GEOGRID VIBRATION FRICTION WELDING MACHINE

GEOGRID VIBRATION FRICTION WELDING MACHINE

1 X Vibration friction welding machine including: main engine,

front steel wire reel rack, front workbench, horizontal belt threading wire reel rack, automatic mesh cutting machine, rear wrap-up machine, automatic reel unloader, wrap-up rod, unloading car

Ⅰ        Welding mold configuration   

1-  Welding width of longitudinal and transverse strips : 10 18mm

2- Welding thickness of longitudinal and transverse strips:  1.5-2.5mm

3-Welding mold tooth surface longitudinal and transverse length and26*26mm

4-Weldable material: PP, PE, PVC, HDPE

5-Single head welding power:    300W

6-Welding unit: 98#

7-Maximum welding transverse width:         6000mm±15mm

8-Friction motor model and size:          57mm

9-Maximum speed of friction motor:    10000r/min

10-Maximum working pressure of welding mold:         0.6 Mpa

11-Welding head descent distance:    75mm

12-Welding head descent cylinder mode:   SDA40*75-B

13-Welding head lowering solenoid valve model:        4V110-DC24V

14-Weldable mesh for welding mold: 50mm, 100mm, 150mm

15-Strip welding method:   one head one strip

16-Horizontal mesh welding cycle:      4.5-5s

17-Weldable transverse width:   4m, 5m, 6m

18-Welding parameter control method:       PLC

Ⅱ-Vertical and horizontal weaving device configuration

1-Waving power:1.1KW

2-Power of threading drive motor frequency

converter:1.1KW

3-Outer diameter of threading pressure wheel:50mm*40mm

4-Wearable strap width:10-15mm

5-Threading speed:0-50hz

6-Pressing wheel cylinder:SDA40*10*10

Clamp-type fixing device configuration

Transverse band propulsion cylinder: SC*175mm

Longitudinal band propulsion cylinder:SDAP20*15mm

Longitudinal band propulsion width: 10-24mm

Ⅳ-Traction device configuration

1-Model of traction network servo motor:130mm-3.8KW

2-Motor operating voltage:AC220v-50hz

3-Motor speed: 2500 r/min

4-Traction roller size:6400*210mm

5-Traction reducer model:R-1:40

6-Assembly method of traction roller:2 below and 1 above

7-Control method:PLC pulse control

8-Horizontal mesh adjustment method:touch screen input 50-500mm

Automatic cutting device configuration

Maximum cutting length:Within 6000mm

Cutter motor speed:4000 r/min

Cutting motor voltage:AC220V

Cutting forward motor power:AC220v to three-phase 110v output

Cutter outer diameter:300mm

Cutting and feeding roller:6500 * 180mm

Power of grid feeding motor:1.5KW

Power of grid feeding motor:AC380v

Cutting method:PLC control

Wrap-up power:1.5KW

Wrap-up reduction ratio:1:50

Unload roll jacking cylinder:SC80 * 250mm

Ⅵ     Main low-voltage electrical equipment technology brand technical configuration

1        CJX2 Contactor: Schneider Electric

2        Miniature DC24V relay       Schneider Electric

3        PLC Touch screen:     Mitsubishi FX3U

4        Touch screen     SamkoonSK-102HE

5        Frequency converter:         Taiwan Shihlin 1.1-2.2KW

6        Remote control system        FXCPU

7        switch power supply Taiwan MEAN WELL NDR-240-24V

Ⅶ    Overall dimensions after installation(m): 7.2*6.5*2.1

Ⅷ   Equipment Parameters       

                    Welding head station 98

          Number of welding head    98

          Maximum output power      2.6-10KW

          Single head output power  50-100W

          External dimensions of equipment

(m)    7.2*2.5*2.1

          Equipment weight      9.6T

          Rated input voltage    AC380V 50-60HZ

          Input voltage form      Three-phase four- wire

          Rated input pressure 0.6~1.0MPa

          Air pressure vessel    ≥0.6~1.0m³

          Barometric flow rate  2.5~3.0m³

          Weldable width 3-4m -5m -6m

          Weldable materials    PP, PE, PVC, PET, PC

          24-hour maximum production     8000-10000㎡

          Production capacity is calculated in 50 meters 35-40 per roll

Ⅸ      Advantages of a new type of geogrid vibration friction welding equipment

1        Faster welding speed, effectively improving production speed, increasing output, and reducing production costs;

2        Compared to traditional machines (ultrasonic welding equipment), new equipment reduces vulnerable parts by 90%;

3        Higher welding effect and strength;

4        Independent welding head designs ensure consistent strength and appearance of each welding point;

5        Reduce electricity consumption by about 65%;

6        Higher degree of automation;

7        Easier to operate and reduce manual labor;

8        Welding products are smoother and more aesthetically pleasing;

9        Lower noise and more environmentally friendly;

10      Suitable for welding raw materials (can weld all plastic materials, including PE, PP, PET, PVC, etc.).

Ⅹ Comparison the Ultrasonic Machine and Vibration Friction Welding Machine:

1- The traditional ultrasonic welding process involves high-frequency vibrations that occur tens of thousands of times per second, causing the overall product to generate heat which is Hammer heat fusion. During the welding process, there is no problem with some products and they can also be perfectly welded (Suitable for materials with high temperature and vibration resistance for internal reinforcement ribs, such as steel wire, etc.).

However, the disadvantage of ultrasonic welding is that it focuses on the overall product due to the characteristics of ultrasound. In ultrasonic welding, it can damage the molecular structure of certain materials. During the welding process, the ultrasonic welding method penetrates from the upper to the lower product that needs to be welded, generating heat for fusion. During the penetration process, the high temperature changes the molecular structure direction of the product, thereby damaging the strength of the product itself. During the welding process, some products cannot withstand high frequency ultrasonic vibration due to their temperature resistance, which can cause 40-50% damage strength (such as fiberglass, polyester, PET, stretched PP, etc.).

Moreover, ultrasound has vulnerable parts, such as molds, transducers, and ultrasonic power supplies, which are all three

major components of ultrasonic wear with extremely high costs.

2 - Vibration friction welding process, vibration friction is completed by a low-power high-speed brushless motor with a drive controller, and multiple precision mechanical components in a complete set of motion coordination. Vibration friction in welded products can adapt to the welding of all materials due to surface friction heating welding (internal reinforcing ribs can be steel wire, fiberglass, polyester, PET, tensile PP, etc.).

Vibration friction machines can also weld products that ultrasonic machines can do. Vibration friction relies on the motor's tens of thousands of times of reciprocating friction per minute during the meshing process of the upper and lower tooth plate, causing the product to be heated and fused. It only generates heat on the surface of the product and does not cause any heat inside the product. Under low power conditions, it can also achieve a welding effect that is 10 times greater than ultrasonic welding in an instant. A separate welding mold design and independent computer control system make the appearance of the product more perfect, and each welding point can maintain stable strength.

Additionally, due to the adoption of a brand-new design and equipment features, the entire machine only requires 30% of the electricity generated by ultrasonic welding, resulting in a significant reduction in electricity costs.

At the same time, it reduces many unnecessary components and has a more stable mechanical design structure,  resulting in fewer vulnerable parts of the equipment (without the need for damage and regular replacement of molds, transducers, and ultrasonic power sources generated by ultrasonic welding equipment), improving the stability and value preservation of the machine, reducing labor costs and equipment downtime, thereby increasing production output,

reducing product costs, and making the product more competitive in the market.