CircuitMaster CFA1000

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CircuitMaster CFA1000
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Introduction

• Crimp Force Analysis Overview
• System Overview/Options
• Force Curve Basics
• CFA1000 Analysis Method
• Teaching Phase
• Production Phase
• Operator Control Parameters

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Introduction continued...

• Machine Interface Options
• Force Calibration Overview
• In the field software upgrades

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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.

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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

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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

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CFA System Overview
Machine I/F
Control Panel
Processing Unit
Encoder
Force Sensor
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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.

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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

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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 lt20mS after BDC)

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Machine Interface

• INTERFACE APPLICATION
• 2 High Speed relays (e.g. Komax 40,
  Opera, Artos TX)
• 2 Power Relays (Benchtop)
• Coaxial Interface (e.g. Komax Alpha
  generation)

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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

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CFA1000 Variants

• Two Different Variants -
• CFA for Machines CFA1000M
• CFA for Benchtop CFA1000B

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I/O Board
Buzzer
High Speed Relays
Aux Inputs
Coaxial Interface
Power Relays
Mains PSU
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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

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Force Curve
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Insulation Crimp Phase
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Main Crimp Phase
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Peak Force Phase
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Insulation in main crimp
Force is increased during the main crimp, due
to the trapped insulation increasing the
effective CSA of the wire
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Cut Fault
Force is reduced in the main crimp phase due to
strands being cut reducing the wire CSA
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Insulation Crimp Fault
Force is reduced in insulation crimp due to
deformed insulation crimp ears.
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Interim Summary

• Seen what constitutes a CFA
• Sensor, Evaluation Unit, GCP, Machine Interface
• Applications of CFA1000
• Force curve
• Salient features
• Some typical faults

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K325 Analysis
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K325 Analysis continued...

• Advantages
• Simple to evaluate
• Disadvantages
• 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 )

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CFA1000 Analysis
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Errors in each zone
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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

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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)

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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

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Teaching Phase

• 1st Cycle Force curve is scaled by the internal
  amplifier to give best possible resolution
• 2nd 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

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Teaching Phase continued

• 3rd - (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 The averaged reference is
  copied to form two references
• STATIC REFERENCE
• DRIFTABLE REFERENCE

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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.

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Production Phase

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

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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.

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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.

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Drift Compensation continued

• If the crimp is good, the driftable 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 bad or stop limits

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Operator Controls

• Only one user limit required
• BLO (Bad Limit Overall)
• All other limits set using factors
• S factor (Stop Factor)
• T factor (Teach Factor)
• D factor (Drift Factor)

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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

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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

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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.

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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.

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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.

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Results display
Prod1 screen Graphical results Error bars
Prod2 screen Tabulated results Error highlighting
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Machine Interface Options

• Signalling via high speed relays
• Coax interface
• Auxiliary inputs and power relays

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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

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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

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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.

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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

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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_at_circuitmaster.co.uk
• W www.circuitmaster.co.uk