Ultrasonic wire harness welding machine welding action

The ultrasonic wire harness welding machine tool is mainly composed of four parts: welding head, anvil connecting block, anvil top block and polymerization module. When welding, the wires are arranged vertically and tightly attached to the anvil connection block. After the foot switch, the polymerization module moves toward the anvil top block, and the anvil connection block is connected to the anvil top block to move downwards, and the line is tight. Pressed in the weld zone, the weld head vibrates and transfers energy to the copper wire, thereby welding the wire harness together.

When welding, except for the vibration of the welding head, the other tool heads are not moving. After the welding is completed, the polymerization module is retracted, the anvil top block is retracted, and the anvil connection block is raised, so that the wire harness can be taken out. Since the welding head is vibrating, and the other tool heads are fixed, in order to prevent welding between the tool heads and the welding head, the welding machine is damaged, so the upper surface of the welding head and the bottom surface of the polymerization module and the side surface of the anvil top block are A gap of 0.025 mm is left on the side of the anvil connection block so that the welding head cannot be in contact with other tool heads.There should also be no debris such as broken copper between these gaps, otherwise the working surface of the tool head will be corroded during welding, and the circuit board may be damaged in severe cases.

Since the ultrasonic vibration is generated by the welding head, the energy is transmitted from the welding head to the anvil top block. Therefore, the closer the energy is to the welding head, the more energy is transferred from top to bottom, so the line should be thick. The wire is placed at the lowermost end, close to the welding head surface, and the thinner wires are arranged vertically upwards in order, so that the thick wire can obtain a large energy, thereby preventing over-welding or insufficient welding. Vertical alignment prevents side soldering and ensures soldering quality.

Ultrasonic welding requirements for wire placement

When performing ultrasonic welding, it is necessary to set relevant parameters such as wire cross-sectional area, wire alignment, pressure, welding pitch, amplitude, width, pressure, energy, and the like. During the welding process, the wires should be vertically overlapped, and the large section lines should be placed close to the welding tool head below to make the welding sufficient; the conductors should be placed close to the anvil surface and close together to make it strong enough after welding. The length of the conductor overlap is generally set to 13 ~ 15 mm, the overlap length is too short, the welding strength is not easy to guarantee, the overlap length is too long, the welding tip is easy to form a lift, and the operation of the next process is inconvenient. Oxidation, broken wires, defects and melting of the insulating layer are not allowed on the surface of the welded surface.

Important parameters and advantages of ultrasonic welding

1) Amplitude is the maximum distance in the direction of vibration from the starting point of vibration, in microns. They interact when welding, which directly affects the welding quality of the wire. Different wires have different settings.

2) The surface of the width polymerization module and the opposite surface of the anvil connection block, the spacing between them during welding, in millimeters, the size of which determines the width of the weld.

3) The pressure is the pressure exerted by the anvil block on the copper wire of the weld zone. The magnitude of the pressure is related to the gas pressure. The direction of action is perpendicular to the direction of vibration, in pounds per square inch.

4) The total energy released by the welding machine during the energy welding process, in joules. That is, when the energy released during welding reaches the set value, the welding is completed.

Ultrasonic welding has its unique advantages:

1 High welding strength, excellent electrical conductivity after welding, extremely low or nearly zero resistivity;

2 welding materials have non-melting, non-fragile conductor characteristics;

3 short welding time, greatly improved efficiency, fast, energy-saving;

4 welding process is stable, On-line detection control;

5 does not need any gas, solder, flux;

6 welding without sparks, smoke, environmentally friendly and safe;

7 improve welding quality, to ensure the reliability of the product conductor performance.

Ultrasonic wire harness welding machine tooling