company news about Ultrasonic Wire Harness Welding Technology

Ultrasonic Wire Harness Welding Technology

1. Welding head difference: There are two types of welding head structures, one is an integral welding head; the other is a split welding head. The advantage of the split welding head is that the replacement cost is low, and the technology is not as good as the overall welding head; everything is relative, the overall welding head technology is better, but the disadvantage is that the replacement cost is high.

2. Texture difference: There are two types of textures, one is straight stripes; the other is reticulated. Straight stripes are more beneficial for the acceleration energy introduced by the ultrasound. For the loose structure of wire harness, both straight grain and mesh pattern can guarantee the welding quality. When the fixture and the welding head are sliding, the mesh shows some disadvantages: it is easy to clamp the wire.

3. Differences in acoustic energy components and structures: Altrasonic adopts the structure of transducer + titanium welding head + welding nozzle, without horn, and the fixing method adopts end face + node auxiliary fixing. The advantage is that it is small in size, but the disadvantage is that the shape of the titanium welding head is strange. When the welding head is damaged, it is troublesome to assemble and disassemble.

Ultrasonic wire harness welding equipment:

Amplitude: The determination of the amplitude is first based on the mechanical properties of the material to be welded. The softer the material, the lower the required amplitude. Secondly, according to the cross-sectional area of ​​the welded wire, the larger the cross-sectional area, the thicker the welding thickness. Considering the ultrasonic wave in the welding direction Attenuation, so the larger the cross-sectional area, the higher the amplitude. For the same machine, when welding 3mm² and 25mm² wire harnesses, the amplitude parameters are basically different by about 30% (so if the ultrasonic equipment does not have the function of continuously adjustable amplitude, how can it adapt to wire harness welding?).

Pressure: The larger the cross-sectional area, the higher the welding pressure. Good equipment is digitally controlled via electro-proportional valves.

Solder Width: According to IPC standards, the knot width to thickness ratio is between 1:1 and 2:1. The larger the cross-sectional area, the closer the knot width and thickness are to 2:1. So when we get a wire harness product, first determine the welding width according to this rule; then determine the approximate welding height according to the width. High-quality welding machines use stepper motors or servo motors to adjust the welding width.

The welding time and welding energy should be determined by trial welding according to the cross-sectional area of ​​the welded wire.