Dukane 403570-01 user manual

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www.dukane.com/us

Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797–4949

Dual Servo Spin Welder

User’s Manual

ISO 9001:2000

Dukane products are manufactured

in ISO registered facilities

Intelligent Assembly Solutions

DUKANE Part No. 403–570-01

Contents

Main Dual Servo Spin Welder Users Manual ISO 9001:2000 Intelligent Assembly Solutions Page Page Page Dukane Dual Ser vo Spin Wel der Contents Page SECTION 1 Introduction Page WARNING Important User Information Read This Manual First Notes and Tips Cautions and Warnings Drawings and Tables Dual Servo Spin Welder Overview Key Dual Servo Spin Welder Features Page SECTION 2 Safety Considerations Page Always wear a face shield when operating the welder. Wel ded par ts m ay b e ho t. Health and Safety Tips Plastics Health Notice Run Switches General Safety Electrical Safety AC Power Receptacle Grounding Mechanical Safety Page SECTION 3 Unpacking and Setup Page Unpacking Welder Packing List Work Area WARNING Securing to Work Bench Bench Capacity Leveling Mounting Holes Page AC Power Head Height Adjustment Control Connectors Base Interface Connector User I/O Connector Slide Kit Connector Page Page Page Touch Screen Display Operational Switches Emergency Stop Switch OptiTouch Run Switches Data I/O Connector Page SECTION 5 Touch Screen Menus Page RUN Mode Screen Layout VIEW PARTS SETUP Menu PRE-WELD Setup TOOL Setup TOP OF STROKE Position TRIGGER Position Part Pickup Option Pre-Spin Orientation Option WELD Setup Weld Method Selection Time Method Rotation Method Distance Method Energy Method WELD OPTIONS Orientation Option Torque Trigger Option Constant Torque Option POST-WELD Setup Hold Setup Page Part Tests Page TOOLS Menu SELECT SETUP Tab UTILITIES Tab SYSTEM SETUP Tab Page Page Setting Time and Date On Touch Screen Parameter Value Range The minimum and maximum values of the welding parameters are listed in Table 5-I. Page Page Page Machine Setup 1. Base Interface Cable 2. AC Power 3. Attach Tooling 4. Adjust Thruster Position on Column 5. Reset E-Stop 6.Turn Power ON 7. Set Tool Parameters 8. Initialize (Home) Welder 9. Align Lower Fixture with Spin Tool 10. Set Vertical Travel Lower Limit Position 11. Set Weld Process Parameters Starting A Weld Cycle Page Dukane Manual Part No. 403-570-01Page 56 DUAL SERVO SPIN WELDER - SETUP SHEET SVT0___2VR SECTION 7 Optimizing Performance Page Spin Welding Process Material Considerations NOTE Control Parameters Surface Speed RPM D Press (Axial) Speed Weld Depth Hold Part Size Page SECTION 8 Welder Data Export Software Page Introduction Hardware and Software Requirements Installation, Startup, and Cable Connections Part Data PART DATA List CLEAR WRITE TO FILE File Write Prole Graphs Plot Data Plot Spin Torque Setpoint WRITE TO FILE Servo and Debug SECTION 9 Troubleshooting Page Welding Process Material Choice Parameter Effects Surface Speed Axial Speed Welder Dukane Manual Part No. 403-570-01 Page 75 Table 9I Welding Process Troubleshooting Problem Symptom Possible Cause Recommended Solution Dukane Manual Part No. 403-570-01Page 76 Table 9-II Machine Display Messages Instructions Faults Dukane Manual Part No. 403-570-01 Page 77 Table 9-II continued. . . Dukane Manual Part No. 403-570-01Page 78 Errors Dukane Manual Part No. 403-570-01 Page 79 Page Page Page Touch Screen Display AC Power Cord Maintenance Page Page Page Contacting Dukane Identify Equipment Intelligent Assembly Solutions Page SECTION 12 Specications Page Tooling Specications Tooling Size Machine Weight Power Requirements Operating Environment Page CE Marking Regulatory Agency Compliance Identication Numbers Page Page Page Base Interface Connector 5 4 3 2 1 6 10 15 14 13 12 11 User I/O Connector Slide Kit Connector Data Port Connector Automation Wiring Page Page Page Page USEFUL UNIT CONVERSIONS 1 in. = 2.54 cm = .025 m 1 lb. = 0.45 kg 1 cm = 0.39 in. 1 m = 39.4 in. 1 kg = 2.20 lb. Moment of Inertia Explanation of Inertia Calculating the Moment of Inertia Tool and Fixture Design Page Page Upper Tool Vacuum Remote Touch Screen Dukane ISO ISO CERTIFICATION CERTIFIED ISO 9001:2000