At Dukane Ultrasonics, we call this "customer-driven design" and it has been our guiding philosophy. By focusing on your needs, we have been first to introduce technological solutions that have become industry standards. Below are some of the industry firsts that you have helped us design over the years.

2000s

• Power Regulation patent
• iPC Process Control Software
• Magnum Transducer with Crush Foil patent
• 15 kHz with Ultra-com

1990s

• 1997 Millennium 4100 40 kHz 1000 watt system
• 1996 DSS Dual Support System - metal welding patent
• 1995 - 1997 Advanced Programmer Plus (APPlus) for the UltraCom
• 1993 - 1995 Man-Machine Interface (MMI)
• 1992 - 1993 Dynamic Process Controller™ (DPC)

1980s

• 1986 - 1988 AUTO-TRAC tuning
• 1985 - 1988 weld by distance
• 1984 - 1987 UltraCom microprocessor process control
• 1984 - 1986 7-inch stroke
• 1983 - 1985 limit switches
• 1982 - 1984 hydraulic speed control
• 1980 - 1983 linear ramp soft start and pulse-width modulation

1970s

• 1978 - 1979 3-bearing press system
• 1974 - 1975 welding with dual pressure
• 1973 - 1974 composite horn technology patented

A composite horn is a half-wave coupler horn with 2 or more half-wave horns attached to it. Composite horns deliver higher amplitude than a single, large horn, distribute the ultrasonic energy to multiple contact points, and often eliminate the need for multiple assembly units or cycles.

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A feature exclusive to Dukane equipment, welding with dual pressure lets you vary the pressure during the assembly process. You can use both pressures during the weld cycle, or one during the weld cycle and one during the hold cycle. Dual pressure can solve some tough applications, such as welding thin-walled components, and improve joint strength, reduce flash, and attain hermetic seals.

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The 3-bearing press system provided a marked improvement in press actuation by minimizing operating friction and providing smoother operation. The virtually frictionless movement allowed the press to be more rigid and reliable.

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Patented Linear Ramp Soft Start accelerates the assembly system's operating power and amplitude in a linear manner, rather than in instantaneous jumps, which create power surges and component stress. Patented Pulse-Width Modulation ensures power is sent to the load with minimal heat energy dissipation. Both innovations vastly improve the reliability, efficiency, and life expectancy of assembly system components.

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This innovation assures precise, repeatable control of horn travel during the weld cycle just before and while the horn is in contact with the workpiece. Hydraulic speed control regulates the material flow in the weld joint and improves the finished appearance of many applications.

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Control, accuracy, and repeatability improved as limit switches became the first means of electronic control for turning on and off the ultrasonic energy at predetermined positions during the weld cycle.

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A 7-inch actuation stroke significantly expanded the range of application sizes that could be assembled by a press system.

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The revolutionary UltraCom ultrasonic process controller, a dedicated microcomputer that gives the user the ability to control and monitor the assembly process, is introduced. No other competitor in the industry can match its versatility and ease-of-use.

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Using a linear encoder in conjunction with the UltraCom, weld by distance sets, measures, and controls precise melt collapse distances. This technology ensures a consistent volume of plastic melts with each assembly, reducing the number of rejects   dramatically.

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The introduction of AUTO-TRAC tuning eliminates the need to manually match the specific horn and transducer frequencies to that of the generator. AUTO-TRAC tuning automatically locks the generator to the resonant frequency of the transducer, even under varying temperature and loading conditions.

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Utilizing a powerful 32-bit RISC microprocessor, the Dynamic Process Controller is the next advancement in process control technology. The DPC combines the functions of the generator, process controller, and multiplexer (networking) into one, space-saving unit. With built-in expansion and upgrade capabilities, the DPC hosts a variety of new design, power, and control features, including line and load regulation, power factor correction, and universal voltage input.

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The MMI, now obsolete, was a portable, lightweight data entry/visual display device used with the Dynamic Process Controller. The MMI employed leading-edge LCD touch screen technology with intuitive menus and prompts for easy user interactivity during setup, data collection, and process monitoring and control. The MMI also eliminated the need for separate keyboard and monitor devices.

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The APPlus products are full-featured, Windows-based software emulations that allow users to control and monitor their Dukane assembly systems using a Windows-compatible PC.

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The DSS System uses an actuator that holds a full-wave horn between two solid boosters. This unique system allows increased size and power capabilities, while maintaining control and rigidity.

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The first 40 kHz ultrasonic assembly system to offer 1000 watts of power, the 4100 system expands the application range of ultrasonics to include larger parts, while maintaining the delicate touch of high frequency.

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The 15 kHz ultrasonic welder extends the range of ultrasonics to low frequency operation with the accuracy of the Ultra-Com microprocessor control and Advanced Programmer Plus control option with full-size computer monitor that continuously displays the process parameters for multiple parts and provides tutorial, menu-driven setup functions.

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Designed using FEA, this heavy-duty 20 kHz transducer includes Dukane's patented crush-foil technology, and provides both slightly higher amplitude and improved operating efficiency. Reduced heating, improved cooling, better stress distribution, and a keyed front slug that improves abuse resistance makes the Magnum Transducer the premium transducer for challenging operations.

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Dukane's iPC is the latest in user-friendly interface for ultrasonic welding systems. The browser-based interface is used to set parameters and display part data, providing a complete graphical environment for communicating with the DPC IV ultrasonic system.

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Dukane's patented approach to controlling amplitude in the continuous processing of fabrics and films results in benefits where abrupt changes in material thickness have produced over-welding or burns when processed on conventional systems.

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