(01) Precise Timings : Ultrasonic Welding is used for quality and precision.
The Precise Sealing largely depends on accurate control of various timing like delay time,
weld time and hold time etc. Normally all the Machines have least count of 0.1 sec., where
as in our System it is possible to set the timings with accuracy of 0.001 sec. These
features helps in accurate settings of timings which is not possible with conventional
Machine which results into:
(a) Over welding of Component.
(b) Deformation of Component.
(c) Low Production Rate.
(d) Excess Consumption of Power and Increase in Cost. (as we can set, if required, 0.245
as weld time which in the conventional Machine will have to be set as 0.3 Sec. Thus,
Ultrasonic energy is applied for 0.055 Sec. more)
The overall result is increase in the life of Generator, Convertor, Booster, Horn.
(02) Shake of Pulse : In addition to delay time, weld time and hold time in
conventional Machine, we provide additional time for shake of pulse, which is after the
hold time. In this, Ultrasonic is applied in the Horn which helps in removing particles
stick to Horn which may result in poor finish and welding quality in the successive
Components.
(03) Self Diagnoses : Our system is having advance Microprocessor Controller
(MPS-3 or MPS-2). This not only helps us for Calibration and quality control but also as a
fault finding tool. Many of the faults are indicating on Microprocessor and immediate
action can be taken by the operator himself to rectify the same. Some of the indications
are as follows :
(1) Faulty Switch.
(2) Broken Connections.
(3) Inadequate Air Pressure
(4) Inadequate Voltage supply. Microprocessor Switches OFF, incase the Voltage is out of the
range for avoiding damage of the system.
(04) Auto Tuning : The Horn supplied by us are properly tuned and when used
with our System, the System will automatically tune with the Horn. In Conventional Machine
the System is to be tuned with the Horn manually which is time consuming.
(05) Horn Life Indication : Normally the Horn supplied by us will be tuned to
the right frequency and ideal loss (Energy consumption during no load conditions) is in
the range of 3 - 6%. For various reasons Horn may fail and failure can be slow proces,
which is indicated by increase in ideal loss. Thus, advance notice is received for
replacements of Horn and one can arrange for spare Horn before failure of the first,
avoiding the stoppage of the Machine.
(06) Voltage Fluctuation :Ultrasonic Output independent of input voltage
fluctuation. Insufficient input voltage will Switch OFF the System for avoiding the damage
of the System. Normally the voltage fluctuation can cause severe damage in other System
resulting into higher maintenance cost.
(07) Capacity Upgradation :Our Equipment are modular type and it is possible
to upgrade Machine from lower capacity to higher capacity easily, where as normally for
higher capacity requirements separate Machine is to be purchased.
(08) Printer Facility :It is possible to connect Printer to the
Microprocessor of the Equipments, which will give hard copy of the various parameters
during welding including, maximum power used, number of welds etc. It is also possible to
get Graph of energy verses time, which help insetting the initial parameters and
determining the quality of the welds.
(09) Longer Life for Consumables :The Precise Time setting through
Microprocessor helps in optimum use of power and avoiding unnecessary loading of the
Component which inturn increase their life.
(10) Titanium Booster :As our System uses Titanium Booster, replacement of
Aluminium Booster which is very common with other System (Due to wearing of threads) is
avoided, resulting in saving in cost and time.
(11) Built in Electronic Booster :Generator of our System can vary Amplitudes
from 70-10%, without changing the Booster. All other System require different Boosters for
different Amplitudes. The Amplitude selection is very important in ultrasonic Welding for
quality and strength. These features saves lot of cost and time involved in, inventory of
various Boosters and changing the same from time to time for various application.
(12) Energy Mode Facility : This feature of our System helps the User to
set precisely the required energy for particular application. The System ensures delivery
of pre-set energy for every Component resulting into consistent quality in Welding.
(13) Quality Control :Microprocessor helps us as quality control tool as the
indication on the same for P-MAX or welding time helps the User to know about the quality
of the weld. The above parameters outside the acceptable limit, indicate poor quality of
weld and the same Component can be rejected without further testing.
(14) Provision for Automation :The Microprocessor Control allows the use of
Rotary Table or similar kind of System, which increases the production considerably
reducing the handling time.
(15) Key-Board Locking :This facility allows the User to lock the Key-board,
so that it is not possible to vary any parameters by any unauthorised person. The change
in the parameters means resetting, resulting into loss of time.
(16) Pneumatic Components :All Pneumatic Components used are of high quality
( FESTO-MAKE ) resulting into trouble free operation.
(17) Swiss Collaboration :As the Equipments are manufactured in collaboration
with Telsonic AG Swtizerland, who are one of the leaders in ultrasonic Technology,
they are of high quality and precision. Further the latest developments by Telsonic are
immediately incorporated in our System.
(18) After Sales Service :This is offered through various Branch Office and
if required from Works, by well-trained Technicians and Engineers.
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