Rinco: More energy-efficient ultrasonic weldi...

More energy-efficient ultrasonic welding processes

(Source: Rinco)
(Source: Rinco)

In view of rising energy costs, further ways of saving electricity are very important for many companies.
Stroke movement and force build-up during welding processes involving ultrasonic welding machines are usually carried out with a pneumatic drive. In recent years, however, the electric drive has increasingly become established.
For a comparison, Rinco Ultrasonics AG, Romanshorn/Switzerland, has compared 2 machines whose frequency, power and stroke are identical. The only thing that was different was the drive. In the case of the Electrical Motion ultrasonic welding machine with electric drive, the idling of the servo control unit (SCU) was also included in the calculations, while the machine with pneumatic drive was operated at 6 bar.
The comparison showed that the Electrical Motion saves 78% energy compared to the pneumatically operated ultrasonic welding machine. The reasons behind this can be found in the welding process itself. For movement tasks, the electric drive is more efficient by a clear margin. While in terms of dwell times, the pneumatic drive has the advantage. To maintain position, the pneumatic machine consumes hardly any energy. However, as the dwell time for ultrasonic welding processes is very short – usually less than a second – the impact of this is almost negligible and is outweighed by the advantage achieved by the electrically driven ultrasonic welding machine.
In addition, the system-related compressed air leaks that occur in compressed air systems and consume energy unnecessarily even during downtimes can be left out of the equation when using the electric drive. This is a particularly important aspect as compressed air is one of the most expensive energy sources in the industry.
Ultrasonic welding machines do not just offer advantages when it comes to saving energy – they can also help to boost quality. Positions can be approached and held more precisely and the stroke movement is also freely programmable.
Welding and cutting processes involving ultrasonics are generally recognized as being energy-saving technologies. Tools do not heat up as they do in thermal welding processes, and there is no need for accessories such as adhesives. Cycle times are short and material can be saved thanks to a narrow weld seam.

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