During the ultr asonic welding process, welding parameters will affect the welding results. These parameters include amplitude, welding distance, welding pressure, welding energy and trigger pressure.
Different types of plastic require different amplitudes. The amplitude can be fine-tuned through the percentage settings in the software, or a wide range of adjustments can be made by replacing amplitude modulators with different ratios. Welding pressure can be adjusted via a knob or software settings. Trigger pressure means that after the welding head presses the product, when the pressure reaches a certain set value, the device starts to emit ultrasonic waves. This value can be adjusted through the knob or software settings.
In fact, there are multiple control modes for the operation of ultrasonic welding equipment. Normally, it is divided into two types: time mode and energy mode.
One is the simple and commonly used mode is the time mode, which sets the duration of the ultrasonic weld without considering other parameters. Another commonly used mode is the energy mode, which sets the energy of the welding. This mode usually requires a microprocessor-based controller to measure and record the energy input during the welding process and calculate the energy (the integral of the energy over the entire time ). In this mode, the ultrasonic vibration always stops when the energy of the piece is reached or the displacement is large. In power mode, when the instantaneous power exceeds the preset power, the ultrasonic vibration stops.
There is also a distance welding mode (position mode) that sets the distance or position of welding. Used to control the final dimensions of the weldment, the ultrasonic mold stops when in contact with the fixture. The welding of different products is suitable for different welding modes. For example, energy welding mode is used for sheet welding, distance welding mode is used for products with large dimensional tolerances, and position welding mode is used for products with height tolerance requirements.
All parameters during the welding process should be monitored and parameters qualified parts should be set to reduce the occurrence of defective parts. Plastic ultrasonic welding is a systematic process. In the early stages of product development, you should cooperate with ultrasonic equipment manufacturers, use the equipment manufacturers’ experience in this field, evaluate product structure and welding design, and conduct welding tests on samples. Das Ultrasound has 15 years of experience in this field. Various fields of application: ultrasonic welding of automotive plastic parts, medical product welding, electronic product welding, plastic packaging welding, etc.
