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Jake Kowalewski
Global Marketing Manager
Phone: 630.485.1182
September 16, 2019

New VW6000 Series with Melt-Match®, a Patented Servo Technology.

Dukane introduces VW6000 Series with Melt-Match®, a new line of servo-driven vibration welding technology. VW6000 Series is designed to simplify the vibration welding process, provide faster cycle times driven by high-speed servo motors and improves weld quality and consistency with a precision welding process. We know that floor space is precious, that’s why the VW6000 Series Vibration Welder provides a larger welding table in the industry’s smallest footprint, 30% smaller than current models. With the VW6000 Series, Dukane is extending its proven and reputable Melt-Match® technology to the 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.

VW6000 -Servo Vibration Welding with Melt Match
VW6000 -Servo Vibration Welding with Melt Match

VW6000 Series 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.

VW6000 Series is Industry 4.0 ready providing remote connectivity for faster diagnosis, data acquisition, and service via most prevalent industrial communication protocols.  VW6000 series 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 VW6000 series welders will be able to be programmed for multiple valves, part presence sensors, and tool IDs.  Dukane is committed to making the VW6000 Series easy to deploy worldwide and offers this new welder in multiple languages (English, Spanish, German, Japanese, Chinese, French, and Czech)

Like all the previous Dukane Vibration Welders, the VW6000 Series is available in different table sizes and tooling weight consideration to effectively weld a wide range of parts. By incorporating all servo-driven controls VW6000 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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