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iQ i220 Pneumatic Press System

Precision and Reliability in a compact size

Rugged Construction using the highest quality components provides superior performance, precision, and reliability. Compact, Single-Rail Linear Ball Slide Assembly System offers accurate positioning, stable movement, and friction-free travel.

Accuracy, Efficiency and Repeatability

Achieve consistent weld process and shorter cycle time with Amplitude Line and Load Regulation. Load Regulation automatically provides constant ultrasound amplitude regardless of the power draw. Ultrasonic output amplitude level is held within +/-1 %, to provide weld process consistency and shorter weld cycle times.

Consistent Weld Results by applying the most suited Welding Mode

Weld by Distance Mode controls the melt collapse distance to ensure that the same volume of material melts on each part so that the finished joint strength is consistent. Weld by Position controls the finished part height to yield uniform assemblies. Weld by Energy Mode delivers a specific amount of energy to the part to enhance process control. Patented Trigger by Power (U.S. Patent 7,475,801) provides more consistent welds by applying a sufficient and repeatable amount of pressure/force to the part before the weld cycle starts.

Reliability and Consistency

Linear Ramp Soft-start algorithm allows the acoustic stack to be brought to operating amplitude smoothly, minimizing start-up surges and abnormal stress to the stack and power supply..

Overview

Dukane iQ i220 ultrasonic welding system is an integrated machine designed for applications that require less process documentation yet are built on the same robust precision mechanical platform as our full featured machines. i220 systems are 100% digitally controlled and provide many advanced features like patented Trigger by Power, Process Limits and multiple setup recipe storage. Weld methods include Time, Energy, Peak Power and an option for Distance.

Key Features

  • 100% Digital Control of all power supply functions and parameters allows for unique configurations and future upgrades or requirements. Includes digital frequency synthesis
  • Data Acquisition Rate of 0.5 ms due to advanced multi-core architecture. Increased weld accuracy and repeatability
  • Digi-Trac tuning automatically tracks the resonant frequency digitally. No need to manually tune the generator during every weld cycle. The output frequency adjusts itself to match the acoustic stack (sonotrode booster and transducer)
  • Programmable Softstart and Softstop (Patented) amplitude can be used to reduce stress on acoustic stacks, or for high-speed application to achieve full amplitude in as short as 0.010 seconds. Factory configurable settings also available
  • Stack Scan feature scans the stack to determine the optimum starting frequency and provides a method for setting the start up frequency (Free Run Frequency)
  • Frequency Tracking feature improves the consistency of starting an acoustic stack if the frequency of the stack changes significantly over a shift or a day
  • User-Accessible, Programmable Advanced Hardware settings allow changes to Free Run Frequency, Frequency Tracking, Frequency Lock/Hold and Frequency Limits, which provides advance settings for difficult acoustic stacks
  • Afterburst include delay and duration time settings.
  • Power Display for checking and monitoring acoustic stack characteristics
  • Eight Unique Setups including Process Parameters, Amplitude and Limits
  • Rugged Construction using the highest quality components provides superior performance, precision, and reliability
  • Compact, Single-Rail Linear Ball Slide Assembly System offers accurate positioning, stable movement, and friction-free travel
  • 7” (178 mm) Stroke with mechanical bottom stop adjustable in 0.001” (0.025 mm) increments
  • Top-of-Stroke Limit Switch for automation application
  • All Controls are Accessible From the Front for convenient set-up and operation
  • Front Panel Lockout allows for remote input to lockout all front panel operator controls
  • Chrome-Plated Column and Titanium Booster are standard
  • Internally Mounted Optional Linear Encoder saves space in multi head and automated installations
  • OSHA-Required Lockout for Air Supply is standard
  • Ergonomic Base and Cycle Activation Switches reduce operator fatigue
  • Status Indicators, In Cycle, and Abort clearly communicate system conditions
  • Twist-Release Emergency Stop Switch meets international safety standards