FASTENINGS & ADHESIVES racing to victory
PRODUCTS & APPLICATIONS ultrasonic welding benefits
Siemens Congleton has, for some time, been taking advantage of the benefits of Telsonic’s ultrasonic welding technology for its intelligent variable speed drive controller products. So, it again turned to the solution in support of a new TPM programme (Total Productive Maintenance) and production line upgrades. The Siemens operator panel, at the stage in production
where the welding must take place, comprises of three main components: polycarbonate front and rear housings, and a PCB. The assembly and subsequent welding of the rear housing to the front housing encapsulates and secures the PCB within the assembly. Using ultrasonic welding as the joining method means it
At the Formula Student Event, organised by the Institute of Mechanical Engineers (IMechE), student teams are invited to design, build, test and race a small-scale Formula-style racing car. The University of Central Lancashire (UCLAN) has been entering Formula Student since 2004, but without major success. However, at this year’s event, which was held at Silverstone in July, UCLAN triumphed ahead of 35 other race teams from across the country. Due to Covid, the team decided to
rebuild its previous car – and deployed LOCTITE products, supplied by sponsor Henkel, in various areas of its build programme, ensuring the car could withstand demanding acceleration, sprint, skid-pad and endurance disciplines which form part of the overall Dynamic Event. The car uses a steel space-frame
chassis with carbon-panel bodywork, while the engine is a Yamaha R6 (four-cylinder, 600cc) served by a bespoke induction and exhaust system. Key to minimising costs without compromising safety or performance was the use of LOCTITE products – as an example, a LOCTITE sealant was used to seal various panels and bodywork components. Carbon fibre is used on the intake system, and the same product was used here to ensure effective seals between the restrictor and plenum chamber. The team also used LOCTITE EA 9497 epoxy adhesive, its 518 gasket sealant, TEROSON PU 6700 multi-purpose bonder, LOCTITE
Hysol H3101 methacrylate adhesive and LOCTITE SI 5075 emergency repair silicone sealing wrap. LOCTITE 603 retaining compound was used for securing bearings into the milled bores of the wishbones. LOCTITE threadlockers are another
widely used solution. Here, products such as LOCTITE 222, 242 and 270 low-, medium- and high-strength threadlocking adhesives more than proved their worth. Nothing came loose except for a couple of bolts that did not have any LOCTITE threadlocker. Additional LOCTITE products used by
the team included LOCTITE EA 9466 epoxy potting resin, LOCTITE LB 8201 multi- purpose lubricating oil, and even LOCTITE SF 7850 natural hand cleaner, which was described as ‘really effective’. “Although it was our previous car, we
made a few improvements and they worked out in our favour as we achieved our best-ever performance,” said Dr Graham Calderbank, senior lecturer at UCLAN’s School of Engineering. “We came 2nd in the Acceleration Event, 2nd in the Endurance Event, 8th in the Skid-pad Event and 10th in the Sprint Event. We therefore scored the most points across the Dynamic Events, picking up a prize at the awards ceremony. The team also won a prize for ‘Most Entertaining Driver’ and the fastest hot lap in a bonus event.”
Henkel
www.henkel.com
is essential that the energy is directed into the joint and not allowed to dissipate into the surrounding features which secure the PCB within the assembly. So, the Telsonic USP3000P welder was integrated as part of a robotic manufacturing cell. The welder is based
around a 20kHz, 3.6kW ultrasonic welding system, complete with electronic proportional pneumatic control and a linear encoder, a configuration which allows the weld collapse height to be measured and controlled precisely. This guarantees that no excess energy is transmitted to other areas of the casing or the PCB beyond the full collapse of the energy director weld feature moulded into the parts. This features Telsonic’s new Telsoflex touchscreen interface control system for intuitive setting and results display, plus the latest MAG generator technology and advanced data streaming output. Siemens has also invested in a second USP3000E system,
configured as a turnkey manual welder, to provide the additional capacity needed to meet expected volume increases for the Siemens IOP/BOP controller range. Both welders have interchangeable tooling and are identical, with part presence sensing incorporated within the fixtures, which are mounted on sliding table assemblies for either robot or manual loading. Each welder is programmed with weld quality limits
and they are interfaced using OPC/UA to Siemens data collection and product barcodes with weld data for every product stored, allowing full traceability and quality control.
telsonic uK tool-less fastening technology
DIRAK D-SNAP tool-less fastening technology is now available from the FDB Panel Fittings Online store. Joining components with SNAP
technology is intended for specialist panel building installations in order to make the assembly/installation process simple. By eliminating the need for tools, DST products can be easily inserted into sheet metal panels and enclosures using pre-punched location holes to connect sheets securely together. DST products are available ex-stock
www.telsonic.com
from FDB Panel Fittings for urgent delivery across their range, which includes fasteners for two metal sheets, single or double fasteners, fasteners that can be disassembled from the outside and/or the inside, and cage nuts to facilitate screw fixing of equipment to the enclosure frame. DST joiners are complemented with a full
choice of hinges, swinghandles, locks and handles using the same D-SNAP technology with the same hole configurations – enabling whole enclosures to be pre-fabricated and assembled on-site – and readily disassembled.
fdb Panel fittings
www.fdb.co.uk
NOVEMBER 2021 design solutions 31
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