The Beahm Designs Balloon Bonder 420-B Model is a thermal die bonder with axial compression, designed for precise and repeatable bonding applications, particularly for short balloon bonds and ultra-smooth lap and butt welds. This system is equipped with dual pneumatic tubing grips, centerline adjustment, adjustable compression, and variable timed cooling, making it suitable for both medical device and nonmedical organizations. The 420B provides a low-cost quick tool alternative to RF die bonding.
Function Description:
The device operates by applying controlled heat and compression to bond materials. It features a seven-parameter operation that is easy to set up and use, simplifying system calibration and process validation. The adjustable clamp pressure varies compression force on the joint, allowing for greater workspace flexibility.
The front panel of the device includes several controls and displays for precise operation:
- Main Power Switch: Toggles system power on and off.
- Start Switch: Initiates the bonding process sequence.
- Stop/Abort/Reset: Interrupts the process sequence and resets the system timer. If "E Stop" is depressed, it resets the system after power up.
- Front Die Temperature Controller: Controls the temperature of the front die head.
- Rear Die Temperature Controller: Controls the temperature of the rear die head.
- Axial Compression Delay Timer: Controls compression delay time.
- Weld Duration Timer: Controls the duration that the die heads are closed and/or in contact with the product.
- Cool Duration Timer: Controls the duration the cooling air flows.
- E Stop: Disrupts power to heaters and internal components.
Parameter Settings:
- Pressure Regulator Setting: Rotate the regulator knob clockwise to increase air pressure, counterclockwise to decrease air pressure output to the die head actuation cylinder.
- Process Timer Setting: Depress the upper half of the blue rocker buttons to increase time duration, and the lower half to decrease it. Depress the timer reset button to accept the new value.
System Operation:
To operate the system, follow these steps:
- Switch main power on.
- Set the die temperature on each temperature controller.
- Set heat timer to desired duration in seconds.
- Set Axial Compression Delay Timer to desired duration in seconds.
- Set Cool Timer to desired duration in seconds.
- Adjust Die Head pressure.
- Adjust Tubing Grip Pressure.
- Position components to be bonded within thermal jaws.
- Depress foot switch/push start button.
- Remove components upon completion of cool duration.
Temperature Controllers (Omega Platinum Model):
The device uses Omega Platinum Model temperature controllers, which are auto-tuned and pre-set for optimal performance. Users can navigate and adjust various parameters:
-
PID Configuration (PRoG > PId.S):
- ACTN (Action direction): Moves up or down to SP1.
- A.to (Autotuning Timeout): Sets a maximum amount of time for autotuning.
- AUto (Autotuning): Initiates autotuning.
- GAIN (Proportional, integral, and derivative factors): Selects factors for manual tuning.
- %Lo (Low clamping limit): For Pulse and Analog outputs.
- %HI (High clamping limit): For Pulse and Analog outputs.
- AdPt (Fuzzy logic adaptive tuning): Selects adaptive tuning.
-
Action Response (PRoG > PId > ACTN):
- dRECT (Direct action): Cooling.
- RVRS (Reverse action): Heating (factory default).
- RVRS/dRCT (Increase or Decrease to SP1): Heating/cooling.
-
Autotune Timeout (PRoG > PId > A.to):
- Sets the amount of time before the Autotune process gives up and times out in Minutes and Seconds (MM.SS). Slowly responding systems should have a longer time-out setting.
-
Autotune (PRoG > PId > TUNE):
- Selects the Autotune (AUto) command. The unit displays StRt.
- Confirms Autotune activation. The unit attempts to optimize the P, I, and d settings by stimulating the system and measuring the response. If the A.to time out period expires before the Autotune operation can complete, the unit displays a failure message E007. If the Autotune operation completes successfully, the unit displays the message “doNE” and the Run mode is switched to IDLE.
The Autotune function adjusts the tuning algorithm depending on the stability of the current process and the error difference between the current process and the Control Setpoint (SP1). If the process is relatively stable (e.g., at room temperature), a bump test is performed to determine the plant characteristics. If the process is not, or if the process is within 10% of Control Setpoint, limit cycle oscillation will be performed with the tuning setpoint taken at the process value when the Autotune function is triggered. Autotuning may be performed as many times as needed or when the operating conditions (i.e., process load, or setpoint) have changed significantly. To obtain good tuning results, ensure the process is stable prior to triggering the autotune function. The process is stable when it is at ambient temperature, or it is tracking Control Setpoint (SP1) in auto mode.
Adjusting Temperature on Controllers (Omega Platinum Model):
- Press the right arrow button one time until “SP-1” is displayed.
- Press the enter button to access the temperature screen.
- Use the left and right arrow buttons to set desired temperature.
- Once the desired temperature is set, press the enter button to return to the main screen. Heaters ramp to correct temperature.
Resetting the Temperature Controller:
Press the "up arrow" to select the operator menu (Oper). See the following chart for the correct settings for the Beahm 420B. Settings to change in RED.
Important Technical Specifications:
| Description |
Range |
Resolution |
Accuracy |
| Temperature Controller |
Ambient-500°F |
1.0 deg. |
±.25% F.S. |
| Die Temperature |
Ambient-500°F |
N/A |
±10°F |
| Heat Duration |
1-9999 seconds |
1.0 sec |
± .1 sec |
| Cool Duration |
1-9999 seconds |
1.0 sec |
± .1 sec |
| Die Pressure |
0-60 psi |
2.0 psi |
± 1.5% F.S. |
Facilities Requirements:
- Voltage: 120/240 VAC (depends on configuration) 50/60 Hz.
- Wattage: 500 max.
- Compressed Air: 60-125 psi, 0.5 SCFM, filtered 50 micron or greater, oil and water-free.
Safety:
- Use eye protection when working with compressed gases and heated materials.
- The maximum observed Sound Pressure Level is below 70 dB(A).
- Caution: high voltage. Remove power and use safety precautions when servicing.
- Caution: hot surface. Contact may cause burn. Allow to cool before servicing.
- Caution: pinch point. Keep hands and body parts clear while in operation.
- Warning: Ensure the machine is unplugged for any servicing or maintenance work. Perform these steps ONLY when the machine is at room temperature.
User Alerts:
Do not use the equipment other than as prescribed. Do not attempt to sit on or climb on the equipment, do not place heavy objects or containers of liquid on the machine, do not to insert any foreign objects into the machine and do not attempt to bypass any guards or otherwise operate the machine in any manner other than that in which it is explicitly intended.
Installation:
- Place the system on a level, sturdy surface at an ergonomically viable height for the user.
- Connect the electrical umbilical to the die dose unit.
- Connect the power cord to the main control unit.
- Connect the air supply to the system and then to a clean, dry, and filtered compressed air source.
- The equipment is not for use with materials that can decompose or ignite below the maximum operating temperature of the machine. Hazards are materials that outgas hazardous substances and or ignite. (260°C/500°F)
- This equipment is not for use in an ATEX environment.
Maintenance Features:
Exchanging Die Heads:
- Caution: Ensure that the die heads are cooled to within 15 degrees of ambient temperature before proceeding with replacement.
- Loosen the set screw located on the top of each die head and withdraw the thermocouple.
- Remove the four screws at the base of each die head.
- Position new die heads in place of removed die heads, install four screws at the base of each die head. Do not overtighten the screws.
- Install the thermocouple in the rear of each die head and gently tighten the set screw to hold them in place.
Cleaning:
- Use 99% isopropyl alcohol to wipe down the outside of the machine. Do not attempt to clean the inside of the machine. Machine should not be washed down.
- Cleaning should be with a soft dry cloth only.
Calibration:
- It is recommended that calibration be performed by a certified service, preferably within the system in the location of use. Calibration procedures are the domain of these service providers.
- Calibration refers to the process of verifying that each of the systems’ instruments that control a process parameter is within manufacturers’ specifications.
- Calibration does NOT refer to the process of measuring the temperature at the center of the tooling and “matching” the value to the temperature controller set point.
- The measured value at the tooling may not match the temperature controller set point and the.
- Calibrate the temperature controller annually.
- Calibrate the timers annually.
- Calibrate the pressure gauge annually.
Diagnostics (Troubleshooting):
| Issue |
Possible Causes |
Solution |
| Temperature not stable |
Die heads replaced. Thermocouple loose |
Auto-tune. Re-install thermocouple(s). |
| Die heads do not close |
Air pressure too low. Timer set to “0”. Valve defective. |
Increase air pressure. Increase Heat Duration. Replace valve. |
| Die head(s) do not heat |
Loose connection to main control unit. Detective Temperature controller. |
Verify secure connections. Replace temperature controller. |
| .Err code in display |
Temperature controller software failure. |
Replace temperature controller. |
| System will not power on. |
Emergency stop switch depressed. IEC power cord not fully connected. |
Rotate switch knob to engage. Verify installation. |
Warranty:
Beahm Designs Inc. (BDI) products are backed by a 1-year warranty on parts and labor. Warranty is void for any Product returned if BDI determines that:
- The asserted defect is not present.
- The asserted defect is attributable to misuse, improper installation, alteration (including removing or obliterating labels and opening or removing external covers (unless authorized to do so by Beahm Designs)), accident or mishandling while in the possession of someone other than Beahm Designs, Inc.
- The Product was not sold to you as new.
Return Material Authorization (RMA):
No Product may be returned directly to BDI without first contacting BDI for a Return Material Authorization (“RMA”) number. If it is determined that the Product may be defective, you will be given an RMA number and instructions for Product return. End Users are required to include a copy of the RMA receipt inside the return box to receive replacement product under warranty. An unauthorized return, i.e., one for which an RMA number has not been issued, will be returned to you at your expense.
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