Welding & assembly.

More versatile and sophisticated controls are what's new in ultrasonic welding, the most numerous type of new assembly equipment at NPE.

Expanded computer control and SPC capability and a greater emphasis on system integration sum up the major technological thrusts evident in welding, sealing and assembly equipment to be introduced at NPE '94. Unlike at NPE '91, there will be less emphasis on brand-new welding processes being introduced at this year's show.

NEWS IN ULTRASONICS 

Sonics & Materials Inc., Danbury, Conn., will introduced a new high-precision 40-kHz ultrasonic welding stand with programmable velocity, pressure, and depth capabilities. The company also will show its new ED-series microprocessor-controlled power supply with multiple programmable features. Also new is a 19-in. rack-mount, autotuning, programmable-amplitude power supply.

The recently introduced Ultra Series  ultrasonic welders from Dukane Corp., St. Charles, Ill., features a heavy-duty, 20-kHz thruster press, a new ergonomically designed baseplate, and an ultrasonic generator available with 2000 or 3000 watts of power. The system features full computer control of all welding functions.

The WPC-2 weld-profile controller is a new microprocessor-based system being launched by Branson Ultrasonics Corp., Danbury, Conn. When used in conjunction with the company's 900 Series power supply, the WPC-2 system offers the capability to profile--or continuously change--amplitude during a welding cycle to provide the best amplitude for each phase of a weld.

This control is a further development of the WPC-1 control that Branson introduced last fall. It allows two levels of amplitude to be set on the same weld cycle. The WPC-1 monitors the welding process for SPC and diagnostic purposes and displays real-time weld-cycle data for key process parameters.

Herrmann Ultrasonics Inc., Schaumburg, Ill., is launching a new "Finite Element Method" (FEM) software program to simulate the performance of ultrasonic weld horns in operation. The program provides a 3-D computer model of the horn geometry, simulating performance options until the optimum horn configuration is determined. The program facilitates design and manufacture of complex horn shapes for specific welding applications, eliminating what has been a costly, trial-and-error process.

Another new product from Herrmann is its VE Dialog series of active-control, CNC ultrasonic actuators. The VE Dialog is designed for automated production or multihead welding applications. The actuators are compact units that have eliminated the machine column and base. Depending on size and power output, the cost of the new series ranges from $10,000 to $30,000.

OTHER WELDING & ASSEMBLY NEWS

Wegener North America Inc., Burr Ridge, Ill., will introduce its new Autotherm hot-air welding gun. It features closed-loop temperature control, which allows operators to preset the desired welding temperatures.

Drader Injectiweld Inc., a unit of Drader Manufacturing Industries Ltd., Edmonton, Alberta, is unveiling a new digital version of its W10,000 hand-held extrusion welder.

And Branson Ultrasonics will show a new High Line linear vibration welder with a new hydraulic variable-speed lift table and clamp system. The new hydraulics are said to provide smooth, accurate platen positioning as well as multiple weld and hold pressures. A linear-displacement transducer (LDT) is used for accurate table positioning and meltdown control during welding. The LDT is said to provide greater position accuracy and weld consistency than limit switches and proximity sensors. This welder, just like ultrasonic models, has menu-driven microprocessor controls that collect welding data for SPC.

Aqua Dot 350 is a new water-based hot-melt adhesive application system from The Freeman Co., Cincinnati. This roll-coating equipment applies an aqueous adhesive onto plastic in a dot pattern. Various models in the Aqua Dot line range up to 30 in. wide.

Spuhl Anderson Machine Co., Chaska, Minn., will be showing its new MD-705 two-component dispensing system designed for gasketing, form molding, and adhesive applications. It meters and mixes silicone, polyurethane, or epoxy adhesives with the capability to monitor flow rates from 0.3 to 100 g/sec.

P.S.M. Fastener Corp., Fairfield, N.J., a manufacturer of threaded inserts, is introducing its Mini-Tech line of inserts designed for small plastic parts.

What to Look For

* Computer-aided design makes complex ultrasonic horns easy.

* Ultrasonic weld amplitude can be profiled on-the-fly.