processing | Joining & assembly
Above: This microfluidic test chip is ultra- sonically welded using 0.1mm high energy directors – in red – to control weld quality
Driven to automate According to Dan Schewe, Regional Sales Manager at plastics welding equipment manufacturer Forward Technology, automation and finished product quality are the key trends driving new developments. “Workforce labour shortages at some injection moulders and keeping piece-part costs competitive are forcing moulders to consider full-automation or semi-automatic assembly solutions for cost reductions,” he says. “In addition, finished part product quality with added process validation capability is now required. This means systems, sensors and programming that verify and monitor that the defined process was fully executed to ensure the parameters used to make a part are actually used. With automation and validation capability, it is now possible to collect process data for later recall - for monitoring or providing proof of the process used, for example“ New designs are also a driver for innovation in
assembly solutions, he says. “Increasingly, projects require additional up-front design consideration and reviews, as well as detailed feedback to drive the product design to be efficient for moulding and assem- bly and fulfil the objectives of the finished part. Much of this work is done prior to the quoting stage, with no real order commitments established between assembly equipment supplier and potentially several customers bidding and working on the same project,“ says Schewe. “In addition, plastic moulding processors are looking
Right: This
Cemas Elettra vibration
welder is being used to join automotive
exterior parts such as spoilers
for efficient machines that can perform multiple operations and minimise labour requirements, as well as smaller machines for cellular manufacturing where a part is processed through several machines positioned side-by-side, typically in a U-shaped layout,“ he adds. Forward Technology sees
continued and significant interest in servo-actuated welding systems over the standard pneumatic and hydraulic based systems. Infrared welding technology, using non-contact heat sources to heat and weld plastics, has also advanced considerably over the past 20 years, the company says, and now offers a cost effective and efficient welding technology option when evaluating an application for assembly. The company has developed several new platforms of infrared welding systems, many of which employ servo-actuation for exact tooling and heat-source
28 INJECTION WORLD | May 2016
positional repeatability. A line of spin welding equip- ment and automation motion control has also benefited from the use of servo motors and actuators for motion control. Durable and repeatable welding systems have now been improved with technical advancements in motion control and heating technologies. “Future developments at Forward Technology include
applying our servo and infrared heating technology to a wider range of applications,” says Schewe. “This could come in the form of growing and stretching our range of standard machines and applying these new technologies to projects requiring automation.”
Capacity demands UK-based supplier of plastic welding equipment Xfurth currently reports buoyant market conditions and is seeing a flow of new projects and enquiries in industries ranging from medical and building products, to packag- ing and cosmetics. “As well as new projects, there are many existing customers whose product demand has increased leading to a requirement for additional machine capacity,” says sales engineer Andrzej Adamek. “Over the past few years there has been a significant
increase in demand from automotive manufacturers, and suppliers to the automotive industry, developing parts for the next generation of vehicles. This has led to increased sales for all welding technologies. In addition, particu- larly in the automotive industry, we are finding that moulders are trying to move away from gluing compo- nents wherever possible and opting for cleaner welding technologies such as vibration, infrared, laser and ultrasonic,“ Adamek says. “This year,through our partner
Cemas Elettra, we have com- pleted a number of projects for a supplier to a major UK automo- tive manufacturer using vibration welding to join together exterior car components such as spoiler mouldings, some of which would have previously been glued.”
Hybrid technologies The increasing complexity of automotive lights has also
prompted Cemas Elettra to develop
a hybrid welding system. “The hybrid system incorpo- rates infrared welding within a vibration welding machine, pre-heating the mating surfaces prior to vibration allowing for a cleaner weld with more flexibility on design,” says Adamek. “Hybrid welding is also used for engine manifolds where a cleaner weld is needed with multiple chambers being welded in a
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PHOTO: HERMANN ULTRASCHALL
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