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No.000126 Simplified Welding Mechanism
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Welding mechanism utilizing a cylinder
Relevant category
Welded Steel Stands
| Product name | Welded Steel Stands- No Hole Type |
|---|---|
| Part number | YSFT100-B100-H300-G80-F80 |
* Orange colored cells in the table below indicate the part numbers used in this example.
Selection criteria
To secure the rigidity of the unit
Available sizes
■Welded Steel Stands- No Hole Type
| Material | Surface Treatment |
|---|---|
| 1018 Carbon Steel | − |
| Black Oxide | |
| Electroless Nickel Plating | |
| 304 Stainless Steel | − |
■Sizes and Dimensions
| Plate (Top Plane, Bottom Plane) | Overall Height (50mm increments) | Screw Dia. (Coarse) | Through Hole Dia. | ||||
|---|---|---|---|---|---|---|---|
| Length | Length Direction Hole pitch (1mm Increment) | Width | Width Direction Hole Pitch (1mm Increment) | Plate Thickness | |||
| 100 | 30〜80 | 100 | 70〜80 | 10 | 100～300 | M10 | φ11 |
| 30〜100 | 120 | ||||||
| 30〜130 | 150 | ||||||
| 125 | 30〜100 | 120 | 95〜100 | ||||
| 150 | 35〜120 | 150 | 95〜120 | 14 | M12 | φ14 | |
| 200 | 35〜170 | 200 | 120〜170 | ||||
Accuracy Info
■Accuracy of Welded Steel Stands Type (Hole Position Specifying Type)
Overall Height Tolerance: ±0.1mm
Parallelism of Plates (Top Plane, Bottom Plane) 0.05／100mm
Plate Heaters
| Product name | Plate Heaters |
|---|---|
| Part number | MPHKH-100-100-V100-W250 |
* Orange colored cells in the table below indicate the part numbers used in this example.
Selection criteria
Suitable for heating the flat shape workpieces.
Available sizes
■Plate Heaters
| No. | Name | Material |
|---|---|---|
| ① | Cover of the Heater | 430 Stainless Steel |
| ② | Mica for Insulation | Synthetic Mica |
| ③ | Nickel-chrome Wire | Nickel Chrome Ribbon Wire |
| ④ | Lead Wire | Nickel Copper Glass Fiber Coated Wire |
| ⑤ | Tube | Glass Fiber |
■Specifications
| Plate External Shape | Voltage (Single phase) V | Electric Power (W) | Electrical Power Density (W/cm²） | Lead Wire Length | ||
|---|---|---|---|---|---|---|
| Length | Width | Plate Thickness | ||||
| 100 | 100 | 4 | 100・200 | 250 | 2.5 | 1000 |
| 150 | 150 | 500 | 2.2 | |||
| 200 | 50 | 200 | 2.0 | |||
| 100 | 400 | |||||
| 250 | 50 | 250 | ||||
| 300 | 50 | 350 | 2.3 | |||
Accuracy Info
■Plate Heaters (with Through Holes), Tolerance of Plate External Shape
Length Tolerance: 0/-2mm
Width Tolerance: 0/-2mm
Plate Thickness Tolerance: ±1mm
Heat Insulating Board
| Product name | Heat Insulating Plates - Standard / Heat Resistant Grade |
|---|---|
| Part number | HIPA4H-100-100-10-F80-G80-N6 |
| Features | Low thermal conductivity, lightweight, excellent heat retention and temperature insulation |
* Orange colored cells in the table below indicate the part numbers used in this example.
Selection criteria
It does not conduct heat to other components.
Available sizes
■Heat Insulating Plates - Standard / Heat Resistant Grade
| Grade | Color | Operating Ambient Temperature |
|---|---|---|
| Standard | White | Room temperature - 220°C |
| Heat Resistance | Gray | Room temperature - 500°C |
■Sizes
| External Shape | Number of Holes | Hole Type | ||
|---|---|---|---|---|
| Plate Thickness | Length | Width | ||
| (Configure in 1mm increments) | ||||
| 3 | 20～800 | 20～600 | 2・4・6 | Through Hole, Counter Bore, Threaded Inserts |
| 5 | ||||
| 10 | ||||
| 15 | ||||
* Selectable Machined Hole Specification will vary with the plate thickness.
Please see the product pages for details.
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Application Overview
Purpose
- Device capable of welding small size workpieces.
- Operation steps:
(1) Horizontal cylinder with a guide advances to clamp a workpiece.
(2) Vertical cylinder with plate heaters descends.
(3) The plate heater welds workpieces 1 and 2.
(4) Vertical cylinder controlled by timer returns to start position.
(5) Clamp cylinder retracts.
Points for use
- An automatic mechanism in which the cylinder raises and lowers the heater and retains the workpiece during welding operation.
- Workpieces are manually inserted and removed by the worker using a dedicated tool (vacuum pad).
Target workpiece
- Resin case outer dimensions: W40ｘD40ｘH6
- Film sheet outer dimensions: W36ｘD36ｘｔ0.5
Design Specifications
Operating Conditions or Design Requirements
- Outer dimensions: W350ｘD250ｘH325
- Heat welding cylinder stroke: 74mm
- Workpiece retention cylinder stroke: 17mm
- Thrust of heat welding cylinder: 235.5N (from manufacturer's catalog)
Required Performance
- Heater power: 142W
Selection Criteria for Main Components
- Plate heater
- Select the size based on heat requirements to weld workpieces and the dimensions of the workpieces.
- Cylinder with a guide
- A cylinder with a guide that can withstand the allowable lateral load of 19N is selected.
Design Evaluation
Verification of main components
- Verify that the selected heater calorific value and cylinder allowable lateral load are sufficient for this application.
- Heat quantity required for the heater
- Mass of heated workpiece: 0.725kg (304 Stainless Steel)
- Specific heat of heated workpiece: 0.11kcal/kg°C
- Temperature rise: 230°C (heated until the temperature of the heated workpiece reaches 250°C)
- Heating time: 0.5 h (idling)
- Heating time: approx. 5sec (workpiece)
- The workpiece heating time should be determined through trial and error because it depends on the size, thickness, and material of the workpiece.
- Efficiency: 0.3
- Calculation formula: power for heater (kw) = mass of heated workpiece (kg) x specific heat of heated workpiece (kcal/kg°C) x temperature rise (°C)/(860 x heating time (h) x efficiency (η)) = 0.142 kW = 142W
- Cylinder with guide
- Weight of parts in moving unit: (0.0975kg + 0.0368kg) x 9.8 = 1.302N
Calculated value is below the allowable lateral load of the selected cylinder.
- Weight of parts in moving unit: (0.0975kg + 0.0368kg) x 9.8 = 1.302N
Other Design Consideration
- Welding time is controlled by a timer.
- A heat insulation material is used to prevent the heat of the heater from being transmitted to the upper and lower moving parts.
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