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 [phone] • FAX [phone]

ISO 9001:2000

Dukane products are manufactured
in ISO registered facilities

www.dukane.com/us

Dual Servo Spin Welder User’s Manual

Copyright © 2009 Dukane
Intelligent Assembly Solutions
2900 Dukane Drive
St. Charles, IL 60174 USA

Notice of Rights:

All rights reserved. No part of this manual including the
interior design, cover design and icons may be reproduced,
transmitted or utilized in any 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

Dukane Manual Part No. 403-570-01

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Dual Servo Spin Welder User’s Manual

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Page iv

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

Dukane Manual Part No. 403-570-01

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Dual Servo Spin Welder User’s Manual

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Page vi

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

Page 1

Dual Servo Spin Welder User’s Manual

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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

Page 3

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.

Dukane Manual Part No. 403-570-01

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Dual Servo Spin Welder User’s Manual

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Dukane Manual Part No. 403-570-01Page 6

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

Dukane Manual Part No. 403-570-01

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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

Page 9

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

G

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.

Dukane Manual Part No. 403-570-01

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Dual Servo Spin Welder User’s Manual

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Dukane Manual Part No. 403-570-01Page 12

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

Dukane Manual Part No. 403-570-01

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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

1

Manual

CD with Dual Servo Spin

1

Welder Utility

Table 3-I Dual Servo Spin Welder Packing List

SVT032VR or
SVT042VR

200-1124-3 or
200-1545-01

403-570-XX

___

Dukane Manual Part No. 403-570-01

Page 15

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.

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

Page 17

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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Dukane Manual Part No. 403-570-01Page 20

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

Dukane Manual Part No. 403-570-01

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Dukane Manual Part No. 403-570-01Page 22

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

Dukane Manual Part No. 403-570-01

Page 23

Dual Servo Spin Welder User’s Manual

Right
Run
Switch

Lower Fixture

Lower Fixture

E–Stop Switch

Left

Run

Switch

ABOR

T

PO

WER

IN CYCLE

T

wist to Reset

T

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

Dimly Lit
Red LED

Brigtly Lit
Red LEDs

1

1

6

6

9

9

5

5

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 nger 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.

Section 4 - Display and Controls

Figure 4–5 Right Operate Switch in Standby
Mode, One LED Dimly Lit

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-9 as shown in Figure 4–7. It provides a

computer connection to export part data, motor load and

position proles. 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. 403-570-01

Figure 4–6 Right Switch in Operate Mode, Both
LEDs Brightly Lit

Figure 4–7 DB–9 Data I/O Connector

Page 25

Dual Servo Spin Welder User’s Manual

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Dukane Manual Part No. 403-570-01Page 26

Section 5 - Touch Screen Menus

SECTION 5

Touch Screen Menus

RUN Mode ....................................................29

Screen Layout ..................................................... 29

VIEW PARTS ................................................30

SETUP Menu ................................................31

PRE-WELD Setup ...............................................31

WELD Setup .......................................................34

POST-WELD Setup.............................................38

TOOLS Menu ...............................................42

SELECT SETUP Tab........................................... 42

UTILITIES Tab ..................................................... 42

SYSTEM SETUP Tab ..........................................43

Setting Time and Date ..................................46

Parameter Value Range ...............................47

Dukane Manual Part No. 403-570-01

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Dukane Manual Part No. 403-570-01Page 28

RUN Mode

When the welder is rst turned on after the E-Stop
switch is reset (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 rst,

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).

Section 5 - Touch Screen Menus

Figure 5–1 Startup Screen With E-Stop Cleared

Screen Layout

The screen has the same basic layout for most of the
selected operations. The
ready state of the machine. To the right of the icon is
the name of the currently loaded

the le name is the

select buttons on the left side below the status icon
select either a

(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 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 elds containing

part data.
sequential part number. The
last weld was within programmed process limits and

displays “–” if no limits were violated, “S” for suspect

part, “B” for a bad part, or “E” for an error. A suspect or

Run mode (RUN), a Weld Setup screen

The

Part Nr

STATUS

Message Area

. eld identies the current

icon indicates the

Setup File

. The three mode

Limits

eld indicates if the

. Below

Figure 5–2 Run Mode Screen With Welder Reset

Dukane Manual Part No. 403-570-01

Page 29

Dual Servo Spin Welder User’s 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

elds indicate the time and date the part

was welded.

Just below the

WELD

label, there are a number of elds

with weld data for the last cycle. The displayed data
lists the:

•

Time

- Weld time (seconds)

•

Rotations -

Number of spin motor rotations

during weld

•

Peak RPM -

•

Peak Torque -

Peak spin motor speed (RPM)

Peak spin motor torque (% of

maximum torque)

•

•

Energy -

Orient. -

Weld energy (Joules)

Welded part angular orientation

(degrees)

•

Weld End -

•

Peak Thrust -

Weld end vertical position (mm)

Peak vertical actuator thrust (% of

maximum thrust)

•

Hold End -

•

Hold Col -

Hold end vertical position (mm)

Hold collapse distance (mm)

•

Cycle -

Total cycle time (seconds)

VIEW PARTS

The

Part Data

displays seven part reports at a time. Each report
occupies two lines and displays the same information
reported on the
last cycle at the bottom and works backwards toward

the top. This is shown in Figure 5–3. The

Page Down

data one screen at a time, Press the
return to the

button on the right side of the screen

RUN

screen. The report starts with the

Page Up

and

buttons permit you to scroll through part

RUN

button to

RUN

screen.

Figure 5–3 VIEW PARTS Screen

Dukane Manual Part No. 403-570-01Page 30

SETUP Menu

The SETUP menu is sub-divided into three tabs:

PRE-WELD, WELD, and POST-WELD that are described

below. Immediately after pressing the SETUP button,
the Security Code screen will appear, prompting for a
numerical 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 welder shown in Figure 5-5. Enter

the spin tool inertia in the TOOL Inertia (kg*cm^2) eld
and the weight in the TOOL Weight (kg) eld. 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

(%) eld species 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.

Section 5 - Touch Screen Menus

Figure 5–4 PRE-WELD Screen for SETUP Menu

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 screen.

Dukane Manual Part No. 403-570-01

Figure 5–5 Tool Setup Screen in PRE-WELD Menu

Figure 5–6 Sample Data Entry Screen

Page 31

Dual Servo Spin Welder User’s 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) eld.

Alternatively, the TOS position can be “taught” by rst

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

nally pressing the Transfer button to assign the current
jog position (displayed in the Jog Pos. (mm) eld) as the

TOS Position.

Figure 5–7 TOP OF STROKE Position Setup
Screen in PRE-WELD Menu

The Move To button is used to move the head to the value
displayed in the Position (mm) eld. After pressing this
button, activate both RUN switches and wait for the
value in the Jog Pos. (mm) eld 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 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) eld or taught

by jogging the head as described in setting the TOP OF

STROKE Position.

Figure 5–8 TRIGGER Position Setup Screen in
PRE-WELD Menu

Dukane Manual Part No. 403-570-01Page 32

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 xture.

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) eld by direct
entry or through the Teach Position button. Optionally,
the Thrust Sense option can be enabled, in which the

head will rst 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 (%) eld. The

Timeout (s) eld sets a time limit between the arrival at

the Position (mm) distance and the point of reaching the
thrust sensing level.

Section 5 - Touch Screen Menus

Figure 5–9 Park Pickup Setup Screen in PRE-WELD
Menu

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 eld. Alternatively, this

orientation can be “taught” by rst 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) eld, 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.) eld) 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.

Figure 5–10 Pre-Spin Orientation Setup Screen in
PRE-WELD Menu

Transfer Button f

The transfer icon should only be used when
visually aligning the pre–spin orientation.
The value displayed in the Jog (Deg.) cell
has to be transferred to the Pre-Spin data

eld.

IMPORTANT

You must select the RUN
mode to test any of the



setups. Both RUN switches
must then be activated
simultaneously.

Dukane Manual Part No. 403-570-01

Page 33

Dual Servo Spin Welder User’s Manual

The Move To button is used to rotate the tool to the value
displayed in the Position (Deg.) eld. After pressing this
button, activate both RUN switches and wait for the

value in the Jog Pos. (Deg.) eld to match the Position

(Deg.) value

WELD Setup

The WELD 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).

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 dened in the PRE-

WELD tab. If Torque Trigger is ON, the weld starts

when the desired spin torque threshold is exceeded (see
Torque Trigger Option below).

Figure 5–11 WELD Main Setup Screen

Time Method

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 species the weld

duration in seconds. Below this entry, a minimum 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

species the spin tool speed, which is constant during
the weld until the start of deceleration. The Dir. eld
species the spin direction. The DONE button causes a

return to the main WELD tab screen.

Figure 5–12 Weld Parameters Screen for Time
Method

Dukane Manual Part No. 403-570-01Page 34

Rotation Method

In this method, the weld duration is controlled by

completing a specied number of spin revolutions. The

Weld Parameters button is used to enter the settings

shown in Figure 5-13. The Weld Rotations eld species

the number of weld revolutions. The actual number
of weld rotations as reported on the RUN screen after
the weld will be larger than the number entered in this

eld and depends on the deceleration and whether nal
orientation is enabled (see Orientation Option below).

The VERT Speed (mm/s), SPIN RPM, and Dir. elds
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 specied absolute or collapse distance. The

Weld Parameters button is used to enter the settings

shown in Figure 5-14. The Vertical (mm) eld species

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 dened 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) eld 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. elds are the

same as in the Time Method. The DONE button causes
a return to the main WELD tab screen.

Section 5 - Touch Screen Menus

Figure 5–13 Weld Parameters Screen for Rotation
Method

Figure 5–14 Weld Parameters Screen for Distance
Method with Collapse Switch Selection

Dukane Manual Part No. 403-570-01

Figure 5–15 Weld Parameters Screen for Distance
Method with Absolute Switch Selection

Page 35

Dual Servo Spin Welder User’s Manual

Energy Method

In this method, weld duration is controlled by the
amount of energy input into the weld joint as determined
by the spin torque and angular rotation. The welder will
maintain a constant spin speed until the programmed
energy is produced. Then the tool will decelerate and
stop. The Weld Parameters button is used to enter the

settings shown in Figure 5-16. The Energy (J) eld
species the weld energy in Joules. As a safety measure,

using the Energy Method requires that the Weld Time

Process Limit be enabled (To set this limit, refer to the

Process Limits description in the POST-WELD menu

later in this manual.). 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. elds are the same as in the Time

Method. Press DONE to return to the main WELD tab
screen.

Figure 5–16 Weld Parameters Screen for Energy
Method

WELD OPTIONS

Several weld options are available, any combination of
which may be enabled simultaneously.

Orientation Option

With this option you can specify the upper tool’s angular
stopping orientation at the end of the weld. To enable it,
press the Orientation button and then the Enable box

on the screen shown in Figure 5-17. The nal weld
orientation is dened in the Weld eld. Two methods set
this value: 1) direct numeric entry into the Weld eld,
or 2) visual alignment by jogging the spin tool to the

desired orientation. To jog the spin tool, 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
shown in the Jog Pos. (Deg.) box. Once the head is in
the desired orientation, use the Transfer arrow button
to set this value as the nal 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 stops moving.
Press DONE to return to the main WELD tab screen.

Figure 5–17 Weld Orientation Option Screen

Dukane Manual Part No. 403-570-01Page 36

Torque Trigger Option

This option species a torque level to sense when the

upper and lower parts make contact. Prior to contact,
the motor is spinning the tool in the air using a very low
amount torque. At contact, there is an increase in the
torque required to maintain 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.) eld species the

torque level at which the weld will start. The Timeout

(s) value species 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

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:

WELD

tab screen.

Section 5 - Touch Screen Menus

Figure 5–18 Weld Torque Trigger Option Screen

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 xture (refer to

TOOLS, SYSTEM SETUP tab menu).

4. Press the RUN button.

5. Run a “dry” cycle (i.e. without parts) by acti-

vating both RUN switches until the spin motor
stops.

6. Read the Peak Torque (%) value on the

RUN

screen. This value represents the torque re­quired to keep the tool spinning in the air.

7. Repeat Steps 5 and 6 several times to determine

the largest torque value.

8. Enable the Torque Trigger Option and set the

Torque (% of max.) eld to be slightly larger (at

least 2%) than the number from the previous

step.

Dukane Manual Part No. 403-570-01

Page 37

Dual Servo Spin Welder User’s 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-y 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.)

eld on the screen. The Max. Torque value is 5% larger

than the Target Torque. If the measured torque exceeds
the 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) eld on the Weld Parameters

screen (in the WELD tab). The Timeout (s) eld species

the maximum weld time before the machine aborts the
cycle and reports an error.

The actual spin torque prole 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 specied 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.

Figure 5–19 Weld Constant Torque Option Screen

Figure 5–20 Graph of Vertical Spin Speed vs. Spin

Torque for Constant Torque Option

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 solidies, beginning

when the spin tool stops. Pressing the Hold Setup button

Figure 5–21 POST-WELD Main Setup Screen

Dukane Manual Part No. 403-570-01Page 38

changes the display to the screen shown in Figure 5-

22. The MODE switch species if the Hold phase will

be controlled by traveling a specied Distance or for a
specied amount of Time.

With Distance MODE selected as shown in Figure 5­22, the parameters for Hold motion are specied in the
elds on the right and are divided into two sections:

DYNAMIC and STATIC. During the Hold, the press will

rst complete the DYNAMIC phase, then the STATIC
phase. In the DYNAMIC phase, the press moves

vertically at the speed specied in
a distance specied in

Collapse (mm)

Speed (mm/s)

. In the STATIC

to

phase, the press will maintain its position for the time

specied 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.

Section 5 - Touch Screen Menus

Figure 5–22 Hold Setup Screen for Distance MODE

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 nal 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 specied 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

response 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 (%) eld 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
the

DYNAMIC

section.

Speed (mm/s)

eld in

Figure 5–23 Hold Setup Screen for Time MODE

Dukane Manual Part No. 403-570-01

Figure 5–24 Graph of Vertical Speed vs. Vertical
Torque for Constant Thrust Option

Page 39

Dual Servo Spin Welder User’s Manual

Part Tests

The Part Tests section is used to dene limits for the

weld proocess and welder behavior for cases where the
process is outside the limits.

The Process Limits button is used to enter limits for

weld process results as shown in Figures 5-25, 5-26,

and 5-27. The following limits are available:

1. Weld Time (s)

2. Weld Rotations

3. Orientation (Deg.)

4. Weld Energy (J)

5. Peak RPM

6. Peak Torque (% of max.)

7. Peak Thrust (% of max.)

8. Cycle Time (s)

9. Vertical Weld End (mm)

10. Hold Collapse (mm)

11. Hold End Position (mm)

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 additional limits, and
the DONE button causes the screen to return to the

POST-WELD main menu.

Figure 5–25 Process Limit Denitions Screen 1 of 3

Figure 5–26 Process Limit Denitions Screen 2 of 3

Figure 5–27 Process Limit Denitions Screen 3 of 3

Dukane Manual Part No. 403-570-01Page 40

The bottom right corner of the POST-WELD screen
contains controls for setting machine behavior when
an out-of-limit condition occurs. The Latch on Failure

button species if the out-of-limit condition will require

an acknowledgement from the user before allowing the
next 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
corner of the screen controls two aspects of machine

function. The rst function is to determine if a 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:

Section 5 - Touch Screen Menus

Figure 5–28 RUN Screen with PART TEST FAILED
Button

• 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 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 eld on the

RUN screen. If the switch is set to Suspect, the Limits

eld will display S if the process was outside the limits.
If it is set to Bad (Abort), the Limits eld 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. 403-570-01

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Dual Servo Spin Welder User’s Manual

TOOLS Menu

SELECT SETUP Tab

Pressing the TOOLS button displays the rst tab
labeled SELECT SETUP. This contains eight buttons

for selecting a setup le as shown in Figure 5–29. The

Machine Cycle Count in the lower right corner is the

total number 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 for

exporting the graph data for the last weld.

Figure 5–29 SELECT SETUP Screen in TOOLS Menu

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 nished.

Copy Setup copies the values of the currently loaded

setup le to the setup le specied. To copy a setup,

press the Destination Setup ID button, enter the desired

number, then press the COPY button. Press the DONE

button when nished.

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. elds can be populated with

tool identication numbers. The Column Position (mm)

Figure 5–30 UTILITIES Screen in TOOLS Menu

Figure 5–31 Record Other Machine Setetings

Screen in UTILITIES Menu

Dukane Manual Part No. 403-570-01Page 42

eld designates the position of the thruster (part of the
welder surrounded by sheet metal covers) relative to
the column as indicated by the scale afxed to the right

side of the column and a white line printed on the rear
of the welder. Once these settings are entered, pressing
the DONE button causes a return to the main UTILITIES
screen, where a 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 prole 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 le.

Section 5 - Touch Screen Menus

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, rst press the

VERTICAL TRAVEL LOWER LIMIT button. Then press

the Initialize button shown on the screen in Figure 5-33,
which will cause the stop block to move all the way

down, which takes 1 minute as indicated by a ashing

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

Figure 5–32 SYSTEM SETUP Tab in TOOLS

Figure 5–33 Vertical Lower Limit Setup Screen

with Initialize Button

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Dual Servo Spin Welder User’s Manual

[.15 in.] above tooling contact, if possible) and press

the Set Position button. The stop block will be moved
up, and a ashing circle will appear next to the DOWN
button when this process is complete, indicating that
the proximity switch is active. Press the DONE 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

prole 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 speed. It is displayed in graphical format

in the Utility and can be exported to an ASCII le.

Pressing the button toggles between On and Off states.
The time required to transfer the data for this option

can be signicant (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.

Figure 5–34 Vertical Lower Limit Setup Screen
with Set Position Button

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.

Dukane Manual Part No. 403-570-01Page 44

The Home Offset (Deg.) eld is used to specify an angular

RUN

SETUP

TOOLS

SELECT

SETUP

SYSTEM

SETUP

UTILITIES

Set Password

WELD

POST­WELD

PRE-

WELD

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 dened
relative to it. Unless a specic situation requires a non-

zero offset, it is most convenient to retain the factory
default value.

The Set Password button is 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.

Section 5 - Touch Screen Menus

Figure 5–35 Password-Protected Screens and
Menus

The buttons English, French, Czech, and German set
the active language on the welder. When one of these
buttons is pressed, the menu language changes to the
selected language and remains in effect while the welder
is powered up. To preserve the language selection
between power cycles, press the Save Language
Select button.

The Software Info button displys a screen with software

revisions of the welder components as shown in Figure

5-36.

Figure 5–36 Welder Software Information

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Dual Servo Spin Welder User’s 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 1 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, rst enter a numeric

value. Then press the corresponding button associ-

ated with that value. For example, 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.

Figure 5-37 Touch Screen - Time and Date 1

Figure 5-38 Touch Screen - Time and Date 2

Figure 5-39 Touch Screen - Time and Date 3

Dukane Manual Part No. 403-570-01Page 46

Section 5 - Touch Screen Menus

Parameter Value Range

The minimum and maximum values of the welding
parameters are listed in Table 5-I.

Screen Parameter Name Min.Value Max.Value Resolution Units

SETUP>

PRE-WELD

TOOL Inertia

0

TOOL Weight 0 25.0 0.1 kg

SPIN Decel. 25 200 1 %

TOP OF STROKE Position 0 140.00 0.01 mm

TRIGGER Position 1.00 140.00 0.01 mm

Part Pickup Position 1.00 140.00 0.01 mm

Part Pickup Thrust 1 100 1 %

Part Pickup Timeout 1 60 1 sec.

Pre-Spin Orientation 0 359.9 0.1 deg.

Weld Time/

Weld Rotations/

Weld Distance (Vertical) /

Energy

0.01 50000 0.01

3000 (SVT012VR)

780 (SVT032VR)

160 (SVT042VR)

1 kg* cm²

sec./

rev./

mm/

Joules

SETUP>

WELD

SETUP>

POST-WELD

TOOLS>

SYSTEM

SETUP

VERT. Speed .01 100.00 0.01 mm/s

SPIN RPM

5

Weld Orientation 0 359.9 0.1 deg.

Trigger Torque

Torque Trigger Timeout 1 60 1 sec.

Constant Torque 1 100 1 %

Constant Torque Timeout 1 60 1 sec.

Hold Speed .01 100 0.01 mm/s

Hold Move Time/

Hold Collapse

Hold Dwell Time 0 100.00 0.01 sec.

Hold Constant Thrust 1 100 1 %

Home Offset 0 359.9 0.1 deg

1

0 140.00 0.01

750 (SVT012VR)

3000 (SVT032VR)

4000 (SVT042VR)

100

1 RPM

1 %

sec./

mm

Table 5–I Welding Parameters

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Dukane Manual Part No. 403-570-01Page 48

Section 6 - Machine Operation

SECTION 6

Machine Operation

Machine Setup..............................................51

Starting a Weld Cycle ...................................54

Stopping a Weld Cycle .................................55

Setup Sheet ............................................ 55-56

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Dukane Manual Part No. 403-570-01Page 50

Section 6 - Machine Operation

ABOR

T

PO

W

ER

IN CYCLE

Tw

i

st to Reset

Tw

ist to Reset

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 3–4) 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 dimensions are given in Figure 3-2. The slot in

the hub is intended to accept a ¼-inch standard dowel
pin assembled to the upper tool for repeatable mounting

orientation. Place the lower xture 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 t.

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.

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 inict­ing serious injury. Never
attempt to retrieve a part
from a spinning tool head.
A l w a y s w e a r a
f a c e s h i e l d w h e n
operating the Dual Servo
Spin Welder. Be extreme­ly careful not to let long
sleeves, necklaces or long
hair become entan g led
in the Dua l Ser vo Spin
Welder during operation.

Always turn machine power
OFF when instalaling or
removing th e spin tool.

Figure 6–1 Setting and Resetting the E–Stop

Dukane Manual Part No. 403-570-01

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Dual Servo Spin Welder User’s 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

WAIT

… indicator above it disappears.

PLEASE

8. Initialize (Home) Welder

The touch screen will now instruct you to

RUN SWITCHES to reset machine

in Figure 5–1. Once the switches are activated, both
servos will rst move to their respective home positions
(corresponding to internal encoder reference pulses
in each servo). Then the spin motor will rotate to the
programmed nal weld orientation set in the SETUP

> WELD tab > Orientation > Weld eld (Figure 5-17),
and the press will move to position set in the SETUP >

PRE-WELD tab > TOP OF STROKE Position > Position
(mm) eld (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.

Activate both

. This is illustrated

9. Align Lower Fixture with Spin

Tool

Place a set of parts in the upper tool and lower xture.

Navigate to the SETUP > 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 xture 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 nished, press the DONE
button and remove the parts.

Dukane Manual Part No. 403-570-01Page 52

Since the welder press force is limited in jog mode for
safety purposes, the machine will disable the servos

and report an error (

OR Vertical servo runaway detected

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).

Fault: Jog thrust limit exceeded

.) if the press is

10. Set Vertical Travel Lower Limit
Position

To protect tooling, set the vertical press travel limit
using the following steps :

1. Navigate to TOOLS > SYSTEM SETUP tab and press
the VERTICAL TRAVEL LOWER LIMIT button.

2. Press the Initialize button and wait 1 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.

Section 6 - Machine Operation

4. Press the Set Position button, and wait until a ashing
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 > 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. 403-570-01

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Dual Servo Spin Welder User’s 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 rst (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 indicated by
the smiley face in the upper left corner of the screen.

If a frowning face appears instead, it signies 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 (dened in SETUP > PRE-TRIGGER tab >

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 dened 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
appears 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.

Dukane Manual Part No. 403-570-01Page 54

Stopping a Weld
Cycle

During normal operation, the cycle stops automatically

when the specied weld and hold phases are completed

and the press returns to the top-of-stroke position. 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.

Section 6 - Machine Operation

Dukane Manual Part No. 403-570-01

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Dual Servo Spin Welder User’s Manual

DUAL SERVO SPIN WELDER - SETUP SHEET

A

PPLICATION

M

ACHINE MODEL

SVT0___2VR

D

ATE

M

ACHINE SETUP NUMBER

TOUCH SCREEN SETTING VALUE

TOOL I

NERTIA (KG*CM

^2)

TOOL W

EIGHT (KG

)

SPIN D

ECEL

. (%)

VAC. S

ENSE

ON  OFF

TOOL S

ETUP

P

ART PRESENT

ON  OFF

TOP OF STROKE P

OSITION

P

OSITION (MM

)

TRIGGER P

OSITION

P

OSITION (MM

)

E

NABLE

P

OSITION (MM

)

ON  OFF

P

ART

P

ICKUP

T

HRUST SENSE

T

HRUST

(%) T

IMEOUT (S

)

ON  OFF

SETUP >
PRE­WELD

OPTIONS

PRE-S

PIN ORIENT

PRE-S

PIN

ON  OFF

METHOD (T

IME

, R

OTATION

, D

ISTANCE

, E

NERGY

)

TIME  ROT  DIST  ENERGY

W

ELD TIME (S

) / W

ELD ROTATIONS

/ V

ERTICAL (MM

) / E

NERGY

(J)

C

OLLAPSE

/ A

BSOLUTE (DISTANCE METHOD ONLY

)

COLLAPSE  ABSOLUTE

VERT. S

PEED (MM/S

)

SPIN RPM

W

ELD

P

ARAMETERS

DIR.

CW  CCW

O

RIENTATION

W

ELD

ON  OFF

T

ORQUE TRIGGER

T

ORQUE

(%

OF MAX

.) T

IMEOUT (S

)

ON  OFF

SETUP >
WELD

OPTIONS

C

ONSTANT TORQUE

T

ORQUE

(%

OF MAX

.) T

IMEOUT (S

)

ON  OFF

MODE (P

OSITION

, T

IME

)

P

OSITION

 T

IME

S

PEED (MM/S

)

M

OVE TIME (S

) / C

OLLAPSE (MM

)

D

WELL TIME (S

)

H

OLD SETUP

C

ONSTANT THRUST

T

HRUST

(%)

ON  OFF

W

ELD TIME (S

)

W

ELD ROTATIONS

O

RIENTATION (DEG

.)

W

ELD ENERGY

(J)

P

EAK

RPM

P

EAK TORQUE

(%

OF MAX

.)

P

EAK THRUST

(%

OF MAX

.)

C

YCLE TIME (S

)

V

ERTICAL WELD END (MM

)

H

OLD COLLAPSE (MM

)

P

ROCESS LIMITS

…

H

OLD END POSITION (MM

)

LOWER LIMIT

UPPER LIMIT

L

ATCH ON FAILURE

ON  OFF

SETUP >
POST­WELD

F

AILURE SWITCH (SUSPECT

/ BAD) S

USPECT



B

AD

VERTICAL TRAVEL LOWER LIMIT L

IMIT POS

. (MM)

TOOLS >
SYSTEM

H

OME OFFSET (DEG

.)

Dukane Manual Part No. 403-570-01Page 56

Section 7 - Optimizing Performance

SECTION 7

Optimizing Performance

Spin Welding Process ..................................59

Material Considerations ................................59

Control Parameters ......................................60

Surface Speed (RPM) ......................................... 60

Press (Axial) Speed ............................................62

Weld Depth .........................................................62

Hold .....................................................................63

Part Size .......................................................63

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Dukane Manual Part No. 403-570-01Page 58

Spin Welding Process

The formal denition of spin welding is “An assembly
process in which thermoplastic parts with rotationally–

symmetric mating surfaces are joined together under
pressure using unidirectional circular motion. The heat
generated 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 ve distinct

phases. In Phase I, the rotational friction generates heat.

Frictional heating is intensied 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 surface 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.

Section 7 - Optimizing Performance

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–eld

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 ow

into the undercut, creating a mechanical union.

Dukane Manual Part No. 403-570-01

Page 59

Dual Servo Spin Welder User’s Manual

Material ller 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.
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.

The following sections are presented for informational
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.

NOTE

Common hygroscopic thermoplatics:
ABS/Polycarbonate (Cycoloy)
Polyoxymethylene (Acetal, Delrin)
Polyamides (Nylon, Zytel)
Polycarbonate (Lexan)
Polycarbonate/Polyester (Xenoy)
Polysulfone (Udel)

Surface Speed

For a xed rotational spin speed (RPM), linear
surface speed increases with weld joint diameter. For
a xed 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 sufcient melting. If the speed is too high,

excessive heat in the joint could result in material
degradation or reduction in viscosity leading to

material ow 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, such as 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

Dukane Manual Part No. 403-570-01Page 60

2000

3000

4000

0

1000

1 2 4 6 8 10 123

RPM

Average Weld Diameter (inch)

D

Spin Speed (rev/min)

v = 240

v = 360

v = 480

v = 120

v = 600

v = 720

v = 960 in/sec

v = 840

120 in/sec = 10 ft/sec — 3 m/sec
240 in/sec = 20 ft/sec — 6 m/sec
360 in/sec = 30 ft/sec — 9 m/sec
480 in/sec = 40 ft/sec — 12 m/sec
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
960 in/sec = 80 ft/sec — 24 m/sec

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:

Section 7 - Optimizing Performance

RPM =

60 v
π D

where

v is 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.

Figure 7–1 Dependence of Spin Speed on the Weld Diameter for Selected Surface Speeds

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Press (Axial) Speed

The press speed affects the amount of contact
pressure between the parts being welded, which is
required to generate frictional heat. The larger the
speed, the larger the rate of heat rise. In combination
with the surface speed, press speed must 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 > 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 specic weld penetration.
Ideally, the weld is sufciently deep to produce a

strong, hermetically sealed assembly. An excessive

depth may lead to the formation of ash (material

that is ejected from the joint area during the weld

and adheres to the assembly), the drawing out of
reinforcing ller material and realignment of the

interchain bonds in the weld plane resulting in a
weak axial weld joint, and possibly part distortion.

Dukane Manual Part No. 403-570-01Page 62

Since weld depth affects the joint strength and the amount

of ash generated, it is important to design the weld joint

properly to meet both requirements simultaneously. The

incorporation of ash trap features is recommended to

produce acceptable appearance without 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.

Section 7 - Optimizing Performance

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 (>3000) is required.

Please contact the Dukane Applications Laboratory (see
Chapter 11) for a recommendation concerning your specic

application.

Weld Diameter

Range (in)

up to 2.0 SVT042VR 4000

.5 to 4 SVT032VR 3000

4 to 7 SVT012VR 750

Machine

Model

Peak RPM

Table 7- I

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Dukane Manual Part No. 403-570-01Page 64

Section 8 - Welder Data Export Software

SECTION 8

Welder Data Export Software

Introduction ...................................................67

Hardware and Software Requirements ........67

Installation, Startup

and Cable Connections ..........................67

Part Data ......................................................68

Prole Graphs...............................................69

Servo and Debug..........................................70

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Dukane Manual Part No. 403-570-01Page 66

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 trou­bleshooting.

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.

Section 8 - Welder Data Export Software

Installation,
Startup, and Cable
Connections

To install the program, Run the setup.exe le located 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 -> All Programs -> Dukane -> 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 com­munications settings should be as follows:

PARAMETER VALUE

Baud Rate 57600

Data Bits 8

Parity NONE

Stop Bits 1

Flow Control Xon/ Xoff

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Dual Servo Spin Welder User’s 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 elds given in the order as

follows:

1. Part number (ID)

2. Test result number

3. Test result symbol

4. Date

5. Time

6. Weld time (sec.)

7. 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 thrust (% 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.

Figure 8–1 Utility Startup Screen

WRITE TO FILE

Writes parts data from the screen to a le on the

computer. After pressing this button, enter the name

of the le where to store the data. Add a .txt or .csv
extension to the end of the le name as the gener­ated le is in ASCII format. Saving the le with a

.csv extension will allow it to be opened directly
with Microsoft Excel™.

Dukane Manual Part No. 403-570-01Page 68

File Write

Sets the write behavior for an existing le. Write Over
overwrites an existing le, while Add On appends data
to the end of the le.

Incoming Data

This indicator will ash when data is being received

from the welder.

EXIT

Exits program.

Prole Graphs

The

PROFILE GRAPHS

contains numerical and graphical representations of the

following weld parameter proles with respect to time

for the last cycle:

1. Spin Position (rev.)

tab, shown in Figure 8-2,

Section 8 - Welder Data Export Software

2. Torque (% of max.) - spin motor torque

3. Vertical Distance (mm)

4. Thrust (% of max.) - vertical actuator thrust

5. Vertical Speed (mm/s)

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 pressing the

DATA

button in the Utilities screen (see Figure 5-30).

EXPORT LAST WELD GRAPH

Plot Data

The prole data is displayed in this box with comma­separated values. The rst 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 prole 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.

Figure 8–2 PROFILE GRAPHS Tab

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Dual Servo Spin Welder User’s 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 le. Add a .txt or .csv
extension to the end of the le name as the
generated le is in ASCII format.

Servo and Debug

The

SERVO PARAMETERS

ability to import a servo tuning database le. 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 modied 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.

tab provides the

The

DEBUG

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.

tab is used to retrieve troubleshooting

Dukane Manual Part No. 403-570-01Page 70

Section 9 - Troubleshooting

SECTION 9

Troubleshooting

Welding Process ...........................................73

Material Choice ...................................................73

Parameter Effects ...............................................73

Troubleshooting ..................................................73

Welder ..........................................................74

Mechanical ..........................................................74

Electrical Power ..................................................74

Base Interface Cable........................................... 74

Machine Display Messages ................................74

Table 9–I Welding Process

Troubleshooting .............................75

Table 9–II Machine Display Messages ... 76-79

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Dukane Manual Part No. 403-570-01Page 72

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

coefcient 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

Insufcient 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.

Section 9 - Troubleshooting

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 sufcient frictional heating. Excessive axial

speed may cause one part to scrape away part of the

surface and produce a lot of ash but insufcient melt

volume.

Weld Depth

Insufcient 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

Insufcient 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.

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Dual Servo Spin Welder User’s Manual

Welder

Mechanical

The part xture should be securely mounted

perpendicular to, and centered under the spin axis.

Electrical Power

Make sure the AC power cord is plugged in to a 240

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.

Dukane Manual Part No. 403-570-01Page 74

Section 9 - Troubleshooting

Table 9–I Welding Process Troubleshooting

Problem Symptom Possible Cause Recommended Solution

Overwelding

Underwelding

Nonuniform or
inconsistent
weld joints

Excessive weld ash

Welded assembly
dimensions are too
small

Low strength weld

Welded assembly
dimensions are too
large

Excessive weld ash

Low weld strength

Failure when leak
tested

Part failure in service

Weld Time or Distance are too large Reduce Weld Time or Distance

Incorrect ash trap design Evaluate and correct ash trap design

Weld Time or Distance are too small Increase Weld Time or Distance

Material difcult to weld due to low friction
coefcient

Warped parts Check part dimensions

Uneven weld interface Check molding process conditions

Fixture and part are not parallel Level xture where necessary

Poor alignment of parts in tool and/or

xture

Insufcient xture support Check for parts shifting during welding

Part walls exing during weld Redesign parts with reinforcing ribs and/or tongue-

Excessive ller or uneven distribution Reduce amount of ller

Degrease joint interface to remove mold release
agent

Consider changing material (i.e. avoid PTFE)

Check that tooling is true to table

Change part or tool dimensions

Improve part tolerance due to cavity

Provide features in parts for rotational driving (i.e.
drive ribs or cavities)

and-groove joints

Final part
orientation
different from
programmed
orientation

Parts not aligned
properly

Improve processing conditions to ensure even

distribution of ller

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 xture Ensure tooling does not allow excessive play

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Dual Servo Spin Welder User’s Manual

Table 9-II Machine Display Messages

Message Description Cause Possible Solution

Instructions

Activate both RUN
SWITCHES to reset
machine

Activate both RUN
SWITCHES to reset
machine after all motion
stops

Resetting of machine at
startup or recovery requires
the activation of both optical
switches on base.

Resetting of machine at
startup or recovery must be
initiated when the spin tool
and press are stationary.

- -

- -

Faults

Axis move aborted

Home index edge not
found

Improper servo operation
request

Jog thrust limit exceeded
OR vertical servo runaway
detected

Operator E-Stop E-stop activated Operator pressed E-stop switch Reset E-stop switch then reset machine

Part pickup not detected

Part presence not detected

RUN SWITCH(ES)
released too soon

Servo CPU no Idle before
Run

Servo CPU program error Motor controller error Internal machine error Contact DUKANE service

Servo database import
failed

Servo param select by
inertia failed

Slide In timeout

Slide Out timeout see Slide In timeout fault
Spin aborted Weld cycle was aborted Internal machine error Contact DUKANE service

Spin at travel limit

Expected servo move was
not completed

Spin or vertical servo motor
internal index pulse(s) not
detected

Servo controller error Internal machine error Contact DUKANE service

Press thrust (force) was
exceeded during jogging
operations OR servo
system entered runaway
condition

Sensor for upper tool
vacuum not activated when
expected

Part presence sensor did
not detect part

Optical switches on base
were de-activated during
weld cycle

Motor controller error Internal machine error Contact DUKANE service

Servo tuning database
import failed

Servo tuning data not
found for the tooling inertia
entered

Slide did not move to the
commanded position within
the allowable time

Number of servo motor
rotations has exceeded
controller counting
capability

Internal machine error

Internal machine error Contact DUKANE service

1. Press is jogged in a way to
produce a force on the parts
larger than allowed in jog
mode (most common cause)

2. Servo system feedback is
malfunctioning

1. No part present to pick up

2. Loss of vacuum between part
and tool

1. Part not present

2. Problem with sensor

Switches were released after weld
cycle started but before the spin
motor stopped

1. Import procedure problem

2. Cable problem

3. Machine component failure

1. Tooling inertia entered is
outside allowable range

2. Servo tuning database is
missing

1. Air pressure to slide too low

2. Slide limit switch improperly
positioned

3. Slide jammed

Weld time or number of rotations
too large

1. Check for obstructions to motion
outside welder

2. Contact DUKANE service

1. Prevent press from applying a large
force on the parts in jog mode

2. Contact DUKANE service

1. Ensure part is present for pickup

2. Check vacuum between part and tool
(line connections, vacuum generator,
tool wear)

1. Ensure part is present

2. Troubleshoot sensing components

Once weld cycle is started, ensure switches
remain activated until spin motor stops (i.e.
at beginning of hold phase)

1. Contact DUKANE for import
procedure

2. Check that the correct cable is used
and that it is securely connected

3. Contact DUKANE service

1. Enter tooling inertia within limits stated
in this manual

2. Contact DUKANE regarding importing
servo tuning database

1. Increase air pressure

2. Adjust slide switch position

3. Ensure slide can move freely

Reduce weld time, distance, or number of
rotations

Dukane Manual Part No. 403-570-01Page 76

Table 9-II Machine Display Messages (continued)

Message Description Cause Possible Solution

Spin motor not on

Spin servo amplier does

not power up

Internal machine error Contact DUKANE service

Section 9 - Troubleshooting

Spin servo amplier faulted

Spin servo tracking error

Spin weld axis aborted

Timeout on servo CPU
Thread 1(thrd1)

Timeout on servo response
to command start

Vertical at travel limit

Vertical motor not on

Vertical servo amplier

faulted

Vertical servo tracking error

Vertical weld axis aborted

Weld trigger position is
below vertical travel lower
limit

1. Excessive spin deceleration

2. Excessive press weld or hold

There is a problem with the

spin servo amplier

The spin servo motor
was not able to execute
the spinning motion
programmed in the setup

Expected spin servo move
was not completed

Motor controller error Internal machine error Contact DUKANE service

Servo system
communication error

Press travel distance
exceeded controller
counting capability

Vertivcal servo amplier

does not power up

There is a problem with the

vetical servo amplier

The vertical servo actuator
was not able to execute the
press motion programmed
in the setup

Expected vertical servo
move was not completed

Cycle will not start since the
programmed press travel is
larger than the set limit

speed

3. Amplier disabled due to

excessive temperature

4. Amplier failed

1. Excessive press weld or hold
speed(s)

2. Excessive spin deceleration

3. Joint weld diameter too large

4. Improper tuning

Internal machine error

Internal machine error Contact DUKANE service

Press travel too large

Internal machine error Contact DUKANE service

1. Amplier disabled due to

excessive temperature

2. Amplier failed

Excessive press weld or hold speed Reduce speed(s)

Internal machine error

1. Vertical travel lower limit set
too high

2. Trigger position too large

1. Reduce deceleration

2. Reduce speed(s)

3. a) Reduce machine duty cycle
b) Ensure temperature around
machine is within operational limits

4. Contact DUKANE service

1. Reduce speed(s)

2. Reduce deceleration

3. Use welder model with larger spin

torque capability

4. Ensure correct tool inertia is entered

in touch screen

1. Check for obstructions to motion

outside welder

2. Contact DUKANE service

Reduce weld time / distance / number of
rotations, or hold distance

1. a) Reduce machine duty cycle

b) Ensure temperature around
machine is within operational limits

2. Contact DUKANE service

1. Check for obstructions to motion

outside welder

2. Contact DUKANE service

1. Lower vertical travel lower limit, if

possible.

2. Decrease Trigger position

Dukane Manual Part No. 403-570-01

Table 9-II continued. . .

Page 77

Dual Servo Spin Welder User’s Manual

Table 9-II Machine Display Messages (continued)

Message Description Cause Possible Solution

Errors

Axis stopped before weld
end

Spin stop before weld start Servo controller error Internal machine error Contact DUKANE service

Timeout on nding vertical

lower limit position

Timeout on torque sense

Timeout on User Upper
Part vacuum detect

Timeout on vertical
distance in constant torque
mode

Vertical stop before starting
spin

Vertical servo contact
sensing failed

Weld aborted by CYCLE
TIME limit

Weld aborted by ROTATE
limit

Weld aborted by RPM limit

Weld aborted by THRUST
limit

Weld aborted by TORQUE
limit

Weld aborted by vertical
servo stop

Weld duration too short

Weld ended at TIME limit

Motion on spin or vertical
axes stopped before weld
ended

Moving the vertical lower
limit up to desired position
failed

The torque trigger was
not detected within the
allowable time

Vacuum was not detected
within timeout

Programmed weld distance
not reached within the

specied time with Constant

Torque option enabled
Vertical (press) motion

stopped before spin motion
started

Welder did not detect
programmed thrust level

Weld cycle stopped
because cycle time
exceeded programmed
process limit

Weld cycle stopped
because number of
revolutions exceeded
programmed process limit

Weld cycle stopped
because motor speed
was outside programmed
process limit

Weld cycle stopped
because weld thrust was
outside programmed
process limits

Weld cycle stopped
because motor torque
was outside programmed
process limits

Vertical (press) motion
stopped before spin motion
weld was complete

Weld duration generated by
programmed parameters is
too short

Weld cycle stopped
because weld time was
outside programmed
process limits

Internal machine error

Limit mechanism malfunctioning Contact DUKANE service

1. Torque trigger value set too
high

2. Parts not loaded

1. Insufcient vacuum

2. Vacuum sensor threshold set
too high

3. Improper part pickup position

1. Timeout too short

2. Constant Torque maximum
vertical speed set too low

Internal machine error

With Part Pickup option enabled
with Thrust Sense, part contact was
not detected

1. Weld process problem

2. Limits too narrow for weld
process

1. Weld process problem

2. Limits too narrow for weld
process

1. Weld process problem

2. Limits too narrow for weld
process

1. Weld process problem

2. Limits too narrow for weld
process

1. Weld process problem

2. Limits too narrow for weld
process

Excessive press weld speed Reduce press weld speed

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. Weld process problem

2. Limits too narrow for weld
process

1. Check for obstructions to motion
outside welder

2. Contact DUKANE service

1. Reduce torque trigger value

2. Ensure parts are properly loaded

1. Increase vacuum capability

2. Decrease required vacuum sensing
level

3. Adjust Position (mm) value in Part
Pickup option

1. Increase timeout value

2. Increase value of VERT. Max (mm/s)
setting in Weld Parameters screen in
setup menu

1. Check for obstructions to motion
outside welder

2. Contact DUKANE service

1. Ensure parts are loaded properly

2. Increase Timeout (s) value

3. Check the Position (mm) value – it
should be set slightly (<5mm) above
expected part contact

1. Check parts to be welded, xturing,

etc.

2. If practical, widen process limit
window or adjust setup parameters

1. Check parts to be welded, xturing,

etc.

2. If practical, widen process limit
window or adjust setup parameters

1. Check parts to be welded, xturing,

etc.

2. If practical, widen process limit
window or adjust setup parameters

1. Check parts to be welded, xturing,

etc.

2. If practical, widen process limit
window or adjust setup parameters

1. Check parts to be welded, xturing,

etc.

2. If practical, widen process limit
window or adjust setup parameters

1. Increase Weld Time, Rotations, or
Distance above the “Min.” value
indicated on the Weld Parameters
setup screen

2. Increase spin deceleration

1. Check parts to be welded, xturing,

etc.

2. If practical, widen process limit
window or adjust setup parameters

Dukane Manual Part No. 403-570-01Page 78

Table 9-II Machine Display Messages (continued)

Message Description Cause Possible Solution

Battery life limit, press
Continue

Lower limit is greater than
upper limit

Move to Top Of Stroke
before welding

Process RPM is too high

TOS to trigger distance is
too small

Vertical weld speed is too
high

Weld duration too short

Weld trigger position is
below vertical travel lower
limit.

The batteries in the PLC
and touch screen need to
be replaced

Lower process limit is
greater than Upper process
limit

Press head is not at Top of
Stroke

Programmed spin motor
weld speed is too high

Distance between Top Of
Stroke position and Trigger
position is too small

Programmed press weld
speed is too high

Weld duration generated by
programmed parameters is
too short

Cycle will not start since the
programmed press travel is
larger than the set limit

Batteries have not been replaced in
approximately 5 years

Improper process limit values
entered

Machine jogged away from Top Of
Stroke position

Programmed spin weld speed is
larger than machine capability

Trigger position is set too high or
Top Of Stroke position is set too
low

Programmed press weld speed is
larger than machine capability

1. Weld Time, Rotations, or

2. Deceleration too low

NOTE: the time for deceleration is
counted as part of the total weld
time or number of rotations

1. Vertical travel lower limit set

2. Trigger position too large

Warnings

Distance too short

too high

Section 9 - Troubleshooting

Contact DUKANE service for information
on battery replacement

Correct process limit values

Move press to Top Of Stroke position by
using the “TOP OF STROKE Position”
screen in setup menu

Reduce spin motor weld RPM

Increase Trigger position value or decrease
Top of Stroke position value

Reduce press weld speed

1. Increase Weld Time, Rotations, or

Distance above the “Min.” value
indicated on the Weld Parameters
setup screen

2. Increase spin deceleration

1. Lower vertical travel lower limit, if

possible.

2. Decrease Trigger position

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Section 10 - Maintenance

SECTION 10

Maintenance

Touch Screen Display ...................................83

AC Power Cord.............................................83

Maintenance .................................................83

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Section 10 - Maintenance

Touch Screen Display

Do not use any solvents or abrasive cleaners on the
touch screen. Apply a small amount of computer cleaner

to a soft towel rst. 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 nal 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.

CAUTION

Never use anything sharp
on the touch screen. Only

use your nger. The screen

is intended for industrial
use, but can be damaged by
scratching or puncturing.

Maintenance

Visually inspect cables once a week, and replace or
repair if necessary.

Lubricate the unpainted area on the front of the
support column as needed with conventional grease.

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Section 11 - Contact Dukane

SECTION 11

Contacting Dukane

Contacting Dukane .......................................87

Identify Equipment ..............................................87

Ultrasonics Division .............................................87

Website ...............................................................87

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Contacting Dukane

Identify Equipment

When contacting Dukane about a service–related

problem, be prepared to give the following
information:

• SVT Model number and serial number

• Any error indicators from the Touch Screen Display

• Description of the problem and steps taken to re­solve it

Some problems can be solved over the telephone,
so it is best to call from a telephone located near the
equipment.

Intelligent Assembly Solutions

Section 11 - Contact Dukane

Mailing Address: Dukane Ultrasonics

2900 Dukane Drive
St. Charles, IL 60174 USA

Phone: [phone]

Fax:

Main (630) 797- 4949

Service & Parts (630) 584- 0796

Website:

www.dukane.com/us

The website has information about our products,
processes, solutions, and technical data. Downloads are
available for many kinds of literature.

You can locate your local representative at:

www.dukane.com/us/sales/intsales.htm

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Section 12 - Specications

SECTION 12

Specications

Tooling Specications ...................................91

Machine Weight ............................................91

Power Requirements ....................................91

Operating Environment.................................91

Dimensions & 5–View Drawing ....................92

Identication Numbers ..................................93

Regulatory Agency Compliance ...................93

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Tooling Specications

220 Volt AC Socket

(NEMA 6–20R)

240 Volt AC Socket

(NEMA 6–20R)

Tooling Size

Refer to Table 5-I for maximum tooling sizes.

Machine Weight

The Dual Servo Spin Welder weighs approximately 400

lbs. (182 kg). It should be mounted on 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.

Section 12 - Specications

Power Requirements

The Dual Servo Spin Welder 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 conguration wall receptacle shown
in Figure 12–1.

Operating
Environment

Operate the Dual Servo Spin Welder within these guidelines:

Temperature: 40°F to 95°F (+5°C to +35°C)

Altitude: 4570 m (15,000 ft)

Air Particulates: Keep the welder dry.

Humidity:

Minimize exposure to moisture, dust
dirt, smoke and mold.

5% to 95% non–condensing @ +5°C to

+30°C

Figure 12–1 240V AC Single–Phase AC Receptacle

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Figure 12–2 Dual Servo Spin Welder Dimensions

NOTE: All specications are subject to change without notice. The specications listed are current at the time of publication.

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Identication Numbers

Welder Model & 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

This mark on your equipment certies that it meets the
requirements of the EU (European Union) concerning

interference causing equipment regulations. CE stands

for Conformité Europeéne (European Conformity). The

Dual Servo Spin Welder complies with the following
CE requirements.

• The EMC Directive 89/336/EEC



Section 12 - Specications

CAUTION

DO NOT make any modifica­tions to the Dual Servo Spin
Welder. The changes may re­sult in violating one or more
regulations under which this
equipment is manufactured.

• The Low Voltage Directive 73/23/EEC.

• The Machinery Directive 89/392/EEC using

EN60204–1:1993 Safety of Machinery – Elec­trical Equipment of Machines. Part 1: Specication
for General Requirements.

Effective 12/29/09:
The Machinery Directive 2006/42/EC.

EN 60204: 2006

Safety of Machinery - Electrical Equipment

of Machines Part 1: General Requirements.

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