Plastic Welding Systems, Ultrasonic Plastic Welding Systems, Ultrasonic Hand Gun, Ultrasonic Tube Sealing Systems, Ultrasonic Continuous Sealing Systems, Ultrasonic Special Purpose Machines

:: Ultrasonic Plastic Welding Systems ::

Construction of ultrasonic machine:-

Ultrasonic energy is mechanical vibratory energy which operates at frequencies beyond audible sound, or 18,000 Hz (18,000 Hz being the upper threshold of the normal human hearing range). Two basic frequencies are used; 20,000 Hz and 40,000 Hz, depending on the application. Selection is based upon the required power levels, the amplitude of vibration required and the size of the ultrasonic tool to be used. Frequency is important because it directly effects the power available and the tool size. It is easier to generate and control high power levels at the lower frequency. Also, ultrasonic tools are resonant members whose size is inversely proportional to their operating frequency. The generation of ultrasonic energy starts with conversion of conventional 50 or 60 Hz electrical power to 20,000 or 40,000 Hz electrical energy by a solid state power supply. (See Figure 3.)

Different types of horn depending about their application are given as follows:-

Ultrasonic Plastic Welding M/C »» »»

DISCRIPTION:-

Well suited to joining of thermoplastics.
Types of plastics used in welding are, Plastics to be joined should be compatible. A common method
is based on trial and error testing. Welding of thermoplastics involves heating, contact, cooling and
bonding. Joints may be weakened by incomplete fusion, oxidation or thermal degradation of the plastic.
Melting may be done by,
1. - gas or electric gun
2. - heated tool
3. - induction heating
4. - friction
5. - spinning

General welding
1. - Operation

1.1. The gun is held 90° to the weld and a rod is inserted.
2.2. Once the rod starts to melt, the gun is turned to a 45° angle and moved steadily along the weld.
3.3. The gun is moved in an elliptical path over the weld with an amplitude of about 1".
4.4. The rod is forced into the groove with a pressure of about 3-6 lbs. This pressure prevents air from        entering the weld. An angle of 45° to 90° is used for the rod.
5.5. When ending a weld, the heat is turned off, and after cooling the rod is twisted off, or for continuous        welds there should be an overlap of 1/2".
6.6. If required a weld can be restarted by cutting the previous weld at an angle, and starting from that        point.

1· Ultra Sonic Welding,
1- Basically a high frequency vibration is directed through a plastic joint. The vibration causes friction, and then heat, often causing a solid bond in less than a second.
2- Frequencies above 20 KHz.
3- The distance the vibration travels has a great deal to do with determining the classification.
4- Very well suited to rigid thermo plastic parts.
5- Good designs make direct application of the vibrations possible.

Testing Plastic Welds
1- A handheld gun can be used to generate arcs. The sparks are generated with voltages up to 55 KV at 200 KHz.
2- Operation
1.1. The gun is calibrated to spark at distances just over the weld thickness (to a ground plate).
2.2. The ground plate is placed behind the weld.
3.3. As the probe is moved over the weld, sparks will jump when a gap in the weld moves between the probe and the ground plate.

THE RANGE OF ULTRASONIC WELDING MACHINES ARE AS FOLLOWS: -

SR.NO.	MODEL	POWER	FREQUENY	DISCRIPTION
MODEL FOR ULTRASONIC PLASTIC WELDING M/C
1	ULTRAWELD1200	1200W	20KHz	PLASTIC WELDING M/C
2	ULTRAWELD1500	1500W	20KHz	PLASTIC WELDING M/C
3	ULTRAWELD2000	2000W	20KHz	PLASTIC WELDING M/C
4	ULTRAWELD3010	1000W	30KHz	PLASTIC WELDING M/C
MODEL FOR ULTRASONIC FABRIC SEALERS
5	ULTRACUT1200	1200W	20KHz	FABRIC CUTTING/SEALING
6	ULTRACUT3010	1000W	30KHz	FABRIC CUTTING/SEALING
MODEL FOR ULTRASONIC TUBE SEALING MACHINES
7	ULTRALABSEAL1200	1200W	20KHz	CUTTING CODING FACILITY
8	ULTRALABSEAL3010	1000W	30KHz	CUTTING CODING FACILITY
MODEL FOR ULTRASONIC HAND HELD GUN
9.	ULTRAGUN 500	500W	30/40KHz	PISTOL TYPE OR STAPLE TYPE GUN
10.	ULTRAGUN 1200	1200W	20KHz	PISTOL TYPE OR STAPLE TYPE GUN

Ultrasonic Plastic Welding M/C

1	ULTRAWELD1200	1200W	20KHz	PLASTIC WELDING M/C
2	ULTRAWELD1500	1500W	20KHz	PLASTIC WELDING M/C
3	ULTRAWELD2000	2000W	20KHz	PLASTIC WELDING M/C
4	ULTRAWELD3010	1000W	30KHz	PLASTIC WELDING M/C

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