04 04 Section 1 – Introduction 04 04 Intelligent Assembly Solutions 05 05 05 05 06 06 06 06 07 07 Model 220 07 07 08 08 20kHz Press/Thruster 08 08 09 09 09 09 10 10 10 10 11 11 11 11 12 12 12 12 13 13 13 13 14 14 14 14 15 15 15 15 16 16 16 16 17 17 17 17 18 18 18 18 19 19 19 19 20 20 20 20 21 21 21 21 22 22 22 22 23 23 Model 340 23 23 24 24 30/40kHz Press/Thruster 24 24 25 25 25 25 User’s Manual Dukane Part No.
Model 220/340 Press User's Manual Copyright © 1996—2007 Dukane Intelligent Assembly Solutions 2900 Dukane Drive St. Charles, IL 60174 USA Notice of Rights: All rights reserved. No part of this manual including the interior design, cover design and icons may be reproduced, transmitted or utilized in any form or by any means, electronic, mechanical, photocopying, recording, or by any information storage and retrieval system, without written permission from Dukane Corporation.
Section 1 – Introduction Revision History Revision Number –00 Addendum 1 –01 –02 –03 Revision History Date 220 Press Manual – Original Release 1996–Oct–30 Revise drawings in Section 1 Specifications – Page 3 2001–Sep–20 Update telephone numbers on covers and in Section 11 Revise Replacement Part List in Section 11 Update Mechanical, Pneumatic and Electrical schematics 2004–Jun–08 Merge all chapters into a single continuous file and 2005–Mar–30 redo the Index and Tabl
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Section 1 – Introduction Table of Contents Section 1 – Introduction About This Manual................................................................................................. 3 Safety................................................................................................................... 3 Safety Recommendations........................................................................................ 3 Special Health Notice – Plastics........................................................
Model 220/340 Press User's Manual Section 4 – Press Options Overview............................................................................................................ 31 Additional Options.............................................................................................. 31 Hydraulic Speed Control...................................................................................... 32 Slow Speed Control and Indicator Flags............................................................
Section 1 – Introduction Section 6 – Systems Test Overview............................................................................................................ 53 Operational Test Of Stack..................................................................................... 54 Procedure for Cycling the System..................................................................... 57 Running Sample Parts, Making Adjustments......................................................
Model 220/340 Press User's Manual Section 12 – Diagrams Electrical Schematic........................................................................................... 105 Pneumatic Layout.............................................................................................. 107 Thruster Mounting Detail.................................................................................... 109 Section 13 – Glossary of Terms . .................................... 113 Index .............................
Section 1 – Introduction SECTION 1 Introduction • This section gives a general introduction to the press, and deals with safety considerations. Dukane Corporation • Dukane Part No.
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Section 1 – Introduction About This Manual This manual provides information to set up, operate, and interface Dukane’s model 220 20kHz Press/Thruster. The manual consists of sections that describe in detail press specifications and functions, installation and testing procedures, and maintenance and troubleshooting steps. Each section describes all of the press functions that are applicable to a standard press/thruster. Note that the manual covers the Model 220 & Model 340 Press/Thruster only.
Model 220/340 Press User's Manual • When ultrasonic plastic assembly equipment is used with automatic material handling equipment as an automated system, a SYSTEM ABORT switch should be located at each operator station. • Use of a foot switch in place of dual palm buttons violates OSHA regulations. • DO NOT touch the horn tip when the system is operating. Touching a horn tip that is vibrating at ultrasonic frequencies can result in serious injury.
Section 1 – Introduction Special Health Notice – Plastics Certain plastic materials, when being processed, may emit fumes and/or gases that may be hazardous to the operator’s health. Proper ventilation of the work station should be provided where such materials are processed. Inquiries should be made to the U.S. Department of Labor concerning OSHA regulations for a particular plastic prior to processing with Dukane ultrasonic equipment.
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Section 1 – Introduction SECTION 2 Installation • This section explains the proper machine placement and adjustments, and the cable connections of the press/thruster. Dukane Corporation • Dukane Part No.
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Section 2 – Installation Installing the Press System The press system consists of a thruster, ergonomic base and support package. It is assembled at the factory for shipment. Unpacking The press system is secured to a wooden pallet and covered with a cardboard carton. The press sits on the pallet and is supported inside the carton by styrofoam blocks. 1. Before unpacking, it is suggested that the press be moved close to the location where it is to be installed. 2. Remove the straps from the carton. 3.
Model 220/340 Press User's Manual The placement of the press system should be by mechanical means. To place the press on the work area, use a pallet lift platform or equivalent. Raise the assembly until the bottom edge of the base is even with the top of the work area as shown in Figure 2-2. Then, carefully slide the press system on to the work area. Installing the Press System Without Machine Base In this configuration, secure the flange to a rigid, level stationary structure.
Section 2 – Installation Installing the Thruster Secure the thruster to a rigid stationary structure by placing the back of the thruster onto the support frame. Align the bolt holes in the thruster with the bolt slots in the support frame. Insert the two mounting bolts (3/8-16 x 1-1/4 inch hexhead or equivalent), with flat washers, as shown in Figure 2-5. Align the thruster with the work surface in both the horizontal and vertical planes to assure parallelism. Tighten the bolts.
Model 220/340 Press User's Manual Cable Connections Press System Top of Stroke cable Air in J40 Grounding Stud The press is not equipped with its own source of compressed air, electrical power, or electrical control and monitoring.
Section 2 – Installation • Ergonomic Base (J35) - Connects the base controls and display to the Press Base Port (J202) on the DPC. The press system requires three cables for proper operation. These cables are part of the cable package that is shipped with the press. A customerprovided air hose ( 5/16 inch dia.) is also required. Connect the following lines and cables to the press system: • Connect the ultrasound coaxial cable to J1 on the thruster.
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Section 2 – Installation FRONT 7.75 inches (196.85 mm) 3.023 inches (76.783 mm) 3.875 inches (98.425 mm) 2.625 inches (66.675 mm) 2.00 inches (50.80 mm) 1.50 inches (38.10 mm) 2.625 inches (66.675 mm) 2.25 inches (57.15 mm) 2.25 inches (57.15 mm) REAR Flange Template Dukane Part No.
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Section 2 – Installation SECTION 3 Control Description • This section describes the arrangement and functions of all the press controls and indicators on the system. Dukane Corporation • Dukane Part No.
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Section 3 – Control Description Overview This section describes the controls, indicators and features for the manual and electronic pressure-regulated (EPR) versions of the Press/Thruster System. The controls on the front of the thruster can be used to manually set the parameters for a given process. The indicators associated with the controls provide a visual indication of the control settings.
Model 220/340 Press User's Manual Manual Controls Refer to Figure 3-1 for the location of the controls. Down Speed Adjustment This control adjusts the downward velocity of the press/thruster slide assembly. Turning the knob clockwise decreases the speed. Turning it counterclockwise increases the speed of descent. Hydraulic Slow Speed Control (optional) This control is used to adjust the point in the down stroke where the hydraulic speed damper is engaged.
Section 3 – Control Description DOWN 00 10 90 30 Pressure 1 Regulator IN E Mechanical Stop Adjust 11 00 70 60 MECH STOP WELD PRESSURE DOWN SPEED HOLD PRESSURE 6 5 4 8 Down Speed Adjust Regulator Select Switch (Optional 7 50 S CR A E 3 IN E Pressure 2 Regulator (Optional 50 40 60 3 4 0 7 70 30 S CR A E 2 5 20 80 6 10 CM Mechanical Stop Indicator Flag CM 0 1 Stroke Position Indicator Flag Slow Speed Indicator Flag 18 1 17 2 2 16 3 15 4 4 14 5 5 13
Model 220/340 Press User's Manual Pressure 2 Regulator In applications where welding with dual pressure is required, this pressure regulator would be set to provide a higher pressure during a portion of the weld cycle. This pressure is also maintained during the hold time.
Section 3 – Control Description Indicators Pressure Gauge The pressure gauge shows the amount of air pressure applied to the upper portion of the air cylinder for the weld-and-hold operation. Ultrasound Active Status Light This LED indicator lights up when the generator is applying ultrasonic power to the horn. Stroke Position Indicator Flag The stroke position indicator flag is not preset prior to press operation. It moves with the slide assembly as the assembly moves down and up.
Model 220/340 Press User's Manual Electronic Pressure Regulator Refer to Figure 3-2 for the location of the controls. The EPR (Electronic Pressure Regulator) option deletes the Pressure 1 and Pressure 2 Regulators and the Regulator Select Switch found on the manual press, and replaces them with the following: • Electronic Pressure Regulator (EPR) that controls the pneumatic pressure on command from the DPC IV.
Section 3 – Control Description DOWN 0.0 mm 1.0 9.0 3.0 50 40 60 3 4 0 7 70 30 Mechanical Stop Adjust 11.00 5 80 20 2 7.0 6.0 MECH STOP Pressure gauge 0 10 PRESSURE DOWN SPEED 6 5 8 7 4 3 Down Speed Adjust 6 90 10 1 5.
Model 220/340 Press User's Manual Ergonomic Base The ergonomic base, shown in Figure 3-3, consists of a base plate, cycle activation switches (black palm switches), abort switch (red palm switch), and a status display screen. At the back of the base is a cable connector for an interface between the DPC and the base front panel. Activation Switch Display Abort Switch Activation Switch Figure 3-3 Ergonomic Base Controls Base Plate The machined base plate is bolted to the top of the ergonomic base.
Section 3 – Control Description Base Status Display The function of the display is to indicate one of three status conditions of the press: • READY - When the abort switch is pulled out, the green “READY” status light indicates that power is applied to the press and it is ready for operation. • ABORT - When the abort switch is pushed in, the red “ABORT” status indicator illuminates. Press operation is no longer possible.
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Section 3 – Control Description SECTION 4 Press Options • This section provides detailed information regarding the installation and operation of the hydraulic speed control (Kinichek), distance encoder, and electronic pressure regulator options. Dukane Corporation • Dukane Part No.
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Section 4 – Press Options Overview This section provides detailed information for the common options for press/thruster operation. These options are: • Hydraulic Speed Control • Distance Encoder • Electronic Pressure Regulator Detailed description, installation, and any applicable alignment or adjustments follow. The optional air cylinders (1.5, 2, and 3 inches in dia.) are factory installed and do not require any field adjustments.
Model 220/340 Press User's Manual Hydraulic Speed Control SLOW SPEED Control and Indicator Flags CM The thruster has a knob labelled “SLOW SPEED” near the bottom of the front panel and an indicator flag in the same slot with the STROKE POSITION indicator flag. Refer to Figure 4-1. The knob and the indicator flag are part of the optional Hydraulic Speed Control Kit. The purpose of the hydraulic speed control is to match the downstroke speed to the material melt flow. This will produce the strongest joint.
Section 4 – Press Options Threaded Rod Contact Block The hydraulic cylinder is mounted in a clamping block. The block is threaded onto a long rod. Turning the SLOW SPEED knob rotates the rod. Plunger This in turn causes the clamping block to ride up or down on the rod, moving the hydraulic cylinder closer to or further from the contact block at rest.
Model 220/340 Press User's Manual Installing the Distance Encoder Purpose To install and calibrate the distance encoder in order to accurately measure the distance of thruster travel. Requirements Parts Right Side Panel Kit consisting of the following: 1. 625-14 Encoder (2 pieces) 2. Encoder Head cable cover bracket 3. Mounting screws and hardware Tools Encoder Scale • Phillips-head screwdriver • Feeler gauge set (0-.
Section 4 – Press Options 4. Connect the cable to the DPC connector J-401 (Thruster Stroke Encoder). 5. Replace the rear panel on the press. 6. Gently slide the encoder head down until the mounting screw holes in the press support base appear in the head’s mounting slots. 7. Center the screw holes in the mounting slots. Secure the encoder head with the two pan-screws but do not tighten them yet. Alignment The purpose of this alignment is to set the internal reference mark for the encoder.
Model 220/340 Press User's Manual 6. Perform the following procedure to test the encoder for the proper setting: a. Run one weld cycle. If the encoder position reads negative (-.xxx), then the encoder is above the “0” reference point used for measuring distance by the DPC. This is the correct setting. Secure the two screws. Proceed to Step 7. xxx = approximately -.125 inch to .-250 inch. b. If the encoder position reads positive (+.
Section 4 – Press Options Electronic Press Controls The electronic press controls consist of the following three components: Electronic Pressure Regulator The electronic pressure regulator, (I/P transducer) is an electro-pneumatic replacement for the manually adjusted air regulator on the press. The I/P transducer converts the electrical signal current (I) into air pressure (P). The Electronic Regulator converts the electrical signal from the DPC into the programmed air pressure.
Model 220/340 Press User's Manual This set of limits is used to ensure that air pressure from the input line has not dropped below the required pressure for an acceptable weld force. The other set of limits is used to monitor the air pressure when the ultrasound is turned on. This feature can be used as an indicator when checking for a trigger or load cell malfunction. A more precise way to monitor trigger force is to use a load cell. The pressure transducer does not require any on-site calibration.
Section 4 – Press Options SECTION 5 Stack/Fixture Setup • This section provides detailed information regarding the proper installation and removal of the stack assembly. It also contains the procedure for assembling and disassembling the stack components. Dukane Corporation • Dukane Part No.
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Section 5 – Stack/Fixture Setup Overview A Dukane press/thruster and a DPC (Dynamic Process Controller) generator can be used to assemble a unlimited variety of parts for every conceivable market segment, including Automotive, Medical, Appliance, Consumer, Packaging and Toy industries. Various techniques and processes, such as welding, staking, swaging, inserting, and spot welding can be used for the different applications. This variety is made possible through the interchange of some system components.
Model 220/340 Press User's Manual Stack Description The stack shown in Figure 5-1 consists of three components: • • • Transducer Booster Horn The transducer and the booster are normally shipped assembled and installed in the press. The horn and/or the fixture may be shipped separately. The stack is easily removed from or installed in the press/thruster. This makes it possible to change the horn or booster. It also makes it easier to perform regular inspections and/or maintenance of the stack components.
Section 5 – Stack/Fixture Setup Changing Stack Components Stack Removal Before removing the stack, perform the following steps: 1. Activate the Abort switch on the front of the base. 2. Power down the DPC. These two steps are necessary to ensure that no power will be accidently applied while removing the stack. 3. While supporting the stack with one hand, loosen the two socket-head bolts that secure the stack access door.
Model 220/340 Press User's Manual Stack Disassembly To separate the stack component carefully follow the instructions below: 1. Use the two spanner wrenches (wrench A and B) provided with the press. Place wrench A on the component to be removed (Refer to Figure 5-3) and wrench B on the one next to it. Turn wrench A in the direction indicated. A B Figure 5-3 Disassembling Components CAUTION To avoid possible injury, press down on the spanner wrench with the palm of the hand.
Section 5 – Stack/Fixture Setup Stack Assembly Before assembling a stack, inspect all of the components for possible damage — especially the surfaces that are to be joined. Look for non-flat surfaces (concave, convex), stress cracks, chips, or gouges. Any of these irregularities will affect the operation of the stack and could cause further damage. Contact the Dukane Ultrasonics Tooling Department concerning a damaged component.
Model 220/340 Press User's Manual Installing a Detachable Tip If the horn has a detachable tip, do the following: 1. Inspect the surfaces of the tip and the horn for any stress cracks, chips or gouges. 2. Coat one of the contact surfaces with a thin coat of high-pressure grease or lubricant. We recommend Dow–Corning #4 (or #111 as an alternate). Figure 5-6 Tip Assembly. Note: Do not apply any lubricant to the tip threads. 3. Thread the tip into the horn.
Section 5 – Stack/Fixture Setup Fixture Installation There are three steps involved in installing a fixture. • Aligning the fixture with the horn • Leveling the fixture to provide the necessary support • Rigidly securing the fixture to the mounting surface Fixture Alignment To safely align the fixture under the horn, use the following procedure. (Refer to Figure 5-8.) 1. Depress the Abort switch.
Model 220/340 Press User's Manual Note: The fixture should be flat on the base. If the fixture is equipped with leveling jack screws, adjust the screws so that they do not interfere with seating of the fixture on the base plate. 6. Place a part in the fixture. 7. Grasping the horn firmly, pull the acoustic stack assembly down until the horn is as close to the part as necessary to align the fixture. 8.
Section 5 – Stack/Fixture Setup 5. Tighten the hold-down cap screws by turning them clockwise until a firm resistance is felt. Note: Do not overtighten the cap screws. This may flex the fixture plate. 6. If any readjustment is necessary, loosen the hold-down screws first. Then readjust the jack screws. The following procedure may be helpful in leveling the fixture in some applications. To perform this procedure, use a piece of carbon paper and a piece of white paper. 1.
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Section 5 – Stack/Fixture Setup SECTION 6 Systems Test • This section provides the testing methods used to ensure that the press system is functioning properly before normal operations start. Dukane Corporation • Dukane Part No.
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Section 6 – Systems Test Overview A Dynamic Process Controller (DPC) must be operating and connected to the press/thruster in order to test the system. For efficient operation of a Dukane ultrasonic assembly system, the ultrasound signal from the Dynamic Process Controller must match the frequency and phase angle (vibrational characteristics) of the stack that is being driven. Each stack has unique vibrational characteristics dependent on the combination of stack components.
Model 220/340 Press User's Manual Operational Test of the Acoustic Stack The following test procedure is suggested before starting the DPC operation, to verify that the vibrational characteristics of the stack fall within the range of the AUTO-TRAC. All Dukane stack components are manufactured to tolerance specifications within this range.
Section 6 – Systems Test 3. Press the DPC TEST button: , and hold it until the display of Figure 6-2 appears on the generator status panel, and the output power and frequency appear on the display screen (Figure 6-3): TEST System Power Output: • • If the power output display remains between 10 and 20 percent and the horn frequency is (220 Press) within 19,500 Hz and 20,500 Hz, the stack is operational. (340 Press) within: 28,500-30,500 Hz, & 39,500-40,500 Hz.
Model 220/340 Press User's Manual 5. Turn the DPC off. Check the stack for proper assembly, damaged components, or dirty mating surfaces. Recheck the ultrasound cable for proper connections. Repeat steps 1 through 4. If the test still fails, go to the next step. 6. Turn the DPC off, remove the stack from the thruster, and remove the horn from the stack. Reinstall the transducer-booster assembly in the thruster and turn the DPC on. Repeat steps 2 through 4.
Section 6 – Systems Test Procedure for Cycling the System 1. Check that you have correctly performed the following: a. Installed the stack in the thruster and bolted the stack access cover closed. b. Secured the fixture in place. c. Performed the “Operational Test of the Acoustic Stack.” 2. Press the ON-LINE button . 3. Verify that all controls on the Press/Thruster and the DPC are set as required for this operation. 4. Place a part in the fixture. 5. Cycle the system.
Model 220/340 Press User's Manual 2. Check the quality of an assembled part for the following: a. Strength of the joint, assembly, or seam. b. Appearance of the assembled part should meet your quality standards. Page 58 Dukane Part No.
Section 6 – Systems Test SECTION 7 Stack Maintenance • This section provides information and explanations on the proper way to care for the stack components. Dukane Corporation • Dukane Part No.
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Section 7 – Stack Maintenance Inspection of the Acoustic Stack Components It is essential that the mating faces between an ultrasonic transducer/booster and a booster/horn be absolutely flat and parallel. If there is any air gap, there will be a loss in power output and efficiency. Coupling may be so poor as to prevent the startup of vibration from the stack, due to the excessive power draw at the mating surfaces.
Model 220/340 Press User's Manual Reconditioning Stack Components Note: The operating efficiency of the equipment will be greatly affected if the mating interfaces of the transducer/booster/ horn stack are not flat, make poor contact with each other, or become corroded. A poor contact condition wastes power output, makes tuning difficult, can affect the noise level, and can cause possible heat damage to the transducer. To restore the interface to the proper condition, do the following: 1.
Section 7 – Stack Maintenance 8. Rotate the part the remaining 120° and repeat. Be certain to perform the same number of strokes at each orientation: Two strokes per rotation. IMPORTANT Use extreme care to avoid multiple strokes at each 1/3 rotation of the part. Loss of flatness and perpendicularity of the interface surface to the centering axis of the part may render the welding system inoperative. 9. Before reinserting a stud in any horn, perform the following for proper engagement of the threads: a.
Model 220/340 Press User's Manual • For horn and booster studs, refer to Table 7-1. Stud ThreadSize Torque foot-lbs Newton-meters 1/2 in x 20 1 1.35 3/8 in. x 24 1 1.35 M8 x 1.25 1 1.35 Table 7-1 Stud Torque Values • For detachable tips on horns, refer to Table 7-2. Tip ThreadSize Torque foot-lbs Newton-meters 1/2 in x 20 30 40.7 3/8 in. x 24 28 37.9 5/16 x 24 25 33.9 1/4 x 28 20 27.
Section 7 – Stack Maintenance SECTION 8 Troubleshooting • This section provides a list of the more common problems that may occur in the various ultrasonic processes. It also provides suggested corrective actions. Dukane Corporation • Dukane Part No.
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Section 8 – Troubleshooting Applications The Troubleshooting section of this manual contains a listing of problems that may occur when using this equipment along with probable causes and recommended solutions for the problems. Regarding solutions, please note the following: Where the solutions section refers to changing a setting for a primary weld characteristic or altering the position of the End-of-Weld limit switch, these adjustment capabilities and controls must be available on your equipment.
Model 220/340 Press User's Manual The generator/digital timer should be any of Dukane’s 20 kHz generators controlled by a digital timer. The process controller is the Dynamic Process Controller™ (DPC). The DPC is equipped with a generator, a processor module, and a combination of control modules. End-of-Weld Limit Switch The End-of-Weld limit switch is used to terminate the ultrasound power burst during a weld cycle as determined by the stroke position of the press head.
Section 8 – Troubleshooting Welding _____________________________________________________________________________________________ Problem Flash (See also Nonuniform welding) Probable Cause Solution Energy director is too large. Reduce the size of the energy director. Reduce the weld time/primary weld characteristic. Reduce the air pressure. Use an interrupted energy director. Shear interference is too great. Reduce the amount of interference. Weld time is too long. Reduce the weld time.
Model 220/340 Press User's Manual Welding _____________________________________________________________________________________________ Problem Internal components are welding together. Probable Cause Solution The internal components are made of the same material. Make the internal components out of different materials. Carefully lubricate the internal parts. Use less horn amplitude by changing to a lower gain booster.
Section 8 – Troubleshooting Welding _____________________________________________________________________________________________ Problem Internal components of work piece damaged during welding. Probable Cause Solution Excessive horn amplitude Reduce the horn amplitude by changing to a lower gain booster. Dampen the excess horn amplitude. Excessive exposure to ultrasound. Reduce the primary weld time and increase the horn amplitude by changing to a higher gain booster.
Model 220/340 Press User's Manual Welding _____________________________________________________________________________________________ Problem Underwelding Probable Cause Solution Insufficient energy is being transmitted to the part. Increase the air pressure. Increase the weld time/primary weld characteristic. Change to a higher gain booster to increase the horn amplitude. Use a more powerful assembly system. Energy is being absorbed into the fixture. Change the type of fixture being used.
Section 8 – Troubleshooting Welding _____________________________________________________________________________________________ Problem Uneven welding (continued) Probable Cause Solution Part dimensions are incorrect. Check the part dimensions. Re-dimension the part, if necessary. Check the molding conditions. The parts are improperly aligned. Check for part shifting during welding. Check the alignment of mating parts. Check for parallelism of the horn, the part, and/or the fixture.
Model 220/340 Press User's Manual Welding _____________________________________________________________________________________________ Problem The parts are marking Probable Cause Solution The horn heats up. Check for a loose stud, tighten if loose. Loosen and then retighten the horn tip. (Refer to Section 5). Reduce the weld time. Ensure that the horn and booster are coupling well (Refer to Section 5). Visually check the horn for cracks. There are high spots in the part. Check the part dimensions.
Section 8 – Troubleshooting Welding _____________________________________________________________________________________________ Problem Welding process not in control (inconsistent weld results on a part-to-part basis) (continued). Probable Cause Solution Part dimensions vary due to mold cavity variations. Perform a statistical study to see if a pattern develops with certain cavity combinations. The resin contains regrind or degraded plastic. Consult with the molder.
Model 220/340 Press User's Manual Insertion _____________________________________________________________________________________________ Problem The insert pulls out easily in use. Probable Cause Solution There is insufficient interference between the hole and the insert. Reduce the size of the molded hole in the plastic. The screw bottoms out in the hole. Use a shorter screw. (Applies to internallythreaded insert). Deepen the hole. The insert gets pushed into the plastic before the plastic melts.
Section 8 – Troubleshooting Insertion _____________________________________________________________________________________________ Problem The boss or the plastic around the boss cracks after insertion. Probable Cause Solution The insert is pushed in before the plastic has melted. Reduce the down speed, air pressure, and/or horn amplitude. Use pre-triggering. The gauge pressure is set too high. Reduce the air pressure. The boss wall is too thin. Increase the thickness of the boss wall.
Model 220/340 Press User's Manual Insertion _____________________________________________________________________________________________ Problem Plastic flows over the top of the insert. Probable Cause Solution The weld time is too long. Decrease the primary weld characteristic. The insert is being driven too deep. Reset the bottom stop. Decrease the primary weld characteristic. There is too much interference between the hole and the insert. Increase the hole diameter, if possible.
Section 8 – Troubleshooting _____________________________________________________________________________________________ Staking _______________________________________________________________________________________________ Problem A ragged or irregularly shaped stake head is formed. Probable Cause Solution The staking cavity is too large. Change to a smaller cavity in the horn. The volume of plastic in the stud is insufficient. Increase the stud height/diameter. The stud is melting at the base.
Model 220/340 Press User's Manual Staking _____________________________________________________________________________________________ Problem There is a loose fit between the staked head and the part being attached (continued). Probable Cause Solution The holding force was removed before the stud head could solidify. If using a dual pressure system, use Pressure 2 in the hold portion of the weld cycle (Pressure 2 should be higher than Pressure 1). Increase the hold time/distance.
Section 8 – Troubleshooting Staking _____________________________________________________________________________________________ Problem The formed stud head stays in the staking cavity as the horn retracts. Probable Cause Solution The stud head has not solidified before the horn retracts. Increase the hold time. The horn tip is heating and not allowing the stud to solidify. Cool the horn tip. Use afterburst.
Model 220/340 Press User's Manual Continous Welding _____________________________________________________________________________________________ Problem Seal not meeting strength requirements. Probable Cause Solution Material traveling too quickly. Decrease speed. Not enough horn amplitude. Increase booster ratio. Inconsistent blends of synthetic material. Evaluate material.
Section 8 – Troubleshooting Continous Welding _____________________________________________________________________________________________ Problem Excessive horn wear. Probable Cause Solution Metal-to-metal contact between the horn and anvil. Use carbide inserts or have horn face carbide-coated. Reduce metal-to-metal contact _____________________________________________________________________________________________ Problem Overloading generators. Probable Cause Solution Loose stack components.
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Section 8 – Troubleshooting SECTION 9 Service/Maintenance • This section provides instructions for periodic servicing of the press/thruster. Dukane Corporation • Dukane Part No.
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Section 9 – Service/Maintenance Six Month Periodic Maintenance 1. Disconnect the generator AC power cord from the AC line receptacle. Then, remove the thruster left and right side covers. 2. Check that all socket-head cap screws in the press/thruster are tight. Check the air cylinder mounting. 3. Wipe or blow away all dirt and grease in the press/thruster. 4. Wipe away all excess oil and any dirt accumulation, especially at the exhaust openings in the transducer housing.
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Section 9 – Service/Maintenance SECTION 10 Contact Dukane/Warranty • This section provides information on factory support, spare parts and warranty data. Dukane Corporation • Dukane Part No.
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Section 10 – Contacting Dukane & Warranty Contacting Dukane Identify Equipment When contacting Dukane about a service–related problem, be prepared to give the following information: • Model number, line voltage and serial number. • Alarm messages from the touch screen display. • Problem description and steps taken to resolve it. Many problems can be solved over the telephone, so it is best to call from a telephone located near the equipment.
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Section 10 – Contacting Dukane & Warranty Replacement Parts List Description Part # Air cylinder 1-1/2” dia. x 7” (30/40K) 804-66 Air cylinder 2-1/2” dia. x 7” 804-33 Air cylinder 9/16” dia.
Model 220/340 Press User's Manual DUKANE CORPORATION NORTH AMERICAN WARRANTY POLICY Subject to the terms, limitations and exclusions set forth below, Dukane Corporation IAS Division (Dukane) warrants to the original Purchaser, unless otherwise expressly agreed to in writing by Dukane, that all equipment and tooling designed and built by Dukane will be free from defects in material or workmanship. Normal wear items are not covered by this warranty.
Section 10 – Contacting Dukane & Warranty DUKANE CORPORATION INTERNATIONAL WARRANTY POLICY Subject to the terms, limitations and exclusions set forth below, Dukane Corporation IAS Division (Dukane) warrants to the original Purchaser, unless otherwise expressly agreed to in writing by Dukane, that all equipment and tooling designed and built by Dukane will be free from defects in material or workmanship. Normal wear items are not covered by this warranty.
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Section 10 – Contacting Dukane & Warranty SECTION 11 Specifications • This section contains a summary of the required components, power requirements and space require- Dukane Corporation • Dukane Part No.
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Section 11 – Specifications Frequency Regulations The ultrasonic system and the equipment installation described in this manual are covered by various FCC and State regulations and local codes. It also meets the various international regulations. Modifications must not be made to the generator or associated cables as such actions may result in violation of one or more of the regulations under which this equipment is manufactured.
Model 220/340 Press User's Manual System Requirements Pneumatic Power Requirements The 220/340 Thruster requires 80-110 psi of clean, dry air. Maximum available clamping pressure is 540 lbs @ 110 psi with a standard 63.5 mm diameter (2.5 inch Dia.) air cylinder. Electrical Requirements The press/thruster uses 24 VDC @ 2 Amps, obtained from the DPC/ generator. The required AC line voltage and current depend on the seGenerator AC Power Requirements lected DPC/generator, as shown in Table 11-2.
Section 11 – Specifications Figure 1-1 Model 220/340 Press Specifications 1.88 (48) 4.48 (114) 9.20 (234) 16.38 (416) 3.50 DIA. COL. (89) 31.34 (796) 39.68 (1008) CL OF HORN & PRESS 56.94 (1450) 12.38 (314) 19.5 MAX (495) LESS HORN 8.50 (216) 4.74 (120) 24.83 (631) 18.58 (472) Figure 11-1(b) Side View of Press Figure 11-1(a) Front View of Press Items Thruster Only Base Column Col C.L. to Horn C.L. Height Inches (mm) 31.34 (796) 4.74 (120) 39.68 (1008) Width/Dia Inches (mm) 4.
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Section 11 – Specifications SECTION 12 Diagrams • This section contains a system electrical schematic, a pneumatic layout and mechanical dimensions for the press/thruster system. Dukane Corporation • Dukane Part No.
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A B C D E F G H J FILENAME: REF FILE: WHT RED P2 J2 2 TRANSDUCER 3 TRIGGER LED 4 CATHODE DS1 ELECTRONIC PRESSURE REGULATOR KIT 438-780 (OPTIONAL) 4 P1 2 J1 BLK BLU 2 1 BLU/BLK ORN WHT 3 P1 1 5 GRN 2 RED 1 J1 1 2 3 5 6 TOP OF STROKE SWITCH DUAL SWITCH DUAL PRESSURE VALVE DOWN VALVE UP VALVE SW2 TRIGGER SWITCH 6 SW3 SW4 2 1 2 1 2 1 BLK BLU WHT/ORN WHT/ORN WHT/VIO WHT/VIO BLK BLK BLK RED BLK RED 7 P1 2 4 3 J1 2 4 3 6 5 5 6 1
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Dukane Part No. 403–556–03 A B C E F G FILENAME: REF FILE: Page 107 1 4002092.dgn ITEM 1 2 3 4 5 6 7 8 9 10 11 DESCRIPTION AIR REGULATOR AIR GAUGE SOLENOID VALVE-MAIN FLOW CONTROL VALVE AIR CYLINDER-POWER AIR CYLINDER MUFFLER AIR FILTER SOLENOID VALVE LOCK-OUT VALVE CHECK VALVE 2 PARTS LIST NOTES: 1. FILTER, CHECK VALVE AND LOCK-OUT VALVE ARE STANDARD ON THE 43A290 FRAME SUPPORT PACKAGE, OR USER SUPPLIED IF THRUSTER IS PURCHASED WITHOUT A FRAME SUPPORT PACKAGE. 2.
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Dukane Part No. 403–556–03 A B C E F G FILENAME: REF FILE: 9.29 236 Page 109 1 4002102.DWG 1 18.58 472 6.36 162 4.48 114 2 2 4.74 121 15.69 399 "A" 3 7.00 (MAX STROKE) 178 31.34 796 3 HORN 10.06 256 11.00 [279.50] 9.20 [233.68] 4.00 102 CL 4 4 24.83 631 12.38 314 1.34 34 10.55 268 5 5 804-36 44.42 1128 7.185 183 .450 11 12.38 314 12.510 318 0.50 R (2 PLCS) 1.18 30 COMPUTER GENERATED DO NOT MANUALLY REVISE 7 M12 X 1.75 6H TAP THRU (5 PLCS) 14.00 356 .
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Section 12 – Diagrams SECTION 13 Glossary of Terms • This section provides the definitions for terms used in this document. Dukane Corporation • Dukane Part No.
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Section 13 – Glossary of Terms Amorphous Plastic A thermoplastic which has a random molecular structure (e.g. ABS, Polycarbonate, Polystyrene). Amplitude The peak-to-peak excursion of a horn or a booster at its workface. It is usually measured in tens of microns or thousandths of an inch. Booster A mechanical transformer used to increase or decrease the amplitude of the horn vibrations. Boss The hollow stud into which an insert is driven.
Model 220/340 Press User's Manual Fixture A device used to align and support the parts to be assembled. It is sometimes referred to as a nest. Flash The overflow of plastic from a welded joint area. Frequency The number of cycles per second measured in hertz (Hz). Gain The ratio of output amplitude to input amplitude of a horn or a booster. When the gain is greater than one, the output amplitude is larger than the input amplitude.
Section 13 – Glossary of Terms Mold Release A substance added to plastics so that parts are easily removed from the mold. Near Field Refers to the distance that ultrasonic energy is transmitted from the horn to the joint interface. When the joint is less than about 0.25 inch or 6mm from where the horn contacts the part, the weld is considered near field. (see Far Field). Nodal Point The point in a booster or horn where little or no linear motion (due to the ultrasonic wave) occurs.
Model 220/340 Press User's Manual Spot Welding An ultrasonic assembly method where two thermoplastic components are joined at localized points. The components joined by spot welding are typically cast or extruded. Staking An ultrasonic assembly technique by which a plastic stud is formed into a rivet head to capture another part, which may be of a dissimilar material. Stud The plastic protrusion that is shaped into a rivet head to attach two parts together during staking.
Section 13 – Glossary of Terms SECTION 14 Index • This section provides a quick, easy reference to names and terms covered in the manual. Dukane Corporation • Dukane Part No.
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Section 14 – Index A ABORT Status Display, Press............................. 27 Abort Switch.............................. 4, 26-27, 43, 47 About This Manual............................................ 3 Accessories.................................................... 3-4 Activation Switches..................................... 26-27 Acoustic Stack, Operational Text................. 54-56 Acoustical Absorbing Materials.......................... 4 Adjusting Press Height.....................................
Model 220/340 Press User's Manual Disassembly, Stack.......................................... 44 Display, Status, Press Base.......................... 26-27 Display, Status, DPC................................... 54-57 Distance Encoder, Alignment....................... 35-36 Distance Encoder, Installation...........12-13, 34-35 Down Speed Adjustment................ 32-34, 70, 76-77 DPC.................... 5, 35, 37-38, 49, 54-57, 68, 100 Dual Activation Switches.......................
Section 14 – Index IN CYCLE Status Display, Press......................... 27 INPUT TEST Display, DPC................................. 54 Inserts....................................................... 76-78 Installing the Distance Encoder.................... 34-36 Installing the Press System............................. 9-11 Installing the Stack........................................... 46 Installing the Press w/o Base............................ 10 Installing the Thruster.................................
Model 220/340 Press User's Manual Pressure, Press Clamping............................... 100 Pre-Trigger Control.......................................... 22 Primary Weld Chararacteristics.............................67 Pulse-Width Modulation, DPC.......................... 53 R READY Status Display, Press . .......................... 27 Reconditioning Stack.................................. 62-64 Regrind In Resin.............................................. 75 Regulator Select Switch....................
Section 14 – Index Trigger Method............................................... 38 Troubleshooting.......................................... 69-83 U Ultrasonic Frequencies............................. 19, 100 Ultrasonic Power Output, DPC........................ 100 Ultrasound Active Status Light............... 21, 23, 25 Ultrasound Contact Button, Stack...................... 42 Unauthorized Modifications............................... 3 Underwelding.................................................
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Section 1 – Introduction Dukane ISO ISO CERTIFICATION Dukane chose to become ISO 9001:2000 certified in order to demonstrate to our customers our continuing commitment to being a quality vendor. By passing its audit, Dukane can assure you that we have in place a well–defined and systematic approach to quality design, manufacturing, delivery and service. This certificate reinforces Dukane's status as a quality vendor of technology and products.
Model 220/340 Press User's Manual Please Refer to our Website At: www.dukane.com/us/sales/intsales.htm To Locate Your Local Representative 220/340 Press User's Manual Part No. 403–556–03 $100.00 Printed in the United States of America Dukane Intelligent Assembly Solutions • 2900 Dukane Drive St. • Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797–4949 Page 126 Dukane Part No.
