Problem Statement
The goal of this project was to develop a bench-top machine to bond layers of a stent graft at a controlled temperature. This machine was to accommodate multiple sizes of stent grafts by means of using interchangeable configuration- specific components while simultaneously providing features to prevent component mismatch. The client required extensive recipe functionality, high machine throughput, and the robustness of commercial production line machinery.
Solution & Results
CKC Engineering developed a turn-key custom heating system to apply heat evenly over the circumference of the client’s product. To accommodate the client’s continuing product development, regular design review meetings with the client ensured the final machine matched their needs. The heater is comprised of a pneumatic clamp with embedded cartridge heaters and RTDs for closed loop temperature control. A pneumatic slide allows the operator to safely load the stent graft into the heaters operating at temperatures as high as 400⁰ C with a push of a button. The heater is contained within a locking enclosure to protect the operator and prevent premature removal of the work part. In addition, two air knives blow cool air over the part at the end of a bond cycle with the operator door interlocked until the part reaches a safe temperature. A HMI touchscreen allows operators to select pre-defined heating recipes depending on the product to be bonded. Engineers can also use the touchscreen to develop and program heating recipes with a password protected login. Sensors were used to distinguish between different sets of change parts and different product sizes, to verify that the installed components match the selected recipe.
The design challenge became insulating the heater elements from the pneumatic actuator to prevent damage to the seals. This was accomplished by using a combination of ceramic plates designed through heat transfer analysis and minimal fasteners.
The resulting machine improved the client's cycle time by 6X and is capable of bonding parts at temperatures as high as 400⁰ C. The machine is configurable to accommodate different sizes of parts via interchangeable heater jaws and is equipped with alarms to detect component mismatch. CKC’s design met all client requirements and has been depolyed in a GMP manufacturing environment.
The design challenge became insulating the heater elements from the pneumatic actuator to prevent damage to the seals. This was accomplished by using a combination of ceramic plates designed through heat transfer analysis and minimal fasteners.
The resulting machine improved the client's cycle time by 6X and is capable of bonding parts at temperatures as high as 400⁰ C. The machine is configurable to accommodate different sizes of parts via interchangeable heater jaws and is equipped with alarms to detect component mismatch. CKC’s design met all client requirements and has been depolyed in a GMP manufacturing environment.
