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iQ Servo Ultrasonic Welding

Key Features

  • Dynamic Servo Motion Control
  • Patented Melt-Match® Technology
  • Patented Melt-Detect™ Technology
  • Industry leading 0.5 ms acquisition rate
  • Superior Data Acquisition
  • Simple calibration procedure – no pneumatic components to adjust
  • Only one device required for calibration (Trigger Force Sensor)
  • All other parameters validated (no adjustment – functional tests only – distance, time & velocity)
  • Linear servo actuator with integral roller screw mechanism
  • 5” (127mm) stroke 20 kHz, 3.5” (89mm) 30/40/50 kHz with a teachable software travel limit
  • Top-of-stroke limit switch for automation application
  • Linear distance encoder with 1 μm resolution.
  • Programmable trigger force .1 lb resolution (1 lb 20 kHz version) Ideal for precise delicate assemblies
  • Programmable home position for reduced cycle time and setup optimization
  • FDA Compliance with features like multi-level password protection, process change audit history and documentation (21 CFR part 11)
  • No operator accessible adjustment knobs or controls ensures validated process remains unchanged. All mechanical changes require a specific tool.
Download Literature

Dukane’s iQ Servo Ultrasonic Welder with patented Melt-Match® technology is the next step in the evolution of ultrasonic welding technology. Melt-Match® (Patent #8,720,516) 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™ (Patent # 8,052,816 and US 8,720,516)) 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.

Combining the efficiency and reliability of a 100% digitally controlled Multi-Core iQ Series power supply with the precision of an advanced servo press, the Dukane Advanced iQ Servo Welder delivers unprecedented repeatability, accuracy and reliability to the ultrasonic bonding process.

iQ Series Ultrasonic Generator/Power Supply

Precise ultrasonic welding requires a consistent and robust power supply. The Dukane iQ Power Supply’s 100% digital control with 0.5 ms multi-core processing rate collects twice as many data points during the welding cycle when compared to the current generation of ultrasonic power supplies. The increased processing speed improves repeatability and enhances the reliability of your welding output and programmed quality controls.


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Servo Controlled Ultrasonic Welding System with Patented Melt-Match®


Patented Melt-Match® Melt-Match® precisely matches the velocity of the ultrasonic stack with the melt flow velocity of the plastic material ensuring optimum molecular intermingling.

100% Electric/Servo
All-electric true servo technology eliminates the variability associated with pneumatic press components and provides unprecedented control to ultrasonic welding process.

0.5 ms Sample Rate Fast collection of data points during the weld improves repeatability and enhances reliability of the welding output and programmed quality controls.

Precise Calibration Displays all Weld parameters, limits and graphs from the weld cycle. 100% digital all-electric control simplifies the calibration and validation process.


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