WAssets Downloads Documents Brochures Leaflets Flyers Tucker DCE-En[1]

8/11/2019 WAssets Downloads Documents Brochures Leaflets Flyers Tucker DCE-En[1]

1/6

TUCKER Technology at its Best: Stud Welding with DCE!

Innovation with fascination: DCE Digitally Controlled Energy

The new dimension of quality for the entire welding process


2/6

0

0 20 40 60 80


DCE Control and Energy Unit

For the rst time weld energy and stud movement are controlled in real time!

With the new DCE Control and Energy Unit(Digitally Controlled Energy) the entire weld-ing process, including all parameters, is mon-itored and controlled through digital signalprocessors (DSPs) in real time.

The stud movement is adjusted electronicallyin real time. In the closed loop, an integratedposition measuring system provides con-stant feedback, with the system responding

immediately and automatically to the chang-ing geometry of the component (closed loopcontrol).

Stud penetration dened

The plunge of the stud into the pool of moltensheet metal gives a clear indication of theweld quality. The DCE series provides studpenetration control, analysis and monitoring.

If necessary, a pre-dened stud penetrationvalue may be programmed. This is especiallyimportant for T-stud or step stud applicationsrequiring dened head dimensions.

Adjustable lift height

For each welding program, the lift height maybe programmed to range between 0.6 mmand 3 mm. Thus, every single application isperfectly adapted to the welding task.

Everything

under control!

Constant weld time,independent of wear!

Even though weld splatter is almost entirelyeliminated by controlled stud movementand weld plunge, ue gases and metal dustcan cause contamination of all componentsinvolved in lift movement of the weld headand stud.

Nevertheless, all welding is done at a con-stantly high level of quality. As an addedbenet, the service life of all spare parts isextended signicantly as are the mainte-nance intervals. Extended residence timeincreases availability and reduces effortsrelating to maintenance and spare parts.

From progress to standard

This TUCKER technology responds to theincreasing role of lightweight constructionmethods in the automotive industry. A newgrade of stud welding which also appliesto thin steel sheets (0.6 mm), high-strengthsteel, aluminum, magnesium, and manysandwich materials and alloys.

From experience to leadership

Today, more than 11,000 TUCKER stud weld-ing systems utilizing a primary modulatedpower control unit are used worldwide. Thisexperience, along with close contacts withexperts in the eld, is a constant source of in-novative ideas which we have implementedin the DCE Control and Energy Unit.

Contact Pilot currentphase

Weldingphase

Plunge phase

Arc voltage

Movement of component Welding current

Time (ms)

s(d)


3/6

Dirt protection tailor-made

to each weld headCleaning is signicantly reduced, maintenance scheduling made easier andmaintenance work can be carried outmore swiftly.


4/6


The New Operating Panel

Optimum Comfort and Security!

Intuitive Interface

Simple, intuitive, menu-driven Windows in-terfaces are todays standard for any situa-tion. Since late 2007, Emhart Teknologies hasbeen providing a new, state-of-the-art oper-ating panel for its DCE generation of equip-ment. High-resolution displays illustrate thecurrent equipment status and visualize anyavailable information and data.

Abbreviations, error codes, and similar aidsare things of the past. On the new operat-ing panel, all information is rendered in plaintext or via common icons.

Software Packages

Programming for steel or aluminum

With the DCE generation of equipment,users are fully enabled to perfectly adaptthe weld process to their requirements.

Ofine programming

This software turns the operating deviceinto a full-edged ofine-programmingunit. It is no longer necessary to use aPC or laptop for data backup or weldingprogram recovery.

Assist features

Products and processes have becomemore complex, yet they are supposed tobe managed by a smaller operating andmaintenance staff. Thats where Assistcomes into play.

At the touch of a button, you get allthe required and accurate pieces ofinformation for the specic weldingequipment parts lists, maintenanceplans, interface drawings, troubleshootingguides etc. Supported by illustrations andpictures, all this enables even someonewho is not an expert to handle the studwelding system in a safe manner notonly, but above all during incidents!

By means of the innovative touch-screentechnology, the size of controls is adapted tothe users current requirements.

The built-in USB interface facilitates thetransfer of rmware, welding programs,measuring data, and fault latches.

The newoperating panel comes

with differentsoftware packages ,providing the right pro-

gram for your application.

Equipment variationsDCE Control and Energy Unit

Easy and safe download of software up-dates without exchange of EPROMS viaash memory directly from PC.

DCE-Link networking software for trans-parent maintenance management featur-ing Ethernet TCP/IP for Internet/Intranetintegration.

Stud arrival sensor mounted on theweld head immediately detects thearrival of the stud, thus speeding up theremaining feeding process.

Stud ID / Car body ID the DCE EnergyUnit is able to receive various produc-tion data through the customer interface.Monitoring the parameters, we link thedata to the current weld data and passthem on to the customer control. Thesedata form the basis of perfect qualitymanagement and efcient improvementprocesses with one goal: zero defects inthe nal assembly.

Customer interfaces apart from aparallel interface, serial eld bus systemslike Interbus, Probus, Modbus, and De-viceNet are available. Additional meansof communication include Ethernet-basedsystems like ProNet or Ethernet IP.

Operation with switches Flexibilityin a production cell may be increased sig-nicantly by means of a feed switches.

Inert gas for aluminum stud or stainlesssteel stud welding, both weld heads andguns may be equipped with an inert gasnozzle.


5/6


Optimum Accessories for Maximum Availability!

Perfectly matched aids

TUCKERs range of accessories provides awide variety of aids completing the automo-bile body-in-white.

Efcient quality assurance

Welding results may be affected by exter-nal factors. This does not necessarily meanbad welding, but merely signies that upperor lower limits of dened parameters wereexceeded.

The welding positions affected are markedimmediately after welding by means of acolor coding system. In the subsequent qual-ity assurance process, the fastening point islocated quickly and efciently.

Testing the right way!

You can choose from a broad range of testingequipment perfectly adapted to the load onthe respective stud.

Power unit DCE 1500 and DCE 1800

for (large-scale) serial production

DCE 15HAfor CKD or small-scale serial production

Feeder , ETF line

Series 20 and 50,predominantly used for threaded studs

Series 12 and 90,predominantly used for earth studs

Series 52 through 55for step studs or T-studs

Fullyautomaticapplication

Semi-automaticapplication

Manualapplication

Power Feeder Welding-unit tool

DCE 1500 ETF 20 LMR 410/420 DCE 1800 ETF 5X LM 310

ETF 90 LM 240ETF 12

DCE 1500 ETF 20 PLM 200 DCE 1800 ETF 5XDCE 15HA ETF 90

ETF 12

DCE 15HA PKE PLM 560 and controlbox(es)

Equipment that Fits any Body-in-white Concept

Weld heads , LM series LM 240 for stationary applications

LM 310 for robot-aided applications

LMR 410/420 for the most difcultwelding position

Weld guns featuring LM technology

For manual and semi-automatic applications

PLM 200 with automatic stud feeder

PLM 560 with manual feed

Tailor-made to the customers manufacturing penetration andbody-in-white concept, the system concept offered by

Emhart Teknologies TUCKER is right for you.

Testing tools

Feeding switches

Nozzles and guide bushings

Color coding

Testing tools

Adapter plates


6/6