Production requirement

How the system addresses it

Continuous functional seam

Contoured tooling develops the melt layer around the complete tank joint.

Controlled collapse

Servo position and speed profiles support dimensional and flash control.

Integrated quality plan

Temperature, motion, cycle result and optional leak data are evaluated together.

Serviceable tooling

Accessible heating zones, connectors and wear parts support preventive maintenance.

Application

Typical joining requirement

Coolant reservoir

Continuous PP or compatible thermoplastic seam with leak-test validation.

Washer-fluid tank

Large contoured joint and variant-specific fixtures.

Expansion tank

Dimensional and pressure-performance requirements defined by the customer.

Fuel-system component

Only after material, safety, ventilation and acceptance requirements are reviewed.

Industrial fluid container

Custom thermal joining for compatible molded thermoplastic halves.

Configuration

Architecture

Best fit

Pneumatic machine

Pressure-based joining

Robust architecture for validated, stable applications.

Servo machine

Programmable speed and position

For tighter collapse control and recipe flexibility.

Quick-change servo

Standardized tooling interface

For related tank variants on one platform.

Weld-and-test cell

Integrated leak or flow test

For one-piece flow and associated result data.

Parameter

Reference value

Engineering note

Reference model family

DZ-350 / DZ-800S / DZ-1000SF

Pneumatic / servo / quick-change servo

Reference max. weld area

350×200 / 800×450 / 1000×600 mm

Confirm against actual part and seam

Reference machine size

1400×1500×2100 to 2200×2400×2800 mm

W×L×H; layout is project-specific

Power supply

380 VAC reference

Destination voltage/frequency to be confirmed

Temperature control

Multi-zone PID

Zone quantity by tool geometry

Joining motion

Pneumatic or servo

Selected from CTQ and takt

Fixture

Dedicated upper/lower support

Datum and clamp plan from part data

Leak testing

Optional

Method, range, stabilization and limits by customer

Cycle time

Project-specific

Includes heating, changeover, joining and cooling

Parameter

Engineering purpose

Tool temperature by zone

Controls heat distribution; use independent PID zones and deviation alarms where required.

Matching / bead-up setting

Establishes contact and compensates for molded-part variation.

Heating time or melt displacement

Develops the melt layer without excessive degradation.

Open / changeover time

Limits cooling and oxidation of the molten surfaces before joining.

Joining force, pressure and speed

Controls melt flow, flash and interface formation.

Weld collapse / final position

Supports dimensional consistency and can be monitored when specified.

Hold and cooling time

Prevents joint movement before sufficient strength develops.

Tool cleaning condition

Supports consistent heat transfer and protects sensitive cosmetic surfaces.

Control element

Available project function

Temperature control

Zone setpoints, actual values, deviation alarms and warm-up release conditions.

Motion and position

Servo or sensor feedback for matching, changeover, joining and final position where included.

Force / pressure monitoring

Project-specific transducer or regulated pneumatic/hydraulic control.

Recipe management

Part-specific temperatures, timings, motion values and inspection limits.

Functional testing

Optional leak, pressure-decay, flow, burst or dimensional checks after welding.

Data exchange

Cycle results and selected parameters can be exported when the interface is included in the scope.

Seam-temperature status

All required zones must be stable before automatic production is released.

Collapse / final position

Position limits detect incomplete seating or abnormal material behavior where servo monitoring is included.

Leak-result association

Part ID, weld cycle and test result can be linked when traceability is specified.

Fixture confirmation

Clamp, part-presence and datum checks reduce loading and variant errors.

Material or design factor

Application guidance

PP and PE families

Common candidates for tanks, reservoirs, pallets and fluid-handling products.

ABS and PC/ABS

Suitable for selected housings and appliance components after grade-level testing.

PA and filled engineering thermoplastics

Moisture and reinforcement can change the thermal process window.

PMMA, PC and optical applications

Protect cosmetic surfaces and validate thermal response and joint design.

Dissimilar resins

Possible only for compatible combinations; verify exact grades and melting behavior.

Option

Project scope

Motion

Pneumatic, servo-electric or project-specific hybrid architecture.

Heating

Independent zones, deviation alarms, tool-ready logic and controlled standby.

Tool cleaning

Manual access or automatic method validated for the resin and residue.

Testing

Pressure decay, flow, burst interface or customer-defined functional check.

Cooling

Fixture cooling, air or application-specific temperature management.

Poka-yoke

Part presence, orientation, variant, insert, fixture and tool verification.

Traceability

Barcode/QR/RFID, cycle-result storage and customer-defined data fields as an option.

Inspection

Vision, displacement, force, leak, pressure, flow or dimensional checks according to the CTQ plan.

Line communication

Signals or industrial network interface; MES connection only when explicitly included.

Safety

Interlocked guarding, safety doors/light curtains, emergency stops and safe reset concept to destination requirements.

Service package

Training, recommended spares, preventive-maintenance plan, remote support and optional on-site support.

Acceptance activity

Typical evidence

Documented scope review

Approved specification, layout, utilities, interfaces, cycle definition and exclusions.

Tool and datum verification

Part location, clamp support, tool identity and changeover checks.

Process-window trials

Representative production parts across agreed material and dimensional variation.

Quality checks

Agreed visual, dimensional, strength, leak, burst or functional test with defined limits.

Repeatability run

Quantity, run duration, operator conditions and acceptance method agreed before FAT.

Safety validation

Guarding, interlocks, emergency stops, reset behavior and maintenance access.

Data and alarm test

Recipes, access levels, pass/fail windows, alarms, identifiers and interface signals.

Training and handover

Operation, changeover, maintenance, backup/restore and agreed documentation.

Stage

Main input or activity

Output / decision

1. Application review

Parts, materials, joint, CTQs, takt and plant standards

Feasibility risks and missing inputs

2. Concept and quotation

Process choice, layout, tooling, controls, interfaces and exclusions

Approved technical and commercial scope

3. Trials and samples

Production-equivalent parts and agreed test method

Process window and sample evidence

4. Detailed engineering

3D design, risk review, I/O, safety and documentation plan

Customer design approval

5. Build and debug

Machine, tooling, programs and internal run-off

Ready-for-FAT review

6. FAT

Agreed parts, run quantity, quality checks, takt and documents

Punch list and shipment release

7. Installation and SAT

Utilities, setup, training and site acceptance run

Production handover by agreed scope

Please provide

Why it is needed

Tank and mating-part 3D data

Used to check envelope, datums, access, tooling and machine layout.

Exact resin grades and fluid exposure

Required for process feasibility and a grade-level trial plan.

Seam drawing and flash allowance

Used to check envelope, datums, access, tooling and machine layout.

Leak/burst test method and limits

Defines measurable trial, FAT and SAT acceptance criteria.

CTQ dimensions and post-weld distortion limit

Required to complete the technical concept and remove quotation assumptions.

Takt, variants and annual volume

Used to size stations, automation, changeover and capacity.

Question

Answer

Can the machine guarantee a leak-tight tank?

Leak performance depends on material, molding, joint design and the validated process. The agreed leak or burst test must be passed on representative production parts.

Can a leak tester be integrated?

Yes. Test pressure, stabilization time, volume, limit, reject handling and data association must be specified.

Is servo motion always required?

No. A pneumatic platform may be sufficient for a stable process. Servo motion is selected when position profiles, collapse monitoring or recipe flexibility add value.

Can the system be used for fuel components?

Potentially, but only after a formal review of the exact resin, fluid exposure, ventilation, safety and customer compliance requirements.

What information is required for an application review?

Please send part 3D data and drawings, exact resin grades, joint or stake details, production-equivalent samples if available, CTQ and test requirements, takt, annual volume, variant mix, utilities and plant standards.

Can Dizo Sonics test our real parts before quotation?

Yes. An application review and representative-part trials are recommended when feasibility, tooling concept or cycle assumptions need evidence. Trial scope, sample quantity and test method are agreed before testing.

How is the final cycle time confirmed?

The committed cycle is based on trials and a complete sequence study including loading, clamping, joining, cooling, inspection, data handling and unloading. Published reference cycles are not universal guarantees.

Which plastic materials can be processed?

Suitability is approved at exact-grade level. Resin chemistry, fillers, moisture, additives, color, recycled content, molded-part variation and joint design can all change the process window.

What documents are supplied with the machine?

The project handover package can include the approved specification and layout, electrical and pneumatic documentation, manuals, maintenance plan, spare-parts list, parameter backup, inspection records and FAT documents according to the contract.

Do you support FAT, installation and SAT?

Yes. FAT and SAT activities are defined in the project plan. Installation, training and on-site support depend on destination, responsibility split and the commercial scope.