Camera Monitors Quality of Ultrasonic Welding

The Flir A-Series has a Gigabit Ethernet interface and trigger/synchronisation capability, offering a complete quality assurance solution for companies using ultrasonic welding in the process line. This welding process joins a top lip to a plastic container, which is then presented for filling. The lid is subsequently applied and a vacuum lift takes the finished product off the production line.

Any weld failure results in the bottom of the container separating from the top, spilling its contents on plant, the factory floor and on the remainder of the batch. A twin Flir camera solution designed by Thermascan completely resolves this problem. This customer's weld is created by two ultrasonic welding probes that respectively join half of the lip to the container with a little overlap. To achieve this, the container is rotated by 185deg. A Flir A320G camera is mounted to monitor the thermal performance of each of the probes and, therefore, the integrity of the weld.

The I/O ports on the Flir camera allow it to perform a monitoring and control function, It works in conjunction with a pneumatic arm that is activated when the weld temperature is not adequate and pushes the reject off the line so there is no danger of it being filled and causing damage. The Flir A320G was the first thermal camera to be GigE Vision and Genicam compatible. This model can also be fully controlled from a PC and comes with a choice of software to suit the application. Flir's own software allows the camera to produce high speed, real-time radiometric images within minutes of set-up.

The Flir A-Series camera for Thermascan is also compatible with Labview, which allows Thermscan to integrate a solution such as this into the customer's management and maintenance system The flexibility of the Flir A-Series means its operation can be tailored to suit the precise need of the application. For example, its output can trigger alarms or activate other control devices such as oven thermostats or cooling sprinkler systems. The technology can also be used to monitor can or container fill levels.

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