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MX系列振动摩擦焊接机

Vibration Welder type MX系列振动摩擦焊接机
型号MX189MX150
Weight of upper tooling max. 75kg/50Kg
上模具重量最大可到75Kg/50Kg
 
 
1.      Design of the machine
     机械结构设计
 
1.1     Frame in welded design
机架设计
made from square steel tube profiles,with 4 vibration reducing feet, adjustable in height, stand-alone design.
      机架由方型钢管焊接而成,下有4只可调整高度的防震地脚,该设备是成熟的标准机型
 
1.2     Sound enclosure
     噪音防护罩
consisting of cassette elements, thickness approx. 100 mm.
由覆有厚度大约100mm的矿物棉的箱体结构组成
To make the assembly procedure simple, the sound enclosure is cut in two and equipped with a quick-acting closure.
为了方便安装,噪音防护罩是独立式的,并配有快速锁定装置
The rear side is provided with a double-wing maintenance door, lockable, with safety switch.
后面是带安全开关的联锁双翼门
The complete equipment is freely placed on the floor.
整个噪音防护罩可在地面上独立安置
The operator’s side is fitted with a pneumatically operated protective door, vertical movement, with integrated safety panel.
操作员一侧配备有一个可移动的带有联动安全杆的垂直气动防护门
The safety panel stops the closing movement when contacted.
在防护门上升的过程中,一旦有物体接触到防护门上的安全杆,防护门会自动停止
The noise level is reduced to lower than LMP 78 dB(A) acc. to DIN 45 635.
根据德国标准DIN 45 635的要求,配备有CPC系统的设备的噪音等级被减少到低于78dB(A)
The window is made of double safety glass.
防护门上配有双层安全玻璃制成的视窗
 
 
1.3     Lifting resp. clamping table
     升降工作台面
Surface of the nest is made in solid welded steel design.
升降台的台面材料是钢
The lifting table is running on spherical liners as well as on guide pillars, mounted to 4 machine stands. It is driven by a hydraulic cylinder, centrally located.
升降台沿着4个固定在设备框架上的导柱上下运动,驱动力有液压工作站给出
The strokes of the table are continuously adjustable. They are controlled by a travel control system.
可移动台面的行程是可连续调整的,由移动控制系统来控制
The table plate of the lifting table is cut out, allowing to load and position also large parts to be welded.
升降台的台面是设计为开口状的,方便上料及固定较大的工件
 Apart from this, the table plate is equipped with a pinhole image for tool mounting.
可移动台面上有专用的模具定位装置
 
1.4 Vibration drive and control
振动系统的驱动和控制
The vibration head is driven by a digital frequency converter. The vibration system consists of:
振动头由数字变频器驱动,振动系统主要考虑以下几个方面:
 

  1. Frame of vibration head
振动头的构架
The frame is made in solid welded construction, with machined surfaces for placing the inner parts of the vibration head.
振动头的构架是极其坚固的金属结构
 
  1. Bedding of vibration head
     振动头的基垫
The bedding consists of several bearing strips, positioned in the machine frame via a 4-point adjusting device and carrying the vibration head by means of vibration reducing elements.
基垫有几个固定在构架上的轴承条组成,通过4点调整装置来支撑振动头,这种方式可有效地减少振动时构架自身的晃动
 
  1. Vibration head
      振动头
The SONICS vibration head works according to the electromagnetic principle. The resonance frequency generates an inter-active magnetic field, allowing an ideal vibration start of the coupled nest.
The amplitude is continuously adjustable, max. 1 mm (corresponding to a friction travel of 2 mm).
To avoid excess vibration there is integrated a spring assembly into the vibration head. It provides both a constant friction travel and, due to its restoring force, the precise positioning of the tools to be welded after concluding the welding process.
SONICS振动头的工作是电磁原理的。由交变电流共振频率产生的磁场,驱动相连接的模具产生往复振动。
振幅是可连续可调的,最大为2mm,(相应摩擦的距离为4mm)
振动头内部有弹性体,它可以防止过度的振动距离,并提供恒定的振幅。由于自身的往复拉力,能确保振动头在焊接结束后回到原始位置,而保证上下焊接工件的准确定位
 
 
 
  1. Amplitude control
     振幅控制
As a standard the machine offers a newly-designed system of amplitude control (in conjunction with the time-pressure steps). By means of this technology there takes place an automatic amplitude change during the various welding phases. Input via the touch panel TP 270 or optionally in case of a  PC via PC control.
该标准机型提供了最新设计的振幅控制系统(与时间控制-压力分步控制模块相连接),采用这个技术,振幅可以在不同的焊接阶段根据设定值进行自动调整,振幅设定可以通过TP270触摸屏或者选用可选件通过PC来实现
 
  1. CPC (Complete Process Control)
     CPC(完善的过程控制)
CPC is a synchronised control procedure for the vibration process with controlled vibration start under load and active braking lower than 60 ms. The two-coil technology together with an optimised vibration head leads to an increase of the utilisation coefficient by more than 50 % in comparison with standard vibration technology. The customer benefits, most of all, from a shortening of welding process periods by approx. 30 – 40 % and a reduction of lint formation.
CPC工艺控制保证在整个焊接过程中,带负载时的起振时间和主制动时间控制在60毫秒内,并具有最佳的振动性能,这种与电流馈电增加量相结合的振动控制技术,其效率比通用振动技术提高了至少50%以上,客户生产效率也因此受益,缩短了30%-40%的焊接周期,同时还减少溶料的产生
 
The system allows both an excellent utilization ratio as well as careful treatment of the vibration system. In addition, the constant welding quality provides the utmost quality certainty even for critical applications.
完善的振动控制技术和极高的系统利用率相结合,意味着即使客户是非常复杂的应用,也可以得到稳定的焊接质量,
 
  1. Automatic frequency resonance control (AFRC)
     自动频率谐振控制
Automatic frequency tuning in connection with CPC, duration approx. 1 s, during tooling exchange and setting up of a new tool, resp.
自动频率扫描与CPC联合运行,耗时大约1秒,通常在更换模具和安装新模具时进行
 
1.5 Hydraulic system with proportional valve
配有比例阀的液压系统
The machine is fitted with a noise-reducing high-performance hydraulic system and designed for the bilaterally triggered hydraulic cylinder. This technology allows considerably increased speeds of movement as well as accuracy of positioning in comparison to the cylinders triggered one-sided only.
As a standard the hydraulic aggregate is positioned outside the machine. Optionally it can be operated within the sound protection cabin.
设备配备有低噪音高性能的液压系统,带有双向触发的液压缸。它比较单项触发的有可以增加移动速度并保证位置精度的优势。标准设备的液压站放置在设备的旁边,客户也可以选择也可以放置在隔音间内的机型。
 
1.6 Pneumatic system
气动系统
Maintenance unit with pressure control and stop valve.
Standard software for the eligible tooling functions like e. g. slide, ejector etc. and equipment with vacuum pumps.
带有压力控制及截止阀的气动系统可以完善地提供焊接需要的各种动作,比如气动顶出工件功能及真空泵等
 
1.7 Electrical control system
电气控制系统
The free-programmable PLC Siemens S7 is installed in a standardised electrical cabinet, stand-alone design. This can either be flanged to the machine or placed separately. In automatic production lines this separate placement may be recommendable.
电气柜内装有西门子可编程序控制器S7,它既能装在设备上,也可以分开安放,在生产线上分开安放有它独有的优势                                                                                        
  • Key switch allowing to select the modes ADJUSTMENT/MANUAL/AUTOMATIC,
    integrated into the operator’s side of the electrical cabinet
在电气柜操作者一边的拨动开关提供调整/手动/自动三种模式
  • Serial interface RS 232 for printer connection at touch panel.
触摸屏处配有RS232打印接口
  • Parts’ counter displayed on the touch panel
触摸屏上显示焊接计数值
  • As a standard there are available 99 memory programs, into which all relevant process parameters and travels are stored. This allows a time-saving adjustment of the machine to 15 different welding jobs during tooling change.
    标准设备提供99个内存程序,它可以存储所有的相关过程参数,可以存储最大15组不同模具的焊接所有参数
  • With the tooling coding system 15 preferred parameter sets are loaded fully automatically.
    15组首选模具的焊接参数自动存储
 
  1. Operator panel
操作面板
The basic outfit of the machine includes the Siemens touch panel TP 270, 6 and 10 “screen, integrated into the operator’s side of the electrical cabinet.
标准设备配备有西门子6-10“的TP270触摸屏。
Parameters important for the welding quality are shown as a graphic after each welding process for each part. The graphic can be printed by means of the serial interface.
每个部件的每次焊接的重要参数都可以以图表的形式显示在触摸屏上,该图表也可以通过RS232接口打印出来
On a display the parameters and the texts of the error diagnosis and the operating texts are shown in plain text. Apart from this the manual functions can be selected via the operating device.
焊接参数,错误诊断信息和操作信息都完整地显示出来,通过操作设备也可以选择手动功能
The parameters can be modified by means of the integrated operational and numerical keys. In addition, they can be secured by a 5-digit code number.
所有参数可以通过功能键和数字键来改进,并可以通过一个5个数字的密码来保护
          The following parameters with actual value display and limit value window can be set:
      下面的参数值和限定值可以通过面板设置
          Times:
时间
          - lifting time
上升时间
          - trigger time
触发时间
          - welding time (in up to 8 different weld pressure zones)
焊接时间(最多8组,在不同的压力值时的焊接时间)
  • cooling time (up to 3 different times)
冷却时间(最多3组)
Pressures: (display as actual value in N)
-  压力(单位值是N)
     - lifting pressure
台面上升时的力
     - trigger pressure
触发时所需的力
     - weld pressures (up to 8 pressures)
焊接时的压力(最多8组)
     - cooling pressure (up to 3 pressures)
冷却时的压力(最多3组)
                                                                                                     

Welding travel

      焊接距离
To be selected in up to 8 steps, analogous to the welding and time profiles, with actual value display and limit value window.
最多8组,类似于时间模式,有设定距离值和上下限值
Amplitude
振幅
To be selected in up to 8 steps, analogous to the pressure, time and travel profiles, also with actual value display and limit value window.
最多8组,类似压力,时间和距离模式,同样有设定值和上下限值
During the welding process the amplitude of the vibration head can be regulated up to max. 2 mm width and in up to 8 steps. Input and display on the operating device.
在焊接过程中,振动头的振幅将被控制在最大2mm的范围内,最多8组,输入并显示在面板上
 
 
 
  1. Operating modes and process control
操作模式和过程控制

In the standard version with PLC and touch panel there can be selected:
标准版本,PLC和触摸屏可以选择如下模式:
  • time welding
时间模式
  • travel welding – total stroke
距离—总行程模式
  • travel welding – welding depth
距离—焊接的深度模式
 
Travel welding: control of the limit values of the welding time
距离模式时可以设定时间为限定值
Time welding: control of the limit values of the welding travel
时间模式可以设定距离为限定值
 

The travel measurement is realised by means of modern laser technology. Accuracy +/- 0.05 mm. The measurement takes place inside the oscillating system (head bridge, clamping table) in order to avoid measuring errors by vibrations, for instance.

      焊接深度的测量由最新式的激光技术来识别,精度为+/-0.05mm,为了避免由于机架振动产生的误差,测量在振动系统内部(桥架和固定台)结构内完成
 
  1. Quality control and process optimisation in a comparison actual/nominal
质量控制和设定/实际值的差异的处理
In each welding step additionally the actual value is displayed graphically or as a text on the touch panel for each welding parameter set by the operator (e. g. pressure, amplitude, travel and time). The system controls and compares simultaneously the nominal data with the actual values, fixing the nominal data as limit values. In case of upper or lower deviation an error message is given on the touch panel.  A re-start is possible only after confirming the error. Error messages may also be collected automatically via a printer (interface RS 232 on the touch panel).
每次焊接后操作者设定的参数(例如压力,振幅,距离和时间)都会以图表或数字值显示在面板上,系统会自动比较设定值和实际值,并参照所设定的限定值,一旦实际值超出限定值的上限或下限,系统会给出错误信息,操作者确认后要重新启动,错误信息也可以自动有RS232接口打印出来
 
The parameter protocol can be printed either for each welded part or e. g. for the 10th or 100th part. In the practice often the printout is started with every 10th part and, after faultless production, a prolongation to every 100th part or other conditions are selected (variations between 1 – 999 parts).
参数打印可以每件打印一次,也可以比如从第10件到第100件的的参数打印出来,通常开始时每10件打印一次,长时间没有问题时,可以延长到每100件打印一次,也可以由操作者自己设定(范围是1-999)
 
 
 
Supplementary to the process data control of the listed operating data the control offers additional possibilities of control like:
另外,还提供以下操作者喜欢用的参数作为数据管理的一部分
  • Amplitude control and supervision as actual value display with limit value window, eligible in 8 steps.
  • 振幅控制和监控—8组中的实际振幅和限定值显示
  • Pressure control as actual value display with limit value window, eligible in 8 steps.
  • 压力控制—8组中的实际压力和限定值的显示
  • Pressure display as actual value in N (power)
  • 压力显示—单位为N
  • Energy supervision as actual value display with limit value window in J (Joule)
  • 能量监控--实际能量和限定值的显示,单位为J
 
This data control comparing actual/nominal value makes it easy to establish the MFU (machine capability).
这些实际/设定值的显示方便客户设定自己的MFU
 

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