How to Use Ultrasonic Metal Welding Machine?

Table of Contents

Ultrasonic equipment consists of the following components:

  1. Ultrasonic electricity box: generate electrodynamic high-frequency vibration
  2. Pneumatic part: the main role is to complete the pressure work needs such as pressurization and pressure-holding in the processing process.
  3. Program control part: control the workflow of the whole machine to achieve a consistent processing effect.
  4. Transducer part (Ultrasonic transducer): convert electric vibration into mechanical vibration, after transmission, amplification, to reach the processing surface.
  5. Amplitude modulator: enhances (converts) mechanical vibration.
  6. Weld head: transmits mechanical vibration to the workpiece.

The three components – transducer, amplitude modulator and welding head – are mechanically fixed together and acoustically coordinate with each other during resonance. In order to direct a specific amount of force through this vibration system to the workpiece, a pneumatic press and feeder are usually required. The type and manner of feeder control will have a substantial impact on the weld results.

The good and bad of Ultrasonic welding depends on the amplitude of the transducer weld head, the added pressure and welding time and other three factors, welding time and head pressure can be adjusted, the amplitude is determined by the transducer and variable amplitude rod.

These three amounts of interaction have a suitable value, the energy exceeds the appropriate value, the amount of plastic melting is large, the weld is easy to deform; if the energy is small, it is not easy to weld firmly, the added pressure can not be too large.

Operation Mode

Examine And Detection

Connect the equipment and turn on the power. Then check whether the accessories are complete and configure the gas source greater than 0.6 MPa.

Installing the Correct Welding Tool Head

After launching the ultrasonic generator, the ultrasonic welding head is installed. To remove the welding tool head, use a special welding tool head removal spanner, spanner the welding tool head clockwise and then gently select and install it manually. The same applies to the installation, which is done manually and then tightened with a special spanner.

The ultrasonic welding head must be installed with a clean surface before installation.

Adjusting the Horizontal Position of the Ultrasonic Welding Head Mould

Loosen the levelling screw of the ultrasonic welding machine, adjust the mould head to the angle position you need, then press the manual down button, observe the level of the mould, and then make the level adjustment.

Test generator panel, test, positioning, reset. The control system of the ultrasonic welding machine enables the operation of the welding parameters, such as frequency, time, amplitude, pressure, etc. to be set.

Welding Test

Before the ultrasonic welding test is carried out, the welding tool head needs to be calibrated by placing a piece of copy paper between two sheets of white paper on the table and pressing the welding tool head down through the action of the cylinder to observe whether the white paper leaves a clear and evenly coloured indentation; if not, the welding tool head is fine-tuned until the indentation on the white paper is clear and even.

Product Test Welding

For the first welding of one size, press the positioning buttons on both heads, then place the profile and adjust the position of the head (so that both ends of the profile come up against the movable positioning blocks of the rear positioning plate) and lock the handle. For the second welding of the same size, putting the profile in and press the positioning button to position it.

After checking that everything is normal (whether the profile is well pressed, whether the temperature is normal, etc.) press the automatic welding button and the welding process is completed automatically until the welded semi-finished or finished product is removed after the reset. After passing the quality inspection of the test welded product, the variable parameter values are locked and the machine is ready for efficient production.

Closing Operation

During operation, if the hand is pressed by the ultrasonic metal welding machine or the profile blocks the welding plate and other extraordinary circumstances, press the emergency stop button to stop the action. Press and then rotate to the right to reset. Turn off the residual gas and accumulated water in the triple. Turn off the heating and control power of each other heads, and then turn off the general power of the equipment.

Manual Ultrasonic Metal Welding Machine Operation Process

The manual ultrasonic metal welding machine is fast, safe, acid-free, solder-free, easy to operate and high-strength. The strength is up to 80% of the original copper wire.

The operation is: manually put the metal wire harness material into the welding base, and the welding parts need to be fixed in the base to keep it immobile. Then step on the footswitch in order to produce ultrasonic metal spot welding.

PLC Ultrasonic Metal Welding Machine Operation Process

Automatic Ultrasonic Wire Splicer For Wiring Harness Welding With PLC can be connected to MES system with powerful traceability and tuning capabilities. With the full-color touch screen of the PLC power supply, the operator can intuitively enter welding parameters, store them in a library, and even recall them with a barcode reading function. Welding results can be viewed as numerical values or as time-based charts, efficient, simple and stable!

The Types of Ultrasonic Welding Methods

Spot Welding

Spot welding refers to sub-point welding for objects for which the welding line is not easily designed, and the same fusion effect can be achieved.

Spot Welding

The vibration system of the spot welder can be divided into several types, such as longitudinal vibration (light structure) system, bending vibration (heavy structure) system, and light bending vibration system in between, according to the vibration condition of the upper sound pole. The light structure is used for small spot welding machines with power less than 500W. Heavy-duty structures are used for kilowatt-class high-power ultrasonic welding machines. The light bending vibration system is suitable for small and medium power welding machines.

Ring Welding

With the ring welding method can form a closed shape weld, using a torsional vibration system. The pad is twisted during soldering, and the amplitude of vibration is symmetrically distributed linearly with respect to the acoustic pole axis, with zero amplitude in the axial zone and large amplitude at the edge of the pad. Obviously ring soldering is suitable for the packaging process of microelectronic devices.

Sometimes ring welding is also used for linear welding seams with particularly high requirements for gas tightness, when partial overlap ring soldering methods can be used, shaped like seam welding to obtain a continuous linear weld. Due to the large area of the ring welding, a large power input is required, so the multi-transducer drive method is often used.

Seam Welding

The vibration system of the seam welder can be divided into several categories according to the vibration state of its pads; longitudinal vibration system; bending vibration system; torsional vibration system and so on. Two kinds are more commonly used. The vibration direction of its pads is perpendicular to the welding direction. And c) the vibration direction is parallel to the welding direction. Seam welding can obtain a sealed continuous weld seam. Usually the workpiece is clamped between the upper and lower pads.

Wire Welding

Wire welding can be seen as an extension of the spot welding method. It is now possible to obtain a 150 mm long wire weld by wire up-sounding the pole last time. This method is suitable for wire sealing of foils.

The Precautions of Operating Ultrasonic Metal Welding Machine

  1. The system is factory set to power on the automatic frequency tracking mode, please be sure to link the transducer, and ensure that the transducer is no-load state in the boot.
  2. If the use of the process, more than the maximum power or current, the system will output overload signal and stop working, at this time can be restored by shutdown or reset, the system rated power 3KW, the peak maximum output 3.5KW when overload, to judge through the panel LED column, when the LED full frame light, that is, the maximum output.
  3. The rear panel transducer lead for high-frequency high-voltage, please be sure to lock the link, so as not to ignite and burn.
  4. If you need to replace the welding die, please make sure the die resonance frequency Fs is higher than 19.50KHz, anti-resonance frequency Fp is lower than 20.50KHz.

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