New Plastic Welders Provide Ultimate Control Over Joining Process

Engineers have many options for welding plastic parts, including ultrasonic, vibration, laser and hot-plate welding. Two of the newest machines for joining plastic parts will be on display at The ASSEMBLY Show this fall.

Rinco Ultrasonics has introduced the Electrical Motion series of ultrasonic welders. Available in 20- and 35-kilohertz frequencies, the servo-driven machine provides superior performance, cost effectiveness, and user-friendly features.

“Our next-generation Electrical Motion 20 and 35 machines take electrically driven ultrasonic welding to a new level, pushing the limits of what our customers can achieve in weld quality and repeatability,” says Serge Patamia, CEO of Rinco Ultrasonics, based in Romanshorn, Switzerland. “We’ve developed a more intuitive ultrasonic system that is faster and more efficient to help manufacturers meet today’s demanding productivity demands.”

Rinco completely redesigned the operating system, which significantly increases screen response time. The Linux Ubuntu operating system is logically structured, self-explanatory, and easy to use. In addition, the new operating system doesn’t require a licensing agreement, like Windows-based systems.

The welder also has a completely new graphical user interface. Ergonomic and intuitive, the interface affords operators much greater flexibility, access and speed. It is easily operated via a 12-inch color touch screen monitor. It also provides programmable password protection, offering many levels of digital security and protection.

In addition to eight welding modes, engineers can set a trigger to initiate the ultrasound. Engineers can choose from the following triggers: time, travel, force or an external signal. Engineers can optimize the welding process by adjusting the stroke of the ram to match the application. Engineers can program the lowering speed, touchdown speed, braking point, force profile and speed profile.

Unlike pneumatic machines, in which the horn returns after every weld cycle to the mechanical home position of the cylinder, the starting position of the Electrical Motion welder can be freely selected to any position. As a result, the weld cycle can often be shortened, depending on the welded object’s geometry.

To prevent lightweight workpieces from potentially sticking to the horn, an after-pulse can be activated.

A new stack mounting feature facilitates easy alignment for quick-change tools. Force and amplitude can be calibrated. The machine offers permanent audit trails, so engineers can track all system errors and adjustments. To ensure quality and process traceability, all events and changes to the parameters are automatically stored in an audit trail protocol. This permanent audit trail help medical device manufacturers comply with the unique requirements of their industry.

Traceability also helps provide quick diagnosis of any problems. With the help of remote access using an internet connection, a Rinco technician can quickly identify any issues and, in many cases, directly correct any parameter errors immediately.

A part counter and a reject counter are integrated into the welder. They can also be set as a limit.

The machine meets ISO 13485 and Class 6 clean room requirements.

The HD-OSW servo spin welder has received a major upgrade, providing greater performance, user-friendly features, and easier integration into for automated assembly systems.
Photo courtesy Forward Technology

Servo-Driven Spin Welder

Rinco’s sister company, Forward Technology, has introduced a newly upgraded version of its HD-OSW servo spin welder. The machine has undergone a major upgrade, providing greater performance, user-friendly features, and easier integration into for automated assembly systems.

“We see strong market demand for our upgraded HD-OSW model, which is an economical, high-performance option that ensures ease of use and integration for both customers and integrators alike,” says Brett Raisanen, president of Forward Technology.

The spin welder provides a range of user-friendly features to facilitate operation with a minimal need for assistance or training. Among the new updates are a fully revamped electrical architecture and controls, higher resolution touch screen, the look and feel of a tablet computer, and an enhanced servo drive for greater performance.

The machine also offers easier export of logged data; easier integration of the machine into plantwide SCADA systems or other network infrastructure; and multiple communication protocol options for ease of integration. This is important for machine builders that now have the option of using their native control architecture without engineering fees or changes to a standard machine.

While the ram is driven by a pneumatic cylinder, the rotation is controlled by a servomotor. The machine is designed for larger diameter, more difficult spin welding applications requiring delivery of high rotational power while maintaining the highest degree of precision.

However, the machine can also be used for small, intricate parts. The high-performance servo package allows for precise torque control in addition to instantaneous stopping, which is required to prevent a small weld from breaking. The machine can orient part halves relative to each other with a positioning accuracy of ±1 degree. Exact start and stop points can be programmed and precisely controlled.

Other improvements include simplified remote support without the need for third-party software or additional hardware; simplified electrical integration; and enhanced diagnostics and messaging for operators and maintenance staff.

For more information on plastics assembly equipment, click www.rincoultrasonics.com or www.forwardtech.com or visit the companies’ booth at The ASSEMBLY Show. Rinco and Forward are two of many suppliers of plastics assembly equipment that will be exhibiting at the show, which will take place Oct. 22-24 at the Donald E. Stephens Convention Center in Rosemont, IL. Besides plastics assembly equipment, you’ll find 250 suppliers of robots, automation, motion control technology, parts feeders, fastening tools, software and other assembly technologies. For more information, visit www.theassemblyshow.com.