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Jake Kowalewski
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September 17, 2019

New Infinity with Melt-Match®, a Patented Servo Technology

Dukane introduces InfinityTM with Melt-Match®, a new line of servo driven ultrasonic welding technology. Dukane launches this new line of servo driven ultrasonic welders, 10 years after launching their disruptive iQ™ servo driven ultrasonic welder.  The InfinityTM model has a completely redesigned thruster, base, and column giving it a state of the art look and feel.  In developing InfinityTM, Dukane had a few simple goals: Easy to use, A robust and precise welder, and Elegance in design and aesthetics.  Over the past 10 years Dukane has perfected ultrasonic servo welding and now with the addition of InfinityTM , they are ready to advance this technology even further.

Infinity with Melt-Match®-Servo Ultrasonic Welding
Infinity with Melt-Match®-Servo Ultrasonic Welding

InfinityTM with patented Melt-Match® provides an infinite number of features to accurately control all phases of the ultrasonic welding process. Patented Melt-Match® technology paired with the upgraded servo actuator and servo controller deliver the fastest approach, while ensuring that the contact force does not exceed the programmed value. A new load cell sensor provides better force sensing, digital force read-out, giving you better control of the trigger and welding force. Patented Melt-Detect™ feature resumes motion once the plastic material has started to melt. By using Melt-Detect™ a user can avoid deformation of energy directors 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.

With InfinityTM, Dukane designed a shorter thruster height to pack more power in a compact system, this is especially useful when InfinityTM is integrated in an automation line.  Dukane also redesigned the column to add significant rigidity to minimize deflection in high force applications and increased the booster rigidity for better weld repeatability.  By integrating the servo controller, fewer interconnected cables, and improved cable handling provides a smaller footprint and overall better appearance.

InfinityTM is Industry 4.0 ready with a new family of ultrasonic generator that provides better ultrasound frequency and amplitude control capabilities. It comes with an easy to swap cassette-style ultrasonic stack assembly with lockable (fixed) horn orientation for tool-less ultrasonic stack installation and removal.  Adding a GUI LCD on the thruster and generator for status/data/alarm display, provides instant feedback at a convenient location. Full compliance with EN 13849 safety standard with STO function.  InfinityTM , like all Dukane products, is designed in compliance with CE Mark, UL, and CSA requirements.

To ensure that InfinityTM delivers the best in class, Dukane offers an optional higher resolution linear encoder down to 0.1µ, improving control of the welding process.  In making this welder easier to use Dukane simplified control of force calibration, distance, and speed verification.  This ensures that InfinityTM  is not only easy to use but delivers the best results in the industry.

InfinityTM is designed with industry’s best servo controller and drive architecture with enhanced processing and communication capabilities.   Dukane continues to advance this technology with nine active US patents and three patents pending on hardware and software features. InfinityTM provides unmatched reliability, repeatability and accuracy to ultrasonic welding.

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2900 Dukane Drive, St. Charles, IL 60174