|Dukane's 5000 Series Vibration Welder|
The Plastic Industry uses linear vibration welders to weld two plastic components, by creating linear oscillatory motion of one part relative to another part. The parts are brought together by force, the oscillatory motion generates heat, which melts the adjacent surfaces of the plastic parts and creates a weld after the parts cool. The vibratory movement of one part relative to another part is generated by two electromagnets positioned between moveable and stationary part of the welder. Both electromagnets apply force along the same coordinate line, but in opposite directions. The electromagnets are energized with a 180-degree phase shift so that when the first electromagnet is energized, the second one is de-energized and vice versa.
|HMI Screen showing 'Q' Factor|
Vibration welders are key investments for many manufacturers. Therefore, manufacturers seek ways to optimize their use and get better ROI on these machines. One of the ways to do so is to rotate tools on the same machine and weld various plastic assemblies. However, the challenge is to monitor and maintain the quality of tools and their proper installation during tooling changes. Calculating and storing the ‘Q’ value for each tool helps in monitoring proper installation. When a user changes the tool, a new ‘Q ‘value is calculated, which serves as a quantitative measure of the tool quality. Difference between original ‘Q’ value stored at the time of factory testing of the tool and the new calculated ‘Q’ value after installation at plant floor can indicate improper installation.
‘Q’ factor of a welder is a function of the quality of its springs, coils, lamination carriers, drives, and the actual upper tooling. While springs, coils, lamination carriers and drives have good repeatability and tight tolerances (since they are standard components shared among the machines), the upper tooling is unique to every part being welded. Therefore, the quality of the tooling design, manufacturing, and installation can have a significant effect on the overall welder performance.
For more information of Dukane's Vibration Welding technology and products visit http://www.dukane.com/us/PVI_VibeWeld.htm or call 630-797-4900.