ES-OSW

The ES-OSW is an extended stroke pneumatic motion controlled orientation (servo motor) spin welder designed for larger diameter, more difficult spin welding applications requiring delivery of high rotational power while maintaining the highest degree of precision while maintaining the capability of additional actuator stroke.

This servo drive spin welder is capable of orienting part halves relative to each other with a positioning accuracy of ± 1.0°. 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 Steel Actuator Support System minimizes deflection of the system under even the highest pressures.

Welded Tubular Steel Support Frame with Leveling Feet and Pneumatic Powered Safety Door provides platform for stand-alone welder operation and optimum personnel protection from machine actuations and debris.

Allen Bradley Servo-Electric Drive/Amp and 0-3500 RPM or 0-5000 RPM Motor insures precise rotational positioning.

Allen Bradley PanelView 300 User Interface simplifies parameter input and allows the following to be displayed:

• RPM
• Weld Mode
• Weld Distances (Collapse & Absolute Distances)
• Hold Time
• Pressures
• Resettable Parts Counter
• Total Machine Cycle Counter
• Diagnostic Display

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

Weld by Revolutions (orientation) or Time, Collapse Distance, Absolute Distance (non-orientation) allows the user enhanced control for applications requiring precision welding.

Time, Collapse Distance and Absolute Distance Pass/Fail Windows allows the 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.

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

Force Control via Electronic Pressure Regulator 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.

Extended 17.0" (432mm) Actuator Stroke permits parts loading/unloading with maximum clearance, as well as allowing welding deep within other components.

2.5” (63mm) Dia. Pneumatic Cylinder allows sufficient force for larger 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.

Built-In User Inputs/Outputs allow integration of part clamping and/or part presence sensors.  Permits external start/stop command functions by customer PLC if used in automation.

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

Rotational Positioning Accuracy:  ± 1.0º

Maximum Motor Speed:  3,500 or 5,000 RPM

Maximum Motor Power:  1.8kW (3,500 RPM), 2.2kW (5,000 RPM)

Maximum Driver Weight:  5.0 lbs (2.3kg)

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

Driver Hub to Base Height Adjustment Range:  19.0” – 25.0” (483mm – 635mm)

Throat Depth (Center of Driver to Column Front):  7.3” (185mm)

Machine Dimensions:  32.0” D x 36.0” W x 78.0” H (813mm x 914mm x 1981mm)

Weight:  ~500 lbs (227kg)

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 two years 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 for the number of user-programmed revolutions (or user-programmed: time, collapse distance or absolute distance) and terminates rotation when desired weld criteria is reached.

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.