PDF User Manual

  1. Home
  2. Manuals
  3. Dukane AN400 Application Note

Dukane AN400 Application Note

Made by: Dukane
Type: Application Note
Category: Welding System
Pages: 10
Size: 0.21 MB

 

Download PDF User Manual



Full Text Searchable PDF User Manual



background image

 - 

11101 

DUKANE 

 

A

A

p

p

p

p

l

l

i

i

c

c

a

a

t

t

i

i

o

o

n

n

 

 

N

N

o

o

t

t

e

e

 

 

AN400

© 

Dukane Corporation 2004. All rights reserved.

 

Dukane Corporation 

2900 Dukane Drive Saint Charles, IL  60174   USA 

Phone (630) 797-4900  FAX (630) 797-4949 

http://www.dukane.com/us

 

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

 


background image

 - 

22102 

DUKANE 

 

A

A

p

p

p

p

l

l

i

i

c

c

a

a

t

t

i

i

o

o

n

n

 

 

N

N

o

o

t

t

e

e

 

 

AN400

© 

Dukane Corporation 2004. All rights reserved.

 

Dukane Corporation 

2900 Dukane Drive Saint Charles, IL  60174   USA 

Phone (630) 797-4900  FAX (630) 797-4949 

http://www.dukane.com/us

 

Intelligent Assembly Solutions 

 
 
 
 

 

J602 User Interface Connector 

 

The J602 User Interface connector is the primary communications link between the DPC IV and user automation 
equipment.  This connector provides status signals that can be used to monitor DPC weld data analysis results as well 
as timing issues related to the processing of the weld sequence.  It also provides the automation with dedicated 
communication lines that allows the automation to control the beginning and the end of a welding sequence.

 

 
 
 
 
 

Pin Number 

DPC Signal Name 

DPC Signal Type 

1 Power 

Supply

+22 VDC (0.5 amp max) 

2 Ground

Power Supply Return 

3 Bad 

Part

Output

4 Suspect Part (see note #2)

Output

5 Good 

Part

Output

6 Ready (see note #1)

Output

7 Isolated 

Output Common

Common Pin for Output Signals 

8 Automation 

Input

Input

9 Automation 

Stop N/C

Input

10 Automation 

Stop N/O

Input

11 

Hand Probe Press Inhibit

Input

12 Input Common

Common Pin for Input Signals 

13 Ground

Power Supply Return 

14  
15 Ground 

Detect

Input

 

Note #1:  This input can be reconfigured in the DPC IV menu choices to activate during 

the following weld sequence event: 

 

 

 

  

In 

Cycle 

  

Sonics 

On 

  

In 

Hold 

 
Note #2:  This input can be reconfigured in the DPC IV menu choices to activate during 

the following weld sequence event: 

 

 

 

  

Network 

Active 

  

Sonics 

On 

 

 

 

Note:    Please refer to the Hardware Setup section of the DPC IV manual for details on 

reconfiguring pin 4 or pin 6 to the required status output signal.

 

 


background image

 - 

33103 

DUKANE 

 

A

A

p

p

p

p

l

l

i

i

c

c

a

a

t

t

i

i

o

o

n

n

 

 

N

N

o

o

t

t

e

e

 

 

AN400

© 

Dukane Corporation 2004. All rights reserved.

 

Dukane Corporation 

2900 Dukane Drive Saint Charles, IL  60174   USA 

Phone (630) 797-4900  FAX (630) 797-4949 

http://www.dukane.com/us

 

Intelligent Assembly Solutions 

 

 
 

 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

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 -  

This setting will produce an open switch condition between the specified output pin and 
the Output Common pin when the output signal is activated. 

 

Maintained Outputs - 

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.

 
 
 
 
 
 
 
 
 
 
 
 

 

Part Number 

Length 

200-1203 10 

FT 

200-1203-15 15 

FT 

200-1203-20 20 

FT 

200-1203-25 25 

FT 

200-1203-30 30 

FT 

 

Pin # 

Conductor Color 

1 Red 
2 Black 

Blue / Black 

4 Green 

White 

5 Blue 

White 

Red / Black 

White /  Black 

8 White 
9 Orange 

10 Blue 
11 

Orange / Black 

12 Red 

White 

13 Green 

Black 

14 Black 

White 

15

Green

 


background image

 - 

44104 

DUKANE 

 

A

A

p

p

p

p

l

l

i

i

c

c

a

a

t

t

i

i

o

o

n

n

 

 

N

N

o

o

t

t

e

e

 

 

AN400

© 

Dukane Corporation 2004. All rights reserved.

 

Dukane Corporation 

2900 Dukane Drive Saint Charles, IL  60174   USA 

Phone (630) 797-4900  FAX (630) 797-4949 

http://www.dukane.com/us

 

Intelligent Assembly Solutions 

 
 
 

 
 

Status Output Signal Descriptions: 

 
 
Bad 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.   

 
Good Part Output - 

(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.

 

 

 


background image

 - 

55105 

DUKANE 

 

A

A

p

p

p

p

l

l

i

i

c

c

a

a

t

t

i

i

o

o

n

n

 

 

N

N

o

o

t

t

e

e

 

 

AN400

© 

Dukane Corporation 2004. All rights reserved.

 

Dukane Corporation 

2900 Dukane Drive Saint Charles, IL  60174   USA 

Phone (630) 797-4900  FAX (630) 797-4949 

http://www.dukane.com/us

 

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:

 

Suspect

Part

Bad Part

Good Part

Ready

Output

Common

J602

Input

Device

Input

Device

Input

Device

Input

Device

+ 24 VDC

PLC

200-1203

Cable

DPC IV

6

7

5

4

3

 

DPC IV status output configuration for use with a PLC requiring sinking inputs. 

 


background image

 - 

66106 

DUKANE 

 

A

A

p

p

p

p

l

l

i

i

c

c

a

a

t

t

i

i

o

o

n

n

 

 

N

N

o

o

t

t

e

e

 

 

AN400

© 

Dukane Corporation 2004. All rights reserved.

 

Dukane Corporation 

2900 Dukane Drive Saint Charles, IL  60174   USA 

Phone (630) 797-4900  FAX (630) 797-4949 

http://www.dukane.com/us

 

Intelligent Assembly Solutions 

 
 
 
 
 
 

Suspect

Part

Bad Part

Good Part

Ready

Output

Common

J602

Input

Device

Input

Device

Input

Device

Input

Device

+ 22 VDC

PLC

200-1203

Cable

DPC IV

Power Supply

Ground

2

6

1

7

5

4

3

 

DPC IV status output configuration for use with a PLC requiring sourced inputs.

 

 


background image

 - 

77107 

DUKANE 

 

A

A

p

p

p

p

l

l

i

i

c

c

a

a

t

t

i

i

o

o

n

n

 

 

N

N

o

o

t

t

e

e

 

 

AN400

© 

Dukane Corporation 2004. All rights reserved.

 

Dukane Corporation 

2900 Dukane Drive Saint Charles, IL  60174   USA 

Phone (630) 797-4900  FAX (630) 797-4949 

http://www.dukane.com/us

 

Intelligent Assembly Solutions 

 

Suspect

Part

Bad Part

Good Part

Ready

Output

Common

J602

+ 22 VDC

200-1203

Cable

DPC IV

Power Supply

Ground

2

6

1

7

5

4

3

Customer

Device

Customer

Device

Customer

Device

Customer

Device

 

DPC IV status output configuration for use when either isolation is required or 
the customer device exceeds the maximum ratings of the DPC outputs.

 

 


background image

 - 

88108 

DUKANE 

 

A

A

p

p

p

p

l

l

i

i

c

c

a

a

t

t

i

i

o

o

n

n

 

 

N

N

o

o

t

t

e

e

 

 

AN400

© 

Dukane Corporation 2004. All rights reserved.

 

Dukane Corporation 

2900 Dukane Drive Saint Charles, IL  60174   USA 

Phone (630) 797-4900  FAX (630) 797-4949 

http://www.dukane.com/us

 

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.

  

 
 
 
 
 

 


background image

 - 

99109 

DUKANE 

 

A

A

p

p

p

p

l

l

i

i

c

c

a

a

t

t

i

i

o

o

n

n

 

 

N

N

o

o

t

t

e

e

 

 

AN400

© 

Dukane Corporation 2004. All rights reserved.

 

Dukane Corporation 

2900 Dukane Drive Saint Charles, IL  60174   USA 

Phone (630) 797-4900  FAX (630) 797-4949 

http://www.dukane.com/us

 

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:

 

Output

Common

J602

+ 24 VDC

DPC IV

200-1203

Cable

PLC

11

2

10

9

8

Auto Initiate

Automation Stop
N/O

Automation Stop
N/C

Hand Probe
Press Inhibit

 

DPC IV system input configuration for use when customer equipment provides contact 
closure signals with not voltage.

 

 


background image

 - 

10 

10101010 

DUKANE 

 

A

A

p

p

p

p

l

l

i

i

c

c

a

a

t

t

i

i

o

o

n

n

 

 

N

N

o

o

t

t

e

e

 

 

AN400

© 

Dukane Corporation 2004. All rights reserved.

 

Dukane Corporation 

2900 Dukane Drive Saint Charles, IL  60174   USA 

Phone (630) 797-4900  FAX (630) 797-4949 

http://www.dukane.com/us

 

Intelligent Assembly Solutions 

10 

 

 

Output

Common

J602

+ 24 VDC

DPC IV

200-1203

Cable

PLC

11

2

10

9

8

Auto Initiate

Automation Stop
N/O

Automation Stop
N/C

+ 24 VDC

Hand Probe
Press Inhibit

 

DPC IV system input configuration for use when customer equipment sources 
voltage to the DPC inputs.