04 04 Intelligent Assembly Solutions 04 04 05 05 05 05 Dual Servo Spin Welder 06 06 06 06 07 07 User’s Manual 07 07 08 08 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 23 23 24 24 24 24 25 25 DUKANE Part No. 403–570-01 25 25 Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St.
Dual Servo Spin Welder User’s Manual Copyright © 2009 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.
Revision History Revision Number - 00 - 01 Revision Summary Date Original release. 10/24/2008 Menu language choices added; Revised Upper Tool Vacuum paragraphs 09/25/2009 Dukane Manual Part No.
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Dukane Dual Servo Spin Welder Contents Section 1 – Introduction 1 Section 2 – Safety Considerations 7 Section 3 – Unpacking and Setup 13 Section 4 – Display and Controls 21 Section 5 – Touch Screen Menus 27 Section 6 – Machine Operation 49 Section 7 – Optimizing Performance 57 Section 8 – Welder Data Export Software 65 Section 9 – Troubleshooting 71 Section 10 – Maintenance 81 Section 11 – Contacting Dukane 85 Section 12 – Specifications 89 Appendix A – Connector Pinouts 95 Appendi
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Section 1 - Introduction SECTION 1 Introduction Important User Information . . . . . . . . . . . . . . . . . . . . . 3 Read the Manual First . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Notes and Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Caution and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Drawings and Tables . . . . . .
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Section 1 - Introduction Important User Information Read This Manual First Before operating the Dual Servo Spin Welder, read this User’s Manual to become familiar with the system. This will ensure correct and safe operation. The manual is organized to allow you to learn how to safely operate this system. The examples given are chosen for their simplicity to illustrate basic setup procedures.
Dual Servo Spin Welder User’s Manual Dual Servo Spin Welder Overview The Dual Servo Spin Welder excels at frictional welding of assemblies and parts which require accurate angular orientation and collapse distance. The parts can be any shape and only the weld joint must be circular. The welder uses two electric servos: a servo motor for spinning the tool, and a servo actuator for moving the machine head up and down. Both servos have highresolution encoders, enabling accurate process control.
Section 1 - Introduction Key Dual Servo Spin Welder Features • • Color touch–screen display uses Color Active Matrix Thin–Film Transistors (TFT) for high contrast and wide viewing angle even under high ambient– lighting conditions. The 192 touch–cells provide a high performance interface. Commercial subassemblies are used to ensure a longer and more economical service life than units built with proprietary components. These readily available items also lessen the need for expensive field service calls.
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Section 2 - Safety Considerations SECTION 2 Safety Considerations Health and Safety Tips....................................9 Plastics Health Notice..........................................10 Run Switches.......................................................10 General Safety.....................................................10 Electrical Safety.............................................11 AC Power Receptacle ......................................... 11 Grounding.....................................
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Section 2 - Safety Considerations Health and Safety Tips Please observe these health and safety recommendations for safe, efficient, and injury-free operation of your welder. In this manual, the term welder and/or dual servo spin welder both refer to the Dual Servo Spin Welder. Proper Installation - Do not operate the Dual Servo Spin Welder until after the electrical system is properly installed. IMPORTANT Always wear a face shield when operating the welder.
Dual Servo Spin Welder User’s Manual Plastics Health Notice Before using any Dukane welding system, be sure you are familiar with OSHA regulations from the U.S. Department of Labor about the particular type of plastic(s) you are using. When plastic materials are being processed, some of them may emit fumes and/or vapors that could be hazardous (e.g. PVC – Polyvinyl Chloride can emit chlorine gas under certain processing conditions).
Section 2 - Safety Considerations Electrical Safety 240V AC Power Receptacle The power cord used on the Dual Servo Spin Welder has a two–blade, grounding type plug designed for 240 VAC at 20 Amps. It is designed to be plugged into a 240 VAC, 20 Amp NEMA type 6–20R receptacle as shown in Figure 2–1. Do not alter the plug or receptacle in any way.
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Section 2 - Safety Considerations SECTION 3 Unpacking and Setup Unpacking Welder.........................................15 Packing List...................................................15 Work Area......................................................15 Secure to Work Bench...................................16 Bench Capacity....................................................16 Leveling................................................................16 Mounting Holes......................................
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Section 3 - Unpacking and Setup Unpacking Welder The Dual Servo Spin Welder is normally packed in a corrugated carton resting on a wooden shipping pallet. To unpack the welder follow these steps. 1. Remove the straps from the carton. 2. Open the top of the carton. Carefully remove any packing materials, cables and documentation. 3. Cut the tape at the bottom corners and unfold the flaps. 4. Remove the corrugated carton, but leave the welder on the pallet. 5.
Dual Servo Spin Welder User’s Manual Securing to Work Bench Bench Capacity The Dual Servo Spin Welder weighs approximately 400 lbs. (182 kg). It should be attached to a table or bench capable of supporting 650 lbs. (295 kg) to accommodate the additional force imposed by the vertical movement of the motor and slide during the spin welding operation. Use mechanical means such as a forklift or hoist to place the servo spin welder on its work bench.
Section 3 - Unpacking and Setup Tooling Hub & Fixture The upper tooling attaches to a hub using four 5/16”- 18 screws, spring lock washers, and flat washers. Figure 3–2 (a & b) gives the dimensions of the tooling hubs. The hubs have precision slots to accommodate an indexing pin on the tool so that the tool can be mounted in a consistent orientation relative to the hub. 3.00 [76.2] B.C. 15X .316 [8.03] 22.5° TYP. The lower tooling fixture attaches to the base platen using M10–1.5 cap screws.
Dual Servo Spin Welder User’s Manual AC Power 240 Volt AC Socket (NEMA 6–20R) The Dual Servo Spin Welder requires a 240 VAC 1– phase outlet rated at 20 Amps. All machine models use the same power cord and plug. The AC power cord is permanently attached to the welder. The other end of the cable has a 240 VAC, 1–phase plug shown in Figure 3–4. This is designed for a NEMA 6–20R configuration wall receptacle shown in Figure 3–5. Directly below the AC cord strain relief is the AC power switch.
Section 3 - Unpacking and Setup Head Height Adjustment The support column features a threaded shaft for adjusting the overall height of the thruster head. The adjustment is secured by three lock nuts which prevent the thruster from moving once the overall height has been established. This is shown in Figure 3–7 and covered in detail in Chapter 6. A reference scale and index pointer are located next to the column to indicate the thruster head height.
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Section 4 - Display and Controls SECTION 4 Display and Controls Touch Screen Display....................................23 Operational Switches....................................24 Emergency Stop Switch.......................................24 Opti–Touch Run Switches....................................25 Data I/O Connector.......................................25 Dukane Manual Part No.
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Section 4 - Display and Controls Touch Screen Display The display is a 4.6 inch (12 cm) wide by 3.5 inch (9cm) tall color LCD screen shown in Figure 4-1. It contains an integrated touch screen with 192 touch–sensitive cells arranged as 16 rows of 12 columns. Touch Screen Display Trigger Indicator Setup parameters and mode selections are programmed through the touch screen. A closeup view of the controls is shown in Figure 4–2.
Dual Servo Spin Welder User’s Manual Operational Switches Emergency Stop Switch A red Emergency–Stop (E–STOP) switch is located in the center of the base as shown in Figure 4–3. The emergency stop switch must be in its reset position before the operate switches will function. To reset the Emergency Stop, twist the large red button about 45 degrees clockwise, which will cause the button to spring out. This is depicted in Figure 4–4.
Section 4 - Display and Controls Opti–Touch Run Switches Located on either side of the base are two optical Run switches. These are shown in Figure 4–3. These switches use Infrared (IR) sensors. They comply with OSHA and CE safety standards. Both switches are identical. Each optical–touch switch has a small red LED which is dimly illuminated whenever the power is on, as shown in Figure 4–5.
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Section 5 - Touch Screen Menus SECTION 5 Touch Screen Menus RUN Mode.....................................................29 Screen Layout......................................................29 VIEW PARTS.................................................30 SETUP Menu.................................................31 PRE-WELD Setup................................................31 WELD Setup........................................................34 POST-WELD Setup..........................................
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Section 5 - Touch Screen Menus RUN Mode When the welder is first turned on after the E-Stop switch is reset (see Figure 4-4), the STARTUP screen is displayed as shown in Figure 5–1 directing the operator to Activate both RUN SWITCHES to reset machine. Press both switches simultaneously and hold until a beep sounds, which will take several seconds.
Dual Servo Spin Welder User’s Manual bad part means one or more of the measured parameters was not within the limits set for the weld cycle. The Time and Date fields indicate the time and date the part was welded. Just below the WELD label, there are a number of fields with weld data for the last cycle.
Section 5 - Touch Screen Menus SETUP Menu The SETUP menu is sub-divided into three tabs: PRE-WELD, WELD, and POST-WELD that are described below. Immediately after pressing the SETUP button, the Security Code screen will appear, prompting for a numerical password. If no password has been set, press the ENTER key. PRE-WELD Setup The PRE-WELD screen, containing a number of settings and options described below, is shown in Figure 5-4.
Dual Servo Spin Welder User’s Manual TOP OF STROKE Position This button is used to set the vertical position to which the welder head returns after completing a weld cycle, as shown in Figure 5-7. A position of 0 corresponds to the highest position (which is also the machine “home” position). A non-zero setting indicates that the Top of Stroke (TOS) position is lower than the home position by the programmed amount. The TOS position can be entered directly by pressing the Position (mm) field.
Section 5 - Touch Screen Menus Part Pickup Option This button enables the Part Pickup option, which is programmed through the screen shown in Figure 59. This option is used in conjunction with automated part feed systems where it is desirable to place the parts to be joined on top of each other in the lower fixture. In this mode, the head travels down to “pick up” the upper part with the tool (without spinning), goes up slightly, and then completes the weld cycle.
Dual Servo Spin Welder User’s Manual The Move To button is used to rotate the tool to the value displayed in the Position (Deg.) field. After pressing this button, activate both RUN switches and wait for the value in the Jog Pos. (Deg.) field to match the Position (Deg.) value WELD Setup The WELD setup is the middle tab in the SETUP menu and is shown in Figure 5-11.
Section 5 - Touch Screen Menus Rotation Method In this method, the weld duration is controlled by completing a specified number of spin revolutions. The Weld Parameters button is used to enter the settings shown in Figure 5-13. The Weld Rotations field specifies the number of weld revolutions.
Dual Servo Spin Welder User’s Manual Energy Method In this method, weld duration is controlled by the amount of energy input into the weld joint as determined by the spin torque and angular rotation. The welder will maintain a constant spin speed until the programmed energy is produced. Then the tool will decelerate and stop. The Weld Parameters button is used to enter the settings shown in Figure 5-16. The Energy (J) field specifies the weld energy in Joules.
Section 5 - Touch Screen Menus Torque Trigger Option This option specifies a torque level to sense when the upper and lower parts make contact. Prior to contact, the motor is spinning the tool in the air using a very low amount torque. At contact, there is an increase in the torque required to maintain a constant angular velocity, at which point the weld is considered to start (i.e. the weld timer and counter are started). Note that the welder begins to sense the torque after reaching the TRIGGER Position.
Dual Servo Spin Welder User’s Manual Constant Torque Option This option sets the welder to function in “Melt-Match” mode, in which the press vertical speed is continuously adjusted to match the rate of plastic melt at the joint. This is achieved by measuring the spin torque and changing the verical speed on-the-fly based on this measurement. The vertical speed is inversely proportional to the spin torque: the lower the spin torque, the higher the vertical speed, and vice versa.
Section 5 - Touch Screen Menus changes the display to the screen shown in Figure 522. The MODE switch specifies if the Hold phase will be controlled by traveling a specified Distance or for a specified amount of Time. With Distance MODE selected as shown in Figure 522, the parameters for Hold motion are specified in the fields on the right and are divided into two sections: DYNAMIC and STATIC. During the Hold, the press will first complete the DYNAMIC phase, then the STATIC phase.
Dual Servo Spin Welder User’s Manual Part Tests The Part Tests section is used to define limits for the weld proocess and welder behavior for cases where the process is outside the limits. The Process Limits button is used to enter limits for weld process results as shown in Figures 5-25, 5-26, and 5-27. The following limits are available: 1. Weld Time (s) 2. Weld Rotations 3. Orientation (Deg.) 4. Weld Energy (J) 5. Peak RPM 6. Peak Torque (% of max.) 7. Peak Thrust (% of max.) 8.
Section 5 - Touch Screen Menus The bottom right corner of the POST-WELD screen contains controls for setting machine behavior when an out-of-limit condition occurs. The Latch on Failure button specifies if the out-of-limit condition will require an acknowledgement from the user before allowing the next cycle to start. This acknowledgement request is indicated by a button on the bottom of the RUN screen as shown in Figure 5-28.
Dual Servo Spin Welder User’s Manual TOOLS Menu SELECT SETUP Tab Pressing the Tools button displays the first tab labeled Select Setup. This contains eight buttons for selecting a setup file as shown in Figure 5–29. The Machine Cycle Count in the lower right corner is the total number of weld cycles that have occurred in the machine’s lifetime.
Section 5 - Touch Screen Menus field designates the position of the thruster (part of the welder surrounded by sheet metal covers) relative to the column as indicated by the scale affixed to the right side of the column and a white line printed on the rear of the welder. Once these settings are entered, pressing the DONE button causes a return to the main UTILITIES screen, where a yellow SAVE OTHER SETTINGS button appears.
Dual Servo Spin Welder User’s Manual [.15 in.] above tooling contact, if possible) and press the Set Position button. The stop block will be moved up, and a flashing circle will appear next to the DOWN button when this process is complete, indicating that the proximity switch is active. Press the DONE button to return to the SYSTEM SETUP screen. The Data Export button controls whether the weld parameter data displayed on the RUN screen (Weld Time, Rotations, etc.
Section 5 - Touch Screen Menus The Home Offset (Deg.) field is used to specify an angular offset of the homing spin orientation. The tooling hub home orientation is set at the factory such that the slot in the hub shown in Figure 3-2a is closest to the front of the machine. This position is the 0 degree reference for the spin motor and all spin orientations are defined relative to it. Unless a specific situation requires a nonzero offset, it is most convenient to retain the factory default value.
Dual Servo Spin Welder User’s Manual Setting Time and Date On Touch Screen The time and date displayed on the touch screen are preset at the factory for US Central Standard Time. They can be changed using the following procedure: 1. Press the upper left-hand corner (marked by 1 in Figure 5-37) and lower left-hand corner (marked by 2) at the same time. The screen shown in Figure 5-38 should appear. 2. Press the “Clock” button. The screen shown in Figure 5-39 should appear. 3.
Section 5 - Touch Screen Menus Parameter Value Range The minimum and maximum values of the welding parameters are listed in Table 5-I. Screen Parameter Name Min.Value TOOL Inertia Max.Value Resolution Units 1 kg* cm² 3000 (SVT012VR) 0 780 (SVT032VR) 160 (SVT042VR) SETUP> PRE-WELD TOOL Weight 0 25.0 0.1 kg SPIN Decel. 25 200 1 % TOP OF STROKE Position 0 140.00 0.01 mm TRIGGER Position 1.00 140.00 0.01 mm Part Pickup Position 1.00 140.00 0.
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Section 6 - Machine Operation SECTION 6 Machine Operation Machine Setup..............................................51 Starting a Weld Cycle....................................54 Stopping a Weld Cycle..................................55 Setup Sheet............................................. 55-56 Dukane Manual Part No.
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Section 6 - Machine Operation Machine Setup IMPORTANT The startup procedure given here is for a new machine that has just been installed. The Dual Servo Spin Welder is capable of developing substantial torque and high rotational velocity. Keep your hands and body away from the tool head during operation. The spinning head is capable of inflicting serious injury. Never attempt to retrieve a part from a spinning tool head. Always wear a face shield when operating the Dual Servo Spin Welder.
Dual Servo Spin Welder User’s Manual 5. Reset E-Stop Reset the emergency stop button by turning clockwise. Refer to Figure 4-4. The status display on the base will change from ABORT in red to POWER in green. 6.Turn Power ON Turn on the AC power switch. 7. Set Tool Parameters On the touch screen, press the SETUP button. Press Enter on the ENTER SECURITY CODE screen if no password has been previously set, or type in the password and then Enter.
Section 6 - Machine Operation Since the welder press force is limited in jog mode for safety purposes, the machine will disable the servos and report an error (Fault: Jog thrust limit exceeded OR Vertical servo runaway detected.) if the press is jogged down too far. If this condition occurs, the welder must be re-initialized by returning to the RUN screen, pressing RESET FAULT button, and repeating welder initialization (Step 8). 10.
Dual Servo Spin Welder User’s Manual Starting A Weld Cycle All weld cycles must be initiated from the RUN screen after the machine is initialized and with the press at the top-of-stroke position. If not already on this screen, press the RUN button first (see Figure 5-2). If you had powered down the welder or pressed the Abort button, the screen may instruct you to press the RESET FAULT button and then reset the machine by activating the RUN switches.
Section 6 - Machine Operation Stopping a Weld Cycle During normal operation, the cycle stops automatically when the specified weld and hold phases are completed and the press returns to the top-of-stroke position. To stop a cycle before it completes, press the E-stop switch on the base, which terminates the cycle and causes power to be removed from both servo motors. Setup Sheet On the following page is a table containing all the machine settings for the Dual Servo Spin Welder.
Dual Servo Spin Welder User’s Manual DUAL SERVO SPIN WELDER - SETUP SHEET APPLICATION DATE MACHINE SETUP NUMBER TOUCH SCREEN SETTING VALUE TOOL INERTIA (KG*CM^2) TOOL W EIGHT (KG) TOOL SETUP SETUP > PREWELD SVT0___2VR MACHINE MODEL SPIN DECEL. (%) VAC.
Section 7 - Optimizing Performance SECTION 7 Optimizing Performance Spin Welding Process...................................59 Material Considerations.................................59 Control Parameters.......................................60 Surface Speed (RPM)..........................................60 Press (Axial) Speed.............................................62 Weld Depth..........................................................62 Hold...........................................................
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Section 7 - Optimizing Performance Spin Welding Process The formal definition of spin welding is “An assembly process in which thermoplastic parts with rotationally– symmetric mating surfaces are joined together under pressure using unidirectional circular motion. The heat generated during the rotational contact melts the plastic in the heat–affected zone forming a weld upon cooling.” Note that the parts themselves can be any shape, only the mating surfaces to be welded need to be circular.
Dual Servo Spin Welder User’s Manual Material filler and surface contaminants (e.g. mold release agent) are two factors that will affect consistency and weld repeatability. Spin welding is more tolerant of contaminants than ultrasonic welding. Spin welding is also less affected by hygroscopic polymers, although they may still require special handling for critical applications. The moisture content can lead to bubble formation in the joint resulting in decreased weld strength.
Section 7 - Optimizing Performance surface speeds between 360 and 600 in./sec. However, speeds of 120 in./sec. and lower have been used with good results. The mathematical relationship between surface speed and spin speed (RPM) is given by the equation: RPM = where 60 v πD v is the surface velocity D is the average weld diameter A plot of the spin speed and average weld diameter for a number of surface speed values is shown in Figure 7-1.
Dual Servo Spin Welder User’s Manual Press (Axial) Speed The press speed affects the amount of contact pressure between the parts being welded, which is required to generate frictional heat. The larger the speed, the larger the rate of heat rise. In combination with the surface speed, press speed must be high enough to cause melting at the interface as opposed to grinding, but not too high as to damage the parts.
Section 7 - Optimizing Performance Since weld depth affects the joint strength and the amount of flash generated, it is important to design the weld joint properly to meet both requirements simultaneously. The incorporation of flash trap features is recommended to produce acceptable appearance without compromising strength. Hold During the hold phase, vertical press travel initially brings the molten parts closer together (dynamic hold) and then allows the molten material to solidify (static hold).
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Section 8 - Welder Data Export Software SECTION 8 Welder Data Export Software Introduction....................................................67 Hardware and Software Requirements.........67 Installation, Startup and Cable Connections...........................67 Part Data.......................................................68 Profile Graphs...............................................69 Servo and Debug..........................................70 Dukane Manual Part No.
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Section 8 - Welder Data Export Software Introduction A Windows™ application named Dual Servo Spin Welder Utility, can be used to capture data exported by the welder to a PC. This application is also capable of importing the servo tuning database, and obtaining messages from the machine that may be useful in troubleshooting. Hardware and Software Requirements The utility requires a PC or laptop running a Windows 2000™, XP™, or Vista™ operating system.
Dual Servo Spin Welder User’s Manual Part Data Upon startup, the screen will appear as shown in Figure 8-1, with the Part Data tab selected by default. The following is a description of the items on this tab: PART DATA List This area contains a series of lines of part data, one line per part. This data is displayed after each cycle if the Data Export option in the System Setup screen on the welder is enabled (See Figure 5-32.). The data is comma delimited with the fields given in the order as follows: 1.
Section 8 - Welder Data Export Software File Write Sets the write behavior for an existing file. Write Over overwrites an existing file, while Add On appends data to the end of the file. Incoming Data This indicator will flash when data is being received from the welder. EXIT Exits program. Profile Graphs The PROFILE GRAPHS tab, shown in Figure 8-2, contains numerical and graphical representations of the following weld parameter profiles with respect to time for the last cycle: 1. Spin Position (rev.
Dual Servo Spin Welder User’s Manual Spin Torque Setpoint If torque triggering is enabled, the Torque Trigger value is displayed in this box for reference as a percentage of the spin motor maximum. WRITE TO FILE Writes the torque data to a file. Add a .txt or .csv extension to the end of the file name as the generated file is in ASCII format. Servo and Debug The SERVO PARAMETERS tab provides the ability to import a servo tuning database file.
Section 9 - Troubleshooting SECTION 9 Troubleshooting Welding Process............................................73 Material Choice....................................................73 Parameter Effects................................................73 Troubleshooting...................................................73 Welder...........................................................74 Mechanical...........................................................74 Electrical Power..............................
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Section 9 - Troubleshooting Welding Process Material Choice A family of thermoplastics is usually compatible with its own type and sometimes with other types. Characteristics to consider are the melting point and coefficient of linear expansion. Even members of the same family may cause problems due to differences in the manufacturing process. For example, an extruded Polyethylene (PE) piece may not weld as well to an injection molded PE piece as it would to another extruded PE piece.
Dual Servo Spin Welder User’s Manual Welder Mechanical The part fixture should be securely mounted perpendicular to, and centered under the spin axis. Electrical Power Make sure the AC power cord is plugged in to a 240 VAC, 1–phase electrical outlet with a 20 Ampere capacity. Check that the circuit is live. Also refer to Electrical Safety in Chapter 2. Base Interface Cable The cable must be plugged in to the base and the back of the press.
Section 9 - Troubleshooting Table 9–I Problem Overwelding Underwelding Welding Process Troubleshooting Symptom Possible Cause Recommended Solution Excessive weld flash Weld Time or Distance are too large Reduce Weld Time or Distance Welded assembly dimensions are too small Incorrect flash trap design Evaluate and correct flash trap design Low strength weld Weld Time or Distance are too small Increase Weld Time or Distance Material difficult to weld due to low friction coefficient Degrease jo
Dual Servo Spin Welder User’s Manual Table 9-II Machine Display Messages Message Description Cause Possible Solution Instructions Activate both RUN SWITCHES to reset machine Activate both RUN SWITCHES to reset machine after all motion stops Resetting of machine at startup or recovery requires the activation of both optical switches on base. Resetting of machine at startup or recovery must be initiated when the spin tool and press are stationary. - - - - Faults 1.
Section 9 - Troubleshooting Table 9-II Machine Display Messages (continued) Message Spin motor not on Spin servo amplifier faulted Description Spin servo amplifier does not power up There is a problem with the spin servo amplifier Cause Internal machine error Contact DUKANE service 1. 2. 1. 2. 3. 3. 4.
Dual Servo Spin Welder User’s Manual Table 9-II Machine Display Messages (continued) Message Description Cause Possible Solution Errors Axis stopped before weld end Spin stop before weld start Timeout on finding vertical lower limit position Timeout on torque sense Timeout on User Upper Part vacuum detect Motion on spin or vertical axes stopped before weld ended Servo controller error Moving the vertical lower limit up to desired position failed The torque trigger was not detected within the allowab
Section 9 - Troubleshooting Table 9-II Machine Display Messages (continued) Message Description Cause Possible Solution Warnings Battery life limit, press Continue Lower limit is greater than upper limit Move to Top Of Stroke before welding Process RPM is too high TOS to trigger distance is too small Vertical weld speed is too high Weld duration too short Weld trigger position is below vertical travel lower limit.
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Section 10 - Maintenance SECTION 10 Maintenance Touch Screen Display....................................83 AC Power Cord.............................................83 Maintenance..................................................83 Dukane Manual Part No.
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Section 10 - Maintenance Touch Screen Display Do not use any solvents or abrasive cleaners on the touch screen. Apply a small amount of computer cleaner to a soft towel first. Clean the panel with the moistened towel. Do not spray or apply a cleaner directly to the interface panel. Remove grease by rubbing lightly with isopropyl alcohol. Afterward, provide a final cleaning using a CAUTION Never use anything sharp on the touch screen. Only use your finger.
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Section 11 - Contact Dukane SECTION 11 Contacting Dukane Contacting Dukane........................................87 Identify Equipment...............................................87 Ultrasonics Division..............................................87 Website................................................................87 Dukane Manual Part No.
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Section 11 - Contact Dukane Contacting Dukane Identify Equipment When contacting Dukane about a service–related problem, be prepared to give the following information: • SVT Model number and serial number • Any error indicators from the Touch Screen Display • Description of the problem and steps taken to resolve it Some 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 12 - Specifications SECTION 12 Specifications Tooling Specifications....................................91 Machine Weight.............................................91 Power Requirements.....................................91 Operating Environment.................................91 Dimensions & 5–View Drawing.....................92 Identification Numbers...................................93 Regulatory Agency Compliance....................93 Dukane Manual Part No.
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Section 12 - Specifications Tooling Specifications Tooling Size Refer to Table 5-I for maximum tooling sizes. Machine Weight The Dual Servo Spin Welder weighs approximately 400 lbs. (182 kg). It should be mounted on a table or bench capable of supporting 650 lbs. (295 kg) to accommodate the additional force imposed by the vertical movement of the motor and slide during the spin welding operation. Use mechanical means such as a forklift or hoist to place the servo spin welder on its work bench.
Dual Servo Spin Welder User’s Manual Figure 12–2 Dual Servo Spin Welder Dimensions NOTE: All specifications are subject to change without notice. The specifications listed are current at the time of publication. Page 92 Dukane Manual Part No.
Section 12 - Specifications Identification Numbers Welder Model & Serial Number The serial number and model number tag for the Dual Servo Spin Welder are located either on the covers on the back of the machine or on the underside of the motor mounting plate just above the tooling hub. Regulatory Agency Compliance CE Marking This mark on your equipment certifies that it meets the requirements of the EU (European Union) concerning interference causing equipment regulations.
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Appendix A APPENDIX A Connector Pinouts Base Interface Connector..............................97 User I/O Connector.......................................98 Slide Kit Connector........................................99 Data Port Connector....................................100 Automation Wiring............................... 100-101 Dukane Manual Part No.
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Appendix A Base Interface Connector The base interface connector is a DB 9–socket connector. A closeup of the base connector is shown in Figure 2–2, and a closeup of the rear thruster connector is shown in Figure 3–8. The pin numbers for the connector are shown in Figure A–1. The pin assignments and signal descriptions are given in Table A—I. A schematic of the Operate and Abort switches connected through the base Interface Connector is shown in Figure A-5.
Dual Servo Spin Welder User’s Manual User I/O Connector The User I/O connector is a HD–15 connector located directly above the base interface connector on the rear of the thruster. The connector is shown in Figure 3–8. This connector provides access to signals for interfacing to custom automation equipment. The pin numbers for the connector are shown in Figure A–2. The pin assignments and signal descriptions are given in Table A-II.
Appendix A Slide Kit Connector The slide kit interface is a round 16–pin connector located directly to the right of the base interface connector on the rear of the thruster. The Dual Servo Spin Welder is prewired to accept a Dukane slide kit without any modification or reprogramming of the press. The connector is shown in Figure 3–8.
Dual Servo Spin Welder User’s Manual Data Port Connector The computer interface connector is located on the back of the welder above the power switch as shown in Figure A-4. It provides a computer connection to export part data and weld profile graphs. The pin numbers for the connector are shown in Figure A–4. Automation Wiring If the Dual Servo Spin Welder will be used in Automation mode, the signals normally generated by the optical switches and abort switch must be reproduced.
Appendix A Figure A–5 Schematic of Operate and Abort Figure A–6 Wiring for Automation Dukane Manual Part No.
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Appendix B APPENDIX B Tooling Moment of Inertia........................................105 Explanaton of Inertia..........................................105 Calculating the Moment of Inertia...................... 105 Tooling and Fixure Design...........................106 Dukane Manual Part No.
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Appendix B Moment of Inertia Explanation of Inertia The moment of inertia is a measure of the mass and the mass distribution of the tool. It is defined mathematically as the product of the mass times the distance of that mass from the axis of rotation squared.
Dual Servo Spin Welder User’s Manual Tool and Fixture Design The most important aspect of tool and fixture design is that it is safe. Please note that using tools not provided by Dukane may result in voiding of the warranty – consult Dukane for details.
Appendix C APPENDIX C Optional Features Upper Tool Vacuum ....................................109 Remote Touch Screen ................................110 Dukane Manual Part No.
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Appendix C Upper Tool Vacuum As an aid in holding the spinning part, the welder can optionally be equipped with vacuum in the upper tool by installing a vacuum system kit (#438963 for models SVT032VR & SVT042VR; and #438-964 for model SVT012VR). This kit includes all components needed to generate, control, and transfer the vacuum to the tool using an external compressed air supply (not provided with welder). It mounts to the welder as shown in Figure C-1.
Dual Servo Spin Welder User’s Manual Remote Touch Screen In situations where it is desriable to provide access to the touch screen some distance away from the welder, the remote touch screen kit (#438-965) can be used. The touch screen is mounted in a separate enclosure as shown in Figure C-2, which can be up to 15 ft. (4.5 m) away from the welder. Two cables (power and communcations) are needed to connect the touch screen with the welder.
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.
Please refer to our website at: www.dukane.com/us/sales/intsales.htm to locate your local representative. Dual Servo Welder User's Manual Part No. 403–570–01 www.dukane.com/us Printed in the United States of America Dukane Corporation • Ultrasonics Division • 2900 Dukane Drive St.
