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Standard RF Welders Just Became Obsolete

Problem 1: Validation Takes Too Long

One of the greatest problems managers face in the medical industry is validation. Production comes to a standstill as engineers try to validate a product, the lack of precision and process control can significantly drive up operating costs or even worse delay the product lunch date.

ONEX RF's Solution

Processes are controlled by our unique computerized controls system. ONEX RF systems are easily validated for all medical applications. By inputting the desired parameters, operators complete validation in a fraction of the time required by traditional machines -- about half the validation time, and with 50-75% less material use.

Problem 2: Arcing

Arcing problems can cost manufacturers hundreds of thousands of dollars in the lifespan of a machine. Arcing destroys film, burns dies, creates work stoppages, and shuts down production. Many manufacturers accept the costs associated with RF arcing as part of doing business. They don’t realize that we have effectively eliminated arcing and all associated costs.

ONEX RF Solution

We use 5 VDC logic to detect slightest current rush when an arc occurs and shut down the output. The older systems use 50 VDC and generate negative 1000 volts to direct the energy path to ground which is switched by a mechanical relay. Obviously TTL logic is much faster than any mechanical relay plus it directly interrupts the output power preventing power discharge through the die. All ONEX RF sealers in the field have been running over 10,000 hours without any die damage. No more die repairs or film waste. More productivity – ONEX RF welders have a dramatic impact on production and profitability.

Problem 3: Limited Controls – “Black Magic”

Operators traditionally have accomplished their tasks by trial and error. Over time they're able to gradually waste less film. They learn to tune the machine manually by memory using the “best guess” theory about what will work. Why some welds were successful and some welds were unsuccessful is a complete mystery to the operator. They commonly referred to this as “Black Magic.”

ONEX RF Automation Solution

We replace the lack of precision and automation in standard machines with our exclusive process monitoring software and control system. There is no guesswork, and no black magic. The controller inputs the appropriate set points and monitors displaying the RF sealing power graph, which helps to visually see the entire cycle then compare with other cycles during validation. We replace mystery and black magic with quantifiable, reliable, and accurate systems.

Problem 4: Poor Repeatability

Traditional machines have extremely poor reproducibility rates. They have arcing problems. They are difficult to tune. They have uneven power. They can destroy up to 50% or more of the film they weld. Combine the outdated machines with human error, and it’s no wonder that reproducibility rates are so low.

ONEX RF Automation Solution

Process variations caused by the indexing dial and press deflection have been addressed and eliminated. The entire welding process can be tuned and retained in the system’s memory. When the system has an even energy flow and precise parameters, there is no more guesswork in the process. ONEX RF welders can exceed 95% reproducibility.

Problem 5: Slow Changeovers

Changeovers can drastically decrease productivity. After installing the dies, old rf sealers require the operator to manually set up the process parameters, which  is ineffective, unreliable, and tedious.

ONEX RF Automation Solution

The touch screen and software-based controls enable you to complete changeovers in a fraction of the time. Simply input the new process parameters, and validate the new process. With ONEX RF, changeovers are done in a flash.

Problem 6: Unreliable, Outdated Power Source

Can you believe that most RF welders are still powered by vacuum tube technology, similar to old transistor radios? The result is a highly variable, unreliable power that leads to poor performance, reproducibility, and high rate of arcing-related incidents.

ONEX RF Automation Solution

Replace the old vacuum tube power source with a cutting edge Solid State RF Generator. The solid state generator uses up to 50% less energy, which saves you money and increases profitability. The solid state generator delivers a precise, reliable energy that virtually eliminates arcing, reduces problems with uneven welds, and alleviates many other problems that often result in down time, burned dies, and decreased productivity.

Problem 7: Burned RF Dies

When a machine arcs, the die either requires cleaning, major repair or full replacement. The repair or a new die can cost up to $10,000. The work stoppages causing machine idle time  and damaged products also increase the headen costs dramatically, thousands of dollars that could be saved are now gone forever. The cost of doing business with old machines can compromise your position in the industry.

ONEX RF Automation Solution

The state of the art ONEX RF Automation machines can eliminate arcing and keep the “burned die replacement” money in your pocket.

Call Us to Find Out What
A Better RF Welder Can Do For You!
1 (626) 358-6639