• da
  • en

Adhesive Welder

Unomedical A/S had to expand their production and use 2 semi-automatic adhesive welders to a production facility in Central America, which back in 2007 received corresponding custom solutions from Allesøe Custom Machinery ApS. It was crucial for the project that the two new adhesive welders were manufactured exactly as previously to ensure that the customer’s operators were not in need of new training and business processes remained unchanged. In close collaboration with the client, Allesøe incorporated minor improvements, and solved the task within the set timeframe.

Unomedical needed to incorporate the newly acquired semi-automatic adhesive welders in an already existing production. It was therefore important that the function of the semi-automate remained unchanged, so that operators did not need to learn new operating procedures.

After an initial meeting and ongoing exchange of information (user requirement specifications, drawings, etc.), Unomedical received an offer within 10 working days, and shortly after the project was launched.

Function of the Semi-automate

The adhesive welder thermal welds plastic items onto a patch until the plastic melts into the woven structure of the patch, thereby avoiding any loosening of glue. Quality control of the weld is conducted on a random basis through a rendering test, in which the operator tests the fracture and tensile strength in an extensometer from Lloyd.

Feeding of subjects is performed manually through a combination of SLC and an electromagnetic safety switch. The operator breaks the light curtain to load subjects without the safety relay goes into emergency stop after completing the process. Laser photocells ensure that a focus point on the patch is positioned correctly.

The semi-automate is equipped with a range of specialized components to ensure that strict production parameters are sustained and the quality of the welding process is not compromised.

Precision pressure regulators, for instance, are fitted with digital readout enabling adjustments in speed and accuracy of pressure increases. Furthermore, the welding process is carefully adjusted to a welding pressure of + / -0.5 Bar with the opportunity to go down to + / -0.01 Bar. Thermal welding is set to + / -3 ° C and welding time has merely a tolerance of + / – 0.2 seconds.

The advanced dialogue through the operator panel is adapted to different users with different levels of education, so that operations do not require lengthy training. For instance, the panel is designed so that readouts and adjustments of production parameters easily can be performed. As such, the operator is continuously updated on the process flow without needing technical assistance from Q/C.

Unomedical had specified a production output of 600 units per hour, but during testing at Allesøe, it was possible to achieve an output of over 700 welded subjects per hour on the semi-automate adhesive welder.

Client involvement is critical in designing custom solutions

The project was characterized by a series of ongoing meetings where details about the solution’s final design was established. Unomedical also had some specific requests for documentation in that the two machines were delivered to a manufacturing facility in Central America, and therefore it was important to have a comprehensive level of documentation and customised operating instructions adapted to different users and languages.

Unomedical designated the programming company Allesøe needed to use during the project, and also purchased certain components for Allesøe to incorporate in the semi-automates. Collaboration with the programming company, AD Control A/S, was handled throughout the project by Allesøe.

“The course of the project was slightly hampered by the fact that many suppliers currently are opeerating with minimum inventory, and certain custom components consequently had a long lead time. Therefore it was crucial to manage the project tightly to ensure that the deadline was met, “says Jakob Bech Larsen, who was project manager and designer on the assignment.