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September 1, 2000
4 Min Read
Joining/welding technologies-Demonstrating that the company is not limited to ultrasonics anymore Dukane Corp. showed a range of new welding machines at NPE. Among those notcovered, or covered in little detail inpre-show coverage, are a line of spin welders, a line of thermal presses, a hot plate welder and a mini ultrasonic slitter. Also new: platen thruster technology and Magnum transducers.
There are two spin welding models available: a 3 hp, 3500 rpm unit and a 5 hp, 1750 rpm unit. Both feature a pre-spin cycle mode, which spins the part before applying pressure (this is designed for softer parts that might collapse under pressure), and a pre-load cycle mode, which applies pressure first then spins (designed for rigid parts).
The direct-drive units have adjustable head height, a 7-in. stroke and can weld by time or distance. Up to 20 set-ups can be stored.
Prices range from $14,000 to $20,000, depending on options and tooling.
There are six units in the Thermal Press line: 1/2-, 1- and 2-ton models with either simple of advanced control. They can be used for heat staking, swaging, thermal insertion or data and code stamping. Head height is adjustable and stroke is up to 3 in.
The advanced models have a touchscreen interface with up to six individual temperature zones. A post-cool staking mode and hydraulic speed control are standard. Shuttle loading is optional.
Prices range between $6500 and $30,000, depending on the number of inserts, temperature zones and other options.
The hot plate welder features a 12- x 24-in. platen size in either horizontal or vertical configurations. It has rack-and-pinion platen motion, which is said to counter-balance the tools so there are no problems in determining the proper tooling weight settings, pneumatic actuation, vacuum part pick-up and multi-zone temperature control.
Unit comes with an Allen-Bradley Micrologix controller and operator interface. Controller holds up to 10 set-ups. Price is $45,000.
The new 40 khz mini slitter seals and cuts in one pass without fraying, beading or smoke. The flat-face horn can be rotated for a fresh cutting surface, as can the 1-in. slitting anvil, thus saving on spare parts. The base can be positioned in a track (with wheels) so it can traverse bolts of material easily and accurately.
Dukane also demonstrated its platen thruster technology, which is designed for automotive and other multi-point welding applications. It can be integrated into any multi-head automated machinery or platen system, such as assembly systems for attaching shoddy pad or interior trim impact crush rib attachment.
Dukane says the unit is usually more efficient and cost-effective than adhesives, hot melts and pressure-sensitive adhesives.
Two frequencies are available: 40 and 20 kHz. Unit can tie in with the Dukane's Dynamic Process Controller (DPC) Level 3 to prevent blemishes and other marks on the cosmetic side of the part. Depending on the number of points to be welded, prices range from $60,000 to $250,000.
Here are some additional features and details on the company's new vibration welders, which first appeared in our May Pre-NPE show issue. p 35:
Digital electronic drive
Force range up to 3100 psi
10, 15 and 20 hp models
Operating frequency range of 200 to 240 Hz
Upper tool weight range of 35 to 110 lb
Programmable amplitude from 0.040 to 0.070 in.
Closed-loop amplitude control
Allen-Bradley SLC 500 Series controller
Rexroth hydraulic system that welds by time and distance
* Price: $78,000 to $85,000 (withouttooling)
Finally, Dukane is now offering Magnum transducers on all of its new ultrasonic welding machines. Existing units can be retrofitted.
These transducers are said to extend service life, increase amplitude and power, improve cooling and reduce over-loading due to a patented 'crush fill' technology that directs energy more efficiently to the horn.
In addition, Dukane has replaced the holding pins that hold the transducer driver in its housing with a keyed mechanism that is said to prevent rotation of the driver in the housing. Cooling holes have been added to the front of the driver to dissipate heat.
St. Charles, IL
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