How to resolve underwelding issues with Dukane Welding System?
To resolve underwelding issues with your Dukane Welding System, consider the following: If insufficient energy is being transmitted to the part, increase the trigger force, reduce weld speed, increase the weld duration, increase the horn amplitude, or use a higher power capacity assembly system. If energy is being absorbed into the fixture, change the type of fixture being used.
What causes diaphragm damage in Dukane iQ Welding System?
Diaphragm damage in a Dukane Welding System can be caused by excessive horn amplitude. Reduce the horn amplitude or dampen the welding area to absorb the excessive vibrations. Excessive exposure to ultrasound can also be a factor; reduce the weld duration and increase the horn amplitude and/or weld speed. Improper gate location/design/thin-wall sections can contribute; check gate placement, change the shape of the gate, add stiffening ribs to the part, and increase the thickness of the material on the underside of the gate area. If using a 15 kHz system, consider using a 20 kHz system. Lastly, the type of horn and/or its placement can cause damage; check for the proper horn/part fit and change the horn if necessary.
What causes overwelding in Dukane iQ Welding System?
Overwelding in the Dukane Welding System is caused by too much energy being transmitted to the part. To resolve this, reduce the trigger force, reduce the weld duration, reduce amplitude setting, or change to a lower gain booster to reduce the horn amplitude.
How to troubleshoot uneven welding with Dukane system?
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.
How to fix misalignment of welded assembly in Dukane iQ Welding System?
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.
Why is my Dukane iQ Welding System melting the part outside the joint area?
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.
What to do if internal components are damaged during Dukane welding?
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.
General| Brand | Dukane |
|---|---|
| Model | iQ Series |
| Category | Welding System |
| Language | English |
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