Via dell’industria, 41

25039 Travagliato (BS)

Tel. 09+030/6863009
Fax. 09+030/6864114
e@mail tlgb@tlgb.it
http: www.tlgb.it

Technical File

. . . . . . . . . .

Potentiometer calibration and test bench

ORDER N°: 208042

CUSTOMER: LANDI RENZO

Technical File Sheet 1/21

TLGB S.r.l. via dell’industria, 41 25039 Travagliato (BS) Italy Tel.(0039) 030-6863009 Fax. (0039) 030-6864114 e@mail tlgb@tlgb.it

TABLE OF CONTENTS
1 MACHINE APPLICATIONS....................................................................3

2 TECHNICAL DATA AND SPECIFICATIONS FOR BENCH INSTALLATION 4

2.1 ENVIRONMENT ........................................................................................4
2.2 POWER SUPPLY........................................................................................4
2.2.1 Electrical equipment .....................................................................4
2.2.2 Compressed air .............................................................................4
2.3 TEMPERATURE AND HUMIDITY ................................................................4
2.4 HANDLING, TRANSPORT AND STORAGE ...................................................4
3 WORK STATIONS ....................................................................................5
3.1 GENERAL DESCRIPTION ...........................................................................5
3.2 OPERATOR INTERFACE ............................................................................6
3.3 TURNING ON BENCH ................................................................................8
4 BENCH COMPOSITION..........................................................................8
4.1 PNEUMATIC EQUIPMENT ..........................................................................9
4.2 ELECTRICAL EQUIPMENT .......................................................................13
4.3 MECHANICAL EQUIPMENT .....................................................................16
5 COMMISSIONING AND OPERATION ...............................................18

6 MAINTENANCE AND FREQUENCY OF CHECKS..........................19

6.1 MAINTENANCE OF PNEUMATIC EQUIPMENT ..........................................19
6.2 MAINTENANCE OF ELECTRICAL EQUIPMENT..........................................19
6.3 MAINTENANCE OF MECHANICAL EQUIPMENT ........................................19
6.4 TROUBLESHOOTING ..............................................................................19
7 SPECIFICATIONS FOR OPERATOR PROTECTION......................20
7.1 ELECTRICAL PROTECTIONS....................................................................20
7.1.1 Direct contact .............................................................................20
7.1.2 Indirect contact ...........................................................................20
7.1.3 Power supply leads .....................................................................20
7.2 EQUIPOTENTIAL CIRCUITS .....................................................................20
7.3 MECHANICAL PROTECTION SYSTEMS ....................................................20
8 CONTROL AND MANAGEMENT FUNCTIONS ...............................21
8.1 STARTING ..........................................................................................21
8.2 EMERGENCY STOP...........................................................................21
8.3 TWO-HANDED CONTROL ...............................................................21
8.4 IN THE EVENT OF BREAKDOWNS.................................................21
9 ANNEXES .................................................................................................21

Technical File Sheet

2/21
1 Machine applications
The bench has the purpose of testing potentiometers.

The bench is suitable for testing potentiometers of the new and old types by means of a
wrenching or horizontal sliding process.

The bench has two asynchronous stations that are fully independent.

The tests conduced on each single part are:

• Stabilising stage repeated "x" times (repetitions can be set up).

• Calibration stage with adjustment (wrenching/loosening or horizontal cover shifting,
depending on model).
• Pressure/resistance curve checking in 10 increase points (can be set up).
• Pressure/resistance curve checking in 10 decrease points (can be set up).
• Pressure and resistance curve acquiring in real time with memorisation of curves.
• Marking, if part passes test.
• Manual screw wrenching for old models.
• Printouts, if enabled.
• Registration.

Technical File Page 3/21

2 Technical data and specifications for bench installation
The bench must be installed by qualified personnel only.
The bench must be commissioned by technicians of TLGB only.
2.1 Environment
The bench has been designed for work in the following conditions:
1. In indoor environments.
2. In clean environments.
3. In environments where no abrupt temperature changes occur. (E.g. in draughty places,
near doors or sources of heat).
4. In environments that do not feature machines causing major electrical disturbance (e.g.
welders, induction furnaces).
5. The presence of machines generating vibration is troublesome.
2.2 Power supply

2.2.1 Electrical equipment

Power supply voltage: 220V single-phase ±10%
Maximum power draw: ~3000VA
Short-circuiting KPAC: 10KA asymmetric

The electrical network must be of the TT type and the power supply cable must have a
2
minimum size of 4 mm

2.2.2 Compressed air

Air must be dehumidified.
Supply pressure: 7 Bar +1/-0.5 Bar for movements; 250 Bar for tests.
Max. consumption: 1000 l/min

2.3 Temperature and humidity

Temperature must range from 5 to 40°C.
Ambient humidity must range from 30% to 95% without condensation.

2.4 Handling, transport and storage

The bench must be transported with care.
The bench rests on an aluminium structure.
If the bench is shifted, feet must be adjusted and flatness checked with a spirit level.
3 Work stations

3.1 General description

The bench is illustrated in figure 1 and is composed of:
• Pneumatic equipment for movements.
• Pneumatic equipment for tests.
• Electrical equipment.
• Structure made up of aluminium profiles.
• Fixtures for holding parts.
• Personal Computer for test management.
• Marker.

Figure 1 - View of Bench

Technical File Page 5/21

3.2 Operator interface
The bench management system consists of a PC, which is located under the bench on the right
hand side.
A monitor, on the bench, displays all machine functions.

Refer to the PC manual for more information.

The only controls outside the PC are on the bench button strips, and include:
1. Start button.
2. Emergency stop buttons.
3. Two-handed controls for starting cycles.
4. Controls for releasing rejects.
5. PC off selector.
6. Cycle stop buttons.
7. Automatic mode button.
8. Manual/Automatic mode selector.
9. Selector for return test.
10. Selector for turning potentiometer adjustment function on/off.
11. Neon lamp on/off selector.

Cycle stop Part releasing

button button

Emergency Cycle start

control button

Figure 2 – Button strip on left hand side of left hand station

 Return test Machine neon
Adjustment sytem
selector lamp on/off
on selector
selector

Cycle start
button

Figure 3 – Button strip on right hand side of left hand station

Adjustment sytem Return test Cycle stop Part releasing

on selector selector button button

Cycle start
button

Figure 4 – Button strip on left hand side of right hand station.

Technical File Page 7/21

 Automatic
mode activation
Start button button PC off
button

Cycle start Manual -

button Automatic Emergency
mode stop control
selector

Figure 5 – Button strip on right hand side of right hand station.

3.3 Turning on bench

The bench must be connected to a 220 Volt single-phase power supply line.
The compressed air inlet must be connected to the 7 Bar circuit and to the high pressure line.
The bench is turned on with the switch on the rear side of the bench. Make sure that the
emergency stop buttons are disengaged then press the Start button.
If all conditions are correct, the bench is ready to perform the tests. The cycle is started by
pressing the cycle start buttons.

4 Bench composition
The bench is composed of the following parts:
- Pneumatic equipment
- Electrical equipment
- Jig for performing tests
4.1 Pneumatic equipment

The pneumatic circuit is of essential importance for correct operation of the bench.

Cylinder valves Cylinder valves

Cylinder pressure
in left hand in right hand
adjustment in
station station
right hand station

Cylinder pressure 7 bar air supply

adjustment in left for air treatment Air pressure
hand station unit switch

Figure 6 – Pneumatic circuit.

Technical File Page 9/21

Air inlet/exhaust
valves, 250 bar Test pressure Test pressure
regulator, 220 bar regulator, 80 bar

Air filters Inlet 250 bar

250 bar

Figure 7 – Pressure inlet.

 Slow
exhausting Calibration test Rapid exhausting
∅ 0.17 unit, 220 bar

Inlet 220 bar Inlet 80 bar

Figure 8 – Valves.

Technical File Page 11/21

 Figure 9 – Pneumatic circuit.

High Pressure
Low Pressure
CONDITIONING AND
AIR INLET AIR INLET FILTERS

CONDITIONING AND
FILTERS MAIN
VALVE

CHECKS:
PRESSURE PRESSURE
SWITCHES, REGULATORS FOR
MAIN VALVE CALIBRATION
CHECKING

CIRCUIT FOR
MOVEMENTS
FUNCTION TEST
CIRCUITS

STATION TESTED
ACTUATOR PARTS

Figure 10 - Block diagram of pneumatic circuit.

4.2 Electrical equipment

For information about the electrical equipment, see attached diagrams.

The electrical equipment is installed under the bench.

It consists of:

• Personal Computer.
• Electromechanical safety equipment.
• Two-handed control device.
• Analogue acquisition cards.
• Input/Output control cards.

220 V power switch

Brushless motor Power supply Two-handed Fuses Brushless motor

drives - linear, on unit safety drives - linear, on left
right hand station 24 volts control units hand station

Figure 11 - Switchboard on rear side

Technical File Page 13/21

 PLC digital Analogue Analogue
controls power supply interface card-
unit PC

Figure 12 - Switchboard on front side

Eyelet
+
+
_
Fastom

MAP

Renault

Figure 13 – Electrical connections of potentiometers

 ELECTRICAL GENERAL PROTECTION
POWER SUPPLY DEVICES

PC FOR MACHINE
MANAGEMENT AND
CONTROL

I/O CARDS

POWER SUPPLY OF OUTPUTS FOR MANUAL TEST RESULT

TRANSDUCERS, MOVEMENT COMMANDS DISPLAY
AMPLIFIER, CONTROL FROM PC MONITOR
A/D CONVERTER

Figure 14 – Block diagram of electrical circuit.

Technical File Page 15/21

4.3 Mechanical equipment

Motor assembly Motor for linear Clamping Delivery

for calibration calibration cylinder pipe
with wrenching

Wrenching Marking unit

motor
advancing

Figure 15 – Mechanical fixture.

.
 Part detecting
sensor Test delivery pipe.
To be replaced on the
basis of the type of part
tested.

Figure 16 – Mechanical detail.

Closed door limit

switch

Figure 17 – Safety devices.

Technical File Page 17/21

5 Commissioning and operation
The bench is tested by TLGB.

The following instructions must be followed:

1. Correctly level the bench.

2. Connect the compressed air supply (7 bar – 250 bar).

3. Check the emergency stop buttons.

4. Hook up the electrical power supply.

5. Turn on the switchboard.

6. Turn on the PC.

7. Press the start button.

8. Select the type of part to test.

9. Start the test cycle with the yellow buttons on the bench.

10. At the end of the test, press the black 'releasing' button (if part is reject).

11. Potentiometer screw wrenching (if selected).

12. Press yellow buttons again after screw wrenching.

6 Maintenance and frequency of checks
The bench must be serviced regularly in order to keep it in perfect working order.
6.1 Maintenance of pneumatic equipment
OPERATION POINT FREQUENCY PRECAUTIONS
Check filters. Weekly maintenance. Exhaust air.
Unit of Press emergency
Check gaskets. Daily.
measurement. stop button.
Check efficiency of Performed automatically by
Under bench.
transducers. program.
Check samples of good
Daily.
parts and rejects.

6.2 Maintenance of electrical equipment

There is no preventive maintenance to perform on electrical equipment. Repair work must be
performed when faults occur.

OPERATION POINT FREQUENCY PRECAUTIONS

Check calibration of
In switchboard Every six months, by TLGB Use samples.
transducers.

6.3 Maintenance of mechanical equipment

OPERATION POINT FREQUENCY PRECAUTIONS
Check if guard opening
cylinders are firmly On cylinders Weekly maintenance Exhaust air
secured in place.
Check if unit is secured On mechanical
Weekly maintenance Exhaust air
in place. equipment

6.4 Troubleshooting
FAULT POSSIBLE CAUSE POSSIBLE FAULT SOLUTIONS
The bench 1. Turn power switch.
Power switch or fuse is out
does not 2. Check for short-circuits or
of order.
come on overloading.
An emergency button is 1. Disengage emergency
The bench
pressed, the Start fuse has button.
does not
blown, there is no air, PC 2. Find possible cause and
START
is off. replace fuse.
1. Check offset of
transducer.
1. Transducer is out 2. Check minimum and
Wrong power supply to
Transducer of order. maximum threshold
transducer or wrong
offset error. 2. A/D card is out of settings.
threshold settings.
order. 3. Check if transducer emits
an electrical signal when
flow changes.

Technical File Page 19/21

7 Specifications for operator protection

7.1 Electrical protections

PROTECTION AGAINST ELECTROCUTION

7.1.1 Direct contact

The electrical equipment is protected by:

1. Cabinet.
2. The cabinet under the bench can only be opened by turning off the power switch.
3. The power switch has a door locking function. Trained personnel can override the
interlocking function by means of a tool.
4. There are no components maintaining a residual power of over 60 Volts.

The cabinet must only be opened by trained and qualified persons. The cabinet may need
to be opened for servicing the electrical or pneumatic equipment. These operations are
described further on.

Active components inside the cabinet - when live - feature an IP2X protection rating.

7.1.2 Indirect contact

1. Automatic interruption of power, in the event of insulation faults, is granted by fuses acting
on the general power supply line and by means of circuit breakers fitted to the single units.
2. Protection by means of PELV. Insulation transformers are employed, with an end of the
secondary winding connected to earth (with the exception of transformers used for
electronic components).
7.1.3 Power supply leads
TLGB is not responsible for supplying a device protecting against overcurrent for power supply
leads.

7.2 Equipotential circuits

A terminal marked "PE" can be found at the front of the cabinet. All earthing terminals
(yellow/green) to which all earthing wires are led are connected to this terminal.

7.3 Mechanical protection systems

The bench is protected by means of fixed guards made of polycarbonate.
The start control is a two-handed control, which is CE certified, and which controls closing of the
guard.
At the front, there is an access so that operators may adjust the pressure regulators on
condition that they are enabled to do so and that they have disengaged the mechanical
protection devices.
However, when locking and releasing commands are given, the guard must be lowered.
8 CONTROL AND MANAGEMENT FUNCTIONS

8.1 STARTING
1. The bench can only be turned on with its cabinet closed.
2. To start the bench with the START button, the emergency stop buttons must be disengaged, the
PC must be on and the TLGB program must be running.
8.2 EMERGENCY STOP
There are no controls and actuators outside the bench.
Emergency stopping is possible only by using electromechanical components (see wiring diagram)
with the following effects:
1. De-energisation of start counter.
2. De-energisation of the main solenoid valve with subsequent exhausting of all air in the circuit.
8.3 TWO-HANDED CONTROL
A CE certified Telemecanique device has been adopted.

8.4 IN THE EVENT OF BREAKDOWNS

The measures that TLGB has adopted to reduce the risks in the event of breakdowns are the
following:
1. Provision of fixed polycarbonate side guards with a thickness of 5 mm.
2. Provision of front movable polycarbonate guards with a thickness of 8 mm.

9 Annexes
The Technical File is provided with the following annexes:
1. Wiring diagrams
2. PC Program User Manual
3. “CE” Declaration of Conformity
4. List of components

Technical File Page 21/21