Medical Device Assembly with Servo Ultrasonic Welding

Eliminate part to part variations, get desired weld strength, and easily validate your welding process with iQ Servo Ultrasonic Welder and Melt-Match® technology.

Watch the video to learn more.

Melt-Match® technology precisely matches the velocity of the ultrasonic stack with the melt flow velocity of the plastic material ensuring optimum molecular intermingling. This produces stronger, more reliable weld results when compared to pneumatic systems.

Melt-Detect™ feature, also referred to as Force Drop ensures complete initiation of melt before prompting the press to initiate downward movement. Melt-Detect™ is especially useful for applications where it is difficult to achieve the required amplitude to melt the parts.

ADVANTAGES OF MELT-MATCH & INFINITE SERVO MOTION CONTROL

Infinite programmable down-speed for increased throughput.
Soft-Touch Trigger Control – Dynamically reduce speed during the brief trigger phase or completely stop all downward motion after trigger force has been achieved.
Dynamic Melt Initiation – ensures critical weld joint geometry is not disturbed or damaged during trigger phase.
Infinite programmable velocity/force control during the weld cycle. Can be programmed as constant velocity/force or multi-step profiled velocity/force.
Multi-Step Amplitude Profiling – Velocity profiles can be linked to multi-step amplitude profiling for enhanced weld process optimization.

CLICK HERE to learn more about iQ Servo Ultrasonic Welding system.

Testimonials

Accuracy & Repeatability

iQ Servo

Our R&D department had a Branson Ultrasonics AED 3.0, but was looking for increased accuracy and repeatability in our welding process. Our manufacturing representatives had experience with Dukane and suggested we should work with the Dukane iQ Servo Welder. The iQ Servo was easily able to achieve our requirements and the simple iQ Explorer II applications software was intuitive. This made process development and optimization very efficient and straight forward.

Chris Redman

Alcon

R&D Engineer

Datasheet

Process Control

iQ Servo

A small plastic stem was being damaged during welding and we were unable to optimize the weld settings on our pneumatic sonic welder. By integrating iQ Servo Ultrasonic Welder with patented Melt-Match® technology; we were able to quickly eliminate the plastic port stem damage problem. The data we collected during the servo process optimization proved to have a tighter standard deviation and a significantly higher process capability (Cpk). The ability to weld at a constant velocity and/or program a custom weld velocity profile greatly improved the welding process. Melt-Match® technology provided stronger weld.

Thim Le

Bard Access Systems, Inc.

Process Engineer

Datasheet

Consistent Results

iQ Servo

The absolute elimination of scrap is a dream come true for our production pipeline. Precise control of horn movement and Dukane’s patented Melt-Detect™ feature in iQ Servo has proven very beneficial for our application. The biggest relief is being able to easily set up a recipe and having the confidence you will get the same weld cycle after cycle, all because of Melt-Match® Technology.

Medical Device Manufacturer

Operations Manager

Datasheet