Plastic Ultrasonic Welding Machine
WELDINGThe typical profile of a joint design for ultrasonic welding has two functions: 1)lts shape of a groove and tongue eases positicning during assembly and maintains In place the parts during the welding cycle. 2)The energy director in the joint concentrates the energy to a small ared supplies at the same time the necessary material for an optimal welding joint The profile of the joint area depends largely on the purpose of the application; it can therefore be shaped quite differently. The settings of the machine, like welding pressure and amplitude, are adjusted to produce a movement of the hom front in phase with the part to be welded. The second part placed in the fixture must stay passive. The motional interference produces friction in the contact area of the two parts. Due to this highly intensive ultrasonic vibration the joint area melts together immediately.Under the pressure applied simultaneousy and some fractions of a second longer than the ultrasonic impulse lasts the melted area solidifies and inseparable joint is produced.
STAKING Ultasonic staking is used to assemble injected plastic parts with parts of another material.Studs on the molded plastic part penetrate the second article to be mounted. The projecting part of these studs is formed into riveting heads with a specially shaped horn tip. The cavity in the horn is big enough to hold the displaced material and form it nicely. The amplitude of the horn has to be adjusted for maximum motional interference between oscillating horn tip and plastic stud. Heat is then produced by friction between the plastic part and the horn tip, which allows an immediate melting in this area. The pressure controlled by the welding machine lets the riveting head solidify after a short hold time. Multi-tip horns are often used for simultaneous staking of different areas on the same part. SPOT WELDINGUltrasonic spot welding id used whenever large plastic parts cannot be placed on a traditional machine. Therefore, the welding head designed as a handgun is brought to the part; either manually or with a robot. The advantage of ultrasonic spot welding is the fact that the parts do not need any special preparation (no energy director required ).Therefore large size vacuum formed parts can also be assembled easily. The ultrasonic horn is built to produce high amplitude. The tip of the horn is shaped in order to penetrate the two layers of material, leaving a typical ring pattern on the workface, while the backside rests smiith and clean. INSERTION OF METAL PIECES A metal piece such as a threaded insert or bolt has to be embedded into an existing hole in a plastic part. The metal piece is contacted by the oscillating horn, which creates friction between the two parts melting the plastic material. The machine pressure displaces the now melted material into the structure on the metal part surface.Once the displaced material has solidified the inserted piece remains tightly seated and resists to tensional as well as to torsion forces.Feature PLL Auto Tuning The PLL Auto Tuning technology synchronize the frequency change of horn and the AMP output. The synchronization expand the auto tuning range, simplify the fabrication of the welding horn. The AMP would output the perfect vibration no matter how the temperature rises of the horn or of the welding environmental, or the abrasion of the horn.Hat would also be able to reduce the welding failure rate. Auto Tuning Range: 15Khz±350Hz,20Khz±500Hz,30Khz±700Hz,40Khz±800Hz. Voltage Feedback Keep the steady output of voltage and amplitude without AVR system. Input voltage variation is allowed between 180V to 240V. This feedback control could guarantee the welding stability. Overload protect The upper and lower specification limits of electric current and voltage can be measured, and the output can be cut out in case there is problem. Soft start protect Effective Soft start protect could remove the harm to the horn at the very beginning of vibration, and eliminate the malfunction at the ultrasonic vibration. (Tunable range:10mses~200mses) Multi-welder cylinder synchronization Air pressure inspection and air cylinder moving speed adjustment, these two function could guarantee the synchronization of the cylinders movement when multiple welders is needed. ModesUltrasonic weldingTwo requirement of the welding surface: A: rationality of welding surface design B: same thermoplastic material of the welding parts Ultrasonic cutting Welding surface of the horn is designed as a blade, the heat produced by the ultrasonic vibration could cut things off. Ultrasonic embedding Insert the metal piece onto the plastic, and make the horn connect the metal part, when ultrasonic welding start the pressure and heat embed the metal into the plastic. Ultrasonic moldingMold two part plastic surface together.Ultrasonic riveting Used in different material plastic welding, one kind plastic rivet prong through the other kind plastic. The surface of the horn is designed in a vaulted shape, so that it could encapsulate the melting plastic rivet to cover the other material plastic during the welding process.
Contact Person: Jenny Yang
Mob:+86 186 5052 3130
Company web: http://newstar-machinery.com
alibaba show room: http://newstar-machinery.com