Ultrasonic welding of plastics is an intricate task. Each application is different and places different requirements on the complex interplay of factors. Acoustic waves – or ultrasound – are converted into mechanical vibrations to generate molecular heat. The weld process is controlled by control software and must be adapted to the geometry and condition of the welded parts, which are made from amorphous or semi-crystalline polymers. The welding tool, the sonotrode, is unique as it is adapted to the application. This is just an example of the complexity involved in ultrasonic welding.
Herrmann Ultrasonics has introduced a new generation of machines for this application, the HiQ. The product line addresses specific ultrasonic welding requirements. The machine lets you configure welding applications in a more targeted and individual manner.
Ultrasonic welding uses 75% less energy than other thermal joining processes because the welding tools remain cold and have a low energy requirement. The ultrasonic vibrations are applied to the joint area for only a matter of milliseconds during welding. The smallest ultrasonic generator of the machines works with an efficiency of more than 80% when powered with up to 6000 W. The HMC (Hybrid Motion Control) flexible drive concept (on the DIALOG unit) helps speed production.
The HiQ DIALOG is a force-profiling unit with four weld forces, extended memory and weld process graphics. The 1000 weld memories each store 300 welds, including all the relevant graphics – making full use of historical monitoring. This feature achieves strong joints for demanding applications. In the user interface, the EasySelect mode eliminates all but the most important primary functions for better usability. You can revert to expert mode, with all functions activated, at the touch of a button. With the QCS (Quick Change System) no tools are needed, and the ultrasonic stack can be mounted without the need for hand tools.
The HiQ VARIO uses proportional valve technology and digital high-performance generators. A range of pneumatic drive units with several stroke and cylinder diameters are available, all of which feature the proportional valve technology. Graphic visualization of the joining process aids the operator when programming process parameters and recording quality information. When selecting a generator, you can choose between three frequencies and several power outputs up to 6000 W. Standard equipment includes multiple USB high-speed interfaces, printer, and Ethernet connections.
The HiQ LOGIC has five welding modes. It includes a travel measuring system and proportional valve technology. Plus, it has five operating modes: time, power, energy, depth RPN and absolute distance. A clear 5.7 in. touch screen allows the operator to parameterize and check the weld process.
The HiQ SOLID machine includes proportional valve technology and digital high-performance generators. The STE model is the basic model, which features two welding modes, time and energy. There is also the optional SDM component with additional distance modes for improved monitoring of weld process.
The VE SLIM LINE series includes one of the smallest, most powerful generators on the market. The generator output is available with up to 6000 W. The actuator widths are narrow. This machine is equipped with a compact 5.7 in. color touchscreen controller and data acquisition for all critical weld parameters is possible.
Filed Under: Machine tool industry + subtractive manufacturing