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TECHNICAL SUPPORT

Customer Support
客户支持您的联系方式和供应商-全球ROPEX德国ROPEXIndustrie-ElektronikGmbH阿道夫-海姆-STR。474321比蒂格海姆-比辛根德国电话:+497142-7776-0传真:+497142-7776-211电子邮件:info@ropex.de 英国意大利斯堪的纳维亚CeetakLtd.Mr.Franklin/Mr.FoxFraserRoad,PrioryBusiness
Engineering Support
Ourknow-how–YoursuccessApplicationsupportIfyoutakeadetailedlookataheatsealingsystem,you’llfindit’softenverycomplexbecauseit’smadeupofseveraldifferentcomponents,allofwhichhavetointeractwithoneanotheroptimally.Eachofthesecomponentshasaspecificimpactontheresults.Wecan’tsimplyassumethateveryuserhasthisexpertiseattheirfingertips;afterall,thetechnologymayonlybeneededveryoccasionally.TheROPEX“ApplicationSupport”departmentistheretohelpnotonlyinthiskindofsituationbutwithallcustomerinquiries.Ourexperiencedtechniciansandengineersprovidetargetedsupportduringtheprojectdevelopmentphaseandbeyond–ifyouwish,fromtheinitialcontactrightthroughtowhenthecompleteheatsealingsystemiscommissioned.Benefitsforyou:EffectiveapproachTimesavingbecausefewermistakesaremadeTheoverallsystemismorereliableSinglepointofcontact
CIRUS
CIRUSheatsealingsystemforthermoplasticfilms.Machineswithahighproductoutput,specialpackagingapplicationsorpackagedgoodsrequirements,selectionofthefilmmaterialundermountingcostpressure–allofthesefactorsresultinfilmtypesthatpresentdauntingchallengesforthesealingsystem.Usersarethusincreasinglyshiftingtheirattentiontowardsissuessuchasseamqualityandconsistentrepeatability,theshortestpossiblesealingtimesandminimalheatstresstothepackagedgoods–nottomentiondemandsforlessdowntimeduetomaintenance,thereplacementofwearingpartsorretooling.ROPEXhastheidealsolutiontotheseproblems:theCIRUSrangeofsealingsystemsandassociatedcomplementarycomponents. TheperfectsolutionTheROPEXCIRUS(CermetIntegratedResistiveUltrafastSensorless)heatsealingsystemistheperfectsolutionwhenitcomestoheatsealingapplications:itisidealwheneverhightemperaturedynamicsarerequiredtoheatandcoolthesealingtool,thesealedseamorpouchhasacomplexcontourandno–oronlyminimal–heatstresstothepackagedgoodsisallowed.Furthermore,theCIRUSsealingtoolneedsvirtuallynomaintenancebecause–unlikeconventionalimpulsesealingbars–ithasnomovingpartslikebarendblocks,whichcouldbreakorbecomejammed,tocompensatethelinearthermalexpansionofthemetalstrip.TheCIRUStechnologyalsoeliminatesproductchangeovertimesbecausedifferentfilmwidthscanbeprocessedwithoutalteringtheactivelyheatedtoollength(inotherwords,thetoolworksindependentlyofspecificformats).Heatingup&coolingdowninafewmillisecondsTheextremelyhightemperaturedynamicsofourCIRUStoolsarearesultoftheirspecialstructure:severalinsulatinglayersareprintedonaplanarstainlesssteelunderlayinascreenprocesspriortoapplyingtheactualheatinglineasapowerresistance.Anelectricalinsulatinglayerisadditionallyincorporatedtoinsulatethetoolandprotecttheresistancelayeragainstexternalinfluences.Eachprintedlayerisburnedinbysintering,sothatafirmbondiscreatedbothbetweentheindividuallayersandwiththeunderlay.Theheatsealelementobtainedinthiswayisthenfusedontoastainlesssteelcoolingsubstructurewithanintegratedchannelthroughwhichwaterflows. HeatingimpulseThisspecialtooldesignenablesnovelcharacteristicscomparedtoclassicheatsealingsystems:forinstance,sincetheheatinglineisonlyafewµmthick,andtheheatcapacityisalsolow,extremelyhightemperaturedynamicsarepossible,namely6000K/s.   HeattransferTheheattransferbetweenthefilmandtheintegratedwatercoolingunitisexcellentbecausetheprintedlayersareexceptionallythin.Thesealedseamthereforecoolsdownveryfastandveryefficiently.ThecombinationoftheCIRUStool’sextremelyhightemperaturedynamicsandthewatercoolingsystemultimatelyresultsinsignificantlyshorterprocesstimesandhigherproductivitythanarepossiblewithconventionalheatsealingmethods.Thethermalexpansionwhichoccursduetothetemperatureriseintheheatinglineandtheunderlayisreducedasaresultofthespecialtoolstructure,sothatCIRUSheatsealingbarsrequirenomechanicalpartstocompensatethiseffect.Brokenspringsorjammedbarendblocks,whichcanbeaproblemwithmetalheatsealelements,areconsequentlyruledout. IndividualheatinglinecontoursIfstandardUPTsealingbarsarenotsuitedforthetaskathand,acustomizedtoolcanbemanufacturedexplicitlyforyourapplication.Inthiscase,aheatsealingtoolisdesignedandbuiltinclosecooperationwiththecustomerbasedonyourdetailedspecifications.Owingtothespecialproductiontechnologywhichisusedfortheheatsealelements,theheatinglinecontourcanbetailoredtoindividualrequirements.Curvedsealinggeometriesarealsopossible,forexamplecircularorellipticalshapes.Overlappingtemperatureprofilescanlikewiseberealized. SystemconfigurationInadditiontotheactualsealingtool,theCIRUSsealingsystemcomprisesatemperaturecontrollerandvariouscomplementarycomponentssuchasacurrentfilter,impulsetransformer,currenttransformerandcounterbar.Thecoolingunitisafurtheressentialpartofthesystem.TheelectricalandthermaldesignofthisintegratedsystemistakencareofbyROPEX.Youalwaysacquireacompletesystem,readytouseinyourapplication:byobservingourtechnicalrecommendations,youcanprofitfromtheoptimizedfunctionalityofthistechnology,whichreducestheeffortforinstallation,startupandmaintenancetoaminimum.
RESISTRON
RESISTRONimpulsesealingsystemforthermoplasticfilms.Modernpackaginghastomeetincreasinglyhighqualityandvisualrequirements.Everfastercycleratesmustbereconciledwiththethinnerandhencemoresensitivefilmtypeswhichareinusetoday.Thismakesitevenmoredifficulttoguaranteearepeatablesealingprocess.The“RESISTRONsealingsystem”developedbyROPEXisacompletesystemconfigurationcomprisedofseveralapplication-specificcomponents.ThetwomostimportantofthesecomponentsaretheREStemperaturecontrollerandtheRESsealingtool.TheRESsealingtoolisaheatsealingbarwithaheatsealingbandandamatchingcounterbarwhicharetailoredtoyourindividualsealingapplication.Bycombiningitwiththesystemcomponents,youobtainacustomizedsystemconfiguration.ImpulsesealingwithheatsealingbandsHeatsealingbandsarebasicallythinmetalstripsorwiresmadefromaspecialresistancealloy,whichmustsatisfycertainphysicalrequirements.Thesestripsareprofiled,formedandcoateddependingontheapplication.TheheatsealingbandperformsadualfunctionintheRESISTRONcontext.Whensuppliedwithpower,itservesasaheatsourceforthesealingprocess.Atthesametime,itactsasatemperaturesensorwhichchangesitsresistanceasthetemperaturerises.TheabilityoftheREStemperaturecontrollertomeasurethisresistancechangerapidlyduringtheheating-upandcooling-downphasesiscrucialforthishighlydynamicandsensorlesscontrolconcept.Thisexplainstherigorousspecificationswhicharedefinedfortheheatsealingbandalloy.Themostimportantcharacteristicsofaheatsealingbandare:TemperaturecoefficientoftheresistanceSpecificresistanceExpansionbehaviorThesecharacteristics,alongwithyourheatsealingapplication,haveadecisiveinfluenceonthespecificationsoftheelectricalcomponentsandthemechanicsofthesealingbar.Theoverallsystemisclearlyverycomplexandallsystemcomponentsneedtointeractoptimallywithoneanother.Ouradvicetoyouistohaveyourheatsealingapplicationcalculatedbyoursupportteam.Acompletesystemcanthenbeputtogetherforyouincludingallessentialcomponentsandsettings. HowtheRESISTRONtemperaturecontrollerworksInordertoobtainanoptimalapplication,thevalueofeachparametermustbedeterminedandthesequenceofstepsadaptedtotheheatsealingtask.ObservingtheseparametersregardlessoftheconditionsinwhichaproductionmachineoperatesisthekeychallengefortheRESISTRONtemperaturecontroller.Extremelypreciseandfastmeasurementsareessentialinordertoaccuratelydetermineandcontrolthetemperatureofaheatsealingband.InaheatsealingsystemwithaRESISTRONtemperaturecontroller,thisisachievedwithoutsensorsbymeasuringthevoltageandcurrentattheheatsealingband.Themeasurementsarerepeatedfiftyorsixtytimesasecond.TheACTUALtemperaturecanthenbecalculatedfromthevoltageandcurrentvaluesusingtheheatsealingband’sresistancecharacteristic.ItissubsequentlycomparedwiththeSETtemperatureandcorrectedifthedifferenceisnotzero.ThisisdonebyalteringthetransformervoltageuntilACT=SET.Evenverylowthermalloadsareinstantlydetectedandcanbecorrectedquicklyandprecisely.Apowercontrollerontheprimarysideofthetransformerworksasanactuator.Sincetheprimarycurrentwhichiscontrolledismuchlower,theheatlossesarealsosmaller,pavingthewayforthecompactcontrollerdesignwhichusersvaluesohighly.HeatsealingbarswithaheatsealingbandTheheatsealingbarwhichactsasthesubstructurefortheheatsealingbandisgenerallymadefromaluminum.Itincorporatesallofthedesignelementsthatarenecessaryinorderforthebandtodoitsjobreliably,forexample:BarendblockstocompensateexpansionElectricalconnectionsforthehigh-currentandmeasurementcablesFixationfortheheatsealingbandHolesforcoolant(ifrequired)InsulatinglayersfortheheatsealingbandThemostpopulardesignisastraightsealingbarwitharectangularsection,whichcomesinlengthsrangingfromafewcentimeterstoseveralmeters.Contouredsealingbarscanbesuppliedwithboth2Dcontours(e.g.circular,angularorcurved)and3Dcontoursforsealingtubesorspouts.Specificdesignrulesapplytothiskindoftool,andhighprecisionisvitaltoachieveahomogeneoustemperaturedistribution.OurdevelopersuseadvancedCADsystemsforthispurpose,tocreateathree-dimensionalviewoftheheatsealingbar.TheCADfilecanthenbesenttothecustomer,whointegratesitintothecompany’sownCADenvironment.HeatsealingbandAsalreadymentionedelsewhere,theheatsealingbandisthemaincomponentinthesealingprocess,whichiswhyparticularattentionshouldbepaidtoanaccurategeometry,aprofilewhichisadequatefortheprocessandcopperedorsilveredpassivezones.Ofcourse,theelectricalcharacteristicsoftheheatsealingbandalloymustbecompliedwith,suchasthespecificresistanceandtemperaturebehavior.Aheatsealingbandwhichisoptimallymatchedtothesubstructureiscrucialtothesuccessofyourimpulsesealingsystem.Wedesignheatsealingbandswhichareindividuallytailoredtoyourrequirementsaswellasamatchingsubstructureonrequest.CustomizedsolutionsIsyourapplicationunusual?Doesitneedacustomizedsolution?Ifso,you’vecometotherightplace!ROPEXhaslongstandingexperienceinimpulsesealingandthedevelopmentofheatsealingapplications,whichmakesusoptimallyqualifiedtoproviderelevantanswersnomatterhowuniquetheproblem.Wedesignaheatsealingbarandbandthatfityourrequirementsprofileandputtogetherexactlythesealingsystemyou’relookingfor.Wecanalsoperform
Process
Continuousheatingvs.impulsesealingTheimpulsesealingprocessisagoodalternativetotheclassic,continuouslyheatedsealingtoolsinwidespreadusewhichprovidesveryefficientsolutionsandmultiplebenefitsincomplexheatsealingapplications.Continuouslyheatedsealingtoolsareusedinthemajorityofsituationswhereplasticfilmshavetobethermallybonded.Thistechnologyinvolvesheatingmetalsealingjawselectricallyandthenmaintainingthempermanentlyatasettabletemperature.Thisisgenerallytheeasiestwaytobondplasticfilmstogether.Unfortunately,however,thistechnologymaybesimplebutitalsohasdrawbacksforthequalityofthesealedseamortheproductivityofthemachinewhichareverydifficulttocompensate.Inparticular,thefactthatthefusedfilmcannotbecooleddowndirectlyintheclosedtool,sothatastronganddurablesealisobtainedassoonasthetwohalvesareopened,isamajordisadvantage.Whenprocessingfilmswherehighelasticforcesresultfollowingthesealingprocess(thickfilmsoraluminumcomposites)owingtothepouchorbaggeometryorthepackagedgoods,additionalcoolingstationsorprocessesmayhavetobeincorporatedinthemachinetoenabletheseamtobeactivelycooledafterthesealingtoolisopened.Thatmeansmorechallengesforthepackagingmachinemanufacturer’sdesignengineersaswellashigherrunningcosts,forinstanceforthecompressedairthatisnecessarytocooltheseam.Theheatwhichisemittedbythecontinuouslyheatedtoolscanlikewisebedetrimentalbothtotheproducttobepackedandtothefilmitself.Onceagain,appropriatedesignmeasuresmustbeintegratedinthepackagingmachinetocompensateforthisundesirableinfluenceofthehotsealingtoolsonthepackagedgoods.Problemssuchasinadmissibleheatstressorhotseamsthatareliabletocomeopencanbeavoidedwiththeimpulsesealingprocess.Theheatoffusionforthefilmisonlyactuallyproducedwhen,andforaslongas,itisactuallyneededforthesealingprocess.Thecurrentwhichispassedthrougharesistorforthispurposecausesatemperaturerisethere.Assoonasthecurrentflowisinterrupted,theresistorstartstocooldownasthegeneratedheatisdissipatedintothetoolortheenvironment.Theheatoffusionwhichwasintroducedintothefilmisthusremovedagainandtheseamiscooled. OtheradvantagesImpulsesealingoffersseveralotheradvantagescomparedtocontinuousheating:LowerpowerconsumptionElectricalenergyisonlyrequiredduringtheheatingphaseofthesealingcycle.Nocurrentisfedtotheheatsealingbandduringthecoolingphase.Continuouslyheatedsealingtoolsareheatedthroughoutregardlessofwhetherornotanyheatisactuallyneeded.Noheating-uporcooling-downtimesImpulsecontrolledsealingtoolshaveonlynegligibleheating-upandcooling-downtimeswhenthemachineisstartedorstoppedcomparedtocontinuouslyheatedalternatives.Continuouslyheatedtoolsconsistofsolidmetalpartswhichhavetobeheatedbeforethemachineisreadytouse.Ifasealingtoolisdueformaintenance,ithastobecooleddownfirst.Delaysofseveralminutesarenotuncommon.Heatsealingbandsheatupandcooldowninjustafewhundredmilliseconds,orintheworstcaseafewseconds. Impulsesealing–perfectcontrolofthesealingprocess!Withclassictimecontrol,currentisfedtoaheatsealingbandforasettabletime.Thebandheatsupcontinuouslyduringthisperiod;attheendoftheheatingcycle,theheatingisswitchedoffandtheheatsealingbandcoolsdownagainbydissipatingheatintotheenvironment.Thismethodofcontrollingtheheatingelementonlyremotelyresemblesimpulsesealingwithaheatsealingband,andthesealingprocessisextremelydifficulttomanagebecausethereisabsolutelynowayofcontrollingthesealingtemperature.Althoughitistheoreticallypossibletocooltheseamunderpressure,sincethesealingtemperaturecannotbecontrolled,itcouldvaryfromoneheatingimpulsetothenext.Eventhoughaconstantheatingpowerissuppliedforaconstantsealingtime,thefinaltemperaturediffersaccordingtothestarttemperatureoftheheatsealingband.Thisisparticularlytrueifthepackagingmachinedoesnotoperateeithercontinuouslyorperiodically.Toavoidthis,itisvitaltocontrolnotonlythesealingtimebutalsothesealingtemperature.Onlythencanwespeakofagenuineimpulsesealingprocessbecauseinthiscaseanidealsquare-waveimpulsewhichismoreorlesssalient,dependingontherateatwhichtheheatsealingbandheatsupandcoolsdown,canbegeneratedforthetemperaturecurveovertime.Thisrectangularshapeensuresarepeatablesealqualityandhighmachineoutputforagivensealingcycletime,withtheoptimalratioofsealingtimetocoolingtime.WithourRESISTRONtemperaturecontrollersforheatsealingbandsandourCIRUSUPTimpulsesealingsystem,ROPEXhascomeupwiththeperfectsolution. RESISTRONorCIRUS?TwoalternativeimpulsesealingprocessesforplasticfilmsEachofthesetechnologiesrepresentsanexcellentalternativeforsealingthermoplasticsusingtheimpulsemethod.TheefficientinteractionoftheRESISTRONtemperaturecontrollerwiththeheatsealingbandandthefactthatallcomponentsinthecontrolloopareindividuallyspecifiedbyROPEXguaranteestheoptimalratioofsealingtimetocoolingtimeforagivensealingtemperature.OwingtothespecialdesignofourCIRUStoolsincombinationwithaUPTtemperaturecontrollerthatisfinetunedtothistechnology,theheatingimpulseswhicharegeneratedarealmostideal.TheCIRUStechnology,inparticular,achievesveryfastheating-upandcooling-downrates,leadingtoextremelyshortprocesstimeswhenplasticfilmsarethermallybonded.Youcanfindamoredetail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