Sonics GXL - Manual (Page 23)

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I N S T R U C T I O N M A N U A L • M O D E L G X L P O W E R S U P P LY
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if too many parts have been installed. If the pre-weld window is violated,
the system will abort the cycle.
➄ Post-Weld Window: If the parts are found within the pre-weld window,
the weld portion of the cycle will begin. Note the “squiggle” line
representing that the parts are now welded together. The weld has been
completed by achieving one of the control set points – time, distance or
energy. The Hold time has completed and the mechanical assembly is just
about to retract away from the parts. The final weld distance will be
captured and compared against the Post-Weld Window settings in the
same manor as the pre-weld in item 4 above. However, since it’s too late
(weld is already completed) to abort the cycle if this check fails and the
window limits have been violated, a potentially “bad” part will be indicated
by digital output and a blinking alarm LED.
➅ Final Welded Position: the final distance (after weld and hold times).
This distance will be reported to the display after the cycle is complete. It
will also be sent to the print line and will be used for qualification against
the post-weld window (item 5). The final distance reported will always be
equal to or greater than the specified distance set point because the air
cylinder will not stop instantaneously.
Distance Menu Parameters
To view and/or enter Distance parameters, press the Distance key to enter
the distance settings menu. The first menu display will show the following:
Distance Inc(remental) – The incremental set point is referenced from the
top of the parts after the ultrasonic horn has made contact and the pressure
switch has closed. The incremental set point distance is added to the
contact position distance to achieve the final travel distance – the point at
which ultrasonics should be stopped. For example, with only the distance
incremental option set, the ultrasonic weld cycle would turn on at the contact
point and run until the incremental set point is reached.
Press the Distance key again (and successively after each menu) to advance
to these next screen displays:
Distance Abs(olute) – the absolute distance set point is always referenced
to the home position of the system, and the exact position of the parts does
not come into play. The absolute set point determines the total travel
distance of the horn. Ultrasonics will stop when the programmed absolute
distance set point has been reached.
Distance Limit Low – sets the minimum weld distance permitted for an
assembly (presumably the minimum weld distance to be traveled to produce
a “good weld”). The weld distance is monitored at the completion of the weld
NOTE: There cannot
be an incremental set
point at the same
time as an absolute
set point. They are
mutually exclusive –
when one is
encountered, the
other will be shut off
automatically.
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