Fastening Technology

1
11.03.04
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Table of Contents Page

• Why fastening technology from CooperTools? 3
• System Overview 4
• Control cabinet centralised design 5
• General system technology 6
• The fastening control system 7
• Tightening module "TM 9
• Touchscreen operating field 12
• Compact fastener control system 16
• General system technology 18
• Modular built-in nutsetter Size 1 22
• Modular built-in nutsetter Size 2 28
• Modular built-in nutsetter Size 3 34
• Modular built-in nutsetter Size 4 40
• Connection and extension cable 46
• Spring-loaded adaptor 48
• Spindle Calibration method 49
• Angle Monitoring 50

3
Why fastening technology from CooperTools?

• 40 years of experience in fastening technology
• More than 20,000 electric nutrunners in service
• Global presence - with world-wide service and
  central communication partners for special
  machines, fastening systems and assembly
  installations.
• Continuous pattern of new development in
  fastening technology
• Innovations in our own assembly plants carry over
  into fastening technology.
• Attractively priced upgrades available for
  hand-held nutsetter electronic control systems
  and modular spindles.
• Exceptionally short commissioning and service
  times resulting from a standardized and
  uncomplicated graphical operator guidance system
  for all of our nutrunners, whether hand-held or
  modular spindles.
• No additional laptop required!
• Reduction of storage costs resulting from the
  modular design of our fastening tools.
• CooperTools offers assistance that is qualified,
  fast and reliable in resolving your assembly and
  fastening sequence problems, right from planning
  and implementation all the way to production
  assistance in your assembly plant.

4
System Overview
Controller m-Pro 400 S
ARCNET
Bus coupler module
Device Net
TM12
TM34
TMH
Interbus
Parallel I/O
1B.. 2B..
3B.. 4B..
17EA.. 47EA.. 67EA..
17EP.. 47EP..
Max. 32 tightening module see page 16
5
Control cabinet centralised designFastening
control system m-Pro 400 S
6
General system technology The fastening control
system

• 1. Constant overview and optical monitoring of
  the process that is currently running.
• The core of the m-Pro 400 S fastening system is
  the main computer an industrial computer with
  integrated input and visualisation unit. Built in
  to the control cabinet doors of the fastening
  system, this combination offers optimum
  convenience in performing production, service and
  quality assurance tasks.
• 2. Space-saving design
• Behind the main computer, the tightening modules
  are arranged on a mounting plate.
• This type of assembly is very economical in terms
  of space. One control cabinet 2000x600x500 in
  size (HxWxD) can house up to 16 fastening
  channels for built-in nutsetters of Size 1 or 2.
• 3. Reduction in inventory and costs
• With only 3 different tightening modules, Cooper
  Tools is readily able to supply any of its
  built-in and hand-held nutsetters.
• 4. High flexibility in use and after-sale
  expansion options
• With one m-Pro 400 S, you can operate up to 32
  built-in nutsetters or hand tools independently
  or in freely programmable groups.
• When there is any doubt, the nutrunners can be
  retrofitted for up to 32 channels easily and
  inexpensively.

7
The fastening control system

• 5. Short commissioning and service times
• Standardised and uncomplicated graphical operator
  guidance system for all nutrunners, whether
  hand-held or built-in .
• The easily comprehensible system diagnostics with
  fault text display results in brief production
  downtimes when service is required.
• The included statistics program and the
  integrated graphic joint analysis are further
  guarantees for rapid problem resolution on
  location.
• For this, no additional laptop is required.
• 6. Flexible, optimised adaptation of the control
  system to the fastening task
• The m-Pro 400 S fastening control system utilises
  all common fastening processes. Easily created
  series of 6 individual fastening stages, the
  parameters of which can all be programmed
  independently, make it simple to program special
  fastening sequences.
• When there is a fault, you can activate a
  subsequent-processing/fault-processing stage,
  which makes targeted programming available.
• 7. Easily integrated into local networks
• All of the interfaces commonly used in the
  automobile industry are available.
• 8. Optimum operational security
• A system test is performed after each rundown.

8
Fastening control system peripherals

• Station controller m-Pro 400 S
• Basis MPC823e Embedded Power PC, 32-bit Version
• LCD display 640x480 pixels in color
• Integrated system bus ARCNET
• Process interface Profibus integrated as slave
• I/O (process) expandable with 16 inputs and 16
  outputs
• Network interface with 10 Mbps integrated on RJ45
• 4 serial interface RS 232
• System with OS 9000, bootable without mech.
  movement of drive, non-interruptible power
  supply is not required

9
Tightening module "TM
10
System description, tightening module

• Measuring section
• 12-bit self-calibrating A/D transformer
• Parameters in EEPROM
• VxWorks 5.3 real-time operating system with
  multitasking capability
• Data exchange with station controller via
  high-speed ARCNET field bus, as well as
  decentralised installation of station controllers
  at a distance of up to 100 metres
• 17 different fastening strategies (sequences)
• Evaluation of 2 transducers (redundant design of
  measuring sensors as per VDI 2862)
• Storage of up to 10 fastening plots minimum
• Evaluation of motor current and resolver angle
• automatic transducer identification Software
  download via ARCNET
• stable, EMV-tested metal cassette
• Comprehensive service messages with text display
  at station controller
• all connections can be made on the front plate
• automatic selection of control parameters for the
  servo part via the measuring board
• Display of current fastening stage and product
  group

11
System description, tightening module

• Servo controller for brushless motors
• 3 types TM12, TM34 and TMH
• Housing shape the same for all 3 types
• Compact design (HxBxD) 280x60x200 mm
• Network filter integrated
• Error information via 2 -digit 7-segment display
• LED for operational readiness and bus activity
• Reset-Button
• ARCNET addressing with 2 BCD switches for
  built-in and hand-held nutsetters
• Protection classification for the housing is
  IP20, i.e. contact safe for objects gt 12 mm, no
  water protection
• all outward-bound voltages and signals are short
  circuit protected
• Temperature monitoring with fault message
• Start-up current limiting and supply voltage
  monitoring
• Direct line power supply (230VAC) can be used for
  TM12
• integrated I²T-controller

12
Touchscreen operating field

• The m-Pro-400S Touchscreen makes operation easy
  by reducing data input to a minimum. Keyboard or
  mouse not required.
• The Windows-oriented graphical user interface
  makes system settings and maintenance quick to
  learn and easy to carry out.
• The colour LCD display behind the Touchscreen has
  proven its worth a million times over
• Icons allow direct calling of frequently used
  functions. Scrolling through long lists of menu
  options is no longer needed. Operating and data
  entry times are reduced.
• Extensive On-line help provides support to the
  operator and reduces service times.

13
Touchscreen operating field

• Integrated diagnostics software displays the
  status of the inputs and outputs and makes it
  possible to set states as desired in order to
  simplify operation and facilitate
  troubleshooting. This reduces commissioning and
  service times and increases system accessibility.
• The hardware configuration is downward-compatible
  with previous versions of the m-Pro-400, making
  it easy to upgrade existing installations.
• The battery compartment is externally accessible,
  so that batteries can be changed quickly and
  easily without parameter loss.
• Expanded password protection with five different
  sets of access rights for ten authorised users
  increases system security.

14
Touchscreen operating field

• The standard software contains all the common
  torque, angle and yield point fastening
  procedures.
• A selection of 10 fastening sequences offers
  sufficient flexibility for fastening different
  types of workpiece via the electronic control
  system.
• 6 fastening stages per fastening sequence enable
  the user to execute complex fastening strategies
  with the standard software.
• A special fault stage enables a comprehensive
  fault-handling routine without the need for
  special software or additional control functions.
• Programmable service messages for preventative
  maintenance reduce downtime and heighten machine
  capability.
• All system warnings are tracked. Analysis by
  trained personnel paves the way for a suitable
  preventative maintenance schedule.

15
Organization of parameters

• The parameters have 10 selectable fastening
  sequences. Each fastening sequence consists of up
  to 6 fastening stages and a selectable relax
  stage. Apart from the fastening sequence each
  stage has a programmable rework routine and a
  coordinated error processing system.
• The rundown of fastening stages during
  production is sequential. Any spindle selection
  is available in each fastening sequence. Every
  spindle can have its own sequence parameter set
  assigned to it in each fastening stage.

16
Compact fastener control system m-Pro-400S

• Control cabinet sizes
• Control cabinet size (type A or B) is a result of
  the number and size of the built-in nutsetters to
  be powered and the power supply made available by
  the customer.
• Mains specification 3 x 400 VAC / N / PE
  DIN/IEC 38
• Standard
• Colour RAL 2004
• Lock double-bit

• Capacity, type A
• Built-in nutsetters, size 1 and 2 ( TM12 ) from 1
  to max.16 pcs.Built-in nutsetters, size 3 and 4
  ( TM34 ) or electric hand-held fasteners (TMH)
  from 1 to max. 8 pcs.
• Capacity, type B
• Built-in nutsetters, size 1 and 2 (TM12) from 17
  to max.32 pcs.Built-in nutsetters, size 3 and 4
  (TM34) or electric hand-held fasteners (TMH)
  from 9 to max. 16 pcs.
• Remark
• The control cabinet capacity specifications
  provided above do not take into account the space
  requirements for additional hardware if several
  fastening systems, working asynchronously, are
  housed in one control cabinet.
• Installations with more than 4 channels are
  equipped with cooling units as per FGE
  (Electrical Clearance List).

17
Order code for Compact fastening control system
m-Pro-400S

• Options available on request
• Interbus S
• Expansion, digital I/O
• Special paint colour
• Special enclosure
• Cross-Check measurement with measuring case
• Sample order for fastening control system 5
  nutrunner size 1,4 nutrunner size 3, 5
  hand-held angular nutsetter 17..
• Special paint colour and customer-specific
  enclosure
• m-Pro- 400S - 0512 - 0434 - 05H
• Optional special paint colour RALXXX
• Optional special enclosure xxx

18
General system technologyThe built-in nutsetter
program

• 4 models for the torque range 5 - 1,100 Nm
• The drive makes use of a high-performance
  brushless direct-current motor, powered by a
  digital servo and controlled by a resolver.
• The nutrunner is connected to the fastening
  electronics using a single cable with a push-pull
  connector.
• A nutrunner change can therefore be carried in
  the shortest possible time.
• The built-in nutsetters are of modular design and
  can therefore be adapted very easily to changes
  in joint positions.
• The built-in torque and angle sensors form a
  single module. Torque measurement takes place
  directly on the output shaft. All torque sensors
  thus operate as action transducers.
• This applies for all known standard models such
  as
• Straight attachment, offset attachment and
  angular head attachment.
• For especially small pitch circle diameters as in
  the case of flywheels, combined gearing with
  integrated action transducers are available as an
  option.
• For all spindle sizes, piggy-back motors are
  available to shorten the design length.
• All built-in nutsetters are homologised for an
  accuracy of 7 of the torque at a cmk value of
  1.67

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Built-in nutsetter - modules
20
Modular built-in nutsetter Offset attachment
with measured value recording and telemetry
transmitter
21
Modular built-in nutsetter Built-in
transduceraction sensor with telemetry
transmitter
22
Modular built-in nutsetterSingle-cable
design Size 15 - 53 Nm Torque/Angle controlled
23
Modular built-in nutsetterSingle-cable
design Size 15 - 53 Nm Torque/Angle controlled
Order no. without spring loaded adapter, see page
48
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Modular built-in nutsetter Single-cable
design Size 15 - 53 Nm Torque/Angle
controlled With redundancy transducer
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Modular built-in nutsetter Single-cable
design Size 15 - 53 Nm Torque/Angle
controlled With redundancy transducer

• Order no. without spring loaded adapter, see page
  48

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Modular built-in nutsetter Single-cable
design Size 126 - 53 Nm Current/Angle controlled
27
Modular built-in nutsetter Single-cable
design Size 126 - 53 Nm Current/Angle controlled
Order no. without spring loaded adapter, see page
48
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Modular built-in nutsetter Single-cable
design Size 225 - 153 Nm Torque/Angle controlled
29
Modular built-in nutsetter Single-cable
design Size 225 - 153 Nm Torque/Angle controlled
Order no. without spring loaded adapter, see page
48
30
Modular built-in nutsetter Single-cable
design Size 225 - 153 Nm Torque/Angle
controlled With redundancy transducer

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Modular built-in nutsetter Single-cable
design Size 225 - 153 Nm Torque/Angle
controlled With redundancy transducer
Order no. without spring loaded adapter, see page
48
32
Modular built-in nutsetter Single-cable
design Size 276 - 153 Nm Current/Angle
controlled
33
Modular built-in nutsetter Single-cable
design Size 276 - 153 Nm Current/Angle controlled
Order no. without spring loaded adapter, see page
48
34
Modular built-in nutsetter Single-cable
design Size 330 - 260 Nm Torque/Angle controlled
35
Modular built-in nutsetter Single-cable
design Size 330 - 260 Nm Torque/Angle controlled
Order no. without spring loaded adapter, see page
48
36
Modular built-in nutsetter Single-cable
design Size 330 - 260 Nm Torque/Angle
controlled With redundancy transducer
37
Modular built-in nutsetter Single-cable
design Size 330 - 260 Nm Torque/Angle
controlled With redundancy transducer
Order no. without spring loaded adapter, see page
48
38
Modular built-in nutsetter Single-cable
design Size 390 - 260 Nm Current/Angle controlled
39
Modular built-in nutsetter Single-cable
design Size 390 - 260 Nm Current/Angle controlled
Order no. without spring loaded adapter, see page
48
40
Modular built-in nutsetter Single-cable
design Size 4120 - 1100 Nm Torque/Angle
controlled
41
Modular built-in nutsetter Single-cable
design Size 4120 - 1100 Nm Torque/Angle
controlled
Order no. without spring loaded adapter, see page
48
42
Modular built-in nutsetter Single-cable
design Size 4120 - 1100 Nm Torque/Angle
controlled With redundancy transducer
43
Modular built-in nutsetter Single-cable
design Size 4120 - 1100 Nm Torque/Angle
controlled With redundancy transducer
Order no. without spring loaded adapter, see page
48
44
Modular built-in nutsetter Single-cable
design Size 4180 - 630 Nm Current/Angle
controlled
45
Modular built-in nutsetter Single-cable
design Size 4180 - 630 Nm Current/Angle
controlled
Order no. without spring loaded adapter, see page
48
46
Connection and extension cable between fastening
electronics and nutrunner

• To satisfy different requirements in wiring of
  nutrunners and fastening electronics, we offer 5
  cable types
• Type A High-flex extension cable, length 2 - 20
  mExtension cable for built-in nutsetters, for
  use in moving machine parts/built-in
  nutsettersOrder No 960430-XXX
• Type B Field cable, length 6 - 50 mDesigned for
  use in non-moving machine parts between built-in
  nutsetters or cables of type AOrder No
  960431-XXX
• Type C High-flex cable, length 4 - 20 m
  Connection cable for built-in nutsetters with TM
  12 or TM 34 for use in moving machine partsOrder
  No 960430-XXX
• Type D Field cable, length 6 - 50 mDesigned for
  use in non-moving machine parts between
  hand-held nutsetters 17/47/67.. or standard
  hand-held nutsetter cable (see Cleco catalogue
  Assembly tools SP 1000).Order No 960948-XXX
• Type E High-flex cable for hand-held nutsetters,
  length 3 - 50 mConnection cable for hand-held
  nutsetters with field cable type D for use in
  moving applicationsStraight connector for
  tool 542778-xmSwivel connector for
  tool 542780-xmXXX stands for cable length in
  dm.Maximum total cable length is 50 m

47
Connection and extension cable between fastening
electronics and nutrunner

• For technical reasons, the maximum cable length
  for types A and C is20 m.
• Field cable of types B and D and the high-flex
  cable are plugged directly into the tightening
  module of the electronic system. the shield
  connection is made at the TM by means of shielded
  clamp S 961062.

• Sample order, cable set for built-in
  nutsetters12 m high-flex extension cable type
  A 960430-12030 m field cable type B 960431-300
• Sample order, cable set for el. hand-held angular
  nutsetters With straight connector on tool15 m
  high-flex cable type E as per catalogue SP
  1000 542778-15m 30 m field cable type
  D 960948-300

48
Spring-loaded adaptor for straight and offset
attachments
Spring-loaded adaptor for angular head attachments
49
Spindle calibration method

• ISO 9000 requires monitoring of the electronic
  measurement sequence for torque and angle.
• CooperTools technology allows you to block the
  built-in nutsetters electronically so as to check
  the torque encoder.
• With the aid of a calibrated electronic torque
  wrench and a suitable tool, a defined torque can
  be applied to the nutrunner attachment, which
  must be identical to the monitor display at the
  fastening control system.
• To test the angle encoder, an angle of 360 is
  specified for the built-in nutrunner at the
  fastening control system in System Test mode. You
  can monitor the test run by making a mark, for
  example, or by using an angle counter disc.

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Angle monitoringSpindle with lower guide plate
Spring-loaded adaptor
Position pinfor Angle Measurement
Measurement ringfor Angle Measurement
Guide
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Angle monitoringSpindle without lower guide plate
Base plate
Measurement ringfor Angle Measurement
Spring-loaded adaptor
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PI ST EN DEC. 2003