DC25 / UB25 - Amada Miyachi Europe

DC25 / UB25 - Amada Miyachi Europe
R E S I S TA N C E W E L D I N G
DC25
/
UB25
Linear DC Welding Controls
• Ultra-fast closed-loop hybrid control provides
extremely stable output waveforms in
constant current, voltage and power modes.
UB25, 50-1000A
output. Superior
low energy control
for micro welding.
• Exceptionally fast rise time permits shorter
weld times, less part deformation, longer
electrode life, and greater weld strength with
more part ductility.
• Single phase operation permits easy
installation and versatility of use.
DC25, 4000A maximum
output. Versatile and
accurate performance
from a single phase
power supply.
PRECISION CONTROL FOR HIGH
RELIABILITY WELDING OF MINIATURE
AND MICRO-MINIATURE PARTS
The DC25 Linear DC welding control is ideal for microjoining
applications which require exceptional control, fast rise times,
and highest quality throughput. The DC25 requires only single
phase input power and can output up to 4000 Amps. Ultra-fast
rise times permit short overall weld times, resulting in less part
deformation and stronger welds. This is extremely important
when welding heat sensitive parts such as miniature battery
cells or sensitive electronic devices.
The UB25 (successor to the Unibond II) provides unsurpassed
levels of control for micro-miniature resistance welding.
Requiring only single phase power, UB25 is a 1000 Amp Linear
DC control with three feedback modes designed to adapt to part
and process variables. This power supply should be used for
smaller applications where closed-loop feedback control and
fast response times are required. Safety critical applications such
as those found in the medical and automotive markets will
benefit from UB25’s precision low energy control.
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• Built-in monitor supports process logging and
data collection for SPC purposes.
• Graphical monitor screen provides visual trace
of energy over time for easy weld parameter
optimization.
TYPICAL APPLICATIONS
Battery tab to lithium ion cell
Halogen lamp filaments
Catheter guide wire assembly
Air bag detonator module
(squib wire)
R E S I S TA N C E W E L D I N G
CURRENT, VOLTAGE AND
POWER FEEDBACK MODES:
Constant Voltage:
INTUITIVE, EASY-TOUSE PROGRAMMING
• Intuitive graphical user interface.
• Dual pulse waveforms programmed in
current, voltage, or power control modes.
• Programming times to 100 µsec
increments provides ultimate control.
• Accurate, built-in monitor displays the
graphical “trace” of weld current, voltage,
power and resistance, along with numerical
peak and average values.
• Easy-to-set limits establish
window for acceptable quality.
process
• User programmable relays can be used in
conjunction with visual and audible signals
for operators and automation interface.
• Compensates for parts misplacement and force
problems
• Reduces weld splash
• Ideal for round (non-flat) parts
Monitor current
Constant Power:
• Varies current and voltage for consistent energy
• Breaks up surface oxides and plating
• Ideal for automation to extend electrode life
Monitor current or voltage
Constant Current:
• Delivers same current regardless of resistance
changes
• Compensates for part thickness changes
• Ideal for flat parts with consistent electrode to part
fit-up
Monitor voltage
EFFECTIVE WELD MONITORING AND PROCESS TOOLS
Run Screen – Shows that 2nd Pulse was inhibited from firing.
Run Screen – Constant power first pulse breaks through oxides.
Run Screen – Shows termination of weld current during weld pulse.
Monitor Screen – Shows 1st Pulse weld current exceeded limit.
Monitor Screen – First pulse time automatically compensates
for varying levels of oxides.
Monitor Screen – Shows weld current exceeding limit.
PRE-WELD FUNCTION
ACTIVE PART
CONDITIONER (APC)
Sends an initial short, low energy pulse
through the assembly, tests key electrical
parameters against pre-set limits, and
inhibits operation if limits are exceeded.
Advanta ges
First pulse adapts weld time to displace
oxides then terminates allowing a second
pulse with upslope to complete the weld
thus avoiding weld splash.
• Prevents unacceptable welds.
Advanta ges
• Prevents electrode damage.
• Brings each part to the same resistance
prior to application of welding current.
• Alerts operator to weld fault.
• Relay outputs can signal automation.
• Provides for consistent welding of
difficult-to-weld oxidized parts.
• Prevents weld splash.
• Increases process yields.
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WELD STOP
Terminates the weld energy during the
welding process if pre-set weld current or
voltage limits are exceeded.
Advanta ges
• Prevents blow-outs and parts damage.
• Prevents electrode damage.
• Alerts operator to weld fault.
• Relay outputs can signal automation.
R E S I S TA N C E W E L D I N G
FULL RANGE OF WELD HEADS FOR THE COMPLETE WELDING SYSTEM
86A/EZ
PRECISION
PARALLEL
GAP WELD
HEAD
The Model 86 weld
head with either foot or patented EZ-Air® actuation provides
precision control for parallel gap welding applications from<0.001
inch (25 microns) to 0.005 inch (0.127mm) in diameter or
thickness. The force range of the 86A/EZ is 0.5 to 20 lbs. (2.289 Newtons). EZ-Air technology prevents overforce and
guarantees force repeatability. The Model 86 is normally matched
with the UB25 power supply.
70 SERIES
WELD HEAD
The Servomotor driven
70 Series weld head
with overforce protection and soft-touch part clamping provides
superior force control from 0.5-15 lbs. with excellent follow-up.
The 70 Series, available in both opposed and parallel gap can
store 32 motion control schedules for position and speed. The
heads are ideal for automation and delicate or critical parts
welding.
MODEL 50
LIGHT
FORCE
WELD HEAD
The 50 Series weld
heads with either foot or
air actuation provide accurate levels of precision required for
welding fine ribbons and wires to substrates. The force range of
the 50F is 40-1000 gram-force (0.39 - 9.8 Newtons),
continuously adjustable with no overforce. Holder options for
either Unitip or Unibond electrodes are available. Model 50 is
normally matched with the UB25 power supply.
88A/EZ
PRECISION
WELD HEAD
The fast rise time and
precision control of the
DC25 make it ideal for battery pack welding. The Miyachi Unitek
88 weld head, with either foot of patented EZ-Air actuation
provide fine levels of precision control required for microjoining
applications from <0.001 inch (25 microns) to 0.04 inch (1mm)
in diameter or thickness. EZ-Air prevents overforce and
guarantees force repeatability. The EZ-Clean feature permits easy
electrode set-up and maintenance.
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R E S I S TA N C E W E L D I N G
SPECIFICATIONS
MODEL NUMBER
Nominal Line Voltage (Single Phase)
Line Voltage Range
Repetition Rate
Setting Ranges:
Current
Voltage
Power
Peak:
Current
Voltage
Power
Output Regulation versus Line Voltage Variance
Output Regulation versus Load Resistance Variance
Output Repeatability Current, Voltage, Power ± of Setting
Weld Period Ranges
First / Second Pulse (msec.) – Ranges Scale
Upslope / Downslope Periods (msec.) – Ranges Scale
Output Accuracy
DC25
DC25/230
UB25
UB25/230
115 VAC 50/60 Hz
230 VAC 50/60 Hz
115 VAC 50/60 Hz
230 VAC 50/60 Hz
+15% / -10%
+15% / -10%
+15% / -10%
+15% / -10%
20kW @ 1 weld/sec for 10 msec (per weld)
5kW @ 1 weld/sec for 10 msec (per weld)
100A - 4000A
5A – 1000A
0.1V - 9.9V
0.01V – 4.9V
0.1kW - 9.9kW
0.01kW – 4.9kW
4000 amps
1000 amps
15V
9V
40kW
10kW
2%
2%
2%
2%
2%
2%
Ranges
Resolution (steps)
Ranges
Resolution (steps)
0.01 - 0.99 / 1.0 - 9.9
0.01 / 0.1
0.01-0.99 / 1.0-9.9 / 10-99
0.01 / 0.1 / 1
0.01 - 0.99 / 1.0 - 9.9
0.01 / 0.1
0.01-0.99 / 1.0-9.9 / 10-99
0.01 / 0.1 / 1
+/-2% of setting plus 2A, .05V or 20W
PHYSICAL CHARACTERISTICS
Dimensions L x W x H Inches (mm)
Weight Lbs (Kg)
20.5 x 9.25 x 12.75 (521 x 235 x 324)
52 (24)
FEATURES
WELD HEAT PROFILE CONTROL
DC25
Weld Pulse Control
Programmable Weld Pulse Segments
Weld Schedule Memory
Weld Schedule Chaining
DC25/230
UB25
UB25/230
Dual pulse with independent control of current, voltage or power on each pulse.
Squeeze, upslope 1, weld 1, downslope 1, cool, upslope 2, weld 2, downslope 2, hold.
Save up to 99 different weld schedules, protected from unauthorized changes.
Allows automatic linking of weld schedule sequence.
BUILT-IN WELD MONITOR FUNCTIONS
Measurement Parameters
Graphic Display
Measurement Selection
Current Measurement Range/Accuracy
Voltage Measurement Range/Accuracy
Power Measurement Range/Accuracy
Alarms
Programmable Weld Energy Limit
Weld Pre-Check
Active Part conditioner
Current, voltage, and power on each pulse.
Back-lit LCD displays programmed and actual weld current, voltage, or power, and upper and lower limits.
Peak or average.
0.1 – 4.0 kA, ±2% of setting ±2 A.
0.005 – 1.00 kA, ±2% of setting ±2 A.
0.1 – 9.9 V, ±2% of setting ±0.05 V.
0.01 – 4.9 V, ±2% of setting ±0.05 V.
0.1 – 9.9 kW, ±5% of setting ±20W.
0.01 – 4.9 kW, ±5% of setting ±20W.
Display alert, four user programmable AC/DC relays; audio alarm.
Terminates weld energy when exceeding user defined current, voltage, or power limits.
Inhibit second weld pulse when first test pulse exceeds user programmed limits.
First pulse current limit in constant power.
I/O AND DATA COMMUNICATIONS
Input
Output
Input Isolation
Control Voltages
Foot Switch Initiation
Firing Switch Input
Remote Control
RS232
RS485
Electrode Voltage
Monitor
Weld Head Air Valve Driver
Alarm Relays
All inputs and outputs are fully isolated.
Selectable: +5V, +24V, sourcing or sinking inputs.
1-level foot switch, 2-level foot switch.
Mechanical or opto firing switch.
Remote weld schedule select, process inhibit, emergency stop.
Change weld schedules and individual parameters.
Change weld schedules and individual weld parameters; “Daisy Chain” unit to unit, unit(s) to host computer.
Weld voltage signal for voltage feedback operation (0 to 10V peak).
RS232/485 Weld data out
24 VAC, 1A; timing controlled by DC25 or UB25.
Four user-programmable mechanical relays; programmable normally open or normally closed contacts:
250 VAC at 5 A; 30 VDC at 5 A. Conditions: weld, end of weld, alarm, out of limits.
ORDERING GUIDE
Specify DC25 or UB25
Included Accessories
Required Accessories
Optional Accessories
Add XXX for voltages other than 115 VAC where XXX is the line voltage. Example: DC25/230 for 230 VAC operation.
Weld cable bolts, D sub-connector, voltage sense cable, voltage sensor clip, manual, CE safety sheet.
Weld head (see previous page): air, electromagnetic or foot actuation.
Datacom kit for DC25 and UB25 system including PC data logging software and interface cables for collecting current, voltage, and power weld data.
Miyachi America Midwest Sales Office:
50384 Dennis Ct., Wixom, MI 48393
T: 248 313 3078 • F: 248 313 3031
[email protected]
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T: (915) 881-8765
[email protected]
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Miyachi Japan
95-3 Futatsuka Noda, Chiba, 278-0016, JP
T:+81-4-7125-6177 • F:+81-4-7125-6170
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Room 01,15th Floor, SML Center, No.610 Xujiahui
Road, Huangpu District, Shanghai 200025, CN
T:+86-21-6448-6000 • F:+86-21-6448-6550
Miyachi Europe
Lindberghstrasse 1 • DE-82178 Puchheim
T: +49 (0) 89 83 94 030 • F: +49 (0) 89 83 94 0310
FOLLOW US ON:
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Specifications subject to change without notice. Copyright© 2014 Miyachi America
Corporation. The material contained herein cannot be reproduced or used in any other way
without the express written permission of Miyachi America Corporation. All rights reserved.
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Av. Ceci, 608 – Bloco 16B – Empresarial Tamboré,
06460-120, Barueri, SP, BR
T: +55 (11) 4193-1187
991-355 01/13
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[email protected] • www.miyachiamerica.com
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