Custom Engineering
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Specialized Equipment Group

We are known throughout the industry for our willingness and ability to meet our customers' specialized needs. The design of our products encourages innovation so that any configuration, from standalone, single-station systems to fully integrated automation, is possible.

Our capabilities include:

• Integration of our assembly equipment into new or existing machinery
• Custom system design and construction
• Custom software development

Our flexible approach:

• Work with your preferred machine builder
• Partner with specialized machine builders
• Build custom machines to your specifications at Dukane

Regardless of the method, working with Dukane's Specialized Equipment Group has many advantages:

• We are a large and stable resource
• We do basic research and we manufacture machines
• We are experts in thermoplastic assembly and ultrasonic welding
• We have the knowledge, experience, and expertise to recommend the best technology, the correct process, and the proper equipment for the assembly task
• We have the people, products and demonstrated technical service and support to serve your assembly needs worldwide

From simple to complex, Dukane can design and build an assembly system for your application(s). Many of the systems we build feature servomotors, optical part sensors, indexing tables and sound enclosures.
　

Custom Engineering Examples

Lean Manufacturing Cell designed for the manual assembly of plastic components to accommodate Ultrasonic, Spin or Heat Staking applications. The main features of the cell are size, safety, ergonomics and robust construction. The Lean cell has a small foot print, while still providing significant workspace for the application. The unique compact safety enclosure is only as large as the equipment inside, leaving more table workspace for staging parts while the equipment cycles. Safety was the driving factor in the design of this work cell. Features like OSHA approved anti-tie down activation switches and all electronically interlocked panels are standard. Pneumatics include an OSHA lock out device and filter regulator with soft start dump valve, providing an extra level of protection during equipment maintenance and setup. All interactions are within the ergonomic reach zone of a sitting operator, which include user interface placed in operator's line of sight, part load area is obstruction free and open on all three sides thanks to the unique door design and an operator foot rest is provided. Press Release

Two Position Assembly Station for plastic assembly can be used for heat staking, spin welding or ultrasonic assemblies. The machine can handle larger plastic assemblies 12 x 6 x 8 inches and has a rotary two position pneumatic reciprocating table, allowing the operator to load the machine while welding. The assembly station has a push button interface and PLC control or an optional HMI touch screen interface. Other features include lexan guarding with lockable doors, casters with leveling feet, dust enclosure for generators, light curtain and vertically sliding pneumatic door.

Dual Welder Rotary Work Cell has a 40" dial on a Camco indexer and two-up tooling, thus double the throughput. The work cell includes part placement and color detection. Miss-loaded parts are automatically returned to the operator. A three-position pneumatic pick-n-place removes completed assemblies and separates suspect bad parts. Two 3000 watt DPC IV Plus systems provide precise weld process controls and consistency feedback. The weld area is fitted with a vacuum to eliminate particulate. The work cell is equipped with an Alan Bradley touch screen user interface with detailed error codes. Quick-change weld nests prevent incorrect parts from being loaded and part orientation errors. The work cell has a compact 60" x 72" footprint.

	Servo-Control X-Y positioning System for Plastics Assembly was developed by Dukane for a project requiring multiple posts welded on a large automotive instrument cluster. The Machine includes a precision, servo-controlled x-y positioning stage with +/-.001 repeatability. The stage includes provisions for up to three quick-change nests. Each nest can contain up to 99 weld points, three part presence sensors, nest vacuum and pneumatic clamps. Weld positions are programmed via the touch screen and can be called up at will for partial assembly tasks. The pictured system includes the ultrasonic welder DPC level IV 2200-watt thruster with time, distance and energy controlled welding plus weld quality monitoring modes. 　 View movie of Servo-Control X-Y Positioning System File Size:  25 MB Requires a broadband internet connection for viewing
	Turnkey Ultrasonics Workcells handles automotive door assemblies. A solid structural bridge eliminates deflection and accepts ultrasonic, thermal or spin-welding thruster heads. Each thruster has easy access and is independently adjustable. The welding process remains visible because of the open-guarding design. Operator controls include part presence feedback for each component, Good/Bad part signals, Cycle Complete signal and manual operation of individual thrusters.
	6-Axis Robotic Welder was built in less time than a conventional multi-headed design. The robotic arm provides a wide range of welding application flexibility. The system features quick-change fixtures with a changeover time of less than two minutes. Fixtures can contain multiple part nests and two groups of clamps, multiple part sensors and two nest vacuum systems. Fixture ID features automatically recall the correct robot program as the fixture is installed (accepts up to five fixtures, each with multiple nests). A mini-thruster on the robot arm automatically compensates for part thickness variation or part warpage, increases the maximum allowable weld pressures without overloading the robot, and provides digital control of the weld pressure via simple touch-screen commands, without having to understand the robot programming language. Manual ultrasonic horn changeover takes less than five minutes. With horn zeroing tooling incorporated into the fixtures, Dukane can provide tooling accompanied with a robot program as new applications arise. 　 View movie of 6-axis Robotic Welder File Size:  16 MB Requires a broadband internet connection for viewing
	Dual Station Ultrasonic Work Cell has a unique design that incorporates two independent weld stations into one compact work cell. Perfect for right and left hand assemblies that require only one operator and minimal floor space. Each station has independent three-position in/out fixture shuttle for ease of load and unloads. Each load station has their own light curtains along with DPC II plus ultrasonic power supplies featuring Dukane’s Patented MPC (Multi-point Control), and bright work lights. The quick-change part holding fixtures have part sensing and clamping for positive alignment and placement detection. The ultrasonic actuators have hydraulic speed control, solid bottom stops, adjustable trigger force switch, pressure gauge and flow controls. They are mounted on a mechanical knuckle that provides x, y, rotational and angular adjustment. This feature is great for contoured assembles that require precision horn alignment to reduce weld marking to class A surfaces. Electrical controls are handled by Control Logix PLC and Panel View Plus touch screen. The user friendly interface software provides manual activation of each sequence for ease of machine setup. Detailed error codes, bad or suspect part alarms, and a part presence map is available.
	SRT-300 Rotary Parts Handling System is designed for economical semiautomatic operation with a freestanding base, welder, 6-station rotary table, dial plate, and safety guarding. Welding, staking, inserting, swaging, and spot welding are compatible welding applications where medium to heavy-duty service is required. Systems are available with part sensing, clamping, automatic eject, suspect bad part separation and other features. The system operates in two modes: one index at a time or at a continuous timed rate.
	Heat staking work cell is ideal for larger plastic applications that require multiple posts staked. It’s designed for applications such as exterior and interior automotive trim, appliance panels’ and large consumer electronic devices. What is unique about this machine is that the independent actuators attach to a solid horizontal bridge, versus other machine designs that incorporate a large moving platen. The independent actuators and universal mounting plates allow relocation of the thrusters and retooling for other applications. Each actuator can be adjusted in the x, y and z-axis, and permits rotational and angular adjustments, to deal with applications that have a contoured shape. When heat staking, the best post strength is achieved when the speed at which the staking tool compresses the post matches the melt velocity of the plastic material. Hydraulic speed control on each actuator provides this advanced level of melt speed control. The thermal controls are modular and can be easily upgraded by the user to add more staking points. Additional PLC expansion is available to add more part clamping, sensing, position sensors and other features in the future. User friendly operation is achieved through a color touch screen HMI and one touch cycle initiation. Safety guarding is on three sides with a light curtain across the operator load area, along with a bright work light. Nests are made from urethane which has been poured to Renwood that is machined directly from customer part CAD data, to eliminate marking of the class A surface of the parts. The lower fixture nest is mounted on a two-position linear ball bearing slide. Servo programmable stop positions are optional. The slide mechanism gives the operator the ability to load the parts at a safe, comfortable distance from the heated thermal tips. Locking casters, leveling feet and fork tubes are available.
	This is a Four-headed staking machine built to use a contoured fixture. The sound enclosure includes single-point activation and a sliding door for safety and sound control.
	An X-Y sliding table for welding a taillight lens. Unique design considerations allowed one horn to be used for a family of different parts.
	This Mini Hot-Plate welder is used to weld cylindrical air filters and the inner support cage to thermoplastic end caps. The system takes up only one fourth the floor area of a conventional unit. It can be ordered with heavy duty casters making it easy to position the welder in your plant. Many applications similiar to this are performed during the molding cycle press side.
	Continuous Feed Tube Seal Cell Unit incorporates dual rigid C frame ultrasonic sealers capable of sealing tubes up to 3” or multiple smaller tubes. This configuration seals tubes horizontally. However, the C frame sealer can be mounted in any orientation. The parts are directly loaded by a separate robot into the welding fixtures. A variable frequency drive and cam indexer automatically checks for part presence, validates part location, feeds the parts to the weld station and separates the parts into lot bins or a suspect bad part bin. This unit is designed for MEDICAL applications; all components have corrosion and particulate deterrents while the positively pressurized enclosure has a class 100,000-filtration system. The ultrasonics used for this application is the most advanced in the industry - Two DPC IV plus probe systems with Time, Distance, Energy, Adjustable Amplitude control and monitoring features. This unit is designed to run 24/7 without an operator. Depending on tube size the cell can produce up to 240 parts per minute

Contact Dukane

For information on custom assembly systems, please contact our Sales department:

Tel:  (630) 797-4900  
Fax: (630) 797-4949     

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