4000W Ultrasonic Metal Welder for Copper Wire Welding
Working Principle:
Ultrasound can produce high-frequency vibration, and we use this kind of vibration to weld non-ferrous metal easily. When the high-frequency vibration wave is transmitted to the surface of the two metal parts to be welded, with a certain pressure, the two parts' surfaces will have friction on each other which leads to the joint of the molecular layers. The advantage is quick, energy-saving, high joint strength, good conductivity, and no sparkles, which is nearly cold status processing. It is designed to weld metal wires.
This machine consists of a power generator, transducer, pneumatic machine body and tooling, and some control components like a wire harness, wire measuring device, and microprocessor. The Power generator can convert the outer voltage (220V, 50 /60hz) into 20KHz (or 15Khz),1000V voltage, and be output after being controlled and regulated by the power generator to work on the transducer. The transducer is a high-effective electrical component, which can convert electrical energy into mechanical energy.
Compared with common electrical motors, the transducer has two advantages: firstly, the transducer can convert the electrical energy to linear vibration, not rotation; secondly, it has very high work efficiency, that is, it can convert 95% of the electrical energy. After converting through the transducer, mechanical energy starts to work on the welding horn. Ultrasonic welding horn is made from alloy material, which is made into a certain shape according to acoustic principle.
Ultrasonic Welding Press:
*Alcoa's fuselage 7075 series high-intensity aviation aluminum alloy material, equipment with high intensity, flexible space agency application;
*Four sets of overloading type guide rail sliding block, high repeat precision, run smoothly
*Germany Festo drive cylinder, Japan SMC pneumatic components, work fast, and stable response and welding maximum pressure can reach 5000 N
*Switzerland Baumer high-precision linear encoder system, the position accuracy can reach 0.01mm
*High precision pressure sensor system, the working accuracy can reach 1N
*real-time feedback monitoring distance and pressure data in the welding process
*Triplet resonance system can rotate in the fuselage 360 degrees
*Precision mechanical stroke limit non-contact photoelectric induction two-hand starting system, safe to use
Touch System:
* 10.1-inch color touch interactive interface
* Multi-core system chip, system response is faster
* The powerful SIT super-intelligent control system is adopted
* 3 kinds of trigger ultrasonic mode and 6 kinds of welding mode to meet the needs of customers
* 6 kinds of the quality control scheme and 2 welding data curve output
* Can store 99 sets of product welding plans and tens of thousands of sets of welding output data
* Has the function of network transmission of welding output data, which can be connected with customer MES system to provide intelligent welding quality process management and traceability function
Ultrasonic System:
* Frequency:20KHz Power:4000W
* Germany imported digital automatic frequency chasing ultrasonic generator
* With automatic amplitude compensation function, stable power output, more reliable welding quality
* real-time LED screen welding frequency and power display
* Provide abnormal alarm: frequency abnormal, current too large, overload power, too high temperature, etc.
* Imported ultrasonic transducer from Germany, P to P amplitude value up to 20 microns
* Transducer and amplitude modulator made of titanium alloy material is easy to disassemble and not easy to damage. The various gain of amplitude modulator is optional
* Can provide long quality assurance service
Control System:
* Germany Beckhoff Fieldbus control module, accurate and stable
* Integrated Japanese SMC pneumatic proportional valve control module, intelligent digital control of welding pressure, ensure the stability of pressure precision control
* Realize the same welding multi-section welding pressure technology
* Support multi-brand bar code recognition scanning gun function
* Support state network RS485 RS232 data transmission
* Support USB data access function
* Support personal PC direct connection control module
* With 2 in 2 out output port expansion
* Internal storage space of the device is 16G
Welding Fixture:
* Design each set of welding fixture independently according to customer product appearance and welding requirements
* Ultrasonic welding head materials are made of powder steel imported from Europe and America. After heat treatment, the hardness can reach 62~63 degrees. It has a high wear-resisting hardness and high toughness so that the welding head can have a longer service life
* Each welding head is analyzed by simulation software to ensure the best production plan
* Welding head center frequency: 19950±100Hz
* The power loss of welding head is less than 200W
* The welding anvil base is made of mould steel imported from Japan, which fully guarantees its service life
Technical Specifications:
| Ultrasonic Generator |
| HMI Interface | 10.1-inch colorful touch screen |
| Motion Control System | pneumatic control |
| Frequency(kHz) | 20KHz |
| Power(W) | 4000W |
| Frequency Adjustment | Intelligent automatic frequency tracking |
| Linear encoder | Digital Display |
| Position accuracy(mm) | Precision ± 0.02mm |
| cylinder stroke(mm) | Φ100*50mm |
| Air pressure control | Proportional valves |
| Generator alert | frequency anomaly/overcurrent/overload power/ excess temperature |
| Relative humidity | 30%-90% without condensation |
| Operation temperature | 5°C to +55°C |
| Air source | Compressed air must be clean, dry, and lubricant free |
| Voltage(V) | 230V 3PNE,±10%;50-60 Hz |
| Dimension(L*W*H)mm | 560*612*750 mm |
| Weight(kg) | about 130kg |
| Controller |
| Control System | SIT Intelligent Control System |
| Language(icon) | Chinese/Japanese/English/Korean |
| Max Air Pressure(mpa) | 0.8mpa |
| Max Welding time(S) | 5S |
| Unit of Size | mm/in |
| Unit of force | Mpa/Bar/Psi/Kpa |
| Trigger method | time/pressure/position |
| Welding method | time mode/relative position/absolute position/energy mode/max power/peak pressure |
| Power Range(W) | ≤4000W |
| Max Welding time(S) | 5S |
| Amplitude control | Single period of amplitude/Segmented amplitude |
| Quality control | time/relative position/absolute position/energy/power |
| Welding curve | 3 groups |
| Operating air method | standard/Multi-Stage |
| Air pressure range(mpa) | 0.05mpa≤0.8mpa |
| Max Pressure(N) | 5000N |
| Parameter management | 99 groups |
Features:
* Strong structure welding body
* imported ultrasonic welding core components
* advanced hardware and software control system
* more than 10 years of ultrasonic metal welding experience technical team
* Germany headquarters technical support
* professional fixture design and production
* 7*24 hours of domestic after-sales service team
* ultra-high comprehensive cost performance
Application:
Automotive, electronics, home appliances, industrial components, electrical wiring components, lighters, toys, gadgets, medical, personal appliances, and more.
Detailed Photos:
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Pneumatic 4000W Ultrasonic Metal Welder for Electronic Copper Cable Bonding Device Images
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