Dukane iq series User Manual page 129

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Problem
Underwelding
Probable Cause
Insufficient energy is being transmitted
to the part.
Energy is being absorbed into the fixture.
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Problem
Uneven welding
Probable Cause
Warped part(s).
The energy director varies in height.
Lack of parallelism between the horn,
the fixture, and the part.
Wall flexure is occurring.
The knockout pin location is in the
joint area
There is insufficient support in
the fixture.
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Dukane Manual Part No. 403-586-02
Welding
Solution
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.
Change the type of fixture being used.
Solution
Check part dimensions.
Check the molding conditions.
Use a higher trigger pressure.
Use a higher hold pressure.
Redesign the energy director to ensure uniform
height.
Use an interrupted energy director.
Make sure the thruster is perpendicular
to the part.
Check the part dimensions.
Add ribs to the part.
Modify the fixture to prevent outward flexure
Redesign the part so the knockout pin
is not in the joint area (Make sure knockout pins are
flush with the surface)
Redesign the fixture to improve the
support in critical areas.
Change to a rigid fixture.
If large sections of urethane are deflecting with a
resilient fixture, add a rigid backup.
Section 9 - Troubleshooting
Continued
Page 121