Ultrasonic Welding Machine: From Principle to Application, Comprehensive Analysis
2025-04-30
In the current booming development of the new energy vehicle industry, Shenzhen Chengguan Intelligent Ultrasonic Equipment Co., Ltd. (referred to as "Chengguan Intelligent Ultrasonic") has precisely targeted industry pain points and launched the CGSF20K2600W series fully automatic ultrasonic welding system. This system is specially designed for welding scenarios of new energy vehicle power batteries and high-voltage wiring harnesses, and can be regarded as a revolutionary work in the industry. This series is equipped with advanced AI adaptive algorithms, like an experienced craftsman, which can monitor welding pressure, amplitude, and temperature in real-time and accurately, greatly improving welding quality. The welding yield rate is as high as 99.8%, which is a 30% increase compared to traditional equipment, significantly reducing the defect rate and production costs. Technology research and development is the core driving force of Chengguan Intelligence. With independently developed multi band transducer technology, covering frequencies of 15kHz-40kHz, the company has greatly expanded the application boundaries of ultrasonic welding technology. With this technological advantage, Chengguan Intelligent Ultrasonic has successfully established strategic cooperation with leading enterprises in the new energy field such as BYD and CATL, deeply integrating into the industry supply chain system. In 2024, Chengguan Intelligent's order volume achieved explosive growth, with a year-on-year increase of 200%, demonstrating the high recognition of its products and technology in the market.
Ultrasonic welding machine is a device that uses ultrasonic energy to achieve material connection, and is widely used in the welding of plastics, metals and other materials. Here is a detailed introduction:
In the field of industrial manufacturing, welding is a key process for achieving material connections. Ultrasonic welding machines, as advanced welding equipment, can simultaneously meet the welding needs of plastics and metals. With their high efficiency, environmental friendliness, and high-quality welding results, they play an important role in multiple industries. Below, we will introduce this type of device to you from the dimensions of principle, structure, advantages, and application scenarios.
Principle Introduction
1. Principle of Ultrasonic Plastic Welding Machine
The ultrasonic plastic welding machine uses the principle of high-frequency vibration to convert electrical energy with a frequency of 20kHz or higher into mechanical vibration of the same frequency through a transducer. The vibration is amplified by the amplitude lever and transmitted to the welding head. The welding head applies vibration energy to the plastic workpiece, causing the plastic surfaces to rub against each other and generate heat. When the temperature reaches the melting point of plastic, the plastic quickly melts. Under sustained pressure, melted plastics merge with each other. After the vibration stops, it cools and solidifies to achieve a firm connection of the plastic.
2. Principle of Ultrasonic Metal Welding Machine
Ultrasonic metal welding also utilizes high-frequency vibration to generate strong friction on the metal surface under pressure. This process not only removes the oxide film on the metal surface, but also raises the interface temperature to achieve the conditions for atomic bonding, thereby achieving atomic level connection without melting the metal, ensuring that the original properties of the metal are not affected.
System Construction
1. Ultrasonic generator
Whether it is a plastic or metal welding machine, the ultrasonic generator plays a core control role. It converts mains electricity into high-frequency AC power and precisely adjusts the output frequency and power. Operators can set parameters on the control panel based on different welding materials, workpiece sizes, and welding requirements to ensure stable and accurate welding processes.
2. Transducer
The transducer is a key component for converting electrical energy into mechanical energy, mainly composed of piezoelectric ceramics. Under the action of high-frequency alternating current output from the ultrasonic generator, piezoelectric ceramics undergo high-frequency expansion and contraction deformation, thereby efficiently converting electrical energy into mechanical energy.
3. Variable amplitude pole
The amplitude lever is used to adjust and amplify the vibration amplitude output by the transducer, so that it reaches the range required for welding. By designing the shape and size of the amplitude rod reasonably, the vibration amplitude can be precisely controlled to meet the requirements of different welding processes and ensure that the vibration can be effectively transmitted to the welding joint.
4. Welding head (mold)
The design and material of welding joints vary depending on the different requirements for plastic and metal welding. Plastic welding joints are usually made of aluminum alloy material, which is lightweight and has good thermal conductivity; Metal welding joints often use tool steel or hard alloys to cope with high pressure and wear during metal welding.
Equipment advantages
1. Efficient and energy-saving
Ultrasonic welding machine has fast welding speed, short single welding time, and can achieve automated continuous production, greatly improving production efficiency. Meanwhile, the equipment has low energy consumption and can effectively reduce production costs compared to traditional welding methods.
2. Good welding quality
The welding process does not involve melting and solidification, avoiding the occurrence of defects such as pores and cracks. The welding joint has high strength and good sealing, which can meet the strict requirements for welding quality in application scenarios.
3. Environmentally friendly and pollution-free
The welding process does not require the addition of auxiliary materials such as flux and solder, and does not produce harmful gases or waste, making it environmentally friendly.
4. Wide applicability
It can weld various plastic materials such as polyethylene and polypropylene, as well as various metal materials such as copper, aluminum, and silver, and can also achieve welding between different materials.
Application scenarios
1. Application of Plastic Welding
In the field of automobile manufacturing, it is commonly used for welding automotive interior parts such as instrument panels and door panels; In the electronic and electrical industry, the assembly of casings for devices such as mobile phones and computers also relies on ultrasonic plastic welding; In the packaging industry, this technology is also used for sealing and connecting plastic packaging containers.
2. Application of Metal Welding
In the electronics and new energy industries, ultrasonic metal welding machines are used for connecting lithium battery electrodes and lugs; In the automotive manufacturing industry, it is commonly used for connecting automotive wiring harnesses and welding engine components; In the aerospace field, it is applied to the welding of aircraft engine components and fuselage structural parts.
Ultrasonic cutting machine is a device that uses ultrasonic vibration for cutting and has a wide range of applications in multiple fields. Here is a detailed introduction to it:
Working principle
The working principle of ultrasonic cutting machine is to convert electrical energy into high-frequency mechanical energy. By using an ultrasonic generator to generate high-frequency electrical signals, the piezoelectric ceramic elements inside the transducer are driven to produce high-frequency vibrations. This vibration is amplified by the amplitude lever and transmitted to the cutting tool, causing the tool to vibrate with small amplitudes at extremely high frequencies (usually between 20kHz and 100kHz). When the cutting tool comes into contact with the material being cut, the energy generated by high-frequency vibration weakens the intermolecular forces inside the material, and the friction between the tool and the material generates heat, further reducing the strength of the material and achieving cutting of the material.
Structural composition
Ultrasonic generator: It is the control core of the equipment, which converts the mains power into high-frequency AC power, provides the required electrical signal for the transducer, and can accurately adjust the output frequency, power and other parameters according to the characteristics and cutting requirements of the cutting material.
Transducer: mainly composed of piezoelectric ceramics and other materials, its function is to convert the high-frequency electrical energy output by the ultrasonic generator into mechanical energy, that is, to generate high-frequency vibration.
Variable amplitude rod: used to amplify the vibration amplitude generated by the transducer, so that the cutting tool can obtain sufficient energy for effective cutting. It is usually designed in different shapes and sizes according to different cutting requirements to achieve the best amplitude amplification effect.
Cutting tool: It directly acts on the material being cut and is usually made of special alloy steel or hard alloy materials to ensure that the tool has good wear resistance and strength under high-frequency vibration. The shape and size of the cutting tool are designed according to different cutting tasks, such as blade type, serrated type, etc.
Mechanical transmission device: including motors, reducers, transmission belts or chains, etc., used to drive cutting tools for linear or curved motion, achieving cutting of materials. Some ultrasonic cutting machines are also equipped with numerical control systems, which can accurately control the movement trajectory of the cutting tool and achieve cutting of complex shapes.
Equipment features
High cutting accuracy: It can achieve high-precision cutting, with neat and smooth cutting edges, small dimensional errors, and can meet the process requirements for high cutting accuracy.
Wide range of applicable materials: it can cut a variety of materials, such as plastic, rubber, leather, cloth, foam, wood, etc., especially for some soft, viscous or brittle materials that are difficult to deal with by traditional cutting methods, ultrasonic cutting has obvious advantages.
Fast cutting speed: Due to the effective reduction of material cutting resistance by ultrasonic vibration, the cutting speed is relatively fast, which can improve production efficiency.
Non thermal deformation: The cutting process generates less heat and does not cause significant thermal deformation of the material, making it particularly suitable for materials that are sensitive to heat.
Environmental protection and energy conservation: There is no need to use tool lubricants or other auxiliary cutting media during the work process, reducing environmental pollution, and the equipment has relatively low energy consumption.
Application Fields
Plastic processing industry: used for cutting various plastic sheets, pipes, films, etc., such as cutting plastic packaging materials, making plastic models, etc.
Clothing and textile industry: It can accurately cut fabrics, leather, etc. for clothing cutting, leather product processing, etc., which can improve cutting efficiency and quality and reduce material waste.
Food industry: suitable for cutting chocolate, candy, pastries and other foods. The edges of the cut products are neat, without producing debris, and can maintain the original shape and taste of the food.
Electronics industry: In the production of electronic components, it can be used to cut insulation materials, circuit board substrates, etc., meeting high-precision cutting requirements.
Medical industry: used for cutting medical rubber products, plastic products, dressings, etc. Its high precision and no thermal damage characteristics help ensure the quality and safety of medical products.
Ultrasonic homogenizer is a device that uses ultrasonic energy to achieve material homogenization treatment, widely used in various fields such as biology, pharmaceuticals, food, and chemical engineering. Here is a detailed introduction to it:
Working principle
Ultrasonic homogenizer uses high-frequency ultrasound to generate cavitation effect and other physical effects in liquid to homogenize samples. Its working method is to place the sample on the oscillating cover plate of the processor, generate high-frequency electrical signals through an ultrasonic generator, drive the piezoelectric ceramic elements inside the transducer to generate high-frequency mechanical vibrations, which are amplified by the amplitude rod and transmitted to the sample through the tool head. Under the action of ultrasound, weak areas in the liquid will produce voids or small bubbles, which will collapse within one acoustic cycle due to the pulsation of ultrasound. This process generates strong mechanical forces, producing rapid jets or acoustic shock near the solid interface and generating large shock waves in the liquid, effectively homogenizing, dispersing, or dissolving cells, tissues, or particles in the sample.
Structural composition
Ultrasonic generator, transducer, amplitude rod, mold, etc
Equipment features
Efficient homogenization: It can achieve sample homogenization in a short period of time, improving work efficiency.
Wide scope of application: it can be used for the treatment of various types of samples, including cells, tissues, lotion, suspensions, etc., and is applicable to many fields such as biology, chemistry, medicine, food, environment, etc.
Easy to operate: Simply place the sample into a suitable container, set the parameters, and start the homogenization process.
Accurate control: Ultrasonic power, working time, temperature and other parameters can be precisely adjusted according to experimental requirements to meet the requirements of different samples and experiments.
Non contact processing: avoids contamination and damage to the sample caused by contact operations such as mechanical stirring or grinding in traditional homogenization methods.
application area
In the field of biology
Pharmaceutical field
Food sector
Chemical industry field