Dukane Welding System AN400 User Manual

Application Note  
DUKANE  
AN400  
Intelligent Assembly Solutions  
Automation Interface Requirements for J602 Basic I/O Interface  
of a DPC 4 Welding System  
The DPC 4 welding system offers several features that are intended to communicate with automation. These features  
allow the automation to control and respond to events that occur during the welding process. This document will provide  
guidelines that will help you interface automation to a DPC welding system per Dukane Corporation’s requirements.  
Information within this document is intended to supplement the information in the DPC 4 manual (Dukane part # 403-557).  
Note: Early production models of the DPC IV welding system referred to J602 as the User I/O interface. The  
functionality of the Basic I/O Interface and the User I/O Interface are identical. Only the name has changed.  
Application Note Topics:  
The J602 Pin assignments  
The 200-1203 Basic Interface Cable  
Status Output Signal Descriptions  
Status Output Interface Examples  
System Input Signal Descriptions  
System Input Interface Examples  
Basic I/O  
Interface  
Dukane Corporation  
2900 Dukane Drive Saint Charles, IL 60174 USA  
Phone (630) 797-4900 FAX (630) 797-4949  
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Application Note  
DUKANE  
AN400  
Intelligent Assembly Solutions  
Pin #  
1
Conductor Color  
Red  
2
Black  
3
4
5
6
7
8
Blue / Black  
Green / White  
Blue / White  
Red / Black  
White / Black  
White  
9
Orange  
10  
11  
12  
13  
14  
15  
Blue  
Orange / Black  
Red / White  
Green Black  
Black / White  
Green  
Part Number  
Length  
200-1203  
10 FT  
200-1203-15  
200-1203-20  
200-1203-25  
200-1203-30  
15 FT  
20 FT  
25 FT  
30 FT  
Status Output signals for the J602 Connector:  
There are four status output signals available on the J602 connector. Each of these outputs are driven by a solid state  
relay that creates a switch closure between the specified output pin and the Output Common pin. These pins can be  
configured within the DPC software menus to provide a signal that accommodates the requirements of most automation  
interface equipment. The available configurations for these output signals are:  
Active High Outputs – This setting will produce a closed switch condition between the specified output pin and  
the Output Common pin when the output signal is activated. (Factory default setting)  
Active Low Outputs -  
Maintained Outputs -  
This setting will produce an open switch condition between the specified output pin and  
the Output Common pin when the output signal is activated.  
This setting will produce an output signal that is maintained from the completion of a  
welding cycle until the beginning of the next welding cycle activation. (Factory default  
setting)  
Pulsed Outputs -  
This setting will produce an output signal that is pulsed a single time for 100 mS as the  
end of the welding cycle.  
Note: Please refer to the Hardware menu section of the DPC IV manual for further information on these features.  
Dukane Corporation  
2900 Dukane Drive Saint Charles, IL 60174 USA  
Phone (630) 797-4900 FAX (630) 797-4949  
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Application Note  
DUKANE  
AN400  
Intelligent Assembly Solutions  
Status Output Signal Descriptions:  
Bad Part Output –  
Good Part Output -  
(J602 pin 3) This status output will activate when the data acquired during the welding sequence  
exceeds one of the user defined boundaries within the Bad Part Limits portion of the user setup.  
Please refer to the Process Limits section of the DPC IV manual for further details on selecting  
and setting up a Bad Part Limit window.  
(J602 pin 5) This status output will activate when the data acquired during the welding sequence  
does not exceed any of the user defined boundaries within the Bad Part Limits portion of the user  
setup. Please refer to the Process Limits section of the DPC IV manual for further details on  
selecting and setting up a Bad Part Limit window.  
Suspect Part Output - (J602 pin 4) This status output will activate when the data acquired during the welding sequence  
exceeds one of the user defined boundaries within the Suspect Part Limits portion of the user  
setup. Please refer to the Process Limits section of the DPC IV manual for further details on  
selecting and setting up a Suspect Part Limit window.  
In Cycle (J602 pin 4 redefined) - This status output will activate when the welding cycle begins. If  
the status outputs have been set for maintained, In Cycle will deactivate when the Hold portion of  
the welding cycle has completed. Please refer to the Hardware Setup section of the DCP IV  
manual for further details on redefining J602 pin 4.  
Sonics On (J602 pin 4 redefined) – This status output will activate when the DPC produces the  
ultrasound welding signal that creates motion in the transducer stack assembly. Activation of this  
signal will occur during the Weld, Scrub, and Afterburst portions of the weld cycle. Please refer to  
the Hardware Setup section of the DCP IV manual for further details on redefining J602 pin 4.  
In Hold (J602 pin 4 redefined) – This status output will activate when the DPC is processing the  
Hold portion of the welding cycle. Please refer to the Hardware Setup section of the DCP IV  
manual for further details on redefining J602 pin 4.  
Ready Output -  
(J602 pin 6) This status output will activate at the completion of the Hold portion of the welding  
sequence. It should be noted that the activation of the Afterburst feature and the return of the  
pneumatic press to the home position will occur after the activation of the Ready Output status  
signal. Please refer to the Process Control section of the DPC IV manual for further information  
on the activation and use of the Afterburst feature. In addition please refer to the Hardware Setup  
section of the DCP IV manual for further details on redefining J602 pin 6.  
Network Active (J602 pin 6 redefined) – This status output will activate when the DPC is an active  
node on a DPC network. Please refer to the Network section of the DPC IV manual for further  
details on setting up a DPC network. Please refer to the Hardware Setup section of the DCP IV  
manual for further details on redefining J602 pin 6.  
Sonics On (J602 pin 6 redefined) – This status output will activate when the DPC produces the  
ultrasound welding signal that creates motion in the transducer stack assembly. . Please refer to  
the Hardware Setup section of the DCP IV manual for further details on redefining J602 pin 6.  
Dukane Corporation  
2900 Dukane Drive Saint Charles, IL 60174 USA  
Phone (630) 797-4900 FAX (630) 797-4949  
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Application Note  
DUKANE  
AN400  
Intelligent Assembly Solutions  
The DPC status output pins can be configured to adapt to several types of automated devices. The ratings for the DPC  
Status output pins are:  
Maximum Voltage Rating = +24 VDC  
Maximum Current Rating = 100 mA  
Status Output Interface Examples:  
+ 24 VDC  
DPC IV  
Bad Part  
Input  
Device  
3
4
Suspect  
Part  
Input  
Device  
5
Input  
Device  
Good Part  
Ready  
6
7
Input  
Device  
Output  
Common  
J602  
PLC  
200-1203  
Cable  
DPC IV status output configuration for use with a PLC requiring sinking inputs.  
Dukane Corporation  
2900 Dukane Drive Saint Charles, IL 60174 USA  
Phone (630) 797-4900 FAX (630) 797-4949  
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Application Note  
DUKANE  
AN400  
Intelligent Assembly Solutions  
DPC IV  
3
4
Bad Part  
Input  
Device  
Suspect  
Part  
Input  
Device  
5
Input  
Device  
Good Part  
Ready  
6
Input  
Device  
7
Output  
Common  
+ 22 VDC  
1
Power Supply  
Ground  
2
J602  
PLC  
200-1203  
Cable  
DPC IV status output configuration for use with a PLC requiring sourced inputs.  
Dukane Corporation  
2900 Dukane Drive Saint Charles, IL 60174 USA  
Phone (630) 797-4900 FAX (630) 797-4949  
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Application Note  
DUKANE  
AN400  
Intelligent Assembly Solutions  
DPC IV  
3
Bad Part  
Customer  
Device  
Suspect  
Part  
4
Customer  
Device  
5
Good Part  
Ready  
Customer  
Device  
6
Customer  
Device  
7
Output  
Common  
+ 22 VDC  
1
Power Supply  
Ground  
2
200-1203  
Cable  
J602  
DPC IV status output configuration for use when either isolation is required or  
the customer device exceeds the maximum ratings of the DPC outputs.  
Dukane Corporation  
2900 Dukane Drive Saint Charles, IL 60174 USA  
Phone (630) 797-4900 FAX (630) 797-4949  
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Application Note  
DUKANE  
AN400  
Intelligent Assembly Solutions  
System Input signals for the J602 Connector:  
There are four system input signals available on the J602 connector. Each of these inputs are configured as sinking  
inputs ( Do not apply voltage to the J602 inputs).  
Automation Input -  
(J602 pin 8) This system input signal is activated by an external dry contact closure to the DPC  
Ground pin on J602 pin2). The minimum duration for the activation of this input is 100 mS. The  
maximum duration of this input is determined by the duration of the weld cycle. This input should  
be deactivated before the end of the weld cycle to avoid an error condition (Associated Error: #  
212 Auto Active at Cycle Start). Please refer to the Initiate Mode section of the DPC IV manual  
for details on the activation and use of the Auto Initiate mode.  
Automation Stop N/O- (J602 pin 9) This system input signal is activated by an external dry contact closure to the DPC  
Ground pin on J602 pin2). The minimum duration for the activation of this input is 100 mS.  
Activation of this input will end the welding cycle and deactivate all valves in the press. This  
system response will continue until the contact closure to the DPC ground is removed. Weld  
cycles that have been stopped due to the activation of this input will not be counted in the part  
count value displayed on the DPC. Please refer to the Initiate Mode section of the DPC IV  
manual for details on the activation and use of the Automation Stop mode (Auto Abort).  
Automation Stop N/C- (J602 pin 10) This system input signal is activated by an removing an external dry contact closure  
to the DPC Ground pin on J602 pin2). The minimum duration for the activation of this input is 100  
mS. Activation of this input will end the welding cycle and deactivate all valves in the press. This  
system response will continue until the contact closure to the DPC ground is replaced. Weld  
cycles that have been stopped due to the activation of this input will not be counted in the part  
count value displayed on the DPC. Please refer to the Initiate Mode section of the DPC IV  
manual for details on the activation and use of the Automation Stop mode (Auto Abort).  
Hand Probe Press Inhibit - (J602 pin 11) This system input is activated by an external dry contact closure to the DPC  
Ground pin on J602 pin2). The minimum duration for the activation of this input is 100 mS.  
Activation of this input is intended to configure the DPC for a probe system functionality. It will  
deactivate all valves for the press during a welding cycle. This system response will continue until  
the contact closure to the DPC ground is removed.  
Dukane Corporation  
2900 Dukane Drive Saint Charles, IL 60174 USA  
Phone (630) 797-4900 FAX (630) 797-4949  
8
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Application Note  
DUKANE  
AN400  
Intelligent Assembly Solutions  
The DPC system inputs are configured for a dry contact closure activation. The following connection diagram indicates  
how to interface automation to the system inputs.  
System Input Interface Examples:  
200-1203  
Cable  
+ 24 VDC  
PLC  
8
Auto Initiate  
9
Automation Stop  
N/O  
10  
Automation Stop  
N/C  
11  
Hand Probe  
Press Inhibit  
2
Output  
Common  
J602  
DPC IV  
DPC IV system input configuration for use when customer equipment provides contact  
closure signals with not voltage.  
Dukane Corporation  
2900 Dukane Drive Saint Charles, IL 60174 USA  
Phone (630) 797-4900 FAX (630) 797-4949  
9
© Dukane Corporation 2004. All rights reserved.  
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Application Note  
DUKANE  
AN400  
Intelligent Assembly Solutions  
+ 24 VDC  
PLC  
DPC IV  
200-1203  
Cable  
+ 24 VDC  
8
9
Auto Initiate  
Automation Stop  
N/O  
10  
Automation Stop  
N/C  
11  
2
Hand Probe  
Press Inhibit  
J602  
Output  
Common  
DPC IV system input configuration for use when customer equipment sources  
voltage to the DPC inputs.  
Dukane Corporation  
2900 Dukane Drive Saint Charles, IL 60174 USA  
Phone (630) 797-4900 FAX (630) 797-4949  
10  
© Dukane Corporation 2004. All rights reserved.  
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