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Web Processing Solutions from Aspect Automation |
Every web processing project is unique, with numerous variables to consider — web width and thickness, material type, web speed and alignment. Aspect Automation examines every project with an eye toward innovative solutions. We leverage our core competencies to provide our customers robust, cost-effective web processing equipment designed to each project’s unique specifications. Our expertise covers a broad range of materials and processes, including die cutting, laminating, island placement, heat-sealing, and precise tension-control. We have extensive experience with extreme tolerance specifications and web widths ranging from 1 to 60 inches wide. Our unparalleled record of collaboration and dedication to remaining at the forefront of technology make Aspect Automation the ideal partner for any web processing project. |
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Web Processing Example System 1 Three polystyrene webs and one coated membrane web were die cut and ultrasonically welded together with a part repeat of approximately 1 inch. Final product was inserted into cartridges, then individually labeled and barcoded in a system producing 1,000 ppm. Aspect Automation was the ideal partner for this client because of our ability to integrate multiple components, our expertise with validation support utilizing GAMP 4, our experience with 21 CFR Part 11 compliance issues, and our use of leading-edge control systems. Key technologies included integration of 54 servo axes and 15 PLCs, continuous motion ultrasonic welding, and SQL database collection capable of tracking 400 MB of data per day. |
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Web Processing Example System 2 Battery cathode material was extruded into a web 3.5 inches wide by 0.030 inches thick. Material was cut, placed, and calendared multiple times before achieving desired thickness. Aspect Automation understood the need for process development prior to design of commercial equipment for this project, and was able to provide calendaring precision with TIR of less than 0.0002 inches. Our expertise at handling fragile webs (0.002 inches thick) further helped ensure success. Key technologies included calendaring rollers repeatable to 0.0001 inches, real-time gap measurement and calibration within 0.0001 inches, and matched servo gearing within 0.25% of set point. |
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Web Processing Example System 3 Three webs — a carrier web, black anode material, and a cellophane separator — traveled at different rates of speed before joining to form a composite web. The anode and cellophane materials were slit, rotary die cut, island-placed onto the carrier web, and hermetically sealed with a line speed of 160 ft/min (2,560 pcs/min). A vision inspection system determined product quality and monitored process trending. Aspect Automation offered the perfect blend of technology and expertise for the numerous process characteristics of this application. Key technologies included island placement within +/- 0.005 inches, hermetic sealing, web cleaning, rotary die cutting, and high speed servo controls. |
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