Filter end cap welding case-machines line for making pleated filters with 7 types of end caps of 69-70mm filter and high flow filters(04)

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Author : indrofiltermachine.com
Update time : 2024-04-08 14:18:02
Filter end cap welding case-machines line for making pleated filters with 7 types of end caps of 69-70mm filter and high flow filters with 11 types of end caps-Part 04
 
On Oct 26th 2023, we wrote part 01 of this case.
Filter end cap welding case-machines line for making pleated filters with 7 types of end caps of 69-70mm filter and high flow filters with 11 types of end caps-Part 01
 
On Feb 23rd 2024, we wrote part 02 of this case.
Filter end cap welding case-machines line for making pleated filters with 7 types of end caps of 69-70mm filter and high flow filters with 11 types of end caps-Part 02
 
On March 9th 2024, we wrote part 03 of this case.
Filter end cap welding case-machines line for making pleated filters with 7 types of end caps of 69-70mm filter and high flow filters with 11 types of end caps-Part 03
 
It is Monday today, after holiday from April 4 to 6, we finally have time to continue with update the blog of this case.
 
Because I have been busy with a new project recently - the production of a high flow production line for a European client.
Although, related works of machines operation videos and manual books were finished on time, our blog of update about videos was delayed by a few days.
Thanks again for your waiting.
 
Today, we are releasing some videos of the pleated filter cartridges making equipment line.
We will start with a video of the production equipment for high flow filter cartridges, followed by a video of the production equipment for small filter cartridges.
We will release the videos according to the production process sequence of the filter element. And the training was also conducted in this way.
 
Videos of high flow filters making machines line
Half finished filters with pleats packs were prepared by customer themselves, so we ignored the pleat making process and started with the pleats pack middle seam welding.
 
We taught customers how to make 20inch high flow filter, how to make 40inch high flow filters and how to make 60inch high flow filters, and how to make high flow filters with outer wrap. Their production processes are almost same, but the detailed processes are a little different.
 
Let us take a 60inch high flow pleated filter cartridge for example.
 1st, pleat packs middle seam welding, use SIIC-M025-MSW-P to do pp membrane pleats pack middle seam welding and use SIIC-M025-MSW-H to do PES/PVDF/PTFE middle seam welding. Because customers time is limited, and this process is simple, we did not spend so long time on it.


 

2nd, high flow filters connector welding, use SIIC-M028-LJW to do cage/core length connector welding.
 


3rd, do pleats pack installation. Insert the seamed pleats pack into PP outer cage of filter manually. This requires more practice for new fresh workers. Because customers time is limited, we just spent less time on this step and start next process.
 
4th, filter pleats cutting, pleas packs edges trimming off, use SIIC-M028-LC to do cutting or trimming off of pleat packs.
 

5th, use above steps to make one 20inch high flow filter module and one 40inch high flow pleated filter module without end caps.
 

6th, welding end caps of 20inch high flow filter and 40inch high flow filters. There are several options here.
Option-1, weld one outlet end cap onto 20inch filter, remember just weld one end, and keep the other end empty. And weld end caps onto both ends of 40inch filter (weld the inlet end cap onto one end of filter and the connector end cap onto the other end of filter).
Option-2, weld one outlet end cap onto 40inch filter, remember just weld one end, and keep the other end empty. And weld end caps onto both ends of 20inch filter (weld the inlet end cap onto one end of filter and the connector end cap onto the other end of filter).
Either option is working. Above processes were done by high filter end cap infrared welder SIIC-M028-ECWH-IR-S.




7th, do connector welding of high flow filters with welder SIIC-M028-LJW. Connect above 20inch filter and 40inch filter to get one piece of 60inch filter. Till now one complete piece of 60inch filter was ready.
 


Videos of high flow filters with outer wrap making machines line.
The processes of making high flow filters with outer wrap (outer belt or band) is almost same, making pleats, do filter pleats cutting, do end cap welding and length connector welding. The main difference is high flow filters with outer wrap need additional process of spiral winding belt onto filter. So then for training of production of high flow filters with outer wraps, we focused on training of the belt spiral winding operation of SIIC-M028-BSW.

 
 

Videos of small diameters pleated filter cartridges making machines line:
Similarly, in order to save time, we ignored the first step of cartridge filter production-making pleats.
1st, middle seam welding, use SIIC-M025-MSW-PP and SIIC-M025-MSW-H to do middle seaming of pleat packs which are made of PP/fiberglass/PTFE/PVDF/PTFE/Nylon membrane and pp support layers. Here, we would like to share more. Middle seamer solutions depend on exact filters media materials and filter dimensions. We custom make as per details of filters from customers. For example, when you filter pleats packs layers number is too high, special solutions are necessary. Or when your single filter length is not the common 10inch, then special solution is necessary. Our experience in the filtering industry has helped us provide customers with the most suitable solutions, not the most expensive.
 
2nd, filter cutting, use SIIC-M025-LC to do filter pleats pack cutting or edges trimming off. We have customized different cutting schemes for different customers before. We still need to emphasize that the most suitable is the best, not the most expensive is the best.
 

Here, let's take a moment to share a small case.
A friend of many years, he purchased a pleated machine through his long-term partners three years ago and was recommended by the manufacturer to be equipped with automatic cutting. The equipment has been in their factory for over a year, but the automatic cutting function has never been used. There are two reasons. Firstly, the pleating machine manufacturer does not have any experience in producing water filtration microporous membrane pleated filter cartridges, but only has experience in dust collector filter cartridges. The recommended solution for him is not entirely suitable. Secondly, due to some special reasons, on the one hand, this friend wants to save money, and on the other hand, his long-term partner was unwilling for him to directly contact the manufacturer and have not arranged for him to come to China for training. And his partner certainly does not have the ability to make detailed equipment manuals on their own, and the supplier they have chosen also does not have the ability to produce detailed equipment manuals.
For various reasons, although the pleating machine was ok, he was dissatisfied with the equipment of this cutting machine, wasting money and time.
The cutting of filter cartridges may seem like a relatively simple process, but it also requires experience and expertise to provide a perfect and suitable solution.
 
We would like to share more about this automatic cutting.
Four years ago, one of our old brand customers wanted to increase the production capacity of filter cartridges. We help them introduce automatic cutting into the pleating process, which involves automatic online cutting during pleating.
We have conducted multiple experiments and tested and verified with different cartridge filter manufacturers. Finally, we found a reasonable cutting plan and formed a drawing. We became the first designer of online cutting for microporous membrane pleated filter cartridges.
We once shared the first generation of automatic cutting drawings with a pleating machine manufacturer.
In the following years, this online cutting solution was imitated and replicated by multiple pleating machine manufacturers.
As long as you purchase an origami machine, irresponsible manufacturers or less professional ones have a 97% chance of recommending automatic cutting to you, without first knowing what kind of filter element you want to produce. Not all filters are suitable for automatic online cutting. Different filter cartridges require completely different cutting schemes due to their different details and specifications.
 
3rd, pleated filter cartridge basic end cap welding, use SIIC-M025-EWCH-IR-S to do basic end cap welding of 10inch filter modules. Weld 4 caps from both ends in each circle (2 caps on each end)

 

4th process and 5th process are the cartridge filter length connector welding and adaptors welding. Customers selected to use infrared welding system as well for these two welding processes. The items selected were SIIC-M025-LJWH-IR-S and SIIC-M025-EW-IR-S.
We just planned to update the welding system of some machines models since this April for all new customers. Compared with old welding system, new welding system is with better stability while its cost is higher. There is no best, only better, we invest funds and manpower every year to continuously research new welding technologies for filter cartridges. After verification, once the filter cartridges are successfully produced and the conditions are mature, we will update the equipment periodically every 1 to 2 years.
 
And these two models SIIC-M025-LJWH-IR-S and SIIC-M025-EW-IR-S are just within the planned updated range.
Because the machines models purchased by customer were just ready there in our workshop, and after obtaining the customer's consent, we spent 3 days to finish the free upgrades for these two machines without any additional cost. The customer felt our dedication and professionalism, they were satisfied. Because we will be busy with some other urgent cases, the machines in urgent case will be shipped in next 1-2 weeks, the updated videos of SIIC-M025-LJWH-IR-S infrared length connector welding and SIIC-M025-EW-IR-S filter adaptor infrared welding will be released in a few days.