Dukane 403570-01 user manual Problem Symptom Possible Cause Recommended Solution

Page 81

Section 9 - Troubleshooting

Table 9–IWelding Process Troubleshooting

Problem

Symptom

Possible Cause

Recommended Solution

 

Excessive weld flash

Weld Time or Distance are too large

Reduce Weld Time or Distance

 

 

 

 

Overwelding

Welded assembly

Incorrect flash trap design

Evaluate and correct flash trap design

 

dimensions are too

 

 

 

small

 

 

 

 

 

 

 

Low strength weld

Weld Time or Distance are too small

Increase Weld Time or Distance

 

 

 

Underwelding

Welded assembly

Material difficult to weld due to low friction

Degrease joint interface to remove mold release

coefficient

agent

 

dimensions are too

 

 

 

 

large

 

Consider changing material (i..e.. avoid PTFE)

 

 

 

 

 

 

 

 

 

Warped parts

Check part dimensions

 

 

 

 

 

 

Uneven weld interface

Check molding process conditions

 

 

 

 

 

 

Fixture and part are not parallel

Level fixture where necessary

 

 

 

Check that tooling is true to table

 

 

 

 

 

 

Poor alignment of parts in tool and/or

Change part or tool dimensions

 

 

fixture

 

 

Excessive weld flash

 

Improve part tolerance due to cavity

 

Low weld strength

Insufficient fixture support

Check for parts shifting during welding

Nonuniform or

 

 

 

 

Provide features in parts for rotational driving (i..e..

inconsistent

Failure when leak

 

weld joints

 

drive ribs or cavities)

tested

 

 

 

 

 

Part walls flexing during weld

Redesign parts with reinforcing ribs and/or tongue-

 

 

 

Part failure in service

 

and-groove joints

 

 

Excessive filler or uneven distribution

Reduce amount of filler

 

 

 

Improve processing conditions to ensure even

 

 

 

distribution of filler

 

 

 

 

 

 

Moisture in parts

Prevent moisture absorption after molding prior to

 

 

 

welding

 

 

 

Dry parts before welding

 

 

 

 

 

 

Deceleration too low

Increase spin deceleration as high as possible (if

 

 

 

set too high, welder will fault with tracking errors)

 

 

Vertical speed too high

Reduce speed to decreased spin torque required

Final part

 

 

 

orientation

Parts not aligned

 

 

Poor tuning

Determine and enter tool inertia correctly into Setup

different from

properly

programmed

 

 

 

 

 

orientation

 

 

Contact DUKANE for special tuning requirements

 

 

 

 

 

 

Parts not held properly by tool or fixture

Ensure tooling does not allow excessive play

 

 

 

 

Dukane Manual Part No. 403-570-01

Page  75

Image 81
Contents Dual Servo Spin Welder Dukane Manual Part No Revision History RevisionSummary Date This page intentionally left blank Dukane Dual Servo Spin Welder ContentsThis page intentionally left blank Introduction SectionThis page intentionally left blank Important User Information Read This Manual FirstDrawings and Tables SVT042VR Dual Servo Spin Welder OverviewKey Dual Servo Spin Welder Features This page intentionally left blank Safety Considerations This page intentionally left blank  Caution Health and Safety TipsRun Switches General SafetyPlastics Health Notice Electrical Safety Mechanical SafetyAC Power Receptacle This page intentionally left blank Unpacking and Setup This page intentionally left blank Packing List Unpacking WelderWork Area Qty Part NumberBench Capacity Securing to Work BenchLeveling Mounting HolesTooling Hub & Fixture Dimensions are in Inches mm20-Amp 240V Figure AC PowerControl Connectors Head Height AdjustmentBase Interface Connector User I/O ConnectorThis page intentionally left blank Display and Controls This page intentionally left blank 1Dual Servo Spin Welder Touch Screen Panel Touch Screen DisplayEmergency Stop Switch Operational SwitchesOpti-Touch Run Switches Data I/O ConnectorThis page intentionally left blank View Parts Touch Screen MenusThis page intentionally left blank Screen Layout RUN ModeView Parts Setup Menu PRE-WELD SetupTool Setup Trigger Position TOP of Stroke PositionPre-Spin Orientation Option Part Pickup OptionWeld Setup Weld Method SelectionTime Method Distance Method Rotation MethodOrientation Option Energy Method18Weld Torque Trigger Option Screen Torque Trigger OptionPOST-WELD Setup Hold SetupConstant Torque Option 22Hold Setup Screen for Distance Mode 25Process Limit Definitions Screen 1 Part Tests28RUN Screen with Part Test Failed Button Select Setup Tab Tools MenuUtilities Tab Third tab is labeled System Setup and is shown in Figure System Setup Tab34Vertical Lower Limit Setup Screen with Set Position Button 35Password-Protected Screens and Menus Setting Time and Date On Touch Screen Parameter Value Range Screen Parameter Name Min.Value Max.Value Resolution UnitsThis page intentionally left blank 55-56 Machine OperationThis page intentionally left blank AC Power Machine SetupAdjust Thruster Position on Column Base Interface CableTurn Power on Reset E-StopSet Tool Parameters Initialize Home WelderSet Weld Process Parameters Set Vertical Travel Lower Limit PositionStarting a Weld Cycle Stopping a Weld Cycle Setup SheetDual Servo Spin Welder Setup Sheet Optimizing Performance This page intentionally left blank Material Considerations Spin Welding ProcessSurface Speed Control ParametersRPM Weld Depth Press Axial SpeedPart Size HoldWeld Diameter Machine Peak RPM This page intentionally left blank Welder Data Export Software Installation, StartupThis page intentionally left blank Hardware Software Requirements Installation Startup, and Cable ConnectionsPart Data List Part DataFile Write Profile GraphsIncoming Data Plot DataSpin Torque Setpoint Servo and DebugWelding Process TroubleshootingThis page intentionally left blank Welding Process TroubleshootingMechanical WelderProblem Symptom Possible Cause Recommended Solution Faults Message Description Cause Possible Solution InstructionsMessage Description Cause Possible Solution Time or number of rotations Message Description Cause Possible Solution ErrorsMessage Description Cause Possible Solution This page intentionally left blank Maintenance This page intentionally left blank Maintenance AC Power CordThis page intentionally left blank Contacting Dukane This page intentionally left blank Intelligent Assembly Solutions Contacting DukaneIdentify Equipment This page intentionally left blank Specifications This page intentionally left blank Machine Weight Tooling SpecificationsPower Requirements Operating Environment2Dual Servo Spin Welder Dimensions Welder Model & Serial Number Identification NumbersThis page intentionally left blank Appendix a Connector PinoutsThis page intentionally left blank Figure A-1Base Interface Connector Base Interface ConnectorSignal Description Function User I/O ConnectorPin Signal Description Function Slide Kit ConnectorAutomation Wiring Data Port ConnectorFigure A-5Schematic of Operate and Abort This page intentionally left blank Tooling Appendix BThis page intentionally left blank Explanation of Inertia Moment of InertiaTool and Fixture Design Appendix C Optional FeaturesThis page intentionally left blank Figure C-1Upper Tool Vacuum System Upper Tool VacuumFigure C-2 Remote Touch Screen Components Remote Touch ScreenDukane ISO

403570-01 specifications

The Dukane 403570-01 is a sophisticated ultrasonic welding machine renowned for its versatility and efficiency in various industrial applications. Designed with advanced technology, this model is favored in sectors such as automotive, medical, textiles, and consumer goods for its ability to provide consistent and reliable weld results.

One of the main features of the Dukane 403570-01 is its state-of-the-art ultrasonic transducer, which converts electrical energy into mechanical vibrations. This high-frequency sound wave technology allows for the joining of materials without the need for additional adhesives or fasteners, making it an environmentally friendly and cost-effective solution for manufacturers. The transducer operates at a frequency of 20 kHz, optimal for producing strong and durable welds.

In addition to its transducer, the 403570-01 is equipped with an advanced generator that provides precise control over the welding process. This generator adjusts the energy output based on the materials being welded and the specific application, ensuring optimal settings for each job. The machine also features a user-friendly control panel that allows operators to easily program and monitor welding parameters such as time, power, and pressure.

The 403570-01 is designed for ease of use and maintenance. Its modular design simplifies servicing and allows for quick replacement of components, ensuring minimum downtime. Additionally, the machine’s lightweight construction enhances portability, making it suitable for both dedicated production lines and on-the-spot repairs.

Another significant characteristic of the Dukane 403570-01 is its versatility in handling various materials, including plastics, metals, and composites. This flexibility opens up a wide array of welding applications, from assembling intricate medical devices to automotive components. Furthermore, it features integrated safety measures that protect both the operator and the machine, reducing the risk of accidents during operation.

In summary, the Dukane 403570-01 stands out due to its advanced ultrasonic technology, user-friendly controls, and versatility in handling various materials. With its robust design and efficient welding capabilities, it is an invaluable asset for manufacturers looking to enhance their production processes and maintain high-quality standards.