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Ultrasonic Welders

iQ Series LE Pneumatic Ultrasonic Press System

Power and Frequencies
1200w | 2400w | 3600w - 20kHz
3600w | 4800w - 15 or 20 kHz

 

Dukane iQ Series LE ultrasonic welding systems are an entry level machine designed for applications that require significantly less process documentation, yet are built on the robust precision mechanical platform as our full featured machines. Available in either 20 kHz or 15 kHz in power ranges from 1200 - 4800 watts. Two main models offer either Time and Energy or Time Energy and Distance. While the LE is an entry level machine advance features like Process Limits, .5 millisecond sample rate, separate Weld and Hold pressures and multiple setup recipe storage with front panel lock out come standard on all LE models.

Easy Fault is exclusive to iQ power supplies. System faults and alarms prompt a fault code (i.e. U501). Enter the code at http://www.dukane.com/easyfault and the easy fault search will provide addition tips and process improvement information. Thus expediting fault /alarm solutions and reducing down time.

Distance Module and Linear Encoder

  • Weld by distance mode controls the melt collapse distance to insure that the same volume of material melts on each part so that the finished joint strength is consistent.
  • Weld by Position controls the finished part height to yield uniform assemblies.
  • All distance parameters (downstroke, trigger delay, weld, hold, absolute weld, total weld, and total stroke distances) are monitored, with upper and lower limits for bad and suspect parts to verify quality and consistency.
  • High quality linear optical encoder with a one-micron resolution for excellent precision and repeatability.
Power and Energy Module
  • Weld by energy mode delivers a specific amount of energy to the work to enhance process control.
  • Monitors all power and energy parameters with upper and lower limits for bad and suspect parts.

Automation Interfacing

Dukane's iQ LE modular welders can be interfaced with external devices and controls (e.g., PLCs). This will require both a 15 pin input cable and 25 pin output cable (optional). Inputs include, 8 Remote Setup Switching, Front Panel Security Lock Out, Reset Latch Input and Cycle Activation. Outputs include 22VDC to power users automation controls, Multiple Programmable status, Numerous fault status, including Good, Bad and Suspect Part, Power Monitor Out and Amplitude Monitor output.

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 travel.
  • 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.

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.
  • 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.
  • Ultra Series Press Compatibility card allows for seamless connection to legacy Duknae Ultra Series welders.

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.