1. © Haller + Erne GmbH 2014 Presentation Worker guidance Holger Erne, Haller + Erne GmbH Welcome!

2. © Haller + Erne GmbH 2014 Contents  Introduction  TKSE-Project  Software for worker guidance  Applications  User interface  Features  Limitations  News for the upcoming version  Other Projects 2

3. © Haller + Erne GmbH 2014 Introduction Overview  Haller + Erne GmbH  Soft- and hardware development since 1987  6 employees  ISO9001 certified since 2012  Data acquisition software for Rexroth tightening systems  Standard products for data conversion:  Q-Das QS-Stat (QTrans V1.1 certified 2005, V2.0 certified 2010 as AQDEF V3.0 Category C)  For Sciemetric QualityWorX (graphs + data)  Worldwide use in the automobile industry, e.g. GM, Ford  Software for worker guidance  Recaro, Benteler  Worker guidance Porsche/Daimler,  Valve assembly Rexroth Lohr  Website www.haller-erne.de 3

4. © Haller + Erne GmbH 2014 Introduction Areas of activity 4 Automation Sensors, control, accessories and software Bolting Socket trays, software, data connection, worker guidance Communication Fieldbus systems, data connection (protocols and databases)  Soft- and hardware for industrial control and communication  Standard solutions and customer- specific solutions  Development: project-related solutions and engineering  Software for collecting process data, converting and archiving  Accessories for Rexroth tightening systems Hardware (e. g. socket trays) Software PC/KG‘s (data-, protocol converter, process control) Internal firmware (VxWorks) for tightening systems (IPM, PLUS) IndraLogic applications and modules (e. g. Modbus-master for tightening systems)

5. © Haller + Erne GmbH 2014 TKSE-project Overview  Small scale series of AMG bodys  Two Nexo‘s per operator  Two operator at one assembly station are working on the same vehicle (left and right side) 5  approx. 20 tasks per side  approx. 100 bolts per side  Requirements:  Ensuring quality (worker guidance, socket tray, tightening and loosening bolts)  Visualization (which steps are up next, what‘s still missing)  Recording and storing data (scanning, Q-data, traceability)  Optimizing the process time

6. © Haller + Erne GmbH 2014 Worker guidance - software Applications  Prototypes and lab  Standalone-operation (without network)  Frequent changes of procedures  Documentation as pdf/printout (w. graph)  Production  Small scale series with multiple stations  Data interface with network, ident systems  Central definition of tasks and tightening specs  Standby workstations  Use as temporary replacement in case of breakdown of station on the line  Usable at multiple stations  Post-treatment  Similar to standby, but initial part status is provided by network 6

7. © Haller + Erne GmbH 2014 Worker guidance - software Topology and data management  Splitting into different components… Two databases – configuration and data “Monitor“ – runtime for the workplace “Configurator“ – editor for configuration  …makes different topologies possible Standalone Offline-configuration Central configuration Online/server-operation  Simple data management Versioning of the configuration Single-file copy/transfer 7

8. © Haller + Erne GmbH 2014 Worker guidance - software Application interface – “Monitor“  Also works for small screens with low resolution  Touch-screen operation  Minimalistic & simple  Only three pages:  Sign-in  Part list  Tightening job 8

9. © Haller + Erne GmbH 2014 Worker guidance - software Application interface – “Monitor“ Job selection 9 Job status Job selection by clicking (touch) Visualization of job state Input: barcode scanner or keyboard Actions Current job

10. © Haller + Erne GmbH 2014 Worker guidance - software Application interface – “Monitor“ Tightening Job 10 tightening results Job Current tool actions Pre-tightening (dark green), final tightening (light green) Tightening status (green: OK, red: NOK, yellow: next position) result of last rundown click/touch: loosen, delete, skip

11. © Haller + Erne GmbH 2014 Worker guidance - software Application interface – “Configurator“  Hierarchy of parts and jobs (job groups)  Reusable jobs in different parts  Color coding for jobs (yellow) and job groups (blue)  Separate definition of bolts and process steps / tool actions 11

12. © Haller + Erne GmbH 2014 Worker guidance - software Application interface – “Configurator“ 12 production series list of barcodes for parts Jobs/Groups for selected part list of all jobs/groups (catalog) list of barcodes for parts/assembly groups Add job to currently selected part menu and tabs Configure parts and barcodes

13. © Haller + Erne GmbH 2014 Worker guidance - software Application interface – “Configurator“ 13 additional functions (pictures/clipboard) properties of the currently selected item picture selection actions create new parts by drag & drop menu and interfaces (tabs) Creating new jobs navigation similar to Windows Explorer Jobs and job groups

14. © Haller + Erne GmbH 2014 Worker guidance - software Application interface – “Configurator“ 14 Active page shown is “bolts” Filtering the displayed bolts: all, pre tightening, final tightening properties of the selected bolt Bolts (double click: add new ; ctrl/shift- click: change size ; right click: menu) Edit bolts list of bolts (with name, number)

15. © Haller + Erne GmbH 2014 Worker guidance - software Application interface – “Configurator“ 15 operation properties (tool, program-number, bit-type, …) actions assigning tightening operations to steps: right click / add operation Edit tightening sequence Bolts (double click: new ; ctrl/shift-click: change size ; right click: menu) drag & drop for changing sequence Active page shown is “tightening sequence”

16. © Haller + Erne GmbH 2014 Worker guidance - software Features – Overview 16 Available functions  Multiple tools per station:  Ergospins  Tightening aggregates  Electronic wrenches/GWK  Single tool active per station  Manual confirmation and notes  Part-hierarchy: part, job groups, jobs  Pre-tightening, final tightening, post-process  Tightening positions in fixed sequence or free selection  Barcode or manual selection of jobs and parts Not supported  Multiple workers working simultaneously at one station  Working on one tightening position with different tools/bits (two tools can be used by using the post-processing feature)  Reloading or editing tightening programs

17. © Haller + Erne GmbH 2014 Worker guidance - software Features – interfaces and expandability  I/O with USB, Profibus, OpenProtocol/IM24V, Modbus- TCP/UDP  Driver interface for bolting systems  CS/KE (Profibus) and OpenProtocol (Nexo)  Electronic wrenches GWK, Saltus  Socket trays (by USB or CS/KE IM24V)  Recognizes location of tightening positions (by Profibus)  Worker-identification (e.g. Euchner-Key)  Data output interfaces  XML-file (“Motis“), text file (“csv“)  Exporting/archiving from local database  Lua-scripting for several application areas 17

18. © Haller + Erne GmbH 2014 Worker guidance - software Special Features  “low cost“ standalone-solution: Nexo + PC + MSTKN  Standard-PC (all-in-one touch) with integrated WLAN-AP  Nexo with direct-WLAN-connection (without CS351)  Socket trays connected over USB  Plausibility check against drawing params/plausibility values  Pre-tightening, final tightening and post-process  interrupting/resuming operation on a part  3 access levels (operator, supervisor (can loosen/delete), admin (can input/change settings))  Core data versioning  Changing a job will create a new version of the job/part  Historical part result data will stay consistent  Report-designer  Report-generator can also generate configuration/master data reports (e.g. list of tools) and customer specific reports 18

19. © Haller + Erne GmbH 2014 Worker guidance – software Startup and configuration  Initial startup  Setup by using installation program  Configuration of stations  Tool interface setup  I/O-interfaces (configure BMS table and evt. Profibus/OpenProtocol)  Texts/headers (engine, vehicle type, …)  Editing ini-files  Defining tightening processes  Customer can do that himself  Use “Configurator“ GUI application 19

20. © Haller + Erne GmbH 2014 Worker guidance - software On the agenda…  Changes planned for current version  Improved error messages  Per tool diagnostics (currently only by tool type/driver)  Text-display on Nexo (if timing gets fixed with V1100)  Changes planned for next version  Enhanced (per job/bolt) loosening operations  Splitting station and process definition, definition of tightening process not depending on tool used (use a „operation name“ instead of tightening program number, so each stations can use different programs numbers)  Improve ease-of-use for configurator  Improved handling of part variants  Improved station/ hardware configuration  Better modularity  Additional scripting areas 20

21. © Haller + Erne GmbH 2014 Presentation Worker guidance Holger Erne, Haller + Erne GmbH Thank you for your attention