How do the ultrasonic welding machines work?

Ultrasonic welding is a very mild joining technology for thermoplastic materials and non-ferrous metals. In the plastic processing industry, the manual workstation has many uses. The user manually loads the plastic parts to be connected and then takes them out from the ultrasonic welder after welding. Depending on the size and geometry of the components, one or more ultrasonic electrodes can be used to weld these components. Some automation solutions support the workflow of producing high-quality thermoplastic products. So, how exactly do the ultrasonic welding machines work? Please let me introduce this to you in the following contents.

Here is the content list:

• What is an ultrasonic welding machine?

• What are the components of an ultrasonic welding machine?

• What is the working process of an ultrasonic welding machine?

What is an ultrasonic welding machine?

The ultrasonic welding machine is one of the most popular welding machines in the welding industry. It is fast, economical, and easy to automate, and is very suitable for mass production, with a maximum productivity of up to 60 parts per minute. The ultrasonic welding machine uses high-frequency ultrasonic energy to generate low-amplitude mechanical vibrations. The vibration generates heat at the joint interface of the welded parts, causing the thermoplastic material to melt and form a weld after cooling. Also, the ultrasonic welding machine is the fastest known since the welding time is usually between 0.1 and 1.0 seconds. Ultrasonic welding is used in almost all major industries. The limitation of ultrasonic welding is that current technology cannot weld large joints in a single operation and specially designed joint details are also required. Ultrasonic vibration can also damage electrical components, although the use of higher frequency equipment can reduce this damage. 

What are the components of an ultrasonic welding machine?

Ultrasonic welding equipment consists of machine presses, generators, transducers, superchargers, ultrasonic generators, and component support tools. To put it more briefly, I will discuss only the most important parts: The generator is used to convert the electrical energy from the single-phase power supply into the correct frequency and voltage. So that the transducer can convert into mechanical vibration mode. The microprocessor unit controls the welding cycle and feeds back key welding information to the user through the user interface. The user interface also allows the operator to enter the required welding parameters. Wielding stack is a machine part that provides ultrasonic mechanical vibration. It is usually a three-part unit consisting of a transducer, a booster and a welding head, and is installed on the welding press at the centre point of the booster part. The stack is a tuned resonator, not like a tuning fork of a musical instrument. To be effective, the resonant frequency of the tuned welding chimney must closely match the frequency of the electrical signal from the generator.

What is the working process of an ultrasonic welding machine?

Ultrasonic welding of thermoplastic materials is a welding technology that uses a mechanical vibration to generate heat through molecular friction. This key function of an ultrasonic welding machine is performed by a dynamic high-performance ultrasonic generator, which continuously generates high-frequency electric vibration. Through the piezoelectric effect in the ultrasonic transducer, it can be converted into mechanical vibration. These vibrations excite the molecules in the plastic, causing them to start moving. The plastic softened and began to melt. Since the components are bonded by bonding or forming joints. After being under pressure for a short period of time, they can be firmly bonded together. This technology is the first choice for mass production in the automotive, electrical, medical, packaging, sanitary and filter industries. Also, If the material and design of the parts are suitable for ultrasonic technology, good bonding quality can be obtained in terms of strength, tightness and visual appearance. 

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