2900 Dukane Drive
St. Charles, Illinois 60174 USA
Phone: (630) 797-4900
Fax (630) 797-4949

For Immediate Release:

View in pdf format

For More Information Contact:
Jason Barton
National Sales & Marketing Manager
(630) 797-4902

RoboWelder Replaces Nine Pneumatic Welders

Sometimes, the solution to a complex problem is a matter of teaming up with the right partner. An automotive manufacturer needed a machine to weld plastic lens/reflector assemblies. Their initial concept would have resulted in a nine-headed unit that was difficult to align and limited to welding similar assemblies. But it couldn't be built due to size constraints and interference problems. The customer brought their design challenge to Dukane. By partnering their collective experiences with teamwork and innovative thinking resulted in a synergistic unit that is immensely more flexible.

By incorporating a 6-axis robotic arm in place of nine pneumatic thrusters, Dukane built the manufacturing cells in less time for slightly more money than conventional multi-head systems. The welding arm is extremely agile yet accurate and requires no modification for different subassemblies. Using the right mix of compatible commercial components (C3) guarantees a reliable machine with a long service life. The smart part-fixture determines whether the subassembly is a left or right hand unit, then selects the correct welding path and adjusts the welding pressure at each weld tab. The ultrasonic generator monitors the weld energy to ensure each value is within specifications. Dukane's long experience in finding optimal solutions to difficult problems brought this project to fruition quickly. The robotic welders provide much greater versatility since the only changes required for producing different assemblies are a new part fixture and a new weld-path parameters program.

Dukane manufactures custom and standard machines at its worldwide headquarters in St. Charles, Illinois, USA. It backs them with their superior warranty and legendary Dukane service and support.

Dukane offers a full range of ultrasonic, vibration, spin and hot plate welders, thermal presses, probes, tooling and software for both OEM and the commercial plastic assembly markets. Dukane is an ISO 9001:2000 certified manufacturer with 24/7 Service. For more information on Dukane's 15kHz Ultrasonic Assembly System, and their complete line of plastic assembly solutions, contact Jason Barton, National Sales and Marketing Manager. He can be reached at (630) 797-4902 or visit their web site