High Frequency Ultrasonic Wire Harness Welding Machine

Hgh Frequency of 20Khz Ultrasonic Metal Welder for Welding Cables and Various Electronic Components

Principle:

Ultrasonic wire harness welding machines do not require flux and external heating, are not deformed by heat, have no residual stress, and require less pre-weld treatment on the surface of the weldment. Not only similar metals, but also between different metals can be welded. Sheets or filaments can be welded to the slab. Ultrasonic welding of good electrical conductors is much less energy than current welding and is commonly used for the soldering of leads for transistors or integrated circuits. When used for sealing welding of drugs and explosive materials, it can avoid the general welding of contaminated drugs due to dissolved objects, and will not explode due to heat. It is the use of ultrasonic waves to weld metal wires. It consists of a power box, transducer, pneumatic host and tool head. In addition, control components such as hubs, traverse devices, and microprocessors are included. The power box converts the usual external voltage (~220V, 50 or 60Hz) into 20000Hz (20KHz), voltage of more than 1 volt, and then is controlled by the power box to output and act on the transducer. A transducer is a highly efficient electrical component that converts electrical energy into mechanical energy. Compared with ordinary motors, there are two major differences between transducers: first, the transducer converts electrical energy into linear vibration instead of rotation; secondly, it works very efficiently and can convert 95% of electrical energy. After conversion by the transducer, mechanical energy is applied to the welding head. The ultrasonic horn is made of titanium alloy and is machined to a specific shape according to acoustic principles to ensure maximum energy transfer.

  
Parameters: 

Structural features of Ultrasonic wire harness welding machine :

The ultrasonic wire harness welding machine consists of two parts: the machine and the ultrasonic power generator.

1. Machine: The machine has a chassis, a guide column, a transducer, a pneumatic system and a bottom mold.

2. Acoustic component: The acoustic component consists of two parts: the transducer and the welding head. The transducer uses a piezoelectric vibrator that converts electrical energy into mechanical vibration. A variator is analogous to a transformer in a circuit and functions as a mechanical damping transformation and amplitude amplification. The welding head is designed according to the welding requirements and the shape of the weldment. It also functions as a secondary impedance transformation and amplitude amplification. In terms of structure and shape, the welding head is not complicated, but it requires the best design, the best materials and good processing techniques. Welding heads with complex shapes and large dimensions are difficult to design and are generally designed by the manufacturer.

3, the air pressure system: the air pressure system is powered by compressed air, through the solenoid valve switching circuit, push the cylinder piston to drive the welding head to move up and down. The pressure regulator is used to control the air pressure, and the one-way throttle valve is used to control the lifting speed.

4. Control circuit: The control circuit performs program control on the welding process. The function keys on the panel can set the welding time according to different objects of welding, delay time, and then step on the foot switch, the ultrasonic welding machine will automatically complete a welding process.

Advantages :

One of the most important advantages of an ultrasonic wire harness welder is its low temperature. The generation of temperature is unavoidable, it is only caused by friction, which is only 1/3 or 1/2 of the melting point of the metal. Since it is frictional heat generation, the internal structure of the wire is not damaged, so the metal wire retains the original performance.

Most of the metals used in electrical products have good thermal conductivity, which makes it difficult to weld by melting. Because the heat is quickly dissipated from the metal surface, it requires more heat to be added to complete the weld. Ultrasonic welding did not encounter these problems. In fact, because no melting occurs, the energy of ultrasonic welding is only 1/30 of that of resistance welding. In other words, the power welding machine with a power of 3KW can complete the work that the resistance welding needs 90KVA, so the cost in the work is also obvious. Ultrasonic welding is a mechanical process in which no current flows through the workpiece, so the conductivity of the metal has no effect. Metal surfaces generally adhere to contaminants and oxide layers. Ultrasonic welding is used without pre-treatment of the metal surface. Ultrasonic vibration can directly remove the attachments and remove them. Another important advantage of ultrasonic welding is the long life of the workpiece. The welding head of the ultrasonic wire harness machine has 4 working faces, which reduces the maintenance cost of the later equipment.

 
Hgh Frequency of 20Khz Ultrasonic Metal Welder for Welding Cables and Various Electronic Components