Applications of handheld ultrasonic welding guns: Revolutionising precision joining

Handheld ultrasonic welding guns have emerged as powerful tools in the field of precision joining, providing a versatile and efficient solution for a wide range of applications. These compact devices use ultrasonic vibrations to create strong, reliable bonds between materials without additional adhesives or fasteners. This article explores the diverse applications of handheld ultrasonic welding guns and how they are revolutionising the world of manufacturing and assembly.

 

Automotive industry

  • Plastic components assembly: Handheld ultrasonic welding guns find extensive use in the automotive industry for assembling plastic components such as interior panels, dashboard parts, and various trim elements. The precision and speed of ultrasonic welding contribute to efficient manufacturing processes.

 

  • Wire harness welding: Ensuring secure connections in wire harnesses is crucial for vehicle functionality. Handheld ultrasonic welding guns provide a reliable method for welding wires, creating durable and vibration-resistant joints in automotive electrical systems.

Electronics and consumer goods

  • Battery pack assembly: In the electronics industry, particularly in producing battery packs for devices like laptops and power tools, handheld ultrasonic welding guns are employed to join plastic components securely. This application ensures the integrity and safety of the battery enclosure.

 

  • Consumer electronics casing: Handheld ultrasonic welding guns offer an ideal solution for assembling casings and enclosures in consumer electronics such as smartphones, tablets, and wearable devices. The precision of ultrasonic welding ensures a seamless and aesthetically pleasing finish.

Medical device manufacturing

  • Disposable medical device assembly: The medical industry benefits from the sterile and precise nature of ultrasonic welding in the assembly of disposable medical devices. Handheld ultrasonic welding guns are used to create leak-proof seals in components like blood filters, drug delivery devices, and diagnostic test kits.

 

  • Surgical instrument production: Surgical instruments require impeccable precision and cleanliness. Handheld ultrasonic welding guns contribute to the assembly of components in surgical tools, providing a secure bond without compromising the integrity of the instruments.

Textile and packaging

  • Non-woven fabric sealing: Handheld ultrasonic welding guns are crucial in sealing and bonding non-woven fabrics in the textile industry. Applications include the production of medical gowns, filters, and various disposable products.

 

  • Packaging industry: In the packaging sector, ultrasonic welding is used for sealing and joining packaging materials, creating tamper-proof seals, and ensuring the integrity of the contents. Handheld devices offer flexibility in applications where automation may not be suitable.

Advantages of handheld ultrasonic welding guns

  • Precision and consistency: Handheld ultrasonic welding guns provide unparalleled precision in joining materials. The controlled application of ultrasonic vibrations ensures consistent and repeatable welds, contributing to high-quality manufacturing processes.

 

  • Fast and efficient: The speed at which handheld ultrasonic welding guns operate enhances production efficiency. With quick cycle times, these devices contribute to streamlined manufacturing workflows, reducing overall production costs.

 

  • Environmentally friendly: Ultrasonic welding eliminates the need for adhesives or additional consumables, making it an environmentally friendly joining method. This feature aligns with the growing emphasis on sustainable manufacturing practices.

Contact M.E.E. for details

Contact us today for more information about our handheld ultrasonic welding guns.

Enhancing precision in specialised welding: The role of VE 35 and VE 20 actuators

In specialised welding, precision is paramount. Industries like automotive manufacturing demand welding solutions that ensure the strength and longevity of welds and enhance productivity and cost-effectiveness. In this pursuit of excellence, M.E.E. is a trusted supplier of specialised welding equipment and utilities, offering various solutions that combine reliability, longevity, accuracy, and cost-effectiveness. Among pir offerings, VE 35 and VE 20 actuators have emerged as indispensable tools, especially tailored to meet the demands of high-precision welding tasks, particularly in the automotive industry.

M.E.E’s commitment to excellence

We have long been at the forefront of providing cutting-edge welding solutions to a diverse clientele. Our commitment to delivering reliability, longevity, accuracy, and cost-effectiveness in equal measure has made us a preferred partner for businesses looking to elevate their welding operations. Our proficiency and extensive product range ensure comprehensive coverage for tasks involving automotive components, aerospace structures, and intricate assemblies.

Type VE 35 actuators: Power and precision combined

The VE 35 actuator is a true workhorse for specialised welding applications. Designed with the utmost precision and robustness in mind, it boasts a range of features that make it an ideal choice for demanding welding tasks.

· Powerful performance: The VE 35 actuator delivers impressive power and force, making it suitable for multiple welding applications, from structural welding in the automotive industry to intricate work on aerospace components.

· Precision control: Precision is the hallmark of this actuator. It offers exceptional accuracy and repeatability, always ensuring consistent and reliable welds.

· Longevity: Built to withstand the rigours of industrial use, the VE 35 actuator is engineered for longevity. It’s designed to endure heavy workloads and provide years of dependable service.

· Cost-effective: While it’s a high-performance piece of equipment, the VE 35 actuator is also cost-effective, offering a balance between performance and affordability that’s hard to beat.

Type VE 20 Actuators: Excellence in Compact Form

For applications where space is a premium but precision cannot be compromised, the VE 20 actuator shines. his compact yet potent actuator has been specifically designed for welding operations that require a high degree of precision and agility.

Compact design: The VE 20 actuator’s compact design allows it to be easily integrated into tight spaces and complex welding setups, making it an excellent choice for applications with spatial constraints.

High-speed operation: Despite its size, the VE 20 actuator doesn’t compromise on speed or power. It excels in delivering rapid and precise welding operations.

Accuracy and consistency: Like its larger counterpart, the VE 20 actuator offers exceptional accuracy and consistency, ensuring that welds meet the most stringent quality standards.

Cost-efficiency: The VE 20 actuator is a cost-effective solution for specialised welding needs by maximising space use and energy efficiency.

Contact M.E.E. for details

Contact us today for more information about our VE 35 and VE 20 actuators.

Unlocking Precision And Efficiency With Handheld Ultrasonic Welding Guns

In today’s fast-paced manufacturing world, precision, speed, and efficiency are key factors determining the success of a production process. Handheld ultrasonic welding guns are one cutting-edge technology that has revolutionised how plastic components are joined together. With their advanced features and unmatched versatility, these powerful tools have become indispensable for manufacturers across various industries.

As a leading company in the field of industrial equipment, M.E.E is at the forefront of providing cutting-edge solutions to its customers. Handheld ultrasonic welding guns are one such innovation. So let’s dive deeper into the benefits of these incredible tools.

What is a  handheld ultrasonic welding guns

First, handheld ultrasonic welding guns offer unparalleled precision. They use high-frequency ultrasonic vibrations to generate heat-melting plastic components, which are then fused to create a strong, durable bond. Achieve precise control, tight tolerances, and minimal part distortion with our exceptional welding process. This precise and controlled process ensures consistent results, eliminating the need for rework or costly rejects and saving time and money in the long run.

In addition to precision, handheld ultrasonic welding guns excel in speed and efficiency. Unlike traditional welding methods requiring time-consuming setup, such as preheating or cooling, ultrasonic welding guns can rapidly weld parts together in seconds. This significantly increases productivity, allowing manufacturers to meet tight production deadlines and scale their operations.

Furthermore, these handheld ultrasonic welding guns offer versatility in the types of materials that can be welded. They can join a wide range of thermoplastic materials, including but not limited to ABS, PVC, PET, PP, and PE. This flexibility makes them ideal for various applications, such as automotive, aerospace, medical devices, consumer goods, and electronics.

Another notable advantage of handheld ultrasonic welding guns is their ergonomic design and ease of use. They are lightweight, portable, and designed with user-friendly interfaces, making them comfortable and convenient. Operators can easily adjust welding parameters, such as amplitude, time, and pressure, to achieve optimal results. Safety features in the guns include built-in sensors that detect anomalies during welding, prioritizing operator safety and component protection.

Finally, handheld ultrasonic welding guns contribute to environmental sustainability. Unlike traditional welding methods requiring adhesives, solvents, or other consumables, ultrasonic welding is solvent-free, clean, and energy-efficient. It produces no harmful fumes or by-products, making it environmentally friendly and compliant with stringent regulations.

 

Contact M.E.E. For Details

Contact us today for more information about handheld ultrasonic welding guns.

The Zinzer Hot Air Gun: The Ultimate Solution For Industrial Heating Needs

When it comes to industrial heating, precision, efficiency, and reliability are of the utmost importance. That’s why M.E.E. offers the Zinzer hot air gun, a cutting-edge solution that meets all these requirements. It’s advanced technology and robust construction makes it the ultimate tool for heating applications in multiple industries.

The Zinzer Hot Air Gun Has Unmatched Precision

The Zinzer hot air gun is designed to provide precise and controlled heating for various materials. Whether you need to heat plastics, metals, or composites, the Zinzer hot air gun delivers accurate temperature control with its digital display and adjustable settings. This allows for precise heating, ensuring consistent results and minimising the risk of overheating or damaging the material. The gun’s ergonomic design also provides easy handling, allowing operators to work comfortably for extended periods without fatigue.

Efficient Performance

The Zinzer hot air gun is powered by a high-performance motor providing a powerful and consistent flow of hot air. This ensures efficient heating, reducing the time required to heat materials and increasing productivity. In addition, it features a quick warm-up time, allowing operators to start working quickly without delays. Furthermore, the Zinzer hot air gun is designed to minimise energy consumption, making it a cost-effective solution for long-term use.

Reliable And Durable

Built to last, the Zinzer hot air gun is made from high-quality materials and features a rugged construction that can withstand harsh industrial environments. Its durable design ensures reliable performance even in demanding conditions, making it suitable for heavy-duty applications. The gun also has safety features such as overheat protection and a cool-down mode, ensuring safe operation and protecting the user from potential hazards.

Versatile Applications

The Zinzer hot air gun is a versatile tool used in various applications across different industries. From automotive and aerospace to construction and plastics, it can easily handle multiple heating tasks. Therefore, it can be used for welding, shrinking, drying, and forming tasks, making it an indispensable tool for professionals in different fields.

Unparalleled Support

M.E.E is committed to providing excellent customer service and support, and the Zinzer hot air gun is backed by comprehensive technical support and warranty. Our experts are always ready to assist with any questions or concerns, ensuring you maximise your investment.

Contact M.E.E. For Details

Contact us today for more information on the Zinzer hot air gun.

Enhancing Precision And Efficiency With Plastic Joining Equipment In Johannesburg

Plastic joining, also known as plastic welding, is a critical process in various industries, including automotive, aerospace, packaging, and electronics. It involves fusing two or more plastic components to create a strong and durable bond. To achieve precise and efficient plastic joining, state-of-the-art equipment is essential. In Johannesburg, M.E.E has emerged as a trusted provider of high-quality plastic joining equipment, delivering cutting-edge solutions to meet the needs of diverse industries.

With a strong reputation for excellence, we’re a leading supplier of plastic joining equipment in Johannesburg. We offer various advanced plastic welding machines and accessories designed to deliver superior performance and reliability. Our product portfolio includes technologies like ultrasonic welding, hot plate welding, vibration welding, and laser welding. These technologies cater to various types of plastics, including thermoplastics, thermoset plastics, and composites, making them suitable for diverse applications.

Advantages Of Using Plastic Joining Equipment From M.E.E

One of the key advantages of using plastic joining equipment from M.E.E is the precision and accuracy offered. Our advanced equipment is engineered to deliver tight tolerances and consistent results, ensuring plastic components are joined with utmost accuracy. This is crucial in industries where the final product’s quality and reliability are paramount. Whether it’s automotive parts, medical devices, or electronic components, our plastic joining equipment guarantees precise and reliable bonding, enhancing the overall performance and durability of the final product.

Efficiency is another critical factor that sets our plastic joining equipment apart. Our state-of-the-art machines are designed to optimise the welding process, reducing cycle times and increasing productivity. Our plastic joining equipment enables seamless and efficient operations with features like automated controls, intuitive interfaces, and advanced monitoring systems. This saves time and minimises waste and rework, contributing to cost savings and improved business profitability.

Our commitment to customer satisfaction is evident in our exceptional customer service and technical support. Our experts provide comprehensive guidance and assistance in selecting the right plastic joining equipment based on each customer’s specific requirements. Additionally, we offer training and after-sales support, ensuring customers can operate the equipment effectively and achieve optimal results. Our customer-centric approach has earned us a loyal customer base in Johannesburg and beyond.

In addition to our cutting-edge plastic joining equipment, we emphasise sustainability. We recognise the importance of environmentally responsible practices and offer solutions promoting sustainability, such as energy-efficient equipment and processes minimising the environmental impact of plastic joining operations.

Contact M.E.E. For Details

If you need plastic joining equipment in Johannesburg, look no further than M.E.E. Contact us today for more information

Hot Air Gun 101

Hot air guns are flameless electric air guns used for various repair and construction tasks. They are useful portable or stationary tools. However, you cannot use hot air guns without proper techniques because of the high temperatures and safety concerns. As a result, it is critical to understand how a heat gun works.

Hot air gun applications

A hot air gun is a multipurpose electric tool that can be used for various tasks. It’s similar to a piece of standard essential equipment you can use for university projects, household repairs, and even tough jobs in your workshop and laboratory.

Hot air guns are primarily used to remove paint from various materials such as wood, metal, and glass. Compared to other electric tools, a heat gun will provide the highest precision when stripping paint. In addition, hot air guns are used in DIY electronic projects and metalworking shops for soldering wires and repairing metal parts. For example, they are excellent for soldering copper pipes.

Putty and old paint can be removed from furniture and walls using an electronic hot air gun. People frequently use them to separate pictures from walls and other hard surfaces because they can melt all types of glue. Furthermore, hot air guns can be used to make various household and decorative items. They are popular among artisans due to their ease of use and accuracy, which is critical for small craft items.

Workers frequently used hair dryers to wrap goods in factories with shrink wraps. However, a hot air gun is much more convenient for shrink wrapping and works much faster than a hairdryer.

Temperature controls

Hot air guns with only one heat setting and one fan speed are intended primarily for paint stripping. More complex models have two or three heat settings, or even fully variable adjustment within a range, and a choice of two, three, or variable airflow speeds.

Any heat gun’s effective temperature can be reduced by holding it further away from the surface but having variable settings gives you more options.

Maximum speed and air flow are generally required for paint stripping. These settings are also needed for other jobs like soldering plumbing joints and freeing rusted nuts. Other heat gun applications require lower air flows and/or lower temperatures. Other applications for the heat gun include drying paint or varnish (30 – 130°C) with caution because dust particles may be blown onto the paint/varnish.

  • 100 – 200°C for drying damp wood before filling or painting.
  • 300 – 400°C for softening adhesive when applying worktop edge trim or lifting floor tiles.
  • 200 – 300°C for bending plastic pipes and heat-shrinking plastic film
  • 330 – 400°C for welding some plastics

A hot air gun should never be used near copper plumbing with solder connectors because the heat can melt the solder and weaken the joints. In addition, special nozzles for purposes other than paint stripping are available.

Operating principles of hot air guns

A hot air gun’s operation is like that of a hairdryer in that both produce heat and emit hot air streams. However, the temperature is much higher than that of a hairdryer, which is why this heat is used to melt various materials.

A fan inside the hot air gun body draws in outside air to create a continuous hot air flow. Corded hot air guns are powered by electricity, whereas cordless ones are powered by batteries.

When the hot air gun is powered up, the heating element produces a high temperature and heats the air. The hot air then exits through a nozzle attached to the heat gun.

When stripping paint, heated air is directed onto the painted surface, softening it so that it can be easily removed with a stripping knife or hook. For the best results, use the hot air gun above the stripping tool to soften the paint just before the stripping tool reaches it. The device is used one-handed, with the stripping tool in the other.

Some heat guns can be used while sitting on a bench, leaving two hands-free to use the hot air for other purposes.

Hot air gun characteristics

Different features and attachments are required to adjust your hot air gun for maximum efficiency. Various brands and models of guns exist, but these features and attachments are almost universal.

Wattage

The general power of a hot air gun typically ranges from 1 000 W to 2 000 W. The higher the wattage, if there are heat and/or airflow controls, the better.

The control switch

The main switch on a hot air gun, located in front of the trigger grip, turns the gun on and off. This “dead man” switch is a hot air gun safety feature turning off the gun when you remove your finger from the trigger.

Temperature control

You can change the temperature depending on the task at hand. Use less than 260°C for materials with low melting points. Otherwise, use a higher temperature that is within the range of your hot air gun. If the proper temperature is not set, things can go wrong, and your workpiece may be damaged.

Airflow controls

Set the low airflow option while working on a small area with a high-temperature setting. However, if you need to work in a large area, always set the airflow to high. Otherwise, the temperature will rise, and the surface will burn.

Thermal cut out

This feature turns off the tool if it becomes too hot. If this occurs, it indicates a flaw in the device or method of use that must be identified and corrected before the hot air gun is used again for safety.

Flex length

Flex lengths of two to three metres are typically fitted, which means that when using an extension lead, the tool can be used at full reach without the socket hanging in mid-air.

Storage

Some hot air guns have a hook from which the tool can be hung. Others have a surface stand that allows the heat gun to be safely ‘rested’ during work pauses and after use. It also enables the gun to be used “hands-free” when two hands are needed on the workpiece.

Setting nozzles

When using a hot air gun, you must use the correct nozzle because they control the hot airflow, which varies depending on the task. Four types of nozzles, each with a different size, are essential for regular work with a heat gun.

  • When you want to concentrate heat on a specific area, use a reducer nozzle.
  • The reflector nozzle wraps around a plastic or copper pipe to distribute heat evenly.
  • A flat nozzle distributes hot air over a larger, narrower area.
  • The glass protector nozzle keeps direct heat off the glass when stripping paint from a window.

Types of hot air guns

Let’s break down the hot air gun list.

Electric heat guns

Corded or cordless electric hot air guns are available. This type of heat gun is the most common and, of course, the most effective for various projects. The popular electric heat gun has an energy-saving system that can help you save money on your electric bill. It’s worth noting that you can use the electric heat gun for multiple projects without running out of power.

Electric hot air guns have largely replaced ‘traditional’ paraffin and bottled gas blowlamps for stripping paint from wood. Although a heat gun’s hot air flow is less dangerous than a naked flame, it can still cause highly flammable items to catch fire, crack glass, and cause injury if directed onto skin. One significant advantage is that the heat is almost instantaneous, allowing the hot air gun to be switched off during breaks, whereas flame blowlamps must be relit if the flame is extinguished.

When used correctly to strip paint, electric heat guns are lightweight, easy-to-use tools that are far less likely to scorch wood or crack glass.

Industrial hot air gun

If you’re looking for a heat gun to help you work in heavy-duty areas, an industrial heat gun is larger but may require electricity.

Gas-powered hot air gun

Because they use a lot of gas while working, gas-powered heat guns are not very popular. Furthermore, gas power heat guns are used in heavy-duty heating areas.

Hot air gun safety

  • Although a hot air gun is safer than a naked-flame blowlamp, it must still be used with caution. Because of the power of these tools (up to 2 000 W), when an extension lead is required, only use a 10 amp or greater lead, and always completely unwind the lead.
  • Never block or cover the air intake grills. The heat gun will overheat and possibly catch fire if the airflow is reduced.
  • Never use the heat gun with the outlet nozzle pressed against a surface. This reduces airflow and can have the same effect as blocking the air inlet grills.
  • Use a heat gun away from flammable materials.
  • Always turn off the tool before placing it on any surface.
  • Allow the tool to cool completely before storing it.
  • While the nozzle is hot, do not place it near anything.
  • Never touch the hot metal nozzle to your skin or clothing.
  • Do not use to remove lead-based paints.
  • Avoid getting paint stuck to the nozzle, and allow the gun to cool before removing any paint.
  • Don’t look down the nozzle while the hot air gun is in use
  • Never insert anything down the nozzle.

FAQs

Q: Are hot air guns more dangerous than torches and flame throwers?

A: Heat guns are less dangerous than torches and flame guns because they are less likely to generate flames and catch fire.

Q: What is a thermal cut-out in a hot air gun?

A: It is a feature that turns off the heat gun when it becomes too hot.

Q: Are heat guns portable?

A: Cordless heat guns are extremely portable and easily transported from one location to another.

Q: How simple are heat guns to use?

A: A hot air gun is simple, but you should always follow the above-mentioned safety tips when using the tool.

Q: How long can a heat gun be used?

A: You can continuously use a hot air gun for nearly 15 to 20 minutes without stopping.

Q: How hot can a hot air gun get?

A: It depends on heat guns. Temperatures vary depending on the type of heat gun used. A standard heat gun can reach temperatures of up to 760°C. When you use an industrial-grade tool, you will also get more temperature.

Q: Can a heat gun start a fire?

A: Using the heat gun for up to 40 minutes without stopping may start a fire. Furthermore, you should inspect the safety features before each use because safety problems cause most fires.

Contact M.E.E. for details

Hot air devices and welding machines from ZINSER are used wherever professionals use hot air. So for all your hot air gun needs and repairs, get in touch with us today for more information.

What is an Ultrasonic Generator?

An ultrasonic generator is one of the great energy generators of our time. Used in a wide variety of applications, it can transmit electrical energy to a particular system’s ultrasonic transducers.

 

It is the function of the ultrasonic generator to convert energy to the right amperage, frequency, and voltage for use. The selection of the ultrasonic generator should be specific to the application for which it will be used. The ultrasonic waveform can also be adjusted so that the energy conversion is optimal in any particular circumstance.

 

M.E.E. are the leading supplier of fully automated ultrasonic generators for plastic joining applications and are on standby to assist you. Contact them today to speak to one of their friendly consultants for more information.

FAQs

As a leading provider of ultrasonic welding equipment and a leader in plastic joining, we have the answers to all your ultrasonic welding questions.

What is ultrasonic welding?

Ultrasonic welding is a solid-state joining process that uses high-frequency ultrasonic acoustic vibrations. These vibrations are applied locally to workpieces that are held together under pressure.

What types of materials can be ultrasonically welded?

Ultrasonic welding is used to join thermoplastics that are soft and rigid and thermoplastic composites. In addition, it can be used to join metals like aluminium, brass, copper, most precious metals, and nickel alloys. The method can also be used to join dissimilar metals.

Is ultrasonic welding waterproof?

Ultrasonic welding does not produce naturally waterproof or airtight joins for products like water tanks, coffee pots, vacuum cleaner casings, etc. However, water or airtightness requirements can be met with proper positioning of the upper and lower plastic shells to be joined, weld line structure, wall thickness, materials, and ultrasonic frequency and power.

Is ultrasonic welding safe?

Ultrasonic welding is safer than many traditional welding methods because it does not require high temperatures or produce fumes. In addition, because it is highly targeted, this technique poses fewer risks that may result from excess electrical energy.

Is heat generated during ultrasonic welding?

Ultrasonic welding generates low amplitude mechanical vibrations using high-frequency ultrasonic energy. These vibrations generate heat where the parts being welded come together. While this heat is sufficient to melt thermoplastic materials, it is insufficient to melt the metals being joined.

What is the highest frequency that can be used in ultrasonic welding?

Ultrasonic welding has a maximum frequency of 70 kHz. The lowest frequency used is 20 kHz, which is barely audible to humans. Higher frequencies can only be perceived as vibrations.

What are the advantages of ultrasonic welding?

In plastic welding, internal heat generation causes less material to be heated, resulting in a smaller heat-affected zone and a lower chance of deformation. In addition, ultrasonic welding produces extremely fast cycle times, typically less than a second.

In metal welding, the metal does not melt during the solid-state process. Instead, it softens to the point where it can be pushed together, resulting in improved strength retention. And in addition to fast cycle times, ultrasonic welding offers greater precision in heating control than most other metal welding processes.

What is a sonotrode?

Sonotrodes are ultrasonic welding tools that vibrate when high-frequency mechanical oscillations are applied. They are designed using the Finite Element Method (FEM), which ensures optimal oscillation behaviour and longevity.

What is the function of sonotrode?

A sonotrode is used in ultrasonic machining, welding, and mixing and generates ultrasonic vibrations that it transfers to a gas, liquid, solid, or tissue. A sonotrode is typically made of a stack of piezoelectric transducers connected by a tapering metal rod.

What is a booster in ultrasonic welding?

Boosters, also known as amplitude transformers, are an essential component of the resonant structure. They change the amplitude provided by the converter and send it to the sonotrode. The amplitude varies depending on the plastic weld component.

How does an ultrasonic booster work?

The ultrasonic booster modifies the transducer’s vibrational output and transfers ultrasonic energy to the horn. In general, the booster provides a method for mounting the ultrasonic stack to a support structure. The ultrasonic horn then makes contact with the load and delivers power to it.

How is a sonotrode fixed to a booster?

The sonotrode is mechanically attached to the ultrasonic stack’s booster. The final amplitude experienced at the sonotrode face, and thus the amplitude used to weld two metal materials, is determined by the shape of the sonotrode.

What is an ultrasonic welding horn?

Ultrasonic horns are a catch-all term for all ultrasonic transmitters and are an essential component of ultrasonic welding equipment. Its purpose is to couple the transducer’s ultrasonic waves into the object being processed. Because it will be transmitting ultrasonic waves, the welding horn must be in a resonant state, meaning its natural resonant frequency must match that of the transducer. Second, the amplitude should be uniform, and the shape of the welding horn’s end face should match the shape of the workpiece to be welded.

What is an ultrasonic generator?

The ultrasonic generator produces a sinusoidal or pulse signal with a specific frequency, which is the working frequency of the transducer. Ultrasonic equipment uses ultrasonic frequencies of 20 kHz, 25 kHz, 28 kHz, 33 kHz, 40 kHz, 60 kHz, and above 100 kHz.

What is an ultrasonic generator used for?

The ultrasonic generator’s function is to convert mains electricity into a high-frequency alternating current signal that is matched with the ultrasonic transducer to drive the ultrasonic transducer to work.

What does HF stand for in welding?

High frequency (HF) welding is the process of fusing materials together by applying a rapidly alternating electric field between two bars in the joint area. It is also known as radiofrequency (RF) or dielectric welding. High-frequency welding only works with thermoplastics with a high dielectric constant, which is determined by the geometry and dipole moment of the molecule.

In general, high-frequency welding is not recommended for polypropylene (PP), polyethylene (PE), polytetrafluoroethylene (PTFE), polycarbonate, or polystyrene. However, because of the impending restrictions on the use of polyvinyl chloride (PVC), a special grade of polyolefin has been developed that can be HF welded.

High-frequency welding is commonly used in the production of medical supplies, including protective clothing, gel- and foam-filled cushions, lumbar support, hydration reservoirs, medical air and water mattresses, and stretcher and bed covers. Other products manufactured through high-frequency welding include flexible storage tanks, inflatable life jackets, flexible ducting, bellows, curtains, conveyor belts, water weights, lifting bags, inflatable boats, life jackets, life rafts, and other buoyancy equipment.

What are barrier materials in welding?

Barrier or buffer materials thermally insulate the weld area, allowing a larger weld area for a given amount of radiofrequency power. Elephantidae, polyester film, or phenolic laminates with high dielectric properties are frequently used to line the base plates. They also keep the edge of a tear-seal electrode from making contact with the bottom plate and causing an arc.

Contact M.E.E. for details

For all your ultrasonic welding equipment needs and repairs, get in touch with us today for more information and offers on our plastic joining equipment, services, and spares.

 

Types and applications of ultrasonic welding equipment

Ultrasonic cutting and welding equipment is frequently used to produce fabric goods. They are also used to connect thermoplastic components to metals like aluminium.

Ultrasonic energy is used to join, cut, pattern, and quilt synthetic fabrics containing no more than 40% natural fabric content.

Ultrasonic welding is accomplished by converting high-frequency electrical energy into high-frequency mechanical motion. High-frequency vibrations, combined with contact force, generate heat by friction at the mating surfaces. As a result, the plastic will melt and form a bond between the parts that are being joined.

Ultrasonic cutting is accomplished by pressing the vibrating horn against a fixed anvil and allowing the horn to push through the fabric, sealing the edge. This method is used to punch holes, cut pre-cut patterns, and cut fabric strips to pre-determined lengths. Food processors slice their products as they come out of ovens, using ultrasonic knives that vibrate 20,000 times per second. The high-frequency vibration creates a nearly friction-free surface between the tool (knife) and the product, removing the possibility of sticking and pinching.

Ultrasonic welding equipment specifications

Ultrasonic cutting and welding equipment is made up of various parts:

· A power supply converts line power at 50 or 60 cycles to high ultrasonic frequency at 20 000 or higher cycles per second. These high-frequency electrical signals can change the frequency based on the ultrasonic stack (converter, booster, and horn).

· A pneumatically controlled press applies pressure to the welded parts and controls the horn’s movement.

· A converter is a device that converts electricity into mechanical vibrations with a high frequency.

· The booster transmits vibration energy, increasing its amplitude, and clamps the horn and convertor to the press.

· The vibration energy is delivered to the material to be worked on via a horn, usually manufactured from titanium or aluminium.

· An anvil or backup tool supports the work material and has channels to allow the horn to completely sever the material and seal the edge. Various ultrasonic welding fixtures hold the material in place. It is critical that the parts are aligned with the welding horn for a successful ultrasonic weld.

Ultrasonic vibrations are transmitted from the horn to the material during operation. This generates frictional heat and fuses the material at the point of contact. The material is cut through, and the edges are sealed at the same time when a cutting edge is used on the anvil.

Ultrasonic welding equipment applications

Ultrasonic welding and cutting are used to replace traditional fabric assembly techniques in clothing production in many ways.

Seams: Making seams or hems in disposable medical products is a common application. Medical garments, face masks, and other items fall into this category. A single row, double row, or triple row of stitches can be simulated using pattern wheels.

Sleeves and cuffs: To effectively weld sleeves and cuffs, cylindrical machines employ a cylindrical arm with a rotary stitch wheel and an ultrasonic system above the wheel.

Slitting or sealing: Ultrasonic slitters cut and seal the edges of synthetic or blended fabrics with precision. As a result, fraying and unravelling are almost completely eliminated.

Hand cutting: A hand-held cutter can cut straight lines or large radius curves.

Plunge cutting: A plunge cutter can cut ribbons, strips, and other materials to length.

Plunge sealing and cutting: Ultrasonic plunge sealing and cutting are performed by advancing single or multiple horns onto materials placed on a fixed anvil.

Adhesive bonding: Thermally activated materials are sandwiched between two non-thermoplastic fabrics, such as cotton, wool, or cotton-wool blends with little synthetic content. The ultrasonic vibrations cause the thermally activated adhesive to flow into the fabric fibres and join them together.

Ultrasonic welding equipment features

When used in the production of synthetic clothing and other fabric products, ultrasonic cutting and welding equipment is an excellent efficiency multiplier. Though woven and nonwoven fabrics are the most used materials for ultrasonic cutters and welders, other plastic and metal components may also be used in this process.

Contact M.E.E. for details

For all your ultrasonic welding equipment needs and repairs, get in touch with us today for more information and offers on our plastic joining equipment, services, and spares.

How ultrasonic welding transformed plastic welding

Plastic welding, or any process that flawlessly bond thermoplastics, has been around for a long time. One of the most ground-breaking approaches developed for this practice is ultrasonic welding. Ultrasonic welding uses sound waves rather than heat or electricity to join two dissimilar components, resulting in a weld that does not require soldering, binders, or adhesives to keep two materials together.

The method was discovered in 1963 when Robert Soloff noticed that sound waves were not limited in the same manner that other plastic welds were. Instead of direct contact between the material and the applicator, an ultrasonic welder may send sound waves around corners and along the edges of rigid plastic. This enabled sound waves to locate the contacting seam that needed to be welded, allowing an ultrasonic weld to reach considerably smaller and tighter areas than conventional types of heat sealing.

Since then, ultrasonic welding has found widespread application in heat sealing and plastic welding applications. Today, ultrasonic welding has replaced glue and screws in various consumer goods, including cellphones and toys.

Because ultrasonic welding does not need a soldering substance or emit any heat or fumes, it is a very environmentally safe and efficient form of thermoplastic welding. In addition, ultrasonic welding, like several other plastic welding technologies, are completed in a fraction of a second. This means materials are bonded as fast as before but ultimately saves money over conventional heat-sealing procedures. Ultrasonic welding machines can also be easily customised to deal with very particular materials.

Because no external material is required, ultrasonic welding can be used in computer and medical applications where debris and foreign matter might have devastating consequences. Furthermore, because of its versatility and speed, ultrasonic welding has become one of the most widely used methods of plastic bonding today.

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