Intelligent Assembly Solutions - Dukane

1 IQ Specifications Intelligent Assembly Solutions Note: Partial data shown here. For complete dimensional data go to: SERVO ULTRASONIC PRESS SYSTEMS. ES. 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 AUTOMATED HAND PROBE PRESS. repeatability, accuracy and reliability to your ultrasonic bonding process. Dynamic Servo Motion Control Patented Melt-Match Technology Robust Rigid Mount Construction Reliable Validation and Calibration Superior data acquisition Available Wattage Frequencies 43S245. 50 kHz 150. 40 kHz 600/900/1200. 30 kHz 900/1200/1800. 43S220. 20 kHz 1200/1800/2400/3600. 43S215. 20 kHz (Super 20) 4800. 15 kHz 4800. Model 43S245.

2 IQ 220 Press iQ Mini Servo iQ Mini Servo System Mini Servo Dimensions iQ 43S220 Thruster System w/Base Thruster w/Base Control Box Base Width (472) (472). Base Depth (631) (631). Base Height (117) (117). Column Height (1132) (674). Maximum Height (1780) (1013). 43S220 20 kHz Housing Width (132) (132) (102) (102) (436). Housing Height (968) (968) (691) (691) (320). Housing Depth (336) (336) (181) (181) (88). Usable Throat (100) (209) (86) (210). Stroke (140) (140) (88) (88). Weight 74 lbs (33 Kg) 250 lbs (114 Kg) 25 lbs ( Kg) 230 lbs (105 Kg) 20 lbs (9 Kg). Maximum Weld Force 550 lbs (2447 N) 550 lbs (2447 N) 150 lbs (667 N) 150 lbs (667 N). 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 e-mail: ISO 9001: 2008 e-mail: Dukane Corporation Ultrasonics Division 2900 Dukane Drive St.

3 Charles, Illinois 60174 USA TEL (630) 797-4900 FAX (630) 797-4949 Dukane Corporation Ultrasonics Division 2900 Dukane Drive St. Charles, Illinois 60174 USA TEL (630) 797-4900 FAX (630) 797-4949. iQ Servo Advantage User Interface Features iQ Dynamic Servo Motion Control iQ FDA Compliance NO Pneumatics! Multi-level password protection Integrated all-electric true servo technology eliminates the Process change audit history and documentation variability associated with pneumatic press components (21 CFR part 11). Process Settings resulting in improved process repeatability and accuracy. Indexed quick change tool system Dynamic Servo Motion Control technology delivers pre- UDI Unique Device Identification cise control of ultrasonic stack velocity, force and location Intuitive menu structure, uses familiar Windows file Integration with barcode scanner and/or laser marker folder layout and icons. providing a more optimized and robust process.

4 System for FDA documentation. One screen process settings page last weld data Repeatable and accurate Servo Motion Control No operator accessible adjustment knobs or controls. displayed simplifies programming. Integrated Melt-Match Technology Ensures validated process remains unchanged. F1 Help command instantly displays explanation of Dynamic Velocity Melt Initiation (DVMI ) All mechanical changes require a specific tool. function. Precise velocity/force control during initial application Clean room friendly User-programmable cycle data screen displays up to of sonic energy allowing for optimization of joint melt No air exhaust to filter 16 unique weld parameters for monitoring operating initiation. (Patented) Stainless steel panels (43S245) parameters. Programmable stack velocity and location control Reduction in cycle time. User programmable process limits are displayed on cycle Cycle Data data screen. Bad Part and Suspect Part limits - up to 13.

5 Ideal for integration into automated Assembly systems parameters are available. Eliminate the need for expen- where high precision and reduced variability is desired. sive SPC packages. Two user-selectable data storage locations store data iQ Calibration and Validation on USB drive, local area network, C drive and generator 100% digital all-electric control simplifies the calibration memory. and validation process. By removing the pneumatic Data is stored based on user-selectable time intervals. components, validating your ultrasonic welding process Shifts can be specified to create unique data file for each has never been easier and is ultimately more reliable. The programmed period. advanced all electric press and digital control features of Save part data from multiple welders to one file option. the iQ Series welder will assure that your calibration/vali- Process Capability (Cpk) Third party independent study com- Ideal for multi-headed weld applications or multi-welder dation will stay in tolerance for a longer time.

6 This provides paring competitive high end pneumatic welder against Dukane work cells. more confidence in the welding output between calibration iQ Servo. Results demonstrate a large increase in the Process Advanced Graphing Capability Index (Cpk), proving the iQ Servo's superior welding Reference footprint consists of the user-selectable weld schedules while maintaining system repeatability. process. graph that gives a tool for finite weld process parameter Simple calibration procedure no pneumatic components Easy Fault optimization. to adjust Seven user-selectable graph parameters -velocity, Easy Fault is a Unique feature to Only one device required for calibration (Trigger Force energy, power, distance, amplitude, frequency, and force Dukane iQ Series power supplies. Sensor) for viewing and storage of each weld. Exportable in CSV. Should there be a system fault or All other parameters validated (no adjustment functional and XML formats for easy integration in SPC programs.)

7 Alarm, the iQ display will prompt a tests only distance, time & velocity) fault code, ( U501 ). Enter the Production analysis screen displays 8-hour shift produc- Optional Dukane calibration/certification prior to shipping. code at Dukane 's website: www. tion statistics: good, bad, suspect quantities and percent- Dukane calibration technicians available for on-site and the quick ages. Ideal for instant monitoring of production. calibrations as required fault search will provide additional tips and process improvement ideas Advanced stack diagnostics includes power and frequency graphs for stack (horn) documentation and iQ GREEN related to the generator fault code. future reference for troubleshooting. Production Data This feature can help expedite No pneumatics = NO compressed Air! Solutions to faults and alarms thus One of the highest cost in manufacturing today is associated iQ Explorer II operates on Windows operating reducing down time.

8 With the energy required to generate compressed air for system independently of the ultrasonic system. pneumatic operations. It is estimated that only 50% of the Usable on most computer platforms, desktop, compressed air generated is used for operation; the rest tablet, notebook or industrial PC, and does not is lost due to leaks and waste. require proprietary hardware from Dukane . iQ Explorer iQ Servo Advantage iQ. Melt-Match Patent #8,052,816 & 7,819,158. The iQ-HMI includes a 15 color industrial PC with Studies show that precisely controlling the velocity of touch screen, compact flash solid state drive (no the ultrasonic stack during the welding cycle provides moving parts), two USB ports, and one Ethernet port. increased weld strength and reduced variability. Windows Embedded Standard operating system. Dukane 's Melt-Match technology precisely Rugged metal housing with mounting holes for matches the velocity of the ultrasonic stack with the standard VESA 75 support arms.

9 IEC C14 plug w/ melt flow velocity of the plastic material ensuring optimum molecular intermingling. This produces internal 110/230 VAC power supply. stronger, more reliable weld results when compared to pneumatic systems. Precise and reliable velocity control with iQ Servo Programmable multi-point velocity profile Programmable static or dynamic (by distance) post weld hold FEATURES. iQ Explorer User Interface Start motion after force drop. Velocity is static until Windows operating system uses familiar file folder menu system senses material melt transition. This reduces part structure, requires no special training to program and stress and provides superior bond strength. (Patent Pending). operate. Programmable motion control modes Touch screen input for ease of programming. All welder Speed mode allows for either constant or 10-segment setup parameters are programmed from one menu page. velocity profile during weld phase.

10 Ethernet connectivity for connection to local area network Force mode allows for either constant or 10-segment or stand-alone applications. force profile during weld phase. Supervisory password control features for lock-out of system controls. Weld by Time. Remote connectivity to Dukane 's 24-hour hotline for Weld by Energy delivers a specific amount of energy to system diagnostics and troubleshooting ensures minimized the part. down time. Weld by Distance controls the collapse distance to ensure that the same volume of material melts on each part so the iQ Process Control The advanced graphing features of the iQ explorer finish joint strength is consistent. To optimize the welding process and produce the strongest software make process optimization simple. An Weld by Absolute Distance controls the finish part height optimized weld process (Melt-Match ) will create a and most consistent weld results, it is critical to look at all to yield uniform assemblies.