DPC III -Dynamic Process Controller� (DPC)

DPC III -Dynamic Process Controller� (DPC)
Intelligent Assembly Solutions
DPC III
Dynamic Process Controller™ (DPC)
INTEGRATED PROCESS CONTROL SYSTEM
DESIGN
• Integrated power supply and process controller
saves space, and simplifies setup and operation
• Modular component design maximizes product
flexibility and cost effectiveness by allowing the
selection of various power levels and process control
features
• Standard 19" (48cm) rack mountable unit available
for easy system integration at minimal cost
• Universal IEC 320 power cord receptacle accommodates most worldwide power requirements
• User interface option available for full-screen process
parameter display
• System upgradeability allows quick installation of
control and/or user interface features not originally
selected
• Retrofittable to existing ultrasonic press systems to
bring precise process control and monitoring features to applications already in production (20 kHz,
30 kHz, & 40 kHz systems only)
• Compatible with current Dukane presses, thrusters,
and probes
• Modular design concept gives maximum product
flexibility and cost effectiveness by allowing selection
of just the control and/or user interface features
necessary for the application
www.dukcorp.com/us • e-mail: [email protected]
Dukane Corporation • Ultrasonics Division • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630 ) 797-4900 • FAX (630 ) 797-4949
DPC III DYNAMIC PROCESS CONTROLLER ™
The DPC III
All of the advanced features and
benefits of Dynamic Process Control
technology combined with the
familiar, user-friendly interface of
our Ultra-Com.
DYNAMIC PROCESS CONTROL
• High performance 16-bit microprocessor addresses more
data in less time for superior performance
• Real-time, multitasking operating system simultaneously
controls and monitors process parameters
• One millisecond sample rate samples cycle parameters
one thousand times per second on a cycle-by-cycle basis
for greater accuracy, consistency, and control
• Primary and secondary control functions offer total
flexibility in process control, reducing rejects and increasing part consistency
• Unique Dual Pressure mode increases the clamp force for
a better melt during the weld cycle, or a tighter assembly
during the hold cycle
• For parts requiring more than one assembly operation and
more than one set of process parameters, Sequencing
mode automatically changes setups after a user-defined
number of process cycles
• Data sampling mode allows user-selectable sample sizes
and intervals for downloading or internal storage of up to
1,000 characteristics
• Nonvolatile setup memory stores 8 setups to eliminate
repetitive setup procedures and conveniently accommodate multiple projects
• Built-in RS-232 serial communications port for real-time
interfacing to external devices such as a printer for
permanent documentation, an optional user interface for
full-screen display, or another computer for additional
data storage or statistical process control (SPC) analysis
• Self-diagnostic error messages simplify troubleshooting
and correcting setup and programming mistakes
• Auxiliary outputs provide automation-ready, in dwell, bad
part and suspect part signals through the auxiliary
connector, leaving the RS-232 serial port free for more
sophisticated data communications
• Programmable bad part limits indicate all parameters
outside the tolerance established for an acceptable part
• Programmable suspect part limits indicate parameters in
a range that would cause a part to be suspect
• User-activated limit indicators label bad and suspect
parts on printouts and an optional user interface showing
out-of-tolerance parameters
• Bad part audible and/or electronic alarm alerts the
operator to any reject parts without having to look at the
user interface
• Separate suspect part audible and/or electronic alarm
tells the operator to set the part aside for inspection
• Power display for checking and monitoring acoustic stack
characteristics
• Optional remote setup switching allows setup selection in
response to a keyed fixture or a PLC signal, minimizing
changeover time and increasing productivity
• Programmable pressure and force by interface with the
electronic pressure regulator, pressure transducer, and
load cell press options offer increased control, repeatability, and consistency
INTEGRATED PROCESS CONTROL SYSTEM
FRONT PANEL INTERFACE
• One line by thirty-two character LCD display shows cycle data
and setup information using terms that are easy to understand
• Six-button keypad makes programming and parameter entry,
selection, or modification fast and easy
OPTIONAL USER INTERFACE
• Full-size monitor displays process parameters for multiple
parts and provides tutorial, menu-driven setup functions
• Full-size, 82-key keyboard provides direct parameter entry
• System power output indicates normal or possible overload
operating condition during the weld cycle
• System status panel displays any of six self-diagnostic
messages, including Fault, Input Test, Overload, On Line,
Overtemperature or Off Line
for faster setup and allows entry of notations and process
memos for permanent storage with setup information
18.42
468
Monitor:
Keyboard:
13” H x 13” W x 13” D
330mm H x 330mm W x 330mm D
1.5” H x 13.63” W x 6.5” D
38mm H x 344mm W x 165mm D
OPTIONAL
RACK MOUNTING
Dimensions
17.26
439
ALLOW 5" (130mm)
BEHIND DPC
FOR CABLING
19.00
488
18.38
467
5.17 5.59
132 142
5.59
142
INCHES
MILLIMETERS
23.75
604
ALLOW OPEN AREA
FOR COOLING AIR
BOTH SIDES
3.82
97
12.35
314
1.69
43
1.60
41
DISTANCE MODULE and LINEAR ENCODER
POWER and ENERGY MODULE
• Weld by distance mode controls the melt collapse
• Weld by peak power mode terminates ultrasound when the
distance to insure that the same volume of material melts
on each part so that the finished joint strength is consistent
• Weld by absolute distance mode controls the finished part
height to yield uniform assemblies
• All distance parameters (downstroke, trigger delay, weld,
hold, absolute weld, total weld, and total stroke distances)
are monitored, with upper and lower limits for bad and
suspect parts to verify quality and consistency
• High quality linear optical encoder with a one-micron
resolution for excellent precision and repeatability
• Graphing capability for plotting a Distance
vs. Time
curve on every weld, either on an optional user interface
or a serial or parallel printer
available joint material is completely melted, compensating
for variations in the molded part
• Weld by energy mode delivers a specific amount of energy to
the work to enhance process control
• Monitors all power and energy parameters with upper and
lower limits for bad and suspect parts
• Graphing capability for plotting a Power vs. Time curve on
every weld, either on an optional user interface or a serial
printer
DPC III DYNAMIC PROCESS CONTROLLER ™
Linear Ramp Soft-Start
AUTO-TRAC tuning
Line Regulation
Load Regulation
Overload Protection
Complete Dukane compatibility
... and much more!
GENERATOR
• Electronic overload protection prevents component
• Patented Pulse-Width Modulation design delivers
power more efficiently with substantially less stress
on the electrical components for superior performance, reliability, and extended service life
failure, reducing costly downtime
• Advanced transformer and inductor designs increase efficiency and reliability of electronic components
• Unique Linear Ramp Soft Start accelerates the
transducer and tooling up to operating amplitude
eliminating mechanical and electrical starting stress
• Line regulation compensates for line fluctuations
assuring consistent amplitude
• AUTO-TRAC tuning using phase lock loop technology automatically locks the generator to the resonant
frequency of the transducer and tooling even under
varying conditions of temperature and loading
• Load regulation assures constant amplitude at
various loads improving assembly consistency
• Dukane exclusive FLOW-THROUGH COOLING
provides on demand thermostatically controlled
cooling system that separates electronic components
from the cooling air flow chamber
• Adjustable amplitude 100% to 40%, allows for fine
tuning of the weld process
MODELS
POWER /
FREQUENCY
100 W 150 W 350 W 500 W 700 W 1000 W 1200 W 1500 W 1700 W 2200 W
20 kHz
2050
2120
30 kHz
2200
3150
40 kHz
4035
50 kHz
70 kHz
2170
4070
4100
5015
7010
Note: All specifications are subject to change without notice. Please consult Dukane Ultrasonics for any updated information.
Form No. 11472-C-04
www.dukcorp.com/us • e-mail: [email protected]
Dukane Corporation • Ultrasonics Division • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797-4949
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