INNOVATIVE FEATURES EXCLUSIVE WITH STAPLA

Sigma QC Module Improves Yield
STAPLA software and hardware quality controls measure process variations created by fluctuations in part tolerances and tool wear. Sigma tolerance statistics are used to determine standard process deviations to set upper and lower tolerance windows for a given application to maintain your QC standards. This decreases defect rates while eliminating time-consuming, trial-and-error manual tolerance settings.



Motorized End-Stop Increases Weld Accuracy
When welding in relative position, a software controlled servomotor sets a mechanical end-stop to correspond with the programmed collapse value. During welding, the exact position of the workpiece is fed hack to the servomotor which then moves into position to terminate the weld to the set collapse value. This new technique compensates for variances in part tolerances to maintain homogenous, repetitive bonds.



Self-Diagnostic System (SDS^TM) Saves Maintenance Time and Costs
Advanced K1-XT software and controls provide instant diagnostics whenever a machine error or faulty weld is detected. As soon as the welding process is interrupted, the controller immediately displays the cause and suggested remedies to return to the weld operation. Providing a simple interface between operator and machine eliminates unnecessary downtime and reduces costs.

K1   ·   Model Comparison Chart

STANDARD FEATURES

K1 USC 3 Controller

• One-Button Input and LCD Microprocessor Screen All programs, menus, and welding parameters can be accessed and set by turning and pressing a single knob.
• Multi-Level Access Authorization -- Separate keys control access to four user levels: Setup, Teach, Operator, and Quality.
• Velocity Control Five settings for down- and return-stroke velocity.
• Auto Frequency and Voltage Regulation Generator actively tracks the performance of the actuator system for self-tuning and compensa- tion of voltage fluctuations.
• Multiple Trigger and Weld Modes -- Energy, time, and absolute distance or relative distance.
• Amplitude Adjustment -- Programmable Amplitude Adjustment in 1% increments during the weld process.
• Force Profiling -- In-process profiling of differ- ent weld forces for optimized joint quality.
• Weld Graph Display Controller graphs all relevant data on LCD display for advanced appli- cation diagnostics.
• Modular Controller Design -- Standard 19 rack mount with multiple I/O and analog inter- faces for ease of integration. PLC function to operate auxiliary devices.
• Auto-Calibration Built-in procedure allows calibration of functional machine components to ISO standards to meet good manufacturing practices and FDA requirements.

K1 Welder/Actuator

• Digital Linear Encoder Digital measurement of height and compensation of part tolerances.
• Quick Exchange Stack -- Indexed tooling clamp for rapid interchange of stack for different applications.
• Leveling Plate Ease of alignment for horn and fixture with pivoting tooling plate.
• Ergonomic Design Slim and narrow configu- ration of the actuator for close side-by-side mounting or integration into automated manu- facturing cells.
• Square Machine Column -- Column design is superior to round column designs by using a rigid structure to eliminate deflection when high forces are applied.

During setup, the K1 XT Controller eliminates operator error that can cause accidental horn to-fixture contact. The controller automatically initiates a low-force contact between the horn and fixture and then sets a mechanical end-stop to prevent accidental contact during the weld cycle that can damage the horn, fixture, converter, and generator. This protects customer investments and ensures the proper operation of the system to maintain quality standards.

Corporate Background

Founded by the engineers who designed and built the world’s first ultrasonic metal welding systems, STAPLA is a global company with offices in Boston, Massachusetts; Frankfurt, Germany; El Paso, Texas; Chicago, Illinois, and Hong Kong. As part of the Schunk Group of 60 companies with over a half billion dollars in yearly revenue, STAPLA has the financial and technical resources needed to support leading automotive, electronics, and medical device companies as well as manufacturers serving specialized markets.

Pre-Sales Support and Collaborative Engineering

STAPLA engineers work closely with customers from initial feasibility studies and design of plastic components to ensure manufacturability, to the design and fabrication of required tooling, selection arid installation of equipment, establishment of quality standards, and training customer personnel. This approach takes the entire process into consideration to ensure the highest level of quality and integrity in customer manufacturing operations.