CircuitMaster CFA1000

Introduction

• Crimp Force Analysis Overview

• System Overview/Options

• Force Curve Basics

• CFA1000 Analysis Method– Teaching Phase– Production Phase

• Operator Control Parameters

Introduction continued...

• Machine Interface Options

• Force Calibration Overview

• In the field software upgrades

CFA Overview• Circuitmaster have over 7000 CFA units

installed around the world.• Units available for Benchtop (CFA1000B)

and Automatic machines(CFA1000M)• Measures the force applied to make the crimp

terminal and compares it with a known good crimp which has been offline tested

• Can detect strip, crimp and misfeed faults.

Customer Benefits

• 100% online testing of quality

• Little or no production rate impact

• Virtual eradication of expensive tool damage

• Reduced downtime

• Reduced scrap

• Quality Assurance

Customer Benefits Continued…

• Powerful tool for your Sales Department• Retrofitable to all crimp presses thus

protecting your investment in the future• CFA will give guidance to novice press

operators to achieve consistently high results

• Intuitive user interface reduces training costs

• Multilingual menus

CFA System Overview

ProcessingUnit

ForceSensor

Encoder

Control Panel

MachineI/F

S:30

E:120

PK:

12.5M: 34

CLR

REF

Circuitmaster CFA1000

Force Sensor

•Preloaded and Sealed at the factory

•Uses Piezoceramic technology

•Mounted inline with the press ram

•Output signal is proportional to the applied force.

Encoder

•Determines angular position of the press

•Produces 1440 pulses per revolution

•Output used to trigger sampling of the force sensor output

•Allows force curves to be overlaid exactly from crimp to crimp

•Timer triggering is also possible

Processing Unit•Evaluates force curve against ‘reference’ curve.

•Interfaces with the machine through one of three machine interface methods

•Interfaces with the operator via the Graphical control panel (GCP)

•Powerful 16Bit Microprocessor allows faster evaluation (Evaluation time <20mS after BDC)

Machine Interface

INTERFACEINTERFACE APPLICATIONAPPLICATION

• 2 High Speed relays (e.g. Komax 40, Opera,

Artos TX)

• 2 Power Relays (Benchtop)

• Coaxial Interface (e.g. Komax Alpha generation)

Graphical Control Panel (GCP)•Simple to use

•Setup via menus

•Online viewing of force curve

•Can be plugged in at any time

•Magnetic backing provides easy mounting

CFA1000 VariantsTwo Different Variants: -

• CFA for Machines CFA1000M

• CFA for Benchtop CFA1000B

I/O Board

Coaxial Interface

Mains PSU

Power Relays

High Speed Relays

Aux Inputs

Buzzer

Force Curve Basics

• Introduction to the force curve

• Differences between a force curve and a K325 type force signature.

• Important features

• Typical faults

• Analysis strategies

Force Curve

Peak Force BDC

Increasing Angle

Incr

easi

ng

For

ce

Peak Force BDC

Increasing Angle

Incr

easi

ng

For

ce

Insulation Crimp Phase

Insulation Crimp

Force increases as toolingcontacts the insulation earsthen reduces as they arefolded and buckle

Main Crimp Phase

Main Crimp Form

Force increases as toolingcompresses the copperstrands.

Peak Force Phase

Peak Force

Force peaks as the pressreaches the extent of itsstroke. Final compaction ofthe wire strands

Insulation in main crimp

ReferenceCurve

Force Curve

Force is increased during the main crimp, due to

the trapped insulation increasing the effective CSA of the wire

Cut Fault

Force CurveReferenceCurve

Force is reduced in the main crimp phase due to strands

being cut reducing the wire CSA

Insulation Crimp Fault

Force Curve

ReferenceCurve

Force is reduced in insulation crimp due to deformed insulation

crimp ears.

Interim Summary

• Seen what constitutes a CFA– Sensor, Evaluation Unit, GCP, Machine

Interface

• Applications of CFA1000

• Force curve– Salient features– Some typical faults

K325 Analysis

CurveMismatch

100Reference of Area

Error of Area%Error

K325 Analysis continued...

AdvantagesAdvantages

• Simple to evaluate

DisadvantagesDisadvantages

• Big localised error gives small overall error

• Size of the error gives no indication of the cause (eg. 3% error over or under crimp?)

• No positional information ( Fault type )

CFA1000 Analysis

Z111

Z2 Z3

Z1 Zone 1

Z2 Zone 2

Z3 Zone 3

Errors in each zone

100in Z1 Reference of Area

in Z1Error of Area% Error Z1

100in Z2 Reference of Area

in Z2Error of Area% Error Z2

100in Z3 Reference of Area

in Z3Error of Area% Error Z3

Zoned Analysis Advantages

• Errors in any one zone are distinct and not affected by results in other parts of the curve

• Process limits and controls can be provided for each individual zone allowing any zone to be made more or less sensitive

• Zones closely match the distinct parts of the crimping process

Zoned Analysis Advantages…

• Signed analysis gives not just the magnitude of the error in each zone but also the sign of the error (Force lower or higher than the reference crimp)

CFA1000 Analysis Phases

• Teaching Phase– Reference curve is recorded and averaged– The Zone Widths and Limits are calculated– A static and driftable reference are produced

• Production Phase– Analysis is performed between the references

and the force curve– Drift compensation is performed

Teaching Phase

• 1st Cycle1st Cycle Force curve is scaled by the internal amplifier to give best possible resolution

• 2nd Cycle2nd Cycle The reference curve is stored and the zone widths and limits are calculated from the reference curve shape and the user entered operating parameters

Teaching Phase continued…

• 3rd - (N-1)th3rd - (N-1)th The analyser evaluates against the Teach Limit, The reference is averaged

to give a closer approximation to the process mean.

• Last Teach Cycle Last Teach Cycle The averaged reference is copied to form two references– STATIC REFERENCE– DRIFTABLE REFERENCE

Teach Phase continued…

The unit switches to the production phase.

• NOTE if the teach limit is exceeded at any time during the teach sequence, the teach phase will start again automatically.

Production Phase

• Analysis is performed in each zone against the driftable referencedriftable reference. The result is compared with the Bad LimitBad Limit and the Stop Stop LimitLimit for that zone.

• Analysis is performed in each zone against the static referencestatic reference. The result is compared with the Drift LimitDrift Limit for that zone.

Production Phase continued…

• The machine is informed of the result either using the high speed relays or the coax interface.

• If the crimp passes, the driftable reference is drift compensated.drift compensated.

Drift Compensation

• All production processes fluctuate randomly due to common causes within the process e.g. press expansion,terminal and wire tolerances.

• Drift compensation allows the driftable reference to follow this fluctuation, in a way that maintains sensitivity to special causes within the process.

Drift Compensation continued…

• If the crimp is good, the driftable referencedriftable reference is allowed to creep towards the last force curve

• The evaluation against the static reference acts as an end stop on this process.

• No drift compensation is applied to crimps which exceed the badbad or stop limitsstop limits

Operator Controls

• Only one user limit required– BLOBLO (BBad LLimit OOverall)

• All other limits set using factors– SS factor (SStop Factor)– TT factor (TTeach Factor)– DD factor (DDrift Factor)

Operator Controls continued…

• Stop Limit = BLO x S factor

• Teach Limit = BLO x T factor

• Drift Limit= BLO x D factor

• Note Above are overall limits, the CFA1000 takes these values and produces limits for the individual zones automatically during teaching depending on the zone widths

Operator Controls continued…

• BLO - Maximum allowable production tolerance

• STOP LIMIT - Value above which tool damage is likely and the machine must be stopped

• DRIFT LIMIT - Maximum allowable production drift

Operator controls continued…

• TEACH LIMIT - Maximum allowable value during the teach phase.

The above values are expressed as PPT or Parts Per Thousand . A Limit set at 80 defines a tolerance of +/- 80/1000 or +/-8%.

Operator controls continued…

• Additionally three zone sensitivity parameters S1, S2 and S3.

• Allow the zone to be made more or less sensitive than the others.

• Useful in problem applications for reducing the effects of noise for example.

Operator controls continued…

• Operating parameters can be edited using the GCP (password protected) or coax interface.

• Alternative analysis mode can be selected to analyse force curve as a K325 would. Can set analyse FROM and UNTIL angles using GCP.

Results display

T5

PK:0.00NC

Prod 150 L0 R

PASS

Prod 2

Esc for end

19 19 32 50 L

0 0 0 0 R

0 0 0

Teach Pass T5 0.00NC

Prod1 screen

Graphical results

Error bars

Prod2 screen

Tabulated results

Error highlighting

Machine Interface Options

• Signalling via high speed relays

• Coax interface

• Auxiliary inputs and power relays

Relays

• Preset modes for benchtop, Komax 40, Alpha generation machines and Artos TX

• Relay matrix allows binding a relay action to a set of specific events

• Events also generated by auxiliary inputs

Relays Continued…

• Events include Teach Fail,Prod Fail, Aux1 Low etc

• Relay Actions are :-– x - Do nothing– 0 - Off (Contacts Open)– 1 - On(Contacts Close)– S - Strobe– T - Toggle

Force Calibration

• Alternative to crimp height in specifying crimping process.

• Achieved using a special test jig

• Adjustable spring– NAMAS approved measurement system

• Force calibration allows CFA1000 to read accurately the peak force applied.

Software Upgrades

• CFA1000 can be reloaded using a laptop computer, serial link and windows 95/NT software

• Reduced cost of ownership, easier upgrading at lower cost as software is developed

• Introduces possibilities for site specific customising of software

Contact Us

Circuitmaster Designs Ltd

Kingsway West Business Park

Moss Bridge Road

Kingsway

Rochdale

Lancashire

OL16 5LW

United Kingdom

T - +44(0)1706 630606

F - +44(0)1706 510401

E – sales@circuitmaster.co.uk

W – www.circuitmaster.co.uk