- SPECIAL REPORTS
Today, more and more manufacturers are facing the challenge of collecting an enormous amount of process performance data, managing it and documenting the results for quality assurance purposes. To effectively manage the assembly process, accurate data collection is critical. Having the machine operator manually collect and report the data is time-consuming and susceptible to human error. Consequently, manufacturers are looking for efficient ways to automatically acquire the data, document it, present it in a graphic format and manage it to improve quality and productivity.
To address the need for an efficient data management tool for assembly presses, SCHMIDT Technology recently introduced the SCHMIDT® DataBase software. Flexible and easy-to-use this optional software is available for all SCHMIDT ServoPresses and TorquePresses equipped with either the PressControl 5000 or the new PressControl 600 modular control system. The software can also work with any of the company’s manual, air and hydro-pneumatic presses equipped with the new PressControl 600. A PLC, which has been integrated into both control systems, provides the press user with 100% in-process monitoring for intelligent process control and facilitates a comprehensive process data acquisition and management capability.
To manage the assembly process and to ensure quality, the results for each press cycle are automatically captured and compared against user-established parameters, which have been entered into the PressControl. At the same time, the control verifies that the ram’s force and distance fall within appropriately placed force/distance windows and stroke tolerances. The pressing performance data results are then instantly displayed on the PressControl’s touch-screen interface panel for the operator to evaluate.
Verifying Component Quality
Equally important, the SCHMIDT PressControl will verify the quality of components and stampings used in the assembly process. For example, if a defective component, either purchased or internally produced, happens to be too short, the resistance exerted on the ram will be different when the components are pressed together. In response, the PressControl will note the deviation and reject the faulty assembly. Immediate corrective action can then be taken thus reducing scrapped assemblies and minimizing rework.
Managing Data for Quality Assurance
For quality assurance, the process performance data collected in the PressControl can be transferred to a USB storage device. Or the data can be transferred via an Ethernet cable and imported into the SCHMIDT DataBase software, which has been installed on one of the manufacturer’s Windows®-based desktop computers or servers. For future qualitative analysis, the DataBase will then store all data, including the full force/distance curve as well as the specific monitoring criteria set up to control the pressing process for that particular part. The data can then be either manually extracted or the Windows® Task Scheduler can be enlisted to automatically transfer the data at predetermined time intervals. The data in the widely supported CSV (.csv) file format can be easily imported into either the manufacturer’s existing quality management system or into Q-DAS statistical process control software, which the SCHMIDT DataBase has been certified for use. The resulting reports, charts and graphs can then be employed to ensure that internal quality standards are being met, to satisfy vendor-certification requirements and to demonstrate proof of regulatory compliance.
Archiving Production Performance Data
Being able to organize and manage the enormous amount of production data can be a monumental challenge. For safety relevant parts, manufacturers are often required to archive production data for several years. By archiving old, rarely used data, production databases can be kept smaller and more manageable. The DataBase software’s data export function allows the user to transfer data to either a production or archival database.
Contact SCHMIDT Technology today and learn how our new DataBase software can significantly improve your quality assurance and productivity.