15khz high precision ultrasonic welder & Tools for plastic welding solution

A.The principle of ultrasonic welding

Ultrasonic plastic welding utilizes high frequency, vertical motion to produce heat and the flow of thermoplastic material at the interface of mated parts. Pressure is maintained after the delivery of energy is stopped to allow re-solidification of interwoven plastic at the joint, securing the parts with a homogeneous or mechanical bond. This process offers an environmentally friendly means of assembly as opposed to conventional adhesives or mechanical fasteners.

Sonic welding, therefore, is very similar to vibration welding. A side note here. There are two types of vibration welding: linear and axial. The most common is linear vibration. In this case, friction is created by a linear, back-and-forth, motion. However, axial, or orbital, vibration welding permits irregular-shaped plastic materials to be welded. In general, vibration welding, like sonic welding, is capable of creating strong, pressure-tight joints at a very rapid rate. Sonic welding is ideal for large or small jobs. It’s also reliable and precise in its applications.Ultrasonic welding can be easily automated in the production process reducing man hours required for production and eliminating the need for adhesives and fasteners. It also cures very quickly, often in less than one second, and produces a clean, tight seal.

B.Function

1. Frequency auto-chasing: intelligent control system, frequency auto tracking.

2. amplitude adjust Infinitely : amplitude adjust Infinitely , amplitude increase and decrease by 5%;

3. intelligent protection: frequency offset protection, output overloading protection, mold damage protection;

4. electrical components: all pneumatic components and main electronic components of the machine are imported from Germany and Japan;

5. fuselage structure: the frame of the machine adopt special steel structure and made by precision cast aluminum CNC machining processing , the frame is more precise and more stable

C.Parameter:

Frequency	15Khz	30KHz
Generator	3000W/5000W	2000W
Welding model	Time model energy model, power model, depth model
Distance micro-adjustment	20-100mm Precision:0.01 mm
The height of the frame in max	280mm
Input Voltage	220V/110V

For joining complex injection molded thermoplastic parts, ultrasonic welding equipment can be easily customized to fit the exact specifications of the parts being welded. The parts are sandwiched between a fixed shaped nest (anvil) and a sonotrode (horn) connected to a transducer, and a ~20 kHz low-amplitude acoustic vibration is emitted.When welding plastics, the interface of the two parts is specially designed to concentrate the melting process. One of the materials usually has a spiked or rounded energy director which contacts the second plastic part. The ultrasonic energy melts the point contact between the parts, creating a joint. This process is a good automated alternative to glue, screws or snap-fit designs. It is typically used with small parts (e.g. cell phones, consumer electronics, disposable medical tools, toys, etc.) but it can be used on parts as large as a small automotive instrument cluster. Ultrasonics can also be used to weld metals, but are typically limited to small welds of thin, malleable metals, e.g. aluminum, copper, nickel. Ultrasonics would not be used in welding the chassis of an automobile or in welding pieces of a bicycle together, due to the power levels required.

Application:

Ultrasonic welding allows you to mold pieces separately and then fuse the multiple units together, creating a more complex single part. It’s a highly precise and low-contaminate process, making it an ideal process for parts used in a variety of applications across many industries including aerospace, automotive, computer, consumer products, electrical, medical and packaging.

Ultrasonic welding is used in the production of items such as:

• Circuits and wiring
• Flash drives and computer disks
• Instrument panels and engine components
• Medical filters and tubing
• Sealing and beverage containers