Vibration Welders

Vibration Welders

Vibration Welders

Product catalog summary
Overview: The MX Series Linear Vibration Welders by Sonics are designed for assembling large or complex thermoplastic parts and can also handle multiple smaller parts simultaneously. They are capable of bonding various thermoplastic materials, including dissimilar materials with compatible melting points, materials with fillers, and composite materials.
Machine Specifications: Each welder features an Allen-Bradley SLC 5/05 PLC operating system with a PanelView Plus 1000 color touch screen for programming and monitoring. The patented AUTO-TUNE feature optimizes the upper tool's frequency for efficiency.
Applications: The welders are suitable for automotive components like carpet and trim, pillars, glove boxes, head and tail lamp assemblies, instrument panels, air intake manifolds, as well as medical devices, fuel tanks, and filters.
Process: Vibration welding involves holding one part stationary while the mating part vibrates against it under pressure, generating heat through friction to bond the parts.
Power & Drive Features: The system includes a digitally controlled electromagnetic drive, automatic tuning, variable output frequency (200 to 250 Hz), and precise amplitude settings. It supports multi-stage welding and detects lower tool weight and travel distance.
Operation Features: The system offers three welding modes (Time, Distance, Energy), a job library for storing settings, and a single-button start. It includes a supervisor access level for security.
Mechanical Design Features: The machine has a tubular steel frame, multiple shock mounts, closed-loop hydraulic pressure control, and a variable force lift table.
Safety & Service Features: Safety features include light curtains, emergency stop, noise insulation, and easy access for tool changes and maintenance.
Dimensional Data: The document provides detailed dimensions for models MX10, MX15, MX20, and MX25, including machine width, depth, height, and table specifications.
Power Data: All models have a maximum clamp force of 5,000 lbs, a 10 horsepower motor, and operate within a frequency range of 200 to 250 Hz.
Weight Data: The gross weight ranges from 7,500 lbs to 9,000 lbs, with upper tool weight limits depending on spring type.
Utility Requirements: The machines require 480 VAC, 3-phase electrical supply, and a minimum of 80 PSI pneumatic pressure.
Patents: The equipment is covered under several U.S. patents, ensuring proprietary technology.
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Catalog excerpts

Vibration Welders-1

Applications • Carpet and Trim to Interior Automotive Panels • Automotive Pillars • Glove Boxes • Head Lamp MX Series Linear Vibration Welding Systems Assemblies • Tail Lamp Assemblies • Instrument Panels • Air Intake Manifolds • Medical Devices • Fuel Tanks • Filters Process PRESSURE LINEAR MOTION The process of vibration welding is based on simple physics. One part is held stationary in a lower tool. Under applied pressure, the mating part is vibrated against the stationary part in a linear direction. This combination of linear motion and pressure creates friction, which in turn, generates heat in the weld joint. The friction brings the two parts to their melt temperatures and bonding occurs. Design Sonics’ MX Series Linear Vibration Welders are designed for assembling large and/ or complex shaped thermoplastic parts. The machines can also be tooled to assemble multiple smaller parts simultaneously. The MX Series can bond virtually all thermoplastic materials, whether injection molded, extruded, formed or thermoformed. Dissimilar materials (with compatible melting points), materials with fillers as well as composite materials and fabrics can also be bonded. Machine Each MX Series Vibration Welder features an Allen-Bradley SLC 5/05 PLC operating system with a PanelView Plus 1000 color touch screen operator interface to program and monitor all parameters of the system insuring quality, consistency and ease in setup and use. Sonics’ patented AUTO-TUNE feature allows the system to detect, set and lock the upper tool’s optimum frequency in seconds. This facilitates maximum efficiency with minimal power to drive the tool at its pre-set amplitude. for more information: 1-800-745-1105 www.sonics.com

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Vibration Welders-2

MX Series Linear Vibration Welding Systems POWER & DRIVE FEATURES • Digitally Controlled Electromagnetic Drive System • Patented Automatic Tuning Automatically detects, sets and locks the upper tool’s optimum frequency in seconds • 200 to 250 Hz Variable Output Frequency • .040″ (1 mm) to .070″ (1.78 mm) Amplitude Setting • ± 0.003″ (.07 mm) Amplitude Accuracy • Return Alignment Accuracy of ± .002″ (.05 mm) • Standard Springs - Up to 90 lb. (41 kg) Upper Tool Weight OPERATION FEATURES • Allen-Bradley SLC 5/05 PLC Operating System • 10.4″ (264 mm) Allen-Bradey PanelView Plus 1000 Color Touch Panel...

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Vibration Welders-3

MECHANICAL DESIGN FEATURES • Tubular Steel Welded Main Frame Construction SAFETY & SERVICE FEATURES • Four Spring Head Bridge For large upper tool capacity • Safety Light Curtains • Multiple “Shock” Mounts Minimizes vibration to the main structure • Heavy Duty Noise Insulation • Emergency Stop • Closed Loop Hydraulic Pressure Control • Integrated Pneumatic Door • Variable Force Two-Speed Hydraulic Lift Table • Hinged Rear Service Doors For easy tool changeovers • Fully Accessible Electrical Service Panel • 10″ (254 mm) per second Lift Table Speed • Easy Access Hydraulic System • Fork Lift Provision...

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Vibration Welders-4

DIMENSIONAL DATA F - Floor to Lift Table Load Height Lift Table Bed - Front to Back Lift Table Stroke Vibration Platen Maximum Clamp Force Output Frequency Range Amplitude Range Approximate Gross Weight Upper Tool Weight - Standard Springs Upper Tool Weight - Heavy Springs POWER DATA (Less Lower Fixture Weight) WEIGHT DATA UTILITY REQUIREMENTS (Other Electrical Voltages Available) Sonics vibration welding equipment and tooling is manufactured under one or more of the following U.S. patent numbers: 6,066,217, 6,227,275, 6,364,977, 6,588,644 Corporate Headquarters 53 Church Hill Road, Newtown,...

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