Process Variation Monitor Manual

Application ‐ Crimp Force Monitoring

Patent No. US 5,841,675 and US 7,216,519

Model CFM2100™ Crimp Force Monitor

Prepared by OES, Inc.

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Table of Contents
Introduction .................................................................................................................................................. 4
How It Works ................................................................................................................................................ 5
Installation .................................................................................................................................................... 8
Force Sensor.............................................................................................................................................. 8
Processor Module ..................................................................................................................................... 8
Installing ForceView™ .............................................................................................................................. 8
Operation .................................................................................................................................................... 12
Creating a Connection............................................................................................................................. 12
Main Screen Overview ............................................................................................................................ 14
Adjusting Tolerances ............................................................................................................................... 18
Adjusting Analysis Regions ...................................................................................................................... 20
Features and Options .................................................................................................................................. 22
Hold Feature ........................................................................................................................................... 22
Editing the Device Name ......................................................................................................................... 23
Popup Mode............................................................................................................................................ 23
Overview Screen ..................................................................................................................................... 23
Configuration Management Tools .......................................................................................................... 24
System Menu .............................................................................................................................................. 26
Tools Menu ................................................................................................................................................. 26
Logging Menu.............................................................................................................................................. 31
Monitor Menu............................................................................................................................................. 31
View Menu .................................................................................................................................................. 32
Windows Menu ........................................................................................................................................... 32
Real Time Mode .......................................................................................................................................... 33
Configuration .............................................................................................................................................. 40
Appendix: Specifications ............................................................................................................................ 49
Appendix: Spare and Replacement Parts.................................................................................................... 51
Appendix: Default Configuration Values..................................................................................................... 52
Appendix: Product Warranty ...................................................................................................................... 54

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 Introduction
The CFM2100™ is one of a full line of crimp force monitors (CFMs) offered by OES. The
CFM2100 is a preferred choice for automatic wire processing machines as the ForceView™ companion
software provides a refined user interface with many advanced features. All OES CFM devices are
capable of detecting crimp defects in a wide range of wire processing applications, offering options for
deployment in both new machine and retro‐fit installations. OES also offers a wide range of force sensor
options with the appropriate sensor determined either by customer preference or application.

A sensor is installed on each crimp press to detect the relative force exerted during the crimping
process. During each machine cycle the CFM2100 captures a representative process signature of the
relative force (vertical axis) versus time (horizontal axis). This signature is compared to a reference or
learn signature and the CFM2100 uses the variation between these signatures to determine a Pass or
Fail for each crimp.

The CFM2100 employs 3 advanced signature analysis algorithms, including the patent pending
Cumulative Deviation Analysis (CDA), with each algorithm concentrates on a particular region of the
force signature. Each analysis algorithm for the subsequent press cycle/signature must fall within the set
tolerances for the crimped part to be considered acceptable.

After the CFM2100 has made an objective decision on the crimping cycle it interfaces with the
machine or press to control or inhibit the process from continuing in the event of variance indicating a
crimp defect. The CFM2100 offers an open architecture machine interface providing a robust and easy
to configure interface. This allows the CFM2100 to connect to any wire processing machine and
peripheral devices such as choppers and/or batch separators.

As a 3rd generation CFM device from OES, the CFM2100 offers a superior signal sampling rate
and faster data processing. The expanded communication options include USB and versatile network
connectivity capability through the Ethernet port.

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How It Works

Learn
Before the learn sequence is started the operator must confirm that the crimping press is set up
properly and is producing repeatable wire crimps within the process specifications (crimp height and
width for example). Any machine set‐up changes such as adjustment of crimp height will require the
monitor to relearn the process. Learning an improperly set up process or an unstable process
dramatically reduces the capability of the CFM2100 to detect process errors. The CFM2100 has many
internal features which optimize the learn curve for minor variations in production; however these
features depend on a stable repeatable process capable of producing good parts.

To initiate the learn sequence press the button (it is possible to restrict access to
the learn feature, please refer to the Security section for details). For a multi‐channel device or multiple
devices when in Multi‐Channel mode all channels/devices will be placed in learn mode.

Once the learn sequence has been started, the

CFM2100 will sample individual crimps and simultaneously
compare these crimp signatures using the specifications in
the Learn Parameters section of the configuration. The first
learn signature is used to configure the internal circuitry of
the CFM2100. The CFM2100 employs a variety of signal
conditioning circuits which are optimized immediately after
this initial signature. After the first signature, the learn
sequence is looking for a number of crimps (Min Cycles)
within the allowable variation (Learn Tolerance %). For
example if the Learn Tolerance is set to 3.0%, then each learn
signature must be within 3.0% of each other and any
signature that varies by greater than 3.0% will be discarded and another sample taken. The learn
process continues to sample the process until the minimum number of signatures is obtained, after
which the CFM2100 will analyze these signatures and calculate the learn curve or reference signature
and then proceed to Run Mode.

Pass/Fail Decision
As mentioned in the previous section, the monitor will default to RUN mode once the learn
process is complete. The monitor now compares the signature of the last machine cycle with the learn
signature in order to determine its PASS/FAIL status. The analysis interprets the variance in the signature
over the analysis regions and compares the amount of variation to the allowable limits or tolerances.
After every machine cycle the CFM2100 will perform the configured machine interface to interact with
the operator and/or wire cutting machine.

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 Gross and Sigma Tolerances
The CFM2100 utilizes two distinct sets of tolerances, Gross and Sigma. The Gross tolerances are
a manually configured fixed limit. If a crimp signature in a particular analysis region varies by a greater
percentage than defined by the Gross tolerance then the part is considered a GROSS FAIL. Similarly, if a
particular analysis region varies by a greater percentage than defined by the Sigma tolerance, then the
part is considered a SIGMA FAIL.

The Sigma tolerances are an optional set of tolerances that are fine tuned to the current status
of the process. When enabled, the Sigma tolerances are automatically calculated after the first 16 good
machine cycles following a learn and recalculated every 64 good machine cycles. The Sigma tolerances
are based on the last machine cycles and are determined by a multiplier (Sigma Limit). Because the
Sigma tolerance is based on the last machine cycles it has the advantage of being able to track the
process and therefore can be closer to the normal process variation.

Curve Analysis
The CFM2100 analyzes each production cycle signature in
three specific regions of analysis using the CDA algorithms mentioned
in the Introduction. The Peak algorithm compares the point or an
average of points representing the highest relative force generated
during the machine cycle. The Horizontal Region algorithm compares
a region of the signature parallel to the x‐axis and uses OES’ patent
pending Cumulative Deviation Analysis (CDA) algorithm. Similarly the
Vertical Region algorithm compares a region of the signature parallel
to the y‐axis, also using OES’ patent pending CDA algorithm.

Peak Analysis
Compares the peak force of the last machine cycle against the peak force of the learn signature.
The peak force is allowed to vary within the limits determined by the Sigma tolerances (if enabled) and
the Gross tolerances.

Peak force is less than the target of Peak force is less than the lower Gross
738eu but greater than the lower Sigma tolerance of 664eu, therefore the crimp
tolerance of 705eu and the lower Gross is considered a GROSS FAIL.Horizontal
tolerance of 664eu, therefore the crimp and Vertical Region Analysis
is considered a PASS.

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 The Horizontal and Vertical Region analysis calculates the percentage of positive and negative
variation across the analysis region. Positive variation is calculated for sections of the last machine
cycles’ signature that are greater than the learn signature. Likewise negative variation is calculated for
sections of the last machine cycle’s signature that are less than the learn signature. The last machine
cycle is allowed to vary by the limits determined by the Sigma tolerances (if enabled) and the Gross
tolerances.

Positive Horizontal Region variation is Positive Vertical Region variation is less

greater than upper Sigma tolerance of than the upper Gross tolerance of
2.2% but less than the upper Gross 15.0%, therefore the crimp is
tolerance of 15.0% therefore the crimp considered a PASS
is considered a SIGMA FAIL

Negative Vertical Region variation is

Negative Horizontal Region variation is greater than lower Gross tolerance of
greater than the lower Gross tolerance 15.0%, therefore the crimp is
of 15.0% therefore the crimp is considered a GROSS FAIL
considered a GROSS FAIL

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 Installation

Force Sensor
OES offers a wide range of sensing options to suit many applications. Please follow the installation
instructions provided with your sensor.

Processor Module
1. Determine a location for the processor module in the machine cabinet that is convenient for
both the sensor cable connection and integration to the wire processing machine. The processor
module has been designed to mount on a standard DIN rail.
2. Route the sensor cable to the sensor ensuring the path will not place the cable in an area where
it could be damaged.
3. Interface the processor module to the machine. Machine specific electrical interface cables
and/or wiring diagrams are available for many different types of automatic cutting machines.
Your OES sales representative will be able to provide you with specific details for your exact
machine type and model.
4. Connect 24VDC to the processor module. An optional 24VDC power supply is available from
your OES sales representative for machine installations that do not have an appropriate power
source.
5. Connect the processor module to the host PC via one of the following methods:
a. USB ‐ Your CFM2100 is supplied with a 2 metre mini USB cable
b. Ethernet – Contact your OES sales representative for optional network cables
c. RS232 – Contact your OES sales representative for the optional RS232 interface kit

To reduce the risks of injury from electrical shock ensure all power is disconnected from the
machine before attempting to install the CFM2100 processor module. Follow the wire processing
machine manufacturer’s instructions for proper disconnect procedures.

Installing ForceView™
Run the ForceView install program located on the CD included with the CFM2100. The
installation program automatically installs ForceView plus any additional required components.

Software Updates
It is recommended to perform a software update after completing the installation. The
ForceView software can automatically search and install any updates provided the PC has an Internet
connection. If an Internet connection is not available, software updates can be obtained from your OES
sales representative.

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Installing the USB Driver
If you are utilizing the USB connectivity of the CFM2100, the following procedure outlines how to
install the USB driver on Windows XP. Other versions of the Windows operating system will follow a
similar procedure. Contact your OES sales representative for more information on the installation
procedure for these versions.

1. Ensure the CFM2100 is ON.

2. Connect the USB cable to both the CFM2100 and the host PC.
3. The windows operating system should automatically discover the new device.

4. Windows will now prompt for the location of the USB Driver. Ensure the software CD included
with the CFM2100 is in the computer’s CD drive and select “Install from a list or specific location
(Advanced)”.

5. Press the “Browse” button

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 6. Select the folder named “CDM 2.02.04 WHQL Certified” on the CFM2100 CD and press “OK”

7. Select “Next”

8. Windows will now install the USB driver. This may take a few minutes.

9. Windows may indicate a warning regarding the USB driver. Press “Continue Anyway”.

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10. Press “Finish”

11. The USB driver installation is complete and the CFM2100 is ready for use

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 Operation

Creating a Connection
• Go to and select to open a new device window.

• Click the button in the lower left corner and select from the available connection
types. The following sections provide detailed information for each connection type.

RS232 Connections
Select the serial port from the list.

USB Connections
Select the USB device from the list.

Ethernet Connections
Select Ethernet from the list.

Connections are automatically stored by ForceView and automatically loaded when

ForceView is started.

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 • The Direct TCP Connection Manager will open and automatically search for any devices on the

local network. Select the device from the Device Discovery window and press .

• It is also possible to manually enter the IP address of the device in the Manual Connection
window.

The LEDs on the RJ45 connector indicate the status of the CFM2100 on the network:

LEFT side LED (Link) RIGHT side LED (Activity)

OFF – No Link Off – No Activity
Amber – 10 Mbps Amber – Half Duplex
Green – 100 Mbps Green – Full Duplex

Double check the network connection, including both the Ethernet cable and Ethernet
switch/router, if the Link light is not illuminated.

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 Main Screen Overview

Current View Current User

Communication Status ForceView Software Version

Firmware Version of attached CFM Device Logging Status (if logging is active status bar will
indicate file path)

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Function Side Bar

Places the CFM device into learn mode.

Graphically edit the location of the VR and HR analysis boundaries.

Select and load a pre‐saved configuration profile directly to the

CFM2100.

Zoom the view of either the curve window or individual analysis trend
charts

View/modify the CFM parameters. Access to the configuration can be

controlled through the security features described later.

Edits the device name

Curve Display

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 Peak Force: Peak force of the last crimp; in this example the peak force is 726eu

Horizontal Region analysis results: Analysis result for the Horizontal Region; in this example the positive
variation was 0.1% and the negative variation was 4.1%

Vertical Region analysis results: Analysis results for the Vertical Region; in this example the positive
variation was 4.2% and the negative variation was 0%

Alignment point: The white dashed line indicates the alignment point; in this example the alignment
point is on the falling edge.

Difference Graph: Graphically illustrates the variation between the run signature and the learn curve.

Production Trends
Peak Trend: Displays the last 20 production parts and illustrates the peak force of each crimp relative to
both the Sigma and Gross tolerances.

Upper Gross Tolerance: In this example the upper Gross tolerance is

258eu

Upper Sigma Tolerance: In this example the upper Sigma tolerance is

249eu

Target Peak Force: In this example the target peak force is 222eu

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 Lower Sigma Tolerance: In this example the lower Sigma tolerance is
195eu

Lower Gross Tolerance: In this example the lower Gross tolerance is

192eu

Horizontal and Vertical Region Trends: Displays the last 20 production parts and illustrates the
Horizontal Region analysis relative to both the Sigma and Gross tolerances.

Upper Gross Tolerance: In this example the upper Gross tolerance is

10.0%

Upper Sigma Tolerance: In this example the upper Sigma tolerance is

3.3%

Target: The target for the Horizontal Region is 0% variance

Lower Sigma Tolerance: In this example the lower Sigma tolerance is

3.8%

Lower Gross Tolerance: In this example the lower Gross tolerance is

10.0%

Counters
Displays the production counters from the CFM2100

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 Adjusting Tolerances
One of the two primary factors on how the CFM2100 determines the PASS/FAIL status of each
machine cycle is the tolerance levels. If the tolerances are improperly set the CFM2100 may identify
good parts as bad, or bad parts as good. Neither condition is acceptable in a production environment as
there will either be a high level of scrap or defective parts progressing to other manufacturing
processes. The tolerances must be set to a level greater than the normal process variation.

Process Variation and the Defect Detection Capability of the CFM2100

In order to limit the number of good parts indicated as bad, it is necessary to set the tolerances to a
level that is greater than the normal process variation of the process. For a process with a high level of
normal variation it would therefore be necessary to set the tolerances to a higher value potentially
limiting the defect detection capability of the CFM device. It is imperative that factors effecting
process variation such as tooling condition, machine lubrication, material consistency, and machine
condition all be considered.

Configuration Menu

• Press the button (It is possible to restrict access to the learn feature, please
refer to the Security section for details).

• To edit the Gross tolerances select

FOR MORE INFORMATION ON THE INDIVIDUAL CONFIGURATION PARAMETERS PLEASE REFER TO THE CONFIGURATION
SECTION OF THIS USER’S MANUAL

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 • To edit the Sigma tolerances select

FOR MORE INFORMATION ON THE INDIVIDUAL CONFIGURATION PARAMETERS PLEASE REFER TO THE CONFIGURATION
SECTION OF THIS USER’S MANUAL

Graphically Adjusting the Gross Tolerances

• It is possible to graphically adjust the gross tolerances provided the current user has
permission (refer to the Security section for more information on user permissions)
• Click on the gross tolerance in the production trend chart and drag the tolerance to the new
value.

• ForceView will prompt to confirm the change

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 Adjusting Analysis Regions
The other primary factor on how the CFM2100 determines the PASS/FAIL status of each
machine cycle is the location of the analysis regions. If the analysis region is positioned improperly the
CFM2100 will not be able to identify the resultant changes in the signature resulting from a bad crimp.
The default settings for both the Vertical and Horizontal Region have been set to provide a high level of
defect detection for the broadest range of applications. Some applications may require fine tuning of
these parameters to ensure the highest level of defect detection. In general, it is best to ensure the
analysis region contains the majority of the variation in the force curve resulting from a defect.

Configuration Menu
• Press the button (It is possible to restrict access to the learn feature, please refer
to the Security section for details).

• To edit the Analysis Regions select

FOR MORE INFORMATION ON THE INDIVIDUAL CONFIGURATION PARAMETERS PLEASE REFER TO THE CONFIGURATION
SECTION OF THIS USER’S MANUAL

Graphically Adjusting Horizontal Region

• Select to highlight the Horizontal Region (provided the current user

has permission – refer to the Security section for more information on user permissions)

• To drag the entire region without changing its size, click anywhere inside the blue area and
drag the region to its new location.

• To drag one of the cutoff lines, click the light blue cut‐off line and drag the line to its new
position

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 • To exit press one of the buttons at the bottom of the graph window

Accept changes and exit

Reset to original state without exiting

Reset to original state and exit

Graphically Adjusting Vertical Region

• Select to highlight the Vertical Region (provided the current user has
permission – refer to the Security section for more information on user permissions)

• To drag the entire region without changing its size, click anywhere inside the pink area and
drag the region to its new location.

• To drag one of the cutoff lines, click the light pink cut‐off line and drag the line to its new
position

• To exit press one of the buttons at the bottom of the graph window

Accept changes and exit

Reset to original state without exiting

Reset to original state and exit

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 Features and Options

Hold Feature
The Hold feature will retain the last 20 machine cycles and allow the user to view a previous
machine cycle and freeze the curve display window on that force signature. The Hold preview is located

directly below the Difference Graph and graphically illustrates the last 10 machine cycles. The on the
left hand side of the preview allows access to the remaining signatures in the Hold buffer.

• Move the cursor to the desired signature to highlight it. The following example reviews the
gross failure indicated by the red signature.

• Selecting the signature will automatically enable the hold feature and update the Curve
Display window with the selected force signature. If logging is enabled, any log comment
will be stored to this log entry. The production trends will continue to update with each
machine cycle.

• It is possible to navigate through the signatures in the Hold buffer.

Scrolls through the buffer without changing the currently selected signature

Scrolls through the buffer updating the Curve Display window

• To disable the Hold feature and display the last machine cycle uncheck the icon

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Editing the Device Name
By default ForceView assigns a generic device name to each attached device. If the attached device
has more than one channel each channel will be identified in the following format Default Name:Cx
where C represents the channel number of the device. The default name is located in the Program
Options section of the Tools menu.

• It is possible to customize the device name by clicking the button

• Enter the new device name and press OK

• The new device name is saved along with the connection and will be automatically reloaded
every time the software is started.

Popup Mode
ForceView includes a Popup Mode which allows for easy integration onto a PC running wire
processing machine software. The Popup Mode creates a small status window for each channel of the
attached CFM device(s). These windows can be easily positioned on top of the machine control software
giving the operator the ability to view the status of the CFM device(s) and the machine control software

simultaneously. To enable the Popup Mode press the button located in the toolbar. The
window(s) can be moved by simply clicking the left mouse button on the top of the window and
dragging the window around the screen.

Overview Screen
ForceView includes an overview feature which allows for easy viewing of multiple devices
connected to the same PC. The overview window creates a small status window for each channel of the
attached CFM device(s). This overview screen gives the operator the ability to view the status of
multiple CFM device(s) simultaneously while providing easy access to the standard ForceView software

screen of each. To enable the Overview screen press the button located in the toolbar.

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 Popup and Overview Features

Signature for the last crimp, screen will flash red when a failure occurs

Place the CFM device into learn mode

Access the configuration for the CFM device

Return to the full ForceView screen for the selected device

Configuration Management Tools

There are three configuration management tools available within the Configuration screen.

Saves the configuration parameters currently in the Configuration screen to a file with the
.settings extension

Loads the Configuration screen with the parameters saved in the .settings file. The parameters
are not sent to the monitor until the button is pressed.

Exports the configuration parameters currently in the Configuration screen to a .CSV file for use
in a spreadsheet program.

Profile Load
The Profile Load feature will load all of the machine independent configuration parameters into
the CFM2100 and provides an easy interface for the operator to select from all of the available profiles.
This feature utilizes the same .settings files from the configuration allowing for easy creation and
transferability of the Profiles from machine to machine and/or manufacturing facility to manufacturing
facility. Once an appropriate Profile has been determined for a particular process the .settings file can be
distributed to all machines and facilities using the same process.

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Loading a Profile

• Press the button.

• Select the profile from the list

• Press the button to send the profile parameters to the CFM2100

Manually Loading a Profile

• To manually load a profile that is not located in the Profile Folder press the

button.
• Select the profile and press Open

Setting the Profile Folder Location

The Profiler window will display all .settings files located in the Profile Folder. The
operator will only need to select the profile name from the list and the profile parameters will
automatically be sent to the CFM2100.

• Press the button to open the Profile window

• The current Profile Folder is displayed at the top.

• To change the Profile Folder location, press the button and select the
new folder location.

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 System Menu

Opens a new connection to a CFM device; in Normal mode each device appears as a new
window with each channel of the device appearing as a separate tab, in Multi‐Channel mode
each device and channel appears as a separate tab in the same window. Once a connection has
been established it will be stored and automatically re‐established each time the software is
started.

Removes the current connection to a CFM device and optionally removes the connection from
the automatic connection feature.

Checks for new updates to the ForceView software (an internet connection is required).
Alternatively, software updates are available from your OES sales representative.

Quits the ForceView software program

Tools Menu

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 Defines the amount of idle time after which any signed in user will be
automatically signed out preventing unauthorized use of restricted areas of the
software.

Defines the default device name for any attached CFM devices

Sets ForceView to start in Popup Mode

Enables the Multi‐Channel mode where each device and channel appears as a
separate tab in the same window. The software must be restarted for this
option to take effect.

Creates a single Popup Window for all attached devices

Configures the options for the Curve Display window

Displays the HR analysis boundaries in the curve display window

Displays the VR analysis boundaries in the curve display window

Off – no axis labels

Samples – axis labeled with sample numbers
Percent – axis labeled with percentage (0% represents start of graph and 100%
represents end of graph)

Off – no axis labels

EU – axis labeled with engineering units
Percent – axis labeled with percentage (100% represents peak of learn curve)

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 Displays X‐axis grid in the curve display window

Displays Y‐axis grid in the curve display window

Displays Alignment point in the curve display window

Configures the colour options for both the curve display window and the production
trend windows

Exports data contained in the log file into Comma Separated Values (.CSV) file format for
manipulation in spreadsheet software programs

• Select the log file to export

• Enter file name and location for exported data

• Select the type of data to export:

Log Data: Exports the process data such as analysis results, user comments, etc. in rows
Curve Data: Exports the raw curve data in columns

• Export the data by selecting the button.

Auto‐Split Large Logs

Ensures .CSV files to meet the size requirements of many spreadsheet software programs by
automatically creating multiple .CSV files

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Functionality to upgrade the firmware of an attached CFM Device

The ForceView software is installed with 2 users, Admin and Default with the option to add
more. When the software is started the default user is automatically signed in. Also, after a
period of inactivity any signed‐in user will be automatically signed out.

Default User Summary

• Admin
ƒ Ability to modify access permissions for users
ƒ Ability to create/remove users
User name: admin
Password: oes
• Default
ƒ Default user
ƒ Full access to all features is enabled when software is installed

Sign In
If access permissions are removed from certain user accounts it will be necessary to sign
in for access to restricted areas of the software. After a period of inactivity any signed‐in
user will automatically be signed out eliminating the possibility of unauthorized use of a
user account.

Modify User Permissions

• Sign in as the Admin user

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 • User access permissions can be modified in the tool

• Select the user in the Users window and press the button to modify
the user’s access permissions. The following options are available:

ƒ Learn – Ability to place CFM device into learn mode

ƒ Configuration – Ability to modify the CFM device configuration
ƒ Realtime – Ability to access the real time tool of ForceView
ƒ Clear Counters – Ability to clear the production counters of the CFM device
ƒ Profiler – Ability to access the profile management tool
ƒ Reset Defaults – Ability to reset the CFM device to the default settings.
ƒ Change Connection – Ability to add/remove connections to CFM devices
ƒ Can Move Popups – Ability to move the location of Popup windows
ƒ Can Access Autogen ‐ Ability to access the Autogen programmer functions
ƒ Can Access Program Options – Ability to modify the Program Options

• Press the to save the changes

Create New User

• Press the button in the tool

• Enter a user name, password, and assign access permissions for the new user

• Press the button to save the new user

Change User’s Password

• With the user signed in, press the button in
section of the menu.
• Enter both the original password along with the new password for the change to
take effect.

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Logging Menu
The ForceView software offers a comprehensive data logging feature where each machine cycle
is stored to the log file, including any configuration changes, until logging is stopped. It is also possible to
add comments to individual machine cycles, helping to identify events that have occurred such as
particular failure types. This log data can be viewed at a later date to help with set‐up issues and fine
tune defect detection. There is also built in capability to export the data, including the raw signature to a
.CSV file for manipulation in a spreadsheet program (more information can be found in the Tools
section).

Opens an existing log file for viewing

Creates a new log file

Appends to the end of an existing log file

Stops logging

The Status Bar will indicate the state of logging as well as the file name if logging is
active

Adding a Comment
• Type the comment in the space provided (once logging has started, comments can only be
added after the first machine cycle).

• To save the comment to the log file press

Monitor Menu

Opens the Real Time mode window, please refer to the Real Time Mode section for more
information on this feature.

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 Displays the current status of the hardware for the attached CFM device

Sensor Connected Sensor Disconnected

Output Activated Sensor Deactivated
Input Active Input Deactivated
Current Gain for Channel

Only available for devices with internal Profile storage capability, such as CFM4000 and
CFM4100

Resets the CFM2100 to the factory default settings (provided the current user has the
permission – refer to the Security section for more information on user permissions)

Clears the production trends and/or counters for the attached CFM devices

View Menu

Display/Hide the Status Bar at the bottom of the viewing window

Selects the displayed language, contact your OES sales representative for languages not listed.

Windows Menu

Closes all device windows

List of all connected devices

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Real Time Mode
Real Time Mode
is a feature which will
allow the CFM2100 to
gather raw data from
the sensor, and is
primarily used to
determine signature
capture parameters and
troubleshoot signature
capture problems for
difficult applications.
Once the signal reaches
the trigger level the
CFM2100 will sample
the raw sensor data for
the configured sample
time. After uploading
the data to the software, the user will have the ability to view and analyze the data with the built in
tools.

Starting Real Time Mode

• Configure the Real Time parameters contained in the Initialization box

Defines the sensor channel of the attached device to

sample from

Signal gain level to be applied to signal

1 – 1.00X 5 –8.00X
2 –2.00X 6 – 10.00X
3 – 4.00X 7 – 16.00X
4 – 5.00X 8 – 32.00X

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 Sample time in seconds

Trigger level to initiate data sampling

In this example the CFM device will sample for 5 seconds from Channel 1 of the attached device
at a gain level 1 (1.00X) once the signal level reaches 3.0% of the sensor’s full scale value

Setting the trigger level to 0.0% will cause data capture to start immediately after pressing the
start button.

Because Real Time Mode is capturing only the raw sensor data it will not make a PASS/FAIL
judgment for the machine cycles. All parts manufactured during Real Time Mode should be manually
inspected to ensure part quality before proceeding to any further manufacturing operations. In
addition, the outputs of the CFM2100 will not perform the configured machine interface functions and
it may be necessary to modify the automatic cutting machine settings to allow operation without the
appropriate machine interface signals.

• Press to initiate Real Time Mode. The CFM2100 is now waiting for the sensor
signal to reach the trigger level. During real time data capture a low resolution preview will be
displayed in the Capture Preview window.

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 • After real time data capture is complete the CFM2100 will upload the raw data to the Real Time
Mode software

• The uploaded data will be displayed in both the Zoom Window and the Parameter Select
Window.

Zoom Window
The Zoom Window displays the entire data capture and allows the user to select regions to be
displayed in the Parameter Select Window.

• To select a region to display in the Parameter Select Window simply click and drag the highlight
box over the section you wish to view.

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 • The selected region will now be displayed in detail in the Parameter Select Window.

• Additionally the and buttons in the Zoom Window can provide further zoom in and
zoom out control

Parameter Select Window

The Parameters tool will automatically calculate the signature capture configuration parameters
based on the placement of markers within the Parameter Select Window. By graphically defining the
start and end points of the valid crimp force signature and a suitable trigger level the software will
calculate valid Pre‐Trigger, Duration, and Start Level parameters. Additionally, if a firing pulse is utilized,
the selection of the firing pulse will allow the software to calculate the minimum External Trigger
Timeout parameter based on the pulses position relative to the crimp force signature.

• To use the Parameters tool ensure the Parameter Select option is enabled in the Mode window.

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• By default the Parameters tool will select Start immediately after the data upload from the
CFM2100 has completed.

The top of the Parameter Select Window displays information regarding the section of the raw
data you are viewing
Location of the Parameter Select Window relative to the complete raw
sensor data; in this example the Parameter Select Window is 3694ms
from the start of data capture
Duration of the Parameter Select Window; in this example the
Parameter Select Window displays 86ms of data
Parameters tool that is currently selected; in this example the Start tool
is selected

• To define the start point on the force signature move the cursor to the appropriate location in
the Parameter Select Window and click the right mouse button. It is best practice to place the
curve start point just before the initial rise of the crimp force signature.

• The Parameters tool will automatically advance to End immediately after the selection of the
curve start point. Using the same method, select an appropriate location for the curve end
point. Again, it is best practice to place the curve end point just after the completion of the
crimp force signature.

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 • The Parameters tool will automatically advance to Trigger immediately after the selection of the
curve end point. Using the same method, select an appropriate trigger level. It is best practice
to place the trigger level above any machine noise that is not associated with the crimp force
signature.

• The Parameters tool will automatically advance to Pulse immediately after the selection of the
trigger level. If the set‐up is utilizing a firing pulse use the same method to select the input’s
firing point. Depending on the type of input and its integration this could be either a rising or
falling edge just prior to the crimp force signature.

• Any of the Parameters tools can be adjusted at any time by selecting the desired tool from the
Parameters menu. The parameter can be adjusted by dragging the current location or selecting
a new location.

Signature Info Window

After selecting the appropriate locations for the Parameters tools, the software will
automatically calculate the signature capture configuration values and display them in the Signature Info
window. If a firing pulse is utilized the External Trigger Timeout will also be calculated.

To send these configuration values to the monitor press the button.

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Configurations Window
The Real Time Mode software also has the ability to utilize the signature capture configuration
tools on multiple crimp force signatures in the raw data. Each configuration set will have its own distinct
curve start point, curve end point, trigger level, and firing pulse.

• To save the current configuration in the Configurations window press the button. The
configuration will be added to the list.

• To view a previously stored configuration select the number from the pull down menu

• To delete a previously stored configuration select the number from the pull down menu and

press the button.

Saving and Loading Real Time Data

• The Real Time Info Window allows the user to enter notes regarding the Real Time data, the
software will automatically insert the time stamp based on the computer’s internal clock.

• To save the current Real Time data including any configurations in the Configurations window

select in the menu. Enter a filename and

location to store the .realtime file.

• To load a previously saved Real Time file select from the

menu.

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 Configuration
Channel

Signature Capture

Pre‐Trigger (ms):
Amount of data captured prior to the trigger point.

Duration (ms):
Amount of data captured after the trigger point. The monitor will automatically shorten
the duration time to an optimal value if applicable.

Start Level (%)

Defines the trigger point for data capture, once the sensor input exceeds the start level
data capture will commence. Defined as a % of the full scale output of the input sensor

Filter (ms)
Sensor input must remain above the start level for the defined time before data capture
will begin. The filter option is often used to eliminate false triggers that could result
from mechanical noise during a machine cycle.

Signature Analysis

Alignment Height (%)

Point on the curve where the reference and production curves will be overlapped for
proper analysis. Alignment point is set as a percentage of the target peak force.

Alignment Slope
Point on the curve where the reference and production curves will be overlapped for
proper analysis. Alignment point can be set to either the rising or falling edge of the
force curve.

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 Determining the Best Alignment Point

The default settings for both the Alignment Height and Slope have been set to cover the broadest
range of applications; however some applications may require changes. In general, it is best to ensure
the alignment point is set to the most consistent and repeatable portion of the force curve. The falling
edge is preferred as this portion of the force curve represents the movement of the press away from
the crimp, and for most processes is extremely consistent. In some rare instances the rising edge may
be preferred; for example a process with highly variable crimp duration will cause excessive nuisance
failures when a falling edge alignment is selected.

Horizontal Region

Enabled/Disabled
Enable or disable the Horizontal
Region (HR) analysis.

Cutoff Limit 1 and 2 (%)

Defines the location of the upper
and lower boundaries for the
Horizontal Region analysis, only
the region of the signature
located between HR1 and HR2
will be analyzed

Vertical Region

Enabled/Disabled
Enable or disable the Vertical
Region (VR) analysis.

Cutoff Limit 1 and 2 (%)

Defines the location of the left
side and right side boundaries for
the Vertical Region analysis, only
the region of the signature
located between VR1 and VR2 will
be analyzed

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 Determining the Location of the Analysis Region

The default settings for both Cutoff 1 and Cutoff 2 are set to provide a high level of defect detection
for the broadest range of applications. Some applications may require fine tuning of these parameters
to ensure the highest level of defect detection. In general, it is best to ensure the analysis region
contains the majority of the variation in the force curve created by the defect.

Peak

Enabled/Disabled:
Enable or disable the Peak analysis.

Samples to Average:
The number of samples used in the calculation of the peak force for the
signature.

Gross Tolerances

Min Peak (eu)

Sets the lowest possible tolerance regardless of the calculated gross tolerance

Example: A gross tolerance of 5% for a peak target of 1000 would result in a calculated
gross tolerance of 50 eu. A Min Peak value of 75 would be larger than the calculated
gross tolerance and would therefore override the gross tolerance to 75.

Max Peak (eu)

Sets the highest possible tolerance regardless of the calculated gross tolerance

Example: A gross tolerance of 20% for a peak target of 1000 would result in a calculated
gross tolerance of 200 eu. A Min Peak value of 150 would be smaller than the calculated
gross tolerance and would therefore override the gross tolerance to 150.

Process Variation and the Defect Detection Capability of the CFM2100

In order to limit the number of good parts indicated as bad it is necessary to set the tolerances to a
level that is greater than the normal process variation of the application. For a process with a high
level of normal variation it may therefore be necessary to set the tolerances to a high value, which
potentially limits the defect detection capability of the CFM device. It is imperative that factors
effecting process variation, such as tooling condition, machine lubrication, material consistency, and
machine condition, all be considered.

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 High Insulation
Special algorithm developed by OES to effectively detect the high insulation failure
condition.

Enabled/Disabled
Enable or disable the High Insulation algorithm

Sensitivity
Sensitivity of the high insulation algorithm with 1 being the most sensitive and 8 being
the least sensitive

Sigma Tolerances
Initially calculated after the first 16 cycles, the sigma tolerances are automatically recalculated
every 64 good pieces. These tolerances are based on the last 64 good pieces and therefore
follow the process very closely and help to optimize defect detection.

Determining If Sigma Tolerances Can Be Used

Because the Sigma Tolerances are based on the stability of the process, it is a possible cause for
nuisance errors. These nuisance errors will occur when a Sigma Tolerance is calculated to a value
which is less than the normal process variation. The minimum settings for each analysis region can be
set to eliminate this problem; however some processes may be too unstable for the Sigma Tolerances
to be utilized correctly.

Sigma Limit
Multiplier used to determine the sigma tolerance for each enabled region. For example
a sigma limit of 3.0 would create a sigma tolerance of +/‐ 3 standard deviations.

Idle Reset (min):

Defines a time frame of inactivity, after which the sigma tolerances are reset. This takes
into account the fact that the behavior and performance of the machine may change
slightly if left inactive for a period of time, and the sigma tolerances will no longer be
applicable when the machine re‐starts. The sigma tolerances will be re‐computed after
the appropriate number of cycles have been completed.

Peak Enabled/Disabled:
Enable or disable the Peak Sigma tolerances.

Peak Min (eu):

The lowest possible Peak sigma tolerance regardless of the sigma calculation

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 Example: If the sigma calculation creates an unrealistic tolerance based on the
production trends, it would override this value and set the tolerance to the minimum.

Horizontal Region Enabled/Disabled:

Enables or disables the Horizontal Region Sigma tolerance.

Minimum Tolerance (%):

Sets the lowest possible HR sigma tolerance regardless of the sigma calculation

Example: If the sigma calculation creates an unrealistic tolerance based on the

production trends, it would override this value and set the tolerance to the minimum.

Vertical Region Enabled/Disabled:

Enables or disables the Vertical Region Sigma tolerance.

Minimum Tolerance (%):

Sets the lowest possible VR sigma tolerance regardless of the sigma calculation

Example: If the sigma calculation creates an unrealistic tolerance based on the

production trends, it would override this value and set the tolerance to the minimum.

ATR (Automatic Target Recalculation)

Processes can change over time due to external influences such as machine cycle rate,
lubrication, heat, material variation, and tooling wear. These process changes may occur
without affecting the quality of the parts produced. The ATR continually tracks process variation
and makes effective adjustments to the learn curve resulting in less unnecessary scrap while
maintaining the highest level of defect detection.

Enabled/Disabled:
Enable or disable the Automatic Target Recalculation feature.

Calculation Rate:
The interval by which the monitor computes the target correction, the HIGH setting will
compute the target correction at a faster rate than the LOW setting.

Sample Rate:
The interval by which the monitor samples the process for the data required in the
target correction calculation, the HIGH setting will sample the process at a faster rate
than the LOW setting.

Channel Settings

Enabled/Disabled
Enables or disables the channel. When a channel is disabled, any part produced is
considered a PASS, regardless of the analysis results.

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 Sensor Mode
Sets the sensor signal mode for the CFM2100:

‐ AC Coupled Tension ‐ AC Coupled Compression

‐ DC Coupled Tension ‐ DC Coupled Compression

Sensor Range
Sensing range of the attached sensor which will be used for proper scaling of the peak
force

Learn Parameters

Learn Tolerance (%)

During the learn process, signatures are captured and compared to obtain the reference
or learn curve. Learn tolerance is the maximum allowable variation between the
individual signatures. If during the learn procedure the signature exceeds the learn
tolerance when compared to the other learn signatures, it will be excluded from the
calculation of the reference target curve.

Min Cycles
Minimum number of signatures required to establish the reference or learn curve. Each
signature must not vary from the other signatures by more than the Learn Tolerance. In
Learn mode, the first press cycle determines the gain level, and is in addition to the
minimum number of cycles required to complete the learn process.

Max Cycles
Maximum number of machine cycles permissible to learn a process. If the CFM device
does not learn a process after the maximum press cycle limit is reached, then the learn
process has failed and will be restarted.

Learn Gain
Gain value override for the sensor input. The gain is normally set to 1.00 automatically
when the learn procedure is started. Following the first machine cycle in the learn
process the monitor analyzes the signature to determine if more gain can be applied for
optimal signal usage. For certain applications, it may be necessary to set the gain
manually to a higher level. The following are the gain level settings of the CFM2100:

Level1–1.00X Level4 – 5.00X Level7 – 16.00X

Level2–2.00X Level5 – 8.00X Level8 – 32.00X
Level3–4.00X Level6 – 10.00X

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Machine Control

Gross Consecutive Fails

Sets the number of consecutive gross fails required to initiate a machine shut down or
interruption; typically set to 1 resulting in each gross failure causing a machine shut
down

Sigma Consecutive Fails

Sets the number of consecutive sigma fails required to initiate a machine shut down or
interruption; typically set to a value greater than 1 resulting in a machine shut down
occurring when a series of sigma fails occurs in a row.

Max Deviation (eu)

Value that the Peak target is permitted to drift above or below its initial target value at
the start of the process. If the Peak target exceeds this amount from the original target
value the machine will be interrupted or shut down.

I/O Settings

Input Settings

Input Type
None: Input Disabled
Firing Pulse: Input will be used as a firing pulse for the assigned channel
Learn: Input will place assigned channel into learn mode
Fail Reset: Input will reset the monitor after a failure when the reset method is
configured for the same input
Disable: Input will Disable/Enable the assigned channel

Input Edge
Disabled: Assigned input functionality is disabled
Rising: Assigned functionality occurs on the rising edge of the input
Falling: Assigned functionality occurs on the falling edge of the input

Assigned Channel
Sets the channel assigned to the input functionality.
Output Settings

Output Type
None: Output Disabled
Pass Output: Output will activate for a good part on the assigned channel
Sigma Fail Output: Output will activate for a sigma fail on the assigned channel
Gross Fail Output: Output will activate for a gross fail and/or consecutive sigma fail
on the assigned channel
Chopper: Output will activate for gross fail and/or consecutive sigma fails
to interface with external chopper mechanisms
Learn: Output will activate when assigned channel are in learn mode
Data Valid: Output will activate when a valid signature is received on the
assigned channel

Assigned Channel
Sets the channel assigned to the output functionality

Pulse Delay (ms)

Delay in milliseconds before the output is activated

Pulse Duration (ms)

Duration of the output in milliseconds

Relay State
Sets the normal state of the relay either normally open (NO) or normally closed (NC)

Chopper
Chopper Station: Number of operations from the crimping station to the external
chopper mechanism
Chop in Run: Chopper output will activate when in RUN mode for all gross
fails and/or consecutive sigma fails
Chop in Learn: Chopper output will activate when in LEARN mode for all parts

Machine Interface

Reset Method
The Gross Fail Output has the option to be reset by a specific action. With this feature
enabled the Gross Fail Output will remain active until the reset method has been
performed. If multiple Gross Fail Outputs are configured, each will use the same Reset
Method. The following Reset Methods are available:

None: Gross Fail Output(s) are disabled

Timer: Gross Fail Output(s) use the delay and duration values set for each
output
Input: Gross Fail Output(s) will remain active until the selected input is
activated

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 When using an Input for the Reset Method caution must be taken to ensure the input selected
for the Reset Method is also configured. Refer to the Input Settings section on how to configure the
Input.

External Trigger Timeout

Time period after the activation of the Firing Pulse during which the crimp process must occur.
If a signature is not detected by the monitor within this time frame the monitor will
automatically initiate the shutdown sequence.

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Appendix: Specifications
Environmental
Operating Temperature: 15 to 50°C (60 to 120°F)

Electrical
Supply Voltage: 24VDC @ 200mA +/‐ 10%
Sensor Input: AC or DC coupled, Tension or Compression (software selectable)
Input 1: 24VDC discrete input
Input 2: 24VDC discrete input
Input 3: 24VDC discrete input
Output 1: 24VDC @ 1A – RELAY dry contact sink or source (switch selectable)
Output 2: 24VDC @ 1A – RELAY dry contact sink or source (switch selectable)
Output 3: 24VDC @ 400mA – MOSFET sink or source (switch selectable)
Output 4: 24VDC @ 400mA - MOSFET sink or source (switch selectable)
USB: Mini USB B type ‐ USB 2.0 compatible
Ethernet: RJ45 ‐ Auto‐Sensing 10Base‐T or 100Base‐TX – User configurable DHCP
or Static IP
RS232: Optional RS232 communication adapter available

V‐ (Supply Voltage)

INPUT 3 V+ (Supply Voltage) OUTPUT 4

INPUT 2 OUTPUT 3

SIGNAL INPUT
(SMA CONNECTOR)
OUTPUT 2
INPUT 1
Ethernet (RJ45) OUTPUT 1
USB (Mini B)

OUTPUT 1
(Relay)

OUTPUT
CONFIG
0VDC OUTPUT 2
24V or (Relay)
0V
24VDC OUTPUT 3
(MOSFET)

OUTPUT 4
(MOSFET)

Physical
Mounting: DIN rail
Dimensions: 89.9mm x 111.5mm x 22.4mm (3.54” x 4.39” x 0.88”)

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 Appendix: Specifications

22.4mm
[1.72"]

111.5mm
[8.59"]

89.9mm
[6.92"]

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Appendix: Spare and Replacement Parts

DESCRIPTION Part #

Processor Module CFM2100

USB Cable AU008B+
RS232 Interface Kit 3G-IK232

Sensor Cables

Sensor cable 10/32-BNC Standard cable AU002E+

Sensor cable 10/32-BNC Heavy Duty cable AU002A
Sensor cable 10/32-BNC with Mounting Block and Heavy Duty cable AU001A
Sensor cable 10/32 Right Angle-BNC with Mounting Block and Heavy Duty cable AU001A
Sensor cable 10/32-BNC 4.5m (180") AU005A
Sensor cable 5/44-BNC Heavy Duty cable AU001B
Sensor cable 5/44-BNC with Mounting Block AU001C
Sensor cable 5/44-BNC with Mounting Block AU004C

SMA - BNC Cables

SMA - BNC Cable 24" (0.6m) AU088C

SMA - BNC Cable 36" (0.9m) AU088A
SMA - BNC Cable 120" (3.0m) AU088D
SMA - BNC Cable 280" (7.0m) AU088E

Force Transducers (SEE CFM-OPTIONS-001)

Force Transducer-Ram Mounted 5000lb range-202M23 AU017A

Force Transducer-Ram Mounted 20000lb range-202M32 AU020A
Force Transducer-Ram Mounted 40000lb range-204M38 AU020C
Force Transducer-Base Plate Mounted 5000lb range-201M83 AU016C
Force Transducer-Megomat Base Plate Mounted 5000lb range-201M89 AU016D

Piezo Strain Transducers

Piezo Strain Sensor High Sensitivity-240M01 AU011A

Piezo Strain Sensor Low Sensitivity-240M03 AU011B

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 Appendix: Default Configuration Values
Channel Settings Channel Settings

Signature Capture ATR (Automatic Target Recalculation)

Pre‐Trigger: 10ms ATR: Enabled
Duration: 80ms Calculation Rate: Low
Start Level: 8% Sample Rate: Medium
Filter: 5ms

Channel Settings
Signature Analysis Channel: Enabled
Alignment Height: 30% Sensor Mode: AC Tension
Alignment Slope: Falling Sensor Range: 5000
Horizontal Region: Enabled
Cutoff Limit 1: 60%
Cutoff Limit 2: 99% Learn Parameters
Vertical Region: Enabled Learn Tolerance: 3.0%
Cutoff Limit 1: 10% Min Cycles: 5
Cutoff Limit 2: 45% Max Cycles: 16
Peak: Enabled Learn Gain: Level 2
Samples to Average: 10

Machine Control
Gross Tolerances Gross Consecutive Fails: 1
Peak: +/‐ 4.5% Sigma Consecutive Fails: 2
Min Peak: 10eu Max Deviation: 100eu
Max Peak: 1000eu
Horizontal Region: +/‐ 10.0%
Vertical Region: +/‐ 10.0% I/O Settings
High Insulation: Disabled
Input 1
Sensitivity: 8
Input Type: Firing Pulse
Input Edge: Disabled
Sigma Tolerances Assigned Channel: Channel 1
Sigma Limit: 4.5
Idle Reset: 20 min.
Input 2
Peak: Disabled
Peak Min: 20eu Input Type: None
Horizontal Region: Disabled Input Edge: Disabled
Minimum Tolerance: 2.0% Assigned Channel: Channel 1
Vertical Region: Disabled
Minimum Tolerance: 2.0%

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Appendix: Default Configuration Values
I/O Settings I/O Settings

Input 3 Output 3
Input Type: None Output Type: Sigma Fail
Input Edge: Disabled Assigned Channel: Channel 1
Assigned Channel: Channel 1 Pulse Delay: 0ms
Pulse Duration: 250ms
Relay State: NO
Output 1
Output Type: Pass
Assigned Channel: Channel 1 Output 4
Pulse Delay: 0ms Output Type: Data Valid
Pulse Duration: 250ms Assigned Channel: Channel 1
Relay State: NO Pulse Delay: 0ms
Pulse Duration: 250ms
Relay State: NO
Output 2
Output Type: Gross Fail
Assigned Channel: Channel 1 Machine Interface
Pulse Delay: 0ms Reset Method: Timer
Pulse Duration: 250ms External Trigger Timeout: 500ms
Relay State: NO

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 Appendix: Product Warranty

• The warranty coverage is for materials and labour for a period of two years from the date of
purchase.
• The warranty is limited to the repair of OES, Inc. PRODUCTS only.
• Any warranty repair performed during the two year period does not extend the warranty
period.
• OES, Inc. warrants the products to be free from defects in materials and workmanship under
normal use and service, but OES’ obligations are limited to repair and replacement of the part(s)
shown to be defective at the time of shipment. OES’ liability shall not exceed the contract price
for the goods claimed to be defective and OES shall not be liable for any special or consequential
damages.
• OES PRODUCTS returned for repair that are damaged by misuse, abuse, negligence, or accident
(all determined by OES) will have the warranty voided and repair charges will be paid by the
customer.
• OES return policy for warranty and non‐warranty repairs is as follows:

All goods claimed as warranty repair shall be returned by the customer to OES or a OES sales
representative prepaid by the customer, including customs brokerage charges, complete will all
necessary customs documentations.

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