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
machinery
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.
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
applications arise.
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.
SRT-300 Rotary Parts Handling System is designed for
economical semiautomatic operation with a freestanding base,
welder, 6-station rotary table, dial plate, and safety guarding.
Welding, staking, inserting, swaging, and spot welding are
compatible welding applications where medium to heavy-duty
service is required. Systems are available with part sensing,
clamping, automatic eject, suspect bad part separation and other
features. The system operates in two modes: one index at a time
or at a continuous timed rate.
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
future.
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
available.
This is a
Four-headed staking
machine built to use a contoured fixture. The sound enclosure
includes single-point activation and a sliding door for safety and
sound control.
An X-Y sliding table for welding
a taillight lens. Unique design considerations allowed one horn to
be used for a family of different parts.
This
Mini Hot-Plate welder is
used to weld cylindrical air filters and the inner support cage to
thermoplastic end caps.
The system takes up only one fourth the floor area of a conventional
unit. It can be ordered with heavy duty casters making it easy to
position the welder in your plant. Many applications similiar to
this are performed during the molding cycle press side.
Continuous Feed Tube Seal Cell Unit incorporates dual
rigid C frame ultrasonic sealers capable of sealing tubes up to 3”
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
