Kistler 2820A10 Owner's manual

Instruction

Manual

STASA QC,

Operating Point

Navigator

Type 2820A...

2820A_002-569e-04.15

Instruction

Manual

STASA QC,

Operating Point

Navigator

Type 2820A...

2820A_002-569e-04.15

Preface

Thank you for choosing a Kistler quality product charac-

terized by technical innovation, precision and long life.

Information in this document is subject to change without

notice. Kistler reserves the right to change or improve its

products and make changes in the content without obli-

getion to notify any person or organization of such

changes or improvements.

as expressly provided herein, no part of this manual may

be reproduced for any purpose without the express prior

written consent of Kistler Group.

Kistler Group

Eulachstrasse 22

8408 Winterthur

Switzerland

Tel. +41 52 224 11 11

Fax +41 52 224 14 14

info@kistler.com

www.kistler.com

2820A_002-569e-04.15 Page 1

Contents

1. Introduction .................................................................................................................................. 3

1.1 STASA QC .......................................................................................................................... 3

1.2 Operating Point Optimization .............................................................................................. 3

2. Installing Program ....................................................................................................................... 5

3. Creating, Saving and Loading Projects .................................................................................... 7

3.1 Creating Project .................................................................................................................. 7

3.2 Saving Project Status .......................................................................................................... 8

3.3 Loading Existing Project ...................................................................................................... 8

4. Defining Project, Machine Parameters and Sensors ............................................................... 9

4.1 "General information" View ................................................................................................. 9

4.2 "Machine parameters" View .............................................................................................. 10

5. Defining Quality Features ......................................................................................................... 12

6. Database ..................................................................................................................................... 15

6.1 Setup Stage....................................................................................................................... 15

6.2 "Design of Experiments (DoE)" View ................................................................................ 16

6.3 "Quality data" View ............................................................................................................ 17

6.4 "Machine settings optimization" View ............................................................................... 20

6.5 Determining Optimal Operating Point ............................................................................... 20

6.6 "Estimated effects of machine parameters" View ............................................................. 23

6.7 "Model values and measured values" View ...................................................................... 25

6.8 "Model statistics" View ...................................................................................................... 25

6.9 "Estimated process capability" View ................................................................................. 27

6.10 "Cycle time costs" view ..................................................................................................... 29

7. Practical example: Creating Project and Defining Machine Parameters and Quality

Features ...................................................................................................................................... 30

8. Practical example: Entering Data of Setup Stage .................................................................. 34

9. Practical example: Optimizing Operating Point ..................................................................... 39

10. List of Figures and Tables ........................................................................................................ 44

Total number of pages 44

Page 2 2820A_002-569e-04.15

Introduction

1. Introduction

Please take the time to thoroughly read this instruction

manual. It will help you with the installation, maintenance,

and use of this product.

To the extent permitted by law Kistler does not accept

any liability if this instruction manual is not followed or

products other than those listed under Accessories are

used.

Kistler offers a wide range of products for use in mea-

suring technology:

 Piezoelectric sensors for measuring force, torque,

strain, pressure, acceleration, shock, vibration and

acoustic emission

 Strain gage sensor systems for measuring force and

torque

 Piezoresistive pressure sensors and transmitters

 Signal conditioners, indicators and calibrators

 Electronic control and monitoring systems as well as

software for specific measurement applications

 Data transmission modules (telemetry)

Kistler also develops and produces measuring solutions

for the engines, vehicles, manufacturing, plastics and

biomechanics sectors.

Our product and application brochures will provide you

with an overview of our product range. Detailed data

sheets are available for almost all products.

If you need additional help beyond what can be found

either online or in this manual, please contact Kistler's

extensive support organization.

1.1 STASA QC

STASA QC is a software package used for operating

point optimization and online quality forecasting with

integral process monitoring. The program does not

require the user to have any expert knowledge of the

mathematical background of the techniques used.

1.2 Operating Point Optimization

This involves determining the machine settings that allow

the target values of the quality features to be achieved as

effectively as possible, while keeping the process as

stable as possible. STASA QC's approach is based on

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STASA QC, Operating Point Navigator Type 2820A...

modeling. This means that, with the aid of data (machine

settings and measured quality features) determined in the

process setup stage with statistical design of experiments

(DoE), the relationship between these settings and

features is "learned", and a simulation model auto-

matically produced for each feature. These models can

then be used to enable the user to test the effect of

changes in the machine setting on the quality features,

without having to test this directly in an experiment on the

machine. STASA QC is also able to use an integral

optimization algorithm to determine the optimal operating

point at which the target values of the quality features

can be best achieved.

The following data is needed for operating point optimi-

zation:

 Machine settings and their values in the statistical

DoE

 Values of the quality features with which the parts

were produced on the basis of the DoE in the setup

stage

Operating point optimization can be performed complete-

ly offline to avoid any need to match interfaces specific to

the machine.

This manual is divided into two parts. The first (Sections

2 to 6) is a general description of the program functions

of STASA QC. The second (Sections 7 to 9) goes

through the optimization process step by step for a

particular example.

Page 4 2820A_002-569e-04.15

Installing Program

2. Installing Program

STASA QC is installed by running setup.exe, which is on

the CD-ROM. The installation process is menu driven.

The program is protected by a dongle against

unauthorized duplication. The included dongle must be

connected to the USB interface of the computer on which

STASA QC is run. The MATRIX dongle software needed

to use the dongle is also installed during the installation

of STASA QC.

The software must be installed with Administrator rights,

otherwise the driver for the dongle is not loaded when

Windows starts.

Note on USB dongle

If the USB dongle is inserted into a free USB slot for

the first time, the Plug&Play manager starts from

Windows and installs the associated driver. If the

driver is not found automatically, it must be installed

manually:

Windows XP, Vista and 7: the dongle driver is

installed via the program "MatrixLockDriver

Setup.exe" in the sub-directory "USB-Dongle

Treiber" on the CD-ROM.

Windows 2003 and Windows 8: The dongle driver is

installed via the Windows Plug&Play manager. The

associated drivers are located in the sub-directory

"USB-Dongle Treiber\Windows 2003 und 8" on the

CD-ROM.

The dongle is only detected in the USB port in which

it was installed.

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STASA QC, Operating Point Navigator Type 2820A...

Note on licensing

To activate the dongle, the license number must be

entered in STASA QC. This is done either when the

program starts, by choosing "Enter License Key" in the

starting dialog box, or by choosing Edit > License Key

from the menu.

Note on language settings

To change language you have to select one of the

available languages in the corresponding list box or go

to menu bar and select Edit > settings..

Note on user managementt

The user management can be activated in the menu

Edit -> User management. If user management is

activate each user has to authenticate by entering user

name and password when starting STASA QC. This

ensures that only authorized persons can use STASA

QC and make changes to project data.

Users and passwords can be added, modified and

deleted in the same menu.

By default the administrator user has the name “admin”

and password “admin”.

Page 6 2820A_002-569e-04.15

Creating, Saving and Loading Projects

3. Creating, Saving and Loading Projects

Master data, optimization results and quality forecasts

are managed in STASA QC in the form of projects. This

means that, for each produced product for which the

machine parameters are to be optimized and, in a further

step, an online quality forecast made, a project is

created. A clear overview of the management of

optimization and forecasting results is therefore

maintained, even if STASA QC is being used for several

optimization tasks.

3.1 Creating Project

There are two ways of creating a new project:

 Immediately after STASA QC starts, a dialog box is

displayed asking whether a new project is to be

created, an existing one opened or the program

closed. Choosing Create New Project opens another

dialog box, which prompts you to enter a name for the

project.

 A new project can also be created by choosing

Project file > New from the menu. In this case as

well, a dialog box prompts you to enter the name of

the new project.

You use the project name to specify the folder in which

the project files (STASA QC files, optimization results,

measurement curves, online forecasting results, etc.) are

saved. These project files are then in a subfolder of

STASA QC named after the project name (generally

C:\Program Files\STASA\STASA-QC\Projects\). A unique

project name must therefore be chosen. It is not possible

to create another project with the same name.

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3.2 Saving Project Status

The project can be saved by choosing Project file >

Save or Project file > Save as from the menu. This

saves the current status of the project.

The project is usually saved under the same name as

when it was created. Project file > Save as can be used

to specify an alternative name for the project file. This is

useful if, for example, different strategies are to be tested

in the DoE, or several intermediate stages are to be

saved.

3.3 Loading Existing Project

An existing project file can be loaded with the dialog box

immediately after the program is started, or by choosing

Project file > Load from the menu.

Page 8 2820A_002-569e-04.15

Defining Project, Machine Parameters and Sensors

4. Defining Project, Machine Parameters and Sensors

Choosing the Project view offers the option of three sub-

views General information, Machine parameters and

Sensors), which are used to enter information about the

project.

Fig. 1: Definition of project

4.1 "General information" View

In this view, the master data for the project, such as

project number, user, customer and various items of

product data are entered. Comments on the project or the

product (part) can also be saved in the project file and a

link to a photo (JPG, GIF or BMP) provided.

A thumbnail of the photo is shown in the logo banner at

the top and can be displayed in a separate window at any

time by double-clicking.

The following information must be entered:

Project name, Project number, Article name, Mold ID,

and Number of cavities.

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STASA QC, Operating Point Navigator Type 2820A...

4.2 "Machine parameters" View

All of the available machine parameters and process

parameters are listed in this view. The following functions

are available. They can be activated with the button of

the same name or by choosing Definitions > Machine

parameters from the menu:

Fig. 2: Adding or editing a machine parameter

Add parameter

This opens a dialog box for defining a new machine

parameter (Fig. 2).

Edit parameter

This is used to change the data, e.g. the Smallest value

of a machine parameter that has already been defined.

The machine parameter currently chosen from the list by

clicking with your mouse is altered.

Delete parameter

This is used to delete the machine parameter currently

chosen from the list by clicking with your mouse.

Import

This is used to read a complete list of machine

parameters from a CSV text file. The CSV file must be

structured according to a fixed convention (see

"Exporting" section and Table 1). To then enable re-

importation into STASA QC of a file edited in Microsoft

Excel, this file must be saved in Excel as a CSV file. In

Excel this is achieved by choosing File > Save as from

the menu and selecting the file type CSV (delimiter-

separated) (*.csv).

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Defining Project, Machine Parameters and Sensors

When reading CSV files, STASA QC can distinguish

whether "." or "," is used in the text file as decimal

separator. Mixed use of the decimal separators is

also possible. To ensure correct reading of files

edited beforehand with Excel, the formatting of the

Excel cells must not, however, contain any thousands

separators.

Export

This exports the defined machine parameters to a text

file. The machine parameters defined by means of Add

parameter are saved in a CSV file. The user is prompted

to enter a filename (extension: .csv). Unless specified

otherwise, this file is saved in the project folder. This is

generally under "My Documents \STASAQC\Project

name", or, in Windows® Vista or Windows® 7 under

"Documents\STASA QC\".

To edit an exported parameters file in Microsoft Excel, for

example in order to define the machine parameters

outside STASA QC (See Section 6 Database), this file

can be opened in Excel by double-clicking, or opened in

the dialog box by choosing Text files (*.prn *.txt *.csv).

To define a DoE outside STASA QC in Excel with this

file, the associated value from the DoE can be entered in

the columns of the corresponding parameter. This

involves the different DoE settings being entered line by

line with the associated sequential number. The "Number

of parts" column contains the number of parts to be

produced in the associated experiment. A * must be

entered in the first column. The following table shows an

example as a guide:

Table 1: Import/Export data format for machine

parameters

M2.0

DEC,

Name

T-Mass

T-Wkz-DS

T-Wkz-AS

t-On

*

Abbreviation

T-Mass

T-Wkz-DS

T-Wkz-AS

t-On

*

Unit

°C

s

*

Max

315

90

100

1,2

*

Min

295

50

60

0,4

*

Increment

5

0,05

*

Setup

Number of parts

Value

*

1

10

305

70

80

0,9

*

2

10

295

60

70

0,4

*

3

10

295

70

80

0,65

*

4

10

300

55

65

1,4

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5. Defining Quality Features

Choosing the Quality features view enables you to enter

these features of the part and their tolerances and target

values (Figure 3).

Fig. 3: View of quality features

The following functions are available, and can be

activated using the button of the same name or the

Quality features menu.

Add quality feature

This opens a dialog box for defining a quality feature. The

definition can distinguish between continuously

measurable features and attributive features (subjectively

evaluated features, which can be divided into classes

(e.g. grades)) by choosing the type (Figure 4).

In defining a quality feature, the cavity for which the

feature is defined must be specified. For a quality feature

that is not to be defined specifically for a cavity, e.g. the

cycle time, "0" is entered instead of the number of the

cavity.

Checking "Copy definitions for all cavities" generates the

quality feature for all cavities with the same data for Unit,

Target value and Tolerances, and the corresponding

Page 12 2820A_002-569e-04.15

Defining Quality Features

attributes for attributive quality features. The saves

manual definition of the quality features for each cavity of

multicavity molds.

It is advisable to choose unique names for the quality

features of each cavity.

If "Copy definitions for all cavities" is checked, the

chosen name is automatically given the extension

"Cav. 1", "Cav. 2", etc.

Fig. 4: Dialog box for defining a quality feature

Attributive feature:

The attributes of the feature can be entered in a text box

separated by a semicolon (without space). The last

attribute must not be followed by a semicolon, otherwise

STASA QC would expect another attribute! (For example:

very good; good; satisfactory; fair).

The following must be observed when entering the

tolerances and the target value:

Last attribute on the list which is still allowable (upper

tolerance attribute): the attribute that is positioned on the

extreme right of the list and is still allowable.

Attribute which should be reached (target attribute): the

attribute that is to function as target value (generally the

same as the best attribute).

First attribute on the list which is allowable (Lower toler-

ance attribute: the attribute that is positioned on the

extreme left of the list and is still allowable.

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Continuous feature:

The physical unit in which the quality feature is measured

must be entered here in addition to the target value and

the tolerance values.

The check box "use feature for online quality forecasting"

can be ticked to specify whether online forecasting is to

be performed for the feature and included in the quality

evaluation. Alternatively, in the list the feature can be

activated (green tick) or deactivated (red cross) by

double-clicking the colored symbol on the left of the

feature.

Edit quality feature

This is used to change the data, for example the target

value of a feature that has already been defined. The

quality feature currently selected in the list by clicking

with your mouse is altered (Fig. 3).

Remove feature

Used to remove the feature currently selected in the list

by clicking with your mouse.

Import

Used to read a complete list of quality features from a

CSV text file. The CSV file must be structured according

to a fixed convention.

Export

This is used to export the defined quality features to a

CSV text file. The features defined with Add quality

feature are saved in a CSV file.

The user is prompted to enter a filename (extension:

.csv).

Unless specified otherwise, this file is saved in the sub-

folder of quality data of the program folder of STASA QC.

This is generally:

C:\Program Files\STASA\stasaQC\Quality data\.

Q2.1

DEC,

name

length

diameter

*

unit

mm

*

Cavity

1

*

type

continuous

*

attributes

NULL

*

UpperTol

58,6

12,08

*

TargetValue

58,55

12,06

*

LowerTol

58,5

12,04

signalfile

experiment-no

use?

value

Table 2: Import/Export data format for defining quali-

ty features

Page 14 2820A_002-569e-04.15

Database

6. Database

The Database view is used to create the database

needed for operating point optimization and creation of

the online forecasting models. This view is used to define

a DoE, on the basis of which the parts of the setup stage

(mold validation) are produced and measured. Subse-

quently, in actual production, the view can be used to

define, produce and measure samples. The Database

view is divided into two sub-views: Design of

Experiments and Quality Data.

Fig. 5: Database View – DoE

6.1 Setup Stage

In the setup stage (mold validation), on the basis of a

DoE different machine settings are used to produce

parts, whose quality features are then measured. This

data is required by STASA QC to learn the relationship

between process data, such as pressure and tempera-

ture curves or machine settings, and the quality features.

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6.2 "Design of Experiments (DoE)" View

This view is used to create the DoE. This can be entered

in the table manually or created automatically using the

Create DoE button (Figure 5).

If settings are entered in the table before the DoE is

created, by clicking the Create DoE button they are

automatically supplemented as optimally as possible to

produce a complete DoE.

The first column of the table contains the number of parts

to be produced for the particular experiment. When all of

the rows of the table have been completed with

experiment settings, one row is automatically added to

the table to enable any number of experiments to be

defined in the DoE.

Shots per setting

This button can be used to change the number of cycles

run and to be measured for each experiment (default:

10).

Import DoE

As an alternative to entering the DoE in STASA QC, an

externally edited DoE can also be imported. This must be

available as a CSV text file in the format defined in

Section 4.2.

Export DoE

This button can be used to export the DoE entered in

STASA QC to a CSV file.

Delete DoE

Deletes the entire DoE. Please take careful note that this

cannot be undone.

Send DoE to CoMo Interface

This prepares the DoE for running on a CoMo Injection

system, provided a license for online quality forecasting

has been purchased.

Get DoE from CoMo Interface

This retrieves the DoE after it has been run on a CoMo

Injection system, provided a license for online quality

forecasting has been purchased.

The created DoE is a suitable proposal for practical

experimentation based on the D-

optimal design

algorithm. In the "DoE" section of the menu Edit >

Settings

, experts can preset the number of

experiments to be performed ("Determine number of

experiments automatically" must be unchecked to

allow this, (default: 10) and the factor levels (default:

2) specified.

Page 16 2820A_002-569e-04.15

Database

6.3 "Quality data" View

This view can be used to enter in a table the quality

measurement results of the parts produced according to

the DoE (Figure 6).

Fig. 6: Quality data view

If the DoE is run with a CoMo Injection system (online

quality forecasting), the first column contains a filename

of the signal data file recorded by the sensors. These

signal files are created automatically if the experiments

documented in the DoE with STASA QC are performed

directly with a CoMo Injection system. The corresponding

files are found in the signal folder "Signaldata\DoEdata1"

of the project. Generally: C:\Program Files\STASA\

stasaQC\Projects\Project name\Signaldata\ Signaldata\

DoEdata1\.

Note: If pure operating point optimization is being carried

out, no signal files are required. The first column then

contains consecutive numbering of the produced parts or

the character „-„.

The second column specifies the number of the

experimental setting of the DoE. This numbering must

agree with that of the DoE in order to ensure the parts

are uniquely related to the machine setting of the

particular experiment.

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