DANBURY, CONN. (October 22, 2019) - Plastic components across the medical, electronics, and automotive industries are becoming increasingly miniaturized, with embedded electronics, intricate designs, and thinner plastic walls. Conventional welders with high or crushing weld forces inhibit safe welding of small and fragile parts. To meet this challenge, Emerson has developed an advanced electro-mechanical actuation system that provides unprecedented control and position accuracy. Its closed-loop force control precisely regulates even ultra-low trigger forces, enabling the GSX-E1 to perform faster, high-performance welding of delicate and intricate components. This advanced actuation system leverages over 70 years of ultrasonic application experience and combines servomechanism, software optimization, and proprietary dynamic follow-through to enable a broad range of weld forces up to 2,500 newtons.
The highly configurable GSX welding platform enables customers to accommodate many different parts and application types by using an array of welding parameters and actuation control modes during a single weld. This ensures better, consistent, quality welds leading to fewer rejects. Tim Herren, Emerson’s Western Region Sales Manager for Assembly Technologies states, “I’ve never been more impressed with the controls and ergonomic interface of a welder. I’m able to optimize the welding parameters in minutes and help the customer weld thousands of parts with zero rejects…something the customer has never been able to do before.” Using a multicore processor and a linear encoder drive, the multi-tier advanced actuation system can be instantaneously adjusted based on real-time feedback. This ensures the same level of precision and repeatability across multiple welders, with post-weld tolerance and part variability measured in microns.