The most technologically advanced ultrasonic welding systems
available today are found in Dukane's
iQ Series equipment. Our
patented, 100% digitally-controlled generator, ultra-rigid press,
coupled with the iQ Explorer ser-interface provides superior
accuracy and ease of use. The generators have new multi-core
processor technology that allows them to operate at a processing
rate of .5 milliseconds. Lockable front panel controls and
position indicators make press systems easy to set up, and they are
perfect for applications requiring machine validation.
iQ
Explorer's intuitive touch-screen graphical menu structure
incorporates a one-page setup screen that makes welder operation
easy to learn and program. Ethernet connectivity, wireless
networking, and multiple USB ports are all options for weld and
graph data storage. Over 25 programmable upper and lower
process limits along with reference, weld graph logic is available
for weld diagnostics and process consistency.
Welder setup parameters are all digitally controlled
and can be calibrated to meet FDA and ISO requirements
Multi-level password options eliminate unauthorized
changes to weld program, assuring part quality and consistency
Weld by time, energy, distance, absolute distance, peak
power and ground detect.
15, 20, 30, 40 kHz frequencies available.
180 - 4800 watt versions, true RMS power.
iQ Generator/Power Supply
Features
iQ Press Features
Rugged construction using the highest quality
components provides superior performance precision and
reliability.
Compact, single-rail linear ball slide assembly
system
offers accurate positioning, stable movement, and
friction-free resistance
Dual pressure increases clamp force to
improve melt during the weld cycle, or to provide
tighter assembly during the hold cycle.
Optional hydraulic slow speed available for
precise, repeatable control of horn travel during the
weld cycle.
7" (178mm) stroke with mechanical bottom stop
adjustable in .001"(.025mm) increments
Top-of-stroke limit switch for automation
application
All controls are accessible from the front
for convenient set-up and operation.
Easy to use front panel position indicators
with universal icons instantly show settings of position
and bottom stop, and optional slow speed, pre-trigger,
and end-of-weld switches
Chrome-plated column and titanium booster are
standard
Internally mounted optional linear encoder
saves space in multi-head and automated installation
Remote pneumatics availability offers
increased flexibility in system integration
OSHA-required lockout for air supply is
standard
Ergonomic base and cycle activation switches
reduce operator fatigue
Status indicators in base for Power, In
Cycle, and Abort clearly communicate system conditions
Twist-release emergency stop switch meets
international safety standards
Press/thruster design provides systems
flexibility and upgradeability, reducing equipment
investment.
Ultra-Ridged support provides reduced
deflection for superior weld consistency. Column
crank and gas strut assist ensures easy setup.
Column can be locked to eliminate unauthorized
adjustments. Standard style support columns
available.
iQPress Options
Hydraulic Speed Control offers precision
hydraulic control of the melt velocity. This is
critical to achieve maximum weld strength in staking,
inserting and shear joint applications.
Magnum Transducer provides a 25% boost in
amplitude Consult Dukane about suitability/application
of this option.
Patented Resonant Mount Booster
Longer Press Columns to increase part load
area height.
Custom Air Cylinder 1.50" (38mm), or
2.00"(51mm) and 3.00" (76mm) diameters.
19" (483mm) Rack or Press-mounted generator
option.
Systematic Ultrasonic Assembly (SUA) training
computer based interactive training modules.
Modules include: Basic Ultrasonic Assembly,
Advanced Ultrasonic assembly and Advance Process
Optimization.
Digital Features
100% digital control
of all power supply functions and
parameters allows for unique configurations and future
upgrades or requirements. Includes digital frequency
syntheses
Industry leading data acquisition rate speed of
.5 ms due to advanced multi-core architecture.
Increased weld accuracy and repeatability.
Digi-Trac
tuning automatically tracks the resonant
frequency digitally. Adjust the output frequency to
match the acoustic stack (sonotrode, booster, and
transducer) this is done for every weld cycle and eliminates
the need to manually tune the generator.
Ultrasonic overload protection, with status indicator for
ease of troubleshooting. The overload power limit is
based on true RMS power output level.
Line Voltage Regulation
compensates for line
fluctuations assuring consistent amplitude.
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.
Linear Ramp Soft-start
algorithm allows the
acoustic stack to be brought to operating amplitude
smoothly, minimizing start-up surges and abnormal stress
to stack and power supply.
Load Regulation provides constant ultrasound
amplitude automatically regardless of the power draw.
The ultrasonic output amplitude level is held to within
1% to provide weld process consistency and reduced weld
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.
RS232 serial configuration port is used for
field software upgrades, troubleshooting and advance
hardware setup with optional PC based
iQ configurator.
Advanced i/O is standard with 25-pin output,
and 15-pin input, user configurable from the utility
menu.
Unique Patent pending modular hardware design
incorporates motherboard/interconnect of internal
components. Reduces internal cabling while
increasing reliability and performance.
Rear panel expansion slots are available to
allow for custom configurations for OEM and cost
effective custom solutions.
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.
Data Sheet:
