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SECTION TITLE


MATERIALS • PROCESSES • FINISHES


modes Time, Energy, Absolute Distance and Relative Distance stored in the control unit, parameters for new welding programs can be set quickly and easily. Te operator can specify which parameters can and cannot be freely changed in a pre-defined area. Indexing saves time when a change has to be made to the workpiece support for welding or the rotary plate on the testing unit. No re-adjustment is required.


FULLY AUTOMATED WELDING, TESTING AND SORTING After the head and head covering have been manually joined and placed in the part-specific tool, the welding process can ensue, with the defined and monitored parameters – power, time and energy – for each head. A light curtain serves as a safety guard. When welding is completed, a gripper transports the head to the testing area and positions it in the workpiece support for the tension test with adjustable force. For example, while the head covering is gripped, a pulling force of about 150 Newton is applied to the head. Te plate moves to the marking station where a height control takes place at the same time. If the part passes the test, a sonotrode with adjusted force applies a system-specific mark. If the part fails the test, the sonotrode applies increased force to destroy the part. In the fourth station a gripper removes the head and puts it into a good parts box or into one of two rejected parts boxes. Te parts that failed the tension test are sorted from parts whose welding parameters or height are outside defined tolerances.


A workpiece support is assigned to each head size and head covering. It can be changed quickly by means of indexing without a re-adjustment


At Playmobil the systems are operated


in three shifts. All welding parameters and test results for each part are captured and stored. Among other things, the data show whether changes have occurred in the process. To ensure a quick return to operation in such cases, the systems are integrated in a network. Technicians from Weber Ultrasonics can log into the systems remotely and resolve problems or make software updates. Tis service contributes to Playmobil’s satisfaction with the ultrasonic welding systems. Te proof is in the form of an order for the third system.


After they have been welded, the heads are automatically conveyed to the testing stations, where the tension test, height control, marking and sorting take place in a synchronised process


40 www.engineerlive.com


For more information visit www.weber-ultrasonics.com


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