PF6K

VW XML Configuration
FW. 2.8.5.39
XML 2.1.R.3.6
Benjamin Harbich, 23.10.2018

Updated by Benjamin Harbich, 19.10.2018

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PF6K SYSTEM – BASIC CONFIGURATION

Virtuelle Stationen / Virtual Station

• To enable the MasterPC to

synchronize the controller’s
internal clock, it is required to
set the time source to
“Manual”. According to the VW
specification, the controller
must show the status of the
MasterPC connection.
• Therefore the startup screen
must be set to “Result screen”
to show the connection status
with the initial screen.
• Also configure the values for
‘Time zone’ and ‘Language’
according to the installation
location.
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PF6K SYSTEM – BASIC CONFIGURATION

Virtuelle Station / XML

• IP Address – from Master-PC

• To reduce the controllers CPU utilization, it
is strong recommended to disable
OpenProtocol in every virtual station.
There might be situations where it is
required to have OpenProtocol active as
well (e.g. if Ubisense TLS is used), but for
regular operation OpenProtocol is not
needed.
• As soon as the XML- protocol adapter is
active, the Task ‘Source Batch’ becomes
activated. If one manually tries to select a
different task, the protocol adapter
immediately reselects the task ‘Source
Batch’.
• In case that someone manually deletes
the source ‘Source Batch’ from the
controller, the systems becomes
unusable!
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PF6K SYSTEM – BASIC CONFIGURATION

Virtual Station / XML / Kurve 3 & 4
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PF6K SYSTEM – BASIC CONFIGURATION

Virtual Station / XML

• IP Address – from Master-PC

• To reduce the controllers CPU utilization, it
is strong recommended to disable
OpenProtocol in every virtual station.
There might be situations where it is
required to have OpenProtocol active as
well (e.g. if Ubisense TLS is used), but for
regular operation OpenProtocol is not
needed.
• As soon as the XML- protocol adapter is
active, the Task ‘Source Batch’ becomes
activated. If one manually tries to select a
different task, the protocol adapter
immediately reselects the task ‘Source
Batch’.
• In case that someone manually deletes
the source ‘Source Batch’ from the
controller, the systems becomes
unusable!
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PF6K SYSTEM – BASIC CONFIGURATION

Virtual Station / XML / Trace 3 & 4
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PF6K SYSTEM – BASIC CONFIGURATION

Virtual Station / XML

AFTER CHANGE
RESTART CONTROLLER!
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PF6K SYSTEM – BASIC CONFIGURATION

Einstellungen / Benutzervorgaben

• Quelle -> ‚Manuell‘ für XML

• Startbildschirm -> ‚Ergebnisbildschirm‘ für XML

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PF6K SYSTEM – BASIC CONFIGURATION

Settings / Preferences

• Source -> ‚Manual‘ for XML

• Startup screen -> ‚Result screen‘ for XML

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PF6K SYSTEM – BASIC CONFIGURATION

Einstellungen / Programme

• According to the KLH specification the whole control, if any

tightening or loosening is permitted must only be taken by
the MasterPC, it is not allowed to configure any “private”
disable directive – the value for “Disable loosening” and
“Disable tightening” must be “Off”.
• If, for some reason, the MasterPC does not take control
about when loosening is permitted, it is technically possible
to force a local loosening policy by setting “Disable
loosening” e.g. to the value “at OK tightening”.
If doing so, you must remember that this setting overrides any
selection made by the MasterPC, and therefore theoretically
might lead to inconsistent behavior.
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PF6K SYSTEM – BASIC CONFIGURATION

Settings / Tightening

• According to the KLH specification the whole control, if any

tightening or loosening is permitted must only be taken by
the MasterPC, it is not allowed to configure any “private”
disable directive – the value for “Disable loosening” and
“Disable tightening” must be “Off”.
• If, for some reason, the MasterPC does not take control
about when loosening is permitted, it is technically possible
to force a local loosening policy by setting “Disable
loosening” e.g. to the value “at OK tightening”.
If doing so, you must remember that this setting overrides any
selection made by the MasterPC, and therefore theoretically
might lead to inconsistent behavior.
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PF6K SYSTEM – BASIC CONFIGURATION

Konfiguration / Werkzeug
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PF6K SYSTEM – BASIC CONFIGURATION

Konfiguration / Werkzeug

• Fulfilling the KHL- specification requirement

about to display the tool enabled state, it is
required to configure the blue LED to ‘Ready
to start’. Having this setting, the blue LED
gets activated every time the tool is enabled
(this implies that a valid program is selected).
• To provide visual feedback to the operator
when the tool is in reverse, it is
recommended to have the setting for “Yellow
flashing” at “Direction switch CCW”.
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PF6K SYSTEM – BASIC CONFIGURATION

Configurations / Tool configuration

• Fulfilling the KHL- specification requirement

about to display the tool enabled state, it is
required to configure the blue LED to ‘Ready
to start’. Having this setting, the blue LED
gets activated every time the tool is enabled
(this implies that a valid program is selected).
• To provide visual feedback to the operator
when the tool is in reverse, it is
recommended to have the setting for “Yellow
flashing” at “Direction switch CCW”.
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PF6K SYSTEM – BASIC CONFIGURATION

Configurations / Tool configuration
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PF6K SYSTEM – BASIC CONFIGURATION

Konfiguration / Werkzeug / Bearbeiten / 1. Werkzeug-LED
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PF6K SYSTEM – BASIC CONFIGURATION

Configuration / Tool Configuration / Edit / 1. Tool-LED
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PF6K SYSTEM – BASIC CONFIGURATION

Konfiguration / Werkzeug / Bearbeiten / 3. Buzzer
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PF6K SYSTEM – BASIC CONFIGURATION

Configuration / Tool configuration / Edit / 3. Buzzer
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PF6K SYSTEM – BASIC CONFIGURATION

Konfiguration / Werkzeug / Bearbeiten / 3. Buzzer
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PF6K SYSTEM – BASIC CONFIGURATION

Configuration / Tool configuration / Edit / 3. Buzzer
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PF6K SYSTEM – BASIC CONFIGURATION

Konfiguration / Werkzeug / Bearbeiten / 3. Buzzer
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PF6K SYSTEM – BASIC CONFIGURATION

Configuration / Tool configuration / Edit / 3. Buzzer
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PF6K SYSTEM – BASIC CONFIGURATION

Konfiguration / Selektorbox

• Nur eine Selektorbox

kann verwendet werden.
• Über Hinzufügen und
Entfernen kann zwischen
4er und 8er Selektorbox
gewählt werden.
• Prüfung muss auf Extern
gestellt werden damit die
Steuerung über XML
erfolgen kann.
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PF6K SYSTEM – BASIC CONFIGURATION

Configurations / Socket selector

• One Socket selector can

be connected.
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PF6K SYSTEM – BASIC CONFIGURATION

Einstellungen / Protokoll-Adapter / ToolsTalk

• ToolsTalk …
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PF6K SYSTEM – BASIC CONFIGURATION

Settings / Server connections / ToolsTalk

• ToolsTalk …
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PF6K SYSTEM – BASIC CONFIGURATION

Einstellungen / Protokoll-Adapter / ToolsNet

• Es wird mindestens
ToolsNet 8.6 zur
Rapportierung benötigt.
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PF6K SYSTEM – BASIC CONFIGURATION

Settings / Server connections / ToolsNet

• ToolsNet 8.6 or higher.

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PF6K SYSTEM – BASIC CONFIGURATION

Controller / Results
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PF6K SYSTEM – TIGHTENING PROGRAMS

Tightening strategies
To fulfill the VW/Audi requirements to a
tightening program, it is mandatory to use the
tightening strategy “Multistep”.
The creation and configuration of multistep
tightening programs must be done with WEB
Interface. The individual program steps within a
tightening are referred to as tightening steps.
Each fastening stage consists of a fastening
strategy that defines at least the shut-off
condition. In addition, each stage can be
assigned to one or more control functions. The
following table shows the six fastening
strategies (AD, AW, ADW, AF, AZ, AX),
including their Parameters.
The matrix defines which stages can be
assigned to each strategy:
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PF6K SYSTEM – TIGHTENING PROGRAMS

Tightening / Steps
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PF6K SYSTEM – TIGHTENING PROGRAMS

Tightening / Steps
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PF6K SYSTEM – TIGHTENING PROGRAMS

Tightening / Monitors
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PF6K SYSTEM – TIGHTENING PROGRAMS

Tightening / Restrictions
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PF6K SYSTEM – TIGHTENING PROGRAMS

<AW> Step

• Default by XML Adapter

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PF6K SYSTEM – TIGHTENING PROGRAMS

<AW> Step
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PF6K SYSTEM – TIGHTENING PROGRAMS

<AW> Step
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PF6K SYSTEM – TIGHTENING PROGRAMS

<AW> Step
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PF6K SYSTEM – TIGHTENING PROGRAMS

<AW> Stufe

• Kleinster einstellbarer
Wert ist für <M+> „0,01
Nm“
• „0,00 Nm“ wird nicht
als Fehler angezeigt
aber verursacht ein
invalides Programm
und wird erst bei
Verwendung im
MasterPC angezeigt.
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PF6K SYSTEM – TIGHTENING PROGRAMS

<AW> Step

• Kleinster einstellbarer
Wert ist „0,01 Nm“
• „0,00 Nm“ wird nicht
als Fehler angezeigt
aber verursacht ein
invalides Programm
und wird erst bei
Verwendung im
MasterPC angezeigt.
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PF6K SYSTEM – TIGHTENING PROGRAMS

Loosening program

At least one program having strategy “Multistep” and operating mode

“Loosening” needs to be prepared. It is recommended to use a single
tightening step with strategy “Loosen to Angle” in here. Since the Torque
value at the end of a loosening step is no subject of interest, at monitor of
type “Peak Torque” should be used in here. For a complete reporting,
also a monitor of type “Angle” is required. It is not needed to set any limit
values in here, but it does not hurt either.
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PF6K SYSTEM – TIGHTENING PROGRAMS

Loosening program
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PF6K SYSTEM – TIGHTENING PROGRAMS

Loosening program

„Activate Loosening program in a Tightening program.“

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PF6K SYSTEM – TIGHTENING PROGRAMS

AD- strategy (tighten strategy
torque)
Definition: “The angle measurement
starts with exceeding the switching
parameter MS, as of any adjustable
threshold is programmable. The final
torque is determined by the switching
parameter MA and must be adjustable
independent of the torque tolerance
values M+ and M-. In addition to the
rotation angle control with upper (W+)
and lower tolerance angle (W-) there
is a turnoff angle WO to be provided
as a security angle. The angle
measurement is only activated as
long as the torque has exceeded the
MS threshold.”
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PF6K SYSTEM – TIGHTENING PROGRAMS

AD- strategy (tighten strategy
torque)
A tightening step of strategy “AD” is configured in TT2 by a “Tighten to Torque” step. The following settings
needs to become applied:

• Tightening step “Tighten to Torque” <step name> :

[AS, VS, ES] “Target Torque” : <MA> “Speed” : <n>

• Monitor “Angle” : Result value: <WI> “Trigger Torque”

: <MS> “Low Limit” : <W-> “High Limit” : <W+> When
configuring the Angle- monitor, it is mandatory important
to set the “Typ” value to “Shut Off Angle”!!
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PF6K SYSTEM – TIGHTENING PROGRAMS

AD- strategy (tighten strategy
torque)

• Monitor “Shut Off Torque” : Result value: <MI> “Low

Limit” : <M-> “High Limit” : <M+>

• Restriction “Maximum Time” : Result value: <tI> 0 : <t->

“Maximum Limit” : <t+>

• Restriction “Maximum Angle” (in most cases this is not

used) “Maximum Limit” : <WO>
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PF6K SYSTEM – TIGHTENING PROGRAMS

AW- strategy (tighten strategy angle)

Definition: “If the screw or

components yield point is
exceeded, depends upon the
predetermined angle WA,
which is started from the
predetermined threshold value
MS. The Angle measurement
is only activated while the
torque has exceeded the MS
threshold.”
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PF6K SYSTEM – TIGHTENING PROGRAMS

AW- strategy (tighten strategy angle)

A tightening step of strategy “AW” is configured in TT2 by a “Tighten to Angle” step. The following settings
needs to become applied:

• Tightening step “Tighten to Angle” <step name> :

[AS, VS, ES] “Target Angle” : <WA> “Speed” : <n>

• Monitor “Angle” : Result value: <WI> “Trigger Torque”

: <MS> “Low Limit” : <W-> “High Limit” : <W+> When
configuring the Angle- monitor, it is mandatory important
to set the “Typ” value to “Shut Off Angle”!
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PF6K SYSTEM – TIGHTENING PROGRAMS

AW- strategy (tighten strategy angle)

• Monitor “Shut Off Torque” : Result value: <MI> “Low

Limit” : <M-> “High Limit” : <M+>

• Restriction “Maximum Time” : <tI> 0 : <t-> “Maximum

Limit” : <t+>

• Restriction “Maximum Torque” “Maximum Limit” :

<MO>

• Restriction “Minimum Torque” (in most cases this is not

used) “Minimum Limit” : <MU>
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PF6K SYSTEM – TIGHTENING PROGRAMS

Example programs

• 4-step tightening
program, ending up with
an torque- step:

o AW => ‘AS’ or ‘FS’

o AD => ‘VS’
o AD => ‘VS’
o AD => ‘ES’

It is very important to adjust the monitors and restrictions for each step added manually. By
default TT2 is adding some monitors / restrictions that are not needed and some are missing.
Furthermore it is strongly recommended by R&D, always to define the step category.
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PF6K SYSTEM – TIGHTENING PROGRAMS

Example programs

• 4-step tightening
program, ending up with
an angle- step:

o AW => ‘AS’ or ‘FS’

o AD => ‘VS’
o AD => ‘VS’
o AW => ‘ES’

It is very important to adjust the monitors and restrictions for each step added manually. By default
TT2 is adding some monitors / restrictions that are not needed and some are missing. Furthermore
it is strongly recommended by R&D, always to define the step category.
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