Section 9 - Troubleshooting
Table
Problem
Symptom
Possible Cause
Recommended Solution
| Excessive weld flash | Weld Time or Distance are too large | Reduce Weld Time or Distance | |
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Overwelding | Welded assembly | Incorrect flash trap design | Evaluate and correct flash trap design | |
| dimensions are too |
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| small |
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| Low strength weld | Weld Time or Distance are too small | Increase Weld Time or Distance | |
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Underwelding | Welded assembly | Material difficult to weld due to low friction | Degrease joint interface to remove mold release | |
coefficient | agent | |||
| dimensions are too | |||
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| large |
| Consider changing material (i..e.. avoid PTFE) | |
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| Warped parts | Check part dimensions | |
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| Uneven weld interface | Check molding process conditions | |
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| Fixture and part are not parallel | Level fixture where necessary | |
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| Check that tooling is true to table | |
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| Poor alignment of parts in tool and/or | Change part or tool dimensions | |
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| fixture |
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| Excessive weld flash |
| Improve part tolerance due to cavity | |
| Low weld strength | Insufficient fixture support | Check for parts shifting during welding | |
Nonuniform or |
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| Provide features in parts for rotational driving (i..e.. | ||
inconsistent | Failure when leak |
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weld joints |
| drive ribs or cavities) | ||
tested |
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| Part walls flexing during weld | Redesign parts with reinforcing ribs and/or tongue- | ||
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| Part failure in service |
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| Excessive filler or uneven distribution | Reduce amount of filler | |
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| Improve processing conditions to ensure even | |
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| distribution of filler | |
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| Moisture in parts | Prevent moisture absorption after molding prior to | |
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| welding | |
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| Dry parts before welding | |
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| Deceleration too low | Increase spin deceleration as high as possible (if | |
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| set too high, welder will fault with tracking errors) | |
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| Vertical speed too high | Reduce speed to decreased spin torque required | |
Final part |
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orientation | Parts not aligned |
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Poor tuning | Determine and enter tool inertia correctly into Setup | |||
different from | ||||
properly | ||||
programmed |
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orientation |
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| Contact DUKANE for special tuning requirements | |
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| Parts not held properly by tool or fixture | Ensure tooling does not allow excessive play | |
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Dukane Manual Part No. | Page 75 |