High Power Ultrasonic Spot Welding 800W Low Energy Consumption

High Power Ultrasonic Spot Welding 800W Low Energy Consumption

Introduction:

Ultrasonic spot welding is a welding technique that uses high-frequency mechanical vibrations to create localized heat and pressure, resulting in the bonding of two materials at specific points. It is commonly used in various industries for its ability to join materials quickly, efficiently, and without the need for additional adhesives or fasteners. Here are some key aspects of ultrasonic spot welding:

1. Principle of operation: Ultrasonic spot welding utilizes the principle of mechanical friction to generate heat at the joint interface. A vibrating tool, called a sonotrode or welding horn, applies high-frequency vibrations to the materials being bonded. The vibrations create friction and heat at the contact surface, softening or melting the materials and allowing them to fuse together.

2. Process steps: The ultrasonic spot welding process typically involves the following steps:

   • Preparation: The materials to be welded are positioned and clamped together, ensuring proper alignment and contact at the desired welding points.

   • Application of vibrations: The sonotrode is brought into contact with the materials at the intended welding spots. An alternating electrical voltage is applied to the transducer, which generates high-frequency vibrations that are transmitted to the sonotrode.

   • Welding phase: The vibrating sonotrode applies pressure to the materials, causing them to deform and generate frictional heat. The heat softens or melts the materials, resulting in molecular intermixing and the formation of a strong bond.

   • Cooling and solidification: After a sufficient welding time, the vibrations and pressure are stopped, and the joint is allowed to cool and solidify, ensuring the formation of a solid and durable bond.

Parameter:

Working principle

When the ultrasonic wave is applied to the thermoplastic plastic contact surface, it will generate tens of thousands of high-frequency vibrations per second. This kind of high-frequency vibration reaches a certain amplitude. The ultrasonic energy is transmitted to the welding zone through the upper welding piece. The welding interface has a large acoustic resistance, so local high temperatures can occur. Also, due to the poor thermal conductivity of plastics, they could not be released in time and gathered in the welding zone, which caused the contact surfaces of the two plastics to melt rapidly, and after a certain pressure was applied, they were merged into one. When the ultrasound stops working, let the pressure last for a few seconds to make it solidify and form, so that a strong molecular chain is formed to achieve the purpose of welding, and the welding strength can be close to the strength of the raw material. The quality of ultrasonic plastic welding depends on the three factors of the transducer welding horn amplitude, the applied pressure and the welding time. The welding time and the welding horn pressure can be adjusted. The amplitude is determined by the transducer and the horn. There is a suitable value for the interaction of these three quantities. When the energy exceeds the suitable value, the melting amount of the plastic is large, and the welded material is easily deformed; if the energy is small, the welding is not easy, and the applied pressure cannot be too large. This optimal pressure is the product of the edge length of the welded part and the optimal pressure per 1mm of the edge.

Advantages:

This switchable ultrasonic spot welding equipment can freely switch between the two holding methods

Pistol type ultrasonic spot welding machine: The shape is designed according to ergonomics. The ultrasonic start switch is located at the trigger of the pistol, which is convenient for lifting and use. It is especially suitable for horizontal or vertical welding operations.
Straight-hold ultrasonic spot welder: The shape is a straight-tube design. The ultrasonic start switch is located on the outside of the straight-tube, which is convenient for hand-held welding and carrying.