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Infinity™

Series Servo Ultrasonic Press Systems QUICK START GUIDE

36

SE

CTION 5 | C

ONTR

OLS

AND

I

NDICA

TORS

Operating Safety Switch Detail

E-Stop Switch Detail

Figure 5-4

E-Stop (ABOrT) Switch

Figure 5-3

Operating Safety Switch

PUSH TO

ACTIVATE

TWIST CLOCKWISE TO RELEASE

RED

STATUS LED

GREEN

POWER LED

ACTIVATION AREA

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Summary of Contents for Infinity 43NSLA

Page 1: ...SERVO ULTRASONIC PRESS SYSTEMS QUICK START GUIDE Infinity Series Globe Americas www dukane com ENVELOPE ussales dukane com ...

Page 2: ...very 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 Specifications subject to change without notice This user s manual documents product f...

Page 3: ...Pressure 6 Electrical Safety 7 North American Power Grounding 7 International Power Grounding 7 Grounding for RFI Suppression 8 Operate Switches 8 STO Safety Modes 8 Regulatory Agency Compliance 9 SECTION 3 Installation 10 Before Installation 11 When to Use Lockout Tagout Devices 11 AC Power Requirements 12 Generators 12 Presses 12 Dukane HMI 12 Unpacking the System 13 Placement on Workbench 13 Ca...

Page 4: ... Indicators 33 Control and Indicators Overview 34 Press System 34 Press Controls and Display 35 Operating Safety Switch Detail 36 E Stop Switch Detail 36 HMI Connections 37 SECTION 6 Operation 38 IQ Explorer 3 Overview 39 Getting Started Using IQ Explorer 3 40 SECTION 7 Specifications 48 Press Specifications 49 Operating Environment 49 Model Outline Drawings 50 Infinity System Number Guide 51 SECT...

Page 5: ...S ection 1 I ntroduction SECTION 1 Introduction ...

Page 6: ...olumn 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 General User Information This Quick Start Guide provides information to set up and operate Dukane s Infinity ultrasonic servo welder Please read it before using the system to become familiar with the equipment to ensure correct ...

Page 7: ... and avoid hazards and recognize the consequences CAUTION statements identify conditions or practices that could result in damage to the equipment or other property WARNING statements point out conditions or practices that could result in personal injury or loss of life Condition or Practice Electrical Hazard Hearing Protection NOTE Note statements provide additional information or highlight proce...

Page 8: ...Infinity Series Servo Ultrasonic Press Systems QUICK START GUIDE 4 S ECTI ON 2 Health and Safety SECTION 2 Health and Safety ...

Page 9: ...rd When an acoustic stack transducer booster horn and tip is energized by the ultrasound signal it presents a potential hazard Stay clear of an energized stack System Abort Switch Install a system abort switch at each operator station when ultrasonic plastic assembly equipment is used with automatic material handling equipment in an automated system Foot Switch Using a foot switch in place of the ...

Page 10: ... cables from system equipment make sure electrical power to the system is turned off and the AC power cords are removed from their receptacles After the cables have been securely connected and the connections and cable routing checked a final time the power may be restored Parts being joined ultrasonically will at times vibrate at audible frequencies Wear ear protectors to reduce annoying or uncom...

Page 11: ...rmally provided for international use are compatible with the power outlet used in many Continental European countries Refer to Figure 2 2 However if your application requires another type of power cord check with your equipment supplier and follow local regulations concerning proper wiring and grounding CAUTION If you have a two prong electrical receptacle we strongly recommend that you replace i...

Page 12: ...oot switch in place of these switches violates OSHA regulations STO Safety Modes There are two modes of operation The STO mode can be activated via a rear panel key switch located behind a cover panel on the press 1 STO Mode The servo is in STO safe torque off when the E STOP switch is activated or the safety switches on the base are inactive This means the safety switches must remain active the e...

Page 13: ...00 4 3 EN61000 4 4 EN61000 4 5 EN61000 4 6 EN61000 4 8 EN61000 4 11 The Low Voltage Directive 2014 35 EU The Machinery Directive 2006 42 EC EN 60204 Safety of Machinery Electrical Equipment of Machines Part 1 General Requirements EN ISO 12100 Safety of Machinery General principles of design risk assessment and risk reduction IP Rating The Infinity generator has an IP International Protection ratin...

Page 14: ...Infinity Series Servo Ultrasonic Press Systems QUICK START GUIDE 10 S ECTI ON 3 I nstallation SECTION 3 Installation ...

Page 15: ...gout LOTO device is a clam shell type device with lockout capability The LOTO device is placed over the plug end of the generator and press electrical cords This effectively prevents access to the energy isolation points See the locked unlocked example of one such device in Fig 3 1 and Fig 3 2 Figure 3 1 Lockout Device In Open Position Unlocked Figure 3 2 Bottom Lockout Device In Closed Position L...

Page 16: ...ps 20A or 30A 3 Phase 1100 3 6 15kHz 15HS500 4Y C0 S N0 5000 380 480V 50 60 Hz 10 Amps 20A or 30A 3 Phase 1100 5 0 20kHz 20HS120 UY C0 S N0 1200 100 240V 50 60 Hz 15 Amp 15A 1300 1 0 20kHz 20HS180 2Y C0 S N0 1800 200 240V 50 60 Hz 10 Amps 15A 1300 1 5 20kHz 20HS260 2Y C0 S N0 2600 200 240V 50 60 Hz 15 Amps 15A 1300 2 2 20kHz 20HS360 2Y C0 S N0 3600 200 240V 50 60 Hz 19 Amps 20A or 30A 1300 3 0 20k...

Page 17: ...terial and temporarily set aside any other system components leaving the press on the pallet 3 Inspect the assembly for any damage before placing it in position Placement on Workbench Do not lift the press by hand Use mechanical means to put the press into place The workbench onto which the press will be placed must be capable of supporting the weight of the system The table below lists the weight...

Page 18: ... 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 Then carefully slide the press system on to the work area It is recommended that the press base be secured to the workbench using the 4 holes indicated in Fig 3 5 Figure 3 4 Pallet Lift Figure 3 5 Mounting...

Page 19: ...automation equipment is used with the system 3 Connect power cords 6 8 4 Arrange cables as desired but do not bundle the power cords 6 8 with any other cables CAUTION Before connecting or disconnecting cables Put power switches for the generator press and any user supplied automation equipment in the OFF position Turn off electrical power Remove AC power cords from their receptacles DO NOT operate...

Page 20: ...scription Standard Length Meters 1 Ultrasound 2 2 Press Interface 2 3 Press Grounding 5 4 Generator Grounding 5 5 HMI Communications CAT 5 RJ45 Ethernet cable 3 6 Press Power Cord line voltage 90 240 VAC 50 60 Hz 10 A 2 7 Generator Power Cord line voltage depends on generator model 2 5 8 HMI Power Cord line voltage 90 240 VAC 50 60 Hz 10 A 2 5 9 Automation I O optional 3 ...

Page 21: ...S ECTI ON 4 Controls and I ndicators Infinity Series Servo Ultrasonic Press Systems QUICK START GUIDE 17 SECTION 4 Tooling Setup ...

Page 22: ...he fixture on the base 2 Initially align the two slots in the fixture over two of the eight mounting holes on the base 3 Install the two fixture hold down bolts with hardened washers as shown in Fig 4 1 but leave the bolts loose at least 1 turn Figure 4 1 Placing the Fixture on the Plate WARNING Any fixture manufactured by a third party must comply with all OSHA and ANSI requirements All fixtures ...

Page 23: ...del 1 Activate the E STOP Abort switch on the front of the press base shown in Fig 4 2 below 2 Turn off power to the generator by placing the AC switch in the 0 position 3 Push the button on the bottom of the transducer door as shown in Fig 4 3 by the arrow labeled 1 The door latch should release 4 Grip the transducer door on both sides and pull down and out as shown in Fig 4 3 by arrows 2 and 3 S...

Page 24: ...ace 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 8 Rotate the two handles to secure the stack in place one at a time as shown in Fig 4 7 until the handles are tight approximately 7 turns 9 Close the transducer clamp as shown in Fig 4 8 10 Latch the clamp as shown in F...

Page 25: ... out b Turn the handle in either direction as needed c Release the handle to let it spring back into place 12 Take the transducer door removed earlier align the pins on the door with the bottom of the slots on the press as shown in Fig 4 11 and push the door against the press 13 Slide the door up as shown in Fig 4 12 until a click is heard which indicates it is latched Figure 4 10 Handle Orientati...

Page 26: ...l 1 Activate the E STOP Abort switch on the front of the press base shown in Fig 4 13 below 2 Turn off power to the generator by placing the AC switch in the 0 position 3 Push the button on the bottom of the transducer door as shown in Fig 4 14 by the arrow labeled 1 The door latch should release 4 Grip the transducer door on both sides and pull down and out as shown in Fig 4 14 by arrows 2 and 3 ...

Page 27: ... the door aside 6 Use the wrench to loosen the 2 screws shown in Fig 4 16 7 Pull the transducer clamp bar straight out as shown in Fig 4 17 by arrow 1 then rotate it 180 degrees counter clockwise and push it back in as shown by arrows 2 and 3 The clamp should rest as shown in Fig 4 18 Figure 4 15 Hex Wrench Location Figure 4 17 Transducer Clamp Bar Figure 4 16 Transducer Clamp Bar Screws Figure 4 ...

Page 28: ...ees clockwise and push it back in as shown by arrows 2 and 3 Figure 4 22 Tighten Clamp Bar Figure 4 23 Transducer Door Pins Figure 4 24 Latching the Door 11 Tighten the 2 clamp bar screws shown in Fig 4 22 12 Take the transducer door removed earlier place the hex wrench inside as shown in Fig 4 23 13 Align the pins on the door with the bottom of the slots on the press as shown in Fig 4 23 then pus...

Page 29: ... button on the bottom of the transducer door as shown in Fig 4 26 by the arrow labeled 1 The door latch should release 4 Grip the transducer door on both sides and pull down and out as shown in Fig 4 26 by arrows 2 and 3 5 Unlock the handle as shown in Fig 4 27 on the next page by rotating it until it stops 6 Pull the handle shown in Fig 4 28 to rotate the transducer clamp until it stops 7 Rotate ...

Page 30: ...Series Servo Ultrasonic Press Systems QUICK START GUIDE 26 S ECTI ON 4 Controls and I ndicators Figure 4 28 Opening Clamp Figure 4 27 Unlocking Clamp Figure 4 29 Unlocking Clamp Figure 4 30 Removing Stack Module ...

Page 31: ... transducer door as shown in Fig 4 32 by the arrow labeled 1 The door latch should release 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 4 33 then set the door aside 6 Use the wrench to loosen the 2 screws shown in Fig 4 34 7 Pull the...

Page 32: ...s Servo Ultrasonic Press Systems QUICK START GUIDE 28 S ECTI ON 4 Controls and I ndicators Figure 4 33 Wrench Storage Location Figure 4 35 Removing Clamp Figure 4 34 Loosening Clamp Figure 4 36 Clamp Resting Position ...

Page 33: ... 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 To separate the stack components follow the instructions below 1 Remove the 4 screws from the bottom of the booster cla...

Page 34: ...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 2 Turn the crank wheel clockwise to raise the thruster or counter clockwise to lower as shown in Fig 4 40 A scale is provided on the column as shown in Fig 4 41 to indicate the thruster position Figure 4 39 Loosening Lock Handles Figure 4 40 Thruster Position Adjus...

Page 35: ...re consistent evenly distributed welds To safely align the fixture under the horn use the following procedure 1 Place unwelded parts into the fixture 2 Ensure the E STOP is released then start up the system normally 3 Perform the following steps in IQ Explorer 3 software a For Trigger Type select Force b Press Teach next to Sensing Start Position 4 Hold the two operate switches to lower the horn B...

Page 36: ...e Jog Direction to Up then activate the operate switches to move the horn up until there is no force on the parts 9 Using carbon paper or a feeler gauge determined which side of the fixture must be raised to make the part level with the horn then turn the corresponding jack screw s clockwise If needed move the horn up or down to aid in this step 10 Tighten the hold down cap screws by turning them ...

Page 37: ...S ECTI ON 5 Controls and I ndicators Infinity Series Servo Ultrasonic Press Systems QUICK START GUIDE 33 SECTION 5 Controls and Indicators ...

Page 38: ...verview 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 Figure 5 1 Typical Press System THRUSTER HMI GENERATOR COLUMN BASE ...

Page 39: ...rvo Ultrasonic Press Systems QUICK START GUIDE 35 Press Controls and Display Figure 5 2 Press Controls and Display THRUSTER DISPLAY INDICATOR HORN THRUSTER POWER SWITCH FIXTURE E STOP OPERATIONAL SWITCHES COLUMN LOCK HANDLES THRUSTER HEIGHT ADJUSTMENT WHEEL ...

Page 40: ...RT GUIDE 36 S ECTI ON 5 Controls and I ndicators Operating Safety Switch Detail E Stop Switch Detail Figure 5 4 E Stop ABORT Switch Figure 5 3 Operating Safety Switch PUSH TO ACTIVATE TWIST CLOCKWISE TO RELEASE RED STATUS LED GREEN POWER LED ACTIVATION AREA ...

Page 41: ...S ECTI ON 5 Controls and I ndicators Infinity Series Servo Ultrasonic Press Systems QUICK START GUIDE 37 HMI Connections Figure 5 5 HMI Connections AC POWER CONNECTION HMI POWER SWITCH ETHERNET PORTS ...

Page 42: ...Infinity Series Servo Ultrasonic Press Systems QUICK START GUIDE 38 S ection 6 Operation SECTION 6 Operation ...

Page 43: ...ith your IT staff about availability One screen operations page Most recent weld cycle and graph data with ability to modify commonly used process settings F1 Help command Instantly displays explanation of function IQ Explorer 3 User Interface It is a peripheral device Operation is independent of the generator and removal or malfunction of the IQ Explorer 3 does not affect machine functionality Ei...

Page 44: ... software and the servo press has been made See Figure 6 8 below STEP 2 Select Unused Setup Click on the Hardware tab Click on the Setup File Name drop down box and select an unused setup as shown in Figure 6 9 Name of the connected welder Names of active welders in the network appear when Show Welders tab is clicked Figure 6 8 Connected Welder Figure 6 9 Setup File Selection Setup file Hardware t...

Page 45: ...rop down box Then program the desired amount of force the press is to apply before ultrasound is activated Next enter the Max Trigger Time This provides a measure of safety insuring the welder will terminate if the welder never achieves the programmed trigger force as shown in Figure 6 11 Figure 6 10 Initiate Mode Figure 6 11 Trigger Force Settings NOTE This Initiate Mode selection assumes there i...

Page 46: ... Sensing Start Position so that the horn is never in contact with the part at this position taking into account the height variability of unwelded parts Failure to do so may result in equipment damage If you do not know the position where this contact is made select the Teach button as shown in Figure 6 12 Note The Sensing Start Position must be set such that the expected sensing distance weld dis...

Page 47: ... a component of the weld method intended to offer a measure of safety If the programmed weld method parameter is not achieved within this time window 2 seconds as shown in the example of Figure 6 14 the system will fault Secondary Method Continue programming weld characteristics by selecting one of the Secondary Methods available Position Energy Peak Power Force Change and Force Rate The purpose o...

Page 48: ...he Trigger Force before the horn will resume the programmed weld motion For example for a Trigger Force of 180 N and a value of 5 for Melt Detect Force Drop the press would stop once the Trigger Force is achieved and resume motion after the force drops by 9 N 5 of 180 N below the Trigger Force or 171 N A starting value of Melt Detect is typically in the 5 10 range The benefit of this option is sig...

Page 49: ...ld and Static Hold These types can be used together or separately Dynamic Hold Method During Dynamic Hold which occurs immediately after the weld phase the press will continue to travel at the programmed hold speed with the ultrasound turned off This feature provides the ability to collapse the molten plastic after the ultrasonic signal is turned off before material solidification This feature can...

Page 50: ...r weld quality 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 This uni...

Page 51: ... 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 Detailed performance graphs for select parameters may also be reviewed by selecting the Graph tab Figure 6 22 Cycle Data Tab Cycle Data Tab ...

Page 52: ...Infinity Series Servo Ultrasonic Press Systems QUICK START GUIDE 48 S ection 7 S pecifications SECTION 7 Specifications ...

Page 53: ...0004 1 0 60 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 Minimize exposure to moisture dust dirt smoke and mold Humidity 5 to 95 Non condensing 5 C to 30 C Non operating storage guidelines Temperature 4 F to 158 F 20 C to 70 C Air Particulates Keep the equipment ...

Page 54: ...0HS120 UY C0 S N0 20K 1200W Infinity Generator Single Phase 400 2678 20HS180 2Y C0 S N0 20K 1800W Infinity Generator Single Phase 400 2678 20HS260 2Y C0 S N0 20K 2600W Infinity Generator Single Phase 400 2678 20HS360 2Y C0 S N0 20K 3600W Infinity Generator Single Phase 400 2678 20HS500 2Y C0 S N0 20K 5000W Infinity Generator Single Phase 400 2700 20HS360 4Y C0 S N0 20K 3600W Infinity Generator Thr...

Page 55: ...hown above 2026 2Y C3 S01 M 2R System Assembly Detailed Description A 20 kHz 2600 Watt Infinity generator with a 220 240 VAC line cord and PROFINET communications module a medium sized Infinity servo press on a rigid support and a 220 240 VAC line cord Table 7 3 Infinity System Number Guide Infinity System Number Guide ...

Page 56: ...Infinity Series Servo Ultrasonic Press Systems QUICK START GUIDE 52 S ection 8 Alarm M essages SECTION 8 Alarm Messages ...

Page 57: ...perate in test perform stack care and maintenance Follow this link to stack care and maintenance proce dure If Stack will not operate in test condition remove horn and re inspect Enable Advanced Process Settings to adjust free run frequency to the in air operating frequency that results from a test Enabling a pre trigger source that allows for full ramp up time to elapse still in air before contac...

Page 58: ...ng frequency drift issue but a weld application setup issue U200 Servo Controller Fault One of several possible problems detected on servo controller Cycle power on the generator If alarm persists contact Dukane U201 Force Duration Exceeded Large amount of force was applied for an excessive amount of time while jogging Cycle power on the generator Do not apply large force for long periods of time ...

Page 59: ...ible comination of the ESTOP inputs was detected The NO and NC E STOP inputs remained at the same logic level for too long Must cycle power on the thruster U230 Servo Under Temp The servo controller temperature is below safe operating conditions Possible failure of servo controller U231 Hall Input Sequence Error An implausible motor hall sensor transition was detected Check servo motor feedback wi...

Page 60: ...meters U411 Part Detected Too Early Contact between the horn and part was detected before reaching the Sensing Start Position Adjust Sensing Start Position to be above contact with part Account for variation of heights of unassembled parts NOTE Repeated occurrences of this alarm may result in costly damage to servo actuator U413 Max Trigger Time Ex ceeded Trigger did not occur within the specified...

Page 61: ...S ECTI ON 9 M aintenance Infinity Series Servo Ultrasonic Press Systems QUICK START GUIDE 57 SECTION 9 Maintenance ...

Page 62: ... slot AC Power Cord The AC power cords should be kept in good condition and free from any cuts The AC plug should be straight with no bent prongs Six Month Periodic Maintenance 1 Disconnect the generator AC power cord from the AC line receptacle and the AC power cord from the thruster Then remove the thruster left and right side covers 2 Check if any fasteners are visibly loose If so contact Dukan...

Page 63: ...d over the telephone so it is best to call from a telephone located near the equipment Mailing Address Dukane IAS 2900 Dukane Drive St Charles IL 60174 USA Phone 630 797 4900 E mail ussales dukane com Fax Main 630 797 4949 Service Parts 630 584 0796 Website The website has information about our products processes solutions and technical data Downloads are available for many kinds of literature Thi...

Page 64: ... The ISO standards establish a minimum requirement for these requirements and starts transitioning the company from a traditional inspection oriented quality system to one based on partnership for continuous improvement This concept is key in that Dukane no longer focuses on inspection but on individual processes Dukane s quality management system is based on the following three objectives 1 Custo...

Page 65: ...Please refer to our website at www dukane com contact us to locate your local representative ...

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