Dukane iq series User Manual page 134

iQ
Series Ultrasonic Press System LE User's Manual
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Problem
The boss or the plastic around the boss cracks after insertion.
Probable Cause
The insert is pushed in before the
plastic has melted.
The gauge pressure is set too high.
The boss wall is too thin.
There is too much interference between
the insert and the hole.
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Problem
The insert is not driven to the desired depth.
Probable Cause
The ultrasound is not on long enough.
Flash fills the hole.
(Applies to an internally-threaded insert.)
There is insufficient air pressure and/or
ultrasonic power.
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Problem
The cycle time is too long.
Probable Cause
There is insufficient ultrasonic power
or the generator overloads.
There is too much interference
between the hole and the insert.
The area of the part being inserted
is not being rigidly supported.
The down speed is slow.
Page 126
Insertion
Solution
Reduce the down speed, air pressure,
and/or horn amplitude.
Use pre-triggering.
Reduce the air pressure.
Increase the thickness of the boss wall.
Increase the hole diameter.
Use a smaller insert.
Solution
Increase the primary weld characteristic. Check the
bottom stop setting.
Increase the depth of the hole.
Increase the air pressure, the ultrasonic
power, or the horn amplitude.
Solution
If using a power control, increase the
power.
Use a more powerful generator.
Increase the hole diameter, if possible.
Use a smaller insert.
Support the part directly under the boss.
Install a metal post directly under the part being
inserted.
Increase the down speed.
Continued
Dukane Manual Part No. 403-586-02