Choosing a high-quality ultrasonic metal welder is a critical decision that requires careful consideration of various technological aspects. As a professional ultrasonic welding machine manufacturer, we will explore in this article the three core technologies essential for ultrasonic metal welding, as well as important factors to keep in mind when purchasing the equipment.
- Frequency Automatic Tracking Technology:
Frequency automatic tracking technology is the linchpin of ultrasonic metal welding. It is a pivotal technology that ensures the stable operation of the equipment. This technology guarantees that the ultrasonic vibrating rod remains in a state of resonance, maintaining amplitude stability and, ultimately, the quality of the welding process.
- Amplitude Steplessly and Continuously Adjustable:
The ability to seamlessly and continuously adjust amplitude is fundamental to equipment performance. This feature, with an adjustable range of 50%, allows for the welding of a variety of metal materials on the same equipment. For example, both aluminum and copper can be welded.
- Three Work Control Modes:
i. Time Mode: This mode controls welding time, serving as one of the most common control modes.
ii. Energy Consumption Mode: By accurately detecting the real current and voltage of the transducer, it achieves high-precision energy output control.
iii. Height Mode: This mode employs high-precision electronic ruler detection to control the compression of the welding workpiece, making it suitable for thicker workpieces.
- Fully Digital Control of Adjustment Parameters and Various System Protection Functions
Fully digital control of an ultrasonic generator for metal welding offers precise adjustment of critical parameters like frequency, amplitude, and welding time, ensuring consistent and accurate welds. This digital technology allows for remote operation, data logging, and real-time monitoring, enhancing process control and quality assurance. Additionally, it incorporates protective functions, such as overcurrent and over-temperature safeguards, along with fault detection and alarms to prevent equipment damage and defects in the welded components.
The user-friendly interfaces and adaptability of digital systems streamline operation and integration with other manufacturing processes, making it a valuable asset in modern manufacturing settings. In essence, fully digital control optimizes ultrasonic metal welding, promoting precision, efficiency, and safety throughout the welding process.
A high-quality transducer, designed for welding metals, should possess two fundamental parameters: dynamic impedance and quality factor (Qm value).
There are two criteria for judging the quality of welding heads: Production Process and Welding Head Life.
- Production Process:
During the manufacturing of welding heads, relevant processes are determined based on welding requirements, including considerations like solder joint size, amplitude ratio, and tooth pattern selection. The resonant frequency of the welding head, for instance, at 20KHZ, should not deviate by more than ±50HZ from the designed resonant frequency.
- Welding Head Life:
The durability of the welding head is contingent on several factors, such as material properties, heat treatment processes, welding metal properties, welding area, tooth depth, and other related elements.
Based on the above content, when purchasing ultrasonic metal welding equipment, the following judgments can be made:
Determine if the equipment incorporates automatic frequency tracking technology. Equipment lacking this feature may require manual frequency adjustment, which can lead to suboptimal performance. It’s essential to check for hidden frequency adjustment knobs, as domestic equipment often conceals them. To verify, request the manufacturer to replace the welding head on-site, use a test ultrasonic button, and monitor the ammeter on the equipment. Deviations from the generator’s set resonant frequency will be evident in the ammeter reading, indicating the absence of automatic frequency tracking.
Assess whether the equipment allows for continuous and stepless amplitude adjustment. Many manufacturers offer only two ways to adjust amplitude:
The first is to change the transformer tap, which is divided into 3 levels.
The second is to change the transformation ratio of the horn and mechanically increase the amplitude. Excessive amplitude often becomes a burden on the system, resulting in poor welding results. but having a continuously adjustable amplitude is vital for versatile welding processes.
Be aware of different working modes, with the “time mode” being the most common. Some manufacturers may use an “energy mode” that measures the entire device’s power consumption, rather than the real current of the transducer. It is crucial to scrutinize this information to prevent misleading details.
Transducer quality isn’t always evident on the surface but can be assessed through parameters. If the manufacturer has an impedance analyzer, request on-site testing to ensure that the dynamic impedance of metal welding transducers remains below 2 ohms, while plastic welding transducers generally have dynamic impedances around 10 ohms.
To test the equipment’s performance, conduct on-site welding. Be cautious of potential false labeling, particularly regarding power capacity. Some manufacturers may label their products with higher power ratings than their transducers can handle.
In conclusion, selecting a high-quality ultrasonic metal welder requires a thorough understanding of the core technologies involved and careful examination of the equipment’s features. Through practical testing and attention to detail, customers can make informed decisions about the performance and capabilities of the equipment they are considering.
WUXI BONNE ULTRASONIC TECHNOLOGY CO.,LTD specializes in the design and manufacture of machines and systems for industrial ultrasonic welding technology. This versatile technology is ideal for permanently joining various metal components, including wire harness welding, terminal welding, metal spot welding, plastic-to-metal welding, and metal rolling welding, among others. One of the primary applications in the emerging new energy automobile industry is the precise connection of instrument panel instruments, center consoles, and engine wiring harnesses. Additionally, our ultrasonic welding solutions are widely applicable across various industries, such as solar energy, battery soft pack welding, electronics, refrigeration, and automation equipment.
Bonne is dedicated to delivering high-quality ultrasonic welding machines and systems. Our team, after in-depth discussions, has collectively identified a set of guiding principles that steer our work. We want to emphasize a key aspect about Bonne – we are a positive and experienced team deeply rooted in the ultrasonic industry. With many years of involvement, we closely monitor the diverse applications of ultrasonic technology, which provides a strong foundation for us to explore tailored solutions for our customers. Our ultimate aspiration is the success of our customers, which we view as our own success. Our core values, including integrity, cooperation, respect, and purposeful exploration, serve as the cornerstones of our growth.
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