ROPEX temperature controller

ROPEX temperature controllerInstructions:

Since 1976, ROPEX has been developing and producing system solutions and welding components for film welding applications, used in various applications in the packaging industry.

Developing a sensorless temperature controller for thin film sealing applications in pulse sealing processes - RESISTRON ®， ROPEX *。

This innovation has generated a large number of temperature controller types with multiple functions and connection options. For many years, ROPEX has been providing personalized development and construction support to customers, offering them specific film sealing strips and necessary system accessories for thermoplastic integral welding solutions.

In addition, CIRUS has also been developed for * ® Pulse welding technology has been a part of the high-tech product portfolio in the packaging industry for over 10 years. CIRUS is a highly dynamic pulse process that allows you to heat up and cool down again in just 50 milliseconds.

RES temperature controller

Welding rod with RESISTRON heating element

RES temperature controller is used for welding rods with heating conductors. In addition, the RES temperature controller can also be used for other welding applications, such as B. for regulating hot air applications.

We offer display and top hat guide rail types as construction methods. The display version is suitable for installation in the control panel and allows you to directly input relevant welding parameters. In addition, the display screen shows the current set value and the temperature reached. The variant design for top hat guide rail installation is intended for installation in control cabinets. The temperature controller provides you with various functions and interfaces to achieve higher-level machine control.

Pulse welding with heated conductor

The basic form of a heating conductor is a thin metal strip or wire made of a special resistance alloy, which must meet certain physical requirements. According to different applications, these metal strips are shaped, molded, and refined. Heating conductors have a dual function in RESISTRON technology. Due to the power supply of the heating conductor, it serves as a heat source for the welding process. Meanwhile, it acts as a temperature sensor by changing its resistance as the temperature increases.

The rapid measurement of resistance changes during heating and cooling stages by RES temperature controllers is the foundation of this high dynamic and sensorless control.

This leads to high requirements for heating conductor alloys. The most important characteristic of a thermal conductor is:

Temperature coefficient of resistance

Specific resistance

Expanding behavior

These characteristics and your welding application have a decisive impact on the size of electrical components and the mechanical structure of welding rods. This reveals the complexity of the entire system and the necessity for precise coordination of all system components.

Therefore, we suggest that you have our customer support calculate your welding application. We will integrate your entire system with all necessary components and settings.

Working principle of RESISTRON temperature controller

In order to achieve optimal application, each parameter must be determined based on its value, and the time sequence of the process must be adjusted according to the welding task. The main task of the RESISTRON temperature controller is to maintain these parameters under all operating conditions of the production machine.

The temperature of the heating conductor can only be accurately determined and controlled through an extremely precise and rapid measurement process. In welding systems equipped with RESISTRON temperature controllers, this is achieved by measuring the voltage and current passing through the heating conductor without the need for sensors. This measurement is performed 50 or 60 times per second.

The actual temperature can be calculated from these voltage and current values using the resistance characteristics of the heating conductor. In the subsequent comparison with the set target temperature, the difference from zero may be corrected. This is achieved by changing the transformer voltage until ACTUAL=TARGET is met. Even the smallest heat load will be immediately recorded and quickly and accurately corrected. The power controller works as an actuator on the primary side of the transformer.

The regulation of much smaller primary currents results in less heat loss and makes the controller highly valuable in terms of compact size.

Welding rod with heating conductor

As a carrier for heating conductors, welding rods are usually made of aluminum and have necessary structural elements to enable the heating conductor to function without interference. These include, for example:

The clamping head at the end of the guide rail serves as expansion compensation

Electrical connection between main current and measuring circuit

Fixed thermal conductor

Coolant hole (if necessary)

Insulation layer of heating conductor

The most common design is a straight rail with a rectangular cross-section, ranging in length from a few centimeters to several meters. For contour welding, there are welding rods used for 2D contours such as rings, corners, or arcs. In addition, 3D contours of welding hoses or nozzles can also be achieved.

When designing such tools, specific design rules must be followed with high precision to achieve uniform temperature distribution. For this purpose, developers use the most modern CAD systems to create 3D views of welding rods. Customers can receive created CAD files and integrate them into their own CAD environment.

heating element

As mentioned elsewhere, the heating conductor is the main element in the welding process, so special attention needs to be paid to geometric accuracy, appropriate contour of the process, and refinement of the passivation zone (copper, silver). Of course, it is necessary to meet the electrical characteristics of the heating conductor alloy, such as specific resistance and temperature characteristics. The matching between the heating conductor and the heating conductor carrier is another prerequisite for a well functioning pulse welding system.

We design your heating element separately according to your needs, and if you are willing, we can also design a suitable carrier.

Personalized solutions

Your application is unusual and requires a separate solution? So you have found a suitable one in ROPEX. Our years of experience in pulse welding and welding application development enable us to provide targeted answers to your personal questions.

We design welding rods and heating elements according to your requirements, and assemble a complete welding system for you. In addition, we can conduct welding tests on your foil at our technical center to quantify the results. Then, you will receive our comprehensive application report, which includes all relevant components, setting parameters required for the welding process, and necessary technical drawings for the mechanical components.

ROPEX temperature controllerModel:

ROPEX UPT6010 Temperature Controller

ROPEX UPT-6011 Temperature Controller

ROPEX UPT6012 Temperature Controller

ROPEX UPT-606 Temperature Controller

ROPEX UPT6006 Temperature Controller

ROPEX UPT-640 Temperature Controller

ROPEX RES-401 Temperature Controller

ROPEX RES-402 Temperature Controller

ROPEX RES-403 Temperature Controller

ROPEX RES-406 Temperature Controller

ROPEX RES-5006 Temperature Controller

ROPEX RES-407 Temperature Controller

ROPEX RES-5007 Temperature Controller

ROPEX RES-5027 Temperature Controller

ROPEX RES-408 Temperature Controller

ROPEX RES-5008 Temperature Controller

ROPEX RES-409 Temperature Controller

ROPEX RES-5009 Temperature Controller

ROPEX RES-5010 Temperature Controller

ROPEX RES-5011 Temperature Controller

ROPEX RES-5012 Temperature Controller

ROPEXLF06480 filter

ROPEXRES-406/400VAC temperature controller