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The SonoPower Digital 3S increases process reliability for ultrasonic applications in industrial component cleaning and electroplating

Digital Generator for Coating, Cleaning

June 27, 2014
3-kW ultrasonic device achieves process stability via 32-bit controller 25 and 40 kHz Automatic settings adjustment Detects, adapts voltage

The SonoPower Digital 3S is WEBER ULTRASONICS' response to stricter requirements for process stability and cost-efficiency in the field of surface technology. The 3-kW ultrasonic generator has several features and a control system based on a 32-bit processor architecture that allows it to adjust settings automatically, which in turn provides greater stability and reliability, while maximizing performance efficiency.

The device is supplied ready-to-connect and is available with the frequencies 25 kHz and 40 kHz.

The SonoPower Digital 3S 32-bit processor architecture is similar to the kind used in smartphones. Employing the frequencies of 25 kHz and 40 kHz, which are frequently used in component cleaning and electroplating, it is suitable for a broad range of applications.

Thanks to the new Weber Sonoscan, the generator automatically determines and sets its operating frequency. This is already performed before any ultrasonic output and thus increases the process reliability for cleaning and electroplating. The continuous monitoring and automatic adjustment of the frequency also ensures that the system always uses the optimal output, even when operating conditions change - for example in the case of temperature fluctuations, when switching over from cleaning to rinsing medium, or when replacing a transducer. Thanks to this new technology, the generator also detects whether a transducer system is connected at all. This prevents damage to the generator due to "dry running."

Of course, conventional generators also are capable of detecting when they get too hot. However, they then simply switch off, which leads to an interruption in the process and requires manual intervention. The new SonoPower Digital 3S is different in this regard, as it independently adapts its fan speed in accordance with the prevailing situation. The parts can then continue to be treated with no loss of performance/quality and without the generator overheating.

In addition to this, the SonoPower Digital 3S is capable of independently detecting the mains voltage and then adapting to this – and not only during installation. It continuously measures the mains voltage and reacts promptly to any overvoltage or undervoltage, as well as to voltage fluctuations. This also contributes to consistent quality of the cleaning or electroplating process.

On the SonoPower Digital 3S, the sweep function and the power output can each be individually adjusted in 1% steps, allowing users to set up various modes exactly as they wish and integrate these into parts-specific treatment programmes. In turn, this allows easy adjustment of the ultrasonic treatment to various or varying ranges of parts. At the same time, the new 32-bit processor architecture makes it possible to further extend the intelligence of the generator, thereby offering flexibility for resolving future tasks.

The new power section of the SonoPower Digital 3S also contributes in this regard, as its output stage is twice as powerful as those used in previous generators. This offers high power reserves for greater safety and reliability, in particular when handling tasks for which previous generators were forced to operate at their limits. Not least thanks to Weber Sonoscan, it is also more tolerant with regard to transducer systems and supply lines. As such, the generator reacts less critically to differences in transducer systems caused by material tolerances, ageing or wear.

Another advantage of the new 3-kW generator is its IEC-compliant PLC interface. It is fully compatible with the programmable logic controllers (PLCs) typically used in the field of automation. The optimal communication between the generator and the PLC that results from this not only simplifies commissioning, but also any potential troubleshooting.