1

Volume

ROEHRIG ENGINEERING, INC.

Advance spring rater

ROEHRIG ENGINEERING, INC.

Advance Spring Software 6.2 August, 2007

IMPORTANT CONTACT INFORMATION

Roehrig Engineering, Inc 100 Lexington Parkway Lexington, NC 27295

Phone 336-956-3800 Fax 336-956-3870 Email: service@roehrigengineering.com

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T able of Contents
SAFETY .............................................4
Definitions..............................................................4 SAFETY notices ....................................................5 Electrical Safety Warnings...................................7 Field Defaults................................................. 34 Directory/Files ............................................... 35 Graph ............................................................. 35 pring rate vs displacement ............................. 35 Force vs Displacement................................... 36 Raw Force vs Displacement .......................... 37 test.................................................................. 38 Create test ...................................................... 38 Delete test ...................................................... 39 Create Step test .............................................. 39 Step test.......................................................... 39 Math syntax ................................................... 40 Functions ....................................................... 40 Syntax ............................................................ 42

REI ADVANCE SPRING RATER 6.2 SOFTWARE USER GUIDE ................8

Introduction...........................................................9 GETTING STARTED .....................................9 ICONS ..............................................................9 creating a test ......................................................10

MAINTENANCE PROCEDURES .... 47

Safety Considerations for Maintenance Procedures .......................................................... 48 Transducers/Sensors ...................................... 50 REI Custom Parts/Assemblies ....................... 50

COLLECTING DATA .......................16

Batch Test.......................................................19 Step Test .........................................................20 Manual operation control................................20

WARRANTY .................................... 52

ANALYZING YOUR DATA...............22 MENUS.............................................27

FILE................................................................27 New Template ................................................28 Save Template ............................................28 Open Template ...............................................28 Save Template ............................................28 Open Spring Data ...........................................28 Printer Setup ...................................................28 Print ................................................................28 Report options ................................................29 Export .............................................................30 EDIT...............................................................30 Cut, Copy, Paste ...........................................30 Preferences (F12)............................................31 Display............................................................31 Test .................................................................32 Units ...............................................................32 Color...............................................................32 Graph ..............................................................32 Smoothing ......................................................33 Math Signals...................................................33

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Chapter

Safety
WARNING The style shown here is used within these manuals to indicate that a WARNING has been given. A Warning relates to any sequence of events, procedure, drill, or situation that could lead to either injury, illness, or death to personnel.

DEFINITIONS WARNING Any comments regarding the threat of injury, illness or death to personnel, due to a particular sequence of events, procedures, drill or situation arising from a particular test configuration will be shown within this manual as a WARNING. The format of such a WARNING paragraph is shown below: CAUTION Any procedure that could lead to damage to equipment BUT NOT injury to personnel will be indicated as a Caution. Shown below is an example of the Caution paragraph style:

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SAFETY NOTICES THE TEST EQUIPMENT DESCRIBED AND WRITTEN ABOUT WITHIN THIS SUITE OF MANUALS MUST BE OPERATED USING PROCEDURES THAT PROVIDE THE MAXIMUM LEVELS OF SAFETY TO PERSONNEL AND TO THE EQUIPMENT ITSELF. All local and National Safety Standards, together with company-specific safety procedures MUST be observed at all times. It is essential that a detailed study of the information contained within Safety Considerations within this manual is made before operating the test equipment. The following guidelines are laid down as MINIMUM recommendations. Ensure that safety interlocks are fully, functional at all times. Only operate the test equipment after ensuring that no personnel are present in any areas that may be regarded as potentially hazardous. This includes the area around the test equipment and its component parts. All potential work area hazards must be properly guarded and all guards correctly closed BEFORE the test equipment is operated. Only trained personnel should operate the test equipment or be allowed to
Caution This is an example of a Caution notice. It is similar to the WARNING style, but has a differerent border. A Caution is given whenever a situation or procedure may cause damage to equipment but WILL NOT cause injury to personnel.

conduct tests using this equipment. The operators MUST be fully conversant with the Safety Considerations, Technical Descriptions and Operating Instructions contained within this manual, before operating the test system. Always ensure that the test equipment is operated within its design limitations.

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The test equipment should only be operated when regular maintenance schedules have been carried out and when it is known that the test equipment is in good working order. If the test equipment is producing unusual or excessive noise and/or vibration, stop the operation of the test equipment until such a time as the systems have been checked for possible faults. Maintenance procedures must only be carried out AFTER ensuring that all pneumatic and power has been dissipated and that the electrical power has been disconnected from the main supply.

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ELECTRICAL SAFETY WARNINGS

WARNING

The electrical power used in this equipment is at a voltage high enough to endanger life. Before carrying out maintenance or repairs, persons concerned must ensure that the equipment is isolated from the electrical supply and tests made to verify that the isolation is complete. When the supply cannot be disconnected, functional testing, maintenance and repair of the electrical components within the equipment is to be undertaken only by qualified electrical or electronic technicians who are fully aware of the dangers involved and who have taken adequate safety precautions. Lethal currents may result with voltages as low as 30 Volts RMS AC, or 50 Volts DC.

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Chapter

REI Advance spring rater 6.2 software User Guide

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INTRODUCTION Thank you for purchasing the REI Advance Spring Rater Program. This manual explains the operation of the Advance Spring 6 software package that is part of your spring checker system. The advance Spring 6 software runs under the Microsoft WINDOWS XP/Vista operating systems. If you are new to these operating systems, refer to the Microsoft manuals that were included with your computer. Go through the tutorial and become familiar with window and mouse operations.

GETTING STARTED This manual is written as a supplement to enhance your factory training, not replace it. It is recommended that you read the entire manual before attempting to operate the spring checker. Some things that may not be clear when first encountered in the manual will be more fully explained later. As an aid, all computer commands and options will appear as a different font: Computer

Command.

ICONS Certain commands can be accomplished by clicking the icon on the tool bar below the menu Bar. Most commands can also be executed using hot key listed on the hot key list or from the pull down menus

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Chapter

CREATING A TEST The create test wizard will walk you through creating a new test. Create test can be launched through the TEST pull down menu, with the ctl + M hotkey combination or the create test icon on the tool bar.

There are three areas that define a test. Pre stroke, test , and test points. Each area can be edited after a test is created.

PRE STROKE The pre stroke option will allow the operator to run the test specimen for a pre selected number of cycles to a defined force.
WARNING : the return position is a gap measurement, entering 0 would be the platens touching.

The number entered in the RETURN POSITION box Figure 1 will determine where the ram will return to between each cycle

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Figure 1

TEST The test window will set the test parameters.

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Figure 2

The following window will set the force number that will be used to calculate the free length of the test piece. If zero is entered the program will use the first non zero force measurement as a free height.

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Figure 3

TEST POINTS The test point window figure 4 is used to set the parameters that will determine the area of the collection the program will use to calculate the spring rate. All data points within the start and end points will be averaged to calculate rate.

Figure 4

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If you select the point validation figure 5 the program will report a pass/fail of the returned data based on the validation points entered. You can select if the validation should applied to the compression, extension, average, or both compression and extension.

Figure 5

The final window will prompt you to name the test. Each test must have a unique name. You can create as many test as you require.

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Chapter

Collecting data
To start a test click on the Test Icon menu or the F11 hotkey. The Spring Test window displays the test parameters for all created test. To create a test, use the Create test wizard. A standard spring test will record data collected dynamically at the interval selected for the complete test range. Click on the arrow to the right of the select test window to view all created test. The three areas of a test description can be edited form the tabs on this page. Pre stroke and test points can be enabled or disabled using the check boxes on those pages. Select Configuration Defines the data card configuration that will be used for this test. Unless you have created a new configuration this will always be Default. Select the spring test to run The pull down arrow to the right of this window allows you to select a test from a list of test you have created. You can have as many spring test created as you need. The parameters for the selected test are displayed in the boxes below this window. Peak force the peak force that this test will compress the spring to, this is the force
that the machine will reverse from compression to extension.

in the toolbar or Test in the Hardware

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Test speed velocity in in/sec of the test. Pause time dwell time at peak force. Measurement interval displacement interval between data points. Spring height force The force the machine will use to define spring free height. Start/End point These define the range the program will use to calculate spring
rate. These numbers may be changed after the test.

To continue the test, click the Start Test button.

From the spring test window

figure 6

use the measure Gap button when the program

does not have a gap measurement recorded (red light displayed). You will need to measure the gap each time you start the program. You will be prompted to enter a block height number if you are using a block between the platens when measuring the stroke Once the gap has been measured and your tool height entered set click Next.

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Insert a tool height number in the Tool Retainer Height box if you are testing the spring with anything that adds to the free height of the spring. If a spring only is being tested this will be set to zero.

Figure 6

1. The next window is a final warning that the test is about to start. The machine will compress the spring to the peak force setting and return to home.

After the test is complete the following window will give you a snapshot of the collected data. The force, displacement, and rate data at the bottom of the results page is calculated based on the start and end points entered at the top of the page, this is the test range. The rate number is a average of all rate data points in the test range. Your start and end point numbers may be changed to view data from

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different areas of the spring. This will not affect the saved data and this point data may be viewed after the data is saved by using the point report. The start point is the distance between the platforms the end point number is also a distance between the platform unless you check Relative to start point. If you enter a number not in the spring range (ie: 3 displacement on a 2 spring) the program will not complete the results section. From this window you can click Finish to save the data file or save and repeat if you wish to run the same test again or Batch test if this is the first of a batch of springs to be tested..

Batch Test The batch test button is designed to give the user the ability to run a number of different springs and save the data as one data file. After running the first spring replace the spring in the machine and use the Batch Test Repeat button to re run the same test. After all the springs have been run use the Finish button to save and name the data file. The individual runs will be saves together in one data file and identified by which number run it was in the batch.

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Step Test
Unlike the standard dynamic collection test, the step test will collect data at user defined displacement points. The machine will stop and hold at each point while the software makes the collection. This is a static collection unlike the dynamic collect in other test types.

Manual operation control

Clicking on the manual control icon will open the manual control panel. If the gap has not been measured (red light on) you will need to measure the gap before running any other test. From this window the operator can manually operate the rater to a displacement or force move. This window is useful to get a

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force reading at a given displacement point. The Gap Move will move to the gap number entered in the move target box (gap is the distance between the spring platforms. Absolute move will move the lower platform the distance entered in the target box. Force move will compress the spring to the force entered in the Force Target window. Relative move will move the lower platform the distance entered in the Move size window. You can click on the up or down buttons to move the entered distance a number of times.

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Chapter

Analyzing your data

When the test is complete and you have named the file, the program will display the trace of the last collected data file automatically figure:7 .File names are displayed in the legend on the left side of the main screen. The program will overlay all open data files. By checking or un-checking the boxes next to the file name the operator is able to hide or show any open files. The compression, extension, or average trace can also be displayed by checking the boxes in the legend. The color of the file trace can be changed using the C hot key. Different graph options are available in the Graph pull down menu or on the toolbar. Graph properties can be modified in the Scale tab at the top of the graph, each graph type is scaled independently. To close a displayed data file highlight the data file and use the delete tool bar button or the delete button on your keyboard, this only closes

the file in the program, the file is still saved in the original file location. To aid the operator in analyzing the graph a movable curser and zoom window are available. Click on the trace to place the curser.. use the right and left arrow keys to move the curser along the trace. The data from each data point will read out on the status bar at the bottom of the screen. To zoom in on a section of the graph place your curser at a point on the graph hold down the left mouse button and drag a box around the area you wish to zoom, or use the zoom tool bar items

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To return to full view use the reset zoom button toolbar, then click paste in a document.

on the tool

bar. You can copy the graph to a document by clicking on the camera icon on the

Legend

Figure 7

By right clicking on the word Graph at the bottom of the legend you can insert more graphs. This is basically another sheet to open data files on. Your data can also be viewed in numeric form by selecting the Report, Point Report, and statistical Report tab at the top of the graph (figure:5).

Report page

- the program will display the data for the file name that is

highlighted in the legend. The up and down arrows can be used to move between file with the data window open. By using the Report box on the right of the screen you can define how the data is displayed. The numeric report can be

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exported to a file or the clipboard in three different formats using the Export box located under the Report box.

Point Report

The point repot can be used to find the force, displacement or rate

at any requested point or as a point referenced from the full length point of the spring (if you enter 1 with the R box checked this point would be 1 from the full length position). By default the full length point will automatically be the first point in the report. If the R box is empty that row will display data at that point in force or displacement depending on the units you select.

Statistical Report

On This page you are able to compare all open data files.

Use the start and end point boxes to define the report area. Data for each spring will be displayed as well as minimum, maximums, average, and standard deviation in compression, extension, and average data.

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figure:6

The scaling tab can be used to define the scaling and orientation of the data on the graph page. Auto scale will size the graph to fit the data trace. The span box will define the minimum scaling of the graph when you are on auto scale. To use span enter a scaling number in the span box (you must have auto scale checked) the program will now keep your scaling at that span and place the trace on the middle of the graph, if the trace is larger than the span the program will auto scale. Using span on the rate axis will keep the trace in the middle of the graph no matter what the rate. To set the scaling remove the check from auto scale and fill in your scaling numbers. From this page you can also define the number of lines per axis, and invert the sign or axis for both the x

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Chapter

MENUS
Each menu displays options and various tasks that can be done in the program. The following is a description of each menu, and what can be found under each menu heading. Please be aware that some sections are for advanced users only and should not be used unless you are familiar with function of the option and how it might affect the data. Main menus are displayed in blue in the following section.

FILE

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New Template
Templates will save all open data files in one file. To make a new template, click on New Template.

Save Template
allows the user to name the template when the save window appears. Templates are saved to a separate directory and named by the user. This option can also be used to save multiple traces on one graph.

Open Template
This menu opens to the directory that stores all templates allowing the user to select a preferred template.

Save Template
Selecting this option will open the save template window. template, give a name to your new template and click Save. To save a new

Open Spring Data

Use this selection to open and graph saved data files.

Printer Setup
Displays the windows print setup screen

Print
All user defined print options are on this screen. The graph layout function allows the user to size his graph, legend, and notes on the paper to fit his needs. The numbers that are entered in the divider box are the percent of the page from top or left that each item will start at. If the notes were positioned at the bottom of the page and set on 90% the note box would start at 90% of the page, measuring from the top of the page. The legend and notes can

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be located on the left, right, top, and bottom of the page or hidden. Moving an item will require a change in the page percent number to keep the graph area the same. In most cases selecting the same print settings on different machines will produce the same size graph on the paper, if you attempt to match graph sizing on different printers it may be necessary to set the size number different to create the same size graphs. Show Logo- Check this box to include a logo on your printed graph. To select a new logo click the small button to the right of the status bar under the show logo box. Select the bit map file you wish to use. The loaded logo file name will appear in the status box. If you select the stretch to fit box, the program will fit the logo to the page without changing the graph size. If this box is not checked the program will display the logo as the saved bitmap size.

Report options
This page defines all parameters for the numeric reports that are printed. To print only the graphs with no report remove all check marks on the Data Report section of this page. To print only the reports without the graphs uncheck the print graph box at the top of the page. The graph and data can be printed on the same page by checking the Graph Size box and adjusting the graph size to fit the data on the graph page, when printing data and graph on the same page the lay out works best on portrait mode.

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Export
from this menu the user can export the raw collected data. Exporting the file will export the data used to display the data on the open graph. (if force vs displacement graph was open the force and displacement channels would be exported). To export selected traces open the signal vs time graph and highlight the traces to export in the legend.

EDIT Cut, Copy, Paste

Use these commands to move or copy data files between open graphs. These commands operate in standard windows format.

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Preferences (F12)
In this window the user can define default settings that control how a test will be run and graphed. Many of these settings can be changed in other parts of the program without affecting the default settings selected on this page. After changing a setting you must hit the enter key before OK or Apply to hold your change on all preferences pages.

Display
. Default graph will define the graph type that the program will open. The legend items will define how the legend id displayed. (figure:7)

figure:7

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Test
The enter Test Description box is used to control when the test description page will be displayed for user to fill in test information

Units
Use this page to set English or metric measurements in displayed data, Custom option allows user to mix systems. To change to a different metric unit click on the unit, use the pull down menu that opens to select a new unit. The CTL-F12 hot key or the unit hotkey can also be used to switch between units.

Color
This window lets the operator select the colors and order of colors that the program will use for displaying data files graph traces. Click on each box to select the color.

Graph
Grid, Cursor Styles, fonts and Trace Width can be modified from the graph page. Trace Width will define the thickness of the data traces as shown on the monitor and printed graph. (figure;8)

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figure:8

Smoothing
Smoothing on this page only affects the look of the graph to aid in comparing graphs, it does not affect the recorded spring rate number. REI recommends a 25 smoothing on the rate channel. In most cases all other channels should have the smoothing set to zero.

Math Signals
Math signals are channels that are not collected but are created with a mathematical operation using constants, math functions and channels. Math channels are treated the same as collected channels and may be graphed and used

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in other math channels. The math syntax for creating math signals is listed at the end of this manual.

Field Defaults
Fields are the pages that have areas for the operator to fill in test and spring information. The fields will be held with the test and displayed on the report tab. The default page allows you to customize the fields to contain the information you need. Clicking on the edit test Defaults will open the window displayed below. By clicking on a cell you can change the name of a field or the number of lines that will be reserved for that field. By using the INSERT key new lines may be added to expand the field page. To delete a line highlight the name by clicking on it and use the delete key. The default boxes can be used for descriptions that you want to appear with each saved data file as a default. Constants are numbers that would be used with math channels. This window allows the use to completely customize the data displayed on the report page.

Click on cell to Highlight that cell, when a cell is highlighted you can modify the contents of that cell

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Directory/Files
From this page the user can define the default file name and default location the data files. By default the program will always return to the last used directory when saving a data file. A user may select there own default location by clicking Use a predefined directory. The button to the right of the file name allows the operator to select another file for the default directory. This page can also be used to define the default file name (Spring Data by default) or have the program us the last entered file name followed by a number that is automatically inserted as a default.

Graph
This window allows you to select what graph format the program uses to display the open data files. Select the graph type you wish to use by clicking on the appropriate graph type or use the hot keys. The following is a short description of each graph type. Options to aid the user in viewing the data are explained in detail in the analyzing your data section starting on page nine. Use the properties page in the Edit menu to find options to change the layout of the graph.

Spring rate vs displacement (figure:10)

depicts the spring rate by calculating the change in force divided by the change in displacement between each recorded data point and plotting these points against spring displacement. The complete trace displays the compression and extension data, the average is the average of the compression and extension. Spring rate vs force is the same graph except the X-axis is force.

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figure:10

Force vs Displacement (figure:11)

Force is the y-axis and displacement the x-axis in this graph.

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figure:11

Raw Force vs Displacement

(figure:12) This graph shows the collected force values compared to displacement without the internal filtering that is built into the program. All other graphs are filtered to eliminate electronic noise. electronic noise may hurt the repeatability of the data. You may view the raw numeric values by clicking the copy button in the Edit pull down menu with this graph open, then open an MS Excel spreadsheet and click on paste. No numeric data is available on the data page for raw data, to view raw numeric data it must be viewed in Excel.

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figure:12

test
This screen is used to perform a spring test as outlined on page five in collecting data

Create test
Standard test profiles are preset from the factory and can be selected in the test box, or modified with the edit button. To create a new test use the create test button. The create test wizard will walk you through the options to create a new test. After you name the new test the program will save that test in the pull down menu on the test page.

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Delete test
Using the delete test button will permanently remove the selected test profile from the from the test profile list.

Create Step test

This wizard will walk you through creating a custom step test

Step test
Test window to execute a step test.

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Chapter

7
All

Math syntax

Functions
The following functions are supported by the Roehrig Math system. functions, unless specifically noted operate on all types of signals.
ABS ( expression )

Returns the absolute value of the expression.

SGN ( expression )

Returns the sign of the expression. If expression is greater then 0, SGN returns 1. If expression is equal then 0, SGN returns 0. If expression is less then 0, SGN returns -1.
SIN ( expression )

SIN returns the sine value of expression. expression is assumed to be in radians.

COS ( expression )

COS return the cosine value of expression. expression is assumed to be in radians.

TAN ( expression )

TAN returns the tangent of expression, expression is assumed to be in radians.

ASIN ( expression )

ASIN returns the sin-1 of expression.

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ACOS returns the cos-1 of expression.

ATAN ( expression ) EXP ( expression )

ATAN returns the tan-1 of expression. EXP returns the values of e to the expression power, or eexpression.
LOG ( expression )

LOG returns the natural log of expression.

SQRT ( expression ) DIFF ( expression )

SQRT returns the square root of expression DIFF differentiates expression with respect to time. expression.
INTG ( expression )

The sample rate of

expression is assumed to be that same of the data being used to evaluate

INTG integrates expression with respect to time. The sample rate of expression is assumed to be that same of the data being used to evaluate expression.
POSITIVE ( expression )

POSITIVE returns the value of expression if it is greater then zero, otherwise POSITIVE returns zero.
NEGATIVE ( expression )

NEGATIVE returns the value of expression if it is less then zero, otherwise NEGATIVE returns zero.
RAD ( expression )

RAD converts expression from degrees into radians.

DEG ( expression )

DEG converts expression from radians to degrees.

MIN ( expression1, expression2, expression3, )

MIN evaluates each individual expression and then returns the minimum of all of the expressions.
MAX (expression1, expression2, expression3, )

MAX evaluates each individual expression and then returns the maximum of all of the expressions.

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AVE (expression1, expression2, expression3, )

AVE evaluates each individual expression and then returns the average of all of the expressions.
UNITS ( symbol , measurement )

UNITS ensures that symbol is returned in measurement units. For example, if Displacement may be in inches or millimeters, UNITS(Displacement, {Mm}) would ensure the Displacement is in millimeters.
TOUNITS ( expression , measurement , targetmeasurement )

TOUNITS assumes expression is in measurement units and forces it to convert to targetmeasurement units.
SMOOTH ( expression , NUMBER )

SMOOTH evaluates expression and averages the values of expression for each of the NUMBER data points before and after the each data point. For example SMOOTH(Displacement, 5) would for each point of displacement it would average the eleven data points to generate the value at that data point. (It uses eleven because it takes 5 points from left, 5 points from the right and the data point itself.)
CYCLE ( expression , opendirection , closedirection )

CYCLE evaluates expression and then clips the data to contains only the opendirection and closedirection portions of the dyno cycle. opendirection and closedirection can be qith ~Rebound, ~Compression, or ~Ignore.

Syntax
expression: binaryop | simpleexpression | ( expression ) simpleexpression: | | | | | | number symbol function unaryoperation conditional smooth cycle

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number: | symbol

NUMBER NAN SIGNAL CONSTANT

function: | | | | | | | | | | | | | | | | | | | |

ABS ( expression ) SGN ( expression ) SIN ( expression ) COS ( expression ) TAN ( expression ) ASIN ( expression ) ACOS ( expression ) ATAN ( expression ) EXP ( expression ) LOG ( expression )| SQRT ( expression )| DIFF ( expression ) INTG ( expression ) POSITIVE ( expression ) NEGATIVE ( expression ) RAD ( expression ) DEG ( expression ) MIN ( argumentlist ) MAX ( argumentlist ) AVE ( argumentlist ) UNITS ( symbol , measurement ) TOUNITS ( expression , measurement , measurement ) expression , argumentlist expression

argumentlist: |

unaryoperation: | binaryop: | | | | | | | | | | | | | |

- expression NOT expression + expression - expression * expression / expression % expression ^ expression > expression >= expression = expression != expression <= expression < expression AND expression OR expression XOR expression

expression expression expression expression expression expression expression expression expression expression expression expression expression expression expression

conditional: |

expression ? expression : expression IF ( expression , expression , expression )

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| | | smooth: direction: | | cycle:

IF ( expression , expression ) IF expression THEN expression IF expression THEN expression ELSE expression SMOOTH ( expression , NUMBER ) ~COMPRESSION ~REBOUND ~IGNORE CYCLE ( expression , direction , direction ) {UNKNOWNUNIT} {} {INCH} {M} {CM} {MM} {IPS} {INCH/SEC} {M/SEC} {CM/SEC} {MM/SEC} {LBS} {NEWTONS} {KGF} {F} {C} {RPM} {HZ} {FT} {MI} {KM} {SEC} {MIN} {HR} {FT/SEC} {MPH} {MI/HR} {KPH} {K/HR} {G} {FT/SEC^2} {MP/SEC^2} {IN*LBS} {FT*LBS} {N*M} {PSI} {BAR} {P} {V} {LBS/IN} {N/MM} {N/CM}

measurement:

44

ROLLER SCREW SERIES

ACTUATOR

(ROSA)

{N/M} {KGF/MM} {KGF/CM} {KGF/M} {OZ} {LBS} {GM} {KG} {FLOZ} {GAL} {L} {DEG} {RAD} {IN*LBS/DEG} {FT*LBS/DEG} {KGF*MM/DEG} {KGF*CM/DEG} {N*MM/DEG} {N*CM/DEG} {N*M/DEG} {NEWTON*CM} {NEWTON*MM} {KGF*MM}{KGF*CM} {KGF*M} {KGF*M/DEG} {%}

45

ROLLER SCREW SERIES

ACTUATOR

(ROSA)

46

7
Maintenance Procedures

Chapter

47

Safety Considerations for Maintenance Procedures

Disclaimer of Responsibility: It is the responsibility of the personnel carrying out the maintenance procedures to ensure that sufficient measures are taken to ensure that UNDER NO CIRCUMSTANCES can the test system move if any maintenance work is being carried out. Any site safety officers should also be on hand to check that measures are taken to prevent the movement of the test system while maintenance is being carried out. Roehrig Engineering, Inc. cannot be held responsible for any injury or death to personnel, or for any damage to equipment or to the building structure cause by the actuator falling while being removed from the test system.

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Machine Frame Components.

Refer to Parts List and Drawings for Machine Frame. Little or no maintenance is required for the machine frame components. Most of these components, including the base frame, the bedplate, and the columns are either fabrications or are machined and thus have no moving parts.

Crosshead
On some models the crosshead itself has clamp/unclamp bolts built into it as well as a clamp/unclamp actuator. The crosshead also has an acme motor screw drive assembly, which may require periodic maintenance. Lock/Unlock The crosshead is locked (clamped) in place through the use of two threaded bolts on lever arms, which are attached to the electric actuator, which is free to move. As one bolt has right-hand threads, and the other has left-hand threads, the actuator clamps the crosshead into position when the electric actuator is fully RETRACTED. The crosshead is in the UNCLAMP position when the electric actuator is in the fully EXTENDED position. NOTE that all motion of the Lock Unlock is accomplished through the PLC Manual Screen, under Crosshead Control. Crosshead assembly driven by a reversing electric motor. Raise/Lower The motor drives both acme screws The Crosshead Raise/Lower motion is accomplished through the use of an acme screw synchronously through the use of a timing belt, which will eventually require replacement if worn or aged. Please note that all motion control for the Crosshead Raise/Lower is also accomplished through the PLC Manual Screen, under Crosshead Control.
Recommended Spare Parts

Recommended spares have been broken down in distinct categories: Transducers, REI Custom Parts/Assemblies, Fuse Chart, and Purchased Parts. Roehrig Engineering adheres to the policy that it is not our intention to profit from spare parts, and provides this service to support previous sales. Items such as Transducers, Fuses, and Purchased Parts can be obtained either through REI, with cost markups to cover order processing charges, or can

49

be obtained directly from the appropriate manufacturer. In the event purchased items are obtained from REI, REI standard warranties apply. If spare parts are purchased directly from manufacturers, warranty claims must be coordinated directly with the component manufacturer. Recommended Spare Parts is not intended to be an entire list of all potentially replaceable items, but rather includes items which REI has identified as either a component required for routing maintenance, a critical component which deems the machine inoperable, or items which may have unusually long lead items.

Transducers/Sensors
Description Load Cell Draw Sensor (String Potentiometer) Encoder Requires REI service for removal/install Part Number 1010ALD-5K-B Wire P510-40 Qty Used 1 1 Interface, Inc., UniMeasure, Replacement recalibration Only reqd for crosshead adjust/control requires Supplier Comments

REI Custom Parts/Assemblies

description Electromagne tic Assy Magtracks EMA Motion Controller nServo 1 Aerotech Motion Controller for EMA Linear Motors Actuator Part Number LEMA-2K 1 Est. Lead Time 8 wks. Custom configuration for use in production test stand(s). Qt Comments

50

Torque Settings Metric Bolts

Bolt Size M4 M5 M6 M8 M10 M12 M16 M20 M24 Torque (Nm) 3.7 7.5 27 31 62 107 260 506 870 Hex Key Size (mm) 3 4 5 6 8 10 14 17 19

Torque Settings Imperial Bolts

Bolt Size 8-32 10-24 -20 3/8-16 -20 5/8-18 -10 1-12 1 -12 Dry Torque 32 in-lb 47 in-lb 9.3 ft-lb 34 ft-lb 94 ft-lb 189 ft-lb 295 ft-lb 783 ft-lb 1137 ft-lb

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2
Volume

Warranty
SERVICE POLICY Roehrig Hardware Under Warranty A one-year warranty comes with the purchase of new Roehrig Engineering manufactured hardware products. Supplemental service plans are also available at additional cost.

1. 2. 3. 4. 5. 6. 7.

The following is a summary of what service can be obtained under the Standard warranty: Factory repairs on hardware product defects; Factory repairs are usually completed within 3 working days of Roehrig Engineerings receipt of the defective item. The customer is responsible for returning the hardware to Roehrig Engineering; Roehrig Engineering will return the hardware via UPS 2 day air service (USA only). If the customer is outside the continental USA, the customer is responsible for all shipping expenses. Expedited service can be arranged at the customers expense; Free technical support, for technical problems and applications, for all trained users; Warranties can be renewed annually on Roehrig Engineering products; A warranty cannot be purchased if the original or renewed warranty has expired. Warranties are transferable to subsequent owners under certain conditions:

The equipment is currently under warranty The new owner undergoes training on the equipment A warranty transfer form is completed, and submitted to Customer Service

Roehrig Hardware Not Under Warranty

E-mail is the preferred method to address non-warranty service problems, out of warranty e-mail we be answered at no charge, or the customer may use the Customer Service Request Form for troubleshooting problems via fax at no charge. REI may charge for phone non-warranty problems If the initial trouble shooting does not resolve the problem, then all factory assessments and repairs will follow the following procedure:

Factory Repairs

1. 2. 3. 4.

The customer sends the part to Roehrig Engineering. The estimated repair cost will be given to the customer prior to the repair. The total cost must be paid prior to beginning of service. System testing, evaluation and repairs can take up to two weeks. However, the part will be scheduled for a service as soon as it arrives at the factory. Roehrig Engineering will return the repaired part via UPS ground service in the USA only. If the customer is outside the continental USA, the customer is responsible for shipping charges. Expedited service can be arranged at the customers expense.

52

Repairs at Customers Facility

1. 2. 3.

Customer will pay all travel expenses of Roehrig Engineering service personnel. Travel rate is $0.485 per mile, plus $35.00 per hour, maximum $200.00 per day. If it is necessary to fly to the customers location, customer will pay full cost of the airline ticket, plus $35.00 per hour, maximum $200.00 per day travel (not including airline ticket). Customer will pay for all replacement parts plus $100.00 per hour labor.

Payment required at time of repair. 4. It may take up to 4 weeks to schedule a service call to the customers location.

Roehrig Engineering Software Under Warranty

A one-year warranty comes with the purchase of all new Roehrig Engineering developed software. The warranty includes:

1. 2.

Free telephone, e-mail and fax support for all trained users. Free updates and new releases of Roehrig Engineering developed software.

Roehrig Engineering Software Not Under Warranty Once the warranty has lapsed on Roehrig Engineering software, the following applies:

1. 2.

REI may charge for telephone support at standard service rates; Questions may be faxes or e-mailed to Roehrig Engineerings customer service department at no charge. Please use the attached form for fax request.

Hardware and Software Training Roehrig Engineerings training program is designed to instruct trainees in the operation of the equipment that the customer has purchase. The training sessions are set up for each trainee to obtain valuable hands on application exposure. This will help the trainees in their everyday use of the equipment. Training for additional personnel, and advanced training is available at additional expense.

53

ROEHRIG INC. Transfer of Warranty Service Plan Agreement

__________________________________(Sellers Name) hereby waives all rights under warranty service policy for: Dynamometer Serial Number:______________ Purchased originally on:___________________(date). ___________________________________(Buyers Name) hereby assumes all rights and obligations of the Hardware and/or Software Warranty Service Policy from: _________________________(Date of Transfer). This transfer is valid only under the following conditions. 100 Lexington Parkway Lexington NC 27295 336 956 3800

ENGINEERING

1. 2. 3.

The Dynamometer is currently under warranty New owner undergoes training from Roehrig Engineering This warranty transfer form is completed, and submitted to Customer Service.

AGREED
________________________________ (Print Sellers Corporate Name) By X____________________________ ____________________________ (Print Name of Signatory) Roehrig Engineering, Inc. Approved by X_____________________________ ____________________________ _____________________________ (Print Buyers Corporate Name) By X_________________________ _________________________ (Print Name of Signatory)

54

Purchase Conditions All Purchase Orders (hereafter, the Order) for Roehrig Engineering provided products and services (hereafter, the Product) are subject to the following terms and conditions, which are agreed to by the Purchaser. 1.00 Payment of Purchase Price Purchaser hereby promises to pay to the order of Roehrig Engineering all deferred portions of the Purchase Price, together with the interest on late purchase price payments payable at 1.5% per month (18% per annum). the Purchaser grants to Roehrig Engineering a security interest in the products sold pursuant to the Order, which may be perfected by UCC-1 Financing Statements to be recorded in the applicable County of the Purchasers business location and filed with the Secretary of States Office, which security interests will remain in effect until payment in full of the purchase price together with the interest on late purchase price payments payable thereon had been received by Roehrig Engineering. If the Purchaser fails to make full payment of the purchase price within the period set out in the Order, Roehrig Engineering shall have the following remedies, which shall be cumulative and not alternative:

1.1 1.2 1.3

A. B. C.

the right to cancel the Order and enter the Purchasers premises to re-take possession of the Product, in which event the Purchaser agrees that any down-payment or deposit shall be forfeited to Roehrig Engineering, as liquidated damages and not as a penalty, and all costs incurred shall be payable by the Purchaser upon written demand. the right to enter the Purchasers premises and remove any Software, components of the Product or other items necessary in order to render the Product inoperative. the right to withhold all services which would otherwise be required to be provided by Roehrig Engineering pursuant to the Warranties set out in Section 5 hereof. terminate any existing software license agreement

pursue any other available remedy, including suing to collect any remaining balance of the purchase price. No waiver by Roehrig Engineering of its rights under these conditions shall be deemed to constitute a waiver of subsequent breaches or defaults by the Purchaser. In the event more than one Product is being purchased pursuant to the Order, unless otherwise set forth herein, each payment received by Roehrig Engineering from Purchaser shall be applied pro rata against the cost of each product rather than being applied to the purchase price of any product. 2.00 Delivery and Transportation

D. E.

2.1 2.2

Delivery dates are estimates and not guarantees, and are based upon conditions at the time such estimate is given. Roehrig Engineering shall not be liable for any loss of damage, whether direct, indirect or consequential, resulting from late delivery of the product. The Purchasers sole remedy if the Product is not delivered within 90 days of the estimated delivery date, shall be to cancel the Order and recover from Roehrig Engineering without interest or penalty, the amount of the down-payment or deposit and any other part of the purchase price which has been paid by the Purchaser. Notwithstanding the foregoing, such right of cancellation shall not extend to situations where late delivery is occasioned by causes beyond Roehrig Engineerings control, including, without limitation, compliance with any rules, regulations, orders or instructions of any federal, state, county, municipal or other government or any department or agency thereof, force majuere, acts or omissions of the Purchaser, acts of civil or military authorities, embargoes, war or insurrection, labor interruption through strike or walkout, transportation delays and other inability resulting from causes beyond Roehrig Engineerings control to obtain necessary labor, manufacturing facilities or materials from its usual sources. Any delays resulting from such causes shall extend estimated delivery dates by the length of such delay. Responsibility for all costs and risks in any way connected with the storage, transportation and installation of the Product shall be borne entirely by the Purchaser. If any disagreement arises as to whether or not damage to the Product was in fact caused in storage, transit or installation, the opinion of Roehrig Engineerings technical advisers, acting reasonably, shall be conclusive.

2.3

3.0 Installation and Operator Training

3.1

The Purchaser shall be responsible for installation of the Product, including, without limitation, the preparation of its premises, the uncrating of the product and setting up of the Product for operation. Purchaser may elect to order contract services from Roehrig Engineering to perform this service should they elect to do so.

4.0 Warranties and Limitation of Liability

4.1 4.2 4.3 4.4

Roehrig Engineering warrants that (subject to Section 4.6), the Product shall be free from defects in workmanship or material affecting the fitness of the product for its usual purpose under normal conditions of use, service and maintenance. Roehrig Engineering warrants that the software shall operate according to specifications and the system shall operate and perform in the manner contemplated in connection with the usual purpose for which it was designed. The warranties set out in paragraphs 4.1 and 4.2 above (together called the Warranties) shall expire at the end of the twelve (12) month period commencing on the first day of the first month after the date of shipment from the Roehrig Engineering factory (the Warranty Period). Subject to the limitations contained in Section 4.6, the Warranties shall apply to any defects found by the Purchaser in the operation of the Dynamometer or the software and is reported to Roehrig Engineering within the Warranty Period. If the Dynamometer or the software is found by Roehrig Engineering, acting reasonably, to be defective, and if the defect is acknowledged by Roehrig

55

Engineering to be the result of Roehrig Engineerings faulty material or workmanship, the Dynamometer or Software will be repaired or adjusted to the extent found by Roehrig Engineering to be necessary, or at the option of Roehrig Engineering, replaced with a new Dynamometer, Software, or parts thereof at no cost to the purchaser. Claims under the Warranties shall be made by delivering written notice to Roehrig Engineering of the defect in the System, Dynamometer, or the Software. Within a reasonable time of receipt of such service personnel and warranty service will be provided at no cost to the Purchaser. If in the reasonable opinion of Roehrig Engineering the dynamometer and Software are not defective, the Purchaser shall pay the cost of service, which shall be the amount that Roehrig Engineering would otherwise charge for that service and shall include, without limitation, shipping, handling, and an hourly service charge.

4.5

The Warranties do no apply to

A.

B. C. D. 4.7 A. B. 4.8 4.9

any defects in any component of a System where, if in the reasonable opinion of Roehrig Engineering, the Dynamometer, Software or System has been improperly stored, installed, operated, or maintained, or if Purchaser has permitted unauthorized modifications, additions, adjustments and/or repair to any part of the System, or which might affect the System, or defects caused or repairs required as a result of causes external to Roehrig Engineering workmanship or the materials used by Roehrig Engineering. As used herein, unauthorized means that which has not been approved and permitted by Roehrig Engineering. The Warranties shall not cover replacement of expendable items including, but not limited to, fuses, diskettes, printer paper, printer ink, printing heads, disk cleaning materials, wear plates, or similar items. The Warranties shall not cover minor preventative and corrective maintenance. Any equipment or its components which was sold or transferred to any party other than the original Purchaser without the expressed written consent of Roehrig Engineering.

Factory Repairs IF SYSTEM IS UNDER WARRANTY: The Purchaser agrees to ship the Product to Roehrig Engineering in the original packing containers. Roehrig Engineering will return the repaired or replaced Product. Roehrig Engineering will incur the expense of the needed part and all return shipping charges to the Purchaser. Roehrig Engineering may authorize of a component of the Product to perform the service. IF SYSTEM IS NOT UNDER WARRANTY: The Purchaser is responsible for the cost of the replacement part or software, and all shipping charges.

Nothing herein contained shall be construed as obligating Roehrig Engineering to make service, parts, or repairs for any product available after the expiration of the Warranty Period. Limitation of Liability Roehrig Engineering shall not be responsible under any circumstances for special, incidental or consequential damages, including, but not limited to, injury or death of any operator or other person, damage or loss resulting from inability to use the System, increased operating costs, loss of production, loss of anticipated profits, damage to property, or other special, incidental, or consequential damages of any nature arising from any cause whatsoever whether based in contract, tort (including negligence), or any other theory of law. Roehrig Engineerings only liability hereunder, arising from any cause whatsoever, whether based in contract, tort (including negligence) or any other theory of law, consists of the obligation to repair or replace defective components in the System or Dynamometer subject to the limitations set out above in this section. This disclaimer of liability for consequential damage extends to any such special, incidental or consequential damages which may be suffered by third parties, either caused directly or indirectly resulting from test results or data produced by the system or any component thereof and the Purchaser agrees to indemnify and save Roehrig Engineering harmless from any such claims made by third parties. to the system.

4.10 The foregoing shall be Roehrig Engineerings sole and exclusive liability and the Purchasers sole and exclusive remedy with respect

THE SOLE RESPONSIBILITY OF ROEHRIG ENGINEERING UNDER THE WARRANTIES IS STATED HEREIN AND ROEHRIG ENGINEERING SHALL NOT BE LIABLE FOR CONSEQUENTIAL, INDIRECT, OR INCIDENTAL DAMAGES, WHETHER THE CLAIM IS FOR BREACH OF WARRANTY, NEGLIGENCE, OR OTHERWISE. OTHER THAN THE EXPRESS WARRANTIES HEREIN STATED, ROEHRIG ENGINEERING DISCLAIMS ALL WARRANTIES INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS. Roehrig Engineering does not authorize any person (whether natural or corporate) to assume for Roehrig Engineering any liability in connection with or with respect to the Products. No agent or employee of Roehrig Engineering has any authority to make any representation or promise on behalf of Roehrig Engineering, except as expressly set forth herein, or to modify the terms or limitations of the Warranties. Verbal statements are not binding by Roehrig Engineering.

4.11 The Warranties extend only to the Purchaser and are transferable, only under the following conditions: A. The Dynamometer is currently under warranty. B. New owner undergoes training. C. A Roehrig Engineering warranty transfer is completed, and submitted to customer service.
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4.13 Oral representations of Roehrig Engineering or its sales representatives, officers, employees or agents cannot be relied upon as
OF THE USES TO WHICH THE SYSTEM WILL BE PUT. ROEHRIG ENGINEERING SPECIFICALLY DISCLAIMS ANY WARRANTY OR LIABILITY RELATED TO THE FITNESS OF THE SYSTEM FOR ANY PARTICULAR PURPOSE OR ARISING FROM THE INABILITY OF THE PURCHASER TO USE THE SYSTEM FOR ANY PARTICULAR PURPOSE.

All claims under the Warranties must originate with the Purchaser, or any subsequent owner, and the Purchaser will indemnify and save Roehrig Engineering harmless from any claims for breach of warranty asserted against Roehrig Engineering by any third party.

4.14 PURCHASER ACKNOWLEDGES THAT IT HAS PURCHASED THE SYSTEM BASED UPON ITS OWN KNOWLEDGE

correctly stating the representations of Roehrig Engineering in connection with the system. Refer to this purchase order, any exhibits hereto and any written materials supplied by Roehrig Engineering for correct representations.

5.0 Design Changes

5.1 The Dynamometer, the Software, and the System are subject to changes in design, manufacture and programming
between the date of order and the actual delivery date. Roehrig Engineering reserves the right to implement such changes without the Purchasers consent; however, nothing contained herein shall be construed as obligating Roehrig Engineering to include such changes in the Dynamometer, Software, or System provided to the Purchaser.

6.0 Non-Disclosure

6.1

All Software including, without limitation, any Roehrig Engineering special user programs, provided to the Purchaser as part of the system, either at the time of or subsequent to the delivery of the Dynamometer, is the intellectual property of Roehrig Engineering. The Purchaser shall not reproduce or duplicate, disassemble, decompile, reverse engineer, sell, transfer or assign, in any manner the Software or permit access to or use thereof by any third party. The Purchaser shall forthwith execute any further assurances in the form of non-disclosure or licensing agreements which may reasonably be required by Roehrig Engineering in connection with the software.

7.0 Entire Agreement / Governing Law / Miscellaneous / Guarantee

7.1 7.2 7.3 7.4 7.5

These Purchase conditions constitute the entire agreement between Roehrig Engineering and the Purchaser in respect to the Product. There are no representations or warranties by Roehrig Engineering, express or implied, except for those herein contained and these conditions supersede and replace any prior agreements between Roehrig Engineering and the Purchaser. No representative of Roehrig Engineering has any authority to modify, alter, delete or add to any of the terms or conditions hereof. Any such modifications shall be absolutely void unless made by instrument in writing properly executed by an actual authorized employee or agent of Roehrig Engineering. The terms and conditions hereof shall be binding upon Roehrig Engineering and the Purchaser, and shall not be construed in accordance with the laws of the State of North Carolina, United States of America. Roehrig Engineering shall be entitled to recover all of its reasonable fees and costs including, but not limited to, its reasonable attorneys fees incurred by Roehrig Engineering in connection with any dispute or litigation arising thereunder or in connection herewith, including appeals and bankruptcy or creditor reorganization proceeds. These conditions shall not be construed more strictly against one party that another as a result of one party having drafted said instrument.

8.0 Definitions

8.1 8.2 8.3 8.4 8.5 8.6 8.7

Roehrig Engineering means Roehrig Engineering, Inc. Purchaser means the party buying the Product who is legally obligated hereunder. Software means all computer programs, including diskettes containing such computer programs sold pursuant to the Order. Product means the Dynamometer, the Software, operating manuals and any other product or merchandise sold pursuant to the Order. System means a combination of the Dynamometer, the Software, the Computer, and optional parts associated with the Dynamometer. Purchase Order means the original document issued from the Purchaser to Roehrig Engineering, listing all parts and/or services to be purchased and the agreed purchase price. Warranty Transfer Form means a document to be completed for the transfer of the Roehrig Engineering Warranty. This document is available from Roehrig Engineering upon request.

57

9.0 Software License Agreement The Software License Agreement is part of the Operating Manual for the product and software System that you have purchase from Roehrig Engineering, Inc. (collectively, the Licenser). By your use of the software you are agreeing to the terms and conditions of this Software License Agreement. Throughout this Software License Agreement, the term Licensee means the owner of the System.

9.1 9.2 9.3 9.4 9.5

The Licenser hereby grants the Licensee the non exclusive right to use the computer software described in this Operating Manual (the Software). The Licensee may sell the software key but may not assign, sub-license, rent or lease the Software to any third party without the Licensers prior written consent. The Licenser further grants the Licensee the right to make a backup copies of the Software media and use the software in demo mode. The Licensee agrees that it will not decompile, disassemble, reverse engineer, copy, transfer, or otherwise use the Software except as permitted by this section. The Licensee is licensed to use the Software only in the manner described in the Operating Manual. Use of the Software in a manner other than that described in the Operating Manual or use of the Software in conjunction with any non-Licenser product which decompiles or recompiles the Software or in any other way modifies the structure, sequence or function of the Software code, is not an authorized use, and further, such use voids the Licensers Warranty as set forth below. The only warranty with respect to the Software and the accompanying written materials is the warranty, if any, set forth in the Quotation/Purchase Order and Service Policy pursuant to which the Software was purchased from the Licenser.

THIS WARRANTY IS IN LIEU OF OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICLUAR PURPOSE WITH RESPECT TO THE SOFTWARE AND WRITTEN MATERIALS. IN NO EVENT WILL THE LICENSER BE LIABLE FOR DAMAGES, INCLUDING ANY LOST PROFITS RO OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE THE SOFTWARE, NOTWITHSTANDING THAT THE LICNESER MAY HAVE BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES, THE LICENSER WILL NOT BE LIABLE FOR ANY SUCH CLAIM BY ANY OTHER PARTY. In the event of any breach by the Licensee of this Agreement, the license granted hereby shall immediately terminate and the Licensee shall return the Software media and all written materials, together with any copy of such media or materials, and the Licensee shall keep no copies of such items. The interpretation of this Agreement shall be governed by the following provisions:

A. B.

This agreement shall be construed pursuant to and governed by the substantive laws of the State of North Carolina (and any provision of North Carolina laws shall not apply if the law of a state or jurisdiction other than North Carolina would otherwise apply). If any provision of this Agreement is determined by a court of competent jurisdiction to be void and non-enforceable, such determination shall not affect any other provision of this Agreement, and the remaining provisions of this Agreement shall remain in full force and effect. If any provision or term of this Agreement is susceptible to two or more constructions or interpretations, one or more of which would render the provision or term void or non-enforceable, the parties agree that a construction or interpretation which renders the term of provision valid shall be favored.

This Agreement constitutes the entire Agreement, and supersedes all prior agreements and understandings, oral and written, among the parties to this Agreement with respect to the subject matter hereof. 9.8 If a party engages the service of an attorney or any other third party or in any way initiates legal action to enforce its rights under this Agreement, the prevailing party shall be entitled to recover all reasonable costs and expenses (including reasonable attorneys fees before trial and in appellate proceeding.

C.

58

59