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Summary of Contents for Dukane Infinity Series
- Page 1 Infinity™ Series SERVO ULTRASONIC PRESS SYSTEMS QUICK START GUIDE www.dukane.com ussales@dukane.com Globe-Am ENVELOPE...
- Page 2 The information contained in this manual is distributed on an “As is” basis, without warranty. While every precaution has been taken in the preparation of this manual, Dukane shall not have any liability to any person or entity with respect to any liability, loss, or damage caused or alleged to be caused directly or indirectly by the instructions contained in this manual, or by the hardware products described herein.
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Page 3: Table Of Contents
Dukane HMI ........ - Page 4 Getting Started Using IQ Explorer 3 SECTION 7 - Specifications Press Specifications Operating Environment Model Outline Drawings Infinity™ System Number Guide SECTION 8 - Alarm Messages Alarm Messages SECTION 9 - Maintenance System Maintenance Six-Month Periodic Maintenance Contacting Dukane Dukane ISO Certification...
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Page 5: Section 1 - Introduction
SECTION Introduction... -
Page 6: Introduction
Introduction Press System Overview The Infinity Series Servo Ultrasonic Press System is used for welding thermoplastics. A typical Infinity™ ultrasonic welding system is shipped completely with a press (thruster, base, and column), generator, an ultrasonic stack (transducer, booster, horn), fixturing, cables, and a HMI (with the IQ Explorer 3 software installed) for application setup and data acquisition. -
Page 7: Drawings And Tables
Drawings and Tables The figures and tables are identified by the section number followed by a sequence number. The sequence number begins with one in each section. The figures and tables are numbered separately. Notes, Cautions and Warnings Throughout this Quick Start Guide, CAUTION and WArNING statements are used. These statements help you to identify and avoid hazards and recognize the consequences. -
Page 8: Section 2 - Health And Safety
SECTION Health and Safety Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE... -
Page 9: General Considerations
Dukane Keep the Cover On - Do not remove any equipment covers unless directed does not assume any responsibility to do so by Dukane. Hazardous electrical voltages are present which could or liability for fixtures manufactured cause injury. -
Page 10: Ultrasonic Pressure
Ultrasonic Pressure CAUTION Parts being joined ultrasonically will at times vibrate at audible frequencies. Wear protectors reduce annoying or uncomfortable sounds. In addition, ultrasound baffles, sound enclosures, or materials that absorb sound may be located to surround the system. Ultrasound pressure level could exceed 90dBA. -
Page 11: Electrical Safety
• Infinity™ Generator • Infinity™ Servo Press • Dukane HMI Each of these components must be grounded, including power grounding and RFI suppression grounding. North American Power Grounding For safety, the power cords used with your system have three-wire, grounding-type power cords. Figure 2-1 illustrates the appropriate electrical outlet to use with the power cords that are included with systems shipped within North America. -
Page 12: Grounding For Rfi Suppression
This filter also prevents ultrasonic rFI from being fed back into the AC power line. Grounding wires are shipped with each system component (green/yellow; 5 meters long; Dukane part number 200-1557). It is important to connect each of these wires to the nearest grounded metal pipe or equivalent earth ground by means of a ground clamp. -
Page 13: Regulatory Agency Compliance
Regulatory Agency Compliance The Infinity™ generator complies with the following Federal Communications Commission regulations. • The limits for FCC measurement procedure MP-5, “Methods of Measurement of radio Noise Emissions from ISM Equipment”, pursuant to FCC Title 47 Part 18 for Ultrasonic Equipment. CE Marking This mark on your equipment certifies that it meets the requirements of the EU (European Union) concerning interference causing equipment regulations. -
Page 14: Section 3 - Installation
SECTION Installation Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE... -
Page 15: Before Installation
Before Installation As you plan for the installation of your system, including generator and press, please consider these important WARNING subjects as listed below: Electrical safety hazards exist inside the • When to use lockout / tagout devices generator, press, and remote controller units . •... -
Page 16: Ac Power Requirements
15 Amps 43NSME 90-240V 50/60 Hz @ 10 Amps 15 Amps Table 3-2 Press AC Power requirements Dukane HMI AC line voltage - 90-260 VAC AC line current - 1 Amp Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE... -
Page 17: Unpacking The System
Unpacking the System The system has been assembled and packaged at the factory for shipment. Depending on the system, components may be packaged in multiple crates or boxes. The press is secured to a wooden pallet and covered with a wooden crate. Components inside the crate are secured with screws, metal bands, and additional packing materials to give reinforcement where needed. - Page 18 The workbench should be sturdy enough to handle more than the weight of the press system. To place the press on the work area, first lift it using the lifting eye bolt shown in Fig. 3-3 below or a pallet lift platform as shown in Fig. 3-4. raise the assembly until the bottom edge of the base is even or slightly above the top of the work area.
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Page 19: Cable Connections
Cable Connections Typical system components are: • Ultrasonic Generator • Press • Make cable connections in the following order, referring to the Fig 3-6 and Table 3-5 on the next page: 1. Connect cables 1-5. Cables 3 and 4 are to be connected to an effectively grounded rod. 2. - Page 20 Figure 3-6 Cable Connections Cable Number Cable Description Standard Length (Meters) Ultrasound Press Interface Press Grounding Generator Grounding HMI Communications (CAT 5 / rJ45 Ethernet cable) Press Power Cord (line voltage: 90-240 VAC, 50/60 Hz, 10 A) Generator Power Cord (line voltage depends on generator model) HMI Power Cord (line voltage: 90-240 VAC, 50/60 Hz, 10 A) Automation I/O (optional) Table 3-5 Cable Connections...
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Page 21: Section 4 - Tooling Setup
SECTION Tooling Setup Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE... -
Page 22: Attaching The Fixture On The Base
WARNING Any fixture manufactured by a third party must comply with all OSHA and ANSI requirements. All fixtures must be guarded as necessary. Dukane does not assume any responsibility or liability for fixtures manufactured by the customer or any third party manufacturer. -
Page 23: Installing The Ultrasonic Stack Module
Installing the Ultrasonic Stack Module For model 43NTME (20 kHz): If the ultrasonic stack module is not installed in the press, follow the instructions below, depending on the model. 1. Activate the E-STOP (Abort) switch on the front of the press base shown in Fig. 4-2 below. 2. - Page 24 5. Unlock the handle shown in Fig. 4-4 by rotating it until it stops. 6. Pull the handle shown in Fig. 4-5 to rotate the transducer clamp open until it stops. 7. Place the ultrasonic stack module into the press by sliding it in as shown in Fig. 4-6. Push it all the way in so that the booster mounting block is inserted onto the pins in the press.
- Page 25 11. The handles must be oriented approximately as shown in Fig. 4-10. Once tightened, the handle orientations can be changed as follows: Pull the handle straight out. b. Turn the handle in either direction as needed. Release the handle to let it spring back into place. 12.
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Page 26: For Model 43Ntla (15 Khz)
Installing the Ultrasonic Stack Module For model 43NTLA (15 kHz): If the ultrasonic stack module is not installed in the press, follow the instructions below, depending on the model. 1. Activate the E-STOP (Abort) switch on the front of the press base shown in Fig. 4-13 below. 2. - Page 27 5. remove the 6 mm hex wrench, Dukane part number 809-721-0013, stored on the inside of the door as show in Fig 4-15, then set the door aside. 6. Use the wrench to loosen the (2) screws shown in Fig 4-16.
- Page 28 8. Place the ultrasonic stack module into the press by sliding it in as shown in Fig 4-19. Push it all the way in so that the booster mounting block is inserted onto the pins in the press. 9. Tighten the (4) screws shown in Fig 4-20. 10.
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Page 29: Removing The Ultrasonic Stack Module
Removing the Ultrasonic Stack Module For model 43NTME (20 kHz): Perform the following steps, depending on the model. The first two steps are necessary to ensure that no power will be accidentally applied while removing the stack. 1. Activate the E-STOP (Abort) switch on the front of the press base shown in Fig. 4-25. 2. - Page 30 Figure 4-27 Unlocking Clamp Figure 4-28 Opening Clamp Figure 4-29 Unlocking Clamp Figure 4-30 Removing Stack Module Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE...
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Page 31: For Model 43Ntla (15 Khz)
4. Grip the transducer door on both sides and pull down and out as shown in Fig. 4-32 by arrows 2 and 3. 5. remove the 6 mm hex wrench, Dukane part number 809-721-0013, stored on the inside of the door as shown in Fig. - Page 32 Figure 4-33 Wrench Storage Location Figure 4-34 Loosening Clamp Figure 4-35 Removing Clamp Figure 4-36 Clamp resting Position Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE...
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Page 33: Removing The Module Block From The Stack
• Use only the tools recommended by Dukane. NEVER clamp a horn, booster, or transducer in a vise or use tools such as pliers, vise grips, etc. Doing so will result in scratches and/or gouges, resulting in stress areas on the surface. This condition will affect the stack operation and could lead to failure of each stack component. -
Page 34: Adjusting The Thruster Position
Adjusting the Thruster Position 1. Before unlocking the handles, hold the adjustment wheel tightly to prevent it from rotating. Unlock all the handles (2 or 3, depending on the model) shown in Fig. 4-39 below by turning them counter-clockwise until they stop (approximately 1/2 turn). -
Page 35: Aligning The Fixture
3. Lock all the handles tightly by turning them clockwise as shown in Fig. 4-42. 4. If desired, the orientation of the handles can be changed once they are locked. referring to Fig. 4-43, pull the handle straight out (1), rotate it in either direction (2), then release it (3). Figure 4-42 Tightening Lock Handles Figure 4-43 Handle Orientation Aligning the Fixture... - Page 36 6. Change the Speed to Low, then move the press down until a light amount of pressure is applied to the parts (approximately 10-20 lbs. [40-90 N]). 7. Turn the four jack screws as shown in Fig. 4-44 clockwise until a slight resistance is felt. 8.
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Page 37: Section 5 - Controls And Indicators
SECTION Controls and Indicators Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE... -
Page 38: Control And Indicators Overview
Controls and Indicators Control and Indicators Overview This section contains information about the visual indicators, manual switches and adjustments of the components in a typical IQ Infinity™ system. The press, generator, and HMI will be discussed. Press System Figure 5-1 shows the controls and indicators for the press, generator, and HMI. THRUSTER COLUMN GENERATOR... -
Page 39: Press Controls And Display
Press Controls and Display THRUSTER POWER SWITCH THRUSTER DISPLAY INDICATOR COLUMN LOCK HANDLES THRUSTER HEIGHT ADJUSTMENT WHEEL HORN FIXTURE E-STOP OPERATIONAL SWITCHES Figure 5-2 Press Controls and Display Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE... -
Page 40: Operating Safety Switch Detail
Operating Safety Switch Detail ACTIVATION AREA STATUS LED GREEN POWER LED Figure 5-3 Operating Safety Switch E-Stop Switch Detail PUSH TO ACTIVATE TWIST CLOCKWISE TO RELEASE Figure 5-4 E-Stop (ABOrT) Switch Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE... -
Page 41: Hmi Connections
HMI Connections AC POWER CONNECTION ETHERNET PORTS HMI POWER SWITCH Figure 5-5 HMI Connections Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE... -
Page 42: Section 6 - Operation
SECTION Operation Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE... -
Page 43: Iq Explorer 3 Overview
Operation IQ Explorer 3 Overview The IQ Explorer 3 software comes standard on a Dukane HMI. This program connects with the Infinity™ generator/press through a user interface and is used for configuration and setup. Key Features IQ Explorer 3 User Interface •... -
Page 44: Getting Started Using Iq Explorer 3
Getting Started Using IQ Explorer 3 STEP 1 - Getting Started Ensure that a proper connection of the IQ Explorer 3 software and the servo press has been made. See Figure 6-8 below. Name of the connected welder. Names of active welders in the network appear when Show Welders tab is clicked. - Page 45 STEP 3 - Set the Cycle Initiation Mode Click on the Process Settings tab. Select Manual from the pull down menu as shown in Figure 6-10. Process Settings tab Select Manual Figure 6-10 Initiate Mode NOTE: This Initiate Mode selection assumes there is a stand-alone, benchtop system with manual operate switches.
- Page 46 STEP 5 - Program the Sensing Speed The Sensing Speed is the speed (inches/millimeters per second) at which the horn will move during the approach just before reaching the trigger position. A typical starting value for Sensing Speed is 1.0 mm/s (0.040 in/s). The Sensing Speed can be set higher for shorter cycle times, or lower for greater trigger force detection accuracy.
- Page 47 STEP 8 - Program Weld Characteristics Primary Method On the Process Settings tab, find Weld > Primary Method, and select Distance. Distance - This is the distance the welder advances once the programmed trigger force is reached. Usually this distance is the height of the energy director, or shear joint of the part being welded.
- Page 48 Enable Melt Detect™ This patented feature is found only on Dukane's servo press systems. If the feature is selected, the system will stop motion once the desired Trigger Force is achieved. The ultrasound will be initiated at this moment. Once the programmed Melt- Detect™...
- Page 49 STEP 11 - Set Ultrasound Amplitude A typical initial ultrasound weld amplitude setting is 100%. The default amplitude setting is 90% as shown below in Figure 6-18. The range for this feature is between 20% and 100%. Figure 6-18 Default Weld Amplitude Setting STEP 12 - Post Weld Settings The post weld phase of the process is sometimes overlooked;...
- Page 50 Static Hold Method After the completion of dynamic hold, if enabled, the press motion stops for a specified amount of time to allow for molten plastic to solidify. This phase is called static hold. To program static hold, set the Static Hold Method to Time, and enter the desired Hold Time. Once the static hold phase is complete, the press retracts back to the Top-of-Stroke position.
- Page 51 STEP 14 - Run Weld Cycle After all the parameters have been programmed, initiate the weld cycle. STEP 15 - View Weld Results View the results at the Cycle Data tab to insure all parameters have been achieved. See the example shown below in Figure 6-22.
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Page 52: Section 7 - Specifications
SECTION Specifications Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE... -
Page 53: Press Specifications
Press Specifications Maximum Weld Maximum Rapid Linear Encoder Maximum Horn Stroke Force Speed Resolution Weight Thruster Model in/s mm/s 43NTME 2450 0.00004 11.4 42NTLA 1000 4450 0.00004 27.3 Table 7-1 Press Specifications Operating Environment Operate the equipment within these guidelines: Temperature: 40°F to 100°F (+5°C to +38°C) Air Particulates: Keep the equipment dry. -
Page 54: Model Outline Drawings
Model Outline Drawings Model Number Description Drawing Number □□□□.□y.C□-S01.L.□S Large Infinity™ System (typically 15 kHz) 400-2685 43NTLA Large Infinity™ Thruster Only (typically 15 kHz) 400-2686 □□□□.□y.C□-S01.M.□S Medium Infinity™ System (typically 20 kHz) 400-2680 43NTME Medium Infinity™ Thruster Only (typically 20 kHz) 400-2681 □□□□.□y.C□-S01.S.□S Mini Infinity™... -
Page 55: Infinity™ System Number Guide
Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE... -
Page 56: Section 8 - Alarm Messages
SECTION Alarm Messages Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE... -
Page 57: Alarm Messages
The following lists of alarms, on pages 53-56, that may appear on the servo press systems containing a generator with a color front panel display or IQ Explorer 3 software. Information on particular alarms may also be obtained on the Dukane '"Easy Alarm" web page below: https:/ /support.dukane.com/EasyAlarm... - Page 58 U200 Servo Controller Fault One of several possible problems detected Cycle power on the generator. on servo controller. If alarm persists, contact Dukane. U201 Force Duration Exceeded Large amount of force was applied for an Cycle power on the generator.
- Page 59 Generator or Press Not Generator or Press Not Ready Wait for initialization process to complete. Ready Cycle power on IQ generator. If alarm persists, contact Dukane. U400 Weld Limits enabled for Weld Limits enabled for continuous oper- Change Weld Mode from Automation.
- Page 60 Alarm Code Alarm Message Explanation Solution U401 Weld Time set to Zero Adjust weld time to be greater than zero. U402 Weld Power set to Zero Adjust weld peak power to be greater than zero. U403 Weld Energy set to Zero Adjust weld energy to be greater than zero.
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Page 61: Section 9 - Maintenance
SECTION Maintenance Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE... -
Page 62: System Maintenance
Disconnect t remove the thruster left and right side covers. 2. Check if any fasteners are visibly loose. If so, contact Dukane for the proper tightening torque. 3. Wipe or blow away all dirt and grease in the thruster. 4. No air is required for the normal operation of a servo press. However, there may be a time when optional cooling accessories were added. -
Page 63: Contacting Dukane
Contacting Dukane Identify Equipment When contacting Dukane about a service–related problem, be prepared to give the following information: • Model number, line voltage and serial number. • Alarm/Fault indicators from the display. Software version (Press INFO. With selection indicators at System Information, press ENTER to get this data). -
Page 64: Dukane Iso Certification
Dukane chose to become ISO 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. - Page 65 Please refer to our website at: www.dukane.com/contact-us to locate your local representative.
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