Hand assembly of magnetic ring sets is slow and skewed? Automatic ultrasonic welding machine feeds by vibratory bowl and indexes by servo dial

The problem

Assembling plastic body, magnet and cap by hand leads to reversed or skewed parts and unstable output; manual welding takt is slow; over-tight pressing jams parts and damages workpieces; and without a feed warning the machine runs empty until someone notices.

Capability

The machine completes automatic feeding, assembly, pressing and ultrasonic welding of magnetic ring sets (plastic body + magnet + cap); only the first loading step is manual, all remaining steps are automatic. Three vibratory feeders distribute the three parts (magnet strips loaded about 1000 at a time); the feeder vision/check system distinguishes part orientation and pneumatically pushes back wrongly oriented parts; a feeder stops as soon as its part is placed. Manipulators move workpieces into positioning moulds station by station while a servo motor and indexing dial rotate one fifth per step; positioning pins are made of tungsten steel; the ultrasonic pneumatic press automatically presses and welds the cap. Finished parts pass a photoelectric check with an alarm until removed, then drop through a guide chute into the bin. Takt about 20-25 seconds per part; assembly accuracy plus/minus 0.1mm; air supply 0.5-0.8MPa (minimum stable 0.6MPa, normal pressing 0.4MPa); over-tight parts can be removed quickly without damage or efficiency loss; PLC control with touch screen, two-level password protection, fault code display and feed-warning detection; production data records capacity, good and NG counts with reset; safety sensors and guards fitted; frame approx. 1200x700x1200mm, AC220V, beige finish.

Key specifications

• 设备功能：塑料件+中间磁铁+封盖三件套自动供料、组装、压制与超声波焊接；仅上料人工，其余全自动
• 供料系统：3套振盘分别分料；磁铁条料一次可放约1000个；振盘检测系统自动区分配件方向，反料气动推回
• 流转定位：伺服电机+分度盘定位，转盘1/5步进；定位针材质钨钢
• 焊接系统：超声波气动冲床自动压制并完成超声波焊接；组装精度±0.1mm
• 生产节拍：约20～25秒/件；各工序可相对独立运行
• 气源要求：0.5～0.8MPa（最低稳定0.6MPa）；正常冲压力度0.4MPa即可实现
• 取件保护：压制偏紧可在不影响效率、不破坏配件和工装的情况下快速取出；成品光电检查，未取走报警
• 控制系统：PLC+触摸屏；两级密码保护；故障代码提示；加料预警检测
• 生产数据：产能、良品与不良品记录、数据清零
• 安全配置：相应部位安装安全检测装置；防护罩；组装灯罩卡头机构

Applications

Automatic assembly and welding of magnetic ring sets, inductor core sets and sensor three-piece sets (plastic body + magnet + cap); automation retrofit of assembly stations for electronic components and small appliance parts; introduction of ultrasonic welding to replace manual hot-melt or gluing

About the manufacturer

Guangdong Endurance Electronic Equipment Co., Ltd provides non-standard customization, drawing confirmation, factory acceptance, on-site installation and commissioning, operation training and lifetime technical service; 12-month warranty and lifetime spare parts supply. Tel: 0760-88500902 / 13416787649. Web: en.zsnaili.com.