Ultrasonic Welding Machines: Models, Specifications, and Applications

Definition of Welding Machines

All machines operating in an up-and-down motion can be classified as welding machines, including spot welders and plastic welding machines. Many non-standard products that utilize this motion can also be broadly categorized as welding ultrasonic textile slitting machines, even if they are not standardized products.

Plastic Welding Machines

Model: AH-15KHZ2000-4200W

Specifications:

• Frequency: 15KHz

• Power: 2000-3200W

• Air Pressure: 0.1-0.8MPa

• Input Voltage: AC 220V-240V

• Welding Stroke: 750mm

• Frame Structure: Round column

• Output Time: 0.01-9.99S

• Operating Modes: Time mode, manual mode

• Lifting Method: Manual handwheel

• Drive System: Pneumatic

• Cooling Method: Air cooling

• Generator Casing: Sheet metal

• Generator Circuit: Digital intelligent automatic frequency tracking

• Control Mode: 485 communication

• Machine Weight: 90kg

• Machine Dimensions (LWH): 6504001050mm

• Generator Dimensions (LWH): 380240130mm

Key Features:

1. Gravity die-cast body with CNC machining for high precision.

2. Key components use imported parts for powerful and stable output.

3. Four leveling screws for quick and efficient mold adjustments.

4. Adjustable working space for various product sizes.

5. Dual-button start mechanism for enhanced safety.

6. Designed for welding, fusing, riveting, spot welding, cutting, and metal embedding of thermoplastic materials, plastic components, and non-woven fabrics.

Applications:

Suitable for welding materials approximately 5cm in size, including thick materials or small plastic components such as charger plugs and charger bases.

Model: AH-15KHZ4200W

Specifications:

• Frequency: 15KHz

• Power: 4200-6000W

• Air Pressure: 0.1-1.0MPa

• Input Voltage: AC 220V-240V

• Welding Stroke: 100mm

• Frame Structure: Round column

• Output Time: 0.01-9.99S

• Operating Modes: Time mode, manual mode, energy mode

• Lifting Method: Manual handwheel

• Drive System: Pneumatic

• Cooling Method: Air cooling

• Generator Casing: Sheet metal

• Generator Circuit: Digital intelligent automatic frequency tracking

• Control Mode: 485 communication

• Machine Weight: 300kg

• Machine Dimensions (LWH): 8007502000mm

• Generator Dimensions (LWH): 380285100mm

Key Features:

1. Gravity die-cast body with CNC machining for high precision.

2. Key components use imported parts for powerful and stable output.

3. Four leveling screws for quick and efficient mold adjustments.

4. Adjustable working space for various product sizes.

5. Dual-button start mechanism for enhanced safety.

6. Designed for welding, fusing, riveting, spot welding, cutting, and metal embedding of thermoplastic materials, plastic components, and non-woven fabrics.

Applications:

Used for larger welding areas, such as 10cm-wide surfaces, which require 4200W power. While both models operate at 15KHz, the higher power of this machine provides greater ultrasonic impact force. It is suitable for welding items like fruit trays, electric toothbrushes, and plastic water cups.

Key Machine Components and Adjustments

• Lower Mold Fixing Frame: Ensures proper positioning and leveling of the lower mold. Once adjusted, the screws are secured to prevent movement.

• Start Switch: After all preparations are complete, the product is placed between the upper and lower molds. The dual-hand button start mechanism ensures safety by requiring both hands to activate welding or cutting.

• Emergency Stop Button: Used in emergencies, such as improper product placement or unexpected situations. Pressing this button will immediately raise the upper mold.

• Manual Handwheel: Adjusts the distance between the upper and lower molds based on different product requirements.

• Leveling Screws: Used to adjust the plane of the welding head. The upper and lower molds should first be brought into contact before fine-tuning the leveling screws for optimal welding results.

Choosing the Right Welding Machine for Different Applications

• Small-Sized Welding (e.g., ≤4cm)
  The AH-50 ultrasonic spot welder (actual size 54mm) is generally used for non-woven fabric bags, Velcro welding, or welding products within 4cm in size. Although the welding head is 54mm, the effective welding area is limited to 4cm due to the required power output. The welding capability also depends on the material thickness.

• Medium-Sized Welding (4cm-7cm)
  When the product width is between 4cm and 7cm, a 100-point welding machine is required. This model supports both round and square welding surfaces within this range.

• Large-Sized Welding (≥9cm)
  If the welding size exceeds 9cm, a 153-point welding machine is needed. However, the welding width should not exceed 1.5cm, and the length should not exceed 13.5cm. This limitation exists because the welding head itself is 2cm wide, and a wider mold would be difficult to fine-tune uniformly.

The reason the welding length cannot exceed 13.5cm is due to the positioning of the cylinder in the center. While side-mounted fixtures provide stability, they only prevent minor misalignment rather than contributing to force distribution.