What are the modes of ultrasonic welding?

Ultrasonic welding is normally divided into two modes: time mode and energy mode.

Time mode of ultrasonic welding

There are several control modes for welding equipment operation. The simplest and most common mode is the time mode, ie the ultrasonic energy acts for a predetermined time without regard to other parameters. Another common mode is the energy mode, which typically requires a microprocessor-based controller to measure and record the energy input during the welding process and calculate the energy (integration of energy over time). In this mode The ultrasonic vibration is maintained until the energy delivered to the component reaches or shifts. In the power mode, the ultrasonic vibration stops when the instantaneous power exceeds the preset power. The contact detection mode is used to control the final size of the weldment, and the ultrasonic mold stops when it contacts the clamp. In this mode, the fixture is usually insulated from the bottom of the device. The improved contact detection mode can be used to control the size of the gap between the ultrasonic mold and the fixture in continuous post-sonic welding. At this time, a servo actuator is often used to move the horn to maintain a constant resistance value.

Ultrasonic welding energy mode

It should be noted that in any of the above process control modes, in order to ensure the quality of the welding, a control parameter can be used, and other parameters are limited. When welding in time mode, the minimum welding energy or power can be set. In this case, when the welding ends, if the second parameter (energy or power) does not reach the preset value, the controller will alert the operator or PLC to check or discard the weldment.

How to test the ultrasonic welding effect in the ultrasonic welding process is urgently needed in the ultrasonic welding production process. The control of the ultrasonic welding effect depends on the type of ultrasonic welding machine used. There are many types of welding equipment, from simple portable welding machines to fully microprocessor controlled ultrasonic welding machines with human-machine communication functions, automatic control welding machines and even built-in statistical program control SPC software. When selecting an ultrasonic welding equipment for a particular application, the first thing to consider is the level of process control required. For spot welding between two polyethylene sheets, a simple hand-held, non-automatic control welding system is sufficient. However, if the medical parts are to be welded, the welding quality and final size requirements are strict, and an ultrasonic welding machine with SPC software micro-processing control is required.