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Model

e-Press

I N S T R U C T I O N

M A N U A L

Sonics & Materials, Inc.

[email protected]

     

www.qoovia-hk.com

હ࿕䲙˄佭␃˅᳝䰤݀ৌ

4RRYLD&RUSRQJ.RQJ/LPLWHG

Hong Kong Office:15B Granville House, 41C Granville Road,T.S.T., Kowloon,Hong Kong

Dongguan Office:6 Hang, No 17, Heng Xin Road Heng Gang Tou, Xin An Qu Chang An,
Dongguan Guangdong, China 523882

Tel:+86(0769)8532-0321 Fex:+86(0769)8532-0145

Tel:+86(00852)61717217 & 81463719 Fax:+86(00852)81479859

WWW.QOOVIA-HK.COM

Содержание e-Press 20EP

Страница 1: ...LRQ RQJ RQJ LPLWHG Hong Kong Office 15B Granville House 41C Granville Road T S T Kowloon Hong Kong Dongguan Office 6 Hang No 17 Heng Xin Road Heng Gang Tou Xin An Qu Chang An Dongguan Guangdong China 523882 Tel 86 0769 8532 0321 Fex 86 0769 8532 0145 Tel 86 00852 61717217 81463719 Fax 86 00852 81479859 W W W Q O O V I A H K C O M ...

Страница 2: ... evidence of having been used in violation of operating instructions or which has had the serial number altered or removed will be ineligible for service under this warranty For components and parts not manufactured by Sonics but included in Sonics manufactured equipment this warranty shall be limited to the warranty as given to Sonics by said original component or part manufacturer Ultrasonic hor...

Страница 3: ...et for proper earth grounding High voltage potential may be present in the converter as a result of temperature changes Do not touch the converter contact unless you first short both pins or the button to the converter case with an insulated tool Never squeeze or grab a vibrating horn Do not modify horn configurations Ultrasonic welders operate above normal audibility for most people Ear protectio...

Страница 4: ...arrier Do not destroy packing materials or move material from one location to another before the carrier makes their inspection VISIBLE LOSS OR DAMAGE Any external evidence of loss or damage must be noted on the freight bill or express receipt and signed by the carrier s agent Failure to adequately describe such external evidence of loss or damage may result in the carrier s refusal to honor a dam...

Страница 5: ...ed space forced air cooling may be necessary to keep the surrounding air within acceptable ambient temperature Periodically check the ventilation grille and clean if necessary The distance between the welding press and motor controls should not exceed 9 feet 3m PREPARATION FOR USE CONNECTIONS Connect the power supply and press in accordance with the following procedure See section 4 0 starting on ...

Страница 6: ...ction of interest For the purposes of this manual references to the GX controller or to the ultrasonic power supply will mean the associated ultrasonic supply and microprocessor controller References to the motor controls or stepper system will mean the transport controls for velocity and distance Certain ultrasonic control parameters can affect the stepper control performance The GX Ultrasonic Po...

Страница 7: ...stem and Connections ____________________________________ 11 5 0 PC Software Installation _____________________________________________ 14 6 0 Stepper Welding Operation ________________________________________ 15 7 0 Quick Start Application Procedure ____________________________________ 17 8 0 Stepper Control Panel ______________________________________________ 19 9 0 GX Power Supply Settings ____...

Страница 8: ...E Press driven actuator is very unique compared to a conventional pneumatic welder With a pneumatic welder the applied force on a part is adjusted by changing the air pressure regulation to the cylinder which drives the horn assembly Continuous pressure is applied to the parts during the welding process Attempts to modify the applied pressure are only marginally successful due to the volume of air...

Страница 9: ... reject rates Press All Transport System Stepper Motor positioning system w ball screw Force Trigger Control 10 150 lbs 1 lb increments 50 650 Newtons 1 Newton increments Vertical Travel Velocity 4 in sec 102 mm sec Weld Velocity 1 and 2 0 001 500 in sec 025 12 7mm sec Weld Distance Ref Parts Contact Diagram Pg 18 Absolute 0 0500 3 500 in 1 27 89 mm Incremental 0 0010 0 5000 in 0 01 12 70mm Motor ...

Страница 10: ...ckage size 15 25 W x 6 5 H x 18 75 D 387 3 x 165 1 x 476 25 mm Weight 21 Lbs 9 5 Kgs Humidity 20 90 non condensing Operating Temperature Range 50 90 F 17 40 C Programming Pentium Class PC required See section 6 Stepper Motor Resolution 42666 counts inch 0 0000234 in count Maximum Motor Case Temperature 125 C Display Two line LCD reports final weld distance EMC e Press controller is not CE approved...

Страница 11: ... and ultrasonic converter with a solid mount booster Additionally a standard computer with Windows operating system is required for programming the stepper system The press assembly has five cables two connect to the ultrasonic power supply GX and three connect to the stepper control box The round cables cannot be interchanged and will only match the appropriate connector shell type on the back pa...

Страница 12: ... your system Stepper Controller 1 J1 Control cable from press to Stepper Control 2 J2 9 Pin base cable from base to stepper control 3 J3 RS232 Communication to PC 4 J4 Power outlet to the press head for motor drive 5 Power line cord that plugs into the appropriate electrical outlet 6 Line fuse 7 Additional fuse for 220v configuration NOTE The RS 232 cable connected between the PC and Controller mu...

Страница 13: ... external trigger source Refer to wiring diagrams at the back of this manual 3 J4 Serial Output 4 J5 External I O 5 The power line cord that plugs into the appropriate electrical outlet 6 Fuse 0 5 amp internal low voltage 7 Line fuse 8 Line fuse NOTE The RS 232 cable connected between the GX Power Supply and the PC must be a null modem cable crossover info qoovia hk com www qoovia hk com W W W Q O...

Страница 14: ... 200 Mhz 32 Meg Ram 2 Gig Drive Windows98 or WindowsXP 2 The system must have two 2 Comm ports available COMM1 2 3 4 etc 3 Program space required Less than 20 Meg for the Stepper Program 4 Data Space Consider Storage space for accumulated Data If you intend to open a disk file to save the Welding Status line after each weld then get the largest Disk drive possible Each line will be about 90 text c...

Страница 15: ...ll be reported on the stepper controller display and the system will be ready for another weld operation The following sequence of events defines the typical weld cycle See section 12 0 for the details of programming the stepper settings Typical Weld cycle 1 The weld cycle is initiated by simultaneous palm button commands 2 The stepper drive head assembly will descend at a high speed to the parts ...

Страница 16: ...upply section is CE marked and has been tested in standard air actuated ultrasonic systems The motor controls are not CE marked Position Accuracy The system uses a stepper motor drive and ball screw which is controlled to 42666 counts per inch and a feedback encoder which reads to 6660 counts per inch 1679 counts per millimeter and 262 counts per millimeter respectively Allowing for lower encoder ...

Страница 17: ...fore sonics starts This is the force applied to the parts before the weld begins Again use the SET function to send these values to the machine 5 Extend the ultrasonic horn using the Align function on the stepper controls front panel Press the Align button and then the system palm buttons The system will extend the horn to the programmed Travel Distance Maintain the button command until Head is Do...

Страница 18: ... practical travel distance If the Upper Tolerance number can be made smaller the parts will be found faster which also improves the cycle time The Lower Tolerance number should be adjusted so that when no parts are installed the system will not hit the lower fixture This is the end of the parts search zone which will cause the system to retract if no parts are found Do not allow the horn to contac...

Страница 19: ...ycles or until the teach function is repeated at a later time The settings are preserved in permanent memory and will be saved during any non powered interval Once the system knows where the parts are located and the expected variation in their vertical dimension upper and lower tolerance settings the production welding process will be accurately repeated for every weld cycle The Stepper Controls ...

Страница 20: ...on is used to initiate the Teach function when used in coordination with the palm buttons Teach Function Press the Teach button to enter the Teach mode As instructed on the LCD screen press both palm buttons and hold them to extend the horn to an unwelded part The horn will apply the programmed force on the part and stop Continue to hold the buttons until the distance to the part is displayed on t...

Страница 21: ...energy mode settings if you are using a GXE power supply The energy limit must be set large enough so that the motor and velocity controls will have sufficient time to complete the weld If energy limits are reached before the weld distance the cycle may be cut short and the system may not reach the programmed distance 5 The Hold timer must be set long enough to allow the second distance movement t...

Страница 22: ...ion screen will prompt the operator to identify which ports are connected to each controller Once the system has been identified and the ports exist within the computer the configuration is stored in a small file that will be used the next time the welding system is powered up The identification screen will not be displayed again provided that the control systems and computer ports are found and v...

Страница 23: ...ring Units When the E Press program begins it will read the presently programmed entries and units from the machine This data will be displayed on the stepper programming form when the system is identified See section 12 0 below for E Press form details Control Forms Two Control Forms are available for programming and monitoring the E Press system the Stepper Setup Form and the Data Logger Form On...

Страница 24: ...ontrollers and preserves the non volatile memory in the Stepper control system A typical setup screen is shown below and illustrates how the motion parameters are set and displayed Each item on the setup screen will be discussed in the following sections as it pertains to the motion control and welding process References to the GX ultrasonic power supply manual will help guide the user in setting ...

Страница 25: ...cations activity It will turn green during communications activity and return to red when the data has terminated It will normally flash after each weld to indicate that the weld data has been sent Next to the communications indicator a small text box shows the last message received from the stepper system This allows the programmer to see the weld distance report during setup and adjustment of a ...

Страница 26: ...d for the second move The hold timer begins when the ultrasonic pulse is terminated even if the head assembly is still in motion Refer to power supply instruction manual for more information 11 11 Distance 2 Distance 2 is set the same way as weld distance 1 except that distance 2 is allowed to equal zero When distance 1 has been met the system will switch to velocity 2 until distance 2 is reached ...

Страница 27: ...saved and recalled to or from a specified file The file selection is handled in the standard windows style When the user has selected a file for the open function the data will automatically be retrieved from the computer file and loaded into the motor controls The save function will capture the present motor control settings and save this data to the specified file for future recall using the Ope...

Страница 28: ...w will be displayed when the Distance 1 or Distance 2 setting receives the focus That means the Total Distance Window will appear when the cursor is clicked in either text window for Distance to highlight or change the numerical values This window will display the sum of Weld Distance 1 and Weld Distance 2 When either distance is changed the Total Distance Window will automatically update and alwa...

Страница 29: ...the ultrasonic welder and a final distance report is sent from the stepper motor controller This presentation combines the status line from each unit and displays one line after each weld Up to 100 lines will be retained on the form They may be reviewed using the vertical slide bar on the right side of the text area The slide bar will automatically be enabled when the viewable text area has been f...

Страница 30: ...green the adjacent function is active When they are red the condition is turned off or waiting for data These indicators are not used for operator selection all selections for this form are made using the menu system along the top line of the form NOTE Line 2 shows No Weld Data This message will display if the GX power supply is not connected to the PC info qoovia hk com www qoovia hk com W W W Q ...

Страница 31: ...tion under the File menu selection allows the user to specify a data file to receive the status line described above File specification is handled in the familiar windows manner Once a file has been selected every status line that follows will be also written to the specified file as well as to the displayed text window If the selected file already exists the operator will be provided the option o...

Страница 32: ...et Stepper The Set Stepper menu selection will unload the monitor logging form and display the Stepper Setup form The Set Stepper form is used to program the motor controls as previously described 5 Notepad The Notepad selection is an easy way to launch the windows system Notepad program Notepad can be used to view the data file created by the file logging operation If the windows Notepad program ...

Страница 33: ...and each unit must be wired with the proper cables The stepper system must be in the ready screen SONICS MATERIALS Press HOME or RESET to return to the ready screen SYSTEM READY 4 The head assembly does not find the home position and keeps trying to run into the upper stop This could happen at initial startup or after a stall has taken place The system has missed the upper limit home signal and is...

Страница 34: ...every weld Data may also be sent to a file for later examination or simultaneously to a printer Lower Tolerance The search window position below the taught position which is the expected minimum limit where the parts will be found If parts are not found before the lower limit position the cycle will be aborted Press The mechanical assembly which holds the ultrasonic stack and provides a rigid plat...

Страница 35: ... to detect the parts Ultrasonic controls The GX ultrasonic controller Weld Time The programmed ultrasonic time in the GX Controller Weld Velocity The programmed speed used to advance the head assembly during the weld time Two speed changes can be programmed during the weld and or hold times Weld Distance The distance to travel during the weld Two weld distance steps can be programmed during the we...

Страница 36: ...t on one page simply enlarge zoom your current on screen view 1 E 3225 Press Signal Conditioning PCB 2 E 3227 Motor Drive Control Box Wiring 3 E 3228 DMC 151 IO Interface 4 E 3229 Electric Press Wiring 5 E 3092 Stepper Line Terminator 6 Schematic Layout Side View 7 Schematic Base Layout 8 Schematic Optional Stand alone Mounting Hub Layout 9 Schematic Exploded Assembly Drawing info qoovia hk com ww...

Страница 37: ...Sonics E Press Manual Page 37 info qoovia hk com www qoovia hk com W W W Q O O V I A H K C O M ...

Страница 38: ...Sonics E Press Manual Page 38 info qoovia hk com www qoovia hk com W W W Q O O V I A H K C O M ...

Страница 39: ...Sonics E Press Manual Page 39 info qoovia hk com www qoovia hk com W W W Q O O V I A H K C O M ...

Страница 40: ...Sonics E Press Manual Page 40 info qoovia hk com www qoovia hk com W W W Q O O V I A H K C O M ...

Страница 41: ...Sonics E Press Manual Page 41 info qoovia hk com www qoovia hk com W W W Q O O V I A H K C O M ...

Страница 42: ...Sonics E Press Manual Page 42 info qoovia hk com www qoovia hk com W W W Q O O V I A H K C O M ...

Страница 43: ...Sonics E Press Manual Page 43 info qoovia hk com www qoovia hk com W W W Q O O V I A H K C O M ...

Страница 44: ...Sonics E Press Manual Page 44 info qoovia hk com www qoovia hk com W W W Q O O V I A H K C O M ...

Страница 45: ...EXPLODED ASSEMBLY DRAWING Sonics E Press Manual Page 45 info qoovia hk com www qoovia hk com W W W Q O O V I A H K C O M ...

Страница 46: ...amage in shipment The system should be sent with all transportation charges prepaid and return method of shipment indicated SHIPPING Because of the problems in the handling of our equipment during shipment it is asked that all customers check the following 1 All module plug in units 2 All wire plug in connections 3 All I C 4 Sonics Materials makes every effort to ship our units in proper working o...

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