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TUCKERTechnologyatitsBest:StudWeldingwithDCE!

Innovationwithfascination:DCE–DigitallyControlledEnergy

Thenewdimensionofqualityfortheentireweldingprocess

0

020406080

TUCKERTechnologyatitsBest:StudWeldingwithDCE!

DCEControlandEnergyUnit

Forthefirsttimeweldenergyandstudmovementarecontrolledinrealtime!

WiththenewDCEControlandEnergyUnit

(DigitallyControlledEnergy)theentireweld-

ingprocess,includingallparameters,ismon-

itoredandcontrolledthroughdigitalsignal

processors(DSPs)inrealtime.

Thestudmovementisadjustedelectronically

lodloop,anintegrated

positionmeasuringsystemprovidescon-

stantfeedback,withthesystemresponding

immediatelyandautomaticallytothechang-

inggeometryofthecomponent(clodloop

control).

Studpenetrationdefined

Theplungeofthestudintothepoolofmolten

sheetmetalgivesaclearindicationofthe

riesprovidesstud

penetrationcontrol,analysisandmonitoring.

Ifnecessary,apre-definedstudpenetration

especially

importantforT-studorstepstudapplications

requiringdefinedheaddimensions.

Adjustableliftheight

Foreachweldingprogram,theliftheightmay

beprogrammedtorangebetween0.6mm

,everysingleapplicationis

perfectlyadaptedtotheweldingtask.

Everything

undercontrol!

Constantweldtime,

independentofwear!

Eventhoughweldsplatterisalmostentirely

eliminatedbycontrolledstudmovement

andweldplunge,fluegasandmetaldust

cancaucontaminationofallcomponents

involvedinliftmovementoftheweldhead

andstud.

Nevertheless,allweldingisdoneatacon-

ded

benefit,thervicelifeofallsparepartsis

extendedsignificantly–asarethemainte-

edresidencetime

increasavailabilityandreducefforts

relatingtomaintenanceandspareparts.

Fromprogresstostandard

ThisTUCKERtechnologyrespondstothe

increasingroleoflightweightconstruction

gradeofstudweldingwhichalsoapplies

tothinsteelsheets(0.6mm),high-strength

steel,aluminum,magnesium,andmany

sandwichmaterialsandalloys.

Fromexperiencetoleadership

Today,morethan11,000TUCKERstudweld-

ingsystemsutilizingaprimarymodulated

experience,alongwithclocontactswith

expertsinthefield,isaconstantsourceofin-

novativeideaswhichwehaveimplemented

intheDCEControlandEnergyUnit.

ContactPilotcurrent

pha

Welding

pha

Plungepha

Arcvoltage

Movementofcomponent

Weldingcurrent

Time(ms)

s(d)

Dirtprotectiontailor-made

toeachweldhead

Cleaningissignificantlyreduced,main-

tenanceschedulingmadeeasierand

maintenanceworkcanbecarriedout

moreswiftly.

TUCKERTechnologyatitsBest:StudWeldingwithDCE!

TheNewOperatingPanel

OptimumComfortandSecurity!

IntuitiveInterface

Simple,intuitive,menu-drivenWindowsin-

terfacesaretoday‘sstandardforanysitua-

ate2007,EmhartTeknologieshas

beenprovidinganew,state-of-the-artoper-

atingpanelforitsDCEgenerationofequip-

-resolutiondisplaysillustratethe

currentequipmentstatusandvisualizeany

availableinformationanddata.

Abbreviations,errorcodes,andsimilaraids

ewoperat-

ingpanel,allinformationisrenderedinplain

textorviacommonicons.

SoftwarePackages

Programmingforsteeloraluminum

WiththeDCEgenerationofequipment,

ursarefullyenabledtoperfectlyadapt

theweldprocesstotheirrequirements.

Offlineprogramming

Thissoftwareturnstheoperatingdevice

intoafull-fledgedoffline-programming

longernecessarytoua

PCorlaptopfordatabackuporwelding

programrecovery.

“Assist“features

Productsandprocesshavebecome

morecomplex,yettheyaresuppodto

bemanagedbyasmalleroperatingand

‘swhere“Assist“

comesintoplay.

Atthetouchofabutton,yougetall

therequiredandaccuratepiecesof

informationforthespecificwelding

equipment–partslists,maintenance

plans,interfacedrawings,troubleshooting

tedbyillustrationsand

pictures,allthinablevensomeone

whoisnotanexperttohandlethestud

weldingsysteminasafemanner–not

only,butaboveallduringincidents!

Bymeansoftheinnovativetouch-screen

technology,thesizeofcontrolsisadaptedto

theur‘scurrentrequirements.

Thebuilt-inUSBinterfacefacilitatesthe

transferoffirmware,weldingprograms,

measuringdata,andfaultlatches.

Thenew

operatingpanelcomes

withdifferent

softwarepackages,

providingtherightpro-

gramforyourapplication.

Equipmentvariations

DCEControlandEnergyUnit

Easyandsafedownloadofsoftwareup-

dateswithoutexchangeofEPROMSvia

flashmemorydirectlyfromPC.

DCE-Linknetworkingsoftwarefortrans-

parentmaintenancemanagementfeatur-

ingEthernetTCP/IPforInternet/Intranet

integration.

Studarrivalnsormountedonthe

weldhead–immediatelydetectsthe

arrivalofthestud,thusspeedingupthe

remainingfeedingprocess.

StudID/CarbodyID–theDCEEnergy

Unitisabletoreceivevariousproduc-

tiondatathroughthecustomerinterface.

Monitoringtheparameters,welinkthe

datatothecurrentwelddataandpass

dataformthebasisofperfectquality

managementandefficientimprovement

processwithonegoal:zerodefectsin

thefinalasmbly.

Customerinterfaces–apartfroma

parallelinterface,rialfieldbussystems

likeInterbus,Profibus,Modbus,andDe-

onalmeans

ofcommunicationincludeEthernet-bad

systemslikeProfiNetorEthernetIP.

Operationwithswitches–Flexibility

inaproductioncellmaybeincreadsig-

nificantlybymeansofafeedswitches.

Inertgas–foraluminumstudorstainless

steelstudwelding,bothweldheadsand

gunsmaybeequippedwithaninertgas

nozzle.

TUCKERTechnologyatitsBest:StudWeldingwithDCE!

OptimumAccessoriesforMaximumAvailability!

Perfectlymatchedaids

TUCKER‘srangeofaccessoriesprovidesa

widevarietyofaidscompletingtheautomo-

bilebody-in-white.

Efficientqualityassurance

Weldingresultsmaybeaffectedbyexter-

esnotnecessarilymean

badwelding,butmerelysignifiesthatupper

orlowerlimitsofdefinedparameterswere

exceeded.

Theweldingpositionsaffectedaremarked

immediatelyafterweldingbymeansofa

ubquentqual-

ityassuranceprocess,thefasteningpointis

locatedquicklyandefficiently.

Testingtherightway!

Youcanchoofromabroadrangeoftesting

equipmentperfectlyadaptedtotheloadon

therespectivestud.

Powerunit

DCE1500andDCE1800

for(large-scale)rialproduction

DCE15HA

forCKDorsmall-scalerialproduction

Feeder,ETFline

Series20and50,

predominantlyudforthreadedstuds

Series12and90,

predominantlyudforearthstuds

Series52through55

forstepstudsorT-studs

Fully

automatic

application

Semi-

automatic

application

Manual

application

PowerFeederWelding-

unittool

DCE1500ETF20LMR410/420

DCE1800ETF5XLM310

ETF90LM240

ETF12

DCE1500ETF20PLM200

DCE1800ETF5X

DCE15HAETF90

ETF12

DCE15HAPKEPLM560

andcontrol

box(es)

EquipmentthatFitsanyBody-in-whiteConcept

Weldheads,LMries

LM240forstationaryapplications

LM310forrobot-aidedapplications

LMR410/420forthemostdifficult

weldingposition

WeldgunsfeaturingLMtechnology

Formanualandmi-automaticapplications

PLM200withautomaticstudfeeder

PLM560withmanualfeed

Tailor-madetothecustomer‘smanufacturingpenetrationand

body-in-whiteconcept,thesystemconceptofferedby

EmhartTeknologiesTUCKERisrightforyou.

Testingtools

Feedingswitches

Nozzlesandguidebushings

Colorcoding

Testingtools

Adapterplates

EmhartTeknologies

49201GratiotAve

Chesterfield,MI48051

Tel.+

Fax+

EmhartTeknologies

TuckerGmbH

111329

D-35387Giesn

Max-Eyth-Stras1

D-35394Giesn

Tel.+49641405-0

Fax+49641405-300

EmhartTeknologies

NPRDivision

3rdFloorParkBuilding

No.6Kioicho3Choume

Chiyoda-ku/Tokyo102

Tel.+813336572-91

Fax+813336572-98

EmhartTeknologies

RefalDivision

RuaRicardoCavatton,226

05038-110-SaoPaulo-SP

Tel.+551138716474

Fax+551138713505

EmhartTeknologies

488JiaLouRoad

JiadingDistrict

Shanghai

Tel.+862159548626

Fax+862159548775

EmhartTeknologies

TuckerS.R.O.

mi65

mi

Tel.+424335465-11

Fax+424335465-66

EmhartTeknologies

TuckerGmbH

ZAdesPetitsCarreaux

2bisavenuedesCoquelicots

94385BonneuilsurMarne

Tel.+331567124-36

Fax+331567124-34

EmhartTeknologies

TuckerGmbH

AgenziaItalia

ViaBuenosAires,27

10134Torino

Tel.+39113173964/65

Fax+39113174830

EmhartTeknologies

TuckerGmbH

OficinaEspãna

Ctra.M-300Km29,700

28802AlcaládeHenares(Madrid)

Tel.+34918770380

Fax+34918896340

EmhartTeknologies

NordicDivision

Box203/Skomaskisgatan2

70144Örebro

Tel.+4619205800

Fax+4619262309

EmhartTeknologies

TuckerGmbH

UKOffice

WallsallRoad/PerryBarr

BirminghamB421BP

Tel.+4412133125-97

Fax+4412133125-48

EmhartTeknologies

BosquedeCidrosacceso

Radiatas#42,

deLasLomas

05120Mexico,D.F.

Tel.+525553267132

Fax+525553267132

EmhartTeknologies

Rm.609SeorinBldg.

45-15Yeoido-Dong

Yeongdeungpo-Ku

150-891Seoul

Tel.+82278392267

Fax+82278392289

TUCKERTechnologyatitsBest:StudWeldingwithDCE!

SpecificationsataGlance

info@

OnlineClipCatalog:

ETFFeedUnitETF20ETF90ETF50ETF52–56

Dimensions(WxDxH):560x495x550x630x400x500x500x400x

440mm482mm500mm500mm

Weight(studxcluded):65kg50kg50kg50kg

Pneumaticnetwork:4.5–6bar4.5–6bar4.5–6bar4.5–6bar

Controland

EnergyUnit

LMWeldHead

LMGun

LM310/LM240PLM200PLM560

Dimensions(WxDxH):102x370x140mm/75x330x240mm50x185x180mm

91x360x135mm

Weight:5.5kg5.5kg1.25kg

Sliderailstroke:50mmmax.––

Studdiameters:Ø3–10mmØ3–10mmØ3–10mm

DCE1500/HADCE1800

Powervoltage:400/440/500VAC400/440/500VAC

Powerfrequency:fN:50/60HzfN:50/60Hz

Weldingcurrentrange:

∆I100A–1500A∆I100A–1800A

Weldtimerange:

∆t6ms–100ms∆t6ms–100ms

s:60/min@I=750A,t=30ms60/min@I=750A,t=30ms

Dimensions(WxDxH):560x565x965mm560x565x965mm

Weight:90kg90kg