Medical Design Briefs - September 2022 - 39

connectivity. Medical and electronics manufacturers can control
and monitor welding equipment from just about anywhere
in a given plant or around the world. They can digitally monitor
the health of their assembly systems by tracking key process
indicators such as frequency or power draw. Variations in these
and other values can provide early indications of problems in
the acoustic stack. This, in turn, helps users identify near-term
maintenance issues and avoid quality problems and unplanned
downtime on the line.
In addition, the advanced data-gathering capabilities of
these digital power supplies also enable users to monitor process
parameters in real time, set high/low limits on weld results,
and configure alarms that flag weld cycles of parts that fall
outside process limits. This capability enables automated badpart
processing and data logging that can be indispensable for
maintaining superior quality as well as the 100 percent traceability
required under standards such as the U.S. Food and
Drug Administration's 21 CFR Part 11.
n Dynamic Mode
Cleanroom applications often involve complex parts with very
tight welding tolerances or high levels of automation. Applications
like these frequently require more advanced welding technology
than older systems that optimize welder performance
around a single factor that is critical to part quality such as energy
(joules per weld), peak power, distance
(part collapse depth), or total weld time.
To overcome the limitations of singlefactor
weld modes, Emerson has developed
a new patent-pending dynamic
mode that is available on the GSX-E1.
Dynamic mode leverages the servoactuation
system, combining
computing power and cuttingedge
algorithms with highspeed
data communications to
monitor, recalculate, and adjust
the weld process
in real time and
achieve an optimized
target result.
When using dynamic
mode, the
manufacturer selects
the single-factor weld
mode - such as energy, distance,
or time - that provides the best results
in a new application. Then,
the user enters two additional
scores, which act as limits for
dynamic mode activity. The
first is a material density
score that essentially characterizes
the hardness or resistance
of the material that is
to
staked,
receive
or
the
inserted
welded,
part
(e.g., a low-density score
equates to a harder, more
resistant material). The
The Branson™ GSX-E1 welder from
Emerson qualifies for an ISO Class
5.5 cleanliness rating. This rating and
other technology and features make
it ideal for cleanroom applications.
(Credit: Emerson)
Medical Design Briefs, September 2022
www.medicaldesignbriefs.com
second is a weld reactivity score, which is used to adjust the degree
of variability allowed in the target result (e.g., a low reactivity
score equals a more homogenous result). Then, dynamic
mode monitors each weld cycle, using the density and reactivity
limits to adjust the cycle in response to specific part-to-part variabilities
throughout the production run.
n Getting to the Right Solution
Focusing on challenging applications in medical and electronic
cleanrooms, along with new equipment and technology
available to help ensure meeting quality and standardscompliance
goals, is critical to advancing applications of new
welding technology; however, not every situation will require
top-shelf features or be best-served by ultrasonic welding.
Working closely with customers, supplier consultants use their
extensive process expertise and consider alternative technologies
- like laser welding, for instance - before recommending
the appropriate equipment. Branson welding solutions, for example,
are backed by deep technical knowledge, decades of application
experience, and a global supply chain with sourcing,
manufacturing, and customer-support capabilities.
This article was written by David Devine, Business Development
Manager, Medical, for Branson Welding and Assembly at
Emerson, St. Louis, MO. For more information, visit www.
emerson.com. With in-depth knowledge of both plastic materials
and assembly technologies, he provides customers with welding
and assembly solutions. Contact: DavidDevine@Emerson.com.
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39
http://www.emerson.com http://info.hotims.com/82325-826 http://www.medicaldesignbriefs.com
Medical Design Briefs - September 2022

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