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© Haller + Erne GmbH 2014 Presentation Worker guidance Holger Erne, Haller + Erne GmbH Welcome!
© 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
© 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 3
© 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)
© 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
© 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
© 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
© 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
© 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
© 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
© 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
© 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
© 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
© 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)
© 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”
© 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
© 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
© 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
© 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
© 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
© Haller + Erne GmbH 2014 Presentation Worker guidance Holger Erne, Haller + Erne GmbH Thank you for your attention
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