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VSIR-1445

Vertical Servo Infrared Welder

The VS-1445 is a vertical infrared platen orientation, servo-electric motion controlled infrared 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.

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

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 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 infrared platen carriage assembly is completely rigid.

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:

  • Weld (Seal) steps by Time, Collapse or Absolute Distance (in 0.001” increments)
  • Faster Transition Times (from Melt to Weld Steps) for stronger bonds

Digital Two-Zone Infrared Energy Control via PLC 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 Incoming Line Voltage Monitor with Alarm Limits preventsoperation of equipment in the event of plant voltage rises/sags outsideof user-defined limits (affecting actual infrared energy output).

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

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

  • Individual Tool Mounting Weld (Seal) Collapse/Absolute Distance, Time, Force & Speed Settings
  • Infrared Platen Assembly Position & Speed Settings
  • Process Verification (Pass/Fail) Windows on: Melt & Seal - Time, Collapse Distance, Absolute Distance; Open Time
  • 5 Digital Infrared Energy Control Steps (10%-100%)
  • 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 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:  14.0” D x 45.0” H (356mm x 1143mm)

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

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

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

Infrared Energy Control Steps:  5

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.Infrared platen advances between part halves.
  • 6. Holding fixtures close to maintain precise 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 opens.
  • 14.Operator unloads welded part(s).