Pain Point: How to Improve Efficiency and Reliability in Plastic Welding?

• Complex geometries and large sizes of plastic parts make it difficult to achieve uniform welding.
• High production volumes require fast mold changes and consistent cycle times.
• Quality standards demand precise welding and reliable sealing to prevent leaks and ensure durability.
• Labor-intensive mold changes lead to increased downtime and reduced efficiency.

Engineering Solution: Dual-Station Ultrasonic Welding Machine by Huazhuo Automation

Key Technical Features

1. Dual-Station Design
   • The machine features two independent workstations, allowing for continuous production and seamless mold changes.
   • Each workstation is equipped with a servo motor for precise control and positioning.
2. Precision Components
   • Servo Motors: High-precision servo motors ensure repeatable positioning accuracy of ±0.02mm.
   • Linear Guides: High-quality linear guides from Hiwin provide smooth and accurate movement.
   • Ball Screws: Direct connection of ball screws and reducers ensures high precision and consistent welding quality.
3. Advanced Control System
   • PLC Control: Siemens PLC ensures reliable and stable operation.
   • Touch Screen Interface: A user-friendly Siemens HMI touch screen allows for easy operation and programming.
   • Safety Features: Safety light curtains and interlocks protect operators during operation.
4. Efficient Mold Change System
   • The machine includes a quick mold change system, allowing mold replacement within 2 minutes.
   • The mold change process is automated, reducing downtime and increasing production efficiency.
5. Welding Process
   • The machine uses a 35KHz ultrasonic generator and transducers to deliver precise and consistent welding.
   • The welding process is monitored and controlled in real-time, ensuring high-quality results.

Technical Specifications

Customize equipment and molds according to the product.

• Machine Dimensions: 2600mm × 2800mm × 2550mm
• Maximum Welding Size: 1100mm × 600mm × 250mm
• Workstation Stroke: Upper platen 500mm / Lower platen 500mm
• Middle Platen Stroke: 800mm
• Max Opening: 1400mm | Min Opening: 400mm
• Power Consumption: 86kW
• Voltage: 380V, 3-phase, 50Hz
• Air Pressure: >0.6MPa

Cycle Time

Results

• Increased Production Efficiency: The dual-station design allows for continuous production, reducing downtime and increasing output.
• Improved Welding Quality: High-precision components and advanced control systems ensure consistent and high-quality welding results.
• Reduced Labor Costs: Automated mold change system reduces the need for manual intervention, lowering labor costs.
• Enhanced Safety: Safety features protect operators, ensuring a safe working environment.

Global Market Outlook

• China: Large-scale applications in Tier-1 automotive suppliers.
• Southeast Asia: Rapid growth in automotive and electronics manufacturing in Malaysia, Thailand, and Vietnam.
• Europe: High demand from premium OEMs and suppliers in Germany and the Czech Republic.
• Americas: Export hubs for automotive and electronics components in Mexico and Brazil.
• Middle East: Emerging markets for plastic component manufacturing in Turkey and the UAE.

Why Choose Huazhuo Automation

• Proven Engineering: Hundreds of successful installations in China.
• Technical Expertise: In-depth design for ultrasonic welding systems, mold alignment, and process control.
• Efficiency: Quick mold change, modular components, and minimized downtime.
• Global Service Network: On-site commissioning and remote troubleshooting.