Emerson HyLine-2i Brochure
Contents
1. 4 500 Ibs 2 040 kg Approx 5 000 Ibs 2 268 kg Approx 6 500 Ibs 2 720 kg Overall 76 wide x 77 5 high x 48 deep 88 wide x 77 5 high x 48 deep 100 wide x 77 5 high x 48 deep Dimensions 1930 x 1969 x 1220 mm 2235 x 1969 x 1220 mm 2540 x 1969 x 1220 mm Lift table Overall 33 5 long x 21 deep 851 x 534 mm 46 long x 21 5 wide 1168 x 546 mm 58 long x 23 wide 1473 x 584 mm Central opening Drive platen 23 5 long x 11 5 wide x 1 3 deep 597 x 292 x 33 mm 38 long x 11 5 wide x 1 75 deep 965 x 292 x 44 4 mm 50 long x 11 5 wide x 1 75 deep 1270 x 292 x 44 4 mm Overall i1 H min 15 4 long x 14 8 wide 390 x 376 mm max 33 long x 18 wide 838 x 457 mm i2 H i3 H min 34 6 long x 14 8 wide 880 x376 mm max 46 long x 20 wide 1168 x 508 mm i4 H i5 H i6 H min 50 2 long x14 8 wide 1276 x 376 mm max 57 long x23 wide 1448 x 584 mm Front opening Variable stroke Noise level Drive power Power requirements Output frequency Ambient temp Driven platen fixture weight capacity i1H i2 H i3 H i4 H i5 H i6 H Max clamp force Amplitude range Lift table speed Total dry cycle time without welding 39 wide x 25 high 991 x635 mm 20 508 mm maximum 83 dBA standard 15 kW 480 VAC 20 amps 3 phase 50 60 Hz 180 240 Hz variable 32 105 F 0 40 C 42. 4 88 Ibs 20 40 kg 4 000 Ibs 17 8 kN 0 020 to 0 070 0 5 to 1 8 mm 10 sec 254 mm sec 5 0 sec at 20 508 mm max stroke 51 wide x 25 high 1295 x 635 mm 20 508 mm maximum 83 dBA standard 15 kW 30 kW 480 VAC 20 amps 3 phase 50 60 Hz 180 240 Hz variable 32 105 F 0 40 C i2 H 77 143 Ibs 35 65 kg i3 H 88 154 Ibs 40 70 kg 6 000 Ibs 26 7 kN 0 020 to 0 070 0 5 to 1 8 mm 10 sec 254 mm sec 5 0 sec at 20 508 mm max stroke 63 wide x 25 high 1600 x 635 mm 20 508 mm maximum 83 dBA standard 30 kW 480 VAC 20 amps 3 phase 50 60 Hz 180 240 Hz variable 32 105 F 0 40 C i4 H 121 188 Ibs 55 85 kg i5 H 132 200 Ibs 60 90 kg i6 H 132 200 Ibs 60 90 kg 6 000 Ibs 26 7 kN 0 020 to 0 070 0 5 to 1 8 mm 10 sec 254 mm sec 5 0 sec at 20 508 mm max stroke Note All sales shall be subject to the Supplier s terms and conditions of sale as described in Branson s quotations and sales contracts BRANSON Branson Ultrasonics Corporation 41 Eagle Road Danbury CT 06813 1961 203 796 0400 Fax 203 796 9838 www bransonultrasonics com e mail info bransonultrasonics com Warranty The HyLine 2i Vibration Welder Models VW 4i1 H VW 6i2 H i3 and VW 8i4 H i5 i6 are warranted to be free from defects two years for parts and one year for labor from the d
3. Vibration Welding BRANSON HyLine 2i Series Models VW 4i1 H VW 6i2 H i3 and VW 8i4 H i5 i6 Linear Vibration Welders S X EMERSON Industrial Automation HyLine 2i Series Models VW 4i1 H VW 6i2 H i3 and VW 8i4 H i5 i6 Linear Vibration Welders GENERAL DESCRIPTION Branson the pioneer in vibration welding with over 35 years of production experience is proud to offer the enhanced version of our popular HyLine 2 Series linear vibration welder Featuring the all new I Class weld heads Branson s HyLine 2i Series welders are complete assembly systems designed to weld parts of various sizes and or irregular shapes The I Class weld heads offer multiple benefits including increased tool weight capacities increased tool weight to frequency ratios higher power drives more plastic joining capacity PPL technology see Machine Description section interchangeable common parts across weld head models global commonality and lower noise output Six models VW 4i1 H VW 6i2 H i3 and VW 8i4 H i5 i6 are available to handle parts up to 58 by 22 1473 by 559 mm or multiple smaller parts The Branson power supplies that drive the weld heads have an adjustable vibrating frequency range of 180 to 240 Hz Modular construction allows the individual vibrator assembly and power supply controller components to be adapted to automated or custom systems Vibration welding is a proven weldin
4. ate of shipment 475 Quaker Meeting House Rd Honeoye Falls NY 14472 585 624 8000 Fax 585 624 1262 6590 Sims Drive Sterling Heights MI 48313 586 276 0150 Fax 586 276 0160 ISO Certifications VW HYLINE 2i Branson Ultrasonics Corporation 2012 The Emerson logo is a trademark and service mark of Emerson Electric Co Revised and printed in the U S A 2 12
5. eling and absorption of mechanical vibrations Vibrator Housing A rigid steel assembly houses the individual vibrator components the main assembly areas are precision machined Weld Head Vibrator The electro magnetic principle of Branson s vibrator assembly is patented and operates in a linear mode The vibrator assembly consists of a set of laminations and cantilever springs suspended from the vibrator housing Electromagnets mounted in the housing act directly upon the mechanical suspension producing a peak to peak reciprocating displace ment of 0 020 to 0 070 inch 0 5 to 1 8 mm at 240 Hz The springs return the vibrator to the precisely aligned position when the electro magnets are de energized ensuring final part alignment PPL Technology Weld Head Drive The Power Package Linear approach delivers consistent power output to the weld head across the machine s frequency range This prevents out of phase mechanical versus electrical resonances and ensures maximum plastic joining capacity across the tooling weight range of the weld head Sound Protection Cabinet The sound protection cabinet is lined with sound absorbing material An automatic vertical sliding access door with acoustic lining is incorporated in the front of the cabinet For operator safety the door automatically retracts if the start buttons are released before the door is closed e Door Drive The
6. g technology capable of producing strong pressure tight joints in thermoplastic parts Frictional heat is generated by pressing the surfaces of two plastic parts together and vibrating one of the parts through a small linear displacement in the plane of the joint When a molten state is reached at the joint interface vibration is stopped and the parts are automatically aligned Clamping pressure is maintained briefly while the molten plastic solidifies to form a bond approaching or equal to the strength of the parent material Linear U i neal pper section vibration clamped and A vibrating Locator bosses Lower section fixtured Process Advantages The major advantage of vibration welding lies in its application to large up to 60 1524 mm long or 24 610 mm wide irregularly shaped parts Even cross ribs which create separate compartments can be sealed The process also works with multi plane and curved surfaces The technology offers the capability of welding more than one part at a time it also readily lends itself to automation Material Compatibility Almost all thermoplastics can be vibration welded regardless of whether they have been injection molded extruded foamed or thermoformed This process when compared with ultrasonic assembly is particularly advantageous for semi crystalline resins such as acetal nylon thermoplastic polyester and polypropylene also polyvinyl chloride cellulo
7. nsures tight control of the pre weld stack up height and precise meltdown capabilities as well as the ability to set the table loading height SPC capabilities The PLC program can provide a data stream toa communications port to enable the user to connect to a computer and log the weld parameters over a period of time The data can then be processed by the user s program to provide a printout in any number of forms bar charts histograms range charts etc Diagnostic program which allows the machine to be compared against a known set of conditions This enhances troubleshooting capabilities by matching the unit s current outputs with a standard set of values recorded during initial setup Digital power supply provides increased starting power and better control of the weld process Self tuning frequency program Pressing a button on the interface will allow the machine to automatically find and store the resonant frequency of the upper tooling mass This known value can then be saved in a preset or manually input the next time the same upper tool is installed for production The frequency range of the unit is variable between 180 Hz and 240 Hz Precise amplitude input and control in arange between 0 020 and 0 70 0 5 1 8 mm The peak to peak welding amplitude can be set at the keypad in 0 001 increments Simple maintenance free electromechanical vibrator with only one moving part and no bearing s
8. sics and elastomers filled and reinforced resins as well as those exhibiting hygroscopic properties Machine Sequence The operator manually loads the parts to be welded The automatic sequence is initiated by activating the start buttons e Sound door closes e Lift table moves to weld position and applies pressure e Weld and hold times sequence e Lift table moves to home position e Sound door opens e Part manually unloaded Automotive e Instrument panels e Clusters e Door panels e Lighting e Reservoirs e HVAC ducts Glove Box e Intake manifolds e Bumpers e Glove boxes e Air resonators Medical e Chest drainage units e Filters e l V units lt gt e Surgical instruments e Insulated food trays e Cassettes Medical Fluid Meter Appliance e Pumps e Spray arms e Shelving e Fill funnels e Liquid dispensers e Water reservoirs e Small large power tools Vacuum cleaner housings e Ducts e Vacuum cleaner accessories Steam lron Reservoir Business Consumer Electronics e Toner housings e Display assemblies e Door stiffeners e Ink jet cartridges e Circuit board encapsulation Packaging e Pallets e Display stands shelves e Point of purchase display blisters Vibration Welding Standard Machine Description Machine Frame Welded construction of steel tubing and profiles incorporates four height adjustable rubber mounts to allow both machine lev
9. two major components for the door drive are an air cylinder and specially designed plastic and steel elements to provide smooth and consistent movement e Rear Access Door The rear panel of the machine is fitted with a full size interlocked door to allow full access to tooling and other machine components e Hydraulic Power Supply completely self contained with drip pan is located inside the rear access door VW HYLINE 2i Key Features Controls system using an Allen Bradley Compact Logix PLC All system parameters are set through an Allen Bradley Panelview Plus 700 optional 1000 The PLC system monitors the welding parameters and controls all functions of the machine including frequency direct reading in Hz weld time melt distance collapse hold time amplitude weld clamp forces and hold clamp forces Storage of up to twenty sets of weld parameters By calling up one of these presets the operator automatically programs the machine to the setpoints for that particular application The system also provides process verification during each weld cycle This verification is a live reading of the actual amplitude force weld time and melt distance occurring during that cycle Linear displacement transducer for table positioning and meltdown The transducer provides a positioning repeatability of 0 001 over the length of the transducer and a meltdown resolution of 0 0005 This e
10. urfaces to lubricate or wear Hydraulic lift clamp system includes two proportional valves to control the speed of the lift table and the clamp force applied to the parts Force profiling The HyLine control has up to four programmable weld forces to provide more accurate control of weld meltdown velocity It also has one programmable hold force e Amplitude profiling Four programmable amplitudes are available for controlling welding e Configurable user I O is available for tooling functions Up to 32 O s are optional Some Available Options e Light curtain e Light curtain protection guards e Duplex electrical outlet 120 V e Dual lift cylinders provides 21 533 mm stroke and table opening depth of 12 5 317 mm e Panel mounted resettable cycle counter e Exterior overhead light e Air system for part eject from tools e Air system for vacuum in upper tool e Air system for slides in bottom tool e Electrical tooling quick disconnect block Turck 8 port e Electrical tooling quick disconnect HAN connector e Pneumatic tooling quick disconnect manifold 8 port e Ext PLC programming port e Three color light tower e PLC window in electrical cabinet e Light in e box e E box fan e E box heat exchanger e Custom color e Machine crating if required e Hydraulic quick change clamping on lower table e ECPL lockout tags VW 4i1 H VW 6i2 H i3 VW 8i4 H i5 i6 Weight Approx
Download Pdf Manuals
Related Search