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Section 6 – Process Control Settings
Dukane Manual Part No. 403-574-01
User- Provided Process
Control Overview
The generator includes a process control system to
control welding process. The basic “B models” can be
programmed to weld by time. “E model” generators can
weld by time and energy. See Figure 11-5 for model
number information.
Manual Welding
Generally, a trained operator will start the welding
process using a hand probe with an activation switch that
starts the welding controller that controls the duration of
the ultrasonic power applied to the parts being welded.
The operator applies an appropriate amount of pressure
to the parts to be ultrasonically joined. Then the operator
activates the welding cycle, and the process controller
begins the ultrasound output for a time (or energy) period
that will reliably weld the nal assembly. The quality of
the nished product is particularly dependent on the skill
of the hand probe operator.
Automated Welding
This automated welding control approach is custom
designed by the user and can be very simple or quite
sophisticated, depending upon the user’s requirements. In
most cases, a Programmable Logic Control (PLC) system
will be used to initiate the welding process. Then the front
panel process controller controls the welding process.
Output signals from the PLC system will determine when
the ultrasound or weld cycle starts. Control signals for a
Multiple Probe Control (MPC) system can also be easily
added, if needed. A variety of ultrasonic welding status
output signals are available to the automation system,
which are useful in monitoring the welding process.
Automated Process Control
Input Signals
Refer to Section 4 for the available input control signals
on the system input connector. The ultrasound/cycle
start activation input will always be used, with the other
available control input signals optional, depending upon
the user’s processing requirements. The Front Panel
Control Lock input and the System Latch Reset input are
used with the front panel controller. The Auto Stop input
provides an added means to shut off the ultrasound output
and the Remote Setup Bit inputs allows the automation
system to switch the system setups remotely.
Status Output Signals
Refer to Section 4 for the available status output signals
that are on the system output connector. Note that some
of the listed status output signals are not functional if
the system is not equipped with certain optional features.
Using the available status output signals, the automation
system can easily monitor when the ultrasound output
is activated and other fault status signals, to assist in
controlling the automated welding process.