iQ Series ES Servo Ultrasonic Welding Press System
Dukane's patented iQ Servo Welder
is the next step in the
evolution of ultrasonic welding technology. 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 your ultrasonic bonding
Dynamic Servo Motion Control
Integrated Melt-Match® Technology
Robust Rigid Mount Construction
Reliable Validation and Calibration
Superior data acquisition
August 2011 article in Plastics Technology
magazine about the benefits of
our servo controlled ultrasonic welder.
iQ Servo Advantage
iQ Dynamic Servo Motion Control - NO Pneumatics!
Integrated all-electric true servo technology
eliminates the variability associated with pneumatic press
components resulting in improved process repeatability and
accuracy. Dynamic Servo Motion Control technology delivers
precise control of ultrasonic stack velocity, force and
location providing a more optimized and robust process.
Repeatable and accurate Servo Motion Control
Integrated Melt-Match® Technology
Dynamic Velocity Melt Initiation (DVMI™)
Precise velocity/force control during initial
application of sonic energy allowing for
optimization of joint melt initiation. (Patented)
Programmable stack velocity and location control
Reduction in cycle time.
Ideal for integration into automated assembly
systems where high precision and reduced variability
Calibration and Validation
100% digital all-electric control simplifies the
calibration and validation process. By removing the
pneumatic components, validating your ultrasonic welding
process has never been easier and is ultimately more
reliable. The advanced all electric press and digital
control features of the iQ Series welder will assure
that your calibration/validation will stay in tolerance
for a longer time. This provides more confidence in the
welding output between calibration schedules while
maintaining system repeatability.
Simple calibration procedure - no pneumatic
components to adjust
Only one device required for calibration
All other parameters validated (no adjustment
- functional tests only - distance, time &
Optional Dukane calibration/certification prior
Dukane calibration technicians available for on-site
calibrations as required
No pneumatics = NO compressed Air!
One of the highest cost manufacturing today is
associated with energy required to generate compressed
air for pneumatic operations. It is estimated that only
50% of the compressed air generated is used for
operation; the rest is lost due to leaks and waste.
iQ FDA Compliance
Multi-level password protection
Process change audit history and documentation
(FDA part 11)
Indexed quick change tool system
UDI - Unique Device Identification
Integration with barcode scanner and/or
laser marker system for FDA documentation.
No operator accessible adjustment knobs or
Ensures validated process remains unchanged.
All mechanical changes require a specific tool.
Clean room friendly
No air exhaust to filter
Stainless steel panels
Studies show that precisely controlling the
velocity of the ultrasonic stack during the
welding cycle provides increased weld strength
and reduced variability. Dukane's
Melt-Match® 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.
Precise and reliable velocity control with iQ
Programmable multi-point velocity profile
Programmable static or dynamic (by distance)
post weld hold
The graphing features of the iQ explorer
software make process (Melt-Match®) optimization
simple. An optimized weld process will create a
constant power output throughout the melt phase of the
Capability (Cpk) - Third party
independent study comparing competitive
high end pneumatic welder against Dukane
iQ Servo. Results demonstrate a large
increase in the Process Capability Index
(Cpk), proving the iQ Servo's
superior welding process.
iQ Generator/Power Supply Features
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
iQ Press Features
Linear servo actuator with integral
roller screw mechanism.
5" (127mm) stroke 20 kHz, 3.5" (89mm)
30/40/50 kHz with electronic teachable
mechanical stop. Adjustable in .001" (.025mm)
Top-of-stroke limit switch for automation
Compact, single-rail linear ball slide
assembly system offers accurate positioning,
stable movement, and friction-free travel.
Programmable trigger force .1 lb
resolution (1 lb 20 kHz version) Ideal for precise
Programmable home position for reduced cycle
time and setup optimization.
Ergonomic base and cycle activation switches
reduce operator fatigue.
Status indicators in base for Power, In
Cycle, and Abort clearly communicate system conditions.
Twist-release emergency stop switch meets
international safety standards.
Ultra-Rigid support provides reduced
deflection for superior weld consistency. Column crank
and gas strut assist ensures easy setup. Column can be
locked to eliminate unauthorized adjustments. Standard
round support columns available.
iQ Press Options
Wide band transducer.
Patented resonant mount booster.
Longer press columns to increase part load area height.
19" (483mm) rack or press-mounted generator option.
Systematic Ultrasonic Assembly (SUA)
training computer based interactive training
modules. Modules include; Basic Ultrasonic Assembly,
Advanced Ultrasonic Assembly and Advance Process
100% digital control
of all power supply functions and
parameters allows for unique configurations and future
upgrades or requirements.
Industry leading data acquisition
rate speed of .5 ms due to advanced multi-core
architecture. Increased weld accuracy and
tuning automatically tracks the resonant
frequency digitally. Adjust the output frequency to
match the acoustic stack (sonotrode, booster, and
Ultrasonic overload protection,
with status indicator for ease of troubleshooting. The
overload power limit is based on true RMS power output
Line voltage regulation
compensates for line fluctuations
assuring consistent amplitude.
design delivers power more efficiently with
substantially less stress on the electrical and acoustic
components for superior performance reliability and
Linear ramp up (soft-start)
algorithm brings the acoustic stack to operating
amplitude smoothly, minimizing startup surges and
abnormal stresses to the stack and power supply.
provides constant ultrasound amplitude automatically
regardless of the power draw. The ultrasonic output
amplitude level is held to within +/-1% to provide weld
process consistency and reduced weld cycle times.
Flow Through Cooling tunnel with a matched
high performance heat sink and thermostatically
controlled fan reduces thermal gradients, minimizes dirt
infiltration and increases component life.
RS232 serial configuration port is used for
field software upgrades, troubleshooting and advanced
hardware setup with optional PC based
Advanced I/O is standard with 25-pin output,
and 15-pin input, user configurable from the utility
Unique Patent pending modular hardware design
incorporates motherboard/interconnect of internal
components. Reduces internal cabling while increasing
reliability and performance.
Rear panel expansion slots are available to
allow for custom configurations for OEM and cost
effective custom solutions.
Primary and secondary weld control parameters
Distance, Energy, and Peak Power.
Bad and suspect process limits include Time,
Time and Energy and Peak Power, with discrete outputs.
These programmable limits provide the means to adapt to
a wide variety of welding applications.
Amplitude adjustment in 1% increments from
100% to 20% through front panel or remote (4-20) mA.
16 setups with individual user ID. (including
Programmable softstart and softstop
amplitude can be used to reduce stress on acoustic
stacks, or for high-speed application to achieve full
amplitude in as short as .010 seconds. Factory
configurable settings also available.
User-accessible programmable advanced hardware
settings allow changes to Free Run
Frequency, Frequency Lock/Hold and Frequency Limits -
providing advance settings for difficult acoustic
Selectable frequency lock and hold feature
system ignores digi-trac automatic tuning feature and
locks to startup stack frequency helps in difficult
applications where the stack couples with a product.
Programmable frequency bandwidth,three
selectable factory settings or user programmable windows
for unique acoustic stacks and applications.
Afterburst control includes delay and duration time
User Interface Features
iQ Explorer Graphic User Interface
Windows operating system uses familiar
file folder menu structure, requires no special
training to program and operate.
Touch screen input for ease of
programming. All welder setup parameters are
programmed from one menu page.
Ethernet connectivity for connection to
local area network or stand-alone applications.
Supervisory password control features for
lock-out of system controls.
Remote connectivity to Dukane"™s 24-hour
hotline for system diagnostics and troubleshooting
ensures minimized down time.
iQ Process Control
To optimize the welding process and produce the
strongest and most consistent weld results, it is
critical to look at all phases of the welding
process for each application.
Programmable home position
Two-stage programmable down speed, allows
for fast approach prior to trigger and reduces cycle
Patented Trigger by Power or pretrigger
by distance modes.
Linear optical encoder with a one-micron
resolution over five inches of usable travel for
excellent precision and repeatability.
is static until system senses material melt
transition. This reduces part stress and provides
superior bond strength. (Patent Pending)
Programmable motion control modes
Speed mode allows for either constant
or 10-segment velocity profile during weld
Force mode allows for either constant
or 10-segment force profile during weld phase.
Weld by Energy delivers a specific amount
of energy to the part.
Weld by Distance controls the collapse
distance to ensure that the same volume of material
melts on each part so the finish joint strength is
Weld by Absolute Distance controls the
finish part height to yield uniform assemblies.
Weld by Peak Power terminates the
ultrasound when the available joint material is
Dynamic hold method allows for precise
programmable collapse distance and programmable
collapse speed, ensuring overall part collapse is
Static hold method stops motion at a
fixed position for a programmable length of time
during the hold phase
iQ Explorer operates on Windows operating system
independently of the ultrasonic system.
Usable on most computer platforms, desktop,
tablet, notebook or industrial PC, and does not require
proprietary hardware from Dukane.
The image on this screen is user configurable
and tied to the part setup file. You can upload an image
of the part. This gives immediate recognition that the
correct setup is being used to control the welding
process for that part.