Dukane Dual Servo Spin Welder 403570-01 - Manual (Page 81)

Dukane Manual Part No. 403-570-01 Page 75
Section 9 - Troubleshooting
Problem Symptom Possible Cause Recommended Solution
Overwelding
Excessive weld flash
Welded assembly
dimensions are too
small
Weld Time or Distance are too large Reduce Weld Time or Distance
Incorrect flash trap design Evaluate and correct flash trap design
Underwelding
Low strength weld
Welded assembly
dimensions are too
large
Weld Time or Distance are too small Increase Weld Time or Distance
Material difficult to weld due to low friction
coefficient
Degrease joint interface to remove mold release
agent
Consider changing material (i .e . avoid PTFE)
Nonuniform or
inconsistent
weld joints
Excessive weld flash
Low weld strength
Failure when leak
tested
Part failure in service
Warped parts Check part dimensions
Uneven weld interface Check molding process conditions
Fixture and part are not parallel Level fixture where necessary
Check that tooling is true to table
Poor alignment of parts in tool and/or
fixture
Change part or tool dimensions
Improve part tolerance due to cavity
Insufficient fixture support Check for parts shifting during welding
Provide features in parts for rotational driving (i .e .
drive ribs or cavities)
Part walls flexing during weld Redesign parts with reinforcing ribs and/or tongue-
and-groove joints
Excessive filler or uneven distribution Reduce amount of filler
Improve processing conditions to ensure even
distribution of filler
Moisture in parts Prevent moisture absorption after molding prior to
welding
Dry parts before welding
Final part
orientation
different from
programmed
orientation
Parts not aligned
properly
Deceleration too low Increase spin deceleration as high as possible (if
set too high, welder will fault with tracking errors)
Vertical speed too high Reduce speed to decreased spin torque required
Poor tuning Determine and enter tool inertia correctly into Setup
Contact DUKANE for special tuning requirements
Parts not held properly by tool or fixture Ensure tooling does not allow excessive play
Table 9–I Welding Process Troubleshooting