Dukane IQ Explorer 3 User manual

IQ Explorer 3
www.dukane.com [email protected]
QUICK START GUIDE

Copyright © 2021
Dukane
2900 Dukane Drive
St. Charles, IL 60174 USA
Noce of Rights:
All rights reserved. No part of this manual including the interior design, cover design and icons may be
reproduced, transmied or ulized in any form or by any means, electronic, mechanical, photocopying,
recording, or by any informaon storage and retrieval system, without wrien permission from Dukane.
Noce of Liability:
The informaon contained in this manual is distributed on an “As is” basis, without warranty. While
every precauon has been taken in the preparaon of this manual, Dukane shall not have any liability
to any person or enty with respect to any liability, loss, or damage caused or alleged to be caused
directly or indirectly by the instrucons contained in this manual, or by the hardware products
described herein.
Specicaons subject to change without noce.
This user’s manual documents product features, hardware, and controls soware available at the me
this user’s manual was published.
Dukane Part Number: 403-620-00
Dukane ultrasonic equipment is manufactured under one or more U.S. Patents.
Find the list of all the Ultrasonic Equipment Patents on our website below:
hps://www.dukane.com/patents/

SECTION 1 - Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Press System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
General User Informaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
AC Power Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
IQ Explorer 3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Key Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 2 - Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HMI Cable Connecons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
System Cable Connecons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
SECTION 3 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Geng Started Using IQ Explorer 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Regulatory Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Contacting Dukane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Dukane ISO Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Contents

SECTION 1 - INTRODUCTION
IQ Explorer 3 QUICK START GUIDE 1
SECTION 1
Introducon

IQ Explorer 3 QUICK START GUIDE 2
SECTION 1 - INTRODUCTION
Press System Overview
The Innity Series Servo Ultrasonic Press System is used for welding thermoplascs. A typical Innity™ ultrasonic welding
system is shipped completely with a press (thruster, base, and column), generator, an ultrasonic stack (transducer, booster,
horn), xturing, cables, and a HMI (with the IQ Explorer 3 soware installed) for applicaon setup and data acquision.
General User Information
This Quick Start Guide provides informaon to set up and operate Dukane’s HMI and IQ Explorer 3 soware. Please read
it before using the system to become familiar with the equipment to ensure correct and safe operaon.
Figure 1-1 Typical Press System
THRUSTER
HMI
GENERATOR
Introducon

SECTION 1 - INTRODUCTION
IQ Explorer 3 QUICK START GUIDE 3
AC Power Requirements
Dukane HMI
AC line voltage - 90-260 VAC
AC line current - 1 Amp
IQ Explorer 3 Overview
The IQ Explorer 3 soware comes standard on a Dukane HMI. This program connects with the Innity™ generator/press
through a user interface and is used for conguraon and setup.
Key Features
IQ Explorer 3 User Interface
• Windows 10 operang system - Familiar le folder menu structure, requiring no special training.
• Touch screen input - Makes programming easier. All welder setup parameters are programmed from one menu page.
(Applies to the HMI or PCs with touch screen, such as tablets.)
• Ethernet connecvity - For communicaons to the Innity™ welder.
• Control - Control feature for locking out system controls that complies with FDA 21 CFR Part 11.
• Remote connecvity - Dukane hotline is available for system diagnoscs and troubleshoong 24-hours a day. (VPN
access to the welder’s network is required. Consult with your IT sta about availability.)
• One screen operaons page - Most recent weld cycle and graph data with ability to modify commonly used process
sengs.
• F1 Help command - Instantly displays explanaon of funcon.
• IQ Explorer 3 User Interface - It is a peripheral device. Operaon is independent of the generator, and removal or
malfuncon of the IQ Explorer 3 does not aect machine funconality.
• Eight user-selectable graph parameters - Velocity, energy, power, distance, amplitude, frequency, force and pressure
for viewing and storage of each weld.
• Producon analysis screen - Displays eight-hour shi producon stascs: good, bad, suspect quanes and
percentages.
• Advanced stack diagnoscs - Includes power and frequency graphs for stack (horn) documentaon and future
reference for troubleshoong.
• Tool idencaon - Uses barcode system to idenfy tooling.
• Work cell - A Dukane Lean Work Cell can be integrated with basic PLC managed operaons.
• Data Analysis for SPC - Feature that aggregates and charts large quanes of cycle data results.
• Barcodes - Feature that allows scanned barcodes from parts to be aributed to cycle data.

IQ Explorer 3 QUICK START GUIDE 4
SECTION 2
Cable Connecons

SECTION 2 - CABLE CONNECTIONS
IQ Explorer 3 QUICK START GUIDE 5
HMI Cable Connecons
Figure 1-1 HMI Connecons
AC POWER CONNECTION HMI POWER SWITCHETHERNET PORTS

IQ Explorer 3 QUICK START GUIDE 6
SECTION 2 - CABLE CONNECTIONS
System Cable Connecons
Typical system components are:
• Ultrasonic Generator
• Press
• HMI
Make cable connecons in the following order, referring to the Fig 1-2 and Table 1-1 on the next page:
1. Connect cables 1-5. Cables 3 and 4 are to be connected to an eecvely grounded rod.
2. Connect cable 9 if oponal automaon equipment is used with the system.
3. Connect power cords 6-8.
4. Arrange cables as desired, but do not bundle the power cords (6-8) with any other cables.
CAUTION
Before connecng or disconnecng cables: Put power switches for the generator, press,
and any user-supplied automaon equipment in the OFF posion. Turn o electrical power.
Remove AC power cords from their receptacles.
DO NOT operate the generator unless the ultrasound coaxial cable is connected, and the
transducer is installed in the thruster. Otherwise, an overload condion could occur, with
possible damage to the generator.

SECTION 2 - CABLE CONNECTIONS
IQ Explorer 3 QUICK START GUIDE 7
Figure 1-2 Cable Connecons
Table 1-1 Cable Connecons
Cable Number Cable Description Standard Length (Meters)
1 Ultrasound 2
2 Press Interface 2
3 Press Grounding 5
4 Generator Grounding 5
5 HMI Communicaons (CAT 5 / RJ45 Ethernet cable) 3
6 Press Power Cord (line voltage: 90-240 VAC, 50/60 Hz, 10 A) 2
7 Generator Power Cord (line voltage depends on generator model) 2.5
8 HMI Power Cord (line voltage: 90-240 VAC, 50/60 Hz, 10 A) 2.5
9 Automaon I/O (oponal) 3

IQ Explorer 3 QUICK START GUIDE 8
SECTION 3
Operaon

SECTION 3 - OPERATION
IQ Explorer 3 QUICK START GUIDE 9
Geng Started Using IQ Explorer 3
STEP 1 - Getting Started
Ensure that a proper connecon of the IQ Explorer 3 soware and the servo press has been made. See Figure 3-1 below.
STEP 2 - Select Unused Setup
Click on the Hardware tab. Click on the Setup File Name drop down box and select an unused setup as shown in
Figure 3-2.
Name of the connected welder.
Names of acve welders in
the network appear when
Show Welders tab is clicked.
Figure 3-1 Connected Welder
Figure 3-2 Setup File Selecon
Setup file
Hardware tab

IQ Explorer 3 QUICK START GUIDE 10
SECTION 3 - OPERATION
STEP 3 - Set the Cycle Initiation Mode
Click on the Process Sengs tab. Select Manual from the pull down menu as shown in Figure 3-3.
STEP 4 - Specify the Trigger Settings
Select Force from the TRIGGER type drop down box. Then, program the desired amount of force the press is to apply
before ultrasound is acvated. Next, enter the Max Trigger Time. This provides a measure of safety insuring the welder
will terminate if the welder never achieves the programmed trigger force as shown in Figure 3-4.
Figure 3-3 Iniate Mode
Figure 3-4 Trigger Force Sengs
NOTE:
This Iniate Mode selecon assumes there is a stand-alone, benchtop system with
manual operate switches.
Process Sengs tab
Select Manual

SECTION 3 - OPERATION
IQ Explorer 3 QUICK START GUIDE 11
Figure 3-5 Sensing Speed and Posion
Figure 3-6 Teach Sensing Start Posion
STEP 5 - Program the Sensing Speed
The Sensing Speed is the speed (inches/millimeters per second) at which the horn will move during the approach just
before reaching the trigger posion. A typical starng value for Sensing Speed is 1.0 mm/s (0.040 in/s). The Sensing Speed
can be set higher for shorter cycle mes, or lower for greater trigger force detecon accuracy.
STEP 6 - Program the Sensing Start Position
The Sensing Start Posion is the actual posion in the machine travel where the system begins to sense for the trigger force
to be achieved. By the me the horn reaches the Sensing Start Posion, it is already moving at the programmed Sensing
Speed. It is crical to program the Sensing Start Posion so that the horn is never in contact with the part at this posion,
taking into account the height variability of unwelded parts. Failure to do so may result in equipment damage. If you do not
know the posion where this contact is made, select the Teach buon as shown in Figure 3-5.
Note:
The Sensing Start Posion must be set such that the expected sensing distance, weld distance and hold distance do not
exceed the Travel Limit.
The Travel Limit must be set to allow the full weld cycle to occur while also prevenng the horn from contacng the xture.
STEP 7 - Teach the Sensing Start Position
Aer clicking Teach, you will see a window similar to the one shown in Figure 3-6. Place an unwelded part into the xture.
Press both operate switches to jog the horn down to within 0.254 - 0.762 mm (0.010 - 0.030 inches) above the part. The
stroke posion of the thruster will be shown in the Current Posion box. Once you are at the desired posion, press Set to
program that distance. Select Exit, and follow instrucons to home the machine.

IQ Explorer 3 QUICK START GUIDE 12
SECTION 3 - OPERATION
STEP 8 - Program Weld Characteristics
Primary Method
On the Process Sengs tab, nd Weld > Primary Method, and select Distance.
Distance - This is the distance the welder advances once the programmed trigger force is reached. Usually this distance is
the height of the energy director, or shear joint of the part being welded.
Max Time is a component of the weld method intended to oer a measure of safety. If the programmed weld method
parameter is not achieved within this me window (2 seconds as shown in the example of Figure 3-7), the system will fault.
Secondary Method
Connue programming weld characteriscs by selecng one of the Secondary Methods available: Posion, Energy, Peak
Power, Force Change, and Force Rate.
The purpose of the secondary method is to end the weld phase if the selected method parameter value is reached. If
Disabled is chosen, there would be no secondary weld method.
Figure 3-7 Primary Method
Figure 3-8 Secondary Weld Method

SECTION 3 - OPERATION
IQ Explorer 3 QUICK START GUIDE 13
STEP 9 - Enable Melt Detect™
This patented feature is found only on Dukane's servo press systems. If the feature is selected, the system will stop
moon once the desired Trigger Force is achieved. The ultrasound will be iniated at this moment. Once the programmed
Melt-Detect™ force drop occurs, which indicates material soening or melng has begun, the moon will connue. This is
the basis for Dukane's exclusive Melt-Detect™ technology.
The value of the Melt-Detect™ Force Drop parameter is used to designate how much the force is to decrease relave to
the Trigger Force before the horn will resume the programmed weld moon. For example, for a Trigger Force of 180 N and
a value of 5% for Melt-Detect™ Force Drop, the press would stop once the Trigger Force is achieved, and resume moon
aer the force drops by 9 N (5% of 180 N) below the Trigger Force, or 171 N. A starng value of Melt-Detect™ is typically
in the 5-10% range. The benet of this opon is signicantly less stress on the parts and stronger weld bonds.
STEP 10 - Specify Weld Profile
Immediately aer Trigger (or Melt-Detect™) occurs, the press changes the speed of moon to the Weld Speed. Enter the
selecons described below as shown in Figure 3-10.
Weld Prole - Select Segmented.
Click the Speed Prole buon - Enter the desired weld prole speeds for segments 1 through 10.
Figure 3-9 Enable Melt-Match
Figure 3-10 Weld Prole and Speeds

IQ Explorer 3 QUICK START GUIDE 14
SECTION 3 - OPERATION
STEP 11 - Set Ultrasound Amplitude
A typical inial ultrasound weld amplitude seng is 100%. The default amplitude seng is 90% as shown below in
Figure 3-11. The range for this feature is between 20% and 100%.
STEP 12 - Post Weld Settings
The post weld phase of the process is somemes overlooked; however, it is important in achieving desired weld results. The
Innity™ servo welder has several exclusive post weld control parameters that can improve weld bond strength and process
repeatability.
Hold Methods
There are two types of hold - Dynamic Hold and Stac Hold. These types can be used together or separately.
Dynamic Hold Method
During Dynamic Hold, which occurs immediately aer the weld phase, the press will connue to travel at the programmed
hold speed with the ultrasound turned o.
This feature provides the ability to collapse the molten plasc aer the ultrasonic signal is turned o, before material
solidicaon. This feature can be benecial in producing superior weld strength and appearance.
To program Dynamic Hold, nd Post Weld > Dynamic Hold Method, and select Distance. Then enter the desired Hold
Distance, Speed, and Max Time. The Max Time parameter is used to terminate the machine cycle if the dynamic hold distance
is not reached within the allowable me window. See Figure 3-12 below.
Figure 3-11 Default Weld Amplitude Seng
Figure 3-12 Dynamic Hold Methods

SECTION 3 - OPERATION
IQ Explorer 3 QUICK START GUIDE 15
STEP 13 - Specify Process Limits Behavior
For each limit that is important to your applicaon, use the drop down menu, and select Display. See Figure 3-14.
These parameters will be displayed on the Cycle Data screen, and may be important for subsequent analysis of the weld
process.
Once the process sengs are fully developed for the applicaon, the Process Limits can be set to Suspect and/or Bad to
idenfy part assemblies of inferior weld quality.
Stac Hold Method
Aer the compleon of dynamic hold, if enabled, the press moon stops for a specied amount of me to allow for molten
plasc to solidify. This phase is called stac hold.
To program stac hold, set the Stac Hold Method to Time, and enter the desired Hold Time. Once the stac hold phase is
complete, the press retracts back to the Top-of-Stroke posion.
This unique feature allows for superior consistency on overall part height. This is unlike a pneumac press that connues to
compress the part during the hold phase. In addion, Stac Hold can contribute to stronger weld bonds. See Figure 3-13
below.
Figure 3-13 Stac Hold Method
Figure 3-14 Process Limits Tab
Process Limits Tab

IQ Explorer 3 QUICK START GUIDE 16
SECTION 3 - OPERATION
STEP 14 - Run Weld Cycle
Aer all the parameters have been programmed, iniate the weld cycle.
STEP 15 - View Weld Results
View the results at the Cycle Data tab to insure all parameters have been achieved. See the example shown below in
Figure 3-15. Detailed performance graphs for select parameters may also be reviewed by selecng the Graph tab.
Figure 3-15 Cycle Data Tab
Cycle Data Tab

IQ Explorer 3 QUICK START GUIDE 17
FCC
The Innity™ generator complies with the following Federal Communicaons Commission regulaons.
• The limits for FCC measurement procedure MP-5, “Methods of Measurement of Radio Noise Emissions
from ISM Equipment”, pursuant to FCC Title 47 Part 18 for Ultrasonic Equipment.
CE Marking
This mark on your equipment ceres that it meets the requirements of the EU (European Union) concerning
interference causing equipment regulaons. CE stands for Conformité Europeéne (European Conformity). The
equipment complies with the following CE requirements.
• The EMC Direcve 2014/30/EU for Heavy Industrial —
EN 61000-6-4:
EN 55011
EN 61000-6-2:
EN61000–4–2
EN61000–4–3
EN61000–4–4
EN61000–4–5
EN61000–4–6
EN61000–4–8
EN61000–4–11
• The Low Voltage Direcve 2014/35/EU.
• The Machinery Direcve 2006/42/EC. EN 60204: Safety of Machinery - Electrical Equipment of Machines
Part 1: General Requirements.
• EN ISO 12100: Safety of Machinery - General principles of design, risk assessment, and risk reducon.
IP Rating
The Innity™ generator has an IP (Internaonal Protecon) rang from the IEC (Internaonal Electrotechnical
Commission).
The rang is IP2X, in compliance with nger-safe industry standards.
The Innity™ generator complies with these standards as veried by TÜV Rheinland.
UL
Tested to Underwriters Laboratories:
UL 61010–1, IEC 61010-1
CAN/CSA
Naonal Standards of Canada: CAN/CSA C22.2 No. 61010–1–12
Regulatory Agency Compliance