We are known throughout the industry for our willingness and ability
to meet our customers' specialized needs. The design of our products
encourages innovation so that any configuration, from standalone,
single-station systems to fully integrated automation, is possible.
Our capabilities include:
Integration of our assembly equipment into new or existing
Custom system design and construction
Custom software development
Our flexible approach:
Work with your preferred machine builder
Partner with specialized machine builders
Build custom machines to your specifications at Dukane
Regardless of the method, working with Dukane's Specialized Equipment
Group has many advantages:
We are a large and stable resource
We do basic research and we manufacture machines
We are experts in thermoplastic assembly and ultrasonic welding
We have the knowledge, experience, and expertise to recommend
the best technology, the correct process, and the proper equipment
for the assembly task
We have the people, products and demonstrated technical service
and support to serve your assembly needs worldwide
From simple to complex, Dukane can design and build an assembly
system for your application(s). Many of the systems we build feature
servomotors, optical part sensors, indexing tables and sound enclosures.
Turnkey solution utilizing Dukane’s iQLinQ™ and patented Multi-Point Control module
Six point ultrasonic work station utilizes iQ Series Auto Plus Ultrasonic Generators, patented Multi-Point Controllers (MPC), and iQLinQ™ for communicating with the main machine interface.
iQLinQ™ is a solution which simplifies communication between Programmable Logic Controllers (PLCs) and Ultrasonic Generators and provides the ability to program the generators from the main HMI via Ethernet.
Dukane’s patented MPC provides each weld station (point) with the ability to have its own unique recipe.
Fixture indexes to three precise positions to allow for multiple probe welding in limited space.
Slide fixture is mounted on top of a tubular steel table with a one-inch thick Blanchard ground top surface.
Light curtains allow for single touch activation from either opto touch switch.
Part presence sensors in the fixture provide Poke Yoke style assembly checks, to prevent improper assemblies.
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Ergonomic Work Cell with unique tooling designed to weld tough to load applications
Tooling and fixture of this machine designed to meet the welding requirements of an angled part. The ergonomic design makes it easy for the operator to load the parts.
Vacuum designed in the tooling detects parts' presence and flattens part surface prior to welding, these features aid in improving weld quality.
Each generator has the ability to control its individual weld process by energy. This allows the machine to utilize the flexibility and space savings of machine mounted probes with the process control of a press.
Light curtains allow for cycle start initiation by the use of one opto touch button.
Frame constructed of tubular welded steel with 1 inch Blanchard ground top and mounted on sturdy and convient rolling locking castors for floor space flexibility.
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Dukane designed and constructed progressive assembly work cell with sound enclosure
Work cell utilizes two 15 kHz rigid mount iQ probe systems with 10” of total stroke.
Dukane’s LS/E Ultrasonic Power Supply has a built in Ethernet port which eases controlling and monitoring each unit from the Allen Bradly 1000 series HMI
LS/E generator provides a closed loop welding process even in a probe platform by utilizing weld by energy.
Fullwave 15 kHz horns perform the work on this challenging application.
Dukane’s tooling engineers have set the industry benchmark by utilizing the latest FEA software available and had simplified designing complicated horns
Ergonomically designed and manufactured fixtures with rigid slide system easily moves to the operator for ease of loading parts and then moves under the welder for reduction of the welder's stroke.
Tooling can easily and quickly be changed out thanks to the quick tooling change concept designed into the upper and lower tooling plates.
Machine is constructed from tubular steel frame and 1 inch thick steel Blanchard ground top.
Fork truck tubes and robust guarded castors in the base makes it easy to move and place.
Sound enclosure mounted on top of the base has engineered sound cancelling foam in the interior of the robust panels, which provides noise reduction during the ultrasonic welding process.
Light curtains with single palm button activation enables operator to move to the next operation during the weld cycle and reduces cycle time.
Front sliding door provides a sealed enclosure and second method of safety during the process.
Dual Ultrasonic Heads with Four-position Rotary Indexer and
Automated Unload Work Cell
This is a highly efficient work cell with its two weld stations
is designed to weld two-piece handles, two at a time. At the load
station, the operator places two bottom part halves into the lower
nest. Next, two upper part halves are put on top of the bottom part
halves. At the touch of the whisker switch the weld cycle starts. A
Camco precision rotary indexer moves the table to weld station one,
then to weld station two. A highly polished contoured horn and
fixture assure that there will be no part marking during the weld
Then the table indexes to the unload station where an integrated
pneumatic vacuum device automatically separates good and bad parts
based on the welders' process control outputs. An included bad part
bin collects the discarded parts. The table is then positioned back
to the operator load station, and a new cycle can begin.
Work cell control is accomplished with the Allen-Bradley
PanelView 600 color touch screen HMI coupled with an expandable A-B
CompactLogixâ„¢ PLC. Ultrasonic signals at the dual welding heads
originate with Dukane's two 20 kHz thrusters that are teamed with
the reliable, advanced Dukane DPC IV process controllers.
Supporting the weld stations is a solid, steel table with a top
one-inch thick and Blanchard ground. Forklift tubes and robust
leveling feet are included for easy, secure positioning.
Polycarbonate panels in an extruded aluminum frame are above the
table, and they surround the work stations. The operator can see the
well-lit interior of the work cell through the clear front access
door panel. Safety features include lockable front and rear access
doors, a light curtain that guards against unintended contact with
the work cell's interior, and two abort switches. Options include
sound deadening and interlocking doors.
Ultrasonic Two-position Rotary Table Work Cell
Custom engineered for optimum efficiency, this work cell features an
economical, manual two-position rotary table. A shot pin operates
for accurate positioning and precision weld placement. The table's
two fixtures allow the operator to load a part in one fixture, while
welding takes place in the other.
At the heart of the work cell are two of Dukane's iQ Series
components. They are the HMI industrial touch screen PC, and the 20
kHz Advanced Press System with rigid support column. A built-in
automatic film system positions film between the ultrasonic horn and
the part to be welded. The film promotes superior welding with no
marking on visible â€œclass Aâ€ surfaces.
The table itself is solid, welded steel with a one-inch thick
Blanchard ground top having extreme rigidity and a highly polished
surface. Rugged leveling feet are standard. The sides of the work
cell have an extruded aluminum frame and black polycarbonate panels.
The front access door is clear and allows the operator to easily see
the whole work area. For additional safety, sound deadening is
available as an option.
A part presence sensor integral to the controls makes operating
the work cell easier. It means that a part must be in place, ready
to weld, before the machine will operate. Controls include the Opto-Touchâ„¢
cycle initiation switch, an abort switch enabling the operator to
end a cycle at any time, and a bright, three-color status light
(yellow - part in place; green - good part; red - fault/bad part).
Heat Staking Work Cell
Specially made for the appliance
industry, this work cell is designed to attach metal clips to the
back of a cosmetic front panel. The heat staker simultaneously heat
stakes two posts on each of eight clips securely attaching them to
The process starts when the operator manually loads a panel into
the fixture, and then loads eight clips onto the panel. The lower
nest is made of urethane to ensure that there is no marking on class
"A" surfaces. Next, four DE-STA-CO clamps are manually positioned to hold the parts in place. Then the work table is moved into place, and one DE-STA-CO clamp is closed to hold the table in position. (Pneumatic clamps and an automated pneumatic slide table is available as an option.) Part sensing detects that all clips are in place, and eight heat staking heads extend (The head has a 5"
stroke.) to form the posts. Watlow temperature controllers monitor
the temperature of each staking tip, and an after staking feature
allows the staked heads to cool. This insures the stakes are solid
before the staking heads retract. The operator manually repositions
the table, and removes the completed part.
Control is provided by an Allen-Bradley Panelview 700 color touch
screen HMI interface. The device can be password protected and is
linked to the expandable A-B CompactLogix™ PLC. In addition, there
is easy access to an Opto-touch switch to begin a cycle, and to two
abort switches if the operator needs to stop the process quickly
The work table is a solid, one-inch thick extruded aluminum piece
with a Blanchard ground top giving the table superior rigidity. The
sides of the work cell have an extruded aluminum frame and clear
polycarbonate panels. The front and rear access doors are
key-lockable. (Interlock doors are an option.) A light curtain
protects the operator, while a Smog-Hog filtration system removes
fumes. The control cabinet can be locked to prevent tampering with
any of the process settings. Rugged leveling feet with swivel
casters are standard.
Triple Ultrasonic Heads in a Full-Front Opening Work Cell
This work cell with its three weld stations is ideally suited for
joining large appliance parts ultrasonically. Work cell dimensions
are approximately: 8' tall by 5' wide and 4' deep.
Typically the operator puts a bottom part half into the custom
tooled aluminum lower nest. Part positioning is made easier by
Delrinâ„¢ blocks that are incorporated into the fixture. Next, the
upper part half is put on top of the bottom part half. DEL-SA-CO
clamps hold the parts in position. (Optional pneumatic clamps are
available.) The operator touches the single Opto-Touchâ„¢ cycle
initiation switch to continue the process.
An Allen-Bradley CompactLogixâ„¢ PLC is teamed with three
dependable Dukane Dynamic Process Controller (DPCâ„¢) systems that
power their ultrasonic heads to complete precision programmed welds.
The completed assembly is removed, and the work cell is ready for
Workstation safety is enhanced by using two individually controlled
interior work lights. Two abort switches - one next to the Opto-Touch
switch, and one on the control panel - enable the operator to end a
cycle at any time, and a bright, three-color light (yellow - part in
place; green - good part; red - fault/bad part) indicates part
status. A light curtain is standard helping to prevent operator
injury in the loading area. When equipped with optional sound
deadening baffles, strain on the ears is diminished.
This work cell has a full-front opening door giving substantial
access to the interior. The door is hinged along one side (the
entire height of the door) and can be safety interlocked as can all
of the doors on the work cell. If any of the doors were to open
while a cycle was underway, the cycle would be aborted immediately.
In addition, when the door is closed, a clear polycarbonate
portion of the door (approximately 51â€ by 22â€) is raised (pneumatic
cylinder assists) before a cycle begins giving access for loading or
work inside the cell. When the operator starts a cycle, this clear
section lowers to close.
The base of the work cell is a solid, steel table with a one-inch
thick Blanchard ground top. Forklift tubes and robust leveling
casters are included for quick, secure positioning. Polycarbonate
panels in an extruded aluminum frame surround the work area. Panels
are finished in accordance with customer specified paint color.
Two Ultrasonic Heads Positioned Horizontally with Pneumatic Part
Clamp Work Cell
This custom-engineered work cell performs two welds in sequence on a
single part. Also, pneumatic part-in-place clamping devices secure
the two halves during the welding process.
Key components of this work cell are Dukane's dual 20 kHz
horizontally mounted ultrasonic welders. These are matched with
advanced DPC IV process controllers. One feature of the process is
that bad part logic forces a pneumatic clamp to hold the
unacceptable part in place until an external reset is completed.
This means parts with inferior welds can be separated from the
Control is provided through a customer-specified push button HMI
that is teamed with an expandable Allen-Bradley CompactLogixâ„¢ PLC. A
whisker switch makes it simple to initiate a cycle, while manual jog
controls, an automated mode, and lighted status indicators are other
Positioned above and around the table is an extruded aluminum
framework with solid polycarbonate doors/panels. However a clear,
polycarbonate access door in the load area allows the operator to
view the parts being welded in the well-lit interior. Each of these
four doors is key lockable. Optionally, the doors can be configured
to interlock. The table top is one-inch thick, Blanchard ground,
solid, welded steel with superior rigidity and exceptional finish.
Forklift tubes, locking casters, and robust leveling feet are
standard and make for easy positioning of the work cell.
Safety features include a bumper safety switch built into the
leading edge of the load area door, and two abort switches that
provide an extra measure of control to stop a cycle at any time.
Sound deadening is available as an option.
Dukane's Custom Systems Group developed a work cell solution
employing a combination of elements to improve parts assembly
with creative results.
The basis for the work cell is a
machine that used the Dynamic Process Controller (DPC)
and the Multi-Probe Control. This equipment insures independent
control of amplitude, weld energy, weld time and parts limits
for each point to be welded. Dukane 30 kHz rigid-mount probes
with boosters and high gain contoured horns are included as
A programmable vision system detects the presence and correct
placement of any clips, fasteners, gaskets, etc. An HMI with
intuitive menu structure allows the operator to monitor and
control the overall processing of parts. In addition, the work
cell has a programmable precision servo position stage.
The cell structure consists of solid bridge construction to
minimize deflection of the cell frame. Fork tubes are used so
that a forklift can easily re-position the work cell. Adjustable
probe mounts allow for accurate parallelism with the part to be
welded. These mounts help reduce weld inconsistencies. Finally,
industry standard safety systems (light curtains as an example)
are integrated into the work cell.
Lean Manufacturing Cell designed for the manual assembly of
plastic components to accommodate Ultrasonic, Spin or Heat
Staking applications. The main features of the cell are size,
safety, ergonomics and robust construction.
The Lean cell has a small foot print, while still providing
significant workspace for the application. The unique compact
safety enclosure is only as large as the equipment inside,
leaving more table workspace for staging parts while the
equipment cycles. Safety was the driving factor in the design of
this work cell. Features like OSHA approved anti-tie down
activation switches and all electronically interlocked panels
are standard. Pneumatics include an OSHA lock out device and
filter regulator with soft start dump valve, providing an extra
level of protection during equipment maintenance and setup.
All interactions are within the ergonomic reach zone of a
sitting operator, which include user interface placed in
operator's line of sight, part load area is obstruction free and
open on all three sides thanks to the unique door design and an
operator foot rest is provided.
Two Position Assembly Station for plastic assembly can be
used for heat staking, spin welding or ultrasonic assemblies.
The machine can handle larger plastic assemblies 12 x 6 x 8
inches and has a rotary two position pneumatic reciprocating
table, allowing the operator to load the machine while welding.
The assembly station has a push button interface and PLC control
or an optional HMI touch screen interface. Other features
include lexan guarding with lockable doors, casters with
leveling feet, dust enclosure for generators, light curtain and
vertically sliding pneumatic door.
Dual Welder Rotary Work Cell has a 40"
dial on a Camco indexer and two-up tooling, thus double the
throughput. The work cell includes part placement and color
detection. Miss-loaded parts are automatically returned to the
operator. A three-position pneumatic pick-n-place removes
completed assemblies and separates suspect bad parts. Two 3000
watt DPC IV Plus systems provide precise weld process controls
and consistency feedback. The weld area is fitted with a vacuum
to eliminate particulate. The work cell is equipped with an Alan
Bradley touch screen user interface with detailed error codes.
Quick-change weld nests prevent incorrect parts from being
loaded and part orientation errors. The work cell has a compact
60" x 72" footprint.
Servo-Control X-Y positioning System for Plastics Assembly
was developed by Dukane for a project requiring multiple posts
welded on a large automotive instrument cluster. The Machine
includes a precision, servo-controlled x-y positioning stage
with +/-.001 repeatability. The stage includes provisions for up
to three quick-change nests. Each nest can contain up to 99 weld
points, three part presence sensors, nest vacuum and pneumatic
clamps. Weld positions are programmed via the touch screen and
can be called up at will for partial assembly tasks. The
pictured system includes the ultrasonic welder DPC level IV
2200-watt thruster with time, distance and energy controlled
welding plus weld quality monitoring modes.
Turnkey Ultrasonics Workcells handles automotive door
assemblies. A solid structural bridge eliminates deflection and
accepts ultrasonic, thermal or spin-welding thruster heads. Each
thruster has easy access and is independently adjustable. The
welding process remains visible because of the open-guarding
design. Operator controls include part presence feedback for
each component, Good/Bad part signals, Cycle Complete signal and
manual operation of individual thrusters.
6-Axis Robotic Welder was built in less time than a
conventional multi-headed design. The robotic arm provides a
wide range of welding application flexibility. The system
features quick-change fixtures with a changeover time of less
than two minutes. Fixtures can contain multiple part nests and
two groups of clamps, multiple part sensors and two nest vacuum
systems. Fixture ID features automatically recall the correct
robot program as the fixture is installed (accepts up to five
fixtures, each with multiple nests). A mini-thruster on the
robot arm automatically compensates for part thickness variation
or part warpage, increases the maximum allowable weld pressures
without overloading the robot, and provides digital control of
the weld pressure via simple touch-screen commands, without
having to understand the robot programming language. Manual
ultrasonic horn changeover takes less than five minutes. With
horn zeroing tooling incorporated into the fixtures, Dukane can
provide tooling accompanied with a robot program as new
Dual Station Ultrasonic Work Cell
has a unique design that incorporates two independent weld stations
into one compact work cell. Perfect for right and left hand
assemblies that require only one operator and minimal floor space.
Each station has independent three-position in/out fixture shuttle
for ease of load and unloads. Each load station has their own light
curtains along with DPC II plus ultrasonic power supplies featuring
Dukane's Patented MPC (Multi-point Control), and bright work lights.
The quick-change part holding fixtures have part sensing and
clamping for positive alignment and placement detection.
The ultrasonic actuators have hydraulic speed control, solid bottom
stops, adjustable trigger force switch, pressure gauge and flow
controls. They are mounted on a mechanical knuckle that provides x,
y, rotational and angular adjustment. This feature is great for
contoured assembles that require precision horn alignment to reduce
weld marking to class A surfaces. Electrical controls are handled by
Control Logix PLC and Panel View Plus touch screen. The user
friendly interface software provides manual activation of each
sequence for ease of machine setup. Detailed error codes, bad or
suspect part alarms, and a part presence map is available.
Heat staking work cell is ideal for larger plastic
applications that require multiple posts staked. It's designed
for applications such as exterior and interior automotive trim,
appliance panels' and large consumer electronic devices. What is
unique about this machine is that the independent actuators
attach to a solid horizontal bridge, versus other machine
designs that incorporate a large moving platen. The independent
actuators and universal mounting plates allow relocation of the
thrusters and retooling for other applications. Each actuator
can be adjusted in the x, y and z-axis, and permits rotational
and angular adjustments, to deal with applications that have a
contoured shape. When heat staking, the best post strength is
achieved when the speed at which the staking tool compresses the
post matches the melt velocity of the plastic material.
Hydraulic speed control on each actuator provides this advanced
level of melt speed control. The thermal controls are modular
and can be easily upgraded by the user to add more staking
points. Additional PLC expansion is available to add more part
clamping, sensing, position sensors and other features in the
User friendly operation is achieved through a color touch screen
HMI and one touch cycle initiation. Safety guarding is on three
sides with a light curtain across the operator load area, along
with a bright work light. Nests are made from urethane which has
been poured to Renwood that is machined directly from customer
part CAD data, to eliminate marking of the class A surface of
the parts. The lower fixture nest is mounted on a two-position
linear ball bearing slide. Servo programmable stop positions are
optional. The slide mechanism gives the operator the ability to
load the parts at a safe, comfortable distance from the heated
thermal tips. Locking casters, leveling feet and fork tubes are
Continuous Feed Tube Seal Cell Unit incorporates dual rigid C
frame ultrasonic sealers capable of sealing tubes up to 3â€ or
multiple smaller tubes.
This configuration seals tubes horizontally. However, the C frame
sealer can be mounted in any orientation. The parts are directly
loaded by a separate robot into the welding fixtures. A variable
frequency drive and cam indexer automatically checks for part
presence, validates part location, feeds the parts to the weld
station and separates the parts into lot bins or a suspect bad part
bin. This unit is designed for MEDICAL applications; all components
have corrosion and particulate deterrents while the positively
pressurized enclosure has a class 100,000-filtration system. The
ultrasonics used for this application is the most advanced in the
industry - Two DPC IV plus probe systems with Time, Distance,
Energy, Adjustable Amplitude control and monitoring features.
This unit is designed to run 24/7 without an operator. Depending on
tube size the cell can produce up to 240 parts per minute