Check out this video explaining why Nordson Medical has been using the cutting edge technology of ultrasonic welding with patented Melt-Match® from Dukane for over 10 years. For more info on Dukane, go to bit.ly/2LnnGNv
Since the introduction of the Dukane IQ ServoPress Ultrasonic Welding System in 2007, the benefit it has brought to their customer base cannot be overstated.
Just ask Schweitzer Engineering Laboratories, Inc. (SEL) –
SEL is a world leader in the design and manufacturing of protection, monitoring, control, communications and metering products for power grids and power systems around the globe.
A few years ago, SEL was facing a difficult challenge when welding a clear lens display screen to the polycarbonate body of one of their indicators, which is used on transformers, switchgear, sectionalizing cabinets, junction boxes and splices. Because the indicator is used in harsh, submersed and corrosive environments, the housing requires a hermetic seal that has to withstand a temperature from -40 to 150 °F. Unfortunately, the pneumatic welding process SEL was using was not giving them the seal they needed.
Eventually, according to Rick Lewis, manufacturing engineering supervisor at Schweitzer, SEL decided to redesign the plastic injection molds and to have ultrasonic welding supplier Dukane Corp. test the parts at the Dukane applications lab in St. Charles, IL. There, using a 20-kilohertz-frequency iQ Series servo-controlled welder, the Dukane specialists discovered that the solution was to vary weld speeds.
“Although old pneumatic systems are capable of varying the force during the weld, the rate of change is restricted due to the time required to move air in or out of the air cylinder,” explains Ken Holt, senior application engineer at Dukane. “Whereas, the servo system is capable of accelerations of 50 inches per second, which is equivalent to changing speed by 1 inch per second in 0.02 second.”
After testing, Dukane determined the optimum varying weld velocity speed setting to be from 0.02 to 0.09 inch per second. Holt says that the unique technology called Melt-Match® in the iQ system also proved helpful for this project. Match Melt® precisely matches the downward motion of the horn to the melt flow characteristics of the plastic to optimize molecular intermingling and produce strong welds. Holt said that Dukane’s Melt-Detect™, which ensures complete initiation of plastic melting before prompting the horn to initiate downward movement, was also a factor in optimizing the process.
Impressed with the lab test results, SEL purchased an iQ welder and integrated it into the robotic assembly cell for the fault indicators. Lewis says the welder works flawlessly. “It’s repeatability and graphing functions make it easier to set up new welding programs,” concludes Lewis. “The welder [also] reduces the engineering time and the number of scrap parts required to set up a new welding process.”
This is yet another example of Dukane’s applications lab expertise, proprietary technology like Melt-Match® and Melt-Detect™ and the second-to-none IQ ServoPress system finding solutions for customers to ensure the best results in their manufacturing and their company’s bottom line.
For more information on Dukane’s products and how we at Production Components can help you with Dukane products, call us at 203 881 3013 or email us at [email protected].
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We are pleased to introduce our newest sales representative, Tom Terrio, who will be representing all of the assembly, production and automation products we carry in CT, Metro NY, NJ and PA.
Tom, with 20 years of sales experience in the manufacturing industry, specifically in systems integration/packaging automation & equipment, printing/industrial roller, blanket, and chemical manufacturing, is excited to join Production Components and would be happy to discuss in person or over phone/e-mail, how he can help our customers with any application solutions they may be seeking.
Please join us in welcoming Tom and don’t hesitate to contact him at: 203 819 2396 or at [email protected].
The Team at Production Components.
Production Components has been in business in New England since 1977, and for the past 40 years we have represented some of the premier manufacturer’s in the field of assembly, automation and production – Schmidt, Graco and Dukane, to name just a few. In addition to our standard products, we have partnered with other local vendors for specific projects which require unique solutions. We have representatives located in Connecticut, Rhode Island and New Hampshire, so we are never more than a few hours away. Production Components works with our principals and partners to come up with solutions that are robust, reliable, and affordable – and we provide continual support of the equipment to make sure that it continues to serve you reliably. We can be reached at our main office in Wallingford, CT at 203 881 3013 or at [email protected].
Check out this video to learn about Dukane’s patented Melt-Detect™ technology for Servo driven Ultrasonic Welding process. This technology ensures complete initiation of melt in the contact area of plastic assembly, before prompting the press to initiate downward movement. This improves weld strength and reduces stress in the welded assembly.
A quick update on advancements in the field of ultrasonic welding from Dukane, who we represent locally.
Ultrasonic plastic welding is the joining or reforming of thermoplastics through the use of heat generated from high-frequency mechanical motion. During the process, high-frequency electrical energy is converted into high-frequency mechanical motion, which in conjunction with applied force, creates frictional heat at the plastic components’ mating surfaces (joint area) and melts to create a molecular bond between the parts. To see an illustration of the basic principle of ultrasonic welding, click below.
What you may not know, is that Dukane is leading the industry with its patented Servo Actuated ultrasonic systems. This technology is exclusive to Dukane and has resulted in very significant improvements in joint strength, flash control, part to part repeatability and consistency. Oh, and the price? It is comparable to our competitor’s “high end” pneumatic solutions, which have not appreciably changed in 20 years!
The Dukane iQ Servo Welder has helped hundreds of our customers improve their production yields, quality, and their bottom line.
We are sure that you will benefit from this technology and look forward to discussing it with you – call us (203 881 3013) for either a phone or in-plant consultation, or visit our resident expert Mark Iannantuoni at our showroom in Wallingford CT for an in-person demo.