Dukane iQ Series ES Ultrasonic Press System - Press/Thruster Manual Manual

Dukane iQ Series ES Ultrasonic Press System - Press/Thruster Manual Manual
Intelligent Assembly Solutions
iQ Series
ULTRASONIC PRESS SYSTEM
ES
User's Manual
Press/Thrusters:
43Q215
43Q220
43Q340
Dukane Part No. 403–569-01
Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797–4900 • FAX (630) 797–4949
ISO 9001:2000
Dukane products are manufactured
in ISO registered facilities
www.dukane.com/us
iQ Series Ultrasonic Press System ES User’s Manual
Copyright © 1996—2009
Dukane Intelligent Assembly Solutions
2900 Dukane Drive
St. Charles, IL 60174 USA
Notice of Rights:
All rights reserved. No part of this manual including the interior design, cover design and icons
may be reproduced, transmitted or utilized in any form or by any means, electronic, mechanical,
photocopying, recording, or by any information storage and retrieval system, without written
permission from Dukane Corporation.
Notice of Liability:
The information contained is this manual is distributed on an “As is” basis, without warranty.
While every precaution has been taken in the preparation of this manual, Dukane Corporation
shall not have any liability to any person or entity with respect to any liability, loss, or damage
caused or alleged to be caused directly or indirectly by the instructions contained in this manual,
or by the hardware products described herein.
Specifications subject to change without notice.
Printed in the United States of America.
Dukane Part Number: 403-569-01
Dukane ultrasonic equipment is manufactured under one or more of the following U.S. Patents:
3,780,926 3,825,481 4,131,505 4,277,710 5,798,599 5,880,580 6,984,921, 7,225,965,
and 7,475,801
Page
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Dukane Manual Part No. 403-569-01
Revision History
Revision
Number
Revision
Summary
Date
- 00Original release. 09/22/2009
- 01
Added stack surface temperature warning
Dukane Manual Part No. 403-569-01
06/15/2017
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iQ Series Ultrasonic Press System ES User’s Manual
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Dukane Manual Part No. 403-569-01
Contents
Section 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . . 1
General User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Health and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Section 2 - Installation . . . . . . . . . . . . . . . . . . . . . . . . 9
Installing the Press System . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Thruster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flange Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
13
14
17
Section 3 - Control Description . . . . . . . . . . . . . . . . 19
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Press Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ergonomic Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
22
25
26
28
Section 4 - Press Options . . . . . . . . . . . . . . . . . . . . . 31
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distance Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Press Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
34
36
39
Section 5 - Stack/Fixture Setup . . . . . . . . . . . . . . . . 41
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Stack Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Changing Stack Components . . . . . . . . . . . . . . . . . . . . . . 45-48
Fixture Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Section 6 - System Test . . . . . . . . . . . . . . . . . . . . . . 53
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Operational Test of the Acoustic Stack . . . . . . . . . . . . . . . . . . 56
Procedure for Cycling the System . . . . . . . . . . . . . . . . . . . . . . 59
Continued
Dukane Manual Part No. 403-569-01
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iQ Series Ultrasonic Press System ES User’s Manual
Contents Continued
Section 7 - Stack Maintenance . . . . . . . . . . . . . . . . . 61
Inspection of the Acoustic Stack Components . . . . . . . . . . . . 63
Reconditioning Stack Components . . . . . . . . . . . . . . . . . . . . . 64
Section 8 - Troubleshooting . . . . . . . . . . . . . . . . . . . 67
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Continuous Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69
70
77
80
83
Pop-up Status Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Section 9 - System Maintenance . . . . . . . . . . . . . . . 87
Six-Month Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . 89
Section 10 - Contacting Dukane . . . . . . . . . . . . . . . . 91
Section 11 - Specifications . . . . . . . . . . . . . . . . . . . . 95
Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97-104
Weights, Dimensions, Operating Environment . . . . . . . . . . .
Pneumatic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interpreting the Model Number . . . . . . . . . . . . . . . . . . . . . . .
Replacement Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulatory Agency Compliance . . . . . . . . . . . . . . . . . . . . . .
105
106
106
107
107
108
Section 12 - Appendices . . . . . . . . . . . . . . . . . . . . . 109
Appendix A - List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Appendix B - List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Index
Page
vi
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Dukane Manual Part No. 403-569-01
Section 1 - Introduction
SECTION 1
Introduction
General User Information . . . . . . . . . . . . . . 3
Health and Safety . . . . . . . . . . . . . . . . . . 4
Dukane Manual Part No. 403-569-01
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iQ Series Ultrasonic Press System ES User’s Manual
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Dukane Manual Part No. 403-569-01
Section 1 - Introduction
General User Information
Read This Manual First
Before operating your ultrasonic system, read this User’s
Manual to become familiar with the equipment. This will
ensure correct and safe operation. The manual is organized
to allow you to learn how to safely operate this equipment.
The examples given are chosen for their simplicity to illustrate basic operation concepts.
This manual provides information to set up, operate, and
interface Dukane’s iQ Series ES presses.
Particular models are listed on the manual cover and in
Section 11 - Specifications.
The manual consists of sections that describe in detail
press specifications and functions, installation and testing procedures, and maintenance and troubleshooting
steps. Each section describes press functions that are
applicable to a standard press/thruster.
NOTE
Note statements provide additional
information or highlight procedures.
Notes, Cautions and Warnings
Throughout this manual we use NOTES to provide information that is important for the successful application and
understanding of the product. A NOTE block is shown to
the right.
In addition, we use special notices to make you aware
of safety considerations. These are the CAUTION and
WARNING blocks as shown here. They represent increasing levels of important information. These statements help
you to identify and avoid hazards and recognize the consequences. One of three different symbols also accompany
the CAUTION and WARNING blocks to indicate whether
the notice pertains to a condition or practice, an electrical
safety issue or a operator protection issue.
CAUTION
Caution statements identify conditions or practices
that could result in damage
to the equipment or other property.
WARNING
Warning statements
point out conditions or
practices that could result in personal injury or
loss of life.
Drawings and Tables
The figures and tables are identified by the section number followed by a sequence number. The sequence number begins with one in each section. The figures and tables
are numbered separately. The figures use Arabic sequence
numbers (e.g. –1, –2, –3) while the tables use roman sequence numerals (e.g. –I, –II, –III). As an example, Figure 3–2 would be the second illustration in section three
while Table 3–II would be the second table in section
three.
Dukane Manual Part No. 403-569-01
 
Condition
or Practice
Electrical
Hazard
Hearing
Protection
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iQ Series Ultrasonic Press System ES User’s Manual
Health and Safety
Please observe these health and safety recommendations for safe, efficient, and injury-free operation of your
equipment.
Proper Installation - Operate system components only
after they are properly installed.
No Unauthorized Modifications - Do not modify your
system in any way unless authorized to do so by Dukane
Corporation. Unauthorized modifications could cause
equipment damage and/or injury to the operator. In addition, unauthorized modifications will void equipment
warranty.
NOTE
These recommendations apply to the
welding system. System in this manual
refers to a complete group of components
associated with the welding of parts, also
known as an ultrasonic assembly system.
A typical iQ Series System consists of
the iQ generator, a press with thruster,
switches, controls, cables, transducer,
booster, horn, and fixture.
Keep the Cover On - Do not remove any equipment cover
unless directed to do so by Dukane Corporation.
Grounded Electrical Power - Operate this equipment
only with a grounded electrical connection.
(See Electrical Safety Grounding Instructions, Page 8.)
Comply with Regulations - You may be required to add
accessories to bring the system into compliance with
applicable regulations (OSHA in the USA) for machine
guarding and noise exposure.
CAUTION
At some time you may be asked
to remove equipment covers by
the Dukane Service Dept. personnel. Before doing so, disconnect
the unit electrically from the incoming line AC
power. If the unit is a press/thruster, lock the
Air Lockout Valve, located on the rear panel,
in its closed position.
See Figure 2-6 on Page 14.
Use Eye Protection - Wear ANSI approved safety impact
goggles.
Continued
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4
Dukane Manual Part No. 403-569-01
Section 1 - Introduction
Health and Safety Continued
Acoustic Stack Hazard - When an acoustic stack (transducer, booster, horn and tip) is energized by the ultrasound
signal, it presents a potential hazard. Stay clear of an
energized stack.
System Abort Switch - Install a system abort switch at
each operator station when ultrasonic plastic assembly
equipment is used with automatic material handling equipment in an automated system.
CAUTION
Parts being joined ultrasonically
will at times vibrate at audible
frequencies. Wear ear protectors to reduce annoying or
uncomfortable sounds. In addition, ultrasound baffles, sound enclosures, or
materials that absorb sound may be located
to surround the system.
Foot Switch - Using a foot switch in place of the optical
touch finger switches (activation switches) violates OSHA
regulations.
Pre-trigger Switch Adjustment - The pre-trigger switch
option starts the horn vibrating before contacting the part
to be welded. To ensure safe operation, adjust the pre-trigger so the ultrasound signal will not activate if the horn is
more than ¼ in (7 mm) from the part to be welded.
System Electrical Cabling - Electrical power must be off
when connecting or disconnecting electrical cables.
WARNING
Keep head, hands, limbs
and body at least six inches
(152 mm) away from an
operating press/thruster. A
vibrating, descending horn
can cause burns and/or crushing injuries.
Continued
Dukane Manual Part No. 403-569-01
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iQ Series Ultrasonic Press System ES User’s Manual
Health and Safety Continued
Do Not Wear Loose Clothing or Jewelry - They can
become caught in moving parts.
Stay Alert - Watch what you are doing at all times. Use
common sense. Do not operate the press when you are
tired or distracted from the job at hand.
Do not Operate the Press - Your judgement or reflexes
could be impaired while taking prescription medications.
If so, do not operate the press. Be familiar with warning
labels and recommended activity restrictions that accompany your prescription medications. If you have any doubt,
do not operate the equipment.
CAUTION
When making cable
connections to system
equipment or disconnecting cables from system
equipment, make sure electrical power
to the system is turned off, and AC
power cords are removed from their receptacles. After the cables have been
securely connected and the connections and cable routing checked a final
time, the power may be restored.
Continued
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6
Dukane Manual Part No. 403-569-01
Section 1 - Introduction
Health and Safety Continued
Special Health Notice–
Plastics
Certain plastic materials, when being processed, may
emit fumes and/or gases that may be hazardous to the
operator’s health. Proper ventilation of the work station
should be provided where such materials are processed.
Inquiries should be made to the U.S. Department of Labor
concerning OSHA regulations for a particular plastic prior
to processing with Dukane ultrasonic equipment.
Activation Switches
The dual finger activation switches comply with OSHA
safety regulations. Using a foot switch in place of the dual
finger activation switches violates OSHA regulations.
Electrical Safety Grounding
CAUTION

If there is any question
about the grounding of
your receptacle, have it
checked by a qualified
electrician. Do not cut
off the power cord grounding prong, or
alter the plug in any way. If an extension cord is needed, use a three-wire
cord that is in good condition. The
cord should have an adequate power
rating to do the job safely. It must be
plugged into a grounded receptacle.
Do not use a two-wire extension cord
with this product.
The iQ Series generator provides the operating power
and power returns. Make sure the generator is grounded
properly.
In addition to the safety considerations, proper grounding
is essential for the effective suppression of RFI (Radio
Frequency Interference). Every generator contains a
RFI filter which blocks noise on the AC power line from
entering the generator control circuitry. This filter also
prevents ultrasonic RFI from being fed back into the AC
power line.
If you experience problems with RFI from the press, run
an additional grounding wire from the press base grounding stud (See Figure 2-6.) to the nearest grounded metal
pipe or equivalent earth ground by means of a ground
clamp. Use at least 14 AWG wire for the connection to
the press base.
CAUTION

To ensure
trouble–free
ground the
chassis and
thruster.
safe and
operation,
generator
the press/
Use a STAR configuration
(illustrated below). Do not
DAISY CHAIN the grounds.
DPC Chassis
Grounding
Lug
#14 Gauge
Stranded or
Solid Wire
Thruster or
Probe Mount
Grounding Lug
#14 Gauge
Stranded or
Solid Wire
Earth
Ground
Dukane Manual Part No. 403-569-01
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Dukane Manual Part No. 403-569-01
Section 1 - Introduction
SECTION 2
Installation
Installing the Press System . . . . . . . . . . . . . 11
Unpacking. . . . . . . . . . . . . . . . . . . . . . . 11
Placement. . . . . . . . . . . . . . . . . . . . . . . 11
Installing the Press System without Machine Base . . 12
Press Height Adjustment. . . . . . . . . . . . . . . . 12
Installing the Thruster . . . . . . . . . . . . . . . . 13
Cable Connections . . . . . . . . . . . . . . . . . 14
Flange Template. . . . . . . . . . . . . . . . . . . 17
Dukane Manual Part No. 403-569-01
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Dukane Manual Part No. 403-569-01
Section 2 - Installation
Installing the Press
System
The press system consists of a thruster, ergonomic base
and support package. It is assembled at the factory for
shipment.
Unpacking
The press system is secured to a wooden pallet and covered
with a cardboard carton. The press sits on the pallet and is
supported inside the carton by styrofoam blocks.
1.
Before unpacking, it is suggested that the press be
moved close to the location where it is to be installed.
2.
Remove the straps from the carton.
3.
Open the carton and remove the packing material and
the cables.
4.
Cut the tape located at the bottom corners and unfold
the flaps.
5.
Remove the carton, as shown in Figure 2-1, leaving
the press on the shipping base.
6.
Inspect the assembly for any possible damage before
placing it in position.
Figure 2-1
Unpacking Press System
Placement
Do not lift the press by hand. Use mechanical means to put
the press into place.
To place the press on the work area, use a pallet lift platform
or equivalent. Raise the assembly until the bottom edge of
the base is even with the top of the work area as shown
in Figure 2-2. Then, carefully slide the press system on to
the work area.
Dukane Manual Part No. 403-569-01
CAUTION
CAUTION
DO NOT
LIFT the
p r e s s
manually.
Lifting and/or moving
the press manually
could result in personal injury. Use mechanical means
to move and place the press.
Page
11
iQ Series Ultrasonic Press System ES User’s Manual
Installing the Press System
Without Machine Base
In this configuration, secure the flange to a rigid, level stationary structure. We recommend socket-head cap screws
M12 -1.75 with a minimum length of 40 mm for securing
the flange to the supporting structure. We recommend a
minimum of 1 inch (25.4 mm) full thread engagement of
the cap screws into the supporting structure. Depending
upon the thickness and material of the supporting structure, longer screws and/or additional hardware may be
required.
Counterbalance
Spring
Support
Housing
Thruster
Height
Adjustment
Handles
A full scale template is provided for locating and drilling
holes in the supporting structure. The template is Figure
2-8 on Page 17.
Press Height Adjustment
The height of the thruster on the column is adjustable. Adjustment is made by first turning the two handles located
on the left rear side of the press.
•
To loosen the grip on the column, turn the handles
counterclockwise, as shown in Figure 2-3a. The
counterbalance spring on the column supports the
weight of the thruster while the handles are loose. If
a thruster is not installed, the unloaded column may
rise up unexpectedly, so be careful to avoid injury.
•
Adjust the column to the desired height.
•
Turn the handles clockwise, as shown in Figure 2-3b,
until tight.
•
To rotate the handles out of the way without loosening or tightening, pull the handles outward, rotate and
release, as shown in Figure 2-4.
Figure 2-2
Example of Press Placement
CAUTION
Exercise caution if a
thruster is not installed on
the support housing. The
counterbalance spring on
the unloaded housing may cause
the assembly to rise up unexpectedly when the height adjustment
handles are loosened.
(a)
– Loosen
(b)
– Tighten
Figure 2-3 To Make Adjustments
Figure 2-4
Page
12
To Relocate Handles
Dukane Manual Part No. 403-569-01
Section 2 - Installation
Installing the
Thruster
Secure the thruster to a rigid stationary structure by
placing the back of the thruster onto the support frame.
Align the bolt holes in the thruster with the bolt slots in
the support frame. Insert the two (hexhead) mounting
bolts (M10-1.5 x 40mm), with flat washers, as shown in
Figure 2-5. Align the thruster with the work surface in
both the horizontal and vertical planes to assure parallelism. Tighten the bolts.
Mounting
Holes
Washers
When mounted to a Dukane column as in the press
configuration, the height of the thruster is adjustable on
the column. If the height of the thruster is not adjustable in your mounting arrangement, you must consider
the distance from the horn tip to the work surface when
determining the position of the thruster.
The distance between the tip of the retracted horn and
the parts in the fixture must be less than the maximum
travelling distance (stroke) of the thruster slide assembly.
If greater, the horn will be unable to contact the parts
during operation. The maximum stroke distance is 177.8
mm (7 inches).
A shorter distance between the retracted horn tip and the
parts in the fixture means a shorter travelling distance
(stroke) during operation which results in two advantages:
•
Mounting Bolts *
Rigid
Mounting
* (2) Hexhead Mounting Bolts
Distance from
horn to work
surface should be
less than 7 inches.
Figure 2-5
M10-1.5 x 40mm
Example of Mounting the Thruster
to a Rigid Structure
A more stable thruster when applying pressure
to the parts
• A shorter duty cycle for a faster production rate
However, make certain, that there is sufficient room for
the placement and removal of parts.
Dukane Manual Part No. 403-569-01
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iQ Series Ultrasonic Press System ES User’s Manual
Cable Connections
Press System
The press is not equipped with its own source of compressed air, electrical power, or electrical control and
monitoring. These functions are provided through the
connectors located on the rear of the thruster.
(Refer to Figure 2-6):
•
Top of Stroke (J207) - This receptacle is factory wired
to a switch in the press/thruster that opens when the
press/thruster slide assembly begins extending and
closes when the slide assembly returns to the fully
retracted (i.e. top-of-stroke) position. This contact
closure is typically used in automated systems to indicate to the controlling mechanism (supplied by the
end user) when the slide assembly is fully retracted. A
Dukane cable (Part Number 438-528) mates with this
receptacle to allow access to the switch contacts.
Top of Stroke Cable
(optional)
Ultrasound Cable
J207
Filtered Air
to Thruster
J1
Grounding Stud
J201
Operation
Control
Cable
Air Filter
NOTE
Under normal usage, do not
apply more than 24 VDC @ 2
Amps to the switch contacts
at J207.
•
Ultrasound (J1) - This input connects the transducer
to the Ultrasound Output (J1) of the iQ Series generator, through a coaxial cable. The electrical welding
signal is transmitted through this cable.
•
Operational Control (J201) - This cable runs from
J201 on the thruster to the generator's Press Port
(J5). The generator provides controls for triggering
the weld, operating the thruster’s pneumatic system,
and providing 24 VDC operating voltage through
this cable. The press driver card in the generator also
provides monitoring for these functions.
•
Air Filter In
Air
Supply
to Filter
Air Supply
Source
Encoder
Cable
Base Control
Cable
Air In - This is a 1/4 NPT threaded receptacle for a
compressed air supply that provides the thruster with
the required pressure of 80-110 psi (5.4 - 7.5 atmospheres) to operate the pneumatic system.
This connector is attached to an air filter on the press.
The input to the filter comes from the air shut-off
valve, located on the back, near the bottom of the
press.
Page
14
Air Shut Off
Valve
J35
Grounding Stud
Figure 2-6
Press Connector Locations
Dukane Manual Part No. 403-569-01
Section 2 - Installation
•
•
Encoder (Optional) - The purpose of the encoder
cable is to connect the distance encoder option to
the generator's Encoder Port (J11). For details on the
Encoder see Section 4: Press Options.
Ergonomic Base (J35) - Connects the base controls
and display to the Base/Abort Port (J7) on the generator.
The press system requires three cables for proper operation. These cables are part of the cable package that is
shipped with the press. A customer-provided air hose
(5/16 inch dia.) is also required.
Connect the following lines and cables to the press
system:
•
Connect the ultrasound coaxial cable from J1 on the
generator to J1 on the thruster.
CAUTION
The compressed air for the
thruster must be clean, dry
and oil free. Any particulate, oil contamination or
moisture can coat or clog the valves,
sensors and cylinder walls. This can
result in premature failure of the
regulator, pressure transducer, air
cylinder or other components of the
pneumatic system.
Top of Stroke
Cable (Optional)
DO NOT operate the generator unless this cable
is connected and the transducer is installed in the
thruster — Otherwise, an overload condition could
occur, with possible damage to the generator.
•
Connect the operational control cable from J5 on the
generator to J201 on the thruster.
•
Connect clean, dry air from an air source to the fitting
located at the lower portion of the support package.
Ultrasound Cable
J1
J207
Filtered Air
to Thruster
Grounding Stud
J201
Figure 2-6 shows the locations of the connections.
•
Encoder cable (optional) - If the press is equipped
with an encoder, the cable will already be wired in.
•
Connect the nine-pin ergonomic base cable from J7
on the generator to J35 on the back of the base.
Thruster Only
For thrusters, the only required connections are the air
line, ultrasound cable, and the operational control cable.
Figure 2-7 shows the location of the thruster connections.
Operation Control
Cable
Figure 2-7
Thruster Connector Locations
Cable/Signal
Generator
Press
Thruster
Ultrasound
J1
J1
J1
Operational Control
J5
J201
J201
Press Base
J7
J35
***
Distance Encoder
J11
Built-in
Built-in
Customer
supplied
control
J207
J207
Because the thruster does not use a support package, the
air source is connected directly to the “Air In” fitting.
Top of Stroke
Thruster systems require that Dukane's cable (Part
Number 200-1546-03) is installed in the iQ generator's
J7 receptacle.
***Dukane's cable (Part Number 200-1546-03) is
See Table 2-I.
Dukane Manual Part No. 403-569-01
installed in the iQ generator's J7 receptacle.
Table 2-I
Generator to Press/Thruster Cables
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iQ Series Ultrasonic Press System ES User’s Manual
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16
Dukane Manual Part No. 403-569-01
Section 2 - Installation
FRONT
7.75 inches
(196.85 mm)
. inches
(76.78 mm )
.875 inches
(98. 5 mm )
.6 5 inches
(66.675 mm)
. inches
(5 .8 mm )
1.5 inches
( 8.1 mm )
.6 5 inches
(66.675 mm)
. 5 inches
(57.15 mm)
Figure 2-8
Flange Template
No Scaling - Actual Size
Dukane Manual Part No. 403-569-01
. 5 inches
(57.15 mm)
R R
F n e Tem
e
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iQ Series Ultrasonic Press System ES User’s Manual
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Dukane Manual Part No. 403-569-01
Section 3 - Control Description
SECTION 3
Control Description
Overview . . . . . . . . . . . . . . . . . . . . . . 21
Manual Controls. . . . . . . . . . . . . . . . . . . 22
Indicators . . . . . . . . . . . . . . . . . . . . . . 25
Electronic Pressure Regulator. . . . . . . . . . . . 26
Ergonomic Base. . . . . . . . . . . . . . . . . . . 28
Dukane Manual Part No. 403-569-01
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Dukane Manual Part No. 403-569-01
Section 3 - Control Description
Overview
This section describes the controls, indicators and features
for the manual and electronic pressure-regulated (EPR)
versions of the Press/Thruster System.
The controls on the front of the thruster can be used to
manually set the parameters for a given process.
The indicators associated with the controls provide a visual
indication of the control settings.
The features used on the control panel are:
•
Metric measurements
•
International symbols to assist in locating the proper
controls and their associated indicators.
Refer to Table 3-I.
Symbol
Reference
Symbol
Reference
Mechanical
Stop
Weld Pressure
Down Speed
End of Weld
Thruster Stroke
Hold
Slow Speed
Direction
Table 3-I Thruster Symbols
Dukane Manual Part No. 403-569-01
Page
21
iQ Series Ultrasonic Press System ES User’s Manual
Manual
Controls
Refer to Figure 3-1 for the location of the controls.
Down Speed Adjustment
This control adjusts the downward velocity of the press/
thruster slide assembly. Turning the knob clockwise decreases the speed. Turning it counterclockwise increases
the speed of descent.
Hydraulic Slow Speed
Control (optional)
This control is used to adjust the point in the downstroke
where the hydraulic speed damper is engaged. The SLOW
SPEED Control knob adjusts to a point along the 7 inches
(177.8 mm) of total available downstroke distance that the
hydraulic Speed Control engages.
Refer to Section 4: Press Options, for detailed information
on the Hydraulic Slow Speed Control.
Hydraulic Slow Speed
Adjustment
The hydraulic slow speed adjustment is an integral part
of the optional hydraulic slow speed control. It sets the
amount of velocity damping of the hydraulic unit. (See
Figure 3-1.) For detailed information on this adjustment,
refer to Section 4: Press Options.
Mechanical Stop Adjustment
The function of the mechanical stop is to halt the downstroke at a predetermined point. It is used in two ways:
•
To stop the downstroke at a particular depth of travel
relative to the fixture/anvil.
•
To prevent the horn from contacting the fixture when
there is no part present. This prevents possible damage to the horn and/or fixture. Never allow the horn to
contact the fixture while ultrasonic power is applied
to the horn. Metal–to–metal contact can void the horn
and/or tooling warranty.
CAUTION

Do not allow the
horn to contact
the fixture while
ultrasonic power is
applied to the horn.
Metal–to–metal contact
can void the horn and/or
tooling warranty.
Pressure 1 Regulator
Pressure 1 regulator is used to set the amount of air pressure applied to the air cylinder during the press downstroke
and weld cycle.
Continued
Page
22
Dukane Manual Part No. 403-569-01
Section 3 - Control Description
Mechanical Stop Adjust
6
7
5
8
4
Down Speed Adjust
3
Pressure 1 Regulator
I
E
NC
REAS
Regulator Select
Switch
50
20
0
7
5
10
1
6
90
4
80
Pressure Gauge
60
3
70
30
40
2
Pressure 2 Regulator
REAS
E
I
NC
0
10
Stroke Position
Indicator Flag
Ultrasound Active Status Light
0
1
Mechanical
Stop Indicator
Flag
2
3
Slow Speed
Indicator Flag
NOTE
To properly set the
indicator flags, adjust
the control until the
middle of the flag lines
up with the desired
setting.
The example to the left
is set for 2 cm.
Hydraulic Slow Speed
Position Adjustment
Hydraulic
Slow Speed
Adjustment
(Velocity
Damping)
Figure 3-1
LOOSEN THE
THUMBSCREW TO
UNLOCK KNOB
20
LOWERS
SPEED CONTROL
TRIGGER
3 5 0
Trigger Control
(Numbers displayed are
for reference only.)
(Manual) Press/Thruster Controls and Indicators - Models 220/340 Shown
Dukane Manual Part No. 403-569-01
Page
23
iQ Series Ultrasonic Press System ES User’s Manual
Manual Controls Continued
Pressure 2 Regulator
In applications where welding with dual pressure is required, this pressure regulator would be set to provide a
higher pressure during a portion of the weld cycle. This
pressure is also maintained during the hold time.
Regulator Select Switch
The Regulator Select switch is used to select Pressure 1
regulator (Weld Pressure) or Pressure 2 regulator (Hold
Pressure) to set the required pressure on each regulator
and for monitoring the pressure gauge.
NOTE
The actual amount of force applied
to the part depends on the following
four factors:
• The setting of the regulator(s)
• The area of the air cylinder
• The mass of the horn used
• The surface area of the horn
Pre-Trigger Control
(Optional)
The pre-trigger control turns the ultrasound on at a preset
point in the thruster downstroke. This control is normally
used in staking and inserting applications. This control
should be set for a distance of approximately 6.25 mm
(.25 inch) above the part.
Trigger Control
Setting the trigger control determines the amount of preload on the part before turning on the ultrasonics.
(Numbers displayed are for reference only.)
End-of-Weld Control
(Optional)
NOTE
The pre-trigger switch option
starts the horn vibrating before
contacting the part to be welded.
To ensure safe operation, adjust
the pre-trigger so the ultrasound
signal will not activate if the horn
is more than ¼ in (7 mm) from
the part to be welded.
This adjustment is set at the point in the stroke of horn
travel (absolute distance) where the ultrasound turns off.
Page
24
Dukane Manual Part No. 403-569-01
Section 3 - Control Description
Indicators
Pressure Gauge
The pressure gauge shows the amount of air pressure
applied to the upper portion of the air cylinder for the
weld-and-hold operation.
Ultrasound Active Status
Light
This LED indicator lights up when the generator is applying ultrasonic power to the horn.
Stroke Position Indicator
Flag
The stroke position indicator flag is not preset prior to
press operation. It moves with the slide assembly as the
assembly moves down and up.
Mechanical Stop Indicator
Flag
This setting indicates where the downstroke will end.
Slow Speed Indicator Flag
(Optional)
This indicator flag is set by the Slow Speed Control. It is
included as part of the Slow Speed Control option. When
set, it indicates the point in the downstroke where the
plunger on the hydraulic speed control is engaged.
Dukane Manual Part No. 403-569-01
Page
25
iQ Series Ultrasonic Press System ES User’s Manual
Electronic Pressure
Regulator
Refer to Figure 3-2 for the location of the controls.
The EPR (Electronic Pressure Regulator) option deletes the Pressure 1 and Pressure 2 Regulators and the
Regulator Select Switch found on the manual press,
and replaces them with the following:
•
Electronic Pressure Regulator (EPR) that controls
the pneumatic pressure on command from the
generator.
•
A pressure transducer that functions as the pressure gauge because it converts pneumatic pressure
into an electrical signal for the generator to use for
feedback control.
and optionally–
•
A load cell that measures applied force. A force
transducer converts the mechanical force applied
to the parts into an electrical signal. This allows the
generator to trigger by force.
Note that this option is only functional when used with
a compatible generator. Refer to Section 4: Press Options, for detailed information.
Page
26
Dukane Manual Part No. 403-569-01
Section 3 - Control Description
4
5
3
2 1 0
Down Speed Adjust
8
7
6
Mechanical Stop Adjust
10
9
Ultrasound Active Status Light
NOTE
Stroke Position
Indicator Flag
0
1
Mechanical
Stop Indicator
Flag
2
3
Slow Speed
Indicator Flag
To properly set the
indicator flags, adjust
the control until the
middle of the flag
lines up with the
desired setting. The
example to the left is
set for 2 cm.
Hydraulic Slow Speed
Position Adjustment
Hydraulic
Slow Speed
Adjustment
(Velocity
Damping)
Figure 3-2
LOOSEN THE
THUMBSCREW TO
UNLOCK KNOB
20
LOWERS
SPEED CONTROL
TRIGGER
(EPR) Press/Thruster Controls and Indicators - Model 215 Shown
Dukane Manual Part No. 403-569-01
Page
27
iQ Series Ultrasonic Press System ES User’s Manual
Ergonomic Base
The ergonomic base, shown in Figure 3-3, consists of
a base plate, cycle activation switches (black finger
switches), abort switch (red palm switch), and a status
display screen. At the back of the base is a cable connector for an interface between the iQ Series generator and
the base front panel.
Base Plate
The machined base plate is bolted to the top of the ergonomic base. It has drilled and tapped holes that line up
with leveling screws in the fixtures to allow easy fixture
leveling for alignment with the horn. For details on the
alignment and leveling of the base plate, see Section 5:
Stack/Fixture Setup.
Right
Operate
Switch
et
Operate
Switch
wer i t re
St p Switc h
Figure 3-3 Ergonomic Base Controls
Activation (Operate)
Switches
Located on either side of the base are two optical (RUN)
switches. These are shown in Figure 3–3. These switches
use Infrared (IR) sensors. They comply with OSHA and
CE safety standards. Both switches are identical.
Each optical–touch switch has a small red LED that is
dimly illuminated whenever the power is on, as shown in
Figure 3–4. When the operator places their finger in the
tray, the LED brightens and a second LED in the opposite
corner of the tray illuminates to indicate the switch has
been activated as shown in Figure 3–5. Both switches must
be activated simultaneously to initiate a weld cycle.
Dimly Lit
Red LED
Figure 3-4
Right Operate Switch in Standby
Mode, One LED Dimly Lit
Brigtly Lit
Red LEDs
Figure 3-5
Page
28
Right Switch in Operate Mode, Both
LEDs Brightly Lit
Dukane Manual Part No. 403-569-01
Section 3 - Control Description
Emergency Stop (Abort)
Switch
A red Emergency–Stop (E-STOP) switch is located in
the center of the base as shown in Figure 3-3. The emergency stop switch must be in its reset position before the
operate switches will function.
T
To reset the Emergency Stop, twist the large red button
about 45 degrees to the right, which will cause the button
to spring out. This is shown in Figure 3–6.
The abort switch applies 24 VDC power to the thruster/
press. Pressing the abort switch causes the generator
to:
— Immediately turn off the ultrasound,
O
R
R
ABORT
Figure 3-6
Setting and Resetting the E–Stop
— Remove electrical power from the press, and
— Initiate a software abort sequence.
Base Status Display
The function of the display is to indicate one of three
status conditions of the press:
•
READY - When the abort switch is pulled out, the
green READY status light indicates that power is
applied to the press and it is ready for operation.
•
ABORT - When the abort switch is pushed in, the
red ABORT status indicator illuminates. Press operation is no longer possible.
•
IN CYCLE - When both activation switches are
pressed, the IN CYCLE display of the status indicator
is ON for the duration of the finger switch activation.
Dukane Manual Part No. 403-569-01
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Dukane Manual Part No. 403-569-01
Section 4 - Press Options
SECTION 4
Press Options
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Hydraulic Speed Control . . . . . . . . . . . . . . . . . . . . . . 34
Distance Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Electronic Press Controls . . . . . . . . . . . . . . . . . . . . . 39
Dukane Manual Part No. 403-569-01
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Dukane Manual Part No. 403-569-01
Section 4 - Press Options
Overview
This section provides detailed information for the common
options for press/thruster operation. These options are:
•
Hydraulic Speed Control
•
Distance Encoder
•
Electronic Pressure Regulator
Detailed description, installation, and any applicable
alignment or adjustments follow.
The optional air cylinders (1.5, 2, and 3 inches in diameter) are factory installed and do not require any field
adjustments.
Additional Options
Dukane can provide high-quality automation equipment
for efficient handling and assembly of parts. This equipment is tailored specifically to your needs. Some of the
available options include pick and place automation,
rotary tables, in-line indexing, conveyors, and walking
beams.
Dukane can also provide standard and custom sound
enclosures. The additional options are not covered in this
manual due to their specialized applications.
Contact your local Dukane representative for more specific information.
Dukane Manual Part No. 403-569-01
Page
33
iQ Series Ultrasonic Press System ES User’s Manual
Hydraulic Speed
Control
6
5
8
4
7
SLOW SPEED Control and
Indicator Flags
3
The thruster has a knob labelled SLOW SPEED near the
bottom of the front panel and a SLOW SPEED indicator
flag. Refer to Figure 4-1.
I
E
NC
REAS
The knob and the indicator flag are part of the optional
Hydraulic Speed Control Kit.
50
60
4
0
7
5
10
1
6
90
3
80
20
30
40
2
70
The purpose of the hydraulic speed control is to match
the downstroke speed to the material melt flow. This will
produce the strongest joint. The Slow Speed Setting knob
adjusts the point along the 7 inch (177.8 mm) downstroke
distance at which the hydraulic speed control will engage.
It should be set to engage just before the horn contacts
the part. The maximum distance over which this kit can
control the downstroke speed is 1 inch (25.4 mm).
REAS
E
I
NC
0
10
NOTE
The middle of the indicator flag, when referenced to the
scale beside the flag slot, shows where the 1 inch (25.4
mm) of slow speed is set to begin.
}
Hydraulic Speed Control Kit
Operation
The hydraulic speed control kit, shown in Figure 4-2,
is a combination impact absorber and hydraulic check
valve.
The kit contains a sealed hydraulic cylinder with an external plunger. The cylinder is mounted to the stationary
part of the thruster.
The kit also has a contact block that is mounted to the
slide assembly of the thruster. When the slide assembly
descends, the contact block descends until it engages the
plunger of the stationary hydraulic cylinder and pushes the
plunger down into the cylinder. The design of the cylinder
resists the downward motion of the plunger by metering
the pure silicone fluid through an adjustable internal flow
aperture, resulting in a constant speed of the slide assembly.
Slow Speed
range is limited to 1" (2.5
cm) above
the Stroke
Position set
point.
LOOSEN THE
THUMBSCREW TO
UNLOCK KNOB
20
LOWERS
SPEED CONTROL
TRIGGER
3 5 0
Figure 4-1 Example of Slow Speed Setting
Continued
Page
34
Dukane Manual Part No. 403-569-01
Section 4 - Press Options
Hydraulic Speed Control Kit
Operation
Continued
The hydraulic cylinder is mounted in a clamping block.
The block is threaded onto a long rod.
Threaded
Rod
Contact Block
Turning the SLOW SPEED knob rotates the rod.
This in turn causes the contact block to ride up or down
on the rod, moving the contact point closer to or further
from the hydraulic cylinder at rest.
This distance determines how far the contact block, and
therefore the slide assembly, must travel before the block
contacts the plunger of the hydraulic cylinder.
The plunger has a maximum travelling distance of one inch
(25.4 mm). The first 1/4 inch (6.4 mm) of travel decelerates
the speed of the slide assembly. The remaining 3/4 inch
(19.1 mm) of travel allows the slide assembly to descend
at a constant slow speed set by the operator.
Plunger
13
Clamping
Collar
The slide assembly can only travel downward a maximum of one inch (25.4 mm) after the block contacts the
plunger.
Hydraulic Speed Control
Adjustment
•
Insert the end of a small screwdriver or similar tool
into the hole (Figure 4-3) in the adjustment shaft of
the hydraulic cylinder, OR,
4
15
3
16
2
17
1
18
0
Indicator Flag
Hydraulic
Cylinder
20
Speed Adjustment
Figure 4-2
Rotating this shaft adjusts the internal metering aperture
which regulates the flow of the silicone fluid. There are
two ways to adjust the hydraulic speed control setting.
First make sure that the slide assembly is fully retracted
(up position). This will uncover the hydraulic damper and
shaft.
•
5
14
Location of the Hydraulic Control
Components
20
Decrease
Increase
Figure 4-3
Adjustment Using the Hole
Locate the slot on the bottom of the cylinder (Figure
4-4). Insert a screwdriver in the slot and adjust the
setting.
20
Just above the shaft is a scale with 30 divisions. On
the adjustment shaft is a vertical groove that indicates where along the scale the speed is set. Zero (0)
is the fastest setting and thirty (30) is the slowest.
Decrease
Increase
Figure 4-4
Dukane Manual Part No. 403-569-01
Adjustment Using the Slot
Page
35
iQ Series Ultrasonic Press System ES User’s Manual
Distance Encoder
Purpose
To install and calibrate the distance encoder in order to
accurately measure the distance of thruster travel.
Requirements
Parts
Kit (P/N 438-783) consisting of the following:
1. Encoder (two pieces; P/N 625-18)
2. Encoder head cable cover bracket
3. Mounting screws and hardware
Right Side Panel
Tools
• Phillips-head screwdriver
• Feeler gauge set (0-.050 inches) or metric equivalent
• 6 inch ruler or metric equivalent
Installation Instructions
Dismantling
1. Facing the front of the press, remove the panel from
the right side of the press. (See Figure 4-5.)
Encoder Scale
Reassembly
1. Mount the cable cover bracket from the kit and secure
it with flathead screws.
2. Attach the encoder scale to the mounting screw holes
in the right side of the thruster with pan-head screws.
Do not tighten.
3. Remove the back panel from the press and route the
encoder head cable, being careful not to interfere with
the press movement.
4. Connect the encoder cable to the generator connector
J-11 (Encoder).
Encoder
Head
Figure 4-5 Distance Encoder Mounting
5. Replace the rear panel on the press.
Continued
Page
36
Dukane Manual Part No. 403-569-01
Section 4 - Press Options
Reassembly
Continued
6. Gently slide the encoder head down until the mounting screw holes in the press support base appear in
the head’s mounting slots.
7. Center the screw holes in the mounting slots. Secure
the encoder head with the two pan-screws but do not
tighten them yet.
Alignment
The purpose of this alignment is to set the internal reference mark for the encoder. This reference mark resets
the distance register in the generator after each thruster
cycle and ensures repeatable distance measurements from
cycle to cycle.
Moving
Encoder
Scale
.039 in (1 mm)
Gap
Stationary
Encoder
Head
1. Check the position of the encoder scale’s mounting
hole slots using the 6" ruler. Measure the distance
from the center of the screw to the edge of the slot
in both directions. When the screws are centered
horizontally, carefully tighten the screws.
2. Measure a vertical distance of 1.375 inches (34.92
mm) up from the bottom edge of the encoder scale,
as shown in Figure 4-6.
3. Adjust the bottom edge of the encoder head to align
to this distance and tighten the screws on the encoder
head.
1.375”
Figure 4-6
Distance Encoder Alignment
4. Push in the ABORT button (on the press base).
Turn on the generator, and set it to measure distance.
5. Set the air pressure to the desired level.
WARNING
Keep hands and clothing
away from an activated
press.
6. Perform the following procedure to test the encoder
for the proper setting:
• Pull out the ABORT button (on the press
base). Allow the thruster to return to top of
stroke.
• If the encoder position reads 0.0000, then the
encoder is set correctly.
• Secure the two screws. Proceed to Step 7.
Continued
Dukane Manual Part No. 403-569-01
Page
37
iQ Series Ultrasonic Press System ES User’s Manual
Alignment Continued
7. Set the gap between the encoder scale and head,
using the feeler gauge .039 inch (1 mm) blade.
8. Measure the gap at the top and bottom of the stroke.
Allowable tolerance, as specified by the encoder
manufacturer, is ±.005. This is a range of from .034
to .044 inches (.864 to 1.12 mm).
9. Tighten all the screws and check the measurements
again.
10. Replace the press/thruster right side panel.
Page
38
Dukane Manual Part No. 403-569-01
Section 4 - Press Options
Electronic Press
Controls
The electronic press controls consist of three
components:
• Electronic Pressure Regulator
• Pressure Transducer, and
• Load Cell
Electronic Pressure
Regulator
The electronic pressure regulator, (I/P transducer) is an
electro-pneumatic replacement for the manually adjusted
air regulator on the press. The I/P transducer converts the
electrical signal current (I) into air pressure (P). The Electronic Regulator converts the electrical signal from the iQ
Series generator into the programmed air pressure.
The pressure value settings, “Method 1” (P1) and “Method
2” (P2), are stored in the Process Setup under Pressure
in the generator. P1 and P2 are set in pounds per square
inch (PSI), or BARS.
To monitor Method 1 and Method 2 values, use the Check
Pressure parameter, contained in the Operate Setup under
View Parameters (on the generator).
The generator uses a pressure transducer to measure the
I/P output pressures.
The I/P transducer installed in this thruster/press does
not require on-site calibration. The unit is equipped with
self- correcting, closed-loop circuitry.
Pressure Transducer
The pressure transducer (P/I transducer) performs the
same function as the air gauge on the press. The P/I
transducer converts air pressure (P) to an electrical signal
current (I). It then sends the signal to the generator. The
generator displays this signal as pressure.
Two sets of upper and lower limits can be monitored with
the pressure transducer:
One set is used to monitor the air pressure before a
cycle starts. Using the bad parts limits, the unit will not
begin a cycle if the air pressure is outside the pressure window that has been set. This set of limits is used to ensure
that air pressure from the input line has not dropped below
the required pressure for an accceptable weld force.
Continued
Dukane Manual Part No. 403-569-01
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39
iQ Series Ultrasonic Press System ES User’s Manual
Pressure Transducer Continued
The other set of limits is used to monitor the air
pressure when the ultrasound is turned on.
This feature can be used as an indicator when checking
for a trigger or load cell malfunction.
A more precise way to monitor trigger force is to use
a load cell.
The pressure transducer does not require any on-site
calibration.
Load Cell
A load cell (force transducer) is a device used to measure
force. A force transducer converts mechanical force into
an electrical signal.
The load cell is used to monitor the force applied to the
part. It sends a signal to the generator to indicate when
the mechanical pressure equals the programmed Trigger
Force. The trigger is the point at which the ultrasound
is turned on.
The Trigger Force parameter is located on the Process
Control Setup under Trigger Method on the generator.
The values for this parameter are in pounds or Newtons.
A force versus time graph can be generated if a printer
or a computer with iQ Explorer software is connected
to the generator.
For most applications the Load Cell is calibrated at the
factory, and does not need any on-site calibration.
Page
40
NOTE
Some customer SOPs require
equipment calibration on-site.
Dukane offers on-site calibration
services and certification.
Contact your Dukane representative.
Dukane Manual Part No. 403-569-01
Section 5 - Stack/Fixture Setup
SECTION 5
Stack/Fixture Setup
Overview . . . . . . . . . . . . . . . . . . . . . . 43
Stack Description. . . . . . . . . . . . . . . . . . 44
Changing Stack Components. . . . . . . . . . . . 45
Stack Removal . . . . . . . . . . . . . . . . . . . . 45
Stack Disassembly . . . . . . . . . . . . . . . . . . 46
Removing a Detachable Tip. . . . . . . . . . . . . . 46
Stack Assembly and Torque Values. . . . . . . . . . 47
Installing a Detachable Tip . . . . . . . . . . . . . . 48
Fixture Installation. . . . . . . . . . . . . . . . . . 49
Fixture Alignment . . . . . . . . . . . . . . . . . . . 49
Fixture Leveling. . . . . . . . . . . . . . . . . . . . 50
Dukane Manual Part No. 403-569-01
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Page
42
Dukane Manual Part No. 403-569-01
Section 5 - Stack/Fixture Setup
Overview
A Dukane press/thruster and a iQ Series generator can be
used to assemble a unlimited variety of parts for every
conceivable market segment, including Automotive,
Medical, Appliance, Consumer, Packaging and Toy
industries. Various techniques and processes, such as
welding, staking, swaging, inserting, and spot welding
can be used for the different applications.
This variety is made possible through the interchange of
some system components. Of these components, the horn
and fixture are usually custom-made for each application,
and the booster that is selected for a job depends on the
required horn output amplitude. Also, the press/thruster
controls are specifically adjusted for each application.
This section provides instructions for setting up these
components of the system in a new installation or when
changing applications.
Dukane Manual Part No. 403-569-01
Page
43
iQ Series Ultrasonic Press System ES User’s Manual
Stack Description
The stack shown in Figure 5-1 consists of three parts:
•
•
•
Transducer
Booster
Horn
The transducer and the booster are normally shipped
assembled and installed in the press. The horn and/or the
fixture may be shipped separately.
The stack is easily removed from or installed in the press/
thruster. This makes it possible to change the horn or booster.
It also makes it easier to perform regular inspections and/or
maintenance of the stack components.
TRANSDUCER
Contact Button
BOOSTER
Transducer Housing
Anti–Rotation Pins
Mounting Stud
Mounting Ring
HORN
Spanner Wrench Hole (Typical)
Figure 5-1
Page
44
Stack Components
Dukane Manual Part No. 403-569-01
Section 5 - Stack/Fixture Setup
Changing Stack
Components
Stack Removal
Before removing the stack, perform the following
steps:
1. Activate the Abort switch on the front of the
base.
2. Power down the generator.
These two steps are necessary to ensure that no
power will be accidently applied while removing
the stack.
3. While supporting the stack with one hand,
loosen the four socket-head bolts that secure
the stack access door.
4. Pull the stack forward and down until the
transducer clears the electrical contact. Refer
to Figure 5-2.
5. Lift the stack out of the housing.
CAUTION

The stack access door on
the press/thruster holds
the stack components
in the stack housing.
Hold the stack by the
HORN or the exposed part of the
BOOSTER when removing or
installing the access door. This will
prevent the stack from falling out
and being damaged.
NOTE
When changing or inspecting any of
the stack components, ALWAYS remove the stack from the thruster.

CAUTION
There may be an electrical charge stored
in the transducer. To
avoid any electrical
shock, do not touch the contact button when removing the stack.
CAUTION
The stack may be hot.
Figure 5-2
Stack Removal
Dukane Manual Part No. 403-569-01
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iQ Series Ultrasonic Press System ES User’s Manual
Stack Disassembly
To separate the stack component carefully follow the
instructions below:
1. Use the two spanner wrenches (wrench A and B)
provided with the press. Place wrench A on the
component to be removed (Refer to Figure 5-3)
and wrench B on the one next to it. Turn wrench A
in the direction indicated.
A
B
Once the component is loose, it can be removed by
hand.
2. To maintain structural integrity, NEVER hold a
transducer by the housing or the booster by the
mounting rings while separating components. Doing
so will result in damage to the unit.
3. Use only the tools recommended by Dukane.
NEVER clamp a horn, booster, or transducer in a
vise or use tools such as pliers, visegrips, etc.. Doing
so will result in scratches and/or gouges, resulting
in stress areas on the surface. This condition will
affect the stack operation and could lead to failure
of each stack component.
Figure 5-3
Disassembling Components

CAUTION
To avoid possible
injury, press down
on the spanner
wrench with the
palm of the hand.
Removing a Detachable Tip
If the horn has a detachable tip, do the following:
1. Use a spanner wrench to hold the horn, as shown in
Figure 5-4.
2. Turn a properly sized open end wrench to loosen the
tip.
NEVER clamp the horn or use a vise to hold it.
Figure 5-4
Page
46
Tip Removal
Dukane Manual Part No. 403-569-01
Section 5 - Stack/Fixture Setup
Stack Assembly
Before assembling a stack, inspect all of the components
for possible damage — especially the surfaces that are to
be joined. Look for non-flat surfaces (concave, convex),
stress cracks, chips, or gouges. Any of these irregularities
will affect the operation of the stack and could cause
further damage. Contact the Dukane Ultrasonics Tooling
Department concerning a damaged component.
When the components have been inspected and are found
to be free of any damage, continue with the following
steps:
1. Inspect the contact surfaces for smoothness and
cleanliness. Pitting or a buildup of old grease and dirt
on the surface will interfere with the transfer of energy
from one component to another.
2. Remove any foreign matter from the threaded stud
and the mating hole. Tighten the stud in the stack
component that is most distant from the transducer
according to the following stud torque values:
Stud Thread
Size
inch-lbs
foot-lbs
Torque
Nt-meters
1/2 in. x 20
12
1
1.35
3/8 in. x 24
12
1
1.35
M8 x 1.25
12
1
1.35
Table 5-I Stud Torque Values
3. Coat one of the contact surfaces with a thin coat of
high-pressure grease. A small packet is supplied with
the system. We recommend Dow–Corning #4 (or #111
as an alternate).
NOTE
Do not apply any grease
or lubricant to the stud.
4. Thread the components together and tighten (Refer to
Table 5-II) by applying torque as follows:
Stack kHz
Torque
inch-lbs
foot-lbs
15
540
45
61
20
420
35
47.5
30
216
18
24.4
40
216
18
Table 5-II Horn/Booster Torque Values
Nt-meters
24.4
Figure 5-5
Dukane Manual Part No. 403-569-01
Assembling Components
Page
47
iQ Series Ultrasonic Press System ES User’s Manual
Installing a Detachable Tip
If the horn has a detachable tip, do the following:
1. Inspect the surfaces of the tip and the horn for any
stress cracks, chips or gouges.
NOTE
Do not apply any lubricant
to the tip threads.
2. Coat one of the contact surfaces with a thin coat of
high-pressure grease or lubricant. We recommend
Dow–Corning #4 (or #111 as an alternate).
3. Thread the tip into the horn. To tighten the tip, use the
open-end wrench for the tip and a spanner wrench to
hold the horn, as shown in Figure 5-6.
Tighten the tip to the following specifications:
Figure 5-6
Tip Stud
Thread
Size
Torque
inch-lbs
foot-lbs
Nt-meters
1/2 in. x 20
360
30
40.7
3/8 in. x 24
336
28
37.9
5/16 in. x 24
300
25
33.9
1/4 in. x 28
240
20
27.1
Tip Assembly
Table 5-III Replaceable Tip Torque Values
Installing the Stack
1. With the stack at the angle shown in Figure 5-7, rest
the booster mounting ring on the pin of the stack
housing.
2. Brace the stack at point A in Figure 5-7, and swing
the stack to a vertical position. The ultrasound contact
button on the transducer should snap under the
electrical contact leaf of the housing.
3. While still supporting the stack in this vertical position,
install the stack access door, and thread the four
socket-head bolts (that hold the door closed) into their
holes.
A
4. If the horn is not properly aligned with the fixture,
rotate the stack to align the horn with the fixture.
5. Finish tightening the socket head bolts until snug.
Figure 5-7
Stack Installation
DO NOT OVER-TIGHTEN!
Page
48
Dukane Manual Part No. 403-569-01
Section 5 - Stack/Fixture Setup
Fixture Installation
There are three steps involved in installing a fixture.
• Aligning the fixture with the horn,
• Leveling the fixture to provide the necessary support.,
and
• Rigidly securing the fixture to the mounting surface.
Fixture Alignment
To safely align the fixture under the horn, use the following
procedure. (Refer to Figure 5-8.)
1. Depress the Abort switch. This allows the acoustic
stack assembly to be lowered by hand and prevents
the system from accidentally cycling.
2. Turn off the power to the generator to prevent accidental ultrasound operation.
3. Place the fixture, with parts, under the horn.
4. Initially align the two slots in the fixture over two of
the seven mounting holes on the base plate.
5. Install the two hold-down bolts with washers, and
finger tighten.
Continued
Fixture
Hold Down Bolts
Fixture Leveling Screws
(Hex socket set screws)
Fixture
Holes for 3–Hole
Mounting Fixture
(12" x 14")
Holes for 4–Hole
Mounting Fixture
(9" x 9")
Figure 5-8
Fixture/Base Layout
Dukane Manual Part No. 403-569-01
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49
iQ Series Ultrasonic Press System ES User’s Manual
Fixture Alignment Continued
6. Place a part in the fixture.
7. Grasping the horn firmly, pull the acoustic stack assembly down until the horn is as close to the part as
necessary to align the fixture.
8. Align the fixture with the horn, and tighten the holddown bolts, or caps crews, to prevent the fixture from
moving.
9. Adjust the mechanical stop of the press so that the horn
stops above the fixture. This prevents pinch points and
avoids horn damage if the acoustic stack assembly
descends when a part is not in the fixture.
NOTE
The fixture should be flat on the
base. If the fixture is equipped
with leveling jack screws, adjust
the screws so that they do not interfere with seating of the fixture
on the base plate.
Fixture Leveling
For most applications, the fixture must be mounted so
that the contacting surfaces on the horn are parallel to the
contacted surfaces on the plastic part. This ensures that a
consistent, even weld will result. To level the fixture, do
the following:
1. Place a part in the fixture.
2. Loosen (turn counterclockwise) the hold-down bolts
or cap screws and the four leveling jack screws on
the fixture plate. Refer to Figure 5-9.
3. Pull the acoustic stack assembly down to the fixture.
Allow the horn and the part to align.
4. Turn the four jack screws clockwise until a slight resistance is felt. Refer to Figure 5-10.
NOTE
Some applications may require the horn to be a few
thousandths of an inch from contact with the fixture.
Special applications may require
the Mechanical (MEC) stop to be
lowered so the horn makes contact with the fixture or anvil. When
this is required, a ground-detect
circuit is needed to terminate the
weld cycle.
5. Tighten the hold-down cap screws by turning them
clockwise until a firm resistance is felt.
Continued
NOTE
Do not overtighten the cap screws.
This may flex the fixture plate.
Figure 5-9
Loosening the Hold–Down
Cap Screws and Jack Screws
Page
50
Figure 5-10
Tightening the Hold–Down
Cap Screws and Jack Screws
Dukane Manual Part No. 403-569-01
Section 5 - Stack/Fixture Setup
Fixture Leveling Continued
6. If any readjustment is necessary, loosen the hold-down
screws first. Then readjust the jack screws.
The following procedure may be helpful in leveling the
fixture in some applications. To perform this procedure,
use a piece of carbon paper and a piece of white paper.
1. Place a sample part in the fixture.
2. Place a piece of white paper on top of the sample
part.
3. Place a piece of carbon paper, carbon side down, on
top of the white paper.
4. Enter the following parameters into the generator:
Weld Time = 0.05
Hold Time = 0.00
Pressure = 20-40 psi
System parameters = Use default settings. See examples on Application Setup Worksheet.
5. Set the trigger control on the thruster so that the pressure switch closes after some pressure is applied.
6. Press the ONLINE button on the generator.
7. Cycle the equipment by activating both finger switches
on the base or by triggering the automation switch.
When one cycle is completed, the pressure developed
between the horn and the sample part will have left marks
from the carbon paper on the white paper. If the fixture
is not level, the carbon markings will be darker in some
areas than in others. All carbon markings will be uniform
when all adjustments have been made properly.
Adjust the leveling of the fixture and repeat this procedure as necessary until you are confident that the fixture
is level.
Dukane Manual Part No. 403-569-01
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52
Dukane Manual Part No. 403-569-01
Section 6 - System Test
SECTION 6
System Test
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Operational Test of the Acoustic Stack . . . . . . . . . . . 56
Procedure for Cycling the System . . . . . . . . . . . . . . . 59
Dukane Manual Part No. 403-569-01
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54
Dukane Manual Part No. 403-569-01
Section 6 - System Test
Overview
A iQ Series generator must be operating and connected to
the press/thruster in order to test the system.
For efficient operation of a Dukane ultrasonic assembly
system, the ultrasound signal from the generator must
match the frequency and phase angle (vibrational characteristics) of the stack that is being driven. Each stack has
unique vibrational characteristics dependent on the combination of stack components. In addition, the characteristics
of a particular stack may vary slightly during operation
because of temperature and loading factors.
To match the generator output signal with the characteristics of a particular stack, the generator output frequency
is adjusted by Dukane’s patented phase-locked-loop DigiTrac pulse-width modulation circuitry.
The Digi-Trac feature automatically adjusts the ultrasound
signal to match the vibrational characteristics of the stack
being driven. When the ultrasound turns on during each
operating sequence, the Digi-Trac circuit monitors the
motion of the stack on a frequency cycle-by-cycle basis
and adjusts the ultrasound signal for the optimum setting.
Because the Digi-Trac continuously monitors each operating sequence, it compensates for vibrational changes that
occur during repeated operations due to heating of the
stack components. It also compensates for changes that
occur over longer time periods due to aging of the piezo
electric crystals in the transducer, or possible wear of the
ultrasonic horn.
The Digi-Trac feature excels in environments hostile to
reliable operation, such as high duty cycles or high stress,
and continuous-duty applications. In such situations, the
Digi-Trac circuit compensates for the unique vibrational
characteristics of each stack due to differences caused by
aging, loading, temperature changes, and differences in
horn configurations.
Dukane Manual Part No. 403-569-01
Page
55
iQ Series Ultrasonic Press System ES User’s Manual
Operational Test of
the Acoustic Stack
The following test procedure is suggested before starting
the generator, to verify that the vibrational characteristics
of the stack fall within the range of the Digi-Trac. All
Dukane stack components are manufactured to tolerance
specifications within this range. A non-Dukane horn,
an improperly assembled stack, or a stack component
that is worn or damaged, can result in vibrational characteristics outside these specifications, and will require
some adjustment. This test reveals the existence of any
problems and directs you to corrective action.
1. Check the following:
a. Make sure that the correct booster and horn for
the application are installed in the thruster.
b. Check the iQ Series system components for
proper grounding.
c. Check the ultrasound cable connections on the
generator and thruster for proper seating and
security.
d. Verify that the horn is not under load (not in
contact with a fixture or part).
2. Turn the iQ Series generator power switch to ON.
The power switch display will start to flash on and
off for LESS THAN 20 seconds. It will then turn
off. This indicates that the system is operating.
If the power switch display stops flashing but remains on, do not go any further, there is a problem
with the input circuit.
3. Using iQ Explorer, go to the Utilities tab. Press the
TEST button, and hold it for the duration of the test
period. See Figure 6-1.
a. System Power Output:
•
•
TEST Button
If the power output display remains
between 10 and 20 percent and the horn
frequency is (220 Press) within 19,500 Hz
and 20,500 Hz, the stack is operational.
(340 Press) within: 28,500-30,500 Hz, &
39,500-40,500 Hz.
Figure 6-1
iQ Explorer Utilities TEST Button
If the power output exceeds the 20% indication, there may be a problem with the
stack.
Continued
Page
56
Dukane Manual Part No. 403-569-01
Section 6 - System Test
Figure 6-2
iQ Explorer TEST, Screen Display
Acoustic Stack Test Continued
b. If an overload fault is displayed, a mismatch has occurred between the generator’s ultrasonic output signal and the
stack.
Refer to Table 8-II, Page 85.
Also see Figure 6-3 that shows an example of an
error that caused cycling to stop.
NOTE
Note the Frequency and Power
values in the graph above.
You have the option of saving the
test data for future reference.
4. While pressing the TEST button, lightly touch
the side of the horn to check for ultrasonic vibrations. If any vibrations are felt, the stack is
operational. If there is no vibration, there may
be a problem with the stack.
If all the indicators pass their tests, the stack is within
the Digi-Trac range.
The generator is operating at the optimum setting
for this stack when the Watts displayed on the graph
(after the test) is between 10 and 20 percent. The
vibration amplitude of the horn and booster and the
mass of the horn determine the amount of energy
needed to vibrate the stack.
•
If the system passes the tests of these four steps,
proceed to the section called Procedure for Cycling the System, Page 59.
•
If one or more of these tests have failed, go to
the next step.
Figure 6-3
iQ Explorer Error Detected - Cycle Stop
Continued
Dukane Manual Part No. 403-569-01
Page
57
iQ Series Ultrasonic Press System ES User’s Manual
Acoustic Stack Test Continued
5. Turn the generator off. Check the stack for proper
assembly, damaged components, or dirty mating
surfaces. Recheck the ultrasound cable for proper
connections. Repeat Steps 1 through 4. If the test still
fails, go to the next step.
6. Turn the generator off, remove the stack from the
thruster, and remove the horn from the stack. Reinstall
the transducer-booster assembly in the thruster and
turn the generator on. Repeat Steps 2 through 4.
If the assembly passes with the horn removed, the horn
is outside the specifications required for operation with
the Digi-Trac preset range. Reassemble the horn to the
stack.
The System tab of iQ Explorer has a section for Advanced Hardware. These features are designed for
unique horns and applications. See Figure 6-4.
Figure 6-4
Page
58
Consult Dukane Corporation before making adjustments to these settings.
If any failure indications are present with the horn
removed, check the booster and the transducer for the
following
• Any visible damage
• Loose or cracked stud
• Pitted or dirty mating surfaces
Make any necessary repairs or adjustments.
Go to Step 7.
7. Repeat Steps 1 through 6.
• If the failure indications disappear, reassemble the
horn to the stack and repeat Steps 2 through 4.
• If any failure indications are still present, do not
run this stack. Return the transducer and booster
to Dukane for analysis.
iQ Explorer System Tab - Advanced Hardware
Dukane Manual Part No. 403-569-01
Section 6 - System Test
Procedure for Cycling
the System
1. Check that you have correctly performed the
following:
a. Installed the stack in the thruster and bolted the
stack access cover closed.
b. Secured the fixture in place.
c. Performed the Operational Test of the Acoustic
Stack as detailed on Page 56 of this section.
2. Verify that all controls on the Press/Thruster and the
generator are set as required for this operation.
3. Place a part in the fixture.
4. Cycle the system.
Activate both opti-touch switches at the same time
to start the system, and hold fingers in place until
the ultrasound starts. Releasing the fingers before
ultrasound starts will abort the cycle.
Dukane Manual Part No. 403-569-01
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Dukane Manual Part No. 403-569-01
Section 7 - Stack Maintenance
SECTION 7
Stack Maintenance
Inspection of the Acoustic Stack Components . . . . . 63
Reconditioning Stack Components . . . . . . . . . . . . . . 64
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Dukane Manual Part No. 403-569-01
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Dukane Manual Part No. 403-569-01
Section 7 - Stack Maintenance
Inspection of the
Acoustic Stack
Components
It is essential that the mating faces between an ultrasonic
transducer/booster and a booster/horn be absolutely flat
and parallel. If there is any air gap, there will be a loss in
power output and efficiency. Coupling may be so poor as
to prevent the startup of vibration from the stack, due to
the excessive power draw at the mating surfaces.
The condition of excessive crowning, or uneven contact
surfaces, is normally made evident by a burnished
appearance around the bolt hole areas of the contact
surfaces. This condition indicates that contact between the
parts occurs only at the burnished areas and not across the
full faces of the mating surfaces. (See Figure 7-1.)
The following flatness tolerances are specified for
Dukane transducers, boosters, and horns used in 20 kHz
applications:
Transducer
.0005 inch
Booster
.0005 inch
Horn
.0005 inch
To check if there may be a flatness problem, first
disassemble the stack and look at the mating surfaces.
If there are burnished areas at the periphery of a contact
surface, that surface may be crowned in the center. Place
a straight edge along the face. Refer to Figure 7-2. If light
can be seen along the edges, it is crowned.
Burnished
Area
Figure 7-1
Example of Burnished Area
Crown
Straight
Edge
Gap
Figure 7-2
The surface may also be depressed in the bolt area. Refer
to Figure 7-3. In this case, there will be contact only at
the peripheral edges and light will be visible beneath the
straight edge in the center region.
Example of Crowning
Gap
Straight
Edge
Figure 7-3
Dukane Manual Part No. 403-569-01
Example of Center Depression
Page
63
iQ Series Ultrasonic Press System ES User’s Manual
Reconditioning Stack
Components
To restore the interface to the proper condition, do the following:
1. Disassemble the transducer/booster/horn stack and wipe
interfaces with a clean cloth or paper towel.
2. Examine all interfaces. If any interface is corroded or
shows a dark, hard deposit, it should be reconditioned.
3. If the interfaces appear to be in good condition, go to
Step 11.
4. If necessary, remove the mounting studs.
NOTE
The operating efficiency of the
equipment will be greatly affected
if the mating interfaces of the transducer/booster/horn stack are not
flat, make poor contact with each
other, or become corroded. A poor
contact condition wastes power
output, makes tuning difficult, can
affect the noise level, and can
cause possible heat damage to the
transducer.
5. Tape a clean sheet of #400 grit (or finer) silicon carbide
wet-or-dry paper to a clean, smooth, flat surface. A piece
of plate glass is usually suitable.
6. Hold the part to be conditioned at its lower end with
your thumb over a spanner wrench hole. Carefully stroke
the part once in one direction (toward you) across the
abrasive paper, as shown in Figure 7- 4. Do not apply
downward pressure. The component’s weight alone
provides sufficient pressure. Perform a second stroke.
IMPORTANT
Use extreme care to avoid tilting the part. Loss
of flatness of interface surfaces may render the
welding system inoperative.
7. Rotate the part 120° (1/3 rotation) to the next spanner
wrench hole. Repeat the procedure outlined in Step 6.
Figure 7-4
Method of Component Resurfacing
8. Rotate the part the remaining 120° and repeat. Be
certain to perform the same number of strokes at each
orientation: Two strokes per rotation.
IMPORTANT
Use extreme care to avoid multiple strokes at
each 1/3 rotation of the part. Loss of flatness
and perpendicularity of the interface surface to
the centering axis of the part may render the
welding system inoperative.
Continued
Page
64
Dukane Manual Part No. 403-569-01
Section 7 - Stack Maintenance
Reconditioning Stack Components
Continued
9. Before reinserting a stud in any horn, perform the
following for proper engagement of the threads:
a. Visually inspect and clean the stud.
b. Clean the threaded hole using a clean cloth or
towel.
c. Tighten the stud to the torque specifications listed
in Table 7-I.
NOTE
Thread deformation may occur
if the studs are overtightened.
Removal of the stud could
damage the threads in the
horn. If this occurs, re-tap the
horn threads and replace the
stud with a new one. Use studs
recommended by Dukane.
10. Reexamine the interface surface and repeat Steps
6 through 9 until most of the contaminate has been
removed. This should not take more than 2 or 3
complete rotations of the part being reconditioned.
11. Reassemble and install the stack, using the procedure
in Section 5 of this manual. Recheck the power supply
tuning. See Section 6, System Test.
Torque Values
See Section 5, Stack/Fixture Setup for torque values:
Table 5-I - Stud Torque Values
Table 5-II - Horn/Booster Torque Values
Table 5-III - Replaceable Tip Torque Values
Dukane Manual Part No. 403-569-01
NOTE
Overtightening stack components may result in horn/booster
studs loosening and unexplained
overloads.
Page
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Dukane Manual Part No. 403-569-01
Section 8 - Troubleshooting
SECTION 8
Troubleshooting
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Primary Weld Characteristics . . . . . . . . . . . . . . . . . . . . . 69
End of Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Staking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Continuous Welding . . . . . . . . . . . . . . . . . . . . . . . . . 83
Pop-Up Status Screens . . . . . . . . . . . . . . . . . . . . . . . 85
Dukane Manual Part No. 403-569-01
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Dukane Manual Part No. 403-569-01
Section 8 - Troubleshooting
Overview
The Troubleshooting section of this manual contains
a listing of problems that may occur when using this
equipment along with probable causes and recommended
solutions for the problems.
Regarding solutions, please note the following:
Where the solutions section refers to changing a setting for
a primary weld characteristic or altering the position of the
End-of-Weld limit switch, these adjustment capabilities
and controls must be available on your equipment.
Primary Weld
Characteristics
Primary weld characteristics refers to methods used to
control the welding process. The characteristics include
Time, Distance, Absolute Distance, Energy, and Peak Power.
To be functional in your system, each characteristic
needs corresponding hardware/software support from
the generator.
Table 8-I shows each characteristic and its equipment
requirements.
Primary Weld
Characteristic
Equipment Requirements
Time
Generator with a digital timer or process controller with a time
function.
Distance
Process controller with a distance measurement function and a
press / thruster equipped with an optical distance encoder.
Absolute Distance
Process controller with a distance measurement function and a
press/thruster equipped with an optical distance encoder, or a press/
thruster with an End-of-Weld limit switch installed.
Energy, Peak Power
Process controller with an energy measurement function.
Table 8-1
Weld Characteristics and Equipment Requirements
End-of-Weld Limit Switch
The End-of-Weld limit switch is used to terminate
the ultrasound power burst during a weld cycle as
determined by the stroke position of the press head.
The switch is generally not used with a system
that contains a process controller with a distance
measurement function or a press/thruster equipped with
an optical distance encoder.
Dukane Manual Part No. 403-569-01
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69
iQ Series Ultrasonic Press System ES User’s Manual
Welding
__________________________________________________________________________________
Problem
Flash (See also Non-uniform welding)
Probable Cause
Solution
Energy director is too large.
Reduce the size of the energy director.
Reduce the weld time/primary weld characteristic.
Reduce the air pressure.
Use an interrupted energy director.
Shear interference is too great.
Reduce the amount of interference.
Weld time is too long.
Reduce the weld time.
Non-uniform joint dimensions.
Re-dimension the joint.
Redesign the joint to be a shear joint or
a tongue-in-groove joint. Contact Dukane's Applications
Lab.
Check the processing conditions.
Part fit or tolerances.
Loosen the part fit.
Loosen the part tolerances.
__________________________________________________________________________________
Problem
Misalignment of the welded assembly
Probable Cause
Solution
Parts are not self-aligning.
Design a means of alignment into the
tooling (fixturing).
Add a means of alignment (e.g., pins
and sockets) to the mating part halves.
Improper support in the fixture.
Redesign the fixture for proper support.
Wall flexure.
Add ribs or gussets to the part.
With a resilient fixture, if large sections
of urethane are deflecting, add a rigid
backup.
Joint design is not properly dimensioned.
Re-dimension the parts.
Incorrect part tolerance/poor molding.
Tighten the part tolerance.
Check the processing conditions.
__________________________________________________________________________________
Continued
Page
70
Dukane Manual Part No. 403-569-01
Section 8 - Troubleshooting
Welding
_______________________________________________________________________________
Problem
Internal components are welding together.
Probable Cause
Solution
The internal components are made
of the same material.
Make the internal components out of
different materials.
Carefully lubricate the internal parts.
Use less horn amplitude by changing to a lower gain booster.
_______________________________________________________________________________
Problem
Diaphragm Damage
Probable Cause
Solution
Excessive horn amplitude.
Reduce the horn amplitude.
Dampen the welding area to absorb the
amplitude.
Excessive exposure to ultrasound.
Reduce the weld time and increase the horn
amplitude and/or air pressure.
Improper gate location/design/thinwall sections.
Check gate placement.
Change the shape of the gate.
Add stiffening ribs to the part.
Increase the thickness of the material on
the underside of the gate area.
If using a 20 kHz system, consider using
a 30 kHz or 40 kHz system.
The type of horn and/or its placement.
Check for the proper horn/part fit.
Change the horn.
_______________________________________________________________________________
Problem
Overwelding
Probable Cause
Solution
Too much energy is being transmitted
to the part.
Reduce the air pressure.
Reduce the weld time/primary weld
characteristic.
Change to a lower gain booster to reduce the horn
amplitude.
Reduce downstroke speed.
_______________________________________________________________________________
Continued
Dukane Manual Part No. 403-569-01
Page
71
iQ Series Ultrasonic Press System ES User’s Manual
Welding
__________________________________________________________________________________
Problem
Internal components of work piece damaged during welding.
Probable Cause
Solution
Excessive horn amplitude
Reduce the horn amplitude by changing to a lower gain
booster.
Dampen the excess horn amplitude.
Excessive exposure to ultrasound.
Reduce the primary weld time and
increase the horn amplitude by changing to a higher gain
booster.
Too much energy transmitted into
the part.
Reduce the horn amplitude.
Reduce the air pressure.
Reduce the weld time/primary weld characteristic.
The components are improperly
mounted (e.g., parts are mounted
too close to the joint area).
Ensure that internal components are mounted properly.
Isolate internal components from the part.
Move the internal components away from areas of high
energy.
Use an external device to dampen energy locally.
__________________________________________________________________________________
Problem
Melting or fracturing of the part (outside of the joint area).
Probable Cause
Solution
Sharp internal corners/thin sections.
Radius all sharp corners.
Dampen motion for any damaged area, if possible.
Excessive horn amplitude.
Reduce the horn amplitude by changing to a lower gain
booster.
A long weld time.
Decrease the weld time and
increase the horn amplitude and/or
the air pressure.
Inherent stress.
Check the molding conditions.
Check the part design.
Reduce the horn amplitude.
__________________________________________________________________________________
Continued
Page
72
Dukane Manual Part No. 403-569-01
Section 8 - Troubleshooting
Welding
_______________________________________________________________________________
Problem
Underwelding
Probable Cause
Solution
Insufficient energy is being transmitted
to the part.
Increase the air pressure.
Increase the weld time/primary weld characteristic.
Change to a higher gain booster to increase the horn
amplitude.
Use a more powerful assembly system.
Energy is being absorbed into the fixture.
Change the type of fixture being used.
_______________________________________________________________________________
Problem
Uneven welding
Probable Cause
Solution
Warped part(s).
Check part dimensions.
Check the molding conditions.
Use a higher trigger pressure.
Use a higher hold pressure.
The energy director varies in height.
Redesign the energy director to ensure uniform
height.
Use an interrupted energy director.
Lack of parallelism between the horn,
the fixture, and the part.
Make sure the thruster is perpendicular
to the part.
Check the part dimensions.
Wall flexure is occurring.
Add ribs to the part.
Modify the fixture to prevent outward flexure
The knockout pin location is in the
joint area
Redesign the part so the knockout pin
is not in the joint area (Make sure knockout pins are
flush with the surface)
There is insufficient support in
the fixture.
Redesign the fixture to improve the
support in critical areas.
Change to a rigid fixture.
If large sections of urethane are deflecting with a
resilient fixture, add a rigid backup.
_______________________________________________________________________________
Continued
Dukane Manual Part No. 403-569-01
Page
73
iQ Series Ultrasonic Press System ES User’s Manual
Welding
_________________________________________________________________________________
Problem
Uneven welding
Continued
Probable Cause
Solution
Part dimensions are incorrect.
Check the part dimensions.
Re-dimension the part, if necessary.
Check the molding conditions.
The parts are improperly aligned.
Check for part shifting during welding.
Check the alignment of mating parts.
Check for parallelism of the horn, the part, and/or the
fixture.
There is a lack of intimate contact
around the joint area.
Check the part dimensions.
Check the part tolerances.
Check for knockout pin marks in the joint area.
Check for misalignment of the mating part halves.
Check for sinks.
Non-uniform horn contact is occurring.
Check the fit of the part to the horn.
Check for proper support in the fixture.
Mold release is on the joint surface(s).
Clean the mating surfaces.
There is a non-uniform distribution of
filler in the plastic material.
Check the molding conditions.
Check the mold design.
The joint design is incorrect.
Redesign the joint.
There is a material or resin grade
incompatibility problem.
Consult with the resin supplier(s).
There is a regrind problem.
Check with the molder.
Check the molding conditions.
There is moisture in the molded parts.
Specify the parts to be “dry as molded”.
Dry the parts by heating them prior to welding.
_________________________________________________________________________________
Continued
Page
74
Dukane Manual Part No. 403-569-01
Section 8 - Troubleshooting
Welding
________________________________________________________________________________
Problem
The parts are marking.
Probable Cause
Solution
The horn heats up.
Check for a loose stud, tighten if loose.
Loosen and then retighten the horn tip.
(Refer to Section 5).
Reduce the weld time.
Ensure that the horn and booster are coupling well
(Refer to Section 5).
Visually check the horn for cracks.
There are high spots in the part.
Check the part dimensions.
Check the fit of the horn to the part.
Use of raised lettering.
Use recessed lettering or relieve the horn around the
lettering.
The part does not fit the fixture
properly.
Check the fixture for proper support.
Check for cavity-to-cavity variations.
Redesign the fixture.
Oxide from the horn is being
transferred to the part.
Place polyethylene film between the horn
and the part.
Use a chrome-plated horn and/or fixture.
The parts contain fillers.
Check the processing conditions.
Reduce the amount of filler in the plastic.
________________________________________________________________________________
Problem
Welding process not in control (inconsistent weld results on a part-to-part basis).
Probable Cause
Solution
A mold release agent is used.
Clean the mating surfaces.
If a mold release agent is necessary, use a
paintable/printable grade.
Incorrect part tolerances.
Tighten the part tolerances.
Check the part dimensions.
Check the molding dimensions.
There are cavity-to-cavity variations.
Check the part dimensions and tolerances.
Check for cavity wear.
Check the molding conditions.
________________________________________________________________________________
Continued
Dukane Manual Part No. 403-569-01
Page
75
iQ Series Ultrasonic Press System ES User’s Manual
Welding
__________________________________________________________________________________
Problem
Welding process not in control (inconsistent weld results on
a part-to-part basis).
Continued
Probable Cause
Solution
Part dimensions vary due to mold
cavity variations.
Perform a statistical study to see if a pattern
develops with certain cavity combinations.
The resin contains regrind or degraded
plastic.
Consult with the molder.
Check the molding conditions.
Reduce the percentage of regrind.
Improve the quality of the regrind.
Fluctuations in the AC line voltage
supplied to the generator.
Upgrade to a generator with line
regulation.
Fluctuations in the air line pressure.
Upgrade to a system with electronic pressure regulation.
Add a surge tank with a check valve to the air line.
Raise the compressor output pressure.
The plastic’s filler content is too high.
Reduce the percentage of filler in the plastic.
Check the processing conditions.
Change the type of filler (e.g., from short to long glass
fibers).
The horn doesn’t fit the part correctly.
Check the part dimensions.
Check for cavity-to-cavity variations.
Obtain a new horn.
The weld cycle is too long.
Reduce the weld cycle time and increase the horn
amplitude or air pressure.
Increase the dynamic trigger force.
There is a lack of parallelism between
the horn, part, and/or fixture.
Check for parallelism between the horn,
part, and fixture.
Check the horn/part fit.
Check the part/fixture fit.
Level the fixture, where necessary.
Rigid fixture reflects vibratory energy.
Dampen the energy by using teflon, neoprene, cork, or
urethane in the nest of the fixture.
__________________________________________________________________________________
Page
76
Dukane Manual Part No. 403-569-01
Section 8 - Troubleshooting
Insertion
_______________________________________________________________________________
Problem
The insert pulls out easily in use.
Probable Cause
Solution
There is insufficient interference between
the hole and the insert.
Reduce the size of the molded hole in
the plastic.
The screw bottoms out in the hole.
Use a shorter screw. (Applies to internallythreaded insert).
Deepen the hole.
The insert gets pushed into the plastic
before the plastic melts.
Use hydraulic speed control.
Increase the horn amplitude and/or decrease the air
pressure.
Use pre-triggering.
The ultrasound remains on after insertion
is complete.
Decrease the primary weld characteristic.
The horn retracts before the plastic
around the insert is solidified.
Increase the hold time.
_______________________________________________________________________________
Problem
Inconsistent insertion of multiple inserts on the same part.
Probable Cause
Solution
The plastic is not melting consistently
around all inserts.
Increase the horn amplitude.
Inserts are pushed into the plastic
before the plastic has melted.
Use hydraulic speed control.
Reduce the down speed.
Use pre-triggering.
Inserts are seated at different heights
within the same part.
Evaluate the support provided by the
fixture. If required, re-level or shim the
fixture.
Measure the horn tip length to check for dimensional
consistency. If a varying length is found, send the
horn to Dukane for modification.
_______________________________________________________________________________
Continued
Dukane Manual Part No. 403-569-01
Page
77
iQ Series Ultrasonic Press System ES User’s Manual
Insertion
________________________________________________________________________________
Problem
The boss or the plastic around the boss cracks after insertion.
Probable Cause
Solution
The insert is pushed in before the
plastic has melted.
Reduce the down speed, air pressure,
and/or horn amplitude.
Use pre-triggering.
The gauge pressure is set too high.
Reduce the air pressure.
The boss wall is too thin.
Increase the thickness of the boss wall.
There is too much interference between
the insert and the hole.
Increase the hole diameter.
Use a smaller insert.
________________________________________________________________________________
Problem
The insert is not driven to the desired depth.
Probable Cause
Solution
The ultrasound is not on long enough.
Increase the primary weld characteristic. Check the
bottom stop setting.
Increase the depth of the hole.
Flash fills the hole.
(Applies to an internally-threaded insert.)
There is insufficient air pressure and/or
ultrasonic power.
Increase the air pressure, the ultrasonic
power, or the horn amplitude.
________________________________________________________________________________
Problem
The cycle time is too long.
Probable Cause
Solution
There is insufficient ultrasonic power
or the generator overloads.
If using a power control, increase the
power.
Use a more powerful generator.
There is too much interference
between the hole and the insert.
Increase the hole diameter, if possible.
Use a smaller insert.
The area of the part being inserted
is not being rigidly supported.
Support the part directly under the boss.
Install a metal post directly under the part being
inserted.
The down speed is slow.
Increase the down speed.
Continued
Page
78
Dukane Manual Part No. 403-569-01
Section 8 - Troubleshooting
Insertion
_________________________________________________________________________________
Problem
Plastic flows over the top of the insert.
Probable Cause
Solution
The weld time is too long.
Decrease the primary weld characteristic.
The insert is being driven too deep.
Reset the bottom stop.
Decrease the primary weld characteristic.
There is too much interference
between the hole and the insert.
Increase the hole diameter, if possible.
Use smaller inserts.
_________________________________________________________________________________
Problem
Melted plastic fills the hole (Applies to internally-threaded inserts).
Probable Cause
Solution
The insert is too long or the hole is
too shallow.
Use a shorter insert or
make the hole deeper.
There is too much interference
between the hole and the insert.
Increase the hole diameter.
Use smaller inserts.
The insert is being driven too deep.
Reset the bottom stop.
Decrease the primary weld characteristic.
_________________________________________________________________________________
Dukane Manual Part No. 403-569-01
Page
79
iQ Series Ultrasonic Press System ES User’s Manual
Staking
________________________________________________________________________________
Problem
A ragged or irregularly shaped stake head is formed.
Probable Cause
Solution
The staking cavity is too large.
Change to a smaller cavity in the horn.
The volume of plastic in the stud is
insufficient.
Increase the stud height/diameter.
The stud is melting at the base.
See the problem section that follows entitled
“The base is melting before the head forms”.
________________________________________________________________________________
Problem
There is excessive flash around the stake head.
Probable Cause
Solution
The staking cavity is too small.
Use a larger cavity in the horn.
The volume of plastic in the stud
is excessive.
Decrease the stud height and/or
diameter.
The stud is not centered in the
horn cavity.
Center the stud under the horn cavity.
________________________________________________________________________________
Problem
The surface below the stake head is distorted.
Probable Cause
Solution
The part is not supported directly
beneath the stud being staked.
Support the fixture with a metal post
beneath the stud being staked.
The trigger force is too high.
Reduce the trigger force.
Use pre-triggering.
________________________________________________________________________________
Problem
There is a loose fit between the staked head and the part being attached.
Probable Cause
Solution
The hole diameter relative to
the stud diameter is too large.
Reduce the hole diameter.
Continued
Page
80
Dukane Manual Part No. 403-569-01
Section 8 - Troubleshooting
Staking
_________________________________________________________________________________
Problem
There is a loose fit between the staked head and the part being attached (continued).
Probable Cause
Solution
The holding force was removed before
the stud head could solidify.
If using a dual pressure system, use
Pressure 2 in the hold portion of the weld cycle
(Pressure 2 should be higher than
Pressure 1).
Increase the hold time/distance.
Increase the stud diameter.
Reduce the size of the staking cavity.
Insufficient force is being applied to
the staked head during the hold time.
Lower the bottom stop for the horn’s
travel.
_________________________________________________________________________________
Problem
The stud is collapsing at its base.
Probable Cause
Solution
There is a sharp corner near the base
of the stud.
Radius the stud at the base.
The stud is not centered in the
horn cavity.
Center the stud under the horn cavity.
Use a knurled tip
The base is melting before the
head forms.
See the problem section below entitled
“The base is melting before the head forms”.
Too much pressure is applied before
the ultrasound is activated.
Use pre-triggering.
_________________________________________________________________________________
Problem
The base is melting before the head forms.
Probable Cause
Solution
The trigger force is too high.
Reduce the trigger force.
Pre-trigger the ultrasound.
The horn amplitude is insufficient.
Increase the amplitude.
The downstroke speed is too fast.
Use hydraulic speed control.
Use a slower downstroke speed.
_________________________________________________________________________________
Continued
Dukane Manual Part No. 403-569-01
Page
81
iQ Series Ultrasonic Press System ES User’s Manual
Staking
_________________________________________________________________________________
Problem
The formed stud head stays in the staking cavity as the horn retracts.
Probable Cause
Solution
The stud head has not solidified before
the horn retracts.
Increase the hold time.
The horn tip is heating and not
allowing the stud to solidify.
Cool the horn tip.
Use afterburst.
_________________________________________________________________________________
NOTE
The use of a knurled horn
tip and a pointed stud
can help solve many of
the above problems.
Page
82
Dukane Manual Part No. 403-569-01
Section 8 - Troubleshooting
Continuous Welding
________________________________________________________________________________
Problem
Seal not meeting strength requirements.
Probable Cause
Solution
Material traveling too quickly.
Decrease speed.
Not enough horn amplitude.
Increase booster ratio.
Inconsistent blends of synthetic material.
Evaluate material.
________________________________________________________________________________
Problem
Inconsistent welding.
Probable Cause
Solution
Non-uniform amplitude horn.
Have horn analyzed for amplitude uniformity.
Variations in anvil (fixture).
Check fixture design and dimensions.
Inconsistency of material.
Evaluate material.
________________________________________________________________________________
Problem
Seal area too great, causing flash.
Probable Cause
Solution
Material traveling too slow.
Increase speed.
Too much amplitude.
Reduce booster ratio.
Excessive air pressure.
Reduce air pressure.
________________________________________________________________________________
Problem
Transducer and/or horn heating up.
Probable Cause
Solution
Not enough air flow to dissipate
heat buildup.
Continuous duty applications require
cooling air (refrigerated air, in some applications). Supply air to the stack interfaces and the horn tips.
________________________________________________________________________________
Continued
Dukane Manual Part No. 403-569-01
Page
83
iQ Series Ultrasonic Press System ES User’s Manual
Continuous Welding
_________________________________________________________________________________
Problem
Excessive horn wear.
Probable Cause
Solution
Metal-to-metal contact between
the horn and anvil.
Use carbide inserts or have horn face
carbide-coated.
Reduce metal-to-metal contact.
_________________________________________________________________________________
Problem
Overloading generators.** See the NOTE below.
Probable Cause
Solution
Loose stack components.
Disassemble, clean and reassemble stack.
Horn failure.
Replace horn.
Transducer failure
Replace transducer.
Booster failure.
Replace booster.
Stack operating frequency shifted
out of tolerance.
Cool stack with air.
_________________________________________________________________________________
**
Page
84
NOTE
Ta b l e 8 - I I , o n t h e n e x t
page, shows Pop-up Status
Screens.
Messages on these screens
indicate generator status,
and appear only on displaycapable generators.
Dukane Manual Part No. 403-569-01
Section 8 - Troubleshooting
Pop-up Status Screens
System Status Signal
Status Text Displayed
Average Overload
AVG OVERLOAD
SIGNAL
DETECTED
An Average Overload fault tripped.
Output power exceeded rated wattage.
Lower the welding pressure or amplitude.
Fault will reset when next weld cycle starts.
POS OVERLOAD
SIGNAL
DETECTED
A Positive Peak Overload fault tripped.
Peak IGBT transistor current exceeded.
Caused by a severe frequency mismatch.
Fault will reset when next weld cycle starts.
NEG OVERLOAD
SIGNAL
DETECTED
A Negative Peak Overload fault tripped.
Peak flyback diode current exceeded.
Caused by a severe frequency mismatch.
Fault will reset when next weld cycle starts.
Positive Peak Overload
Neagative Peak Overload
End of Weld
End of Cycle
Overtemperature Fault
END OF WELD
SIGNAL
DETECTED
Automation activated End of Weld input.
This ends the weld, then the old time begins.
Activation prevents the start of next cycle.
Status message displayed a few seconds.
END OF CYCLE
SIGNAL
DETECTED
Automation activated End of Cycle input.
This terminates the weld cycle (no hold).
Activation prevents the start of next cycle.
Status message displayed a few seconds.
SYSTEM OVER TEMP
SIGNAL
DETECTED
Frequency Lock Lost
FREQUENCY LOCK LOST
SIGNAL
DETECTED
Current Loop Fault
System Power Fault
Front Panel Lock
Empty Setup
System Status or Fault Explanation
System Overtemperature fault detected.
Check that cooling fan is operational. Check for
dust build-up in cooling channel.
Fault will reset when system cools down.
Resonant freqency lock not found, or lost.
Check for a defective stack component or assembly.
Check for stack couplilng to the fixture.
Fault will reset when next weld cycle starts.
CURRENT LOOP FAULT
SIGNAL
DETECTED
Remote Control current loop fault detected.
Current loop current is less than 2MA.
Check current loop wiring and loop source.
this fault will set minimum amplitude level.
SYSTEM POWER FAULT
SIGNAL
DETECTED
System power supply fault detected.
Check that AC line input level is normal.
Likely there will be no power for the LDC.
Service is required if this fault is displayed.
FRONT PANEL LOCKED
KEYPAD ENTRY NOT
ALLLOWED
Front Panel Lock input is activated.
Front Panel changes are not allowed.
Warning pops-up if user attempts changes.
Status message displayed a few seconds.
THE CURRENT SETUP
IS EMPTY AND NEEDS
TO BE CONFIGURED
Warning text pops-up if a setup is empty.
User must program a valid welding setup.
Table 8-II Pop-Up Status Screens
Dukane Manual Part No. 403-569-01
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Dukane Manual Part No. 403-569-01
Section 9 - System Maintenance
SECTION 9
Maintenance
Six-Month Periodic Maintenance . . . . . . . . . . . . . . . . 89
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Dukane Manual Part No. 403-569-01
Section 9 - System Maintenance
Six-Month Periodic
Maintenance
1. Disconnect the generator AC power cord from the AC
line receptacle. Then, remove the thruster left and right
side covers.
2. Check that all socket-head cap screws in the press/
thruster are tight. Check the air cylinder mounting.
3. Wipe or blow away all dirt and grease in the press/
thruster.
4. Wipe away all excess oil and any dirt accumulation,
especially at the exhaust openings in the transducer
housing. There should be very little, if any, oil accumulation at the air exhaust opening. We recommend
that no oil get into the press/thruster pneumatics.
Regular accumulation of oil at the air exhaust opening
means that some oil is getting into the pneumatics. To
rectify this problem, route the air for the press/thruster
through an “oil mist reclassifier”.
5. Check the press/thruster slide operation for smooth
downward motion. Wipe away any accumulated
grease, but do not apply any solvents. If movement is
not smooth, the lower bearing may be greased with
AFB lithium grease in the standard grease fitting
provided.
6. Ensure that all wire and cable connections are secure
in the press/thruster and are not rubbing or showing
wear. If they do show wear or rubbing then reroute to
eliminate the problem.
7. Remount and secure the press/thruster covers and
reconnect the generator AC power cord to the AC line
receptacle.
Dukane Manual Part No. 403-569-01
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90
Dukane Manual Part No. 403-569-01
Section 10 - Contacting Dukane
SECTION 10
Contacting Dukane
Dukane Manual Part No. 403-569-01
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Dukane Manual Part No. 403-569-01
Section 10 - Contacting Dukane
Contacting Dukane
Identify Equipment
When contacting Dukane about a service–related problem,
be prepared to give the following information:
• Model number, line voltage and serial number.
• Fault/error indicators from the LCD display.
• Software version (Press INFO. With pointer at System
Information, press ENTER to get this data.)
• Problem description and steps taken to resolve it.
Many problems can be solved over the telephone, so it is
best to call from a telephone located near the equipment.
Ultrasonics Division
Mailing Address:
Dukane Ultrasonics
2900 Dukane Drive
St. Charles, IL 60174 USA
Phone:
(630) 797–4900
Fax:
Main
(630) 797–4949
Service & Parts (630) 584–0796
Website
The website has information about our products, processes,
solutions, and technical data. Downloads are available for
many kinds of literature.
You can locate your local representative at:
www.dukane.com/us/sales/intsales.htm
Dukane Manual Part No. 403-569-01
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Dukane Manual Part No. 403-569-01
Section 11 -Specifications/Drawings
SECTION 11
Specifications
Press/Thruster Outline Drawings . . . . . . . . . . . . 97-101
Pneumatic Schematic . . . . . . . . . . . . . . . . . . . . . . . 102
Electrical Schematics . . . . . . . . . . . . . . . . . . . . 103-104
Weights, Dimensions, Operating Environment . . . . 105
AC Power Requirements . . . . . . . . . . . . . . . . . . . . . 106
Compressed Air Requirements . . . . . . . . . . . . . . . . 106
Interpreting the Model Number . . . . . . . . . . . . . . . . 107
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . 107
Regulatory Agency Compliance . . . . . . . . . . . . . . . 108
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Dukane Manual Part No. 403-569-01
Section 11 -Specifications/Drawings
Figure 11-1 Layout - 215 Press and Thruster
Dukane Manual Part No. 403-569-01
Page
97
iQ Series Ultrasonic Press System ES User’s Manual
32.00
[813]
5.19
[132]
q
17.18
17.18
[436]
[436]
1.75
1.75
[47]
[47]
DETAIL 1
SEE SEE
DETAIL
1
10.82
10.82
[275]
[275]
q
[100]
3.94
3.94
[100]
[31]
1.22
1.22
[31]
7.77
.77
[197]
[197]
1.31
1.31
[33]
[33]
13.68
13.68
[347]
[347]
1.26
1.26
[32]
[32]
q
IN
[MM]
7.00
[178]
STROKE
2.45
[62]
DETAIL 1
1.94
[49]
7.0 ONLY WITH OPTIONAL
7.0/178
[178]
HYDRAULIC SPEED CONTROL
14.17
[360]
[360]
14.17
SEE NOTE 1
AIR IN
BNC
12.99
12.99
[330]
[330]
.99
.99
[25]
[25]
7.48
7.48
[190]
[190]
U/SU/S
BNC
AIR IN
1.26
1.26
[32]
[32]
1.18
1.18
[30]
[30]
2.58
2.58
[66]
[66]
Dukane Manual Part No. 403-569-01
98
Page
Layout - 220 Thruster
Figure 11-2
5.60
5.60
[142]
[142]
OPTIONAL IQ
GENERATOR
Section 11 -Specifications/Drawings
9.29
[236]
7.0 [178]
ONLY WITH
OPTIONAL HYDRAULIC SPEED CONTROL
1.75
[44]
17.14
[435]
12.38
[314]
14.75
[375]
12.38
[314]
24.84
[631]
23.70
[602]
17.09
[434]
44.09
[1120]
14.00
[356]
12.38
[314]
16 . 50
[419]
8. 250
[210]
99
Page
Dukane Manual Part No. 403-569-01
31.94
[811]
1.45
[37]
7.00 MAX.
5.38
[137]
STROKE
TYPICAL HORN
[381]
OPTIONAL
GENERATOR
XGT MODEL
SHOWN
4.75
[121]
15.00 MAX.
12.43
[316]
7.24
[184]
5.19
[132]
18.58
[472]
(PART HEIGHT+FIXTURE)
[178]
Figure 11-3 Layout - 220 Press
iQ Series Ultrasonic Press System ES User’s Manual
9.29
[236]
2.80
[71]
4.74
[121]
1.75
[45]
16.44
[418]
32.10
[815]
.80
[20]
7.00
(MAX STROKE)
[178]
CL HORN
9.25
[235]
5.17
[131]
3.94
[100]
24.83
[631]
12.38
[314]
10.55
[268]
15.65
[398]
1.34
[34]
14.00
[356]
.77
[19]
THRUSTER CL
BOOSTER END
2.87
[73]
44.42
[1128]
804-36
1.18
[30]
12.38
[314]
15.50/[394]
14.17/[360]
11.81/[300]
9.86/[250]
8.250
[210]
6.69
[170]
REAR MOUNTING SURFACE OF PRESS
SCALE 1:2
16.50
[419]
.7 X .7 NOTCH FOR
ENCODER CABLE
M10 X 1.5
(4 PLCS)
1.26/[32]
3.65
1.26/[32] [93]
10MM DIA. DOWEL PIN HOLE.
(2) PLCS.
Dukane Manual Part No. 403-569-01
100
Page
6.36
[162] 4.48
[114]
18.58
[472]
Figure 11-4 Layout - 340 Press and Thruster
Section 11 -Specifications/Drawings
2.76
[70.2]
ONLY WITH
OPTIONAL
HYDRAULIC
SPEED CONTROL
4.75
[120.6]
32.58
[827.5]
17.25
[438.3]
.85
[21.6]
15.00 MAX
[381]
(Part Height
+ Fixture)
1.75
[44.6]
SEE NOTE 2
SEE NOTE 3
10.81
[274.5]
5.16
[131.0]
24.84
[630.0]
12.38
[314.3]
15.58
[395.8]
1.24
[31.5]
3.94
[100.0]
10.57
[268.5]
2.32
[58.9]
44.09
[1120.0
M
RN
C
101
Page
Dukane Manual Part No. 403-569-01
7.20
[182.8]
5.24
[133.2]
18.58
[471.9]
Layout - 340 Press and Thruster
Figure 11-5
iQ Series Ultrasonic Press System ES User’s Manual
Figure 11-6
Page
102
Pneumatic Schematic (All iQ ES Presses)
Dukane Manual Part No. 403-569-01
Section 11 -Specifications/Drawings
Figure 11-7
Electric Schematic 215
Dukane Manual Part No. 403-569-01
Page
103
iQ Series Ultrasonic Press System ES User’s Manual
Figure 11-8
Page
104
Electric Schematic 220 & 340
Dukane Manual Part No. 403-569-01
Section 11 -Specifications/Drawings
Weights
Press (includes base and column)
Model Number
Thruster
Pounds
Kilograms
Pounds
Kilograms
43Q215
322
146
93
42
43Q220
170
77
45
20
43Q340
170
77
45
20
Shipping: Add 10 pounds (2.3 kg) to unit weight for packing materials
Table 11- I
Weights
Dimensions Dimensions - in (mm)
Press (includes base and column)
Model Number
43Q215
Height
Width
Depth
18.6 (475)
24.8 (630)
77.8 (1980) high
61 (1550) low
43Q220
56.94 (1450)
43Q340
NOTE: Add 4" (100 mm) behind the press/thruster for air input line and cable connections.
Table 11- II
Dimensions
Operating Environment
Operate the equipment within these guidelines:
Temperature:
40°F to 100°F (+5°C to +38°C)
Air Particulates:
Keep the equipment dry.
Minimize exposure to moisture, dust, dirt, smoke
and mold.
Humidity:
5% to 95% Non–condensing @ +5°C to +30°C
Nonoperating storage guidelines:
Temperature:
-4°F to 158°F (-20°C to +70°C)
Air Particulates:
Keep the equipment dry.
Minimize exposure to moisture, dust, dirt, smoke
and mold.
Humidity:
5% to 95% Non–condensing @ 0°C to +30°C
Dukane Manual Part No. 403-569-01
Page
105
iQ Series Ultrasonic Press System ES User’s Manual
Compressed Air Requirements
For all press/thruster models, Dukane recommends 80-110 psi of clean, dry air.
Maximum available clamping pressure:
Model
Force Generated at
110 psi (lb)
Standard Air Cylinder
Diameter (in)
43Q215
775
3.00
43Q220
540
2.50
43Q340
190
1.75
Table 11- III
Clamping Pressure
AC Power Requirements
The press/thruster uses 24VDC @ 2 Amps, obtained from the iQ Series generator to
which it is connected. The AC line voltage and current needed depend on whichever
generator has been chosen for your system. See the table below.
Operating
Frequency
Generator
Model Number
Overload
Power
Ratings
(Watts)
Input AC Power Requirements
Nominal AC Volt
@ Maximum RMS Current
15kHz
15XX360-2X-XX-XX
3600
200-240V 50/60 Hz @ 25 Amps
15kHz
15XX480-2X-XX-XX
4800
200-240V 50/60 Hz @ 30 Amps
20kHz
20XX120-1X-XX-XX
1200
100-120V 50/60 Hz @ 15 Amps
20kHz
20XX120-2X-XX-XX
1200
200-240V 50/60 Hz @ 8 Amps
20kHz
20XX180-2X-XX-XX
1800
200-240V 50/60 Hz @ 12 Amps
20kHz
20XX240-2X-XX-XX
2400
200-240V 50/60 Hz @ 15 Amps
20kHz
20XX360-2X-XX-XX
3600
200-240V 50/60 Hz @ 25 Amps
20kHz
20XX480-2X-XX-XX
4800
200-240V 50/60 Hz @ 30 Amps
30kHz
30XX090-1X-XX-XX
900
100-120V 50/60 Hz @ 8 Amps
30kHz
30XX090-2X-XX-XX
900
200-240V 50/60 Hz @ 8 Amps
30kHz
30XX120-1X-XX-XX
1200
100-120V 50/60 Hz @ 15 Amps
30kHz
30XX120-2X-XX-XX
1200
200-240V 50/60 Hz @ 8 Amps
30kHz
30XX180-2X-XX-XX
1800
200-240V 50/60 Hz @ 12 Amps
40kHz
40XX060-1X-XX-XX
600
100-120V 50/60 Hz @ 8 Amps
40kHz
40XX060-2X-XX-XX
600
200-240V 50/60 Hz @ 5 Amps
40kHz
40XX090-1X-XX-XX
900
100-120V 50/60 Hz @ 15 Amps
40kHz
40XX090-2X-XX-XX
900
200-240V 50/60 Hz @ 8 Amps
40kHz
40XX120-1X-XX-XX
1200
100-120V 50/60 Hz @ 15 Amps
40kHz
40XX120-2X-XX-XX
1200
200-240V 50/60 Hz @ 8 Amps
Table 11- IV
North America/
Japan
AC Outlet Rating
30 Amps
15 Amps
30 Amps
15 Amps
AC Power Requirements
NOTES:
An X used above in the Model Numbers is a “wildcard” character meaning any valid character code combination.
Maximum line current requirement is specified at the minimum nominal AC line voltage and the rated power level.
Page
106
Dukane Manual Part No. 403-569-01
Section 11 -Specifications/Drawings
Interpreting the Model Number
iQ Series Ultrasonic Press System
Model
Number
Power
43Q215
43Q220
43Q340
Standard Options
D
E
L
P
H
S
15kHz and Super 20 kHz
X
X
X
X
O
O
20kHz
X
X
X
X
X
X
30kHz and 40kHz
Table 11-V
X
X
Interpreting the Model Number
X
X
X
X
D - Distance encoder
E - Electronic pressure regulator
L - Load cell
P - Basic dual air pressure
H - Hydraulic speed control
S - Pre-trigger/end of weld limit
switches
X = available
O = unavailable
Replacement Parts - iQ Series ES Presses
Part Number
Part Description
Press Model
43Q215
43Q220
43Q340
High pressure grease packet
X
X
X
User's Manual iQ Series Ultrasonic Press System ES
X
X
X
iQ main valve assembly
X
X
X
Air pressure gauge (NOT needed if standard option E is installed)
X
X
X
721-31-00013 Transducer door hex key 43Q215
X
O
O
721-31-00056 Transducer door hex key 43Q220/43Q340
474-33
403-569
430-03-0026
697-113
O
X
X
721-44
43Q340 spanner wrench
O
O
X
721-68
43Q215 / 43Q220 spanner wrench
X
X
O
804-33
Primary air cylinder, 2 1/2 " bore X 7"
O
X
O
804-52
Air pressure regulator (NOT needed if standard option E is installed)
X
X
X
804-62
Primary air cylinder 3" bore X 7"
X
O
O
804-63
Counter balance air cylinder 9/16" bore X 11"
O
X
X
804-66
Primary air cylinder 1 1/2 " bore X 7"
O
O
X
804-71
Counter balance air cylinder 1 1/16 bore X 11"
X
O
O
Electronic air pressure regulator (when optional E feature is installed)
X
X
X
430-03-0036
Optical distance encoder (when optional E feature is installed)
X
X
X
430-03-0045
625-18
Dual pressure valve assembly (when optional P feature is installed)
X
O
O
430-03-0035
Dual pressure valve assembly (when optional P feature is installed)
O
X
X
Hydraulic speed control cylinder (when optional H feature is installed)
O
X
X
804-18
Table 11-VI
Replacement Parts
Dukane Manual Part No. 403-569-01
X = available
O = unavailable
Page
107
iQ Series Ultrasonic Press System ES User’s Manual
Regulatory Agency
Compliance
FCC
The generator complies with the following Federal
Communications Commission regulations.
• The limits for FCC measurement procedure MP-5,
“Methods of Measurement of Radio Noise Emissions from ISM Equipment”, pursuant to FCC Title
47 Part 18 for Ultrasonic Equipment.
CE Marking
This mark on your equipment certifies that it meets
the requirements of the EU (European Union) concerning interference causing equipment regulations.
CE stands for Conformité Europeéne (European
Conformity). The equipment complies with the following CE requirements.
• The EMC Directive 2004/108/
EC for Heavy Industrial —
EN 61000-6-4: 2001
EN 55011: 2003
EN 61000-6-2: 2001
EN61000–4–2
EN61000–4–3
EN61000–4–4
EN61000–4–5
EN61000–4–6
EN61000–4–8
EN61000–4–11
CAUTION
DO NOT make any modifications to the generator
or associated cables as
the changes may result
in violating one or more
regulations under which
this equipment is manufactured.
• The Low Voltage Directive 2006/95/EC.
• The Machinery Directive 98/37/EC.
EN 60204-1: 2006
Safety of Machinery - Electrical Equip-
ment of Machines Part 1: Specification
for General Requirements.
Effective 12/29/09:
The Machinery Directive 2006/42/EC.
EN 60204: 2006
Safety of Machinery - Electrical Equipment of Machines Part 1: General Requirements.
Page
108
Dukane Manual Part No. 403-569-01
Section 12 -Appendices
SECTION 12
Appendices
Appendix A, List of Figures . . . . . . . . . . . . . . . . . . . . 111
Appendix B, List of Tables . . . . . . . . . . . . . . . . . . . . . 112
Dukane Manual Part No. 403-569-01
Page
109
iQ Series Ultrasonic Press System ES User’s Manual
This page intentionally left blank
Page
110
Dukane Manual Part No. 403-569-01
Section 12 -Appendices
Appendix A
List of Figures
No.
Description
Page
2-1
Unpacking Press Systems.............................................................................................11
2-2
Example of Press Placement.........................................................................................12
2-3
To Make Adjustments.....................................................................................................12
2-4
To Relocate Handles......................................................................................................12
2-5
Example of Mounting the Thruster to a Rigid Structure.................................................13
2-6
Press Connector Locations............................................................................................15
2-7
Thruster Connector Locations........................................................................................16
2-8
Flange Template.............................................................................................................17
3-1
(Manual) Press/Thruster Controls and Indicators (Model 220 and 340)........................23
3-2
(EPR) Press/Thruster Controls and Indicators (Model 215)...........................................27
3-3
Ergonomic Base Controls...............................................................................................28
3-4
Right Operate Switch in Standby Mode.........................................................................28
3-5
Right Operate Switch in Operate Mode..........................................................................28
3-6
Setting and Resetting the E-Stop Switch.......................................................................29
4-1
Example of Slow Speed Setting.....................................................................................34
4-2
Location of the Hydraulic Control Components..............................................................35
4-3
Adjustment Using the Hole.............................................................................................35
4-4
Adjustment Using the Slot..............................................................................................35
4-5
Distance Encoder Mounting...........................................................................................36
4-6
Distance Encoder Alignment..........................................................................................37
5-1
Stack Components.........................................................................................................44
5-2
Stack Removal...............................................................................................................45
5-3
Disassembling Components...........................................................................................46
5-4
Tip Removal...................................................................................................................46
5-5
Assembling Components...............................................................................................47
5-6
Tip Assembly..................................................................................................................48
5-7
Stack Installation............................................................................................................48
5-8
Fixture/Base Layout.......................................................................................................49
5-9
Loosening the Hold Down Cap Screws and Jack Screws..............................................50
5-10
Tightening the Hold Down Cap Screws and Jack Screws..............................................50
6-1
iQ Explorer Utilities TEST Button...................................................................................56
6-2
iQ Explorer TEST Screen Display..................................................................................57
6-3
iQ Explorer ERROR Detected - Cycle Stop...................................................................57
Continued
Dukane Manual Part No. 403-569-01
Page
111
iQ Series Ultrasonic Press System ES User’s Manual
Appendix A
No.
Description
Continued
List of Figures
Page
6-4
iQ Explorer System Tab - Advanced Hardware..............................................................58
7-1
Example of Burnished Area............................................................................................63
7-2
Example of Crowning.....................................................................................................63
7-3
Example of Center Depression......................................................................................63
7-4
Method of Component Resurfacing............................................................................... 64
11-1
Layout - 215 Press and Thruster....................................................................................97
11-2
Layout - 220 Thruster.....................................................................................................98
11-3
Layout - 220 Press.........................................................................................................99
11-4
Layout - 340 Press and Thruster..................................................................................100
11-5
Layout - 340 Press and Thruster..................................................................................101
11-6
Pneumatic Schematic (All iQ ES Presses)...................................................................102
11-7
Electric Schematic (215)..............................................................................................103
11-8
Electric Schematic (220 and 340)................................................................................104
Appendix B
List of Tables
No.
Description
2-I
Generator to Press/Thruster Cables................................................................................ 15
5-I
Stud Torque Values.......................................................................................................... 47
5-II
Horn/Booster Torque Values............................................................................................ 47
5-III
Replaceable Tip Torque Values........................................................................................ 48
8-I
Weld Characteristics and Equipment Requirements........................................................ 69
8-II
Pop-up Status Screens.................................................................................................... 85
11-I
Weights.......................................................................................................................... 105
11-II
Dimensions.................................................................................................................... 105
11-III
Clamping Pressure........................................................................................................ 106
11-IV
AC Power Requirements............................................................................................... 106
11-V
Interpreting the Model Number......................................................................................107
11-VI
Replacement Parts........................................................................................................107
Page
112
Page
Dukane Manual Part No. 403-569-01
Section 13 - Index
SECTION 13
Index
Dukane Manual Part No. 403-569-01
Page
113
iQ Series Ultrasonic Press System ES User’s Manual
This page intentionally left blank
Page
114
Dukane Manual Part No. 403-569-01
Section 13 - Index
A
Cable Connections, Press System Continued
Abort Switch 5, 28, 29, 37
AC Power Requirements 106
Acoustic Stack
Access Door 45
Assembly 47
Changing Components 45
Component Maintenance 63
Burnished Surfaces 63
Crowning 63
Depressions 63
Overtightening 65
Reconditioning 64
Resurfacing 64
Thread Deformation 65
Description 44
Disassembly 46
Fixture Setup 49
Hazard 5
Inspection 63
Installing 48
Removal 45
Removing Detachable Tip 46
Testing 56
Activation Switches 7, 28
Appendices 109
Appendix A, List of Figures 111
Appendix B, List of Tables 112
B
Base
Abort Switch 28
Activation Switches 28
Status Display
Abort 29
In Cycle 29
Ready 29
Booster 44, 63, 64
C
Cable Connections, Press System
Air In 14
Base Control 14
Encoder 14
Grounding Stud 14
Operation Control 14
Dukane Manual Part No. 403-569-01
Top of Stroke 14
Cable Connections Thruster
Air In 15
Grounding Stud 15
Operation Control 15
Top of Stroke 15
CE Marking 108
Cautions 3
Clamping Pressure 106
Compressed Air Requirements 106
Controls
Electronic Press 39
Pressure Regulator 39
Pressure Transducer 39
Load Cell 40
Manual 22
Down Speed 22
End of Weld 24
Hydraulic Slow Speed 22
Mechanical Stop 22
Pressure 1 Regulator 22
Pressure 2 Regulator 24
Pre-trigger 24
Trigger 24
D
Digi Trac 55, 56, 57
Dimensions 105
Distance 69
Absolute 69
Encoder 36
Drawings 3
Outline, Layout 97-104
Dukane ii, 3, 4, 93
Page
115
iQ Series Ultrasonic Press System ES User’s Manual
E
I
E-Stop Switch 28, 29
In Cycle 29
Electrical Safety Grounding 7
Emergency Stop Switch 28, 29
Indicators
Electronic Pressure Regulator 26
Mechanical Stop Indicator Flag 25
Pressure Gauge 25
Slow Speed Indicator Flag 25
Stroke Position Indicator Flag 25
Ultrasound Active Status Light 25
End-of-Limit Switch 69
Installing the Press System 11
Energy 69
Installing the Thruster 13
Electronic Press Controls 39
Electronic pressure Regulator 39
Pressure Transducer 39
F
Figures
List 111
Fixture
Alignment 49
Installation 49
Leveling 50
Flag (indicator)
Mechanical Stop 23, 25, 27
Slow Speed 23, 25, 27, 34
Stroke Position 23, 25, 27
Flange Template 17
G
Grounded Electric Power 4
H
Health and Safety
Abort Switch 5
Ear Protectors 5
Grounding 7
Keep Cover On 4
Plastics 7
Horn 44, 63, 64
Page
116
iQ Explorer 40, 56
Advanced Hardware 58
Error Detected 57
TEST Screen Display 57
Utilities TEST Button 56
L
Lists
Figures 111
Tables 112
Load Cell 40
M
Maintenance 87
Six-month 89
Model Number
Interpreting 107
N
Notes 3
O
Operating Environment 105
Operate Switches 28
Dukane Manual Part No. 403-569-01
Section 13 - Index
P
S
Peak Power 69
Schematics
Electrical 103-104
Pneumatic 102
Plastics 7
Pop-up Status Screens 85
Power Requirements 106
Press
Installing
Height Adjustment 12
Placement 11
Unpacking 11
Without Machine Base 12
Options
Distance Encoder 36
Alignment 37
Dismantling 36
Reassembly 36
Electronic Pressure Regulator 39
Load Cell 40
Pressure Transducer 39
Hydraulic Speed Control
Adjustment 35
Indicator Flag 34
Kit Operation 34
Slow Speed Range 34
Pressure
Compressed Air 106
Gauge 25
Regulator 26, 39
Transducer 39
Screws
Cap and Jack
Loosening 50
Tightening 50
Service 93
Specifications 95
AC Power Requirements 106
Electrical Schematics 103-104
Interpreting the Model Number 107
Pneumatic Schematic 102
Press/Thruster Outline Drawings 97-101
Regulatory Agency Compliance 108
Replacement Parts 107
Weights, Dimensions, Operating Environment 105
Staking 80
Status Screens 85
Stroke Distance Maximum 13
System 4
Cycle Procedure 59
Primary Weld Characteristics 69
T
R
Tables 3
List 112
Ready 29
Regulatory Agency Compliance 108
Replacement Parts 107
Test
System 53
Thread Deformation 65
Thruster
Cable Connections 15
Installling 13
Layout Drawing 98
Mount to Rigid Structure 13
Dukane Manual Part No. 403-569-01
Page
117
iQ Series Ultrasonic Press System ES User’s Manual
T Continued
Time 69
Tip
lnstalling Detachable 48
Removing Detachable 46
Torque Values 47-48
Transducer 44, 63, 64
Pressure 39
Troubleshooting 67
Continuous Welding 83
Insertion 77
Staking 80
Welding 70
U
Unauthorized Modifications 4
V
Vibration 57, 63
Vibrational Characteristics 55
W
Warnings 3
Website 93
Weights 105
Welding 70
Continuous 83
Wrench
Spanner 46
Page
118
Dukane Manual Part No. 403-569-01
Dukane ISO
ISO CERTIFICATION
Dukane chose to become ISO 9001:2000 certified in order to demonstrate to our customers
our continuing commitment to being a quality
vendor. By passing its audit, Dukane can assure
you that we have in place a well–defined and
systematic approach to quality design, manufacturing, delivery and service. This certificate
reinforces Dukane's status as a quality vendor
of technology and products.
To achieve ISO 9001:2000 certification, you
must prove to one of the quality system registrar groups that you meet three requirements:
1. Leadership
2. Involvement
3. Quality in Line Organizations and Quality
System Infrastructure.
The ISO 9001:2000 standard establishes a
minimum requirement for these requirements
and starts transitioning the company from a
traditional inspection–oriented quality system
to one based on partnership for continuous
improvement. This concept is key in that Dukane no longer focuses on inspection, but on
individual processes.
Dukane's quality management system is based
on the following three objectives:
1. Customer oriented quality. The aim is to
improve customer satisfaction.
2. Quality is determined by people. The aim
is to improve the internal organization and
cooperation between staff members.
3. Quality is a continuous improvement.
The aim is to continuously improve the
internal organization and the competitive
position.
ISO 9001:2000
CERTIFIED
Dukane products are manufactured in ISO
registered facilities
Please refer to our website at:
www.dukane.com/us/sales/intsales.htm
to locate your local representative.
iQ Series Ultrasonic Press System ES User's Manual
Part No. 403 – 569– 01
www.dukane.com/us
Printed in the United States of America
Dukane Intelligent Assembly Solutions • 2900 Dukane Drive St. • Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797–4949
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