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Identifying and resolving issues with tapper performance – Customer own driving equipment There are a number of reasons why tapper performance might vary. These notes are produced to help you eliminate some of the possible causes and hopefully resolve the issue. If any of the detail is not clear or you need further advice at any stage please contact us for assistance. Physical factors The performance of the tapper will vary due to the angle of operation, the material to which it impacts and the holding force or means of fixing to the surface. Additionally, the method of retaining the tapper may cause fouling of the core, any means of securing the tapper that involves compression may distort the structure causing increase of friction and hence poor performance, this may be permanent. It is thus important to assess these factors when considering performance and any testing for consistency must be done in the same manner. Sometimes dust and debris can enter the tapper and cause poor performance or erratic behaviour, the tappers can be cleaned. Heat from the coil of the tapper due over use inadvertently or deliberately will also affect the magnetic properties causing permanent weakening of the field and could cause distortion to the plastic parts which would increase friction. Note all our products in series 3 and above include thermal monitoring to avoid this issue. Where MST3 and above tappers are used with non-thermal sensing driving equipment, overheating is still possible. There are also tolerance factors to consider, as in all engineering manufacture and materials it is impossible to reproduce an exact copy. Currently we are not able to supply or test force characteristics, they do not form part of the specification. Finally, it is possible that if you have re-stuck the cone to the core then excess glue could cause rubbing within the bore and it needs to be removed. Eliminate as many variables as possible The first step is to eliminate variations caused by driving differences of individual channels and to ensure each device is tested consistently. For this test you will need your driving equipment and control software. 1. Disconnect all tappers from your driving equipment and remove all adaptations you have added to each tapper. They should be as supplied. Note on MST3 and above tappers you will need an adapter. 2. Make a note of the serial number of each taper, this can be found written on a sleeve along the connecting wires. A table is supplied at the end of this document. 1 3. Clean each tapper by first removing the core. Carefully insert a pin through the air hole at the rear (on the label) and push the core out. Examine the core and bore clean using a damp lint-free piece of material and re-insert the core. 4. Connect the first tapper on the list to the first channel of your equipment. Lightly grasp the tapper between thumb and forefinger and apply your usual stimulus. Take care not to exceed ratings. 5. Make a note of the tapper’s performance against the serial number on your list. 6. Replace the tapper with the next on the list and repeat steps 3 & 4 above for the remaining tappers. If you find a wide variation in performance between the tappers after performing this test, then send your results to us. We may subsequently ask you to return one or all of the tappers for our examination. If the performance of the tappers is similar and good then there is an issue with your driving equipment or software, these aspects should be investigated and the problems resolved. If the performance of the tappers is consistent but poor, then it may indicate that your driving equipment is inadequate or faulty or there is a problem with your software delivering an adequate pulse width. Check equipment and software performance You will need access to test equipment (an oscilloscope) to check your equipment and control software is performing satisfactory. You will also require an adapter if you are using an MST3 or above tapper and a special monitoring adapter, which you can make locally, see below or obtain from us for a nominal fee. You should first complete the test as described in the preceding section and ensure that the tappers have no added components. 1. Disconnect any tappers connected to your driving equipment. 2. Connect adapter lead to channel 1 of your equipment. 3. Connect oscilloscope to monitor points on the adapter. 4. Apply your usual stimulus. 5. Make a note of voltage and pulse width; a table is supplied at the end of this document. These respectively should be 12V and >= 5ms. 6. Connect a tapper to the adapter whilst still monitoring with the oscilloscope. 7. Apply your usual stimulus. 2 8. Record the results, these should be the same as obtained in step 5. If the results are quite dissimilar, then there is a problem with your equipment; it could be faulty or inadequate to drive a tapper. 9. Repeat steps 2 – 8 for all other channels using the same tapper. In all cases you should expect voltage amplitude to be about 12V and pulse width >=5ms. If this is not the case then there is something wrong with your driving equipment and/or control software. You have now checked that the driving equipment is performing well for one tapper on every channel. It might be that your equipment cannot accommodate all the tappers due to an inadequate power supply. The next sequence provides a way in which you can check this. Check for adequate drive power If after the above tests you are still experiencing poor performance on some tappers, it may be due to an overall inability for your equipment to deliver enough power for all the tappers. 1. Connect adapter, tapper and oscilloscope on channel 1 2. Apply usual stimulus. 3. Record voltage and pulse width, table supplied at the end of this document. 4. Add a second tapper to channel 2 of your equipment and repeat steps 2 & 3. 5. Add, the remaining tappers, one at a time and repeat steps 2 & 3. The results obtained should be almost identical, if there is a decreasing voltage as each extra tapper is added, then your equipment is unable to deliver enough power for the tappers to work properly for multi-channel operation. Note if after conducting the above tests you experience different performance on a few channels, then there may be some equipment issue with particular channels. The above sequence of tests can be repeated monitoring one of the under performing channels to see if any voltage drop occurs as the number of tappers is increased. 3 If your tests indicate that there is a problem with one or more tappers, then contact us for further assistance. M & E Solve 6 Estelle Close Rochester Kent ME1 2BP UK Telephone: +44 (0) 1634 306439 Fax: +44 (0) 1634 306439 Email: [email protected] Do not return any items to us without first obtaining authorization and a returns number; this can be obtained from: [email protected] 4 Monitor test adapter The monitor test adapter is a simple junction that enables two items (a tapper and oscilloscope) to be connected to one equipment channel. You will need a plug and socket for your system and some wire. You will also require some tools for terminating and a soldering iron. To each terminal of the plug solder two insulated wires. Form a pair of wires, one from each terminal of the plug and solder each of the pair to a terminal of the socket. The other pair of wires on the socket are the monitor (oscilloscope) connection and can have bare ends. Note, if you are using our standard jack for connections, ‘tip’ and ‘ring’ terminals are used. If you have fitted your own plugs then you will need to determine what connections have been used. It is important that the wire ends are kept separate and that after you have made up the adapter you check to ensure there are no shorts. A short circuit or wire ends that touch may damage your equipment. Warning ensure to correctly identify which is the ground (earth) connection of the monitor leads and that this is connected to oscilloscope ground otherwise damage to your equipment may result from improper connection. We are able to supply at nominal fee a clearly labelled, correctly wired test adapter in any of our standard connector range. 5 Tappers on common channel Channel used ______________ Date of test ___________________________ Serial no. Comments 1 2 3 4 5 6 7 8 9 10 6 Equipment check Date of test ___________________________ Equipment No tapper connected Voltage Pulse width 1 2 3 4 5 6 7 8 9 10 7 Tapper No. ______ connected Voltage Pulse width Multi-channel operation Channel no. monitored ______________ Date of test ___________________________ Tappers in system 1 Serial no. Voltage 2 3 4 5 6 7 8 9 10 8 Pulse width