High Frequency Welding Machines

Transcription

1 High Frequency Welding Machines Types Applications Sliding Table Welding Auto Carpet Welding Rotary Table Welding Other Auto Parts Welding Inline Welding Conv eyor Belt Welding Tarpaulin Welding Special machines Contents 1. Schirmacher Welding Machines P Special Applications in Automotive Production P Examples P5

2 1.Schirmacher Welding Machines 1.1 Outstanding Welding Solutions Constant research to find new concepts and further development of existing concepts culminates in a product range of machines that convinces by its reliability and innovative technology. Numerous design models make it possible to combine various components to put a custom-made integral solution at the customer s disposal. In combination with our loading and unloading handling equipment, your production process can be automated and linked up with all process steps both upstream and downstream. 1.2 High frequency Equipment All welding machines are equipped with a fully closing screening cover. Thus the machine is free of perturbing radiation and complies with the strictest EMC provisions. The influence of external controls is ruled out. We use only in-house designed and built HF generators. Depending on the customer s requirements, you can choose from an extensive range of generators with power outputs between 4 and 25kW. The servo-electric control drive in the capacitor box provides for a rapid and accurate setting of the power value. Single Sliding Table TAM 97B-1SM 1.3 High frequency Welding processes During HF-welding, high-frequency alternating current produces an electric AC field between the welding tool (electrode) and the counterpressure plate that brings the molecules of the pad film and carpet into oscillation. Because of the resulting frictional heat, the film material melts and penetrates the carpet fibres under pressure forming thus a solid joint. Neither than welding tool nor the counterpressure plate are heated. Cooling or temperature control is available as optional equipment. 1.4 Automation To link the process steps fully or partially, the welding machine must be equipped with handing devices. Loading devices for the pad film and unloading swiveling devices for the carpet are part of this equipment. They are designed and constructed in the well-known Schirmacher quality in accordance with the customer s requirements. Fully automatic carpet production line with Schirmacher TSM and pad loading device. 1.5 Control Beside PVC with good welding properties, a great number of other pad materials is used today. These materials call for individual power output setting. This is the reason why Schirmacher developed its TSM control with automatic HF power control. Thus it is possible to adapt the HF output during welding (stepped welding). Additionally the program offers a great number of setting options for cycle time and welding result optimization. The parameter memory facilitates calling set values. HF power control: example of a welding curve 2

3 HF-power: power value for each single time interval (0.2=20%-9.9=99%) Welding time(ts) (s=schweissen): divided into five steps, with an assigned power value for each step Cooling time (tk) (k=koolen): Ramp: setting the control speed (rapid - slow) Position: starting position of the capacitor Siemens PLC controls and control panels with plain-text display for status messages and fault indication form the standard equipment of the carpet welding machines. Other PLC controls are optional. 1.6 HF-generator HS The HF generator with a power output of 25kW has almost become standard equipment in the automotive industry. Thus spare part storage is facilitated and the availability of the generator increased. 1.7 Service The reliability of the welding machines is supported by an efficient technical support service. Important spare parts are always on stock. Additionally the optional remote troubleshooting system makes it possible to localise and correct faults more rapidly and economically. 2. Special Applications in Automotive Production 2.1 Carpet Welding Machine More than 25 years of experience in the design and manufacture of carpet welding machines which are in use world-wide make us the right partner for your business. Because of their standardized unit design, the welding systems can be incorporated into the machine as you like. Thus, in the event of a later model replacement, the existing welding system can be easily added on or adapted. This is the great advantage of our modular design concept. There are following standard welding systems to choose from: System 1 heel pad LHD System 2 tunnel pad LHD System 3 foot rest LHD System 4 heel pad RHD System 5 foot rest RHD System 6 wheel housing pad RHD Vertical Carpet Welding M achine TSM 98 V-3D 3

4 2.1.A Models The number of parts to produce and the production process applied determine the table design. Beside the table size the number of tables can be chosen freely. There are the following standard models to choose from: Single sliding table machines Can be extended later to form a double sliding table machine Double sliding table machines With manual loading by two operators Two-station turntable machines With manual loading by one operator Three-station turntable machines Partly automatic Four-station turntable machines Fully automatic Three-station turntable machine TSM 97C-3D HF welding electrode. As a supplier of integral solutions we also supply the welding tool in a plane or three-dimensional design according to your specification. 2.1.B Working principle: Loading of the pad film Loading of the carpet HF-welding Unloading and conveying to foaming station (overhead conveyor) 2.2 Other Applications in Automotive Parts Production Schirmacher offers varities of special-purposed welding machines for automotive parts production. This large-area welding machine is used for a wide range of products in the automotive industry. Trunk mats (welding of spare wheel cover reinforcements and friction strip welding), convertible tops, sliding canvas sun roofs and door trim panels are examples for large-area welding applications. This machine is also available with different table sizes. HF-Sliding table welding machine B Table size: mm Closing force:100kn HF Power: 25kW While type B2000 and SM are practically used for smaller trim parts such as sunvisors. HF Single Station Welding Machine B 2000 HF Single Station Welding Machine B S M Table size: mm Table size: mm Closing force:18kn Closing force:18kn 4

5 3. Examples 3.1 References Audi A2 - BMW 3rd / 5th Serie - Ford Mondeo - Mercedes SLK - Opel Astra,Epsilon, Saphira - Porsche 982, VW Colorado, VW Polo, Golf, Passat, New Beetle as well as various models of Chrysler, Skoda, Seat, Peugeot and Volvo. 3.2 Application Examples 1. Foot rest & Heal Pad Toyota Carpet GM Opel Carpet 1 Heel Pad (LHD) 1 Heel Pad (LHD) 2 Foot Rest (RHD) 3 Tunnel Pad (LHD) 2. Headlining Audi Soft Top Carbriolet Open Sunroof Folded Sunroof Unfolded 3. Sun visor BMW Sun Visor 4. Trunk, door panel, etc. Trunk Cover 5