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Handheld Ultrasonic Welding Machine

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Shanghai Huashuo: Your Professional Handheld Ultrasonic Welding Machine Manufacturer!

 

Shanghai Huashuo Intelligent Equipment Co., Ltd. s a company specializing in the production and processing of automation machinery, mechanical accessories and other products. Our company has had technical exchanges and cooperation with many German-funded enterprises at the beginning of its establishment. By combining German advanced technology and scientific management mode, it has formed a complete R&D, assembly, testing, and marketing system.

 

Our Advantages
 

Various Products
Our company provides High Shear Disperser, Emulsifier, Homogenizer, Colloid mill, Powder-liquid mixer, Grinding machine, Vacuum Emulsifier, Ultrasonic Disperser, Ultrasonic Welding, Ultrasonic Cutting, Ultrasonic Homogenizer, Ultrasonic Emulsifier, Ultrasonic Transducer, Ultrasonic Generator, Ultrasonic Milling Machine.

 

Advanced Equipment
Our company has advanced production equipment including CNC lathe, CNC milling machine, Polytec laser doppler vibrometer and Resistance furnace temperature controller, which has a high level of automation and intelligence.

 

Product Application
Dye dispersion, food homogenization, ink dispersion, oil-water emulsification, graphene dispersion, graphene preparation, alumina dispersion, metal melt refinement, ultrasonic dispersion, ultrasonic homogenization, ultrasonic emulsification, non-woven fabric welding, PP/PE Welding and cutting, food cutting and processing, ultrasonic auxiliary equipment.

 

Integrated Process Technology
Our company provides customers with complete process technology solutions, ultrasonic welding, ultrasonic dispersion and other ultrasonic equipment and supporting processes, including grinding, emulsification, dispersion, homogenization, stirring, mixing, Drying, cooling, ultrasonic dispersion, extraction, emulsification, welding, cutting, testing and other processes.

 

First 12 Last

Convenient operation, handheld type, work good for plastic, fabric and plastic.

 

 

Introduction to Handheld Ultrasonic Welding Machine

 

 

Handheld Ultrasonic Welding Machine is a kind of machine using ultrasonic welding technology. It can be used to weld a huge range of plastic components of all shapes and sizes, creating a strong and reliable bond. It is therefore extensively used across several industry sectors, for a variety of applications.

 

Components of Handheld Ultrasonic Welding Machine
 

Generator
The ultrasonic welding machine generator converts electrical energy with a resonant frequency into the required voltage and high frequency. In addition, it has a microprocessor responsible for driving the welding cycle and providing important welding communications through the user interface.

 

Mechanical Press
The mechanical press holds the welding system and applies the force that holds the weld joint together. It has a pressure gauge and regulator that allows the operator to adjust the force applied to the system.

 

Weld Stack
The welding stack consists of the transducer, booster, and welding horn that are mounted on the welder press at the center point of the booster. It is responsible for providing ultrasonic machine vibrations, the frequency of which must be close to that of the generator to obtain a quality weld joint.

 

Sensor
The transducer or converter converts high-frequency electrical energy into mechanical vibrations. It consists of several piezoelectric ceramic disks placed between two titanium blocks. In addition, the electrodes are made of thin metal plates between the piezoelectric disks.

 

Booster
The booster has two functions. First, it amplifies the vibrations generated by contracting and expanding and transfers them to the welding head. Second, it serves as a base for the weld pile on the welding machine.

 

Welding Horn
The welding head is responsible for transferring the vibrations to the welded part. It is made of aluminum or titanium. However, aluminum is only suitable for small-volume applications because it wears. To reduce wear, most welding heads have hardened tips.

 

Support Tool
The support tool serves to hold the lower part of the machine during the welding process. It is the base of the machine and is designed to match the contours of the workpiece.

 

Working Principle of Handheld Ultrasonic Welding Machine

Parts in Fixture
The two thermoplastic parts to be assembled are placed together, one on top of the other, in a supportive nest called a fixture.

 

Ultrasonic Horn Contact
A titanium or aluminum component called a horn is brought into contact with the upper plastic part.

 

Force Applied
A controlled force or pressure is applied to the parts, clamping them together against the fixture.

 

Weld Time
The ultrasonic horn is vibrated vertically 20,000 (20 kHz) or 40,000 (40 kHz) times per second, at distances measured in thousandths of an inch (microns), for a predetermined amount of time called weld time. Through careful part design, this vibratory mechanical energy is directed to limited points of contact between the two parts. The mechanical vibrations are transmitted through the thermoplastic materials to the joint interface to create frictional heat. When the temperature at the joint interface reaches the melting point, plastic melts and flows, and the vibration is stopped. This allows the melted plastic to begin cooling.

 

Hold Time
The clamping force is maintained for a predetermined amount of time to allow the parts to fuse as the melted plastic cools and solidifies. This is known as hold time. 

 

Horn Retracts
Once the melted plastic has solidified, the clamping force is removed and the ultrasonic horn is retracted. The two plastic parts are now joined as if molded together and are removed from the fixture as one part.

 

Advantages of Handheld Ultrasonic Welding Machine
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Gentle On Materials
Ultrasonic welding of plastics generates very little heat from friction between the materials, which is particularly beneficial for sensitive materials such as mono-materials for packaging. The handheld ultrasonic welding machines themselves remain cool. This prevents deformation or loss of quality that can occur with conventional welding processes. This reduces scrap rates and increases production output.

 

Fast Cycle Rates Thanks To Minimal Welding Times
The ultrasonic welding process of handheld ultrasonic welding machine is extremely fast. Depending on the application, strong and permanent connections can be made in minimal welding times of 200 to 300 milliseconds. The efficiency of this process not only saves time, but also enables an increase in production capacity.

 

Saving Resources Without Additional Joining Agents
The elimination of additional joining agents such as adhesives or solder is a major advantage of handheld ultrasonic welding machines. The materials are joined by frictional heat alone. This not only reduces material usage and thus costs, but also minimizes rework and waste. Recyclability is also increased without the addition of joining agents.

 

Eco-Friendly & Future-Proof
Minimal energy use, no harmful chemicals, hardly any scrap: ultrasonics is one of the most environmentally friendly joining processes. The technology thus helps companies achieve their sustainability goals and also ensures increasing efficiency in manufacturing.

 

Ideal For Complex Component Shapes
Handheld ultrasonic welding machine is also suitable for components with complex geometries, allowing a wide range of design possibilities. This is particularly important in industries where innovative shapes are in demand.

 

Perfect For Integration Into Automated Lines
The high speed and precision of handheld ultrasonic welding machine makes it ideal for integration into automated production lines. This increases efficiency and enables consistent production of high volumes.

 

No Mechanical Weak Points
Handheld ultrasonic welding machine creates a strong, permanent connection at the molecular level. Compared to conventional joining methods, which can have potential weak points, ultrasonic welding eliminates these risks. The even distribution of the sonic energy ensures robust connections without weak points.

 

Application of Handheld Ultrasonic Welding Machine

 

 

Medical Industry
The medical industry uses several ultrasonically welded parts such as face masks, blood and gas filters, and arterial and anesthesia filters. The welding technique is perfect for such products due to the welded joints. Furthermore, most of these products come from dissimilar materials made using medical plastics, such as ABS and polyethylene, for which the welding technique is compatible. Therefore, ultrasonic welded joints’ cost is low but has good quality making them perfect for medical products.

 

Automobile Industry
The automobile industry uses handheld ultrasonic welding machines to join plastics and make components such as door panels, instrument panels, and steering wheels. The process is suitable due to the indirect heat, which does not affect the workpiece. Furthermore, it has low capital costs, automation, low cycle times, and flexibility.

 

Aerospace Industry
The handheld ultrasonic welding machine is suitable for manufacturing parts for the aerospace industry. The machine is popular here due to the accuracy, speed, quality of welded joint, and use of indirect heat.

 

Electronic Industry
The handheld ultrasonic welding machine is applicable in the electronic industry in joining wired connections. Accordingly, creating small and delicate circuits is easier, more accurate, and more efficient. Aside from that, it is also applicable in assembling electric motors, capacitors, and storage media due to its reliability and welded joint quality.

 

How To Select Handheld Ultrasonic Welding Machine

 

Power and Frequency
To ensure optimal welding performance, carefully assess the power and frequency requirements of your application. Higher power capabilities allow for welding larger and more complex components. Additionally, the appropriate frequency selection is vital based on the thickness and nature of the materials being welded. Higher frequencies are suitable for thinner materials, while lower frequencies are ideal for thicker materials.

 

Welding Modes
Evaluate the available welding modes offered by the handheld ultrasonic welding machine, such as time, energy, and collapse distance control. Different modes provide flexibility and precision in controlling the welding process. Determine which mode best aligns with your specific welding needs and allows for easy adjustment of weld parameters.

 

Control and Monitoring Features
Consider handheld ultrasonic welding machines equipped with advanced control and monitoring features. These features enable real-time monitoring of key parameters such as amplitude, energy, and time. Additionally, machines with data logging capabilities facilitate tracking of process variables, ensuring consistency and traceability in production.

 

Tooling Compatibility
Ensure that the handheld ultrasonic welding machine is compatible with a wide range of tooling options. This compatibility allows for flexibility in adapting to various component designs and joint configurations. Moreover, consider machines that offer quick and easy tooling changeovers, minimising downtime and increasing overall productivity.

Reliability and Durability
Select a handheld ultrasonic welding machine from a reputable manufacturer known for reliability and durability. Prioritise machines constructed with high-quality components and robust design. Additionally, it is crucial to consider the availability of technical support, spare parts, and maintenance services to ensure uninterrupted operation and longevity of the machine.

 

 
FAQ

 

Q: What is ultrasonic welding?

A: Ultrasonic welding is an industrial process whereby high-frequency ultrasonic acoustic vibrations are locally applied to work pieces being held together under pressure to create a solid-state weld. It is commonly used for plastics and metals, and especially for joining dissimilar materials. In ultrasonic welding, there are no connective bolts, nails, soldering materials, or adhesives necessary to bind the materials together. When used to join metals, the temperature stays well below the melting point of the involved materials, preventing any unwanted properties which may arise from high temperature exposure of the metal.

Q: How does the ultrasonic welding process work?

A: Setup: The two pieces to be joined are assembled in the fixture. The fixture, also known as the anvil or the nest, holds these parts in place during the welding process.
Horn contact: When the two parts are placed, the horn, also known as the sonotrode, is placed in contact with the upper part of the piece, pressing down toward the fixture. The horn is the part that transmits the mechanical vibration to the two pieces to be welded.
Pressure applied: When the horn and the parts are placed, the pressure is applied to the setup using a pneumatic or electric driven press.
Weld time: Upon applying pressure, the horn is vibrated vertically at a high frequency and transmits the mechanical vibration energy to the two pieces in the fixture. The frequency can be between 15 and 70 kilohertz (kHz) and is most commonly 20 kHz. The mechanical vibration generates heat energy at the contact point between the parts of the workpiece, causing them to melt and fuse.
Hold time: After the weld time has elapsed, the vibration stops, and the system maintains pressure on the two pieces, causing them to fuse together and form a strong weld.
Retraction: As soon as the weld has cooled and solidified, the pressure is released, and the horn is retracted, allowing the welded part to be removed from the fixture.

Q: What materials can be ultrasonic welded?

A: A wide array of plastic and metal materials can be ultrasonically welded. Thermoplastics with a crystalline molecular structure are the most common choices, including acrylonitrile butadiene styrene (ABS), polyphenylene oxide (PPO), polystyrene (GPPS) and polyethylene (PE). Metallic choices include soft metals such as aluminum, copper and brass.

Q: What should be paid attention to when using ultrasonic welding machine?

A: The output power of the ultrasonic welding machine should be measured: The output power of the ultrasonic plastic welding machine depends on the diameter, thickness, material and design process of the piezoelectric ceramic wafer. Once the ultrasonic sensor is formed, the maximum power is determined. The ultrasonic generator can accurately track the power of each welding, helping production to be reviewed in a timely manner and reducing the defective rate.
Ultrasonic welding parameters need to be evaluated: The output power, vibration frequency, amplitude range and other issues should be considered according to the workpiece material, welding line area, whether there are electronic components in the workpiece, whether it is sealed, etc.
The structure of the ultrasonic welding horn needs to be rigorously inspected: Conventional ultrasonic mold manufacturers have a set of strict inspection procedures, and the processing dimensions are simulated and verified by computer software to ensure quality. These processes are generally impossible to achieve. If there is no reasonable design and mold, the reaction problem will not be obvious in the welding of small workpieces, and various defects will appear with high power. In severe cases, the power components are directly damaged.

Q: What are the important factors of ultrasonic plastic welding?

A: The welding time and the welding head pressure can be adjusted with the amplitude determined by configuration of the converters and rods. Generally, the main variables are:
Amplitude rods and converters.
Welding head pressure.
Welding time.
Hold time.
The adjustment must be precise. If the frequency is too high or the amount of time the signal is applied is too long, the plastics can easily deform outside of the boundaries of the connection points. If the applied energy is too weak, then a poor connection forms.

Q: What are the application areas of ultrasonic plastic welding?

A: Ultrasonic plastic welding is suitable for virtually all thermoplastics. When planning welds between semi-crystalline plastic pieces of work, it is important to remember that the weld behaviour of these plastics differs considerably from that of amorphous plastics.
Ultrasonic plastic welding can be used to a limited extent for joining together two different thermoplastics (amorphous plastics). Ultrasonic welding is not suitable for use with thermo setting plastics. Today ultrasonic welding is used in every industry that processes plastics. Most common uses are in the Automotive, Medical, Textile, Food, Plastics, and Packaging industries.

Q: What are the potential hazards and risks of ultrasonic welding machines?

A: While ultrasonic welding machines offer significant advantages, it is essential to be aware of potential hazards and take appropriate precautions. Here are some of the key risks associated with ultrasonic welding:
Electric Shock: Ultrasonic generators require careful handling due to the presence of high voltage. Before making any electrical connections, ensure that the power supply is turned off. Use a power socket with a grounding terminal to prevent electric shocks.
Pressure and Vibration: Ultrasonic welding involves downward pressure and intense vibrations. It is crucial to avoid placing hands or fingers under the welding head during operation to prevent injury accidents.
High Voltage: Non-professionals should refrain from opening the ultrasonic generator's shell, as it generates high voltage. Only trained personnel should handle any maintenance or repair work.
Capacitor Discharge: Before operating the ultrasonic generator, it is necessary to turn off the power switch, unplug the main power plug, and wait for at least two minutes to allow the capacitor to discharge fully. Failure to do so may result in high voltage-related accidents.
Testing Precautions: When testing the ultrasonic generator, ensure that the common end of the high voltage is not connected to the earth. Use a multimeter that is not grounded and operates on battery power. Using improper testing methods may lead to electric shock incidents.

Q: What precautions should be taken when using ultrasonic plastic welding machines?

A: Welding Must Be Possible Between Two Welding Materials
Some welded parts of different materials cannot be welded, but theoretically, they can all be welded. However, there is a problem that ultrasonic welding is not suitable when the melting point of the welded part is above 350 degrees Celsius. This is because ultrasonic welding uses instantaneous energy to melt molecules, and this welding moment cannot exceed 3 seconds. If the welding cannot be completed within 3 seconds, it indicates that it is unknown and not suitable, so attention should be paid when selecting welding parts.
The Thermal Resistance Of The Welded Component Is Higher Than Its Melting Point
Ultrasonic waves propagate through the solid through the welded component, but when they pass between two welded components, they propagate in the air. The sound resistance of ultrasound propagation in air is greater than that in solid. The larger the sound resistance, the higher the heat generated. Therefore, the temperature of the contact part between the two welded parts is higher, reaching the melting point first. When propagating inside the welded part, the sound resistance is smaller, the temperature is relatively lower, and it will not reach the melting point.
Requirements For Connection Area And Distance
The welding contact area between two welded components should meet the welding requirements and should not be too large or too small. Excessive contact can lead to scattered welding energy, insufficient welding strength, and even inability to weld together. The contact point is too small, the welding is not firm, and it is easy to break. The longer the distance, the greater the energy loss, so the welding distance needs to be controlled.
The Importance Of Ultrasonic Molds
The production of ultrasonic welding head molds can only be completed through a strict set of procedures, which cannot be achieved by ordinary small workshops. Therefore, do not buy ultrasonic molds from small manufacturers, as it will cause poor welding.
Maintain a Constant Output Power Of The Machine
When working, it is necessary to ensure that the output power of the ultrasonic plastic welding machine is constant, and should not be too high or too low, as it may have adverse effects on the welded parts.
When using ultrasonic plastic welding machines, special attention should be paid to the above points to help you better use the ultrasonic plastic welding machine.

Q: How to maintain ultrasonic welding machines?

A: Keep ultrasonic plastic welding equipment clean, tidy, well lubricated and safe to operate. This includes tightening loose fasteners in time, adjusting the clearance of the moving parts, and so on. That is, "clean, lubricate, tighten, adjust, anti-corrosion" cross-operation method. Practice has proved that the service life of the equipment depends largely on the daily maintenance of the ultrasonic welding machine.
Maintenance is divided into daily maintenance, primary maintenance, secondary maintenance and tertiary maintenance according to the size and difficulty of the workload.
Daily maintenance: Also known as routine maintenance, the main content is to clean, lubricate, fasten parts that are easy to loosen, and check the integrity of parts. Most of this type of maintenance is external to the equipment.
Primary maintenance: The main content is the general tightening, cleaning, lubrication, fastening, and some need to be adjusted. Daily maintenance and first-level maintenance can be completed by the frontline operator.
Secondary maintenance: The main content is internal cleaning, lubrication, partial disassembly inspection and adjustment.
Three-level maintenance: It is mainly to check and adjust the main part of the equipment, and replace the parts that meet the specified wear limit when necessary. In addition, the wear and tear of the main components is measured, identified and recorded. Secondary maintenance and tertiary maintenance are required for the operator to complete the training.

Q: What are the limitations of ultrasonic welding machines?

A: Material limitations: Ultrasonic welding is appropriate for many thermoplastics but isn’t ideal for all. The ultrasonic welding process requires a lower moisture content in the materials that it welds. Materials with high moisture content require vibration welding, which is an entirely different technique. Exceptionally strong, hard thermoplastics are also more challenging to handle using this technique.
Size limitations: While ultrasonic welding is highly useful for many thermoplastics and specific types of metals, it is not appropriate for all applications involving these materials. First of all, ultrasonic energy is not enough to produce large joints greater than 250 mm in length. The power output of the transducer is insufficient to handle anything larger than that. Additionally, thick materials are not easily vibrated using mechanical vibration energy, making ultrasonic vibration an ineffective welding technique for thicker materials.
Joint type limitations: Ultrasonic welding can only be used on specifically designed joints, called lap joints, where parts directly overlap one another with a flat surface. Corner, butt, tee and edge joints cannot be effectively welded using this technique.

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