Ultrasonic Welding Vibrator

The principle of Ultrasonic Welding Vibrator is to achieve high-frequency vibration with large amplitude by applying pre-stress to counteract the expansion stress of piezoelectric ceramics. Due to the high instantaneous power required for welding transducers, they have high requirements for materials and processes, and are classified as high-power acoustic energy transducers. Usually, a high-power and large-amplitude vibration system is composed of a horn and a working head to complete ultrasonic welding of materials such as plastic and metal. Ultrasonic welding is the use of ultrasonic vibrations generated by transducers to generate high-frequency friction and heat on the contact gap surface of the welded object under pressure, thereby achieving the goal of thermal fusion welding.

Ultrasonic welding transducers are high-power transducers that operate in gaps or pulses, and their power is generally calculated based on instantaneous peak power.

Specifciation of Ultrasonic Welding Vibrator

FAQ

Q: The common problems in the use of ultrasonic welding vibration sensor

Ultrasonic transducer chip cracking, weak ultrasonic wave, easy overload, electrode chip ignition, electrode chip cracking, serious heating, abnormal sound, leaky wave, chip dislocation, etc. these problems are caused by the following reasons:

1. there is an assembly problem with the ultrasonic generator (ultrasonic power supply or ultrasonic electric box) or the mold (ultrasonic welding head).

Solution: check the installation of these components for any problems. If you still cannot find the cause, you can contact our online technician to help you solve the problem.

2. the product quality is OK, but the capacitance and frequency do not match.

This is the most common case. If not, the sensor performance is poor and the welding is unsafe. The sensor is overloaded, and resulting in dislocation, cracking, fracture of the wafer, fracture of the screw, aluminum crack or burning of the box power supply tube. But now the mostly ultrasonic equipment is equipped with automatic detection and overload protection alarm devices, which can effectively prevent the possibility of equipment damage.

And why the ultrasonic welding vibrator has unstable welding effect; and has serious heating

This is because the ceramic chip is an insulator and the sensor is not powered on. It is only used as a capacitor. In order to make the sensor work, it is actually necessary to apply a high AC voltage to the sensor capacitor by driving the circuit for charging and discharging the sensor capacitor. Under the action of alternating electric field, the piezoelectric ceramic plate expands and deforms synchronously, forming the longitudinal vibration of the whole transducer, thus driving the vibration of the horn and the die. Therefore, if the capacitor is not well matched, the welding is not firm; The frequency converter is seriously heated, the electrode is burnt out, and the power supply of the high-power tube is burnt out.

Why the ultrasonic welding transducer's electrode ear has been cracking or burning?

As the ultrasonic welding sensor works continuously for a long time, the temperature of the sensor will rise, and it resulting in an increase in capacitance, which may vary by more than 50%. If the capacitance cannot be matched effectively, the phase difference between current and voltage in the circuit will be very large, the power factor will be very low, and the virtual power will be very high. Although the current is very large, the frequency converter has no power supply and it is easy to heat, and the power supply device is also easy to heat and damage. This may cause cracking or burning of the common sensor electrode ears.

Solution: Suspend use until the equipment is started after cooling. Usually, when it vibrates discontinuously,that will with little overload.

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