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Dukane Intelligent Assembly Solutions
iQ Series Servo Ultrasonic Press Systems

iQ Series Servo Ultrasonic Press Systems

Product catalog summary

Overview
The document provides a detailed description of Dukane's iQ Advanced Servo Welders, highlighting their integration of digital control with advanced servo technology for ultrasonic welding applications. These systems are designed to enhance precision, repeatability, and reliability in welding processes.

System Features
Dukane's iQ Advanced Servo Welders feature Dynamic Servo Motion Control, Melt-Match® Technology, and robust data acquisition capabilities. They offer a compact, single-rail linear ball slide assembly for accurate positioning, a linear distance encoder with 1 μm resolution, and thrust capacities varying with frequency. The ergonomic design includes status indicators and an emergency stop switch, ensuring user safety and convenience.

Specifications
The iQ series includes models with varying frequencies and wattages, such as the 43S245 and 43S220. Maximum weld forces range from 150 lbs to 550 lbs, with dimensions and weights differing across models.

iQ Servo Advantage
The system offers an intuitive Windows-based interface, user-programmable settings, and advanced data storage options. It supports multiple weld parameters and provides production analysis for monitoring.

Dynamic Servo Motion Control
This technology eliminates pneumatic variability, enhancing process repeatability and accuracy. It includes programmable velocity and location control, ideal for automated systems.

Calibration and Validation
The all-electric control simplifies calibration, ensuring long-term reliability and system repeatability. Optional calibration services are available from Dukane.

Environmental and Compliance Features
The system is pneumatic-free, reducing energy costs associated with compressed air. It complies with FDA standards, featuring multi-level password protection and process change audit history.

Process Control
Pre-weld, weld, and post-weld controls are programmable, allowing for precise control over the welding process. The system supports various welding modes, including time, energy, and distance-based controls.

Graphing and Analysis
Advanced graphing features facilitate process optimization, with exportable data formats for integration into SPC programs.

Mechanical and Digital Features
The iQ system includes a linear servo actuator, ergonomic design, and robust mechanical support. Digital features include 100% digital control, fast data acquisition, and automatic tuning for consistent performance.

Options
Available options include a Magnum transducer for increased amplitude, wide band transducer, resonant mount booster, longer press columns, and rack or press-mounted generator options.

iQ Generator/Power Supply Features
Features include 100% digital control, fast data acquisition rate, Digi-Trac tuning for automatic frequency adjustment, ultrasonic overload protection, and modular hardware design.

Mechanical Features
Includes a flow-through cooling tunnel with heat sink and fan, RS232 serial configuration port for software upgrades, and advanced I/O with configurable input and output pins.

iQ Process Control
Offers pre-weld control with programmable home position and down speed, multiple weld control modes, and post-weld control with dynamic and static hold methods.

iQ Explorer User Interface
Features a Windows-based interface with touch screen input, Ethernet connectivity, and remote diagnostics support.

Conclusion
Dukane's iQ Servo Ultrasonic Press Systems provide advanced technology for precise and reliable ultrasonic welding, enhancing process control, reducing variability, and ensuring compliance with industry standards.

Catalog excerpts

iQ Series Servo Ultrasonic Press Systems-1

Intelligent Assembly Solutions Note: Partial data shown here. For complete dimensional data go to: SERVO ULTRASONIC PRESS SYSTEMS System Features Dukane’s patented iQ Advanced Servo Welders are the next step in the evolution of ultrasonic welding technology. Combining the efficiency and reliability of a 100% digitally controlled Multi-Core iQ Series power supply with the precision of an advanced servo press, the Dukane Advanced iQ Servo Welder delivers unprecedented repeatability, accuracy and reliability to your ultrasonic bonding process. ES AUTOMATED HAND PROBE • Dynamic Servo Motion Control • Patented Melt-Match® Technology • Robust Rigid Mount Construction • Reliable Validation and Calibration • Superior data acquisition Available Frequencies 43S245 50 kHz 40 kHz 30 kHz Model 43S245 Dimensions Base Width Base Depth Base Height Column Height Maximum Height Housing Width Housing Height Housing Depth Usable Throat Stroke Weight Maximum Weld Force iQ Mini Servo Thruster Mini Servo Control Box Note: All specifications are subject to change without notice. Please consult Dukane Ultrasonics for any updated information. #10-0038-01 www.dukane.com/us • e-mail: [email protected] Dukane Corporation • Ultrasonics Division • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797-4949 www.dukane.com/us • e-mail: [email protected] Dukane Corporation • Ultrasonics Division • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • T

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iQ Series Servo Ultrasonic Press Systems-2

iQ Servo Advantage iQ Dynamic Servo Motion Control – NO Pneumatics! Integrated all-electric true servo technology eliminates the variability associated with pneumatic press components resulting in improved process repeatability and accuracy. Dynamic Servo Motion Control technology delivers precise control of ultrasonic stack velocity, force and location providing a more optimized and robust process. • Repeatable and accurate Servo Motion Control • Integrated Melt-Match® Technology • Dynamic Velocity Melt Initiation (DVMI™) Precise velocity/force control during initial application of sonic energy...

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iQ Series Servo Ultrasonic Press Systems-3

The iQ-HMI includes a 15” color industrial PC with touch screen, compact flash solid state drive (no moving parts), two USB ports, and one Ethernet port. Windows Embedded Standard operating system. Rugged metal housing with mounting holes for standard VESA 75 support arms. IEC C14 plug w/ internal 110/230 VAC power supply. Melt-Match® Patent #8,052,816 & 7,819,158 Studies show that precisely controlling the velocity of the ultrasonic stack during the welding cycle provides increased weld strength and reduced variability. Dukane’s Melt-Match ® technology precisely matches the velocity of the ultrasonic...

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iQ Series Servo Ultrasonic Press Systems-4

iQ Generator/Power Supply Features Ultra-Rigid iQ Servo Press Spare Custom Configurable Interconnect Slot Rigid All Metal Chassis CE Compliant Power/Switch Circuit Breaker Features • Linear servo actuator with integral roller screw mechanism. IEC Power Inlet Connector Ultrasound Output • 5" (127mm) stroke 20 kHz, 3.5” (89mm) 30/40/50 kHz with electronic teachable mechanical stop. Adjustable in .001" (.025mm) increments. • Top-of-stroke limit switch for automation application • Compact, single-rail linear ball slide assembly system offers accurate positioning, stable movement, and friction-free...

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iQ Series Servo Ultrasonic Press Systems-5

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iQ Series Servo Ultrasonic Press Systems-8

Note: Partial data shown here. For complete dimensional data go to: http//www.dukane.com/us/DL_DrawingsLayout.asp 7.85 “[199] Measurements: In. (mm) Note: All specifications are subject to change without notice. Please consult Dukane Ultrasonics for any updated information. #10-0038-01 www.dukane.com/us • e-mail: [email protected]

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