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VAIR-1015

Vertical Air/Pneumatic Infrared Welder

The VAIR-1015 is a vertical infrared platen orientation, pneumatic motion controlled infrared welding system capable of welding parts up to 10” x 15” (254mm x 381mm) or multiple smaller parts.  Customized variants of this model are available.

This vertical systems twin motion (left and right) tool mounting platens allows independent control of force/speed on each part half when coming together in the weld phase.

When compared to horizontal platen systems, vertical systems typically:

  • reduce risk of molten material possibly dripping onto the infrared platen during the melt step (resulting in premature emitter failure)
  • 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)

Optional Features.

Please view our product options below. Click the option for a larger image.

Standard Features

Ultra-Rigid Construction utilizing tubular steel framework with leveling feet and linear ball slides/bearings designed for precise tool alignment through decades of use.

Digital Two-Zone Infrared Energy Control with Emitter Burnout Alarm ensures even heating and precise energy control. Burnout alarm halts operation of the machine in the event of platen emitter failure.

Digital Incomming Line Voltage Monitor with Alarm Limits prevents operation of equipment in the event of plant voltage rises/sags outside of user-defined limits (affecting actual infrared energy output).

Allen Bradley MicroLogix Programmable Logic Controller (other controllers quoted upon request).

Allen Bradley PanelView Plus 600 Touch-Screen User Interface simplifies parameter input and allows the following to be displayed:

  • Melt, Weld (Seal) & Open Time Digital Control & Display
  • 5 Digital Infrared Energy Control Steps (10%-100%)
  • Resettable Parts Counter
  • Non-Resettable Total Machine Cycle Counter
  • Diagnostic Display
  • Machine Alarms (storage up to 99)

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

5 Weld Program/Setup Memory allows storage for instant recall, minimizing tool change time.

External 120VAC Duplex Electrical Outlet allows user to easily connect small auxiliary equipment such as computers, printers, radios, etc.

0.75 HP, 1725 RPM, 25.0 in/Hg (0.56kW, 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.

Automatic Cycle Start on Manual Safety Door Closure eliminates the need to actuate start button(s).  Door is equipped with captured lock and is interlocked to prevent opening while machine is in cycle.

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

Vent Hood with Exhaust Fan evacuates airborne smoke from the operator location.

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 Infrared Platen Capacity:  10.0" D x 15.0" H (254mm x 381mm)

Infrared Platen Carriage Stroke (back-front):  12.0” (305mm)

Infrared Platen Assembly Lateral Stroke (side-side):  1.5” (38mm)

Infrared Energy Control Range:   10% - 100% (in 1% increments)

Infrared Energy Control Steps:   5

Tool Mounting Platens:  10.0” D x 15.0” H (254mm x 381mm)

Moving Tool Mounting Platens:  Dual – Left & Right

Daylight Opening (between Tool Mounting Platens):  21.0” (533mm)

Tool Mounting Platen Stroke (ea):  6.0” (152mm)

Maximum Clamp Force:  660 lbs @ 80 PSI (2.94kN @ 5.4 Bar)

Front Door Opening:  17.5” W x 33.0” H (445mm x 838mm)

Machine Dimensions:  43.5” D x 65.0” W x 72.0” H (1105mm x 1651mm x 1829mm)

Weight:   ~1500 lbs (682kg)

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 closes safety door.
  • 3.Safety door locks.
  • 4.Part halves are automatically held with vacuum or mechanical grippers.
  • 5.Infrared platen advances between part halves.
  • 6.Holding fixtures close to make contact with precise mechanical hard-stops on the infrared platen which maintain spacing between the parts and the infrared platen without actual contact.
  • 7.Infrared platen energizes, heating joint areas of part halves.
  • 8.Infrared platen de-energizes and holding fixtures retract away from infrared platen.
  • 9.Infrared platen retracts.
  • 10.Holding fixtures apply part halves together, welding parts together.
  • 11.One holding fixture releases its clamping mechanism.
  • 12.Holding fixtures open, retaining welded part(s) in one fixture.
  • 13.Safety door unlocks.
  • 14.Operator opens safety door.
  • 15.Operator unloads welded part(s).