Dukane 403570-01 User Manual
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Dukane 403570-01 User Manual

Dukane 403570-01 User Manual

Dual servo spin welder
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Intelligent Assembly Solutions
Dual Servo Spin Welder
User's Manual
DUKANE Part No. 403–570-01
Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797–4949
ISO 9001:2000
www.dukane.com/us
Dukane products are manufactured
in ISO registered facilities

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  • Page 1 Intelligent Assembly Solutions Dual Servo Spin Welder User’s Manual DUKANE Part No. 403–570-01 Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797–4949 ISO 9001:2000 www.dukane.com/us Dukane products are manufactured...
  • Page 2 Printed in the United States of America. Dukane Part Number: 403-570-01 Dukane ultrasonic equipment is manufactured under one or more of the following U.S. Patents: 3,780,926 3,825,481 4,131,505 4,277,710 5,798,599 5,880,580 6,984,921, 7,225,965, and 7,475,801.

  • Page 3: Revision History

    Revision History Revision Revision Number Summary Date - 00 Original release. 10/24/2008 - 01 Menu language choices added; Revised Upper Tool Vacuum paragraphs 09/25/2009 Page iii Dukane Manual Part No. 403-570-01...
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  • Page 5: Table Of Contents

    Dukane Dual Servo Spin Welder Contents Section 1 – Introduction Section 2 – Safety Considerations Section 3 – Unpacking and Setup Section 4 – Display and Controls Section 5 – Touch Screen Menus Section 6 – Machine Operation Section 7 – Optimizing Performance Section 8 –...
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  • Page 7: Section 1 - Introduction

    Dual Servo Spin Welder Overview . . . . . . . . . . . . . . . 4 Dual Servo Spin Welder Key Features . . . . . . . . . . . . 5 Page 1 Dukane Manual Part No. 403-570-01...
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  • Page 9: Important User Information

    –I, –II, –III). As an example, Figure 3–2 would be the second illustration in section three while Table 3—II would be the second table in section three. Condition Electrical Crush or Practice Hazard Hazard Page 3 Dukane Manual Part No. 403-570-01...

  • Page 10: Dual Servo Spin Welder Overview

    Both servos have high- resolution encoders, enabling accurate process control. Dukane offers three models: SVT012VR, SVT032VR, and SVT042VR. Model differences are in the maximum speed, power and torque of the spin servo motor (the same vertical servo actuator is used in each).

  • Page 11: Welder Features

    Spin and vertical servo load and position data can be downloaded to a PC for review via RS-232. • Digital timer for weld time and hold time gives precise control of the spin welding process. Page 5 Dukane Manual Part No. 403-570-01...
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  • Page 13: Section 2 - Safety Considerations

    Mechanical Safety ........11 Dukane Manual Part No. 403-570-01...
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  • Page 15 No Unauthorized Modifications - Do not modify your welder . Dual Servo Spin Welder in any way unless authorized to do so by Dukane Corporation. Unauthorized modifications may cause injury to the operator and/ or equipment damage. In addition, unauthorized modifications will void the equipment warranty.

  • Page 16: Plastics Health Notice

    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.

  • Page 17: Electrical Safety

    Be extremely careful not to let long sleeves, ties, necklaces or long hair become entangled in the welder during operation. Always turn machine power off when installing or removing tooling. Dukane Manual Part No. 403-570-01 Page 11...
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  • Page 19: Section 3 - Unpacking And Setup

    Slide Kit Connector ..........19 Dukane Manual Part No. 403-570-01...
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  • Page 21: Work Area

    Table 3-I. Inspect the welder for SVT042VR damage. Report any damage immediately to the carrier 200-1124-3 or and to Dukane Ultrasonics Service at (630) 762–4900. Base Interface Cable 200-1545-01 Also see Section 11 for information on contacting...

  • Page 22: Bench Capacity

    12mm or 7/16” diameter bolts. We recommend that you securely attach the welder base to the work table using these mounting holes. " Holes On 13 " Centers Figure 3–1 Mounting Hole Locations on Base Page 1 Dukane Manual Part No. 403-570-01...

  • Page 23: Tooling Hub & Fixture

     .000 (66.8) 1.000 25.40 5 PLACES .35 [8.9] - .001 - .03 inches (millimeters) Dimensions are in INCHES [mm] Figure 3–3 Lower Base Fixture Mounting Figure 3–2b Upper Tooling Hub Dimensions for SVT012VR Dukane Manual Part No. 403-570-01 Page 17...
  • Page 24 Figure 3–4 20–Amp 240V Figure 3–5 20–Amp 240V is identical on all models and is shown in Figure 3–6. Plug Receptacle AC Power Cord AC Power Switch Figure 3–6 AC Power Switch and Power Cord Page 1 Dukane Manual Part No. 403-570-01...

  • Page 25: Control Connectors

    To the right of the DB–9 base interface connector is a round 16–pin connector for controlling the optional Slide Kits. This is shown in Figure 3–8. The pinout for this connector is given in Appendix A. Figure 3–8 Electrical Control Connectors Dukane Manual Part No. 403-570-01 Page 1...
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  • Page 27: Section 4 - Display And Controls

    Data I/O Connector ........25 Dukane Manual Part No. 403-570-01...
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  • Page 29 Chapter 5. The touch cell on the right labeled displays part data for the previously welded Part Data assemblies. Upper Tooling Figure 4–1 Dual Servo Spin Welder Touch Screen Panel Figure 4–2 Startup Screen Dukane Manual Part No. 403-570-01 Page 3...
  • Page 30 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. E–Stop Switch Figure 4–3 Operate Switches and E–Stop Figure 4–4 Setting and Resetting the E–Stop Page 4 Dukane Manual Part No. 403-570-01...
  • Page 31 A pinout of the Data I/O connector is provided in Appendix A. Detailed information on the data that can be obtained from the welder is given in Chapter 8. Figure 4–7 DB–9 Data I/O Connector Dukane Manual Part No. 403-570-01 Page 5...
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  • Page 33: Section 5 - Touch Screen Menus

    Parameter Value Range .......47 Page 7 Dukane Manual Part No. 403-570-01...
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  • Page 35: Run Mode

    “–” if no limits were violated, “ ” for suspect part, “ ” for a bad part, or “ ” for an error. A suspect or Page  Dukane Manual Part No. 403-570-01...

  • Page 36: View Parts

    This is shown in Figure 5–3. The Page Up buttons permit you to scroll through part Page Down data one screen at a time, Press the button to return to the screen. Figure 5–3 VIEW PARTS Screen Page 30 Dukane Manual Part No. 403-570-01...

  • Page 37: Setup Menu

    A “frowning” face will be displayed on the screen if this signal is not active. Press the button to return to the DONE PRE-WELD setup screen. Figure 5–6 Sample Data Entry Screen Page 31 Dukane Manual Part No. 403-570-01...
  • Page 38 Position can be TRIGGER entered directly into the Position (mm) field or taught by jogging the head as described in setting the TOP OF Figure 5–8 TRIGGER Position Setup Screen in Position. STROKE PRE-WELD Menu Page 3 Dukane Manual Part No. 403-570-01...
  • Page 39 You must select the RUN pressing the buttons and activating the DOWN mode to test any of the RUN switches. setups . Both RUN switches must then be activated simultaneously . Page 33 Dukane Manual Part No. 403-570-01...
  • Page 40 The . field specifies the spin direction. The button causes a DONE Figure 5–12 Weld Parameters Screen for Time Method return to the main tab screen. WELD Page 34 Dukane Manual Part No. 403-570-01...
  • Page 41 VERT Speed (mm/s) SPIN RPM same as in the Time Method. The button causes DONE a return to the main tab screen. WELD Figure 5–15 Weld Parameters Screen for Distance Method with Absolute Switch Selection Page 35 Dukane Manual Part No. 403-570-01...
  • Page 42 After selecting this button, activate Weld both RUN switches until the spin tool stops moving. Press to return to the main tab screen. DONE WELD Page 3 Dukane Manual Part No. 403-570-01...
  • Page 43 Repeat Steps 5 and 6 several times to determine the largest torque value. Enable the and set the Torque Trigger Option field to be slightly larger (at Torque (% of max .) least 2%) than the number from the previous step. Page 37 Dukane Manual Part No. 403-570-01...

  • Page 44: Post-Weld Setup

    Hold phase of the weld cycle. During this phase, the molten plastic cools and solidifies, beginning Figure 5–21 POST-WELD Main Setup Screen when the spin tool stops. Pressing the button Hold Setup Page 3 Dukane Manual Part No. 403-570-01...
  • Page 45 0. This value is entered in the field in Speed (mm/s) section. DYNAMIC Figure 5–24 Graph of Vertical Speed vs . Vertical Torque for Constant Thrust Option Page 3 Dukane Manual Part No. 403-570-01...
  • Page 46 … button shows additional limits, and More Limits button causes the screen to return to the DONE Figure 5–26 Process Limit Definitions Screen 2 of 3 main menu. POST-WELD Figure 5–27 Process Limit Definitions Screen 3 of 3 Page 40 Dukane Manual Part No. 403-570-01...
  • Page 47 If it is set to , the field will display Bad (Abort) Limits if the process parameter was lower than the Lower limit, and if the process parameter was higher than the Upper limit. Page 41 Dukane Manual Part No. 403-570-01...

  • Page 48: Tools Menu

    The Upper fields can be populated with Tool Nr . Lower Tool Nr . tool identification numbers. The Figure 5–31 Record Other Machine Setetings Column Position (mm) Screen in UTILITIES Menu Page 4 Dukane Manual Part No. 403-570-01...

  • Page 49: System Setup Tab

    When this step is completed, the screen will change as indicated in Figure 5-34. Next, jog the head Figure 5–33 Vertical Lower Limit Setup Screen down to the desired travel limit position (at least 4 mm with Initialize Button Page 43 Dukane Manual Part No. 403-570-01...
  • Page 50 Automatic system and requires a switch closure contact on the User I/O HD-15 connector (see Figure 3–9). A pinout of the User I/O connector and automation wiring information are provided in Appendix A. Page 44 Dukane Manual Part No. 403-570-01...
  • Page 51 To preserve the language selection between power cycles, press the Save Language Select button. button displys a screen with software Software Info revisions of the welder components as shown in Figure 5-36. Figure 5–36 Welder Software Information Page 45 Dukane Manual Part No. 403-570-01...
  • Page 52 5. Wait several seconds for the touch screen to return to normal operation before welding. Figure 5-38 Touch Screen - Time and Date 2 Figure 5-39 Touch Screen - Time and Date 3 Page 4 Dukane Manual Part No. 403-570-01...

  • Page 53: Parameter Value Range

    SETUP> 140 .00 0 .01 Hold Collapse POST-WELD Hold Dwell Time 100 .00 0 .01 sec . Hold Constant Thrust TOOLS> SYSTEM Home Offset 359 .9 0 .1 SETUP Table 5–I Welding Parameters Page 47 Dukane Manual Part No. 403-570-01...
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  • Page 55: Section 6 - Machine Operation

    Setup Sheet ..........55-56 Dukane Manual Part No. 403-570-01...
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  • Page 57: Base Interface Cable

    22mm hex. The lead screw has 8 threads per inch, so 1 turn moves the head 1/8-inch (3.18 mm). c) Tighten the rear locking nuts. Dukane Manual Part No. 403-570-01 Page 51...

  • Page 58: Turn Power On

    . Change the vertical RUN SWITCHES jog speeds as needed and use the button to move the head up if desired. When finished, press the DONE button and remove the parts. Page 5 Dukane Manual Part No. 403-570-01...
  • Page 59 > tab menu. TOOLS SELECT SETUP Input the desired weld process settings in the PRE- , and tabs in the WELD WELD POST-WELD SETUP menu as described in Chapter 5. Dukane Manual Part No. 403-570-01 Page 53...
  • Page 60 If a cycle terminates abnormally, a fault message will be displayed on the screen describing the error condition. The fault must be cleared and the welder reset before another cycle can be initiated. Page 54 Dukane Manual Part No. 403-570-01...
  • Page 61 Setup Sheet On the following page is a table containing all the machine settings for the Dual Servo Spin Welder. An electronic version is provided on the CD included with the machine. Dukane Manual Part No. 403-570-01 Page 55...
  • Page 62 OF MAX YCLE ERTICAL OLLAPSE OSITION ON  OFF ATCH ON AILURE AILURE WITCH USPECT USPECT  TOOLS > VERTICAL TRAVEL LOWER LIMIT IMIT SYSTEM FFSET SETUP MANUAL SETTING VALUE HRUSTER OSITION ON OLUMN Page 5 Dukane Manual Part No. 403-570-01...

  • Page 63: Section 7 - Optimizing Performance

    Part Size ............63 Dukane Manual Part No. 403-570-01...
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  • Page 65: Spin Welding Process

    By designing the weld joint with an undercut, the polymer with the lower melting temperature will flow into the undercut, creating a mechanical union. Dukane Manual Part No. 403-570-01 Page 5...

  • Page 66: Control Parameters

    Some materials, such as PVC, can be readily welded for a wide range of values, while others require a narrow range. Commonly quoted values in the literature recommend using Page 0 Dukane Manual Part No. 403-570-01...
  • Page 67 840 in/sec = 70 ft/sec — 21 m/sec 960 in/sec = 80 ft/sec — 24 m/sec 2000 1000 Average Weld Diameter (inch) Figure 7–1 Dependence of Spin Speed on the Weld Diameter for Selected Surface Speeds Dukane Manual Part No. 403-570-01 Page 1...
  • Page 68 Page  Dukane Manual Part No. 403-570-01...

  • Page 69: Part Size

    For diameters under 4 inches, the SVT032VR model is recommended due to its torque capacity. The SVT042VR model is used where high RPM (>3000) is required. Please contact the Dukane Applications Laboratory (see Chapter 11) for a recommendation concerning your specific application.
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  • Page 71: Section 8 - Welder Data Export Software

    Servo and Debug ......... .70 Page 5 Dukane Manual Part No. 403-570-01...
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  • Page 73 Startup, and Cable Connections To install the program, Run the setup.exe file located in the Dukane Dual Servo Spin Utility Installer folder on the CD supplied with the welder and follow the prompts on the screen. Once installed, run the program. It can be accessed through: Start Menu ->...
  • Page 74 ASCII format. Saving the file with a .csv extension will allow it to be opened directly with Microsoft Excel™. Page  Dukane Manual Part No. 403-570-01...
  • Page 75 The icons immediately above the plot contain tools for a more detailed examination of the plot. Both the horizontal and vertical scale end values can be changed by double-clicking on the desired number and entering a new value. Page  Dukane Manual Part No. 403-570-01...
  • Page 76 The procedure of changing the database should only be performed with guidance from Dukane. Improper execution of the procedures could render the welder inoperable. tab is used to retrieve troubleshooting...

  • Page 77: Section 9 - Troubleshooting

    Troubleshooting ......75 Table 9–II Machine Display Messages . . . 76-79 Dukane Manual Part No. 403-570-01 Page 71...
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  • Page 79: Welding Process

    Hold Time Insufficient holding time may prevent the plastic from solidifying and forming a strong permanent bond. Troubleshooting Table 9-I lists some potential problems with the weld process and suggested solutions. Dukane Manual Part No. 403-570-01 Page 73...

  • Page 80: Electrical Power

    ABORT and POWER indicators on the base status display will not function. Machine Display Messages A list of all machine messages, their meaning, and possible solutions to problems are given in Table 9-II. Page 74 Dukane Manual Part No. 403-570-01...
  • Page 81 Determine and enter tool inertia correctly into Setup different from properly programmed orientation Contact DUKANE for special tuning requirements Parts not held properly by tool or fixture Ensure tooling does not allow excessive play Dukane Manual Part No. 403-570-01 Page 75...
  • Page 82 Contact DUKANE service Number of servo motor rotations has exceeded Weld time or number of rotations Reduce weld time, distance, or number of Spin at travel limit controller counting too large rotations capability Page 7 Dukane Manual Part No. 403-570-01...
  • Page 83 Lower vertical travel lower limit, if below vertical travel lower programmed press travel is too high possible . limit larger than the set limit Trigger position too large Decrease Trigger position Table 9-II continued. . . Dukane Manual Part No. 403-570-01 Page 77...
  • Page 84 Weld process problem because weld time was etc . Weld ended at TIME limit Limits too narrow for weld outside programmed If practical, widen process limit process process limits window or adjust setup parameters Page 7 Dukane Manual Part No. 403-570-01...
  • Page 85 Cause Possible Solution Warnings The batteries in the PLC Battery life limit, press Batteries have not been replaced in Contact DUKANE service for information and touch screen need to Continue approximately 5 years on battery replacement be replaced Lower process limit is...
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  • Page 87: Section 10 - Maintenance

    Maintenance ..........83 Page 1 Dukane Manual Part No. 403-570-01...
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  • Page 89: Ac Power Cord

    Maintenance Visually inspect cables once a week, and replace or repair if necessary. Lubricate the unpainted area on the front of the support column as needed with conventional grease. Page 3 Dukane Manual Part No. 403-570-01...
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  • Page 91: Section 11 - Contacting Dukane

    Contacting Dukane ........
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  • Page 93: Identify Equipment

    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 re-...
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  • Page 95: Section 12 - Specifications

    Identification Numbers ........93 Regulatory Agency Compliance ....93 Dukane Manual Part No. 403-570-01 Page ...
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  • Page 97: Power Requirements

    40°F to 95°F (+5°C to +35°C) Altitude: 4570 m (15,000 ft) Air Particulates: Keep the welder dry. Minimize exposure to moisture, dust dirt, smoke and mold. Humidity: 5% to 95% non–condensing @ +5°C to +30°C Dukane Manual Part No. 403-570-01 Page 1...
  • Page 98 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  Dukane Manual Part No. 403-570-01...

  • Page 99: Identification Numbers

    EN60204–1:1993 Safety of Machinery – Elec- trical Equipment of Machines. Part 1: Specification for General Requirements. Effective 12/29/09: The Machinery Directive 2006/42/EC. EN 60204: 2006 Safety of Machinery - Electrical Equipment of Machines Part 1: General Requirements. Dukane Manual Part No. 403-570-01 Page 3...
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  • Page 101: Appendix A - Connector Pinouts

    Automation Wiring ......100-101 Dukane Manual Part No. 403-570-01 Page 5...
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  • Page 103 Interface Connector is (Power OFF when Abort switch pushed) Abort Signal shown in Figure A-5. Ground Ground Ground Automation Input +24 VDC Power Table A-I Pin Assignments and Signal Description for the Base Interface Connector Dukane Manual Part No. 403-570-01 Page 7...
  • Page 104 Activate to initiate a weld cycle (500 ms min .) with Start Type set to Automation Input Common Input Common Connection Spare Input 1 Not Used Table A-II Pin Assignments and Signal Description for the User I/O Connector Page  Dukane Manual Part No. 403-570-01...
  • Page 105 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. The...
  • Page 106 Figure A-6 shows a wiring diagram and a Figure A–4 Data Port Connector Location description of the required signals. Figure A–5 Data Port Connector Pins Page 100 Dukane Manual Part No. 403-570-01...
  • Page 107 Appendix A Figure A–5 Schematic of Operate and Abort Figure A–6 Wiring for Automation Dukane Manual Part No. 403-570-01 Page 101...
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  • Page 109: Appendix B - Tooling

    Calculating the Moment of Inertia ..... 105 Tooling and Fixure Design ......106 Dukane Manual Part No. 403-570-01 Page 103...
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  • Page 111 The inertia would be calculated as follows: Inertia, cylinder = .098* .0028* 6.4* (10.1) = 18.1 kg-cm Inertia, void = .098* .0028* 2.5* (7.6) = 2.3 kg-cm Inertia, tool = Inertia, cylinder – Inertia, void = 16 kg-cm Dukane Manual Part No. 403-570-01 Page 105...
  • Page 112 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. Several aspects should be considered when tooling is not purchased from Dukane: •...

  • Page 113: Appendix C - Optional Features

    Remote Touch Screen .......110 Page 107 Dukane Manual Part No. 403-570-01...
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  • Page 115 The spin tool must be designed to interface with the kit. In addition, the welder must be configured to work with certain features of the kit. Please re- fer to DUKANE document 403-580 (Servo Spin Welder Vacuum System User Guide) for further details.
  • Page 116 The enclosure includes mounting brackets for attachment to an external support (refer to Dukane drawing #400- 2283 for dimensions). This kit can be used with any Dual Servo Spin Welder model.
  • Page 117 By passing its audit, Dukane can assure traditional inspection–oriented quality system you that we have in place a well–defined and...
  • Page 118 Dual Servo Welder User's Manual www.dukane.com/us Part No. 403–570–01 Printed in the united States of America Dukane Corporation • ultrasonics Division • 2900 Dukane Drive St. • Charles, Illinois 60174 uSA • TEL (630) 797-4900 • FAX (630) 797–4949...

This manual is also suitable for:

Svt012vrSvt032vrSvt042vr

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