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Dukane 403570-01 manual

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Table of contents for the manual

  • Page 1

    04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 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 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 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.[...]

  • Page 2

    Dukane Manual Part No. 403-570-01 Page ii Dual Servo Spin W elder User ’ s Manual Copyright © 2009 Dukane Intelligent Assembly Solutions 2900 Dukane Drive St. Charles, IL 60174 USA Notice of Rights: All rights reserved. No part of this manual including the interior design, cover design and icons may be reproduced, transmitted or utilized in any [...]

  • Page 3

    Dukane Manual Part No. 403-570-01 Page iii R e v i s i o n H i s t o r y Revision Revision Number Summary Date - 00 Original release. 10/24/2008 - 01 Menu language choices added; Revised Upper T ool V acuum paragraphs 09/25/2009[...]

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    Dukane Manual Part No. 403-570-01 Page iv Dual Servo Spin W elder User ’ s Manual This page intentionally left blank[...]

  • Page 5

    Dukane Manual Part No. 403-570-01 Page v Section 1 – Introduction 1 Section 2 – Safety Considerations 7 Section 3 – Unpacking and Setup 13 Section 4 – Display and Controls 21 Section 5 – T ouch Screen Menus 27 Section 6 – Machine Operation 49 Section 7 – Optimizing Performance 57 Section 8 – W elder Data Export Software 65 Section 9[...]

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    Dukane Manual Part No. 403-570-01 Page vi Dual Servo Spin W elder User ’ s Manual This page intentionally left blank[...]

  • Page 7

    Dukane Manual Part No. 403-570-01 Page 1 Section 1 - Intr oduction Important User Information . . . . . . . . . . . . . . . . . . . . 3 R e a d t h e M a n u a l F i r s t............................ 3 N o t e s a n d T i p s .................................. 3 C a u t i o n a n d W a r n i n g s ............................ 3 D r a w i n g s a n [...]

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    Dukane Manual Part No. 403-570-01 Page 2 Dual Servo Spin W elder User ’ s Manual This page intentionally left blank[...]

  • Page 9

    Dukane Manual Part No. 403-570-01 Page 3 Section 1 - Intr oduction NOTE NOTE statements provide additional in- formation or highlight procedures. C A UTION C A U T I O N s t a t e m e n t s i d e n - tify cond ition s or practices tha t c ould r esult i n damag e to the e qu i p m en t or o t h e r pr o p e r t y . W ARNING W AR NI N G s ta t em e [...]

  • Page 10

    Dukane Manual Part No. 403-570-01 Page 4 Dual Servo Spin W elder User ’ s Manual The Dual Servo Spin W elder excels at frictional welding of assemblies and parts which require accurate angular orientation and collapse distance. The parts can be any shape and only the weld joint must be circular . The welder uses two electric servos: a servo motor[...]

  • Page 11

    Dukane Manual Part No. 403-570-01 Page 5 Section 1 - Intr oduction • Fixture thr oat depth is a generous 8”. • V ertical servo actuator operation with adjustable 5” (127 mm) stroke assures quiet operation and is environmentally safe. • Industry-standard logic controller and motor controller means replacement parts are readily available. ?[...]

  • Page 12

    Dukane Manual Part No. 403-570-01 Page 6 Dual Servo Spin W elder User ’ s Manual This page intentionally left blank[...]

  • Page 13

    Dukane Manual Part No. 403-570-01 Page 7 Section 2 - Safety Considerations Health and Safety T ips ................................... 9 Plastics Health Notice ......................................... 10 Run Switches ...................................................... 10 General Safety .................................................... 10 Ele[...]

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    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 8 This page intentionally left blank[...]

  • Page 15

    Dukane Manual Part No. 403-570-01 Page 9 Section 2 - Safety Considerations IMPORT ANT N e v e r o p e r a t e t h e D u a l S e r v o S p i n W e l d e r w i t h t h e p r o t e c t i v e s h e e t m e t a l r e m o v e d . T h i s i s a n u n s a f e pra ctice and can resu lt in inju r y . IMPORT ANT Alwa ys w ear a fa ce sh ield wh en oper atin g[...]

  • Page 16

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 10 Plastics Health Notice Before using any Dukane welding system, be sure you are familiar with OSHA regulations from the U.S. Department of Labor about the particular type of plastic(s) you are using. When plastic materials are being processed, some of them may emit f[...]

  • Page 17

    Dukane Manual Part No. 403-570-01 Page 1 1 Section 2 - Safety Considerations IMPORT ANT Alwa ys tu rn of f the A C powe r a t t h e p o w e r s w i t c h b e f o r e s e r v i c i ng o r wo r k i n g on t h e we lder . F ai lur e to turn of f the A C pow er is an un sa fe pra cti ce a nd can re s u lt i n i nj ury or de a t h. GND G 240V Gr oun din[...]

  • Page 18

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 12 This page intentionally left blank[...]

  • Page 19

    Dukane Manual Part No. 403-570-01 Page 13 Section 2 - Safety Considerations Unpacking Welder ........................................15 Packing List ..................................................15 W ork Area .....................................................15 Secure to W ork Bench ..................................16 Bench Capacity .......[...]

  • Page 20

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 14 This page intentionally left blank[...]

  • Page 21

    Dukane Manual Part No. 403-570-01 Page 15 Section 3 - Unpacking and Setup Qty Item Part Number 1 Dual Servo Spin Welder SVT012VR or SVT032VR or SVT042VR 1 Base Interface Cable 200-1 124-3 or 200-1545-01 1 Dual Servo Spin Welder Manual 403-570-XX 1 CD with Dual Servo Spin Welder Utility ___ U n p a c k i n g W e l d e r The Dual Servo Spin W elder i[...]

  • Page 22

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 16 W ARNING DO NOT LIFT the Dual Ser- vo Spin Welder manually . Lifting and/or moving the welder manually could re- sult in personal injury . Use me ch an ic al mea ns to mo ve and place the welder . T wo 1 / 2 " Holes On 13 1 / 4 " Centers S e c u r i n g t [...]

  • Page 23

    Dukane Manual Part No. 403-570-01 Page 17 Section 3 - Unpacking and Setup Dimension s are in INCHES [mm ] 3.60 [91.4]  1.000 - .001 .000 + 25.40 - .03 .00 + [ ]  .30 [7.6] .21 [5.3] 22.5° TYP.  3.00 [76.2] B.C.  .316 [8 .03] 15X .250 - .000 .002 + 6.35 - .00 .05 + [ ] 5.90 [149.9]  1.000 - .001 .000 + 25.40 - .03 .00 + [ ]  .35 [[...]

  • Page 24

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 18 24 0 V ol t A C Pl u g (N EM A 6 –2 0P ) 24 0 V ol t A C Pl u g (N EM A 6 –2 0P ) 24 0 V ol t A C So c ke t (N EM A 6 –2 0R ) 24 0 V ol t A C So c ke t (N EM A 6 –2 0R ) AC Power Switch AC Power Cord A C P o w e r The Dual Servo Spin W elder requ ires a 24 0[...]

  • Page 25

    Dukane Manual Part No. 403-570-01 Page 19 Section 3 - Unpacking and Setup H e a d H e i g h t A d j u s t m e n t The support column features a threaded shaft for adjusting the overall height of the thruster head. The adjustment is secured by three lock nuts which prevent the thruster from moving once the overall height has been established. This i[...]

  • Page 26

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 20 This page intentionally left blank[...]

  • Page 27

    Dukane Manual Part No. 403-570-01 Page 21 Section 4 - Display and Contr ols T ouch Screen Display ...................................23 Operational Switches....................................24 Emergency Stop Switch ...................................... 24 Opti–T ouch Run Switches ................................... 25 Data I/O Connector.......[...]

  • Page 28

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 22 This page intentionally left blank[...]

  • Page 29

    Dukane Manual Part No. 403-570-01 Page 23 Section 4 - Display and Contr ols T o u c h S c r e e n D i s p l a y The display is a 4.6 inch (12 cm) wide by 3.5 inch (9cm) tall color LCD screen shown in Figure 4-1. It contains an integrated touch screen with 192 touch–sensitive cells arranged as 16 rows of 12 columns. Setup parameters and mode selec[...]

  • Page 30

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 24 Righ t Run Swit ch Lo wer Fixtu re Lo wer Fixtu re E–St op S witc h Left Run Switch ABOR T PO WER IN CYCLE T wist to Reset T wist to Reset O p e r a t i o n a l S w i t c h e s Emergency Stop Switch A red Emergency–Stop ( E–STOP ) switch is located in the cent[...]

  • Page 31

    Dukane Manual Part No. 403-570-01 Page 25 Section 4 - Display and Contr ols Dim ly Lit Red LE D Bri gtl y Lit Red LED s 1 1 6 6 9 9 5 5 Op ti –T ou ch Run Sw it ch es Located on either side of the base are two optical RUN switches. These are shown in Figure 4–3. These switches use Infrared (IR) sensors. They comply with OSHA and CE safety stand[...]

  • Page 32

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 26 This page intentionally left blank[...]

  • Page 33

    Dukane Manual Part No. 403-570-01 Page 27 Section 5 - T ouch Screen Menus RUN Mode ....................................................29 Screen Layout ..................................................... 29 VIEW P ARTS ................................................30 SETUP Menu ................................................31 PRE-WELD Setup .[...]

  • Page 34

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 28 This page intentionally left blank[...]

  • Page 35

    Dukane Manual Part No. 403-570-01 Page 29 Section 5 - T ouch Screen Menus R U N M o d e When the welder is rst turned on after the E-Stop switch is reset (see Figure 4-4), the ST ARTUP screen is displayed as shown in Figure 5–1 directing the operator to Activate both RUN SWITCHES to reset machine . Press both switches simultaneously and hold u[...]

  • Page 36

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 30 bad part means one or more of the measured parameters was not within the limits set for the weld cycle. The T ime and Date elds indicate the time and date the part was welded. Just below the WELD label, there are a number of elds with weld data for the last cy[...]

  • Page 37

    Dukane Manual Part No. 403-570-01 Page 31 Section 5 - T ouch Screen Menus Figure 5–6 Sample Data Entry Screen S E T U P M e n u The SETUP menu is sub-divided into three tabs: PRE-WELD , WELD , and POST -WELD that are described below . Immediately after pressing the SETUP button, the Security Code screen will appear , prompting for a numerical pas[...]

  • Page 38

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 32 T OP OF STROKE Position This button is used to set the vertical position to which the welder head returns after completing a weld cycle, as shown in Figure 5-7. A position of 0 corresponds to the highest position (which is also the machine “home” position). A no[...]

  • Page 39

    Dukane Manual Part No. 403-570-01 Page 33 Section 5 - T ouch Screen Menus T ransfer Button f The transfer icon should only be used when visually aligning the pre–spin orientation. The value displayed in the Jog (Deg.) cell has to be transferred to the Pre-Spin data eld. IMPORT ANT Y ou must select the RUN mode to test any of the setups. B oth [...]

  • Page 40

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 34 The Move T o button is used to rotate the tool to the value displayed in the Position (Deg.) eld. After pressing this button, activate both RUN switches and wait for the value in the Jog Pos. (Deg.) eld to match the Position (Deg.) value WELD Setup The WELD se[...]

  • Page 41

    Dukane Manual Part No. 403-570-01 Page 35 Section 5 - T ouch Screen Menus Rotation Method In this method, the weld duration is controlled by completing a specied number of spin revolutions. The Weld Parameters button is used to enter the settings shown in Figure 5-13. The Weld Rotations eld species the number of weld revolutions. The actua[...]

  • Page 42

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 36 Energy Method In this method, weld duration is controlled by the amount of energy input into the weld joint as determined by the spin torque and angular rotation. The welder will maintain a constant spin speed until the programmed energy is produced. Then the tool w[...]

  • Page 43

    Dukane Manual Part No. 403-570-01 Page 37 Section 5 - T ouch Screen Menus T orque T rigger Option This option species a torque level to sense when the upper and lower parts make contact. Prior to contact, the motor is spinning the tool in the air using a very low amount torque. At contact, there is an increase in the torque required to maintain [...]

  • Page 44

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 38 Figure 5–21 POST -WELD Main Setup Screen Constant T orque Option This option sets the welder to function in “Melt-Match” mode, in which the press vertical speed is continuously adjusted to match the rate of plastic melt at the joint. This is achieved by measur[...]

  • Page 45

    Dukane Manual Part No. 403-570-01 Page 39 Section 5 - T ouch Screen Menus changes the display to the screen shown in Figure 5- 22. The MODE switch species if the Hold phase will be controlled by traveling a specied Distance or for a specied amount of T ime. W ith Distance MODE selected as shown in Figure 5- 22, the parameters for Hold moti[...]

  • Page 46

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 40 Part T ests The Part T ests section is used to dene limits for the weld proocess and welder behavior for cases where the process is outside the limits. The Process Limits button is used to enter limits for weld process results as shown in Figures 5-25, 5-26, and [...]

  • Page 47

    Dukane Manual Part No. 403-570-01 Page 41 Section 5 - T ouch Screen Menus The bottom right corner of the POST -WELD screen contains controls for setting machine behavior when an out-of-limit condition occurs. The Latch on Failure button species if the out-of-limit condition will require an acknowledgement from the user before allowing the next c[...]

  • Page 48

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 42 T O O L S M e n u SELECT SETUP T ab Pre ssi ng th e T OOLS button displays the rst tab labeled SELECT SETUP . This contains eight buttons for selecting a setup le as shown in Figure 5–29. The Machine Cycle Count in the lower right corner is the total number [...]

  • Page 49

    Dukane Manual Part No. 403-570-01 Page 43 Section 5 - T ouch Screen Menus eld designates the position of the thruster (part of the welder surrounded by sheet metal covers) relative to the column as indicated by the scale afxed to the right side of the column and a white line printed on the rear of the welder . Once these settings are entered,[...]

  • Page 50

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 44 [.15 in.] above tooling contact, if possible) and press the Set Position button. The stop block will be moved up, and a ashing circle will appear next to the DOWN button when this process is complete, indicating that the proximity switch is active. Press the DONE[...]

  • Page 51

    Dukane Manual Part No. 403-570-01 Page 45 Section 5 - T ouch Screen Menus The Home Offset (Deg.) eld is used to specify an angular offset of the homing spin orientation. The tooling hub home orientation is set at the factory such that the slot in the hub shown in Figure 3-2a is closest to the front of the machine. This position is the 0 degree r[...]

  • Page 52

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 46 S e t t i n g T i m e a n d D a t e O n T o u c h S c r e e n The time and date displayed on the touch screen are preset at the factory for US Central Standard Time. They can be changed using the following procedure: 1. Press the upper left-hand corner (marked by 1 [...]

  • Page 53

    Dukane Manual Part No. 403-570-01 Page 47 Section 5 - T ouch Screen Menus Screen Parameter Name Min.V alue Max.V alue Resolution Units SETUP> PRE-WELD TOOL Inertia 0 3000 (SVT012VR) 780 (SVT032VR) 160 (SVT042VR) 1 kg* cm² TOOL Weight 0 25.0 0.1 kg SPIN Decel. 25 200 1 % TOP OF STROKE Position 0 140.00 0.01 mm TRIGGER Position 1.00 140.00 0.01 m[...]

  • Page 54

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 48 This page intentionally left blank[...]

  • Page 55

    Dukane Manual Part No. 403-570-01 Page 49 Section 6 - Machine Operation Machine Setup..............................................51 Starting a W eld Cycle ...................................54 Stopping a W eld Cycle .................................55 Setup Sheet ............................................ 55-56 SECTION 6 Machine Operation[...]

  • Page 56

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 50 This page intentionally left blank[...]

  • Page 57

    Dukane Manual Part No. 403-570-01 Page 51 Section 6 - Machine Operation IMPORT ANT Th e Dual Ser vo Spin Welder i s c a p a b l e o f d ev e l o p i n g substantial torque and high r o t a t i o n a l v e l o c i t y. Ke e p y our hands and b ody away fro m the to ol hea d d ur ing o p e r a t i o n . T h e s p i n n i n g he a d is c ap a bl e o f[...]

  • Page 58

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 52 5. Reset E-Stop Reset the emergency stop button by turning clockwise. Refer to Figure 4-4. The status display on the base will change from ABOR T in red to POWER in green. 6.T urn Power ON T urn on the AC power switch. 7. Set T ool Parameters On the touch screen, pr[...]

  • Page 59

    Dukane Manual Part No. 403-570-01 Page 53 Section 6 - Machine Operation Since the welder press force is limited in jog mode for safety purposes, the machine will disable the servos and report an error ( Fault: Jog thrust limit exceeded OR V ertical servo runaway detected .) if the press is jogged down too far . If this condition occurs, the welder [...]

  • Page 60

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 54 S t a r t i n g A W e l d C y c l e All weld cycles must be initiated from the RUN screen after the machine is initialized and with the press at the top-of-stroke position. If not already on this screen, press the RUN button rst (see Figure 5-2). If you had power[...]

  • Page 61

    Dukane Manual Part No. 403-570-01 Page 55 Section 6 - Machine Operation Stopping a W eld Cycle During normal operation, the cycle stops automatically when the specied weld and hold phases are completed and the press returns to the top-of-stroke position. T o stop a cycle before it completes, press the E-stop switch on the base, which terminates [...]

  • Page 62

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 56 DUA L SERVO SPIN WELDER - SETUP SHEET A PPLI CATION M ACH INE M ODEL SVT0___2VR D ATE M ACH INE S ETUP N UMB ER TOUCH SCREEN SETT ING VA LUE TOOL I NER TIA ( KG * CM ^2) TOOL W EI GHT ( KG ) SPIN D ECEL . (%) V AC . S ENSE ON  OFF TOOL S ETUP P AR T P RESE NT ON [...]

  • Page 63

    Dukane Manual Part No. 403-570-01 Page 57 Section 7 - Optimizing Performance Spin W elding Process ..................................59 Material Considerations ................................59 Control Parameters ......................................60 Surface Speed (RPM) ......................................... 60 Press (Axial) Speed ..........[...]

  • Page 64

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 58 This page intentionally left blank[...]

  • Page 65

    Dukane Manual Part No. 403-570-01 Page 59 Section 7 - Optimizing Performance . S p i n W e l d i n g P r o c e s s The formal denition of spin welding is “An assembly process in which thermoplastic parts with rotationally– symmetric mating surfaces are joined together under pressure using unidirectional circular motion. The heat generated du[...]

  • Page 66

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 60 NOTE Common hygroscopic thermoplatics: ABS/Polycarbonate (Cycoloy) Polyoxymethylene (Acetal, Delrin) Polyamides (Nylon, Zytel) Polycarbonate (Lexan) Polycarbonate/Polyester (Xenoy) Polysulfone (Udel) Material ller and surface contaminants (e.g. mold release agent[...]

  • Page 67

    Dukane Manual Part No. 403-570-01 Page 61 Section 7 - Optimizing Performance 2000 3000 4000 0 1000 1 2 4 6 8 10 12 3 RPM A verage Weld Diameter (inch) D Spin Speed (rev/min) v = 240 v = 360 v = 480 v = 120 v = 600 v = 720 v = 960 in/sec v = 840 120 in/sec = 10 ft/sec — 3 m/sec 240 in/sec = 20 ft/sec — 6 m/sec 360 in/sec = 30 ft/sec — 9 m/sec [...]

  • Page 68

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 62 Press (Axial) Speed The press speed af fects the amount of contact pressure between the parts being welded, which is required to generate frictional heat. The larger the speed, the larger the rate of heat rise. In combination with the surface speed, press speed must[...]

  • Page 69

    Dukane Manual Part No. 403-570-01 Page 63 Section 7 - Optimizing Performance Since weld depth affects the joint strength and the amount of ash generated, it is important to design the weld joint properly to meet both requirements simultaneously . The incorporation of ash trap features is recommended to produce acceptable appearance without co[...]

  • Page 70

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 64 This page intentionally left blank[...]

  • Page 71

    Dukane Manual Part No. 403-570-01 Page 65 Section 8 - W elder Data Export Software Introduction ...................................................67 Hardware and Software Requirements ........67 Installation, Startup and Cable Connections ..........................67 Part Data ......................................................68 Prole Graph[...]

  • Page 72

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 66 This page intentionally left blank[...]

  • Page 73

    Dukane Manual Part No. 403-570-01 Page 67 Section 8 - W elder Data Export Software I n t r o d u c t i o n A W indows™ application named Dual Servo Spin W elder Utility , can be used to capture data exported by the welder to a PC. This application is also capable of importing the servo tuning database, and obtaining messages from the machine that[...]

  • Page 74

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 68 Figure 8–1 Utility Startup Screen P a r t D a t a Upon startup, the screen will appear as shown in Figure 8-1, with the Part Data tab selected by default. The following is a description of the items on this tab: P ART DA T A List This area contains a series of lin[...]

  • Page 75

    Dukane Manual Part No. 403-570-01 Page 69 Section 8 - W elder Data Export Software Figure 8–2 PROFILE GRAPHS T ab File W rite Sets the write behavior for an existing le. Write Over overwrites an existing le, while Add On appends data to the end of the le. Incoming Data This indicator will ash when data is being received from the welde[...]

  • Page 76

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 70 Spin T orque Setpoint If torque triggering is enabled, the T orque T rigger value is displayed in this box for reference as a percentage of the spin motor maximum. WRITE T O FILE W rites the torque data to a le. Add a .txt or .csv extension to the end of the l[...]

  • Page 77

    Dukane Manual Part No. 403-570-01 Page 71 Section 9 - T roubleshooting W elding Process ...........................................73 Material Choice ................................................... 73 Parameter Effects ............................................... 73 T roubleshooting .................................................. 73 W eld[...]

  • Page 78

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  • Page 79

    Dukane Manual Part No. 403-570-01 Page 73 Section 9 - T roubleshooting W e l d i n g P r o c e s s Material Choice A family of thermoplastics is usually compatible with its own type and sometimes with other types. Characteristics to consider are the melting point and coefcient of linear expansion. Even members of the same family may cause proble[...]

  • Page 80

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 74 W e l d e r Mechanical The part xture should be securely mounted perpendicular to, and centered under the spin axis. Electrical Power Make sure the AC power cord is plugged in to a 240 V AC, 1–phase electrical outlet with a 20 Ampere capacity . Check that the c[...]

  • Page 81

    Dukane Manual Part No. 403-570-01 Page 75 Section 9 - T roubleshooting Problem Symptom Possible Cause Recommended Solution Overwelding Excessive weld ash Welded assembly dimensions are too small Weld Time or Distance are too large Reduce Weld Time or Distance Incorrect ash trap design Evaluate and correct ash trap design Underwelding Low s[...]

  • Page 82

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 76 Message Description Cause Possible Solution Instructions Activate both RUN SWITCHES to reset machine Resetting of machine at startup or recovery requires the activation of both optical switches on base. - - Activate both RUN SWITCHES to reset machine after all motio[...]

  • Page 83

    Dukane Manual Part No. 403-570-01 Page 77 Section 9 - T roubleshooting T able 9-II continued. . . Message Description Cause Possible Solution Spin motor not on Spin servo amplier does not power up Internal machine error Contact DUKANE service Spin servo amplier faulted There is a problem with the spin servo amplier 1. Excessive spin decele[...]

  • Page 84

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 78 Message Description Cause Possible Solution Errors Axis stopped before weld end Motion on spin or vertical axes stopped before weld ended Internal machine error 1. Check for obstructions to motion outside welder 2. Contact DUKANE service Spin stop before weld start [...]

  • Page 85

    Dukane Manual Part No. 403-570-01 Page 79 Section 9 - T roubleshooting T able 9-II Machine Display Messages ( continued ) Message Description Cause Possible Solution W arnings Battery life limit, press Continue The batteries in the PLC and touch screen need to be replaced Batteries have not been replaced in approximately 5 years Contact DUKANE serv[...]

  • Page 86

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  • Page 87

    Dukane Manual Part No. 403-570-01 Page 81 Section 10 - Maintenance SECTION 10 Maintenance T ouch Screen Display ...................................83 AC Power Cord.............................................83 Maintenance .................................................83[...]

  • Page 88

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  • Page 89

    Dukane Manual Part No. 403-570-01 Page 83 Section 10 - Maintenance C A UTION Never use anything sharp on the touch screen. Only use your nger. The screen is intended for industrial use , but can be d amag ed by scratching or puncturing. T o u c h S c r e e n D i s p l a y Do not use any solvents or abrasive cleaners on the touch screen. Apply a [...]

  • Page 90

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  • Page 91

    Dukane Manual Part No. 403-570-01 Page 85 Section 1 1 - Contact Dukane Contacting Dukane .......................................87 Identify Equipment .............................................. 87 Ultrasonics Division ............................................. 87 Website ............................................................... 87 SECTI[...]

  • Page 92

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  • Page 93

    Dukane Manual Part No. 403-570-01 Page 87 Section 1 1 - Contact Dukane C o n t a c t i n g D u k a n e Identify Equipment When contacting Dukane about a service–related problem, be prepared to give the following information: • SVT Model number and serial number • Any error indicators from the T ouch Screen Display • Description of the probl[...]

  • Page 94

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  • Page 95

    Dukane Manual Part No. 403-570-01 Page 89 Section 12 - Specications SECTION 12 Specications T ooling Specications ...................................91 Machine W eight ............................................91 Power Requirements ....................................91 Operating Environment.................................91 Dimensions [...]

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  • Page 97

    Dukane Manual Part No. 403-570-01 Page 91 Section 12 - Specications T o o l i n g S p e c i  c a t i o n s T ooling Size Refer to T able 5-I for maximum tooling sizes. M a c h i n e W e i g h t The Dual Servo Spin W elder weighs approximately 400 lbs. (182 kg). It should be mounted on a table or bench capable of supporting 650 lbs. (295 kg) t[...]

  • Page 98

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 92 NOTE: All specications are subject to change without notice. The specications listed are current at the time of publication. Figure 12–2 Dual Servo Spin Welder Dimensions[...]

  • Page 99

    Dukane Manual Part No. 403-570-01 Page 93 Section 12 - Specications C A UTION D O NO T m ak e a n y m o di f ic a - t i o ns t o t h e Du a l Se r v o Sp i n Welder . T he chang es may r e - s u l t i n v i o l a t i n g o n e o r m o r e r e g u l a t i o n s u n d e r w h i c h t h i s e q u i p m e n t i s m a n u f a c t u r e d .  CE Mar[...]

  • Page 100

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  • Page 101

    Dukane 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 AP[...]

  • Page 102

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  • Page 103

    Dukane Manual Part No. 403-570-01 Page 97 Appendix A 1 1 6 6 9 9 5 5 Pin Signal Description Left Optical Switch Output 1 Right Optical Switch Output 2 +24 VDC Switched by E-Stop 3 Abort Signal 4 Ground 5 Ground 6 Ground 7 Automation Input 8 +24 VDC Power 9 (Power OFF when Abort switch pushed) B a s e I n t e r f a c e C o n n e c t o r The base int[...]

  • Page 104

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 98 Pin Signal Description Function 1 T op-Of-Stroke Status Output ON when press is at T op-of-Stroke position 2 V acuum On Output, Part Pickup ON when welder calls for vacuum to be turned ON with Part Pickup mode enabled 3 Bad Part Status Output ON when weld process is[...]

  • Page 105

    Dukane Manual Part No. 403-570-01 Page 99 Appendix A 1 2 3 7 1 1 1 5 6 1 0 1 4 1 6 S l i d e K i t C o n n e c t o r The slide kit interface is a round 16–pin connector located directly to the right of the base interface connector on the rear of the thruster . The Dual Servo Spin W elder is prewired to accept a Dukane slide kit without any modi?[...]

  • Page 106

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 100 D a t a P o r t C o n n e c t o r The computer interface connector is located on the back of the welder above the power switch as shown in Figure A-4. It provides a computer connection to export part data and weld prole graphs. The pin num ber s f or the con nec[...]

  • Page 107

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

  • Page 108

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  • Page 109

    Dukane Manual Part No. 403-570-01 Page 103 Appendix B APPENDIX B T ooling Moment of Inertia........................................105 Explanaton of Inertia ......................................... 105 Calculating the Moment of Inertia ..................... 105 T ooling and Fixure Design ..........................106[...]

  • Page 110

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  • Page 111

    Dukane Manual Part No. 403-570-01 Page 105 Appendix B USEFUL UNIT CONVERSIONS 1 in. = 2.54 cm = .025 m 1 lb. = 0.45 kg 1 cm = 0.39 in. 1 m = 39.4 in. 1 kg = 2.20 lb. M o m e n t o f I n e r t i a Explanation of Inertia The moment of inertia is a measure of the mass and the mass distribution of the tool. It is dened mathemati - cally as the produ[...]

  • Page 112

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 106 T o o l a n d F i x t u r e D e s i g n The most important aspect of tool and xture design is that it is safe. Please note that using tools not provided by Dukane may result in voiding of the warranty – consult Dukane for details. Several aspects should be con[...]

  • Page 113

    Dukane Manual Part No. 403-570-01 Page 107 Appendix C Upper T ool V acuum ...................................109 Remote T ouch Screen ............................... 1 10 APPENDIX C Optional Features[...]

  • Page 114

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  • Page 115

    Dukane Manual Part No. 403-570-01 Page 109 Appendix C U p p e r T o o l V a c u u m As an aid in holding the spinning part, the welder can optionally be equipped with vacuum in the up- per tool by installing a vacuum system kit (#438- 963 for models SVT032VR & SVT042VR; and #438-964 for model SVT012VR). This kit includes all components needed t[...]

  • Page 116

    Dual Servo Spin W elder User ’ s Manual Dukane Manual Part No. 403-570-01 Page 1 10 R e m o t e T o u c h S c r e e n Figure C-2 Remote T ouch Screen Components In situations where it is desriable to provide access to the touch screen some distance away from the welder , the remote touch screen kit (#438-965) can be used. The touch screen is moun[...]

  • Page 117

    Dukane ISO ISO CER TIFICA TION Duka ne chose to become ISO 9001:2 000 certi- fied in order to demonstrate to our customers our continuing commitment to being a quality ve ndo r . By pass in g its audi t, Du ka ne ca n ass ure you that we have in place a well–defined and systematic approach to quality design, manu- facturing, delivery and servic[...]

  • Page 118

    Duk ane Corpo rati on • Ult raso nics Div isio n • 2900 Duk ane Drive St. • C harl es, Illi nois 601 74 U SA • TEL (63 0) 79 7-49 00 • F AX (6 30) 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 r efer to our website at : www .dukane.com/us/sales/in[...]