Ultrasonic wire harness welding machine welding process
The assembly of ultrasonic wire harness welding machine is mainly composed of welding head, anvil connecting block, anvil top block and polymerization module. During welding, the lines are vertically arranged and attached to the anvil connecting block. After the foot switch, the polymerization module moves towards the anvil top block, and the anvil connecting block moves downward together with the anvil top block, pressing the lines tightly in the welding area, the welding joint generates vibration and transfers energy to the copper wire, so that the wire harness is welded together. During welding, except for the vibration of the welding joint, the other tool heads are still. When the welding is complete, the polymer module retract, the anvil top block retract, and the anvil connecting block rises to remove the harness. Since the welding joint is vibrating and other tool heads are fixed, in order to prevent the formation of welding between each tool head and the welding joint from damaging the welding machine, a gap of 0.025mm is left between the surface of the welding head and the bottom surface of the polymerization module, the side of the anvil top block and the side of the anvil connecting block, so that the welding joint cannot contact with other tool heads. These gaps should not be left between the debris such as copper, otherwise welding will cause tool head working surface corrosion, serious damage to the circuit board. Because ultrasonic vibration is produced by the welding head, its energy is by the welding head is passed to the anvil block, so the more close to the welding head, the greater the energy and the energy was passed down from on, so should be bold lines when line is placed on the bottom, close to the welding head, a fine line in turn vertically upward, to get the big energy, this can make the bold lines to prevent welding or welding. The vertical alignment can prevent side welding and ensure welding quality.
Ultrasonic welding wire placement requirements
When carrying out ultrasonic welding, it is necessary to set the relevant parameters, such as: wire section area, wire alignment, pressure, welding distance, amplitude, width, pressure, energy and so on. During the welding process, the wires should be vertically overlapped, and the large section line should be near the welding tool head below, so as to make the welding full. The conductor should be placed close to the anvil surface, close to each other, so as to be strong enough after welding; The length of conductor overlap is generally set at 13 ~ 15 mm, the overlap length is too short and the welding strength is not easy to guarantee, the overlap length is too long and the welding end is easy to become warped, which is inconvenient for the next procedure. No oxidation, wire break, defect and melting of insulation layer are allowed on the welding surface.
Four important parameters and advantages of ultrasonic welding
1) Amplitude: in vibration direction, maximum distance from the vibration starting point, unit is micron. During welding, they interact with each other, which directly affects the welding quality of the line. Different lines have different Settings.
2) Width: the distance between the surface of the polymerization module and the relative surface of the anvil connecting block during welding is in millimeters, and its size determines the Width of the welding.
3)The Pressure on the copper wire in the welding area acted by the anvil top block, the size is related to the air Pressure, and the direction of action is perpendicular to the vibration direction, the unit is pound/square inch.
4)In the welding process, the total Energy released by the welding machine is in joule. That is, when the energy released during welding reaches the set value, the welding is completed.
Ultrasonic welding has its unique advantages:
(1) fusion strength is high, welding conductivity is superior, the resistance coefficient is very low or almost zero; (2) the welding material is not molten, not fragile conductor characteristics; (3) welding time is short, the efficiency is greatly improved, fast, energy saving; (4) stable welding process, online detection and control; (5) do not need any gas, solder, flux; 6 welding without sparks, smoke, both environmental protection and safety; Improve welding quality, ensure the reliability of the product conductor performance.
Contact Person: Ms. Hogo Lv