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How to use the ultrasonic welding machine correctly? what are the errors in the ultrasonic?

Date:Jun 29, 2018

How to use the ultrasonic welding machine correctly?  what are the errors in the ultrasonic?

 

At present, ultrasonic welding machines have been widely used in such industries as product packaging, cutting, riveting, embossing, and punching, there are many difference in using and requirements.  Solving the problem of misunderstanding in the work of ultrasonic welding machine. For these misunderstandings we need to  how to properly use the ultrasonic welding machine, please pay attention to the following points : misunderstanding in the welding principle, some people has a misunderstanding of the ultrasonic energy transfer. They believed that the sonic is welded at the contact surface. It is actually a misunderstanding. The real welding principle is: After the transducer converts electrical energy into a machine, it conducts through the molecules of the workpiece. The acoustic impedance of acoustic waves in solids is much smaller than that in air. Sound resistance, when the ultrasonic passes through the joint of the workpiece, the sound resistance in the gap is large, and the heat energy generated is quite large. The temperature first reaches the melting point of the workpiece, plus a certain pressure, so that the seam welds. The other parts of the workpiece will not be welded due to low thermal resistance and low temperature. The principle is similar to Ohm's law in electrotechnics.

 

Ultrasonic welding machine has special required for the welded material. Not all materials can be welded. This is a big misunderstanding to believe that any material can be welded. Some materials of different kinds can weld better. Some are basic fusions and some are not fused. The melting point of the same material is the same, from the principle of welding can be, but when the melting point of the welded workpiece is greater than 350 °C, it is not suitable for ultrasonic welding. Because ultrasonic is the moment to dissolve the molecules of the workpiece, the judgment basis is within 3 seconds, it can not be well welded, we should choose other welding processes, such as hot plate welding. In general, ABS is the easiest to be welded , and nylon is the most difficult to be welded.

 

 

Misunderstanding of welding workpieces:

Ultrasonic energy is instantaneously explosive, welding points should be points or lines, and the distance of transmission should be consistent with ultrasonic welding. Some people think that as long as it is a plastic material, no matter how the joint surface can be welded well, it is also a misunderstanding. When momentary energy is generated, the larger the joint area, the more severe the energy dispersion, the worse the welding effect, and even the inability to weld. In addition, the ultrasonic waves are transmitted longitudinally, and the energy loss is proportional to the distance. The remote welding should be controlled within 6 cm. The welding line should be controlled between 30 and 80 wires. The arm thickness of the workpiece must not be less than 2 mm, otherwise it will not weld well, especially for products that require air tightness.

 

Misunderstanding of welded structure:

HORN has a variety of types. The shape of the workpiece determines the appearance of the mold. However, the size, curvature, and material of each part must be strictly calculated. Some people mistakenly believe that it is only a metal block. Whether the design is reasonable has a direct impact on the mold's efficiency, longevity, and product pass rate. In severe cases, it will directly burn out the generator. The material of the mold is generally magnesium aluminum 7075, while some people use lower quality materials or counterfeit 7075 to reduce costs. Regular mold manufacturers have a set of strict inspection procedures for feeding materials. The processing dimensions are processed and simulated by computer software. Quality is guaranteed. These workshops cannot be done by general workshops. If the molds are not designed and manufactured properly, the reaction problems are not obvious when welding small workpieces. When the power is high, there are various drawbacks. In severe cases, power components are damaged directly.

 

Misunderstanding of Ultrasound output power :

The level of the ultrasonic output power is decided by the diameter and thickness of the piezoelectric ceramics, the material, and the design process. Once the transducer is shaped, the maximum power is also determined. Measuring the level of the output energy is a complex process. It is not correct that when the size of transducer is bigger, the larger the energizer, the more power circuits the circuit uses, the greater the output energy. It requires a fairly complex amplitude meter to accurately measure its amplitude. The amount of energy consumed does not reflect the level of the ultrasonic power output. For example,  If the longitudinal energy is low and the current consumption is large, the efficiency of the equipment is low and the reactive power is large.

 

Misunderstanding in Ultrasonic welding machine type :

It should be considered the material of the workpiece, the area of the bond wire, whether there are electronic components in the workpiece, and whether air tightness is required when we choose the type of ultrasonic welding machine . It is also a misconception that the higher power is better. If you do not know too much about ultrasound, it is best to consult a regular ultrasonic production plant engineering and technical personnel, if possible, then it is best to communicate to the factory site, do not blindly listen to the misleading of some informal ultrasound sales staff. The imitation equipment has the following fatal flaws: First, the quality of the purchased material cannot be guaranteed, and the core technology of the second production process is not mastered. Equipment often shows instability in medium and high power work, low product qualification, and sometimes equipment damage. For a power transformer that drives a transducer, the parameters of the magnetic material used cannot be measured. Magnetic saturation flux density (Bs) Magnetic induction (Bm), Effective permeability (Ue), Remanent flux density (Br), Coercivity Force (A / M), loss factor (tan £), temperature coefficient (au / K-1), winding process is very particular about the package expansion vacuum leaching epoxy resin. These test equipment and production environment home-style factory can not be done. Therefore, when purchasing ultrasound equipment, it is best to look at the company's situation, do not blindly obey the salesman touted, do not just look at the price. Only in this way we can reduce unnecessary troubles in the future.


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