Soft & Hardware Solutions for Industrial Control and Worker Guidance

1. Welcome!

2. Contents • Introduction • TKSE-Project • Software forworkerguidance • Applications • User interface • Features • Limitations • News fortheupcomingversion • Other Projects 2

3. IntroductionOverview • Haller + Erne GmbH • Soft- andhardwaredevelopmentsince 1987 • 6 employees • ISO9001 certifiedsince 2012 • Data acquisitionsoftwarefor Rexroth tighteningsystems • Standard productsfordataconversion: • Q-Das QS-Stat (QTrans V1.1 certified 2005, V2.0 certified 2010 as AQDEF V3.0 Category C) • ForSciemetricQualityWorX (graphs + data) • Worldwide use in the automobile industry, e.g. GM, Ford • Software forworkerguidance • Recaro, Benteler • Worker guidance Porsche/Daimler, • Valveassembly Rexroth Lohr • Website www.haller-erne.de 3

4. IntroductionAreas ofactivity • Soft- andhardwareforindustrialcontrolandcommunication • Standard solutionsandcustomer-specificsolutions • Development: project-relatedsolutionsandengineering • Software forcollectingprocessdata, convertingandarchiving • Accessoriesfor Rexroth tighteningsystems • Hardware (e. g. socket trays) • Software PC/KG‘s (data-, protocolconverter, processcontrol) • Internal firmware (VxWorks) fortighteningsystems (IPM, PLUS) • IndraLogicapplicationsandmodules (e. g. Modbus-master fortighteningsystems)

5. TKSE-projectOverview • Small scaleseriesof AMG bodys • TwoNexo‘s per operator • Twooperator at oneassemblystationareworking on the same vehicle (leftandrightside) • approx. 20 tasks per side • approx. 100 bolts per side • Requirements: • Ensuring quality (worker guidance, socket tray, tightening and loosening bolts) • Visualization (which steps are up next, what‘s still missing) • Recording and storing data (scanning, Q-data, traceability) • Optimizing the process time 5

6. Worker guidance - softwareApplications • Prototypes and lab • Standalone-operation (without network) • Frequent changes of procedures • Documentation as pdf/printout (w. graph) • Production • Small scale series with multiple stations • Data interface with network, ident systems • Central definition of tasks and tightening specs • Standby workstations • Use as temporary replacement in case of breakdown of station on the line • Usable at multiple stations • Post-treatment • Similar to standby, but initial part status is provided by network 6

7. Worker guidance - softwareTopologyanddatamanagement • Splitting into different components… • Twodatabases – configurationanddata • “Monitor“ – runtimefortheworkplace • “Configurator“ – editorforconfiguration • …makes different topologiespossible • Standalone • Offline-configuration • Central configuration • Online/server-operation • Simple datamanagement • Versioningoftheconfiguration • Single-file copy/transfer

8. Worker guidance - softwareApplicationinterface – “Monitor“ • Also worksforsmallscreenswithlowresolution • Touch-screen operation • Minimalistic & simple • Onlythreepages: • Sign-in • Part list • Tighteningjob 8

9. Worker guidance - softwareApplicationinterface – “Monitor“ Job selection Current job Job status Visualization of job state Job selection by clicking (touch) Input: barcode scanner or keyboard Actions 9

10. Worker guidance - softwareApplicationinterface – “Monitor“ Tightening Job Job tightening results Tightening status (green: OK, red: NOK, yellow: next position) Pre-tightening (dark green), final tightening (light green) click/touch: loosen, delete, skip actions Current tool result of last rundown 10

11. Worker guidance - softwareApplicationinterface – “Configurator“ • Hierarchyofpartsandjobs (jobgroups) • Reusablejobs in different parts • Color codingforjobs(yellow) andjobgroups (blue) • Separate definitionofboltsandprocesssteps / toolactions 11

12. Worker guidance - softwareApplicationinterface – “Configurator“ Configurepartsandbarcodes production series Jobs/Groups for selected part list of all jobs/groups (catalog) menu and tabs Add job to currently selected part list of barcodes for parts list of barcodes for parts/assembly groups 12

13. Worker guidance- softwareApplicationinterface – “Configurator“ Creatingnewjobs picture selection additional functions (pictures/clipboard) Jobs and job groups menu and interfaces (tabs) create new parts by drag & drop navigation similar to Windows Explorer properties of the currently selected item actions 13

14. Worker guidance - softwareApplicationinterface – “Configurator“ Edit bolts Bolts (double click: add new ; ctrl/shift-click: change size ; right click: menu) list of bolts (with name, number) Filtering the displayed bolts: all, pre tightening, final tightening Active page shown is “bolts” properties of the selected bolt 14

15. Worker guidance - softwareApplicationinterface – “Configurator“ Edit tighteningsequence Bolts (double click: new ; ctrl/shift-click: change size ; right click: menu) drag & drop for changing sequence assigning tightening operations to steps: right click / add operation operation properties (tool, program-number, bit-type, …) actions Active page shown is “tightening sequence” 15

16. Worker guidance - softwareFeatures – Overview • Available functions • Multiple tools per station: • Ergospins • Tightening aggregates • Electronic wrenches/GWK • Single tool active per station • Manual confirmation and notes • Part-hierarchy: part, job groups, jobs • Pre-tightening, final tightening, post-process • Tightening positions in fixed sequence or free selection • Barcode or manual selection of jobs and parts • Not supported • Multiple workers working simultaneously at one station • Working on one tightening position with different tools/bits (two tools can be used by using the post-processing feature) • Reloading or editing tightening programs 16

17. Worker guidance - softwareFeatures – interfacesandexpandability • I/O withUSB, Profibus, OpenProtocol/IM24V, Modbus-TCP/UDP • Driver interfaceforboltingsystems • CS/KE (Profibus) andOpenProtocol (Nexo) • Electronic wrenchesGWK, Saltus • Socket trays(by USB or CS/KE IM24V) • Recognizeslocationoftighteningpositions (byProfibus) • Worker-identification(e.g. Euchner-Key) • Data outputinterfaces • XML-file (“Motis“), textfile(“csv“) • Exporting/archivingfromlocaldatabase • Lua-scripting forseveralapplicationareas 17

18. Worker guidance - softwareSpecial Features • “lowcost“ standalone-solution: Nexo + PC + MSTKN • Standard-PC (all-in-onetouch) withintegratedWLAN-AP • Nexowithdirect-WLAN-connection (withoutCS351) • Socket traysconnectedover USB • Plausibility check againstdrawingparams/plausibilityvalues • Pre-tightening, final tighteningand post-process • interrupting/resumingoperation on a part • 3 accesslevels (operator, supervisor (canloosen/delete), admin (caninput/changesettings)) • Core dataversioning • Changing a job will create a newversionofthejob/part • Historical partresultdata will stayconsistent • Report-designer • Report-generator can also generateconfiguration/masterdatareports (e.g. listoftools) andcustomerspecificreports 18

19. Worker guidance – softwareStartup andconfiguration • Initial startup • Setup byusinginstallationprogram • Configurationofstations • Tool interfacesetup • I/O-interfaces (configure BMS tableandevt. Profibus/OpenProtocol) • Texts/headers (engine, vehicle type, …) • Editingini-files • Definingtighteningprocesses • Customer can do thathimself • Use“Configurator“ GUI application 19

20. Worker guidance - softwareOn theagenda… • Changes planned for current version • Improved error messages • Per tool diagnostics (currently only by tool type/driver) • Text-display on Nexo (if timing gets fixed with V1100) • Changes planned for next version • Enhanced (per job/bolt) loosening operations • Splitting station and process definition, definition of tightening process not depending on tool used (use a „operation name“ instead of tightening program number, so each stations can use different programs numbers) • Improve ease-of-use for configurator • Improved handling of part variants • Improved station/ hardware configuration • Better modularity • Additional scripting areas 20

21. Thank you for your attention