Ultrasonic hand welding machine related knowledge

Ultrasonic hand welder is a common process method used in automobile wiring harness. It uses electric energy to generate high-frequency oscillation friction and convert it into heat energy, so that the physical properties of metals are changed and fused together. Compared with soft welding, welding is stable and reliable, and basically There is no pollution; this technology is widely used in the automotive wiring harness industry, and some equipment operators at home and abroad are based on the basic knowledge discussed before, let's talk about the details of the development and application of ultrasonic welding technology.

First, the general types and functions of ultrasonic hand welder welding machines are introduced on the basis. Because our company has been using German schunk (Hunk) equipment, I will take it as an example to give a simple introduction (non-advertising, I have not taken advertising fees, pure technical exchange); First, the welding machines for traditional wire harnesses are roughly divided into three categories, one is Minic II, and the applicable wire diameter range is 0.5mm2 ~30mm2, it is estimated that this is also one of the machines widely used in China, because this machine was mainly pushed in the early stage, so I won't say much about the detailed technical parameters here.

The second category is Minici IV, which has been mainly pushed since 2015 (about). The main difference from the previous one lies in the structure of hardware, especially the welding head. The lines are finer and tighter. It is suitable for welding wires with smaller wire diameter, such as two 0.35mm2 ABS wires (naturally bent). The standard applicable wire diameter range is 0.13mm2 ~~ 15mm2.

The third category is Minici III, which was mainly pushed in 2017. From the line diameter range, it looks like the combination of II and IV is 0.13mm2 ~~ 30mm2. It also adds some other practical functions, such as additional lighting of the welding head of the ultrasonic hand welder, optimization of welding head lines, optimization of software, etc. However, due to the short promotion time, it is estimated that few companies are using it in the market.

It is worth mentioning that with the emergence of new technologies, the welding spot quality confirmation function of ultrasonic hand welding machine has been further improved. Previously, it was only cut off on the welding machine (if the judgment is poor, cut off, and the cutter function is selected); This time, a separate welding spot quality confirmation instrument was simply made. If bad welding spots are found (height/width not up to standard/burr too much/length of area C in area B, etc.), destroy it directly, which is also an optional function.

In addition, for the three key parameters "amplitude"/"power"/"pressure", it is also equipped with a test instrument to facilitate its own timing calibration.

Let's mention the side limit device. During the welding process, the wires are held by hand and placed in the welding area. If you don't pay attention to the stability or shake your hand, it will affect the welding quality. Therefore, this limit function is added. Simply speaking, a metal stop is added to apply an external force to fix the copper wire.

In order to verify the practicability of this function, we have done many experiments and found a rule: if the number of wires involved in welding is odd, the side pulling force (Lateral peer force) will be stable and relatively, if it is even, it will fall off easily.

The consequence of falling off may be that individual copper wires are stripped off and do not become a whole, commonly known as "floating wire"

So we ask the supplier to change the software parameters. For even-numbered wires, this function is automatically activated before welding to increase the limit to ensure the welding quality

However, as long as you enable this function, the problem will follow, because to weld wires of different cross sections, the thickness is inconsistent, setting a position obviously cannot be suitable for all wires, what is the gap between the limit stop?

I came up with a compromise plan. Don't fix the screw of the stopper with tools. Find a suitable range of common wire diameters and fix it with strong glue. Maintain it regularly (return the stopper to the correct position)

The above information is for reference only, thank you!

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