JOINING AND ASSEMBLY | INNOVATION
technology improves process control while substantially increasing the available power. Forward Technology says that the DLVW-4848-
LX is particularly suited for welding of large automotive parts, such as intake manifolds, instrument panels, and engine covers, along with plastic pallets for the transportation and logistics industries. In the plastic pallet industry, the vibra- tion welder is an effective alternative to hot plate systems, offering significant cycle time reductions. These large welders can easily be integrated into automated systems for further labour reduction and increased throughput. Herrmann Ultraschall has developed two
software tools – FSC and SonicCalibrate – for quality assurance in the ultrasonic welding process. To ensure the required accuracy and tightness during joining, the company says that these software tools provide support in controlling the ultrasonic system. They enable reproducibility and traceability for the manufacturing process and fine adjustment and amplitude control for demanding materials. To achieve a reproducible welding result and a constant welding process, it must be ensured that the relevant machine parameters have the same values reproducibly. The SonicCalibrate software is used to calibrate and verify the weld depth, weld force, sonotrode speed and amplitude. The correctly set speed prevents damage to sensitive seam geometries. In addition, it influences the maximum joining speed and the displacement of the melt in the subsequent joining process. The amplitude is decisive for the introduction of the ultrasonic power into the component and is therefore dominant in melt formation and the joining process. This is particularly important for sophisticated medical parts. The FSC software offers the functionality to comply with the strict regulations of the US FDA (21 CFR Part 11) for tracking, as often required in the food, pharmaceutical and medical industries. It includes user administration and authentication as well as control of user authorisations. In addition, changes to the system are recorded in an audit trail. Herrmann Engineering provides encompass- ing support for welding process development: weldability tests, sample parts, seam design, technical implementation, TCO analysis, prototype tools and training. Rinco Ultrasonics has achieved ISO 14644-1 class 6 certification for its Standard 3000 ultrasonic welding machine and has been officially approved for use in cleanrooms. Testing was carried out by CAS Clean-Air-Service AG and the Standard 3000 has also satisfied all requirements regarding
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Above: Herrmann Ultraschall has developed two software tools, FSC and SonicCalibrate, for quality assurance in the ultrasonic welding process, which has many medical technology applications
maximum permitted particle concentration. The cover panel on the Standard 3000 press and the generator housing are made from stainless steel, a high-quality, hygienic material that is particularly resistant to damage from cleaning agents, making it a good choice for cleanrooms. The company adds that the certification to ISO 14644-1 provides customers with the assurance that the Standard 3000 can be used in ISO class 6 cleanrooms. The generator can be connected to an exhaust air system via the air vents. This makes the Standard 3000 well suited to all welding tasks in cleanrooms.
Weldable materials Lanxess has supplied PA 6 to provide a cost-effec- tive monolayer solution for a double-shell, welded motorcycle fuel tank. Materials for motorcycle tanks need to meet stringent requirements. The company says that this means, for example, that only small amounts of fuel should be able to diffuse through the tank walls. The materials need to demonstrate a high level of tenacity and ductility, particularly in the event of a crash, offer high design flexibility for complex tank geometries, and should be cost- effective to process. BMW Motorrad’s models F 900 R and F 900 XR have been able to meet all of these requirements using a single material. The tanks in both machines are made from Durethan BC550Z 900116 DUSXBL. The unreinforced and impact-modified PA 6 is injection moulded into two half-shells, which are then welded to form a tank by means of hot plate welding. The tanks are a joint development of BMW Motorrad and Röchling Automotive Italia in collaboration with Lanxess. “Our material comfortably meets the stringent
May 2021 | INJECTION WORLD 43
IMAGE: HERRMANN ULTRASCHALL
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