Vibration Welding Machine Manufacturer Hot Plate Welding Machine Manufactur
Vibration welding is a process that generates frictional heat to melt two thermoplastic parts together without the use of adhesives. The resulting weld is clean, economical and versatile.
Welds plastic products including thermal insertion, hot staking and medical port/plate welding. Features closed loop process controls & touch screen interface.
Welding Materials
The vibration welding process produces a side-to-side scrubbing motion that creates frictional heat and generates a weld. It is used to join large plastic components that would otherwise require the use of adhesives or mechanical fasteners. The scrubbing action of the Vibration welding machine Manufacturer helps to disperse the heat evenly across the weld surface and reduces the amount of energy needed to create the weld.
The process is suitable for all thermoplastic materials including polypropylene (PP), polyethylene (PE), polystyrene, acrylonitrile butadiene styrene (ABS), thermoplastic polyester, cellulosics, phenolics, and elastomers. In addition to the standard polyethylene and PP, it is also possible to weld a variety of other types of polycarbonate, such as styrene-acrylonitrile blends (ASA), and terephthalate acrylonitrile blends (PBT).
Vibration welding is capable of producing welds with a wide range of weld thicknesses. The weld strength of the finished joint depends on the pressure applied during the welding cycle. High weld pressures lead to longer cycle times and lower threshold penetrations, while low weld pressures result in higher cycle times and unacceptably high threshold penetrations.
One major electrical appliance manufacturer switched a production line of glass-filled PP dishwasher pump housings from hot Hot Plate welding machine Manufacturer because it was faster, cheaper, easier, and safer. It also eliminated the need for ventilation equipment, because it does not produce toxic fumes.
Controls
Welding with vibration is controlled by the amplitude and frequency of the oscillation. The process also relies on clamp pressure and weld time to control the strength of the resulting weld. It is important to set these controls properly for the specific materials and part geometry being welded.
In addition to setting the amplitude and frequency, the energy that is used during welding can be set by selecting the power mode. This will determine the amount of energy that is delivered to the plastic during each weld cycle. Using low power modes will reduce the weld cycle time and allow higher amplitudes to be used without overheating the materials.
When compared to other welding processes, vibration welding is not sensitive to surface preparation. It is possible to weld parts with no fasteners or inserts, and it is easy to incorporate other components such as electromagnetic preforms, adhesives, or solvents.
Hybrid vibration welding allows the use of an infrared preheat before applying linear vibration to weld two components together. This improves weld aesthetics and eliminates particulate flash.
Vibration welding is ideal for large components, such as the battery enclosures found in electric vehicles. In fact, CEMAS offers a machine capable of welding an entire automotive glovebox, LH and RH instrument panels at the same time, as well as air-intake manifolds and cooling ducts. It is also possible to use vibration welding for a range of small, complex parts that would otherwise be difficult to mass-produce with other methods, including elastomeric material components and fiberglass-reinforced plastics.
Vibration Welding Safety
As with any welding process, safety measures transform HF welding from a potentially dangerous activity to a carefully controlled exercise in precision. Plant personnel should be thoroughly trained by in-house personnel or equipment Ultrasonic welding machine Manufacturer representatives. They should be familiar with the basics of HF welding, fault diagnostics and equipment features, lockout and tagout procedures, preventive maintenance options, etc. They should also be aware of common snag hazards that can occur while working on high-powered equipment. These include wearing ties, chains and jewelry that may snag on equipment or other items within the work area, sneakers or regular shoes that can snag on machinery, and baseball caps that don’t offer enough protection against machine accidents.
Vibration welders provide the same benefits as traditional hot plate machines, but they can also be used to join dissimilar thermoplastic parts and even plastic parts molded in different ways (injection, extruded, blow, compression or rotational). The linear vibration process creates friction and heat between components and melts and bonds them together. Its fast cycle time reduces particulate flash and improves weld aesthetics.
A fully enclosed cabinet with exhaust fans provides maximum operator safety. A touch panel human-machine interface enables quick and easy setup. Interlocked safety doors and full guarding prevent unsupervised operation. A digital PID temperature control function ensures a more stable welding temperature. Recipe based variants like pressure, time, part and temperature variation allow for optimum weld quality.
Installation
Vibration welding is a contactless process that eliminates the need for cleaning or solvents. It also does not produce smoke, a problem with some traditional hot plate systems that requires the use of ventilation equipment. It is less affected by surface contaminants such as mold release or dust and is somewhat less sensitive to moisture content, although highly hygroscopic materials must be pre-dried to prevent bubble formations.
LARGE PART CAPABILITY – Vibration welding machines can accommodate parts that are larger than those possible with other methods, such as adhesive or spin welding. Examples include automotive glove boxes, LH & RH rear bumpers and filters.
CONVENIENT HANDLING – The weldment can be completed before the parts cool enough for handling, allowing other assembly operations to proceed immediately. Compared to other assembly methods, this improves overall cycle times.
COMPATIBILITY – The vibration welder can be used on most thermoplastics, including filled and reinforced resins. The resulting welds are strong and hermetic.
Linear vibration welding consists of two elements: a linear vibrator suspended from springs and a clamp plate operated by a hydraulic cylinder that lifts it to meet the vibrating platen. The parts sit on fixtures that are custom-designed to fit the contours of each application. Depending on the needs of each job, these fixtures can include: a. external shoulder fixture, b. recessed fixture or c. multiple internal rib fixture.
