TPT March 2025

ARTICLE

Thermatool Corp

Thermatool’s development of quad contact assemblies (Figure 4) has significantly enhanced electrical performance by allowing higher power levels. These advanced assemblies can withstand increased downforce pressures, which allows them to maintain optimal contact even under demanding conditions. As a result of these improvements, the incidence of arcing – an undesirable electrical discharge that can lead to damage and inefficiency – is greatly reduced. This combination of higher power capacity and lower arcing contributes to more reliable and efficient operation in various applications. Advanced sensors Thermatool’s next-generation XPERT™ HF welders are available in a contact

Figure 4: HF quad contact assembly

welding configuration, engineered with advanced sensors and IIoT connectivity, setting high standards in weld quality and operational uptime. Equipped with an integrated sensor suite, these welders deliver precise real-time monitoring and diagnostics, including temperature trending, load analysis and comprehensive subsystem status reporting. This capability empowers operators to make real-time adjustments during the welding process, enhancing weld integrity, supporting predictive maintenance and minimising unplanned downtime to maximise equipment longevity. Additionally, Thermatool’s service team can access this data remotely upon request, ensuring faster issue resolution and reducing downtime. The Thermatool+ Customer portal complements the IIoT connected XPERT™ welders with an array of advanced features. For instance, condition-cased monitoring alerts are triggered instantly when fault conditions, abnormal trends or deviations in load values are detected. Subscribers to the WeldMetric™ IoT service gain unparalleled insights by benchmarking their mass flow data against industry standards, enabling mill managers to optimise process efficiency and unlock insights previously unattainable. Conclusions As modern HF welding equipment becomes more versatile, it can handle a wider range of materials and thicknesses. This flexibility allows manufacturers to address a broader spectrum of applications and more easily adapt to changing production needs. These trends indicate a dynamic future for HF contact welding, characterised by technological advancements and increased efficiency. As the industry continues to innovate, manufacturers can expect even greater improvements in process control, operational efficiency, data analytics and sustainability.

Thermatool Corp info@thermatool.com www.thermatool.com

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MARCH 2025