Dukane iQ Series - User Manual

Other manuals for Dukane iQ Series

Quick Start Guide30 pages

Operating Instructions4 pages

Application Note16 pages

Questions and Answers

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Lauren FieldsDec 1, 2025
Why are parts marking when using Dukane iQ?
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  Peter HunterDec 1, 2025
  Parts marking during welding with a Dukane system can occur due to several reasons. It may be caused by insufficient force during welding. Increase trigger force and weld speed. If using Match Detect, decrease the value of the parameter After Force Decreases By. If the horn heats up, check for a loose stud and tighten if necessary, or loosen and retighten the horn tip. Ensure the horn and booster are coupling well, and visually check the horn for cracks. Reduce the weld duration. High spots in the part, use of raised lettering, or improper fit of the part to the fixture can also cause marking. Check the part dimensions, the fit of the horn to the part, and the fixture for proper support. If oxide from the horn is being transferred, place polyethylene film between the horn and the part or u...
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Nathan EvansAug 23, 2025
What to do if internal components are damaged during Dukane welding?
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  Malik EvansAug 23, 2025
  If internal components of your workpiece are damaged during welding with the Dukane system, it may be due to excessive horn amplitude or exposure to ultrasound, or too much energy transmitted into the part, or components are improperly mounted. Try reducing the horn amplitude by decreasing the amplitude setting or changing to a lower gain booster, and dampen the excess horn amplitude. Also, reduce the primary weld duration and increase the horn amplitude and/or weld speed. Ensure that internal components are mounted properly and isolated from the part. Move the internal components away from areas of high energy and use an external device to dampen energy locally.
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wfischerAug 25, 2025
Why is my Dukane iQ Welding System melting the part outside the joint area?
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  meghan14Aug 25, 2025
  Melting or fracturing outside the joint area with your Dukane Welding System can occur due to sharp internal corners or thin sections. Radius all sharp corners and dampen motion for any damaged area, if possible. Excessive horn amplitude can also be a factor, so reduce the horn amplitude by decreasing the amplitude setting or changing to a lower gain booster. A long weld duration may also cause this issue; decrease the weld duration and increase the horn amplitude and/or the weld speed. Lastly, inherent part stress can contribute, so check the molding conditions, check the part design, and reduce the horn amplitude.
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Carl LiAug 26, 2025
How to fix misalignment of welded assembly in Dukane iQ Welding System?
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  Cynthia CantuAug 27, 2025
  To fix misalignment in your Dukane Welding System, consider these points: If parts are not self-aligning, design a means of alignment into the tooling or add a means of alignment to the mating part halves. If there's improper support in the fixture, redesign the fixture for proper support. For wall flexure, add ribs or gussets to the part, or add a rigid backup to a resilient fixture if large sections of urethane are deflecting. If the joint design is not properly dimensioned, re-dimension the parts. For incorrect part tolerance or poor molding, tighten the part tolerance and check the molding conditions.
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Michael WheelerAug 27, 2025
How to troubleshoot uneven welding with Dukane system?
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  Richard WilliamsAug 27, 2025
  To troubleshoot uneven welding with your Dukane system, check the following: If the part is warped, check part dimensions and molding conditions. Use a higher trigger force, increase dynamic hold distance, and increase static hold time. If the energy director varies in height, redesign it to ensure uniform height or use an interrupted energy director. Ensure parallelism between the horn, fixture, and part, and check part dimensions. If wall flexure is occurring, add ribs to the part or modify the fixture. If the knockout pin location is in the joint area, redesign the part. If there's insufficient support in the fixture, redesign it to improve support or change to a rigid fixture.
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david95Sep 23, 2025
What to do if the Dukane Welding System generator fault does not reset?
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  Megan MaloneSep 23, 2025
  The generator needs servicing.
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kennethhessSep 16, 2025
What does 'Generator Fault Peak Overload' mean on Dukane Welding System?
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  Carl LowerySep 16, 2025
  The 'Generator Fault Peak Overload' error indicates that the peak IGBT transistor current has been exceeded, typically due to a severe frequency mismatch. The fault will reset when the next weld cycle starts.
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anthonybrownSep 18, 2025
What happens when Dukane Welding System shows overtemperature?
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  Robert PageSep 18, 2025
  When the system cools down, the overtemperature fault will automatically reset.
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Rhonda SpencerSep 8, 2025
How to fix weak welds with Dukane Welding System?
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  Keith MckinneySep 8, 2025
  Weak welds are often caused by insufficient energy being transmitted to the part. To address this, you can increase the weld pressure, increase the weld duration (either by adjusting the Time or Energy settings), or switch to a higher gain booster. This will increase the amplitude and, consequently, the energy delivered to the weld.
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Jerry CookSep 5, 2025
Why is Dukane Welding System process not in control?
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  Kimberly JonesSep 5, 2025
  If your Dukane Welding System process is not in control, leading to inconsistent weld results, it may be due to a mold release agent being used. Clean the mating surfaces; if a mold release agent is necessary, use a paintable/printable grade. Incorrect part tolerances can also cause this; tighten the part tolerances and check the part dimensions and molding dimensions. Additionally, cavity-to-cavity variations can contribute; check the part dimensions and tolerances, check for cavity wear, and check the molding conditions.