sigPOD Press

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BENEFITS • Enhanceddefectdetection

• Built-indiagnosticsforpressmachinery

• Quickersetupandeasiermaintenancethancompetitivesystems

• Lowestmonitoringcostperramintheindustry

• Multiplechannelsystemcanmonitorupto4rams

• Setupwizardallowsconfigurationwithinminutes

• Collect,graphicallyviewandanalyzedatafromupto4ramssimultaneouslyusingintuitive,operatorfriendlyinterfaces

• Integratedtouchscreenoptionwitheasymachinemountandpanelmount

FEATURES

Software• Industry’sbestsoftwareforassembly

andpress-fitmonitoring• Exceptionalcolordisplay,graphics,

menusystem,setupwizard

Packaging• Compactindustrialhardwarecanbe

installedinapanelcutout,DINrailmountedormachine/wall/desktopmounted

• NEMA12(IP67)modelsalsoavailable• Modularterminalconnectorplugsfor

AnalogandDigitalI/Oconnectionssimplifyinstallationandwiring

QuickandEasySetup• Out-of-the-boxfunctionalityin

standaloneornetworkedoperation• 32modeltypes• Setupwizardmakesiteasyto

configureinamatterofminutes• UnmatchedDataCollection• Upto8analogchannels,16bitA/D• Upto4encoderinputchannels

IntuitiveUserInterface• Simpleandintuitiveoperatordisplays• Touchscreennavigationoption• Operator,engineerandsupervisor

accountswithpasswordsecurity

MultipleDataViews• Status:seepartteststatus(passorfail)• Curves:viewdatacurves(e.g.Forcevs.

Distance)withoverlaidlimits• Histogram:seeStatisticalProcess

Control(SPC)datafortestcycle• Trend:viewtrendsfrommultipletests• History:reviewthousandsoftest

cyclesandparthistoryrecords• Limits:viewcurrentlimits

DetailedDataManagementandReporting• Local&remotestorageoftestresults

organizedbymodel,part,ram,etc.• SPCreporting• Widerangeofanalysisfeatures

available• Statisticallylearnedtestlimits

Connectivity• Communicationwithstation

controllerviadiscreteI/O• Optionalfieldbussupportfor

communicationthroughindustrystandardhardware(RS232,RS485,10/100BaseT)andprotocols(Devicenet1,Profibus1,Interbus1,EthernetI/P,ModbusTCP)

ApplicationsDesignedtobeusedwithanymechanicalpress:• Hydraulic• Servo• Airpressure• Airoveroil

Assembly Press-Fit mOnitOring system

sigPOD Press

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OVERVIEW

sigPODPressisdesignedtomonitorassemblypressoperationsandprovidereal-timeanalysisofthedatatoidentifydefectiveparts,faulty

pressmachinery,andoutofcontrolassemblyprocesses.Itmeasuresforcevs.timeorforcevs.distancesignaturesforeachpartcycle,and

thenanalyzesthecurve(s)inmillisecondstoprovideaninstantpass/failoutputforeachpressram.Compatiblewithalmostallloadcelland

distancesensors,sigPODPressisavailableinsingleramormultipleramconfigurations,andcanbenetworkedtogethertoprovidehigher

levelinsightintoassemblyprocessesbycollectingdataacrosstheentireassemblyline.ThestandardsigPODPresscansupporttraditional

hydraulicrampresssystems,servomotorbasedpresses,airpressureorair-over-oilsystems,crimpingmachines,andalmostanyother

mechanicaloperationthatexhibitsaforce-distancesignature.

sigPODPressprovidesextensivehardwareandsoftwarefunctionsforparttest,analysisanddataconnectivity:

1 to 8 Analog Inputs

1 to 4 Encoder Inputs

sigPOD Press

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UNMATCHED DEFECT DETECTION

AttheheartofsigPODPressisSciemetric’s

ProcessSignatureVerification(PSV),

themostadvancedyeteasiesttouse

signatureanalysistechnologyavailable

tomonitorandcontrolmanufacturing

processes.PSVisbasedonascientific

analysisofeachpresswaveform,which

dramaticallyimprovestheaccuracyof

defectdetectionresultinginreliablepass

orfaildecisionmaking.Thedatacollected

bysigPODPressalsoprovidesimportant

informationforreporting,analysisand

yieldimprovement.

EASE OF SETUP

Afterasimple15minutesetup,thesigPOD

Pressisreadytogo.Thefirsttimeyoustart

upthesigPODPress,thesystembeginsthe

SetupWizardwhichprovidesanautomated

step-by-stepwalkthroughtoquickly

configurethesystemtoyourneeds.Youcan

returntotheWizardatanytimetomake

changes.Foreachstep,theWizardprovides

bothatestingmodeandanadjustment

modetoensurethattheconfiguration

exactlymatchestheindividualram

characteristicsofthepressmachines.

sigPODPresssupportshandshakingwith

thepresscontrolleroverindustrystandard

networks(Fieldbus,Ethernet/IP).Press

type(presstoahardstoporpresstoa

presetdepth)andRappingoperation

areautomaticallymanagedduring

handshake.Handshakeisconfigurable

forbothinterlockandnon-interlock

mode,allowingsigPODPresstowork

inenvironmentswhereonlyminimal

handshakeinformationisavailablefrom

thepresscontroller.

MULTIPLE GRAPHICAL DATA VIEWS

ThesigPODPressscreensdisplaysystem

information,showtestresultsintables

andgraphs,andprovideicon-based

buttonstonavigatequicklyandeasily

fromonetestandassemblymonitoring

functiontoanother.Theuserlevel

determinestheinformationdisplayed

andthemenuchoicesavailable:sigPOD

Pressprovidesoperator,engineer,and

supervisoruseraccountstocontrol

accesstosystemcriticalfunctionssuchas

calibration,limitmanagement,andsystem

maintenance.

Multiplewaystoviewthepressdata

ensuresthatoperatorsandengineers

canimmediatelydetectanyproblems

andtakeaction.sigPODPressprovides

multiple‘features’thatcanbetoggled

asgraphicaloverlaysonthepressdata

tohighlightandtracktrends.Sample

featuresincludeInsertionForcelimits,

InsertionDepthlimitsandAlignment

Force.Featurescanbeoverlaidonto

livedataoronanypreviouslycollected

historicaldata.Duringpressoperation,the

operatorcanchoosetographicallyview

onlythecurrentpartbeingmanufactured

oracompositeofallpartsbuiltduringa

productioncycle.

Thefollowingscreensnapshotshighlight

thevariousviewsofsigPODPress:

DefectsDetectedIdentify product abnormalities:

• Wrongorientation(e.g.backwards)

• Crackedparts

• Overorundersizeparts

• Tolerancestack-up

• Notfullyinserted

Identify machining or process abnormalities:• Badmachinealignment

• Improperlubrication

• Wrongramspeed

(timebasedcollections)

• Loosefixtures

• Damagedseals

• Lowhydraulicpressure

• Binding

PARTS

A

A

B

B

C

C

D

D

E F

E

CORRECTASSEMBLY

Missing part

Excessive distance

Insufficient distance

Incorrect insertion

Incorrect part

F Incorrect orientation

sigPOD Press

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STATUS VIEW

Highlevelstatusscreenallowsoperatorandsupervisorstoquicklyassessthepartteststatus.Thetopbannerindicatestheoverallpartstatus,serialnumber,model,keysystemoutputs,andcyclestatisticsandisavailableonallscreens.Theoverallteststatusandthestatusforeachpressramareindicatedwithlargestatusindicators.Asystemfaultcanberesetfromthisscreenandwiththerightloginaccesstheusercanexittheapplication.

CURVES VIEW

Allowstheusertoreviewfeaturesandcurvedataforeachpressramandprovidesalistoffeatureswiththeirlimits,values,andunits.Thefeaturevalueandtheexceededlimitareindicatedinredifthefeaturefailedforeasyrecognitionofthefailurecondition.Thecurrentfeatureishighlightedinthefeaturelistandthegraphindicatestherangeandlimitsforthathighlightedfeature.Theusercanselectthedesiredpressramabovethefeaturetableandviewitsfeaturesandcurve.DatacanbeviewedasForcevs.displacement,Forcevs.TimeorDisplacementvs.Time.

HISTOGRAM VIEW

Reviewofindividualfeaturevaluedistributionsthroughahistogramview.Indicatorsforthenominalcurve,specificationlimits,andcontrollimitsareselectablebytheuser.HistogramtableindicatesfeatureswithStatisticalProcessControl(SPC)statisticsincludingtotalnumberofentries,numberoffailedparts,percentageoffailedparts,andCpkvalues.

 

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StatusView–Main

TREND VIEW

Reviewoftrenddataforeachfeature.Indicationofnominalcurve,specificationlimits,andcontrollimits.TrendtableindicatesfeatureswithSPCstatisticsincludingtotalnumberofentries,numberoffailedparts,percentageoffailedparts,andCpkvalues.

HISTORy VIEW

Eachtestcycleresultsinatestrecordthatincludesfeaturevalues,limitsandthecollectedcurves.sigPODPresscanstorethousandsoftheserecordslocallyforreviewpurposes.Whenatestrecordisselectedthecurvesscreenisloadedwiththeselectedtestrecorddataandplacedinpausemodeforreview.

SETTING LIMITS

Therearemultipleviewsforviewinglimits:curves,histogram,trend,properties,andmodels.

Featuresviewwithmultiplefeaturesdisplayed

 

 

 

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LOAD CELLS AND DISTANCE SENSORS sigPODpresscanworkwithalmostanytypeofloadcellanddistancesensoravailable.Itisrecommendedthatallpress-fitoperationsbecharacterizedbymeasuringthecompleteforce-distancesignaturesincethisresultsingreaterreliability,butifthisisnotpractical,sigPODPresscanalsomonitorforce-timesignatures.

LoadCells–sigPODsupportsbothunamplifiedandamplifiedstraingagesensors,normalDCvoltagesensors,mAsensors,piezoelectricsensors,andmore.Forstraingages,sigPODPresshasabuilt-ininstrumentationamplifierwithprecisionDCexcitationsowiringisverysimple:justconnectthe4wiresoftheloadcelldirectlytothePODandsettheamplifiergainandcalibrationinsoftware.

sigPODPressalsosupportstwotypesofpiezosensors:directchargeamplifiedloadcellsandICPsensors.Inbothpiezocases,acompactsignalconditionerisavailablewhichplugsintoeachsigPODanalogchannelandprovidesaBNCconnectorreadyforthesensor.

DistanceSensors–sigPODPresscanworkwithmostdisplacementsensorsincludingencodertype(linearorrotary),DCLVDTs,voltagepotentiometers,mAoutputsensors,andmore.IfACLVDTsaretobeused,anexternalsignalconditionerwillberequired.

• Theencoderinputscanbe

configuredtomonitorasinglephase

pulse(countermode),oratwo

phaseA-Bpulsetotrackdirection

(quadraturemode).Eachencoder

channelprovidesa5voltsource

topowerthesensor,andhasinput

overloadprotectiontoprotectthe

channelfromwiringfaultsorother

failures.Theencoderinputscanbe

usedtomeasurelineardisplacement

datasuchaswithaSONYDLprobe.

AUTOMATIC LIMIT MANAGEMENT & SPCDuringinstallation,theSetupWizardautomatically‘learns’theinitialpresscontrollimitsandallowstheoperatortomanuallyadjustthemasneeded.Asproductionpartsaremeasured,sigPODPresscontinuouslycapturesstatisticsandcalculatestheoptimaltestlimits.Whenreviewingproductiondetails,theoperatorcanthenchoosetoenabletheseproposedcontrollimits,ensuringthatoptimumyieldisachieved.Advancedlimitmanagementresultsinfewerfalsefailuresthananyotherpress-fitmonitoringsolution.

DATA COLLECTION, STORAGE AND TRANSFERInstandalonemode,sigPODPresswillreliablycapturetolocalstorageallparttestdataincludingmodel,partandpressprocesssignatures.Whenthelocalstoragereachesaconfigurablethresholdlimit,theoperatorisnotified(viascreenalertandemail)thatdataneedstobebackedup.Aone-buttonpressbackupwillcopytestdatatoUSBkeyandcleanthesystemforthenextpressoperation.

HANDSHAKING & COMMUNICATIONSigPODPressisequippedtocommunicateoversimplediscreteI/O,orasanoption,withoneoftoday’smostcommonindustrystandardprotocols.MultiplecommunicationhardwareoptionsincludeRS232serialand10/100BaseTEthernet,dependingonhardwaremodel.

Supportedcommunicationprotocolsinclude:

• Devicenet1

• Profibus1

• Interbus1

• EthernetI/P

Serialnumberscanbereceivedviatheseinterfacessothetestresultscanbemadetraceable.NumerictestresultscanalsobetransmittedviaEthernetI/PorserialoutputinsimpleASCIIformat,allowingdataintegrationwiththemostMESorERPsystems.

Compatible with three main types of load cells:• Straingage

• PiezoICP

• Piezochargeamplifier

1SelectedfieldbusavailableonsigPOD12xxsystemsonly.

sigPOD Press

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Power• SupplyVoltage:24VDC(18VDCminimum,36VDC

maximum)• PowerAdapterInput:100–240VACRMSat50Hz,1.5A• PowerConsumption:48Wmaximum,30Wtypical

Processor• SystemMemory:1GBRAM• DataMemory:40GBHDminimum• Ethernet:1or2(seechart)• USB:2• RS232:1• Monitor:SVGAConnector• Keyboard/Mouse:USB

General• OperatingTemperature:5to40˚C(41to104˚F)• OperatingHumidity:8%-90%• Environment:NEMA12(IP52)Model12xxonly• PaintFinish:Blackbackedpowder

PressConfiguration• Numberoframs:1to4simultaneous.Optionsavailable

formorerams(e.g.32simultaneous)• Numberofmodels:Upto32uniquepressconfigurations• Ramdisplacementtypes:Analogsensor,Digitalencoder,

Time• Forcesensor:Amplified(powered)orunamplified

(notpowered)• Models/recipes:32• Typicalanalysistime:<100ms(dependentupon

complexityofanalysis)• Responsetotrigger:<50ms

Learn Mode• AutomaticlearningofSetContactzone,

AlignmentZone,InsertionZone• GraphicallyAdjustzonesusingleft/rightbuttons• AutomaticlearningofLimits:MaxForce,InsertForce,

AlignForce,InsertionForce,InsertionDepth,InsertionWork

• AdjustLimitsasneededafterlearn

SetupCheck• Shuntcalibration:Ifenabled,set%FullScale,Rawvalue

(Volts)andTolerance(%FullScale)• Handshaking: Presstohardstop,Presstopresetdepth,IgnoreRapping

operation; Standardhandshake(interlockedtoPLC)orMinimized

handshake(non-interlockedtoPLC)• Handshakecheck• Fieldbusinterfaces:Profibus,DeviceNet,Interbus,Ethernet/IP

SSR Inputs• NumberofChannels:8• Characteristics:opticallyisolated,commonlead,

bi-directional• Powerstates:16VDCon,8VDCoff

SSR Outputs• NumberofChannels:8• Characteristics:SPST,opticallyisolated,normallyopen,

bi-directional• Powerstates:switch±60VDCor40VACat1A16VDCon,

8VDCoffAnalogInput• NumberofChannels:2,4• InputRanges:Seemodelchart• InputAccuracy: ±0.02%for±1Vrangeandgreater; ±0.05%forrangeslessthan1V• Resolution:16bitA/D,±32,768counts• MaximumSampleRate:10kHz• InputImpedance:10Gohmsinparallelwith100pF

(820Ohmsnopower)• CrossTalk:75dBadjacentchannels, 90dBnon-adjacentchannels• CMRR:(DCto60Hz) 75dB(Model12xx) 92dB(Models14xx,1302) 100dB(Model15xx)• OverloadProtection:±25Vforupto2channelspowered

and±15Vwhenoff

AnalogExcitation• ExcitationVoltage:+10VDC• MaximumCurrent:100mAperchannel• Accuracy:±0.1%• MaximumNoise:100μV• ShortCircuitProtection:Continuous

Encoder Input• NumberofChannels:Seemodelchart(2or4)• Sensors:Rotaryencodersandlinearscales• InputVoltage:5VTTL• SignalType:Quadratureorsinglephase• MaxInputFrequency:10MHzTTL,50kHzOpenCollector• Counter:32bit(±2x109counts)• InputProtection:+24Vor-18Vwithoutdamage• SensorPower:+5VDC@150mA,currentlimited

DigitalInputs• NumberofChannels:8withcommonreturnline• Polarity:Bidirectional• IsolationVoltage:±120V(Opticallyisolated)• Inputcurrent:lessthan2.3mA• Inputforlowstate:8VDCmaximum• Inputforhighstate:16VDCminimum• MaximuminputVoltage:±48V• Switchingspeed:2msec

DigitalOutputs• NumberofChannels:8withcommonreturnline• Polarity:Bidirectional• IsolationVoltage:120V(Opticallyisolated)• SwitchingCapability:±1A@±48VDCorVACpeak• ContactResistance:>100MOhmsoff;<0.5Ohmson• PowerOnState:AllOff

• Switchingspeed:8ms

TEChNICALSPECIFICATIONS

2 / 4±10, 2, 0.1, 0.033 V

2/48 In / 8 Out

650 MHz512 MB60 GB2 V1.0

1Ethernet I/PModbus TCP

ProfibusDeviceNet Interbus

XP Embedded7.5 x 9.66 x 4.2 (199 x 241 x 107)

3

1202/04

Analog InAnalog Range

Encoder InDigital I/OProcessor

MemoryHD

USBEthernet

Industrial Networks (optional)

Operating SystemSize Inch (mm)

NEMA 12 (IP 52)

8±10, 5, 2, 1, 0.5, 0.2, 0.1 V

28 In / 8 Out

1.6 GHz1 GB

120 GB4 V2.0

2Ethernet I/PModbus TCP

XP Embedded8 x 6.5 x 8 (203 x 165 x 203)

-

1508

4/8±10, 5, 1, 0.2 V

28 In / 8 Out

1.6 GHz1 GB

120 GB4 V2.0

2Ethernet I/PModbus TCP

XP Embedded8 x 6.5 x 8 (203 x 165 x 203)

-

2±10, 5, 1, 0.2 V

18 In / 8 Out

1.6 GHz1 GB

40 GB4 V2.0

1Ethernet I/PModbus TCP

XP Embedded8 x 4.5 x 8 (203 x 114 x 203)

-

1404/08NEW! 1302

SIGPODPRESSmODELS

sigPOD Press

8

10.4”TOUChSCREEN 12xxmODELS

11.5

8.3

2.14

CL

2.2

4.3

11.0

ADJUSTABLE STAND 0-90

3.50

3.50

4X .31

MACHINE MOUNT

2X PANEL MOUNTBRACKET

PANEL MOUNT

mOUNTINGOPTIONS

3

3

1202/04

MACHINE MOUNT

PANEL MOUNT

WALL MOUNT

DIN RAIL

3

3

3

3

1508 1608 Expander

3

3

3

3

3

1404/081302

sigPODoffersarangeofmountingoptions.Seethefollowingpagesformoreinformation.

sigPOD Press

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1302AND1608mODELS

9.4

8.0

8.4

4.9

2X PANEL MOUNT BRACKET

PANEL MOUNT (1302 with integrated monitor only)

4.5

9.40

.8

.7

3.77

8.90

2X .38

2X .27

4.5

8.0

.3DIN RAIL, DIN 3, 35 X 15MM (W x H)

WALL MOUNT

DIN RAIL MOUNT

mOUNTINGOPTIONS

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ABOUT SCIEMETRIC

Since1981,Sciemetric’sprocessmonitoringandqualitymanagementsystemsandsoftwarehaveenabledsomeoftheworld’sleadingautomotive,medicalandindustrialmanufacturerstogainvisibilityintoandcontrolovertheirmanufacturingprocesses.Ontheproductionfloor,ProcessSignatureVerification(PSV™)technologyprovidesthemostaccuratedeterminationofprocesshealthandpartqualitywhilecollectingalldata.ManufacturingmanagersuseSciemetric’sanalytictoolstotransformthedataintoactionableinformationtoreducecosts,managequality,andmaximizeyieldwhileprovidingproofofprocesscomplianceandcompleteline-widetraceability.

www.sciemetric.cominquiries@sciemetric.com1-877-931-9200©2010SciemetricInstruments,Inc.Allbrandandproductnamesaretrademarksorregisteredtrademarksoftheirrespectivecompanies.Productsandspecificationssubjecttochangewithoutnotice.

Rev1,March2010

6.5

8.0

.3

DIN RAIL, DIN 3, 35 X 15MM (W x H)

6.5

9.4

.8

.7

5.75

5.75

8.90

2X .38

2X .27

DIN RAIL MOUNT

WALL MOUNT

14xx-15xxmODELS

mOUNTINGOPTIONS