Application of Turck BL67 in Ultrasonic Welding of Fuli Mould

Whether using bonding, riveting, screwing or welding, when we join raw materials together, the right joining technology plays an increasingly important role in product design and production efficiency. Even if it is "just" joining two plastic components, the numerous joining technologies can make it difficult for users to choose, including heated tool welding, hot air riveting, hot contact riveting, infrared welding, laser welding and ultrasonic welding/riveting. Automotive interiors are particularly suitable for surface welding and cold tool riveting, so ultrasonic welding/riveting is usually chosen. Ultrasonic welding Ultrasonic welding

is

a technology that uses high-frequency vibrations (ultrasonic waves are between 20KHz and 40KHz) that are beyond the range of human hearing to join plastics. Ultrasonic waves are generated by a generator that converts the low-frequency energy provided by the AC power supply into higher-frequency ultrasonic oscillations. The mechanical resonant element (consisting of a converter, amplitude transmission element and ultrasonic welding electrode) connected to the generator is installed in a pneumatic cylinder. By using an ultrasonic generator, the mechanical oscillations generated by the converter under pressure are provided to the thermoplastic adhesive. In the joining area, the ultrasonic energy causes friction between molecules and interfaces, thereby heating and softening the plastic components. The depth of penetration of the ultrasonic generator into the plastic is a criterion for the quality of the joining area, and in this case, each material has its own optimum value.

The need for a powerful I/O system

The large number of input and output signals transmitted in an ultrasonic welding system makes a powerful I/O bus system a must. After a comprehensive market analysis, Fulmi, one of the leading suppliers of ultrasonic welding systems, decided to choose Turck's BL67 solution. "After comparing the conventional market I/O bus systems, I came to the conclusion that Turck's system is the best because its high transmission speed meets our requirements." Thorsten Geldmacher, technical project manager responsible for the introduction of the I/O system, explains Fulmi's decision to choose BL67. For switch boxes, this system combines all the advantages of modern IP20 bus terminal systems, thus converting them to the current IP67 area.

The advantages of such a solution are obvious. The BL67 system can be connected directly to the sensor without a junction box. This saves material and assembly time, and the large number of signals together helps to reduce costs. In addition, the BL67 system is very flexible and can be adapted to future requirements. If more I/O channels are needed in the future, additional modules can be easily installed under existing conditions without further costs. The BL67 system is connected to the Fulmi system via profibus, but it can also be used for other bus systems. In addition to the high transmission speed, the decision-makers at Fulmi were also impressed by the insulation and connection standards of the BL67. The hot swap function ensures smooth operation of the workshop, and modules with problems can be replaced in a flash while in working order. The value created

by the high-frequency

ultrasonic welding system of the I/O system is amazing for everyone. For Fulmi, the decisive factor was the ability to pass the I/O system without additional wiring cabinets, but through the welding required to transmit the high-frequency signals. This concept was finally implemented in close cooperation with Turck. A 19" rack with relay printed circuit boards is used to distinguish high-frequency signals. Fulimo uses the BL67 I/O system for high-frequency transmission in its current serial system. Ultrasonic welding can therefore be easily controlled by software. "Thanks to the BL67's outstanding capabilities in fieldbus-oriented signal transmission and sensor technology, Turck has provided us with a solution that meets our high standards and stringent requirements." ", says Detlev Böl, technical director at Hamburg-based Fulimo Plastics Connectors GmbH. The high-frequency signal is transmitted via the orange cable through the BL67.

The BL67 has proven itself in comprehensive field tests in Fulimo ultrasonic welding systems. Johnson Controls Interiors, an automotive supplier in Lüneburg, Germany, is one of many customers that has purchased a Fulimo welding system with a Turck I/O system. At its Lüneburg plant, Johnson Controls produces door panels for the new Volkswagen Tiguan, which was presented at the International Motor Show in September 2007. Fulimo Group, a leading supplier of production equipment for high-quality plastic components for the automotive industry.

As an expert in sensor, fieldbus, HMI and connector technology, Turck not only equips Fulimo ultrasonic welding systems with fieldbuses, but also supplies special sensors and connectors for detecting pneumatic cylinders. Changing materials in the welding process - from leather to plastic without manual intervention - requires sensors that can detect the penetration depth of contactless ultrasonic welding. "The solution provided by Turck for this not only meets the technical specifications, but also meets Fulimo's high quality standards. "Böl said.

The result of this cooperation - the Fulimo magnetic field simulation sensor can be replaced with new materials during operation without updating the system, and due to its compact design, it can be directly installed on the T or cylinder using standard connectors. The result of this cooperation - the Fulimo magnetic field simulation sensor.