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4P Plastic spin welder

4P Plastic spin welder

Product description


Model

KLP-4P

Motor power  

4P

Power supply

380v/50hz, or 220v,60hz

Welding time

0.01~9.99 seconds

Pressure

0~7kgs/cm2

Air pressure

0.5~0.8mpa

Maximum welding height

550mm

Workable material

PP,PE, PET, Nylon, PA66

Net weight

400kgs

Dimension

900*700*1800mm

Technology


What is spin welder?

The process of spin welder: uses heat generated by rotational friction at the joint line to weld thermoplastic parts with rotationally symmetric joints, the spin welder applies pressure axially while rotating one part against its stationary mate, and the resulting friction generates heat that melts the parts together, KEEPLEADER™ has vertical and horizontal style, or clarified by upper or bottom rotation in generating spin friction

Advantages of the spin welder: process include high quality permanent joint, hermetic seals, lower equipment cost, ease of assemble, energy efficient operation, no ventilation required, immediate handling, entrapment of other parts, far-field welding capability and no additional material requirements, KEEPLEADER™ adopts renown brand components for quality assurance

Material considerations: material that can be friction (e.g. vibration) welded can also be joined with spin welder, the semi crystalline thermoplastics are more readily joined using spin welder that ultrasonic welding or hot melt, hot plate welding. Using compatible polymers, spin welder is capable of making reliable seals, far-field welding is easier with spin welder that ultrasonic welding, additional parts can be entrapped between the upper and lower pieces during spin welding. Joining of dissimilar polymers is possible using the spin welder process although it generally produces lower strength weld joints. By designing the weld joint with an undercut, the polymer with lower melting temperature will follow into the undercut, creating a mechanical union. Material filler and surface contaminants (e.g.: mold release agent) are two factors that will affect consistency and weld repeatability, spin welder is more tolerant of hygroscopic polymers, although they may still require special handling for critical applications, the moisture content can head to bubble formation in the joint resulting in decreased weld strength, KEEPLEADER™ recommend a simplest method to check the possibility of spin welding: using a heated iron wire to melt the welding parts, if it is molten and sticky, that’s to say your parts is possible for spin welder  

Joint design considerations

01: Part joint must be on a circular axis

02: Joint design should allow for adequate collapse distance

03: Final orientation of part if necessary

04: If At all possible the upper part would be designed for use with drive features, place for upper tool to grasp welding parts

05: The joint area must be designed so that there is no other part contact interference

KEEPLEADER™ intelligent assemble solutions offers no charge feasibility study and joint design review of your welding assembly

Control parameters:

There are several primary process control parameters that affect weld quality, they are the surface velocity of the weld joint, press (axial) speed, weld depth, and hold distance and time

Surface speed:

For a fixed rotational spin speed (RPM), linear surface speed increases wit weld joint diameter, for a fixed weld joint diameter, surface speed increases with motor RPM. Smaller diameter parts therefore usually require more PRM that larger parts of the same material, if the surface speed is too low, an adequate amount of heat will not be generated to cause sufficient melting, if the speed is too high, excessive heat in the joint could result in material degradation or reduction in viscosity leading to material flow away from the joint. The selection of the proper surface speed depends to a large degree on the material and joint geometry of the parts being welded. Some materials, such as PVC, can be readily welded for a wide range of values, while others require a narrow range commonly quoted values in the literature recommend using, KEEPLEADER™ adopts digital display, which is visual for resetting, has different programmable channel to save for different welding parts, is easier to choose for each shifting work

Press (Axial) speed

The press speed affects the amount of contact pressure between the parts being welded, which is required to generate friction heat, the large the speed, the larger the rate of heat rise, in combination with the surface speed, pressure speed must be high enough to cause melting at the interface as opposed to grinding, but not too high as to damage the parts, excessive press can also lead to stalling of the spin motor as more torque is required to maintain constant spin speed, KEEPLEADER™ has positional spin welder, which can smart choose the press speed, is a feasibility of special design joining slot,

Weld depth of spin welder

The determination of the proper weld depth is highly dependent on the application; the weld joint is typically designed for a special weld penetration. Ideally, the weld is sufficiently deep to produce a strong, hermetically sealed assembly. An excessive depth may lead to the formation of flash (material that is ejected from the joint area during the weld and adheres to the assembly), the drawing out of reinforcing filler material and realignment of the interchain bonds in the weld plane resulting in a weak axial weld joint, and possibly part distortion

Since weld depth affects the joint strength and the amount of flash generated, it is important to design the weld joint proper to meet both requirements

Simultaneously, the incorporation of flash trap features is recommended to produce acceptable appearance without compromising strength

Since weld depth affects the joint strength and the amount of flash generated, it is important to design the weld joint properly to meet both requirements simultaneously. The incorporation of flash trap features is recommended to produce acceptable appearance without compromising strength. KEEPLEADER™ can set the data of welding depth, also can make a precision setting by mechanical device KEEPLEADER™

Spin welder hold.

During the hold phase, vertical press travel initially brings the molten parts closer together (dynamic hold) and then allows the molten material to solidify (static hold). Amourphous plastic will normally take longer to solidify those semi crystalline plastics. The dynamic hold distance is typically a small value compared to the weld distance. An approximate staring point for initial application setup is 10% of weld distance, the static hold time vary depending on the size of the part, but is usually in the 1-3 seconds range, KEEPLEADER™ can provide pneumatic holding device or manual clamping device, also can train for self-built purpose to save your cost 

Constant torque

Melt-match mode, in which the press vertical speed is continuously adjusted to match the rate of plastic melt at the joint, the is achieved by measuring the spin torque and changing the vertical speed on-the-fly based on this measurement, the vertical speed is inversely proportional to the spin torque, the lower the spin torque, the vertical speed is illustrated in figure 5-20. The welder will adjust vertical speed for a measured spin torque along the lines shown, the torque target is the desired spin torque, which is entered into the torque (% of max) field on the screen, the max torque value is 5% larger that the target torque. If the measured torque exceeds the max torque, the vertical value will be 0 until the torque drops below the maximum. The max speed is the maximum allowable vertical speed, which will occur if the measured torque is 0. This value is entered in the vert. Max (mm/s) field on the weld parameters screen (in the weld tab), the actual spin torque profile achieved during the weld will depends on the torque (% of max) and the vert Max (mm/s) settings for a particular application for example, if the actual spin torque is consistently below the specified tor, the vert. Max (mm/s) will need to increased to caused the welder to move down faster, causing a rise in the spin torque, KEEPLEADER™ has dual servo motors configuration under requested, so, its worth for this investment  

Team support at KEEPLEADER™

Our knowledgeable applications staff regularly address issues such as Joint design recommendations, material compatibility, detailed application feasibility report, and troubleshooting expertise, KEEPLEADER™ offer technology and equipment that is reliable, efficient and controllable and back it up with unparalleled

Product uses


4P Plastic spin welder

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4P Plastic spin welder