Bumper Welding System

The Task To design a ultrasonic plastic welding system to weld bumper. The Solution In this case, the task is successfully accomplished by designing an ultrasonic plastic welding system having 9 welding actuators, 9 horns with cooling pipes & 3 ultrasonic generators. The Advantages Short cycle times 40 sec for 9 welding pointsControllable & repeatable processAesthetic welding jointsHigh quality achieved ...

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Linear + Rotary Welding of Filters

The Task To design a rotary ultrasonic plastic welding system to weld the linearly welded filter. The Solution In this case, the task is successfully completed by designing a system wherein after loading the component on the rotation fixture, Ux. Table slides towards the fixture and rotation of rotation fixture, Ux. Head 1 starts resulting in welding of the filter along its circumference. The Advantages Short cycle times- 30 secControllable & repeatable processAesthetic &...

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Rapid Welding With The New 3-Axis Robot

The Task To design an ultrasonic plastic welding system to weld the door panels. As plastics have continued to replace other materials in the design and manufacture of automobiles, the joining of plastic components has increasingly become a critical issue thus it becomes necessary to develop rapid welding techniques for welding such assemblies. The Solution In this case, the challenge was processed by designing an ultrasonic plastic welding system with a new robot which welds in fr...

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Precise Welding Of Brass Terminals

The Task To design an ultrasonic metal welding machine to weld brass terminals. An electronics company will use brass terminals in switches, sockets, etc to achieve more strength and highly conductive welds. The Solution In this case, the challenge was processed by designing an ultrasonic metal welding machine consisting of 4000N press, SG-22 3000 W, 20kHz generator, half wavelength special steel alloy sonotrode, special fixture and micro-processor controller 4 to achieve strong we...

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Welding Of The Automotive Component Parts

The Task To design an ultrasonic plastic welding system to weld the tail light assembly. The Solution In this case, the task was completed by designing a system having a special quick tool changing mechanism (cassette type), a winder-unwinder arrangement to locate the item which is to be welded and a dedicated horn-fixture arrangement to weld the tail light assembly. The Advantages Very short tool change over timeShort cycle timeStrong weldsNo damage cause to the surface fini...

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Top Cover Welding of Gear Housing

The Task To design an ultrasonic plastic welding machine to weld top cover of the gear housing.The gear housing is the casing that protects the mechanical components of a gear box from the outside world. So this casing should be welded properly to attain high strength. The Solution In this case, the customer was previously using German machine and wanted us to make a machine with the same standards. The challenge was successfully completed by designing an ultrasonic plastic weldin...

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