Dukane 403-570-01 - Manuals

Dukane Manual Part No. 403-570-01 Page 3 Section 1 - Introduction NOTE NOTE statements provide additional in-formation or highlight procedures . CAUTION CAU TI O N st atement s i den -tify conditions or practices that could result in damage to the equipment or other proper ty . WARNING WARNING state...

Dukane Manual Part No. 403-570-01 Page 7 Section 2 - Safety Considerations Health and Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Plastics Health Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Run Switches . . . . . ...

Dukane Manual Part No. 403-570-01 Page Section 2 - Safety Considerations IMPORTANT N e v e r o p e r a t e t h e D u a l S e r v o S p i n W e l d e r w i t h t h e p r o t e c t i ve s h e e t m e t a l removed . This is an unsafe practice and can result in injury . IMPORTANT Always wear a face shi...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page 10 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...

Dukane Manual Part No. 403-570-01 Page 11 Section 2 - Safety Considerations IMPORTANT Always turn off the AC power at the power switch before ser vicing or working on the welder . Failure to turn off the AC power is an unsafe practice and can result in injury or death . GND G 240V Grounding Lug J35 ...

Dukane Manual Part No. 403-570-01 Page 13 Section 2 - Safety Considerations Unpacking Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Packing List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Work Area . ...

Dukane Manual Part No. 403-570-01 Page 15 Section 3 - Unpacking and Setup Qty Item Part Number 1 Dual Servo Spin Welder SVT012VR orSVT032VR orSVT042VR 1 Base Interface Cable 200-1124-3 or200-1545-01 1 Dual Servo Spin Welder Manual 403-570-XX 1 CD with Dual Servo Spin Welder Utility ___ Unpacking Wel...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page 1 WARNING DO NOT LIFT the Dual Ser-vo Spin Welder manually. Lifting and/or moving the welder manually could re-sult in personal injury. Use mechanical means to move and place the welder. Two 1 / 2 " Holes On 13 1 / 4 ...

Dukane Manual Part No. 403-570-01 Page 17 Section 3 - Unpacking and Setup Dimensions are in INCHES [mm] 3.60 [91.4]  1.000 - .001 .000 + 25.40 - .03 .00 + [ ]  .30 [7.6] .21 [5.3] 22.5° TYP.  3.00 [76.2] B.C.  .316 [8.03] 15X .250 - .000 .002 + 6.35 - .00 .05 + [ ] 5.90 [149.9]  1.000 - .001 .0...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page 1 240 Volt AC Plug (NEMA 6–20P) 240 Volt AC Plug (NEMA 6–20P) 240 Volt AC Socket (NEMA 6–20R) 240 Volt AC Socket (NEMA 6–20R) AC Power Switch AC Power Cord AC Power The Dual Servo Spin Welder requires a 240 VAC 1– phase outl...

Dukane Manual Part No. 403-570-01 Page 1 Section 3 - Unpacking and Setup Head HeightAdjustment 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 heig...

Dukane Manual Part No. 403-570-01 Page 1 Section 4 - Display and Controls Touch Screen Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23Operational Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Emergency Stop Switch . . . . . . . . ....

Dukane Manual Part No. 403-570-01 Page 3 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. ...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page 4 Right Run Switch Lower Fixture Lower Fixture E–Stop Switch Left Run Switch ABORT POWER IN CYCLE Twist to Rese t Twist to Rese t Operational Switches Emergency Stop Switch A red Emergency–Stop ( E–STOP ) switch is located i...

Dukane Manual Part No. 403-570-01 Page 5 Section 4 - Display and Controls Dimly Lit Red LED Brigtly Lit Red LEDs 1 1 6 6 9 9 5 5 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 comp...

Dukane Manual Part No. 403-570-01 Page 7 Section 5 - Touch Screen Menus RUN Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Screen Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

Dukane Manual Part No. 403-570-01 Page 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 bo...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page 30 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 numbe...

Dukane Manual Part No. 403-570-01 Page 31 Section 5 - Touch Screen Menus Figure 5–6 Sample Data Entry Screen 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 ...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page 3 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 ...

Dukane Manual Part No. 403-570-01 Page 33 Section 5 - Touch Screen Menus Transfer Button f The transfer icon should only be used when visually aligning the pre–spin orientation . The value displayed in the Jog (Deg.) cell has to be transferred to the Pre-Spin data field. IMPORTANT You must select th...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page 34 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 P...

Dukane Manual Part No. 403-570-01 Page 35 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 speci...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page 3 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 pr...

Dukane Manual Part No. 403-570-01 Page 37 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 a...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page 3 Figure 5–21 POST-WELD Main Setup Screen 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 t...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page 40 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 re...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page 4 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...

Dukane Manual Part No. 403-570-01 Page 43 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 o...

Dukane Manual Part No. 403-570-01 Page 47 Section 5 - Touch Screen Menus Screen Parameter Name Min.Value Max.Value Resolution Units SETUP> PRE-WELD TOOL Inertia 0 3000 (SVT012VR) 780 (SVT032VR) 160 (SVT042VR) 1 kg* cm² TOOL Weight 0 25 .0 0 .1 kg SPIN Decel . 25 200 1 % TOP OF STROKE Position 0 1...

Dukane Manual Part No. 403-570-01 Page 4 Section 6 - Machine Operation Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51Starting a Weld Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54Stopping a Weld Cycle . . . ....

Dukane Manual Part No. 403-570-01 Page 51 Section 6 - Machine Operation IMPORTANT The Dual Servo Spin Welder is capable of developing substantial torque and high rot ational velocit y. Keep your hands and body away from the tool head during o p e r a t i o n . Th e sp i n ni n g head is capable of i...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page 5 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...

Dukane Manual Part No. 403-570-01 Page 53 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 dow...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page 54 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...

Dukane Manual Part No. 403-570-01 Page 55 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 t...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page 5 DUAL SERVO SPIN WELDER - SETUP SHEET A PPLICATION M ACHINE M ODEL SVT0___2VR D ATE M ACHINE S ETUP N UMBER TOUCH SCREEN SETTING VALUE TOOL I NERTIA ( KG * CM ^2) TOOL W EIGHT ( KG ) SPIN D ECEL . (%) V AC . S ENSE ON  OFF...

Dukane Manual Part No. 403-570-01 Page 57 Section 7 - Optimizing Performance Spin Welding Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59Material Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59Control Parameters . . . . . . . . . . . . ....

Dukane Manual Part No. 403-570-01 Page 5 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 ...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page 0 NOTE Common hygroscopic thermoplatics:ABS/Polycarbonate (Cycoloy) Polyoxymethylene (Acetal, Delrin) Polyamides (Nylon, Zytel) Polycarbonate (Lexan) Polycarbonate/Polyester (Xenoy) Polysulfone (Udel) Material filler and sur...

Dukane Manual Part No. 403-570-01 Page 1 Section 7 - Optimizing Performance 2000 3000 4000 0 1000 1 2 4 6 8 10 12 3 RPM Average Weld Diameter (inch) D Spin Speed (rev/min) v = 240 v = 360 v = 480 v = 120 v = 600 v = 720 v = 960 in/sec v = 840 120 in/sec = 10 ft/sec — 3 m/sec240 in/sec = 20 ft/sec — ...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page 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...

Dukane Manual Part No. 403-570-01 Page 3 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 recommend...

Dukane Manual Part No. 403-570-01 Page 5 Section 8 - Welder Data Export Software Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 Hardware and Software Requirements . . . . . . . .67Installation, Startup and Cable Connections . . . ...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page Figure 8–1 Utility Startup Screen 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 Thi...

Dukane Manual Part No. 403-570-01 Page Section 8 - Welder Data Export Software Figure 8–2 PROFILE GRAPHS Tab 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...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page 70 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 o...

Dukane Manual Part No. 403-570-01 Page 71 Section 9 - Troubleshooting Welding Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 Material Choice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Param...

Dukane Manual Part No. 403-570-01 Page 73 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...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page 74 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 2...

Dukane Manual Part No. 403-570-01 Page 1 Section 10 - Maintenance SECTION 10 Maintenance Touch Screen Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83AC Power Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83Maintenance . ...

Dukane Manual Part No. 403-570-01 Page 3 Section 10 - Maintenance CAUTION Never use anything sharp on the touch screen. Only use your finger. The screen is intended for industrial use, but can be damaged by scratching or puncturing. Touch Screen Display Do not use any solvents or abrasive cleaners o...

Dukane Manual Part No. 403-570-01 Page 5 Section 11 - Contact Dukane Contacting Dukane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87 Identify Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Ultrasonics Divisio...

Dukane Manual Part No. 403-570-01 Page 7 Section 11 - Contact Dukane Website The website has information about our products, processes, solutions, and technical data. Downloads are available for many kinds of literature. You can locate your local representative at: www.dukcorp.com/us/sales/intsales....

Dukane Manual Part No. 403-570-01 Page Section 12 - Specifications SECTION 12 Specifications Tooling Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91 Machine Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91Power Re...

Dukane Manual Part No. 403-570-01 Page 1 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 ...

Dukane Manual Part No. 403-570-01 Page 3 Section 12 - Specifications CAUTION DO NOT make any modifica-tions to the Dual Ser vo Spin Welder . The changes may re-sult in violating one or more regulations under which this equipment is manufac tured .  CE Marking This mark on your equipment certifies t...

Dukane Manual Part No. 403-570-01 Page 5 Appendix A Base Interface Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97User I/O Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98Slide Kit Connector . . . . . . . . . . . . . . . . . . . . . . . ...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page 100 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 ...

Dukane Manual Part No. 403-570-01 Page 103 Appendix B APPENDIX B Tooling Moment of Inertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105 Explanaton of Inertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Calculating the Mo...

Dukane Manual Part No. 403-570-01 Page 105 Appendix B USEFUL UNIT CONVERSIONS 1 in . = 2 .54 cm = .025 m 1 lb . = 0 .45 kg 1 cm = 0 .39 in . 1 m = 39 .4 in . 1 kg = 2 .20 lb . Moment of Inertia Explanation of Inertia The moment of inertia is a measure of the mass and the mass distribution of the too...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page 10 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. Seve...

Dukane Manual Part No. 403-570-01 Page 107 Appendix C Upper Tool Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109Remote Touch Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 APPENDIX C Optional Features

Dukane Manual Part No. 403-570-01 Page 10 Appendix C Upper Tool Vacuum As an aid in holding the spinning part, the welder can optionally be equipped with vacuum in the up- per tool by installing a vacuum system kit (#438-963 for models SVT032VR & SVT042VR; and #438-964 for model SVT012VR). This ...

Dual Servo Spin Welder User’s Manual Dukane Manual Part No. 403-570-01 Page 110 Remote Touch Screen Figure C-2 Remote Touch Screen Components 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 us...

Dukane ISO ISO CERTIFICATION Dukane chose to become ISO 9001:2000 certi-fied 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, manu-...

Dukane Corporation • ultrasonics Division • 2900 Dukane Drive St. • Charles, Illinois 60174 uSA • TEL (630) 797-4900 • FAX (630) 797–4949 Part No. 403–570–01 Dual Servo Welder User's Manual Printed in the united States of America www.dukcorp.com/us Please refer to our website at : www.dukcorp.com/us...