Introduction: Hot plate welding machine mainly uses temperature device(can be set from HMI) to control the hot plate temperature(heating method: hot plate heating and infrared heating) to achieve plastic parts’ welding. Hot plate is in the middle of both plastic parts, when the plastic parts close to or touch the hot plate, then both sides plastic material starts heating and melting, when it achieves set depth and time, upper tool and lower tool will be separated, and then the hot plate return to home position, both plastic parts join together, once it achieve set securing depth, the plastic material starts cooling and secured. When the secured time arrived, open the lower tool and upper tool, then the welding process is finished.
Main function: the hot plate welding machine driven mode can be servo motor, pneumatic or hydraulic, welding temperature, heating time, cooling time, welding depth, pressure, welding time…etc parameters can be adjusted per different product requirement. Per welding program requirement, it can choose semi-automatic or full automatic mode. Per different products requirement, the program recipe can be adjusted, can be equipped with a trolley for quick changing tool, the machine is equipped with quick changing tool function, and it adopts safety door and safety curtain, to guarantee the operators’ safety.
Servo motor hot plate welding machine: The upper and lower side adopts precise linear bearings, while hot plate is guided by precise linear guides, using servo motor for driving force, ensuring precise positioning and multi-speed operation of the hot plate welding machine.
Upper tool plate adopts high quality steel plates that is made aging treatment.
The hot plate welding machine provides many areas emergency stop function, and adopts safety curtain, which is provides more safety for the operator.
machine main frame is consist of four welding parts, which are made by square tube, rough plate welding, using tempering treatment , and machining by large size hot plate welding machine.
precision guide rail: upper and lower silde movement is guided by four sets precision guide rail.
servo gear motor：upper tool, lower tool, hot plate movement is adopted servo motor drive, can adjust heat staking depth, time and torque much conveniently and quickly.
safety hang tooth: when slide table is stoped at any postion can protect it safe.
displacement sensor：can make sure movement absolute value of slide table
precision grinding gear rack: slide table movement is driven by two sets gear rack, which can protect parallelism of slide table.
upper/lower slide table:is made by rough plate, after welding it, use tempering treatment , and machining by large size hot plate welding machine.
hot tool slide table:is made by rough plate, after welding it, use tempering treatment , and machining by large size hot plate welding machine.
upper and lower servo motor can make sure max closing pressure 1200KG, servo motor control precision 0.02mm
safety door: safety door is consist of sheet metal, is driven by a set cylinder, can protect the operator’s safe.
insultation door: is consist of sheet metal, double open door, driven by a set cylinder, can reduce radiation of hot plate.
upper cold tool pneumatic-electric plug-in structure
upper cold tool auto lock tool structure
hot tool auto lock tool structure
hot tool heating line auto change plug in structure
lower cold tool auto lock tool structure
lower cold tool pneumatic-electric plug-in structure
Machine safety and control
1、Safety device
⊙Machine equiped two start button and one emergy stop switch
⊙Machine equiped safety curtain
⊙Product checking sensor
⊙Machine equiped safety door ,side door equiped door sensor
2、Control system
⊙Machine used PLC control system and touch screen, can set each welding parameter
⊙Electrical and pneumatic system is separated
⊙Electrical parts all use quality componets like Siemens, Weidmuller and ETC.
3、PLC funcation and touch sreen display
⊙Auto/Manual mode can change in the touch screen
Munal mode-Driving parameter,time can set in the touch screen.
Auto mode: automatic running , parameter real-time display . Cycle time less than 1 minute.
⊙Counting display and set
⊙Parameter setting need password , avoid incorrect set by wrong person
PLC program can add or reduce according to customer requirement. Different product can save different program. The program name can be set.
Hot plate welding tool: hot plate adopts high-quality forged brass and is machined as a whole part to fit the hot plate welding equipment perfectly, especially for automotive lighting.
The lower tool and upper tool is machined by shaped aluminum material, for the product surface, we make mirror surface or Teflon coating, or Teflon cloth sticking on the nest, to prevent the product surface scratched.
Automatic change tool process:
1.After press the tool exchange button, upper and lower tool move to sealing position
2.Lower tool open auto lock tool.
- upper and lower tool close, all move to setting position.
3.The auto fixing system for the hot plates open
- hot tool move to melting postion
- lower tool up, hot tool’s lock tool clamp open at the same time.
6.. upper slide table up to some distance, and leave hot tool from hot tool fixed plate.
- hot tool slide plate back to original position.
- upper cold tool down to getting off position of change tool .
- upper cold tool clamp structure open.
10.auto change tool program is finished, pull the tool onto the trolley by operator, then change tool is finished.
- the whole auto change tool program is only 3 mins.
Hot plate welding machine Operation：
⊙ Turn on power,start heating（pre-heating about half hour）
⊙ Loading product
⊙ Press two start button, hot tool return, pull out upper and lower tool and touch hot tool, heating for a while.
⊙ when time is up, hot tool return, upper and lower tool sealing for a while with pressure.
⊙ After finish it, open the clamp, upper and lower tool return, operator unload the product.
⊙Cycle time: it depends on different product
Before the automotive lighting project starts, we often make a feasible analysis for our customers
the auto lamp design is totally meet hot plate welding requirement, can be welded by hot plate welding machine. To be better guarantee welding quality of auto lamp, we suggest some optimizations per our experience of similar product.
1.Plastic deformation is the common characteristic, to prevent this affecting the welding quality, we usually suggest adding turnup on the product edge. From this way, our tool will correct the product deformation, and make better welded product.
please see the red circle which is added turnup before.
2.Except adding turnup to correct deformation, there is also another solution can reduce it: add reinforcing rib on the product to weld it better.
please see the red circle which is added reinforcing rib before.
the height of lamp housing welding rib is 2mm, our minimum requirement is 2mm, so the welding rib is a little low, we suggest adding 1mm of the welding rib, to keep better quality.
Please see the red part, which is the welding ribs
- Can the seat cover be added on the terminal block?
confirm to add（OK）
Terminal block shielded line on fixture, need to be confirmed
confirm to add shielded line(OK)
Temperature of the welding rib surface,selection of thermocouple
confirm J type thermocouple(OK)
Under the comparison of inner wall space of datum plane, an ID confirmation problem proposal is required, and the housing edge position;
Due to the replacement of the welding angle, the secondary side has been made slider,no need confirmation.（OK）