Manufacturers are always looking for ways to increase machine efficiency to save cost. This is a recurrent theme and is a constant challenge to find new ways to push the envelope. As an industry leader in ultrasonic welding technology, Herrmann Ultrasonics recognizes these challenges and looks for ways to apply cost and time saving measures to ultrasonic welding processes.
The VARIO series can be configured to completely suit the user’s needs. For that purpose, it provides multiple pneumatic drive modes with different stroke designs – all with reliable and programmable proportional valve technology. Generators are also available in three different frequencies and several power ratings of up to 6200 W. Setup and change-over times significantly influence the efficiency of manufacturing. The VARIO product line significantly reduces these times. For example, with the help of the quick-change system (QCS), the aligned weld tools can be changed to a new application in less than a minute, including the VARIO control weld process data. Up to 32 different weld applications are stored in the fully integrated controller.
Precise weld force control: Joining force is a critical variable for the quality of a weld. It significantly influences the joining velocity and thus also optimum strength of the weld. With the VARIO welder it is possible to program a variable weld force in two stages. As a result, a controlled buildup of the plastic melt is obtained, which is a suitable condition for welding at maximum strength and tightness. The force switch-over is implemented through a proportional valve, which has been specifically configured for this type of highly precise and fast control.
Ultimate production safety: Manufacturers using the VARIO for different devices will benefit from new safety measures, adding immense production security. The first is an RFID reader, which has been integrated into the tooling, guaranteeing that the right tool is installed for the production. Not only is it built into the sonotrode but also into the fixture. The ultrasonic welding system automatically associates the correct parameter setting for parts to be welded with the installed tooling. Adding a second level of security is the integration of a custom sensor, which depends on what the manufacturer wants to detect — such as color, label, shape, and so on. Before each ultrasonic welding process, it verifies that the correct part regarding shape or color has been placed into the fixture. If the system recognizes a mismatch, it locks the process, alarms the operator or puts the system on hold. Both features can be easily integrated into the successful HiQ series ultrasonic welding machines or VE actuator series, without having to add any additional external hardware or software. All elements are already available within the software setup package.
The HiQ VARIO with RFID reader and more will be shown at NPE 2018. Visit booth #W-8153 to see demonstrations.
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 managed by sophisticated control software and must be adapted to the geometry and condition of the welded parts, which are made from amorphous or semi-crystalline polymers. Each welding tool, known as the sonotrode, is unique, as it is adapted to the application at hand. Ultrasonic welding is very suitable for the medical manufacturing industry. For more information, visit www.herrmannultrasonics.com.