Dukane 403570-01 Message Description Cause Possible Solution Errors, Time or number of rotations

Page 84

Dual Servo Spin Welder User’s Manual

Table 9-II

Machine Display Messages (continued)

 

 

 

 

 

 

 

 

 

 

Message

Description

 

Cause

 

Possible Solution

 

 

 

 

 

 

 

 

 

 

 

 

 

Errors

 

 

 

 

 

 

 

 

 

 

 

Axis stopped before weld

Motion on spin or vertical

 

 

1.

Check for obstructions to motion

 

axes stopped before weld

Internal machine error

 

outside welder

 

end

 

 

 

 

ended

 

 

2.

Contact DUKANE service

 

 

 

 

 

 

Spin stop before weld start

Servo controller error

Internal machine error

Contact DUKANE service

 

Timeout on finding vertical

Moving the vertical lower

 

 

 

 

 

limit up to desired position

Limit mechanism malfunctioning

Contact DUKANE service

 

lower limit position

 

failed

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The torque trigger was

1.

Torque trigger value set too

1.

Reduce torque trigger value

 

Timeout on torque sense

not detected within the

 

high

 

 

2.

Ensure parts are properly loaded

 

 

 

allowable time

2.

Parts not loaded

 

 

 

 

 

 

 

 

 

1.

Insufficient vacuum

1.

Increase vacuum capability

 

 

 

 

2.

Decrease required vacuum sensing

 

Timeout on User Upper

Vacuum was not detected

2.

Vacuum sensor threshold set

 

 

level

 

Part vacuum detect

within timeout

 

too high

 

 

 

3.

Adjust Position (mm) value in Part

 

 

 

 

3.

Improper part pickup position

 

 

 

 

 

Pickup option

 

 

 

 

 

 

 

 

Timeout on vertical

Programmed weld distance

1.

Timeout too short

1.

Increase timeout value

 

distance in constant torque

not reached within the

2.

Constant Torque maximum

2.

Increase value of VERT.. Max (mm/s)

 

specified time with Constant

 

setting in Weld Parameters screen in

 

mode

 

Torque option enabled

 

vertical speed set too low

 

setup menu

 

 

 

 

 

 

 

Vertical stop before starting

Vertical (press) motion

 

 

1.

Check for obstructions to motion

 

stopped before spin motion

Internal machine error

 

outside welder

 

spin

 

started

 

 

2.

Contact DUKANE service

 

 

 

 

 

 

 

 

 

 

 

1.

Ensure parts are loaded properly

 

Vertical servo contact

Welder did not detect

With Part Pickup option enabled

2.

Increase Timeout (s) value

 

with Thrust Sense, part contact was

3.

Check the Position (mm) value – it

 

sensing failed

 

programmed thrust level

 

 

not detected

 

should be set slightly (<5mm) above

 

 

 

 

 

 

 

 

 

 

 

 

expected part contact

 

 

 

Weld cycle stopped

1.

Weld process problem

1.

Check parts to be welded, fixturing,

 

Weld aborted by CYCLE

because cycle time

 

etc..

 

2.

Limits too narrow for weld

 

 

TIME limit

 

exceeded programmed

2.

If practical, widen process limit

 

 

 

process

 

 

 

process limit

 

 

window or adjust setup parameters

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Weld cycle stopped

1.

Weld process problem

1.

Check parts to be welded, fixturing,

 

Weld aborted by ROTATE

because number of

 

etc..

 

2.

Limits too narrow for weld

 

 

limit

 

revolutions exceeded

2.

If practical, widen process limit

 

 

 

process

 

 

 

programmed process limit

 

 

window or adjust setup parameters

 

 

 

 

 

 

 

 

 

Weld cycle stopped

1.

Weld process problem

1.

Check parts to be welded, fixturing,

 

 

 

because motor speed

 

etc..

 

Weld aborted by RPM limit

2.

Limits too narrow for weld

 

 

was outside programmed

2.

If practical, widen process limit

 

 

 

 

process

 

 

 

process limit

 

 

window or adjust setup parameters

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Weld cycle stopped

1.

Weld process problem

1.

Check parts to be welded, fixturing,

 

Weld aborted by THRUST

because weld thrust was

 

etc..

 

2.

Limits too narrow for weld

 

 

limit

 

outside programmed

2.

If practical, widen process limit

 

 

 

process

 

 

 

process limits

 

 

window or adjust setup parameters

 

 

 

 

 

 

 

 

 

Weld cycle stopped

1.

Weld process problem

1.

Check parts to be welded, fixturing,

 

Weld aborted by TORQUE

because motor torque

 

etc..

 

2.

Limits too narrow for weld

 

 

limit

 

was outside programmed

2.

If practical, widen process limit

 

 

 

process

 

 

 

process limits

 

 

window or adjust setup parameters

 

 

 

 

 

 

 

Weld aborted by vertical

Vertical (press) motion

 

 

 

 

 

stopped before spin motion

Excessive press weld speed

Reduce press weld speed

 

servo stop

 

 

 

weld was complete

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.

Weld Time, Rotations, or

1.

Increase Weld Time, Rotations, or

 

 

 

 

 

Distance too short

 

 

 

Weld duration generated by

 

 

Distance above the “Min..” value

 

Weld duration too short

2.

Deceleration too low

 

 

programmed parameters is

NOTE: the time for deceleration is

 

indicated on the Weld Parameters

 

 

 

too short

 

setup screen

 

 

 

counted as part of the total weld

 

 

 

 

 

2.

Increase spin deceleration

 

 

 

 

time or number of rotations

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Weld cycle stopped

1.

Weld process problem

1.

Check parts to be welded, fixturing,

 

 

 

because weld time was

 

etc..

 

Weld ended at TIME limit

2.

Limits too narrow for weld

 

 

outside programmed

2.

If practical, widen process limit

 

 

 

 

process

 

 

 

process limits

 

 

window or adjust setup parameters

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Page  78

Dukane Manual Part No. 403-570-01

Image 84
Contents Dual Servo Spin Welder Dukane Manual Part No Revision History RevisionSummary Date This page intentionally left blank Contents Dukane Dual Servo Spin WelderThis page intentionally left blank Section IntroductionThis page intentionally left blank Important User Information Read This Manual FirstDrawings and Tables Dual Servo Spin Welder Overview SVT042VRKey Dual Servo Spin Welder Features This page intentionally left blank Safety Considerations This page intentionally left blank Health and Safety Tips  CautionRun Switches General SafetyPlastics Health Notice Electrical Safety Mechanical SafetyAC Power Receptacle This page intentionally left blank Unpacking and Setup This page intentionally left blank Unpacking Welder Packing ListWork Area Qty Part NumberSecuring to Work Bench Bench CapacityLeveling Mounting HolesDimensions are in Inches mm Tooling Hub & FixtureAC Power 20-Amp 240V FigureHead Height Adjustment Control ConnectorsBase Interface Connector User I/O ConnectorThis page intentionally left blank Display and Controls This page intentionally left blank Touch Screen Display 1Dual Servo Spin Welder Touch Screen PanelOperational Switches Emergency Stop SwitchData I/O Connector Opti-Touch Run SwitchesThis page intentionally left blank Touch Screen Menus View PartsThis page intentionally left blank RUN Mode Screen LayoutView Parts Setup Menu PRE-WELD SetupTool Setup TOP of Stroke Position Trigger PositionPart Pickup Option Pre-Spin Orientation OptionWeld Setup Weld Method SelectionTime Method Rotation Method Distance MethodEnergy Method Orientation OptionTorque Trigger Option 18Weld Torque Trigger Option ScreenPOST-WELD Setup Hold SetupConstant Torque Option 22Hold Setup Screen for Distance Mode Part Tests 25Process Limit Definitions Screen 128RUN Screen with Part Test Failed Button Select Setup Tab Tools MenuUtilities Tab System Setup Tab Third tab is labeled System Setup and is shown in Figure34Vertical Lower Limit Setup Screen with Set Position Button 35Password-Protected Screens and Menus Setting Time and Date On Touch Screen Screen Parameter Name Min.Value Max.Value Resolution Units Parameter Value RangeThis page intentionally left blank Machine Operation 55-56This page intentionally left blank Machine Setup AC PowerAdjust Thruster Position on Column Base Interface CableReset E-Stop Turn Power onSet Tool Parameters Initialize Home WelderSet Vertical Travel Lower Limit Position Set Weld Process ParametersStarting a Weld Cycle Setup Sheet Stopping a Weld CycleDual Servo Spin Welder Setup Sheet Optimizing Performance This page intentionally left blank Spin Welding Process Material ConsiderationsControl Parameters Surface SpeedRPM Press Axial Speed Weld DepthPart Size HoldWeld Diameter Machine Peak RPM This page intentionally left blank Installation, Startup Welder Data Export SoftwareThis page intentionally left blank Installation Startup, and Cable Connections Hardware Software RequirementsPart Data Part Data ListProfile Graphs File WriteIncoming Data Plot DataServo and Debug Spin Torque SetpointTroubleshooting Welding ProcessThis page intentionally left blank Troubleshooting Welding ProcessWelder MechanicalProblem Symptom Possible Cause Recommended Solution Message Description Cause Possible Solution Instructions FaultsMessage Description Cause Possible Solution Message Description Cause Possible Solution Errors Time or number of rotationsMessage Description Cause Possible Solution This page intentionally left blank Maintenance This page intentionally left blank AC Power Cord MaintenanceThis 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 Tooling Specifications Machine WeightPower Requirements Operating Environment2Dual Servo Spin Welder Dimensions Identification Numbers Welder Model & Serial NumberThis page intentionally left blank Connector Pinouts Appendix aThis page intentionally left blank Base Interface Connector Figure A-1Base Interface ConnectorUser I/O Connector Signal Description FunctionSlide Kit Connector Pin Signal Description FunctionData Port Connector Automation WiringFigure A-5Schematic of Operate and Abort This page intentionally left blank Appendix B ToolingThis page intentionally left blank Moment of Inertia Explanation of InertiaTool and Fixture Design Optional Features Appendix CThis page intentionally left blank Upper Tool Vacuum Figure C-1Upper Tool Vacuum SystemRemote Touch Screen Figure C-2 Remote Touch Screen ComponentsDukane 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.