An automated integrated solution for the heat sealing of the air bag inside the air massager

To address the automated integration requirements of heat sealing for the inner bladder air bags in air massagers, and combining high-frequency welding technology with the properties of medical-grade materials, the following solution is proposed:

I. Core Equipment Selection

High-Frequency Heat Sealing Machine Configuration: A 15KW high-frequency output machine (oscillating tube 8T85RB) is recommended, supporting both hydraulic and pneumatic pressurization modes. The platen size can be customized up to 400*600mm to meet the mass production needs of TPU air bags.

Automatic Turntable System: An integrated four-station turntable design enables continuous operation from loading to welding to unloading to quality inspection. The single cycle time can be reduced to 8-12 seconds, improving efficiency by 60% compared to traditional methods.

II. Process Parameter Optimization

Welding Parameter Combination

High Frequency: 27.12MHz
Mold Temperature: 80-100℃ (TPU material)
Welding Pressure: 0.3-0.5MPa
Pressure Holding Time: 3-5 seconds

Material Pretreatment
Medical-grade TPU film (Shore hardness 85A-95A) is used. Plasma treatment (300W, 30 seconds) is required before welding to improve weld strength.

III. Automated Integration Solution

Vision Positioning System
Equipped with a 5-megapixel industrial camera, achieving ±0.1mm accuracy positioning of the air bag, compatible with rapid switching between multiple mold specifications.

Quality Inspection Module
Integrates an airtightness tester (detection accuracy 0.01ml/min) and a tensile testing machine (ASTM D1876 standard) to achieve 100% online inspection.

IV. Production Data Management

MES System Integration
Supports OPC UA protocol, real-time acquisition of key parameters such as welding temperature, pressure, and time, and generation of SPC analysis reports. Self-diagnosis of faults: Built-in 5557 American-style spark protection system automatically shuts down and sends an alarm code to the central control screen in case of an anomaly.

Note: For actual deployment, it is recommended to conduct small-batch trial production first, focusing on verifying the matching between the turntable cycle time and welding quality. Medical-grade products must additionally comply with ISO 13485 system requirements.