Dukane Dual Servo Spin Welder 403570-01 User Manual

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Dukane Manual Part No. 403-570-01Page 4Dual Servo Spin Welder User’s ManualThe Dual Servo Spin Welder excels at frictional welding of assemblie

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Dukane Manual Part No. 403-570-01Page 95Appendix A Base Interface Connector ...97User I/O Connector...

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Dukane Manual Part No. 403-570-01Page 97Appendix A 11669955PinSignal DescriptionLeft Optical Switch Output1Right Optical Switch Output2+24 VDC Switch

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 98Pin Signal Description Function1 Top-Of-Stroke Status Output ON when pres

Dukane Manual Part No. 403-570-01Page 99Appendix A 123711156101416Slide Kit ConnectorThe slide kit interface is a round 16–pin connector loca

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 100Data Port ConnectorThe computer interface connector is located on

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

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Dukane Manual Part No. 403-570-01Page 103Appendix BAPPENDIX BToolingMoment of Inertia...105 Explanaton of Inert

Dukane Manual Part No. 403-570-01Page 5Section 1 - Introduction• Fixture throat depth is a generous 8”.• Vertical servo actuator operation with adju

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Dukane Manual Part No. 403-570-01Page 105Appendix BUSEFUL UNIT CONVERSIONS1 in. = 2.54 cm = .025 m 1 lb. = 0.45 kg 1 cm = 0.39 in. 1 m = 39.4 in. 1 k

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 106Tool and Fixture DesignThe most important aspect of tool and xture desi

Dukane Manual Part No. 403-570-01Page 107Appendix CUpper Tool Vacuum ...109Remote Touch Screen ...

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Dukane Manual Part No. 403-570-01Page 109Appendix CUpper Tool VacuumAs an aid in holding the spinning part, the welder can optionally be equipped wit

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 110Remote Touch ScreenFigure C-2 Remote Touch Screen ComponentsIn situati

Dukane ISOISO CERTIFICATIONDukane chose to become ISO 9001:2000 certi-fied in order to demonstrate to our customers our continuing commitment to being

Dukane Corporation • Ultrasonics Division • 2900 Dukane Drive St. • Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797–4949Part No. 403–

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Dukane Manual Part No. 403-570-01Page 7Section 2 - Safety ConsiderationsHealth and Safety Tips ...9 Plastics Health

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Dukane Manual Part No. 403-570-01Page 9Section 2 - Safety ConsiderationsIMPORTANTN ev e r o p e r a t e t h e D u a l Ser vo Spin Welder w

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 10Plastics Health NoticeBefore using any Dukane welding system, be s

Dukane Manual Part No. 403-570-01Page 11Section 2 - Safety ConsiderationsIMPORTANTAlways turn off the AC power at the power switch before servici

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Dukane Manual Part No. 403-570-01Page 13Section 2 - Safety ConsiderationsUnpacking Welder ...15Packing List ...

Dukane Manual Part No. 403-570-01Page iiDual Servo Spin Welder User’s ManualCopyright © 2009 Dukane Intelligent Assembly Solutions 2900 Dukane Dr

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Dukane Manual Part No. 403-570-01Page 15Section 3 - Unpacking and SetupQty Item Part Number1 Dual Servo Spin WelderSVT012VR orSVT032VR orSVT042VR1 Ba

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 16WARNINGDO NOT LIFT the Dual Ser-vo Spin Welder manually. Lifting and/

Dukane Manual Part No. 403-570-01Page 17Section 3 - Unpacking and SetupDimensions are in INCHES [mm]3.60 [91.4]1.000-.001.000+25.40-.03.00+[ ].30 [

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 18240 Volt AC Plug(NEMA 6–20P)240 Volt AC Plug(NEMA 6–20P)240 Volt AC Socke

Dukane Manual Part No. 403-570-01Page 19Section 3 - Unpacking and SetupHead HeightAdjustmentThe support column features a threaded shaft for a

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Dukane Manual Part No. 403-570-01Page 21Section 4 - Display and Controls Touch Screen Display ...23Operational Switc

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Dukane Manual Part No. 403-570-01Page 23Section 4 - Display and Controls Touch Screen DisplayThe display is a 4.6 inch (12 cm) wide by 3.5 inch (9cm

Dukane Manual Part No. 403-570-01Page iiiRevision HistoryRevision RevisionNumber Summary Date - 00 Original release. 10/24/2008 - 01

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 24RightRunSwitchLower FixtureLower FixtureE–Stop SwitchLeftRunSwitchABORTPO

Dukane Manual Part No. 403-570-01Page 25Section 4 - Display and Controls Dimly Lit Red LED Brigtly LitRed LEDs11669955Opti–Touch Run SwitchesLocated

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Dukane Manual Part No. 403-570-01Page 27Section 5 - Touch Screen Menus RUN Mode ...29 Screen Layou

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Dukane Manual Part No. 403-570-01Page 29Section 5 - Touch Screen Menus RUN ModeWhen the welder is rst turned on after the E-Stop switch i

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 30bad part means one or more of the measured parameters was not within t

Dukane Manual Part No. 403-570-01Page 31Section 5 - Touch Screen Menus Figure 5–6 Sample Data Entry ScreenSETUP MenuThe SETUP menu is sub-divided i

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 32TOP OF STROKE PositionThis button is used to set the vertical position to

Dukane Manual Part No. 403-570-01Page 33Section 5 - Touch Screen Menus Transfer Button f The transfer icon should only be used when visually aligni

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Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 34The Move To button is used to rotate the tool to the value displayed in t

Dukane Manual Part No. 403-570-01Page 35Section 5 - Touch Screen Menus Rotation MethodIn this method, the weld duration is controlled by com

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 36Energy MethodIn this method, weld duration is controlled by the a

Dukane Manual Part No. 403-570-01Page 37Section 5 - Touch Screen Menus Torque Trigger OptionThis option species a torque level to sense when the up

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 38Figure 5–21 POST-WELD Main Setup ScreenConstant Torque OptionThis option

Dukane Manual Part No. 403-570-01Page 39Section 5 - Touch Screen Menus changes the display to the screen shown in Figure 5-22. The MODE swi

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 40Part TestsThe Part Tests section is used to dene limits for the

Dukane Manual Part No. 403-570-01Page 41Section 5 - Touch Screen Menus The bottom right corner of the POST-WELD screen contains controls fo

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 42TOOLS MenuSELECT SETUP TabPressing the TOOLS button displays the r

Dukane Manual Part No. 403-570-01Page 43Section 5 - Touch Screen Menus eld designates the position of the thruster (part of the welder surrounded

Dukane Manual Part No. 403-570-01Page vSection 1 – Introduction 1Section 2 – Safety Considerations 7Section 3 – Unpacking and Setup 13Section 4 –

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 44[.15 in.] above tooling contact, if possible) and press the Set P

Dukane Manual Part No. 403-570-01Page 45Section 5 - Touch Screen Menus The Home Offset (Deg.) eld is used to specify an angular offset of the homin

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 46Setting Time and Date On Touch ScreenThe time and date displayed on

Dukane Manual Part No. 403-570-01Page 47Section 5 - Touch Screen Menus Screen Parameter Name Min.Value Max.Value Resolution UnitsSETUP>PRE-WELDTO

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Dukane Manual Part No. 403-570-01Page 49Section 6 - Machine OperationMachine Setup...51Starting a Weld Cyc

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Dukane Manual Part No. 403-570-01Page 51Section 6 - Machine OperationIMPORTANTThe Dual Servo Spin Welder is capable of developing substantial torq

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 525. Reset E-StopReset the emergency stop button by turning clockwise. Refe

Dukane Manual Part No. 403-570-01Page 53Section 6 - Machine OperationSince the welder press force is limited in jog mode for safety purposes, the

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Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 54Starting A Weld CycleAll weld cycles must be initiated from the RUN scree

Dukane Manual Part No. 403-570-01Page 55Section 6 - Machine OperationStopping a Weld CycleDuring normal operation, the cycle stops automatically when

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 56 DUAL SERVO SPIN WELDER - SETUP SHEETAPPLICATION MACHINE MODELSVT0___2V

Dukane Manual Part No. 403-570-01Page 57Section 7 - Optimizing PerformanceSpin Welding Process ...59Material Considera

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Dukane Manual Part No. 403-570-01Page 59Section 7 - Optimizing Performance.Spin Welding ProcessThe formal denition of spin welding is “An as

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 60NOTECommon hygroscopic thermoplatics:ABS/Polycarbonate (Cycoloy) Polyox

Dukane Manual Part No. 403-570-01Page 61Section 7 - Optimizing Performance200030004000010001 2 4 6 8 10 123RPMAverage Weld Diameter (inch)DSpin Speed

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 62Press (Axial) SpeedThe press speed affects the amount of contact p

Dukane Manual Part No. 403-570-01Page 63Section 7 - Optimizing PerformanceSince weld depth affects the joint strength and the amount of ash generat

Dukane Manual Part No. 403-570-01Page 1Section 1 - IntroductionImportant User Information . . . . . . . . . . . . . . . . . . . . 3Read the Manual Fi

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Dukane Manual Part No. 403-570-01Page 65Section 8 - Welder Data Export SoftwareIntroduction ...67 Har

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Dukane Manual Part No. 403-570-01Page 67Section 8 - Welder Data Export SoftwareIntroductionA Windows™ application named Dual Servo Spin Welder

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 68Figure 8–1 Utility Startup Screen Part DataUpon startup, the screen

Dukane Manual Part No. 403-570-01Page 69Section 8 - Welder Data Export SoftwareFigure 8–2 PROFILE GRAPHS Tab File WriteSets the write behavior for a

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 70Spin Torque SetpointIf torque triggering is enabled, the Torque Trigger v

Dukane Manual Part No. 403-570-01Page 71Section 9 - TroubleshootingWelding Process ...73 Material Choice ...

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Dukane Manual Part No. 403-570-01Page 73Section 9 - TroubleshootingWelding ProcessMaterial ChoiceA family of thermoplastics is usually compatib

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Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 74WelderMechanicalThe part xture should be securely mounted perpendi

Dukane Manual Part No. 403-570-01Page 75Section 9 - TroubleshootingProblem Symptom Possible Cause Recommended SolutionOverweldingExcessive weld ashW

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 76Message Description Cause Possible SolutionInstructionsActivate both RUN

Dukane Manual Part No. 403-570-01Page 77Section 9 - TroubleshootingTable 9-II continued. . . Message Description Cause Possible SolutionSpin motor no

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 78Message Description Cause Possible SolutionErrorsAxis stopped before weld

Dukane Manual Part No. 403-570-01Page 79Section 9 - TroubleshootingTable 9-II Machine Display Messages (continued)Message Description Cause Possible

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Dukane Manual Part No. 403-570-01Page 81Section 10 - MaintenanceSECTION 10MaintenanceTouch Screen Display ...83AC Pow

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Dukane Manual Part No. 403-570-01Page 83Section 10 - MaintenanceCAUTIONNever use anything sharp on the touch screen. Only use your nger. The screen

Dukane Manual Part No. 403-570-01Page 3Section 1 - IntroductionNOTENOTE statements provide additional in-formation or highlight procedures.CAUTIONCAUT

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Dukane Manual Part No. 403-570-01Page 85Section 11 - Contact DukaneContacting Dukane ...87 Identify Equipment ..

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Dukane Manual Part No. 403-570-01Page 87Section 11 - Contact DukaneContacting DukaneIdentify EquipmentWhen contacting Dukane about a service–related

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 88This page intentionally left blank

Dukane Manual Part No. 403-570-01Page 89Section 12 - SpecicationsSECTION 12SpecicationsTooling Specications ...91M

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Dukane Manual Part No. 403-570-01Page 91Section 12 - SpecicationsTooling SpecicationsTooling SizeRefer to Table 5-I for maximum tooling sizes.Machi

Dual Servo Spin Welder User’s ManualDukane Manual Part No. 403-570-01Page 92NOTE: All specications are subject to change without notice. The specic

Dukane Manual Part No. 403-570-01Page 93Section 12 - SpecicationsCAUTIONDO NOT make any modifica-tions to the Dual Servo Spin Welder. The