Selector operation and workflow
The selector indicator LEDs guide the operator through a tightening task. The LEDs show which socket to pick and put on the tool for the next tightening.
The indicator LEDs can be controlled by the connected controller and its program using the Auto mode, or by an external control unit, using the External mode.
The external control unit can be a PLC or any other factory management system connected to the Power Focus 6000 controller with an Open protocol or Fieldbus communication link.
If using External mode to control the LEDs, the controller acts only as a relay station. The external control unit sends commands to the Power Focus 6000 about selector LED commands and the controller forwards these commands to the selector.
If using Auto mode, the controller tightening program, the batch sequence configuration and the socket selector device configuration control the LEDs.
The Power Focus 6000 controller can have many selector configurations. Each configuration may have a different number of active sockets, regardless if they are used or not. Place sockets in all the used positions.
If bits are used, place the sharp end upwards. This is to protect the sensor at the bottom of the holder.
There are two LED's for each socket or bit position. These LED's guide the operator to pick the correct socket or bit for the next tightening. The following LED patterns can be shown.
A | Outer and inner LED white and flashing | B | Both LED's switched off |
C | Inner LED steady white | D | Outer LED steady white |
E | Outer LED steady red |
Depending on the configuration in the controller, an operator can perform tightenings in a fixed order or in a free order pattern. Examples will describe both correct an faulty scenarios.
Rules for indicator LEDs - fixed order tightening
A task is selected by the controller and the selector requests that one particular socket is lifted. The request signal is a white flashing LED (inner and outer LEDs)
Action | Pos 1 | Pos 2 | Pos 3 | Pos 4 |
|---|---|---|---|---|
Lift the requested flashing socket. |  |  | | |
The correct requested socket is lifted. The tightening can start
Action | Pos 1 | Pos 2 | Pos 3 | Pos 4 |
|---|---|---|---|---|
The correct socket (2) is lifted. The tightening can start. | |  | | |
The wrong socket is lifted. The selector indicates the lifted socket and continues to request the desired socket. The tightening can not start until the wrong socket is replaced and the correct socket is lifted.
Action | Pos 1 | Pos 2 | Pos 3 | Pos 4 |
|---|---|---|---|---|
The wrong socket (1) is lifted. The requested socket (2) is flashing. | | | | |
Two sockets are lifted and no tightening can be performed. The tightening can not start until the wrong socket is returned.
Action | Pos 1 | Pos 2 | Pos 3 | Pos 4 |
|---|---|---|---|---|
Both the correct socket (2) and wrong socket (1) are lifted. The tightening can not start. | | | | |
An error case, lighting up a red light, only occurs if a tightening is performed, the socket is returned and is picked up again. This applicable for single tightening or when a batch is completed.
Tightening position 2 has been completed and returned. Position 3 is requested. Lifting position 2 again, results in a error showing a red light as it is completed. Lifting position 1, results in a steady white as this position is not done and not requested. The tightening can not start until the erroneous sockets are returned and the requested socket (3) is lifted.
Action | Pos 1 | Pos 2 | Pos 3 | Pos 4 |
|---|---|---|---|---|
A tightening or batch with sockets 2 has been completed and returned. It is now lifted again. Socket 3 is requested. Socket 1 is also lifted. The tightening can not start. | |  | | |
Rules for indicator LEDs - free order tightening
The selector requests that one of several sockets is lifted (free order tightening). The request signal is a white flashing LED (inner and outer LEDs). The tightening program is selected when an acceptable socket is lifted.
Action | Pos 1 | Pos 2 | Pos 3 | Pos 4 |
|---|---|---|---|---|
Lift a socket among the flashing options. | | | | |
One socket is lifted and a tightening program is selected. The tightening can start. The remaining request LEDs are switched off.
Action | Pos 1 | Pos 2 | Pos 3 | Pos 4 |
|---|---|---|---|---|
A socket (3) is lifted. The tightening can start. | | | | |
Two sockets are lifted and no tightening program is selected. The tightening can not start until one socket is returned. No other sockets are requested and those LED's are switched off.
Action | Pos 1 | Pos 2 | Pos 3 | Pos 4 |
|---|---|---|---|---|
Two sockets (2 and 3) are lifted. The tightening can not start. | | | | |
An error (red light) only occurs if a tightening is completed, the socket is returned and is picked up again. This is applicable for a single tightening or when a batch is completed. A free order batch sequence allows sockets to be returned and picked up and will not show an error until the batch is completed.
In a free order tightening, position 3 is completed and the socket has been returned. Socket 1 or 2 is requested - first row.
Position 3 is picked up again. As this batch is completed, an error will show. The remaining LEDs are switched off - second row.
Lifting position 1, results in a steady white as this position is not completed. The tightening can not start until the erroneous socket is returned - third row.
Action | Pos 1 | Pos 2 | Pos 3 | Pos 4 |
|---|---|---|---|---|
A tightening or batch with sockets 3 has been completed and returned. Positions 1 or 2 are requested | | | | |
A tightening or batch with sockets 3 has been completed and returned. It is now lifted again. An error is indicated | | | | |
Two sockets are lifted. One is an error and one is an option to use. A tightening can not be performed until one socket is returned. | | | | |
One socket is selected, a tightening program is selected and a tightening can be performed. | | | | |
Definitions
Certain definitions must be known to be able to follow the examples. For detailed information see the Power Focus 6000 configuration manual.
Parameter | Description |
|---|---|
Batch | A number of tightenings that use the same tightening program and the same socket. |
Batch sequence | A number of batches were each batch has a different tightening program and were the batch may have a different socket. |
Batch counter | A counter that keeps track of each tightening within a batch and batch sequence. The total count summarizes all tightenings within a batch sequence. |
Fixed order | The tightenings have to be performed in a fixed order as it is defined in the controller configuration. The LEDs on the selector will guide the operator through the process. |
Free order | The operator is free to choos the order of tightenings. The LEDs on the selector show the available options. |
external mode | The selector LEDs are controller by an external master that communicates through the controller. |
Auto mode | The selector LEDs are controller by the program in the Power Focus 6000 controller. |
Operator task example
At an imaginary station, an operator has to perform the following task:
Use program AA three times with socket number 2.
Use program BB two times with socket number 3.
Use program CC one time with socket number 1.
We create one batch sequence with 3 batches. The total number of tightenings is six. We use a selector with 4 positions. A table is used as the score chart.
Action | Batch count | Program | Pos 1 | Pos 2 | Pos 3 | Pos 4 |
|---|---|---|---|---|---|---|
No task selected. | 0 | | | | |
External mode = OFF, fixed order tightening
The fixed order program is configured in the controller and is set up as follows:
Use program AA three times with socket number 2.
Use program BB two times with socket number 3.
Use program CC one time with socket number 1.
Action | Batch count | Program | Pos 1 | Pos 2 | Pos 3 | Pos 4 |
|---|---|---|---|---|---|---|
No task selected. | 0 | | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Task selected by controller. First tightening in first batch. Socket nr 2 requested. | 0 | AA | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Socket nr 2 picked up. | 0 | | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Tightening OK. Socket not returned. Next tightening using the same program and socket. | 1 | AA 1(3) | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Tightening OK. Socket not returned. Next tightening using the same program and socket. | 2 | AA 2(3) | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Tightening OK. Socket not returned. Next tightening using a different socket which is requested by the flashing LED nr 3. | 3 | AA 3(3) | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Socket nr 2 returned and requesting socket nr 3. | 3 | | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Socket nr 3 picked. | 3 | BB | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Tightening OK. Socket not returned. Next tightening using the same program and socket. | 4 | BB 1(2) | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Tightening OK. Socket not returned. Next tightening using a different socket which is requested by the flashing LED nr 1. | 5 | BB 2(2) | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Socket nr 3 returned and requesting socket nr 1. | 5 | | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Socket nr 1 picked up. | 5 | CC | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Tightening OK. Socket not returned. Operator informed through other signaling that the batch sequence is completed and OK. | 6 | CC 1(1) | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Socket nr 1 returned. Task completed. | NA | | | | |
At the end of the batch sequence, the task can be deselected resulting in that all LEDs switch off. It also possible that the task restarts automatically. This is controlled by the Power Focus 6000 controller.
Action | Batch count | Program | Pos 1 | Pos 2 | Pos 3 | Pos 4 |
|---|---|---|---|---|---|---|
Task deselected at completion of the batch sequence. No task selected. | 0 | | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Restart of batch sequence. Task selected by controller. First tightening in first batch. Socket nr 2 requested. | 0 | AA | | | | |
External mode = OFF, free order tightening
The batch sequence is configured in the controller and is set up as follows:
Use program AA three times with socket number 2.
Use program BB two times with socket number 3.
Use program CC one time with socket number 1.
In the free order tightening, we have decided to do them as follows:
Make 2 tightenings with socket nr 3 and program BB.
Make 1 tightening with socket nr 2 and program AA.
Make 1 tightening with socket nr 1 and program CC.
Make 2 tightenings with socket nr 2 and program AA.
Action | Batch count | Program | Pos 1 | Pos 2 | Pos 3 | Pos 4 |
|---|---|---|---|---|---|---|
No task selected. | 0 | | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Task selected by controller. Request socket 1,2, or 3. | 0 | | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Socket nr 3 picked up. | 0 | BB | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Tightening OK. Socket not returned. Next tightening using the same program and socket. | 1 | BB 1(2) | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Tightening OK. Socket not returned. Batch finished, new options is to pick up nr 1 or 2. | 2 | BB 2(2) | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Socket nr 3 returned. | 2 | | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Socket nr 2 picked. | 2 | AA | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Tightening OK. Socket not returned. | 3 | AA 1(3) | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Socket nr 2 returned. Options is to pick up nr 1 or 2. | 3 | NA | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Socket nr 1 picked up. | CC | | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Tightening OK. Socket not returned. Batch finished, new options is to pick up nr 2. | 4 | CC 1(1) | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Socket nr 1 returned. | 4 | | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Socket nr 2 picked. | 4 | AA | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Tightening OK. Socket not returned. Next tightening using the same program and socket. | 5 | AA 2(3) | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Tightening OK. Socket not returned. Operator informed through other signaling that the batch sequence is completed and OK | 6 | AA 3(3) | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Socket nr 2 returned. Task completed. | | | | |
At the end of the batch sequence, the task can be deselected resulting in that all LEDs switch off. It also possible that the task restarts automatically. This is controlled by the Power Focus 6000 controller.
Action | Batch count | Program | Pos 1 | Pos 2 | Pos 3 | Pos 4 |
|---|---|---|---|---|---|---|
Task deselected at completion of the batch sequence. No task selected. | 0 | | | | | |
--------------------- | -- | ----- | ----- | ----- | ----- | |
Task selected by controller. Request socket 1,2, or 3. | 0 | | | | |
