Dukane iQ Series User Manual (English)

Other manuals for Dukane iQ Series

Quick Start Guide30 pages

Operating Instructions4 pages

Application Note16 pages

Questions and Answers:

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holdercarolynSep 1, 2025
What causes diaphragm damage in Dukane iQ Welding System?
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  Dr. Jennifer Daniels DDSSep 1, 2025
  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.
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Oscar ThompsonAug 29, 2025
What causes overwelding in Dukane iQ Welding System?
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  Jennifer MeyerAug 29, 2025
  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.
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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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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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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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costajaclynAug 22, 2025
How to prevent flash in Dukane Welding System?
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  Kristen RodriguezAug 22, 2025
  To prevent flash in your Dukane Welding System, consider these points: If the energy director is too large, reduce its size, decrease the weld distance, or use an interrupted energy director. If shear interference is too great, reduce the amount of interference. If the weld time is too long, reduce the weld distance or increase weld speed. For non-uniform joint dimensions, re-dimension or redesign the joint. If part fit or tolerances are off, loosen the part fit or tighten the part tolerances.
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arthur92Sep 15, 2025
What to do for 'Generator Fault Over Temperature' on Dukane Welding System?