For manufacturers to compete favorably with imports, it becomes critical that manufacturers embrace integrative and automation capabilities with their welding processes. Integrative solutions include additional functionality built-in with each fabric welder or heat sealer purchased. Automation means repeatability with accuracy and speed, i.e., pulse packet (Puls2™) sealing technology produces seals faster than any other comparable sealing method. A few examples of integrated automation solutions may include:
• Adding an Automatic PocketMaker using clamping for full control at high speeds
• Integrating Slot/Punching pre or post welding
• Including a FlangeClamp to assist in material release
• Welding a reinforcement vinyl edge strip to reduce fraying
• Adding a zipper and/or keder strip fixturing with infinite control and positioning
• Addition of a Laser Dot for alignment
• Including Magnetic Grippers to hold materials in position
• Adding one or more Shuttle Systems for improved process automation
With 25 years experience you can be rest assured our engineers have had to tackle lots of exciting challenges. Our record is 100% solved! Which means we’ve always found a solution to better handle your production requirements as they integrate with fabric welding or heat sealing applications. Another benefit of letting us help you automate your existing processes is our focus on Machine Learning. People are good at many things. Machines are better at others. When we employ Machine Learning, our heat sealers can, for example, self-maintain operations for reduced or to eliminate maintenance downtime. So, by now I’m sure you are beginning to realize that with a sealing technology faster and better than anything else you’ve seen coupled with automated solutions, your manufacturing costs will decrease while efficiencies increase. Return on Investment (ROI) can be a very short time, making an investment in automation a simple one to make.
What are you waiting for? Call us today.
Our integrative and automation solutions have been added to our QUAD 4-sided automatic pocketing to L-shaped systems to repositioning one of our NovaPULS™ TableTops upside down within a complex splicing operation. Simpler machine-level automation could be a TableTop or Automated Pulse Sealer with fixturing to automate adding zippers, keders or splines to each sealed product. Regardless of which way you decide, all our Pulse Sealers are Automation-ready, and can be integrated as part of a machine-level or full process automation system. The following represent examples of Integrative and Automated solutions designed and manufactured by Nova Products.
QUAD Automatic PulseSealer
What began as our 4-by-x all-in-one heat sealer evolved to become the world’s largest heat sealing machine. The QUAD Automatic PulseSealer uses our proprietary, patent pending and revolutionary Puls2™ Sealing technology to make up to four 4-sided pocket seals in a minute, significantly less time than any competitive product available. Not only are the seals made fast, but the quality is second to none.
The QUAD consists of: 4 NovaPULS™ Welders formed as a rectangle, Material Rollstand to feed material, a huge table located and spans between the 4 welders, an Exit System, and TouchScreen PLC Control System.
Arranged to produce 4 pocket or flat finished seals and can be used to form Lamar-style pockets (3-inch pocket with 1-inch seal) and/or CircleGraphics(ECO)-style (3 ¼-inch parallel on 2 to 3 layers of material) seals along the circumference to finish a poster, billboard or other product. Sealers can produce up to 4 completely sealed posters/banners per minute. Sealers can be fixed or continuously adjusting in size to form seals varying between 8-ft by 15-ft to 24-ft by 60-ft or any variation of your choice. Illustration. Lamar Graphics’ Transformer is, a Novaseal® QUAD Pulse Sealer and is Lamar’s key production advantage for fabrication of posters. Each Pulse Sealer is activated using our Poster-type press, and, our presses can be modified to include Slit Press option to slit materials compliant with ClearChannel’s slit specification.
Novaseal® proprietary magnetic gripper technology is used to move and locate printed material. To optimize smooth and fast movement of materials, Nova Products (the manufacturer of Novaseal® branded products) has teamed with Maxcess International. Maxcess provides a family of products and services to assure material feeding is accurate, exact and continuously repeatable without using pinching rollers used in our first QUAD system. Incoming materials are tension controlled to eliminate telescoping and assure high speed guidance without comprising safety. Whether your application is continuous or for an occasional single poster at a time, our PLC-driven motion controls is the most versatile for high speed heat sealing production available today.
Each poster includes barcoding to define whether the seals should be Lamar-style or CircleGraphics-style, as well as finished size. Next, our high speed control system modifies machine to meet finishing parameters. All of this happens without losing production time. And, if you are limited on power, or prefer to use less power, our PowerDistribution optimizer can be integrated with our Pulse Sealing technology.
Automatic NovaPULS™ with Shuttle System
Shuttle systems can be configured for length required. For example, the shuttle system shown in photo inset is used to make a 42-foot seal with a 17-foot PulseSealer on 80-foot shuttle track system. Materials to be heat sealed are loaded onto a conveyor system, and moved left-right in 17-foot indexed seals. Our proprietary End-to-End sealing technology results in a completed long-length seal without witness marks from one seal to the next. Shuttle moves in both directions. This example of process automation also includes a laser activated alignment system, as well as multiple sealing configurations for various applications from keder/zipper attachment to overlap sealing of dissimilar materials.
Whether you need a system to automatically heat seal splice materials or you need specialized functionality, Novaseal®-branded TableTop PulseSealer provides a low-cost, relatively light-weight, intergratable solution. And with our Automation-ready feature built-in to every PulseSealer, you can purchase a stand-alone NovaPULS™ TableTop today, and integrate automated functionality in the future.
For additional functionality, consider an NovaPULS™ Automatic factory floor model configured with two 294-inch sealing bars separated by an infinitely variable distance. In this example, one of the two heat sealers was used to heat seal dissimilar materials and the other heat sealer used to make a tightly wound keder and heat seal the keder section to a heavy weight vinyl material. Although considered machine-level automation, this same machine was designed for future full process automation.
Automation is not limited to PulseSealers. Consider a customized heated platen sealer. Photo inset (left) shows a heated platen sealer that was integrated into a full process automation for medical products. In this case, the design was customer-specified for a machine that fits between several other components. Automation-ready meant that variable heat controls, operational controls and automatic interchangeable heating platen removal was controlled from a central operating system via WiFi communications.
AUTOMATION. INTEGRATIVE SOLUTIONS. MACHINE LEARNING. CUSTOMIZATION.
Nova Products is an engineering design and solutions driven company. Our team of engineers include a physicist, mechanical engineers, an electrical engineer, materials engineering and an automation engineer. All designs are modeled using solid modeling and finite element analysis software. Together with intensive project management tools and a crew of machinists, technicians and administrators, we can tackle just about any heat sealing and/or heat sealing automation application.
Affordable Automation is all made possible with SuperFast Puls2™ Sealing Technology.
We have direct experience working with our proprietary pulse packet sealing technology. Additionally we have a thorough knowledge of wedge welding, heated platen (die) sealing.
With Nova Products, Automation, Machine Learning & Customized Integrative Solutions are only limited by your imagination.