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Ultrasonic Welders

iQ Series LS Ultrasonic Power Supply

Dukane iQ LS Ultrasonic Power Supplies were designed specifically for automated ultrasonic systems for the automotive, aerospace, packaging, textile, and food industries.

  • Available in bench top or panel mount.
  • The iQ series ultrasonic generators and power supplies are all built around our patented digital design. Compact in size, they provide the highest power density in the smallest package, while incorporating our exclusive flow through cooling.
  • These ultrasonic generators are designed to handle the toughest applications and environments, capable of operating either in continuous duty or high-speed automation.
  • Our industry leading 0.5 millisecond multi-core processing speed provides the highest level of accuracy and repeatability.
  • The unique modular design allows for custom configurations and ultimate flexibility.

Flow Through Cooling

 

Trigger by Power (U.S. Patent 7,475,801)

The feature provides more consistent welds by providing a sufficient and repeatable amount of pressure/force to be applied to the part before the weld cycle starts. Trigger by Power is a cost effective alternative to Trigger by Force. However, unlike Trigger by Force, Trigger by Power does not require additional, expensive components such as a load cell, amplifier board and cabling. The system uses the ultrasonic stack as a load cell. When the ultrasound is activated, the amplitude is ramped up to the Trigger Amplitude setting and held there until enough force is applied to the part to reach the Trigger Power settings. At that point the weld cycle begins and continues until the weld control parameter (Time, Energy or Power) is reached. For details see Dukane Application Note 506.

Panel Mount Generators

 

iQ Generator/Power Supply Features

Digital Features

  • 100% digital control of all power supply functions and parameters allows for unique configurations and future upgrades or requirements. Includes digital frequency synthesis.
  • Industry leading data acquisition rate speed of .5 ms due to advanced multi-core architecture. Increased weld accuracy and repeatability.
  • Three step system safe power up sequence 1) AC line inrush current protection, 2) Supervisory System Monitor 3) Plug and Play configuration ID.
  • Digi-Trac tuning automatically tracks the resonant frequency digitally. No need to manually tune the generator during every weld cycle. The output frequency adjusts itself to match the acoustic stack (sonotrode booster and transducer).
  • Ultrasonic overload protection, with status indicator for ease of troubleshooting. The overload power limit is based on true RMS power output level.
  • Temperature Drift Compensation allows for seamless acoustic stack operation, and automatically compensates for acoustic stack temperature changes
  • Patented Pulse-Width Modulation design delivers power more efficiently with substantially less stress on the electrical and acoustic components for superior performance, reliability and extended life.
  • Selectable frequency lock and hold feature system ignores digi-trac automatic tuning feature and locks to startup stack frequency - helps in difficult applications where the stack couples with a product.
  • Programmable frequency bandwidth, three selectable factory settings or user programmable windows for unique acoustic stacks and applications.

  • User-accessible programmable advanced hardware settings allows changes to Free Run Frequency, Frequency Lock/Hold and Frequency Limits - providing advance settings for difficult acoustic stacks.
  • Integrated Digital Frequency Readout accurately displays operating frequency of the acoustic stack. This is perfect for acoustic stack diagnostics.
  • Amplitude adjustment in 1% increments from 100% to 20%, through front panel or remotely (Optional 4-20mA analog, Profibus, EtherNet I/P or RS 232).
  • Line and Load Regulation amplitude is maintained independent of load force and incoming line voltage variations. Through a closed-loop amplitude control, the amplitude regulation maintains output amplitude be correcting for fluctuations in line voltage and output power loading. Maintained within 1% to provide weld process consistency and shorter cycle times.
  • Programmable Digital Linear Ramp Up algorithm allows the acoustic stack to be brought to operating amplitude smoothly, minimizing start-up surges and abnormal stress to the stack and power supply. This can be shortened to accommodate faster cycle times and lengthened to accommodate larger sonotrodes/horns.
  • Programmable Digital Linear Ramp Down allows the acoustic stack amplitude to be brought down from operating amplitude to zero in a controlled manner. Eliminates unpredictable acoustical ring down for better weld quality, longer stack life and potentially faster cycle times.

Mechanical Features

  • Flow Through Cooling tunnel with a matched high performance heat sink and thermostatically controlled fan reduces thermal gradients, minimizes dirt infiltration and increases component life.
  • Highest power density per unit of volume.  Most power in the smallest package at highest duty cycle.  Low and high profile configurations available.
  • Patented modular hardware design incorporates motherboard/interconnect of internal components.  Reduces internal cabling while increasing reliability and performance.
  • Advanced i/O is standard with 25-pin output, and 15-pin input, user configurable from the utility menu.  
  • Standard 19" (48cm) Rack mountable for easy system integration at minimal cost.
  • Compatibility with all Dukane standard transducers, helps reduce inventory requirements and provides interchangeability with your existing DPC or Ultra series components

Menu Controls

  • Primary and secondary weld control parameters Time, Energy, and Peak Power.
  • Bad and suspect process limits include Time, Time and Energy and Peak Power, with discrete outputs.  These programmable limits provide the means to adapt to a wide variety of welding applications.
  • Amplitude adjustment in 1% increments from 100% to 20% through front panel or remote (4-20) mA. 
  • 16 setups with individual user ID.
    (including Amplitude %)
  • Programmable softstart and softstop amplitude can be used to reduce stress on acoustic stacks, or for high-speed application to achieve full amplitude in as short as .010 seconds.  Factory configurable settings also available.

  • User-accessible programmable advanced hardware settings allow changes to Phase Shift, Free Run Frequency, Frequency Lock/Hold and Frequency Limits - providing advance settings for difficult acoustic stacks.
  • Selectable frequency lock and hold feature system ignores digi-trac automatic tuning feature and locks to startup stack frequency helps in difficult applications where the stack couples with a product.
  • Programmable frequency bandwidth,three selectable factory settings or user programmable windows for unique acoustic stacks and applications. 
  • Afterburst control includes delay and duration time settings.