M55 780384 Welding Box M F V 1 2-En

MANUFACTURING PAGE:1/15
EDITION: 1.2
Fiat
Fiat Group Automobiles SpA ENGINEERING DATE: Mar. 2011
BODY IN WHITE
M55.780384: Capitolato fornitura inverter per controlli MFDC per pinze robot di saldatura
SPECIFICATION OF INVERTER
SUPPLIER FOR MFDC
CONTROL ROBOT
WELDING-GUN
M55.780384
Fiat
Fiat Group Automobiles SpA
Le informazioni contenute in questo documento sono proprietà di FIAT GROUP AUTOMOBILES SpA .
E’ vietata la riproduzione, anche parziale, senza preventiva autorizzazione scritta di FIAT GROUP AUTOMOBILES SpA.
FIAT GROUP S.p.A. si riserva il diritto di modificare, senza preavviso, le specifiche descritte in questo documento.
The contained information in this document are ownership of FIAT GROUP AUTOMOBILES SpA.
The reproduction is forbidden, also partial, without preventive authorization written of FIAT GROUP AUTOMOBILES SpA.
FIAT GROUP S.p.A. reserve him the right to modify, without warning, the specifications described in this document.
EDITION: 1.2
Fiat
BODY IN WHITE
INDEX
VARIATION LIST FROM PREVIOUS EDITION ........................................ 3

1. OBJECT............................................................................................. 4
2. GENERALS CONDITIONS .................................................................. 4
3. CHARACTERISTICS REQUESTED ....................................................... 5
4. DOCUMENTATION ............................................................................ 8
5. DELIVERY......................................................................................... 8
6. WARRANTY ...................................................................................... 8
7. SPARE PARTS SUPPLIER .................................................................. 8
8. ACTIVITY LOADED OF THE CONTROL ROBOT SUPPLIER ................... 9
REQUIREMENTS OF THE SOFTWARE OF WELDING’S CONTROL
CENTRALIZATION .............................................................................. 10
EDITION: 1.2
Fiat
BODY IN WHITE
Variaton list from previous edition
Edition Modify pages and variation description
Edition 1.1 Complete document: revise the content and the complete re-
22/02/2010 impagination.
Edition 1.2
Modified paragraph 3 and 7
10/03/2011
EDITION: 1.2
Fiat
BODY IN WHITE
THE REQUESTED ARE DIVIDE IN THIS MODE:
1. Object
2. Generals conditions
3. Characteristics requested
4. Documentation
5. Delivery
6. Warranty
7. Spare parts supplier
8. Activity loaded of the control robot supplier
1. OBJECT
The following specification having for object the inverter supplier for the welding system at
robotized resistance at Medium Frequency that must be integrated with the control robot.
2. GENERALS CONDITIONS
In reply at what forsee on the General Specification of supplier FGA M55.780013, with
prominence of the paragraph “PRODUCTION ELEMENTS ACTIVITY DURING THE PROCESS
PHASE ”.
All the various intervention phases that must be done in course of the installation and starting
machine are to regarding "Handling key", with the own warranty of functioning.
EDITION: 1.2
Fiat
BODY IN WHITE
3. CHARACTERISTICS REQUESTED
Electrical inverter characteristics:
- Electronics operating voltage: +24Vdc.
- Input/output operating voltage: +24Vdc.
- Power supply operating voltage: da 380 Vac -15% a 500 Vac +10% three-phase.
- Power supply frequency 50 Hz /60 Hz.
- Max output current > 10% F.d.U. ton = 200ms 555 A.
- Nominal Current 100% F.d.U. 270A.
- Output voltage 500 Vac / 1000 Hz.
- Water cooler .
- The cooler inverter plates must be tested at 100% at pressure of 10 BAR for the time of one
hour and don’t must to present weakness points due at the planarity workings between plate
and INVERTER group. Possibles cooler inserts must to guarantee a minimum section of the wall
between liquid cooler and dissipation surface minimum 1,5mm constant for all the insert
length.
- Max weight: 25 kg.
- Overall: maximum dimensions (mm.) : L250 x A463 x P280.
Connection:
- Configuration possibility , parameterization, programming and ed impostation of all the
weldings points parameters:
• in local, through of a notebook utilization or of a programming portable terminal
connected by a serial port.
• in remote, through the programming robot terminal.
• in remote, through Ethernet network line and PC centralizing. On this PC it must be
presents also the data managment functionality.
- Comunication and robot control via Can Bus e/o Fieldbus definitive from the General
Specification like for the master robot.
EDITION: 1.2
Fiat
BODY IN WHITE
Extended funzionality:
- Control software and auto adaptation of the point Voltage/Current quality, with the
reading of the electrodes voltage. Basis characteristics:
o Real time valuation of the weldings points quality.
o Real time regulation of welding current/time.
o Classification of the welding point.

o Managment of the welding’s splash reduction.
o Verify of the wires integrity for the electrodes voltage reading.
EDITION: 1.2
Fiat
BODY IN WHITE
Base diagnostic:
- Local display for the visualization result welding/alarm code.
- Presence control of the power supply inverter three-phase.
- Verify of the intermediate inverter’s circuit working (DC-BUS).
- Diagnostic of a short circuit on the inverter output.
- Power supply diagnostic 24Vdc I/O.
- Input / output:
- Power supply 24V electronic.
- Power supply 24V Input/Output with diagnostic.
- Input 24V Temperature Converter.
- Output 24V Inverter Ready.
- Analog output for the control of a servo-analog valve.
- Characteristics:
- Command 0-10V o 4-20 mA.
- Input signal STATUS servo valve.
- Output signal ENABLE servo valve.
- Relay output for a serious alarm.
- Analog input for the secondary voltage reading.
- Analog input for electrode voltage reading.
- Analog input generic 0-10V.
- Input/output 24V avaiable for the managment of the welding cell, controller by a robot via
bus :
- Minimum 16 Digital Input avaiable.
- Minimum 16 Digital Output avaiable.
- Minimum 1 Analog Output avaiable.
- Minimum 1 Analog Input avaiable.
- The operator’s interface and the command menu must be of great intuition and of easy
utilize.
EDITION: 1.2
Fiat
BODY IN WHITE
4. DOCUMENTATION
It’s requested the « User Manual and Maintenance » in italian language and in the installing
plant’s language of the supplier’s machinery.
5. DELIVERY
For the delivery’s conditions, it make reference at the R.d.A. module (Request of Purchase).
It’s requested the delivery of the goods in object with weekly expiry date, nearby the place.
6. WARRANTY
The warranty must be total on each component of the good in object and inclusive of the
transport and of the substitution of the defect elements.
The period of the warranty it shall be of 24 month..
7. SPARE PARTS SUPPLIER

It’s requested timing of supplying of the spare parts in function of the locations of the various
productive places:
SITE DELIVERY’S TIMING

Plant Italy By max 12 h
Plant Poland By max 12 h
Plant South America By max 12 h (by locals partner)
Plant China By max 12 h (by locals partner)
Plant India By max 12 h (by locals partner)
Show in the column the delivery’s timing expected.
EDITION: 1.2
Fiat
BODY IN WHITE
8. ACTIVITY LOADED OF THE CONTROL ROBOT SUPPLIER

The following activity are charged at the control supplier:
Inverter integration in an appropriate Box fixed in the own control.
Integrated managment with control of the safety’s applications.
Media Panel, pneumatic box and water.
Wirings between the cabinet contained the welding Timer, the robot control and all the
peripheral equipments on board machine.
Robot comunication software.
Test of complete pack (cabinet welding-obot-control).
The installation and the start-up of all the line don’t will be care of the Timer welding’s
producer. The Timer welding producer’s must be guarantee a number of hours sufficients of
putting on service for each installation.
Service and After Sales, must guarantee only the welding’s inverter.
Parametrization and system’s setting must’nt be included in the offer, but at request shall be
quoted on FGA specifics.
Welding’s tests on new materials in the reference equipped laboratory, at the aim to find the
best parameters list to put in the welding’s Timer.
EDITION: 1.2
Fiat
BODY IN WHITE
Requirements of the Software of welding’s control

centralization
SUMMARY
AIM ...........................................ERRORE. IL SEGNALIBRO NON È DEFINITO.
REQUIREMENTS ........................ERRORE. IL SEGNALIBRO NON È DEFINITO.
APPLICABILITY .........................ERRORE. IL SEGNALIBRO NON È DEFINITO.
RESPONSIBILITY ......................ERRORE. IL SEGNALIBRO NON È DEFINITO.
REFERENCE ...............................ERRORE. IL SEGNALIBRO NON È DEFINITO.
ENCLOSURES.............................ERRORE. IL SEGNALIBRO NON È DEFINITO.
EDITION: 1.2
Fiat
BODY IN WHITE
Requirements
Generals Characteristics
Operative System. The centralization’s software must be designed for work on PC (laptop,
desktop, industrials e notebook) with Operative System Microsoft Windows XP.
User’s Interface. Must be based on windows (Windows GUI).

All the software’s functions (communication, diagnostic, programming and monitoring) must
be having an own independent window and activable at the same time with all the others
(Interface type MDI: Multi-Document-Interface).
All the functions of all the windows must be accessible through keyboard or function keys
(MLB: Mouseless Browsing).
Besides the user’s interface must be thinking for the interaction with the touch screen.
Network Interface. The supervision’s software must talk with the welding controls second
the technology for the locals data LAN Ethernet IEEE 802.3.
At last, must be possible made a not centralized communication (Peer-To-Peer) through the
serial protocol RS485/RS232C.
Data exportation. All the information must be exportated in bounded text characters ASCII
(file .CSV).
This kind of data can be utilized in every other application Microsoft Windows (Notepad, Word,
Excel, etc.).
Multi-Language support. The software must be support the main language: Italian, English,
Deutschland, French, Spanish, Polish, Czechoslovak, Nederland, Portuguese.
Operating characteristic
The software must be monitoring in continuous mode the network’s status and of the welding
controls with communications and to visualize the relative status of informations, like shall be
describe in this section.
All the mains functionality, with the relative windows, must be accessible through an interface
based on a menu.
The main’s windows must to consent the visualization of each welding control present on the
network, organized in logic entity called “groups”.
This visualization’s layout shall be completely independent from the physical network used for
connected the welding controls.
The characteristical data of each function (windows) must can be printable on a compatible
printer with Microsoft Windows.
EDITION: 1.2
Fiat
BODY IN WHITE
Safety and Accesses Control

The software must can to consent the access mode of protect type and free.
The data’s visualization, typically parameter or programmes, must to happen in free access
mode, that is without request the user’s acknowledgement.
Every data’s saving inside the welding controls, in case is qualified the access protect mode,
shall must request the user’s authentication between name-user and password.
The user’s authentication shall can become in traditional mode through the digit from the
keyboard or through the reading of the electronic key (optional).
Must be available like minimum five safety’s levels : Guest, Operator, Programming, Specialist,
Administrator.
Must to can be define even at ten safety’s levels.
The Administrator’s user shall have the unlimited access at all the software functions and shall
have the possibility of programming the safety’s levels and to define the names and the
passwords of all the users.
Each software’s functional area (programming, monitoring, communication, diagnostic) can be

assigned at differetns safety’s levels.
System Monitor
The software shall must be in position to display the function’s state of each welding control on
the network through a graphic representation updated just in time.
The state must be indicated if the control is connected at the network or not, if the control is in
off-line programming state (see the Programming section), if are been done some modify in
the last hours, if the control is in state of alarm or of error.
Network Analysis. Must be available the analysis and the diagnosis of the communication
network traffic as well as of the correct connection between the centralization software and the
welding controls connected.
Welding Analysis. For each selected control, must be possible to obtain just in time a welding
diagnosis and of all the own most important parameter.
Alarm Analysis. This function consent to display, to memorize and to print to the last 50 o
500 alarms checked in each selected control, with date and hour of each event.
Must be after to possible to reset the active alarms.
Input/Output Analysis . Deve essere possibile visualizzare in tempo reale lo stato degli
ingressi e delle uscite fisiche sul campo.
EDITION: 1.2
Fiat
BODY IN WHITE
Electrodes pre-alarm situation. It’s necessary a functionality that permit the monitoring
just in time of all the stepper’s meters (electrodes), the cables and the colourings tools of all
the network welding controls.
Modify Analysis. It’s necessary one function that display the events chronology of all the
modify done from the operators at the welding parameters. This function consent to catch up
possible critics situations or parameterizations gone lost.
Each modify shall be located with date-hour, operator, functionality, modify parameter
(before/after).
Report. Must be exist a statistic of the anomaly regarding at the production shift.
Each control must report:
- The weldings total made given in time.
- The total of the alarms.
- The incidence on the total of the alarms of the weldings done from each program.
- The incidence number of alarm of each program.
- The incidence of each alarm of the weldings done and of the alarm of each program.
Programming
Off-line Programming. Must can be possible to edit all the welding parameters on on-line
mode (on the welding control selected or off-line (on database SQL) or mixed (on-line and or
database at the same time). In this case it come to realize a kind of “auto-learning” or all the
field-data are shift on the database like imagine of the current situation and each modify of
the data in the controls it’s strike-again immediately on the database.
Fast Programming.
Must to exist some procedures for to propagate in fast mode the modify at the generals
parameters (setup) on all the configures controls, like also can be possible to propagate the
modify make happened at one specific welding program on other selected programs in the
same control.
Must be possible to copy in fast mode welding programs and stepper from one control to
another one.
Must be exist a functionality that allow in fast mode and through basics operations the
substitution of one control for the maintenance. It comes saved inside the entire contained of
the source control memory and loaded on a destination control.
Must be exist a functionality that allow of loaded/update the firmware of all the selected
controls.
Unify Programming. The welding programmings edit either for the controls in Low Frequency
or for that in Mid Frequency (MF) must to happen through a unique interface.
Further must be possible to programming, for the MF that support this functionality,
programming the welding times indifferently in thousand-seconds or network cycles.
Always on the same interface must be possible to access at the quality system programming.
(Weld Quality System).
EDITION: 1.2
Fiat
BODY IN WHITE
Export/Import Programming. Must be possible to export in CSV format all the welding
programmings of one control and in dual mode, to can import from the same format file.
Master Parameters. Each welding programming, like for each stepper, must to have an own
restore copy (or of reference) that can be saved and restored in Editing phase. This
functionality it shall be done thanks at the assistance of a connected database.
Stepper’s Programming. Must be possible to create the curve of auto-increase

Force/Current in list mode and graphic.
Spot Reference. It’s necessary a functionality that permit to create a mapping between the
name point CAD and the programming that perform the welding on the control..
This mapping become trough a unambiguous numeric index that become exchanged from the
robot and the welding controls through the fieldbus I/O.
Selected one welding point through his index is possible to access directly at the control and at
the programming and to bring about at this correction and adaptation.
The entire list must can be export and import on/from file in CSV format.
Database SQL
Purpose.
The off-line programming that is the simulation of the installation, become possible from the
utilize of a data base contained all the data in a welding line.
These data included: the line configuration, the welding parameters of each device and the
relatives events of the same: welding results and alarms.
With the off-line programming it’s possible to prepare “at table” a new production scenery in
anticipate at the availability of the installation, bound to at the minimum timing the phase of
final tuning.
Advantage. The database must be project in the way to make each data significant a record of
list easily identifiable. The structural data must be explode in atomics unambiguous data (or
“in clear”).
Like this, external applications of reporting and data introduction can easily to access and to
create diagrams, statistics, etc.
Connection.
Must can be possible the connection at the local database (on the used PC) or remote (on PC
or network Server).
Must be possible that more than one centralization software connected at once centralized
database.
Maintenance.
The database must can be created and deleted like do you want, in local mode or remote.
It must to have the possibility to do with simple operations, the Backup and the Restore of the
job database.
Must be possible to limitate in automatic the data dimension.
EDITION: 1.2
Fiat
BODY IN WHITE
Data Storage
Must be exist a function of data storage that save (funzione di Backup function) the data that
made the Setup (Configuration) the welding Programming, the Steppers and the Spot
Reference of each welding control.
This kind of data can be successively loaded on the welding control (Restore function).
Data Log
Must be available the functionality that allow to memorize on a disco and in text format (file
.CSV), for each welding control on the network, the result of each welding, the historical of the
alarm done and the historical of each modify made.
Compatibility
The upgrades (new release) of the centralization software, must be compatible with the basis
version of the project.
Inter-operability
The centralization software must be expandible (next applications) at the end of comunicate
with all the other managment systems of the line (SCADA) through the communication
channels software standard (example OPC).
Applicability
The following proceeding is applicable on centralization of the welding controls.
References Normes
UNI EN ISO 9001:2000 - par. 4.2, Requests regarding at the documentation
Praxis, norme, corporate instructions

Title Document File
Quality Manual Section 1 manual.doc
Enclosures
Enclosure Title Document File
01 Flow Diagram W00.01.00.01 W00010001.xls

M55 780384 Welding Box M F V 1 2-En

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

M55 780384 Welding Box M F V 1 2-En

Caricato da

Copyright:

Formati disponibili

MANUFACTURING PAGE:1/15

VARIATION LIST FROM PREVIOUS EDITION ........................................ 3

Variaton list from previous edition

Edition Modify pages and variation description

THE REQUESTED ARE DIVIDE IN THIS MODE:

7. Spare parts supplier

8. Activity loaded of the control robot supplier

o Classification of the welding point.

7. SPARE PARTS SUPPLIER

SITE DELIVERY’S TIMING

Show in the column the delivery’s timing expected.

8. ACTIVITY LOADED OF THE CONTROL ROBOT SUPPLIER

Requirements of the Software of welding’s control

AIM ...........................................ERRORE. IL SEGNALIBRO NON È DEFINITO.

REQUIREMENTS ........................ERRORE. IL SEGNALIBRO NON È DEFINITO.

APPLICABILITY .........................ERRORE. IL SEGNALIBRO NON È DEFINITO.

RESPONSIBILITY ......................ERRORE. IL SEGNALIBRO NON È DEFINITO.

REFERENCE ...............................ERRORE. IL SEGNALIBRO NON È DEFINITO.

ENCLOSURES.............................ERRORE. IL SEGNALIBRO NON È DEFINITO.

User’s Interface. Must be based on windows (Windows GUI).

Safety and Accesses Control

Must to can be define even at ten safety’s levels.

Each software’s functional area (programming, monitoring, communication, diagnostic) can be

Stepper’s Programming. Must be possible to create the curve of auto-increase

Praxis, norme, corporate instructions

Potrebbero piacerti anche