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Ultrasonic Welders

iQ Series ES Pneumatic Ultrasonic Welding Press System

The most technologically advanced ultrasonic welding systems available today are found in Dukane's iQ Series equipment.  Our patented, 100% digitally-controlled ultrasonic generator, ultra-rigid press, coupled with the iQExplorer user-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 ultrasonic welding 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.

  • Ultrasonic 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.

iQ Press 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.