Project Overview

Case: A major medical technology company is prepared to launch a new blood collection product line. Unlike conventional blood collection devices, this product uses a multi-piece design. As a result, Tri-Power Design (TPD) needed to develop an automated assembly machine. The required cycle time was 20 parts per minute, or 1,200 parts per hour.

Solution: Tri-Power Design built and supplied an automated assembly machine using an eight-position indexing dial. The system ultrasonically welds a dispenser body and dispenser tip while capturing a single internal ball. As a result, the machine completes each assembly in less than three seconds.

Ultrasonic Welding and Quality Requirements

Design Challenges: The machine required a maximum scrap rate of no more than one damaged or incomplete weld per 600 parts. In addition, assembled parts needed to remain defect-free when inspected under 10× magnification. Acceptable ultrasonic welds had to show no flash, stress marks, or functional surface defects. Finally, the system needed to support long-term production with an annual capacity of 2.5 million units.

Call 973.227.8214 or email us today to learn more about the Drive Unit Test Rig.