With the continuous improvement of people's material level, the car has gradually become a way of life from the initial means of transportation. It is precisely because of this change in consumption Xi that automobile manufacturers need to continuously innovate the technology of auto parts such as oil pipe fittings, fuel tanks, oil cups, instrument panels, lights, doors, airbags, and built-in speakers to ensure the comfort and safety of vehicles in daily driving. And this kind of "involution" innovation has also opened a "new competition point" for auto parts manufacturers.
However, some automotive parts involve complex structural design, which makes welding work quite challenging. How to call the appropriate parameters for welding according to the material characteristics of the parts and components to ensure the welding quality and stability of the welding process is a problem that manufacturers need to consider.
In this issue, let's walk into the application scenarios of ultrasonic welding and see how Lingke ultrasonic provides corresponding solutions to the pain points of the industry to help manufacturers achieve perfect welding.
Customer pain points
Brought by the customerNylon + 35% fiberglassThis kind of workpiece was previously welded with 15kHz ultrasonic equipment, and the defect rate was as high as 50%. Therefore, the production of such products must be fully inspected, which not only increases the cost input, is time-consuming and laborious, but also reduces the production efficiency.
Customer requirements
Welding requirements
The welding is firm and does not fall off;
0.No leakage or air leakage under 4MPa pressure
There must be no cracks, indentations, scratches and other wounds.
Equipment Requirements:
According to the formula of different products, the relevant parameters of the corresponding product welding are directly called when the production is changed
The device supports saving 100 sets of welding formulas
Stable welding quality;
The equipment is equipped with quality management function (abnormal welding quality alarm);
The equipment can be connected to other auxiliary signals such as gratings, solenoid valves, etc
Equipment welding quality data recording and export function;
The net stroke of the equipment is required to be 500mm (except for welding fixtures, the distance from the installation base plate to the transducer);
The equipment has six welding modes: time, energy, power, absolute depth, relative depth and pressure mode, which can be switched in real time according to the actual welding needs of the product to meet the best welding effect.
Resolution process
Disassembly analysis: The application engineer dismantled the workpiece to check the internal welding situation, and concluded that the welding area of the automobile oil pipeline fittings is small and the glass fiber content is very high, so it is easy to damage the workpiece structure when using 15kHz ultrasonic welding, resulting in high defective products.
Prescribe the right medicine: According to the actual situation of the workpiece and the specific requirements of the customer, the application engineer recommended the use of L3000 servo ultrasonic welding machine after comprehensive consideration.
Rush molding: The mold production department expedites the production of test molds that meet the requirements.
Successful welding: The next morning, after the ultrasonic welding machine is installed with a new mold, whether it is 2pcs or 6pcs welding test, the welding can be completed in a very short time, and the customer's requirements for firm welding, no air leakage, no liquid leakage, no crushing and so on.