MCR-I 72

The MCR-I 72 is a pneumatic motion controlled Orientation (Servo Motor) Spin Welder designed for smaller diameter, more delicate spin welding applications requiring the utmost precision.  This servo drive spin welder is capable of orienting part halves relative to each other with a positioning accuracy of ± 0.5°. Exact start (home) and stop (final orientation) points can be programmed and precisely controlled.

When compared to non-orientation models, orientation (servo motor) systems typically: 

• permit precise orientation/alignment of part halves relative to one another.
• allow precise depth welding (collapse distance or absolute distance) when orientation is not required.
• enable welding of larger parts with more difficult to weld materials.
• are much easier to automate as the driver rotational position may be precisely programmed between welding cycles, allowing easier loading of the upper part half into the driver. 
• allow faster cycle times as the system begins welding while the parts are clamped together, eliminating the time required to build up to RPM as found on inertial systems.  

Standard Features:

Ultra-Rigid Rectangular Column minimizes deflection of the system under even the highest pressures.

Modular Design allows adaptability to a variety of production configurations. Controller and servo amplifier heights may be repositioned or removed from the press and relocated to a user preferred position.

Infranor Servo-Electric Drive/Amp and 0-7000 RPM Motor with Microprocessor Control allows wide range of operating speeds and ensures precise rotational positioning ±0.5°.

Graphic Backlit LCD Display Operator Interface Panel & Multi-Level Passcode Protection simplifies parameter input, limits parameter adjustment to qualified personnel only and allows the following to be displayed:

• Graphic Display of Distance & Power (based on motor torque) vs. Time
• RPM
• Weld Steps 1 & 2 (Time, Collapse Distance, Absolute Distance or Reactive Weld System (RWS) with or without part-part orientation
• Start & Stop Rotational Positions
• Hold Time
• Pressure Profile
• Resettable Parts Counter
• Total Machine Cycle Counter
• Diagnostic Display

Precision Optical Linear Stroke Encoder enables welding by Time, Collapse Distance or Absolute Distance with a repeatability of ±0.001 (±0.025 mm) and/or alarm monitoring these values.

Welds with or without Orientation using: Time, Collapse Distance, Absolute Distance or RWS-Reactive Welding System allows user enhanced control for applications requiring precision welding.

Time, Collapse Distance and Absolute Distance Pass/Fail Windows allows user to set min/max alarm limits for bad parts for quality control purposes.

Multi-Level Passcode Protection limits parameter adjustment to qualified personnel only.

20 Weld Program/Setup Memory allows storage for instant recall, minimizing tool change time.

External Serial Communication Port (RS232) allows data output from system to customer computer.

Force Control via Dual Proportional Valve for Pneumatic Pressure Control allows user to program individual settings for initial part contact pressure, weld pressure and cooling pressure in passcode protected memory.  Reduces cycle times and improves repeatability.

3.9" (100mm) Press Stroke permits loading/unloading with adequate clearance for most parts.

2.5" (63mm) Dia. Pneumatic Cylinder allows more than ample force for most spin welding applications.

Spin Initiation (Trigger) by Height with Programmed Delay-Time simplifies setup.   No limit switches to adjust when changing part height.  Head-Down step used to “teach” system target part height.  System retains learned height setting in programmed memory.

Zero Force Cycle Activation Switches reduce operator fatigue.

Lockable Mechanical Stop prevents shift/migration of stop setting in even the worst vibrating environments.

Two English, Spanish or French Language Manuals provides detailed documentation and instruction of installation, operation, setup, maintenance & troubleshooting procedures.

Rotational Positioning Accuracy:  ± 0.5º

Maximum Motor Speed:  7,000 RPM

Maximum Motor Power:  0.9kW

Maximum Driver Weight:  1.0 lbs (0.5kg)

Maximum Clamp Force:  390 lbs @ 80 PSI (1.7kN @ 5.4 Bar)

Driver Hub to Base Height Adjustment Range:  4.5” – 17.5” (114mm – 445mm)

Throat Depth (Center of Driver to Column Front):  8.3” (211mm)

Machine Dimensions:  26.0” D x 17.8” W x 48.0” H (660mm x 452mm x 1219mm)

Weight:  ~220 lbs (100kg)

Color:  Forward Technology Two-Tone Gray (unless otherwise specified)

Electrical Requirements:  240 VAC, 1 Phase, 20A, 60 Hz

Pneumatic Requirements:  80 PSI, 0.375” ID (5.4 Bar, 10mm ID) Supply Line

Warranty:  Free from materials and workmanship defects for one year from delivery.

Sequence of Operation:

1. Operator loads part halves into holding fixture and driver.

2. Operator initiates both cycle activation switches.

3. Actuator moves driver & rotating part half (typically without rotation) into contact with the stationary fixtured part half.

4. Operator is permitted to release cycle activation switches after part to part contact is made.

5. Servo motor spins parts at user-programmed RPM until the minimum a) Time, b) Collapse Distance, c) Absolute Distance or d) Reactive Welding System AND final axis of rotation (degrees) of the weld is achieved. If orientation is not required, user may program RPM and one of the above methods without final axis of rotation.

6. Welded parts cool under pressure.

7. Actuator retracts to home position and servo slowly rotates to user-programmed home position.

8. Operator removes welded part from fixture.