Slide 1: Thermal Processing Systems • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 2: Spin Welding • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 3: Agenda       What is Thermal Processing? Why Thermal Processing? Products Competition Applications / Tooling Manuals • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 4: What is Thermal Processing? Thermal Processing is defined as any of the following processes:       Thermal Insertion Heat Staking Swaging Thermal Degating Thermal Stamping Embedding • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 5: Thermal Insertion Advantages:  Allows multiple inserts to be pressed-in simultaneously Accommodates a large variety of of insert designs and profiles Operator comfort - minimal noise More cost effective when compared to an ultrasonic welder with a composite horn Typically the same or higher pull-out retention verses Ultrasonics     • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 6: • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 7: Heat Staking Advantages:   Electronic component friendly Multiple planes can be staked simultaneously Allows higher density of welds compared to Hot Air/Cold Upset or Ultrasonic Staking. Greater variety of shaped heads can be formed Operator comfort - minimal noise    • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 8: Swaging Advantages:    Similar to Heat Staking Electronic component friendly Great variety of shapes can be formed Operator comfort - minimal noise  • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 9: Thermal Degating Advantages:  Multiple gates removed simultaneously Simple and reliable construction More ergonomically friendly than manually clipping gates Operator comfort - minimal noise    • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 10: Thermal Stamping Thermal Stamping is a process where a heated stamp wheel is used to serialize or date stamp components.  Can be used on nonplastic materials Date code or consecutive numbers Decorative logos   • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 11: Thermal Embedding Thermal Embedding is a process where two dissimilar materials are joined mechanically  Can be used on nonplastic materials Allows dissimilar materials to be joined.  • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 12: Why Thermal Processing?    Accommodate Customers Sales Entry Point Recapture Staking Market • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 13: Accommodate Customers  Keep Existing Branson Customers Loyal – Keep Competition Out A better solution for multiple inserts/stakes on multiple levels Faster cycle times – multiple inserts/stakes Satisfy Customers who dislike Ultrasonics – Noise – Flakes    • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 14: Sales Entry Point  Selling TP can open the door for future projects that require Sonics, Hot Plate, Vibration, etc… • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 15: Recapture Staking Market  Historically Staking has accounted for 510% of Ultrasonics sales. Last five years Staking has dwindled to > 1% Staking hasn’t gone away – we have lost it to Heat!   • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 16: Products Thermal Processing Products    201 301 401 • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 17: TPM 201  Up to 4 individual temperature zones with individual PID controls Dual cylinder - ¼ ton capacity 4” tooling stroke with Frelon bushings and hardened steel shafts Tooling Platen 6” x 6” Touch-Pad Operator Interface     • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 18: TPM 201 Standard features include:   Unitronics operator interface/controller. Discrete, full-function temperature controllers with ramp and soak and self-teach mode. Temperature control monitoring and alarm. Post cooling. Shuttle control. Standard Branson Palm Buttons (Ergo Base).      Two 2" bore cylinders, 4" stroke with two Frelon bushings with hardened steel shafts, including fine adjustment features for platen height. 18-½" maximum working height without upper and lower tooling.  • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 19: TPM 201 Standard features include:    Macro and micro adjustment for platen height. Resettable shift/parts counter and life cycle counter. Adjustable hydraulic rate control for end of travel, adjustable from 0 to 0.5 inch.   Pressure regulator, gauge and filter with lock out/tag-out. Full positional feedback for software control of beginning and end of stroke signal • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 20: TPM 201 Optional features include:       Table with leveling feet or casters Part shuttle with 8" stroke Rotary table Post cooling Light curtain Remote start • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 21: TPM 201  Electrical Specifications – Power requirement: 120V AC, 15 amps,1-phase, 60 Hz Weight: Approx. 130 lbs. Height adjustment: 18" Throat depth: 6" Dimensions: • Overall machine: 21" wide x 28" deep x 41" high • Tooling platen: 6" wide x 6" deep • Tooling stroke: 4" Mechanical Specifications – – – –   Pneumatic – Clean (5 micron), dry air, 80 psi @ 20 CFM min • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 22: TPM 201 Stroke Adjustment Locking Knob Macro Height Adjustment Touchpad Interface Rate Control Lock Screw Access Temperature Controllers (Heat Zones) On/Off Switch • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 23: TPM 201 Slow Speed Rate Control Adjustment • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 24: TPM’s 201 / 301 Temperature Controller Touchpad Interface • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 25: TPM 201 Flow Controls Filter/Regulator Tooling Connectors Control Cable • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 26: TPM 301  Up to 8 individual temperature zones with individual PID controls 6” Bore Cylinder, 1400 – 2800 lbs 4” tooling stroke with dual hardened shafts, four precision ball bearings for maximum deflection resistance Tooling Platen 8” x 14” Touch-Pad Operator Interface     • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 27: TPM 301 Standard features include:   Unitronics operator interface/controller. Discrete, full-function temperature controllers with ramp and soak and self-teach mode.      Temperature control monitoring and alarm. Post cooling. Shuttle control. Two hand anti-tie-down Palm Buttons 6" bore cylinder, 4" stroke with four precision ball bearings with hardened steel shafts, including fine adjustment features for platen height. 20” maximum working height without upper and lower tooling.  • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 28: TPM 301 Standard features include:   Macro and micro adjustment for platen height. Adjustable hydraulic rate control for end of travel, adjustable in 1/8” increments from 0 to ½ inch. Pressure regulator, gauge and filter with lock out/tagout.  Full positional feedback for software control of beginning and end of stroke signal  • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 29: TPM 301 Optional features include:       Table with leveling feet or casters Part shuttle Rotary table Post cooling Light curtain Remote start • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 30: TPM 301  Electrical Specifications – Power requirement: 220-240V AC, 15 amps,1-phase, 60 Hz  Mechanical Specifications – Weight: Approx. 320 lbs. – Height adjustment: 20" – Throat depth: 6.8" – Dimensions: • Overall machine: 20" wide x 24" deep x 48" high • Tooling platen: 14” wide x 8" deep • Tooling stroke: 4"  Pneumatic – Clean (5 micron), dry air, 80 psi @ 20 CFM min • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 31: TPM 301 Flow Controls Touchpad Temperature Controllers • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 32: TPM 301 Slow Speed Adjustment Micro Stroke Adjustment Macro Platen Adjustment Lock Ring Platen Macro Height Lock Screws • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 33: TPM 301 Slow Speed Height Adjustment Knob • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 34: TPM 301 Tooling Connector(s) (Heat Zones) Control Cable • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 35: TPM 401    Up to 16 individual temperature zones with individual PID controls 1, 1½ or 2½ ton cylinders 4” tooling stroke with four twin die precision ball bushing and hardened steel shafts Tooling Platen 21½ x 9½ Touch-Screen Operator Interface   • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 36: TPM 401 Standard features include: • Automation Direct 205 PLC • Automation Direct 6" operator interface touch screen. • Operator interface temperature control, on/off zone selection. • Temperature control monitoring and alarm. • On/off ramp and soak, post cooling and shuttle control. • Contactless opti-touch with two hand anti-tie-down. • 5" bore, 4" stroke (1 ton) press cylinder with 4 precision twin die set ball bushings, 4 hardened steel shafts, including fine adjustment features for platen height. • 23-½" maximum working height without upper and lower tooling. • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 37: TPM 401 Standard features include: • Macro and micro adjustment for platen height. • Re-settable shift/parts counter and life cycle counter. • Dual speed downward traverse, rapid traverse down flow control, slow traverse down flow control and traverse up flow control. • Pressure regulator, gauge and filter, air dump valve with lock out/tag-out. • Full positional feedback for software control of beginning of stroke, end of stroke, and slow speed position • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 38: TPM 401 Optional features include:        8, 12, or 16 temperature zones 6" bore, 4" stroke (1-½ tons) press cylinder 8" bore, 4" stroke (2-½ tons) press cylinder 5" bore, 6" stroke (1 ton) press cylinder 6" bore, 6" stroke (1-½ tons) press cylinder 8" bore, 6" stroke (2-½ tons) press cylinder Table with leveling feet or casters • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 39: TPM 401 Optional features include:        Part shuttle with 12" stroke Rotary table Extended column height Custom throat depth Post cooling Light curtain Remote start • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 40: TPM401  Electrical Specifications – Power requirement: 220 - 240V AC, 20 amps,1-phase, 60 Hz  Mechanical Specifications – Weight: Approx. 650 lbs. – Height adjustment: 14.25" – Throat depth: 8.75” – Dimensions: • Overall machine: 36" wide x 36" deep x 51" high • Tooling platen: 21.5" wide x 9.5" deep • Tooling stroke: 4"  Pneumatic – Clean (5 micron), dry air, 80 psi @ 20 CFM min • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 41: TPM 401 Macro Height Adjustment Micro Platen Adjustment Touchscreen Operators Interface • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 42: TPM 401 Tooling Connectors (Heat Zones) • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 43: TPM 401 Flow Controls Filter / Regulator • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 44: Competition    Dukane Sonitek Toman Tool • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 45: Competition • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 46: Dukane Two Models • 48xx1TS • Up to Six 350 W Heaters • ¾ & 1 Ton Cylinders • 48xx2TS • Up to Twelve 350 W Heaters • 1½ Ton Cylinder • • 16”x20”x8” Max Part Size MATP Thermal Probes • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 47: Dukane MAPT Probe • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 48: Sonitek  Multiple Models o TS100 - Hand Operated Bench Press Thru HighTonnage 4 Post  EZ 500 – Most Popular Model o 3000 Installs MP500 adds Digital Control All Models offer PID Control “Invented Post Cooling” Offer “Conversion Kits” for Sonic Welders     • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 49: Sonitek • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 50: Sonitek • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 51: Toman Tool  Multiple Models o 2010 Hand Operated Bench Press Thru 2040 Assembly System  Offer“Conversion Kits” for Sonic Welders Most Models Limited to 2 – 6 Heat Zones Small Tooling Platen o 3”x 4” o 6” x 6”   • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 52: Toman Tool • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 53: Toman Tool • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 54: Product Matrix System 201 301 401 Zones 1-4 1-8 4,8,12,16 Tonnage ¼ Ton Up to 1.4 Tons (Via Air Pressure Platen 6” x 6” 14” x 8” 21.5” x 9.5” 1,1½, 2½ Ton • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 55: Applications: 201 • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 56: Applications: 201 • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 57: Applications: 401 • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 58: Applications: 401 • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 59: Applications: Custom • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 60: Applications: Custom • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding
Slide 61: • Ultrasonic Welding • Vibration Welding • Hot Plate Welding • Spin Welding • Laser Welding • Thermal Processing • Metal Welding ? Questions