Dukane probe generators offer the option to monitor and weld by distance using an analog (LVDT) sensor. Integrating this feature support into our generator offers several advantages over competitive systems. They are as follows:
Cost savings over PLC based distance systems
PLC based systems require the purchasing of separate analog input modules. The Dukane distance option requires no additional hardware. Only the sensor itself is needed.
Increased Accuracy due to .5msec Response to Distance Sensor Input
Integrating Weld by Distance into the generator means the generator is responding to changes in distance every .5msec. This offers a significant advantage over PLC based systems which can take as much as 20 msec or longer to respond to distance sensor feedback to end the weld.
Single Source for Process Control
All weld processes are controlled through the generator. This results in seamless integration for programing all aspects of the weld control. Competitive systems require a PLC interface for sensing the weld position. This results in the weld process control being split between two different control platforms, adding significant complexity to the programing and user interface. With Dukane’s integrated distance feature, the generator completely manages the weld process.
The second advantage to this is the single source for Bad Part Limits. Programing is on single page. This greatly simplifies data collection for quality assurance and record keeping.
The Ability to Create Graphs for Process Analysis
Using iQ Commander, the weld process can be graphed, for detailed process feedback. This is a significant asset when fine tuning a weld process.
Competitive Systems Must Integrate a Mechanical Trigger Method to Sense Part Contact, Making true Weld by Distance Impractical for Multi-Probe Systems
Dukane’s Patented Trigger by Power enables determination of part contact without the use of any external components. Competitive systems would require additional mechanical sensors, adding complexity and increased cost, not practical for probe systems. As such, competitive systems can only weld by final position, and are unable to compensate for variance in part height as required for true weld by distance.
Analog Position Sensor Input
Each MPC probe has a corresponding dedicated analog input that accepts a 0-10 volt signal from an linear position (LVDT) sensor. The position value can be used for Pre-Trigger position, Weld by Collapse Distance, or Weld by Position.
Programmable Distance for Each Weld Point
Each probe generator can store up to 16 different setups*. Each setup is selected and programed via an Industrial Network Communication Protocol. Once each setup is programed, the generator only needs an MPC probe number and a start command. The generator will take care of the rest.
*Dukane’s Auto Plus MPC generator features 8 distance sensor inputs. AiM features 2 distance inputs.
The Ability to Accurately Sense Part Contact Using Dukane’s Patented Trigger by Power
The Trigger by Power feature activates ultrasound at a low amplitude while the horn is above the part. When part contact occurs, the generator senses the increased power requirement caused by the load of part contact. This increase in power tells the generator to begin the weld portion of the cycle. The generator ramps up the amplitude and initiates the measurement process for the primary weld control method. This defines the trigger point for Weld by Distance, Weld by Energy, or Weld by Time. Tests in real world applications have shown this method of triggering to provide a highly repeatable trigger point. Because the amplitude is operating at a low level prior to part contact, part damage normally associated with pre-triggering is prevented. No other competing systems can offer this patented feature.
Additional Process Settings Available as Secondary Controls
In addition to Weld by Distance, secondary controls can also be used such Weld by Energy, Weld by Peak Power, or Weld by Time. The generator will end the weld if any parameter threshold is met.
Part Detection Through Process Limits
Process Limits can be set based on the trigger position. For instance, if part contact is not recognized within the expected downstroke position, the weld cycle can be automatically aborted. This can be used to detect part misloads, or parts that have been previously welded. In addition, setting a maximum weld position can prevent part burn through, which would otherwise cause costly damage to the part and potentially to the weld stack assembly or fixture.