Semi-automatic Ultrasonic Welding Machine
1,Equipment Overview
1.Equipment usage: suitable for welding between positive plates and aluminum foil of prismatic battery, and welding between cathodic tab and aluminum foil.
2.Production efficiency: about 25ppm (depending on the proficiency of manual operation and the number of polar ear layers).
3.Scope of application:
| SN |
Name |
Specification |
| 1 |
Material of substrate (positive plate) |
aluminum foil |
| 2 |
Thickness of substrate (positive plate) |
0.09-0.015mm |
| 3 |
Gasket (positive tab) material |
Aluminum tab |
| 4 |
Thickness of gasket (positive tab) |
0.2 |
| 5 |
Maximum number of laminations |
10-50 layers |
4.Equipment size:
1) Generator size: about 520×410×170mm (length × width × Height).
2) Head size: about 480×200×480mm(length × width × Height).
2. Reference weight of equipment: About 60kg.
5.Working process
Manually place the cell on the welding platform
Foot switch Welding tab
Power core complete the process
2,Equipment structure diagram
Appearance drawing (for reference only)
3,Equipment function and description
| SN |
Name |
Function |
Qty |
| 1 |
The ultrasonic generator |
The frequency converter changes the power frequency current to the oscillation current with ultrasonic frequency of 20kHz |
1 set |
| 2-01 |
Vibration system transducer |
Piezoelectric effect converts the ultrasonic frequency electric energy fed by the generator into mechanical vibration energy |
1 set |
| 2-02 |
Vibration system - horn |
Change amplitude |
1 set |
| 2-03 |
Vibration system - welded joints |
Apply mechanical energy to the interface of the metal sheet to be welded |
1 set |
| 3 |
Frame (head) |
Mechanical components and pneumatic components of fixed vibration system |
1 set |
| 4 |
Connect the cable |
Connect the ultrasonic generator to the frame (head) |
2 pcs |
1. Circuit part (function and implementation mode)
| SN |
Item |
Function |
| 1 |
power switch |
Control main power supply |
| 2 |
AC contactor |
Main power current connection |
| 3 |
Switching Mode Power Supply |
Constant voltage and current (constant amplitude) |
| 4 |
Ultrasonic generator - main board |
Generate oscillating electrical signals. |
| 5 |
Ultrasonic generator power amplifier module |
Electric power amplification. |
| 6 |
Ultrasonic generator - output transformer |
Oscillation signal output, impedance matching. |
| 7 |
Program controller-LOGO |
Working time program control |
| 8 |
Program controller panel-LOGO-TD |
operation panel |
1. Pneumatic part
2. Tooling positioning fixture
1)The platform is made of bakelite
2) When welding the positive or negative tab, replace the positioning fixture, as well as the welding head, and adjust the parameters.
4,Process performance
1. The principle of the equipment is that the transducer converts the ultrasonic high-power oscillation signal into the mechanical energy of the corresponding frequency, which is applied to the interface of the metal sheet to be welded, so that the joint of the metal sheet can generate heat instantly, and then the particles in the metal lattice can be started, so that the molecules at the joint of the metal sheet can penetrate each other and be welded together to complete the welding.
2. Adopt advanced constant current and constant voltage circuit technology, and the ultrasonic amplitude is continuously adjustable.
3. Adopt intelligent ICs chassis control system with secondary ultrasonic function; The system has the function of power on self-test, intelligent segmentation of vibration pair, automatic tracking, and signal transmission on the computer.
4. The mechanical structure of the machine head adopts German x guide rail structure, with high precision.
5. It has a voltage protection system (the range of power supply voltage is 220V ~ 250V); The output power and working frequency of the machine will not be affected during the automatic constant voltage period.
6. It has overload protection system.
7. It has overcurrent protection.
8. It has automatic compensation for unstable power supply frequency.
9. With welding overload protection signal feedback.
10. Computer data monitoring and data uploading.
11. Intelligent ICs system: intelligent chip digital circuit, high-density integrated central processing system, millisecond level sampling control.
12. Intelligent segmentation and automatic tracking of amplitude. 1% - 100% amplitude can be set within 0-1000ms to adapt to different welding processes.
13. The system does not need to be recalibrated after self-test, automatic frequency search, welding head replacement or mold repair.
14. The frequency is automatically tracked during operation. During operation, the frequency of the welding head and the transducer will shift with the change of temperature and load. The welding machine can automatically search and track the resonant frequency of the transducer in the whole range, so as to ensure that the transducer always works in the resonant state, ensure the high-efficiency operation of the equipment, and make the welding more stable and reliable.
15. Match various welding modes such as energy and intelligent time: different welding modes adapt to different welding process requirements to achieve better welding effect.
16. 7-20 welding parameters can be preset in advance to meet different welding process requirements. The operator can directly access the data to weld, which greatly improves the work efficiency.
17.7 inch high-definition touch screen, intuitive chart operation interface.
18. The welding effect of each time is displayed on the high-definition man-machine exchange touch screen through data, and the welding process is displayed in a curve.
19. Each welding data can be transmitted to the monitoring computer, so that the welding data can be traced and the defective rate can be reduced.
20. Intelligent system security protection and monitoring.
21. The alarm output and reset function can set different alarm values to make the quality control more in place.
22. Multi level password protection can be set to separate the debugging interface of managers from the operator's operation interface.
5,Main parameters of equipment
| SN |
Name |
Specification |
| 1 |
Welding mode of tab |
Horizontal / vertical, to be determined before placing an order |
| 2 |
Solder joint length |
18-36mm |
| 3 |
Solder joint width |
3mm |
| 4 |
Solder joint depth |
0.1-0.6mm |
| 5 |
Welding time |
Within 1S |
| 6 |
Number of solder joint rows |
2 row |
| 7 |
pressure |
0.1MPa~1MPa,adjustable |
| 8 |
Time adjustment range |
0.2~0.8/s,0~60S adjustable |
| 9 |
Service life of welding surface |
≥100,000 |
| 10 |
Welding head material |
Imported high speed steel |
| 11 |
stand-off height |
1mm |
| 12 |
Solder joint / grain distribution status |
Straight lines or meter shaped lines on the upper welding head; Lower mold chequer |
| 13 |
Height from welding surface to welding head |
>5mm |
| 14 |
Length of welding head |
≥130mm |
| 15 |
Available welding surface of welding head |
2 pcs |
| 16 |
Installation direction of welding head |
transverse |
| 17 |
Amplitude adjustable range |
semi-cycle: 20~40um |
| 18 |
Frequency difference between transducers |
≤400Hz |
| 19 |
Impedance difference between transducers |
≤4Ω |
| 20 |
Capacitance difference between transducers |
≤400PF |
| 21 |
Insulation resistance between transducer and housing |
≥30MΩ |
| 22 |
Bearable power |
4200W+(peak value) |
| 23 |
Welding tension |
≥300N |
| 24 |
Frequency control mode |
Built in frequency adjustable |
| 25 |
Constant amplitude function |
Switching power supply constant voltage and current (constant amplitude) |
| 26 |
Stepless adjustable amplitude |
Stepless adjustable |
| 27 |
Ultrasonic frequency |
20KHz |
| 28 |
appearance |
There shall be no false welding, penetration and leakage, and the welding shall be firm and penetrated layer by layer |
| 29 |
Design service life of equipment |
8~10 years |
6,Main spare parts
| SN |
Name |
Brand |
Remark |
| 1 |
transducer |
Chip German Thai |
|
| 2 |
Luffing lever |
Wei Sheng |
|
| 3 |
Welding head |
Yishengbai imported materials |
|
| 4 |
Chip processor |
USA ID Company |
|
| 5 |
X guide |
CPC |
|
| 6 |
Cylinder |
AirTAC |
|
| 7 |
Solenoid valve |
AirTAC |
|
| *Some spare parts are not listed one by one, and the actual configuration shall prevail* |
7,Installation environment requirements
1. Installation space:above 700×1200×650mm(L×W×H)
2. Compressed air: after drying, filtering and stabilizing, the outlet pressure is greater than 5.0~7.0kgf/cm²(0.5~0.7Mpa)
3. Power supply:AC220V/380V/50Hz/60Hz.
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