With the targeted development of two new innovative small-size plumbing products that were to be produced in ultrasonic and spin welding operations, LSP was looking for a rotary table solution to replace their antiquated assembly line manual processes and ineffective conveyor options.
For over 40 years, LSP Products Group, Inc. (LSP / Irving, TX) has been developing innovative polymer products for the plumbing industry. With a manufacturing plant featuring 11 injection molding machines, LSP molds all of their wholesale plastic plumbing parts in the USA.
Since the welders have applied force pressure and small part size, rotary indexing tables present a perfect option for small progressive production. LSP’s Director of Mfg. Engineering, Marshall Henningsen, soon began to investigate value-added possibilities by contacting industry leading specialist for rotary tables and automation, WEISS North America, Inc. (Willoughby, OH). Discussions soon began on optimal rotary table engineering solutions for LSP’s ultrasonic and spin welding machine designs.
FORCEFUL PROBLEM / SOLUTION
Originally, LSP was planning on building and implementing their own automation internally on their chassis, however, the WEISS sales and engineering team provided them with a 3D CAD model of a WEISS chassis along with a unique configuration proposal based on their TC (TC150/TC220) Series of rotary tables.
A key design element that both machines had to address was overcoming the excessive downward forces (400 lbs.) from the servo-driven welders, to melt plastic that was exacted onto the index table’s tool plate in repeated production.
To overcome this, an anvil back-up support was designed underneath to absorb the intense loads from the welders−ultimately promoting longer production life for the tables and plates.
The cornerstone to achieving each chassis system’s production goals, was implementing WEISS’ third generation configuration TC heavy duty rotary table – TC150 (six station) and TC220 (eight station).
Both tables feature a hard coat anodized plating finish on the aluminum jig plate. This coating is essential in providing superior durability versus the intense downward force pressure subjected on the anvil that supports the plate.
Delivering the highest reliability and precision, the robust rotary table series features standard stationary post, center standard through hole, high-load bearing, and large cam followers with needle roller bearings for the following LSP polymer plumbing part product applications:
TC150-6 STATION / LSP PROFILE
LSP is producing a new, quarter-turn valve hammer arrester made out of polymer vs. traditional copper. The patented, first of its kind plastic hammer arrester smooths out pressure in-line on hoses used for washing machines, toilets, ice makers, etc.
Utilized for degreasing and inserting components in ultrasonic welding operations in six stations, the WEISS chassis system includes the TC150 index table (32″ diameter, 3/4″ thickness), tool plate, machine frame, and an anvil back-up support for the tool plate.
TC220-8 STATION / LSP PROFILE
In production of their new, engineered plastic quarter-turn valve to be used in plumbing industry applications such as ice makers, faucets, etc… − LSP leveraged the WEISS eight station chassis system. The semi-automated system includes the TC220 index table (42″ dia., 3/4″ thickness), tool plate, machine frame, and an anvil back-up support for the tool plate.
Production features eight spin-welders at each station that use radial motion, and apply over 100 lbs. of force pressure to friction-weld plastic part halves. WEISS designed the anvil support located underneath the center of the tooling head, to effectively offset the force applied to the parts and the table during repeated station loading, unloading, component insertion, and station greasing.
DURABLE CONCLUSION
Both units are in the early stages of advanced production of the innovative LSP polymer plumbing parts. Notably, the inclusion of the anvil back-up support will ensure advanced longevity for the system’s core index table and tool plate against repeated welding production force pressures.
According to LSP’s Henningsen,
“The WEISS TC150 and TC220 chassis systems provided us with a cost-efficient solution to achieve our unique small plastic part production goals. Additionally, their quality controlled design is readily adaptable to adding pick-and-place units for full automation in the future.”
WEISS TC Series rotary tables offer robust design with smooth, jerk and impact-free motion and extremely long service life−backed by a 4 year warranty.