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Spin Welder User’s Manual

Section 5 – Theory of Operation

Page 25

Page 24

Dukane Manual Part Number 403-547-03

Dukane Manual Part Number 403-547-03

Spin Welder User’s Manual

Section 4 – Installation

Page 25

Page 24

Dukane Manual Part Number 403-547-03

Dukane Manual Part Number 403-547-03

s

eCTion

5

Theory of Operation

•  Spin Welding Process
•  Material Considerations
•  Control Parameters
•  Initial Settings
•  Part Size

Spin Welding Process .....................................27
Material Considerations .................................27
Control Parameters ........................................28

  Axial Pressure ................................................. 28
  Surface Velocity (RPM) ................................... 29
  Weld Time ..................................................... 29
HoldTime ....................................................... 30

Initial Settings ................................................30

  Axial Pressure ................................................. 30
  RPM (Surface Velocity) ................................... 31
  Weld Time ..................................................... 33
HoldTime ....................................................... 33

Part Size .........................................................33

Dukane Corporation •

• Ultrasonics Division

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Summary of Contents for SVB031

Page 1: ...174 USA TEL 630 797 4900 FAX 630 797 4949 S P I N W E L D E R S P I N W E L D E R Dukane Part No 403 547 03 User s Manual www dukane com us SVB031 3 HP SVB051 5 HP Intelligent Assembly Solutions Intelligent Assembly Solutions Dukane products are manufactured in ISO registered facilities ISO 9001 2008 ...

Page 2: ...orm or by any means electronic mechanical photocopying recording or by any information storage and retrieval system without written permission from Dukane Corporation Notice of Liability 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 Corporation shall not have any liability to...

Page 3: ...sive counterbalance force setting on page 55 New Division and 24 Hour Service Phone Numbers New Consolidated Domestic and Intn l Warranty Updated ISO Certification to 9001 2000 Revised web address and Dukane contacts 2010 July 02 Revised Figure 4 2 Tool Mounting Hub Dimensions 2010 Nov 15 03 Corrected typographical errors pages 30 33 43 and 45 2011 Oct 19 Updated copyright page content page i Upda...

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Page 5: ...ystem Requirements 10 Physical Space 10 Electrical 10 Pneumatic 10 Major Components 10 Spin Welder Rear View 11 Spin Welder Front View 12 Section 3 Safety 13 Safety Regulations 15 Plastics Health Notice 15 Palm Switches 15 General Safety 15 Electrical Safety 16 AC Power 16 Grounding 17 Mechanical Safety 17 Pneumatic Safety 17 Section 4 Installation 19 Work Area 21 Securing to Work Table 21 Bench C...

Page 6: ...l Functions 35 AC Power 37 AC Switch 37 AC Fuses 37 Operate Controls 38 Palm Switches 38 Emergency OFF 39 Status Display 39 Pneumatic Controls 40 Air Pressure Regulator 40 Regulator Gauge 40 Down Speed Control 41 Counterbalance Regulator 41 Controller Interface 41 Display 41 Keypad 41 Number Keys 42 Function Keys 42 Display Format Keys 42 Motor Speed Control 43 Mechanical Controls 43 Height Adjust...

Page 7: ...l Regulator 52 8 Down Speed Adjustment 52 9 Counterbalance Regulator 52 10 Enable System 52 Height Adjustment 52 Stroke Adjustment 53 Stop Lock 53 Bottom Stop Adjustment 53 Start Of Weld 54 End Of Weld 54 Pneumatic Adjustments 54 Front Regulator 54 Counterbalance Regulator 55 Down Speed Adjustment 56 Motor Speed Control 56 User Interface 57 Power Up Sequence 57 Operating Menus 58 SETUP 58 RUN Menu...

Page 8: ...Annual Maintenance 69 Gas Spring 69 Lubricate Slides 70 Section 9 Troubleshooting 71 Welding Process 73 Material Choices 73 Parameter Effects 73 Surface Velocity 73 Axial Pressure 73 Weld Time 73 Hold Time 73 Welder Troubleshooting 74 Pneumatics 74 Mechanical 74 Electrical Power 74 Base Interface Cable 74 AC Motor Controller 76 User Interface 76 Section 10 Contacting Dukane 79 Identify Equipment 8...

Page 9: ...pecifications 83 Energy Requirements 85 Pneumatic 85 AC Power 85 Operating Environment 85 Dimensions 86 Identification Numbers 87 Welder Model and Serial Number 87 Base Model and Serial Number 88 Appendix A List of Figures Tables 89 Appendix B Electrical Schematic 93 Index 97 ...

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Page 11: ...ant User Information 3 Read This Manual First 3 Notes and Tips 3 Caution and Warnings 3 Drawings and Tables 3 Manual Organization 4 Spin Welder Key Features 5 Introduction Important Information Manual Organization Key Features Section 1 Dukane Corporation Ultrasonics Division ...

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Page 13: ...tements help you to identify and avoid haz ards and recognize the consequences One of three different symbols also accompany the CAUTION and WARNING blocks to indicate whether the notice per tains to a condition or practice an electrical safety issue or a hand protection issue Drawings and Tables The figures and tables are identified by the section number followed by a sequence number The se quenc...

Page 14: ...on describes the Spin Welding process and gives guide lines for part size Section 6 Controls and Their Functions de scribes all the controls and their func tion or purpose Section 7 Operational Setup describes basic system checkout adjustment and op eration Section 8 Maintenance gives a schedule of sug gested preventive maintenance Section 9 Troubleshooting provides helpful tips for identifying an...

Page 15: ...us 20 94 tool hub height can be increased an additional 6 with a special order assembly request The hub can easily accommodate up to 12 diameter tooling Photoelectric Start Of Weld and End Of Weld switches for trouble free and reliable operation Built inAir Pressure Gauge and Regulator means the Spin Welder is ready to operate Pneumatic Operation with adjustable 7 stroke assures quiet operation an...

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Page 17: ...on 2 Unpacking Unpacking System Packing List System Requirements Major Components Unpacking System 9 Packing List 9 System Requirements 10 Physical Space 10 Electrical 10 Pneumatic 10 Major Components 11 Rear View 11 Front View 12 Dukane Corporation Ultrasonics Division ...

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Page 19: ... Figure 6 7 If you ordered custom tooling with your Spin Welder it may be installed with a sample part under the tool hub for shipping Leave the locking levers tightened until the Spin Welder has been installed in its work area Packing List After removing the shipping container check that you have the items listed in Table 2 1 Inspect the Spin Welder for damage Report any damage im mediately to th...

Page 20: ...responding wall receptacle is illustrated in Figure 2 2 Note that the geometry of the 240VAC 20A 3Ø plug is slightly different from a 120 240VAC 20A 1Ø NEMA L14 20P configuration and also from a 480VAC 20A 3Ø NEMA L16 20P configuration All three geometries are incompatible with each other to prevent accidental overloads Pneumatic Additionally the Spin Welder requires a clean dry compressed air sup...

Page 21: ...er Spin Welder Serial Number Air Exhaust Diffuser Compressed Air Inlet Top Of Stroke Connector Base Interface Connector J8 Counterbalance Regulator AC Power To Press Upper Dovetail Lock Main AC Disconnect and Fuse Enclosure AC Power Switch Lockout Lower Dovetail Lock AC Enclosure Lockout Press Height Adjustment Crank AC Power Cord 240VAC 3 Phase Base Serial Number Base Interface Connector J35 Base...

Page 22: ...splay Keypad Pressure Regulator Gauge Pressure Regulator Adjustment Down Speed Adjustment Motor Speed Control Upper Press Housing Bottom Stop Indicator Flags Front Access Panel Lower Motor Housing Tooling Hub Height Adj Rack Gear Height Adj Gas Spring Bottom Stop Adjustment Bottom Stop Adj Lock Base Platen Left Palm Switch Status Display Left Mounting Hole Right Mounting Hole Emergency OFF Switch ...

Page 23: ... Safety Regulations Electrical Safety Mechanical Safety Pneumatic Safety Safety Regulations 15 Plastics Health Notice 15 Palm Switches 15 General Safety 15 Electrical Safety 16 AC Power 16 Grounding 16 Mechanical Safety 17 Pneumatic Safety 17 Dukane Corporation Ultrasonics Division ...

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Page 25: ... switches comply with OSHA safety regulations Using a foot switch in place of the dual palm activation buttons violates OSHA regulations General Safety Before performing any maintenance or service on the Spin Welder locks and tags should be applied to all energy isolating switches Anything that might restore energy to the Spin Welder must be locked out You may be required to add accessories to bri...

Page 26: ... nance or servicing The cover can also be locked to prevent unauthorized access Figure 3 1 shows the AC power switch and the two lockouts Before per forming any service or tests turn off the AC power switch disconnect the AC power cord from the AC receptacle and lock the switch handle in the OFF position Never attempt to lockout the AC power by pulling the fuses WARNING Always turn the AC power OF...

Page 27: ... com promise the safety of the power ground 14 AWG wire has a diameter of 1 63mm or 0 064 Mechanical Safety The SpinWelder is capable of developing substantial torque and high rotational velocity Keep your hands and body away from the tool head during operation The spinning head is capable of inflicting serious injury Never attempt to retrieve a part from a spin ning tool head Always wear safety g...

Page 28: ...e tool head The Spin Welder uses a 3 inch 76 mm diameter air cylinder which converts the air pressure to mechanical movement and has a force multiplica tion factor of seven This means that at the full 100 psi 6 9 bar the air cylinder is capable of exerting 700 pounds 318 kg of force This much force can result in serious injury to the operator WARNING Tighten all compressed air connections secure l...

Page 29: ... Secure to Work Table Tooling Attachment Compressed Air Control Cable AC Power Connection Work Area 21 Secure to Work Table 21 Bench Capacity 21 Leveling 21 Mounting Holes 21 Tooling Attachment 21 Compressed Air Connection 22 Control Cables 22 Base Interface Cable 22 Top Of Stroke Cable 23 AC Power Connection 23 Dukane Corporation Ultrasonics Division ...

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Page 31: ...der be leveled to within one degree This can be accomplished using a carpenter s level One degree corresponds to ap proximately one quarter of an inch 6 mm deviation across the 16 inch 406 mm width of the platen Mounting Holes The base of the Spin Welder has two mounting holes in the front as shown in Figure 4 1 The two holes will accept either 12mm or 7 16 diameter bolts We recommend that you sec...

Page 32: ...r than 110 psi 7 6 bar The air is attached to the rear of the press using a standard 3 8 NPT fitting The location is shown in Figure 4 3 A sintered metal diffuser is attached to the exhaust port directly below the air connection If your compressed air supply contains any oil or moisture you should attach a pre filter between the compressed air supply line and the Spin Welder Control Cables Base In...

Page 33: ... press control input connector is a 4 contact connector for the optional Top Of Stroke cable Dukane Part No 438 528 This connection utilizes the Top Of Stroke output from the spin welder controls and is only required if you are using the custom automation feature This is a normally open contact which closes at the top of the stroke It is limited to a maximum of 24 Volts and 1 Amp The cable pinout ...

Page 34: ...40V 240V 240V GND G X Y Z Note that X is narrower than Y or Z switch enclosure are three fuses for the 240 VAC three phase power rated at 20 Amps The power switch and fuses are identical on both the 3 HP and 5 HP models TheAC power switch has a provision to lock the handle in the OFF position during any maintenance or servicing The cover can also be locked to prevent unauthorized access ...

Page 35: ...n Spin Welding Process Material Considerations Control Parameters Initial Settings Part Size Spin Welding Process 27 Material Considerations 27 Control Parameters 28 Axial Pressure 28 Surface Velocity RPM 29 Weld Time 29 HoldTime 30 Initial Settings 30 Axial Pressure 30 RPM Surface Velocity 31 Weld Time 33 HoldTime 33 Part Size 33 Dukane Corporation Ultrasonics Division ...

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Page 37: ...e III This is an unsteady state in which the temperature quickly increases and viscous flow is initiated resulting in a large increase in melt thick ness This is accompanied by a sharp rise in the melt weld penetration velocity Once the melting process is initiated heat is then generated by internal friction within the molten region This continues in Phase IV until a steady state equilibrium is re...

Page 38: ...at will affect consis tency and weld repeatability Spin welding is more tolerant of contaminants than ultrasonic welding Spin welding is also less affected by hygroscopic polymers although they may still require special handling for critical applications The moisture content can lead to bubble formation in the joint resulting in decreased weld strength Control Parameters Axial Pressure There are t...

Page 39: ...with mo tor RPM Smaller diameter parts therefore usually require more RPM than larger parts and typically cannot tolerate as much axial pressure However the same percentage change in axial pressure has a larger effect than the same percentage change in RPM in determining the time required to initiate weld forma tion and the depth to which the weld penetrates The previous statement is a generalizat...

Page 40: ...xial Pressure This is the most difficult parameter to estimate You will require less pressure with an electric mo tor spin welder than with an inertial welder due to the inertial welder s loss of kinetic energy A rough estimate can be derived from a specific pressure of 1 7 MPa 1 7x106 Nt m 2 of projected joint area This translates to roughly 250 pounds per inch2 of weld surface area total wetted ...

Page 41: ...ial pressure The basic expres sion commonly seen is v πDN where v is surface velocity inch sec π 3 14 D averagediameterofthejoint inch N angular velocity rev sec but N RPM 60 so we can write v The initial target for v is in the 360 to 600 inch sec range This corresponds to the common quoted val ues of 30 to 50 ft sec Surface velocities as low as Figure 5 2 Dependence of the Surface Velocity on the...

Page 42: ... careful to compare graphs in the same units Solving the previous expression for RPM gives us RPM A plot of this expression is shown in Figure 5 3 Now we have RPM plotted as a function of weld joint diameter D for eight different values of v ranging from 120 to 960 inch sec 60 v π D 2000 3000 4000 0 1000 1 2 4 6 8 10 12 3 RPM Average Weld Diameter inch D Rotational Velocity rev min v 240 v 360 v 4...

Page 43: ...eration time in order to achieve the desired weld penetration Once the polymers reach Phase III an increase in welding time does not significantly yield an increase in weld strength Excessively long weld times may draw out reinforcing filler and realign the interchain bonds in the weld plane resulting in a weak axial weld joint It may also lead to part distortion in extreme cases Hold Time The hol...

Page 44: ...The overlap between the two models is large enough and the variability in applications diverse so that only very general recommendations can be made Please contact the DukaneApplications Laboratory see Section 10 for a recommendation concerning your specific application Table 5 1 Weld Joint Diameters for 3 HP and 5 HP Models Model Minimum Diameter Maximum Diameter 3 HP 1 25 32 mm 5 125mm 5 HP 4 10...

Page 45: ...tor Speed Control Height Adjustment Bottom Stop Switch AC Power 37 AC Switch 37 AC Fuses 37 Operate Controls 38 Palm Switches 38 Emergency OFF 39 Status Display 39 Pneumatic Controls 40 Regulator 40 Down Speed Control 41 Counterbalance 41 Controller Interface 41 Keypad 41 Display 41 Motor Speed Control 43 Height Adjustment 43 Bottom Stop 44 Dukane Corporation Ultrasonics Division ...

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Page 47: ...osure are three 250 Volt 20 Amp SLO BLO Fuses Figure 6 2 shows the interior of the switch box and the location of the fuses Turn off both the AC power and compressed air before opening the cover to inspect the fuses Disconnect theAC power before testing or servicing the fuses If a fuse has blown determine the cause of the fault and correct the condition before replacing the fuse s and applying pow...

Page 48: ...hes comply with OSHA safety regulations and require simultaneous activation to start the spin welder The switches must be held until the Start Of Weld opti cal switch is triggered see Start Of Weld in Section 7 The palm switches are shown in Figure 6 3 ight and alm witch Left Hand Palm Switch Figure 6 3 Base with the Dual Palm Switches Figure 6 2 AC Power Enclosure Showing the Three Fuses 20 Amp F...

Page 49: ...deactivated The air is allowed to bleed out of the downstroke air cylinder The press may lower if the pneumatic counterbalance is set too low To reset the spin welder twist the Emergency OFF switch clockwise and out as shown in Figure 6 4 Status Display Directly to the left of the Emergency OFF switch is the status display The display is blank when theAC power is OFF When AC power is on and the Em...

Page 50: ...gure 6 5 The pressure regulator knob is a ten turn control About five turns are required to change the setting from 0 to 100 psi 6 9 bar Turning the knob clock wise increases the pressure Regulator Gauge The applied air pressure is indicated on the regulator gauge located directly above the regulator control knob The gauge has a 1 5 diameter dial with a range of 0 to 100 psi 0 to 7 kg cm2 and is s...

Page 51: ...25 lbs 57kg The knob which regulates the amount of counterbalance force applied is located on the rear of the spin welder below the AC power cable grommet It is identical to the front panel pressure regulator and is shown in Figure 6 6 Turning the knob clockwise increases the counterbalance force and raises the motor and slide The application of the counterbalance is controlled by an internal sole...

Page 52: ... F2 They are used to display any application screen assigned to the key Display Format Keys The remaining eight gray keys with white letters are for display navigation or data formatting The function of each key is listed here MENU Returns to the main menu of the applica tion MODE Accesses special features and configura tions of operating parameters PREV Steps back through a sequence of linked scr...

Page 53: ... nominally 3500 RPM for the 3 HP model and 1750 RPM for the 5 HP model Mechanical Controls Height Adjustment This hand crank shown in Figure 6 7 sets the press assembly rest height Counterclockwise rotation NOTE The maximum motor speed setting is 999 which corresponds to 99 9 3HP 3496 RPM and 5HP 1748 RPM The lowest practical setting for spin weld ing is about 100 which corresponds to 10 0 3HP 350...

Page 54: ...ounterclock wise before the press height is adjusted and tight ened clockwise once the desired height is reached The dovetail locks are also shown in Figure 6 7 Bottom Stop The bottom stop adjustment knob shown in Figure 6 8 raises and lowers the bottom stop This in turn Figure 6 8 Bottom Stop Adjustment and Lock Bottom Stop Lock Bottom Stop Lock Bottom Stop Adjustment Bottom Stop Adjustment Indic...

Page 55: ...41mm Counterclockwise ro tation raises the flag to the top of the scale which lengthens the stroke Clockwise rotation lowers the flag to the bottom of the scale and reduces the stroke The figure shows a setting of about 4 inches measured from the bottom of the scale which is the same as the downstroke Bottom Stop Lock This knob locks the bottom stop adjustment in place to prevent any accidental ch...

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Page 57: ... Checklist Bottom Stop Adjustment Pneumatic Adjustments Motor Speed Control Operating Menus Terminology 49 Tooling Capacity 50 Setup Checklist 51 Press Height Adjustment 52 Bottom Stop Adjustment 53 Pneumatic Adjustments 54 Regulator 54 Counterbalance 55 Down Speed 56 Motor Speed Control 56 User Interface 57 Power Up Sequence 57 Operating Menus 58 Input Parameters 62 Dukane Corporation Ultrasonics...

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Page 59: ...ght up to speed This method is called pre load Weld Time The time during which the upper part is being ro tated to heat the thermoplastic interfaces and form the weld joint is called the weld time The minimum programmable weld time is 0 01 seconds The maxi mum programmable weld time is 9 99 seconds A typical value might be 0 5 second Hold Time After the weld time is completed the parts must be hel...

Page 60: ...ub center line See Figure 7 1 for the relevant dimensions Fixture Height The following measurements are taken with a 0 5 thick tooling hub the AC power ON and the counterbalance regulator adjusted so that the motor and hub are fully retracted upward The adjustment range is achieved by unlocking the dovetail locks and rotating the hand crank The normal maximum height between the platen and upper hu...

Page 61: ...tor as shown in Figure 7 2 These are identified as 4 and 18 on the major components view Figure 2 3 4 Connect AC Power Make sure the AC switch enclosure is securely closed Plug in the AC power cord to a 240 VAC 60Hz 3 phase outlet This safely grounds the spin welder Leave the AC power switch OFF 5 Connect Compressed Air Turn the front air pressure regulator all the way counterclockwise Turn the re...

Page 62: ...ounterbalance to function properly 9 Counterbalance Regulator Adjust the rear counterbalance regulator by first turning the knob clockwise CW until the motor and tool hub fully retract upward into the press housing Turn the knob counterclockwise until the motor and hub gently drop down against the me chanical stop Now slowly turn the knob CW back until the motor and hub fully retract again There i...

Page 63: ... stroke of four inches Turning the knob counterclockwise will cause the flag to rise on the scale which will increase the stroke Clockwise rotation lowers the flag which results in a shorter stroke Adjust the bottom stop to slightly less than the de sired stroke Press the Emergency OFF button The hub should lower until it reaches the bottom stop setting Make any final adjustments in the lower fixt...

Page 64: ...itch triggers 0 005 0 127mm above the bottom stop setting to allow for system momentum If you are in a weld by dis tance mode this marks the end of the weld cycle and terminates the process The End Of Weld switch has no effect on a weld by time operation Pneumatic Adjustments Front Regulator The front panel regulator see Figure 6 5 controls the amount of air pressure applied to the 3 air cylin der...

Page 65: ...per adjustment of the counterbalance will enable you to achieve better control of the down speed adjustment If the counterbalance is set too high it will adversely affect the down speed adjustment or the press may not descend at all If the counterbalance is set too low it will allow the air to escape from the air cyl inder when the Emergency OFF switch is pushed in This in turn will allow the moto...

Page 66: ...eed setting is a flow control device so the amount of air released from the air cylinder dur ing down stroke is dependent upon the pressure set by the front panel regulator Higher pressure gives a faster down speed The initial setting should be approximately 1 1 2 to 2 1 4 turns open at a pres sure regulator setting of 40 psi Excessively high counterbalance forces may adversely affect the adjustme...

Page 67: ... motor may fail to reach the selected RPM within the controller s acceleration time window User Interface Power Up Sequence 1 When the Spin Welder is initially powered up the LCD display will light and remain blank for approximately one second 2 The processor then tests the display for one second by turning on every pixel 3 The display is again cleared and the processor verifies the system memory ...

Page 68: ...s step press 1 then press the enter key in the lower right hand corner To set the bottom stop turn the counterbalance regulator CCW to allow the motor and hub to drop down to the limit stop see Step 9 on page 52 Once the stop has been set the display will indicate it has recognized the setting Now turn the counterbalance regulator CW to allow the motor and hub to rise back up The display now promp...

Page 69: ...or all data except for the initial Menu selection 1 WELD BY DIST 2 WELD BY TIME PUSH E STOP TO BEGIN SETUP SET BOTTOM STOP 1 BYPASS STOP SET 1 PRE LOAD 2 PRE SPIN PART PICKUP 1 YES 2 NO SET MAX TIME LIMIT 1 50 SET WELD TIME 75 SET HOLD TIME 50 SET HOLD TIME 50 1 RUN 2 SETUP 3 MODIFY 1 RUN 2 SETUP 3 MODIFY SET PICKUP TIME 1 00 SET PRE LOAD TIME 25 SETUP Menu Push Emergency OFF Button In Turn Counte...

Page 70: ...y press both palm switches to start operation The RUN menu flowchart is shown in Figure 7 9 MENU 1 RUN Menu MACHINE READY PART COUNT 0 1 RUN 2 SETUP 3 MODIFY MACHINE READY PART COUNT 9999 WORKING WELD TIME HOLD TIME WORKING MACHINE READY PART COUNT 1 Maximum Part Count Counter Can Be Reset in MODIFY Menu Counter Incremented Down Stroke Upstroke Start of New Weld Cycle End of Weld Cycle Display Ind...

Page 71: ...RUN 2 SETUP 3 MODIFY MODIFY Menu PRE SPIN Was Selected in SETUP Menu PRE LOAD Was Selected in SETUP Menu Counter is not reset Counter is reset to zero Checks Which Mode Was Selected in the SETUP Menu Check If PART PICKUP Was Selected in SETUP Menu Part Pickup YES Part Pickup NO MENU 1 2 2 1 3 Figure 7 10 MODIFY Menu Flowchart MODIFY Menu To modify the parameter values press the MENU key then 3 to ...

Page 72: ... times are 0 01 and 9 99 seconds respectively Atypical value might be 1 0 second PRE LOAD TIME This is the amount of time that the tool hub spends in the lowered position applying a preloading pres sure to the upper and lower parts to be welded This setting is only available if the Pre Load mode was selected The minimum and maximum values are 0 01 and 9 99 seconds respectively A typical value migh...

Page 73: ... PREV Key In the Setup menu the Previous key recalls the data value entered previous to the current one displayed This key does not work in Modify menu NEXT Key The Next key skips the currently displayed value and steps to the next input parameter in either the Setup or Modify menu PREV NEXT ...

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Page 75: ...wer Cord Plug Weekly Maintenance Monthly Maintenance Annual Maintenance User Interface Panel 67 Cleaning 67 Display 67 Keypad 67 AC Power Cord 67 Weekly Maintenance 68 Pre Filter 68 Exhaust Diffuser 68 Visual Inspection 68 Monthly Maintenance 68 Slides and Motor Shaft 68 Rear Counterbalance 68 Annual Maintenance 69 Gas Spring 69 Lubricate Slides 70 Dukane Corporation Ultrasonics Division ...

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Page 77: ...ht and should not require any maintenance other than occasional cleaning Keypad Use your finger to press the control keys Do not use sharp objects on the keys If your hands are greasy or contaminated with dirt use a soft object like a pencil eraser AC Power Cord The AC power cord should be kept in good condi tion and free from any cuts and abrasions The AC plug should be straight with no bent pron...

Page 78: ...ual Inspection Visually inspect the cables and air lines once a week Replace or repair any damaged cables or air lines Monthly Mainte nance Slides Motor Shaft Once a month clean the exposed vertical slides and rack teeth of any accumulated debris and dirt Clean the lower motor shaft area to allow an unobstructed flow of cooling air These areas are identified in Figure 8 2 Rear Counterbalance Check...

Page 79: ...These two items function separately and should not be confused with each other If the gas cylinder has lost pressure it will not provide suf ficient restoring force at its maximum extension and should be replaced The gas spring cannot be recharged Contact your local Dukane representa tive for the correct part number or you can try and obtain one directly from Fairchild Fasteners at 818 998 1412 Th...

Page 80: ... Three are clearly visible and one is hidden behind the Dukane name plate of the upper gas spring support bracket Cut out an access hole to gain access to this grease fitting see Figure 8 4 The lower fitting is shown in Figure 8 3 The two fittings on the opposite side are vis ible in Figure 6 7 They are adjacent to the dovetail locking levers Each fitting is accompanied by a small red label advisi...

Page 81: ...403 547 03 Section 9 Troubleshooting Welding Process Welder Troubleshooting User Interface Welding Process 73 Material Choice 73 Parameter Effects 73 Welder Troubleshooting 74 Pneumatics 74 Mechanical 74 Electrical Power 74 Base Interface Cable 74 AC Motor Controller 76 User Interface 76 Dukane Corporation Ultrasonics Division ...

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Page 83: ...reach its melting temperature Instead it may simply erode away part of the material and stick by a clawing effect The surface velocity is determined by both the weld joint diameter and the motor speed Axial Pressure In conjunction with surface velocity axial pressure determines whether the plastic reaches the melting temperature Both speed and pressure are needed to produce sufficient frictional h...

Page 84: ... to Electrical Safety in Section 3 Base Interface Cable The cable must be plugged in to the base and the back of the press If the cable is not plugged in or has a fault the palm switches will not initiate any action Also the ABORT and POWER indicators on the base status display will not function Table 9 1 lists the internal connector pinout and wire color Table 9 1 Base Interface Connector Pinout ...

Page 85: ...to the Micrologic Controller A more detailed schematic is shown in Appendix B Figure 9 1 Block Diagram of Electrical Components Speed Control 24 VDC Power Supply Master Control Relay A B Motor Controller AC Motor Start Of Weld End Of Weld Optical Switches Main AC Disconnect Fuses A B Micrologic PLC Controller 240 VAC 3 Phase Line Input Top Of Stroke Connector Safety Switch Base Interface Connector...

Page 86: ... which exits the diagnostic test menu The Core ROM B System RAM C System ROM D Program ROM E and Watchdog Timer H tests all either pass or fail The correct message is that the test passed then press any key to continue The Keyboard Test F is self explanatory and tests the response of every key in sequence on the key pad Do not try to run the Comm Port G test as this requires an external DC supply ...

Page 87: ...iagnostic Tests Core ROM Diagnostic Tests Reset TEST FUNCTIONS Menu Display Then Alternates in Checkerboard Pattern All Pixels Are Turned On First One Checkerboard Pattern Is Displayed Any Code Works Until Access Code is Set Eight Tests plus Reset Press Enter Key to Initiate Test Press NEXT or PREV Key to Select Test Select Reset to Exit TEST Menu MODE 4 4 NEXT 1 Display Test is Terminated Next Te...

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Page 89: ...03 547 03 Section 9 Troubleshooting Page 79 Dukane Manual Part Number 403 547 03 Section 10 Contacting Dukane Dukane Support Website FAX Telephone Numbers Identify Equipment 81 Our Website 81 Mailing Address 81 Phone Number 81 Dukane Corporation Ultrasonics Division ...

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Page 91: ... problems can be solved over the telephone so it is best to call from a telephone located near the equipment Intelligent Assembly Solutions Mailing Address Dukane Ultrasonics 2900 Dukane Drive St Charles IL 60174 USA Phone 630 797 4900 Fax Main 630 797 4949 Service Parts 630 584 0796 E mail ussales dukane com Website www dukane com us The website has information about our products processes so lut...

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Page 93: ... Manual Part Number 403 547 03 Section 11 Specifications Energy Requirements Operating Environment Dimensions Model Serial Numbers Energy Requirements 85 Pneumatic 85 AC Power 85 Operating Enviornment 85 Dimensions 86 Identification Numbers 87 Base Model and Serial Number 88 Dukane Corporation Ultrasonics Division ...

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Page 95: ...nt 3 HP 12 Amps 2 2kW 5 HP 18 Amps 3 7kW The spin welder uses three identical AC fuses One of the fuses is shown in Figure 11 1 They are each SLO BLO type FLNR 20 fuses rated at 250 VAC Operating Environment Operate and store the Spin Welder within these guidelines Oparating Temperature 32 F to 122 F 0 C to 50 C Humidity 5 to 95 Non condensing 0 C to 30 C Altitude 1 000 m 3 300 ft without derating...

Page 96: ...e 11 2 Front View and Dimensions Figure 11 3 Side View and Dimensions 13 94 354 55 88 1419 21 50 546 16 50 419 18 58 472 inches millimeters 20 94 MAX 532 WITH SPECIAL FACTORY CONFIGURATION 26 94 684 27 75 705 inches millimeters 8 50 216 13 66 347 7 63 194 6 38 162 6 25 158 12 25 311 3 90 ...

Page 97: ...Y SPACED AND POSITION WITHIN 015 DIA ON 2 TWO BOLT CIRCLES 8 PLACES 7 00 inch BOLT CIRCLE 125 0 mm BOLT CIRCLE 12 00 inch BOLT CIRCLE 18 58 472 24 84 631 LOCATED AT TRUE M12 X 1 75 6H TAP THRU 5 PLACES inches millimeters 0 50 12 7 Identification Numbers Welder Model Serial Number The serial number and model number tags for the Spin Welder are located on the rear of the upper housing just below the...

Page 98: ... Part Number 403 547 03 Figure 11 6 Base Serial Number Location Base Model and Serial Number The base is Dukane model number 438 749 The serial number tag is located on the rear of the base above the Base Interface connector as shown in Figure 11 6 ...

Page 99: ...Section 11 Specifications Page 89 Dukane Manual Part Number 403 547 03 Appendix A List of Figures List of Tables Dukane Corporation Ultrasonics Division ...

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Page 101: ... in OFF and ON Positions 37 Figure 6 2 AC Power Enclosure and Fuses 38 Figure 6 3 Base With Dual Palm Switches 38 Figure 6 4 Base Status Display and Emergency OFF Switch 39 Figure 6 5 Front Panel Controls Display and Gauge 40 Figure 6 6 Counterbalance Regulator 41 Figure 6 7 Dovetail Locks and Height Adjustment 43 Figure 6 8 Bottomstop Adjustment and Lock 44 Figure 7 1 Tooling Capacity Range Adjus...

Page 102: ... Pinout 74 Figure 9 1 Block Diagram of Electrical Components 75 Figure 9 2 Motor Controller LEDs 76 Figure 9 3 TEST Function Flowchart 77 Figure 11 1 FLNR 250V 20AMP SLO BLO Fuse 85 Figure 11 2 Front View and Dimensions 86 Figure 11 3 Side View and Dimensions 86 Figure 11 4 Top View of Base and Dimensions 87 Figure 11 5 Spin Welder Serial Model Number Location 87 Figure 11 6 Base Serial Number Loc...

Page 103: ...trical Schematic Page 93 Dukane Manual Part Number 403 547 03 Appendix A List of Figures and Tables Page 93 Dukane Manual Part Number 403 547 03 Appendix B Electrical Schematic Dukane Corporation Ultrasonics Division ...

Page 104: ...Spin Welder User s Manual Page 94 Dukane Manual Part Number 403 547 03 This page intentionally left blank ...

Page 105: ... N O N O N C TOS L1 L2 G BLK RED 12VDC 12VDC GRN ORN 0VDC BLU WHT BLU WHT GRN GRAY BLK BLU 0VDC BLK BLU ORN ORN 24VDC BLK ORN SAFETY SW 1 SAFETY SW 2 24 VDC 240 VAC MAIN DISCONNECT 240 VAC 20 AMP 20 AMP 20 AMP 24V 0VDC ALLEN BRADLEY MICROLOGIC 1000 AC POWER IN L1 L2 L3 L1 L2 L3 A B 1600 SERIES MOTOR CONTROLLER MOTOR T1 T2 T3 SPEED CONTROL WELD T1 T2 T3 COM 0 1 2 3 4 5 6 7 8 ABORT SS1 SS2 COM END O...

Page 106: ...Spin Welder User s Manual Page 96 Dukane Manual Part Number 403 547 03 This page intentionally left blank ...

Page 107: ...om Stop Adjustment 44 53 Bottom Stop Indicator Flag 44 Bottom Stop Lock 45 C Cable Color Code 23 74 Cable Connections 23 75 B 3 Cable Part Number 23 Cable Pinout 23 Compressed Air Lockout 51 Compressed Air Prefilter 51 68 Compressed Air Requirements 10 22 87 Compressed Air Safety 17 18 Connector Pinout 23 74 97 Control Cable 23 75 Counterbalance Regulator 41 52 55 68 D Diagnostic Tests 77 Dimensio...

Page 108: ...27 Front Panel Cleaning 67 Function Keys 42 Fuses AC 37 38 85 G Gas Spring 69 Gauge Pressure Regulator 40 Grounding 17 H Health and Safety 15 18 Height Adjustment 43 52 Hold Phase 27 Hold Time 30 33 49 73 Hygroscopic Thermoplastics 28 I IN CYCLE Status 39 Initial Settings 30 33 Installation 19 24 Internet Site 81 ISO 9001 Certification 5 K Keypad 40 41 Key Functionality 41 42 63 L Locking Ring Dow...

Page 109: ...s 58 61 OSHA Safety Requirements 15 17 38 P Packing List 9 Palm Switches 38 Part Identification Drawing 11 12 Part Pickup Mode 62 Part Size Considerations 33 34 Penetration Velocity 27 Phases of Spin Welding Process 27 Pickup Time Setting 62 Placement Considerations 10 21 Plastics Health Notice 15 Pneumatic Diagram 55 Pneumatic Lockout 51 Pneumatic Safety 17 18 Power Requirements 10 87 POWER Statu...

Page 110: ...olenoid 41 55 Figure 7 6 Specifications 85 88 Start Of Weld 54 STATUS Display 39 Steady State Phase 27 Stroke Adjustment 53 Surface Velocity 27 73 Switch AC Power 37 52 T TEST Functions Menu 77 Thermoplastic Considerations 28 73 Theory of Operation 27 34 Timer 49 Tooling Capacity 50 Tooling Hub 21 Top Of Stroke Connector 23 75 Troubleshooting 74 77 U Unpacking 9 User Interface Display 40 41 W Wear...

Page 111: ...em Infrastructure The ISO 9001 2008 standard establishes 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 follow...

Page 112: ...Dukane Drive St Charles Illinois 60174 USA TEL 630 797 4900 FAX 630 797 4949 Spin Welder User s Manual Printed in the United States of America www dukane com us Please refer to our website at www dukane com us sales intsales htm to locate your local representative ...

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