Joining & assembly | processing
Increasingly complex part designs and more demanding polymer materials are challenging welding technology developers to come up with innovative equipment and process solutions. Mark Holmes reports
Improving the welding process
Part integration may be high on the priority list for today‘s product designers but the fact remains that many plastic injection moulded components will require one or more subsequent assembly and joining steps, according to Thomas Herrmann, chief executive offi cer of Herrmann Ultraschall, a leading manufacturer of ultrasonic welding machinery. “A few years ago we thought that the trend towards multi-component injection moulding would replace bonding on a large scale. However, that has not been the case,” he says. In fact, Hermann says demands on post-moulded as-
sembly and joining technology providers are intensify- ing. “Products get more sophisticated and consumer expectations have risen,” he explains. “We see a bright future for joining methods that are able to measure, evaluate and improve joining quality. When it comes to the point of joining within the value chain, it is often the case that signifi cant value has been created which needs to be preserved.“ One of the most noticeable trends across the entire
global manufacturing sector is the need to lift quality while remaining effi cient and cost competitive. “Look and feel are becoming increasingly important to achieve market share, even in developing regions such as China and India,“ he says. Process management is also moving up the agenda for
many plastics processors and their customers. “The hot topic right now is Industry 4.0 – the connected industry or smart factory. As providers of ultrasonic welding
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technology we are in a leading position. The heart of the ultrasonic welding system – the digital ultrasonic generator – already collects a vast amount of process data and can communicate this to other production control systems. Now it is all about ‘smart connecting’ and creating suitable and manageable ‘data packages’ for other participants within the production chain.” As a supplier of ultrasonic welding equipment, Herrmann Ultraschall typically fi nds itself in competition with laser, vibration and hot plate welding or mechanical processes such as screwing and gluing. While ultrasonic welding has physical limits – not all shapes and materials can be welded – Herrmann asserts it is the fastest and arguably the most precise joining technology. Parameters can be set for the process to evaluate and optimise each single ultrasonic weld step. This means the process is repeatable – a characteristic he argues is not shared with all other technologies.
Membrane solutions Herrmann Ultraschall has introduced a number of new products to meet the evolving demands of the injection moulding industry. “The number of plastic components with integrated membranes is on the rise – especially in the automotive, electronics and medical industries,” according to Herrmann. “These membranes are used as fi lter media or pressure-compensating elements. In the assembly process, previously costly pre-tailored membranes had to be removed from a carrier belt by
May 2016 | INJECTION WORLD 25
Main image: Hermann
Ultraschall built this complex 220mm by 180mm
sonotrode with varying weld
contour height for medical products
maker Genicon
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