VS-1445

The VS-1445 is a vertical heat platen orientation, servo-electric motion controlled hot plate welding system capable of unparalleled control and ultra-precise welding of parts up to 14" x 45" (356mm x 1143mm) or multiple smaller parts.  Customized variants of this model are available.

When compared to horizontal platen systems, vertical systems typically:  

• allow faster tooling changeovers
• allow ergonomically easier and more positive operator loading and unloading of the tooling
• ensure more precise part half alignment during welding (less scrap) as no special part-part alignment features must be designed into the parts themselves (required for accurate machine pick-up of one part half on horizontal systems)  

The vertical servo systems twin motion (left and right) tool mounting platens allow independent control of collapse/absolute distance, time, force & speed on each part half, both against heat platen when in melt phase and against each other in weld phase. Typical hard-stops found in use on most systems are eliminated.

Standard Features:

Ultra-Rigid Stopless Construction utilizing tubular steel framework and linear guide shafts/bearings with Rack/Pinion alignment mechanism designed for extremely precise tool repeatability without measurable deflection through decades of use.  The heat platen carriage assembly is completely rigid and is thermally isolated from the heat platens themselves.  Rigidity of heat platen carriage construction allows system to perform precise melt of one part half only at full force against heat platen without deflecting the assembly.

100% Servo-Electric Motion Control enables unsurpassed weld repeatability, improved process control and optimal motion control by allowing user to program precise tool mounting platen positions, speeds and forces without need for mechanical hardstops within the tooling.  Advantages:

• Melt & Weld (Seal) steps by Time, Collapse or Absolute Distance (in 0.001” increments)
• Faster Transition Times (from Melt to Weld Steps) for stronger bonds
  Allows Programming of Individual Melt Duration (set by Time, Collapse or Absolute Distance) of one part half prior to the other.  Typically used when welding dissimilar materials.
• Soft-Touch Contact of Part Halves to heat platen (Melt) and each other (Weld/Seal), increases Teflon cloth/coating life.
• Pre-Melt Joint Softening Control further increases Teflon cloth/coating life by allowing positioning of parts to within ~0.005” of the heat platen and then stop for a programmable time to achieve softening of the joint prior to contact with the Teflon cloth/coating on the heat platen.

  Digital Four-Zone Temperature Control via PLC with Heater Burnout Alarm ensures even heating and precise temperature control and temperature alarm limits. Burnout alarm halts operation of the machine in the event of platen heater failure.
  

  Programmable Automatic Heat Platen Startup (Time/Date Based) saves production time as the machine can be user programmed to automatically initialize warm-up of heat platen before start of production.
  
  Allen Bradley CompactLogix Programmable Logic Controller (other controllers quoted upon request)
  simplifies parameter input and allows the following to be displayed:
  

  Allen Bradley PanelView 1000 Plus Color Touch-Screen User Interface simplifies parameter input and allows the following to be displayed:
  

  • Individual Tool Mounting Platen Melt & Weld (Seal) Collapse/Absolute Distance, Time, Force & Speed Settings
  • Heat Platen Assembly Position & Speed Settings
  • Melt Offset Parameters (melt of one part half prior to the other) for Dissimilar Materials
  • Process Verification (Pass/Fail) Windows on: Melt & Seal - Time, Collapse Distance, Absolute Distance; Open Time
  • Digital Temperature Control Settings and Alarm Limits
  • Machine Alarms  & Diagnostics
  • PLC Input/Output Status
  • Detailed Help Menus

  Pendant Arm Mounted User Interface allows easy repositioning of interface panel to optimal location based on preference of user.
  
  Multi-Level Passcode Protection limits parameter adjustment to qualified personnel only.
  
  25 Weld Program/Setup Memory with Alpha-Numeric Program Naming allows storage for instant recall, minimizing tool change time.
  
  External Ethernet Communication Port and 120 VAC Outlet allows bi-directional communication for interfacing between customer computer and PLC as well as detailed data output.  Single 120VAC outlet allows user to easily connect small auxiliary equipment such as computers, printers, radios, etc.
  
  1.0 HP, 1725 RPM, 25.0 in/Hg (0.75kW, 1725 RPM, 63.5cm/Hg) High Capacity Vacuum Pump System designed to secure even the largest parts within the tooling.  Eliminates the need for separate venturi-vacuum systems for each tool.   
  
  Pneumatic Power Sliding Safety Door with Zero Force Cycle Activation Switch and Door Safety Tapeswitch provides optimum personnel protection while reducing operator fatigue.  
  
  Hinged Access Panels with Safety Interlock Switches allows extensive access while providing maximum personnel protection.
  
  Vent Hood with Exhaust Fan evacuates airborne smoke and particulate from the operator location when welding at high temperatures without coatings.  
  
  Interior Viewing Lights enhance visibility of the welding process for the operator.
  
  Two English Language Manuals provides detailed documentation and instruction of installation, operation, setup, maintenance & troubleshooting procedures.
  
  Maximum Heat Platen Capacity:  14.0” D x 45.0” H (356mm x 1143mm)
  
  Heat Platen Carriage Stroke (back-front):  25.0” (635mm)
  
  Heat Platen Assembly Lateral Stroke (side-side):  0.0” (0.0mm) Rigid
  
  Thermal Temperature Range:  100ºF – 1000ºF (38ºC – 538ºC)  Tooling & Application Dependant
  
  Tool Mounting Platens:  15.5” D x 45.0” H (394mm x 1143mm)
  
  Moving Tool Mounting Platens:  Dual – Left & Right
  
  Daylight Opening (between Tool Mounting Platens):  38.0” (965mm)
  
  Tool Mounting Platen Stroke (ea):  14.0” (356mm)
  
  Minimum Tool Mounting Platen Depth Adjustment:  0.001” (0.025mm)
  
  Maximum Clamp Force:  1700 lbs (7.57kN)
  
  Front Door Opening:  38.0” W x 71.0” H (965mm x 1803mm)
  
  Machine Dimensions:  85.3” D x 149.0” W x 102.0” H (2167mm x 3785mm x 2591mm)
  
  Weight:  ~7500 lbs (3409kg)
  
  Color:  Forward Technology Two-Tone Gray (unless otherwise specified)
  
  Electrical Requirements:  480 VAC, 3 Phase, 60 Hz
  
  Pneumatic Requirements:  80 PSI, 0.5” ID (5.4 Bar, 13mm ID) Supply Line   System includes Filter, Regulator & Lubricator
  
  Warranty:  Free from materials and workmanship defects for one year from delivery.
  
  

  Sequence of Operation:

  1. Operator loads part halves into holding fixtures.

  2. Operator initiates cycle activation switch.

  3. Safety door closes.

  4. Part halves are automatically held with vacuum or mechanical grippers.

  5. Heat platen advances between part halves.

  6. Holding fixtures apply part halves to heat platen.

  7. Holding fixtures retract from heat platen.

  8. Heat platen retracts.

  9. Holding fixtures apply part halves together, welding parts together.

  10. One holding fixture releases its clamping mechanism.

  11. Holding fixtures open, retaining welded part(s) in one fixture.

  12. Safety door opens.

  13. Operator unloads welded part(s).

Digital Four-Zone Temperature Control via PLC with Heater Burnout Alarm ensures even heating and precise temperature control and temperature alarm limits. Burnout alarm halts operation of the machine in the event of platen heater failure.

Programmable Automatic Heat Platen Startup (Time/Date Based) saves production time as the machine can be user programmed to automatically initialize warm-up of heat platen before start of production.

Allen Bradley CompactLogix Programmable Logic Controller (other controllers quoted upon request)
simplifies parameter input and allows the following to be displayed:

Allen Bradley PanelView 1000 Plus Color Touch-Screen User Interface simplifies parameter input and allows the following to be displayed:

• Individual Tool Mounting Platen Melt & Weld (Seal) Collapse/Absolute Distance, Time, Force & Speed Settings
• Heat Platen Assembly Position & Speed Settings
• Melt Offset Parameters (melt of one part half prior to the other) for Dissimilar Materials
• Process Verification (Pass/Fail) Windows on: Melt & Seal - Time, Collapse Distance, Absolute Distance; Open Time
• Digital Temperature Control Settings and Alarm Limits
• Machine Alarms  & Diagnostics
• PLC Input/Output Status
• Detailed Help Menus

Pendant Arm Mounted User Interface allows easy repositioning of interface panel to optimal location based on preference of user.

Multi-Level Passcode Protection limits parameter adjustment to qualified personnel only.

25 Weld Program/Setup Memory with Alpha-Numeric Program Naming allows storage for instant recall, minimizing tool change time.

External Ethernet Communication Port and 120 VAC Outlet allows bi-directional communication for interfacing between customer computer and PLC as well as detailed data output.  Single 120VAC outlet allows user to easily connect small auxiliary equipment such as computers, printers, radios, etc.

1.0 HP, 1725 RPM, 25.0 in/Hg (0.75kW, 1725 RPM, 63.5cm/Hg) High Capacity Vacuum Pump System designed to secure even the largest parts within the tooling.  Eliminates the need for separate venturi-vacuum systems for each tool.   

Pneumatic Power Sliding Safety Door with Zero Force Cycle Activation Switch and Door Safety Tapeswitch provides optimum personnel protection while reducing operator fatigue.  

Hinged Access Panels with Safety Interlock Switches allows extensive access while providing maximum personnel protection.

Vent Hood with Exhaust Fan evacuates airborne smoke and particulate from the operator location when welding at high temperatures without coatings.  

Interior Viewing Lights enhance visibility of the welding process for the operator.

Two English Language Manuals provides detailed documentation and instruction of installation, operation, setup, maintenance & troubleshooting procedures.

Maximum Heat Platen Capacity:  14.0” D x 45.0” H (356mm x 1143mm)

Heat Platen Carriage Stroke (back-front):  25.0” (635mm)

Heat Platen Assembly Lateral Stroke (side-side):  0.0” (0.0mm) Rigid

Thermal Temperature Range:  100ºF – 1000ºF (38ºC – 538ºC)  Tooling & Application Dependant

Tool Mounting Platens:  15.5” D x 45.0” H (394mm x 1143mm)

Moving Tool Mounting Platens:  Dual – Left & Right

Daylight Opening (between Tool Mounting Platens):  38.0” (965mm)

Tool Mounting Platen Stroke (ea):  14.0” (356mm)

Minimum Tool Mounting Platen Depth Adjustment:  0.001” (0.025mm)

Maximum Clamp Force:  1700 lbs (7.57kN)

Front Door Opening:  38.0” W x 71.0” H (965mm x 1803mm)

Machine Dimensions:  85.3” D x 149.0” W x 102.0” H (2167mm x 3785mm x 2591mm)

Weight:  ~7500 lbs (3409kg)

Color:  Forward Technology Two-Tone Gray (unless otherwise specified)

Electrical Requirements:  480 VAC, 3 Phase, 60 Hz

Pneumatic Requirements:  80 PSI, 0.5” ID (5.4 Bar, 13mm ID) Supply Line   System includes Filter, Regulator & Lubricator

Warranty:  Free from materials and workmanship defects for one year from delivery.

Sequence of Operation:

1. Operator loads part halves into holding fixtures.

2. Operator initiates cycle activation switch.

3. Safety door closes.

4. Part halves are automatically held with vacuum or mechanical grippers.

5. Heat platen advances between part halves.

6. Holding fixtures apply part halves to heat platen.

7. Holding fixtures retract from heat platen.

8. Heat platen retracts.

9. Holding fixtures apply part halves together, welding parts together.

10. One holding fixture releases its clamping mechanism.

11. Holding fixtures open, retaining welded part(s) in one fixture.

12. Safety door opens.

13. Operator unloads welded part(s).