Prior to investing in Dukane’s iQ Servo Ultrasonic Welder technology, the biggest challenge for this manufacturer was misalignment of the thin PET films during the assembly process. Scrap rate was more than 30%. The iQ Series Servo Ultrasonic Welding System with patented Melt-Match® technology solved the assembly alignment problems and provided accurate, repeatable and reliable process. By using the digital process control from the iQ Series Servo Ultrasonic Welders, they have produced 20+ million Test Strip assemblies in less than three years while reducing their scrap rate to less than 5%.
|iQ Series Servo Ultrasonic Welding System|
In the final stage of the weld cycle, the iQ Servo system also gives the flexibility to program Dynamic and/or Static Hold. Dynamic Hold will have the horn further compress the parts after the ultrasonics has been turned off. Static Hold has the weld horn hold its final end-of-weld position for a given amount of time. In this application, Static Hold has been programmed. This gives the materials enough time to solidify without misalignment. Once the Static Hold time has been completed, the horn then returns to its home (or Top of Stroke) position ready for the next weld cycle. This was the most helpful feature for these thin PET Test Strips.
Another major advantage of using iQ Servo system is the ability to duplicate a known process on multiple iQ Servo Systems without any variation in weld results. In this application, this feature was of major benefit for the manufacturing company. They were able to install multiple iQ Servo Systems for their growing need without investing extra time or effort in fine-tuning the process for each welder.
Dukane’s extensive product line of servo-driven technology and our professional sales and engineering team will collaboratively work with customers to provide the best solution for their given application. For more information on iQ Series Servo Ultrasonic Welder and other Ultrasonic Welding products visit http://www.dukane.com/us/ or call 630-797-4900.