PRODUCT SPECIFICATIONS FORMCENTER FOR DESIGN AND MANUFACTURING EXCELLENCE

ULTRAFASTCAPACITOR BANKThe Ultrafast Capacitor Bank designed, built, and tested by the Center for Design and Manufacturing Excellence (CDME) consists of the energy storage/delivery system, the programmable logic controller (PLC), and the human machine interface (HMI) systems. The capacitor bank is capable of charge to 13kv with 4.2kJ stored energy, which is the maximal allowed safe charge condition. The maximum discharge current is 300 kA. The safety of the operator, the system and the surrounding environment are the primary focuses of the system. The PLC manages the charging, discharging, and synchronization of the external mechanical system (robots and other manufacturing systems). The HMI is programmed to create a simple and logical interface for the operator to control the system and manage the processes.

KEY FEATURES AND BENEFITS• Ideal for vaporizing foil actuator welding, electromagnetic

and electrohydraulic forming

• Low inductance design for fast current rise

• Simple and logical interface for the operator

• Configured to manage the charging, discharging, andsynchronizing of the external mechanical system

APPLICATIONSThe design of the capacitor bank makes for a compact system with a very fast rise time. The system is a pulse power supply suitable for use with a variety of impulse based forming and joining technologies, such as vaporizing foil actuator welding, electromagnetic and electrohydraulic forming. These technologies are fast and efficient methods of joining, forming and shearing. Through these technologies, materials such as aluminum, copper, brass, and low carbon steel can be joined to other materials including metals, plastics, composites, and glass. These technologies have specific potential in the manufacturing of components for automotive, aerospace, and consumer electronics. The Ultrafast Capacitor Bank can be used to create products ranging specifically from aircraft torque tubes and surgical staplers, to appliance motors. The further applications of this technological advancement pertain to collision welding and the use of vaporizing foil actuated welding (VFAW). Currently, the use of VFAW in the metal working industry is limited. The use of the Ultrafast Capacitor Bank could contribute to the expansion of this impulse based technique in manufacturing and industrial applications.

OVERVIEW An overview of the basic specs that define and distinguish the Ultrafast Capacitor Bank system.

Dimensions

-55in H x 30 in W x 45 in L-450 lb

Safety

-Manual safety shutdown-Every opening has a safety switch that will discharge the system-Emergency stop buttons on the control panel (one hard and onesoft)

-Light curtain system proximity alarm turns off the system when anoperator gets too close

Controls

-Pedestal/Control panel, touch screen, and safety key

Output

-Flat horizontal output electrodes for connecting to the actuator

Touch Screen (on control panel)

-Monitors the voltage levels, controls, and status of charger-All data that user needs to know within 6 main screens-System setup, warnings, data presentation

Maintenance

-10,000 shot maintenence interval-Sandpaper or simple cleaning

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LEARN MORE ONLINE CDME.OSU.EDU

TECHNICAL SPECSDetailed functions and features that define the Ultrafast Capacitor Bank. Additional information is available at iml.osu.edu.

Output

Electronics Shelf

Capacitor

INTERFACEThe HMI subsystem allows the Ultrafast Capacitor Bank to be operated either in Multishot or Single shot mode.

Nominal Energy Range: 0.3-4.2kJ

Absolute Maximum Energy: 5.6kJ (50μF at 15kV)

Maximum Output Current: 300 kA

Capacitor Shot Life: 50,000 to 5,000,000

Charging Rate: 1kJ/sec

Supply Voltage: 180 – 250 VAC

Human Machine Interface: Tethered pedestal mounted interface controls

Capacitor Unit:: 3× (3 in series) parallel

Switching Mechanism: Single 4 channel triggered spark gap

Enclosure: Robust fully metallic enclosure with lifting eyes

Buss: Horizontal clamp buss

Safety Features:

-Audible/visual alarms with charge (full, charging or residual)

-Safety contactor with dump resistor and failure detection

-Manual safety discharge to grounding rod

-Laser Light Curtain around front of system (around work table)

-Lock-Out/Tag Out on transformer switch

-Emergency Stop that Dumps Capacitor to Ground

-Door Interlocks Dump Capacitor to Ground

-Keyed Access to Control Pedestal

Additional Info: Pressurized synthetic air or nitrogen required(dry, less 10 ppm hydrocarbon) for switch electrode protection

Interface Welcome Screen

The interface welcome screen shows on boot and allows single or multi-shot modes to be selected.

Single Shot Interface

The single shot interface allows the machine to be configured for a single shot with selected parameters.

Multi-Shot Interface

The multi-shot interface allows the machine to be configured for a counted number of shots with the same parameters.

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