4000W Ultrasonic Metal Welder for Copper Wire Welding

Working Principle:

Ultrasound can produce high-frequency vibration, and we use this kind of vibration to weld non-ferrous metal easily. When the high-frequency vibration wave is transmitted to the surface of the two metal parts to be welded, with a certain pressure, the two parts' surfaces will have friction on each other which leads to the joint of the molecular layers. The advantage is quick, energy-saving, high joint strength, good conductivity, and no sparkles, which is nearly cold status processing. It is designed to weld metal wires.
This machine consists of a power generator, transducer, pneumatic machine body and tooling, and some control components like a wire harness, wire measuring device, and microprocessor. The Power generator can convert the outer voltage (220V, 50 /60hz) into 20KHz (or 15Khz),1000V voltage, and be output after being controlled and regulated by the power generator to work on the transducer. The transducer is a high-effective electrical component, which can convert electrical energy into mechanical energy.
Compared with common electrical motors, the transducer has two advantages: firstly, the transducer can convert the electrical energy to linear vibration, not rotation; secondly, it has very high work efficiency, that is, it can convert 95% of the electrical energy. After converting through the transducer, mechanical energy starts to work on the welding horn. Ultrasonic welding horn is made from alloy material, which is made into a certain shape according to acoustic principle.

Ultrasonic Welding Press:

*Alcoa's fuselage 7075 series high-intensity aviation aluminum alloy material, equipment with high intensity, flexible space agency application;
*Four sets of overloading type guide rail sliding block, high repeat precision, run smoothly
*Germany Festo drive cylinder, Japan SMC pneumatic components, work fast, and stable response and welding maximum pressure can reach 5000 N
*Switzerland Baumer high-precision linear encoder system, the position accuracy can reach 0.01mm
*High precision pressure sensor system, the working accuracy can reach 1N
*real-time feedback monitoring distance and pressure data in the welding process
*Triplet resonance system can rotate in the fuselage 360 degrees
*Precision mechanical stroke limit non-contact photoelectric induction two-hand starting system, safe to use

Touch System:

* 10.1-inch color touch interactive interface
* Multi-core system chip, system response is faster
* The powerful SIT super-intelligent control system is adopted
* 3 kinds of trigger ultrasonic mode and 6 kinds of welding mode to meet the needs of customers
* 6 kinds of the quality control scheme and 2 welding data curve output
* Can store 99 sets of product welding plans and tens of thousands of sets of welding output data
* Has the function of network transmission of welding output data, which can be connected with customer MES system to provide intelligent welding quality process management and traceability function

Ultrasonic System:

* Frequency:20KHz Power:4000W
* Germany imported digital automatic frequency chasing ultrasonic generator
* With automatic amplitude compensation function, stable power output, more reliable welding quality
* real-time LED screen welding frequency and power display
* Provide abnormal alarm: frequency abnormal, current too large, overload power, too high temperature, etc.
* Imported ultrasonic transducer from Germany, P to P amplitude value up to 20 microns
* Transducer and amplitude modulator made of titanium alloy material is easy to disassemble and not easy to damage. The various gain of amplitude modulator is optional
* Can provide long quality assurance service

Control System:

* Germany Beckhoff Fieldbus control module, accurate and stable
* Integrated Japanese SMC pneumatic proportional valve control module, intelligent digital control of welding pressure, ensure the stability of pressure precision control
* Realize the same welding multi-section welding pressure technology
* Support multi-brand bar code recognition scanning gun function
* Support state network RS485 RS232 data transmission
* Support USB data access function
* Support personal PC direct connection control module
* With 2 in 2 out output port expansion
* Internal storage space of the device is 16G

Welding Fixture:

* Design each set of welding fixture independently according to customer product appearance and welding requirements
* Ultrasonic welding head materials are made of powder steel imported from Europe and America. After heat treatment, the hardness can reach 62~63 degrees. It has a high wear-resisting hardness and high toughness so that the welding head can have a longer service life
* Each welding head is analyzed by simulation software to ensure the best production plan
* Welding head center frequency: 19950±100Hz
* The power loss of welding head is less than 200W
* The welding anvil base is made of mould steel imported from Japan, which fully guarantees its service life

Technical Specifications:

Features:

* Strong structure welding body
* imported ultrasonic welding core components
* advanced hardware and software control system
* more than 10 years of ultrasonic metal welding experience technical team
* Germany headquarters technical support
* professional fixture design and production
* 7*24 hours of domestic after-sales service team
* ultra-high comprehensive cost performance

Application:

Automotive, electronics, home appliances, industrial components, electrical wiring components, lighters, toys, gadgets, medical, personal appliances, and more.

Detailed Photos:

Incorporated in 2015, K& M Technologies Ltd is one-stop solution provider in plastic welding business, especially in ultrasonic plastic welding, ultrasonic non-woven fabric sealing and cutting, hot plate welding, water filter welding lines...

From June 2021, We started the cooperation with a famous brand Dongho Ultrasonics, and co-established a new company Sincere Sonics to handle the overseas market of Dongho brands ultrasonic welding machines.

We have the professional team for the design of the equipment based on over 25 years' experience of the main staff in this industry.

We have sold to more than 100 countries in the world in the past years, including coutries from Asia, Europe, South America, North America, Oceania and Africa.

Our product series include QD series, ME series, SS series and Dongho Series for ultrasonic welding machines; AY series for filter welding machines and hot plate welding machines.

Now we have agents in Turkey, India, Ukrane, Maylasia, Vietnam and we are looking for more agents or distributors around the world who can take good care of the aftersales services in the country or territory.