Ultrasonic Welding Cell utilizes 6-axis robot.

Press Release Summary:

ULTRAROBOT incorporates robotics for assembly of multiple plastic components. End of arm weld head utilizes 2-4 different weld horns to accommodate different welding operations without tool change. Windows®-based CNC controller, DIALOG Touch, controls all weld processes and interfaces with robot without PLC. Ethernet port allows ULTRAROBOT to interface directly with plant networks or off-site QC departments via Web for remote diagnostics.

Original Press Release:

Herrmann Ultrasonics Introduces "ULTRAROBOT": Flexible System for Ultrasonic Plastic Assembly

Shrinking high volume products and growing multiple version lower volume products, especially in the automotive industry, have forced manufacturers to look for more flexible assembly solutions. In the past, ultrasonic plastic assembly systems were custom designed to assemble specific products. This is no longer acceptable for most manufacturers. Today's requirements include maximizing flexibility and floor space and minimizing tool change set-up time. Herrmann Ultrasonics has developed "ULTRAROBOT", a flexible ultrasonic welding cell incorporating robotics, for the assembly of multiple plastic components. The ULTRAROBOT eliminates the need for time consuming set-up and tool changes.

One of the key features of this assembly solution is a six- axis robot. This component can be supplied by any robotics manufacturer, as long as the end of arm load and welding forces are taken into consideration when sizing the robot.

A second key feature is the specially designed end of arm weld head, utilizing two different (up to 4) weld horns to accommodate different welding operations without tool change.

Another important component is Herrmann Ultrasonics' WINDOWS© based CNC controller "DIALOG touch", which controls all weld processes and interfaces with the robot without the need for a PLC. A separate, optimized weld program can be established for each weld position, providing the possibility to switch between weld modes, using different forces or amplitudes and setting individual min/max weld process control windows. The table below illustrates a selection of different weld positions in an actual production cell. In this example, 8 different automotive interior components require a total of 46 staking operations and 22 welding operations. This cell contains 6 separate fixtures in two separate load/unload positions. Robot efficiency is maximized by rotating the end of arm weld horns and switching weld modes/parameters as often as needed (up to 200 times).

All Herrmann Ultrasonics' "DIALOG touch" controllers are equipped with an Ethernet port, allowing the ULTRAROBOT to interface directly with plant networks or off-site QC departments via the world-wide-web for remote diagnostics. This also allows users to monitor and modify weld process parameters that provide closed-loop data collection and parts tracking.

For more information on the ULTRAROBOT, please contact Vasko Naumovski or Michael Cherdron at Herrmann Ultrasonics at Herrmann Ultrasonics, telephone (847) 985-7344.

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