Dukane 403-570-01 User Manual

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Intelligent Assembly Solutions

Dual Servo Spin Welder

User’s Manual

DUKANE Part No. 403–570-01

Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797–4949

ISO 9001:2000

Dukane products are manufactured in ISO registered facilities

www.dukane.com/us

Dual Servo Spin Welder User’s Manual

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: 403-570-01

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 5,880,580 6,984,921,

7,225,965, and 7,475,801.

Page ii

Dukane Manual Part No. 403-570-01

Revision History

Revision Revision Number Summary Date

- 00 Original release. 10/24/2008

- 01 Menu language choices added;

Revised Upper Tool Vacuum paragraphs 09/25/2009

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Dukane Manual Part No. 403-570-01

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 – Specications 89

Appendix A – Connector Pinouts 95

Appendix B – Tooling 103

Appendix C – Optional Features 107

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Dukane Manual Part No. 403-570-01

Section 1 - Introduction

SECTION 1

Introduction

Important User Information . . . . . . . . . . . . . . . . . . . . 3

Read the Manual First . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Notes and Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Caution and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Drawings and Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Dual Servo Spin Welder Overview . . . . . . . . . . . . . . . 4

Dual Servo Spin Welder Key Features. . . . . . . . . . . . 5

Dukane Manual Part No. 403-570-01

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Dukane Manual Part No. 403-570-01Page 2

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. A NOTE block is shown to the right.

NOTE statements provide additional information or highlight procedures.

Section 1 - Introduction

NOTE

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 gures and tables are identied by the section

number followed by a sequence number. The sequence number begins with one in each section.

The gures and tables are numbered separately. The gures use arabic sequence numbers (e.g. –1, –2, –3) while the tables use roman sequence numerals (e.g. –I, –II, –III). As an example, Figure 3–2 would be the

second illustration in section three while Table 3—II would be the second table in section three.

CAUTION

CAUTION st atements identify conditions or practices that could result in damage to the equipment or other property.

WARNING

WARNING statements point out conditions or practices that could result in personal injury or loss of life.

Dukane Manual Part No. 403-570-01

Condition or Practice

Electrical Hazard

Crush Hazard

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Dual Servo Spin Welder User’s 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 highresolution encoders, enabling accurate process control.

Dukane offers three models: SVT012VR, 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 specications:

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 xture throat depth

of 8-inches, 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 SVT012VR 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.

Dukane Manual Part No. 403-570-01Page 4

Section 1 - Introduction

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

eld service calls.

• Ultra–rigid square support column minimizes load

deection for precise and repeatable operation.

• Column–mounted direct drive 2.5 or 4.2 HP spin servo motor for faster cycle times and quick deceleration to prevent bond shearing and to produce stronger joints.

• 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.

• Several menu languages available: English,

Czech, French, and German.

• ISO9001Certication means that the Dual Servo Spin Welder is manufactured to exacting quality standards.

• 24–month domestic warranty assures you of reliability and quality construction.

• Digital rotary encoders are built into the servo motors for maximum reliablity. The spin motor

encoder accurately measures and controls the nal angular orientation to within 0.1° (1 part in 3600),

and the vertical actuator encoder measures 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proles.

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.

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Section 2 - Safety Considerations

SECTION 2

Safety Considerations

Health and Safety Tips ...................................9

Plastics Health Notice .........................................10

Run Switches ......................................................10

General Safety ....................................................10

Electrical Safety ............................................11

AC Power Receptacle ........................................ 11

Grounding ........................................................... 11

Mechanical Safety ........................................11

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Dukane Manual Part No. 403-570-01Page 8

Health and Safety Tips

Please observe these health and safety recommendations

for safe, efcient, 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.

Section 2 - Safety Considerations

Proper Installation - Do not operate the Dual Servo Spin Welder until after the electrical system is properly installed.

NoUnauthorizedModications- Do not modify your Dual Servo Spin Welder in any way unless authorized to do so by Dukane Corporation. Unauthorized

modications may cause injury to the operator and/

or equipment damage. In addition, unauthorized

modications 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 qualied electrician.

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.

IMPORTANT

Always wear a face shield when operating the welder.

CAUTION

Wel d ed parts may be hot.



IMPORTANT

N e v e r o p e r a t e t h e D u a l Ser vo Spin Welder w i t h the protective sheet met al removed. This is an unsafe practice and can result in injury.

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 inuence of alcohol or drugs. Read the warning

labels on prescriptions to determine if your judgement

or reexes are impaired while taking drugs. If there is

any doubt, do not operate the machine.

Dukane Manual Part No. 403-570-01

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Dual Servo Spin Welder User’s 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 nger run switches comply with OSHA safety

regulations. Using a foot switch in place of the dual

nger 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.

Dukane Manual Part No. 403-570-01Page 10

GND

240V

Grounding

Lug

J35 – Base

Interface

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 qualied

electrician.

Section 2 - Safety Considerations

Figure 2–1 240VAC–20A Receptacle Wiring

Grounding lugs are also provided, one on the back of the base (see Figure 2-2) and one on the back of the welder 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

inicting 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.

Figure 2–2 Grounding Lug on Base of Dual Servo Spin Welder

IMPORTANT

Always turn off the AC power at the power switch before servicing or working on the welder. Failure to turn off the AC power is an unsafe practice and can result in injury or death.

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Section 2 - Safety Considerations

SECTION 3

Unpacking and Setup

Unpacking Welder ........................................15

Packing List ..................................................15

Work Area .....................................................15

Secure to Work Bench ..................................16

Bench Capacity ...................................................16

Leveling ...............................................................16

Mounting Holes ...................................................16

Tooling Hub & Fixture ...................................17

AC Power .....................................................18

Height Adjustment ........................................19

Control Connectors.......................................19

Base Interface Connector ...................................19

User I/O Connector .............................................19

Slide Kit Connector .............................................19

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Dukane Manual Part No. 403-570-01Page 14

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

aps.

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 prevent accidental kinking or pinching of the power cable.

Section 3 - Unpacking and Setup

Packing List

After removing the 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 can be inspected in processing any claims that may arise.

Work Area

Allow sufcient area on either side of the Dual Servo

Spin Welder for handling material, work pieces and

xtures. 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.

Qty Item Part Number

SVT012VR or

1 Dual Servo Spin Welder

1 Base Interface Cable

Dual Servo Spin Welder

Manual

CD with Dual Servo Spin

Welder Utility

Table 3-I Dual Servo Spin Welder Packing List

SVT032VR or SVT042VR

200-1124-3 or 200-1545-01

403-570-XX

___

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Dual Servo Spin Welder User’s Manual

Two 1/2" Holes

On 131/4" Centers

Securing to Work Bench

Bench Capacity

The Dual Servo Spin Welder weighs approximately 400

lbs. (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 nal

position.

Leveling

We recommend that the Dual 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

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.

Dual Servo

Spin Welder has two mounting

WARNING

DO NOT LIFT the Dual Servo Spin Welder manually. Lifting and/or moving the welder manually could result in personal injury. Use mechanical means to move and place the welder.

Figure 3–1 Mounting Hole Locations on Base

Dukane Manual Part No. 403-570-01Page 16

Dimensions are in INCHES [mm]

3.60 [91.4]

1.000

.001

.000+

25.40

.03

.00+

[ ]



.30 [7.6]

.21 [5.3]

22.5° TYP.

3.00 [76.2] B.C.

.316 [8.03]15X

.250

.000

.002+

6.35

.00

.05+

[ ]

5.90 [149.9]

1.000

.001

.000+

25.40

.03

.00+

[ ]



.35 [8.9]

.50 [12.7]

5.00 [127.0] B.C.

.404 [10.26]4 x

(EQUALLY SPACED)

45°

.376

.000

.003+

9.55

.00

.08+

[ ]

Dimensions are in INCHES [mm]

8.25

(209.6)

16.50 (419)

13.25

(336.6)

0.50 RADIUS

DIA. HOLES

TYP.

2.25

(57.2)

2.63

(66.8)

12.38

(314.5)

7.61

(193.3)

1.52/(38.6)

1.50/(38.1)

2.00/(50.8)

3.02/(76.7)

7.00 inch BOLT CIRCLE

125.0 mm BOLT CIRCLE

12.00 inch BOLT CIRCLE

6H TAP THRU

5 PLACES

6.05

(153.7)

inches

(millimeters)

0.50

(12.7)

M10 X 1 .5 2B TAP THRU E QUALLY SPACED AND L OCATED AT TRUE POSITIO N WITHIN 0 .015 DIA ON

(2) TWO BOLT CIRCLES 8 PLACES

M12 X 1.75

24.84 (631)

(12.7)

Tooling Hub & Fixture

The upper tooling attaches to a hub using four 5/16”- 18

screws, spring lock washers, and at washers.

Figure 3–2 (a & 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 xture 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.

Section 3 - Unpacking and Setup

Figure 3–3 Lower Base Fixture Mounting

Dukane Manual Part No. 403-570-01

Figure 3–2a Upper Tooling Hub Dimensions for Models SVT032VR and SVT042VR

Figure 3–2b Upper Tooling Hub Dimensions for SVT012VR

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Dual Servo Spin Welder User’s Manual

240 Volt AC Plug

(NEMA 6–20P)

240 Volt AC Plug

(NEMA 6–20P)

240 Volt AC Socket

(NEMA 6–20R)

240 Volt AC Socket

(NEMA 6–20R)

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 conguration wall receptacle shown in Figure 3–5.

Directly below the AC cord strain relief is the AC power switch. The 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.

Figure 3–4 20–Amp 240V

Plug

Figure 3–5 20–Amp 240V

Receptacle

AC Power Cord

AC Power Switch

Figure 3–6 AC Power Switch and Power Cord

Dukane Manual Part No. 403-570-01Page 18

Head Height

Section 3 - Unpacking and Setup

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 may 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.

Height Adjustment

Knob

Lifting Eyes

Height Adjustment

Lock Nuts (3)

Connector

J35

Figure 3–7 Height Adjustment and Lock Nuts

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 a round 16–pin connector for controlling the optional

Slide Kits. this connector is given in Appendix A.

Dukane Manual Part No. 403-570-01

This is shown in Figure 3–8. The pinout for

Figure 3–8 Electrical Control Connectors

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Section 4 - Display and Controls

SECTION 4

Display and Controls

Touch Screen Display ...................................23

Operational Switches....................................24

Emergency Stop Switch ...................................... 24

Opti–Touch Run Switches ...................................25

Data I/O Connector.......................................25

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Section 4 - Display and Controls

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.

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

assemblies.

displays part data for the previously welded

A closeup view of the controls

Touch

Screen

Display

Trigger

Indicator

Upper Tooling

Hub

Figure 4–1 Dual Servo Spin Welder Touch Screen Panel

Figure 4–2 Startup Screen

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Dual Servo Spin Welder User’s Manual

Right Run Switch

Lower Fixture

E–Stop Switch

Left

Run

Switch

ABOR

WER

IN CYCLE

wist to Reset

Operational Switches

Emergency Stop Switch

A red Emergency–Stop ( 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.

E–STOP

) switch is located

Figure 4–3 Operate Switches and E–Stop

Figure 4–4 Setting and Resetting the E–Stop

Dukane Manual Part No. 403-570-01Page 24

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