Linear Vibration Welder

Linear Vibration Welder

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In vibration welding the welding surfaces are heated up and melted by a friction movement. Like in all other welding procedures they are welded under pressure. The important parameters are: frequency amplitude welding pressure The welding process consists of 4 phases. Optimum welding conditions are achieved with the CPC technology submitted for patent application (please see CPC) Typical applications in the automotive industry: e.g. spoilers, instrument panels, glove boxes, deposit shelves, motor covers, servo-oil reservoirs, filters, trim strips and shock absorbers, suction pipes. in the home appliances industry: e.g. for washing machine parts, base plates of tumble driers, door reinforcements. General technical products: e.g. motor saw housings, siphon traps for water drains, gas counters, printer cartridges etc Quality control and process data monitoring by normative/actual value comparison. During each welding operation a touch panel (TP) displays additionally, graphically or in a description field, the actual value of each welding parameter set by the operator (e.g. pressure, amplitude, displacement and time). The system controls and compares simultaneously the entered data with the actual values while the entered data is considered as a limiting value. In the case of this value falling below or exceeding the TP displays an error message. A restart is possible only after acknowledging the error. Error messages may also be collected automatically via a printer (interface RS 232 on the TP). The parameter protocol can be printed either for each welded part or e.g. after a number of 10 or 100 parts. In practice it is frequently started with a print after each 10 part which is increased to each 100 part in the failure-free production phase. The settings can vary between 1 and 999 parts. CPC - Complete Process Control guarantees a controlled vibration startup under load and an active braking with 60 ms as well as optimum vibration performance during the whole welding process. By this in combination with the two-increased current feed capacity an increase in efficiency of approx. 50 % in comparison with standard vibration technology is achieved. The customer benefits from shorter welding process periods of approx. 30 - 40 % and a reduction of lint formation. Above this the active braking reduces the mechanical stress of the welding seam during the cooling phase. Frequency up to max. 260 Hz. makes short friction welding times possible and increases productivity. All models are also available with low frequency of approx. 120 Hz and increased amplitude up to approx. 4 mm Amplitude control: As standard the machine is fitted with a new amplitude control (in connection with the time-pressure levels). With this technology the amplitude is automatically modified during the different welding phases. Welding power to be selected in up to 8 steps, analogously to the weld and time profiles with actual value acquisition and parameterization. Pressure display as actual value in N (power) Lifting table: Displacement measuring system for lifting table with actual value acquisition and parameterization. Particularly important for the application of various tools (data saved in the tool program). Control of welding displacement with high-precision laser technology as actual value acquisition and parameterization, to be selected in up to 8 steps. Energy control as actual value acquisition with parameterization in J (Joule) Operating modes:Operating modes:Operating modes:Operating modes: time welding control of the weld displacement parameters displacement welding - total stroke control of the weld time parameters travel welding - welding depth The displacement measurement is realized by means of the latest laser technology. Tolerance +/- 0.05 mm. In order to avoid measurement errors by vibrations the measurement takes place inside the oscillating system (head bridge, clamping table) Automatic frequency resonance control (AFRC): Automatic single search run in connection with the CPC, approx. 1 s, in case of tool exchange or commissioning of a new tooling Principal advantages of the vibration welding technology: Welding of a continuous seam also in large parts, like the welding of air channels in I-panels Principle of local heating up due to friction only at the welding surfaces Low energy consumption Very short welding times in a range of seconds Extensive material range for almost all thermoplastics In this way critical thermoplastics like polyamides and different thermoplastics like PMMA with PC and ABS can also be easily combined. Apart from this a solid combination can also be achieved with different materials like composite wood material with thermoplastics. Weldable plastics Semi-crystalline, non-reinforced or reinforced materials are of particular importance, e.g. in all polyamides also with glass fiber portion and other reinforcement components in PE, non-reinforced or with reinforcement components like e.g. talcum. Additionally all important material for the manufacturing of machined parts, like e.g. ABS, SAN, PC, PMMA, PBT and blends like e.g. PP/EPDM, PC + PBT, PPE + PA or welding of plastics with other materials like textile and resin bound fiber material as well as composite wood material. Operating device In its basic version the machine is equipped with a SIEMENS touch panel TP 270 (6 or 10“ screen). The parameters which are relevant for the welding quality are shown as a graphic after each welding cycle for each part. The graphic can be printed by means of the serial interface. On a display the parameters, the trouble shooting and the operating instructions are shown in plain text. Apart from this the manual functions can be selected via the operating device. The parameters can be modified by the integrated operational and numerical keys. In addition, they can be saved as a 5-digit code number. Electrical control The freely programmable PLC Siemens S7 is installed in a standardized electrical cabinet This can either be flanged to the machine or placed separately. In automatic production lines for example this separate placement is recommended. Noise protection cabin consisting of cassette elements with mineral wool, thickness approx. 100 mm. To facilitate the assembly procedure, the noise protection housing is divided and equipped with a quick-locking mechanism. For maintenance purposes the rear side is provided with a lockable double-wing door with safety switches. The complete equipment is placed free-standing on the floor. The operator's side is equipped with a vertically movable pneumatically operated protective door with integrated safety bar. The safety bar stops the closing movement upon contact. With the CPC system the noise level is reduced to lower than 78 dB according to the German standard DIN 45 635. The protection door is equipped with a window made of double safety glass. Tooling State-of-the-art tooling design for all applications taking into account sensitive visible surfaces, like lacquered, leathered, fine-grained or foamed surfaces. Manufacturing and optimization according to customer CAD data. Modell LVW 2020 LVW 2046 LVW 2061 Frequency of vibration head (Hz) 260 260 260 Amplitude (mm) 0,35 - 2,0 0,35 - 2,0 0,35 - 2,0 Welding surface (cm²) up to 110 up to 200 up to 300 Dimensions of lifting table (LxW mm) 520 x 520 1000 x 500 1550 x 500 Max. welding pressure (kN) 4,7 19,8 31,4 Weight of upper tooling (kg) max. 15 40/50 50 Touchpanel - Unit (Zoll) 6 " 6 " 6 " Modell LVW 2261 LVW 2371 LVW 2871 Frequency of vibration head (Hz) 240 100 -180 100 -180 Amplitude (mm) 0,35 - 2,00 0,35 - 2,00 0,35 - 2,00 Welding surface (cm²) up to 450 up to 600 up to 600 Dimensions of lifting table (LxW mm) 1550 x 560 1800 x 600 1800 x 700 Max. welding pressure (kN) 40 47 47 Weight of upper tooling (kg) max. 120 200 220 Touchpanel - Unit (Zoll) 10 " 10 " 1

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