Distribution Services, Plastics Assembly Systems, Dynamic Process Controllers, Vibration Welders, and Thermal Press
Innovative Assembly Solutions
We have been providing solutions for plastic assembly for over 20 years. Some of the solutions we offer are as follows: Designed Ultrasonic Horns; where the amplitude is verified and finite element analysis is done Designed and built Complete Assembly Cells Solutions for Fabric and Film Solutions for the Food Industry We provide distribution services for companies such as Dukane Corporation and Ergo Chef. Dukane Corporation offers: Horn manufacturing Applications Lab Custom manufacturing Injection molding and assembly Food processing Plastic welding: laser; vibration; thermal; hot plate, spin and infra-red
We have been providing solutions for plastic assembly for over 20 years.
Some of the solutions we offer are as follows:
We provide distribution services for companies such as Dukane Corporation and Ergo Chef.
Dukane Corporation offers:
Ultrasonic Plastic and Vibration Welders
Dukane's next generation of technologically advanced ultrasonic welders for plastics assembly is available in 15, 20, 30, 40, 50 and 70 kHz frequencies. These components are available as single units or standalone assembly systems, or they may be integrated into automated machinery. Listed below is the range of products offered. Model 220 20 kHz Plastics Assembly System This features the narrow profile Model 220 press/thruster and Dynamic Process Controller. Like the Model 210, the Model 220 can be used as a bench top press or as a thruster mounted in multihead or automated systems. Narrow 4.5" (114mm) width for close center-to-center thruster positioning Exclusive dual pressure capability Full range of process controls 7-inch stroke with adjustable bottom stop High-performance Magnum™ transducer is standard Power levels from 500 to 2200 watts - Model 215 20/15 kHz Plastics Assembly System - Model 340 30/40 kHz Thruster Plastics Assembly System - Model 405 40 kHz Remote Thruster System A compact ultrasonic welder with a remote pneumatics unit specifically designed for mounting in multihead or automated systems. Narrow 3.125" (79mm) width for close center-to-center thruster positioning Exclusive dual pressure capability 4-inch stroke with adjustable bottom stop Remote pneumatics unit can be relocated and consolidated with other system controls Power levels from 350 to 1000 watts Dynamic Process Controllers™ (DPCs) Integrated Process Control Systems The heart of any ultrasonic plastics assembly system, Dukane’s Dynamic Process Controllers is the industry’s most sophisticated and comprehensive process controllers. Available in various power levels and frequencies, our four distinct DPCs are engineered to meet every level of control required for today’s ultrasonic assembly applications. Choice of power levels, frequencies, microprocessors and control features Designed for global utilization with multilingual menus and text Universal IEC 320 power cord receptacle to accommodate most worldwide power requirements Compatible with Dukane current DPC Series and ULTRA presses, thrusters, and probes 40/30 kHz Platen Thruster Specifically designed to be integrated into multihead, automated machinery utilizing platens, platen thrusters are the low-cost solution for spot welding, staking, or swaging when multiple weld points are necessary. Made of stainless steel and aluminum for superior performance, precision, and reliability 1.5" (38mm) bore air cylinder provides 170 pounds of force at 100 psi 6-inch stroke standard. 2" and 4" available Up to 5 degrees of adjustability for precise horn placement or leveling Additional system components available to expand or supplement platen capabilities SRT-50 Rotary Parts Handling System A space-saving, self-contained unit that can be operated as a manual or semi-automatic system is designed for light to medium duty service. Mounts to any Dukane ultrasonic thruster 20" (508mm) diameter aluminum dial plate 6-station Camco roller gear index table is standard with 4, 8, 12, 24, and 32 stations available Allen-Bradley Micrologics Programmable Controller is standard Single knob control for RUN/JOG. Separate push button control for STOP Safety guarding provides viewing access to the welding area Air ejection of parts is available SRT-300 Systems are available for heavy duty service - SRT-300 rotary parts handling system 20 kHz, 30 kHz and 40 kHz Probe and Hand-held Probe Systems Lightweight, portable tools suited for short production runs requiring spot welding, staking, or inserting Machine-mountable and readily adaptable to customer actuation or automation 20 kHz power levels from 500 to 3000 watts; 30 kHz in 1500 watts; 40 kHz power levels from 350 to 700 watts Operates with the DPC I, DPC II, DPC II Plus, and DPC IV Plus. Pistol Grip for 20 kHz Probes Vibration Welders Linear vibration welders require no additional materials and provide energy efficient operation with permanent assembly and hermetic sealing. Other advantages include large part capability, internal joints, immediate handling, high production rates and entrapment of other parts. The machine can handle painted and mold release parts. VWB3900 Advanced Large Part Vibration Welder Dukane Corporation is introducing their newest and largest vibration welder within their product line at NPE 2006. The 3900 Advanced linear vibration welder boasts a 72" wide and 24" deep hydraulic lift table. The ultra rigid table structure is guided by four dovetail slides and eight reciprocating bearings. The 3900 can swing an upper tool mass of 250 pounds while maintaining a frequency above 200-hertz utilizing a 30-hp digital drive. With these features Dukane can weld instrument panels, bumpers, large appliance housings and other large plastic assemblies. Large structural parts that have critical surface finishes are ideal applications for the 3900 series welder. With data tracking the quality of these assemblies can be monitored with the Dukane Advanced Control System. VWB3500 Vibration Welder Features: Electromechanical vibration head assembly (200-240 Hz) Super rigid four rail table slide system Solid state 15hp digital vibration drive Full color touch screen display Intuitive and interactive comprehensive help menu Part parameter monitoring with programmable limits Choice of either English or Spanish menu structure Automatic tuning Programmable amplitude 0.040" to 0.070" (1.0 to 1.8mm) Weld by time and weld by time and weld by distance (absolute or meltdown) Less than 80 db in operation (continuous measurement) Specifications: Table size 38" x 18" (965mm x 455mm) Upper tool weight 35-90 pounds (15-40kg) Low 41" (1040mm) lift table height VWB3700 Vibration Welder Features: Electromechanical vibration head assembly (200-240 Hz) Super rigid four rail table slide system Solid state 20hp digital vibration drive Full color touch screen display Intuitive and interactive comprehensive help menu Part parameter monitoring with programmable limits Choice of either English or Spanish menu structure Automatic tuning Programmable amplitude 0.040" to 0.070" (1.0 to 1.8mm) Weld by time and weld by time and weld by distance (absolute or meltdown) Less than 80 db in operation (continuous measurement) Specifications: Table size 52" x 24" (1320mm x 610mm) Upper tool weight 90-150 pounds (40-68kg) Low 41" (1040mm) lift table height
Dukane's next generation of technologically advanced ultrasonic welders for plastics assembly is available in 15, 20, 30, 40, 50 and 70 kHz frequencies. These components are available as single units or standalone assembly systems, or they may be integrated into automated machinery.
Listed below is the range of products offered.
Model 220 20 kHz Plastics Assembly System
This features the narrow profile Model 220 press/thruster and Dynamic Process Controller. Like the Model 210, the Model 220 can be used as a bench top press or as a thruster mounted in multihead or automated systems.
- Model 215 20/15 kHz Plastics Assembly System
- Model 340 30/40 kHz Thruster Plastics Assembly System
- Model 405 40 kHz Remote Thruster System
A compact ultrasonic welder with a remote pneumatics unit specifically designed for mounting in multihead or automated systems.
Dynamic Process Controllers™ (DPCs)
Integrated Process Control Systems
The heart of any ultrasonic plastics assembly system, Dukane’s Dynamic Process Controllers is the industry’s most sophisticated and comprehensive process controllers. Available in various power levels and frequencies, our four distinct DPCs are engineered to meet every level of control required for today’s ultrasonic assembly applications.
40/30 kHz Platen Thruster
Specifically designed to be integrated into multihead, automated machinery utilizing platens, platen thrusters are the low-cost solution for spot welding, staking, or swaging when multiple weld points are necessary.
SRT-50 Rotary Parts Handling System
A space-saving, self-contained unit that can be operated as a manual or semi-automatic system is designed for light to medium duty service.
- SRT-300 rotary parts handling system
20 kHz, 30 kHz and 40 kHz Probe and Hand-held Probe Systems
Linear vibration welders require no additional materials and provide energy efficient operation with permanent assembly and hermetic sealing. Other advantages include large part capability, internal joints, immediate handling, high production rates and entrapment of other parts. The machine can handle painted and mold release parts.
VWB3900 Advanced Large Part Vibration Welder
Dukane Corporation is introducing their newest and largest vibration welder within their product line at NPE 2006. The 3900 Advanced linear vibration welder boasts a 72" wide and 24" deep hydraulic lift table. The ultra rigid table structure is guided by four dovetail slides and eight reciprocating bearings. The 3900 can swing an upper tool mass of 250 pounds while maintaining a frequency above 200-hertz utilizing a 30-hp digital drive. With these features Dukane can weld instrument panels, bumpers, large appliance housings and other large plastic assemblies. Large structural parts that have critical surface finishes are ideal applications for the 3900 series welder. With data tracking the quality of these assemblies can be monitored with the Dukane Advanced Control System.
VWB3500 Vibration Welder
Features:
Specifications:
VWB3700 Vibration Welder
Thermal Press and Welders
Heat Staking Thermal Press: Model 48Hxx1TS and Model 48Hxx2TS Thermal Presses heat the staking post/insert while applying pressure axially to permanently set the parts. Advantages of the thermal heat staking / inserting process include: Reliable permanent inserts No particulates or noise Multiple level inserting/heat staking Multiple size inserts No whitening when degating Better cosmetic appearance when heat staking and swaging High tolerance to mold release, colorants and other additives Tolerant of resin grade variations and regrind percentages Low initial equipment cost Ease of operation and assembly Handles slippery thermoplastics Easier maintenance in a low-tech environment Heat Staking Press Features 120V AC model (up to 6 x 350 watt heaters) and 240V AC model (up to 12 x 350 watt heaters) 3/4 ton, 1 ton and 1 1/2 ton models Digital zone heat controller (80° F to 999° F) Modular master/slave temperature controllers Digital timer for weld time and post-cool Easy to use LCD touchscreen display Setup mode jogs head down for probe alignment Ultra rigid steel H-frame chassis eliminates flexing to reduce functional and cosmetic defects Pneumatic thruster with 4-inch (100mm) stroke Hydraulic speed control standard Modular configuration means no more knockouts and hand wiring of relays and controllers Prewired and preprogrammed for optional slide kits, post cool, and fixture clamping. Optical (zero force) safety switches Applications Thermal press applications include heat staking, inserting, embossing, date coding and degating. Automotive industry for door panels, map pockets, light-pipe staking, consoles, arm rests and switch clusters. Medical applications include blood-processing equipment, chemical pumps, fittings, flow meters, IV drug delivery and surgical instruments. Consumer Product applications include personal computers, portable telephones, laser printers, copy machines, video games, speakers and appliance components. Industrial applications include conveyor systems, gears, pulleys, couplings, and motor housings. Thermal presses are also used in Toy Manufacturing and the Sporting Goods industry. Dukane heat staking thermal presses can work with a variety of materials including most amorphous and semi-crystalline thermoplastics as well as liquid crystal polymers. Some difficult to weld plastics are well suited to the thermal process including lubricious materials such as PTFE. Soft thermoplastics such as PE and PP react favorably to thermal inserting along with brittle materials such as 50% mineral-filled PPO (Ryton) which flakes when subjected to ultrasonics. Spin Welders Dukane Ultrasonics offers a range of advanced, high quality spin welders in stand alone or fully automated units for today's advanced applications. Dukane spin welders work with most thermoplastics, will accommodate large diameter parts, and easily achieve hermetic seals. Dukane's spin welding equipment provides precise control of the melt temperature and contains the ability to weld large, complex parts. The result: excellent weld strength and hermetic seals every time. Hot Plate Welders The ideal assembly solution for medium, contoured, or complex thermoplastic parts is hot plate welders. Designed for versatility and easy tooling changeover to accommodate a variety of parts. Typical hot plate welding applications include fuel tanks, reservoirs, taillight lenses, and vent ducts. The welder easily achieves hermetic seals, and finished part weld strength approaches that of the virgin material. - HHB1223P Horizontal Hot Plate Welder - HHB1229P Horizontal Hot Plate Welder Laser Welding of Plastics Dukane Corporation’s Intelligent Assembly Solutions division is one of the world’s leading suppliers of plastic assembly solutions for over 35 years. As new technologies emerge, Dukane has incorporated these new technologies into their line-up. With so many diverse applications, we found it necessary to address our customers' needs with many different bonding processes. Using new laser technologies allows us to provide a welding solution to customers that require a method that has benefits that one would not get from other bonding methods. Laser Welding Concept The laser beam penetrates the upper "transparent" component and is converted into heat by the absorbing lower component. Since both components need to be pressed together (as in other methods), heat is conducted from the absorbing lower component allowing both parts to melt and create a bond only where the laser beam is directed. Clamping of the plastic components that are to be assembled is still essential so that intimate contact is made to allow the laser beam to melt exactly where the parts need to be bonded together. Nearly all thermoplastics can be welded using the proper laser components. Special additives/pigments also allow welding of dark to dark materials as well as transparent to transparent combinations. It's all about color, specifically what color the laser thinks your part is. Parts that appear very dark to the human eye can be either transmissive or absorptive, depending on the formulation of the pigment. Even joints that require optical clarity (clear-to-clear) can be achieved. Laser welding of thermoplastics depends on many of the same rules of resin compatibility that the other processes do, but is more forgiving of resin chemistry or melt temperature differences than most other plastic welding processes. Advantages of Laser Welding No particulate is generated Vibration-free process Hermetic seals are achievable No wear on the tooling Optically perfect weld joint area High-precision Simple joint geometry
Thermal Presses heat the staking post/insert while applying pressure axially to permanently set the parts. Advantages of the thermal heat staking / inserting process include:
Heat Staking Press Features
Applications
Thermal press applications include heat staking, inserting, embossing, date coding and degating.
Automotive industry for door panels, map pockets, light-pipe staking, consoles, arm rests and switch clusters. Medical applications include blood-processing equipment, chemical pumps, fittings, flow meters, IV drug delivery and surgical instruments. Consumer Product applications include personal computers, portable telephones, laser printers, copy machines, video games, speakers and appliance components. Industrial applications include conveyor systems, gears, pulleys, couplings, and motor housings. Thermal presses are also used in Toy Manufacturing and the Sporting Goods industry.
Dukane heat staking thermal presses can work with a variety of materials including most amorphous and semi-crystalline thermoplastics as well as liquid crystal polymers. Some difficult to weld plastics are well suited to the thermal process including lubricious materials such as PTFE. Soft thermoplastics such as PE and PP react favorably to thermal inserting along with brittle materials such as 50% mineral-filled PPO (Ryton) which flakes when subjected to ultrasonics.
Dukane Ultrasonics offers a range of advanced, high quality spin welders in stand alone or fully automated units for today's advanced applications. Dukane spin welders work with most thermoplastics, will accommodate large diameter parts, and easily achieve hermetic seals. Dukane's spin welding equipment provides precise control of the melt temperature and contains the ability to weld large, complex parts. The result: excellent weld strength and hermetic seals every time.
The ideal assembly solution for medium, contoured, or complex thermoplastic parts is hot plate welders. Designed for versatility and easy tooling changeover to accommodate a variety of parts. Typical hot plate welding applications include fuel tanks, reservoirs, taillight lenses, and vent ducts. The welder easily achieves hermetic seals, and finished part weld strength approaches that of the virgin material.
- HHB1223P Horizontal Hot Plate Welder
- HHB1229P Horizontal Hot Plate Welder
Dukane Corporation’s Intelligent Assembly Solutions division is one of the world’s leading suppliers of plastic assembly solutions for over 35 years. As new technologies emerge, Dukane has incorporated these new technologies into their line-up. With so many diverse applications, we found it necessary to address our customers' needs with many different bonding processes. Using new laser technologies allows us to provide a welding solution to customers that require a method that has benefits that one would not get from other bonding methods.
Laser Welding Concept
The laser beam penetrates the upper "transparent" component and is converted into heat by the absorbing lower component. Since both components need to be pressed together (as in other methods), heat is conducted from the absorbing lower component allowing both parts to melt and create a bond only where the laser beam is directed. Clamping of the plastic components that are to be assembled is still essential so that intimate contact is made to allow the laser beam to melt exactly where the parts need to be bonded together.
Nearly all thermoplastics can be welded using the proper laser components. Special additives/pigments also allow welding of dark to dark materials as well as transparent to transparent combinations. It's all about color, specifically what color the laser thinks your part is. Parts that appear very dark to the human eye can be either transmissive or absorptive, depending on the formulation of the pigment. Even joints that require optical clarity (clear-to-clear) can be achieved. Laser welding of thermoplastics depends on many of the same rules of resin compatibility that the other processes do, but is more forgiving of resin chemistry or melt temperature differences than most other plastic welding processes.
Advantages of Laser Welding
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