SyStem SolutionS for AutomAtion

SyStem SolutionS for AutomAtion

Systems supplier for cutting-edge information and control technologyOur company, EST Elektronische Schraub- und Steuerungstechnologie GmbH & Co. KG, is part of the SCHMID Group and as such is represented on a stand-alone basis in the market. EST also benefits from inter-disciplinary integration within the SCHMID Group's pool of knowledge and expertise. Working independently of any particular sector, EST serves the demanding need to develop and realise data, control and process solutions geared to the future. The areas of use are the large field of automation technology and the networking of produc-tion and assembly systems, here in particular for con-trolling production, tracking parts and documenting pro-cess data. This nowadays is a significant issue in regards to the traceability of fitted parts in the event of a product liability case.

Efficiency and process reliabilityIn this area EST provides systems for the control and monitoring of screwing and press-fitting processes. The units used here are the flexE12 computer-assisted con-trol units and regulators developed in house. Integrated within them in addition to the processing/metering func-tion is software PLC functionality. The programming lan-guage conforms to the IEC1131-3 international standard.

Qualified service and practically-oriented trainingEST supports and facilitates the solution for your visions. Take advantage throughout our customer-oriented pro-ject management process of years of experience and top expertise, which will continue to provide you with support beyond the end of the project through the range of train-ing, support and maintenance services that we offer.

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ISO/VDA certificationEST is certified to DIN EN ISO 9001/2008 VDA 6.4.

ISO/IEC standardEST has been assessed compliant with the international ISO/IEC15504 (SPICE) standard. On the basis of this international standard, assessors evaluate company processes, placing the emphasis on software development.

uniquelydifferent

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realisation of individual requirements

experienced project engineers as point of contact

feasibility testing

most effective method of realisation

Constant dialogue between project team and client

Short lines of communication

optimisation of costs

forward-looking certainty, standards and productivity

Central project handling

utilisation of cross-project synergies

Assistance through to the final result

Post-project support

expertise passed on in training sessions

Bespoke maintenance contracts

Periodic checks and adjustment of the systems

Group of companies with extraordinary pool of knowledge and expertise

VISIONS

SERVICE

SYNERGY

CUSTOMER FOCUS

EXPERTISE

infinitelyinfinitelyViSiOnArYViSiOnArY

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PROJECT MANAGEMENTEST offers comprehensive engineering services for project managing fitting out production and assembly equipment with control systems.

REALISATIONOne of EST's particular strengths is offering clients 'turnkey' solutions.

Selection of sensor and actuator technology

Planning the control concept, including determining the hardware (PlC) components

Planning the operating concept

Planning the visualisation concept

Planning the it concept, including determining the network architecture and the computer systems

Producing the hardware documentation using various CAe systems (e.g. ePlAn, ruPlAn, etc.)

Creating the software for the PlC systems

Creating the software for production-related it functions

Assembly and wiring of switch cabinets

installing system electrics using cutting-edge technologies (bus systems, hardware components, etc.)

System commissioning through to handover ready for use

emC checks carried out by an accredited service provider

Adjusting, optimising and setting parameters, etc. of the process (-joining) workflows

Providing after-sales service alongside the production operation

FLEXIBLE

EFFICIENT

LOW MAINTENANCE

FAST

COST EFFECTIVE

Other important areas, in which the products and systems (hardware and software) developed by EST are used, are:Assembly/screw-fitting equipmentElectronically controlled joining processesProduction metering systems and data backup

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SCrEW-fAStEninG AnD PrESS-fittinG ContRol SyStemS

flexE12 C series

· A range of versions, including for master/slave system architecture within assembly lines

· 1- or 2-channel control unit in compact housing

Version: flexE12 CM (master unit)· 10.4“ touchscreen for programming and

visualisation· SSD for data storage· Freely programmable operating/signalling

elements and binary I/O signals· Diverse serial interfaces· USB interface (including on device front)· Ethernet interface· Profinet interface· Hybrid plug connector for thightening tools,

presses and force / path measuring systems

Version: flexE12 CS (slave unit)· Profinet interface· Ethernet interface· Hybrid plug connector for thightening tools,

presses and force / path measuring systems

System structure: CM + CS

Various different versions of the master/slave system architectures are possible for equipping process-con-trolled workstations within an assembly line/island. Up to 8 flexE12 CS (slave units) can be activated from a flexE12 CM (master unit), which can be assigned to any workstation. The slave units can also be freely assigned within an assembly system. The programming / setting the parameters of up to 8 flexE12 CS (slave units) can be done from a flexE12 CM (master unit) or from the main computer.

The flexE12 CS (slave units) can be configured for dif-ferent assembly processes. Activation and analysis of an electronic torque wrench is, for example, possible. It is also possible, to integrate control of wrench socket boxes into such a system architecture.

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flexE12 E range

Version: flexE12 master unit· Developed by EST· Windows 7 / 10 operating system· Ethernet interface· Profinet device interface· Profinet master interface· 4 USB interfaces· SSD for data storage

Version: flexE12 MSR / servo unit· Developed by EST· Multilayer· SMD technology· Highly integrated system modules· Integrated plug connectors· Choice of 1- or 2-channel compact design· Master functionality via multiple MSR/

servo units with standard IPC· Switch cabinet installation

· On-board power supply units· Integrated servo amplifier· LCD matrix display· Profinet interface· Integrated Profinet switch· Digital inputs/outputs· Analogue inputs/outputs· 4 serial interfaces· Produced using cutting-edge

manufacturing technologies

By virtue of the modular structure on both the hardware and software side, plus the configurable sensor interface, it is possible to use the units for controlling various differ-ent processes (e.g. thightening, press-fitting, measuring coefficients of friction, path measurement, etc.).

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tHiGHteninG toolS AnD JoininG moDuLES

flexE12tool spindle

· BG0, BG1, BG2, BG3 torque range of 1 Nm to 1800 Nm

· EC motor· Planetary gears· Chip for storing screwdriver data· Transducer

- Law of motion principle- Contactless- Digital telemetry- Integrated rotation angle sensors

· Floating tool holder· Modular design· Suitable for reverse operation (by the motor

reversing its direction of rotation)· Configurations

- Coaxial downforce- Offset downforce- Angled downforce- Diverted downforce

Handheld spindle

· Pistol-grip and handheld offset screwdrivers' torque range of 3 Nm to 220 Nm

· EC motor· Planetary gears· Chip for storing spindle data· Sensor

- Law of motion/reaction principle - Integrated rotation angle sensors

· Integrated design· Configurations

- Pistol-grip screwdriver- Straight spindle- Right angle spindle

· Coaxial downforce· Transducer with plausibility

measuring circuit· Redundant transducer

· Offset downforce· Transducer with plausibility

measuring circuit· Integrated transducer

· Transducer with plausibility · Angled downforce· Transducer with plausibility

measuring circuit

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flexnuka socket box

· Modular set-up with service door· Profinet connection· Process indicators· Infinitely variable setting of the tool preparation

position· Adjustable tool encoder plates· Electric presence monitoring

flexE12 press joining modules

· Operated by electric motor· Press-in force range of 1 kN to 100 kN· EC motor· Absolute recording of press-in path· Digital recording of press-in force· Programmable monitoring process

- Path-dependent control of force progression- Control of the press-in depth- Control of the block force

· Programmable control functions- Pressing in to 'Depth'- Dynamic block force adaptation

· Joining module· Motor with stopping

brake· 2-circuit safety brake

(option)

· Coaxial downforce· 1800 Nm· Redundant transducer

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DAtA AnD inFoRmAtion teCHnoloGy

flexPara parameter setting

Whole lines of stations can be managed via flexPara. Each station gets configured related to the previously selected joining technology (thightening, pressing, path measurement). It is also possible to combine multiple technologies with each other within one station. The process programmes can be built up on a modular basis from individual functions and from sets of func-tions. A multitude of control and monitoring functions are available for this. Type-related parameter setting (e.g. vehicle or engine type) is also supported. In ad-dition to the transmission of target data for control purposes, also available for the exchange of data are a benchmark run, data backup function and the system administration function.

In this area, being a renowned systems supplier well-es-tablished in the marketplace, EST project manages net-work architectures for, as an example, central setting of parameters, visualisation, recording of production and quality data, etc.

Electronically controlled joining processes represent one of EST's key areas of activity. EST offers for this flex-ible, universal systems for control and monitoring. The flexE12 system's control units used here are products

developed by EST itself. The two applications that serve as the current flexE12 generation of control units' user interface are flexPara (parameter settings) and flexVisu (visualisation). flexPara and flexVisu were developed by EST using NET technology and thus provide a very good basis for further development and client-specific solu-tions. Incorporating client requests, EST produces for these the specially tailored specification documents.

flexVisu visualisation

Process data is depicted via flexVisu. Here too the flex-ible approach continues. The actual values shown can be chosen via a selection screen. Furthermore, a range of different forms of presentation (e.g. large display) are available, enabling users to pick the appropriate form for the application in question. The progression of the process can be presented both as a single curve and as an array of multiple curves. Any image (e.g. a photo of the component concerned) can be incorporated for the display of the thightening position. The status of the individual thightening points is shown via a change of colour.

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initiAL tEnSion flexsonic mEASurinG SYStEm

flexMIS employee information system

Another of EST's specialist areas is the project man-agement and development of employee information systems (flexMIS). These are usually special solutions specific to the client and application. In most cases, in addition to the software solution, they cover the project management of the network architecture and the sup-ply of the components being used. They might, for in-stance, show the employee the assembly sequence, the screw connection points and the status messages. Via a touch-panel the employee is able to report various different processing and/or assembly problems.

Signal transmission module

Spindle socket with integrated ultrasonic transducer

task:

The principle of how a screw connection works is based on the pressing together of the parts to be connected. The process force is derived in the main from the screw's initial tension. Initial tension is the parameter that determines the quality of every screw connection. The screw breaking or working loose are the two extreme consequences of incorrectly set initial tension.

It is generally accepted that the influence of the stress or strain caused by initial tension on the time span of ultrasonic waves makes it possible to determine a screw's initial tension, expansion or elongation. The flexsonic system exploits this so-called 'acousto-elastic effect' to control the screwdriver based on the screw's initial tension.

Solution:

· Evaluation of the ultrasound propagation through use of specially selected ultrasonic transducers

· Integration of the ultrasonic transducer into the spindle socket, taking into consideration suitability for high-volume production

· Signal transmission module working on a contactless basis· Automated measurement and analysis· Control of the thightening process using the time span measurement

results recorded· Continual comparison of the calculated characteristic curve

Technical details and descriptions of the system and procedure are contained in the special EST flexsonic literature.

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engine production Six hundred thightening channels, in the form of sin-gle and multiple spindles, are used in this project. For reasons of process reliability various different thighten-ing systems were equipped with a screw point control function. Via the EST visualisation interface the worker is shown the screw point to be worked. After the screw has been screwed in, the result (OK or NOK) is indicated by means of a colour change.

When using absolute path measuring systems, the po-sition of the respective screw point can be automatically parameterised/taught via the EST system software. The path measuring systems can, for example, be directly connected to the EST screw control system via a Profinet interface.

Communication with the daisy-chaining control system is via a standardised Profinet interface, which is identi-cal for all thightening channels (automated stations and handheld spindles).

engine assemblyBalancer shaft joining station Using this automated station, the so-called balancer shaft gets automatically joined into the crankcase. The balancer shaft stands ready on a collecting point that is fed by an automatic stacking mechanism. After the component car-rier moves into the station, the centring pin moves through the storage bars in the crankcase into the centre of the balancer shaft. Via the clamp-like joining mechanism, the balancer shaft is now fed into the crankcase. This joining movement is performed by the aforementioned NC axis. The progression of the force along the path is checked during the movement in the form of multiple freely pro-grammable monitoring windows. The joining process is extremely sensitive and therefore places high technical demands on machine construction and monitoring elec-tronics. In addition to the complete control system, EST also project managed and supplied the integrated force /path measuring equipment, which is based on the flexE12 system.

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rear-axle differen-tial assemblyThis manufacturing system was specially developed for a new production concept for assembling the rear-axle differential. Created for putting the differential together was a new assembly line thoroughly geared to adding val-ue. The assembly line is so flexibly designed that it can produce 4 case sizes, fitting each out automatically. The component carrier circulation is guided by a low-floor transfer system. The cycle time is 58 seconds. The as-sembly line's space requirement is 18 x 110 metres. The 18 automated stations with 5 semi-automatic stations and 6 manual workstations enable extreme flexibility. The force displacement of all pressing-in processes is mon-itored by means of an electric spindle. At full utilisation with multiple machines in operation, 9 operatives work on the system. Using this concept, it has been possible to reduce throughput times substantially.

yield point measur-ing test benchThis test bench developed as part of a client commission is used to examine screw connections around wheel mount-ings on motor vehicles. One of the components that EST developed for this application is a so-called measuring hub with integrated sensors. Using this and downstream sys-tem amplifiers, it is possible via an EST system software package to monitor the behaviour of the complete screw assemblage. This is necessary in order to simulate differ-ent levels of loading of the screw connection such as arise during the journey.

the scope of services provided by eSt

· The complete mechanics, project management, design, manufacture and assembly

· Thightening and measuring equipment, project management, programming and parameter setting

· Process checks

· Documentation system for the process engineering's results

· Control systems, project management and implementation

· Integrated software for remote maintenance

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assembly bench Zsb modules Assembly stationThis project deals with an EST assembly station for the assembly of heat exchangers. In addition to the assem-bly and handling mechanisms, also included within the scope of the project are a thightening system, a label-printing unit and various containers for the provision of materials.

flexaccu

the scope of services provided by eSt

· The complete mechanics, project management, design, manufacture and assembly

· Thightening equipment, project management, programming, parameter setting, screwdriver handling with absolute path-measuring systems and weight compensation

· Documentation system (for quality status), label printer with automatic handling / label attachment

· Control systems, project planning and running, integrated software for remote maintenance

Hardware and software development for wireless module with WLAN technology (WLAN 802.11b/g 2.4GHz) for rechargeable spindles. This wireless module made by EST was developed as part of an R&D project for a client. Below is some technical information about the development:

· WLAN 802.11b/g 2.4 GHz

· Multilayer

· Up to max. 16 spindles can be connected to one master unit

· Each spindle has a unique ID (e.g. 0345001)

· Sleep mode for saving battery power

· Integrated interfaces: barcode scanner, display, acoustic signal generator

· Temporary storage of data on the wireless module in case no wireless connection exists (e.g. when performing screw connections inside a vehicle ('Faraday cage'))

· Batteries changed without losing data

· Central parameter setting and visualisation

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gearbox assemblyAs part of a gearbox assembly project the software for visualising and setting the parameters of the adjustment and measurement process was 'developed' by EST. This is an extremely complex process. While the bevel drive gear spins, the screw connection of the collar nut there for fastening is performed. Simultaneously with the star-ting torque, the frictional torque of the bevel drive gear's mounting gets measured. As during / coincident with the making of the screw connection within a certain range a joining process is also being monitored, these actual process values have to be offset based on an algorithm developed by EST. The pictures show samples of the user interface.

intake module assemblyThis semi-automatic workstation is for the assembly of intake modules.

The quadruple thightening system is manually moved forward by the operative and then the fully automatic, 3-stage, synchronised screwing process (1 x torque and 2 x oblique tightening) is started. After the screw connection has been made, the system moves fully automatically to the home position. Next, further screw connections are made using a handheld spindle, which is integrated into the thightening control unit as an additional tool.

For process monitoring and traceability all actual screw connection values, the scanned-in serial numbers, the type and the date/time are transmitted to a central system by TCP/IP protocol. If for any technical reasons it is not possible to transmit the data, it is temporarily stored fully automatically on the thightening control unit.

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www.schmidgruppe.de

EST Elektronische Schraub- + Steuerungstechnologie GmbH & Co. KGHeidenheimer Straße 47 · 73447 Oberkochen GermanyTelefon +49 (0) 7364 96990-0Telefax +49 (0) 7364 96990-48info@est-technologie.dewww.est-technologie.de