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Dual Servo Spin Welder

1. METHOD Time ROTATION DISTANCE ENERGY TIME ROT DIST ENERGY WELD TIME s WELD ROTATIONS VERTICAL MM ENERGY J COLLAPSE ABSOLUTE DISTANCE METHOD ONLY COLLAPSE ABSOLUTE WELD SETUP PARAMETERS VERT SPEED MM S WELD SPIN RPM Dir cw ccw ORIENTATION WELD ON OFF OPTIONS TORQUE TRIGGER TORQUE OF MAX TIMEOUT S ON OFF CONSTANT TORQUE TORQUE OF MAX TIMEOUT S ON OFF MODE Position TIME Position TIME SPEED MM S HOLD SETUP Move TIME S COLLAPSE MM DWELL TIME S CONSTANT THRUST THRUST ON OFF WELD TIME s WELD ROTATIONS ORIENTATION DEG SETUP gt WELD ENERGY J POST WELD PEAK RPM PROCESS LIMITS PEAK TORQUE OF MAX LOWER LIMIT UPPER LIMIT PEAK THRUST OF MAX CYCLE TIME S VERTICAL WELD END MM HOLD COLLAPSE MM HOLD END POSITION MM LATCH ON FAILURE ON OFF FAILURE SWITCH SUSPECT BAD Suspect BAD TOOLS gt VERTICAL TRAVEL LOWER LIMIT Limit Pos MM SYSTEM SETUP HOME OFFSET DEG Page 56 Dukane Manual Part No 403 570 00 Section 7 Optimizing Performance Optimizing Performance Spin Welding Process 2 Ee e 59 Material Considerations cccccscceeeeeeees 59 Control Parameters cccccseeceeesee
2. Dukane Manual Part No 403 570 00 7 00 177 8 9 84 249 9 8X M10 1 5 BASE HOLES J D 7 00 177 8 MODEL 12 00 304 8 DIM SVTO32VR amp SVTO42VR SVTO12VR 13 4 340 10 5 267 A 39 2 997 40 1 1019 B 7 3 185 21 4 536 6 4 163 20 5 513 T st T 3 g H H H o fen a S i i ol i j j d i j al i oo i j i H 1 1 i I A k i j 1 i j Ki j B il i j H ji Kei I EL 64 9 1648 1 41 0 1041 MAX H 1 l A H i 45 7 1162 H gt 2 j p i i 1 H I j i i d di I l S dl Yod By I 3 1 1 L I I 1 H H l B 8 6 219 _ V Page 92 Identification Numbers Welder Model amp Serial Number The serial number and model number tag for the Dual Servo Spin Welder are located either on the covers on the back of the machine or on the underside of the motor mounting plate just above the tooling hub Regulatory Agency Compliance CE Marking C This mark on your equipment certifies that it meets the requirements of the EU European Union concerning interference causing equipment regulations CE stands for Conformit Europe ne European Conformity The Dual Servo Spin Welder complies with the following CE requirements e The EMC Directive 8
3. application Weld Diameter Machine Peak RPM Range in Model up to 2 0 SVTO42VR 4000 SVTO32VR 3000 SVTO12VR 750 Table 7 1 Dukane Manual Part No 403 570 00 Section 7 Optimizing Performance Page 63 Dual Servo Spin Welder User 5 Manual This page intentionally left blank Page 64 Dukane Manual Part No 403 570 00 Section 8 Welder Data Export Software Welder Data Export Software EEGEN 67 Hardware and Software Requirements 67 Installation Startup and Cable Connections AN 67 Part De 68 Profile Ee 69 Servo and Ee DEE 70 Dukane Manual Part No 403 570 00 Page 65 Dual Servo Spin Welder User 5 Manual This page intentionally left blank Page 66 Dukane Manual Part No 403 570 00 Section 8 Welder Data Export Software Introduction A Windows application named Dual Servo Spin Welder 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 may be useful in trou bleshooting Hardware and Software Requirements The utility requires a PC or laptop running a Windows 2000 XP or Vista operating system A straight DB 9 cable is needed to interface to the welder The cable must be terminated with a male connector where it connects to the welder Installation Startup and Cable Connections To install the program Run the setup exe file located
4. POST WELD Figure 5 13 Weld Parameters Screen for Rotation Method POST WELD Figure 5 14 Weld Parameters Screen for Distance Method with Collapse Switch Selection POST WELD Figure 5 15 Weld Parameters Screen for Distance Method with Absolute Switch Selection Page 35 Dual Servo Spin Welder User 5 Manual Energy Method In this method the 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 at which point the tool will decelerate and stop The Weld Parameters button is used to enter the settings shown in Figure 5 16 The Energy J field specifies the weld energy in Joules As a safety measure the use of the Energy Method requires that the Weld Time Process Limit be enabled refer to the Process Limits description in the POST WELD menu later in this manual on how to set this limit If the Upper Weld Time Limit is exceeded during the weld the machine will stop the cycle and report an error The VERT Speed mm s SPIN RPM and Dir fields are the same as in the Time Method The DONE button causes a return to the main WELD tab screen WELD OPTIONS Several weld options are available any combination of which may be enabled simultaneously Orientation Option This option is used to specify the angular stopping orientation of the upper tool at the en
5. Number Summary Date 00 Original release 10 20 2008 Dukane Manual Part No 403 570 00 Page iii Dual Servo Spin Welder User s Manual This page intentionally left blank Page iv Dukane Manual Part No 403 570 00 Dukane Dual Servo Spin Welder Contents Section 1 Introduction 1 Section 2 Safety Considerations 7 Section 3 Unpacking and Setup 13 Section 4 Display and Controls 21 Section 5 Touch Screen Menus 27 Section 6 Machine Operation 49 Section 7 Optimizing Performance 57 Section 8 Welder Data Export Software 65 Section 9 Troubleshooting 71 Section 10 Maintenance 81 Section 11 Contacting Dukane 85 Section 12 Specifications 89 Appendix A Connector Pinouts 95 Appendix B Tooling 103 Appendix C Optional Features 107 Dukane Manual Part No 403 570 00 Page v Dual Servo Spin Welder User s Manual This page intentionally left blank Page vi Dukane Manual Part No 403 570 00 Section I Introduction Introduction Important User Information 3 Read the Manual Fish scececece scene ee den 3 Notes and TDS ects a EE e bids em tere 3 Caution and VEER A E EE 3 Drawings and RE UE 3 Dual Servo Spin Welder Overview 4 Dual Servo Spin Welder Key Features 5 Dukane Manual Part No 403 570 00 Page 1 Dual Servo Spin Welder User 5 Manual This page intentionally left blank Page 2 Dukane Manual Part No 403 570 00 Sect
6. Page 60 NOTE Common hygroscopic thermoplatics ABS Polycarbonate Cycoloy Polyoxymethylene Acetal Delrin Polyamides Nylon Zytel Polycarbonate Lexan Polycarbonate Polyester Xenoy Polysulfone Udel Dukane Manual Part No 403 570 00 Section 7 Optimizing Performance surface speeds between 360 and 600 in sec However speeds of 120 in sec and lower have been used with good results The mathematical relationship between surface speed and spin speed RPM is given by the equation RPM 60 v xD where vis the surface velocity D is the average weld diameter A plot of the spin speed and average weld diameter for a number of surface speed values is shown in Figure 7 1 4000 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 480 in sec 40 ft sec 12 m sec 3000 600 in sec 50 ft sec 15 m sec 720 in sec 60 ft sec 18 m sec 840 in sec 70 ft sec 21 m sec E 960 in sec 80 ft sec 24 m sec Fa 2000 OD Q 01 E a 1000 RPM 0 1 2 3 4 6 8 10 12 D gt Average Weld Diameter inch Figure 7 1 Dependence of Spin Speed on the Weld Diameter for Selected Surface Speeds Dukane Manual Part No 403 570 00 Page 61 Dual Servo Spin Welder User 5 Manual Press Axial Speed The press speed affects the amount of contact pressure between the parts being welded which is required
7. repair if necessary Lubricate the unpainted area on the front of the support column as needed with conventional grease Dukane Manual Part No 403 570 00 Section 10 Maintenance Page 83 Dual Servo Spin Welder User 5 Manual This page intentionally left blank Page 84 Dukane Manual Part No 403 570 00 Section 11 Contact Dukane Contacting Dukane Contacting Dukane EEN 87 Identify Equipment ccsseeeeeeeeeeeeeeeees 87 Ultrasonics DIVISION vivcsncuscaraucsssaseresencaecacencantsiasiions 87 Ate 87 Dukane Manual Part No 403 570 00 Page 85 Dual Servo Spin Welder User 5 Manual This page intentionally left blank Page 86 Dukane Manual Part No 403 570 00 Contacting Dukane Identify Equipment When contacting Dukane about a service related problem be prepared to give the following information e SVT Model number and serial number Any error indicators from the Touch Screen Display Description of the problem and steps taken to re solve it Some problems can be solved over the telephone so it is best to call from a telephone located near the equipment Ultrasonics Division Mailing Address Dukane Ultrasonics 2900 Dukane Drive St Charles IL 60174 USA Main Phone 630 797 4900 Main Fax 630 797 4949 Service amp Parts Fax 630 584 0796 Website The website has information about our products processes solutions and technical data Downloads are available for m
8. shown in Figure C 2 it passes through the inside of the tooling hub and exits on the inside of the O ring at the bottom With holes between the top of the tool and the part cavity the vacuum holds the part in the tool while it is spinning or at rest Figure C 1 Upper Tool Vacuum System Dukane Manual Part No 403 570 00 Appendix C The welder is programmed to drive the vacuum on and off in one of two ways With Part Pickup mode dis abled the vacuum signal pin 5 on User I O connec tor is ON when the machine is ready to run a cycle and OFF at the beginning of the hold phase In this mode the vacuum shuts off after a period of inactiv ity of 5 minutes to conserve air To re energize the vacuum one of the RUN switches must be activated With Part Pickup mode enabled the vacuum signal pin 2 on User I O connector is ON after pickup time elapses and OFF at the end of the hold phase Please refer to Table A II for vacuum connection pinouts Additional details on the vacuum system are provided in Dukane document 403 580 Servo Spin Welder Vacuum System User Guide VACUUM TRANSFER ASSEMBLY VACUUM ON HUB Page 109 Dual Servo Spin Welder User 5 Manual VACUUM INLET NON ROTATING VACUUM TRANSFER ASSEMBLY VACUUM ON HUB Figure C 2 Upper Tool Vacuum Transfer Assembly Remote Touch Screen In situations where it is desriable to m provide access to the touch screen some distance away from the REMOTE
9. SPIN RPM and Dir fields are the same as in the Time Method The DONE button causes a return to the main WELD tab screen Distance Method In this method the weld duration is controlled by vertical travel to a specified absolute or collapse distance The Weld Parameters button is used to enter the settings shown in Figure 5 14 The Vertical mm field specifies the travel distance depending on the position of the Collapse Absolute switch located on the bottom of the screen If the switch selection is Collapse as shown in Figure 5 14 the travel distance is measured relative to the trigger point If the switch selection is Absolute as shown in Figure 5 15 the travel distance is measured from the press topmost or 0 position also referred to as the home position The Teach Position button is available in the Absolute Distance mode which allows the position to be defined by physically jogging the press down to the desired weld end position The layout of the Teach Position screen is very similar to the TRIGGER Position screen shown in Figure 5 8 Directly below the Vertical mm field is the minimum weld distance which is automatically calculated by the welder based on other parameters such as speed and deceleration The VERT Speed mm s SPIN RPM and Dir fields are the same as in the Time Method The DONE button causes a return to the main WELD tab screen Dukane Manual Part No 403 570 00 Section 5 Touch Screen Menus
10. Screen Menus kes mn Se Del Figure 5 9 Park Pickup Setup Screen in PRE WELD Menu POST WELD Figure 5 10 Pre Spin Orientation Setup Screen in PRE WELD Menu Transfer Button lt 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 field Page 33 Dual Servo Spin Welder User 5 Manual The Move To button is used to rotate the tool to the value displayed in the Position Deg field After pressing this button activate both RUN switches and wait for the value in the Jog Pos Deg field to match the Position Deg value POST WELD Weld Parameters WELD Setup The WELD setup is the middle tab in the SETUP menu and is shown in Figure 5 11 This screen contains the weld METHOD selection Time Rotation Distance and Energy a button for entering Weld Parameters and settings for several OPTIONS related to the weld phase Orientation Torque Trigger and Constant Torque Figure 5 11 WELD Main Setup Screen Weld Method Selection One of the available modes must be selected to perform a weld Regardless of the method the weld is considered to start at different points depending on the Torque Trigger option setting If Torque Trigger is OFF the weld starts at the Trigger Position defined in the PRE WELD tab If Torque Trigger is ON the weld starts when the desired spin to
11. can be inspected in processing any claims that may arise Work Area Allow sufficient area on either side of the Dual Servo Spin Welder for handling material work pieces and fixtures Provide ample room so that the movement of an operator or helper does not interfere with the work of another Also be aware that under extreme conditions small droplets of molten plastic may be spun off from the upper part Dukane Manual Part No 403 570 00 Section 3 Unpacking and Setup Qty ltem Part Number SVTO12VR or SVTO32VR or SVT042VR Dual Servo Spin Welder 200 1124 3 or Base Interface Cable 200 1545 01 1 Dual Servo Spin Welder 403 570 XX Manual 1 CD with Dual Servo Spin Welder Utility Table 2 Dual Servo Spin Welder Packing List Page 15 Dual Servo Spin Welder User 5 Manual Securing to Work Bench Bench Capacity The Dual Servo Spin Welder weighs approximately 400 Ibs 182 kg It should be attached to a table or bench capable of supporting 650 lbs 295 kg to accommodate the additional force imposed by the vertical movement of the motor and slide during the spin welding operation Use mechanical means such as a forklift or hoist to place the servo spin welder on its work bench There are two 3 4 inch lifting eyes located at the top of the column see Figure 3 7 for a lifting ring or strap Remove any remaining plastic wrap after the welder is in its final position Leveling We recommend that the Du
12. head Always wear a face shield when operating the Dual Servo Spin Welder Be extreme ly careful not to let long sleeves necklaces or long hair become entangled in the Dual Servo Spin Welder during operation Always turn machine power OFF when instalaling or removing the spin tool Figure 6 1 Setting and Resetting the E Stop Page 51 Dual Servo Spin Welder User 5 Manual 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 ABORT in red to POWER in green 6 Turn Power ON Turn on the AC power switch 7 Set Tool Parameters On the touch screen press the SETUP button Press Enter on the ENTER SECURITY CODE screen if no password has been previously set or type in the password and then Enter Press the TOOL Setup button and enter the TOOL Inertia kg cm 2 and TOOL Weight kg Press the RUN button and wait until the PLEASE WAIT indicator above it disappears 8 Initialize Home Welder The touch screen will now instruct you to Activate both RUN SWITCHES to reset machine This is illustrated in Figure 5 1 Once the switches are activated both servos will first move to their respective home positions corresponding to internal encoder reference pulses in each servo Then the spin motor will rotate to the programmed final weld orientation set in the SETUP gt WELD tab gt Orientation gt Weld field Figure 5 17 and the pr
13. in the air using a very low amount torque At contact there is an increase in the torque required to maintain a constant angular velocity at which point the weld is considered to start i e the weld timer and counter are started Note that the welder begins to sense the torque after reaching the TRIGGER Position To enable this option press the Torque Trigger button and then the Enable box on the screen shown in Figure 5 18 The Torque of max field specifies the torque level at which the weld will start The Timeout s value specifies the amount of time the welder will wait between reaching the TRIGGER Position and the sensing of the torque trigger If torque trigger does not occur within this time the machine will abort the cycle and display an error The DONE button causes a return to the main WELD tab screen For this option to work properly the torque trigger value must be set above the torque required to keep the spin tool running before part contact i e in free air To set the torque trigger value correctly follow these steps 1 Program all welder settings as desired refer to other sections in this manual if needed 2 Disable the Torque Trigger Option 3 Verify that the VERTICAL TRAVEL LOWER LIMIT is set properly to prevent the possibility of contact between the tool and fixture refer to TOOLS SYSTEM SETUP tab menu 4 Press the RUN button Run a dry cycle i e without parts by acti vating both R
14. is larger than the set limit 1 Vertical travel lower limit set too high 2 Trigger position too large 1 Lower vertical travel lower limit if possible 2 Decrease Trigger position Dukane Manual Part No 403 570 00 Page 79 Dual Servo Spin Welder User Manual This page intentionally left blank Page 80 Dukane Manual Part No 403 570 00 Dukane Manual Part No 403 570 00 Section 10 Maintenance Maintenance Touch Screen Display 83 AC Power Cd 83 Mamtenance 83 Page 81 Dual Servo Spin Welder User 5 Manual This page intentionally left blank Page 82 Dukane Manual Part No 403 570 00 Touch Screen Display Do not use any solvents or abrasive cleaners on the touch screen Apply asmall amount of computer cleaner to a soft towel first Clean the panel with the moistened towel Do not spray or apply a cleaner directly to the interface panel Remove grease by rubbing lightly with isopropyl alcohol Afterward provide a final cleaning using a mild detergent and rinse with clean water Do not use any sharp objects on the display It should not be touched unnecessarily It is lit by a long life LED backlight and should not require any maintenance other than occasional cleaning AC Power Cord The AC power cord should be kept in good condition and free from any cuts and abrasions The AC plug should be straight with no bent prongs Maintenance Visually inspect cables once a week and replace or
15. on the RUN screen listing the parameter for which the limit was exceeded The second function is to set the character displayed in the Limits field on the RUN screen If the switch is set to Suspect the Limits field will display S if the process was outside the limits If it is set to Bad Abort the Limits field will display B if the process parameter was lower than the Lower limit and E if the process parameter was higher than the Upper limit Dukane Manual Part No 403 570 00 PROCESS DATA Part Nr 12345678 Date 11422733 Limits Time 11 22 33 x qx ELD cx Time Gei 1 66 Rotations 26 4 Peak RPM 1200 Peak Toraue 15 Enersy J gt 366 Orient Des gt 52 3 Held End mm gt 86 00 Peak Thrust 25 Hold End mm gt 80 20 Hold Col mm gt 6 26 ens Part Data Cycle ts Figure 5 28 RUN Screen with PART TEST FAILED Button Page 41 Dual Servo Spin Welder User 5 Manual TOOLS Menu SELECT SETUP Tab Pressing the TOOLS button displays the first tab labeled SELECT SETUP This contains eight buttons for selecting a setup file as shown in Figure 5 29 The Machine Cycle Count in the lower right corner is the total number of weld cycles that have occurred in the machine s lifetime UTILITIES Tab The middle tab named UTILITIES and shown in Figure 5 30 contains buttons for renaming copying and erasing setups as well as a button for accessing a screen to record other machine settings and one fo
16. parts The screen shots on this page all show the RUN mode The RUN screen is the default startup screen This screen needs to be selected in order to initiate a weld cycle Just below the PROCESS DATA label as shown in Figure 5 2 there are a number of fields containing part data The Part Nr field identifies the current sequential part number The Limits field indicates if the last weld was within programmed process limits and displays part B for a bad part or E for an error A suspect or ce 99 if no limits were violated S for suspect Dukane Manual Part No 403 570 00 Section 5 Touch Screen Menus Activate both RUN SWITCHES to reset machine PROCESS DATA Part Nr 12345678 Date 11422733 Limits Time 11 22 33 _ HELD lTime Gei 1 66 Rotations 26 4 Peak RPM 1266 Peak Toraue 15 Enersy J gt 366 Orient Des gt 52 3 Held End mm gt 80 00 Peak Thrust x 25 Hold End cmm 80 20 Hold Col lt mm gt 4 20 Cycle ts 9 53 Part Data Figure 5 1 Startup Screen With E Stop Cleared PROCESS DATA Part Nr 12345678 Date 11722733 Limits Time 11 22 33 e WELD Time s 1 88 Rotations 26 4 Peak RPM 1266 Peak Toraue CO 15 ser Enersy lt J 300 Orient Des gt 52 3 Held End cmm 80 00 Peak Thrust 25 Hold End mm gt 84 28 Hold Col cmm 6 26 Cycle 5 9 53 Part Data Figure 5 2 Run Mode Screen With Welder Reset Page 29 Dual Servo Spi
17. the distance to within 0004 0 01 mm Weld by time number of rotations distance absolute or relative and energy Built in sensors give you the choice of weld methods and triggering by position or by spin torque Parameter monitoring with programmable upper and lower limits of weld time rotations angular orientation energy peak RPM peak torque and cycle time Weld process profiles Spin and vertical servo load and position data can be downloaded to a PC for review via RS 232 Digital timer for weld time and hold time gives precise control of the spin welding process Dukane Manual Part No 403 570 00 Section I Introduction Fixture throat depth is a generous 8 Vertical 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 ISO 9001 Certification means that the Dual Servo Spin Welder is manufactured to exacting quality standards 24 month domestic warranty assures you of reliability and quality construction Page 5 Dual Servo Spin Welder User 5 Manual This page intentionally left blank Page 6 Dukane Manual Part No 403 570 00 Dukane Manual Part No 403 570 00 Section 2 Safety Considerations Safety Considerations Health and Safety Te 9 Plastics Health Ne eeeed eiigegg eteeeuee tee eetegedek 10 Run EST e E 10 Ge
18. the drawing out of reinforcing filler material and realignment of the interchain bonds in the weld plane resulting in a weak axial weld joint and possibly part distortion Page 62 Dukane Manual Part No 403 570 00 Since weld depth affects the joint strength and the amount of flash generated it is important to design the weld joint properly to meet both requirements simultaneously The incorporation of flash trap features is recommended to produce acceptable appearance without compromising strength Hold During the hold phase vertical press travel initially brings the molten parts closer together dynamic hold and then allows the molten material to solidify static hold Amourphous plastics will normally take longer to solidify than semicrystalline plastics The dynamic hold distance is typically a small value compared to the weld distance An approximate staring point for initial application setup is 10 of weld distance The static hold time can vary depending on the size of the part but is usually in the 1 3 second range Part Size Machine model selection will mostly depend on the weld diameter of the parts Refer to Table 7 I for approximate guidelines For diameters under 4 inches the SVT032VR model is recommended due to its torque capacity The SVT042VR model is used where high RPM gt 3000 is required Please contact the Dukane Applications Laboratory see Chapter 11 for a recommendation concerning your specific
19. 6 EET E 16 Mounting Te 16 Tooling Hub amp Fixture ec sccis scasoticnnatssinenanwantanns 17 AC POWT eebe ER 18 Height Adjustment uk 19 Control CONNMECHOSS cccssecessersesseseaseenens 19 Base Interface Connector oensssennneonnereenreernne 19 User I O Goamedorus uuunsvantmsissmesev 19 Slide Kit Connector eegenen ege 19 Page 13 Dual Servo Spin Welder User 5 Manual This page intentionally left blank Page 14 Dukane Manual Part No 403 570 00 Unpacking Welder The Dual Servo Spin Welder is normally packed in a corrugated carton resting on a wooden shipping pallet To unpack the welder follow these steps 1 Remove the straps from the carton 2 Open the top of the carton Carefully remove any packing materials cables and documentation 3 Cut the tape at the bottom corners and unfold the flaps 4 Remove the corrugated carton but leave the welder on the pallet 5 Leave the power cable wrapped up until after the welder has been placed in its working area and you are ready to begin hooking up power This will pre vent accidental kinking or pinching of the power cable Packing List After removing g shipping container check that you have the items listed in Table 3 I Inspect the welder for damage Report any damage immediately to the carrier and to Dukane Ultrasonics Service at 630 762 4900 Also see Section 11 for information on contacting Dukane Save all shipping and packing materials so they
20. 9 336 EEC The Low Voltage Directive 73 23 EEC The Machinery Directive 89 392 EEC using EN60204 1 1993 Safety of Machinery Elec trical Equipment of Machines Part 1 Specification for General Requirements Dukane Manual Part No 403 570 00 Section 12 Specifications Page 93 Dual Servo Spin Welder User Manual This page intentionally left blank Page 94 Dukane Manual Part No 403 570 00 Dukane Manual Part No 403 570 00 Appendix A APPENDIX A Connector Pinouts Base Interface Connechor 97 User UO Connechor esses eeeeea 98 Slide Kit CGonnechor enerne 99 Data Port Connector 100 Automation Wiring rrrrrrrrrrnnrrrrennnnn 100 101 Page 95 Dual Servo Spin Welder User Manual This page intentionally left blank Page 96 Dukane Manual Part No 403 570 00 Base Interface Connector The base interface connector is a DB 9 socket connector A closeup of the base connector is shown in Figure 2 2 and a closeup of the rear thruster connector is shown in Figure 3 8 The pin numbers for the connector are shown in Figure A 1 The pin assignments and signal descriptions are given in Table A I A schematic of the Operate and Abort switches connected through the base Interface Connector is shown in Figure A 5 Dukane Manual Part No 403 570 00 Appendix A Figure A 1 Base Interface Connector Signal Description 1 Left Optical Switch Output Right Optical Switch Output 3 24 VDC Sw
21. 9 as shown in Figure 4 7 It provides a computer connection to export part data motor load and position profiles A pinout of the Data I O connector is provided in Appendix A Detailed information on the data that can be obtained from the welder is given in Chapter 8 Dukane Manual Part No 403 570 00 Section 4 Display and Controls Dimly Lit Red LED Figure 4 5 Right Operate Switch in Standby Mode One LED Dimly Lit Brigtly Lit Red LEDs Figure 4 6 Right Switch in Operate Mode Both LEDs Brightly Lit a H po ie ZE Figure 4 7 DB 9 Data I O Connector Page 25 Dual Servo Spin Welder User 5 Manual This page intentionally left blank Page 26 Dukane Manual Part No 403 570 00 Dukane Manual Part No 403 570 00 Section 5 Touch Screen Menus Touch Screen Menus FINN ES 29 MICRO NAY OU cccacacedecetenetesetiedcsttanstetetctemecicedecntes 29 VIEW PARTS iescsscnnrzaccnnacsamunaciccuasstancesecsaaalen 30 EP 31 PRE WELD E siccisistninssstvscivevsnnanzivnseicetbedaanitios 31 WELD SSW EE 34 GREIS RE E 38 EG SEE E 42 SELECT SETUP E E 42 E E TE eee 42 SYSTEM SETUP Va iivcscicisndecaxadiveSorsninesaatdivsadencs 43 Setting Time and Date NN 46 Parameter Value Range cccccssssseeeeenes 47 Page 27 Dual Servo Spin Welder User 5 Manual This page intentionally left blank Page 28 Dukane Manual Part No 403 570 00 RUN Mode When the welder is first turned on after the E Stop switch is reset
22. Automation Dukane Manual Part No 403 570 00 Page 101 Dual Servo Spin Welder User Manual This page intentionally left blank Page 102 Dukane Manual Part No 403 570 00 Dukane Manual Part No 403 570 00 Appendix B APPENDIX B Tooling Moment of Inerta 0annaannonneneneneneennnennnn 105 Explanaton Of Inertia vagaunaqgsnsnemmademiniakuis 105 Calculating the Moment of Inertia 105 Tooling and Fixure Deen 104 Page 103 Dual Servo Spin Welder User 5 Manual This page intentionally left blank Page 104 Dukane Manual Part No 403 570 00 Moment of Inertia Explanation of Inertia The moment of inertia is a measure of the mass and the mass distribution of the tool It is defined mathemati cally as the product of the mass times the distance of that mass from the axis of rotation squared For a cyl inder spinning around its axis the formula for the mo ment of inertia is Inertia 1 8 M D where Inertia is in kg cm M is the mass in kg D is the cylinder diameter in cm Taking into account material density the formula can be rewritten as Inertia 098 p L D where p is the density in kg cm Lis the cylinder length in cm Calculating the Moment of Inertia For spin welder applications most tools will have a geometry close to a cylinder with internal cutouts for the parts To estimate the inertia of such a tool first calculate the inertia of a solid cylinder then the
23. Data Port Connector 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 profile graphs The pin numbers for the connector are shown in Figure A4 Automation Wirin If the Dual Servo Spin Welder will H used in Automation mode the signals normally generated by the optical switches and abort switch must be reproduced Figure A 6 shows a wiring diagram and a description of the required signals Page 100 Figure A 4 Figure A 5 Data Port Connector Location Data Port Connector Pins Dukane Manual Part No 403 570 00 Appendix A DB 9 BASE INTERFACE CONNECTOR O GND 24V Ges GND 24V LEFT ABORT RIGHT OPTO SWITCH SWITCH OPTO SWITCH Figure A 5 Schematic of Operate and Abort Ba DB 9 CONNECTOR MALE SIGNAL OPTO SWITCH 1 OPTO SWITCH 2 24VDC SWITCHED ABORT INPUT GND TO DB 9 BASE INTERFACE CONNECTOR GND GND AUTOMATION INPUT 24VDC SWITCH DESIGNATIONS SWITCH FUNCTION USE SWITCH CURRENT CLOSE FOR MINIMUM OF 10 SECONDS TO HOME MACHINE AT MACHINE HOMING STARTUP OR AFTER FAULT RESET NOTE ABORT SWITCH SW2 MUST BE IN POSITION SHOWN TO HOME MACHINE ABORT AS SHOWN SYSTEM IS UNABORTED TOGGLE TO ABORT 500 mA AUTOMATION MOMENTARY CLOSURE MIN 0 5 SEC STARTS WELD CYCLE lt 20 mA Figure A 6 Wiring for
24. E service Press is jogged in a way to produce a force on the parts larger than allowed in jog mode most common cause Servo system feedback is malfunctioning Operator E Stop E stop activated Operator pressed E stop switch Reset E stop switch then reset machine 1 Ensure part is present for pickup 2 Check vacuum between part and tool line connections vacuum generator tool wear Part presence notdetected Part presence sensor did 1 Part not present 1 Ensure part is present H not detect part 2 Problem with sensor 2 Troubleshoot sensing components RUN SWITCH ES Optical switches on base Switches were released after weld Once weld cycle is started ensure switches were de activated during cycle started but before the spin remain activated until spin motor stops i e released too soon weld cycle motor stopped at beginning of hold phase akg SES Motor controller error Internal machine error Contact DUKANE service Contact DUKANE for import Import procedure problem procedure Cable problem Check that the correct cable is used Machine component failure and that it is securely connected Contact DUKANE service Tooling inertia entered is _ Enter tooling inertia within limits stated outside allowable range in this manual Servo tuning database is Contact DUKANE regarding importing missing servo tuning database Air pressure to slide too low Slide limit switch improperly positioned Slide jammed Slide Out timeout see Slide In tim
25. EL LOWER LIMIT button 2 Press the Initialize button and wait I minute 3 Press the DOWN button then activate both RUN SWITCHES to move the head down to the posi tion where the lower limit proximity switch should be activated at least 4 mm 15 in above tooling contact if possible since the physical hard stop is lower than the switch position by this distance To change speed select a different setting in the VERT Jog Speed box 4 Press the Set Position button and wait until a flashing red circle appears next to the DOWN button 5 Press DONE 11 Set Weld Process Parameters Select the desired setup number 1 through 8 setup 1 is default from the TOOLS gt SELECT SETUP tab menu Input the desired weld process settings in the PRE WELD WELD and POST WELD tabs in the SETUP menu as described in Chapter 5 Dukane Manual Part No 403 570 00 Section 6 Machine Operation Page 53 Dual Servo Spin Welder User 5 Manual Starting A Weld Cycle 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 first see Figure 5 2 If you had powered down the welder or pressed the Abort button the screen may instruct you to press the RESET FAULT button and then reset the machine by activating the RUN switches After the reset process is completed the welder is ready to run a cycle which is
26. EQUALLY SPACED AND LOCATED AT TRUE POSITION WITHIN 0 015 DIA ON 2 TWO BOLT CIRCLES 8 PLACES 7 00 inch BOLT CIRCLE 125 0 mm BOLT CIRCLE 12 00 inch BOLT CIRCLE l 1 52 38 6 1 50 38 1 t M12 X 1 75 6H TAP THRU 2 5 PLACES inches millimeters Figure 3 3 Lower Base Fixture Mounting Dukane Manual Part No 403 570 00 Section 3 Unpacking and Setup 3 00 76 2 B C 15X 316 8 03 22 5 TYP 250 008 e 35 83 RR 1 000 20 25 40 23 21 5 sl 001 03 Dimensions are in INCHES mm Figure 3 2a Upper Tooling Hub Dimensions for Models SVTO32VR and SVTO42VR 5 00 127 0 B C 4 x 404 10 26 EQUALLY SPACED b 376383 0 5533 149 9 50 12 7 pl J 35 8 9 T het e om 25 4023 Dimensions are in INCHES mm Figure 3 2b Upper Tooling Hub Dimensions for SVTO12VR Page 17 Dual Servo Spin Welder User 5 Manual AC Power The Dual Servo Spin Welder requires a 240 VAC 1 phase outlet rated at 20 Amps All machine models use the same power cord and plug The AC power cord is permanently attached to the welder The other end of the cable has a 240 VAC 1 phase plug shown in Figure 3 4 This is designed for a NEMA 6 20R configuration wall receptacle shown in Figure 3 5 Directly below the AC cord strain relief is the AC power switch Th
27. Intelligent Assembly Solutions DUKANE Dual Servo Spin Welder User s Manual DUKANE Part No 403 570 00 ISO 9001 2000 Piores acnes DA ART www dukcorp com us Dual Servo Spin Welder User s Manual Copyright 2008 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 form or by any means electronic mechanical photocopying recording or by any information storage and retrieval system without written permission from Dukane Corporation Notice of Liability The information contained is this manual is distributed on an As is basis without warranty While every precaution has been taken in the preparation of this manual Dukane Corporation shall not have any liability to any person or entity with respect to any liability loss or damaged caused or alleged to be caused directly or indirectly by the instructions contained in this manual or by the hardware and software products described herein Printed in the United States of America Dukane Part Number 403 570 00 Dukane ultrasonic equipment is manufactured under one or more of the following U S Patents 3 780 926 3 825 481 4 131 505 4 277 710 5 798 599 and 5 880 580 Page ii Dukane Manual Part No 403 570 00 Revision History Revision Revision
28. TOUCH SCREEN welder the remote touch screen kit l 438 965 can be used The touch screen is mounted in a separate enclosure as shown in Figure C 3 which can be up to 15 ft 4 5 m away from the welder Two cables power and communcations are needed to connect the touch screen with the welder The enclosure includes mounting brackets for attachment to an external support refer to Dukane drawing 400 2283 for dimensions This kit can SONEK GASE be used with any Dual Servo Spin 200 1590 Welder model COMMUNICATIONS CABLE 200 1593 Figure C 3 Remote Touch Screen Components Page 110 Dukane Manual Part No 403 570 00 DukanelSQ ISO CERTIFICATION Dukane chose to become ISO 9001 2000 certi fied in order to demonstrate to our customers our continuing commitment to being a quality vendor By passing its audit Dukane can assure you that we have in place a well defined and systematic approach to quality design manu facturing delivery and service This certificate reinforces Dukane s status as a quality vendor of technology and products To achieve ISO 9001 2000 certification you must prove to one of the quality system regis trar groups that you meet three requirements 1 Leadership 2 Involvement 3 Quality in Line Organizations and Quality System Infrastructure The ISO 9001 2000 standard establishes a minimum requirement for these requirements and starts transitioning the company from a t
29. The moisture content can lead to bubble formation in the joint resulting in decreased weld strength Control Parameters There are several primary process control parameters that affect weld quality They are the surface velocity of the weld joint press axial speed weld depth and hold distance and time Thefollowing sections arepresented forinformational purposes only and are in no way meant to serve as a rule or formula The information is collected from publicly available books and papers It is presented here to provide you with a general guideline for setting the initial parameters Surface Speed For a fixed rotational spin speed RPM linear surface speed increases with weld joint diameter For a fixed weld joint diameter surface speed increases with motor RPM Smaller diameter parts therefore usually require more RPM than larger parts of the same material If the surface speed is too low an adequate amount of heat will not be generated to cause sufficient melting If the speed is too high excessive heat in the joint could result in material degradation or reduction in viscosity leading to material flow away from the joint The selection of the proper surface speed depends to a large degree on the material and joint geometry of the parts being welded Some materials suchas PVC can be readily welded for a wide range of values while others require a narrow range Commonly quoted values in the literature recommend using
30. UN switches until the spin motor stops 6 Read the Peak Torque value on the RUN screen This value represents the torque re quired to keep the tool spinning in the air T Enable the Torque Trigger Option and set the Torque of max field to be slightly larger at least 2 than the number from the previous step Dukane Manual Part No 403 570 00 Figure 5 18 Section 5 Touch Screen Menus POST WELD Weld Torque Trigger Option Screen Page 37 Dual Servo Spin Welder User 5 Manual Constant Torque 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 measuring the spin torque and changing the verical speed on the fly based on this measurement The vertical speed is inversely proportional to the spin torque the lower the spin torque the higher the vertical speed and vice versa To enable this option press the Constant Torque button and then the Enable box on the screen shown in Figure 5 19 The relationship between the spin torque and vertical speed is illustrated in Figure 5 20 The welder will adjust vertical speed for a measured spin torque along the lines shown The Torque Target is the desired spin torque which is entered into the Torque of max field on the screen The Max Torque value is 5 larger than the Target Torque If the measured torque exceeds t
31. al Servo Spin Welder be leveled to within one degree This can be accomplished using a carpenter s level One degree corresponds to approximately one quarter of an inch 6 mm deviation across the 16 inch 406 mm width of the platen Mounting Holes The base of the Dual Servo Spin Welder has two mounting holes in the front as shown in Figure 3 1 The two holes will accept either 12mm or 7 16 diameter bolts We recommend that you securely attach the welder base to the work table using these mounting holes Page 16 WARNING DO NOT LIFT the Dual Ser vo Spin Welder manually Lifting and or moving the welder manually could re sult in personal injury Use mechanical means to move and place the welder i Two 1 Holes On 1314 Centers Figure 3 1 Mounting Hole Locations on Base Dukane Manual Part No 403 570 00 Tooling Hub amp Fixture The upper tooling attaches to a hub using four 5 16 18 screws spring lock washers and flat washers Figure 3 2 a amp b gives the dimensions of the tooling hubs The hubs have precision slots to accommodate an indexing pin on the tool so that the tool can be mounted in a consistent orientation relative to the hub The lower tooling fixture attaches to the base platen using M10 1 5 cap screws See Figure 3 3 for the detailed measurements of the mounting holes in the base platen _ 950 DIA HOLES 12 7 0 50 RADIUS 12 17 M10 X 1 5 2B TAP THRU
32. ample Figure 3 2 would be the second illustration in section three while Table 3 II would be the second table in section three Dukane Manual Part No 403 570 00 NOTE NOTE statements provide additional in formation or highlight procedures WARNING 155 WARNING statements point g out conditions or practices p that could result in person p Paste al injury or loss of life gp aa 9 9 Hy e AN Electrical Crush Hazard Hazard Condition or Practice Page 3 Dual Servo Spin Welder User 5 Manual Dual Servo Spin Welder Overview The Dual Servo Spin Welder 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 for spinning the tool and a servo actuator for moving the machine head up and down Both servos have high resolution encoders enabling accurate process control Dukane offers three models SVTO12VR SVT032VR and SVT042VR Model differences are in the maximum speed power and torque of the spin servo motor the same vertical servo actuator is used in each Model specifications SVT012VR 750 RPM 4 2 HP 47 ft lb Torque Spin Motor SVT032VR 3 000 RPM 4 2 HP 16 ft lb Torque Spin Motor SVT042VR 4 000 RPM 2 5 HP 10 ft lb Torque Spin Motor All models have a 5 inch stroke a fixture throat depth of 8 i
33. ane Manual Part No 403 570 00 Touch Screen Display 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 selections are programmed through the touch screen A closeup view of the controls is shown in Figure 4 2 The left side of the display remains visible for most of the selected functions The icon in the upper left corner indicates machine status Below that are three touch cells for Run mode RUN Weld and Post Weld Setup SETUP and Setup Utilities TOOLS The functions of these buttons are covered in Chapter 5 The touch cell on the right labeled Part Data displays part data for the previously welded assemblies Dukane Manual Part No 403 570 00 Section 4 Display and Controls Touch Screen Display Trigger Indicator Mert Match Upper Tooling Figure 4 1 Dual Servo Spin Welder Touch Screen Panel PROCESS DATA Part Nr 12345678 Date 11 22 33 Limits Time 11 22 33 WELD _______ _ Time s 1 600 Rotations 20 4 Peak RPM 1200 Peak Toraue gt 15 sem Enersy CJ 348 Orient Des gt 52 3 Held End cmm 80 00 Peak Thrust x 25 Hold End cmm 30 20 Hold Col cmm 4 20 Cycle s GARE Part Data Figure 4 2 Startup Screen Page 23 Dual Servo Spin Welder User 5 Manual Operati
34. any kinds of literature You can locate your local representative at www dukcorp com us sales intsales htm Dukane Manual Part No 403 570 00 Section 11 Contact Dukane Page 87 Dual Servo Spin Welder User 5 Manual This page intentionally left blank Page 88 Dukane Manual Part No 403 570 00 Section 12 Specifications Specifications Tooling Specifications Lununuuuirrnnrsenisn nn 91 Machine le Lu nenene 91 Power Requirement cccccccssseceeeseeeees 97 Operating Environment AANEREN 97 Dimensions amp 5 View Drawing rrrrrennnnn 92 Identification Numbers 93 Regulatory Agency Compliance 0000u 93 Dukane Manual Part No 403 570 00 Page 89 Dual Servo Spin Welder User Manual This page intentionally left blank Page 90 Dukane Manual Part No 403 570 00 Tooling Specifications Tooling Size Refer to Table 5 I for maximum tooling sizes Machine Weight The Dual Servo Spin Welder weighs approximately 400 Ibs 182 kg It should be mounted on a table or bench capable of supporting 650 Ibs 295 kg to accommodate the additional force imposed by the vertical movement of the motor and slide during the spin welding operation Use mechanical means such as a forklift or hoist to place the servo spin welder on its work bench There are two 3 4 inch lifting eyes located at the top of the column see Figure 3 7 for a lifting ring or strap Power Requirements The Dual Servo Spin Wel
35. below the weld starts at the TRIGGER Position This position should be set slightly higher than the position at which the parts to be welded start to come in contact Above this position the spin motor is being accelerated from rest to the weld RPM and the head is moving rapidly down After reaching this position the spin RPM and vertical speeds are maintained at the programmed values The TRIGGER Position can be entered directly into the Position mm field or taught by jogging the head as described in setting the TOP OF STROKE Position Page 32 POST WELD Position mm Transfer 198 Pos cmm L 12 88 Figure 5 7 TOP OF STROKE Position Setup Screen in PRE WELD Menu POST WELD Figure 5 8 TRIGGER Position Setup Screen in PRE WELD Menu Dukane Manual Part No 403 570 00 Part Pickup Option This button enables the Part Pickup option which is programmed through the screen shown in Figure 5 9 This option is used in conjunction with automated part feed systems where it is desirable to place the parts to be joined on top of each other in the lower fixture In this mode the head travels down to pick up the upper part with the tool without spinning goes up slightly and then completes the weld cycle To enable this option toggle the Enable button to On and set the pickup position in the Position mm field by direct entry or through the Teach Position button Optionally the Thrust Sense option can be enabled i
36. d of the weld To enable it press the Orientation button and then the Enable box on the screen shown in Figure 5 17 The final weld orientation is defined in the Weld field There are two methods for setting this value 1 direct numeric entry into the Weld field or 2 visual alignment by jogging the spin tool to the desired orientation To jog the spin tool first select the SPIN Jog Speed Low Medium or High and the jog direction JOG or JOG then activate both RUN switches to rotate the tool The current spin tool orientation is displayed in the Jog Pos Deg box Once the head is in the desired orientation the Transfer arrow button is used to set this value as the final Weld orientation To aid in visually setting the orientation the press can be jogged vertically by selecting the DOWN or UP buttons and activating both RUN switches The Move To button allows the spin tool to be rotated to the programmed Weld orientation After selecting this button activate both RUN switches until the spin tool Page 36 POST HELD Ss Ze E j Figure 5 16 Weld Parameters Screen for Energy Method POST WELD Figure 5 17 Weld Orientation Option Screen Dukane Manual Part No 403 570 00 stops moving The DONE button causes a return to the main WELD tab screen Torque Trigger Option This option specifies a torque level to sense when the upper and lower parts make contact Prior to contact the motor is spinning the tool
37. der housing You should connect a separate 14 AWG ground wire between these lugs and an effectively grounded metal pipe This will minimize any external electrical interference from leaking into the Dual Servo Spin Welder control circuitry This will not compromise the safety of the power ground 14 AWG wire has a diameter of 1 63mm or 0 064 Mechanical Safety The Dual Servo Spin Welder is capable of developing substantial torque force and high rotational velocity Keep your hands and body away from the tool head during operation The spinning head is capable of inflicting serious injury Never attempt to retrieve a part from a spinning tool head Always wear a face shield when operating the spin welder Be extremely careful not to let long sleeves ties necklaces or long hair become entangled in the welder during operation Always turn machine power off when installing or removing tooling Dukane Manual Part No 403 570 00 Section 2 Safety Considerations Figure 2 1 240VAC 20A Receptacle Wiring J35 Base Interface P Grounding Lu Figure 2 2 Grounding Lug on Base of Dual Servo Spin Welder Page 11 Dual Servo Spin Welder User s Manual This page intentionally left blank Page 12 Dukane Manual Part No 403 570 00 Dukane Manual Part No 403 570 00 Section 2 Safety Considerations Unpacking and Setup Unpacking Weider AAA 15 Packing E EE 15 Work MEL EE 15 Secure to Work Bench 16 ee 1
38. der requires a 240 VAC 1 phase outlet rated at 20 Amps All welder models use the same power cord and plug The AC power cord has a 240 VAC single phase plug which is designed for a NEMA 6 20R configuration wall receptacle shown in Figure 12 1 Operating Environment Operate the Dual Servo Spin Welder within these guidelines 40 F to 95 F 5 C to 35 C 4570 m 15 000 ft Keep the welder dry Minimize exposure to moisture dust dirt smoke and mold 5 to 95 non condensing 5 C to 30 C Temperature Altitude Air Particulates Humidity Dukane Manual Part No 403 570 00 Section 12 Specifications 240 Volt AC Socket NEM 6 20R Figure 12 1 240V AC Single Phase AC Receptacle Page 91 NOTE All specifications are subject to change without notice The specifications listed are current at the time of publication Figure 12 2 Dual Servo Spin Welder Dimensions Dual Servo Spin Welder User 5 Manual 5 23 132 9 4 K Do 7 5 8190 COLUMN MOUNTING PAD Law 4X M12 1 75 COLUMN HOLES 6 04 153 4 CENTER OF TOOLING HUB amp BASE BOLT PATTERN 9 36 237 6
39. dual finger run switches violates OSHA regulations General Safety Before performing any maintenance or service on the Dual Servo Spin Welder locks and tags should be applied to all energy isolating switches Anything that might restore energy to the welder must be locked out You may be required to add accessories to bring the system into compliance with applicable regulations for operator safety In the United Sates these regulations are administered by OSHA Page 10 Dukane Manual Part No 403 570 00 Electrical Safety AC Power Receptacle The power cord used on the Dual Servo Spin Welder has a two blade grounding type plug designed for 240 VAC at 20 Amps It is designed to be plugged into a 240 VAC 20 Amp NEMA type 6 20R receptacle as shown in Figure 2 1 Do not alter the plug or receptacle in any way Grounding It is important for operator safety that the receptacle grounding wire be installed properly and securely attached to an effectively grounded rod The function of the ground wire is to keep the Dual Servo Spin Welder base and housing at earth potential In the event of a short circuit from one of the AC lines to the case the circuit breaker will open protecting the equipment and operator If there is any question about the grounding of your AC power have it checked by a qualified electrician Grounding lugs are also provided one on the back of the base see Figure 2 2 and one on the back of the wel
40. e parts are loaded properly 2 Increase Timeout s value 3 Check the Position mm value it should be set slightly lt 5mm above expected part contact 1 Check parts to be welded fixturing etc 2 If practical widen process limit window or adjust setup parameters Weld aborted by ROTATE limit Weld cycle stopped because number of revolutions exceeded programmed process limit Weld process problem Limits too narrow for weld process N a 1 Check parts to be welded fixturing etc 2 If practical widen process limit window or adjust setup parameters Weld aborted by RPM limit Weld cycle stopped because motor speed was outside programmed process limit Weld process problem Limits too narrow for weld process 1 Check parts to be welded fixturing etc 2 If practical widen process limit window or adjust setup parameters Weld aborted by THRUST limit Weld cycle stopped because weld thrust was outside programmed process limits Weld process problem 2 Limits too narrow for weld process 1 Check parts to be welded fixturing etc 2 If practical widen process limit window or adjust setup parameters Weld aborted by TORQUE limit Weld cycle stopped because motor torque was outside programmed process limits Weld process problem Limits too narrow for weld process 1 Check parts to be welded fixturing etc 2 If practical widen process limit window or adjust
41. e switch combines the functions of a power switch and a 20 Amp circuit breaker The breaker switch is identical on all models and is shown in Figure 3 6 Page 18 240 VoltAC Socket NEMA 6 20R DAD Voie NE live NNN Figure 3 4 20 Amp 240V Figure 3 5 20 Amp 240V Plug Receptacle COLUMN POSITION INPUT VOLTAGE 240 VAC 20 A 50 60 Hz AC Power Switch Figure 3 6 AC Power Switch and Power Cord Dukane Manual Part No 403 570 00 Head Height Adjustment 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 is shown in Figure 3 7 and covered in detail in Chapter 6 A reference scale and index pointer are located next to the column to indicate the thruster head height Control Connectors Base Interface Connector On the rear of the housing is the base control input connector as shown in Figure 3 8 The Base Interface cable Part No 200 1124 3 or 200 1545 01 is a supplied part and is included with the welder see Table 3 I Connect one end of the cable to the rear thruster connector and the other end to the Base Interface connector J35 as shown in Figure 3 7 The control cable carries the operate and emergency stop signals from the optical operate switches and abort switch on the base If you are using custom automation you ma
42. eed mm s P Figure 82 PROFILE GRAPHS Tab Page 69 Dual Servo Spin Welder User 5 Manual Spin Torque Setpoint If torque triggering is enabled the Torque Trigger value is displayed in this box for reference as a percentage of the spin motor maximum WRITE TO FILE Writes the torque data to a file Add a Gr or csv extension to the end of the file name as the generated file is in ASCH format Servo and Debu The SERVO PARAMETERS tab ug the ability to import a servo tuning database file This database contains parameters necessary for proper operation of the machine for different upper tool sizes It is set at the factory and stored on the welder in non volatile memory It will need to be modified only in cases where the database requires customization The procedure of changing the database should only be performed with guidance from Dukane Improper execution of the procedures could render the welder inoperable The DEBUG tab is used to retrieve troubleshooting information from the welder if it is not operating properly The welder will display the letters DB on the upper left side of the touch screen when it is put in debug mode If the use of this function becomes necessary instructions will be provided by Dukane Page 70 Dukane Manual Part No 403 570 00 Dukane Manual Part No 403 570 00 Section 9 Troubleshooting Troubleshooting Welding tee 73 Material ee te 73 Parameter Effects rrrrrrrn
43. eeeeeeeees 60 Surface Speed HPM 60 Press Axial Speed EE 62 Weld Depth rororo eai 62 ele ME 63 Part SE 63 Dukane Manual Part No 403 570 00 Page 57 Dual Servo Spin Welder User 5 Manual This page intentionally left blank Page 58 Dukane Manual Part No 403 570 00 Spin Welding Process The formal definition 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 during the rotational contact melts the plastic in the heat affected zone forming a weld upon cooling Note that the parts themselves can be any shape only the mating surfaces to be welded need to be circular The spin welding process is divided into five distinct phases In Phase I the rotational friction generates heat Frictional heating is intensified with both axial press vertical and joint surface velocities In Phase II the friction results in abrasive forces which strip off surface roughness generating wear particles causing the surfaces of the polymer to begin to melt As the polymer reaches its crystalline melting point or glass transition temperature it enters Phase III where heat starts to be generated by internal friction within the molten region This continues in Phase IV where the temperature of the molten layer remains relatively constant Because plastics are poor conductors of heat the s
44. en Dukane Manual Part No 403 570 00 changes the display to the screen shown in Figure 5 22 The MODE switch specifies if the Hold phase will be controlled by traveling a specified Distance or for a specified amount of Time With Distance MODE selected as shown in Figure 5 22 the parameters for Hold motion are specified in the fields on the right and are divided into two sections DYNAMIC and STATIC During the Hold the press will first complete the DYNAMIC phase then the STATIC In the DYNAMIC phase the press moves vertically at the speed specified in Speed mm s to a distance specified in Collapse mm In the STATIC phase the press will maintain its position for the time phase specified in Dwell Time s It is possible to bypass either the DYNAMIC or STATIC phases by programming a 0 collapse distance or a 0 dwell time respectively With Time MODE selected as shown in Figure 5 23 the parameters for specifying the hold time are vertical speed in Speed mm s the motion duration in Move Time s and time for maintaining the final position in Dwell Time s In addition the Constant Thrust option is available in the Time MODE in which the press travels down until reaching a specified vertical thrust i e compression force To enable this option press the Constant Thrust button The relationship between the vertical torque and vertical speed is illustrated in Figure 5 24 The press will adjust vertical speed as a respon
45. enta tion accuracy and repeatability tool should be as light as possible to allow for rapid deceleration and to keep machine energy consumption to a minimum tool should be balanced as accurately as possible to avoid excessive machine vibration and bearing wear bottom fixture should grip the part firmly to maintain accurate weld orientation and prevent undesirable vibrations during welding Page 106 Dukane Manual Part No 403 570 00 Appendix C APPENDIX C Optional Features Upper Tool Vacuum merete 109 Remote Touch Screen ccccceceeceeeee eee 110 Page 107 Dukane Manual Part No 403 570 00 Dual Servo Spin Welder User Manual This page intentionally left blank Page 108 Dukane Manual Part No 403 570 00 Upper Tool Vacuum As an aid in holding the spinning part the welder can optionally be equipped with vacuum in the upper tool Two different kits are available a complete vacuum system kit which includes all components needed to generate control and transfer the vacuum to the tool 438 963 for models SVT032VR E SVTO42VR 438 964 for model SVT012VR and a vacuum trans fer kit which provides a means for transferring vacuum not supplied from a non rotating fitting to the rotating tool 438 952 for models SVT032VR amp SVT042VR 438 958 for model SVT012VR The vacuum system kit is shown in Figure C 1 and the transfer kit in Figure C 2 When vacuum is supplied to the 5 16 8mm air fitting
46. eout fault Spin aborted Weld cycle was aborted Contact DUKANE service Number of servo motor rotations has exceeded Weld time or number of rotations Reduce weld time distance or number of controller counting too large rotations capability Home index edge not found Press thrust force was Jog thrust limit exceeded exceeded during jogging OR vertical servo runaway operations OR servo detected system entered runaway condition Prevent press from applying a large force on the parts in jog mode 2 Contact DUKANE service Sensor for upper tool No part present to pick up Part pickup not detected vacuum not activated when 2 Loss of vacuum between part expected and tool Servo database import Servo tuning database failed import failed Servo tuning data not found for the tooling inertia entered Servo param select by inertia failed Slide did not move to the Slide In timeout commanded position within the allowable time Increase air pressure Adjust slide switch position Ensure slide can move freely Spin at travel limit Page 76 Dukane Manual Part No 403 570 00 Table 9 Il Machine Display Messages continued Section 9 Troubleshooting Message Description Cause Possible Solution Spin motor not on GEESS Internal machine error Contact DUKANE service not power up Spin servo amplifier faulted Spin servo tracking error Spin weld axis aborted Timeout on servo CPU Thread 1 thrd1 There i
47. ess will move to position set in the SETUP gt PRE WELD tab gt TOP OF STROKE Position gt Position mm field Figure 5 8 The switches can be deactivated once a beep sounds The homing procedure is complete after the second beep sounds and the indicator directly below the yellow face icon becomes green 9 Align Lower Fixture with Spin Tool Place a set of parts in the upper tool and lower fixture Navigate to the SETUP gt TRIGGER Position menu press the DOWN button and select Me or Hi in VERT Jog Speed Jog the press head down to a position where the weld joint can be used to align the lower fixture by activating both RUN SWITCHES Change the vertical jog speeds as needed and use the UP button to move the head up if desired When finished press the DONE button and remove the parts Page 52 Dukane Manual Part No 403 570 00 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 Vertical servo runaway detected if the press is jogged down too far If this condition occurs the welder must be re initialized by returning to the RUN screen pressing RESET FAULT button and repeating welder initialization Step 8 10 Set Vertical Travel Lower Limit Position To protect tooling set the vertical press travel limit using the following steps 1 Navigate to TOOLS gt SYSTEM SETUP tab and press the VERTICAL TRAV
48. he Max Torque the vertical speed will be 0 until the torque drops below the maximum The Max Speed is the maximum allowable vertical speed which will occur if the measured torque is 0 This value is entered in the VERT Max mm s field on the Weld Parameters screen in the WELD tab The Timeout s field specifies the maximum weld time before the machine aborts the cycle and reports an error The actual spin torque profile achieved during the weld will depend on the Torque of max and the VERT Max mm s settings for a particular application For example if the actual spin torque is consistently below the specified target the VERT Max mm s will need to be increased to cause the welder to move down faster causing a rise in the spin torque POST WELD Setup The POST WELD setup is the right tab in the SETUP menu and is shown in Figure 5 21 The screen is divided into two sections Hold Setup and Part Tests Hold Setup The Hold Setup button is used to enter parameters related to the Hold phase of the weld cycle During this phase the molten plastic cools and solidifies beginning when the spin tool stops Pressing the Hold Setup button Page 38 POST HELD Figure 5 19 Weld Constant Torque Option Screen VERTICAL SPEED Max Speed Torque Max Target Torque Figure 5 20 Graph of Vertical Spin Speed vs Spin Torque for Constant Torque Option HELD Hold Setur Figure 5 21 POST WELD Main Setup Scre
49. ician Comply with Regulations You may be required to add accessories to bring the system into compliance with applicable OSHA Occupational Safety and Health Administration regulations for machine guarding and noise exposure Operate Safely Keep your hands and body away from the tool head during operation Always wear a face shield when operating the spin welder Be extremely careful not to let long sleeves necklaces or long hair become entangled in the spin welder during operation Do not operate the welder if under the influence of alcohol or drugs Read the warning labels on prescriptions to determine if your judgement or reflexes are impaired while taking drugs If there is any doubt do not operate the machine Dukane Manual Part No 403 570 00 Section 2 Safety Considerations Page 9 Dual Servo Spin Welder User 5 Manual 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 fumes and or vapors that could be hazardous e g PVC Polyvinyl Chloride can emit chlorine gas under certain processing conditions Make sure you use proper ventilation whenever these plastics are processed Run Switches The dual finger run switches comply with OSHA safety regulations Using a foot switch in place of the
50. in the Dukane Dual Servo Spin Utility Installer folder on the CD supplied with the welder and follow the prompts on the screen Once installed run the program It can be accessed through Start Menu gt All Programs gt Dukane gt Dual Servo SpinWelder Utility Connect the cable between the Data Port on the weld er located above the power switch on the rear of the welder and a serial port on the PC or a USB to serial converter If a converter is to be used the serial com munications settings should be as follows PARAMETER VALUE Baud Rate 57600 Data Bits a 8 NONE Stop Bits Flow Control Xon Xoff Dukane Manual Part No 403 570 00 Page 67 Dual Servo Spin Welder User 5 Manual Part Data 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 PART DATA List This area contains a series of lines of part data one line per part This data is displayed after each cycle if the Data Export option in the System Setup screen on the welder is enabled See Figure 5 32 The data is comma delimited with the fields given in the order as follows i Part number ID 2 Test result number S Test result symbol 4 Date 5 Time 6 Weld time sec T Number of weld revolutions 8 Weld energy Joules 9 Peak spin motor RPM 10 Peak spin motor torque of max 11 Weld orientation degrees 12 Peak vertical th
51. indicated by the smiley face in the upper left corner of the screen If a frowning face appears instead it signifies that the welder is not ready for one of several reasons for example the part presence sensor is not activated if the Part Present option is enabled To run a cycle press both RUN switches simultaneously The press will begin to descend and spin motor will accelerate Both servos will reach their programmed weld speeds by the time the press reaches the trigger position defined in SETUP gt PRE TRIGGER tab gt TRIGGER Position The Trigger Indicator see Figure 4 1 will turn on when the weld starts which occurs at the Trigger position if the Torque Trigger Option is disabled or when the trigger torque is sensed if the Torque Trigger Option is enabled The weld phase continues until the selected welding parameter time number of rotations vertical distance or energy has been reached at which point the Trigger Indicator turns off The spin motor then stops and the welder begins the hold phase during which the press moves according to the settings defined in the Hold Setup menu To complete the cycle the press retracts to the top of stroke position and the RUN screen is populated with weld process data results The base switches must remain actuated until the start of the hold phase otherwise the cycle will be aborted and no weld data will be displayed If a weld cycle completes successfully the smiley face appea
52. inertia of the void created for the part using the density of the tool material and then subtract the two values Example Aluminum tool with outside dimensions D 4 in 10 1 cm L 2 5 in 6 4 cm P 0 1 b in density of Aluminum 0028 kg cm Appendix B USEFUL UNIT CONVERSIONS 1 in 2 54 cm 025 m 1 Ib 0 45 kg 1 cm 0 39 in 1m 39 4 in 1 kg 2 20 Ib Part void D 3 inches 7 6 cm L 1 inch 2 5 cm The inertia would be calculated as follows Inertia cylinder 098 0028 6 4 10 1 18 1 kg cm Inertia void 098 0028 2 5 7 6 2 3 kg cm Inertia tool Inertia cylinder Inertia void 16 kg cm Dukane Manual Part No 403 570 00 Page 105 Dual Servo Spin Welder User 5 Manual Tool and Fixture Design The most important aspect of tool and fixture 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 considered when tooling is not purchased from Dukane tool nest should be designed such that part being held is firmly retained in the tool so that it does not fall out before being welded tool should surround part being held where pos sible the exterior of the tool should be a con tinuous cylindrical surface i e avoid protruding parts rotational play between tool and part should be minimized this will affect the angular ori
53. ing the EXPORT LAST WELD GRAPH DATA button in the Utilities screen see Figure 5 30 Plot Data The profile data is displayed in this box with comma separated values The first line is a header row containing the following parameters total number of samples sampling rate prior to trigger ms sampling rate during weld ms sample number at which weld started torque trigger setting of max 10 Plot The plot shows all the profile curves vertical axis with respect to time horizontal axis in milliseconds The icons immediately above the plot contain tools for a more detailed examination of the plot Both the horizontal and vertical scale end values can be changed by double clicking on the desired number and entering a new value Dukane Manual Part No 403 570 00 Section 8 Welder Data Export Software DUKANE Dual Servo Spin Welder Utility DUKANE Plot Data Dual Servo Spin Welder Utility 1 2 PART DATA PROFILE GRAPHS SERVO PARAMETERS DEBUG r incoming Data WEE EE 0 000000 296 000000 310 000000 326 000000 S 572 000000 30 EEN 0000 1 800000 3 700000 5 700000 7 500000 8 600000 Spin Torque Setpoint of max Plot Ba 45 0 4 5 0 O 20 40 60 80 100 120 140 160 180 Si 220 240 260 280 300 320 340 360 380 400 420 440 460 460 ime millseconds EXIT Spin Position rev S Torque of max MA Vertical Distance mm MZ Thrust of max B Vertical Sp
54. ings are entered pressing the DONE button causes a return to the main UTILITIES screen wherea yellow SAVE OTHER SETTINGS button appears Press this button then Save and DONE on the following screen to retain the settings in memory The EXPORT LAST WELD GRAPH DATA button is used to send weld profile data information for the last cycle to an externally connected computer via the Dual Servo Spin Welder Utility refer to Chapter 8 This data includes the spin torque spin orientation vertical thrust vertical position and vertical speed It is displayed in graphical format in the Utility and can be exported to an ASCII file SYSTEM SETUP Tab The third tab is labeled SYSTEM SETUP and is shown in Figure 5 32 The welder contains an assembly used to limit the downward travel of the press to prevent tooling from coming in contact This assembly consists of a mechanical stop block with an integral proximity switch whose position is adjusted via an elevator screw driven by a small DC motor If during normal operation the press travels down and the proximity switch becomes active the press motion will quickly decelerate to a stop The actual physical hard stop is approximately 4 mm below this position since the stop block includes a cushion to protect the vertical servo actuator from damaging impact loads To set the lower limit proximity switch position first press the VERTICAL TRAVEL LOWER LIMIT button Then press the Initialize button
55. interface to a Left Right or an In Out slide kit and provides activation signals to extend and retract the slide table as well as readouts of the table position switches It also provides an input for a signal from a part presence sensor The pin numbers for the connector are shown in Figure A 3 The pin assignments and signal descriptions are given in Table A III SES SSES Pin SignalDescription Activate when slide is in Out Left position Output common connection ON when press is at Top of Stroke position In Out Slide Identificaiton Input Activate to designate connected slide as In Out type ensure Pin 8 is disconnected Left Right Slide Identificaiton Input Activate to designate connected slide as Left Right type ensure Pin 7 is disconnected Part Presence Sensor Input Activate when part presence is sensed 10 11 Slide In Right Output ON when welder calls for slide to move to the In Right position 12 Slide Home Status Output ON when slide is in Home position NOTE home slide position is Out Left 13 Ready Status Output ON when welder is ready to initiate a weld cycle 14 Slide Out Left Output ON when welder calls for slide to move to the Out Left Position 15 16 24V DC Switched 24V DC switched connection Power OFF when Abort switch pushed Table AJ Pin Assignments and Signal Description for the Slide Kit Connector Dukane Manual Part No 403 570 00 Page 99 Dual Servo Spin Welder User Manual
56. ion I Introduction Important User Information Read This Manual First Before operating the Dual Servo Spin Welder read this User s Manual to become familiar with the system This will ensure correct and safe operation The manual is organized to allow you to learn how to safely operate this system The examples given are chosen for their simplicity to illustrate basic setup procedures Notes and Tips Throughout this manual we use NOTES to provide information that is important for the successful application and understanding of the system ANOTE block is shown to the right Cautions and Warnings In addition we use special notices to make you aware of safety considerations These are the CAUTION and WARNING blocks as shown here They represent increasing levels of important information These statements help you to identify and avoid hazards and recognize the consequences Different symbols also accompany the CAUTION and WARNING blocks to indicate whether the notice pertains to a general condition or practice an electrical safety issue a hand protection issue or other condition Drawings and Tables The figures and tables are identified by the section number followed by a sequence number The sequence number begins with one in each section The figures and tables are numbered separately The figures use arabic sequence numbers e g 1 2 3 while the tables use roman sequence numerals e g I II 0 As an ex
57. itched by E Stop Power OFF when Abort switch pushed Abort Signal Ground Ground ls Automation Input 24 VDC Power Table A I Pin Assignments and Signal Description for the Base Interface Connector Page 97 Dual Servo Spin Welder User Manual User I O Connector The User I O connector is a HD 15 connector located A directly above the base hee on the 100000 ei rear of the thruster The connector is shown in Figure ORORORORO 1514131211 3 8 This connector provides access to signals for interfacing to custom automation equipment The pin a tor the compota are sinw in Figure E Figure A 2 User I O Connector The pin assignments and signal descriptions are given in Table A II Input signals such as Vacuum On Sense can be configured as sourcing or sinking using 24 VDC and Input Common For example to activate the Vacuum On Sense input connect Input Common to ground and provide 24VDC on the input pin Outputs such as Ready Status are provided through relays rated at IA Q24VDC Outputs provide contact closure to Output Common when active Signal Description Fumeten Cid Top Of Stroke Status Output ON when press is at Top of Stroke position acuum On Output Part Pickup ON when welder calls for vacuum to be turned ON with Part Pickup mode enabled Bad Part Status Output ON when weld process is outside defined limits with Bad option enabled Suspect Part Status Output ON when we
58. ld Speed f or Hold Move Time POSTED fhoid Dwel Time o Hold Constant Thrust 1 TOOLS gt SYSTEM Home Offset 359 9 0 1 SETUP Table 5 I Welding Parameters Dukane Manual Part No 403 570 00 Page 47 Dual Servo Spin Welder User 5 Manual This page intentionally left blank Page 48 Dukane Manual Part No 403 570 00 Dukane Manual Part No 403 570 00 Section 6 Machine Operation Machine Operation Machine SEP i wcsccccscsarsnentetmecenvosticnmaanmerens 51 Starting a Weld Cycle AAA 54 Stopping a Weld Cycle 55 Setup SMOG issascccccvinsanssapanataceedscsenasaannnes 55 56 Page 49 Dual Servo Spin Welder User 5 Manual This page intentionally left blank Page 50 Dukane Manual Part No 403 570 00 Machine Setup The startup procedure given here is for a new machine that has just been installed 1 Base Interface Cable Attach the base interface cable from the rear of the base to the back of the thruster housing as shown in Figures 3 7 and 3 8 2 AC Power Insert the AC power plug refer to Figure 34 into a 240 VAC 1 Phase NEMA type 6 20R receptacle rated at 20 Amps The correct style outlet is shown in Figure 3 5 Do not alter the plug or receptacle in any way Refer to the section on Electrical Safety in Chapter 2 if you have any questions Ensure the AC Power Switch is in the OFF position see Figure 3 6 3 Attach Tooling Attach the upper tooling to the hub and torque tightly The hub dime
59. ld process is outside defined limits with Suspect option enabled Vacuum On Output No Part ON when welder calls for vacuum to be turned ON with Part Pickup mode Pickup disabled signal is deactivated if idle time between cycles is more than 5 minutes one of the RUN SWITCHES must be turned on to reactivate signal Ready Status Output ON when welder is ready to initiate a weld cycle 7 Output Common Output Common connection Fixture Clamp 1 Right Output Function depends on configuration Without slide or In Out slide ON at start of cycle OFF at end of cycle With Left Right slide ON at start of cycle when slide is commanded to move to In Right position OFF at the end of cycle 1 2 3 4 5 Fixture Clamp 2 Left Output Function depends on configuration Without slide or In Out slide not used With Left Right slide ON at start of cycle when slide is commanded to move to Out Left position OFF at the end of cycle 5 Table A Pin Assignments and Signal Description for the User I O Connector 0 1 2 3 4 1 1 1 1 1 1 Page 98 Dukane Manual Part No 403 570 00 Appendix A Slide Kit Connector 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 Welder is prewired to accept a Dukane slide kit without any modification or reprogramming of the press The connector is shown in Figure 3 8 The connector will
60. n Welder User 5 Manual bad part means one or more of the measured parameters was not within the limits set for the weld cycle The Time and Date fields indicate the time and date the part was welded Just below the WELD label there are a number of fields with weld data for the last cycle The displayed data lists the e Time Weld time seconds e Rotations Number of spin motor rotations during weld e Peak RPM Peak spin motor speed RPM e Peak Torque Peak spin motor torque of maximum torque e Energy Weld energy Joules e Orient Welded part angular orientation degrees e Weld End Weld end vertical position mm e Peak Thrust Peak vertical actuator thrust of maximum thrust e Hold End Hold end vertical position mm e Hold Col Hold collapse distance mm e Cycle Total cycle time seconds VIEW PARTS The Part Data button on the right side of the screen displays seven part reports at a time Each report occupies two lines and displays the same information reported on the RUN screen The report starts with the last cycle at the bottom and works backwards toward the top This is shown in Figure 5 3 The Page Up and Page Down buttons permit you to scroll through part data one screen at a time Press the RUN button to return to the RUN screen Page 30 POST WELD Part Pickup Ea Uz Figure 5 3 VIEW PARTS Screen Dukane Manual Part No 403 570 00 SETUP Menu The SETUP menu is
61. n which the head will first travel to the Position mm distance then continue to travel until the vertical actuator thrust i e force exceeds the value set in the Thrust field The Timeout s field sets a time limit between the arrival at the Position mm distance and the point of reaching the thrust sensing level Pre Spin Orientation Option This button enables the Pre Spin Orientation option which is programmed through the screen shown in Figure 5 10 This option is used in conjunction with the Part Pickup option in applications where before welding the parts are placed on top of the other and the initial pre spin angular orientation is different than the welded orientation To enable this option toggle the Enable button to On The Pre Spin Orientation can be entered directly in the Pre Spin field Alternatively this orientation can be taught by first pressing the JOG or JOG buttons depending on desired direction of rotation and selecting the jogging speed from the SPIN Jog Speed Low Medium or High field then activating both RUN switches to rotate the spin tool to the desired orientation and pressing the Transfer button to assign the current jog position displayed in the Jog Pos Deg field as the Pre Spin Orientation To aid in setting the orientation the head can be moved by pressing the DOWN or UP buttons and activating the RUN switches Dukane Manual Part No 403 570 00 Section 5 Touch
62. nal limits and the DONE button causes the screen to return to the POST WELD main menu Page 40 Figure 5 25 Process Limit Definitions Screen 1 of 3 Figure 5 26 Process Limit Definitions Screen 2 of 3 Figure 5 27 Process Limit Definitions Screen 3 of 3 Dukane Manual Part No 403 570 00 Section 5 Touch 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 specifies if the out of limit condition will require an acknowledgement from the user before allowing the next cycle to start This acknowledgement request is indicated by a button on the bottom of the RUN screen as shown in Figure 5 28 The Suspect Bad Abort button in the right lower comer of the screen controls two aspects of machine function The first function is to determine ifa weld cycle will be aborted if the process parameter falls outside the limits If Suspect is selected the machine cycle will complete regardless of the process limit results If Bad Abort is chosen the machine cycle will continue if any process parameter falls below the Lower limit or be terminated if it exceeds the Upper limit for the following parameters e Weld Time s Weld Rotations Peak RPM Peak Torque of max Peak Thrust of max Cycle Time s In the case of cycle termination the machine will report an error message
63. nches and a vertical maximum thrust of 700 pounds Both SVT032VR and SVT042VR models have the same maximum vertical clearance of 21 3 inches 541 mm between the bottom of the tooling hub and top of the mounting base The SVTO12VR model has a clearance of 20 4 inches 518 mm The Dual Servo Spin Welders were designed to provide a reliable long and economical service life and meet the applicable CE regulations Page 4 Dukane Manual Part No 403 570 00 Key Dual Servo Spin Welder Features Color touch screen display uses Color Active Ma trix Thin Film Transistors TFT for high contrast and wide viewing angle even under high ambient lighting conditions The 192 touch cells provide a high performance interface Commercial subassemblies are used to ensure a longer and more economical service life than units built with proprietary components These readily available items also lessen the need for expensive field service calls Ultra rigid square support column minimizes load deflection for precise and repeatable operation Column mounted direct drive 2 5 or 42 HP spin servo motor for faster cycle times and quick deceleration to prevent bond shearing and to produce stronger joints Digital rotary encoders are built into the servo motors for maximum reliablity The spin motor encoder accurately measures and controls the final angular orientation to within 0 19 1 part in 3600 and the vertical actuator encoder measures
64. neral Safety c cccccccccecsseeeeeceeneeeneceneeeeeennee 10 See 11 AC Power Receptacle A 11 GO EE 11 Mechanical Safety muuus emnene 11 Page 7 Dual Servo Spin Welder User s Manual This page intentionally left blank Page 8 Dukane Manual Part No 403 570 00 Health and Safety Tips Please observe these health and safety recommendations for safe efficient and injury free operation of your welder In this manual the term welder and or dual servo spin welder both refer to the Dual Servo Spin Welder Proper Installation Do not operate the Dual Servo Spin Welder until after the electrical system is properly installed No Unauthorized Modifications Do not modify your Dual Servo Spin Welder in any way unless authorized to do so by Dukane Corporation Unauthorized modifications may cause injury to the operator and or equipment damage In addition unauthorized modifications will void the equipment warranty Keep the Sheet Metal Intact Do not remove any of the protective sheet metal enclosing the motor or controls The servo motors and drives have exposed electrical terminals which could cause injury or death if touched Grounded Electrical Power Operate this equipment only with a properly grounded electrical connection Refer to the NEMA Type 6 20R wiring diagram in Figure 2 1 and receptacle photo in Figure 3 5 If there is any question about the grounding of your AC power have it checked by a qualified electr
65. ng Welding Process Troubleshooting Symptom Possible Cause Recommended Solution Overwelding Underwelding Nonuniform or inconsistent weld joints Final part orientation different from programmed orientation Dukane Manual Part No 403 570 00 Excessive weld flash Welded assembly dimensions are too small Low strength weld Welded assembly dimensions are too large Excessive weld flash Low weld strength Failure when leak tested Part failure in service Parts not aligned properly Weld Time or Distance are too large Reduce Weld Time or Distance Incorrect flash trap design Evaluate and correct flash trap design Weld Time or Distance are too small Increase Weld Time or Distance Material difficult to weld due to low friction Degrease joint interface to remove mold release coefficient agent Consider changing material i e avoid PTFE Warped parts Check part dimensions Uneven weld interface Check molding process conditions Fixture and part are not parallel Level fixture where necessary Check that tooling is true to table Poor alignment of parts in tool and or fixture Change part or tool dimensions Improve part tolerance due to cavity Insufficient fixture support Check for parts shifting during welding Provide features in parts for rotational driving i e drive ribs or cavities Part walls flexing during weld Redesign parts with reinforcing ribs and or tongue and groove joints Exce
66. nsions are given in Figure 3 2 The slot in the hub is intended to accept a inch standard dowel pin assembled to the upper tool for repeatable mounting orientation Place the lower fixture on the base and attach it loosely so it can be aligned later 4 Adjust Thruster Position on Column The rear support column of the Dual Servo Spin Welder features a threaded shaft for adjusting the overall height of the thruster head The adjustments are shown in Figure 3 7 The thruster height should be adjusted properly to ensure that the weld head has enough travel to perform the weld within the 5 inch stroke limit and that the welded assembly can readily be removed from the tooling To adjust the position complete the following steps a Loosen the three rear nuts which lock the head assembly in place The nuts are 22mm wide but a 7 8 inch socket will also fit b Raise or lower the head by turning the adjustment lead screw on top which is also a 22mm hex The lead screw has 8 threads per inch so 1 turn moves the head 1 8 inch 3 18 mm c Tighten the rear locking nuts Dukane Manual Part No 403 570 00 Section 6 Machine Operation IMPORTANT The Dual Servo Spin Welder is capable of developing substantial torque and high rotational velocity Keep your hands and body away from the tool head during operation The spinning head is capable of inflict ing serious injury Never attempt to retrieve a part from a spinning tool
67. onal Switches Emergency Stop Switch A red Emergency Stop E STOP switch is located in the center of the base as shown in Figure 4 3 The emergency stop switch must be in its reset position before the operate switches will function To reset the Emergency Stop twist the large red button about 45 degrees clockwise which will cause the button to spring out This is depicted in Figure 4 4 Page 24 Left Right Run D Run Switch SCHT Switch E Stop Switch Figure 4 3 Operate Switches and E Stop o ag press STATUS wist to Reset r T OFF Ss i j Figure 4 4 Setting and Resetting the E Stop Dukane Manual Part No 403 570 00 Opti Touch Run Switches 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 standards Both switches are identical Each optical touch switch has a small red LED which is dimly illuminated whenever the power is on as shown in Figure 4 5 When the operator places their finger in the tray the LED brightens and a second LED in the opposite corner of the tray illuminates to indicate the switch has been activated as shown in Figure 4 6 Both switches must be activated simultaneously to initiate a weld cycle Data I O Connector A connector for output data is provided on the rear of the welder above the power switch This connector is a female type DB
68. peed It is displayed in graphical format in the Utility and can be exported to an ASCII file Pressing the button toggles between On and Off states The time required to transfer the data for this option can be significant several seconds depending on weld duration and may adversely affect cycle rate as the welder will not be ready to run another cycle until the transfer is complete The Start Type button toggles from Manual to Automatic each time it is pressed Manual is used for most operations Automatic is used in an automated system and requires a switch closure contact on the User I O HD 15 connector see Figure 3 9 A pinout of the User I O connector and automation wiring information are provided in Appendix A Page 44 SELECT SETUP UTILITIES Move To TOS ser Limit Pos Cmm Jos Pos Cmm J Set pg Op Position S Figure 5 34 Vertical Lower Limit Setup Screen with Set Position Button Dukane Manual Part No 403 570 00 The Home Offset Deg field 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 reference for the spin motor and all spin orientations are defined relative to it Unless a specific situation requires a non zero offset it is most convenient to retain the factory default value The Set Password button i
69. r exporting the graph data for the last weld Rename Setup allows a name up to 26 characters The keypad has the letters a through z and a caps key for A through Z plus the numbers 0 through 9 and a space key To rename a setup enter a new name and then press the RENAME button under the new name Press the DONE button when finished Copy Setup copies the values of the currently loaded setup file to the setup file specified To copy a setup press the Destination Setup ID button enter the desired number then press the COPY button Press the DONE button when finished Erase Setup clears all setup parameter values and restores them to factory defaults To erase a setup press the ERASE button and then the DONE button The OTHER MACHINE SETTINGS button is used as a notepad feature in recording the information shown in Figure 5 31 and is provided as a convenience feature for restoring the complete machine setup The Upper Tool Nr and Lower Tool Nr fields can be populated with tool identification numbers The Column Position mm Page 42 UTILITIES SYSTEM SETUP Figure 5 31 Record Other Machine Setetings Screen in UTILITIES Menu Dukane Manual Part No 403 570 00 field designates the position of the thruster part of the welder surrounded by sheet metal covers relative to the column as indicated by the scale affixed to the right side of the column and a white line printed on the rear of the welder Once these sett
70. raditional inspection oriented quality system to one based on partnership for continuous improvement This concept is key in that Du kane no longer focuses on inspection but on individual processes Dukane s quality management system is based on the following three objectives 1 Customer oriented quality The aim is to improve customer satisfaction 2 Quality is determined by people The aim is to improve the internal organization and cooperation between staff members 3 Quality is a continuous improvement The aim is to continuously improve the internal organization and the competitive position ISO 9001 2000 CERTIFIED Dukane products are manufactured in ISO registered facilities Please Refer to our Website At www dukcorp com us sales intsales htm To Locate Your Local Representative ci RTO www dukcorp com us Printed in the United States of America Dukane Corporation e Ultrasonics Division e 2900 Dukane Drive St e Charles Illinois 60174 USA TEL 630 797 4900 e FAX 630 797 4949 Dual Servo Welder User s Manual Part No 403 570 00
71. reen Dukane Manual Part No 403 570 00 Section 5 Touch Screen Menus POST WELD Figure 5 6 Sample Data Entry Screen Page 31 Dual Servo Spin Welder User 5 Manual TOP 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 non zero setting indicates that the Top of Stroke TOS position is lower than the home position by the programmed amount The TOS position can be entered directly by pressing the Position mm field Alternatively the TOS position can be taught by first pressing the DOWN button and selecting the VERT Jog Speed Low Medium or High then activating the RUN switches to jog the head to the desired position and finally pressing the Transfer button to assign the current jog position displayed in the Jog Pos mm field as the TOS Position The Move To button is used to move the head to the value displayed in the Position mm field After pressing this button activate both RUN switches and wait for the value in the Jog Pos mm field to match the Position mm value TRIGGER Position This button is used to set the vertical position at which the spin tool and machine head reach the programmed weld speeds as shown in Figure 5 8 If Torque Triggering is disabled see
72. rnnnrrrrrrnrnnnrrrnrrnnnnnnn 73 Troubleshooting EE 73 NA EE 74 POLE let 74 Electrical POW ST oicccccrcsacezccsbecnmmeentienccacaredehanemexs 74 Base Interface Cable L iL uuaumsmeimnmamnmimnioisui in 74 Machine Display Messages eeeeeeeeesseeeeeeeee 74 Table 9 1 Welding Process teilen ee le EE 75 Table 9 1 Machine Display Messages 76 79 Page 71 Dual Servo Spin Welder User Manual This page intentionally left blank Page 72 Dukane Manual Part No 403 570 00 Section 9 Troubleshooting Welding Process 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 coefficient of linear expansion Even members of the same family may cause problems due to differences in the manufacturing process For example an extruded Polyethylene PE piece may not weld as well to an injection molded PE piece as it would to another extruded PE piece Parameter Effects Surface Speed Insufficient surface speed may not allow the plastic to reach its melting temperature Instead it may simply erode away part of the material and stick by a clawing effect The surface speed is determined by both the weld joint diameter and the spin motor speed Axial Speed In conjunction with surface velocity axial speed determines whether the plastic reaches the melting temperature Both surface and axial speed are needed to produce sufficien
73. roper process limit values entered Correct process limit values Move to Top Of Stroke before welding Press head is not at Top of Stroke Machine jogged away from Top Of Stroke position Move press to Top Of Stroke position by using the TOP OF STROKE Position screen in setup menu Process RPM is too high Programmed spin motor weld speed is too high Programmed spin weld speed is larger than machine capability Reduce spin motor weld RPM TOS to trigger distance is too small Distance between Top Of Stroke position and Trigger position is too small Trigger position is set too high or Top Of Stroke position is set too low Increase Trigger position value or decrease Top of Stroke position value Vertical weld speed is too high Programmed press weld speed is too high Programmed press weld speed is larger than machine capability Reduce press weld speed Weld duration too short Weld duration generated by programmed parameters is too short 1 Weld Time Rotations or Distance too short 2 Deceleration too low NOTE the time for deceleration is counted as part of the total weld time or number of rotations 1 Increase Weld Time Rotations or Distance above the Min value indicated on the Weld Parameters setup screen 2 Increase spin deceleration Weld trigger position is below vertical travel lower limit Cycle will not start since the programmed press travel
74. rque threshold is exceeded see Torque Trigger Option below Time Method Status In this method the weld duration is controlled by time After choosing this method the Weld Parameters button is used to enter the weld settings shown in Figure 5 12 The Weld Time s entry specifies the weld duration in seconds Below this entry a minimum weld POST WELD time value is displayed This value corresponds to the time needed for decelerating i e slowing down and stopping the servo motors and is included as part of the total weld time The VERT Speed mm s sets the press weld speed in millimeters per second The SPIN RPM specifies the spin tool speed which is constant during the weld until the start of deceleration The Dir field specifies the spin direction The DONE button causes a Figure 5 12 Weld Parameters Screen for Time return to the main WELD tab screen Method Page 34 Dukane Manual Part No 403 570 00 Rotation Method In this method the weld duration is controlled by completing a specified number of spin revolutions The Weld Parameters button is used to enter the settings shown in Figure 5 13 The Weld Rotations field specifies the number of weld revolutions The actual number of weld rotations as reported on the RUN screen after the weld will be larger than the number entered in this field and depends on the deceleration and whether final orientation is enabled see Orientation Option below The VERT Speed mm s
75. rs to indicate that the machine is ready to run another cycle If a cycle terminates abnormally a fault message will be displayed on the screen describing the error condition The fault must be cleared and the welder reset before another cycle can be initiated Page 54 Dukane Manual Part No 403 570 00 Stopping a Weld Cycle During normal operation the cycle stops automatically when the specified weld and hold phases are completed and the press returns to the top of stroke position To stop a cycle before it completes press the E stop switch on the base which terminates the cycle and causes power to be removed from both servo motors Setup Sheet On the following page is a table containing all the machine settings for the Dual Servo Spin Welder An electronic version is provided on the CD included with the machine Dukane Manual Part No 403 570 00 Section 6 Machine Operation Page 55 Dual Servo Spin Welder User 5 Manual DUKANE DUAL SERVO SPIN WELDER SETUP SHEET APPLICATION MACHINE MODEL SVTO 2VR DATE MACHINE SETUP NUMBER TOUCH SCREEN SETTING VALUE TOOL INERTIA KG CM 2 TOOL WEIGHT KG TOOL SETUP SPIN DECEL Vac SENSE ON OFF Ge 7 PART PRESENT ON OFF WELD TOP OF STROKE Position POSITION MM TRIGGER POSITION POSITION MM PART ENABLE POSITION MM ON OFF OPTIONS PICKUP THRUST SENSE THRUST TIMEOUT S ON OFF PRE SPIN ORIENT PRE SPIN ON OFF
76. rust of max 13 Cycle time sec 14 Weld end distance mm 15 Hold relative collapse distance mm 16 Hold end distance mm CLEAR Clears parts data from PC screen WRITE TO FILE Writes parts data from the screen to a file on the computer After pressing this button enter the name of the file where to store the data Add a txt or csv extension to the end of the file name as the gener ated file is in ASCII format Saving the file with a csv extension will allow it to be opened directly with Microsoft ExcelTM Page 68 Dual Servo Spin Welder Utility 1 2 Figure 8 1 Utility Startup Screen Dukane Manual Part No 403 570 00 File Write Sets the write behavior for an existing file Write Over overwrites an existing file while Add On appends data to the end of the file Incoming Data This indicator will flash when data is being received from the welder EXIT Exits program The PROFILE GRAPHS tab shown in Figure 8 2 contains numerical and graphical representations of the following weld parameter profiles with respect to time for the last cycle Spin Position rev Torque of max spin motor torque Vertical Distance mm Thrust of max vertical actuator thrust Vertical Speed mm s v 4 3 ie es This data is exported by the welder after each cycle if the Graph Export option in the System Setup screen is enabled see Figure 5 32 It can also be exported on demand by press
77. s a problem with the spin servo amplifier The spin servo motor was not able to execute the spinning motion programmed in the setup Expected spin servo move was not completed Excessive spin deceleration Excessive press weld or hold speed Amplifier disabled due to excessive temperature Amplifier failed Excessive press weld or hold speed s Excessive spin deceleration Joint weld diameter too large Improper tuning Internal machine error Reduce deceleration Reduce speed s a Reduce machine duty cycle b Ensure temperature around machine is within operational limits Contact DUKANE service Reduce speed s Reduce deceleration Use welder model with larger spin torque capability Ensure correct tool inertia is entered in touch screen Check for obstructions to motion outside welder Contact DUKANE service Motor controller error Internal machine error Contact DUKANE service Timeout on servo response Servo system e H ys Internal machine error Contact DUKANE service to command start communication error Vertical at travel limit Vertical servo amplifier faulted Vertical servo tracking error Vertical weld axis aborted Weld trigger position is below vertical travel lower limit Press travel distance exceeded controller counting capability There is a problem with the vetical servo amplifier The vertical servo actuator was not able to execute the press motion programmed in the setup Expec
78. s used to set the password which must subsequently be entered to change programmed machine settings The default password is 0 zero so that password protected screens are easily accessed by just pressing the Enter key on the Enter Password Code screen The password is a numerical value with a maximum 10 digit value of 4 294 967 295 The password protected screens and menus are shown in Figure 5 35 The Software Info button displys a screen with software revisions of the welder components as shown in Figure 5 36 Dukane Manual Part No 403 570 00 Section 5 Touch Screen Menus SELECT lt SETUP a ome torp gt f syste lt SETUP Set Password Figure 5 35 Password Protected Screens and Menus SELECT SETUP UTILITIES Figure 5 36 Welder Software Information Page 45 Dual Servo Spin Welder User 5 Manual Setting Time and Date On Touch Screen 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 in Figure 5 37 and lower left hand corner marked by 2 at the same time The screen shown in Figure 5 38 should appear 2 Press the Clock button The screen shown in Figure 5 39 should appear 3 To change the date and time first enter a numeric value Then press the corresponding button associ ated with that value For example
79. se to the measured vertical thrust along the lines on the graph The Thrust Target is the desired vertical thrust which is entered into the Thrust field on the screen The Max Speed is the maximum allowable vertical speed which will occur if the measured thrust is 0 This value is entered in the Speed mm s field in the DYNAMIC section Dukane Manual Part No 403 570 00 Section 5 Touch Screen Menus Figure 5 22 Hold Setup Screen for Distance MODE Figure 5 23 Hold Setup Screen for Time MODE VERTICAL SPEED Max Speed Figure 5 24 Graph of Vertical Speed vs Vertical Torque for Constant Thrust Option Page 39 Dual Servo Spin Welder User 5 Manual Part Tests The Part Tests section is used to define 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 5 27 The following limits are available Weld Time s Weld Rotations Orientation Deg Weld Energy J Peak RPM Peak Torque of max Peak Thrust of max Cycle Time s Vertical Weld End mm Hold Collapse mm Hold End Position mm d p it Er ov ae eS o k To enable a limit press the ON OFF box to the left of the description and enter the Lower and Upper values Any combination of limits can be enabled simultaneously The More Limits button shows additio
80. see Figure 4 4 the STARTUP 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 until a beep sounds which will take several seconds A second beep will sound a few seconds after the first indicating that the welder is ready to run a weld cycle the bar under the smiley face will become green at the same time The message area is now clear and the STATUS icon in the upper left has changed to a smiley face with a green band below it as shown in Figure 5 2 If when the switches are activated as described above the tooling hub begins to oscillate instead of rotating smoothly press the E Stop and then check that the correct tooling inertia is entered as described later in this manual in the SETUP Menu under TOOL SETUP Screen Layout The screen has the same basic layout for most of the selected operations The STATUS icon indicates the ready state of the machine To the right of the icon is the name of the currently loaded Setup File Below the file name is the Message Area The three mode select buttons on the left side below the status icon select either a Run mode RUN a Weld Setup screen SETUP or the Setup Utilities screen TOOLS The selected mode is indicated by a darkened button The center of the screen displays the parameters from the last weld cycle The Part Data button on the right displays a report of previously welded
81. setup parameters Weld aborted by vertical servo stop Vertical press motion stopped before spin motion weld was complete Excessive press weld speed Reduce press weld speed Weld duration too short Weld duration generated by programmed parameters is too short 1 Weld Time Rotations or Distance too short 2 Deceleration too low NOTE the time for deceleration is counted as part of the total weld time or number of rotations 1 Increase Weld Time Rotations or Distance above the Min value indicated on the Weld Parameters setup screen 2 Increase spin deceleration Weld ended at TIME limit Weld cycle stopped because weld time was outside programmed process limits 1 Weld process problem 2 Limits too narrow for weld process 1 Check parts to be welded fixturing etc 2 If practical widen process limit window or adjust setup parameters Page 78 Dukane Manual Part No 403 570 00 Table 9 Il Machine Display Messages continued Section 9 Troubleshooting Message Description Cause Warnings Possible Solution 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 service for information on battery replacement Lower limit is greater than upper limit Lower process limit is greater than Upper process limit Imp
82. shown on the screen in Figure 5 33 which will cause the stop block to move all the way down which takes minute as indicated by a flashing message When this step is completed the screen will change as indicated in Figure 5 34 Next jog the head down to the desired travel limit position at least 4 mm Dukane Manual Part No 403 570 00 Section 5 Touch Screen Menus Set Password seve TT Figure 5 32 SYSTEM SETUP Tab in TOOLS es KS bel fm Figure 5 33 Vertical Lower Limit Setup Screen with Initialize Button Page 43 Dual Servo Spin Welder User 5 Manual 15 in above tooling contact if possible and press the Set Position button The stop block will be moved up and a flashing circle will appear next to the DOWN button when this process is complete indicating that the proximity switch is active Press the DONE button to return to the SYSTEM SETUP screen The Data Export button controls whether the weld parameter data displayed on the RUN screen Weld Time Rotations etc is sent out to a computer connected to the welder after each cycle refer to Chapter 8 Pressing the button toggles between On and Off states The Graph Export button controls whether the weld profile data captured for the last weld is sent out to a computer connected to the welder after each cycle refer to Chapter 8 This data includes the spin torque spin orientation vertical thrust vertical position and vertical s
83. ssive filler or uneven distribution Reduce amount of filler Improve processing conditions to ensure even distribution of filler Moisture in parts Prevent moisture absorption after molding prior to welding Dry parts before welding Deceleration too low Increase spin deceleration as high as possible if set too high welder will fault with tracking errors Vertical speed too high Reduce speed to decreased spin torque required Poor tuning Determine and enter tool inertia correctly into Setup Contact DUKANE for special tuning requirements Parts not held properly by tool or fixture Ensure tooling does not allow excessive play Page 75 Dual Servo Spin Welder User Manual Table ol Machine Display Messages Message Description Cause Possible Solution Resetting of machine at startup or recovery requires the activation of both optical switches on base Activate both RUN Resetting of machine at SWITCHES to reset startup or recovery must be machine after all motion initiated when the spin tool stops and press are stationary Activate both RUN SWITCHES to reset machine Check for obstructions to motion Internal machine error outside welder Contact DUKANE service Expected servo move was Axis move aborted not completed Spin or vertical servo motor internal index pulse s not Internal machine error Contact DUKANE service detected Improper servo operation eee H Servo controller error Internal machine error Contact DUKAN
84. 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 password If no password has been set press the ENTER key PRE WELD Setup The PRE WELD screen containing a number of settings and options described below is shown in Figure 5 4 TOOL Setup This button is used to specify parameters related to the tooling assembled to the weldershownin Figure 5 5 Enter the spin tool inertia in the TOOL Inertia kg cm 2 field and the weight in the TOOL Weight kg field Pressing the numerical value cell displays a data entry screen shown in Figure 5 6 That also displays the minimum and maximum values allowed The SPIN Deceleration field specifies the spin motor deceleration as a percentage of motor maximum This value can exceed 100 when welding parts because friction in the weld joint assists the spin motor in stopping The Vac Sense and Part Present buttons at the bottom allow the vacuum sensing and part presence options to be enabled or disabled With either option enabled an appropriate external input must be provided For example if the Part Present option is enabled a part present signal must be activated before a weld cycle is allowed to initiate A frowning face will be displayed on the RUN screen if this signal is not active Press the DONE button to return to the PRE WELD setup sc
85. t frictional heating Excessive axial speed may cause one part to scrape away part of the surface and produce a lot of flash but insufficient melt volume Weld Depth Insufficient welding depth may not allow the melt to propagate far enough into the plastic to achieve the necessary melt volume and the required weld strength Hold Time Insufficient holding time may prevent the plastic from solidifying and forming a strong permanent bond Troubleshooting Table 9 I lists some potential problems with the weld process and suggested solutions Dukane Manual Part No 403 570 00 Page 73 Dual Servo Spin Welder User 5 Manual Welder Mechanical The part fixture 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 VAC 1 phase electrical outlet with a 20 Ampere capacity Check that the circuit is live Also refer to Electrical Safety in Chapter 2 Base Interface Cable The cable must be plugged in to the base and the back of the press If the cable is not plugged in or has a fault the base switches will not initiate any action and the ABORT and POWER indicators on the base status display will not function Machine Display Messages A list of all machine messages their meaning and possible solutions to problems are given in Table 9 II Page 74 Dukane Manual Part No 403 570 00 Table 9 I Section 9 Troubleshooti
86. ted vertical servo move was not completed Cycle will not start since the programmed press travel is larger than the set limit 2 Dukane Manual Part No 403 570 00 2 Press travel too large Amplifier disabled due to excessive temperature Amplifier failed Internal machine error Vertical travel lower limit set too high Trigger position too large Reduce weld time distance number of rotations or hold distance a Reduce machine duty cycle a Ensure temperature around machine is within operational limits Contact DUKANE service Excessive press weld or hold speed Reduce speed s Check for obstructions to motion outside welder Contact DUKANE service Lower vertical travel lower limit if possible Decrease Trigger position Table 9 II continued Page 77 Dual Servo Spin Welder User 5 Manual Table 9 lII Machine Display Messages continued Message Description Cause Errors Possible Solution 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 Servo controller error Internal machine error Contact DUKANE service Timeout on finding vertical lower limit position Moving the vertical lower limit up to desired position failed Limit mechanism malfunctioning Contact DUKANE service Timeo
87. to generate frictional heat The larger the speed the larger the rate of heat rise In combination with the surface speed press speed must be high enough to cause melting at the interface as opposed to grinding but not too high as to damage the parts Excessive press speed can also lead to stalling of the spin motor as more torque is required to maintain constant spin speed The Dual Servo Spin Welder is capable of operating in two different press speed modes With the Constant Torque Option in SETUP gt WELD tab disabled the press speed is constant during the weld With the Constant Torque Option enabled the press speed is variable so as to keep the spin torque constant see Chapter 5 The latter case resembles the operation of a pneumatically driven press where the press speed is the result of the melt rate under given air pressure and spin speed conditions Selection of the optimum press speed depends on the material and joint geometry of the parts as well as the surface speed A range for initial experimentation is 0 5 to 2 0 mm s Weld Depth The determination of the proper weld depth is highly dependent on the application The weld joint is typically designed for a specific weld penetration Ideally the weld is sufficiently deep to produce a strong hermetically sealed assembly An excessive depth may lead to the formation of flash material that is ejected from the joint area during the weld and adheres to the assembly
88. to set the month to May press 5 and then the Mon button 4 After setting the time and date press the Exit button on this screen and on the next screen 5 Wait several seconds for the touch screen to return to normal operation before welding Page 46 PROCESS DATA Part Nr 99992 Limits Time 12 66 68 Date 05706707 WELD Time lt s 2 00 Nr of Turns 20 0 Peak RPM 1200 Peak Ta 4 23 Eneray cJ 100 Orient Des gt Stroke s gt 0 25 Cycle lt s 3 50 View Stored Part Data Figure 5 37 Touch Screen Time and Date 1 Memory Used Revision Firmware i Boot Aa Hardware Af 67666 Free 194344 Total 262144 Flash 6 Clock COMH1 Conputer 8 56 68 Contrast 37 28 SEP 66 part u EZ S8C F Figure 5 38 Touch Screen Time and Date 2 SET TIME AND DATE 9 58 23 28 SEP 66 Time is in 24 hour format Figure 5 39 Touch Screen Time and Date 3 Dukane Manual Part No 403 570 00 Section 5 Touch Screen Menus Parameter Value Range The minimum and maximum values of the welding parameters are listed in Table 5 I Parameter Name Min Value Max Value Resolution Units EE Inertia 3000 SVTO12VR 780 SVTO32VR 160 SVT042VR TOOL Weight o Setups SPIN Dece JS EL 3509 og ds Weld Time Weld Rotations Weld Distance Vertical Energy VERT Speed SETUP gt SPIN RPM WELD SSES ES 0 om Weld Orientation o Ho
89. urface heat is transferred slowly to the interior and much of it remains localized At this point the rotation is stopped and we enter Phase V where the molten material is allowed to cool under pressure for a short period called the Hold Time Material Considerations Materials that can be friction i e vibration welded can also be joined with by spin welding The semicrystalline thermoplastics are more readily joined using spin welding than ultrasonics Using compatible polymers spin welding is capable of making reliable hermetic seals Far field welding is easier with spin welding than with ultrasonic welding Additional parts can be entrapped between the upper and lower pieces during spin welding Joining of dissimilar polymers is possible using the spin weld process although it generally produces lower strength weld joints By designing the weld joint with an undercut the polymer with the lower melting temperature will flow into the undercut creating a mechanical union Dukane Manual Part No 403 570 00 Section 7 Optimizing Performance Page 59 Dual Servo Spin Welder User 5 Manual Material filler and surface contaminants e g mold release agent are two factors that will affect consistency and weld repeatability Spin welding is more tolerant of contaminants than ultrasonic welding Spin welding is also less affected by hygroscopic polymers although they may still require special handling for critical applications
90. ut on torque sense The torque trigger was not detected within the 1 Torque trigger value set too high 1 Reduce torque trigger value Timeout on User Upper Part vacuum detect allowable time 2 Parts not loaded 2 BUF parts areproperly loaded de 1 Increase vacuum capability 1 Insufficient vacuum 2 Decrease required vacuum sensing Vacuum was not detected within timeout 2 Vacuum sensor threshold set too high 3 Improper part pickup position level 3 Adjust Position mm value in Part Pickup option Timeout on vertical distance in constant torque mode Programmed weld distance not reached within the specified time with Constant Torque option enabled Timeout too short Constant Torque maximum vertical speed set too low N a 1 Increase timeout value Increase value of VERT Max mm s setting in Weld Parameters screen in setup menu Vertical stop before starting spin Vertical press motion stopped before spin motion started Internal machine error 1 Check for obstructions to motion outside welder Contact DUKANE service Vertical servo contact sensing failed Weld aborted by CYCLE TIME limit Welder did not detect programmed thrust level Weld cycle stopped because cycle time exceeded programmed process limit With Part Pickup option enabled with Thrust Sense part contact was not detected Weld process problem 2 Limits too narrow for weld process 2 1 Ensur
91. y have separate operate and abort switches but these still connect to the press control input on the welder Both the base and thruster connectors are the same DB 9 type The pinout for this connector is given in Appendix A User I O Connector Directly above the DB 9 base interface connector is a HD 15 User I O connector for custom automation applications This is shown in Figure 3 8 The pinout for this connector is given in Appendix A Slide Kit Connector To the right of the DB 9 base interface connector is around 16 pin connector for controlling the optional Slide Kits This is shown in Figure 3 8 The pinout for this connector is given in Appendix A Dukane Manual Part No 403 570 00 Section 3 Unpacking and Setup Height Adjustment Knob _ Lifting Eyes Height Adjustment Lock Nuts 3 TJ J35 Figure 3 7 Height Adjustment and Lock Nuts Figure 3 8 Electrical Control Connectors Page 19 Dual Servo Spin Welder User 5 Manual This page intentionally left blank Page 20 Dukane Manual Part No 403 570 00 Dukane Manual Part No 403 570 00 Section 4 Display and Controls Display and Controls Touch Screen Display 23 Operational Gwitches 24 Emergency Stop Zelter agegzegegrugusesbugeg iegeeeeeg 24 Opti Touch Run Zwee oust rregsgeiteeugregegesr rien 25 Data WO CGonnedbhuLus4vsvaaimsve 25 Page 21 Dual Servo Spin Welder User 5 Manual This page intentionally left blank Page 22 Duk

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