Plastic Assembly Technologies

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Extol G1 Vortex Servo Spin Welder

Spin welding is a frictional process for welding cylindrical parts to each other or cylindrical parts to other mating surfaces. Heat is created at the plastic interface by holding one part stationary, while rotating the other part at a controlled RPM while applying pressure. The frictional heat generates a melt on the plastic surfaces once the plastic melt temperature is achieved. After the melt layer is created, the spin rotation is stopped as pressure continues to be applied to the parts, allowing the molten plastic to solidify.

The three fundamental variables that create a successful spin welding process are the speed of rotation, the time cycle of the spin, and the pressure applied to the joint. The weld time duration variable can be controlled by time or the depth of weld. The speed of the rotation is most successfully controlled by using servo motors while the pressure is applied pneumatically. The control settings for these variables are dependent upon the plastic material and the size of the part. In most cases, the spin weld process is very fast.

Machine Dimensions:
Width 14” (355 mm)
Depth 23” (585 mm)
Maximum height 61.5”
(1560 mm)
Maximum work window (no
tooling) 19.5” (495 mm)
Weight 425 lbs, (195 kg)

There are numerous advantages to the spin welding process. Spin welding can achieve excellent weld strengths and hermetic welds at a fast cycle rate. The process is very energy efficient and no consumables are required. Unlike ultrasonic welding, the process is not dependant upon the acoustical transmission properties of the materials, so it is feasible to weld materials that are not easy to weld ultrasonically. It is also feasible to weld parts without surface marking. Additionally, if limited motion is available in the part design, it is possible to use a servo controlled spin welder to create an oscillatory motion and still bond the plastic surfaces. The spin welding process has proven successful in a large variety of applications and can be easily automated for applications requiring a high production rate.

Extol's Vortex G Series servo spin welders have a heavy-duty cast machine base with integrated start buttons, and feature fully integrated power supply, controls, and operator interface, a pneumatic actuated press with a 4” (100mm) stroke, and easy automation integration. See below for additional technical information on Extol's spin welders and for a partial options list.

Technical Description:
Fully integrated power supply, controls, and operator interface
Pneumatic actuated press with 4” (100mm) stroke
Proportional pressure control for precise force adjustments
5.7” (145mm) color touch-screen HMI with intuitive graphical screen format
      with password protection
Linear Voltage Displacement Transducer (LVDT) provides weld-by-depth
      control Standard on-board data logging for the previous 50 cycles
True process monitoring with high/low alarm limits for final angle, collapse
      travel, total travel and weld time
Rigid square column with 17” (430mm) height adjustment
Storage for (16) tool recipes
Servo controlled spin axis motor; 2Hp (1.5kW) programmable speed -
      5000RPM maximum
Heavy-duty cast machine base with integrated start buttons
Resettable and lifetime cycle counters
Manual mode provides complete pneumatic and servo control to
      dramatically simplify the set-up process
Easy automation integration
Four weld modes available (Dynamic or Static Triggering):
- Orientation mode: which controls final part position within +/- 1.0 degree
- Distance modes:
▪ Collapse travel, controls weld joint displacement
▪ Total travel, controls the final part height
- Time mode: which controls weld duration
Two operation modes:
- ‘Standard’ mode, operator loads the components into the upper and lower tooling
- ‘Part Pickup’ mode, operator loads all components into the lower nesting
Utility requirements:
- Electrical supply: 200-240VAC, 3 phase, 50/60 Hz, 10 Amp
- Compressed air supply: 80psi clean, dry, non-lubricated air

Partial Options List:
‘Stage II’ Ethernet data collection package
Upper tool vacuum or air pressure for part retention
Vortex models G3 and G5 provide gear-reduction high-torque capability
for large part/surface area applications
Part presence sensing
Adjustable height ‘ErgoStation’ powered work surface
Extol Rotary Indexer system integration

For a PDF file with information on Extol's spin welders, click on: Extol Spin Welder PDF

For additional information or to place an order, please refer to the Contact Us page.