We have a range of equipment aimed at the OEM market for specialist machine builders.
The highly experienced team here at TELSONIC UK can also offer bespoke automated production systems to further match the demands of your business, integrating all the TELSONIC UK portfolio and other 3rd party equipment.
Automated Productions Systems Telsonic UK Automation
Customer Case 1: Cut'n'Seal Ultrasonics
Customer Case 2: EID Tag Assembly
CE and UKCA Certification
CE certification indicates that products being sold into the European Economic Area have been examined and assessed to meet the stringent criteria for health and safety. Within the UK, the UKCA mark came into force on the 1st Jan 2021, although CE marking will continue to be recognised in the UK until the end of 2022.
Telsonic UK adhere strictly to the requirements for both CE and UKCA Certification. As part of our scope of supply for the automated systems which we design and build, we provide a comprehensive documentation package, comprising of a full set of manuals and a complete technical file, which includes the calculations for stopping distances for machines with light guards and a full risk assessment.
Robotic Ultrasonic Welding Cell
Assembly of Automotive Doors
This bespoke rotary table based automated system was designed and built by Telsonic UK for the production of automotive door components. Two six axis robots, each with dual AC450 actuators, convertors, and double length FEM designed sonotrodes, complete a total of 72 front door weld points and 43 Rear door weld points. Operator safety for unload and re-load operations is assured by the incorporation of light guard systems.
Stand Alone Ultrasonic Welding Cell
Assembly of Automotive “B” Pillars
The plastic welding system is used to weld left and right-hand “B pillar” assemblies, joining seat belt cowls to the polypropylene pillars. Correct assembly is assured through the use of sensors to detect that all parts are in place, including the cowl, main pillar substrate and the airbag cover. A slide table with a rod less cylinder, linear rails & carriages are used to move the part to the second position.
The machine also senses two colour variants of each of the three parts and also checks that metal clips and black felts are in position using a combination of inductive and camera sensors. Quality limits are also set for both weld delivery and collapse of the weld features.
Bespoke Automated Assembly System
Automated Ultrasonic Assembly & Test Machine
This system incorporates an infeed conveyor which is loaded by a robot from bespoke designed de-stacking stations. The machine also performs pick and place and final assembly tasks. Scan welding operations are completed with a servo system, and the ultrasonics used on this machine are 3 x Telsonic MAG-E 2.4kW generator modules and 3 x SE2024S converters & boosters with bespoke FEM designed sonotrodes. There is also a weld integrity test station, and any parts which fail are automatically removed from the machine and segregated.
Semi-Automated Ultrasonic System
Filter Media Side Seaming Operations
This stand alone ultrasonic welding machine uses a Telsonic USP3000E Press, and a heavy duty electric-servo driven table which indexes filter media pleat packs progressively under the welding head. The machine has a universal clamping system for the pleats, including a servo operated pre-opening jaw to accommodate all variants of pleat, and pneumatically operated final clamping for the lip of the jaws. Light guards protect the operator during the load and unload sequences. The machine has an HMI / PLC system which is used to control and configure all part related adjustments and table movements. Multiple weld recipe settings, for all of the product permutations, are also accessed via the HMI, and process monotoring is used to ensure quality and consistency.
Ultrasonic Insertion System
Brass Inserts into Plastic Mouldings
This purpose designed ultrasonic insertion machine is used to press threaded brass components into a plastic moulding. Components to be processed are placed into a multi-product nest. A total of 5 x AC450-100 actuators, mounted together with SE3512-C converters, complete with MAG E generators, mounted into the main control cabinet with customer specific FEM designed sonotrodes, use ultrasonic energy to assemble the brass inserts to the electrical boxes. Product and cycle variations are determined using the operator HMI display where all the parameters can be modified as required.
Benchtop Plastic Staking Machine
Incorporating Automated Indexing “X” Axis
This benchtop ultrasonic plastic staking machine integrates a Telsonic AC450-100 actuator, SE3510 Converter, and MAG generator. Electrical actuators for the X-Y movement, coupled to a bespoke designed nest plate, make it possible for a complete welding cycle to be initiated at the push of a button. The system has multiple interchangeable nests for different variants with the recipe changes selected via the HMI.
Laser Marking System
Multiple Marking Recipes
In this system, a Keyence MDX-2500 Laser Marker has been integrated into a bespoke product specific and laser safe enclosure. Parts are loaded into a safety interlocked drawer which presents them to the marking position. The cycle is triggered using the HMI display where variable marketing recipes can be selected as required.
Semi-Automated Ultrasonic Welding System With Programmable X-Axis
In this highly flexible semi-automated system, a Telsonic USV300 actuator, together with a linear encoder, are mounted to a belt driven X axis. This configuration allows for parts of varying lengths to be welded. During processing, the parts are held in position using a vacuum table.
Operator safety is guaranteed using light curtains on both sides of the machine. An HMI mounted to an adjustable swing arm provides both ergonomic and easy selection of recipes.
