Executive Summary
Benefits of adopting electric actuators in projection welder machines

This white paper explores the significant benefits of adopting electric actuators in projection welder machines, replacing traditional hydraulic cylinders. These machines are essential for the manufacturing of TO can devices and hermetically sealed units critical in telecommunications, military, and sensor technology sectors. The transition to electric actuators offers improvements in precision, efficiency, better energy efficiency and operational costs.

Introduction

Projection welding is a vital process in the assembly of TO can devices and hermetically sealed components. These components require high precision and reliability, particularly in high-stakes fields like telecommunications and military applications. Traditionally, hydraulic cylinders have been used to provide the force needed in these welding operations. However, recent technological advances have made electric actuators a viable and superior alternative.

Comparison of Hydraulic Systems and Electric Actuators

Disadvantages of Hydraulic Systems?

Hydraulic cylinders operate based on fluid dynamics, using oil under pressure to create movement and force. While effective for generating high force, they pose several disadvantages:

• Maintenance and Reliability: Hydraulic systems require regular maintenance of seals, hoses, and the hydraulic fluid. Leaks and fluid contamination can lead to system failures and downtime especially in a glovebox environment.
• Environmental Impact: Oil leaks from hydraulic systems pose environmental risks and necessitate stringent disposal methods of used fluids.
• Operational Inefficiency: Hydraulics often suffer from energy losses due to fluid friction and leakage, reducing overall system efficiency.

What are the advantages of Electric Actuators?

Electric actuators use electrical energy to generate motion and force through motors and mechanical assemblies, such as ball screws or belts. They provide several advantages:

• Precision and Control: Electric actuators offer superior precision and repeatability, critical in welding applications where dimensional accuracy is paramount. We use an in-line load cell that constantly measure the applied force and feedback to the control unit to optimise the pressure output.
• Energy Efficiency: These systems convert electric energy directly into mechanical energy with minimal losses, significantly enhancing overall energy efficiency.
• Reduced Environmental Impact: With no need for hydraulic oil, electric actuators eliminate risks of fluid leaks and environmental contamination.
• Lower Operational Costs: Electric actuators require less maintenance compared to hydraulic systems, reducing long-term operational costs.

Benefits of Transitioning to Electric Actuators

Enhanced Product Quality

Electric actuators provide consistent pressure and precise control over movement, which is crucial for achieving high-quality welds in TO can and hermetically sealed devices.

Increased Production Efficiency

The direct drive mechanism of electric actuators can reduce the cycle times of welding operations. Faster response times and precise control over the actuation process lead to increased throughput and higher production rates.

Enhanced Data Integration and Traceability

A significant advantage of electric actuators is their ability to provide detailed operational data back to the control programmable logic controller (PLC). This data can be exported and analysed to improve traceability of the welding process, ensuring compliance with quality standards and facilitating continuous process improvements. This capability is crucial in industries where documentation and precision are paramount.

Cost Reduction

The lower maintenance requirements, reduced energy consumption, and increased lifespan of electric actuators decrease the overall cost of ownership compared to hydraulic systems.

Sustainability

By eliminating hydraulic oil and associated disposal issues, electric actuators offer a more sustainable solution, aligning with global environmental protection standards.

Conclusion

The transition from hydraulic cylinders to electric actuators in projection welding machines presents numerous advantages, including improved product quality, operational efficiency, cost savings, and environmental sustainability. Adopting electric actuators aligns with the industry's move towards more reliable, efficient, and clean technology solutions, particularly vital in sectors such as telecommunications, military, and sensors.

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