Dukane 403-570-01 user manual Dual Servo Spin Welder Overview, SVT042VR

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Dual Servo Spin Welder User’s Manual

Dual Servo Spin Welder Overview

The Dual Servo Spin Welder excels at frictional welding of assemblies and parts which require accurate angular orientation and collapse distance. The parts can be any shape and only the weld joint must be circular. The welder uses two electric servos: a servo motor for spinning the tool, and a servo actuator for moving the machine head up and down. Both servos have high- resolution encoders, enabling accurate process control.

Dukane offers three models: SVT012VR, SVT032VR, and SVT042VR. Model differences are in the maximum speed, power and torque of the spin servo motor (the same vertical servo actuator is used in each).

Model specifications:

SVT012VR

750 RPM, 4.2 HP, 47 ft-lb Torque Spin Motor

SVT032VR

3,000 RPM, 4.2 HP, 16 ft-lb Torque Spin Motor

SVT042VR

4,000 RPM, 2.5 HP, 10 ft-lb Torque Spin Motor

All models have a 5-inch stroke, a fixture throat depth of 8-inches, and a vertical maximum thrust of 700 pounds. Both SVT032VR and SVT042VR models have the same maximum vertical clearance of 21.3 inches (541 mm) between the bottom of the tooling hub and top of the mounting base. The SVT012VR model has a clearance of 20.4 inches (518 mm).

The Dual Servo Spin Welders were designed to provide a reliable, long, and economical service life and meet the applicable CE regulations.

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Dukane Manual Part No. 403-570-01

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Contents Dual Servo Spin Welder Dukane Manual Part No Revision Revision HistorySummary Date This page intentionally left blank Contents Dukane Dual Servo Spin WelderThis page intentionally left blank Section IntroductionDukane Manual Part No Read This Manual First Important User InformationDrawings 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  CautionGeneral Safety Run SwitchesPlastics Health Notice Mechanical Safety Electrical SafetyAC Power Receptacle This page intentionally left blank Unpacking and Setup This page intentionally left blank Work Area Unpacking WelderPacking List Qty Part NumberLeveling Securing to Work BenchBench Capacity Mounting HolesDimensions are in Inches mm Tooling Hub & FixtureAC Power 20-Amp 240V FigureBase Interface Connector Head Height AdjustmentControl Connectors 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 SwitchOpti-Touch Run Switches Data I/O ConnectorBrigtly Lit Red LEDs This page intentionally left blank Touch Screen Menus View PartsThis page intentionally left blank RUN Mode Screen LayoutView Parts PRE-WELD Setup Setup MenuTool Setup TOP of Stroke Position Trigger PositionPart Pickup Option Pre-Spin Orientation OptionWeld Method Selection Weld SetupTime Method Rotation Method Distance MethodEnergy Method Orientation OptionTorque Trigger Option 18Weld Torque Trigger Option ScreenHold Setup POST-WELD SetupConstant Torque Option 22Hold Setup Screen for Distance Mode Part Tests 25Process Limit Definitions Screen 128RUN Screen with Part Test Failed Button Tools Menu Select Setup TabUtilities 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 Adjust Thruster Position on Column Machine SetupAC Power Base Interface CableSet Tool Parameters Reset E-StopTurn Power on 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 SpeedSpin Rev/minSpeed Average Weld Diameter inchPress Axial Speed Weld DepthHold Part SizeWeld 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 ListIncoming Data Profile GraphsFile Write 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 Ultrasonics Division Contacting DukaneIdentify Equipment WebsiteThis page intentionally left blank Specifications This page intentionally left blank Power Requirements Tooling SpecificationsMachine Weight 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