Professional mask manufacturers
Huitong Automatic
Add:No. 298, Tunxi Road, Dayu Industrial Zone, Wanjiang District, Dongguan City Tel:0769-21688352
Contact:Mr. Chen

Six common problems with ultrasound

1, the welding process artifacts misunderstanding
Ultrasonic energy is instantaneously erupted, and the welding line should be in point or line and the transmitted distance must conform to the ultrasonic welding method. Some people think that as long as it is a plastic material, no matter how the joint surface can be welded well, this is the wrong understanding, when the instantaneous energy is generated, the larger the joint area, the more severe the energy dispersion, the worse the welding effect, and even can not be welded. Ultrasonic waves are transmitted longitudinally, and the energy loss is proportional to the distance. The long distance should be controlled within 7.5 cm. The welding line should be controlled in the best condition between 0.3-0.8mm, the wall thickness of the workpiece can not be less than 2mm, otherwise it can not be well welded, especially the products that require water tightness.
2, workpiece material misunderstanding
Ultrasonic welding machine is required for the welding of the workpiece material, not all materials can be welded, some people think that any material can be welded, this is a major misunderstanding, some of the different materials can be a good welding, some basic welding, Some are not fused. The melting point of the same material is the same, from the principle of welding. However, when the welding workpiece has a melting point of more than 350 degrees, it is not suitable for ultrasonic welding. Because ultrasonic is the moment to make the workpiece molecules melt, the judgment basis is within 1-3, can not be a good welding, it should choose other welding processes, such as hot plate, rotary melting, vibration and friction. In general, ABS material is the easiest to weld, because the melting point is low and the hardness is also hard, whereas nylon is the most difficult to weld.
3, ultrasonic selection errors
The output power, oscillation frequency, and amplitude range used should be considered based on the material of the workpiece, the area of ??the wire, the presence or absence of electronic components in the workpiece, and whether air-tightness is required. Misconception that the greater the power, the better. This is also a misunderstanding. If you don't know much about ultrasound. It's best to consult a regular ultrasonic production plant engineering and technical personnel. If conditions permit, it is best to communicate to the factory site. Do not blindly listen to the misleading of some informal ultrasound sales personnel. The companies that currently manufacture related equipment are particularly complex. Most of them are home-based workshops, and they are imitations of the circuit, and they understand the working principle. Imitation equipment has a fatal flaw. One is that the quality of the raw materials purchased cannot be guaranteed, and the core technology of the second production process is not mastered. The equipment often shows instability in mid-power and high-power work, and the product qualification rate is low. Sometimes the equipment is damaged. For transducer power transformers, the magnetic material parameters used cannot be measured, magnetic saturation flux density (Bs), magnetic induction intensity (Bm), effective permeability (Ue), residual magnetic flux density (Br), coercive force (A/M), etc., the winding process is rather complicated and these home-style workshops cannot be done. Therefore, to purchase ultrasound, it is best to first understand the company's situation, do not blindly obey the salesman touted, and do not only price. Only in this way can we reduce unnecessary trouble in the future.
4, ultrasonic output power error
Ultrasonic output power, the same as the diameter and thickness of the piezoelectric ceramics, material, design process, the transducer shape, the maximum power will be stereotyped, measuring the output energy size is a complex process. The bigger the transducer is, the more the power circuit is used in the circuit, the greater the output energy, and it must be a fairly complex amplitude measuring instrument to accurately measure its amplitude. Since most users do not know much about super-shinbo, In addition, the misleading sales staff gives the consumer a wrong understanding. How much energy is consumed does not reflect the size of the output ultrasonic power. For example, low vertical energy generation and large current consumption can only indicate the efficiency of the equipment and no power. Say.
5, misunderstanding on the principle of welding
A considerable number of people involved in ultrasonic welding for many years have misunderstood the transmission of ultrasonic energy. It is considered that sound waves are welded at the contact surface. This is actually a misunderstanding. The real welding principle is that after the transducer converts electrical energy into mechanical energy, it passes through the workpiece. When the material molecules conduct, the acoustic impedance of the acoustic wave in the solid is much smaller than the acoustic resistance in the air. When the acoustic wave passes through the joint of the workpiece, the acoustic resistance in the gap is large, the heat energy generated is quite large, and the temperature first reaches the melting point of the workpiece. With a certain amount of pressure, the seam welds, and the other part of the workpiece will not be welded because of low acoustic resistance and low temperature. Its principle is similar to Ohm's law.
6, misunderstanding of the welding structure
There are various types of ultrasonic molds, and the shape of the workpiece determines the shape of the mold. However, the size, curvature, and material of each part must be strictly calculated. Some people mistakenly think that it is only a metal block. Whether the design is reasonable or not directly affects the efficiency, lifespan, product qualification rate of the mold, and directly burns the generator when severe. The material of the mold is generally magnesium aluminum 7075, and some people use inferior materials to reduce costs. Regular mold manufacturers have a set of strict inspection procedures for feeding materials. The processing dimensions are processed and simulated by computer software. Quality is guaranteed. These workshops cannot be done by general workshops. Without reasonable design, the molds made are not obvious when welding small workpieces. When the power is high, there are various drawbacks. In the event of serious damage to components.
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