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Jake Kowalewski
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Phone: 630.485.1182
September 17, 2019

New LFVW 6970 with Melt-Match®, a Patented Servo Technology.

Dukane introduces LFVW 6970 with Melt-Match®, a new line of servo-driven low-frequency vibration welding technology designed to weld large parts with servo precision.  LFVW simplifies the low-frequency vibration welding process, provide faster cycle times driven by high-speed servo motors and improves weld quality and consistency with a precision welding process. Dukane designed LFVW to have a single piece construction which includes a control cabinet, sound enclosure, and a robust frame to reduce installation time and cost for the user. It eliminates disassembling and assembling of the machine between site to site movement and provides longer machine life while reducing rigging cost. With the LFVW 6970, Dukane is extending its proven and reputable Melt-Match® technology to the Low-Frequency Vibration Welding process. Melt-Match® is a Dukane patented plastic welding process to repeatably detect melt transition from solid to a molten state, then accurately controlling the melt flow of a thermoplastic material during the weld and transitioning from the molten to solid-state.

LFVW6970-Low Frequency Vibration Welding
LFVW6970-Low Frequency Vibration Welding

LFVW 6970 with Melt-Match® provides an infinite number of features to accurately control all phases of the vibration welding process, ensuring you achieve a quality weld on all your parts. Reduce cycle time and ensure consistent welds with a servo drive and servo controller that deliver the fastest approach and always provides the optimal contact force. With Melt-Match®, Dukane provides better force sensing and digital force read-out, giving you better control of the trigger and welding force. This patented Melt-Detect™ feature resumes motion once the plastic material has started to melt. By using Melt-Detect™ a user can avoid weld joints deformation and cold welds during the welding process, get uniform melt, and a hermetic seal. Melt-Match® parameters control the welding process “in motion” with real-time closed-loop force control in addition to the real-time velocity control. Force and weld velocity can be programmed in 10 independent segments to match the melt flow rate of the material.

LFVW 6970 is Industry 4.0 ready providing remote connectivity for faster diagnosis, data acquisition, and service via most prevalent industrial communication protocols LFVW 6970 is equipped with Dukane’s proprietary and easy to use HMI software to deliver the most efficient process control by providing real-time graphing of amplitude, force, and collapse distance, with additional data to control, monitor, diagnose, and evaluate the welding process. The HMI software can store up to 200 Weld Setups/Recipes for the continued success of different parts or manage parts from different vendors. On tool controls assure parts are present, held in place, and reduce manual errors, all LFVW 6970 welders will be able to be programmed for multiple valves, part presence sensors, and tool IDs.  Dukane is committed to making the LFVW 6970 Series easy to deploy worldwide and offers this new welder in multiple languages (English, Spanish, German, Japanese, Chinese, French, and Czech)

By incorporating all servo-driven controls LFVW 6970 eliminates hydraulic power unit but inherits all the other proven mechanical features of Dukane’s previous generations of Vibration Welders. It includes four continuously supported rails with eight reciprocating bearings to eliminate table chattering, improve table alignment, and eradicate unwanted machine resonance. Large mechanical mass of the linear vibration head coupled with the solid welded tubular steel frame construction eliminates machine failure due to vibration process and provides one of the quietest machines in the industry, reducing operator fatigue. Optional automatic load/unload station, indexing part conveyors, adjustable safety switches and quick tool changing cart makes it more operator friendly.

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