Ultrasonic Welding System Joins Multiple Joints at Once
MS Ultrasonic configured a MULTI machine to perform more than 60 ultrasonic spot welds on a bumper assembly.
The MS sonxMAC MULTI can be used for ultrasonic welding of instrument panels, door trims, rear spoilers, trim elements, pillar and luggage compartment trims, and bumper coverings.
The MS sonxMAC MULTI is designed to perform multiple processing steps on a single assembly. Those steps could be ultrasonic punching, welding, staking, cutting, or embossing.
Ultrasonic welding is a form of friction welding that joins parts together by vibrating them against each other. The parts are clamped together while a vibrating tool called a horn transfers ultrasonic energy to the joint interface. Heat is generated through a combination of friction and hysteresis. Amplitudes of 20 to 80 microns are usually produced at the end of the horn. When the ultrasonic vibrations stop, the molten material solidifies and a weld is achieved.
In plastic welding applications, ultrasonic vibrations are applied vertically, and the parts are heated to their melting point.
Cycle times are short. The entire welding process takes 0.5 second or less.
Ultrasonic welding offers many advantages to assemblers. It is a fast, efficient, flexible process that offers quick tooling changeover. No warm up or cool down time is necessary, and the process does not require elaborate ventilation.
Ultrasonic welding is most often used to assemble relatively small products, such as toys or medical devices, in quick “one-shot” processes. However, it can be used to assemble much larger products, such as automotive interior assemblies, and systems can be designed to weld or form multiple joints simultaneously.
That’s the idea behind the new MS sonxMAC MULTI from MS Ultrasonic Technology LLC in Howell, MI.
The modular system can be used for ultrasonic welding of instrument panels, door trims, rear spoilers, trim elements, pillar and luggage compartment trims, and bumper coverings.
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The system is designed to perform multiple processing steps on a single assembly. Those steps could be ultrasonic punching, ultrasonic welding, ultrasonic staking, ultrasonic cutting, ultrasonic embossing, and insertion of clips and screws.
The machine can be operated as a standalone system that is loaded and unloaded manually, or it can be integrated into automated assembly lines with robots. It can be configured so that one set of parts can be loaded and unloaded, while a second set of parts is being welded.
Strategically located clamps ensure precise part positioning. Sensors monitor quality and provide process documentation.
Recently, MS Ultrasonic configured a MULTI machine to perform more than 60 ultrasonic spot welds on a bumper assembly. The machine accommodates numerous feed units in a small space. All the ultrasonic components in the machine—feed units, converters, generators and sonotrodes—were developed and produced in-house.
For more information on ultrasonic welding systems, click www.ms-ultrasonic.com or visit the company’s booth at The Assembly Show, which will be held Oct. 27-29 at the Donald E. Stephens Convention Center in Rosemont, IL.
Besides plastics joining technology, you’ll find more than 200 suppliers of automation, fastening tools, robotics, software, presses, workstations, adhesives, dispensing and curing technology, and test and inspection equipment.
For more information on plastics joining equipment, read these articles:
Form-in-Place and Cure-in-Place Gaskets
Process Control for Dispensing Gaskets
New Technology for Form-in-Place Gaskets
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