Horizontal Three Battery Air/Pneumatic Hot Plate Welder

The system design is ideal for welding:

  • Battery covers to cases.
  • Battery manifold covers to case covers.

Optional Features.

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Standard Features

Ultra-Rigid Construction utilizing a tubular steel framework with leveling feet and linear guide shafts & bearings designed for precise tool alignment through decades of use.

Polymer Pass-Thru Conveyor System allows pass-through assembly of the battery components in the production line. Conveyor system is fully guarded end-to-end. Customer is responsible for further guarding of adjacent, supplied infeed/outfeed coveyor segments to fully compley with OSHA standards.

Fully Automatic Cycle/Start & Operation enables system to cycle without operator intervention based on part flow down the assembly line. System recognizes entry of batteries into the welder via power conveyor and automatically starts the welding cycle when the batteries are in the welding position.

Pneumatically Actuated In-Feed Diverter System controls quantity and rate of entry of pre-assembled battery components into the welding positions. Presence sensors verify battery components are properly staged in the in-feed area and enables actuation of diverter to allow components to continue into welding positions.

Pneumatically Actuated Locating Rail ensures precise location of battery components entering on the conveyor system. Presence sensor detects correct positioning of battery on conveyor stop block and enables actuation of locator rail to properly square battery in position for welding. Upon completion of welding, the locating rail and conveyor stop blocks retract allowing welded product to exit system on conveyor.

Digital Three-Zone Temperature Control via PLC with Heater Burnout Alarm ensures even heating and precise temperature control with 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 MicroLogix PLC with PanelView Plus 7 - 600 Color 5.7

Sequence of Operation

  • 1.Pre-assembled unwelded battery covers & cases move down customer’s assembly line conveyor to the in-feed diverter section of the welder’s feed-thru conveyor.
  • 2.Unwelded battery assemblies are detected via a part presence sensor on the conveyor and are held against a mechanical stop within the in-feed diverter section of the conveyor prior to entry into welding positions.
  • 3.When already welded batteries have exited the welding area, the diverter assembly indexes one unwelded battery assembly at a time past the mechanical stop to allow passage of battery down the conveyor to the welding position.
  • 4.As battery assemblies move toward the welding area, part presence sensors on the conveyor detect their presence and pneumatically actuated stop blocks hold batteries in the correct position.
  • 5.When all batteries have entered the welding area and are detected in correct position by part presence sensors, a pneumatically actuated locator rail moves outward to position batteries against an opposing fixed rail, squaring them in preparation for welding.
  • 6.Conveyor motion stops and welding cycle starts automatically.
  • 7.Upper holding fixtures descend downward and upper battery covers are automatically held with vacuum and/or mechanical grippers.
  • 8.Upper holding fixtures retract upward with upper battery covers.
  • 9.Heat platen advances forward between battery covers and cases.
  • 10.Heat platen descends and contacts lower battery cases.
  • 11.Upper holding fixtures apply upper battery covers to heat platen.
  • 12.Upper holding fixtures retract from heat platen.
  • 13.Heat platen raises from lower battery cases and retracts rearward.
  • 14.Upper holding fixtures apply upper battery covers & lower battery cases, welding batteries together.
  • 15.Upper holding fixtures release clamping mechanisms.
  • 16.Upper holding fixtures retract and welded batteries remain atop feed-thru conveyor.
  • 17.Pneumatic locator rail and conveyor stop blocks retract and conveyor motion starts.
  • 18.Welded batteries are indexed out of machine via feed-thru conveyor.