![]() It mainly has three parts, the booster, welding horn, and transducer. The welding stack provides the required ultrasonic vibrations. The welder gets the necessary communication through the microprocessor unit of the generator. After this, the transducer converts this electrical energy into mechanical vibrations. The generator converts electrical energy from the primary source (Single phase) to the needed voltage and frequency. You can adjust the welding force through a pressure gauge or regulator. It has a base plate holding the cooling jig and a pneumatic cylinder that exerts pressure. You use this to hold the welding system and apply force. To understand the working principle, you need to understand all its parts. Converting HF electrical energy into mechanical motion, the plastic material forms a molecular bond after melting. The ultrasonic welding process uses high-frequency ultrasonic vibrations around 20 kHz to 40 Khz to join two thermoplastic pieces. ![]() The advantages of Ultrasonic Wire Splice harness welding machine.The requirements of the ultrasonic metal welding process.The Types of Ultrasonic Metal Welding Products.Ultrasonic Wire Splice Quality Variables.Two types of Ultrasonic Wire Splicing Machines.In-Depth Look at Ultrasonic Wire Splice.Ultrasonic Wire Splice: Step 6: Horn Retracts.What is the Process of ultrasonic welding?.A better option, ultrasonic wire splice, is becoming popular in new applications, especially in automotive. ![]() For example, it is challenging to have tight control of the process, and in areas where the temperature is too high, you cannot trust the integrity of the spliced ends. On the other hand, soldering is also a good solution but has drawbacks. Another issue is that it causes high electrode wear, which operators must pay regular attention to. However, the biggest drawback is high heat generation, damaging the spliced materials. Compared to soldering, you prefer resistance welding in applications with nickel or steel or where the bundle of wires is too small. You generally use soldering and resistance welding methods for wire splicing because they are trusted and reliable solutions in many applications. ![]()
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