100% digital control of all power supply functions and parameters allows for unique configurations and future upgrades or requirements. Includes digital frequency syntheses
Industry leading data acquisition rate speed of .5 ms due to advanced multi-core architecture. Increased weld accuracy and repeatability.
Digi-Trac tuning automatically tracks the resonant frequency digitally. Adjust the output frequency to match the acoustic stack (sonotrode, booster, and transducer) this is done for every weld cycle and eliminates the need to manually tune the generator.
Ultrasonic overload protection, with status indicator for ease of troubleshooting. The overload power limit is based on true RMS power output level.
Line Voltage Regulation compensates for line fluctuations assuring consistent amplitude.
Temperature Drift Compensation allows for seamless acoustic stack operation, and automatically compensates for acoustic stack temperature changes.
Patented Pulse-Width Modulation design delivers power more efficiently with substantially less stress on the electrical and acoustic components for superior performance reliability and extended life.
Linear Ramp Soft-start algorithm allows the acoustic stack to be brought to operating amplitude smoothly, minimizing start-up surges and abnormal stress to stack and power supply.
Load Regulation provides constant ultrasound amplitude automatically regardless of the power draw. The ultrasonic output amplitude level is held to within 1% to provide weld process consistency and reduced weld cycle times.
Dukane iQ Series LE ultrasonic welding systems are an entry level machine designed for applications that require significantly less process documentation, yet are built on the robust precision mechanical platform as our full featured machines. Available in either 20 kHz or 15 kHz in power ranges from 1200 - 4800 watts. Two main models offer either Time and Energy or Time Energy and Distance. While the LE is an entry level machine advance features like Process Limits, .5 millisecond sample rate, separate Weld and Hold pressures and multiple setup recipe storage with front panel lock out come standard on all LE models.
The most technologically advanced ultrasonic weldingcontrol features available today are found in Dukane’s iQ Series equipment. Our patented, 100% digitally controlled generator, ultra-rigid press, coupled with the iQ Explorer user-interface provide superior accuracy and ease of use. The generators have new multi-core processor technology that allows them to operate at a processing rate of .5 milliseconds.
iQ Explorer’s intuitive touch-screen graphical menu structure incorporates a one-page setup screen that makes welder operation easy to learn and program. Ethernet connectivity, wireless networking, and multiple USB ports are all options for weld and graph data storage. Over 25 programmable upper and lower process limits along with reference, weld graph logic are available for weld diagnostics and process consistency.
iQ Press Features
Rugged construction using the highest quality components provides superior performance precision and reliability.
Compact, single-rail linear ball slide assembly system offers accurate positioning, stable movement, and friction-free resistance Dual pressure increases clamp force to improve melt during the weld cycle, or to provide tighter assembly during the hold cycle. Optional hydraulic slow speed available for precise, repeatable control of horn travel during the weld cycle.
178mm stroke with mechanical bottom stop adjustable in .001"(.025mm) increments
Top-of-stroke limit switch for automation application
All controls are accessible from the front for convenient set-up and operation.
Easy to use front panel position indicators with universal icons instantly show settings of position and bottom stop, and optional slow speed, pre-trigger, and end-of-weld switches
Chrome-plated column and titanium booster are standard
Internally mounted optional linear encoder saves space in multi-head and automated installation
Remote pneumatics availability offers increased flexibility in system integration
OSHA-required lockout for air supply is standard
Ergonomic base and cycle activation switches reduce operator fatigue
Status indicators in base for Power, In Cycle, and Abort clearly communicate system conditions
Twist-release emergency stop switch meets international safety standards
Press/thruster design provides systems flexibility and upgrade ability, reducing equipment investment.
Ultra-Ridged support provides reduced deflection for superior weld consistency. Column crank and gas strut assist ensures easy setup.
Column can be locked to eliminate unauthorized adjustments.
Standard style support columns available.
Weld by distance mode controls the melt collapse distance to insure that the same volume of material melts on each part so that the finished joint strength is consistent.
Weld by Position controls the finished part height to yield uniform assemblies.
All distance parameters (downstroke, trigger delay, weld, hold, absolute weld, total weld, and total stroke distances) are monitored, with upper and lower limits for bad and suspect parts to verify quality and consistency.
High quality linear optical encoder with a one-micron resolution for excellent precision and repeatability.
Power and Energy Module
Weld by energy mode delivers a specific amount of energy to the work to enhance process control.
Monitors all power and energy parameters with upper and lower limits for bad and suspect parts.