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Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797–4949

Dual Servo Spin Welder

User’s Manual

ISO 9001:2000

Dukane products are manufactured

in ISO registered facilities

Intelligent Assembly Solutions

DUKANE

Part No. 403–570-01

Содержание 403570-01

Страница 1: ...22 23 24 25 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 www dukane com us Dukane Intelligent Assembly Solutions 2900 Dukane Drive St Charles Illinois 60174 USA TEL 630 797 4900...

Страница 2: ...e of Liability The information contained is 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 sha...

Страница 3: ...ane Manual Part No 403 570 01 Page iii Revision History Revision Revision Number Summary Date 00 Original release 10 24 2008 01 Menu language choices added Revised Upper Tool Vacuum paragraphs 09 25 2...

Страница 4: ...Dukane Manual Part No 403 570 01 Page iv Dual Servo Spin Welder User s Manual This page intentionally left blank...

Страница 5: ...Touch Screen Menus 27 Section 6 Machine Operation 49 Section 7 Optimizing Performance 57 Section 8 Welder Data Export Software 65 Section 9 Troubleshooting 71 Section 10 Maintenance 81 Section 11 Con...

Страница 6: ...Dukane Manual Part No 403 570 01 Page vi Dual Servo Spin Welder User s Manual This page intentionally left blank...

Страница 7: ...ge Section 1 Introduction Important User Information 3 Read the Manual First 3 Notes and Tips 3 Caution and Warnings 3 Drawings and Tables 3 Dual Servo Spin Welder Overview 4 Dual Servo Spin Welder Ke...

Страница 8: ...Dukane Manual Part No 403 570 01 Page Dual Servo Spin Welder User s Manual This page intentionally left blank...

Страница 9: ...standing of the system A NOTE block is shown to the right Cautions and Warnings In addition we use special notices to make you aware of safety considerations These are the CAUTION and WARNING blocks a...

Страница 10: ...maximum speed power and torque of the spin servo motor the same vertical servo actuator is used in each Model specifications SVT012VR 750 RPM 4 2 HP 47 ft lb Torque Spin Motor SVT032VR 3 000 RPM 4 2...

Страница 11: ...nents These readily available items also lessen the need for expensive field service calls Ultra rigid square support column minimizes load deflection for precise and repeatable operation Column mount...

Страница 12: ...Dukane Manual Part No 403 570 01 Page Dual Servo Spin Welder User s Manual This page intentionally left blank...

Страница 13: ...Page Section 2 Safety Considerations Health and Safety Tips 9 Plastics Health Notice 10 Run Switches 10 General Safety 10 Electrical Safety 11 AC Power Receptacle 11 Grounding 11 Mechanical Safety 11...

Страница 14: ...Dual Servo Spin Welder User s Manual Dukane Manual Part No 403 570 01 Page This page intentionally left blank...

Страница 15: ...emove any of the protective sheet metal enclosing the motor or controls The servo motors and drives have exposed electrical terminals which could cause injury or death if touched Grounded Electrical P...

Страница 16: ...g conditions Make sure you use proper ventilation whenever these plastics are processed Run Switches The dual finger run switches comply with OSHA safety regulations Using a foot switch in place of th...

Страница 17: ...ator If there is any question about the grounding of your AC power have it checked by a qualified electrician Grounding lugs are also provided one on the back of the base see Figure 2 2 and one on the...

Страница 18: ...Dual Servo Spin Welder User s Manual Dukane Manual Part No 403 570 01 Page 12 This page intentionally left blank...

Страница 19: ...er 15 Packing List 15 Work Area 15 Secure to Work Bench 16 Bench Capacity 16 Leveling 16 Mounting Holes 16 Tooling Hub Fixture 17 AC Power 18 Height Adjustment 19 Control Connectors 19 Base Interface...

Страница 20: ...Dual Servo Spin Welder User s Manual Dukane Manual Part No 403 570 01 Page 14 This page intentionally left blank...

Страница 21: ...fter the welder has been placed in its working area and you are ready to begin hooking up power This will pre vent accidental kinking or pinching of the power cable Packing List After removing the shi...

Страница 22: ...orklift or hoist to place the servo spin welder on its work bench There are two 3 4 inch lifting eyes located at the top of the column see Figure 3 7 for a lifting ring or strap Remove any remaining p...

Страница 23: ...eters 0 50 12 7 M10 X 1 5 2B TAP THRU EQUALLY SPACED AND LOCATED AT TRUE POSITION WITHIN 0 015 DIA ON 2 TWO BOLT CIRCLES 8 PLACES M12 X 1 75 24 84 631 12 7 Tooling Hub Fixture The upper tooling attach...

Страница 24: ...cord and plug The AC power cord is permanently attached to the welder The other end of the cable has a 240 VAC 1 phase plug shown in Figure 3 4 This is designed for a NEMA 6 20R configuration wall re...

Страница 25: ...nterface connector J35 as shown in Figure 3 7 The control cable carries the operate and emergency stop signals from the optical operate switches and abort switch on the base If you are using custom au...

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Страница 27: ...l Part No 403 570 01 Page 21 Section 4 Display and Controls Touch Screen Display 23 Operational Switches 24 Emergency Stop Switch 24 Opti Touch Run Switches 25 Data I O Connector 25 SECTION 4 Display...

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Страница 29: ...w of the controls is shown in Figure 4 2 The left side of the display remains visible for most of the selected functions The icon in the upper left corner indicates machine status Below that are three...

Страница 30: ...Switch A red Emergency Stop E STOP switch is located in the center of the base as shown in Figure 4 3 The emergency stop switch must be in its reset position before the operate switches will function...

Страница 31: ...LED in the opposite corner of the tray illuminates to indicate the switch has been activated as shown in Figure 4 6 Both switches must be activated simultaneously to initiate a weld cycle Data I O Con...

Страница 32: ...Dual Servo Spin Welder User s Manual Dukane Manual Part No 403 570 01 Page 26 This page intentionally left blank...

Страница 33: ...Menus RUN Mode 29 Screen Layout 29 VIEW PARTS 30 SETUP Menu 31 PRE WELD Setup 31 WELD Setup 34 POST WELD Setup 38 TOOLS Menu 42 SELECT SETUP Tab 42 UTILITIES Tab 42 SYSTEM SETUP Tab 43 Setting Time an...

Страница 34: ...Dual Servo Spin Welder User s Manual Dukane Manual Part No 403 570 01 Page 28 This page intentionally left blank...

Страница 35: ...same basic layout for most of the selected operations The STATUS icon indicates the ready state of the machine To the right of the icon is the name of the currently loaded Setup File Below the file n...

Страница 36: ...energy Joules Orient Welded part angular orientation degrees Weld End Weld end vertical position mm Peak Thrust Peak vertical actuator thrust of maximum thrust Hold End Hold end vertical position mm...

Страница 37: ...ssing the numerical value cell displays a data entry screen shown in Figure 5 6 That also displays the minimum and maximum values allowed The SPIN Deceleration field specifies the spin motor decelerat...

Страница 38: ...button is used to move the head to the value displayed in the Position mm field After pressing this button activate both RUN switches and wait for the value in the Jog Pos mm field to match the Positi...

Страница 39: ...i e force exceeds the value set in the Thrust field The Timeout s field sets a time limit between the arrival at the Position mm distance and the point of reaching the thrust sensing level Pre Spin Or...

Страница 40: ...f Torque Trigger is OFF the weld starts at the Trigger Position defined in the PRE WELD tab If Torque Trigger is ON the weld starts when the desired spin torque threshold is exceeded see Torque Trigge...

Страница 41: ...of the Collapse Absolute switch located on the bottom of the screen If the switch selection is Collapse as shown in Figure 5 14 the travel distance is measured relative to the trigger point If the swi...

Страница 42: ...sly Orientation Option With this option you can specify the upper tool s angular stopping orientation at the end of the weld To enable it press the Orientation button and then the Enable box on the sc...

Страница 43: ...e machine will abort the cycle and display an error The DONE button causes a return to the main WELD tab screen For this option to work properly the torque trigger value must be set above the torque r...

Страница 44: ...que the vertical speed will be 0 until the torque drops below the maximum The Max Speed is the maximum allowable vertical speed which will occur if the measured torque is 0 This value is entered in th...

Страница 45: ...ODE selected as shown in Figure 5 23 the parameters for specifying the hold time are vertical speed in Speed mm s the motion duration in Move Time s and time for maintaining the final position in Dwel...

Страница 46: ...3 Orientation Deg 4 Weld Energy J 5 Peak RPM 6 Peak Torque of max 7 Peak Thrust of max 8 Cycle Time s 9 Vertical Weld End mm 10 Hold Collapse mm 11 Hold End Position mm To enable a limit press the ON...

Страница 47: ...ed the machine cycle will complete regardless of the process limit results If Bad Abort is chosen the machine cycle will continue if any process parameter falls below the Lower limit or be terminated...

Страница 48: ...and a space key To rename a setup enter a new name and then press the Rename button under the new name Press the Done button when finished Copy Setup copies the values of the currently loaded setup fi...

Страница 49: ...SYSTEM SETUP and is shown in Figure 5 32 The welder contains an assembly used to limit the downward travel of the press to prevent tooling from coming in contact This assembly consists of a mechanical...

Страница 50: ...ected to the welder after each cycle refer to Chapter 8 This data includes the spin torque spin orientation vertical thrust vertical position and vertical speed It is displayed in graphical format in...

Страница 51: ...ro so that password protected screens are easily accessed by just pressing the Enter key on the Enter Password Code screen The password is a numerical value with a maximum 10 digit value of 4 294 967...

Страница 52: ...own in Figure 5 38 should appear 2 Press the Clock button The screen shown in Figure 5 39 should appear 3 To change the date and time first enter a numeric value Then press the corresponding button as...

Страница 53: ...P WELD Weld Time Weld Rotations Weld Distance Vertical Energy 0 01 50000 0 01 sec rev mm Joules VERT Speed 01 100 00 0 01 mm s SPIN RPM 5 750 SVT012VR 3000 SVT032VR 4000 SVT042VR 1 RPM Weld Orientatio...

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Страница 55: ...Dukane Manual Part No 403 570 01 Page 49 Section 6 Machine Operation Machine Setup 51 Starting a Weld Cycle 54 Stopping a Weld Cycle 55 Setup Sheet 55 56 SECTION 6 Machine Operation...

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Страница 57: ...eptacle in any way Refer to the section on Electrical Safety in Chapter 2 if you have any questions Ensure the AC Power Switch is in the OFF position see Figure 3 6 3 Attach Tooling Attach the upper t...

Страница 58: ...s will first move to their respective home positions corresponding to internal encoder reference pulses in each servo Then the spin motor will rotate to the programmed final weld orientation set in th...

Страница 59: ...and press the VERTICAL TRAVEL LOWER LIMIT button 2 Press the Initialize button and wait 1 minute 3 Press the DOWN button then activate both RUN SWITCHES to move the head down to the posi tion where th...

Страница 60: ...aches the trigger position defined in SETUP PRE TRIGGER tab TRIGGER Position The Trigger Indicator see Figure 4 1 will turn on when the weld starts which occurs at the Trigger position if the Torque T...

Страница 61: ...leted and the press returns to the top of stroke position To stop a cycle before it completes press the E stop switch on the base which terminates the cycle and causes power to be removed from both se...

Страница 62: ...GY J COLLAPSE ABSOLUTE DISTANCE METHOD ONLY COLLAPSE ABSOLUTE VERT SPEED MM S SPIN RPM WELD PARAMETERS DIR CW CCW ORIENTATION WELD ON OFF TORQUE TRIGGER TORQUE OF MAX TIMEOUT S ON OFF SETUP WELD OPTIO...

Страница 63: ...0 01 Page 57 Section 7 Optimizing Performance Spin Welding Process 59 Material Considerations 59 Control Parameters 60 Surface Speed RPM 60 Press Axial Speed 62 Weld Depth 62 Hold 63 Part Size 63 SECT...

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Страница 65: ...where heat starts to be generated by internal friction within the molten region This continues in Phase IV where the temperature of the molten layer remains relatively constant Because plastics are po...

Страница 66: ...ngsectionsarepresentedforinformational purposes only and are in no way meant to serve as a rule or formula The information is collected from publicly available books and papers It is presented here to...

Страница 67: ...20 in sec 60 ft sec 18 m sec 840 in sec 70 ft sec 21 m sec 960 in sec 80 ft sec 24 m sec Figure 7 1 Dependence of Spin Speed on the Weld Diameter for Selected Surface Speeds surface speeds between 360...

Страница 68: ...led the press speed is variable so as to keep the spin torque constant see Chapter 5 The latter case resembles the operation of a pneumatically driven press where the press speed is the result of the...

Страница 69: ...line plastics The dynamic hold distance is typically a small value compared to the weld distance An approximate staring point for initial application setup is 10 of weld distance The static hold time...

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Страница 71: ...Page 65 Section 8 Welder Data Export Software Introduction 67 Hardware and Software Requirements 67 Installation Startup and Cable Connections 67 Part Data 68 Profile Graphs 69 Servo and Debug 70 SECT...

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Страница 73: ...be terminated with a male connector where it connects to the welder Installation Startup and Cable Connections To install the program Run the setup exe file located in the Dukane Dual Servo Spin Util...

Страница 74: ...rder as follows 1 Part number ID 2 Test result number 3 Test result symbol 4 Date 5 Time 6 Weld time sec 7 Number of weld revolutions 8 Weld energy Joules 9 Peak spin motor RPM 10 Peak spin motor torq...

Страница 75: ...ta is exported by the welder after each cycle if the Graph Export option in the System Setup screen is enabled see Figure 5 32 It can also be exported on demand by pressing the EXPORT LAST WELD GRAPH...

Страница 76: ...eters necessary for proper operation of the machine for different upper tool sizes It is set at the factory and stored on the welder in non volatile memory It will need to be modified only in cases wh...

Страница 77: ...ocess 73 Material Choice 73 Parameter Effects 73 Troubleshooting 73 Welder 74 Mechanical 74 Electrical Power 74 Base Interface Cable 74 Machine Display Messages 74 Table 9 I Welding Process Troublesho...

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Страница 79: ...away part of the material and stick by a clawing effect The surface speed is determined by both the weld joint diameter and the spin motor speed Axial Speed In conjunction with surface velocity axial...

Страница 80: ...th a 20 Ampere capacity Check that the circuit is live Also refer to Electrical Safety in Chapter 2 Base Interface Cable The cable must be plugged in to the base and the back of the press If the cable...

Страница 81: ...to table Poor alignment of parts in tool and or fixture Change part or tool dimensions Improve part tolerance due to cavity Insufficient fixture support Check for parts shifting during welding Provide...

Страница 82: ...presence not detected Part presence sensor did not detect part 1 Part not present 2 Problem with sensor 1 Ensure part is present 2 Troubleshoot sensing components RUN SWITCH ES released too soon Optic...

Страница 83: ...or Internal machine error Contact DUKANE service Timeout on servo response to command start Servo system communication error Internal machine error Contact DUKANE service Vertical at travel limit Pres...

Страница 84: ...e time exceeded programmed process limit 1 Weld process problem 2 Limits too narrow for weld process 1 Check parts to be welded fixturing etc 2 If practical widen process limit window or adjust setup...

Страница 85: ...r weld RPM TOS to trigger distance is too small Distance between Top Of Stroke position and Trigger position is too small Trigger position is set too high or Top Of Stroke position is set too low Incr...

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Страница 87: ...Dukane Manual Part No 403 570 01 Page 81 Section 10 Maintenance SECTION 10 Maintenance Touch Screen Display 83 AC Power Cord 83 Maintenance 83...

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Страница 89: ...el Remove grease by rubbing lightly with isopropyl alcohol Afterward provide a final cleaning using a mild detergent and rinse with clean water Do not use any sharp objects on the display It should no...

Страница 90: ...Dual Servo Spin Welder User s Manual Dukane Manual Part No 403 570 01 Page 84 This page intentionally left blank...

Страница 91: ...Dukane Manual Part No 403 570 01 Page 85 Section 11 Contact Dukane Contacting Dukane 87 Identify Equipment 87 Ultrasonics Division 87 Website 87 SECTION 11 Contacting Dukane...

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Страница 93: ...olve it Some problems can be solved over the telephone so it is best to call from a telephone located near the equipment IntelligentAssembly Solutions Mailing Address Dukane Ultrasonics 2900 Dukane Dr...

Страница 94: ...Dual Servo Spin Welder User s Manual Dukane Manual Part No 403 570 01 Page 88 This page intentionally left blank...

Страница 95: ...ge 89 Section 12 Specifications SECTION 12 Specifications Tooling Specifications 91 Machine Weight 91 Power Requirements 91 Operating Environment 91 Dimensions 5 View Drawing 92 Identification Numbers...

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Страница 97: ...eyes located at the top of the column see Figure 3 7 for a lifting ring or strap Power Requirements The Dual Servo Spin Welder requires a 240 VAC 1 phase outlet rated at 20 Amps All welder models use...

Страница 98: ...er s Manual Dukane Manual Part No 403 570 01 Page 92 NOTE All specifications are subject to change without notice The specifications listed are current at the time of publication Figure 12 2 Dual Serv...

Страница 99: ...with the following CE requirements The EMC Directive 89 336 EEC The Low Voltage Directive 73 23 EEC The Machinery Directive 89 392 EEC using EN60204 1 1993 Safety of Machinery Elec trical Equipment of...

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Страница 101: ...kane Manual Part No 403 570 01 Page 95 Appendix A Base Interface Connector 97 User I O Connector 98 Slide Kit Connector 99 Data Port Connector 100 Automation Wiring 100 101 APPENDIX A Connector Pinout...

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Страница 103: ...nterfaceconnectorisaDB9 socketconnector A closeup of the base connector is shown in Figure 2 2 and a closeup of the rear thruster connector is shown in Figure 3 8 The pin numbers for the connector are...

Страница 104: ...ion Without slide or In Out slide not used With Left Right slide ON at start of cycle when slide is commanded to move to Out Left position OFF at the end of cycle 10 Spare Output 2 Not Used 11 Spare O...

Страница 105: ...Function 1 Ground Ground connection 2 No Connection 3 Slide Out Sense Left Input Activate when slide is in Out Left position 4 Output Common Output common connection 5 Top of Stroke Output Closed at T...

Страница 106: ...ion to export part data and weld profile graphs The pin numbers for the connector are shown in Figure A 4 Automation Wiring If the Dual Servo Spin Welder will be used in Automation mode the signals no...

Страница 107: ...Dukane Manual Part No 403 570 01 Page 101 Appendix A Figure A 5 Schematic of Operate and Abort Figure A 6 Wiring for Automation...

Страница 108: ...Dual Servo Spin Welder User s Manual Dukane Manual Part No 403 570 01 Page 102 This page intentionally left blank...

Страница 109: ...Dukane Manual Part No 403 570 01 Page 103 Appendix B APPENDIX B Tooling Moment of Inertia 105 Explanaton of Inertia 105 Calculating the Moment of Inertia 105 Tooling and Fixure Design 106...

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Страница 111: ...rmula can be rewritten as Inertia 098 L D4 where is the density in kg cm3 L is the cylinder length in cm Calculating the Moment of Inertia For spin welder applications most tools will have a geometry...

Страница 112: ...does not fall out before being welded tool should surround part being held where pos sible the exterior of the tool should be a con tinuous cylindrical surface i e avoid protruding parts rotational pl...

Страница 113: ...Dukane Manual Part No 403 570 01 Page 107 Appendix C Upper Tool Vacuum 109 Remote Touch Screen 110 APPENDIX C Optional Features...

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Страница 115: ...ed to gener ate control and transfer the vacuum to the tool us ing an external compressed air supply not provid ed with welder It mounts to the welder as shown in Figure C 1 The spin tool must be desi...

Страница 116: ...the remote touch screen kit 438 965 can be used The touch screen is mounted in a separate enclosure as shown in Figure C 2 which can be up to 15 ft 4 5 m away from the welder Two cables power and comm...

Страница 117: ...Infrastructure The ISO 9001 2000 standard establishes a minimum requirement for these requirements and starts transitioning the company from a traditional inspection oriented quality system to one bas...

Страница 118: ...s Illinois 60174 USA TEL 630 797 4900 FAX 630 797 4949 Part No 403 570 01 Dual Servo Welder User s Manual Printed in the United States of America www dukane com us Please refer to our website at www d...

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