You won’t surprise anyone with stretch ceilings for a long time, but not everyone knows that their production is consistent and quite difficult process, the execution of which without specialized equipment It's simply impossible. IN in this case, this is a soldering machine suspended ceilings.
Welding PVC films is produced by high-frequency current - hence the name “High-frequency machine”. The instructions in this article will introduce you in general terms to soldering technology.
Your attention will also be offered a video on the topic: “Machine for suspended ceilings.”
What is a HDTV machine
High-frequency film soldering is considered today the most in a quality way connections of polyvinide chloride fabrics. In this case, the seams are not only sealed, but also practically invisible.
Creating a strong welded joint is the main requirement for HDTV machines:
- The essence of the soldering method is this: the edges of the film being welded are quickly heated, and their fusion is carried out at the molecular level. Since the heating is spot-based, the material itself does not heat up, which means it is impossible to spoil it.
- The machine consists of two main elements. This is a welding press and a generator, the power of which should be determined by the size of the blades being connected. In the place where the soldering will be done, the material is clamped with a press.
- Since the machine is electric, it has devices and components that prevent accidental damage to the material. They also ensure the safety of the equipment as a whole. One of them is a device that suppresses the occurrence of an electric arc, which poses a danger not only to the material, but also to the electrode.
All HDTV machines are equipped with magnetic diffusers that suppress interference created by electromagnetic radiation and interfere with the work of others. electrical appliances. In fact, the surrounding working space carefully screened.
And, of course, it is impossible to do without a fuse. A special relay protects the machine from power surges.
Electrodes for PVC welding
As with any welding, electrodes are also used here, only special type. They look like a flat metal ruler, one edge of which is clamped in the press, and the second acts on the material being welded.
Take a look at the photo below - you can clearly see how this happens: the edges of the film are aligned, and the red line shows where the seam will go.
- Electrodes for high-frequency welding are made of aluminum, brass or steel. Depending on the thickness of the fabric, they may have different designs and size. Their peculiarity is that they not only heat the seam, transferring press pressure and current to the material being welded, but also cool it after soldering.
- It is very convenient that the fabric to be welded can be positioned to the electrode at any angle. This makes it possible to minimize the amount of material waste and work defects. By applying the fabric successively to the capacitor lining (the second name for the electrode), you can get a long seam.
But not every polymer material lends itself well this species welding The higher the polyvinyl chloride content, the better. Its minimum content in fabric is 30%.
Materials containing polyester, polyethylene and polypropylene are not suitable for HDTV welding.
Process of working on the machine
The HDTV machines themselves are quite simple and reliable to operate. They have two types of drives: foot or pneumatic.
They can be programmed to perform multiple operations. The duration is also adjustable welding process and press pressure, and all this is done using the control unit.
- Automation allows you to speed up work, create a canvas of any size, and also make do with a minimum number of personnel - that is, one operator. Having such equipment, making a suspended ceiling with your own hands is not at all difficult.
- This is what many private traders take advantage of, providing these services to the public. They purchase a used HDTV machine for suspended ceilings and start their own business. The price of the ceiling in this case will be lower than in specialized companies, but it is not a fact that the quality will be at the same level.
Welding methods
In principle, the method of welding PVC film can be not only spot welding, but also roller welding. It looks like this: two rotating disks evenly move the material, increasing pressure and temperature.
The appearance of the weld may differ significantly, but this does not affect the quality of the connection in any way.
- There is also a press welding method, which is considered universal. This method can be used to solder not only end-to-end, but also overlapping, or gusset. The type of seam depends on the thickness and quality of the material being welded, as well as the expected loads during its operation.
- The main load in a suspended ceiling is its own weight, which large area the premises can be quite significant. The thickness of the seam has a great influence on its mechanical strength. It should not be too thin, or, conversely, stand out in relief. To prevent this from happening, the electrodes must be selected correctly.
- By the way, tension fabrics are welded not only when their width is not enough for the entire room, but also for the purpose. Thus, its design is often carried out, one of the options of which we see in the picture above.
In this case, two types of fabric are welded, differing not only in color, but also in surface texture: one is glossy, the other is matte. This way you can make a rainbow, a chessboard, or a geometric pattern made up of triangles.
It turns out very beautifully, the main thing is that the welding quality is excellent.
Stretch ceiling structures made from synthetic materials (polyvinyl chloride) look impressive and last a long time. They have a long service life.
The material comes from the manufacturer in rolls. The length of the skein is no more than three meters. Much more is needed to cover the ceiling. Companies that install suspended ceilings are forced to lengthen synthetic material using special HDTV machines. The equipment welds the film using high frequency current. That's why the machine is called that.
The equipment is expensive not only because it is purchased imported, but also due to its electronic and technical content. The work is practically automated. But in practice, the HDTV machine is serviced by two people - an operator and an assistant.
How does a high-frequency machine for making suspended ceilings work?
When processing synthetic stretch ceiling material, we obtain a final product suitable for use. The junction cannot be detected even with the naked eye. The joining of the film sides occurs so imperceptibly. The strength of the manufactured ceiling canvas is ideal. High frequency electricity does its job at a high quality level. During the soldering process, the polyvinyl chloride fabric is heated to the required temperature and welded. The connection mode is set by the operator directly on the machine using the control panel.It is worth noting that there is a lot of equipment for welding PVC film, but the HDTV machine remains unsurpassed in this matter in many respects. It has in its design:
- Control block;
- movable body;
- fixed bed;
- pneumatic unit;
- electrode welding unit.
Highly productive equipment. The HDTV machine is capable of performing a large amount of work per shift. The process can be programmed, making it easier for the operator to complete the task. The high-frequency machine is universal. It is easy to produce synthetic film of any metric size.
What is the use of HDTV in industry?
Using a high-frequency machine it is easy to “weave” synthetic fabric. No problem to get ceiling covering For large areas. Setting up the equipment is simple. By setting the automatic film sealing mode, you can significantly increase the productivity of the machine. This is helped by the control unit, with which it is easy to provide unique automatic configuration of the equipment.
- Low financial costs of the production process.
- Good profitability. The payback of the HDTV machine occurs within a year. At some enterprises, the return of the funds spent occurs in a shorter period of time.
- The ease of production of suspended ceilings, their high quality, consistently high demand.
As a result, workshops for the production of seamless synthetic stretch ceilings are not only being built, but are being successfully developed. For companies involved in the production of suspended ceilings from synthetic films, the HDTV machine is a real find. It is easy to put the business on an industrial basis and make a profit.
Structural composition of the machine
Considering other advantages of HDTV equipment, it is necessary to note its safety. The machine is equipped with a system for suppressing the occurrence of an electric arc, since its occurrence between the electrodes is an extremely undesirable phenomenon that can catastrophically damage the synthetic film. Electronic circuit, integrated into the control unit, when a rudimentary spark appears, automatically reduces the HDTV power.
The machine is protected from interference. The equipment is equipped with devices that suppress magnetic scattering. There are clamps for high electrical frequencies. HDTV equipment is shielded from other machines and systems.
The installed electric current relay will turn off the equipment in the event of a sudden increase in voltage or minimize its impact on the operation of the machine.
The workplace of the operator and his assistant is free. Nothing prevents the production of finished products. This is one of the dominant features of the design of the HDTV machine. It is open for maintenance and there are no hard-to-reach areas for minor or major repairs.
The aesthetics of the HDTV machine are excellent. There are no sharp corners, the protection of dangerous components is made according to European patterns and remains unsurpassed today.
What is the productivity of HDTV machines?
Manufacturers of high-frequency equipment design and build machines with high productivity rates. HDTV machines are intended for use in industrial scale. Their performance is fully consistent with a priori goals. The fact is that such machines not only weld suspended ceilings, but they are used for mass production:
- souvenir cosmetic bags;
- telephone cards;
- goods for office supplies;
- various covers;
- albums;
- tents (welding);
- welding of containment booms when oil and its products spread on water;
- manufacturing upholstery material for bicycle seats and so on.
As you can see, the range of uses of HDTV machines is wide. No one would risk creating innovative equipment just for welding suspended ceilings. Based on the above, the equipment performance is high. The uniqueness of HDTV machines is that when switching production from one type of product to another, there is no need to re-equip the equipment. This also increases the productivity of the machines.
How to use the machine?
Provide quality work the machine is capable of an operator trained for this task. The person undergoes special training. Knowledge of all technological switchings, compliance with the rules of operation of the machine, ensures productive work equipment. To put the machine into operation it is necessary;
- connect electric current to it;
- provide workplace operator with the necessary source material;
- put the machine into operation by setting the necessary options on the control panel;
- have time to place synthetic material under the welded unit.
- Remove and package finished products.
For productive use of equipment, the listed manipulations are sufficient to complete the production task.
After finishing work, the operator must clean the machine from residual welded material and turn off the power.
What is the operating principle of the HDTV machine for suspended ceilings?
In order to use high-frequency welding equipment productively and for a long time, you need to know the principle of its operation. And it is based on a unique method of heating material surfaces. That is, on dielectric heating of a synthetic film that does not conduct electric current one hundred percent. A special machine unit welds the sides of the prepared material, ensuring a seamless connection. Side welding is performed with or without filler material.
Seamless connection of the sides of the canvas occurs in the thermal environment created by the capacitor plates (electrodes). The capacitor is integrated into the oscillating mechanism of the generator, which produces RF. Electrodes are not only elements for supplying current, but also perform the function of pressing the sides of the material, standard cooling of the canvas for suspended ceilings.
note
Synthetic film material can be welded at a dielectric loss factor of 0.1. Such materials include:
- polyvinyl chloride;
- polyurethane and so on.
You can use various electrodes on the machine, depending on the thickness of the material being welded. The functionality of the HDTV machine is such that it is possible to create manipulations depending on the electrodes used. This creates conditions for adjusting the length of the working area.
Using HDTV machines, companies solve many production problems. They increase financial solvency, provide people with services and products that are always liquid.
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Unified Tariff and Qualification Directory of Works and Professions of Workers (UTKS), 2019
Part No. 2 of Issue No. 41 ETKS
The issue was approved by Resolution of the Ministry of Labor of the Russian Federation dated May 28, 2002 N 37
(As amended by Order of the Ministry of Health and Social Development of the Russian Federation dated November 11, 2008 N 640)
HDTV installation operator
§ 116. HDTV installation operator of the 4th category
Characteristics of work. Maintenance of the HDTV installation in accordance with the specified technological regime. Laying, heating, pressing, cooling and unloading glass products. Participation in installation, unloading of the pot and casting of glass melt on the casting table. Maintenance of electrical equipment of the site. Repair of main components of HDTV installation. Monitoring the operation of control and measuring instruments. Selection of generator mode. Accounting for plant loading and glass products output.
Must know: device, circuit and rules for controlling the HDTV installation; mode of heating and pressing of glass products, switching circuit of measuring instruments and limit values of their readings; types of marriage and measures to prevent it.
Comments on the profession
The given tariff and qualification characteristics of the profession “ HDTV installation operator» serve for billing of works and assignment tariff categories according to article 143 Labor Code Russian Federation. Based on the above job characteristics and the requirements for professional knowledge and skills, a job description for an HDTV installation operator is drawn up, as well as documents required for interviews and testing when hiring. When drawing up work (job) instructions, pay attention to general provisions and recommendations for this release of ETKS (see.
Stretch ceiling structures made from polyvinyl chloride films have excellent appearance, confirmed by the photos on the site, and excellent performance characteristics. At the same time, rolls of material do not exceed three meters, so there is a need to connect strips of fabric into a single surface. For this purpose, companies specializing in production and installation tension systems, have special equipment at their disposal. Welding of sheets is carried out with high-frequency current, for which high-frequency machines for suspended ceilings are used.
Design and performance of HDTV machines
Equipment for creation stretch fabrics allows you to obtain an almost invisible seam at the junction of the strips of material. In terms of strength, it does not differ from the entire section. The edges of the welded sections of material are heated and joined under the influence of high-frequency current, and after they cool, an even and very strong seam is formed, which is almost invisible.
Among the equipment intended for PVC manufacturing films, high-frequency machines for suspended ceilings with a movable body and a pneumatic drive stand out. They are capable of processing a large number of products per work shift. This modern equipment can be programmed and thus the work of the operator working on such a machine is greatly simplified.
The HDTV machine for suspended ceilings allows you to produce fabric of almost any size, including very large ones ceiling structures. At the same time, the ease of setting up the equipment and performing most of the welding process in automatic mode makes it possible to save time and increase operator productivity.
The HDTV machine for the production of tension fabrics consists of the following main components:
- Control block. Ensures the operation of the equipment and allows flexible configuration of the machine to operate in automatic mode.
- Electric arc suppression device. Its formation is undesirable and can damage the material for making the tension fabric and the working welding electrode. Specially provided electrical diagram, available in the machine, at the slightest sign of sparks, automatically reduces the power in the HDTV generator and thus prevents the formation of an electric arc, dangerous for the blade and electrode.
- Interference Suppressor. The HDTV machine for suspended ceilings must be equipped with a magnetic dispersion suppressor and high frequency stabilizers, which are necessary to prevent the possibility of leakage electromagnetic radiation, which cause harm and interfere with the operation of other electrical appliances operating in the same production premises. The operating principle of this part of the machine is to shield the surrounding working space.
- Safety mechanism. Since power surges can occur in the electrical networks supplying a workshop, there is a need to protect machine tools from this adverse effect. The current relay provided in the equipment will protect the power supply, welding device and generator lamp.
Operating principle of HDTV machines
In the HDTV production workshop, the machine for suspended ceilings is serviced by one operator, who is trained to work on it. The operating principle of equipment for connecting tension fabrics is based on dielectric heating of the fabrics prepared for welding. In this case, the process can be performed with or without filler material.
The advantage of using an additive is high speed welding performance, uniformity and the ability to selectively supply heat. Soldering is done between metal electrodes - they are also called capacitor plates; it is included in the oscillatory circuit of a lamp generator tuned to a high frequency. Electrodes are required not only to supply electricity to the joint, but also to apply pressure to the web and to cool the surface of the material. The seam between the capacitor plates can be completely welded in just one operation. Serial connection Using a rectangular electrode, long seams are formed.
The machine for suspended ceilings allows you to get almost invisible seams, regardless of whether the components of the fabric were the same color or different. Welding using high frequency current is performed with polymer materials, whose dielectric loss coefficient is more than 0.01. These include polyurethane, polyvinyl chloride and others.
If materials that have a lower coefficient are joined, contact-dielectric welding is used, during which one of the above-mentioned polymers must be applied to the electrodes, resulting in overlapping or T-shaped seams. To perform butt welding, circuits with one-sided or two-sided arrangement of metal electrodes are used. The flexible setting of the HDTV machine allows you to adjust the distance in the working area depending on the type of electrode used.
The technology for welding sheets for suspended ceilings on HDTV machines involves the use of different electrodes depending on the thickness of the PVC film. The fabric produced using such equipment is reliable and retains its original aesthetic characteristics after completion of the welding process.
HDTV machine for the production of suspended ceilings, look at the video:
The HDTV machine is also used in practice for the production of airbags installed in cars, beach bags, stationery, some types of shoes, and rain and sun umbrellas.
