MEGA single or double workstation shuttle high frequency welder is made for special projects in the automotive and airplane construction industry where high frequency welding and sealing applications require precision large flat surface for product positioning and complex shape welds.
Mega is a perfect machine for production of laminated PU foam embossing, car/truck door panels and tops, automotive and airline carpeting and seat covers, car trunk floors and covers, as well as medical, laboratory, rehabilitation equipment, safety vests, reflective signs, etc. Optional heated electrode platen with temperature presets gives high accuracy for consistent welding.
The machine is equipped with special quick change electrode holder. Custom-built tooling and electrodes are available upon request. We have our own in-house tooling department which will design and make any electrode and die required for any demanding production needs.
With the use of touch screen HMI and programmable PLC, the operator can easily input multiple weld/seam recipes. MEGA series have HF power outputs from 15kW to 30kW for heavy production loads and special projects using reinforced heavy-duty materials. All these options make this machine a perfect tool for high-end production where precision, durability and strength is the key.
Full diagnostic testing and certification of the local factory EMC/EMS parameters according to the latest guidelines required by the CE & UL standards. We have our own ISO 17025 certified production control and EMC laboratory providing validation of each required process parameters and the whole technological production cycle.
High frequency welders manufactured by Zemat Technology Group are designed and built in accordance with current European requirements for machine safety and energy efficiency. The machine design incorporates technical solutions that enhance welding process stability, reduce energy losses, and increase production repeatability.
HF Smart Control™ is a set of structural and electronic solutions implemented in high frequency welders, including:
The HF/RH welders use high frequency generators with microprocessor-based power control, enabling precise adjustment of energy to the process parameters. The system continuously monitors operating conditions and dynamically regulates power in real time. As a result, energy consumption can be reduced compared to heat sealing technologies and many impulse-based systems. The actual level of savings depends on the material, application, and process settings.
The ATS ensures precise impedance matching and automatic generator tuning during machine operation. This stabilizes the welding process, reduces the risk of instability, and minimizes the possibility of arcing. Fast reflected power control protects HF circuit components and improves weld repeatability.
Modern HF generators achieve energy efficiency levels of approximately 70–90%, depending on configuration and operating conditions. Band-pass filters reduce harmonic distortion, while lower thermal losses decrease heating of machine components. This results in stable operation and extended service life of key components.
