Ultrasonic Welding Sensor

Nowadays, ultrasonic sensors are used more and more widely, such as non-woven fabric welding, plastic hose welding, packaging welding and so on. There are high requirements for the fixed installation of ultrasonic welding sensors. Regardless of the structural form of ultrasonic transducers, they will have a fixed installation position, which is usually the node of vibration and theoretically has zero amplitude. However, in practical application, a rubber pad is added to absorb the vibration, which is used to completely isolate the transmission of the ultrasonic transducer vibration to the flange fixed plate.

FAQ

Q: The installation of ultrasonic welding sensor shall pay attention to the following points:

1. The transducer of the ultrasonic welding machine must be perpendicular to the mounting surface of the flange;

2. Both sides of the fixed edge of the ultrasonic horn are completely filled with rubber pads, usually is nylon plastic gaskets;

3. The flange pressing plate must ensure that the ultrasonic welding sensor cannot rotate correspondingly, and there is usually a positioning device to prevent rotation;

4. The vibration edge of the ultrasonic horn shall not contact any metal part of the flange to avoid abnormal sound and leakage wave;

5. The ultrasonic transducer is divided into positive and negative electrodes, which shall not be wrongly connected. The electrodes shall be subject to shock absorption and insulation treatment

6. The connecting wire of the ultrasonic transducer shall be long enough and soft, because the head of the ultrasonic welding machine is in a reciprocating state for a long time to avoid fracture.

Q：What about the main functions of ultrasonic welding parts?

1. The ultrasonic electric box is responsible for power output and protection of various components (including control programs); Reasons for easy damage: (issues with its own quality and protective function);

2. The Ultrasonic Welding Sensor is the core component of the entire ultrasonic system; Responsible for converting high-frequency and high-voltage into mechanical vibration energy. Reasons for easy damage: (high no-load power consumption and poor material quality);

3. Amplifiers are responsible for amplitude amplification; Reasons for easy damage: (high no-load loss and aluminum alloy material).

4. The mold is responsible for pressure welding products (terminal output, amplitude, maximum, determining the working frequency of the entire system); It is the most easily damaged component in the entire system. Reasons for easy damage: Materials and manufacturing processes (sound waves tremble, heat, and the most common is high no-load power loss).

If the mold design and manufacturing are not reasonable, there may be large frequency deviation, sound waves shaking, and overheating. The most common is the high loss of no-load power, which leads to other components working under overload and poor conditions (working with diseases and overload). The system protection alarm will only be triggered when the parameter deviation limit is reached (warning: the protection system will not be triggered when the parameter deviation of each component is too large but the protection limit is not reached). If working for a long time in such a situation, it will accelerate the shortening of the entire system service life, and even directly damage any component of the entire system (mold cracking, followed by aluminum alloy amplitude modulators, aluminum alloy transducers, and finally the generator assembly) if the generator protection is not timely.

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