Smart Detection™ System

Fully integrated "plug & play" weld control and pneumatic "smart" servo cylinder"

The Smart Detection™ system is a plug & play system that brings a range of features to the welding environment that

  • improves productivity,
  • reduces costs and
  • reduces operational risks

And, most importantly, it does this all at a cost level far below equivalent technologies that are purchased separately and that require time consuming and costly integration.

SECONDARY CONTACT MONITORING

Electrodes come together under low force and will automatically retract if an obstruction is met prior to the programmed pinch gap.

Full welding force is not applied until contact with the work piece is sensed and in the pinch gap zone.

However if contact (secondary circuit closed) is sensed in the open position no movement occurs.

Contact is sensed via two independent means:

  1. Measurement of the force in the servo system.
  2. ENTRON's electrical secondary contact detector unit (SCM2), hence providing dual redundant operation.

DUAL REDUNDANT COMMUNICATION

SD System’s servo and weld controller are linked by both discrete signals via Ethernet and via a modbus communication channel.

With risk reduction in mind, the system employs a dual-threaded architecture to drive these channels independently, and the status of this I/O can be viewed using the NetFlash programming software.

Correct correlation of the two is required before any motion can be initiated.

PRODUCTION SPEED, LOW-FORCE APPROACH

With previous systems, “low-force” was synonymous with “slow-speed” which negatively impacted productivity and encouraged the risk reduction option to be defeated.

The SD System’s low-force approach does not require this slow-speed compromise and can be easily set-up to achieve the best results for both risk reduction and production output.

Stack Up Height Confirmation, Obstruction Detection, Programmable Retract, Mid & Weld Positions:

  1. The SD system can be programmed and can detect changes from pre referenced weld positions.
  2. The measuring system can measure to one mil (0.001 inches).
  3. The measuring system can also be use to measure machine secondary deflection that occurs when weld force is applied.

Programmable Weld Force & Cylinder Speed:

SD System’s closed loop control ensures repeatable & constant weld force throughout the entire weld regardless of work piece deformation.

Detection of a Missing Component

The SD System uses the same intelligence to detect a missing component (such as a missing nut during projection welding) as it also does for obstruction detection and stack up height confirmation.

intelligent pneumatic servo valve 9Intelligent Pneumatic Servo Valve

  • Controls all motion of the cylinder
  • Calibrated during its production, no further adjustment
  • Serviceable by end users

At the core of the SD System is an intelligent pneumatic servo valve which controls all motion of the cylinder.

This valve is calibrated during its production and never needs further adjustment.

If anything happens to the electrical or mechanical components of the servo valve, the end users’ maintenance staff can;

  • disconnect the four cables,
  • remove four cap heads,
  • remove the push fit air pipe
  • and change the defective servo valve and replace it with a new pre-calibrated valve, which are kept in stock and are readily available from Tuffaloy.

Optionally, the SD cylinder’s servo valve can also be equipped with a fail-safe valve which can be used to mechanically override the entire electrical system, forcing the electrodes apart when an unexpected dangerous condition is detected.

netflash windows based 10NetFlash Software

  • NetFlash™ is shipped with the iPAK SD control
  • Timer Firmware easily upgraded in the field

The SD System is programed using ENTRON’s proprietary NetFlash Windows based software.

NetFlash is provided along with the system at time of purchase and is easily upgraded in the field at end users’ facilities.

Once set-up the SD System can be operated using a traditional pendant but when connected to an PC, the programmability and end user experience are greatly enhanced during the operation of the welder.

Production and Cycle Time Reduction

Quick reference function allows you to change jobs in seconds.

reduce costsThe reference position for the weld position is taught in with the weld schedule, and can changed for a new job in less than 5 seconds.

Programmable retract/mid position

The retract position can be programmed to minimize the stroke distance required to reach the weld position. This is common to all weld schedules and reduces cycle time with no mechanical adjustments!

Headset mode

This allows the electrodes to come together under low force for the operator to adjust alignment in a single step (During this sequence the control will not weld). This means no need to make multiple adjustments to check Electrode alignment. Using the Headset function is a quick effective way to tip dress the electrodes engaged under low force. This helps ensure parallel weld faces.

System pre-weld checking

The SD system will not fire the weld current until the secondary contract signal is present with the electrodes in the correct working zone and programmed weld force is reached.

 
 
 

Video

 

Details

Features

R2 Benefits and Features

  • Secondary Contact Monitor, Generation 4 (SCM4)
  • Low Force Approach
  • Pinch Gap Detection
  • Compatible with ALL S2H Controls
  • Works w/ ALL S2H controls with retraction
  • Ross CAT4 Safety Valves
  • EATON CAT4 Safety Relay
  • EATON HMI operator interface
  • Initiation Confirmation

SD Benefits and Features

  • Secondary Contact Monitor, Generation 2 (SCM2)
  • Low Force Approach
  • Pinch Gap Detection
  • Integrated Servo Driver
  • Intelligent Pneumatic Servo Cylinder
  • Stack up Height Confirmation
  • Obstruction Detection
  • NO Adjustment required
  • Programmable retract, mid and weld positions
  • Programmable weld force
  • Programmable cylinder speed
  • Detection of a missing component
  • Multiple electrode force change during the Weld (4X)
  • Head Set (Tip Alignment Check)
 

Find out more

Let Our Team Answer Your Questions About The Smart Detection™ System