Ultrasonic metal welding machines have been widely used in various fields and industries, but many friends still don’t know the basic knowledge of ultrasonic metal welding machines. Let us introduce to you the specific applications of ultrasonic metal welding machines.
1) Nickel-metal hydride batteries Nickel-metal hydride batteries Nickel mesh and nickel sheet are mutually fused.
2) Lithium batteries, polymer batteries Copper foil and nickel sheet are mutually fused, aluminum foil and aluminum sheet are mutually fused.
3) Wires are mutually fused, braided into one and multiple fused.
4) Wires are mutually fused with various electronic components, contacts, and connectors.
5) Large heat sinks, heat exchange fins, and honeycomb cores of various home appliances and automotive products are mutually fused
6) Electromagnetic switches, fuseless switches and other high-current contacts, and mutual fusion of dissimilar metal sheets.
7) Sealing the end of the metal tube.
Important parameters for ultrasonic welding machine operation
Amplitude parameters:
For materials needing welding,amplitude is an essential parameter which acts like temperature: it indicates when towel the two together or not. If temperatures don’t meet threshold levels, welding won’t take place successfully. Temperatures that reach too high could result in raw materials being burned off, structures damaged and strength reduced – with each manufacturer choosing different transducers the output from these will differ accordingly. Adjusting the ratios between amp rod and welding head allows users to customize working amplitude of welding heads according to specific needs. Transducer output amplitude ranges between 10-20mm while working amplitude is usually 30mm; ratio between amp rod and welding head depends upon factors like shape of amp rod/welding head combination as well as ratios between front-back area ratios of amp rod/welding head combination(s).
Frequency Parameters:
Every ultrasonic welding machine from different manufacturers features its own center frequency – 20KHz or 40KHz is typical – while its working frequency depends heavily upon mechanical resonance frequencies within transducer, booster and welding horn components. To achieve consistent performance of the horn resonators, generator frequency must be tuned according to mechanical resonance frequency; each component serves as a half-wavelength resonator. Generator and mechanical resonance frequencies typically operate within an acceptable frequency range (generally +-0.5KHz), within which welding machines can usually perform optimally. At each horn fabrication step, we take great care in setting its resonant frequency within tolerance; that means ensuring its difference from its design frequency is less than 0.1KHZ for example for 20KHz horn our frequency control range will be 19.90-20.10 KHz with an error margin of less than 5%.
Spot processing accuracy:
Because the ultrasonic welding head works under high-frequency vibration, it should try to maintain a symmetrical design to avoid unbalanced stress and lateral vibration caused by the asymmetry of sound wave transmission (the welding head we use for welding uses the longitudinal transmission of ultrasonic vibration for the entire resonant system). Unbalanced vibration can cause the welding head to heat up and break.
Ultrasonic welding is applied to different industries and has different requirements for processing accuracy. For particularly thin workpieces such as the welding of lithium-ion battery electrode and tabs, the coating of copper/aluminum foil, etc., the requirements for processing accuracy are very high. All our processing equipment uses CNC equipment (such as machining centers, etc.), so as to ensure that the processing accuracy meets the requirements.
