https://emersonexchange365.com/community-hubs/welding-assembly-cleaning/Learn best practices and tips and post questions for our Discrete and Industrial experts. en-USTelligent Community 13https://emersonexchange365.com/community-hubs/welding-assembly-cleaning/f/discussions-questions/8036/ultrasonic-welder-reject-limitsFri, 21 Jun 2019 20:07:00 GMTcd40bb2b-3d49-4868-939d-417119b40291:93b752a3-7165-4d26-8268-18bd8dfe6987Kenlly AdamesHello everybody, I just joined this group and I'm not sure if this is to answer specific technical questions or if this to talk about ultrasonic welding in general, but here goes my question and you let me know: I set up a reject limit for welding collapse distance, let's say I set it up to collpase 0.0004 in and set the reject limits between 0.0003 and 0.0005 in. I then monitor the weld results screen to check the values of each welding cycle. I notice the cycle is 0.00041, 0.00043, etc. but always within the limits, but anyways an alarm is generated. When I go to the alarm it says "Actual value = 0.0007", so the value on the result screen is different from the value on the alarm, and that happens on every cycle. I have not found a way to correct that, not even by calling Branson technical support. Can anybody help? Thanks in advance!https://emersonexchange365.com/community-hubs/welding-assembly-cleaning/f/discussions-questions/7794/video-how-ultrasonic-sealing-technology-is-improving-package-designMon, 04 Mar 2019 20:16:00 GMTcd40bb2b-3d49-4868-939d-417119b40291:b5f8f9a0-7db9-4114-ac31-91d9623fe70dMike MedianaThermal sealing is common in the packaging industry, but it has it's challenges and limitations. In this video, I explain how ultrasonic sealing technology can help you avoid product loss, contamination and achieve faster line maintenance. www.youtube.com/watch Do you have questions about ultrasonic sealing process? Reply below.ultrasonic sealingthermal sealingPackagingFood and Beveragehttps://emersonexchange365.com/community-hubs/welding-assembly-cleaning/b/welding-assembly-cleaning-blog/posts/tips-for-effective-ultrasonic-plastic-weldingTue, 19 Feb 2019 15:33:00 GMTcd40bb2b-3d49-4868-939d-417119b40291:0b072b33-b50b-42e4-ae4b-7cd58aa0ed54Jim CahillUltrasonic welding is: …an industrial technique whereby high-frequency ultrasonic acoustic vibrations are locally applied to workpieces being held together under pressure to create a solid-state weld . It is commonly used for plastics , and especially for joining dissimilar materials . In ultrasonic welding, there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the materials together. This technology goes back and was patented in the 1960s by two people, one of whom : …was a lab manager at Branson Instruments where thin plastic films were welded into bags and tubes using ultrasonic probes. Tarick Walton Mike Diker Today, the Branson brand of material joining and cleaning solutions is part of Emerson. In a Medical Design & Outsourcing article, 5 tips for ultrasonic plastic welding success , Emerson’s Tarick Walton and Mike Diker highlight considerations where ultrasonic welding technology is an effective solution. The five considerations include: Part design (e.g. geometry, joint design, wall thickness) Material selection Actuation technology Equipment adaptability Global support I’ll highlight a few of these tips and invite you to read the article for the rest. For the part design consideration: Avoid design pitfalls by engaging early with application experts about the details of part design. Among the most critical aspects of design for ultrasonically welded parts are part geometry and joint style. For example, if hermetic sealing is essential for product performance, consider using tongue-and-groove joints rather than chisel-step or other joints. Understand the compatibility/incompatibility of the thermoplastics to be welded: Once you’ve selected material types for part design, ensure that your supply chain can manufacture (e.g. injection mold) tight-tolerance parts consistently. In the event that a material is adapted or changed, it’s good to reevaluate the process with the help of your ultrasonic supplier, since weld parameter changes or even equipment changes may be required. Because weld quality and strength tie closely to part design and materials, recognize that even small changes can have significant effects on the joining process. Learn more in the Ultrasonic Plastic Welding section on Emerson.com . You can also connect and interact with other plastic welding experts in the Welding, Assembly & Cleaning group on Emerson.com. The post Tips for Effective Ultrasonic Plastic Welding appeared first on the Emerson Automation Experts blog.Precision Welding-Assembly-CleaningMike DikerBransonTarick Waltonultrasonic weldinghttps://emersonexchange365.com/community-hubs/welding-assembly-cleaning/f/discussions-questions/7736/branson-equipment-s-quality-control-featuresFri, 08 Feb 2019 13:15:00 GMTcd40bb2b-3d49-4868-939d-417119b40291:a35d6b5c-762b-4ad7-9f88-637421e89719Julia DanielQuality control has become a top concern over the last 30 years within every industry. With the introduction of Six Sigma and ISO certification, quality control is no longer confined to manufacturing facilities but to areas that include service, healthcare and even education. It is no surprise that one of the biggest concerns our customers have is quality. No matter the industry the desire to have a low rejection rate is a top priority. With rejection rate low, the customer has more sellable products generating higher revenue which is the end goal. Quality control is rooted in the ability to set reasonable tolerances for production and the ability to track the data. The difficulty comes with figuring out what those tolerance levels are and tracking the parts to ensure they fall within those tolerances. It is not feasible to have an operator measure and inspect every part. With some customers, medical in particular, the company is almost required to do this because failure in the field is not an option. Branson equipment has features that help solve this issue and allow for individual part inspection. Branson’s 2000X series has the capabilities to set suspect and reject limits within the power supply. This means that with each individual part the welder will monitor the limit you have programed and will alert you if the weld results are suspect and require further inspection or if they are a reject. The suspect and reject limits can be set to monitor a variety of controls including: Energy, collapse distance and time. With this capability the operator will immediately know if the part is within specification or not. This also allows for the quality manager to be alerted if this is a onetime issue or if the parts/ process needs to be further evaluated to find the root cause of the high rejection or suspect rate. This is only one feature Branson equipment offers to aid in maintaining quality and repeatability for our customers. Is quality control a main concern that you or your customers have when it comes to bonding their products?ultrasonicsSix SigmaBransonisoqualityquality controlhttps://emersonexchange365.com/community-hubs/welding-assembly-cleaning/f/discussions-questions/7735/ultrasonic-bonding-in-the-nonwoven-industryFri, 08 Feb 2019 13:13:00 GMTcd40bb2b-3d49-4868-939d-417119b40291:1b4ba266-b8ab-482e-a832-194ced6422cdJulia DanielIn my recent article for Nonwoven Industry I discussed the advantages of using ultrasonic bonding for the nonwoven industry. The nonwoven industry has been a long-time customer of ultrasonic equipment. Emerson offers Branson ultrasonic equipment that can slit, bond, seal or quilt nonwoven synthetic materials to meet a wide range of medical and non-medical application requirements. Medical applications include surgical face masks, face shields, disposable hygiene products, gowns, and filter media. Non-medical uses for this versatile technology include consumer and personal care products, baby diapers and training pants, mattress pads, seat cushions and covers, household mops and cleaning products, disposable vacuum and filter bags, and more. The biggest growth we have seen for ultrasonic technology in recent years is in the medical industry. Because ultrasonic technology can create strong, repeatable results, withstand sterilization processes all while lowering the risk of contamination by eliminating the introduction of solvents and glues to the manufacturing process makes it valuable for medical customers. New opportunities are everywhere, driven in the short term as manufacturers learn more about the value and versatility of this process and in the longer term by changing demographics. As the number of older citizens in the U.S. and many western countries continues to grow as a share of total population, the demand for medical, sanitary, consumer care, bedding, seating, cleaning, and filtration products will only continue to grow. So too will the need to produce these products efficiently, with maximum cleanliness and minimum risk of contamination. The unique ability of ultrasonics equipment to handle a broad scope of nonwoven product manufacturing—slitting, cutting, embossing, quilting and bonding—offers the perfect solution to this growing need. In addition, Branson ultrasonics technology can meet clean room manufacturing requirements, where required, and provide the data monitoring and storage capabilities needed to meet the highest regulatory requirements. These and other ultrasonics capabilities will only continue to evolve and expand in the future. Ultrasonics bonding offers several advantages over other bonding methods: Because it uses friction to heat the material so that it bonds to itself without the use of glue or solvents which in turn creates a huge cost savings for customers. It also lowers the risk of contamination by eliminating the introduction of another product. Ultrasonics also can lower the likelihood of damaging nonwoven filter media, even the most delicate, thanks to our range of frequencies. What are some nonwoven textile applications you or your customers have that could benefit from ultrasonic bonding over traditional solvents or glue?nonwovendiaperstextilesdisposableMedicalultrasonicConsumer Goodshttps://emersonexchange365.com/products/welding-assembly-cleaning/f/discussions-questions/7734/adhesives-or-welding-for-plastic-part-assemblyFri, 08 Feb 2019 11:23:00 GMTcd40bb2b-3d49-4868-939d-417119b40291:c925a96e-4011-4b14-a362-593abe865011Alyssa OrtizOne of the best things you can do, both for the design of your product and the success of your business, is to make design choices that keep your assembly options open. Emerson’s Tarick Walton, Global Product Manager for Branson Assembly Technologies, discusses options manufacturers can use for assembling plastic parts and understanding which option is best for their product design. www.appliancedesign.com/.../95990-adhesives-or-welding-for-plastic-part-assemblyhttps://emersonexchange365.com/community-hubs/welding-assembly-cleaning/b/welding-assembly-cleaning-blog/posts/plastic-parts-assembly-adhesives-or-weldingWed, 07 Nov 2018 18:35:00 GMTcd40bb2b-3d49-4868-939d-417119b40291:d3d38998-0dfb-42b8-beef-ccfda310e806Jim CahillFrom sleek, curvy headlights on fancy automobiles to built-for-purpose designs such as earbuds, medical devices and consumer packaging, plastics are part of our daily lives. Adhesives have typically been used in assembling these plastic parts into their finished form. In an Appliance Design article, Adhesives or Welding for Plastic Part Assembly? [free site registration required], Emerson’s Tarick Walton contrasts the two approaches. Tarick opens noting that the decision on assembly technology is based on two factors: …business factors and part factors. Business factors involve your product lines and production needs, and the degree of speed, flexibility, and scalability that are needed in your assembly operations. Part-related factors go right to the part itself: its performance requirements, shape, and materials of construction. Branson GSX Ultrasonic Welding Platform Some advantages of adhesive-based assembly include flexibility in shapes, plastic materials and sizes. It can be a solution for: …low-quantity assembly jobs, including part prototypes, pre-production product samples, or production runs that include parts that include optional components of differing sizes or shapes. Disadvantages of adhesive-based assembly is increased care and maintenance to keep the applicator clean and free of clogs and blockages. The adhesive: …must be applied with consistency and care to ensure a complete and cosmetically pleasing bond. As the production rate increases, the cost of the consumable adhesive increases. Ultrasonic welders, such as the Branson ultrasonic plastic welding products, provide: …manufacturers with a high degree of flexibility through modularity of the tooling setup. By using a single ultrasonic welder and a range of part-specific tooling, manufacturers can produce a variety of different parts on a single assembly line. These ultrasonic welders work by creating friction between the parts to be joined. The: …mechanical vibrations are transmitted to the interface between the parts, where it is focused on a triangle-shaped bead, the energy director, which focuses the vibration to create intermolecular and surface friction. This friction creates heat and a subsequent melt, which solidifies into a welded bond. While upfront capital costs can be higher for ultrasonic welding technology and associated tooling, the costs associated with consumables and more frequent maintenance are avoided. Generally: …those with production volumes ranging from tens of thousands to millions per year generally realize a significant financial benefit with an ultrasonic welding process. Read the article for more on advantages in assembly cycle times, material considerations, parts geometry, and design considerations. Visit the Ultrasonic Plastic Welding area of Emerson.com and see the Branson GSX Ultrasonic Welding Platform video to learn more about this reliable sealing and parts assembly technology. The post Plastic Parts Assembly—Adhesives or Welding? appeared first on the Emerson Automation Experts blog.Precision Welding-Assembly-Cleaningplastic weldingBransonTarick Waltonultrasonic weldinghttps://emersonexchange365.com/community-hubs/welding-assembly-cleaning/b/welding-assembly-cleaning-blog/posts/advantages-of-ultrasonic-welding-for-packaging-applicationsWed, 27 Sep 2017 17:34:00 GMTcd40bb2b-3d49-4868-939d-417119b40291:f689e4d5-a136-496e-8d60-0b97ddee565eJim CahillToday on the final day of PACK EXPO 2017, Emerson’s Mike Mediana presented on the topic, Migrating from Traditional Package Sealing Technologies to Ultrasonics in Flexible Packaging Applications . Mike’s presentation focused on how consumer preference is driving the increasing demands for flexible packaging in the medical, consumer product, and food and beverage industries. He shared how ultrasonic sealing technology helps machine builders and end users transition away from rigid to flexible packaging. From a consumer standpoint, demand has built for packaging which supports convenience for on-the-go lifestyles, single-serve, flexible packages to reduce unused portions, and an increasing health consciousness and desire for fresh, all natural products. For packagers, these demands translate into increased complexity. A PMMI 2015 Flexible Packaging Market assessment report highlighted some specific challenges in requirements for thinner gauge materials for pouches, new & complex shapes and designs, more frequent changeovers, and increased scrappage and waste. These challenges create operational issues including higher risk of quality issues on line or on shelf, leaking product resulting in downtime, and a greater need for operator skills. The conventional practice of thermal package sealing has several shortcomings in trying to address these challenges. Seal failure is more likely due to contamination in seal area, variation in the materials used, and the use of thinner materials. The result is more downtime and less throughput from the packaging line due to leaking pouches, machine variation and waiting time between outages. Mike contrasted ultrasonic welding technology for packaging seals from traditional thermal sealing in several areas. From a potential contamination standpoint, ultrasonic welding seals through contaminants instead of encapsulating them. From an energy usage standpoint, ultrasonic is an active cool tool process versus a conductive, hot tool process. Instead of the heat flowing through the conductor bar through the material, ultrasonic welding generates heat by friction induced by the ultrasonic frequency. As a result, it is less dependent on the material and thickness. Control of this sealing process is also more flexible using ultrasonic technology. The result is a clean, consistent weld that is fast and efficient to keep the packaging machines productive and with much less risk of contamination. Less packaging material is also needed since the seal width can be reduced and less headspace needed between the product and the seal. Mike noted that since packaging requirements can vary quite a bit, Emerson’s Branson brand consultants can work with packagers on performing an in-depth review of the requirements to design the right ultrasonic welding solution, which considers size and shape of the packaging, package material, product in package, weld requirements, and cycle rates. He shared a case study of nut butter producer which had been using a thermal sealing process. They were experiencing issues with product leakage, oil trapped in the seal area, and an excessive seal failure rate. After switching to the Branson ultrasonic welding for seals, they experienced improved weld integrity, zero seal failures in testing and a 900% increase in stores carrying their product. He closed the presentation sharing types of applications where ultrasonic sealing technology is a good fit: continuous motion form-fill-seal, spout welding, pouch side welding and industrial valve bags. Visit the Branson area of the Emerson website to learn more about ultrasonic welding technology and applications. The post Advantages of Ultrasonic Welding for Packaging Applications appeared first on the Emerson Automation Experts blog.ultrasonic sealingPrecision Welding-Assembly-CleaningPACK EXPOBransonPACKEXPOFood & Beverageultrasonic weldingPackagingMike Mediana