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Working principle of ultrasonic wire harness welding

The vibration of anything makes a sound, and any sound is made by vibration. The human ear can only detect sounds in a range as high as 18,000 (18K) Hz. Higher frequency sounds we call ultrasonic. Ultrasonic waves produce high-frequency vibrations that allow easy welding of non-ferrous metals. Ultrasonic wire harness welding machine is the derivative equipment of ultrasonic metal welding machine. It is mainly used in the welding of copper wire and aluminum wire of automobile harness and motorcycle harness. So it's often called a car harness welder.

Characteristics of ultrasonic wire harness welding machine

No need of flux and external heating, no deformation due to heat, no residual stress, no high requirements on the surface of welding parts. Not only similar metals but also dissimilar metals can be welded together. Thin slices or filaments may be welded to thick plates. Ultrasonic welding of a good conductor has much less energy than current welding and is often used to weld the leads of transistors or integrated circuits. When used for sealing welding of drugs and explosive materials, it can avoid contamination of drugs due to dissolved objects in general welding, and won't explode due to heat. It is the use of ultrasonic waves to weld metal wires. It consists of power box, transducer, pneumatic main engine and tool head.

In addition, control components such as a hub, a conductor measuring device and a microprocessor are included. The power box can convert the usual external voltage (~220V,~380V,50 or 60Hz) into the voltage of 20000Hz (20KHz) and 0V, and then output it to the transducer after being regulated and controlled by the power box. The transducer is an efficient electrical element which can convert electrical energy into mechanical energy. Compared with ordinary motors,

There are two main differences between transducers: first, they convert electrical energy into linear vibrations rather than rotation; Second, it is very efficient, able to convert 95% of the electricity. After conversion by the transducer, mechanical energy is applied to the welding head. Ultrasonic welding head made of titanium alloy, and according to the acoustic principle of processing into a specific shape, so as to ensure the large transmission of energy.