Ingersoll-Rand (India) Limited

LIST OF FIGURES S.No. LIST OF FIGURES Page No.1.1 Company Profile 32.1 Solution Business 52.2 Ergonomic Handling 62.3 Precision Fastening 72.4 Fluid Solutions 8 3.1 Electronics Lab 9 3.2 ICD/M Controllers 10 3.3 Siemens PLC 10 3.4 Control panel having Siemens PLC 12 3.5 Allen-Bradley PLC 12 3.6 QM series DC tool 20 3.7 QE series DC tool 21 3.8 Inputs 24 3.9 Outputs 25 3.10 Power head port 26 3.11 Terminal switch 26 4.1.a Actual design 27 4.1.b Layout 28 4.1.c Side view 28 4.1.d Upper view 29 4.2 Powerhead srtup mode 30 4.3 Config 1 assigned 31 S.No. LIST OF FIGURES Page No. 4.4 Parameters 32 4.5 Program parameters32 4.6 Program parameters33 4.7 Config 2 assigned 34 4.8 Program parameters34 4.9 Program parameters35 4.10 General setup 35 4.11 Controller 1 I/Os 36 4.12 Controller 2 I/Os36 4.13 Controller 3 I/Os37 4.14 ETA 39 4.15 Sound level meter39 5.1 Actual Design40 5.2 Side view 41 5.3 Readings 43 5.4 RI Bracket tightening43 5.5 Readings 44 5.6 Housing screw44 5.7 Readings45 5.8 RI shaft tightening45 5.9 Readings46 5.10 Cable anchoring46 5.11 Readings47 5.12 B Mount bracket47 S.No. LIST OF FIGURES Page No. 5.13 PC adapter48 5.14 Profibus connector48 5.15 Actual layout49 5.16 I/O of controller50 6.1 Appearance of ZEN PLC52 7.1 Steps of program60

TABLE OF CONTENTS

S.No. TABLE OF CONTENTS Page No. 1. COMPANY PROFILE 3 1.1 Overview 3 2. DEPARTMENT OF WORKING 5 2.1 Solution Business 5 2.2 Ergonomic Handling System 6 2.3 Precision Fastening 7 2.4 Fluid Solutions 8 3. EED 9 3.1 Electronics Lab 9 3.2 Research & Development 10 3.2.1 Application 10 3.3 Testing, Support, Training 11 3.3.1 Application 11 3.4 DC Tools 20 3.4.1 QM series DC tools 20 3.4.2 QE series DC tools 21 3.5 ICS software 22 3.6 Power head setup 25 4. PROJECT 1 30 4.1 Introduction 30 S.No. TABLE OF CONTENTS Page No. 4.2 Customer and its requirements 33 4.3 Drawing39 4.4 Problems faced40 4.5 Quality check40 5. PROJECT 242 5.1 Introduction42 5.2 Customer and its requirements43 5.3 Drawing51 6. . PROJECT 352 6.1 Introduction52 6.2 Applications/Projects54 6.3 Other projects/applications58 7. OTHER PROJECTS AND APPLICATIONS59 7.1 Introduction59 7.2 US Controller testing59 7.3 NPD Lab/EB testing lab62

CHAPTER ONECOMANY PROFILE

Ingersoll-Rand (India) Limited

Fig.1.11.1 OverviewINGERSOLL Rand India Private Limited was founded in Kolkata in 1921, one of the first American investments in India. In 1958 the company opened a branch office in Ahmedabad and in 1963 the head office was shifted to Mumbai. INGERSOLL Rand established its first manufacturing plant in Naroda, Ahmedabad in 1965 and in 1977 became a public limited company.INGERSOLL RAND is a $14 billion global diversified industrial company, driven by employees who are proud to offer products and solutions people use every day to create a positive impact in their world. Driven by a 100- year-old tradition of technological innovation, we enable companies and their customers to create progress.With a major emphasis on Innovation to drive Productivity, the company has had many firsts to its credit. INGERSOLL Rand is a pioneer in bringing centrifugal technology into India and started when centrifugal technology was hardly known and accepted. In recent times, with the focus shifting to energy efficient compressor technology, INGERSOLL Rand launched the award-winning Nirvana energy saving rotary compressors. The company continues to bring latest technologies to India and launch localized products keeping in mind the requirements of the Indian market. Not just path-breaking technologies and products, INGERSOLL Rands key strength is its world class service that it provides to its customers across the country.Ingersoll Rand Industrial Products Pvt. Limited is a part of Ingersoll Rand's Industrial Technologies Sector .Ingersoll Rand's experienced workforce is committed to produce high quality assembly equipments and is provided with modern manufacturing & test facilities. All critical operations are done in house. The company has been certified to comply with ISO 9001 requirements. Ingersoll Rand Industrial Products Pvt. Limited lays great emphasis on pre & after sales service to help customers select appropriate technology and products to exactly match their applications and requirements as well as to ensure optimum utilization of equipments supplied. Ingersoll Rand Industrial Products Pvt. Limited also manufactures and markets a complete range of accessories.Ingersoll Rand's portfolio of businesses are divided into four distinct sectors.The Climate Solutions sector delivers energy efficient HVACR solutions for customers globally. Its brands includeHussmann, a manufacturer of refrigeration and food merchandising solutions,Thermo King, transport temperature controls, andKrack, warehouse refrigeration, andTrane, a provider of energy efficient heating, ventilating and aire conditioning systems, building contract services, world class parts support and advanced controls for homes and commercial buildings.The Industrial Technologies sector provides products, services and solutions that enhance energy efficiency, productivity and operations.Ingersoll Randbranded products range from complete compressed air systems, tools and pumps to material and fluid handling systems and environmentally friendly microturbines. Also included in this sector isClub Car, the global leader in golf carts and utility vehicles.The Residential Solutions sector comprises brands such asSchlage, Schlage LiNK andTrane. Products, services and solutions include mechanical and electronic locks, heating and air conditioning systems, indoor air quality solutions, advanced controls, portable security systems and remote home management.Security Technologies sector products include electronic and biometric access control systems, locks andlocksets,door closers, floor closers,exit devices, steel doors and frames, portable security devices, decorative hardware, cabinet hardware and time, attendance and personnel scheduling systems from brands likeSchlage.In 2007, the Security Technologies sector started to move the Falcon, Monarch and Dor-O-Matic brands into a new single brand ofFalcon Door Hardware. The individual brands will lose their identity in 2008 and 2009.

Ingersoll Rand Industrial Products Pvt. Limited - Factory and North/East ZoneSales office: - 37-A, Site 4, Sahibabad Industrial Area, Ghaziabad -201 010 U.P

CHAPTER TWODEPARTMENT OF WORKING(SOLUTIONS)

Ingersoll Rand Industrial Products Pvt. Limited- South Asia Solution Centre.2.1 Solution Business Fig.2.1

2.2 Ergonomic Handling System

Fig.2.2

2.3 Precision Fastening

Fig.2.3

2.4 Fluid Solutions

Fig.2.4

CHAPTER THREEEED LAB(RESEARCH AND DEVELOPMENT)

3.1 Electronics Lab

Fig.3.1

3.2 Research & Development 3.2.1 APPLICATIONS ICD/M Controllers ICD ICMFig.3.2The IC12D Series of controllers give you full closed loop-control in an industry leading compact size. With features like 1/4 VGA color display and intuitive programming interface, the IC12D units provide unmatched performance and value. These controllers have full communication capability using Ethernet, RS232, Field bus or standard I/O. Units may be programmed either through the key pad or via a PC running ICS software. IC12D Controllers will self identify and operate all QE and QM Series of tools making set-up and operation an easy task. 1/4 VGA 216 color display Ethernet, RS232 and I/O communication Device Net and Profibus available Dual mode power supply: 90 - 120 VAC and 200 - 240 VAC Operating range of 0 to 50 degrees C Operates all QE and QM Series Tools Multiple mounting optionsThe IC12M Series of controllers give you full closed loop-control in an industry leading compact size. With standard features like multiple torque strategies, digital display and Parameter Transfer Key, the IC1M units provide unmatched performance and value. These controllers have full communication capability using Ethernet, RS232, Fieldbus or standard I/O. Units may be programmed either with the Parameter transfer Key or via a PC running ICS software. A 0 to 60 degree C (32 to 140 F) internal operating range allow these units to be used in the most demanding conditions without risk of overheating. IC12M Controllers will self identify and operate all QE and QM Series of tools making set-up and operation an easy task.

One Line digital display Ethernet, RS232 and I/O communication DeviceNet and Profibus available Dual mode power supply: 90 - 120 VAC and 200 - 240 VAC Operating range of 0 to 60 degrees C Operates all QE and QM Series Tools Multiple mounting options EOR PRINTFollowing steps are there-1. Controller should be in power head mode (CAN address should be 1).2. EOR print settings should be as follows:-

3. The output screen looks like-

4. Most required step-

SQL Queries

SQLsometimes referred to asStructured Query Language) is a programming languagedesigned for managing data inrelational database management systems (RDBMS).The most common operation in SQL is the query, which is performed with the declarativeSELECTstatement.SELECTretrieves data from one or moretables, or expressions. StandardSELECTstatements have no persistent effects on the database. Some non-standard implementations ofSELECTcan have persistent effects, such as theSELECT INTOsyntax that exists in some databases. Queries allow the user to describe desired data, leaving thedatabase management system (DBMS)responsible forplanning,optimizing, and performing the physical operations necessary to produce that result as it chooses.

PLC

Fig.3.3Fig.3.3 shows Siemens PLCAprogrammable logic controller(PLC) orprogrammable controlleris adigital computerused forautomationof electromechanicalprocesses, such as control of machinery on factoryassembly lines,amusement rides, orlight fixtures. PLCs are used in many industries and machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed-up ornon-volatile memory. A PLC is an example of ahardreal timesystem since output results must be produced in response to input conditions within a bounded time, otherwise unintended operation will result.More recently, PLCs are programmed using application software on personal computers. The computer is connected to the PLC throughEthernet,RS-232,RS-485orRS-422cabling. The programming software allows entry and editing of the ladder-style logic. Generally the software provides functions for debugging and troubleshooting the PLC software, for example, by highlighting portions of the logic to show current status during operation or via simulation. The software will upload and download the PLC program, for backup and restoration purposes. In some models of programmable controller, the program is transferred from a personal computer to the PLC through aprogramming boardwhich writes the program into a removable chip such as anEEPROMorEPROM.The functionality of the PLC has evolved over the years to include sequential relay control, motion control,process control,distributed control systemsand networking. The data handling, storage, processing power and communication capabilities of some modern PLCs are approximately equivalent todesktop computers. PLC-like programming combined with remote I/O hardware, allow a general-purpose desktop computer to overlap some PLCs in certain applications. Regarding the practicality of these desktop computer based logic controllers, it is important to note that they have not been generally accepted in heavy industry because the desktop computers run on less stable operating systems than do PLCs, and because the desktop computer hardware is typically not designed to the same levels of tolerance to temperature, humidity, vibration, and longevity as the processors used in PLCs. In addition to the hardware limitations of desktop based logic, operating systems such as Windows do not lend themselves to deterministic logic execution, with the result that the logic may not always respond to changes in logic state or input status with the extreme consistency in timing as is expected from PLCs. Still, such desktop logic applications find use in less critical situations, such as laboratory automation and use in small facilities where the application is less demanding and critical, because they are generally much less expensive than PLCs.

Fig .3.4

Fig .3.4 shows panel having Siemens PLC CPU.The main difference from other computers is that PLCs are armored for severe conditions (such as dust, moisture, heat, cold) and have the facility for extensiveinput/output(I/O) arrangements. These connect the PLC tosensorsand actuators. PLCs read limitswitches, analog process variables (such as temperature and pressure), and the positions of complex positioning systems. Some usemachine vision. On the actuator side, PLCs operatemotors, pneumaticorhydrauliccylinders, magneticrelays,solenoids, or analog outputs. The input/output arrangements may be built into a simple PLC, or the PLC may have external I/O modules attached to a computer network that plugs into the PLC.A PLC program is generally executed repeatedly as long as the controlled system is running. The status of physical input points is copied to an area of memory accessible to the processor, sometimes called the "I/O Image Table". The program is then run from its first instruction rung down to the last rung. It takes some time for the processor of the PLC to evaluate all the rungs and update the I/O image table with the status of outputs.. This scan time may be a few milliseconds for a small program or on a fast processor, but older PLCs running very large programs could take much longer (say, up to 100 ms) to execute the program. If the scan time was too long, the response of the PLC to process conditions would be too slow to be useful.As PLCs became more advanced, methods were developed to change the sequence of ladder execution, and subroutines were implemented.]This simplified programming and could also be used to save scan time for high-speed processes; for example, parts of the program used only for setting up the machine could be segregated from those parts required to operate at higher speed.Special-purpose I/O modules, such as timer modules or counter modules, could be used where the scan time of the processor was too long to reliably pick up, for example, counting pulses from a shaft encoder. The relatively slow PLC could still interpret the counted values to control a machine, but the accumulation of pulses was done by a dedicated module that was unaffected by the speed of the program execution.PLCs may need to interact with people for the purpose of configuration, alarm reporting or everyday control. Ahuman-machine interface(HMI) is employed for this purpose. HMIs are also referred to as man-machine interfaces (MMIs) and graphical user interface (GUIs). A simple system may use buttons and lights to interact with the user. Text displays are available as well as graphical touch screens. More complex systems use programming and monitoring software installed on a computer, with the PLC connected via a communication interface.PLCs have built in communications ports, usually 9-pinRS-232, but optionallyEIA-485orEthernet.Modbus,BAC netorDF1is usually included as one of the communications protocols. Other options include variousfield busessuch asDevice NetorProfibus. Other communications protocols that may be used are listed in theList of automation protocols.Most modern PLCs can communicate over a network to some other system, such as a computer running aSCADA(Supervisory Control And Data Acquisition) system or web browser.PLCs used in larger I/O systems may havepeer-to-peer(P2P) communication between processors. This allows separate parts of a complex process to have individual control while allowing the subsystems to co-ordinate over the communication link. These communication links are also often used forHMIdevices such as keypads orPC-type workstations.PLC programs are typically written in a special application on a personal computer, then downloaded by a direct-connection cable or over a network to the PLC. The program is stored in the PLC either in battery-backed-upRAMor some other non-volatileflash memory. Often, a single PLC can be programmed to replace thousands ofrelays. Under theIEC 61131-3standard, PLCs can be programmed using standards-based programming languages. A graphical programming notation calledSequential Function Chartsis available on certain programmable controllers. Initially most PLCs utilized Ladder Logic Diagram Programming, a model which emulated electromechanical control panel devices (such as the contact and coils of relays) which PLCs replaced. This model remains common today.IEC 61131-3 currently defines five programming languages for programmable control systems:function block diagram(FBD),ladder diagram(LD),structured text(ST; similar to thePascal programming language),instruction list(IL; similar toassembly language) andsequential function chart(SFC)[8]. These techniques emphasize logical organization of operations. While the fundamental concepts of PLC programming are common to all manufacturers, differences in I/O addressing, memory organization and instruction sets mean that PLC programs are never perfectly interchangeable between different makers. Even within the same product line of a single manufacturer, different models may not be directly compatible. Fig .3.5Fig .3.5 shows Allen-Bradley PLCPLCs are well-adapted to a range ofautomationtasks. These are typically industrial processes in manufacturing where the cost of developing and maintaining the automation system is high relative to the total cost of the automation, and where changes to the system would be expected during its operational life. PLCs contain input and output devices compatible with industrial pilot devices and controls; little electrical design is required, and the design problem centers on expressing the desired sequence of operations. PLC applications are typically highly customized systems so the cost of a packaged PLC is low compared to the cost of a specific custom-built controller design. On the other hand, in the case of mass-produced goods, customized control systems are economic due to the lower cost of the components, which can be optimally chosen instead of a "generic" solution, and where the non-recurring engineering charges are spread over thousands or millions of units.For high volume or very simple fixed automation tasks, different techniques are used. For example, a consumerdishwasher would be controlled by an electromechanicalcam timercosting only a few dollars in production quantities.Amicrocontroller-based design would be appropriate where hundreds or thousands of units will be produced and so the development cost (design of power supplies, input/output hardware and necessary testing and certification) can be spread over many sales, and where the end-user would not need to alter the control. Automotive applications are an example; millions of units are built each year, and very few end-users alter the programming of these controllers. However, some specialty vehicles such as transit buses economically use PLCs instead of custom-designed controls, because the volumes are low and the development cost would be uneconomic. Very complex process control, such as used in the chemical industry, may require algorithms and performance beyond the capability of even high-performance PLCs. Very high-speed or precision controls may also require customized solutions; for example, aircraft flight controls.Single-board computersusing semi-customized or fully proprietary hardware may be chosen for very demanding control applications where the high development and maintenance cost can be supported. "Soft PLCs" running on desktop-type computers can interface with industrial I/O hardware while executing programs within a version of commercial operating systems adapted for process control needs. Programmable controllers are widely used in motion control, positioning control and torque control. Some manufacturers produce motion control units to be integrated with PLC so thatG-code(involving aCNCmachine) can be used to instruct machine movements. PLCs may include logic for single-variable feedback analog control loop, a "proportional, integral, derivative" or "PID controller". A PID loop could be used to control the temperature of a manufacturing process, for example. Historically PLCs were usually configured with only a few analog control loops; where processes required hundreds or thousands of loops, adistributed control system(DCS) would instead be used. As PLCs have become more powerful, the boundary between DCS and PLC applications has become less distinct.PLCs have similar functionality asRemote Terminal Units. An RTU, however, usually does not support control algorithms or control loops. As hardware rapidly becomes more powerful and cheaper,RTUs, PLCs andDCSsare increasingly beginning to overlap in responsibilities, and many vendors sell RTUs with PLC-like features and vice versa. The industry has standardized on theIEC 61131-3functional block language for creating programs to run on RTUs and PLCs, although nearly all vendors also offer proprietary alternatives and associated development environments.In recent years "Safety" PLCs have started to become popular, either as standalone models (Pilz PNOZ Multi, Sick etc.) or as functionality and safety-rated hardware added to existing controller architectures (Allen Bradley Guard logix, Siemens F-series etc.). These differ from conventional PLC types as being suitable for use in safety-critical applications for which PLCs have traditionally been supplemented with hard-wired safety relays. For example, a Safety PLC might be used to control access to a robot cell withtrapped-key access, or perhaps to manage the shutdown response to an emergency stop on a conveyor production line. Such PLCs typically have a restricted regular instruction set augmented with safety-specific instructions designed to interface with emergency stops, light screens and so forth. The flexibility that such systems offer has resulted in rapid growth of demand for these controllers.As an example, say a facility needs to store water in a tank. The water is drawn from the tank by another system, as needed, and our example system must manage the water level in the tank.Using only digital signals, the PLC has two digital inputs fromfloat switches(Low Level and High Level). When the water level is above the switch it closes a contact and passes a signal to an input. The PLC uses a digital output to open and close the inletvalveinto the tank.When the water level drops enough so that the Low Level float switch is off (down), the PLC will open the valve to let more water in. Once the water level rises enough so that the High Level switch is on (up), the PLC will shut the inlet to stop the water from overflowing. This rung is an example of seal-in (latching) logic. The output is sealed in until some condition breaks the circuit.| || Low Level High Level Fill Valve ||------[/]------|------[/]----------------------(OUT)---------|| | || | || | || Fill Valve | ||------[ ]------| || || |

An analog system might use a waterpressure sensoror aload cell, and an adjustable (throttled) control (e.g. by a valve) of the fill of the tank.

SCADA Power heads Integration New Developments Proving the new developments Validating the Customer requirements

3.3 Testing, Support and Training3.3.1 APPLICATION Testing New Software Release Under development Hardware of Controller Online EOR print Capabilities

Support Guiding service persons at customer site by reproducing similar setup Solving QMS issues by real setup Training Providing training and awareness sessions to new learners by practical work 3.4 DC tools

3.4.1 QM series DC tools Fig. 3.6 QM Series DC spindles are the workhorse of your multispindle application. With four platforms that provide broad torque and speed coverage, Ingersoll Rand QM spindles deliver the highest level of performance, durability, and reliability in the industry. The QM3, QM5, QM7, and QM9 platforms are so durable, in fact, that we stopped testing them after three million fault-free cycles.With our QM spindles on your assembly line, youll be able to redefine the productivity of your process.

The QM Series Fixtured spindles were developed to meet the high production and duty cycles required in many of today's manufacturing facilities. Designed to work either alone or in multiple, these spindles when teamed with an IC Controller, will deliver the quality and performance your fastening application may require. The QM5 Series has a torque range up to 90 Nm and speeds up to 590 RPM. With their compact 44 mm center to center distance, optional spindle lengths and multiple mounting options, they will fit most any application.

The QM Series Fixtured spindles were developed to meet the high production and duty cycles required in many of today's manufacturing facilities. Designed to work either alone or in multiple, these spindles when teamed with an IC Controller, will deliver the quality and performance your fastening application may require. The QM7 Series has a torque range up to 220 Nm and speeds up to 273 RPM. With their 70 mm center to center distance, optional spindle lengths and multiple mounting options, they will fit most any application.

The QM Series Fixtured spindles were developed to meet the high production and duty cycles required in many of today's manufacturing facilities. Designed to work either alone or in multiple, these spindles when teamed with an IC Controller, will deliver the quality and performance your fastening application may require. The QM9 Series has a torque range up to 2500 Nm and speeds up to 278 RPM. With their 89 mm center to center distance, optional spindle lengths and multiple mounting options, they will fit most any application.

3.4.2 QE series DC tools Fig. 3.7The Ingersoll Rand QE Series handheld tools take productivity, ergonomics, and reliability to new levels. With angle, inline, push-to-start, offset and motor configurations, four motor platforms, and torque coverage to 400 Nm, our QE Series tools are engineered for enhanced productivity with impressive features.The QE Series of fixtured angle wrenches when teamed with the IC Series Controllers provide superior accuracy and durability to meet your fastening requirements where the tool needs to be mounted to a fixture or reaction arm. This series offers a torque range from 2.6 Nm to 400 Nm with speeds up to 1230 RPM. Models in the chart show units with an activation from the controller or machine start. Other variations are available with trigger or lever start and there are different angle head and spindle options. Please contact your local Ingersoll-Rand distributor or Solution Center for additional information. The non-contacting switches, heavy duty gear train and DC brushless motor create a durable package that will keep your maintenance cost down and your production line running.The QE Series of fixtured inline nutrunners, when teamed with the IC Series Controllers provide superior accuracy and durability to meet your fastening requirements in situations where the tool needs to be mounted to a fixture or reaction arm. The QE Fixtured Inline series offers a torque range from 0.3 Nm to 230 Nm with speeds up to 3,000 RPM. Models in the chart show units with an activation from the controller or machine start. Other variations with trigger or lever start and additional spindle options are available. Please contact your local Ingersoll-Rand distributor or Solution Center for additional information. For production applications requiring high or extreme duty cycles, the QM Series provides additional options.

3.5 ICS SoftwarePaired with an Insight ICD or ICM controller and a computer, our groundbreaking ICS Software Suite makes it possible to more precisely control and monitor your fastening process. Optimizing your system is as simple as selecting the software package from the four available that best fits your requirements.

ICS ConnectICS Connect provides operators the ability to access and program basic fastening strategies, as well as view cycle data with a single IC12D or IC12M controller via a one-to-one Ethernet connection. ICS Connect is supplied standard with all IC12D and IC12M controllers.

ICS NetworkICS Network enables programming of multiple IC12D and IC12M controllers connected through a local area network (LAN) or direct connection. This option also allows operators to program advanced fastening strategies including yield and prevailing torque control. Finally, ICS Network unlocks the patented TactAlert feature of the QE Series tools that provides the operator with tactile feedback of a tool fault or NOK signal through gentle mechanical oscillation in the grip surface, reducing reliance on visual or audible signals.ICS EnterpriseICS Enterprise offers advanced programming and management of a network of up to 500 IC12D or IC12M controllers using QE tools, QM spindles, or multispindle systems. This package includes all elements of ICS Connect, Network, and MultiSync, and also enables ODBC-compliant database archiving, searching, and statistics processing.ICS MultiSyncThe ICS MultiSync package facilitates set-up and control of multispindle systems consisting of up to 100 spindles in groups of up to 40 spindles. This package also offers advanced multispindle fastening strategies, remote monitoring, and data archiving.

3.5.1 ICS Operational modes

Working in Network (Live) ModeThis is the default mode of operation. When you are operating in this mode, you are viewing (live) data from the controller to which you are connected. At the top of the work sub screen, the Source indicator will display the text Network. In addition, the Controller ID drop box will be populated with all detected controllers on the network. To connect with a controller and see the current settings/data, frst select the desired controller from the Controller ID drop box. Next select the desired spindle (always 1) and then (if appropriate) select the confguration. Once this is complete, the appropriate data is read from the controller and displayed. The data, once displayed, can either be saved to the local drive (via the save command) for later inspection or edited and sent back to the controller (via the send button on the tool bar). The data can be refreshed at any time via the refresh button.

Working in Database (Local) ModeThe database mode is used to view data fles that have previously been saved to the local PC hard drive. Click on the Database button in the Main toolbar to switch to database mode. To view a set, select the controller from the Controller ID drop box, the spindle from the Spindle drop box, and the Data Set desired from the Date Time stamp.

Working in Archive ModeThe Archive Mode is used to view Data fles that have been previously saved automatically to the SQL database. Click on the Archive button in the Main toolbar to switch to Archive Mode. At the top of the work sub screen, the Source indicator displays the text Archived DB. To view a Data Set, select the controller from the Controller ID drop box, the spindle from the Spindle drop box, and the Data Set desired from the Date Time stamp.3.5.2 Assigning Inputs/Outputs to the controllerAll the inputs/outputs are assigned to the controller through General setup in ICS software. The Assign Inputs tab provides you with a method of assigning input behaviours to physical input locations on the controller. The software detects and restricts multiple assignments of one behaviour. To assign an input, frst click on the input for which you wish to assign a behaviour. Then click on the behaviour that you wish to assign to the input and click on the assign (left pointing arrow) button. To de-assign an input, frst click on the input to which you wish to de-assign a behaviour. Then click on the de-assign (right pointing arrow) button. To deassign all behaviours click on the de-assign all button.

Fig. 3.8 shows assign inputs in General setupNote: For safety reasons, after the new input assignments are sent to the controller, they will not take efect until the controller is rebooted.The Assign Outputs tab provides you with a method of assigning output behaviours to physical output locations on the controller. To assign an output, frst click on the output for which you wish to assign a behaviour. Then click on the behaviour to which you wish to assign the output and click on the assign (left pointing arrow) button. To de-assign an output, frst click on the output to which you wish to de-assign a behaviour. Then click on the de-assign (right pointing arrow) button. To de-assign all behaviours, click on the de-assign all button. If the time for the output is set to zero, the output will remain active until a new cycle is started. To set an expiration time for the output, enter a time into the time column for the appropriate output (it will remain on for that number of seconds once initially activated).

Fig, 3.9 shows assign outputs in General setup.

3.6 Powerhead setup modeA group of Insight units synchronized together to perform a multiple bolt tightening task is called a Power head. If you are arranging a series of Insight controllers together in this way, you must link them in a daisy chain fashion to create a Power head Synchronization Bus. These can comprise up to 40 Insight controllers. You must also set each controllers two rotary address switches depending on its location in the chain.1. On the frst Insight controller in the powerhead, the top rotary switch must be set to 0, while the bottom switch is set to 1.2. Connect a powerhead synchronization cable to the bottom powerhead connector on the frst controller.

Fig. 3.10Fig. 3.10 shows port for powerhead connector3. Connect the other end of the same cable to the top powerhead connector on the second unit in the chain.4. On the second controller, set the top rotary switch on the second unit to 0, with the bottom switch set to 2.5. Continue using this same pattern of cabling and rotary settings up to 40 units. NOTE: The top rotary switch is set to 1 for units 10-19, 2 for units 20-29, 3 for units 30-39, and 4 for unit 40.6. Set the terminal block for the frst and last units in the chain to 1 On and 2 Of,.as shown below.

Fig. 3.11Fig. 3.11 shows terminal switchNOTE: All other units in the power head should be set to 1 Of and 2 Off.

CHAPTER FOURPROJECT 1THREE SPINDLE DC NUT RUNNER BOLTTIGHTENING MACHINE

4.1 IntroductionApplication- DOOR TOP HINGE BOLT TIGHTENING.Three Spindle DC Nut Runner Bolt Tightening Machine includes three QM series Spindles in Power head. All the three spindles are attached to three Controllers in power head mode through tool cable. In power head mode, one controller is master and the other two controllers are slave. They are synchronized to each other through power head connector.Following figures shows the machine view and design-

Fig. 4.1.a.shows actual design

Fig. 4.1.b shows layoutFig. 4.1.c shows side view

Fig. 4.1.d shows upper viewFig. 4.1 a, b, c, d shows actual design of machine with detailsAll the Controllers are programmed through ICS software installed in a PC/Laptop. In ICS software, program is done through Advance setup in powerhead mode. In Advance setup, different strategies can assigned t the controller attached to the spindle.Basically, in Bolt tightening case, the main strategy is Torque and other includes angle and backout.The Advanced Setup screen is similar to the Quick Setup screen, but it provides access to all confguration parameters, allowing programming of multistep strategies. Confgurations are loaded, edited, and saved on an individual basis. Advanced Setup is available on the Network, MultiSync, and Enterprise versions of ICS software. Navigating to Setup/Advanced displays the Advanced Setup screen, use the drop boxes to select a Controller, Spindle, and Confguration for programming (for Data Base mode, select new or a previously saved Confguration).

4.2 Customer and its requirementsCustomer- Whirlpool of India Ltd.- FaridabadRequirements- Whirlpool of India Ltd, manufactures refrigerators. For tightening of door top hinge of refrigerator which includes self- threaded bolts is done by this three spindle nut runner bolt tightening machine.Following are the strategies and requirements of the customer including program in powerhead mode-1. Firstly, the program is made in powerhead mode, in which Group 1 contains three spindles attached to three controllers respectively as shown in Fig. 4.2.

Fig. 4.22. Secondly, Spindle 1 attached to controller 1(master controller) is assigned config 1 made in advance setup, which is automatically assigned to other two spindles attached to other two controllers respectively according to the customer requirement as follows-Requirements- - All the three bolts should finally be tight at target torque of 8 Nm.

Fig. 4.3Fig. 4.3 shows the config 1 asigned to spindle 1.The config 1 includes following parameters as shown in Fig. 4.4 - Engage parameter Angle parameter Torque parameter Backout parameter Torque parameterFig. 4.4- All the bolts should move 1000 angles with a free speed of 100%.Fig. 4.5- Then, they should be attain a torque of 6 Nm.Fig. 4.6- If there is a bolt which gets damaged or there is a bolt which gets free, then the bolt is reopen after 6 Nm totque step by backout step.Fig. 4.7- At last, all the bolts are tightened at a torque of 8 Nm with a free speed of 50%.Fig. 4.8- Now, if customer has to do rework or customer rehit the tightened bolts at a torque of 8 Nm, then all bolts are reopened at 4000 angles by a final back out action in congif 3Fig. 4.8Fig. 4.9Fig. 4.10 shows general setup of operation of spindles4.3 Drawing4.3.1 Inputs and outputs of all three controllersFig. 4.11 shows i/os of master controllerFig. 4.12 shows I/O of controller 2

Fig. 4.13 shows I/O of controller 3

4.4 Problems facedFollowing were the problems faced during installation and running the machine-- One of the controllers got hanged.Solution- Controller restarted.- One or two spindles were not running showing calibration failed on the main screen of the controllers.Solution- The spindles were loosen and tightened using Allen key and checked using tool test in diagnostic mode of controller (tested ok).4.5 Quality Check-Quality check is done using Expert torque analyzer (ETA).It is used for measurement of actual torque at which the bolts are tightened.ETA is used to see how much variation is there in the target torque which is 8 Nm in this case and the actual torque delivered. Transducer is attached with the ETA and to the socket.When the bolt is tightened, the value is shown on ETA. For each spindle, it is measured separately. Readings are noted separately for each spindle. Then, the target torque appearing on the main screen of the controller and the actual torque delivered are compared. The readings are copied in the tabular form and Cp and Cpk values are calculated using the formula. According the values of Cp and Cpk, the range of sigma is calculated. For highest the range should be between 5 and 6 sigma. The graph is also plotted against variation of torque. Fig. 4.14- Quality check is also done through Sound level meter. It is done to check the sound of the three spindles attached to sockets during running time. The sound level should be between 50 db 80 db.

Fig. 4.15 CHAPTER FIVEPROJECT 2DC TOOL SYSTEM

5.1 IntroductionApplication- 05 NOS DC TOOLSFive Spindle DC tool system includes five different QE series Spindles of different torque capacity for five different applications. All the five spindles are attached to five Controllers separately through tool cables. All the five machines are programmable through PLC using Siemens PLC and profibus settings is done in PLC and the program is also based on profibus settings. All the controllers have profibus port. All of them are attached to profibus connectors through PLC.This is done to fetch the data to the PC/laptop. The machine is mainly used for tightening of different bolts of different parts of TATA Nano engine..Following figures shows the machine view and design-

Fig. 5.1 shows actual design

Fig. 5.2 shows side view

5.2 Customer and its requirements with different applicationsCustomer- TATA SANAND, LUCKNOWThe different Applications and Requirements according to the customer are as follows-1. RI Bracket tighteningIn this type of application, the requirement of customer is-Target torque- 23 NmHigh limit- 25 NmLow limit- 21 NmFree speed- 50%The program with torque strategy is made in the controller itself using Quick setup mode. The readings noted are as follows-

Fig. 5.3 shows readings

Fig. 5.4 shows RI Bracket tightening2. RI Shaft tighteningIn this type of application, the requirement of customer is same as in RI Bracket tightening.The program with torque strategy is made in the controller itself using Quick setup mode. The readings noted are as follows-

Fig. 5.5 shows reading

Fig. 5.6 shows RI Shaft tightening3. Housing Screw tighteningIn this type of application, the requirement of customer is same as in RI Bracket tightening.The program with torque strategy is made in the controller itself using Quick setup mode. The readings noted are as follows-

Fig. 5.7 shows reading

Fig. 5.8 shows Housing screw tightening4. Cable Anchoring Bracket tighteningIn this type of application, the requirement of customer is same as in RI Bracket tightening.The program with torque strategy is made in the controller itself using Quick setup mode. The readings noted are as follows-

Fig. 5.9 shows reading

Fig. 5.10 shows cable Anchoring Bracket tightening5. B Mount Bracket tighteningIn this type of application, the requirement of customer is-Target torque- 40 NmHigh limit- 42 NmLow limit- 38 NmFree speed- 50%The program with torque strategy is made in the controller itself using Quick setup mode. The readings noted are as follows-

Fig. 5.11 shows reading

Fig. 5.12 shows B Mount Bracket tightening6. All the controllers are connected to each other only through Profibus cable connectors to the input and output of profibus connector. The starting terminal is PLC with termination ON and the ending terminal is fifth controller with termination ON in profibus connector. The controllers are connected to the Ethernet hub in main panel and also to PC with the Ethernet cable. The PC is connected to PLC with PC Adapter.

Fig. 5.13 shows PC Adapter

Fig. 5.14 shows Profibus connector7. The most important requirement of customer was the setup of SQL on its PC.SQL setup is needed to see all the data including the cycle log, peak torque, peak current, peak angle, barcode, shutdown code, and other parameters in the SQL database. For this, the ICS Connect should be in database mode. The data can be seen in SQL management studio in ICS common EOR data out option. The profibus addresses for five controllers are as follows-22- Controller 123- Controller 224- Controller 325- Controller 426- Controller 5The complete layout of the machine DC tool system can be shown as follows-Fig. 5.15 shows actual layout8. The program using Siemens PLC is fed to the PLC for running the machine using profibus settings.5.3 Drawing5.3.1 Inputs and Outputs of Controller

Fig 5.15 shows I/O of controllerThe all five controllers have same I/Os except in place of sp1 reject and accept, it will be sp2, sp3, sp4, and sp5 (sp denotes spindle).Instead of Cycle 1 complete, it will be cycle 2, cycle 3, cycle 4, and cycle 5.The I/Os are given to the controller through ICS Enterprise software.On connecting the Profibus cable to all the controllers, we can also see the data on PC in SIMATIC Software inside profibus settings (data includes the target torque and target angle).

CHAPTER SIXPROJECT 3OMRON ZEN PLC PROGRAMMING AND ITS APPLICATIONS

6.1 IntroductionOmron ZEN PLC programming is used for different auto mechanical processes or different automotive applications or projects. The ZEN programmable logic module provides a total of 10 I/O points (6inputs and 4 outputs). It has two types of controllers:LCD type: with display screen and keypad.LED type: without display screen and without operating keypad.The following are some of the most important features: Capacity to carry out small scale automatic control at low cost. Ladder diagram programming directly in the LCD type CPUs is possible. Maximum program capacity of 96 lines. Very small dimensions: 90 x 70 x 56 mm. Easy to set up and reduced wiring time. Upgradable up to 18 inputs and 16 outputs using 3 expansion modules. Protection against power supply faults (battery optional). Programs easily copied using optional memory cassette. Programming and monitoring by computer. Large switch capacity up to 8A /contact with 250 VAC. Direct AC inputs between 110 and 240 VAC. Equipped with 8 configurable timers in 4 operating modes and 3 timerranges. Also equipped with 8 counters this can work either inclined or declined. Clock-calendar functions. 2 analog inputs in voltage mode (0 to 10 V). Possibility of configuring input filters to avoid noise influence. The program can be protected by a password. Screen menus displayed in 6 languages

Fig. 6.1 shows external appearance of ZEN PLC

6.2 Applications/ProjectsA) 2SPINDLE BOLT TIGHTENING MACHINE

This project includes tightening of 2 bolts of connecting rod by 2 spindles in power head mode. This project includes various Inputs and Outputs. This project is programmable using ZEN PLC as programmed above. The outputs of above program mainly includes- power head down, power head up, Spindle 1 tightening over, gang advance, gang reset, and ok condition as shown by Q symbol.The inputs mainly includes- start push button, emg stop, stop button, tightening start, free speed, config select, forward, reverse..

B) Traffic light/ Street light working with Traffic

This project includes the working of three traffic lights- Green, yellow, and red along with the movement of the traffic. This program shows the working of Whole Street light along with the movement of traffic.The inputs include- Red light, yellow light and green light. The outputs mainly include- traffic 1 start and traffic 2 start as shown by Q symbol.6.3 Other projects/applications based on ZEN PLCOther applications and projects I am working on includes- Automatic welding machine, tightening machine, different types of movement of cylinder in different directions, lightening control in offices and companies and some other big applications.

CHAPTER SEVENOTHER PROJECTS AND APPLICATIONS

7.1 IntroductionThis chapter mainly includes other projects and applications, which area in continuation are as follows-- US Controller testing- NPD (New product development)This includes EB development testing lab.- 2 Spindle Connecting Rod Bolt Tightening Machine7.2 US Controller testingThis includes testing of US DC Controllers arrived for testing. This testing is going on in all parts of world in Ingersoll Rand..US Controller arrived has some modifications as compared to previous ICD Controllers. These Controllers are IC12D and have modified control board in the circuit and other version RISC band control board. Testing of both the controllers 1 going on tightening of bolts by DC Tools attached to the controllers. This DC tools includes QM series spindles. This testing includes-1. Testing both the controllers in single mode. This is done by programming the controllers in quick setup mode with a target torque of 15 Nm attached to the spindles of max. torque of 90 Nm. 2. Testing both the controllers in power head mode. This done by programming the controllers in power head setup mode in the ICS Connect software through Ethernet cable attached to both the controllers. Power head cable is also attached to each other, so that one is master controller and other is slave controller by changing their CAN address.The program includes two configurations as follows-- Configuration 1-Target torque- 15 NmHigh limit- 18 NmLow limit- 12 NmFree speed- 50%Gang Count- 3Auto increment- 2- Configuration 2-Target torque-30 Nm, High limit- 36 Nm, Low limit- 24 Nm, Gang count- 0, Auto increment- 1Connections-1. Inputs to PLC are connected from O/P terminal of the controller (Master).2. Outputs from PLC are connected at I/P terminal of the controller (Master).3. Both controllers are connected to PC through Ethernet cable for view of Cycle log in ICS Connect software.4. Both controllers are connected to each other in power head mode through power head cable. Three conditions for not ok-1. Cycle stop in between when push button (stop) is pressed.2. Bolts thread slipping.3. Tool rehitting.PLC Inputs-X0- Push button (cycle start).X4- Accept. X6- Push button (stop)PLC Outputs-Y0- Forward.Y1- Reverse.Y3- Free speed.Master controller I/Ps-2-I-1- Free speed.2-I-3- Forward.2-I-4- Reverse.Master controller O/Ps-1-O-1- In cycle.1-O-2- Cycle complete.1-O-3- Accept.The tightening procedure is programmed and controlled by MITSUBISHI FX PLC, which include following steps-

Fig. 7.1 shows steps of program 7.3 NPD testing lab/EB labThere is research study of development of new product in NPD department. After the research is over and study over that product is over, it is developed and manufactured for testing in EB lab.After the product is passed in EB testing lab, it goes for manufacturing.Two types of testing is done in testing lab before manufacturing of product as follows-1. Performance testingIn this type of testing, the performance of the product is tested based on certain parameters. Instruments used for performance testing are as follows-- Dynamometer ControllerUsing this type of instrument, air motor of different torque capabilities are tested and in the output of this testing, the torque, power (hp), current, and speed of the air motor is calculated as shown in the controller. The dynamometers available in the lab are of 25 Nm, 3.25 Nm, and 1 Nm torque capabilities. Readings are noted and graph is plotted.- Champion tester (ISU-5393 Tester up to 15 Nm)In this, the capability test is performed. All the air tool including small screw tighteners air tools are tested with champion testers. The Air tools are attached to the soft joints and hard joints, then tested. This testing is also programmable using PLC. In the output of this testing, the torque is calculated. Variations are calculated and then Cp, Cpk values are calculated to know the shift in the torque. Graph is plotted by the software itself.2. Endurance testingIn this type of testing, the life cycle of the tool is tested. The life cycle test is done inside the grinder. All the tools are tested. This is programmable using OMRON PLC.VFD (Variable frequency drive)It is used for testing of angle head of the tool. This can be programmable and manual. This can be run through software and all the parameters example- torque can be calculated. It is programmable according to the motor capability and parameters which is used in this testing.

REFERENCES

1. Websites

www.ingersollrandproducts.comwww.ingersollrand.co.iwww.omron.co.inwww.siemens.co.inwww.irtools.co.inwww.mitsubishielectric.co.in

2. Manuals

ICS ManualDC tools ManualPLC ManualZEN PLC ManualICD Controllers ManualFX PLC ManualSQL setup Manual

3. Assembly Catalogues Cordless catalogues IR tools catalogues ETA Catalogue Sound level meter Catalogue

90781128880