Sonics E-Press - Manual (Page 25)

Sonics E-Press Manual Page 25
11.1 Units
– Select the English or Metric system of units by clicking the appropriate indicator. This should be
the first option selected when beginning an application because switching units will automatically default
the associated parameters. If the programming units are changed by the operator, the weld parameters
will be set to the minimum settings for the new Units selection. If the operator changes back to the
original units prior to a SET button command, the displayed values will again be set to match the original
machine values. The allowed programming limits provide different resolutions for Metric or English
selection so that whole decimal positions can be used. This will avoid incrementing entries by 2.54 etc.
The programmer must provide all weld values. The system does not automatically convert from Metric
to English or the reverse. The selection for Units and Weld Mode will determine the range of values
allowed for welding and speed settings. See Table 12.1. Note: Reference calculator function.
11.2 Weld Mode
– Select Absolute or Incremental Welding by clicking the appropriate circular indicator.
Absolute welding is referenced from the encoder home position. Selecting absolute welding means that
the reference weld distance is measured from home. Absolute distances must be coordinated when
using the second weld distance control. This means that Weld Distance 2 must be greater than Weld
Distance 1 etc. Ex: It would not be possible to weld first to 2.25 inches and then to 2.00 inches.
Absolute welding would be used when the final dimension of a welded part is to be controlled.
Incremental Welding is referenced from the location where the parts are compressed by the horn and
the applied force is equal to the Force Trigger setting. An incremental weld will first travel to Weld
Distance 1 using Weld Velocity 1 and then continue for and additional Weld Distance 2 using Weld
Velocity 2 (if Weld Distance 2 is set to a non-zero value).
11.3 Communications
– The communications window does not contain any programmable parameters. This
is an indicator box used to identify communications 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 welding application without switching back and forth to monitoring
screens.
11.4 Machine Values
– These are the present programmed parameters that have been sent to the motor
controllor. The Green SET button is the only operator interaction on the right side of the screen as
described above. When the SET button is clicked, the parameters that have been set by the
programmer are transferred to the motor controllor. To recall the settings from the machine refer to the
File Recall section below. The SET function will also attempt to qualify entries as much as possible.
Appropriate messages will be displayed to help the operator select values that not would create
operational errors.
11.5 Force Trigger
– The force trigger value is the amount of force which will be applied before the ultrasonics
is turned on and the weld begins. This is also the force applied during the teach mode described in 9.5.
Force is measured by a load cell located between the actuator and the moving head assembly. The
conditioned force signal is wired to the motion controller which moves the motor and monitors the force.
11.6
Travel Distance – This programmed distance is used for the Align function and will be the travel
distance to unwelded parts during the welding cycle. The Align Function is initiated by simultaneous
activation of the front panel Keyswitch and the Align switch (see Align Function). It extends the carriage
by the programmed travel distance to allow for fixture alignment and adjustment. During a “Teach”
operation, the system will find the actual distance to the parts.
11.7 Weld Velocity 1
– The weld velocities are entered as RPS (motor revolutions per second) values
because actual weld velocity numbers would be too small to comprehend. The programmer would have
to enter too many decimal digits to change a setting. Weld velocity 1 represents the speed which will be