What is the Normal Application of ultrasonic welder?

What is the Normal Application of ultrasonic welder?

Ultrasonic welding is a process that converts 50/60 Hz current into 15, 20, 30 or 40 KHz electrical energy through an ultrasonic generator. The converted high-frequency electrical energy is converted into mechanical motion of the same frequency again through a transducer, and then the mechanical motion is transmitted to the welding head through a set of amplitude-changing horn devices. The welding head transmits the received vibration energy to the joint of the workpiece to be welded, where the vibration energy is converted into heat energy by friction to melt the plastic. Ultrasonic waves can not only be used to weld hard thermoplastics, but also to process fabrics and films.
The main components of an ultrasonic welding system include an ultrasonic generator, a transducer/horn/welding head triplex, a mold and a frame.

Working principle: When ultrasonic waves act on the contact surface of thermoplastic plastics, high-frequency vibrations of tens of thousands of times per second will be generated. This high-frequency vibration with a certain amplitude will transmit ultrasonic energy to the welding area through the upper weldment. Since the acoustic resistance of the welding area, i.e. the interface between the two welds, is large, local high temperature will be generated. Due to the poor thermal conductivity of plastics, it cannot be dissipated in time and gathers in the welding area, causing the contact surface of the two plastics to melt rapidly. After a certain pressure is applied, it will be fused into one. When the ultrasonic wave stops acting, the pressure is allowed to continue for a few seconds to solidify and form, thus forming a strong molecular chain to achieve the purpose of welding, and the welding strength can be close to the strength of the raw materials. The quality of ultrasonic plastic welding depends on three factors: the amplitude of the transducer welding head, the applied pressure and the welding time. The welding time and welding head pressure can be adjusted, and the amplitude is determined by the transducer and the horn. There is an appropriate value for the interaction of these three quantities. When the energy exceeds the appropriate value, the amount of plastic melted is large and the weld is easy to deform; if the energy is small, it is not easy to weld firmly, and the applied pressure cannot be too large. This optimal pressure is the product of the side length of the welded part and the optimal pressure per 1mm of the edge.

Ultrasonic welding is an efficient and environmentally friendly welding technology that is widely used in many fields. Its advantages mainly include the following points:

1. Fast welding speed: Ultrasonic welding uses high-frequency vibration to make the molecules on the surface of the weldment rub against each other to generate heat, achieving rapid welding. The welding time usually takes only a few seconds to tens of seconds. Compared with traditional welding methods, it greatly improves production efficiency and is especially suitable for large-scale production.

2. High welding strength: Ultrasonic welding can combine welds at the molecular level, and the weld strength formed is high, which can reach or even exceed the strength of the weldment itself, effectively ensuring the welding quality and the performance of the weldment.

3. Good welding quality: During the welding process, impurities such as the oxide film on the surface of the weldment will be broken and removed under the action of ultrasonic vibration, making the welding interface purer, reducing the generation of welding defects such as pores and slag inclusions, and making the weld uniform and beautiful, with stable and reliable welding quality.
4. Little damage to materials: Ultrasonic welding is a non-contact welding method. During the welding process, there is no need to apply excessive pressure and heat to the weldment, avoiding the influence of high temperature and mechanical force on the performance of the weldment material, such as deformation and embrittlement, etc. It is particularly suitable for some heat-sensitive or easily deformed materials.
5. Environmental protection and energy saving: During the ultrasonic welding process, there is no need to add welding materials such as flux and welding rods, no harmful gases and smoke will be generated, and there is no pollution to the environment; at the same time, due to the fast welding speed and low energy consumption, it has a good energy-saving effect.
6. Strong adaptability: Ultrasonic welding can weld a variety of materials, including metal and metal, metal and plastic, plastic and plastic, etc., and can also realize the welding of weldments of different shapes and sizes, and can also adapt to weldments of complex shapes.
7. Easy to automate: Ultrasonic welding equipment is simple to operate, with high control accuracy, easy to integrate with automated production lines, realize automation and intelligence of the welding process, and improve production efficiency and consistency of product quality.

In today's automobile manufacturing industry, technological innovation continues to promote the improvement of production efficiency and product quality. Among them, ultrasonic plastic welding machines, as a key technology, are gradually changing the production methods of automotive parts. ​

Ultrasonic plastic welding machines use high-frequency vibration waves to transmit to the surface of plastic parts, so that high-speed friction and instantaneous temperature rise occur between the contact surfaces, thereby achieving efficient welding of plastics. This technology has extremely wide applications in the field of automobile manufacturing. From plastic parts of the car body to car interiors and exterior parts, ultrasonic welding technology can be seen. ​

In the manufacturing of automotive plastic parts, ultrasonic plastic welding machines play an irreplaceable role. For example, in the welding of car door panels, headlights, dashboards and other parts, the equipment can quickly and firmly connect different plastic parts together. Taking the welding of car headlights as an example, traditional welding methods may have problems such as weak welding and poor sealing, while ultrasonic plastic welding technology can achieve seamless welding, ensure the waterproof and dustproof performance of the headlights, extend the service life, and improve product quality and reliability.​

Ultrasonic welding is an efficient and environmentally friendly welding technology that is widely used in many fields. Its advantages mainly include the following points:

1. Fast welding speed: Ultrasonic welding uses high-frequency vibration to make the molecules on the surface of the weldment rub against each other to generate heat, achieving rapid welding. The welding time usually takes only a few seconds to tens of seconds. Compared with traditional welding methods, it greatly improves production efficiency and is especially suitable for large-scale production.

2. High welding strength: Ultrasonic welding can combine welds at the molecular level, and the weld strength formed is high, which can reach or even exceed the strength of the weldment itself, effectively ensuring the welding quality and the performance of the weldment.

3. Good welding quality: During the welding process, impurities such as the oxide film on the surface of the weldment will be broken and removed under the action of ultrasonic vibration, making the welding interface purer, reducing the occurrence of welding defects such as pores and slag inclusions, and making the weld uniform and beautiful, with stable and reliable welding quality.
4. Little damage to materials: Ultrasonic welding is a non-contact welding method. During the welding process, there is no need to apply excessive pressure and heat to the weldment, avoiding the influence of high temperature and mechanical force on the performance of the weldment material, such as deformation and embrittlement, etc. It is particularly suitable for some heat-sensitive or easily deformed materials.
5. Environmental protection and energy saving: During the ultrasonic welding process, there is no need to add welding materials such as flux and welding rods, no harmful gases and smoke will be generated, and there is no pollution to the environment; at the same time, due to the fast welding speed and low energy consumption, it has a good energy-saving effect.
6. Strong adaptability: Ultrasonic welding can weld a variety of materials, including metal and metal, metal and plastic, plastic and plastic, etc., and can also realize the welding of weldments of different shapes and sizes, and can also adapt to weldments of complex shapes.
7. Easy to automate: Ultrasonic welding equipment is simple to operate, with high control accuracy, and is easy to integrate with automated production lines to realize the automation and intelligence of the welding process, improve production efficiency and consistency of product quality.