Principle of ultrasonic metal welding machine

Principle of ultrasonic metal welding machine
Used for secondary connection equipment of metal products.

1.Overview of ultrasonic metal welding:
Ultrasonic metal welding equipment referred to as ultrasonic gold welding machine.
Ultrasonic metal welding technology was discovered in the early 20th century. With the continuous progress of science and technology, the types of ultrasonic metal welding machines are increasing, and the welding field is also expanding. General classification of ultrasonic metal spot welding machine, ultrasonic metal hobbing welding machine, ultrasonic metal sealing and cutting machine, ultrasonic metal wire harness welding machine. According to the frequency can be divided into: high frequency (50K Hertz above) metal welding machine, medium frequency (30-40K Hertz) metal welding machine, low frequency (20K Hertz).

2.composition
Simply speaking, it is composed of three parts: ultrasonic generator, body and welding head. Comprises a base, a main box, ultrasonic electric control box and a manual control device, the base side is provided with an ultrasonic electric control box, the upper part of the base is provided with a main box, the main box is provided with a manual control device, the ultrasonic electric control box comprises a box,PLC program controller and a power switch; The main box is provided with a cylinder and an ultrasonic transducer; Manual control device includes air pressure gauge and solenoid valve. The utility model has the advantages of changing the longitudinal welding to the transverse welding, has a wide range of application, and is easy to realize automatic and manual operation; And lithium, nickel metal hydride battery electrode, silicon photovoltaic cells, electrical appliances, automotive electrical appliances, refrigeration equipment of copper tube welding. PLC touch screen man-machine interface for welding program control, power, frequency to adjust; Short welding time, no need for any flux, gas, solder, welding spark free, environmental protection and safety.

3.Working principle:
Ultrasonic metal welding is the use of high-frequency vibration wave transfer to the two metal surface to be welded, under the condition of pressure, so that the two metal surfaces friction with each other to form the fusion between the molecular layer, its advantages are fast, energy saving, high fusion strength, good electrical conductivity, no spark, close to cold processing; The disadvantage is that the welded metal parts can not be too thick (generally less than or equal to 5mm), the solder joint position can not be too large, the need for pressure. In short, metal welding machine is to use the energy generated by high frequency vibration, the same or dissimilar metals, under the appropriate pressure through cold grinding and horizontal movement of metal surface molecules interinfiltration, to achieve the purpose of welding. This welding principle is applied to both metal rolling welding and metal sealing and cutting.

4.Characteristics of ultrasonic metal welding:
1, welding: two welded objects overlap, the ultrasonic vibration pressure synthesis of solid form, the joint time is short and the joint part does not produce casting structure (rough surface) defects.
2. Mold: Compared with ultrasonic welding and resistance welding, mold life is long, mold repair and replacement time is less, and it is easy to realize automation.
3, energy consumption: the same metal between different kinds of metal can be ultrasonic welding, compared with electric welding energy consumption is much less.
4, pressure welding comparison: ultrasonic welding compared with other pressure welding, the pressure is smaller, and the amount of variation is less than 10%, and cold pressure welding the workpiece deformation of 40%-90%.
5. Welding treatment: ultrasonic welding does not require the pretreatment of the surface to be welded and the post-processing after welding as other welding.
6, welding advantages: processing ultrasonic welding without flux, metal filler, external heating and other external factors.
7, welding effect: ultrasonic welding can minimize the temperature effect of the material (welding zone temperature does not exceed 50% of the absolute melting temperature of the metal to be welded), so that the metal structure does not change, so it is very suitable for welding applications in the field of electronics.

5.Application:
Ultrasonic gold welding machine is suitable for welding of multi-strand stranded wire and bar wire, welding of rotor and rectifier, welding of rare metal electrical joint, welding of large size wire and terminal, welding of copper terminal and beryllium copper alloy, welding of electromagnetic wire terminal, welding of brush-braided copper wire and main power cable, welding of multi-metal wire end, welding of multi-strand stranded wire and terminal, welding of multi-strand stranded wire and terminal. Welding of contact assembly, welding of multi-strand stranded copper wire and beryllium copper terminal, welding of engine outlet wire end, welding of wire terminal and molding terminal, welding of thick copper sheet and aluminum sheet, welding of braided wire terminal and engine brush, connecting between batteries by welding, welding of nickel plating lead and platinum lead of temperature resistance device, Welding of small metal sheet and metal mesh, metal foil sheet, solid copper conductor and brass terminal, copper braided wire and brass terminal, brush frame assembly, solid copper wire and rare metal alloy wire, etc. Generally used for copper, aluminum, tin, nickel, gold, silver, molybdenum, stainless steel and other non-ferrous metal material sheet, fine rod, wire, sheet, belt and other materials for instant welding, the total thickness of up to 2-4mm; It is widely used in automotive interior parts, electronics, electrical appliances, motors, refrigeration equipment, hardware products, batteries, solar energy, transportation equipment and other industries.

6. According to its process can be divided into:
1. Fusion
2. Implant
Step 3: Shape
4. Riveting
5. Shock down
6. Spot welding
7. Hot melt
Advantages of Ultrasonic metal welder；
1, high reliability: through time, energy, power and high limit monitoring, ensure excellent process control;
2, cost saving: avoid consumables such as solder, flux, bending and brass materials, make ultrasonic welding has the best economic benefits of the process;
3, low energy consumption: the energy required by ultrasonic welding is less than resistance welding;
4, tool life: ultrasonic tools are finished with high-quality tool steel, with excellent wear resistance, easy installation, high welding accuracy;
5, high efficiency and automation: typical welding speed is not more than 0.5 seconds, small size, less maintenance work, strong adaptability, make ultrasonic equipment become the first choice of automatic assembly line;
6, low working temperature: because ultrasonic welding does not produce a lot of heat, so it will not make the metal workpiece annealing, will not melt the plastic shell, nor need cooling water;
7, in addition to insulation: in most cases, the high-frequency friction of ultrasonic welding makes it unnecessary to strip the insulation of enameled wire or to pre-clean the surface of the workpiece;
8, dissimilar metal welding: for different or similar metal (such as copper + copper or aluminum + copper) has excellent welding penetration mixing effect;
9, equipment features: It through the time, energy, limit, frequency detection, to ensure the welding accuracy, vertical (non-fan) pressure system, after welding plane height uniform, simple adjustment.