and moving the mouse or by clicking on the arrows on the left or right.

  • Page 32: Right Side Of The Toolbar (Device Control Bar)

    (30) Device info PAL: a field opens with the most important settings options of the PAL Drop-down menu for switching the measuring device, e.g. for using a PAL 4000 Name of the unit (PAL 3001 or PAL 4000) Serial number of the connected unit Drop-down menu for selecting the serial port to which the PAL is connected.
  • Page 33 PAL 3001 – Operation Manual – Version 2.1.11 (31) Activate/deactivate measurement recording: by clicking on the button, recording of the measured values of the PAL 3001 can be switched on and off again. Click on the "Teach in" button to switch off the measurement recording.
  • Page 34 PAL 3001 – Operation Manual – Version 2.1.11 33) Info field about connected external devices (e.g. crimp monitor): clicking on the button opens a field with the most important setting data Drop-down menu for switching to another external device (e.g. CFM-PRO touch, FSI, etc.)
  • Page 35 PAL 3001 – Operation Manual – Version 2.1.11 By clicking on the button, the external device can be disconnected from the measurement recording. Click again to reactivate the external device. (35) Charge status display external device: is only displayed if an external device with rechargeable battery.
  • Page 36 (38) Temperature: temperature recording of a current press analysis The left temperature display shows the temperature inside the PAL 3001 during the recording of a new press analysis. The right temperature display in brackets shows the temperature inside the PAL 3001 matching a loaded press...

  • Page 37: Menu Bar With Drop-Down Menus

    PAL 3001 – Operation Manual – Version 2.1.11 13.1.3 Menu bar with drop-down menus (50) (51) (52) (53) (54) (55) (56) (57) (50) Menu Project Opens the dialogue for creating a new press project (13.1 - 1). Menu item is only active in the start screen and allows you to open the project tree (overview of all presses) or to create a new project.
  • Page 38 PAL 3001 – Operation Manual – Version 2.1.11 (51) Menu Session A new press check is started (13.1.1 - 6). The data of a press analysis are saved (13.1.1 - 3). Close the working view and switch to the empty start view.
  • Page 39 Shows entries in the logbook such as firmware version and number of service load measurements (13.1.1 - 15). Function is not available for PAL 3001 (PAL 4000 only) Submenu PAL-specific data Click to activate or deactivate the external crimp monitor (13.1.2 - 34).
  • Page 40 PAL 3001 – Operation Manual – Version 2.1.11 (55) Menu View Click to activate or deactivate the toolbar. Click to activate or deactivate the control bar. Working view with both "Toolbar" and "Device Control Bar" switched on: Working view with "Toolbar" deselected:...
  • Page 41 PAL 3001 – Operation Manual – Version 2.1.11 (56) Menu Window Curve progression for height measurement Curve progression for force measurement Curve progression of the crimp monitor Curve progression of the force and height measurement superimposed on each other Course of selectable variables during a measurement recording.

  • Page 42: Working View In Pal Pc Software

    PAL 3001 – Operation Manual – Version 2.1.11 13.2 Working view in PAL PC software 13.2.1 Bar chart (70) (71) (72) (73)

  • Page 43: Measurement Curves And Statistical Values

    PAL 3001 – Operation Manual – Version 2.1.11 (70) Axle labelling of the ordinate The axis labelling shows the unit of the measured values (mm, kN or American units such as inch or lbs). The numerical values indicate the mean value, the upper and lower warning limits and the upper and lower threshold values.
  • Page 44 PAL 3001 – Operation Manual – Version 2.1.11 (74) PAL shut height measurement Measuring curve for one press cycle Red = reference curve Green = loaded reference curve Yellow = current measuring curve Numerical value of the current measuring curve...
  • Page 45 PAL 3001 – Operation Manual – Version 2.1.11 (75) PAL reference force measurement Measuring curve for one press revolution Red = reference curve Green = loaded reference curve Yellow = current measuring curve Numerical value of the current measurement curve (maximum value in the curve)
  • Page 46 PAL 3001 – Operation Manual – Version 2.1.11 (76) Crimp monitor force curve Measuring curve for one press revolution Red = reference curve Green = loaded reference curve Yellow = current measuring curve Numerical value of the current measurement curve (maximum value in the curve)

  • Page 47: Test Documents

    PAL 3001 – Operation Manual – Version 2.1.11 14 Test documents A test document can be generated from the machine capability test that is displayed in the work screen. The document type is a PDF. Click on the pdf icon.

  • Page 48: Header

    14.1 Header 1 Identification number (Press ID) of the press that was tested. 2 Serial number of the PAL 3001 with which the test was carried out. 3 Firmware number of the PAL with which the test was carried out.

  • Page 49: Footer On The Left Side

    PAL 3001 – Operation Manual – Version 2.1.11 14.3 Footer on the left side Number of remaining service cycles Version number of the PAL PC software Number of recorded measurement curves PAL temperature from the beginning to the end of recording...

  • Page 50: Curve Chart

    PAL 3001 – Operation Manual – Version 2.1.11 14.5.2 Curve chart Actual Curves The largest and smallest curve from all individual measurements is entered in the document. 14.5.3 Number chart Statistics All numerical values of the individual measurements are entered. The largest and smallest individual...

  • Page 51: Normal Distribution

    PAL 3001 – Operation Manual – Version 2.1.11 14.5.4 Normal distribution Gaussian distributions The values of the individual measurement are entered in a Gauss diagram. 15 Calculation of the statistical values To calculate the Cmk for the force curves, a reference peak value is needed to which all subsequent force curves refer.
  • Page 52 PAL 3001 – Operation Manual – Version 2.1.11 With these values the machine capability Cmk is calculated: The smaller value of the two results is used as Cmk: Cmk = Min (Cmk1, Cmk2) The Cmk calculation for the shut height is slightly different from the force values.

  • Page 53: Testing External Crimp Monitors

    PAL 3001 – Operation Manual – Version 2.1.11 16 Testing external crimp monitors Crimp monitor CFM-MX / CFM-MX (N) Both single-channel and two-channel units can be tested. Plug the RS232 interface cable into the RS232-CH2 connector of the crimp monitor and connect it on the PC side to the second channel of the USB 2.0 to 2 x RS232 adapter.
  • Page 54 PAL 3001 – Operation Manual – Version 2.1.11 Variant 2: Activate or change the crimp monitor in an existing press project. Click on this button. The entry field “Device” opens. Select CFM-MX from the drop-down menu. In the drop-down menu, select which measuring channel is to be tested on the crimp monitor.
  • Page 55 PAL 3001 – Operation Manual – Version 2.1.11 Transmit calibrated PAL force to crimp monitor If the calibrated peak force of the PAL 3001 does not match the peak force of the crimp monitor after the first measurement, this can be corrected by clicking on the "gear icon".
  • Page 56 PAL 3001 – Operation Manual – Version 2.1.11  Please consider your environmental responsibility before printing this document. Version legend: Date Version Responsible Revision 2008 1.0.0 Lothar Schreiner Change: Original state 27.06.2022 2.1.11 L. Schreiner / M. Fundamental revision of all chapters...

This manual is also suitable for:

Pal 4000

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