Compared with other methods of joining metal or plastic parts, such as fasteners or adhesives, welding and soldering offer many advantages. Welding is better for creating permanent joints that must be strong and watertight. It can also create a seamless appearance between the parts, and it can create an electrically conductive joint. Here are four new products for welding and soldering.

Workcell for Robotic Soldering

The MRC500 is a customizable workcell for robotic soldering. Its mechanical structure is designed to work with a wide range of process equipment, material handling and guarding systems. In its basic configuration, the MRC500 is a standalone, semiautomatic machine. At the other extreme, it can be equipped with SMEMA conveyors, collaborative robots, rotary indexing tables and other automation components.

The cell can be outfitted with any of MTA’s soldering heads: soldering iron, induction, or microflame. In the case of the MLH45 laser head, the cell can be designed specifically for laser soldering with laser-safe guarding. 

The main features of the cell include a welded frame construction; a three-axis Cartesian robot with optional rotary axis at the head; a work area measuring 500 by 500 millimeters; and an industrial PC controller with intuitive, menu-driven programming software.

Since soldering heads are fairly heavy, the robot is driven by large DC stepper motors to provide sufficient strength to actuate the head quickly. The X, Y and Z axes have robust ballscrew actuators for precise actuation. A repeatability of 20 microns assures the soldering process is accurate and consistent.

See this company at The ASSEMBLY Show South April 16-17 in Nashville, TN.

MTA Automation Inc.
https://mtarobotics.com 

Image courtesy of Sunstone Engineering LLC

Resistance Welder for EV Batteries

One of the biggest challenges when welding EV batteries is finding a welder capable of welding highly conductive metals, such as copper and aluminum. Inside a lithium-ion battery are various copper or aluminum components that carry electrical current. These components are commonly joined to either similar or dissimilar metals. If the joint is not made properly, there is a potential for voltage drops due to the resistance between the two pieces.

The Omega PA250i welder was designed to weld copper tabs to battery cans. It can weld copper battery tabs up to 0.5 millimeter thick. A motorized weld head provides greater control, precision and uniformity to every weld. The power supply lets engineers fine-tune each weld. As a result, battery manufacturers can produce lighter, more compact battery packs without compromising power or capacity.

With this welder, the metal parts are fused together at the weld spot for a continuous connection and no voltage drops. Surface contaminants are burned off, allowing for strong, clean welds.

The device can weld any combination of metals, such as copper to aluminum. The heat-affected zone is small and localized to ensure no degradation to the battery. The welder provides enough energy to make the weld without affecting the integrity of the cell.

Sunstone Engineering LLC
www.sunstonewelders.com 

Image courtesy of Emerson

Laser Welder Automates Assembly of Small Plastic Parts

The Branson GLX-1 laser welder joins small, complex or delicate plastic parts. Its small footprint and modular design make it compatible for use in ISO-8 clean room environments, while an integral automation controller simplifies installation and interfaces with robots and other devices.

Its precise, servo-based actuation controls give engineers greater freedom to design and join small components with three-dimensional contours, such as sensors, catheters and wearables with microfluidic parts. The welder can join high-performance and blended polymers and components with complex joint geometries or preassembled parts without risk of damage due to heat or vibration. Laser welds are completed without flash or part marking, giving parts a superior aesthetic appearance.

To support increased interest in recycling, the GLX-1 can also safely and nondestructively “un-weld” plastics in common medical devices and wearables. This disassembly capability enables reclamation and reuse of valuable internal components while enhancing sustainability initiatives and reducing waste.

The GLX-1 welder relies on Emerson’s simultaneous through-transmission infrared laser-welding technology. The unit’s high-power laser banks offer configurable power levels up to a maximum of 250 watts per bank.

An advanced servo-driven actuator provides precise, repeatable, closed-loop control over downforce. An optional, closed-loop pneumatic control is also available. Efficient and accurate tool changeover is ensured, thanks to an RFID function that recognizes and matches weld recipes with production tooling.

The GLX-1 also provides connectivity and security, with weld data collection, transfer, and security features simplifying weld-data transfer over internal customer networks. Operational and security features are accessed through the welder’s intuitive 12-inch touch-screen HMI, which is mounted on a swiveling arm for easy viewing.

The welder connects with plant networks to meet IIoT or communication requirements, offering data interface gateway and fieldbus interface gateway compatibility, a USB port and an OPC-UA interface.

Emerson
www.emerson.com

Image courtesy of FRIMO Innovative Technologies

Infrared Welding System Joins Large Plastic Parts

This infrared welding system joins large plastic parts with 3D contours. Thermoplastics can be welded using infrared radiation. The radiation is absorbed by the plastic and transformed into heat. The surface layer melts, and the plastic components are then joined by pressing them together. Infrared heat is transferred without contact. Heat input is fast, specific and energy-efficient.

Power-controlled and time-controlled infrared emitters allow for precise and controlled welding. Typical applications are automotive instrument panels, door trims and center consoles with complex 2D or 3D contours. The process does not create particles, which is particularly useful for joining air-duct pipes, fluid containers, tanks, battery compartments and filter housings. The technology can create gas-tight joints, and it can be used to weld glass-reinforced plastics.

Modular tooling can be equipped with glass bulb or foil emitters. Tooling can be swapped in 5 minutes.

FRIMO Innovative Technologies
www.frimo.com