Ultrasonic Wire Connect Welding
Ultrasonic welding does not require the surface of molten material to connect them. On the contrary, it applies high-frequency vibration to two metal workpieces that need to be connected. These two metal workpieces are placed between the "welding head" and the "anvil". The lower workpiece is "caught" by the teeth on the anvil and fixed in place. The frame drives the welding head to press the upper workpiece down until the upper and lower workpieces are in close contact and pressed.
Working principle of ultrasonic wire connect welding equipments
For a long time, laser or resistance welding technology has been used to melt materials to bond high-strength ferrous metals. However, when it comes to the soft non-ferrous foil required for EV Batteries, the melting point becomes a problem. For non-ferrous metals, melting of materials will produce intermetallic compounds or corrosion, which will lead to premature wear of materials and connections, leading to battery failure. In addition, when bonding multiple foil layers (100 or more layers in some cases), melting such a thin and fragile material may lead to almost insoluble problems.
Ultrasonic welding does not require the surface of molten material to connect them. On the contrary, it applies high-frequency vibration to two metal workpieces that need to be connected. These two metal workpieces are placed between the "welding head" and the "anvil". The lower workpiece is "caught" by the teeth on the anvil and fixed in place. The frame drives the welding head to press the upper workpiece down until the upper and lower workpieces are in close contact and pressed.
Then the welding head vibrates horizontally with high frequency to generate vibration energy and remove surface pollutants and other coatings on the joint surface of upper and lower workpieces. The friction caused by vibration will remove the unevenness of the joint surface and produce a clean and continuous welding area, so that atomic energy can spread freely across the joint surface to the other side. When the vibration stops, this free diffusion of atoms will recrystallize into a fine grain structure equivalent to that of cold worked metals. The whole welding cycle is completed in a fraction of a second.
Parameters：
| Product number | LX20-P2000 | LX20-P4500 |
| Power supply | Single phase voltage AC220V-50Hz | Three phase voltage AC380V-50Hz |
| Air supply | Compressed air 0.1-0.6MPa | |
| Usage environment | Temperature 25 ± 5% humidity 30-90 | |
| Ultrasonic peak power | 2000W | 4500W |
| Maximum power of the machine | 2600W | 4800W |
| Ultrasonic frequency | 20KHz+0.5K | 20KHz+0.5K |
| Maximum ultrasound time | 4S | 4S |
| Adjustable accuracy of ultrasound time | 0.01S | 0.01S |
| Ultrasonic mold connection thread size | 1/2*20UNF | 1/2*20UNF |
| Weldable copper and aluminum wire sizes | 0.5-20mm² | 2.5-50mm² |
| Equipment size |
Frame: 20×48×22(cm) Chassis: 48×20×36(cm) |
Frame: 20×49×19(cm) Chassis: 48x20x36(cm) |
Advantages of ultrasonic wire connect welding process
1.Applicable to all kinds of non-ferrous materials
2.Establish permanent metallurgical bonding between different metals
3.No melting - no change in the chemical or metallurgical properties of the material
4.Very suitable for welding high conductivity alloys; The reactivity of the material is irrelevant
5.Do not produce intermetallic compounds, particles or reactions that cause corrosion
6·It is very suitable for connecting thin and fragile metal films and structures
7·A variety of control methods can realize process customization, high repeatability and statistical process control SPC (statistical process control)
8·Low energy input (energy consumption is 30 times lower than that of fusion welding or resistance welding); No consumables
9·The total cost is lower than other welding processes
Machine installation method
1. Place the welding machine on the workbench and place the vibration box near the machine body where it is easy for the operator to observe and adjust. (The workbench should be able to withstand a force of 150kg, with a height of approximately 600-800mm, and should not be placed in damp or dusty areas.)
2. Grounding: Connect one end of the grounding wire to the grounding knob behind the vibration box and the other end to the ground.
3. Connection between the vibration box and the body: Connect the output cable plug and control cable plug of the body to the vibration box socket.
4. Connect the air pressure source: Connect the high-pressure air pipe to the clean and dry air pressure source and lock the air filter inlet joint on the welded body with a pipe bundle. (Air pressure source pressure is 6-8kg/cm)
5. Connect to power: Connect the power cord and plug behind the vibration box to an AC220V, 1 Å 60/50HZ power supply
For more details of Ultrasonic Wire Connect Welding Machine, please feel free to contact us !
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