Industrial Systems

Ultrasonic Plastic Welding

Ultrasonic assembly uses ultrasonic vibratory energy which is transmitted through the parts to melt and bond thermoplastic materials. This technique is fast, efficient, non-contaminating and requires no consumables. In addition to welding, ultrasonic processes can be used to insert, stake, stud weld, degate, and spot weld thermoplastics as well as seal, slit, and laminate thermoplastic films and fabrics.

Branson's 2000 Series ultrasonic assembly systems are available in several levels of control, including time, energy, energy compensation, distance, and force. They are designed for superior performance, ease of use, and data management. These systems include an enhanced UPS power supply module with Branson's patented closed loop circuitry providing superior performance, consistency, and reliability.

2000 Series systems are available in 15, 20, 30, and 40 kHz. The power supplies have increased power output for three of these frequencies: 20 kHz units are rated at 1100, 2200, and 3300 Watts; 30 kHz is available in 1500 Watts; and 40 kHz are available in 400 and 800 Watts. The 15 kHz systems are rated at 3300 Watts. New low power units are rated at 150 and 500 Watts; and new high-power units are available at 6000 Watts.

Branson also offers a 2000 Series Integrated Welder which combines power supply and welder in one benchtop unit. Integrated welders are available with distance welding capability.

All Branson systems may be used in manual, semi-automated, or fully-automated environments. The actuator may be mounted directly to a machine frame, with a fixed support on a column and hub, or as a stand-alone system on a base with ergonomic light-force palm button switches.

Hand-held welders – available in 20, 30, and 40 kHz – are compact, lightweight tools ideal for assembly of large parts or those with hard-to-reach joint areas. They are available with a pistol grip or sleeve with the trigger switch on the side for versatility in operation.

Vibration Welding

Vibration welding uses the frictional heat generated at the joint interface of two parts to be welded to melt the plastic. Two methods are available from Branson: linear and orbital vibration welding. With linear welding, the heat energy is achieved by moving one part relative to its mating piece under pressure through a given displacement or amplitude. With the orbital process, the upper section is vibrated using constant velocity orbital motion – circular motion in all directions. With both processes, once the desired amount of weld has been achieved, vibration is stopped, and the parts are held together under a clamp force for a short period of time, allowing the weld to solidify.

Branson's vibration welders are designed to withstand the abuses typically encountered in a rugged industrial environment. They offer state-of-the-art process control, improved ergonomic features, rapid setup capability, and meet all safety regulations. Several different-sized models are available. Depending on the model, standard linear vibration welders can assemble parts of any size up to 55" long by 20" wide. Multiple parts per cycle can also be welded. Three series of linear vibration welders are available - L Series, Hy-Line, and Ultra Hy-Line, offering multiple control levels. In addition, Branson offers the Mini II vibration welder; with a footprint of only 36" by 38", this welder will handle parts up to 7" by 9".

Orbital vibration welders can operate at low weld amplitudes – less than 0.030" in some applications, which reduces part clearance requirements and enables welding of unsupported vertical walls. Parts up to 12" in diameter may be orbital welded. Constant velocity orbital motion results in more welding power in short weld times. Omnidirectional motion enables welding of taller, unsupported vertical walls. No wall is ever perpendicular to welding motion since motion is in all directions.

Standard features include closed loop amplitude control, adjustable frequency, and ergonomically designed opto-touch sensors. New process verification software for validating weld quality on critical applications is also available.

Spin Welding

Spin welding joins thermoplastic parts with a circular joint area by bringing the part interfaces together, under pressure, with a circular, spinning motion. One part is held stationary in a fixture, while the other is rotated against it under pressure. At least one section must be circular. The frictional heat that is generated causes the part interfaces to melt and fuse together, creating a strong, hermetic seal.

Spin welders are available in servo-powered or inertial models. The SW200 Series spin welders are precision servo-driven spin welding systems which allow radial tool orientation within 1°. Branson spin welders are easy to use – either as free-standing units, or integrated into automated systems. Primary control of the system is through an operator interface, which allows for RPM (revolutions per minute) control from 250 to 7000 RPMs (depending on model), revolutions per cycle and hold time. The controller monitors these in addition to motor torque for quality control monitoring. A dual servo model is available with servos controlling both the rotation and weld depth.

Hot Plate Welding

Hot plate welding is a direct thermal welding technique that uses a heated platen to contact the mating surfaces of the parts to be assembled. This technique permits a wide latitude in designing parts with complex, irregular shapes – the joint can be curved in all planes, and welding of internal walls is possible. It is applicable to most thermoplastics, and is especially effective on semi-crystalline resins such as polyethylene and polypropylene. The process is suitable for parts up to 72" x 24" or multiple smaller parts.

Hot plate welding equipment is designed with either vertical or horizontal temperature-controlled heat platen assemblies. (The hot plate welder shown uses a horizontal heat platen.) The part surfaces are melted by contact with the heat platen and then precisely pressed together to form a final assembly. Servo-driven models are also available, giving the user greater control over weld results than is possible with conventional mechanical stops.

Larger custom systems are available for even larger parts, including a pallet welder for parts up to 60" x 48". This is a flow-through machine where the operator places one half of the part on top of the other (the parts are designed with self-aligning features) and slides them into the machine on ball supports. After automatic clamping of the two halves, the weld cycle takes place, and after cooling the welded assembly is ejected out the back of the machine. The estimated cycle time is one minute.

Riveting

Baltec radial forming machines manufacture products with superior joint strength, superior finish, and virtually no grain distortion. Radial forming is highly versatile in its ability to form ferrous and non-ferrous metals, die cast materials and case-hardened fasteners. And because the machines can be set to precise pressures, it has been used successfully in conjunction with assemblies containing Bakelite, ceramics, glass, and other brittle materials. Radial forming facilitates riveting of precision parts, precious metals and various thermoplastics. You can also engrave, mark, coin and burnish surfaces.

Edge Folding

Edge folding technology achieves a more economical and repeatable part by process secure edge folding technique to pillar trims, package trays, arm rests, center consoles and headliner systems and visors.

Punching and Trimming

The perimeter edge of a product can be created by stamping or cutting. Holes and features that can not be formed by primary tooling can be achieved through punching. Each cutting procedure is chosen according to the applied production materials – fascia panels or door panels.

Gluing and Joining

Many automotive components utilize the snap fit of attachments like Clips, J-nuts, and x-mas trees to provide a means of securing a Trim Panel to body sheet metal. By incorporating innovative, custom solutions our process ensures the benefits of good ergonomic design and error proofing.

Torque and Tightening

Epic Equipment & Engineering has produced manual, semi-automatic and automatic machines to feed and drive fasteners. These systems incorporate Air, D/C and Servo driven Screw and Nut Drivers. Depending on your application we can recommend the appropriate control scheme and level of automation for bolt tightening, screw feeding and driving, fastener counts and error proofing and torque verification..

Testing

Epic Equipment & Engineering has designed and built systems to test and inspect components. These can be stand alone test stations or integrated in an automated assembly line. Types of testing offered, leak, torque, visual inspection, efforts test and in-line vehicle sequencing systems.

Automated Assembly

Epic Equipment works with customers to optimize labor content and volume requirements to meet their requirements in projects such as HVAC registers, I/P Clusters and underhood components.