A manufacturer of moulded plastic electrical conduit components was previously installing in-house designed brass inserts into many of their own products using a single horn ultrasonic welder. As part of this time consuming task, the operator would load the part into a nest, place an insert into the hole, and activate the unit. This frequently caused great difficulty due to undersized holes and an unconventional insert shape. These problems have been overcome with investment in Spirol’s Model PH Platen Multi-tip Heat Insertion machine.
Using the original method, the results were poor and excess molten material created an unsightly appearance whilst the insert was frequently positioned out of location. Secondary operations were also required to remove the excess material and a high percentage of parts were rejected. Production speeds were slow at a rate of one finished part (two inserts per part) per minute and sometimes took even longer depending on the complexity of the part.
After reviewing their entire process, Spirol recommended a total assembly solution with the use of a versatile Model PH Platen style Heat Insertion System in conjunction with a Spirol INS 29 brass insert, along with the proper hole size. The machine was provided with quick-change tooling sets to allow the assembly of over ten different style parts. Each tooling set was designed to accommodate from three to six parts depending upon size. The operator can now load six parts, two inserts per part, before activating the machine. All twelve inserts are installed simultaneously.
The conductive heat method, with consistent pneumatic installation pressure, has resulted in the highest quality insertions, excellent appearance and performance – and no rejects. This new process yields six completed assemblies in the same time it previously took for one.
This production improvement alone has allowed the machine to pay for itself in less than one year. The customer can also add additional tooling sets to accommodate new parts as they are designed and marketed.
For further information contact Spirol Industries Ltd, Princewood Road, Corby, Northants, NN17 4ET, Tel: 01536 444800, Fax: 01536 203415, email: uksales@spirol.com, www.spirol.com
