2nd Generation Henrob Controller: Operation and Maintenance Manual For Henrob Self-Pierce Riveting System

OPERATION AND MAINTENANCE
MANUAL FOR HENROB

SELF-PIERCE RIVETING SYSTEM
2nd Generation Henrob Controller

DeviceNet Internal Communications
Manual Part Number: 30-00105
HENROB© Corporation
35455 Veronica Drive, Livonia, Michigan 48150
Telephone: (734) 521-3000, (800-4-HENROB)
Facsimile: (734) 521-3001
www.henrob.com
Page ii ©2012 Henrob Corporation
Table of Contents
Table of Contents ...............................................................................................iii
1.0 Safety Precautions .....................................................................................1

1.1 General Safety Precautions....................................................................1
1.2 Safety Precautions For Electric Servo Henrob Equipment .....................1
1.3 Warnings.................................................................................................2
1.4 Cautions..................................................................................................2
1.5 Notes ......................................................................................................2
2.0 System Overview........................................................................................3

2.1 Riveting Process Overview.....................................................................4
2.1.1 Starting Condition.........................................................................5
2.1.2 Clamping ......................................................................................5
2.1.3 Start Of Insertion ..........................................................................5
2.1.4 End Of Insertion / High Clamp Load.............................................5
2.1.5 Tool Retracted..............................................................................6
2.2 Tool Motion During Riveting Cycle .........................................................6
2.2.1 Tool Motion – Standard ................................................................7
2.2.2 Tool Motion – Fly Across Space...................................................8
2.3 Servo Rivet Setter...................................................................................9
2.3.1 Speed .........................................................................................10
2.3.2 Partial Retract.............................................................................10
2.4 Compliant..............................................................................................11
2.4.1 Effect of Tool Orientation on the Compliant Device ...................11
2.4.2 Effect of Robot Acceleration on Compliant Devices...................12
2.4.3 Types of Compliant Devices.......................................................12
2.5 Spot Parameter Setup ..........................................................................13
2.5.1 Manual Spot Parameter Adjustment ..........................................13
2.5.2 Spot Parameter Entry via Text File ............................................16
2.6 I/O Communications .............................................................................18
2.7 External I/O...........................................................................................19
2.7.1 Cables ........................................................................................19
2.7.2 Turck BL20 PLC Link .................................................................19
3.0 Henrob Servo Controller ..........................................................................20

3.1 Front Panel Controls................................................................................21
3.1.1 480V Isolator Disconnect  .......................................................21
3.1.2 HMI (Human Machine Interface)  ............................................21
3.1.3 System Disable switch  ...........................................................21
3.1.4 Illuminated green push switch ................................................21
3.1.5 Auto, Manual, Maintenance switch  ........................................21
©2012 Henrob Corporation Page iii

3.2 Internal Panel Layout ........................................................................... 22
3.3 480V Power and 24V Supplies............................................................. 23
3.3.1 480V isolator disconnect & Ground Lug .................................... 23
3.3.2 Three phase fuse....................................................................... 23
3.3.3 24V DC power supply (10A) ...................................................... 23
3.3.4 DC Power loss buffer and fuse .................................................. 24
3.3.5 Buffered circuit breaker (4 channel)........................................... 24
3.3.6 Unbuffered circuit breaker (4 channel) ...................................... 25
3.4 Servo Drive Sub-System ...................................................................... 26
3.4.1 Line filter .................................................................................... 26
3.4.2 Servo Drive Components........................................................... 26
3.4.3 Capacitor bank........................................................................... 27
3.4.4 Servo Drive I/O .......................................................................... 27
3.5 Servo Drive Inputs................................................................................ 28
3.5.1 I1: Advance Pushbutton (X31.3) ................................................ 28
3.5.2 I2: Retract Pushbutton (X31.4) .................................................. 28
3.5.3 I3: Mode Switch Channel A (X31.5)........................................... 28
3.5.4 I4: Mode Switch Channel B (X31.6)........................................... 28
3.5.5 I5: Start Request Pushbutton (X31.7) ........................................ 28
3.5.6 I6: No EStop Condition (X32.4) ................................................. 29
3.5.7 I7: Drive Enable (X32.5) ............................................................ 29
3.6 Servo Drive Amplifier Outputs .............................................................. 29
3.6.1 IO8: Spare (X32.6)..................................................................... 29
3.6.2 IO9: Spare (X32.7)..................................................................... 29
3.6.3 IO10: Allow Enable (X32.8) ....................................................... 29
3.6.4 IO11: Drive Power On (X32.9) ................................................... 29
3.6.5 RLY: Spare (X31.1 & X31.2)..................................................... 29
3.7 Motor Control & Safety Circuit.............................................................. 30
3.7.1 Internal Structure ....................................................................... 30
3.7.2 Safety Circuit Operation............................................................. 31
3.7.3 Enabling Pendant.......................................................................... 32
3.8 Connection Arrangements.................................................................... 33
3.9 Connection Pinouts .............................................................................. 34
3.9.1 Enabling Pendant Socket. (X503).............................................. 34
3.9.2 Ethernet Programming Port ....................................................... 34
3.9.3 Ethernet to tool connection tool I/O ........................................... 34
3.9.4 EthernetIP connection to customer............................................ 34
3.9.5 Ethernet Data Connection to customer / Spare ......................... 35
3.9.7 Motor Power (X220)................................................................... 35
3.9.8 Motor Feedback (X902) ............................................................. 35
3.9.9 Tool I/O Power (X1505) ............................................................. 36
3.9.10 EStop Connection Socket - (X613) ........................................... 36
3.9.10 Contactor Feedback - (X1512) ................................................. 36
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4.0 Installation.................................................................................................37
4.1 Transportation.......................................................................................39
4.2 Installation.............................................................................................40
5.0 Reprogramming Henrob Controllers ......................................................41

5.1 Programming Bosch Servo Drive .........................................................41
5.2 Programming the Pilz Safety Controller................................................42
5.3 Programming the RivMon unit ..............................................................42
5.4 Configuring the System ........................................................................43
5.4.1 Systems using default comms and remote I/O box....................43
5.4.2 System using customer comms and Ethernet tool I/O. ..............44
6.0 Operator Interface (HMI & Front Panel Controls) ..................................45

6.1 Front Panel Controls.............................................................................45
6.1.1 System Disable button ...............................................................45
6.1.2 System Enable button ................................................................45
6.1.3 Auto, Manual, Maintenance switch.............................................45
6.2 Automatic Mode Of Operation ..............................................................46
6.2.1 Verify Home................................................................................46
6.2.2 Auto Mode Screen......................................................................47
6.3 Manual Mode ........................................................................................48
6.3.1 Manual Mode Screen .................................................................49
6.4 Maintenance Mode ...............................................................................52
6.4.1 Homing a Tool ............................................................................52
6.4.2 Calibrating a Tool .......................................................................53
6.4.3 Maintenance Mode Screen ........................................................54
6.5 HMI Screens............................................................................................55
6.5.1 Status Bar...................................................................................55
6.5.2 Main Window..............................................................................56
6.5.3 Icon Button Bar...........................................................................56
6.6 HMI Home Screen ................................................................................57
6.6.1 Communications (Comms) Screen ............................................58
6.6.2 System Error Status Screen.......................................................59
6.6.3 System Error Log .......................................................................60
6.6.4 Password Control .......................................................................61
6.6.5 Tool Details ................................................................................62
6.6.6 Tool IO Status ............................................................................64
6.6.7 Spot Settings ..............................................................................65
6.7 Spot Parameter Entry ...........................................................................66
6.7.1 Creating/Changing Spot Parameters .........................................67
6.7.2 Application Mapping ...................................................................69
6.8 Communications Display ......................................................................70
6.8.1 Cell/Robot Communications Display ..........................................70
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6.8.2 Drive I/O Display........................................................................ 71
6.9 Preventive Maintenance....................................................................... 72
6.10 Utilities Menu........................................................................................ 74
6.10.1 Backup RivMon to SD................................................................ 75
6.10.2 Load/Save Spot Parameters...................................................... 76
6.10.3 Active Tools ............................................................................... 77
6.10.4 Error/Warning Thresholds.......................................................... 78
6.10.5 Calibrate Touchscreen............................................................... 79
6.10.6 Change Language ..................................................................... 79
6.10.7 System Configuration ................................................................ 80
6.10.8 Change Type ............................................................................. 82
7.0 RivMon Riveting Process Monitoring (if equipped)................................. 83

7.1 RivMon Process Measurements .......................................................... 84
7.1.1 Start Distance ............................................................................ 84
7.1.2 End Distance ............................................................................. 85
7.1.3 Peak Force ................................................................................ 85
7.1.4 Insertion Distance ...................................................................... 86
7.1.5 Insertion Time ............................................................................ 86
7.1.6 Insertion Velocity ....................................................................... 86
7.2 Types of Riveting Errors (Decoded Fault Causes)............................... 87
7.2.1 Missing Rivet ............................................................................. 87
7.2.2 Double Rivet .............................................................................. 88
7.2.3 Speed Too Fast/Speed Too Slow.............................................. 88
7.2.4 Thin Material/Thick Material....................................................... 88
7.2.5 Rivet Too Long/Rivet Too Short ................................................ 89
7.2.6 Head Too High/Head Too Low .................................................. 89
7.2.7 Insertion Time ............................................................................ 89
7.2.8 Hard Material/Soft Material ........................................................ 89
7.2.9 Unknown Fault........................................................................... 89
7.3 RivMon Screens ................................................................................... 90
7.3.1 RivMon Overview Screen – No Fault Active .............................. 90
7.3.2 RivMon Overview Screen – Active Fault ................................... 91
7.3.3 Tool Results Overview Screen .................................................. 92
7.4 History .................................................................................................. 93
7.4.1 Tolerance Band Modification – Direct Modification.................... 95
7.4.2 Tolerance Band Modification – Numeric Entry........................... 97
7.5 Curves – Position, Vel. & Force Vs Time ............................................. 98
7.6 Curves – Force Vs Displacement......................................................... 99
7.6.1 Force Vs Displacement Tolerance Adjustment........................ 101
7.7 Curves – Velocity Vs Displacement ...................................................... 102
7.7.1 Velocity Vs Displacement Tolerance Adjustment .................... 104
7.8 Detected Process Errors .................................................................... 105
Page vi ©2012 Henrob Corporation

7.8.1 Err 1: Start Position Far Too Small...........................................105
7.8.2 Err 2: Start Position Too Small .................................................105
7.8.3 Err 3: Start Position Too Large.................................................105
7.8.4 Err 4: Start Position Far Too Large ..........................................105
7.8.5 Err 5: End Position Far Too Small............................................105
7.8.6 Err 6: End Position Too Small ..................................................106
7.8.7 Err 7: End Position Too Large ..................................................106
7.8.8 Err 8: End Position Far Too Large............................................106
7.8.9 Err 9: Insertion Disp. Far Too Small .........................................106
7.9.10 Err 10: Insertion Disp. Too Small .............................................106
7.8.11 Err 11: Insertion Disp. Too Large .............................................106
7.8.12 Err 12: Insertion Disp. Far Too Large.......................................106
7.8.13 Err 13: Insertion Time Too Small..............................................106
7.8.14 Err 14: Insertion Time Too Large .............................................107
7.8.15 Err 15: Start Velocity Too Small ...............................................107
7.8.16 Err 16: Start Velocity Too Large ...............................................107
7.8.17 Err 17: Peak Force Too Small ..................................................107
7.8.18 Err 18: Peak Force Too Large..................................................107
7.8.19 Err 19: Left Vel. Vs Disp. Curve Below.....................................107
7.8.20 Err 20: Left Vel. Vs Disp. Curve Above ....................................107
7.8.21 Err 21: Left Vel. Vs Disp. Curve at Start...................................107
7.8.22 Err 22: Left Vel. Vs Disp. Curve at End ....................................108
7.8.23 Err 23: Left Force Vs Disp. Curve Below..................................108
7.8.24 Err 24: Left Force Vs Disp. Curve Above .................................108
7.8.25 Err 25: Left Force Vs Disp. Curve at Start................................108
7.8.26 Err 26: Left Force Vs Disp. Curve at End .................................108
7.8.27 Err 27-31: Spare.......................................................................108
8.0 Error Message & Fault Recovery ..........................................................109

8.1 Faults Before Riveting ........................................................................110
8.1.1 System Faults...........................................................................111
8.1.2 Magazine Faults .......................................................................112
8.2 Faults During Riveting ........................................................................113
8.2.1 System Faults...........................................................................113
8.2.2 RivMon Faults ..........................................................................114
8.2.3 Drive Faults During Operation..................................................115
8.2.4 Motion Faults During Operation ...............................................116
8.3 Fault After Riveting .............................................................................117
9.0 Henrob Standard Communications .........................................................119

9.1 Signals from Cell/Robot to Henrob Controller .......................................120
9.1.1 Cycle Setter (Input Bit 0) ..........................................................120
9.1.2 Retract Setter (Input Bit 1)........................................................122
©2012 Henrob Corporation Page vii

9.1.3 Force Complete (Input Bit 2).................................................... 123
9.1.4 Fault Ack – Acknowledge Fault Input Bit 3 .............................. 124
9.1.5 Clear Rivet Set Input Bit 4 ....................................................... 125
9.1.6 Dry Cycle Input Bit 5 ................................................................ 126
9.1.7 Close Setter Input Bit 6............................................................ 126
9.1.8 Open Setter Input Bit 7 ............................................................ 126
9.1.9 Cut Tape Input Bit 8................................................................ 127
9.1.10 No Home Allowed Input Bit 9................................................... 128
9.1.11 Pulse Heartbeat In (0.5s) Input Bit 15...................................... 128
9.1.12 Spot Parameter Selection & RivMon Input Bits 16..23 ........... 128
9.2 Signals from Henrob Controller to Robot ........................................... 129
9.2.1 Ready to Cycle Output Bit 0 .................................................... 129
9.2.2 In Cycle Output Bit 1............................................................... 129
9.2.3 Cycle Complete Output Bit 2 ................................................... 129
9.2.4 No Fault Output Bit 3 ............................................................... 129
9.2.5 Rivet Set Output Bit 4 ............................................................. 129
9.2.6 Home Position Output Bit 5 ..................................................... 129
9.2.7 Partial Position Output Bit 6..................................................... 129
9.2.8 Locked for Movement Output Bit 7 .......................................... 129
9.2.9 Tool Disabled Output Bit 8....................................................... 129
9.2.10 Rivets Low Output Bit 9 ........................................................... 130
9.2.11 Correct Rivet/Empty Output Bit 10........................................... 130
9.2.12 Heartbeat out Output Bit 11 ..................................................... 130
9.2.13 Preventive Maintenance Signals Output Bits 29..31............... 130
10.0 Customer Specific Communication – Option 1................................... 131

10.1 Signals from Robot to Henrob Controller ........................................... 133
10.1.1 Reset Anti-Double Rivet – Clear ‘Rivet Set’ Flag Input 1........ 133
10.1.2 Cut Tape – Cut used tape Input 2............................................ 133
10.1.3 Dry Cycle – Select Dry Cycle Mode Input 4............................. 133
10.1.4 Force Rivet Complete Input 5 ................................................. 134
10.1.5 ID0/1/2/3/4/5/6/7 – Spot Select Input 16 – 23 .......................... 134
10.1.6 Start Riveting Input 24 ............................................................ 135
10.1.7 Move To Requested Opening Input 25 .................................... 136
10.1.8 Fault Reset – Acknowledge Fault Input 30 .............................. 137
10.2 Signals from Henrob Controller to Robot ........................................... 138
10.2.1 Ready To Operate – Ready to start a new action Output 0 ..... 138
10.2.2 System In Auto Output 1.......................................................... 138
10.2.3 No Fault – No Fault currently active Output 2.......................... 138
10.2.4 Rivets Low – Rivet Spool Running Low Output 3 .................... 138
10.2.5 Fault Code (Bits 0-7) – Current fault Code Output 8-15 .......... 138
10.2.6 Ready To Start – Ready to start a new action Output 24 ........ 138
10.2.7 Gun Home – Tool Fully Open Output 25 ................................. 138
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10.2.8 Gun Open – Tool at Required Opening Output 26...................138
10.2.9 Cycle Complete – Action Complete Output 27.........................139
10.2.10 LS Fixed – Linear Slide Fixed Output 28..................................139
11. Record of Amendments ............................................................................141
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Page x ©2012 Henrob Corporation

SAFETY PRECAUTIONS • 1
1.0 Safety Precautions
It is the responsibility of the purchaser to ensure that Henrob equipment is used

and operated within a SAFE system of work. It is important that only trained
personnel use this equipment. Please contact Henrob™ Corporation for more
details.
1.1 General Safety Precautions

Ensure all body parts are clear of the tool before actuating the machine. Self-
Pierce riveting equipment operates at high forces and can cause serious injury if
used improperly.
Do Not cycle the rivet setter without appropriate material and upsetting die in
position.
Do Not attempt to set a rivet on top of a previously inserted rivet (This is referred
to as a Double Rivet).
Do Not operate the equipment without suitable eye protection.
Follow all warnings cautions and notes in operation and maintenance manuals.
1.2 Safety Precautions For Electric Servo Henrob Equipment

Do Not obstruct the flow of cooling air around the Electric Servo Controller
Cabinet.
Do Not switch on the Electric Servo Controller Cabinet or operate the rivet setter
with the electrical enclosure open (except qualified maintenance personnel
carrying out fault finding).
Do Not switch on or operate the Electric Servo Controller Cabinet with the motor
power, motor control, tool I/O, or motor feedback cables disconnected.
©2012 Henrob Corporation Page 1

1 • SAFETY PRECAUTIONS
1.3 Warnings
Warnings are inserted directly before procedures in this manual. Warnings
identify potential hazards that may cause serious injury or death to operating and
maintenance personnel working on the Henrob Self-Pierce Riveting System.
All personnel working on Henrob equipment shall read, familiarize themselves

with and heed these warnings.
WARNING: The Rivet Setter can generate very high forces.

WARNING
1.4 Cautions
Cautions are to prevent possible damage to the component parts of the Henrob
Rivet Setter.
All personnel working on Henrob Equipment shall read, familiarize themselves

with, and heed these cautions.
CAUTION: Only qualified personnel should perform service on

the Henrob riveting equipment. The electrical connections
should not be accessed until a thorough understanding of the
CAUTION system is obtained. See the appropriate schematics before
performing any adjustments or alterations.
1.5 Notes
The Note icon is inserted where appropriate to aid service personnel when
working on Henrob equipment
Note: Please check for and report any damage to the

equipment upon arrival at your premises.
NOTE
Page 2 ©2012 Henrob Corporation

Henrob Servo Controller • 3
2.0 System Overview
The major components contained in a complete system are as follows:
 Electrical Control Cabinet

 Rivet Setter Assembly
 Electrical (Motor Power, Motor Encoder, hardwired or Ethernet I/O, 24VDC)
 Pneumatic services
 Tool Changer (optional)
 Stand (optional)
Please note the I/O Distribution Box or valve island (hardwire or Ethernet) is
usually mounted on the bracket that interfaces with the robot or pedestal stand
For more connection details please refer to the schematic system overview
contained in the control cabinet drawing.

3 • Henrob Servo Controller
2.1 Riveting Process Overview
The rivet insertion operation

Spool of Rivets
starts with the rivet-laden tape
coming off the spool and entering
Rivet Laden the feed tube through the end of
Tape
rivets sensor.
The tape travels through the feed

tube and into the guide bush
assembly.
End of Rivets
As the rivets enter the guide bush
Sensor
Powered assembly they pass under the
Spool Winder Feed Tube Anti Pull Back (APB) device
which ensures proper orientation
and position.
Tape Cutter The first rivet in the tape is

stopped directly under the punch
Linkage Bracket by a ‘cup’ in the nose switch
housing, and is sensed by the
rivet present sensor.
Guide Bush
Assembly During the RivMon monitored
Sprocket rivet insertion cycle, the punch
Drive advances and pushes the first
Tape Guide rivet out of the tape through the
Spent Tape nose and into the materials being
joined.
Rivet Present
Rivet Laden When the next rivet needs to be
Sensor
Tape brought into position, the sprocket
drive pulls the spent tape through
guide bush assembly until the
rivet present sensor signals that
the rivet is in position.

2.1.1 Starting Condition
The process begins with the material to be

riveted situated between the nose and die of the
rivet tool. The rivet is shown in the nose of the
tool just below punch.
2.1.2 Clamping
The robot brings the die up against the bottom

surface of the material to be joined. The nose of
the rivet setter advances and applies a `low’
clamp force to press the sheets together.
2.1.3 Start Of Insertion
The punch begins to drive the rivet into the top

sheet of the material. While the bottom sheet
begins to be formed by the die.
2.1.4 End Of Insertion / High Clamp Load
The rivet is pressed fully home but during the

last 0.5mm of punch travel, a `high’ force clamp
is applied by the nose insert to the material
around the rivet. This flattens out the local spot
area as well as inducing compressive stress.

2.1.5 Tool Retracted
At the completion of the insertion, the punch

retracts, the clamp force is released and the
nose moves up off the material.
After the tool has retracted the robot would

move the die away from the material, and move
to the next location.
2.2 Tool Motion During Riveting Cycle

Depending upon the setting speed being used, one of the two following motion
profiles will be used depending on which will give the shortest cycle time. These
are as follows:
Standard Cycle In this motion the system accelerates to the setting velocity in
a single motion.
Fly Across Space In this motion, if space allows, the tool will accelerate to a
higher velocity to close the nose-to-die gap quickly, and then
decelerate to the final setting velocity.
The fly-across-space profile uses slower accelerations and

decelerations due to extra power used to control the motion.
Hence for smaller nose-to-die distances the standard motion
profile will normally be used.
The form of these motion profiles is discussed below.
Note: The presence of a flywheel will affect the acceleration and deceleration
rates used as the system applies approximately the same amount of power
to the motor during the riveting cycle, thus for a given applied motor current,
the allowable acceleration rate will be higher without the added inertia of a
flywheel.

2.2.1 Tool Motion – Standard

Below is a simplified graph of the motion undertaken to insert a rivet using the
standard, non fly-across-space, motion profile.
1. Cycle starts with the setter at home, with zero motor current and punch
velocity.
2. Punch reaches required velocity and motor current drops to maintain
velocity.
3. Rivet reaches material, and motor current jumps to try and maintain
velocity.
4. End of rivet insertion as punch velocity reaches zero, before being back
driven by the C-Frame.
5. Tool is accelerated backwards.
6. Tool attains retract velocity and motor current drops.
7. Tool approaching final position, so tool is decelerated using the motor as a
brake (regenerating electrical current).
8. Tool stops at final position, and motor current returns to zero.

2.2.2 Tool Motion – Fly Across Space

Below is a simplified graph of the motion undertaken to insert a rivet using the ‘fly-
across-space’ motion profile.
1. Cycle starts with the setter at home, with zero motor current and punch
velocity.
2. Tool accelerates to high speed to close down opening.
3. Tool decelerates to the required setting speed (regenerating electrical
current).
4. Tool attains setting speed prior to rivet touching material.
5. Rivet reaches material, and motor current jumps to try and maintain
velocity.
6. End of rivet insertion as punch velocity reaches zero, before being back
driven by the C-Frame.
7. Tool is accelerated backwards.
8. Tool attains retract velocity and motor current drops.
9. Tool approaching final position, so tool is decelerated using the motor as a
brake (regenerating electrical current).
10. Tool stops at final position, and motor current returns to zero.

2.3 Servo Rivet Setter

The Henrob Servo Rivet Setter is an inertial type tool. The actuator part of the rivet
setter spins like a flywheel, storing the energy necessary to set a rivet. The
actuator is a roller screw specifically designed for the Henrob tool and has a much
larger rotating mass than would typically be found in such a screw. As the roller
screw spins it moves the actuator push rod forward or backwards, depending upon
which way it is spinning.
If necessary, an additional flywheel can be mounted on the top of the pulley to

further increase the inertial mass of the system.
The advantages of using an inertial system over a torque type tool, where a motor
and reduction gear are used to simply press a rivet into the spot, are:
 Smaller (more compact) and lighter rivet setter.
 Much faster cycle time.
 Simple belt drive transmission.
 Stable force over time and temperature.
 Minimal need for feedback sensors.
Spot parameters are used to control the Velocity, Partial Retract and the Compliant
for the chosen spot. In Automatic mode there can be up to 255 sets of parameters
saved for each tool and are automatically selected by the controller during the
riveting cycle. When switched to Manual mode, the parameters will revert to the
last settings used in the Automatic mode, although these settings can be modified
if required.

2.3.1 Speed
The Speed Limit for a given tool is the maximum value which can be sent as a
commanded speed to the tool.
The actual force the rivet setter applies to the spot must not exceed 60 kn.
Systems fitted with RivMon are able to measure this force for each and every
cycle. The rivet setting velocity must never be increased beyond that approved by
Henrob during installation without reference to RivMon to verify force. Doing so
may result in tool damage and/or invalidate the warranty.
2.3.2 Partial Retract

The robot can instruct the rivet setter to drive to or retract to a partial position.
 The partial retract distance is calculated from the calibrated distance.
 The partial retract distance is the distance from the material to the nose of
the setter.
 The partial retract distance can be selected from the robot.
 In a normal ‘Auto’ riveting cycle the setter returns to this distance but does
not pause on the advance stroke.
 The setter can be advanced to the partial retract with a ‘Go To Opening’
command.
 If no partial retract is selected the setter will return to its (fully open) home
position.
The partial retract opening can be made in 5mm steps from a minimum of 25mm to
a maximum of 250mm.

2.4 Compliant
Henrob Self Piercing Rivet (HSPR) spots require high forces to set the rivets. The
setting force is supplied by the setter and is reacted by the die through the c-frame.
This force is high enough that it can cause significant elastic deflection in the c-
frame (up to 5mm on some flexible c-frames).
As the c-frame deflects due to the rivet setting

loads, the work piece will have to move with the c-
frame/die. If the work piece is stiff or rigidly
supported this may result in distortion to the work
piece or a poor quality spot as a result of the
setting forces being reacted by the work piece.
Deflection of the c-frame may be compensated for

however by allowing the tool to lift while keeping
the die in the same relative position to the work
piece, as the c-frame deflects. This is achieved by
the use of a compliant device.
The compliant device uses a pneumatic cylinder to react the weight of the tool.
The air pressure within the cylinder is set to give the tool neutral, to slightly
negative buoyancy. That is to say the force exerted by the pneumatic cylinder is
equal to or slightly lower than the tool weight. As the setter tries to deform the
work piece (due to c-frame deflection), and with the tool set to have neutral
buoyancy, the tool will “float” about the joint assisted by the pneumatic cylinder.
2.4.1 Effect of Tool Orientation on the Compliant Device
When the tool/compliant device is in the

vertical orientation the pneumatic cylinder
will have to react the full tool weight. At
the other extreme, when the tool is in a
horizontal orientation, the full tool weight
will be taken by the compliant device
supports, so very little air pressure is
required to give the tool neutral
buoyancy.

At orientations between vertical and horizontal the air pressure will have to be
varied according to the tool orientation to achieve neutral buoyancy. In robot
applications where the tool can have a significant number of different orientations
the variation in air pressure for each orientation may be achieved using an optional
proportional valve.
At each rivet position (and tool orientation) the proportional valve pressure is set to
achieve neutral buoyancy of the tool. Every time the Henrob tool goes to a rivet
position in the future, the Henrob control system will set proportional valve delivery
pressure to the pressure required to achieve neutral buoyancy at that position.
If the tool is operated in the inverted orientation (riveting direction upwards) then
the air supply is simply directed to the other side of the pneumatic cylinder and the
proportional valve delivery pressure set for that tool orientation.
2.4.2 Effect of Robot Acceleration on Compliant Devices

When using a compliant device on robot mounted tools it is imperative that the
pneumatic cylinders have enough force to lock the compliant device under all load
conditions. When designing tools for use on a specific robot, Henrob ensures that
the complaint device is capable of holding the tool locked during normal robot
accelerations and during an Emergency Stop.
2.4.3 Types of Compliant Devices

Henrob offer their tools in 3 basic configurations:
 With no Compliant Device fitted

 With a Linear Slide type Compliant Device fitted
 With a Pivoting type Compliant Device fitted

2.5 Spot Parameter Setup

Before the system can operate in automatic mode the spot parameters need to be
configured. Each tool can be configured for up to 256 different spot locations/types.
It is recommended that each individual rivet location uses a different set of
parameters as this allows for fine adjustment after the system has been installed.
There are two ways to setup the spot parameters, the first being via manual input
via the HMI, and the second being via a text file loaded from a USB storage device
loaded into the system.
2.5.1 Manual Spot Parameter Adjustment
Pressing on the tool graphic on the

Home screen will display the Tool
Details page.
To reach the Spot Settings, press

the third tab along the bottom of the
screen.

Repeatedly pressing on the Spot 8 Spot View:

Settings tab will cycle through three
different versions of the screen
showing the spots in groups of 8, 32
and 128 respectively.
To modify the parameters at any

spot you first need to enter a
password of a sufficient access
level.
32 Spot View:
Once the password is entered a
pencil icon will be displayed which
allows you to edit the selected spot
parameters. It is also possible to
modify a spot by selecting it twice –
the first to highlight it, and the
second to enter the modification
screen.
In the table, any spot which does

not have a RivMon application 128 Spot View:
associated with it will be displayed
with a red border.

The spot editing screen will show

the parameters which may be
modified - ID, Velocity, Partial
Retract and Compliant.
Pressing on any of these entries will

call up the corresponding parameter
keypad, through which the
parameter may be modified.
See section 6.7.1 for more detail.
If an application does not have a

RivMon application associated with
it then the ‘View App Mapping’
button on the images will be
replaced by a ‘Map Spot to App’
button.
This button will associate the Spot

with one of the 256 available
RivMon applications.
Pressing the ‘View App Mapping’

button will show a table of the
RivMon applications which have
been allocated.
This process is repeated for each of the riveting locations, and the spot number is
passed to the Henrob controller at each location at or before the riveting command
is issued.

2.5.2 Spot Parameter Entry via Text File

The above described process may be quite time consuming if there are a lot of
different joints to be programmed.. For that reason a second method of entry is
available. This method allows parameter lists to be taken from a text file located on
a USB storage device when plugged into the top USB port of the RivMon HMI.
Section 6.10.1 describes the process and required steps to transfer files from a
USB drive to the RivMon. The system will look on the USB drive for a file called
‘SysXXX_Joints.csv’, where XXX is the System ID of the controller, located in a
RivMon directory in the base folder of the USB device. If the system fails to find a
file with it’s own system number it will look in the same directory for a file called
‘SysAll_Joints.csv’.
For example if the USB device were drive E: when plugged into the PC, then the
files the system will look for would be:
E:\RivMon\SysXXX_Joints.csv or
E:\RivMon\SysAll_Joints.csv
This file needs to be in pure ASCII text format – care should be taken if a file is
exported from Microsoft Excel as it can place embedded control characters which
can disturb the data input. Use a text editor to create/modify these files.
The data in this file needs to be in the following format:
Sys,Tool,Joint,Speed,Opening,NoHome,Comply,Rivet,NextRiv,ID
402,1,1,200,250,0,3,1,1,1000
402,1,2,210,50,0,3,1,1,1001
402,1,3,205,250,0,3,1,1,1002
402,1,1,200,250,0,3,1,1,1003
402,2,1,200,250,0,3,1,1,2000
402,2,2,210,50,0,3,1,1,2001
402,2,3,205,250,0,3,1,1,2002
402,2,1,200,250,0,3,1,1,2003

When the system imports its data, it will only pull in the lines of the file which have
the same System ID. Therefore it is possible to generate a SysAll_Joints.csv file
which will hold the joint data for a number of systems such as:
Sys,Tool,Joint,Speed,Opening,NoHome,Comply,Rivet,NextRiv,ID
402,1,1,200,250,0,3,1,1,1000
402,1,2,210,50,0,3,1,1,1001
402,1,3,205,250,0,3,1,1,1002
403,1,1,200,250,0,3,1,1,2000
403,1,2,200,250,0,3,1,1,2001
403,1,3,210,50,0,3,1,1,2002
404,1,1,205,250,0,3,1,1,3000
404,1,2,200,250,0,3,1,1,3001
Once all the parameters have been loaded, it will still be necessary to use the
manual screens to press the ‘Map Spot to App’ button on any of the joints loaded
which require a RivMon application to be mapped.
The most efficient way to do this is to select the first joint, enter the parameter entry
screen and then press the ‘Map Spot to App’ button. It would then be possible to
use repeated pressing the right arrow button and the ‘Map Application’ button until
each of the spots was mapped.

2.6 I/O Communications

The controller communicates with the rivet feed related devices mounted on the
rivet tool via DeviceNet.

2.7 External I/O
2.7.1 Cables
There are 4 cables that connect from the control cabinet to the tool, these are as
follows:
1. Motor Power (with motor temperature feedback)
2. Motor Feedback.
3. DeviceNet communications to tool.
4. 24VDC Auxiliary power
Note: Whenever the motor power cable is connected or

disconnected there should be no active power supply between
the tool and control box as this cable carries 480V 3 phase for
NOTE the operation of the motor.
2.7.2 Turck BL20 PLC Link

The Turck BL20 PLC controls the I/O on the
rivet setter.

3.0 Henrob Servo Controller
Each Henrob Servo Controller is capable of operating either a single permanently

attached tool, or multiple tools (presently 7 is the default maximum) when using a
tool changer.
It is a self-contained controller, designed to operate Henrob fixed automation or
robotic servo rivet tools in ‘Auto’ mode by interchanging parameters and signals to
initiate the riveting cycle within the automation system from an external control
device such as a robot. Each rivet tool may also be run in a ‘Manual’ mode using
parameters controlled by set points differing from the automation system using a
hand-held pendant to initiate the riveting cycle.
The force required to set a rivet is controlled by the Motion Controller, which is
directed by the built-in PLC, to give the correct operating sequence. There are a
varying number of control features such as feed and process monitoring, which are
available as options.
The Henrob Servo Controller is comprised of the following:
 Bosch Servo Drive, with Ethernet communications for internal use and
either a separate Ethernet or DeviceNet port for the external (customer)
communications.
 Pilz programmable safety controller, which ensures the power leaving the
servo controller is removed whenever the tool is required to be changed, or
following an EStop condition.
 24VDC power supply, which is split into eight protected channels. Four of
the channels are supplied via a capacitor based power loss buffer which
provides sustained 24V for around 10 seconds after main power is
removed.
 This sustained supply is used by the RivMon HMI, Servo Drive Controller
and Safety Controller and Ethernet switch. This allows the system to
complete an orderly shutdown without loss of data when power is
unexpectedly removed.
 Cable connections for Motor Power, Motor Feedback, Henrob Ethernet

communications and customer communications.

3.1 Front Panel Controls




3.1.1 480V Isolator Disconnect 

This is the flange mount isolator to switch off and on the main 480 VAC power to
the cabinet.
3.1.2 HMI (Human Machine Interface) 

This touch screen has various functions and allows the operator to input
parameters to the system as well as fault diagnostics.
3.1.3 System Disable switch 

This is used to disable the drive and disconnects the drive output preventing power
from reaching the motor.
3.1.4 Illuminated green push switch 

This is used to enable the drive, reestablishing motor power. When illuminated the
servo motor can be powered.
3.1.5 Auto, Manual, Maintenance switch 

This switch switches the mode of the control panel between maintenance, manual
and automatic

3.2 Internal Panel Layout
8 7 6 5
9
10
11
4
12
3
13
2
14
15 16 17 18
1 24VDC, 10A, Power Supply 10 Unbuffered DC Circuit Breaker

2 Three Phase Fuse Module 11 Ethernet Switch
3 Main Disconnect 12 Motor Contractor
4 Main Ground Lug 13 EStop connection PCB
5 Capacitor Module 14 Turck Ethernet
6 Servo Drive Amplifier & Controller 15 Safety Controller
7 EStop Relay 16 Control relays
8 Power Loss Buffer & Fuse 17 Motor Contractor
9 Buffered DC Circuit Breaker 18 Three Phase Filter

3.3 480V Power and 24V Supplies
3.3.1 480V isolator disconnect & Ground Lug

The 480V disconnect allows the power to the Henrob controller to be disconnected
locally. It should be noted that if the system is turned off using this disconnect there
will still be live 480V wires (connected to the top of the disconnect) within the
controller, and hence safe working procedures and remote lockout are required for
certain operations.
The Henrob controller needs a good quality ground connection and a ground lug is
provided near the main disconnect to allow the ground wire provided by the
customer to reliably connected to the Henrob system.
3.3.2 Three phase fuse

After passing through the fused rotary disconnect, the 480V is routed through a
bank of additional fuses. These provide an extra level of protection, and improve
the system’s short circuit rating.
3.3.3 24V DC power supply (10A)

All of the controls within the servo controller, as well as the external I/O, operate
from 24VDC. This is provided by a three phase switched mode power supply
(PSU) which can supply up to 10A of continuous current. The 480V three phase
supply for the power supply is provided via the three phase fuses.
The output current from the PSU supplies two DC circuit breaker modules. One of
which provides the I/O power and is connected directly, while the second used for
controls power is routed via a capacitor based power buffer. This second path will
have 24V power for approximately 10 seconds after main power has been
removed.
The power supply is rated to provide over twice the maximum current required,
which ensures the long term reliability of the system.

3.3.4 DC Power loss buffer and fuse

To ensure both the RivMon and the Drive can shut down in an orderly manor when
power is removed, a DC power buffer is added between the main power supply
and those devices which require power during shutdown. This device is rated to
provide up to 3A for 7 seconds, the system typically draws around 1.5A from this
supply and thus the power is maintained for 10-15 seconds.
The main reasons for this power off delay are that in the event of an unexpected
power loss:
1. Allows the RivMon HMI to save its data to the memory card to prevent data
loss.
2. Allows the drive to know and ‘save’ where the tool was prior to power off, to
aid in recovery upon resumption of power.
3. Ensures the motor contactor remains energized with contacts closed while
the tool is brought to a halt.
4. Allows Ethernet communication between system elements while the system

is powering off.
As the buffer is only rated to supply a maximum of 3A, a 3A fuse is located

downstream to ensure excess power is not drawn from the buffer.
3.3.5 Buffered circuit breaker (4 channel)

All four devices which require power during a power loss event are connected to a
channel DC circuit breaker module fed from the fuse in the output of the power
buffer.
The function of the four buffered DC supplies, and their current settings, are as
follows:
Channel Setting Wire # Function

V1 1A 317 RivMon Power
V2 2A 318 Bosch Servo Drive Power
V3 1A 319 Safety Controller Power & Ethernet Switch
V4 1A 320 Internal Buffered 24VDC

3.3.6 Unbuffered circuit breaker (4 channel)

For those devices that do not need to be maintained following a power loss event,
a second four channel DC circuit breaker module is provided.
The function of the four unbuffered DC supplies, and their current settings, are as
follows:
Channel Setting Wire # Function

V1 1A 313 Pushbutton 24VDC
V2 1A 314 IO 24V
V3 2A 315 External Solenoid 24V
V4 1A 316 Control 24V

3.4 Servo Drive Sub-System

This is the main control component within the system. It controls the complete
riveting system logic as well as the drive motion control, holds all the parameters,
application number tables for application number to force settings, rivet selection
and compliant setting.
3.4.1 Line filter

The three phase line filter is located within the power feed to the servo drive and is
designed to reduce the effect of high frequency noise on the incoming power lines
to the controller.
The line filter also reduces the amount of high frequency noise emitted from the
Henrob controller back into the supply lines, reducing the influence of the servo
controller on external devices.
3.4.2 Servo Drive Components

The servo drive consists of two components, the amplifier section, which is the
main unit, and the secondary control section which is mounted in the front of the
amplifier and provides the logic section of the drive.
The servo drive is powered via a 480VAC 3-Phase supply. The power is provided
from the main system disconnect after passing through a 10A fuse and the power
filter.
The output from the motor drive amplifier passes through a contactor controlled by
the Programmable Safety Controller, which ensures no motor power is routed
outside of the electrical enclosure when the system is in a disabled state.
WARNING: When the main disconnect on the Henrob

controller is shut off it takes a minimum of two minutes for
power stored in the drive capacitors to dissipate. Make
WARNING sure there is no residual voltage before working within the
electrical panel.

3.4.3 Capacitor bank

When the tool is decelerated, the motor is turned into a generator and the energy
captured is added to the servo drive’s DC bus. The base drive’s DC bus does not
have sufficient capacity to hold all the additional energy recovered and would need
to burn the excess energy off over an internal shunt resistor. This is both wasteful
on energy, but also generates a significant amount of heat within the control box.
This is resolved using an additional capacitor module mounted to the right of the
servo drive connected to the drive’s DC bus. A control ribbon cable connection is
also made.
The capacitor module allows all the energy generated by the motor to be captured,
and reused reducing the overall energy consumption of the system.
Note: In certain instances, such as when an EStop is performed with the tool in
fast motion, the deceleration rate required may case the shunt resistor to
fire momentarily, this should be an infrequent occurrence which should not
change the controller temperature noticeably.
3.4.4 Servo Drive I/O

The servo drive unit has integrated discrete I/O whose functions are controlled via
the program loaded into the unit. The connections for these I/O are provided by the
X31 and X32 terminal block connections on the front of the drive.
The drive I/O consists of a single relay output (RLY), seven 24V digital inputs
(I1..I7) and four signals which can be configured to be either an input, or an output
(IO8..IO11). Currently the four configurable signals are setup as outputs, but two of
these signals, as well as the RLY output are currently not used.

3.5 Servo Drive Inputs

There are seven discrete 24VDC inputs available on the drive. They may be
accessed via the screw terminal block on the front of the drive.
3.5.1 I1: Advance Pushbutton (X31.3)

This signal is generated by the (-) pushbutton on the enabling pendant, and
instructs the system to perform an operation when switched into manual or
maintenance modes.
In general, pressing the advance (-) pushbutton will cause the tool to advance
towards the die. - indicating the nose to die gap gets smaller.
3.5.2 I2: Retract Pushbutton (X31.4)

This signal is generated by the (+) pushbutton on the enabling pendant, and
instructs the system to perform an operation when switched into manual or
maintenance modes.
In general, pressing the retract pushbutton will cause the nose of the tool to move
away from the die. + indicating the nose to die gap gets larger.
3.5.3 I3: Mode Switch Channel A (X31.5)

This signal is generated by the mode selector switch when switched into either the
Maintenance or Manual Modes.
3.5.4 I4: Mode Switch Channel B (X31.6)

This signal is generated by the mode selector switch when switched into the
Automatic or Manual Modes.
I3 I4 Operating Mode
0 0 Power Off
1 0 Maintenance Mode
0 1 Automatic Mode
1 1 Manual Mode
3.5.5 I5: Start Request Pushbutton (X31.7)

This signal is generated by the green ‘System Enable’ pushbutton on the front of
the control cabinet. This input to the servo drive will cause the drive to in turn
request power to be re-applied to the motor, when the system is able to be
restarted (i.e. no external EStop is ensuring motor power is removed).

3.5.6 I6: No EStop Condition (X32.4)

This input is active whenever there is no external EStop condition. When no input
is present the system will not attempt to start a new action. If an action is in
progress, then this input will cause the system to come to a controlled stop at the
earliest possible time.
3.5.7 I7: Drive Enable (X32.5)

This input is connected to the Drive S2 Safety Circuit, and is used to allow the drive
to output power to the motor. Before this signal is asserted, the contactor between
the drive and motor would be closed, and this contactor is maintained until after the
drive is disabled.
3.6 Servo Drive Amplifier Outputs

There are four discrete 24VDC 0.5A outputs available on the drive (IO8..IO11) and
a relay output (RLY). They may be accessed via the terminal block on the front of
the drive.
3.6.1 IO8: Spare (X32.6)

3.6.2 IO9: Spare (X32.7)
These outputs (which may be reconfigured as inputs) are not currently used, but
are reserved for a stack light if one is required to be installed.
3.6.3 IO10: Allow Enable (X32.8)

This signal is connected to the programmable safety controller, and is active when
power can be connected to the motor. The safety controller can override this signal
if an external system hold signal is active.
3.6.4 IO11: Drive Power On (X32.9)

This signal is generated by the S2 safety circuit, within the drive, and is connected
to the safety controller as a feedback to signal when the drive has been enabled
correctly and also to ensure EStop actions are performed correctly.
3.6.5 RLY: Spare (X31.1 & X31.2)

This output is not currently used, but is reserved for a red stack light if one is
required to be installed. This output can switch 1A of 24V.

3.7 Motor Control & Safety Circuit
3.7.1 Internal Structure
The circuitry associated with preventing

power being sent to the tool mounted servo
motor makes use of both a Cat 3 EStop (S2
Safety) circuit within the drive and a contactor
with force guided auxiliary contacts between
the drive output and the motor.
When an EStop is active the drive’s S2

Safety circuit is triggered 0.5s before the
contactor is de-energized. The S2 circuit is
only re-energized 0.5s after the contactor has
been switched on.
Before the drive is EStopped, the

programmable safety controller will allow up
to two seconds for the drive to complete any
action being performed, and will disable the
drive and de-energize the contactor either
when the drive’s action has completed or
after the two second timer has expired
(whichever is sooner).
The maximum amount of time that power can be applied to the motor after an
EStop is two seconds, but in normal operation power will typically be removed after
approximately 0.5 seconds.
The safety controller has three sets of dual channel inputs, the external EStop
input channel from the cell/robot, a dual channel from the door mounted ‘System
Disable’ pushbutton, and an enabling pendant. There is also an input from the
servo drive controller which signals when it is acceptable for power to be applied to
the motor. This signal would not be present during tool change procedures.
When the Henrob Servo Controller is switched to Manual or Maintenance modes it

is possible to bypass the external EStop by pressing and holding the enabling
switch on the manual pendant.

3.7.2 Safety Circuit Operation

In order to ensure complete safety and full functionality of Henrob servo system,
the safety circuit for the Henrob system should be linked into the robot drives. In
this manner, the Henrob safety circuit is made and broken in line with the robot
drives switching on and off. This allows for manual and maintenance functions to
be performed inside the cell as well as allowing the use of robot teach functions.
The electric setter will react differently to the safety circuit being broken depending
on the state of the tool and whether it is in full auto, or it is in Teach Mode or a
manual or maintenance modes:
3 Stage Stop - Full Automatic
 E-stop circuit interrupted
 The drive Software checks where it is in the cycle, if it is close to or is in the

process of setting a rivet, it allows the rivet to insertion to complete and
then stops. If it is not close to setting the rivet or in a retract move then it
initiates an immediate motion stop.
 After motion stops the drive is disabled. If after 2s from the E stop initiation
the drive is still in motion, the system will preemptively disable the drive.
 0.5s after the drive is disabled, the 3PH power output stage to the motor is
mechanically broken
3 Stage Stop - Manual functions (enabling pendent released)
 E-stop circuit interrupted
 Software immediately initiates stopping of all motion.
 After 0.7s the hardwired Enable signal to the Drive is dropped - The drive is
disabled at this point and no longer powers the motor.
 0.5s after the drive is disabled, the 3PH power output stage to the motor is
mechanically broken.

3.7.3 Enabling Pendant

The enabling pendant uses a two-hand design and allows users to safely operate
the controller in manual or maintenance mode. There are three switches on the
unit – Tool Advance (-), Tool Retract (+), and a large three position enabling
switch.

3.8 Connection Arrangements

All the connections, other than the main power input, for the controllers are located
on the bottom of the enclosure and are detailed in this section.
2 3 4 5
6
1
7
8 11
9 10
1 Enabling Pendant Socket. (X503)
2 Spare connection
3 Ethernet connection to customer
4 Ethernet to tool connection tool I/O
5 Ethernet Programming Port
6 I/O Power (X1505)
7 Not used
8 Motor Feedback (X902)
9 Motor Power (X220)
10 Contactor Feedback (X1512)
11 E/Stop Connection Socket (X613)

3.9 Connection Pinouts
3.9.1 Enabling Pendant Socket. (X503)

The hand pendant, which is used to operate the servo tool in ‘manual’ or
‘maintenance’ modes, is attached to this socket.
X503: Enabling Pendant
1. Enable A1
2. Enable B1
3. Enable B2
4. N/C
5. Enable A2
6. N/C
7. N/C
8. N/C
9. Advance In (+)
10. Advance Out
11. Retract In (+)
12. Retract Out
SH - PE
3.9.2 Ethernet Programming Port

This connection is used to connect to the RivMon, Bosch drive and any other
Ethernet device on the ‘Henrob’ network within the riveting system. This allows the
system to be reprogrammed or monitored without needing to open the control
cabinet.
3.9.3 Ethernet to tool connection tool I/O

The Henrob system communicates with the I/O on the tool via Ethernet, either
directly or via an intermediate I/O box which converts the Ethernet communication
into discrete I/O.
This Ethernet network needs to remain isolated from all other Ethernet networks as
a common IP addressing scheme is used for all controllers, and interconnecting
the networks will cause an IP conflict and unpredictable behavior.
3.9.4 EthernetIP connection to customer

This socket allows for the connection of the external EthernetIP communication
inputs and outputs of the Henrob SPR system, when this format of communication
is being used.

3.9.5 Ethernet Data Connection to customer / Spare

When EthernetIP communication is being used this socket is available for data
transfer between the customer and the Henrob system. At present there is no
functionality enabled on this port, but may be added upon request.
3.9.7 Motor Power (X220)

This supplies the 3 phase AC power for the motor. This connector also provides
the temperature feedback from the motor.
3.9.8 Motor Feedback (X902)

This supplies feedback from the motor. This feedback takes the form of a
hyperface encoder
X902: Motor Feedback

3.9.9 Tool I/O Power (X1505)

The cable which runs to the tool I/O junction box on the tool or external I/O box is
connected to this socket, and provides the 24V power for both any electronics
(Control) or outputs (Solenoid).
X1505: Tool I/O Power
3.9.10 EStop Connection Socket - (X613)
This connection provides the input and output signals

for the E-Stop circuit.
Pin Description
The ‘EStop In’ are provided via the cell/robot, whereas
the ‘EStop Out’ signals allows the customer to sense 1 EStop In A1
the state of the System Disable button. 2 EStop In A2
3 EStop Out B1
The inputs require a dual volt-free (relay) contact 4 EStop Out B2
within the cell/robot as the signals sent from the
5 PE
Henrob controller on signals A1 & B1 need to be
routed back via A2 & B2 respectively.
3.9.10 Contactor Feedback - (X1512)
This connection provides feedback from the Pin Description

contactors. The contacts between 1 & 2, and 4 & 5 1 Signal 2
open when the motor contactors are enabled. 2 Signal 2
3 Spare
4 Signal 1
5 Test Output

Installation • 4
4.0 Installation
HENROB Self-Piercing Riveting Equipment is designed for use in general industrial

environments. It is not intended for use out of doors or in explosive or other
hazardous environments.
Large Fixed (pedestal) Tools should be bolted to the floor if necessary to ensure
they cannot be accidentally knocked over.
The Henrob Self-Piercing Rivet Setter is not suitable for riveting brittle materials
that could shatter during the riveting process (e.g. glass). If in doubt of the
suitability of the material to be riveted consult either Henrob or their Distributor.
Normal noise levels of Henrob Self-Piercing Riveting Equipment are below 74 dB

but the impact noise when the Rivet Setter meets the work-piece will depend on
the application (i.e. parts being riveted & the holding Jig design).
Do not attempt to operate or service the equipment unless you have been trained
to do so by an authorized person, and have studied this manual.
WARNING: The Rivet Setter can generate very high forces.

WARNING
It is most important that the following safety precautions are observed:
 Always wear approved safety glasses when operating the equipment or

observing it closely.
 Never put any part of your body in between the Rivet Setter and upsetting
die while the servo panel is operating. Serious injury will result.
 Trap points exist around the sprocket drive unit. Do not hold, or allow others
to hold, on to the sprocket drive parts when the equipment operates.
 The sprocket drive unit could draw-in (entangle) loose clothing, hair etc.
during operation. Do not wear loose clothing (i.e. ties etc) and tie back or
cover long hair while operating the Rivet Setters. Handles on the Riveting
Tool should be positioned so that normal clothing is not a hazard.
 Robotic Tools are fitted with a pneumatically actuated spent tape cutter.
Keep fingers clear at all times. Isolate pneumatic and electrical supplies
before attempting any maintenance on this unit.

4 • Installation
 Do not cycle the Rivet Setter unless a rivet has been loaded, as this could
cause damage to hardened steel components.
 Do not cycle the Rivet Setter without the correct work piece material in
position as damage to the die can result.
 Do not set a rivet on top of a previously inserted rivet as this can cause
rivets to stick in the Nose preventing further rivet setting. Double riveting
can cause damage to Punch & Nose Insert Assemblies.
 Do not set the riveting Loads above the Tool’s maximum operating loads for
the Rivet Setter or C-frame, as indicated on the label fixed to the Rivet
Setter and/or C-frame. The riveting load is controlled by the setting
velocity/force on Servo Tools.
 Do check the condition of the cables and hoses before operating the
equipment.
 Always check that the Rivet Setter is securely mounted in the C-frame
before operating the Rivet Setter.
 Isolate Power from the control box before attempting any maintenance on
the equipment. Lockout procedures should be followed as appropriate.
 Certain functions can only be performed inside the cell when the system is
in Maintenance or Manual mode. To operate the rivet setter in these
conditions an enabling pendant must be attached to the X503 socket. When
the cell door is opened, the cell E-stop disables the Henrob controller. The
use of the enabling pendant with a deadman’s switch will allow the Henrob
controller to be enabled, bypassing the cell E-stops.
 Do not fit worn or broken parts to the Rivet Setter.
 Do not fit parts obtained from any source except Henrob or an approved
distributor, without Henrob’s prior agreement.
 Contact Henrob or an authorized engineer for help if you are in doubt of

your ability to operate or maintain the equipment.
Note: Please check for and report any damage to the

equipment upon arrival at your premises.
NOTE

Installation • 4
4.1 Transportation
WARNING: Henrob Rivet Tools, Cubes, Magazine stands &

Control Cabinets are heavy. Observe normal Health & Safety
WARNING at Work practices for lifting and moving heavy loads.
When lifting a Rivet Tool use the hole provided for a lifting eye (top of the C Frame)
if appropriate, or a sling using suitable webbing slings ensuring that strain is taken
by the major items (C Frames & Mounting Brackets) and that no strain is put on
accessories such as sprocket drive, magazine storage devices and hose or
electrical components.
Unless otherwise requested on the order, Riveting Equipment will normally be

packed suitable for short term storage. In storage it should be protected from dust,
moisture & excessive temperature (i.e. store at 5-40C). If the equipment is
unpacked it should be suitably protected from damage. If it is not to be used for
some time (i.e. over 6 months) then additional measures may be required, consult
Henrob for details.
If Riveting Equipment is to be transported it should be packed to ensure parts

cannot move in service. Packing should prevent damage as well as protect from
dirt, dust & moisture.

4 • Installation
4.2 Installation
To install the riveting system, the following services are required.
 Electrical - 460/480VAC 10A, 3-Phase supply
 Air - 6 Bar minimum clean, dry, filtered, non lubricated.
The servo riveting tool is mounted onto the robot or other fixed or moving
automation structure. (Normally this is the responsibility of the appointed system
integrator.)
The control box or stand option that the control box is mounted on should be on a
stable floor as close as possible to the robot, in order to keep cable lengths to a
minimum.
The control box can be assembled as mentioned above to a stand which can be
free standing or bolted to the floor, ancillary device’s such as rivet feed cubes and
stands etc. should be mounted as per the relevant instruction manual.
Holes should not be drilled into the control box itself.
All connecting cables and hoses between the control box, robot mounted servo
riveting tool and ancillary equipment should be routed so that no fouls or damage
to the cables can occur once the robot is in action or in normal working procedures
The encoder cable should be kept separate from any main power cables to
decrease the effect of adverse high frequency noise from external equipment. This
is particularly applicable where the encoder cable is routed inside trunking, where
installed.

Reprogramming Henrob Controllers • 5
5.0 Reprogramming Henrob Controllers
5.1 Programming Bosch Servo Drive

The simplest way to reprogram the Bosch servo drive within the Henrob Controller
is by changing the files stored on the MMC memory card which is installed in the
front of the controller. To update the software follow the sequence below:
1. Turn off the power to the Henrob Controller and wait for the capacitors to
dissipate.
2. Remove the MMC card from the front of the servo drive
3. Insert the card into a memory card reader and connect to a PC.
4. Create a backup folder on the PC and copy the contents of the memory
card into the folder.
5. Delete the entire contents of the MMC card to ensure no incorrect

interaction between the new and older software.
6. Copy the new software onto the memory card. In some circumstances it is
sometimes required to copy the drive firmware file (which is normally the
largest file on the card) from the backup taken previously. This allows new
software to be emailed as a smaller file if needed.
7. Remove the MMC card from the PC, after ensuring the ‘PC Safe Removal’
process was used, and insert the card back into the servo drive with the
label pointing to the left.
8. Reapply the drive power and confirm any statements displayed on the
servo drive’s LCD screen – by pressing the ENT button.
9. Once the boot has completed, the new software should be operating in the
system.

5 • Reprogramming Henrob Controllers
5.2 Programming the Pilz Safety Controller

The Pilz safety controller is programmed via a PC using software available from
Pilz. When the controller is programmed the code is stored on a removable
memory card, which looks like a phone SIM card.
If the safety controller needs to be replaced the memory card can be removed and
inserted in the replacement unit. In the event that the memory card has been
damaged, a pre-programmed replacement card can be supplied by Henrob
Corporation.
5.3 Programming the RivMon unit

The RivMon unit is a Linux based embedded controller, which operates from
software loaded on the internal Flash memory. To replace the software you can
use either a PC, or more simply by cloning the programs from a master SD card
following the process below:
1. Power off the RivMon and remove the SD data card.
2. Ensure that the jumper JP1 next to the speaker on the back side of the
RivMon is installed, then insert the master SD card into the memory card
socket.
3. Power on the RivMon and connected a PC using hyperterminal (or similar)

to connect to the RivMon’s IP address of 10.10.50.195 using the telnet
protocol.
4. When connected a prompt message will be displayed. Enter the following

command:
createmtdroot 
5. After around 20 minutes the prompt message will return indicating that the
RivMon unit has been reprogrammed.
6. Turn off the power to the RivMon unit and remove the master SD card.
7. Removed the jumper at JP1 installed in step 2, placing it on just one pin for
storage.
8. Reinstall the data SD card removed in step 1.
9. Reapply the power to the RivMon and check its operation.

Reprogramming Henrob Controllers • 5
5.4 Configuring the System

By default there are a number of operational parameters which are set to values
which may not be correct for a specific application. These parameters are mainly
adjusted via the System Configuration screen in the utilities menu (see section
6.10.7 for additional detail)
With the correct password level entered it is possible to adjust the settings as
follows:
5.4.1 Systems using default comms and remote I/O box

For these systems the following settings would be configured:
1. RivMon Online/Bypassed as required/allowed. This prevents the RivMon

system from generating process errors.
2. UDP I/O
3. Spot 0 Invalid, to prevent unwanted cycles.
4. RivMon Enabled/Disabled as required/allowed. This hides the RivMon
displays.
5. At or Above Mid, rather than At Mid for partial retract signal.

6. Fast Close Manual Mode – standard operation.
7. Comms Style: Default
8. System ID – Controller serial number or station number.

5 • Reprogramming Henrob Controllers
5.4.2 System using customer comms and Ethernet tool I/O.

For these systems the following settings would be configured:
1. RivMon Online/Bypassed as required/allowed. This prevents the RivMon

system from generating process errors.
2. ModbusTCP I/O
3. Spot 0 Invalid, to prevent unwanted cycles.
4. RivMon Enabled/Disabled as required/allowed. This hides the RivMon
displays.
5. At or Above Mid, rather than At Mid for partial retract signal.

6. Fast Close Manual Mode – standard operation.
7. Comms Style: Ford
8. System ID – Station Number.

Operator Interface • 6
6.0 Operator Interface (HMI & Front Panel Controls)
6.1 Front Panel Controls
6.1.1 System Disable button

Disable the system by pressing the red Disable button. This action will stop all
moving parts in a controlled manner.
6.1.2 System Enable button

Pushing the momentary green Motor On button that is located on the front door of
the cabinet will enable the rivet setter and allow the system to operate. When the
green Motor On button illuminates, the system is powered up and the Henrob
drives are enabled. When in Auto mode, an external control device may
automatically enable the system without operator intervention.
6.1.3 Auto, Manual, Maintenance switch

This switch changes the operating mode of the control panel from maintenance to
manual to automatic.
‘Auto’ selected - allows a robot, or other external controller, to control the

riveting process through the customer communications interface. In this mode
the manual pendant is disabled.
‘Manual’ selected – a manual pendant is used to provide the advance and

retract signals required to carry out riveting process. The rivet feed system is
usually enabled in manual mode. In this mode the signals from the cell/robot
are not active.
‘Maintenance’ selected – a manual pendant is used to provide advance and

retract signals to the electric setter in order to home and calibrate the tool. In
this mode the signals from the cell/robot are not active.

6 • Operator Interface
6.2 Automatic Mode Of Operation
Switching the Mode Switch to the

AUTO position will give control of
the riveting system over to
commands sent to the system via
fieldbus communications link.
In this mode it is imperative that the safety circuit is fully implemented and active so
that no person can be injured by an unexpected movement.
In Auto mode the system is totally controlled via the fieldbus interface, together
with the hard-wired EStop circuit. The motor is powered up by removing any
hardware EStop and then selecting the relevant tool ID via the communications
link.
Once the tool is enabled, the system will automatically home if required to ensure
the Henrob controller knows the current position of the tool.
The robot can then initiate tool movement and riveting via signals sent over the
fieldbus network, as discussed later in the Robot Communications section of this
manual. It is also possible for the robot to put the system into a Dry-Cycle mode
which is useful for system run off and testing without needing to set rivets.
The speed with which the system sets the rivet, as well as the final position for any
movement is also controlled via signals over the fieldbus.
6.2.1 Verify Home

The function of a ‘Verify Home’ is to make sure that the ‘Home’ datum position is
still true to the system. This is performed in full auto or dry cycle after a fault has
been generated. It does this by reversing the actuator into the hard stop at low
speed and checking the distance from the datum position against that which was
recorded during the ‘home’ routine.
This will check for the mechanical integrity of the system, for example:-
• Broken belt
• Degraded belt resulting in it jumping teeth
• Failed shear pin

6.2.2 Auto Mode Screen

In full auto, the robot will have control of the riveting unit, which will allow it to
command the following functions:
 Rivet setting
 Tape Cutting
 Partial retract position
 Driving the setter to a partial position without setting a rivet
Auto allows a robot or other external controller to control the riveting process
through DeviceNet or Ethernet I/O communications, or other automatic features as
‘Dry Cycle’ or robot in teach functions.
Note: The system has to be enabled in order to use the ‘manual’

and ‘maintenance’ functions. To achieve this in a robot cell, the
NOTE
robot must be put into teach and the robot drives must be on.
• Take the setter to a safe working position.
• Switch the robot to teach and the servo panel to ‘Maint’ or ‘Manual’
• Plug in the Henrob pendant.

Use the three position handle on the robot pendant to enable or disable the drives
on the servo panel to allow functioning of the tool. The Henrob pendant is not
wired in to the cell/customers safety circuit; it is only used to give commands to the
Henrob Drive/PLC.

6.3 Manual Mode

MANUAL position will give control of
the riveting system over to commands
sent to the system via the manual
pendant, with parameters set via the
HMI.
In this mode it is possible to perform the same riveting operations as implemented

for automatic mode so it is important that the safety circuit is fully implemented and
active to ensure that no person can be injured by an unexpected movement.
In manual mode the motor may be started via the front mounted ‘Motor Start’
button if there is a tool physically connected to the control cabinet – sensed via the
tool ID plug. If the robot performs a soft EStop, by dropping its tool select bits, the
motor power will not be removed.
In Manual mode the setting speed and partial retract are set via the HMI screen.
Whenever the system is switched to Auto the manual parameters are modified to
match the robot values to ensure the rivet is set at the correct speed for each
particular location. When switched into Manual mode it is possible to change these
values.
If the system is set to ‘Manual’ and rivet ‘FEED ON’, then pressing and holding the
advance button will cause the rivet setter to advance, set a rivet, retract and cut the
tape. This option may be used for setting individual rivets.
CAUTION: Do not perform this procedure unless sample

material is installed between the nose and the die. Failure to
do this can result in equipment damage and/or severe personal
CAUTION
injury
If the system is set to ‘Manual’ and rivet ‘FEED OFF’, then pressing and holding
the advance button will cause the rivet setter to advance to the material at full
speed and retract without a rivet being fed to the nose. This should not be done.
If the system is set to ‘Manual’ and ‘DRY CYCLE’ ‘Is On’ via the robot, pressing
and holding the advance button will cause the rivet setter to advance at a fixed
slow rate to a point near the material without a rivet and retract. The ‘DRY CYCLE’
can be used to simulate setting a rivet without actually feeding a rivet. It is useful
in setting up spots for an automated system as a ‘Dry Run’. ‘DRY CYCLE’
overrides the rivet feed setting to ‘FEED OFF’.

Releasing the advance button during the advancing phase will stop the advancing
of the rivet setter. Pressing and holding the retract button will cause the rivet setter
to retract.
Note: Once a retract is initiated, the tool must be retracted to its

selected opening, manually set opening, or full home position
NOTE
before another ‘advance’ should be initiated.
6.3.1 Manual Mode Screen

In Manual mode a pendant is used to provide the advance and retract signals
required to carry out riveting process. The rivet feed system defaults to manual
mode. When switched to Manual mode, the parameters will the same as the last
Automatic parameter used. The force select can be set from the HMI on the screen
shown below. If the Compliant is not enabled, there will be a dashed line.
Press the parameter to be changed. The keypad will appear allowing the change.

On the bottom of the Manual mode screen there are these buttons.
Dry On/Off This button selects the dry cycle mode of operation when
under the control of the manual pendant. In dry cycle mode the
tool advances to 10mm of the material, pauses, and then
retracts to the requested final position.
Hollow Die This mode is used during initial system runoff with a special
die which allows the system to test the feed system without
needing material. It will advance to a stop at the calibrated
stroke before returning to the final requested position. This
mode should only be used when instructed by Henrob
personnel.
Slow Move In this mode the actuator will advance and retract at a slow
speed only when the corresponding button is pressed on the
pendant. If there is a rivet sensed in the nose, the tool will stop
10mm from the material. If there is no rivet in the nose it will
stop with the punch traveling 10mm past the point at which the
nose touches the material.
This function is primarily used to check the operation of the

tool, as well as the orientation the tool is being presented to
the workpiece.
Feed On/Off This button requires the correct password level to operate, and
will control whether the tool needs a rivet within the nose
before it cycles. This is used to allow rivets to be inserted
manually for test coupons, and should only be used by trained
personnel with the knowledge of Henrob.
CAUTION: Cycling the tool without a rivet at full setting

speed will cause very high forces to be generated in the
tool. It is therefore imperative that the person using this
CAUTION
function be knowledgeable and fully trained with the system.

Test Comp This toggle switch will send the current compliant setting to the
valves mounted on the tool while the system is outside of the
riveting cycle. It is used to allow the best compliant pressure
and setting to be determined for each individual riveting
location.
The solenoid power needs to be active for the compliant

valves to operate, which is indicated by the green light being
illuminated on the door of the controller.
Cut Tape This button will toggle the tape cutter, allowing a manual cut of
the spent rivet tape. The button will automatically be turned off
after the tape cut has been completed.
The solenoid power needs to be active for the tape cut valve to
operate, which is indicated by the green light being illuminated
on the door of the controller.
Back This button will return the display to the front screen.

6.4 Maintenance Mode

MAINT position will give control
of the riveting system over to
commands sent to the system via
the manual pendant.
The functions within this mode are reduced to homing (holding the retract (+)
button) and calibrating (holding the advance (-) button) the tool. No feed or high
speed movement will be invoked.
In this mode the safety circuit is still important, but the system is operating in a slow
and less hazardous manor.
6.4.1 Homing a Tool

The function of a ‘Home’ routine is to allow the system to establish a mechanical
datum point, so that all positional calculations and movements are performed with
reference to this datum. The system achieves this by slowly moving into its
backstop and moving forward two markers.
A ‘Home’ must be performed after the following:
 System has been powered down
 The motor feedback connections have been broken and remade
 A drive fault has occurred
 New software has been downloaded
To “Home” the rivet setter, the system needs to be enabled, either via the front
panel controls or using the enabling switch on the pendant. Motion will be possible
when the green light on the door of the controller is illuminated. Move the mode
selector switch to ‘Maint’ position then press and hold the retract (+) button on the
pendant.
The rivet setter will be seen to move away from the die to the fully open position
and then move forward slightly, it will then repeat the move into the backstop
before returning to the ‘home’ position where it stops. The retract button may be
released after all movement has completed.

6.4.2 Calibrating a Tool

Before a tool can be used to set rivets, the system needs to be taught the stroke of
the tool. This allows the system to know when it is approaching the material – to
facilitate the fly-across-space motion to reduce cycle time, and also to allow the
retract distance to be correctly calculated.
Note: The rivets must be removed from the feed mechanism

before commencing calibration.
NOTE
To calibrate the tool, ensure that power to the tool is enabled using either the door
mounted controls or the enabling switch on the manual pendant. Ensure the tool
has been homed by pressing and holding the retract (+) button on the pendant until
all motion has been completed.
Once the tool has been homed, with no rivets loaded into the tool, place a
representative thickness of material on the die of the tool and then press and hold
the advance (-) button on the manual pendant (with the motor power enabled)
while the tool fully advances at a slow speed, pauses with the punch touching the
material, and then fully retracts. Once the tool has come to a stop in the fully
retracted position, the advance button can be released.
After the tool has been calibrated it will be possible to view the tool’s stroke from
the maintenance mode tool screen as shown below.
The tool must be recalibrated to ensure the rivet setter operates correctly after any
of the following events:
 A new tool is installed

 A tool with a different stroke is used
 The nose-to-die distance is changed on a single tool
 A tool is rebuilt or otherwise had maintenance performed on it
 The thickness of the material into which the rivet is being inserted is
changed.
 If the Servo Drive has been replaced or reprogrammed
 If the setter position changes in the C-frame

6.4.3 Maintenance Mode Screen
Pressing the tool mode icon, shown right, on the bottom of the
main screen with the system switched to maintenance mode will
call up the screen shown below.
This screen is used mainly for reference, to verify the Tool Stroke and Current
Position, but with the correct password level it is possibly to modify the various
tool parameters as described in Section 6.7.

6.5 HMI Screens

The HMI main screen shows an overview of the system, status information and
user functions.
6.5.1 Status Bar
At the top of the screen is a status bar. It shows the name of the current screen
being displayed, if applicable, as well as the currently selected tool and on the right
the time is displayed.
Lastly at the extreme right of the bar is a status icon showing whether the Ethernet
communication between the RivMon HMI and the Bosch Servo Drive is active
(Green) or inactive (Red). This icon will also turn red following a power loss event
after the data within the HMI has been saved to the SD card.

6.5.2 Main Window
The main section of the display, an example of which is shown above, will show
the content required for the selected screen.
6.5.3 Icon Button Bar
At the bottom of the display is the Icon Button Bar. This provides the buttons to
select various sub-screens and options depending on the screen being displayed.
A common button at the right hand side of this bar is the Back button, which will
take you back to the previous screen in the hierarchy.

6.6 HMI Home Screen

Below is a typical RivMon HMI home screen, with the various elements listed.
1 2 3 4
14 13 12 11 10 9
Item Description
Tool selected on the HMI. Pressing on this will call up the tool settings screen.
The blue line is the actuator’s ‘temperature’ gauge. The bar shrinks every cycle
1
and grows every 5 minutes without a cycle. It is used by RivMon when deciding on
fault causes.
Cycle Count on current tool. This value counts the number of cycles a particular
2
tool has performed.
3 Current Time.
4 HMI connection status with Drive (green = online, red = offline)
5 Display of Current Spot Number and RivMon Application.
6 Enter Preventive Maintenance Screens
7 Display Results and Tolerance Editing (if equipped with RivMon)
8 Display RivMon screens Error Matrix (if equipped with RivMon)
9 Select to display Utilities Menu, if password entered, or enter password screen.
10 Display Password Entry Screen
11 Display Communications Screen, to show signals to/from cell or robot controller
12 Display Error Logs
13 RivMon (Auto, Manual or Maintenance)
14 Shows current RivMon/HMI version

6.6.1 Communications (Comms) Screen

Pressing on the Comms button at the bottom right hand side of the home screen
enables the user to access the communication screen.
The communication screen is split into three sections. The left side shows the
communications from the Cell/Robot, the center showing the communications to
the Cell/Robot. The right side showing the operational mode, any faults present
and if there is any preventive maintenance due. The screen appearance will vary
slightly depending upon whether the system is configured for ‘Henrob Standard’ or
‘Customer specific’ comms. The specific style of communication is set from the
System Configuration option in the Utilities menu during initial installation.
The screen displayed

on the left shows the
Henrob Standard
Communications
Protocol.
The screen shown

left, shows the
customer specific
communication
protocol display. The
upper right side of
the screen shows the
Point, which indicates
the spot parameter
setting.

On the bottom of the Comms screen is a ‘Drive IO’ button. Pressing this button will
bring up the Drive I/O Status screen. This screen shows the status of the Drive’s
physical Inputs and Outputs as well as whether the tool is “OK To Disconnect.”
At the bottom of the display is the RivMon online status. If the RivMon is offline, the
button is red. Pressing the button, with the correct password level, will toggle the
RivMon online/offline status
6.6.2 System Error Status Screen
When a process
error occurs the top
bar of the display
turns red as shown
left. This red bar will
remain until the tool
cycles again without
a fault or the
individual fault(s) are
acknowledged.
When a fault occurs the appropriate error message will appear at the bottom of the
display. This fault status can be reset by the cell / robot or manually (password
protected by customer request) by switching to manual and pressing the error
message box.

6.6.3 System Error Log

Pressing on the Error Log button at the bottom right hand side of the home screen
enables the user to access the System Error Log display.
This screen shows the tool number, fault, time and date that individual faults
occurred. If RivMon is enabled, there will be a button with the RivMon Process
error log.
Pressing the Error Log button again will, if the RivMon is enabled, call up a display
of the last RivMon error messages. Pressing the ‘Sys Errors’ button will return to
the list of system errors.

6.6.4 Password Control

Various operations in the RivMon system can only be performed by qualified,
authorized personnel – such as setting preventative maintenance (PM) intervals
and modifying tolerance bands. A multi-level password system protects these
settings
Pressing the “Hand” icon at the

bottom right hand corner of the
main display will call up the
Password Control screen.
A password value is entered using the numeric keypad. The “<” key deletes the
last number entered. The “C” key clears the whole entry. Once the correct code
has been entered the “Ent” key is pressed. If the code entered is valid, the access
level will be highlighted in green as shown above for level 0.
Pressing the “Lock” button (pad lock icon) will change the access status to Level 0
(Restricted), Pressing the “BACK” button will return to the previous screen with the
currently selected password level.
A timeout function will automatically reset the password to Level 0 (Restricted)

after five minutes of inactivity.

6.6.5 Tool Details

Pressing on the tool on the Home screen will display the Tool Details page.
The Tool Details screen contains three tabs: Tool Overview, Tool I/O and Spot
Settings. The Tool Overview tab shows an overview of the tool setup: tool stroke,
internal stroke, flywheel, current position, setter home, absolute position valid and
setting speed. Using the correct user level it is possible to select a different internal
stroke and other tool configuration settings.
The values and options are as follows:

Current Position This is a readout of the current position, relative to the ‘Home’
position of the rivet setter. It is not possible to modify this
value. An ‘Unknown’ display indicates that the tool needs to be
homed either manually or via automatic operation.
Tool Stroke This is a display of the calibrated stroke of the tool. This value
is the distance from the home position until the punch would
touch the material surface. It is set using the calibration
procedure in Maintenance mode. Note: this is not the nose to
material working stroke of the tool but the total travel of the
actuator roller screw.
Internal Stroke This value, often known as the Nose Length, is the distance
the punch travels within the nose of the tool. Thus a 160mm
stroke tool with a 72mm nose would have a nose to material
distance when fully open of (160-72)=88m.
This value is used when calculating whether it is possible to

stop prior to the rivet insertion phase of stroke beginning if an
EStop condition is present during the advance portion of the
cycle. And how far to retract off the material for a given ‘Partial
Retract’ or after an EStop.
Pressing on this box, with the correct password, will cycle

through the available distances – 32/72/102mm (this setting is
dependent upon the tool configuration being used).
Max Speed This value may be modified in 50mm/s intervals between 100
and 400mm/s. Pressing on the left side of the box reduces the
value to 100mm/s before wrapping around to 400mm/s, while
pressing on the right side increases the value up to 400mm/s
before wrapping around to 100mm/s.
If the system is asked to cycle at a higher speed than this

setting then a fault message will be displayed.
Compliant This value allows the type of compliant being used ‘None’,
‘Standard’, or ‘Advanced’ to be selected. At present all tool
assemblies will be either ‘None’ or ‘Standard’, with ‘Advanced’
being available upon request.
Flywheel As the tool sets the rivet using the energy stored in the tool via
inertia; it is often advantageous – especially for 5mm rivets –
to install an additional flywheel element to increase the inertial
mass of the rivet setter allowing higher force for a given speed.

Selecting a flywheel will change the force calculated by

RivMon, as well as modify the accelerations and decelerations
performed by the tool during normal motions.
A.P.B This informs the system as to whether the tool is fitted with an
Anti-Pull-Back device in the nose which prevents the sprocket
tape from being pulled back during motion.
Depending on the setting of the A.P.B status, the system will

modify how the rivet is fed.
Nose There are presently two options for this. Std which would be
the standard nose design, and Air which injects air into the
nose during the advance move of the rivet setter to aid in
setting very short rivets.
Spool There are presently two options for this. Air which is a
pneumatic spool with associated brake – operated from a
pneumatic valve, and Mech which uses a mechanical spring
spool or other design which is self contained and requires no
control logic.
6.6.6 Tool IO Status

The Tool IO Status tab shows the status of the tool inputs and outputs.
This screen shows the current status of the digital I/O mounted on the tool. The
display is only updated approximately once per second, so signals, either high or
low, which are active for a period shorter than one second may not be displayed.

6.6.7 Spot Settings

The Spot Settings tab shows the current parameter and allows the user to add or
change parameters. Pressing the parameter will display the Spot Velocity &
Component Settings screen that will be explained in 6.7.
Pressing the Spot Settings tab

again will allow 32 parameters to
be seen on the screen.
Pressing the Spot Settings tab

once again will allow 128
parameters to be seen on the
screen.

6.7 Spot Parameter Entry

The RivMon system allows multiple different spots to be monitored, although any
number of similar rivet joints can be compared against these spot styles. The
screen below maps the Tool/Spot combination onto a specific application.
Applications can be inserted, deleted or sorted by tool/spot number using the
buttons at the bottom of the screen.
To create/change spot parameters press the pencil icon, this brings up the Spot
Velocity & Compliant Settings screen shown below.

6.7.1 Creating/Changing Spot Parameters
The Spot Velocity & Compliant Settings screen allows the user to create and
modify the spot parameters.
2
10
9 8 7 6 5 4
1 Tool & Spot Identification number

2 Parameter Entry Window
3 Backspace - Deletes last number entered.
Man Spot [0] - Saves the current parameters when switched to
4
manual mode.
Map Spot to App- Shown when the application isn’t’
mapped
5
View App Mapping - Brings up the Application
Mapping screen
6 Deletes current Spot ID
Home OK allows the tool to open fully.

7
No Home allows the tool to open only to the Partial setting.
8 Saves settings to a portable USB drive in a folder labeled “RivMon”

9 Moves to the next or the previous Spot ID
10 Parameter input section

To create/change a spot parameter:
1. Press the input section box of the setting to be changed. The chosen box
will turn blue, indicating the change can be made.
2. To change the value, enter the desired velocity/spot number using the
keypad and press enter.
3. To change the Compliant, choose from the options from a menu that
appears after pressing the Compliant input section box.
4. When a new spot has been entered a button will appear on the bottom of
the screen called View App Mapping.
5. To map the new spot number to an application, press the View App
Mapping button. The application will then be shown in the Mapping screen.

6.7.2 Application Mapping

The RivMon system can monitor 256 different spot types, although it could
theoretically have 7 tools with 256 spots (1792 in total), hence the need to map the
rivet spots – Tool/Spot on to the available RivMon applications.

6.8 Communications Display

Pressing on the Comms button at the bottom right hand side of the home screen
enables the user to access the Cell Communications screen. This screen shows
the current status of the signals passing between the Fixture Controller and the
Cell.
Note: If there is a fault code displayed then this code is displayed as a fault
message in a box located at the bottom of the screen.
6.8.1 Cell/Robot Communications Display
There are signals passing in each direction with the active signals being received
by the Henrob system being shown as green squares, and the active signals being
sent from the Henrob system to the main system being shown as light blue
squares.

6.8.2 Drive I/O Display
The Drive IO screen shows the drive operating mode which is shown as pink
squares. The physical drive inputs and outputs that are currently active are shown
as green squares.

6.9 Preventive Maintenance
To enter the preventative maintenance screen press on

the maintenance box on the home screen.
The Tool PM Detail Screen has five bar graphs

indicating the percentage of cycles before the next
recommended PM interval for the Rivet re-fill, Die and
Punch change and other maintenance. When the bar is
green PM is not due, when the bar turns yellow PM will
be due soon, and turns red PM is required. Ignoring the
PM needs will not result in a fault condition or the tool
being blocked from cycling. However failure to carry out
required PM may result in reduced system life and
reliability as well as invalidate the warrantee on some
components.
After the maintenance has been done, it should be “acknowledged” by pressing

the ‘Change’ button. If the same operation has been performed to all the tools
monitored by the HMI at the same time, then pressing the “Change All” will reset
the count for all the tools.
The actual PM periods would be set on a per application basis.

Pressing a “Change” or “Change All”

button will either prompt for a password
(Level 1) or ask for a confirmation prior to
resetting the counter, as shown right.
Press the appropriate button to continue,

or if not pressed within 5s the screen will
be removed with no action taken.
Pressing on the bar graph bar itself will call up the screen shown below:
This screen allows the Warning and Change settings for each of the PM settings to
be adjusted. These PM settings can be saved/loaded to/from the Data SD card
using the red (save) and load (green) disc buttons, with a Yes/No confirmation
screen.

6.10 Utilities Menu
Pressing on the gears on the home screen will

display the Utilities Menu page, as shown below.
This screen provides access to a number of system

configuration screens, as well as some of the
screens enabling data backup and restoration.

6.10.1 Backup RivMon to SD

User files can be saved to an SD card by pressing the Backup to SD button on the
Utilities Menu enabling the user to access the Load/Save System Data screen.
The Load/Save System Data screen allows process data and tolerance bands to
be saved using three user stores. Once saved, these sets of data can then be
loaded back into the system at any time by qualified, authorized personnel.
In addition to the three user stores there is a auto save that carries out a save on
shutdown and a timed save that carries out an automatic save every 24 hours.
The necessary information is saved on an

SD card that is located on the back of the
HMI unit inside the door of the controller.

6.10.2 Load/Save Spot Parameters

The Load/Save Spot Params will load spot (joint) parameters from the USB drive
on the RivMon unit.
1 Place a thumb drive into the

USB port.
The system needs the data to

be located in a ‘RivMon’
directory in the root directory of
the thumb drive.
2 Press Load/Save Spot Params.
3 The screen, shown right will

appear. When loading it looks
for a .csv file named:
Sys(SystemID)_Joints.csv or
SysAll_Joints.csv.
It will always save the file with

the system ID in the description.
4 Press the green ‘All’ to load the parameters into the RivMon, or the red ‘All’
button to save all the parameters to the SD Card. It is possible to load/save the
parameters for a single tool.
5 While the parameters load, this icon will appear.
6 After the USB device has been located and the parameters are
being loaded or saved, this icon will appear.
7 Once the system has finished the icon will change and pressing BACK to
return to the Utilities Menu.

6.10.3 Active Tools
Pressing Active Tools will bring up a screen

that shows the tools presently monitored in
green. Pressing on an inactive tool will
activate the monitoring for that tool.
The System Overview screen shows the tools that are currently monitored.

6.10.4 Error/Warning Thresholds
Pressing Error/Warning Thresholds

allows the number of consecutive errors
of each specific type that need to be
present before a system fault is
generated.
In general the end of stroke measurements would be set to 1 which will set an
alarm following a single event, while the other faults may be set to 2 thus requiring
two consecutive deviations before an alarm is set. This ensures that the more
significant issues, such as missing or double rivets cause the system to stop
immediately, but allows transient process variations to be filtered.
The Warning > Fault setting allows multiple consecutive warnings to be seen by
the system as a fault.

6.10.5 Calibrate Touchscreen
Selecting the ‘Calibrate Touchscreen’

option from the second utilities menu
will call up a series of screens with a
displayed green cross. Press, and
release the screen as close to the
center of the cross as possible.
The system uses the readings from the four corners of the display, as well as the
center to calculate the scaling values needed to translate a screen press to X&Y
coordinates. It is also possible to invoke this screen by pressing and holding the
screen while power is applied.
Once calibrated, the settings are stored to the memory card, and the screen should
not need to be calibrated unless there is a hardware change.
6.10.6 Change Language
Pressing Change Language will allow

the user to change the language. The
system will cycle through the available
languages, updating the screen text to
match. For reference the ‘Change
Language’ button is the second for the
top on the right hand column of the
Utilities Menu (see section 6.9.)

6.10.7 System Configuration
Pressing System Configuration will bring

up a screen that shows some options
that are may be included with the
system. If the button is green, the option
is currently enabled.
RivMon Online This button will toggle the RivMon Online/Bypassed status if
allowed. In the bypass mode RivMon is active but does not
fault out the system.
UDP I/O This button will toggle I/O communications format between the
custom UDP protocol used by the Phoenix I/O box, and
Modbus TCP used by the Turck I/O modules.
Spot 0 Invalid This button will toggle whether it is acceptable to cycle the
system with Spot (Joint) 0 selected. If the spot is Invalid the
system will generate a fault message. This is to prevent
inadvertent riveting cycles on systems which are programmed
to return to spot 0 after each rivet.
RivMon Enabled This button will toggle the RivMon Enabled/Disabled status if
installed. In the disabled mode RivMon monitoring is inactive
and none of its screens are visible.

At Mid This button will toggle whether the system needs to be within
2mm of the requested position to generate an ‘At Opening’
signal, or whether any position above the partial setting is
acceptable.
Cycle Timeout This button will toggle whether a fault message is generated if
the advance/cycle setter signal is active for an excessive
length of time.
RivMon Monitor This button will toggle a customer specific RivMon

configuration mode.
Comms. Bridge This button will toggle a customer specific communications

option.
FAck Password This button will toggle whether a password is required to

manually reset a fault code from the HMI.
Fast Close Mode This button will toggle the operation of the manual riveting
cycle. It should remain as Fast Close for the majority of
applications.
Comms. Style This button will toggle between the available communications
styles, with the active style being displayed.
System ID This button will jump to a screen where the System ID (used to
load save spot parameters) may be adjusted. By default the ID
is set to the controller’s serial number, but may be changed as
needed to a station or robot number. The range allowable is 0
to 32000.

6.10.8 Change Type
Pressing Change Type will bring up a

screen that shows the customer specific
applications. If the button is green, the
option is currently enabled.

RivMon • 7
7.0 RivMon Riveting Process Monitoring (if enabled)
The RivMon™ process monitoring

system is an electronic device that
collects data during normal
production on the Henrob self pierce
riveting system. The data can then
be used for a variety of diagnostic
functions and process monitoring
analysis. The main hardware
components are a compact
electronic unit, which also functions
as the main system HMI.
During the rivet insertion process, the punch position is captured 1000 times per
second by the servo drive. At the end of the insertion this block of captured data is
sent via Ethernet to the RivMon unit for analysis.
This analysis consists of generating position, velocity and ‘force’ traces from the
sampled data and then generating a number of process measurements which,
together with the process curves, are compared against previously saved tolerance
data. The RivMon then broadcasts accept/reject codes as necessary for the cycle
and proceeds on accordingly.
Once the analysis is complete the result is transmitted back to the Servo Drive
controller. The system will only generate a finished signal to the cell/robot controller
when the response has been received from the RivMon. Typically the RivMon has
sent the response to the drive before the nose of the rivet setter has left the
material, and therefore has no impact on the cycle time of the system.
Functional features of the RivMon™ system include:
 Capture up to 16 process traces for manual interpretation.
 Hold the process measurement trend display for up to 256 applications,

with 256 sample points per trend measurement.
 Detect gross riveting problems, such as missing rivet.
 Count the rivets inserted with the punch and die and prompt for
replacement when their life is approached (PM Screen).
 Allow process curves to be viewed on the built-in display.
 Communicate problems and PM issues back to robot/cell controller as

required. (Automation controlled tools only.)

7 • RivMon
7.1 RivMon Process Measurements

The RivMon system is designed to capture a number of process variables during
the rivet insertion sequence, and these measurements, listed below, allow the
system to detect when a rivet insertion has deviated from the allowable range, and
to generate an error to prevent the potential continuation of bad parts being made.
7.1.1 Start Distance

This is the distance from the home position at the point when the system senses
that the rivet has touched the material.
This position is influenced factors such as panel gaps which are not able to be
brought together by the nose prior to the rivet that point. Therefore the tolerance
band should be set wider (normally ±0.5mm) than for the end position.

RivMon • 7
7.1.2 End Distance

This is the maximum distance the punch moves from the home position while
setting the rivet. As the tool comes to a complete stop, with the material drawn
together, the end position can be measured with much more accuracy than the
start position.
The RivMon has a hardware peak position capture circuit to capture this position
automatically with the maximum possible accuracy. This position is influenced by
the material thickness, C-Frame deflection as well as the setting depth of the rivet.
An acceptance tolerance would typically be set to around ±0.2mm.
7.1.3 Peak Force

The force (F) generated by the tool is derived from the deceleration (A) multiplied
by the inertial mass of the tool (M) together with the static torque (T) imposed by
the motor. F=MA+T.
If the peak force is excessive the operating life of the tool may be reduced
significantly. To prevent this, a maximum peak force value is imposed.

7 • RivMon
7.1.4 Insertion Distance

This is the change in position between the start and end distances above. This
gives an indication of the length of the rivet being inserted. The variation in this
value is due to the combination of tolerances in the previous two measurements.
An acceptance tolerance of around ±0.5mm would typically be applied.
Using the graphics for the start and end distance, the following conditions would
result in a noticeable change in the insertion distance – Missing Rivet, Missing
Material and Short Rivet.
7.1.5 Insertion Time

The time taken to insert the rivet (time from the start to the end distance
measurements) is measured in milliseconds. This measurement is normally very
consistent, and varies mainly when there is a significant issue such as a missing or
double rivet. An acceptance tolerance of around ±5mS would typically be applied.
7.1.6 Insertion Velocity

Each spot type requires a specific amount of energy to insert the rivet into the
combination of materials being joined. This energy is delivered primarily by the
inertia stored in the tool as it advances at the specified speed.
By monitoring the velocity of the tool at the point at which the rivet touches the
material the amount of energy available for setting the rivet can be sensed.
If too much or too little inertial energy is delivered the rivet may not be inserted to
the correct depth. An acceptance tolerance of around ±5mm/s from the required
velocity would typically be applied.

RivMon • 7
7.2 Types of Riveting Errors (Decoded Fault Causes)

The RivMon system uses the process errors detected above to lead the user to the
probably cause. It displays the most likely cause of the error, but also lists those
that it thinks may apply given the current set of process errors.
The errors currently decoded are:
7.2.1 Missing Rivet

This is an equipment error which would occur if there is an intermittent nose switch
failure. Henrob equipment requires the nose switch to cycle on and off each cycle
to prevent the production of parts without rivets. Nose switches typically fail by
jamming or with a proximity sensor failure. A failed nose switch could be held on,
which would indicate the rivet is present when it is absent, or held off which would
generate a feed fault.
A missing rivet can also happen if the tape is pulled from the nose as the tool
advances. This is typically due to feed system set up.
This error will not be caused by a rivet missing from the tape as the feed system
advances to the next rivet in the tape.

7 • RivMon
7.2.2 Double Rivet

This occurs if the system rivets twice at the same location. In which case the start
position is normally acceptable but the end position is far too small.
Note: It is important that the nose is checked for a possible blockage and /or
damage if this fault occurs.
7.2.3 Speed Too Fast/Speed Too Slow

These errors are due to the setter not inserting the rivet at the correct velocity. It
may be caused by using the incorrect Spot ID at a given riveting location or a
mechanical failure in the actuator.
7.2.4 Thin Material/Thick Material

These errors are generated when the process errors could be generated by
material which is outside normal tolerances, possibly due to the addition of material
or the lack of one of the parts to be joined.

RivMon • 7
7.2.5 Rivet Too Long/Rivet Too Short

These errors are generated when the process errors could be generated by a rivet
which is outside normal tolerances. In most cases the material error will be more
likely.
7.2.6 Head Too High/Head Too Low

These errors are generated when the deviation in process results could be
generated by a rivet not set to the correct depth.
7.2.7 Insertion Time

This error is generated when the time taken to insert the rivet is either too long or
short. It may be caused by a large panel gap between the parts being riveted.
7.2.8 Hard Material/Soft Material

These errors are generated when the process errors could be generated by
material which is outside allowable tolerances. This could lead to an incorrect
Force or Velocity vs Displacement curve while maintaining the start and end
positions.
7.2.9 Unknown Fault

If the fault characteristics do not match any of the above errors then this error
message will be displayed.

7 • RivMon
7.3 RivMon Screens
When the RivMon process monitoring is enabled, there will be two boxes, Results
and Error Matrix, located on the right hand side of the display underneath the
Maintenance bar graph. Pressing on either of these boxes will call up RivMon
screens as described below.
7.3.1 RivMon Overview Screen – No Fault Active
Pressing on the Error Matrix box will call up a screen showing the trend display for
the process measurements, and if the correct password has been entered, buttons
to allow the tolerance band to be retaught.

RivMon • 7
7.3.2 RivMon Overview Screen – Active Fault
When an error is present, pressing on the Error Matrix (highlighted above) will call
up the screen shown. This screen displays the most likely reason for the process
error on the displayed tool, together with a list of possible causes. The possible
causes are deduced from the process errors listed in the matrix, with each red
square representing a process error number from the table in Section 8.3.
When an error is sensed, but on inspection was deemed a valid spot, it is possible
to add the ‘error’ tolerances as acceptable from the last cycle using the Teach App
button. If the error relates to a velocity or force displacement band deviation the
Add Curves button will allow the last cycles curve to be added to the composite
tolerance band curves.
It is recommended that until the user is familiar with the system, that these buttons
are not used as their effects are not visible on the display which could lead to
unintentional modification of the tolerance bands.

7 • RivMon
7.3.3 Tool Results Overview Screen
Pressing on the Results box, on the right hand side of the Tool Overview screens,
as shown above, results in the Tool Results screen, above, being displayed. This
screen shows the measurements taken during the rivet insertion, with each being
shown as a bar relative to the current tolerance band for that measurement.

RivMon • 7
7.4 History
Pressing on the chart display on the overview screen will enlarge the display. This
screen also allows access to the individual measurements such as Start and End
Distance. The Error/Warn box will display the error and warning tolerance bands
respectively.
When the correct password level is active, the Ave and Last buttons will be
displayed.
If the Ave button is pressed the

tolerance is recalculated based
upon the average of the last 32
cycles.
Only those cycles which lie within

the current tolerance band will be
used to prevent a bad reading from
distorting the tolerance band.
If the Last button is pressed the

tolerance is recalculated based only
upon the last riveting cycle.
Often this is pressed to reset the

coarse tolerance before pressing
the Ave button above.

7 • RivMon
Pressing on the one of the measurement tabs at the bottom of the screen will call
up the graph for that particular measurement.
Pressing on the Error/Warning box will show the trace compared to the current
warning tolerance.

RivMon • 7
7.4.1 Tolerance Band Modification – Direct Modification

With correct password level entered it is possible to modify the nominal value and
tolerance band size for each of the measurements using the [Nom][Abv][Blw]
boxes to select the entry to be modified (which illuminates when selected). Once
selected it is possible to modify the value using the [+][++][-][--] buttons to increase
or decrease the value by a small or larger amount.
Pressing the “Error/Warn” button at the bottom left of the screen changes between
the error and the warning tolerances that are being modified.
Pressing the cycle button to the right of the Error/Warn button, or pressing on the
desired parameter on the toolbar, changes which parameters tolerances are being
modified.
As a general rule it is
recommended that the
variation in the parameter
does not exceed 50% of the
allowable tolerance. Thus if
a reading varied between
99.5 and 100.5 (nominally
100) the minimum working
tolerance band should be set
at 99 to 101.

7 • RivMon
Pressing the Error/Warn box will

toggle the display between showing
the graph displayed against the
error or warning tolerance bands
respectively.
After all the

tolerances have been
adjusted the history
trace will have been
modified, and the
displayed variation
may be significantly
different.
The tolerance band

should also be
verified after the
system has been
operating for a period
of time to ensure the
tolerance values are
still acceptable.

RivMon • 7
7.4.2 Tolerance Band Modification – Numeric Entry

The Tolerance Band Modification screen allows the various parameters associated
with a result – Minimum, Nominal and Maximum – to be modified for both the error
and warning by authorised users.
Pressing the “Error/Warn” button at the bottom left of the screen changes between
the error and the warning tolerances that are being modified.
Pressing the cycle button to the right of the Error/Warn button, or pressing on the
desired parameter on the toolbar, changes which parameters tolerances are being
modified.
The numbers entered/modified must always follow the following rule:
 Minimum Value < Nominal Value < Maximum Value
 Also, as a general rule it is recommended that the variation in the

parameter does not exceed 50% of the allowable tolerance. Thus if a
reading varied between 99.5 and 100.5 (nominally 100) the minimum
working tolerance band should be set at 99 to 101

7 • RivMon
7.5 Curves – Position, Vel. & Force Vs Time

Pressing the curves button at the bottom of the screen calls up the graph display,
showing the Position, Velocity & Force Vs Time graph. This display is for reference
only, and is not directly linked to the monitoring results other than as a display of
the captured traces. Pressing the button again will display 16 curves on top of each
other.
On the left hand side of the screen is a list of the last 16 cycles, indicating the spot
number used, and whether the monitoring results found an error (Red number) of a
good cycle (Green number). The current trace is highlighted in a brighter shade.
It is possible to manually select a

single trace by pressing on the
number on the left, or cycling
through the traces by pressing to
the right of the numbers at the
bottom and top of the list as shown
by the red circles on the image on
the right.

RivMon • 7
7.6 Curves – Force Vs Displacement

Pressing the Force Vs Displacement curves button at the bottom of the screen
calls up the graph display shown below. Pressing the button a second time will
show the traces for the last sixteen cycles.
The graph shows the force, calculated based upon the tool punch deceleration,
against the punch displacement during the rivet insertion. The actual sampled
points are shown as little crosses on the line drawn. On the left hand side of the
display is a list of the last traces, and whether the rivet with inserted without any
monitored error.
Pressing the graph button again will toggle the system to draw the last 16 traces
for the current tool over the top of each other.

7 • RivMon
Pressing the
Error/Good box will
toggle the display of
the last error or good
cycle, highlighted as
a red or green trace.
It should be noted
that the error trace
may still be within the
tolerance band if the
error cause was
unrelated to the
velocity vs
displacement curves.

RivMon • 7
7.6.1 Force Vs Displacement Tolerance Adjustment

When the correct password level has been entered the Delete and Add icons are
shown next to the back button.
The Red Trashcan icon will

DELETE the current tolerance band,
as shown right, and reset the graph
scale to display the current curve.
Pressing the + icon will add the

displayed tolerance region around
each of the sample points to
generate a tolerance band.
The size of the region can be

modified by pressing on the circles.
It is also possible to select another

of the last 16 curves and generate a
composite tolerance band.
After the tolerance has been

modified, the changes need to be
confirmed by pressing the green
tick/check icon.
A confirmation message will be

displayed and the appropriate
button would be pressed.
In general this curve would be taught on a single rivet insertion, and then modified
as needed to compensate for normal production variations.

7 • RivMon
7.7 Curves – Velocity Vs Displacement

Pressing the Velocity Vs Displacement curves button at the bottom of the screen
calls up the graph display shown below. Pressing the button a second time will
show the traces for the last sixteen cycles.
This graph shows the punch velocity against the punch position during the rivet
insertion process. Pressing the graph button again will toggle the system to draw
the last 16 traces for the current tool over the top of each other.

RivMon • 7
Pressing the
Error/Good box will
toggle the display of
the last error or good
cycle, highlighted as
a red or green trace.
It should be noted
that the error trace
may still be within the
tolerance band if the
error cause was
unrelated to the
velocity vs
displacement curves.

7 • RivMon
7.7.1 Velocity Vs Displacement Tolerance Adjustment

When the correct password level has been entered the Delete and Add icons are
shown next to the back button.
The Red Trashcan icon will

DELETE the current tolerance band,
as shown right, and reset the graph
scale to display the current curve.
Pressing the + icon will add the

displayed tolerance region around
each of the sample points to
generate a tolerance band.
The size of the region can be

modified by pressing on the circles.
It is also possible to select another

of the last 16 curves and generate a
composite tolerance band.
After the tolerance has been

modified, the changes need to be
confirmed by pressing the green
tick/check icon.
A confirmation message will be

displayed and the appropriate
button would be pressed.
In general this curve would be taught on a single rivet insertion, and then modified
as needed to compensate for normal production variations.

RivMon • 7
7.8 Detected Process Errors

The RivMon system differentiates between small errors and large errors for most
measures. Small errors are generally faults in the riveting process where as large
errors are generally riveting equipment errors. Differentiating allows the system to
provide better troubleshooting guidance.
The Process Errors detected by the system, and displayed in the error matrix as
red numbered squares are as follows:
7.8.1 Err 1: Start Position Far Too Small

The punch displacement when the rivet touches the material grossly failed to reach
the lower tolerance set for the application. This would normally occur if the rivet
were too long (e.g. 6mm rather than 5mm) or an additional piece of material were
added (e.g. three sheets rather than two).
7.8.2 Err 2: Start Position Too Small

The punch displacement when the rivet touches the material did not reach the
lower tolerance set for the application. This would normally occur if the material
being processed were too thick or the panel gap between the parts was not able to
brought together prior to the rivet hitting the material.
7.8.3 Err 3: Start Position Too Large

The punch displacement when the rivet touches the material exceeds the upper
tolerance set for the application. This would normally occur if the material being
joined were outside tolerance.
7.8.4 Err 4: Start Position Far Too Large

The punch displacement when the rivet touches the material grossly exceeds the
upper tolerance set for the application. This would normally occur if either the rivet
were too short (e.g. 5mm instead of 6mm) or missing, or that the one of the sheets
of material being joined were missing.
7.8.5 Err 5: End Position Far Too Small

The punch displacement at the end of rivet insertion grossly failed to reach the
lower tolerance set for the application. This would normally occur if a double rivet
event happened, the rivet was too long (e.g. 6mm rather than 5mm), or an
additional piece of material were added (e.g. three sheets rather than two).

7 • RivMon
7.8.6 Err 6: End Position Too Small

The punch displacement at the end of rivet insertion did not reach the lower
tolerance set for the application. This would normally occur if the material being
processed were too thick, such as if a 1.5 mm sheet was replaced with a 2mm
sheet.
7.8.7 Err 7: End Position Too Large

The punch displacement at the end of rivet insertion exceeds the upper tolerance
set for the application. This would normally occur if the material being joined were
too thin.
7.8.8 Err 8: End Position Far Too Large

The punch displacement at the end of the rivet insertion grossly exceeds the upper
tolerance set for the application. This would normally be due to a missing rivet or
that the one of the sheets of material being joined were missing.
7.8.9 Err 9: Insertion Disp. Far Too Small

The change in displacement during the rivet insertion grossly failed to reach the
lower tolerance limit. This would normally be due to a missing rivet, a rivet which
was too short, a double rivet, or missing material.
7.9.10 Err 10: Insertion Disp. Too Small

The change in displacement during the rivet insertion did not reach the lower
tolerance limit. This would normally be due to a rivet which was too short, or
material which was too thin.
7.8.11 Err 11: Insertion Disp. Too Large

The change in displacement during the rivet insertion exceeded the upper
tolerance limit. This would normally be due to a long rivet, thick material or an
excessively large panel gap that could not be drawn together fully prior to the rivet
being inserted.
7.8.12 Err 12: Insertion Disp. Far Too Large

The change in displacement during the rivet insertion grossly exceeded the upper
tolerance limit. This would normally be due to an excessive panel gap or an extra
layer of material.
7.8.13 Err 13: Insertion Time Too Small

The time taken to insert the rivet did not reach the lower tolerance limit. This would
normally be due to a missing or double rivet.

RivMon • 7
7.8.14 Err 14: Insertion Time Too Large

The time taken to insert the rivet exceeded the upper tolerance limit. This would
normally be due a long rivet or additional material.
7.8.15 Err 15: Start Velocity Too Small

The punch velocity at the point the rivet touched the material did not reach the
lower tolerance limit. This would normally be due to the setter not being able to
attain the setting velocity in the stroke available. Note: the minimum nose to die
gap is 25 mm.
7.8.16 Err 16: Start Velocity Too Large

The punch velocity at the point the rivet touched the material exceeded the upper
tolerance limit. This would normally be due to velocity overshoot due to not having
sufficient torque to accelerate the tool. This would typically be due to insufficient
power supplied to the motor, due to a faulty servo amplifier in the Servo Controller.
7.8.17 Err 17: Peak Force Too Small

The peak force calculated from the punch deceleration and static motor torque did
not reach the lower tolerance limit. This could be caused by an incorrect
rivet/material combination, a missing rivet or double rivet.
7.8.18 Err 18: Peak Force Too Large

The peak force calculated from the punch deceleration and static motor torque
exceeded the upper tolerance limit. This could be caused by using an excessive
setting speed in combination with material outside normal tolerances.
7.8.19 Err 19: Left Vel. Vs Disp. Curve Below

The Velocity Vs Displacement curve tracked below the preset tolerance band. This
suggests that the punch slowed down too quickly. This could be caused by a
double rivet.
7.8.20 Err 20: Left Vel. Vs Disp. Curve Above

The Velocity Vs Displacement curve tracked above the preset tolerance band. This
suggested that the punch did not slow at the correct point. This would normally be
due to a missing rivet or material (e.g. two sheets rather than three).
7.8.21 Err 21: Left Vel. Vs Disp. Curve at Start

The Velocity Vs Displacement curve started before the preset tolerance band. This
is equivalent to the Start Position Too Small error mentioned above, and is a
second means of detecting this error

7 • RivMon
7.8.22 Err 22: Left Vel. Vs Disp. Curve at End

The Velocity Vs Displacement curve ended after the preset tolerance band. This is
equivalent to the End Position Too Large error mentioned above.
7.8.23 Err 23: Left Force Vs Disp. Curve Below

The Force Vs Displacement curve tracked below the preset tolerance band. This
suggested that the punch slowed down too slowly and would be due to excessively
thick material.
7.8.24 Err 24: Left Force Vs Disp. Curve Above

The Force Vs Displacement curve tracked above the preset tolerance band. This
suggested that the punch was being slowed down too quickly and would be due to
a missing rivet or material.
7.8.25 Err 25: Left Force Vs Disp. Curve at Start

The Force Vs Displacement curve started before the preset tolerance band. This is
equivalent to the Start Position Too Small error mentioned above.
7.8.26 Err 26: Left Force Vs Disp. Curve at End

The Force Vs Displacement curve ended after the preset tolerance band. This is
equivalent to the End Position Too Large error mentioned above.
7.8.27 Err 27-31: Spare

These errors are not currently used, and may be used for future upgrade.

Error Message & Fault Recovery • 8
8.0 Error Message & Fault Recovery
The Henrob system can generate two styles of fault – system faults which are
related to the operation of the riveting equipment (feed faults for example), and
process errors which may be generated even when the equipment is operating
correctly when there is a significant variation in one of the measured process
values (see the RivMon section of this manual).
These errors are combined into a single error map 1..255 where the location within
this range of values will have an influence on how the error is handled.
The ranges are as follows:
Range Description Recovery type

0 No Active Fault No action needed
Reset fault and retry at same point
1..63 Before Fault
allowed
During Fault Reset fault and retry only after part
64..191
System Fault has been manually inspected
Reset fault and move to next
192..255 After Fault
location as required

8 • Error Message & Fault Recovery
8.1 Faults Before Riveting

If a fault occurs during the cycle but before the rivet has been set, the system will
react in the following manner:
No partial position has been selected. On reset:
- The setter will perform a verify home

- The setter will set the rivet
- The setter will retract to its home position and send out an EOS
A partial position has been selected. On reset:

- The setter will set the rivet
- The setter will retract to its partial position and send out an EOS
Note: The fault recovery assumes that the ‘Cycle Tool’ from the
robot is maintained throughout the recovery process. If not, the
system will assume a new riveting position, and will set a rivet. If
NOTE the fault should cause the system to lose its position e.g. Encoder
hardware Fault, the system will perform a true home instead of a
verify home.

8.1.1 System Faults
Faults Before Riveting Possible Cause

System Faults
1 Feed Fault - This fault occurs if the system cannot pull the rivet into the
Can't see rivet nose under the punch, and is caused by the nose switch
not being activated by the rivet being fed.
Possible causes: Distorted tape preventing the tape
advancing fully or that the nose switch is no longer
operating properly.
Recovery Action: Check Rivet Supply, Feed Path And
Nose Switch. Remove a number of rivets (3-5) from the
tape to get a clean section of tape to feed into the nose.
2 Feed Fault – Low Riv This is the same fault as above, but generated when the
Low Rivet sensor is low which indicates that the tape end
has been reached and is thus the most likely reason for
rivets not feeding into nose.
3 RivMon not 'Ready' When the RivMon process monitoring system is installed
it must be responding to status messages sent by the
drive.
Possible causes: RivMon comms failure.
5 Tool Mismatch - The Tool requested by the Robot does not match the Tool
ID of the currently selected tool.
6 Invalid Spot ID - Check spot ID
7 Speed Too Low Requested speed < 50 mm/s
8 Speed Too High Requested speed exceeds limit for tool.
9 Insufficient Opening This error is generated when a nose to die distance is too
small to allow the tool to reach speed
10 Abs. Pos. Invalid Motion command when position is unknown
11 Homing Fault This fault occurs if the system cannot complete a correct
home move, possibly caused by a damaged or jammed
rivet setter.
Recovery Action: Check rivet setter for mechanical
malfunction, and replace with spare as necessary while
repair is performed.
12 Tool Not Calibrated Calibrated stroke is < 50mm
13 Bad Calibration Calibrated stroke is > 270mm

8.1.2 Magazine Faults
Faults Before Riveting Possible Cause

Magazine Feed Specific Faults
16 Wrong Rivet in Nose Incorrect rivet (A/B) loaded into nose
17 Pusher Can’t Retract Mag/Blow feed pusher in the nose feeder can’t retract
18 Can’t Feed Rivet A Rivet A can’t be fed from the tool to the nose
19 Can’t Feed Rivet B Rivet B can’t be fed from the tool to the nose
20 Cube Empty Rivet A Rivet A bulk feeder is empty
21 Cube Empty Rivet B Rivet B bulk feeder is empty
22 Can’t Escape Rivet A Rivet A can’t be loaded into the tube
23 Can’t Escape Rivet B Rivet B can’t be loaded into the tube
24 Can’t Fill Rivet A Rivet A can’t be fed thru the tube into the feeder
25 Can’t Fill Rivet B Rivet B can’t be fed thru the tube into the feeder
26 Docking Error Unable to dock correctly
27 Gate Error Gate on dock won’t open/close

8.2 Faults During Riveting

Faults During Riveting are faults that occur while the rivet is being set. In these
cases the operator/maintenance personnel needs to check if a rivet has been
inserted or not and then skip to the next rivet or recycle at the current position.
These are listed in four categories: System, RivMon, Drive and Motion faults.
8.2.1 System Faults
Faults During Riveting Possible Cause

System
64 Can’t Reset Drive Fault This fault occurs if the system cannot reset the drive
65 Nose Switch Fault This fault occurs if the nose switch does not go off during
the retract of the rivet setter after setting a rivet. This
switching verifies that the nose switch sensor is working
correctly.
Possible causes: A bent trigger, or a trigger jammed by
tape debris, or that the nose switch proximity sensor is no
longer operating properly.
Recovery Action: Check and clean Feed Path and
confirm correct nose switch operation.
66 Double Rivet This occurs if the system rivets twice at the same location.
In which case the start position is normally acceptable but
the end position is far too small.

8.2.2 RivMon Faults

RivMon (if installed)
96 RivMon: This fault occurs when the system cycles but the RivMon
Not Triggered cycle toggle bits don’t match the tools cycled.
97 Missing Rivet: This error is likely where the start displacement and end
displacement are too large.
98 Double Rivet This occurs if the system rivets twice at the same location.
In which case the start position is normally acceptable but
the end position is far too small
99 Speed Too Fast The punch velocity at the point the rivet touched the
material exceeded the upper tolerance limit.
100 Speed Too Slow The punch velocity at the point the rivet touched the
material did not reach the lower tolerance limit.
101 Thin Material This process error could be generated by material which
is outside normal tolerances, possibly due to the lack of
one of the parts to be joined.
102 Thick Material This process error could be generated by material which
is outside normal tolerances, possibly due to the addition
of material.
103 Rivet Too Long This error is generated by a rivet which is outside normal
tolerances. In most cases a material error will be more
likely.
104 Rivet Too Short This error is generated by a rivet which is outside normal
tolerances. In most cases a material error will be more
likely.
105 Head Too High This error is generated by a deviation in process results
could be generated by a rivet not set to the correct depth.
106 Head Too Low This error is generated by a deviation in process results
could be generated by a rivet not set to the correct depth.
107 Insertion Time The time taken to insert the rivet exceeded the upper or
lower tolerance limit
108 Vel vs Disp Above The Velocity Vs Displacement curve tracked above the
preset tolerance band. This suggested that the punch did
not slow at the correct point. This would normally be due
to a missing rivet or material (e.g. two sheets rather than
three).
109 Vel vs Disp Below The Velocity Vs Displacement curve tracked below the
preset tolerance band. This suggested that the punch
slowed down too quickly. This could be caused by a
double rivet.
110 Force vs Disp Above The Force Vs Displacement curve tracked above the
preset tolerance band. This suggested that the punch was
being slowed down too quickly, as would be the case due
to a missing rivet or material.
111 Force vs Disp Below The Force Vs Displacement curve tracked below the
preset tolerance band. This suggested that the punch
slowed down too slowly, as would be the case due
excessive material.

8.2.3 Drive Faults During Operation

Drive
128 Overload Shutdown This fault is generated when the drive has received an
overload and shutdown
129 Amplifier Over Temp Check amplifier temperature (<100degC)
130 Motor Over Temp Check cables & motor case temperature (<100degC)
131 Drive Class 1 Bit 3 Not used
132 Bad Control Voltage Voltage is out of range
133 Encoder Error This is generated by an encoder fault
135 Over Current This fault is generated when the drive has received a
current overload
136 Over Voltage This fault is generated when the drive has received a
voltage overload
137 Under Voltage This fault is generated when the drive has not received
enough current to operate the drive
139 Excessive Deviation Difference expected and current position becomes
excessive
140 Comms Error This is generated by a comms error
141 Position Limit This is generated when the position exceeds the allowable
limits
143 Man. Specific Manufacturer specific fault

8.2.4 Motion Faults During Operation

Motion
160 Home Up: This is generated by a fault during Home Up process
161 Home Stop: This is generated by a fault during Home Stop process
162 Home Down: This is generated by a fault during Home Down process
163 Return to Zero: This is generated by a fault when the tool cannot return
to zero
164 Cal Down: This is generated by a fault during the Calibration Down
165 Cal Up: This is generated by a fault during the Calibration Up
166 Pre Retract: This is generated by a fault during the Pre-Retract
167 Rivet Phase 1: This is generated by a fault during high speed motion
168 Rivet Phase 2: This is generated by a fault during motion at setting
velocity
169 Retract: This is generated by a fault during the Retract
170 Drive Reset: This is generated by a fault during the Drive Reset
171 Close Tool: This is generated by a fault while the tool is trying to slow
close
172 Open Tool: This is generated by a fault while the tool is trying to slow
open
173 Quick Stop: This is generated by a fault caused the tool to stop
before finishing the cycle or the E-Stop

8.3 Fault After Riveting

If a fault occurs during the cycle but after the rivet has been set, the system will
react in the following manner:
If no partial position has been selected. On reset:

- Stop and send out an EOS
If a partial position has been selected. On reset:

- Move forward to the requested partial position
- Stop and send out an EOS
After Faults Possible Cause

192 Can't finish retract Can’t return to requested position – This is typically due to
an encoder feedback failure but could also be caused by a
mechanical failure in the tool or hang up on an external
structure.
193 Cycle Timeout (opt) Command left active for an excessive amount of time after
cycle completes.


Communications: Standard • 9
9.0 Henrob Standard Communications
The Cell or Robot communicates with the Servo Drive Controller via fieldbus link,
typically an Ethernet IP or DeviceNet depending upon customer specification at
order placement. The Drive Controller then acts upon the commands as
necessary. The drive communicates with the Rivmon/HMI to display these signals.
The communications between the Cell/Robot and the Henrob controller are shown
in the table below.
To Robot From Robot

Ready to Cycle 0 Cycle Setter
In Cycle 1 Retract Setter
Cycle Complete 2 Force Complete
No Fault 3 Fault Ack
Rivet Set 4 Clear Rivet Set
Home Position 5 Dry Cycle
Partial Position 6 Close Setter
Locked For Movement 7 Open Setter
Tool Disabled 8 Cut Tape
Rivets Low 9 No Home Allowed
Auto Mode 10 -
- 11 -
- 12 -
- 13 -
- 14 -
Heartbeat Out 15 Heartbeat In
Fault Code Joint ID
0 – No Fault Used to set Speed (mm/s)
1…63 – Before Fault 16-23 Partial (x5mm)
64..191 – During Fault Compliant (A/B or Prop.)
192..255 After Fault and Rivet (Mag/Blow feed)
Aux Status Aux Command
24-28
0..31 0..31
Tool 0..7
PM 0..7 29-31
(0- Disables tool)

9 • Communications: Standard
9.1 Signals from Cell/Robot to Henrob Controller
9.1.1 Cycle Setter (Input Bit 0)

This signal from the cell/robot, when held active, instructs the Henrob system to
perform a complete riveting cycle using the currently selected tool. The setting
speed and final opening are selected using the values specified in the table
corresponding to the Joint ID selected as discussed previously.
Before this signal is asserted the Henrob system must be giving the robot the
‘Ready to Cycle’ signal as discussed later in this chapter. While the system is
riveting the robot will be given the ‘In Cycle’ status signal, and finally either a
‘Cycle Complete’ or the ‘No Fault’ signal will drop out (indicating a fault state) and
a fault will be generated. If the ‘Cycle Setter’ signal is dropped prior to the cycle
completing the system will bring the tool to a stop at the next appropriate moment,
in a similar way to when the system is EStopped within the riveting cycle.
Typical Good Cycle

Cycle Setter
Ready to Cycle
In Cycle
Cycle Complete
Rivet Set
Time

Typical Bad Cycle

Cycle Setter
Ready to Cycle
In Cycle
Cycle Complete
No Fault
Time
After receiving the ‘Cycle Complete’ or a fault code is generated the ‘Cycle
Setter’ command should be dropped, and if no fault occurred the ‘Ready to Cycle’
signal should return.
If a fault occurred then it needs to be investigated to determine the appropriate

recover action and then cleared either from the robot by setting the Fault Ack bit
high or manually, before a new cycle can be initiated.

9.1.2 Retract Setter (Input Bit 1)

This command instructs the Henrob system to fully open the setter if the Joint ID is
0. If a Joint ID other than 0 has been chosen the setter will retract to the chosen
Joint ID location.
Typical Good Cycle

Cycle Setter
Ready to Cycle
In Cycle
Cycle Complete
Time
Typical Bad Cycle

Force Complete
Fault Ack
Ready to Cycle
In Cycle
No Fault
Time
This fault is generated if the final position is not within 2mm of the requested
opening.

9.1.3 Force Complete (Input Bit 2)

If the system gets out of sync, with the cell/robot waiting for the finished signal after
the finished signal had been asserted and then dropped, and then this signal can
be reasserted until the finished signal is present once more. This will cause the tool
to retract to its home position.
Typical Good Cycle

Force Complete
Ready to Cycle
In Cycle
Cycle Complete
Time
Typical Bad Cycle

Force Complete
Fault Ack
Ready to Cycle
In Cycle
No Fault
Time
It should be noted that if some of the systems inserted rivets then

the Rivets Set signal may be active preventing further riveting on
NOTE
that part.

9.1.4 Fault Ack – Acknowledge Fault Input Bit 3

This command resets any faults that may be present. If the movement command
has not been removed the system will attempt to complete the requested action
following a fault acknowledge. If the movement command has been removed the
system will wait for the movement command to be reapplied before completing the
action. It is recommended that the movement command is removed when ‘No
Fault’ goes low. This ensures unintended motion is prevented.
Movement Command Dropped on Fault (Recommended)

Cycle Setter/
Retract Setter
Fault Ack
No Fault
Time
Movement Command Maintained on Fault

Cycle Setter/
Retract Setter
Fault Ack
No Fault
Time

The ‘Fault Reset’ signal informs the Henrob system that the fault has be found
and resolved. The Henrob system is now able to move to a ready state.
Fault Reset
Ready to Start
Cycle Complete
No Fault
Time
9.1.5 Clear Rivet Set Input Bit 4

This signal instructs the Henrob system that the rivet setter has been moved since
the last rivet was inserted and can thus remove the ‘Rivet Set’ flag. The ‘Rivet Set’
flag prevents multiple rivets from being inserted by accident at a single location.
Clear Rivet Set
Rivet Set
Time

9.1.6 Dry Cycle Input Bit 5

This signal instructs the system to enter dry cycle mode. In this mode, the tool
moves to approx. 10mm from the part before returning to the requested final
position. It is used to enable the system to be cycle tested for an extended period
without needing parts and rivets to be present. This signal does not initiate any
motion it merely changes the type of motion performed by the ‘Cycle Setter’
signal.
The dry cycle function is selected from the robot and allows the riveter to step
around the part in full auto without setting rivets.
 The setter will not clamp on the material but will move to 10mm from the
material.
 The compliant settings, (if fitted), for full auto will still be used
 The requested speed of movement will be used for the dry cycle.
 Dry cycle should be selected before initiating the cycle otherwise the rivet
will be set.
It is recommended that the rivets are taken out of setter nose before
initiating a large number of dry cycles to prevent the spool from
becoming tangled.
NOTE
9.1.7 Close Setter Input Bit 6

This signal is used during teaching and instructs the rivet setter to slowly advance
toward the material. If there is no rivet present, the setter will stop when the nose
reaches the material. If there is a rivet present, the setter will stop with the nose
approximately 10mm from the material. If the signal is dropped the motion will stop.
9.1.8 Open Setter Input Bit 7

This signal instructs the Henrob system the rivet setter to slowly retract to fully
open. If the signal is dropped the motion will stop.

9.1.9 Cut Tape Input Bit 8

This command instructs the Henrob system to cut the used tape to prevent it from
becoming entangled in the tool or component being riveted. Before the tape cut
command can be performed the ‘Ready to Cycle’ status signal must be present,
which indicates that the system is able to cut the tape. The ‘Cut Tape’ signal may
be held on until the ‘Cycle Complete’ signal becomes active or it can also be
pulsed for 0.5s.
Handshake
Cut Tape
Ready to Cycle
In Cycle
Cycle Complete
Time
Pulse
Cut Tape 0.5s
Ready to Cycle
In Cycle
Cycle Complete
Time
With a robotic application a tape cut will typically be performed at discreet points in
a cycle rather than at every rivet.
In manual mode the tape is only cut when the operator holds the retract button on
the pendant for an extended period of time after the tool has reached the fully
retracted position, or via the HMI.

9.1.10 No Home Allowed Input Bit 9

This signal instructs the Henrob system that homing the tool at the current position
is not possible due to potential obstructions in the path of the sprocket drive/guide
bush assembly. In these cases if a home is absolutely necessary the tool will need
to be moved out into an unobstructed position before being homed and then
returned to the correct opening prior to being returned to the original position. This
signal is only used when there are obstructions, and will not be required in most
installations.
9.1.11 Pulse Heartbeat In (0.5s) Input Bit 15

This signal instructs the Henrob system that the comms are active. A high signal
cause ‘Heartbeat Out’ to go high and a low signal causes ‘Heartbeat Out’ to go
low.
9.1.12 Spot Parameter Selection & RivMon Input Bits 16..23
These signals combine to create a 8-bit

binary number (0-255) which selects
the spot parameters to be used for the
current location.
The spot ID controls the force with

which the rivet is set - This is achieved
by controlling the speed (and therefore
the stored energy) at which the actuator
is traveling at the time the rivet meets
the material – as well as the final retract
position.
Due to the distance needed to accelerate the tool up to 400mm/s maximum and
the minimum opening allowed is limited to 25mm.

9.2 Signals from Henrob Controller to Robot
9.2.1 Ready to Cycle Output Bit 0

This signal informs the robot that the Henrob servo controller is ready to start a
new action. This can include commands to set a rivet, move to another opening, or
cut the tape.
9.2.2 In Cycle Output Bit 1

This status signal informs the robot that an action is in progress.
9.2.3 Cycle Complete Output Bit 2

This status signal informs the robot that an action has completed successfully.
9.2.4 No Fault Output Bit 3

This status signal informs that there are no faults present. When low the fault code
can be seen on the fault # bits.
9.2.5 Rivet Set Output Bit 4

This status flag informs the robot that a rivet has been set at the current position
and that any further riveting command will be ignored until the flag has been
cleared with a ‘Clear Rivet Set’ signal. Attempting to recycle will generate a fault
code.
9.2.6 Home Position Output Bit 5

This status signal informs the robot that the tool is in the home position. (Fully
Open)
9.2.7 Partial Position Output Bit 6

This status signal informs the robot that the tool is at or above the currently
selected opening, as specified by the Spot ID, If the Spot ID is ‘0’ and ‘0’ is
configured as an invalid spot number the opening from the last valid Spot ID is
used.
9.2.8 Locked for Movement Output Bit 7

This status signal informs the robot that the compliant is locked down and the tool
will not move as the robot moves to the next position.
9.2.9 Tool Disabled Output Bit 8

This status signal informs the robot that the tool has been disconnected from
power, and may be used to initiate a tool change procedure.

9.2.10 Rivets Low Output Bit 9

This status signal informs the robot that the rivet spool or bulk feeder is nearly
empty.
9.2.11 Correct Rivet/Empty Output Bit 10

This status signal informs the robot that the correct rivet is in place as specified by
the Spot ID or the nose is empty and awaiting a feed and the setter can move to
the part.
9.2.12 Heartbeat out Output Bit 11

This status signal informs the robot that the comms are active.
9.2.13 Preventive Maintenance Signals Output Bits 29..31

When preventive maintenance is required on one of the components on the tool,
such as a die change the value of the three bit value on output bits 29 to 31 as
shown below.
If more component change is requested, the value will cycle around the values
requiring attention, with each value being output for 2s before moving to the next
value.
If no component requires attention then the output value on these bits will be zero.
# 31 30 29 Component
0 0 0 0 No PM needed
1 0 0 1 Rivets
2 0 1 0 Die
3 0 1 1 Punch
4 1 0 0 GB
5 1 0 1 Tool
6 1 1 0 Spare
7 1 1 1 Spare

Customer Specific Communications• 10
10.0 Customer Specific Communication – Option 1
The communication signals between the Cell/Robot and the Henrob controller
when using the optional communication format, are shown in the table below.
The numbers indicate the I/O bit within the Henrob controller and the Robot offset
value used within the Robot I/O mapping.
Note: Any entry in gray is not implemented/required by the Henrob system, and
is a legacy signal or for other applications.
Input from Cell/Robot Output to Cell/Robot

- 0 Ready To Operate
Reset Anti-Double Rivet 1 In Auto
Cut Tape 2 No Fault
- 3 Rivets Low
Dry Cycle 4 -
Force Rivet Complete 5 -
- 6 -
- 7 -
Linear Slide Bit 0 8 Fault Code Bit 0
ID0 - Spot Select Bit 0 16 -
Start Riveting 24 Ready To Start
Move to Requested Pos. 25 Home Position (Basic)
Close Spindle 26 Partial Position (Home)
Open Spindle 27 Cycle Complete
LS Away 28 LS Fixed
LS To Part 29 -
Fault Reset from Robot 30 -
- 31 PM Due Bin 1

10 • Customer Specific Communications
Optional Communication signals continued…
Input from Robot Output to Robot

- 32 [0] PM Due Bin 2
Request To Dock (Mag) 33 [1] PM Due Bin 4
Fill Magazine 34 [2] PM Due Bin 8
Dock Complete 35 [3] -
- 36 [4] -
- 37 [5] -
- 38 [6] -
- 39 [7] -
- 40 [8] -
- 41 [9] -
- 42 [10] -
- 43 [11] Comm OK
- 44 [12] Clear To Dock
Tool ID Bin 1 45 [13] Fill Complete
Tool ID Bin 2 46 [14] Magazine Low
Tool ID Bin 4 47 [15] Correct Rivet/No Rivet
Tool ID Bin 8 48 [16] Clear Rivet At Nose
Ready To Connect 49 [17] Tool Connected
Ready To Disconnect 50 [18] Tool Disconnected
- 51 [19] -
- 52 [20] -
- 53 [21] -
- 54 [22] -
- 55 [23] -
- 56 [24] -
- 57 [25] -
- 58 [26] -
- 59 [27] -
- 60 [28] -
- 61 [29] -
- 62 [30] -
- 63 [31] -

10.1 Signals from Robot to Henrob Controller
10.1.1 Reset Anti-Double Rivet – Clear ‘Rivet Set’ Flag Input 1

After each rivet has been set a flag, ‘Rivet Set’ indicating this fact is set. Before
another riveting cycle can be performed this flags needs to be cleared using the
‘Part Indexed’ signal. Which should be held high until the ‘Rivet Set’ flag is low
and then dropped low.
10.1.2 Cut Tape – Cut used tape Input 2

This command instructs the Henrob system to cut the used tape to prevent it
from becoming entangled in the tool or component being riveted.
Before the tape cut command can be performed the ‘Ready’ status signal must
be present, which indicates that the system is able to cut the tape. The ‘CutTape’
signal may be held on until the ‘Finished’ signal becomes active or it can also be
pulsed for 0.5s.
The tape cutter is cycled by a solenoid valve. In its

de-energized condition, the blade is held open
allowing tape to pass freely through the cutting
aperture. When a cut is required the valve is
cycled and the tape is cut.
With a robotic application a tape cut will typically

be performed at discreet points in a cycle rather
than at every rivet.
In manual mode the tape is only cut when the

operator holds the retract button on the pendant
for a period of time after the tool has reached the
fully retracted position.
10.1.3 Dry Cycle – Select Dry Cycle Mode Input 4

This signal instructs the system to enter dry cycle mode. In this mode, the tool
moves to approx. 10mm from the part before returning to the requested final
position. It is used to enable the system to be cycle tested for an extended period
without needing parts and rivets to be present.

10.1.4 Force Rivet Complete Input 5

This signal instructs the system to terminate the current operation, which has
stalled, and allow further operations to be accepted.
Typical Good Cycle

Force Complete
Ready to Cycle
Cycle Complete
Time
Typical Bad Cycle
Force Complete
Fault Ack
Ready to Cycle
No Fault
Time
10.1.5 ID0/1/2/3/4/5/6/7 – Spot Select Input 16 – 23
These signals combine to create a 8-

bit binary number (0-255) which
selects the spot parameters to be
used for the current location. The spot
ID controls the force with which the
rivet is set - This is achieved by
controlling the speed (and therefore
the stored energy) at which the
actuator is traveling at the time the
rivet meets the material – as well as
the final retract position.
Due to the distance needed to accelerate the tool up to 400mm/s the minimum
opening allowed is limited to 25mm.

10.1.6 Start Riveting Input 24

This signal from the robot, when held active, instructs the Henrob system to
perform a complete riveting cycle using the currently selected tool. The setting
speed and final opening are selected using the ‘Spot ID’ signals discussed
previously.
Before this signal is asserted the Henrob system must be giving the robot the
‘Ready To Start’ signal as discussed later in this chapter. A ‘Finished’ On or ‘No
Fault’ Off signal will be given depending on whether the riveting cycle was
performed correctly or a fault occurred.
If the ‘Cycle Setter’ signal is dropped the system will bring the tool to a stop at the
next appropriate moment, in a similar way to when the system is EStopped within
the riveting cycle. After receiving the Finished or Fault signal the Cycle Setter
command should be dropped, and if no fault occurred the Ready signal should
return. If a fault occurred then it needs to be cleared, either from the robot or
manually, before a new cycle can be initiated.
Typical Good Cycle

Start Riveting
Ready to Start
No Fault
Finished
Time
Typical Bad Cycle
Start Riveting
Fault Reset
Ready to Start
Cycle Complete
No Fault

10.1.7 Move To Requested Opening Input 25

The ‘Move To Requested Opening’ command instructs the setter to move to the
position specified as the final position for the selected location. If no rivet point is
specified (=0), then the system will retract to the fully open position, to allow tool
movement. No rivet is set during this movement.
Typical Good Cycle

Move To Requested Opening
Ready to Start
No Fault
Finished
Time
Typical Bad Cycle

Move To Requested Opening
Fault Reset
Ready to Start
Cycle Complete
No Fault
Time

10.1.8 Fault Reset – Acknowledge Fault Input 30

This command resets any faults that may be present. If the movement command
has not been removed the system will attempt to complete the requested action
following a fault acknowledge. If the movement command has been removed the
system will wait for the movement command to be reapplied before completing
the action.
Cycle Setter/
Retract Setter
Fault Ack
No Fault
Time
The ‘Fault Reset’ signal informs the Henrob system that the fault has be found
and resolved. The Henrob system is now able to move to a ready state.
Fault Reset
Ready to Start
Cycle Complete
No Fault
Time

10.2 Signals from Henrob Controller to Robot
10.2.1 Ready To Operate – Ready to start a new action Output 0

new action. This can be to set a rivet, move to another opening, or cut the tape.
10.2.2 System In Auto Output 1

This signal informs the robot that the Henrob servo controller communications is
working correctly, and is switched into Auto mode, which gives control of the rivet
setting to signals sent from the robot.
10.2.3 No Fault – No Fault currently active Output 2

This status signal informs the robot that there is currently no fault active, and
should be active for cycling to be initiated.
10.2.4 Rivets Low – Rivet Spool Running Low Output 3

This status signal informs the robot that the rivet spool is nearly empty. This
signal is generated via either a sensor on the tool, or via software. If this signal is
active, care should be taken before taking the tool in to start riveting a new part.
10.2.5 Fault Code (Bits 0-7) – Current fault Code Output 8-15
This status signal informs the robot that a fault is currently active (if non-zero).
10.2.6 Ready To Start – Ready to start a new action Output 24

new action. This can be to set a rivet, move to another opening, or cut the tape.
This also requires a rivet to be sensed at the nose of the tool, and may be used
to automatically switch to a backup tool.
10.2.7 Gun Home – Tool Fully Open Output 25

This status signal informs the robot that the tool is within 2 mm of the fully open
position. This signal should be checked before any robot movement requiring the
tool be fully open to prevent the tool from crashing into the part.
10.2.8 Gun Open – Tool at Required Opening Output 26

This status signal informs the robot that the tool is at or above the currently
selected opening. This signal will change if the opening command signals
change which prevents an old status from causing a tool crash.

10.2.9 Cycle Complete – Action Complete Output 27

This status signal informs the robot that an action has completed successfully.
10.2.10 LS Fixed – Linear Slide Fixed Output 28

This status signal is always active as there is no linear slide control within the
Henrob system. It is included for compatibility with other systems.


Record of Amendments• 11
11. Record of Amendments
The information in this manual will be subject to revisions in accordance with

alterations made to the equipment described. Users of this manual should check
that they are in possession of the latest issue relevant to the equipment
purchased.
Issue Amendment Date of revision Text affected
A R01957 10/12/2012 Initial release

HENROB© Corporation
35455 Veronica Drive, Livonia, Michigan 48150
Telephone: (734) 521-3000, (800-4-HENROB)
Facsimile: (734) 521-3001
www.henrob.com

2nd Generation Henrob Controller: Operation and Maintenance Manual For Henrob Self-Pierce Riveting System

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OPERATION AND MAINTENANCE

MANUAL FOR HENROB

2nd Generation Henrob Controller

Manual Part Number: 30-00105

Table of Contents ...............................................................................................iii

1.0 Safety Precautions .....................................................................................1

2.0 System Overview........................................................................................3

3.0 Henrob Servo Controller ..........................................................................20

©2012 Henrob Corporation Page iii

Page iv ©2012 Henrob Corporation

5.0 Reprogramming Henrob Controllers ......................................................41

6.0 Operator Interface (HMI & Front Panel Controls) ..................................45

©2012 Henrob Corporation Page v

7.0 RivMon Riveting Process Monitoring (if equipped)................................. 83

Page vi ©2012 Henrob Corporation

8.0 Error Message & Fault Recovery ..........................................................109

9.0 Henrob Standard Communications .........................................................119

©2012 Henrob Corporation Page vii

10.0 Customer Specific Communication – Option 1................................... 131

Page viii ©2012 Henrob Corporation

11. Record of Amendments ............................................................................141

©2012 Henrob Corporation Page ix

Page x ©2012 Henrob Corporation

1.0 Safety Precautions

It is the responsibility of the purchaser to ensure that Henrob equipment is used

1.1 General Safety Precautions

Do Not operate the equipment without suitable eye protection.

1.2 Safety Precautions For Electric Servo Henrob Equipment

©2012 Henrob Corporation Page 1

All personnel working on Henrob equipment shall read, familiarize themselves

WARNING: The Rivet Setter can generate very high forces.

All personnel working on Henrob Equipment shall read, familiarize themselves

CAUTION: Only qualified personnel should perform service on

Note: Please check for and report any damage to the

Page 2 ©2012 Henrob Corporation

2.0 System Overview

The major components contained in a complete system are as follows:

 Electrical Control Cabinet

©2012 Henrob Corporation Page 3

2.1 Riveting Process Overview

The rivet insertion operation

The tape travels through the feed

Tape Cutter The first rivet in the tape is

Page 4 ©2012 Henrob Corporation

2.1.1 Starting Condition

The process begins with the material to be

The robot brings the die up against the bottom

2.1.3 Start Of Insertion

The punch begins to drive the rivet into the top

2.1.4 End Of Insertion / High Clamp Load

The rivet is pressed fully home but during the

©2012 Henrob Corporation Page 5

2.1.5 Tool Retracted

At the completion of the insertion, the punch

After the tool has retracted the robot would

2.2 Tool Motion During Riveting Cycle

The fly-across-space profile uses slower accelerations and

The form of these motion profiles is discussed below.

Page 6 ©2012 Henrob Corporation

2.2.1 Tool Motion – Standard

©2012 Henrob Corporation Page 7

2.2.2 Tool Motion – Fly Across Space

Page 8 ©2012 Henrob Corporation