Process and Quality Management System for Resistance...

HARMS & WENDE QST GmbH

Process and Quality Management System for Resistance Welding

Company

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PoWER SERvicE PQS RES PQS viSioN

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Comprehensive quality assurance starts with HARMS & WENDE

Our approach

We think in processesOptimised process management is the foundation for constant high quality and efficiency

We think in productsQuality assurance requires optimised control technology and process moni-toring

We think as a teamObjectives are defined in close cooperation with our customers.

Our core competences

• Process quality assurance systems for resistance welding and other joining technologies• Component documentation and optical inspection• Marketing and servicing of welding control systems from Harms & Wende GmbH & Co. KG• Services in the fields of training, analysis, optimisation and commissioning• Specialist advice for micro joining, component design and joining solutions

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Your task

Meeting stringent quality requirements at minimum costs.

Our solution

PROfit & lOSS ACCOuNt

iN-liNE DOCuMENtAtiON

iN-liNE PROCESS MONitORiNg

QuAlitY ASSESSMENt

iN-liNE PROCESS ANAlYSiS & OPtiMiSAtiON

PQS SYStEM iNtEgRAtiON

Our solutions

• Spot welding

• Projection welding

• Small parts welding

• Alternating current (AC)

• Direct current (DC)

• Medium frequency (MF)

• High frequency (HF)

• Capacitor discharge (CD)

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PQS hardware options

Genius welding controllerGenius is a modular control system consisting of a board rack for several plug-in cards.

The PQS system can thus be easily integrated into this weld-ing control unit without any further hardware requirements. This is further facilitated by the PQS-Ready option.

QUADRIGO measuring moduleQUADRIGO MM stands for practical and sturdy modular measurement modules designed for universal use. They pro-vide an economical and powerful platform for your quality assurance system.

QUADRIGO MASTERDesigned for the reliable storage of large volumes of data and user-friendly control of the monitoring system. Can be integrated together with the QUADRIGO measurement mod-ule in a QUADRIGO box.

QUADRIGO VISUStores and visualises all relevant information. For easy control of the measurement modules and monitoring software. Elegant housing.

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Cost-effective quality and process management, reducing risk of product liability claims and complaints

Instant reduction in material and labour costs as in-process inspection intervals can be significantly reduced

Fast and safe process enabling, even upon start-up

Comprehensive process analysis & visualisation for the identification of optimisation options

Permanent availability of all key process and QA data for quick response in the event of an error

Easy integration into new plants and all conventional control and joining systems

Suitable for most standard resistance welding methods (spot, projection, capacitor discharge welding)

Reference plants in operation at renowned automotive suppliers and manufacturers

Competent on-site support from our experienced team of experts

Linking of joining process data and visual inspections through PQS Vision

Safety & efficiency – when and where you need it!

Advanced in-line monitoringtechnology tailor-made for your

production!

top 10 advantages of PQS system

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16 17Copyright by HARMS+WENDE QST GmbH 2011 Technische Änderungen vorbehalten

Non-destructive testing

PQS System integration

The universal QUADRiGo MM measuring modules provide maximum flexibility and independence.Designed as an installation module, the QUADRiGo MM can be easily integrated into existing control or switch cabinets. Alternatively, the PQS system can be integrated into Harms & Wende Genius controls.There is no need for any additional hardware, as only a few additional input/output signals need to be handled by the unit control system.

Profit & loss account

Apart from detailed information, continuous monitoring and seamless documentation, PQS helps you significantly reduce material and labour costs.

inline documentation


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inline process analysis and optimisation

Process control is the prerequisite for consistent quality. PQS actively supports the user in • Assessing the current process situation, • Determining the correct welding parameters, • Rapidly and efficiently optimising processes.

Quality assessment

Preparation of PQS inline quality monitoring through targeted test part removal and standard testing (destructive). Measured values are stored directly and assigned to each component and each joint. All process data recorded by PQS are available.

inline monitoring

The standard random sampling test is replaced by an automated, verifiable solution. Reliable monitoring with maximum error recognition.


PQS SYStEM iNtEgRAtiON(in any welding unit)by means of QuADRigO MM

Your welding station / robot

Tap of measured variablescurrent - measuring coilvoltage - tapForce - 0 to 10v standardDisplacement - 0 to 10v standard

Field-bus connection interbus,Profibus, Devicenet, Profinet etc.or 24 volt interface

Signal transfer seam number,component end, component typeerror messages, status requests

Tap of the analog process current,voltage, displacement, force

Simple signal tap thanks to PQS-RESsensor box

QUADRiGo-MM 1000Measuring module for control cabinet installation with 24 volt supply voltage

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The universal QUADRiGo MM measuring modules provide maximum flexibility and independence. Designed as an installation module, the QUADRiGo MM can be easily integrated into existing control or switch cabinets.

PQS System integration

SPOt WElDiNg

PROJECtiON WElDiNg

Alternating current (AC)Direct current (DC)Medium frequency (MF)Capacitor discharge (CD)

Transmission of the monitoring setting to the QUADRiGo measurement module via Ethernet

Transmission of the process data to the PQS software via Ethernet

RQS-RES software packageincluding database installed on an industrial Pc system

Step 1

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PQS SYStEM iNtEgRAtiON(in welding unit with genius inverter)

Strom, Spannung und Weg

Weg - optional

Your welding station / robot

Pick-up of the measurements current - measuring coilvoltage - tap Displacement - optional

Signal transfer seam number,component end, component typeerror messages, status requests

Tap of the analog process current,voltage, displacement

Simple signal tap thanks to PQS-RESsensor box

Field-bus connection interbus,Profibus, Devicenet, Profinet etc.or 24 volt interface

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via Ethernet an die GENiUS-Steuerung

The PQS-Ready option must be activated in Genius inverter. The PQS system can be easily integrated in our control solution. if the Genius inverter is equipped with the PQS-Ready option, all you requi-re is a PQS software licence.

There is no need for any additional hardware, as only a few additional input/output signals need to be handled by the unit control system.

Transmission of the monitoring setting to the GENiUS controls via Ethernet

Transmission of the process data to the PQS software via Ethernet

SPOt WElDiNg

PROJECtiON WElDiNg

RQS-RES software packageincluding database installed on an industrial Pc system

Step 1

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PROCESS ANAlYSiS & OPtiMiSAtiON

component

Picture of the group of joints eases orientation.

Display of the welding station with welded joint. Separate data collection and evaluation for each joint. By clicking on the spot number in the analysis overview. current characteristics, voltage characteristics, power or displacement characteristicsand resistance curves will be displayed.

Detailed informationon each individual joint

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Step 2

Unit graphic

image of the welding cell or unitmakes orientation easier.

All the important information on up to16 robots or welding stationsis displayed simultaneously online.

cell overview with group classification

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PROCESS ANAlYSiS

The signal characteristics of mechanical and electrical variables are recorded continuous-ly and their spread over the process time is displayed in the background as a coloured distribution (current, voltage, resistance, force and displacement). This way, the first information on the stability of the process can be obtained.

Detailed analysis - signal characteristics

The effective values for all the measured values are calculated and documented continuously. Furthermore, all the relevant process data such as time, date, unit, component recognition and welding station.

Based on the data previously recorded, an initial stability analysis is made for each joint.

Detailed analysis - effective values

Evaluation of process variations

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Step 2


Process control is the prerequisite for consistent quality. PQS actively supports the user in• Assessing the current process situation,• Determining the correct welding parameters, • Rapidly and efficiently optimising processes.

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PROCESS OPtiMiSAtiON

Unit and stability analysis at your fingertips

Based on the data and signal characteristics previously recorded. PQS creates a complete stability analysis of all the joints. Process weak points are revealed -the process is optimised.

Unit and stability analysis of the joint

All the process data on the joint analysed are obtained by pressing a button. This makes it easier to optimise parameterisation or to set the controllers, for example.

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Step 2


Process control is the prerequisite for consistent quality. PQS actively supports the user in• Assessing the current process situation,• Determining the correct welding parameters, • Rapidly and efficiently optimising processes.

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QuAlitY ASSESSMENt

Documenting test results

clicking on “Prüfbericht eingeben” opens the screen for documentation of the test results. All the components marked as a test work piece are listed here.

Enter the actual values determined

Here, the quality determined (spot diameter, torque, etc.) is entered. in addition, further remarks (e.g. the test force, type of fracture, etc.) can be entered in the “Work piece info” and “Spot information” windows.

Test part analysis

For example, the respective sizes of plug can be selected for later analysis. The corresponding resistance characteristic is displayed compared to the total distribution of all welds for the corresponding spot.

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Step 3

Quality assessment

Preparation of PQS inline quality monitoring through targetedtest part removal and standard testing (destructive). Measured values are stored directly and assigned to each component and each joint. All process data recorded by PQS are available.

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iN-liNE PROCESS MONitORiNg

Evaluation of process data and test data

Teaching of process monitoring= Activation of the quality assurance

Now the quality characteristics achieved arecompared with the real process dataand the learning of the process monitoringbegins.

The intelligent Q-SAvE technology ensures an automatic clustering of process data within the carefully tested process range. The comparison between process and quality data by the process owner is important at this point. The setting so found then forms the basis for the iNLiNE-process and quality assurance.

inline monitoring activated

The monitoring setting for each joint, found individually by pressing a button, is enabled. The process is monitored continuously for deviations for each joint. The Q-stop strategy can be matched to the individual user’s requirements. The Q-Stop of the unit is then transmitted to the robot, PLc or machine and the affected component is ejected.

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Step 4

inline monitoring

The standard random sampling test is replaced by an automated, verifiable solution. Reliable monitoring with maximum error recognition.

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EXAMPlES Of fAultSQuiCK DEtECtiON BY PQS

Deutlich weniger fehlerhafte P

Spot welding

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Poor fit and spot to small

Force too high and spot to small

Poor fit, poor bond and internal spatter

Edge welding

You will produce far fewer defective products!

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Projection welding

PP SS

Produkte in Ihrer Produktion!

Step 4

You will produce far fewer defective products!

oK

Energy too high, spattering

Poor repositioning

one projection is missing

Two projections are missing

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iN-liNE DOCuMENtAtiON

The samples selected for verification samples and their test results are administered in the PQS system and form the basis for a complete proof of quality. PQS technology offers the greatest possible protection against poor production quality.

Test data

The process stability can be determined at any time. Review of the optimisation potential ofthe joining processes at any time. All process and quality data are permanently recorded and stored.

Process stability

component documentation and evaluations

All the process and quality data aredocumented in their entirity. A good precondition for a successful customer audit.

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Step 5

inline documentation

PQS records all analog process data as waveforms (e.g. current, voltage, force and displacement). All production data, monitoring and test results are documented. The prerequisite for an auditable proof of quality is thus established.

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PROfit & lOSS ACCOuNt - COSt SAviNgS

total costs including investments

Destructive standard test (material + disposal costs)

PQS iN-liNE QuAlitY ASSuRANCE

(material + disposal + investment costs)

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Profit & loss account


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Step 6

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PQS SAMPlE CONfiguRAtiON

Symbol Designation

MM 1000

MM 2000

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Symbol Bezeichnung

Instandhalter

Bediener

Maschine, Buckelpresse oder Schweißzange

MASTER

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Symbol Bezeichnung

Instandhalter

Bediener


VISU PLUS

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Symbol Bezeichnung

Instandhalter

Bediener


VISU Base

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Symbol Bezeichnung

Instandhalter

Bediener

Maschine, Buckelpresse oder SchweißzangeMachine, projection welding press

or welding tongs

Genius inverter with PQS-Ready option

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Welcome to QST-Solutions.

on the following pages we would like to show you three tasks that can be performed with our solutions. Based on system sketches, possible solutions are presented as a combination of QUADRiGo-MM, QUADRiGo-MASTER and QUADRiGo-viSU.

Due to the high flexibility and the modular structure of our hardware family, practical solution proposals can thus be drawn up quickly and economically. The aim is to show you the technical possibilities in principle.

of course, our partners and system specialists are looking forward to help with your specific task.

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uSE Of QuADRigO MMconnection to any welding control unit (no GENiUS in place)

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Configuration example 1Unit with 7 measuring points

Your requirement: implement specificationsobjective: configure entire system for maximum of 7 measuring pointsProcedure: Resistance weldingReserve: No system reserve desired in the hardware conceptDescription: System with 3 projection welding machines and 2 rotary table stations with 2 robots each. Spot welding and projection welding are carried out. capacitor discharge welding, medium-frequency controls, and A/c power technology are used

Our solution for 7 measuring points with one visualisation and control unit

Rotary table with 2 robots

Projection welding machine



Rotary table with 2 robots

System components used3x QUADRiGo MM2000 with 2 measuring points1x QUADRiGo MM1000 with 1 measuring points1x QUADRiGo viSU-plus7x PQS licence

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Our solution for 7 measuring points with one visualisation and control unit

use of PQS with gENiuS inverter Genius inverter with PQS-Ready option available

Configuration example 1Unit with 7 measuring points

Your requirement: implement specificationsobjective: configure entire system for maximum of 7 measuring pointsProcedure: Resistance welding

Description: System with 3 projection welding machines and 2 rotary table stations with 2 robots each.Spot welding and projection welding are carried out.operation with GENiUS medium-frequency control.

Rotary table with 2 robots Rotary table with 2 robots




System components used7 x Genius inverter PQS-Ready7 x PQS licence1 x QUADRiGo viSU-PLUS

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Notes

To find out more, simply give us a call!+49 3722 89081 0

www.hwh-qst.de

Disclaimer:

Every effort has been made to ensure that the information in this document is correct and valid at the time of going to print. HARMS & WENDE QST GmbH reserves the right to change the specifications of the described products as a result of its continuous improvement policy. HARMS & WENDE endeavours to inform its QA technology customers at the earliest possible opportunity of any such changes. For the latest information, contact your HARMS & WENDE QA technology partner. The colours depicted in this brochure might deviate somewhat from the actual colours of our products.

All rights reserved.Reproduction, in whole or in part, is only permitted with the prior written consent of HARMS & WENDE QST GmbH.

company member of

Our core competences

• Process quality assurance systems for resistance welding and other joining technologies• Component documentation and optical inspection• Marketing and servicing of welding control systems from Harms & Wende GmbH & Co. KG• Training, analysis, optimisation and commissioning services• Specialist expertise for micro joining, component design and joining solutions

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HARMS & WENDE QST GmbHQualitätsSicherungsTechnologie

Nordstrasse 2509247 chemnitz / Röhrsdorf

Phone: +49 3722 89081 0Fax: +49 3722 89081 299

E-mail: [email protected]: www.hwh-qst.de

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