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Chapter 5: Automated Welding

Overview

The Linear DC Basic welding unit has been designed to be able to be integrated into automated 
welding systems. To aid in this integration the welder has the ability to output a series of sensing 
inputs, control output signals, and notification signals. 

OUTPUTS

Logic:

Weld Good Signal State

Weld No Good Signal State

Weld was good

Closed (Grounded) 

Open

Weld was not good

Open

Closed (Grounded) 

Welder Welding/No weld has happened

Open

Open

Error

Closed (Grounded) 

Closed (Grounded) 

•   Weld Good: If this signal (Open Collector) is closed (grounded) it indicates that the previous 

weld was considered within the tolerances set by the user. If this signal and “Weld No Good” 
signal are both open at the same time then the welder is either welding or hasn’t made 
a weld since being turned on. Recommend at least a 1K Ohm resistor pulled to “Limited 
+12VDC” for a 12VDC Logic signal (active low).

•  Weld No Good: If this signal (Open Collector) is closed (grounded) it indicates that the 

previous weld was considered out of limits on the comparator. If this signal and “Weld No 
Good” signal are both open at the same time then the welder is either welding or hasn’t 
made a weld since being turned on. Recommend at least a 1K Ohm resistor pulled to 
“L12VDC” for a 12VDC Logic signal (active low).

•  Welder Ready: If this signal (Open Collector) is closed (grounded) it indicates that the welder 

is ready to weld.  If this signal is open it indicates that the welder is not ready to weld.  This 
can be because the unit has not been put in a weld ready state. To do this press the button 
on the top left of the Retina touch display labeled “No Weld”.  This signal can also be open 
indicating that a weld is occurring. Recommend at least a 1K Ohm resistor pulled to “Limited 
+12VDC” for a 12VDC Logic signal (active low).

SENSORS AND INPUTS

•  Voltage Feedback: The Linear DC welding unit is capable of measuring output voltage in 

Содержание Linear DC

Страница 1: ...Sunstone Welders Linear DC User Manual...

Страница 2: ...Button Save Button Load Button Video Tab Schedules Tab Operational States Button Weld On Weld Off Button Chapter 4 Start Welding Example Project Setup Perform a Weld Chapter 5 Automated Welding Overv...

Страница 3: ...eering we are committed to producing quality products and ensuring com plete owner satisfaction If you require assistance after reading this manual please contact us with the information provided belo...

Страница 4: ...not block WELDER INFO Welder information is found here TERMINALS Connect weld head or welding attachments cables here FUSE 20A Fuse DIN CONNECTION PORTS Connect welding attachment DIN Connections here...

Страница 5: ...SETUP BACK PANEL CONNECTIONS Positive Terminal Connect one of the cables from weld head or welding hand attachment to the positive terminal with the included 20 screw Caution Terminal and or cable ca...

Страница 6: ...o negative and positive terminals on the back of the Linear DC 2 Connect weld head actuation cable to Weld Head Actuation DIN connection port on the back of the welder 3 See weld head manual for instr...

Страница 7: ...hment actuation cable to Weld Head Actuation DIN connection port on the back of the welder Precautions HANDLING PARTS BEING WELDED Caution Pieces that have been welded can be HOT Always use caution wh...

Страница 8: ...D ON At this point engage the emergency stop button After this the welder should automatically go into a WELD OFF state The button on the top left of the screen will change from WELD ON to WELD OFF If...

Страница 9: ...either type in their desired parameter in the numeric keypad or slide their finger on the slider bar to move the weld parameter value up or down The slider bar was designed to react to the speed of t...

Страница 10: ...e in th root directory of the USB thumb drive follow the steps below 1 Insert the USB stick into the USB slot on the side of the welder 2 Touch the update welder button ENTER TEST SUITE This is used f...

Страница 11: ...ettings After touching the save button follow these steps 1 Type in a name for the new setting or choose an existing saved setting on the left and it will be replaced with the current setting 2 Insert...

Страница 12: ...tton Touch the Load Button to open previously saved weld parameters Simply scroll through the options on the left of the screen then select the desired previously saved weld parameter Then touch the l...

Страница 13: ...13 Videos Tab Select from the tabs on the left to watch promotional settings and technique videos...

Страница 14: ...ters are attainable with the connected weld path resistance The user has the option to have the welder stop operation when the Precheck fails or to continue welding with a warning message or signal Th...

Страница 15: ...e precheck setup go to the weld head screen and set up the weld head in either manual or automatic mode See weld head section below for details about the parameters on this screen Resistance Resistanc...

Страница 16: ...low heat is required Dual pulse welds are helpful when the piece is dirty or has oxides plating on it The first pulse preheats the part and burns off any oxides helping the second pulse to perform the...

Страница 17: ...wer frequency is less pulses Upslope The length in milliseconds for the weld amount to increase to the weld voltage Weld Sets the duration of how long the max weld voltage is applied in milliseconds D...

Страница 18: ...Monitored voltage current or power This displays the actual voltage current or power that was achieved on the previous weld The number will be 0 if the comparator was turned off on the previous weld...

Страница 19: ...ill stop welding and alert the user anytime the voltage current or power goes out of the min max range that was set 3 Flag and continue weld The welder will continue welding but will alert the user th...

Страница 20: ...ontrolling a weld head and the Linear DC with two separate foot pedals 3 Automatic Select this when controlling a weld head and the Linear DC with one foot pedal or when attaching to a PLC Weld Discha...

Страница 21: ...r having made contact with the piece This allows the part to be settled well and give greater consistency between welds The Squeeze option must be selected in order to use this function Hold Time The...

Страница 22: ...ere are two start trigger options One must be selected before entering welding parameters Foot Pedal Controlled by user pressing the foot pedal PLC Controlled Controlled by user using a PLC Programmab...

Страница 23: ...when stored energy levels are too low and transitions from this state when sufficient stored energy levels have been reached Welder and user interface settings may be adjusted in this state however n...

Страница 24: ...nality of the WELD state may be performed in this state COOLING NO WELD Many of the components inside the welding unit generate significant amounts of heat under various operational conditions that if...

Страница 25: ...tions and discharge all stored energy in the welder as quickly as possible This state is activated by the user when the external emergency stop signal is sent to the welder or when the welder detects...

Страница 26: ...26 Chapter 4 Start Welding Example Project Setup Below is an example project we preformed welding a piece of Nitinol Foil to a Tantalum plate PRECHECK PULSE 1 SETTINGS...

Страница 27: ...27 COMPARATOR WELD HEAD...

Страница 28: ...rt 3 With the Linear DC in a no weld state check the part height Check for obstructions or anything that could short between and electrodes 4 Verify that the weld head is actuating see chapter 1 Weldi...

Страница 29: ...ngly Keep in mind that the effect that voltage has on a weld is not linear i e a weld made at 4 volts is not twice as powerful as a weld made at 2 volts It is closer to four times more powerful The we...

Страница 30: ...d to Limited 12VDC for a 12VDC Logic signal active low Weld No Good If this signal Open Collector is closed grounded it indicates that the previous weld was considered out of limits on the comparator...

Страница 31: ...C The user interface provides triggering options for when this signal is active Foot Trigger 1 and 2 These signals give weld delivery systems the ability to signal the Linear DC welding unit when to s...

Страница 32: ...ce of the material The figure below shows an example of a micro scale surface profile On the micro scale material surfaces are rough and only contact in a limited number of locations In the first few...

Страница 33: ...ent from weld to weld and is not dependent on the user ELECTRODE CONFIGURATIONS This figure shows several electrode configurations used in resistance welding Example A is called a direct weld Current...

Страница 34: ...e Most of the time if this happens the unit can be turned off and back on and the problem will be resolved If the warnings keep on showing up then please contact support and we will gladly help resolv...

Страница 35: ...0 1 10 0V at 10mV Step Power 0 01 20kW at 10W Step Peak Current 4000A Peak Voltage 10V Peak Power 20kW Weld Period Ranges weld time each section Squeeze hold Periods Ranges msec 0 100 0 5 Resolution...

Страница 36: ...t the work area is clean and safe for welding before starting any weld job Wear appropriate eye protection while using the weld head Do not install or operate unit near combustible surfaces Do not ins...

Страница 37: ...t of the welding path such as swapping electrodes or cables turn the unit off Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Properly install and ground th...

Страница 38: ...heat rapidly Repetitive welds in the same location can also cause metal to heat rapidly Avoid touching weld spots immediately after the weld has been performed as they will be hot Do not touch hot wel...

Страница 39: ...ng operation or storage Secure welding unit during transport so that it cannot tip or fall MAGNETIC FIELDS CAN AFFECT IMPLANTED MEDICAL DEVICES Wearers of pacemakers and other implanted medical device...

Страница 40: ...ion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Canadian Electrical Code Part 1 CSA Standard C22 1 from Canadian Standards Association Stan...

Страница 41: ...41...

Страница 42: ...SUNSTONE ENGINEERING R D CORPORATION 1693 American Way Suite 5 Payson UT 84651 1 877 786 9353 toll free 1 801 658 0015 international SunstoneWelders com...

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