More Than Productivity. The new standard of cost efficient tightening

Transcription

1 The new standard of cost efficient tightening Advanced Process control Easy Integration User-Friendly Interface Unmatched Flexibility More Than Productivity

2 The new standard of Cost Efficient Tightening In an era of FLEXIBLE manufacturing and the race to ZERO-fault assembly, Desoutter is proud to introduce the new standard of Cost Efficient tightening for safety-critical applications: the CVI3 assembly system. This new system offers unequalled COST EFFICIENCY for all plants thanks to the best combination of advanced process control, easy integration, user-friendly interface & unmatched flexibility. The CVI3 system integrates UNIQUE added value INNOVATIONS: Workgroup with 1 unique Network/Fieldbus connection Embedded 4-Ethernet port switch with 2 possible networks CVIKEY Access Level software with unlimited profiles CVILOGIX software to replace interface PLC C OST E FFIC 2

3 for the most demanding industries Automotive (Car and Tiers) Fact: Quality standards strongly influence customer choice Need: Process flexibility, easy integration & tightening data traceability CVI3 Benefit: Delivers all 3 and meets your high productivity requirements. Heavy vehicles (Trucks, Trailers and Bus) Fact: Vehicle reliability is customer profitability Need: Tightening quality & reliability CVI3 Benefit: Builds your products right first time every time to reduce warranty cost. Off Road (Agricultural and Construction Equipment) Fact: Customer productivity depends on equipment durability Need: Robust assembly quality & operator ergonomics CVI3 Benefit: Meets your quality requirements with low noise & vibration levels IENCY 3

4 Advanced Process Control Workgroup: Pilot your station from 1 unique controller with 1 access point Assembly Process management for up to 6 controllers Unique access point for Network / Fieldbus Control your production process from 1 controller with only 1 Network / 1 Fieldbus connection Save on Fieldbus connections costs Save on Fieldbus card costs Save on Network connections costs Assembly Process: Error-proof your multi-step process with a visual flowchart Up to 250 Assembly process (sequences) in a VISUAL flowchart Manage your Assembly process in STATIC Mode (stored in controller) or DYNAMIC mode (sent from external source: PLC ) START conditions: identification of the pieces to assemble, selection of the process by IO, fieldbus Reduce errors with a complete Assembly process report (including identifiers, tightening results...) PROCESS: sequence of tightening which is using Psets as tightening recipes + ID (barcode...) PROCESS: sequenc tightening which is us Psets as tightening recipes + ID (barcode Save on Rework & Warranty costs POST processing: repeat, tool locking Tightening strategies: Pick the best one to combine high quality & productivity All BASIC + ADVANCED tightening strategies included in standard High monitoring flexibility for maximum error proofing (current, slip off, stick slip, yield, torque rate) Get the job done right first time on each of your applications Save on Reject & Rework costs 4

5 elink (tool embedded modules): Put the error-proofing at your operator s finger tip 3 compact tool modules for embedded Error Proofing Pset selector / Barcode reader / I/O Selector Multi-positions over 270 Barcode reader PSet Selector Error-proof your station with 0 waste in motion I/O selector Save on productivity & quality costs Save on wiring costs for external accessories (barcodes, Pset selection box) Ergostop: Optimize quality level with enhanced operator comfort Electronic control of the reaction force Easy configurable (duration only) No need for calibration Ergostop ON e of ing...) Improve quality level through enhanced ergonomics Save on injury costs Save on reject costs 5

6 Easy Integration Embedded Ethernet switch: Remove external switch from your installation Ethernet switch with 4 Ethernet ports (2 possible networks) Simplify your networking infrastructure by removing external switches Save on IP addresses & network connection costs Complete Fieldbus offer: Increase your flexibility with Fieldbus dynamic mapping Fieldbus available in controller (embedded Fieldbus) or with Fieldbus card : Ethernet IP, ProfiNet, Modbus TCP, Profibus DP, DeviceNet, CC-Link Dynamic memory mapping (Drag&Drop) Enjoy seamless Fieldbus installation with Plug & Play cards Save on installation & configuration costs Accessory ebus: Error-proof your station with plug & play accessories ebus connection to daisy chain up to 15 accessories Socket tray, operator panel, stack light, I/O expander, HMI Simplify error proofing integration on your station Save on installation & configuration costs 6

7 Tool hot swap: Swap tool in seconds without switching off the controller Tools can be disconnected / reconnected without needing to switch OFF controllers Save time during tool change or maintenance operation Save on maintenance intervention time Cable auto-locking system: Enhance operator comfort & safety Cable auto-locking system embedded on tool handle Get rid of loose cables which cause maintenance issues Save on cable maintenance costs 7

8 User-Friendly Interface CVIPC: Set-up your system in seconds with an intuitive & visual software Configure any CVI3 controllers (CVIPC2000 start-up link included) Collect & display results & curves (SQL database like in CVINET) Network or point to point Ethernet access One powerful software to manage all your controllers & fastening operations Fast learning curve thanks to an intuitive & visual interface Save on training costs Save on multiple software licence costs CVIMONITOR: Monitor results, maintenance & diagnostic data in real-time without software licence Real-time process monitoring with results, curves & statistics Real-time maintenance monitoring with I/O status, counters (controller, tool, cable) Troubleshooting with alarms history (logs), problem solving guidance Free access (no software licence needed) Start real-time diagnostic from any PC connected to the production network Decrease intervention time thanks to proactive monitoring functions Save on maintenance time on the production line Save on software licences CVIKEY: Give the right access to the right people CVIKEY software to create/manage access levels Plug&Play USB key Unlimited number of profiles (4 profiles already available by default) Set up the right access levels for the right people Save on password headaches 8

9 Reporting 4 colors LEDs: Customize your operator feedback with 360 visibility 4 colors reporting LEDs (green/yellow/red/blue) Fully configurable according to customer needs Tailor made operator feedback for optimized error proofing Save on external reporting devices Embedded service feedback: Get advanced preventive maintenance data 3 configurable counters & alarms Automatic alarm when maintenance threshold is reached The system informs you when it is time for a service Save on curative maintenance costs 9

10 Unmatched Flexibility epod - Functions key: Upgrade your system features to fit your specific needs Plug&Play key to increase memory storage (results, curves) & activate optional functions (workgroup, Ethernet fieldbus, customer protocols) Realtime backup Pay for the function you need Plug&Play installation in seconds wherever the plant is located Save on backup costs Save on installation costs Remote programming: Visualize & program your line controllers without PC Remote visualization of data/curves Remote programming Up to 20 controllers Available for CVI3 Vision only Visualize & program up to 20 controllers without a PC Save on programming software licences & station PC CVILOGIX - Soft PLC: Remove interface PLC from your installation Same functions as an external PLC 2 levels: Ladder (Basic) / Automation (Advanced) IEC compliant Eliminates the need for interface PLC to fit with the customer I/O signal specification Save on PLC purchasing, installation & maintenance costs Save on additional wiring 10

11 Embedded fixturing: No need for special mounting brackets or reaction plate Embedded fixturing points (3) & indexing point (1) Tool angle head width unchanged Safe mounting plate fixturing Quick positioning during installation Better guidance for special head / extensions with no additional components needed Save on installation time Save on fixturing material costs Save on maintenance costs High sensitivity torque transducer: Get a wider torque range per tool Strain gage type torque transducer High sensitivity ( mV/V) Wider torque range per tool = less tools needed for multi-torque applications Better accuracy / repeatability Save on tool inventory Save on quality costs 11

12 Proven Cost Efficiency Example 1: Workgroup Simulation Money Bag Case: Workgroup of 6 controllers 1 unique Fieldbus connection instead of 6 1 unique Fieldbus card instead of 6 Less Fieldbus wiring Fieldbus connection: 1 x $1000 (instead of 6 x $1000 = $6000) Fieldbus card: 1 x $1100 (instead of 6 x $1100 = $6600) Additional wiring: $300 Fieldbus connection savings: $5000 Fieldbus card savings: $5500 Additional wiring savings: $300 TOTAL $10800 Example 2: Embedded Ethernet switch Case: Daisy chained network of 4 controllers 1 unique Ethernet connection instead of 4 less network wiring Simulation Network connection (IP address): 1 x $800 (instead of 4 x $800 = $3200) Additional wiring: $200 Money Bag Network connection savings: $2400 Additional wiring savings: $200 TOTAL $

13 Satisfied Customers PSA Production Engineer Very easy to integrate on the line, the CVI3 assembly system is also very flexible. We managed to significantly cut production costs with leaner stations. VOLVO Quality Manager I don't take any chance with process control on the production line. The assembly process allowed us to map our entire production process and get the job done right first time on each of the applications. Thanks to Desoutter, we cut warranty claims & rework costs. 13

14 R.O.I / Desoutter RightWay Desoutter RightWay focuses on six key areas that play an important part in the performance of your production lines. Understanding your needs and your expectations on these points will contribute to significant process improvements. PRODUCTIVITY Remove bottlenecks to raise workstation productivity and overall line performance. QUALITY Improve the quality of final goods and reduce quality-related costs by implementing advanced error-proofing solutions that detect and fix defects at the workstation. ERGONOMICS Reduce work-related musculoskeletal disorders to improve operator morale, cut absenteeism and minimize operator turnover. SAFETY Lower on-the-job injuries and the costs associated with lost time and medical costs. ENERGY Fight rising energy costs by adopting energy-efficient best practices and technologies. PLANNING Help you accelerate process improvement projects by providing your planning department with valuable resources and expertise. 4-STEP METHODOLOGY Analyse ON THE FACTORY FLOOR Follow-up IMPLEMENTATION AND SUPPORT Propose DEMONSTRATING FEASIBILITY Prove PROVE THE PAYBACK CO 2 Reduction Yearly savings Payback Ton/year EUR months Desoutter performed an audit, transformed my process and gave high benefits in term of return on invest Senior Process Engineer - Car manufacturing - Germany 14

15 Energy Efficiency / Desoutter GreenWay Since 2008, DESOUTTER has introduced the Desoutter GreenWay to sharpen its focus on achieving its environmental targets by basing its environmental work on certified management systems. DESOUTTER is permanently monitoring the Environnmental impact in the product life cycle stages. DESOUTTER follows a clear 4-steps ECO Development process. Environmental Impact in the Life Cycle Stages Material Manufacturing Transport Use End-of-life Choice of material use in the tool with recyclability potential Machining parts Assembly Logistic impact Spares Energy consumption Lubrication Tool Disposal Recycling parts Impact t on the environment 14% 6% 2% 70% 8% * Preservation of the environment Development of eco-friendly products: * Average values of Desoutter products ASSESSMENT - Reduce waste - Use recycled material - Use ecofriendly packaging ASSESSMENT - Standardisation & parts - Increased durability Protecting THE ENVIRONMENT Preserving RESOURCES & RECYCLE ASSESSMENT - Reduce noise levels - Reduce dust emissions - Reduce vibration levels Preventing POLLUTION 15 Saving ENERGY ASSESSMENT - Reduce energy consumption - Optimize tool vs application

16 Controllers / Controllers - Overview Ethernet port dedicated to CVIPC software USB port for USB key (access level control and data download/upload) epod port 2 USB ports Auto-Sensing Voltage V CVI3 Function CVI3 Vision I/O connector (8/8) GFI Circuit breaker (Earth fault & over current protection) Plug&Play Field bus card port RS232 port ebus port (Bus dedicated to Error Proofing Integration accessories - EPI) Ethernet switch with 4 Ethernet ports (2 possible networks) 8 pin female Tool connector Report LEDs (yellow, green, red) 122 x 32 full graphic display 5.7 touch screen, 1/4 VGA color 6 buttons Keypad On / Off switch Dedicated CVIPC Ethernet port + USB port FEATURES CVI3 CVI3 Controllers FUNCTION Weight - kg (lbs) 9.4 (20.7) 9.5 (20.9) Volume (dm 3 ) Color touchscreen (5,7") Storage Pset results (torque, angle, date, time, report) Pset curves (OK/NOK) Sequence results Event log storage (number of events) Basic Functions Nbr of Psets Nbr of steps per Pset Barcode reading (standard and 2D) Learning mode Quick Pset Tubenut release Advanced Functions Access Level Control/Management with unlimited profiles ID input to select Sequence (up to 4 different identifiers) Number of Sequences Network/Fieldbus Access point per group of up to 6 controllers Advanced Soft PLC (in option with CVILOGIX) Remote Programming for a group of up to 20 controllers from 1 controller Full sequencing control for a group of up to 6 controllers (static/dynamic) Tightening strategies *Control: torque, angle, torque OR angle, torque AND angle, yield point, torque rate *Monitoring: yield point, torque rate, 2nd torque, 2nd angle, 2nd part angle, current, slip off, stick slip Connectivity Configurable I/O 8/8 8/8 USB ports (2 + 1 front) Embedded Ethernet switch (4 ports + 1 front 2 networks) Dedicated Bus for up to 15 accessories in daisy chain Optional Fieldbus Plug&Play Fieldbus card port (EthernetIP, ProfiNet A/B, Modbus TCP, DeviceNet, Profibus, CC-Link) Fieldbus dynamic memory mapping VISION 16

17 Controllers A B PIC MODEL PART CONSUMPTION MAIN DIMENSIONS WEIGHT REF NUMBER (CURRENT) SUPPLY WIDTH HEIGHT DEPTH 115V 220V 50/60 Hz mm in. mm in. mm in. kg lb. A CVI3 Function A 2A Single-phase B CVI3 Vision A 2A Single-phase CVIMONITOR included with controller: License free remote software for realtime monitoring of results, curves, I/O status & maintenance indicators. POWER CORD to be ordered with the controller 1 PLUG DESCRIPTION PART NO. A European B US C UK D Chinese A B C D epod2 OPTIONAL ACCESSORIES PART NO. Fieldbus modules 1 Profibus module ProfiNet module (1 port) ProfiNet module (2 ports) DeviceNet module EtherNet IP module Modbus TCP module CC-Link module epod epod epod epod epod customer Softwares CVIPC - 1 user CVIPC - 5 user CVIPC - 25 user CVI NET - 1 cont CVI NET - 10 cont CVI NET - 25 cont CVI NET - 50 cont CVIKEY (access level management on USB key) CVILOGIX - Basic (Basic Ladder with Function Bloc Diagrams) CVILOGIX - Advanced (Advanced workbench for Automation) Table mounting Wall mounting

18 Tools EAD & EID New EB motors with higher Energy efficiency elink for embedded accessories (Barcode scanner, Pset selector, I/O selector) Cable Auto-locking system 4 colors configurable reporting LEDs (360 visibility) Monobloc slim angle head with Spiral cut gears Torque Range - Portable electric nutrunners Angle head tools (EAD) - Widest Torque Ratio (Tmax/Trpm) 5.2 ROTATIONAL SPEED rpm EAD EAD EAD EAD EAD EAD EAD EAD EAD EAD EAD EAD Torque Nm In-line tools (EID) - Widest Torque Ratio (Tmax/Trpm) 5.9 ROTATIONAL SPEED rpm EID EID EID EID EID EID EID EID EID Torque Nm Pistol tools (ERP) ROTATIONAL SPEED rpm ERP3L 2000 ERP5L 2000 ERP10L 1540 ERP20L 790 ERP20S 1540 ERP30S 1070 ERP40S 680 ERP3LT 2000 ERP5LT 2000 ERP10LT 1540 ERP20LT 790 Torque Nm

19 Angle head electric nutrunners 3 to 105 Nm (2.2 to 77 ft.lb) to 1300 rpm MODEL h H ØA ØB ØC D mm in. mm in. mm in. mm in. mm in. mm in. EAD EAD EAD EAD EAD EAD Accessories: see page 22 MODEL PART SQUARE TORQUE FREE LENGTH WEIGHT NUMBER DRIVE MIN. RECOM- MAX. MIN. RECOM- MAX. SPEED MENDED MENDED in. Nm Nm Nm ft.lb ft.lb ft.lb rpm mm in. kg lb. EAD Sq. 3/ EAD Sq. 3/ EAD Sq. 3/ EAD Sq. 3/ EAD Sq. 1/ EAD Sq. 1/ Angle head electric nutrunners 35 to 660 Nm (26 to 487 ft.lb) to 430 rpm MODEL h H ØA ØB ØC D mm in. mm in. mm in. mm in. mm in. mm in. EAD EAD EAD EAD EAD EAD Accessories: see page 22 MODEL PART SQUARE TORQUE FREE LENGTH WEIGHT NUMBER DRIVE MIN. RECOM- MAX. MIN. RECOM- MAX. SPEED MENDED MENDED in. Nm Nm Nm ft.lb ft.lb ft.lb rpm mm in. kg lb. EAD Sq. 1/ EAD Sq. 3/ EAD Sq. 3/ EAD Sq. 3/ EAD Sq. 3/ EAD Sq. 3/

20 In-line electric nutrunners 3 to 75 Nm (2.2 to 55.3 ft.lb) to 1200 rpm MODEL ØA ØB ØC mm in. mm in. mm in. EID EID EID EID EID Accessories: see page 22 MODEL PART SQUARE TORQUE FREE LENGTH WEIGHT NUMBER DRIVE MIN. RECOM- MAX. MIN. RECOM- MAX. SPEED MENDED MENDED in. Nm Nm Nm ft.lb ft.lb ft.lb rpm mm in. kg lb. EID Sq. 3/ EID Sq. 3/ EID Sq. 3/ EID Sq. 3/ EID Sq. 1/ In-line electric nutrunners 20 to 360 Nm (14.7 to ft.lb) to 670 rpm MODEL ØA ØB ØC ØD mm in. mm in. mm in. mm in. EID EID EID EID Accessories: see page 22 MODEL PART SQUARE TORQUE FREE LENGTH WEIGHT NUMBER DRIVE MIN. RECOM- MAX. MIN. RECOM- MAX. SPEED MENDED MENDED in. Nm Nm Nm ft.lb ft.lb ft.lb rpm mm in. kg lb. EID Sq. 1/ EID Sq. 1/ EID Sq. 3/ EID Sq. 3/

21 Pistol grip electric nutrunners 0.35 to 42 Nm (0.26 to 31 ft.lb) to 2000 rpm A B C D CVI II Adapter needed Accessories: see page 22 PIC MODEL PART OUTPUT TORQUE ROTATIONAL LENGTH WEIGHT REF NUMBER DRIVE MIN. RECOM- MAX. MIN. RECOM- MAX. SPEED MENDED MENDED in. Nm Nm Nm ft.lb ft.lb ft.lb rpm mm in. kg lb. A ERP3L Hex. 1 /4 F A ERP5L Hex. 1 /4 F A ERP10L Hex. 1 /4 F A ERP20L Hex. 1 /4 F A ERP20S Hex. 1 /4 F B ERP30S Sq. 3 / C ERP40S Sq. 3 / D ERP3LT Hex. 1 /4 F D ERP5LT Hex. 1 /4 F D ERP10LT Hex. 1 /4 F D ERP20LT Hex. 1 /4 F

22 Accessories Cable for EAD & EID tools PART NO. Tool cable 2.5m (8.2ft) Tool cable 5m (16.4ft) Tool cable 10m (32.8ft) Tool cable 15m (49.2ft) Extension cable for EAD & EID tools PART NO. Ext. cable 8m (26.2ft) Ext. cable 16m (52.5ft) Ext. cable 32m (105ft) Ext. cable 50m (164ft) ebus cable PART NO. ebus cable 1m (3.3ft) ebus cable 2m (6.6ft) ebus cable 5m (16.4ft) ebus cable 15m (49.2ft) ebus Termination plug Other Accessories ITEM PART NO Socket tray - 4 positions Operator Panel (advanced) Stack Light I/O Expander Bit tray Suspension bail - non swivelling Suspension bail - swivelling Second start lever Telescopic output Handle lever Angle head protection AH Angle head protection AH Angle head protection AH Angle head protection AH Angle head protection SH Angle head protection SH Finger Protection AH Finger Protection AH Finger Protection AH Y cable for RS232 port Adapter for ERAL/ERDL/ERP/EME PART NO. CVI II Adapter

23 Torque Reaction Arms & Balancers MODEL PART NO. MAX. TORQUE TOOL LOAD FOR NUTRUNNERS TOOL CLAMP Ø INCLUDED Nm ft.lb kg ft mm in. D53 linear arm D ERP D ERP D EAD20 EID25 ERP D53-25X Extended reach EAD20 EID25 ERP D EAD32-50 EID Order clamp D EAD EID separately D53 folded arm D53-5S ERP D53-12S ERP D53-25S EAD20 EID25 ERP D53-50S EAD32-50 EID Order clamp D53-100S EAD EID separately MODEL PART NO. MAX. TORQUE LENGTH FOR NUTRUNNERS TOOL CLAMP Ø INCLUDED Nm ft.lb mm in. mm in. TRA telescopic reaction arm TRA ERP TRA ERP TRA ERP TRA EAD20 EID25 ERP TRA EAD20 EID25 ERP TRA EAD20 EID25 ERP TRA EAD20 EID25 ERP TRA EAD32-50 EID32-44 ERP TRA EAD32-50 EID32-44 ERP TRA EAD32-50 EID32-44 ERP TRA EAD EID TRA EAD EID Order clamp TRA EAD EID separately TRA EAD EID TRA EAD EID TRA EAD EID Order balancer separately TOOL CLAMP PART NO. TOOL DIA. FOR ARM mm in. Universal clamp D53 Clamp mm D53-5/12/25 TRA-12/25 D53 Clamp 40-50mm D53-5/12/25 TRA-12/25 TRA Clamp 28-49mm D53-5/12/25 TRA-12/25 TRA Uni holder 50 & 100mm D53-50 / 100 TRA-50 / 100 Specific diameter clamp Holder, Dia 34mm (12 & 25Nm) D53-5/12/25 TRA-12/25 Holder, Dia 36,5mm (12 & 25Nm) D53-5/12/25 TRA-12/25 Holder, Dia 38mm (12 & 25Nm) D53-5/12/25 TRA-12/25 Holder, Dia 44mm (12 & 25Nm) D53-5/12/25 TRA-12/25 Spline clamp Clamp for ERDL4 -EDC Spline D53-50 / 100 TRA-50 / 100 Clamp for ERDL D53-50 / 100 TRA-50 / 100 Clamp for 200 ERDL4-ECD TRA-200 Clamp for 200 ERDL TRA-200 Welded clamp (to be welded with TOC) Clamp to weld D53-50 / 100 TRA-50 / 100 Clamp to weld TRA-200 Balancers FOLDED ARMS MIN. MAX. CABLE MODEL PART NO. CAPACITY CAPACITY TRAVEL WEIGHT kg lb kg lb m ft kg lb Welded clamp (to be welded with TOC) 5DF DF DF

24 Softwares: Softwares & Data CVIPC - programming CVINET - Data Collection Easy Control Ethernet connection manager 100% Traceability 3D Curves screen, display of one or several curves User-friendly interface Easy setting with Quick Pset & learning mode Fast learning curve with contextual help Complete Assembly line view in the tree area Intuitive Pset setting with curve templates Advanced process control Error-proofed with real time consistency check Complete process logic mapping including tightening & non-tightening operations with Assembly process Statistical analysis (ISO, CNOMO, NF) Display and print (Histograms, SPC, Control charts) High flexibility Dynamic mapping for I/O, fieldbus with Drag & drop function 2 ways transfer of all parameters between stations & PC Real time access to tool parameters/counters (partial/total number of cycles performed by the tool/cable) Test mode to check torque transducer, angle encoder, brushless motor Complete backup/restore of stations CVI-Collector Single software installation on the main server Data collection linked to Identification Number as station number / part number / tools number/ a free field for special needs Auto uploading of missing data (FIFO inside controllers) Overview of all controllers connected CVI-Viewer Multi -user installation View tightening results View tightening curves Customized report: Date range filtering Data linked to an Identification Number View of maintenance information CVI-Net saves more than 40 parameters plus the results at the end of each tightening. Real time quality control of the network Alarm in case of disconnection and FIFO inside controllers Automatic uploading of missing data from controllers. Traceability All results with Identification Number can be exported to another database for long time saving The display of one or more curves allows you to analyse and make tightening comparisons Printing report Printing of all tightening of a vehicle or a component by scanning the bar code number 24

25 Overview & Softwares data for Software CVIKEY - Access Level Management CVIMONITOR - Real Time monitoring Tailor made protection Intuitive software to create/manage access level Protection guaranteed by unique profile keys created by the administartor (locked against copy) Simple interface Plug&Play USB key 4 profiles already available by default High flexibility Unlimited number of profiles Set up the right access level for the right people CVIMONITOR included with controller: License free remote software for real-time monitoring of the assembly line Real-time process monitoring Results Curves Statistics Real-time maintenance monitoring I/O status Counters (controller, tool, cable) Troubleshooting Alarms history (logs) Problem solving guidance 25

26 More Than Productivity English Copyright 2011 January Issue 1