Sonics e-Press 20EP User manual
Model
e-Press
I N S T R U C T I O N M A N U A L
Sonics & Materials, Inc.
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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
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Sonics E-Press Manual Page 2
WARRANTY
Sonics & Materials, Inc., hereinafter referred to as "Sonics", warrants its products for a period of one year from the date of original
shipment against defects in materials and workmanship under normal installation, use and maintenance as described in the
operating instructions which accompany such equipment. During the warranty period, Sonics will, at its option, as the exclusive
remedy, either repair or replace without charge for material and labor, the part(s) which prove upon our examination to be defective,
provided the defective unit is returned to us properly packed with all transportation charges F.O.B. Sonics dock, Newtown, CT.
Warranty period on equipment rentals that are converted to purchase are deemed to have commenced on the date of original rental
equipment shipment.
Ultrasonic plastics welding horns constructed of titanium or aluminum are guaranteed against defects for a period of one year from
date of shipment. Sonics will repair or replace a cracked or defective horn once without charge, if failure occurs within the warranty
period.
Ultrasonic plastics welding horns constructed of steel are guaranteed against defects for a period of ninety days from date of
shipment. Sonics will repair or replace a cracked or defective steel horn once at a charge of 50% of the original purchase price, if
failure occurs within the warranty period.
Ultrasonic metal welding horns constructed of titanium or steel are guaranteed against defects for a period of one year from date of
shipment. Sonics will repair or replace a cracked or defective horn once without charge, if failure occurs within the warranty period.
Sonics warrants its ultrasonic converters for a period of one year from date of shipment with a one-time replacement if a converter
proves to be non-repairable.
When customer site service is required, all travel, living and related expenses will be billed at cost. In-warranty service labor time
(including travel time) at the customers facility is provided Monday through Friday (excluding holidays) from 8:00 am to 5:00 pm. Any
in-warranty service time requested outside of these days and hours will be billed at 150% of Sonics current rate per hour for such site
service work.
LIMITATION OF WARRANTY
This warranty does not apply to items subject to normal wear and tear or, to equipment or tooling which has been subject to
unauthorized repair, misuse, abuse, negligence or accident. Misuse includes operation of equipment with tooling that is not qualified
for the equipment or tooling not properly installed on the equipment. Equipment which, in our judgment, shows 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 horns supplied by Sonics are manufactured to exacting specifications and are tuned to vibrate at a specific frequency.
Using an out-of-tune horn will cause damage to the equipment and may result in warranty nullification. Sonics assumes no
responsibility for converters, horns or fixtures not supplied by Sonics or for consequential damages resulting from their usage.
Ultrasonic converters showing signs of excessive heat or contamination, such as but not limited to, oils and moisture, are not covered
by this warranty.
Warranty does not apply to ultrasonic horns quoted as prototype, experimental or of unusual design which, in our judgment are more
likely to fail in use.
Warranty does not apply to re-sharpening of ultrasonic blade type cutting or slitting horns.
Warranty does not apply to knurl pattern wear on ultrasonic plastics and metal welding horns and tips.
Warranty does not apply to ultrasonic horn or tip face wear when used with plastics that are molded with fillers, such as but not
limited to, glass or talc.
This warranty does not apply to ultrasonic plastics welding equipment, horns or fixtures where metal-to-metal tooling contact time is
in excess of 250 milliseconds.
This warranty does not apply to used or re-built equipment.
This warranty is non-transferable.
Data supplied in Sonics instruction manuals has been verified and validated and is believed adequate for the intended use of the
equipment. If the equipment or procedures are used for purposes other than those specified herein, confirmation of their validity and
suitability should be obtained in writing from Sonics. Otherwise Sonics does not guarantee results and assumes no obligation or
liability.
This warranty is in lieu of any other warranties, either express, implied, or statutory. Sonics neither assumes nor authorizes any
person to assume for it any other obligation or liability in connection with the sale of its products. Sonics hereby disclaims any
warranty or merchantability or fitness for a particular purpose. No person or company is authorized to change, modify, or amend the
terms of this warranty in any manner or fashion whatsoever. Under no circumstances shall Sonics be liable to the purchaser or to
any other person for any incidental or consequential damages or loss of profit or product resulting from any malfunction or failure of
this Sonics product.
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WARNING
SAFETY PRECAUTIONS
READ BEFORE INSTALLING OR
USING THE EQUIPMENT
This system has been designed to assure maximum operator safety. However, no design can completely
protect against improper usage. For maximum safety and equipment protection, observe the following
warnings at all times and read the instruction manual carefully before you attempt to operate the equipment.
–The equipment has safety devices that require both hands to be on the palm buttons until the horn contacts
the work piece. Do not defeat or modify these safety devices.
–Do not use with foot switch unless alternate means of pinch-point protection is provided.
–High voltage is present in the equipment. Disconnect plug before removing cover or servicing.
–Make sure equipment is properly grounded with a 3-prong plug. Before plugging in equipment, test outlet 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 protection is recommended.
- Do not affix any device to any portion of the horn.
Information contained in this manual is subject to change without notice. Sonics & Materials, Inc. is not
responsible for any typographic errors.
© Sonics & Materials, Inc. 2009 Printed in U.S.A. Rev 2/09
®
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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
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Sonics E-Press Manual Page 4
INSPECTION
Prior to installing the equipment, perform a visual inspection to detect any evidence of damage which might
have occurred during shipment. Before disposing of any packing material, check it carefully for small items.
The equipment was carefully packed and thoroughly inspected before leaving our factory. Responsibility for
its safe delivery was assumed by the carrier upon acceptance of the shipment. Claims for loss of damage
sustained in transit must therefore be made upon the carrier, as follows.
CONCEALED LOSS OR DAMAGE - Concealed loss or damage means loss or damage which does not
become apparent until the merchandise has been unpacked. The contents might have been damaged in
transit due to rough handling even though the container may not show external damage. When the damage is
discovered upon unpacking, make a written request for inspection by the carrier’s agent within 48 hours of the
delivery date. Then file a claim with the carrier since such damage is the carrier’s responsibility. The form
required to file such a claim will be supplied by the carrier. 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 damage claim. The form required to file such a
claim will be supplied by the carrier.
If the system or any unit is damaged, contact the Sales Department at Sonics & Materials, Inc. “Sonics” will
arrange for repair or replacement of damaged equipment without waiting for the claim against the carrier to be
settled, provided a new purchase order is issued to cover the repair or replacement costs. Should any
damage, shortage or discrepancy exist, please notify us immediately.
ELECTRICAL POWER
The E-Press motor controls require a fused, single phase, standard 3-terminal grounding type electrical
receptacle capable of supplying 105-125 volts, 50/60 Hz, 10 amp service, or 200-240 volts, 50/60 Hz, 5 amp
service, depending on the voltage option. See the Model Specification and Accessory List –section 3.0.
MODEL @ 115 VAC @ 230 VAC
20EP or 40EP 10 amps 5 amps
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LOCATING THE EQUIPMENT
The system should be installed in proximity to the electrical source, and it is supplied with an 8 Ft power cord.
The area should be free from excessive dust, dirt, corrosive fumes and extremes of temperature and humidity.
Allow at least 10 inches (25 cm) in back of each unit for cabling convenience.
All welding press models should be placed on a sturdy level bench capable of supporting a minimum of 500
pounds (227 kg).
The power supply and motor controller should be located so that the front panel controls are visible and
accessible. Sufficient space should be allotted around the unit to ensure adequate ventilation. If the power
supply and motor controller must be housed in a confined 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
page 11 for additional information and a connection diagram.
1. Using cables provided, connect the power supply to the press. Do not strain or kink the cables. When
going around corners, allow as wide a bend as possible. Do not run the cables parallel to any power line
within a distance of less than 1 foot (30 cm).
2. Plug the power supply line cords into the electrical outlets. To prevent the possibility of an electrical
shock, ensure that the line cords are properly grounded.
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IMPORTANT SERVICE LITERATURE
Please read carefully before operating the equipment
The plastics assembly system supplied with this instruction manual is constructed of the finest available
components with workmanship that meets or exceeds our highest manufacturing standards. It has been
thoroughly tested and inspected before leaving the factory and when used in accordance with the procedures
outlined in this manual, will provide you with many years of safe and dependable service.
MANUAL INFORMATION
We continually strive to keep up with latest electronic developments by adding circuit and component
improvements to our equipment as soon as they are developed and tested.
In order to move around the manual quickly, hyperlinks are provided in the following Table of Contents (TOC)
for each major section. Click the hyperlink to move directly to the selected section. At the top of each linked
heading you will find a TOC link to return to the Table of Contents. This should help to minimize continuous
page up/down key-strokes to find a section 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 Power Supply manual must be considered an
integral part of understanding the Stepper Welding System.
Basic Windows familiarity is assumed. The user must be familiar with Windows based file selection and
mouse operations. Consult a Windows tutorial if these operations are unfamiliar. Manual descriptions will not
address these basic concepts.
Internet familiarity is also assumed. URL addresses have been included in a few sections to assist with
downloads for viewing this manual. If Internet access is not available these references may be ignored.
Manuals for all new Sonics & Materials products are provided on CD.
We reserve the right to make any changes in the design or construction of our equipment at any time, without
incurring any obligation to make any change whatsoever in units previously delivered.
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TABLE OF CONTENTS
GENERAL
Warranty Information ____________________________________________________ 2
Safety Precautions _____________________________________________________ 3
Inspection ____________________________________________________________ 4
Utilities Required _______________________________________________________ 4
Locating the Equipment _________________________________________________ 5
Preparation for Use _____________________________________________________ 5
Manual Information ______________________________________________________ 6
This Table of Contents ___________________________________________________ 7
System_Operation
1.0 Introduction to Plastic Welding _________________________________________ 8
2.0 The Stepper Welding System __________________________________________ 8
3.0 Product Specifications _______________________________________________ 9
4.0 Physical System 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 ___________________________________________ 21
10.0 Running the Stepper Utility Program __________________________________ 22
11.0 Stepper Setup Form________________________________________________ 24
12.0 Data Logger Form _________________________________________________ 29
MAINTENANCE
Stepper Trouble-shooting Guide ___________________________________________ 33
Glossary of Terms ______________________________________________________ 34
Drawing List ___________________________________________________________ 36
Return/Repair Notes ____________________________________________________ 45
Shipping______________________________________________________________ 45
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System Operation
TOC
1.0 Introduction to Plastic Welding TOC - For an introduction to ultrasonic plastic assembly –Refer
to the GX Power Supply Instruction Manual supplied with the ultrasonic power supply - pages 6 through 8.
These sections discuss the basic principles of ultrasonic assembly and the major ultrasonic components –
converter, booster and horn. The E-Press welding system is identical except that a solid mount booster is
used that will not flex under applied pressure. To achieve the best desired assembly accuracy of the stepper
system, a solid mount booster is required.
2.0 The Stepper Welding System TOC - The Stepper Welder System (E-Press Model) is designed for
precision plastic welding applications with dimensional requirements beyond the capabilities offered with a
standard air actuated ultrasonic press. The system will control the final weld position with a tolerance of
+0.0003 inches. Finished assemblies are produced with a weld repeatability that is not possible with any other
plastic welding process. The advancing speed of the ultrasonic horn is controlled with a stepper motor drive,
which exactly repeats the defined profile for position and velocity every time. The results are repeatable welds
with exact final dimensions of the bonded components when compared with air driven actuators (material
dependent). The system is offered as a transport option with standard Sonics & Materials 20 kHz and 40 kHz
ultrasonic power supplies.
The E-Press actuator assembly is a completely rigid system. Solid booster technology is used to mount the
stack assembly into the actuator head. These boosters do not contain O-rings, which are found in
conventional ultrasonic boosters. O-rings can move and distort as pressure is applied resulting in horn
movement on the parts and weld quality problems. With this rigid system the horn will not move and full
capability of the stepper motion controls can be achieved.
Welding with an 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 that is present.
Pressure cannot be changed instantaneously as long as the air system has pressure. A notable lag will occur
between changing the regulator settings and any actual pressure change. In most cases, the weld will be
completed long before the pressure change could affect the weld in any appreciable way. With the stepper
system, force can be controlled precisely through a digital velocity profile.
The E-Press system uses the programmed weld velocity to control the applied force directly. This applied
force is also dependent on ultrasonic amplitude, which controls the level of heat available, and therefore the
amount of molten plastic that will be produced between the parts. The resultant force will be a function of
heat (ultrasonics) to melt the plastic and velocity to drive the parts together. The faster the horn moves into
the parts the greater the force. The greater the heat that’s available to melt the plastic, the lower the force,
because the plastic will flow out from under the horn. Best application results will be provided by careful
balance of velocity, distance and ultrasonic amplitude. With the velocity and distance precisely controlled, the
actual weld cycle time will also be exactly repeatable because the velocity profile will be the same every time.
The E-Press controls are packaged in the same size chassis as the Sonics & Materials ultrasonic power
supply so that they can be stacked together. This provides a standard ultrasonic supply whether the customer
application requires velocity controls with the stepper transport or a standard air actuated system. Both units
should be located so that they are accessible to the operator for initial setup and programming.
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3.0 System Specifications
TOC
Application Types:
-The E-Press Model is best applied to applications that require precise dimensional control,
repeatability or improved bonding strength. Special materials and delicate components will also
benefit from the velocity profile offered by the EP System.
-Clean room applications that cannot allow the pressurized air systems required by conventional
ultrasonic welders.
-Marginal conventional ultrasonic applications may be stabilized to improve weld quality and reduce
production 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 Position Accuracy: 0.0003 in. ( 0.007mm).
Parts search zone (Ref Parts Contact Diagram Pg. 18):
Upper Tolerance 0.0010 –0.1000 in.
(0.025 –2.500mm).
Lower Tolerance 0.0010 –0.1000 in.
(0.025 –2.500 mm)
Fixture Mounting Thread: 3/8 –16 (10 mm).
Maximum Stroke: 3.5” (89 mm).
Motor Stall Force: >500 Lbs. (2225 Newtons).
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20 kHz e-Press Dimensions:
Press Height: 48” (1219.2 mm)
Weight: 210 Lbs. (95 Kgs)
Maximum opening for parts and fixture: 10”(254 mm)
Depth: 25” (635 mm)
Width: 14” (355.6 mm)
Motor Control:
AC Power: 115 VAC @ 10 amp fuse rating.
230 VAC @ 5 amp fuse rating.
Package 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.
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4.0 Physical System and Connections TOC –Physically the system is contained in three separate
packages –The stepper controller, the ultrasonic power supply and the motor press assembly. Several cables
are required to connect the various pieces together –see cable diagrams on the following pages. The
ultrasonic supply and the motor controller are packaged in similar size chassis and should be positioned for
easy programming access and cabling. The press assembly contains the motor, motor position encoder, force
sensor, linear positioning actuator 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 panels of the control units.
A termination connector is supplied and must be used on the stepper system if a computer will not be used to
monitor the stepper controls. This connector terminates the hardware handshake lines. Drawings for some of
these cables are contained in the Maintenance section of this manual.
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Cable Connections for Stepper Controller and Ultrasonic Power Supply
The drawings below and on the next page show the back connections of the Stepper and Ultrasonic controls.
Match the cables from the press to the appropriate connections noted below. (The interconnecting cables will
be supplied with 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 must be a straight one-to-one cable
(Do not use a null modem cable.)
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GX Power Supply
1. J1, a round, 12-pin RF cable that connects the welding press to the power supply.
2. J2, an actuation cable that connects the power supply to a trigger source (press cable or 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).
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5.0 PC Software Installation TOC –A Pentium class PC is the minimum required as the programming
and monitoring interface to the stepper welder system. The computer is used to program the stepper distance
and velocity controls. Once the application is setup and running properly, the computer may be removed. The
system will run the programmed profile without further commands from the computer. A termination jumper
must be connected to the stepper controls in order to terminate the communication signals.
The following computer requirements should be considered when selecting a PC for the Stepper Utility
Program.
Recommended minimum computer requirements for the E-Press welder:
1. Minimum Computer: Pentium 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 characters in length.
5. Software: Windows98/XP; Microsoft Office 97 or later.
The Stepper control programs are provided on CD. Select the appropriate directory and run the setup
program from that directory. For the Stepper Control Utility, run the .exe file entitled G-Series EP Utility from
the c:|EP Utility directory. A Sonics Directory will be created and the files will be installed in the standard
installation technique. See section 10.0 to run the E-Press utility program.
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6.0 Stepper Welding Operation TOC –The stepper welding process is similar to the conventional
ultrasonic process. The application parts are positioned in the fixture and dual palm buttons are pressed
simultaneously to initiate a weld. A cycle begins by advancing the horn to the parts at a fixed approach
velocity. The approach velocity has been selected based on the mass of the head mechanism and the
maximum acceleration that can be used without stalling the stepper motor.
Just above the parts, the velocity is reduced to a search speed in order to locate the parts for assembly. This
protects the parts from impact damage that could result from a higher speed contact. The parts search will
continue for a distance equal to the width of the programmed tolerance window or until the parts are found.
When the ultrasonic horn contacts the assembly, pressure will increase quickly. The applied force is
measured and monitored until the trigger set-point is reached defining the parts’ location and positively seating
the plastic interface joints. The trigger is satisfied and ultrasonics will be turned on to begin the plastic weld.
The defined weld motion profile will continue as the ultrasonic energy melts the plastic joints.
When the weld velocity and distance profiles have been executed, the weld is complete and ultrasonics will be
turned off. If a hold time has been programmed, the motion will be stopped and the system will wait for the
specified time period. Hold time is normally used to allow the plastic joint to solidify while the parts are held in
position to complete the bonding process.
The system will retract to the home position to end the weld cycle. The final weld distance will 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 position taught by the
“Teach Command”, less the upper tolerance setting.
3. The system searches for the parts at a slower search speed. The parts are detected when the force
builds to the programmed Force Trigger set-point. If the parts are not found by the time the system
has traveled to the lower tolerance setting, the cycle is aborted and the head retracts automatically.
Parts may not be positioned in the fixture.
4. When the parts are found, the specified incremental or absolute weld will begin. The ultrasonics is
turned on and the motor continues to travel at the programmed Velocity #1 until the programmed
Distance #1 is reached.
5. If a second weld distance has been entered (anything but a zero value) then the weld will continue
after the first distance using the parameters for the second distance settings. The travel motion
proceeds using welding Velocity #2 until Distance #2 is reached. Ultrasonics will be on or off during
this period controlled by the Weld indicator associated with the Travel #2 parameters. If “Off” has
been selected for ultrasonics during this period then the ultrasonic hold time must be set long enough
to allow for the movement plus any additional Hold time is required by the application after the move is
complete. See section 12.10.
6. When the distance has been satisfied, the ultrasonics will be turned off by a cutoff command issued to
the GX power supply.
7. The system waits for the hold time specified for the welder controls.
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8. When the weld cycle is complete, the system ascends to the home position (up).
9. The stepper controller transmits the final distance report and the GX ultrasonic controller transmits the
weld status information.
Power Up –The stepper system has two separate power switches - a green membrane key on the GX power
supply and an identical green key on the E-Press Motor Control box. Both units should be powered up before
the computer system is turned on. The order is not critical.
Safety Note –The stepper welding system will retract to the head up position whenever the Red Emergency
Stop button on the front of the press is engaged. The Stepper Controller will remain powered during an
emergency stop condition in order to step the mechanism in the reverse direction. It does not power down
with engagement of the Emergency Stop button. This action is necessary due to the force that can be applied
by the screw mechanism! Just stopping all movement is not an acceptable action because the applied
pressure will not be removed. The pitch of the screw mechanism is very small, it may not be easy to release
the pressure by human intervention. It could be difficult for the operator to manually lift the press assembly.
Depending on the customer application, additional protection may be required by local laws or the European
community. In some applications where operators may be directly exposed to danger areas additional
guarding may be required. The ultrasonic power supply 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 resolution and a small backlash within the
system, the position accuracy will be + 0.0003 inch (+ 0.007 mm). The indicated position numbers on the
stepper and logger screens represent the measured motor movement. Any mechanical deflection caused by
large pressures applied to the “Parts to be Welded” will degrade the accuracy numbers (with respect to the
parts dimensions). Typical deflection measurements for each type of press are provided in the Maintenance
section at the end of the manual. The operator should be aware that large pressures approaching 500 LBS
can be applied very quickly. If the ultrasonic amplitude is too low and the plastic is not hot enough to melt,
then large pressures can be applied with only a few steps of the motor system. If pressures exceeding 500
LBS are applied, the motor system may stall. The system must be reset with the RESET button on the back of
the controller panel.
Applications –A stepper application project involves careful setting of the stepper and ultrasonic controls.
Distance and velocity controls are set using the stepper setup utility program in combination with the Stepper
Control panel switches and display. The ultrasonic controls are adjusted with the GX power supply control
panel.
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7.0 Quick Start Setup Procedure for a Typical Application TOC –This section is intended to
be a quick startup checklist for an operator who is familiar with the E-Press welding system. Users who are
unfamiliar with the system should read this manual and the GX power supply manual, prior to welding any
parts. After reading those manuals, return to this section with a full understanding of the system interactions
between distance, speed and ultrasonic controls.
Setting up the system to weld a typical part is really very easy but can seem involved due to the movement
and ultrasonic controls required. In order to make full use of the precise distance and velocity welding
functions, the ultrasonic power supply will be set so that the time or energy settings are beyond the expected
weld requirements. The stepper movement should reach the programmed position before either time or
energy settings are reached. Steps to prepare a typical part for welding are identified below. The computer
interface must be connected and running properly to set up a part for welding. Once the machine is set up,
the computer can be disconnected without effecting the welding process provided that the termination jumper
supplied is installed on the back Stepper Controller chassis. Details of the settings are further described
below, but the quick start directions can help the proficient user.
1. Install the horn and fixture on the machine.
2. Release the column locking clamps, raise the Ultrasonic head to provide clearance of at least 4
inches (101.6 mm) above the parts and fixture. Secure the clamps.
3. Set the unwelded parts into the fixture with proper orientation.
4. Set the desired travel and welding parameters using the stepper utility software program. (click SET
function to transfer values). See section 9.0 for the stepper controls description. Set the travel
distance value large enough to place and remove the parts. Enter the upper and lower tolerances
expected. These numbers should account for the variation in the molded parts. Set the upper
tolerance to 0.0100 in (0.300 mm); Set the lower tolerance to the thickness of the top part (0.100
inches max). This prevents the horn from contacting the fixture while looking for the parts. Enter the
force trigger level desired before 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 Down” is displayed on the LCD
screen.
6. Again release the locking clamps and lower the head assembly so that the horn contacts the top of
the unwelded parts. Now position and align the horn, parts and fixture. Lock the column clamps
and secure the fixture.
7. Return the Head to the Home position by pressing the HOME button.
8. Teach the system where the parts are located: Press the TEACH button. Per screen instructions,
press the palm buttons and keep depressed until the distance to the part is displayed on the LCD
screen. The system will move the horn to the unwelded parts and apply the programmed pressure.
This contact distance will be remembered for the welding function.
9. Press the HOME button to return the press head to the home position.
10. Set the Weld mode for Incremental, the Weld Velocity #1 to .02 in/sec and Weld Distance #1 to
0.0100 inches (let’s go slow for the first weld). Set Weld Distance #2 to 0. Again use the SET
function to send these values to the machine.
11. Set the ultrasonics on the GX power supply for a longer weld time than necessary to complete the
weld. Force Trigger must be disabled. The Delay Time must be set to 0.01 seconds (stepper
controller needs this delay); Hold time to 1 second (or desired); Afterburst to 0.00 and the Time Limit
High to 9.99 seconds. Set the amplitude to approximately 80% to assure sufficient melt. These
parameters are programmed from the GX power supply. See the GX manual for further assistance.
12. If using a GXE power supply with energy welding controls, set the Energy parameters for a higher
Energy number than will be delivered during the weld time. The distance should control the weld in
most cases when using the Stepper system. If the ultrasonics times out or reaches the energy limit
before the programmed distances are achieved, then the cycle will not be complete. The control
parameter (distance, energy or time) which wins the race to its programmed setting will end the
present weld cycle. If a distance is not achieved, check the time or energy settings to see that the
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programmed velocities can reach the desired position within the timer/energy settings. Velocity
settings and distances, timers, limits and amplitude settings are all interactive and must be
considered when setting up a stepper application.
13. The system should be ready to try a weld, be sure that parts are installed prior to initiating a weld
cycle. Don’t damage the fixture or horn.
14. Simultaneously press the left and right palm buttons (black buttons) on the press base to begin a
weld cycle.
Further adjust the settings as necessary to produce the optimum weld cycle time by using the shortest
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 contact the fixture.
Parts Contact Diagram
Teach Position - The Distance to
unwelded parts with the programmed
force applied.
Upper Tolerance
Lower Tolerance
marks the end of
the search zone.
Parts Search Zone - Begin
searching for parts here.
(Teach minus upper tolerance)
Weld Distance - The incremental
weld distance is referenced from
the parts found position each
cycle.
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8.0 Overview of the Stepper Controls TOC –The stepper front panel is shown below. It contains
several switches and an LCD display necessary to initiate setup functions that are used to align the parts and
fixture and to teach the system where the parts are located (the distance to the unwelded parts).
The “Align” button is used first to extend the ultrasonic horn by the programmed travel distance toward the
parts. Adjust the ultrasonic horn for proper fit against the unwelded parts and lock the head assembly into
position using the column lock handle. Apply enough pressure to the lock handle so the head will not be able
to move under normal welding pressures. Then use the “Home” button to return the head to the home or full
up position.
The operator must then use the “Teach” button to execute the Teach Function. This function must be used
one time after initial alignment or whenever the column, fixture or parts are changed or adjusted. The system
will learn where to find the parts by extending the head assembly until force is detected on the parts. This
position will be remembered for subsequent weld cycles 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 Front Panel
8.1 On/Off Button –The On/Off button turns the unit on and off.
8.2 LCD Display –The LCD display will show the weld distance report after every cycle. In addition, the
display shows instructions and feedback in accordance with the operations in progress. It is also used to
examine the presently programmed weld parameters so that a computer is not required once a system has
been setup for production operations.
8.3 Align Button - The Align button is used to initiate the Align function (when used in coordination with
the palm buttons) or to examine weld setting parameters.
View settings -To view settings, as instructed on the display, press and hold the Align button for 2
seconds, then release. The LCD screen will then display a weld parameter, such as Force Trigger.
Then press the Align button to scroll through the present settings. Press the Home button to leave
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Sonics E-Press Manual Page 20
the parameter display mode, or the Align button to continue viewing current settings. The system
must be returned to the ready screen prior to initiating the next weld cycle.
Align Function –To use the Align function, simply depress the Align button, but do not hold it down as
above. The LCD screen will display the Align Mode screen with a message indicating “Home to Abort,
Palm Buttons to Start.” Press and hold the palm buttons until the display reads: “Head is in Position.
Press Home when Done.”
If the palm buttons are released too early, the LCD screen will display the message “Head is not Down.
Press Home and Try Again.”
8.4 Home Button –The Home button is used to return the assembly to the up or home position after the teach
or align function. It is also used to exit the Align parameter display mode as described and/or to abort the
teach or align function.
8.5 Teach Button - The Teach button 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 the LCD screen, i.e., “2.9990 in. to Part. Press Home when Done.”
At this point, the position has been “taught” and it is OK to press the Home button to return the head to the
Home position. If the palm buttons are released before the horn contacts the parts, the display will read
“Position has not been Taught. Press Home and Try Again.”
8.6 Reset Button –There is a Reset button located at the back of the controller. Press the reset button to
restart the motion controller after a motor stall, usually caused by excessive applied force or if the distances or
speeds have been set outside the practical application. Check the program settings and re-teach the system.
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