weld machine

Ultrasonic welding is a process used to join two plastic parts together to form a strong, finished assembly. The process relies on high-frequency (ultrasonic) vibrations being generated and applied to the parts via a horn. Welding occurs as the vibrations are absorbed in the interface between the two parts, generating friction and causing the plastic to melt. The ultrasonic vibrations are generated by a series of components, including the power supply, converter, booster and horn, which ultimately delivers the mechanical vibration to the parts.

Ultrasonic welding machine principle

The role of the power supply is to convert the incoming line voltage (at 50 or 60Hz) into a new frequency. This electrical energy then is sent to the converter, which as the name implies, converts the electrical energy into mechanical vibrations. The converter consists of piezoelectric ceramic discs, which expand and contract at the rate of the supplied electrical energy. The magnitude of the vibrations is referred to as amplitude, a term that becomes very important when specifying an ultrasonic system for a given application. The vibrations then are transmitted through the booster, which typically increases the amplitude by a predetermined multiple, also known as gain. Finally, the booster’s output amplitude is transmitted through the horn, where it then can be delivered to the plastic parts.

Ultrasonic welding machine conposition

An ultrasonic generator (power supply)

hcsonic ultrasonic generator
hcsonic ultrasonic generator
The ultrasonic generator converts the 110VAC or 220VAC electrical supply current into a high frequency, high voltage electrical signal.

An ultrasonic converter (transducer)

The ultrasonic converter utilizes the high frequency electrical signal from the generator and converts it into linear, mechanical movement. This conversion ccurs through the use of piezo-electric ceramic disks that expand when a voltage is applied.
Ultrasonic transducer

An ultrasonic booster

Ultrasonic booster and round flange
Ultrasonic booster and round flange
The ultrasonic booster is a tuned component that mechanically adjusts the amount of linear vibratory movement from the converter to the required level for the specific application to produce optimal welding performance. The booster also provides a safe, non-vibrating location to clamp onto the welding tools.

An ultrasonic welding tool (horn/sonotrode)

The ultrasonic welding horn is a custom made tool that is engineered to vibrate at a specific frequency. These tools are painstakingly designed using computer modelling technology for optimum performance and longevity.Ultrasonic tools must be tuned to match the frequency of the system. This tuning procedure requires consideration of the horn’s mass, length and geometry.Common tool head sizes are 150 * 40mm and 110 * 20mm.
welding tool (horn/sonotrode)
Ultrasonic welding tool (horn/sonotrode)

Sectional view of ultrasonic welding machine WW1530L

aotomatic welding machine 15K
Sectional view of ultrasonic welding machine WW1530L

Longer service life

Transducer prestress

All piezoelectric transducers for ultrasonic welding are of the Langevin type — i.e., one or more piezoceramics that are mechanically compressed (prestressed) between a front driver and a back

Transducer cross section
Transducer cross section
Transducer Relative axial amplitudes
Transducer Relative axial amplitudes

Because piezoceramics are weak in tension, a static compressive prestress must be applied to prevent the piezoceramics from ever experiencing tensile stresses when the transducer vibrates ultrasonically. In addition, the prestress assures that the piezoceramic interfaces make good contact so that the acoustic waves transmitt well with minimum loss. We use the most convenient center screw design.

A specific prestress can be obtained by tightening the transducer center screw to tighten the transducer. The traditional method is to use a torque wrench for tightening, but this parameter is
affected by many factors and often has deviations.

Prestress vs torque Langevin type transducers
Prestress vs torque Langevin type transducers

When the tightening of the ultrasonic transducer is insufficient, its impedance is large, which will cause serious heat generation; when the tightening is excessive, it is easy to cause problems such as damage to the ceramic sheet (crystal crack) and durability. Transducer is the most important part of ultrasonic welding equipment. So it is very important to accurately tighten the transducer and obtain the best prestress.

Get the best prestress of the transducer
Get the best prestress of the transducer

Piezoelectric ceramic sheet

Piezoceramics are typically classified as “soft” or “hard”. Hard piezoceramics are used for power applications. Among hard piezoceramics there are two basic types, generally designated as PZT4 and PZT8 (PZT stands for lead-zirconate-titanate of which the piezoceramics are composed). Different manufacturers may have their own designations for these types but the general performance is similar. Our device uses PZT8 piezoelectric ceramics, which has better relative performance.

Nominal piezoceramic properties at low electric field conditions
Nominal piezoceramic properties at low electric field conditions

Advantages of ultrasonic welding

  • Does not need external heat source: The primary advantage of ultrasonic welding is that it doesn’t need an external heat source. The heat is self-generated between the materials.
  • Fast: Since the frequency of vibrations is very high, ultrasonic welding is one of the fastest welding methods available in the industry.
  • Possibility of automation: Ultrasonic welding being uncomplicated in many ways, it is easy to automate. The ultrasonic machine comes with sensors that constantly monitor the temperatures.
  • Clean and strong joint: The contact surfaces melt/fuse upon welding, and it produces a very clean and strong joint.

Ultrasonic welding has many advantages when compared to traditional welding technologies. Many industries use it due to these specific combinations of merits.

Application of ultrasonic welding

Ultrasonic welding is an eco-friendly process that takes seconds, consumes very little energy and reduces costs while maintaining a high degree of quality. The equipment fuses contact points on cell phones and other consumer electronics that are generally inaccessible with other welding methods. These techniques can be adapted to a wide range of commercial and industrial applications. In the food industry, the ultrasonic welding process is used to create a hermetic seal. It can fasten blister packs and facilitate the manufacturing of a variety of products, including toys, disposable lighters , pipettes and intravenous catheters.

Ultrasonic welding is commonly used in the plastics, aerospace and automotive industries to join similar materials. It is particularly useful in the production of medical products. Since the process does not introduce exhaust or other contaminants and the welds do not degrade, the manufacturing equipment can be used in a clean-room environment.

Ultrasonic welding Machine tips

Ultrasonic welding is very effective at sealing or welding plastics. However, you cannot weld all types of plastics.ike metals, plastics also have different types. And it is very important to ensure that the plastics to be welded are chemically compatible.If you try welding polyethylene and polypropylene, it may melt together, but there will be no chemical bond. A chemical bond is important for creating strong weld joints.Another factor to keep in mind while welding any material through welding is maintaining a uniform contact area.
Attributes Parameter Attributes Parameter
Brand HCSONIC Item Model WW1530L
Maximum Power output 2200W Frequency 15KHZ
Maximum Amplitude 10µm Working model Continuous, intermittent
Weldable materials Thermoplastic materials Welding Head Material Steel
Welding Head Size 270*25mm  Driven Type Electric
Technical Support Video, mail, phone Warranty One year, except horn
Full Set Weight 21KG Place of Origin China
hcsonic naming rules
hcsonic ultrasonic equipment naming rules
Production time: within 15 days or according to customer requirements.
Shipping method: DHL, FedEx, UPS, TNT, sea or air.

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