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Programming Software BOS 6000

Programming Software BOS 6000. Training BOS 6000. 1. Basics 2. Starting BOS6000 3. Entering welding parameters and settings 4. Auxiliary functions 5. Diagnosis 6. Setup 7. Spot reference 8. Electrode prewarning 9. Error table 10. Plant layout 11. Protocol function

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Programming Software BOS 6000

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  1. Programming Software BOS 6000

  2. Training BOS 6000 1. Basics 2. Starting BOS6000 3. Entering welding parameters and settings 4. Auxiliary functions 5. Diagnosis 6. Setup 7. Spot reference 8. Electrode prewarning 9. Error table 10. Plant layout 11. Protocol function 12. Compare 13. Calibration 14. Installing BOS6000

  3. Training BOS 6000 1. Basics BOS5000 + BOS6000 BOS6000: Structure GUI, Database Communication interfaces

  4. Programming Software BOS 5000 • For local and centralprogramming • by portable or stationary computer • for Windows NT, Windows 2000 ...

  5. Programming Software BOS 5000 Timer setup Spot reference Entry of welding parameters Help

  6. Programming Software BOS 6000 (1/2) • for local and central programming • by laptop or central PC • for Windows 2000, XP .. • via V24 (RS232), Ethernet (TCP/IP) Interbus (Ethernet) Profibus FMS. • data base allows acces to parameters via Office tools. BOS 6000

  7. WeldingControl ProcessModule ServogunControl Programming Software BOS 6000 (2/2) The common user interface for provides programming, diagnosis, protocoll, documentation by a single tool.

  8. What is BOS6000? 32 Bit Application, Integrated SQL Server Supported Operation Systems: Windows 2000, Windows XP, Successor ... System Requirements: Pentium III min. 800Mhz, min. 128MB RAMmax. 3 GB HD, IE 5.0 Idea: • All data are stored in a local database! Advantages: • Easy data exchange with external applications • Quick access for display of overviews

  9. GUI Core Data Base BOS 6000: Structure • Task management • Calculation • Protocol management • Interface to drivers (V24, Ethernet, Profibus) • Parameters • Timer and Spot reference • Protocol memory • All texts • Data frames for timer types

  10. BOS 6000 GUI • Positions of windows are stored • Actual values can be displayed in colour • Dimension of icons in overview can be changed • All settings can be exported and imported

  11. Communication Interfaces of BOS 6000 • V24 (RS232) • Ethernet (TCP/IP) • InterBus (Ethernet) • ProfiBus FMS

  12. Training BOS 6000 2. Starting BOS6000 Start window: User name, password Timer reference window Online / offline mode

  13. BOS 6000: Start Password • Username: User, Everyone, Service, System, WeldMaster … • Icon on the desktop • Password (Default for User: bos6000)

  14. Timer Reference Add the timer name Add any reference comment select your comm Channel this is your software communication method V24, Ethernet….etc If you are connecting via Ethernet, then insert the IP address here Select Online or Offline mode Select the direction of data flow, on initial communication When the information has been installed, press ok, then select the Continue button to access the program data To add a new or additional timer, select the Add button first, the Add/change Timer box will then appear above

  15. Training BOS 6000 3. Entering welding parameters and settings Connection setup window Programming window General notes Sequence tab Heat Stepper tab Ext. Sequence tab General settings tab Electrode tab

  16. Timer Status Monitor the Status and Description window, if a red bar appears and stays then there is a problem with your communication path, cable, or the timer may be off. Monitor the Status and Description window, a yellow bar should proceed a green bar. This indicates that communication path is operational, and the database is being populated with the timer information. Please be patient, on the initial start-up it can take up to 5 minutes to gather all the data for the database. All subsequent connections will only take seconds to get on-line

  17. BOS 6000: Programming - New Login - Timer Reference - Spot Reference - Plant Layout - Log (Protocol) - Compare - Overview • Programming(Sequence,Stepper,General,Electrode,Power Unit • Setup (Stepper curves,Error reference,Communication) • Correction(Heat, Pressure) • Export Data • Autobackup • Timer Change • Copy • Firmware Update • New Login - Correction - Setup - Programming

  18. Program Page The spot number, program and communication status is found at the top of program page, as well as the drop down menu’s The raised tab indicates the page that is currently being viewed All functions/pages can be quickly accessed via the “icons” that are situated at the top of the pages. A single click will select the required page, and another single click will return you to your previous screen.

  19. Icons Plant layout Protocol Error Table Compare Pre-warning Table Parameter Overview Login Spot reference Comments Rights Administration Timer reference Overview Spot reference Table Program Page (Parameter data) Correction Diagnosis (i/o interface) Set-up

  20. Program Tabs By selecting individual tabs within the pages you can navigate around the software at the click of a button Dependent on the timer status, you can see if the timer is online, or offline. Blue is working offline Green is working online You can also see at a glance if the weld has a pre-heat, a post heat, or even if upslope or down slope.

  21. BOS 6000: Programming Sequence • SequenceSettings • SequenceTiming and Heat Parameters • Monitoring Settings • Actual Values

  22. Sequence The sequence screen allows the user to see the critical weld parameters at a glance Program Pressure Weld time Current Hold Squeeze Conversion from cycles to milliseconds. 5 cycles = 100msec I.e. multiply by 20 to convert Cycles to milliseconds Or divide by 20 to convert milliseconds to cycles

  23. Sequence To select a weld program:- to access the required program, simply select the program from the up/down buttons, or type in the actual program number. The electrode number will update when a program is selected. To select a spot number:- utilising the down arrow select the required spot number, and the program that is associated with it will automatically appear Inhibit Seq (P) (Inhibit this program sequence) This needs to be set to “Off”, if not then the weld sequence will be inhibited for this program only • Sequence:- There are 3 sequence options, Single: 1 weld sequence per start signal • Repeat: 1 weld sequence repeated until the start signal is dropped • Seam: 1 weld permanently on till the start signal is dropped Weld On/Off Int (P) (Internal weld on/off) This needs to be set to On, if not then the weld will be turned Off for this program only

  24. Sequence • Monitoring:- Mix or Standard • Standard mode: the actual current is determined by the complete weld cycle including any cool times • Mix mode: the actual current is determined by the individual weld times • *see illustration on the next sheet

  25. Sequence

  26. Sequence Regulation:- Mix or Standard If mix is selected, weld 1 & weld 3 can be programmed in PHA (phase angle) or KSR (constant current) mode If standard is selected then weld 1 and weld 3 can only be programmed in the same mode as weld 2

  27. Sequence: PHA = Phase Angle Control • Programmed in scale units % • The greater the %Ht, then the greater %age of current flowing Phase angle, fixed value determined by program Half-cycle of mains voltage 31° 130 ° - Electrical degrees 0° 180 ° 120 99 0 -15 - Scale units (%) High current Programmable range Low current

  28. Isec ~ 1. Measurement 3. Current correction 2. Phase shift KSR Uprim. Weld Timer Sequence: KSR = Constant Current Regulation • Programmed in Kilo Amperes (kA) • The current measuring device (Toroid) determines the actual current • This is compared to the command value • The timer can then adjust the phase angle ( if required )so that the command value can be achieved

  29. Sequence Electrode:- electrodes can be selected Reweld:- If this function is activated and a low weld current occurs with the start signal still high, the control will automatically attempt to reweld the program, if the weld is low again a weld fault is output. Note:- if there is no current, then a reweld will not be activated

  30. Sequence Impulse:- This function indicates how many times the weld 2, cool 2 function is repeated during 1 weld sequence. If the impulse function has a figure greater than 1, then the portion of the program that is inside the yellow shape is repeated however many times is programmed

  31. Sequence The time monitoring enables the weld time to be monitored and limits can be set to ensure that if the weld time is greater than or lower than the set limits, an error is produced

  32. Sequence As with many functions within the BOS6000 software, if a function is not programmed, the window may not be visible, e.g. if the impulse is at 1, • then the COOL 2 time is not visible.

  33. Sequence However, if the impulse were increased to a number greater than 1, then the cool 2 time becomes visible The same can be said for the monitoring and regulation parameters With the kA Monit set to Off, no extra parameters are visible.

  34. Sequence • When the monitoring is activated, all the tolerance band parameters become visible

  35. Sequence 1 2 3 4 Repeat factor, is the number of consecutive welds allowed between the conditional tolerance band and the lower tolerance band 1 2 4 3

  36. Sequence Ref, kA is the programmed reference current Act. Ref. kA is the actual current achieved Average PHA is the actual Phase angle required to achieve the required current

  37. BOS 6000: Programming Ext. Sequence • PressureProfile • Programmable Output • Time Monitoring

  38. Extended Sequence from this page the pressure profile function can be activated. When the profile is activated the force can be programmed to a specific value at any time during the weld sequence. The force can be altered up to 10 times during the weld process Please note, as with all parameters, if the cursor is placed in a programmable area, upper and lower limits of the selected parameter will appear at the base of the screen

  39. BOS 6000: Programming Heat Stepper Settings for • Tip Dressing • HeatStepper • Start Range

  40. Heat Stepper Heat increase % between tip dresses Max Wear:- The number of welds over which the heat is stepped (incremented)

  41. Heat Stepper Heat increase % between tip dresses Tip Dress Steps:- The number of dress steps (10) Dress-Request:- The number of welds before the max wear that the tip dress request output is activated Heat stepper:- activation on/off Wear factor:- individual welds can be given a greater or lesser “weighting”, dependent on the actual wear to the tips Max Wear:- The number of welds over which the heat is stepped (incremented) (500) Max Wear:- The number of welds over which the heat is stepped (incremented) Warn Wear:- Number of welds before the end of the max-life, that pre-warning becomes active (50) Please note:- The Max life is calculated by the multiplying (Max Wear x tip dress steps) + Max Wear i.e. (500 x 10) + 500 = 5500 welds Wear/comp:- The number of welds taken to complete one cycle Dress new Electrode:- The weld is inhibited, until the gun is dressed, immediately after the electrode has been replaced i.e. 5450 welds

  42. BOS 6000: Programming General Settings • GlobalElectrodeSetup • SequenceSetup • I/OParameters • Settings for CurrentMeasurement

  43. General Set-Up If activated the weld will be inhibited when max life is reached Mode Pressure Output: There are several options for pressure output, 4-20mA, 0-20mA, this project requires 0-10V output to the prop valve The (S) indicates that the function will be activated for ALL programs Max Weld Time, this is the control of the max weld time, for all programs, normally 0 … 2000msec, but here set to 600msec Max Rewelds:- this the number of consecutive welds allowed that are inside the conditional tolerance band

  44. General Set-Up If activated the weld will be inhibited when max life is reached Mode Pressure Output: There are several options for pressure output, 4-20mA, 0-20mA, this project requires 0-10V output to the prop valve The (S) indicates that the function will be activated for ALL programs Max Weld Time, this is the control of the max weld time, for all programs, normally 0 – 2000mS, but here set to 600mS A measuring loop check is a verification of the current sensor in the secondary circuit. On : Measuring loop test active, sensor faults are detected. Off : Measuring loop test not active, sensor faults are not detected. Max Rewelds:- this the number of consecutive welds allowed that are inside the conditional tolerance band Current measurement selects the type of monitoring, either secondary or primary

  45. General Set-Up The Fade out time parameter is used to suppress the natural current rise at the beginning of the weld time for current measurement The Trail current parameter is used to activate or deactivate measurement of the trail current after the last weld time. On : The trail current is included in the measured result. Off : The trail current is not included in the measured result. The trail current must match the settings of the external current meter for comparative measurements.

  46. BOS 6000: Programming Electrode Parameters • Current Limitation • ForceLimitationand Settings • MF TrafoSelection

  47. Electrode Set-Up The %I Prewarning parameter indicates the heat value (in scale divisions SKT) for which an imminent %I limitation is to be detected for the electrode displayed. Upper currrent limit is the maximum programmable set limit of the current in the individual electrode Bosch sensors have been adjusted to 150 mV / kA. When using third-party sensors, the appropriate transmission ratio can be programmed using the Toroid sensitivity parameter the reference current sensor can be programmed using the Toroid sensitivity 2 parameter. For details on the measuring range, see the next sheet

  48. Electrode Set-Up

  49. Electrode Set-Up Transformer type can be selected. This automatically sets the transformer ratio, and the diode type The Diode supervision/monitoring parameter may be used to deactivate diode monitoring (secondary diodes of the welding transformer). The computational emulation of the welding diode temperature determines whether the junction temperature is rising to more than 150°C, the switch off temp can be programmed from this parameter Actual welding diode temp Actual Mains supply Voltage

  50. Electrode Set-Up For the calibration procedure, see handbookTimer and I/O level of your control, chapter Scaling (Force Scaling, Current Scaling)

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