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Definition of ultrasonic auto plastic welding:
Ultrasonic welding is a high-tech technology of sintered plastic products. The use of this technology can replace past production of flux, adhesives, buckles or other mechanical fixation, thereby improving the production efficiency and reduce costs. These welders combine technical sophistication with ease of use. They can be easily integrated in your production facilities. The principle of ultrasonic welding is through the ultrasonic generator to convert high-frequency electrical energy into higher frequency mechanical movement, then mechanical movement through a set of amplitude can be changed to the transmission device to the welding head. The welding head transmits the received vibration energy to the joint portion of the workpiece to be welded, in which the vibration energy is converted into heat energy by friction and the plastic is melted. Ultrasonic not only can be used to weld hard thermoplastics, but also can process fabrics and films. ALTRASONIC will find the best solution for your thermoplastic welding needs.
1. application in riveting, forming and welding
2. light weight, easy to take, easy to operate (handheld)
3. Equipped with welding timer
4. Easty to set time welding
5. Equipped with an overload protection circuit( Voltage, current, phase, temperature, output)
6. FET power output
7. Automatic resonance
8. Maintain the amplitude function automatically
9. Starting: achieving maximum power with 105msec
Conditions of Affacting Ultrasonic Welding
Ultrasonic automotive plastics as the condition of ultrasonic welding, the most important is the time to apply welding energy (vibration, welding time) length and pressure, of course, other conditions are also very important. Welding temperature ultrasonic welding material viscosity flow temperature. Otherwise the material will not melt.
With the amplitude, the higher the amplitude, the higher the temperature rise. The pressure is applied to the molded article using a cylindrical gaze. General compressed air pressure is 0.1-0.3MPa (pressure gauge), sometimes higher. But if the use of high pressure, it will hinder the cylindrical vibration.
The welding time varies depending on the material and the shape of the product. The welding time of some molded articles is only 0.2 seconds. Over time will cause excessive welding and produce a lot of flash and bubble, resulting in poor airtight, must pay attention. Cooling (holding) time For crystalline plastic, if the temperature below the melting point, the connection will be solidified, usually the pressure time is maintained between 0.1-0.2 seconds. AMMA plastic).
Principle of Sound Barrier Contton Ultrasonic Welder
When the ultrasonic role in the thermoplastic plastic contact surface, it will generate tens of thousands of times per second, high frequency vibration, this high-frequency vibration, ultrasonic energy through the ultrasonic wave transmitted to the mold to ultrasonic welding material surface, it will produce high-temperature materials. Plastic contact surface resulting in rapid melting, coupled with stress, it blend and coagulation, so that to achieve the purpose of ultrasonic welding.
Applications In Automobile:
Ultrasonic Spot Welding is mainly used in automotive interior parts. Ultrasonic spot welding in sound-proof cotton of engine cover, trunk and wheel casing, and hallstand felt. Ultrasonic Riveting Welding can be used in automobile air-conditioning outlet welding, car rear view mirror, car door handles, hand car door and so on.
Automotive plastic parts are mostly welded in non-standard ultrasonic welding equipment, long multi-station design, with PCL program control and LCD operation, large automotive complex workpiece welding, including different directions of the welding surface, in multiple locations.
Components of Ultrasonic Welding
Horn, Booster and Transducer
Principle of Amplifying
They can amplify the amplitude at a particular ratio step by step. For example, the transducer amplitude is 6mm, the booster can amplify it triply to 18mm, and then the horn can make it to 36mm. However, the work life of horn would be shortened with the amplification of amplitude. The required amplitude differs with the welding material.
There are three common horn material:
high price, excellent performance good toughness and low loss, difficult to be processed;
Its amplitude can reach to 60mm.
low price, fast loss, easy to be processed;
Its highest amplitude less than 300mm.
too hard to be made as horn;
its highest amplitude less than 25mm;
It is suitable for cutting but the blowpipe need to be added in for its cooling.