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Dukane Intelligent Assembly Solutions
SERVO ULTRASONIC PRESS SYSTEMS

SERVO ULTRASONIC PRESS SYSTEMS

Product catalog summary

Overview
Dukane's iQ Advanced Servo Welders are designed for ultrasonic welding applications, combining digital control with advanced servo technology to enhance precision, repeatability, and reliability.

System Features
The welders feature Dynamic Servo Motion Control, patented Melt-Match® Technology, and robust construction. They eliminate pneumatic variability, offer reliable validation and calibration, and provide superior data acquisition.

Specifications
The systems are available in various models with different frequencies and wattages. They include a compact, single-rail linear ball slide assembly for accurate positioning, a linear distance encoder with 1 μm resolution, and a thrust capacity of up to 560 lb (2500 N) at 20 kHz. Programmable for trigger force and home position, they optimize cycle time and setup.

Options and Accessories
Optional features include a Magnum transducer, wide band transducer, resonant mount booster, and longer press columns. Configurations include a 19” rack or press-mounted generator.

Power Supply Features
The iQ power supply offers 100% digital control, advanced data acquisition, automatic tuning, overload protection, line voltage regulation, and load regulation for consistent performance. It features a modular hardware setup to reduce internal cabling.

Mechanical Features
The system includes a flow-through cooling tunnel, RS232 serial configuration port, and advanced I/O options, designed for easy field software upgrades and custom configurations.

iQ Explorer User Interface
The interface uses a Windows operating system with a touch screen for ease of programming. It offers Ethernet connectivity, supervisory password control, and remote diagnostics support.

Process Control
The iQ system optimizes the welding process through programmable pre-weld and post-weld controls, including programmable motion control modes and various weld modes (by time, energy, distance, etc.).

iQ Servo Advantage
The system's advanced graphing features and intuitive menu structure simplify process optimization, allowing for detailed monitoring and storage of weld parameters, supporting production analysis and advanced diagnostics.

Environmental and Compliance Features
The system is energy-efficient, eliminating the need for compressed air. It complies with FDA requirements, offering multi-level password protection and process change audit history.

Conclusion
Dukane's iQ Advanced Servo Welders provide a sophisticated solution for ultrasonic welding, offering enhanced control, efficiency, and reliability. The system's digital and servo technologies ensure superior welding outcomes and process consistency.

Catalog excerpts

iQ Specifications Intelligent Assembly Solutions Note: Partial data shown here. For complete dimensional data go to: SERVO ULTRASONIC PRESS SYSTEMS http//www.dukane.com/us/DL_DrawingsLayout.asp 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 PRESS • 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 Wattage 150 600/900/1200 900/1200/1800 43S220 20 kHz 1200/1800/2400/3600 43S215 20 kHz (Super 20) 4800 15 kHz 4800 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 43S220 Thruster 5.2 (132) 38.0 (968) 13.2 (336) 3.94 (100) 5.50 (140) 74 lbs (33 Kg) 550 lbs (2447 N) iQ 220 Press System w/Base 18.6 (472) 24.8 (631) 4.6 (117) 44.6 (1132) 70.1 (1780) 5.2 (132) 38.0 (968) 13.2 (336) 8.2 (209) 5.50 (140) 250 lbs (114 Kg) 550 lbs (2447 N) iQ Mini Servo Thruster 4.0 (102) 27.2 (691) 7.1 (181) 3.38 (86) 3.50 (88) 25 lbs (11.4 Kg) 150 lbs (667 N) iQ Mini Servo System w/Base 18.6 (472) 24.8 (631) 4.6 (117) 26.5 (674) 39.9 (1013) 4.0 (102) 27.2 (691) 7.1 (181) 8.3 (210) 3.50 (88) 230 lbs (105 Kg) 150 lbs (667 N) Mini Servo Control Box 43S220 – 20 kHz 17.2 (436) 12.6 (320) 3.5 (88) 20 lbs (9 Kg) Measurements: In. (mm) 43S245 – 30/40/50/ kHz 43S215 – 15 or 20 kHz 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] ISO 9001: 2008 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 • TEL (630) 797-4900 • FAX (630) 797-4949

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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 Explorer iQ Servo Advantage iQ 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...

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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. 15-Pin Input 25-Pin Output 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...

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