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Optimum oscillation for the best connections
Setting the pace for ultrasonic welding of thermoplastics
Whether the automotive industry, medical engineering, telecommunications, electronics, packaging technology, the household appliances industry or the field of solar technology – plastic parts are in use in virtually all sectors of industry today and require secure bonds to be created using welding or riveting. As an innovative, efficient and environmentally-friendly technology, ultrasound is increasingly replacing conventional processes here. Weber Ultrasonics Weld & Cut GmbH (WUW) develops and manufactures ultrasonic solutions that are tailored to the diverse welding, bonding and cutting tasks of the various sectors and industries. These solutions not only excel through their incredible process speeds, but also their consistently high processing quality - key characteristics that facilitate both safe and highly cost-efficient processes. This is supported by the individual full-scope service, which ranges from application consulting, through engineering, testing at a dedicated laboratory and machine design, right through to commissioning and global after-sales service.
From individual components, all the way to complex customized systems
With the innovative SONIC DIGITAL MULTI PURPOSE ultrasonic generators, the MULTI PURPOSE ultrasonic converters, boosters, sonotrodes and workpiece holders, WUW offers all components needed for bonding and cutting thermoplastics from a single source. This guarantees solutions that are optimally tailored to the particular field of deployment and ensures reproducible results of consistently high quality in all applications.
The compact HSM 35 ultrasonic handheld welding modules have been designed for flexible use in the field of plastic bonding. There are several different versions available with power outputs of up to 800 W, all of which operate at a frequency of 35 kHz and excel through their extremely low weight and ease of use. They represent the ideal solution in all applications where the costs associated with serial or customized machines cannot be justified, or when spatial flexibility is required.
The OPAL ultrasonic welding machine, a highly effective unit which can be used for various applications in the field of plastic bonding, is available with power outputs of up to 5,000 W and in the standard frequencies of 20, 30 and 35 kHz. The welding power can be easily and conveniently adjusted via a controller on the machine head. The operating modes of Time, Energy or Power Output are selected on the SONIC DIGITAL MULTI PURPOSE generator. The ability to program a wide range of process windows for monitoring or interrupting the welding process, either directly on the generator or using a handheld control unit, ensures process stability.
With the SAPHIR DIGITAL, WUW has designed an ultrasonic welding machine with a maximum power output of 5,000 W for the strictest requirements in the field of plastic bonding. It is available in the standard frequencies of 20, 30 and 35 kHz, and its compact, modular design allows it to be used at various frequencies. As it is equipped with an adjustable carriage and a generously dimensioned adjustment plate, the SAPHIR DIGITAL can be used to weld parts of the most diverse shapes and sizes. And its torsion-resistant stand designs allows extremely high welding forces to be applied.
Alongside the proportional technology and a high-precision travel measuring system, the intelligent SAPHIR welding process control also makes an important contribution to the extremely fast cycle times and high degree of process reliability enjoyed by these ultrasonic welding machines. It facilitates seamless process control and process monitoring, yet is extremely easy to use via the touch screen display.
Large, fully automated welding systems are extremely user friendly and easy to control with the newly developed PPC-Touch, a Windows-based panel PC with remote maintenance. Well-thought-out features, such as highlighting reference values for welding certain parts, a code for up to 32 workpiece holders with automatic selection of the corresponding welding program, an intelligent good/bad parts counter and graphical evaluation of the welding process for each part, guarantee maximum process stability, as well as seamless monitoring and documentation. The system is operated via a convenient 15'' touchscreen display.
The OPAL and SAPHIR DIGITAL units are also available as ultrasonic welding systems with corresponding feed units for automation and integration into production lines. In addition to this, WUW develops and configures plug-in ultrasonic units, ultrasonic generators and welding process controls for customized engineering solutions.
Thanks to the comprehensive range of modular assemblies WUW is able to design and manufacture customized systems that are optimally suited for plastic parts which cannot be processed using standard machines due to their size or shape.
Alongside the entire range of products for ultrasonic welding, Weber Ultrasonics will also be presenting its innovative solutions for ultrasonic cleaning and disintegration of biogenic sludge with ultrasonic technology at the MECSPE trade fair in Parma from 21 to 23 March 2013 (Stand L30 in Hall 6). www.weber-ultrasonics.com
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