Aluminum Ultrasonic Welding Horn Guidelines Ultrasonic Air Horn

15Khz Aluminum Ultrasonic welding horn design guidelines ultrasonic sonotrode

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Introduction:

The ultrasonic welding horn contains several key acoustic vibration characteristics such as resonance length, amplification factor, strain maximum point, and position of displacement nodes. The most simple and commonly used ultrasonic welding horns are divided into exponential shape, catenary shape, conical shape and stepped shape according to the shape, and they all belong to a single horn. Welding horns should be designed and developed separately for different welding applications. RPS-SONIC has more than ten years of practical experience in ultrasonic design. We can design the corresponding horn according to the welding needs of customers. Then, the natural frequency and modal analysis are performed by the finite element method, and a new horn is designed to meet the functional requirements of effective transmission and uniform distribution of vibration energy. In the design process, combined with the parametric modeling, full factor experimental design optimization (DOE) and probabilistic design system (PDS) modules of ANSYS, the parameter design and robust design are performed, and the geometric size is adjusted so that the natural frequency of the horn matches the ultrasonic frequency The corresponding modal amplitude is uniform on the working surface, which reduces the problem of local structural stress concentration, and has good adaptability to changes in parameters of materials and the environment. The designed tooling is completed and put into use at one time, which avoids the waste of time and cost caused by repeated trimming of the tooling. Through practical cases, the longitudinal vibration theory of a single horn is compared with the actual results of the hornand the finite element analysis. It is verified that the theoretical method is suitable for the design of four types of plastic welding horn with simple cavities. The prepared parameter solution and model drawing program can be used for rapid prototype design of ultrasonic plastic welding horns. Compared with the current ultrasonic plastic welding horns, which rely heavily on finite element analysis and empirical design methods, rapid prototyping methods are more accurate, efficient, and easy to operate.
With the help of the software of the finite element analyzer, the reject rate of the hornis greatly reduced, and the output of the horn is evenly and effectively maximized.

The main issues for ultrasonic welding horn:

1) Uneven amplitude across the face of the horn was causing a weak weld at both ends of the seal area and

2) The horns were cracking and had to be replaced at an unacceptable rate .

Both of these problems are caused by the uneven force on the cross section of the horn. The horn received too much ultrasonic power at a point, which caused cracking. At the same time, too much energy gathers at one point, resulting in insufficient capacity of other parts, low output, and uneven welding. How to effectively avoid this problem requires us to work hard when designing. Using the FEA analyzer, finite element analysis is performed when the horn is designed, and the force on the horn section can be clearly known. The uniform and strong force on the horn section is the ideal state. as the picture shows:

Why RPS-SONIC HORN:

1. Every horn will be designed by FEA system , so that to confirm the End face of the ultrasonic horn with uniform force

2. All ultrasonic horns with three months warranty.

3. Specialized in high power ultrasonic for more than ten years

4. Every ultrasonic horn with 24hours old testing before shipment.

5. Good packing, no packing problem during the 10 years exporting business.

6. Every customer will get purchase records and there are certain rewards after accumulation

Service and shipment

• Warranty one year for transducer.
• You can contact us for technical inquiry any time.
• We supply OEM service for oversea customer, also will keep Confidentiality for our customers.
• We supply customized products service for small quantity also.
• Shipment by FED-EX /DHL/UPS/TNT

R-Responsibility P-Products S-Service

sale the right products instead of the expensive one

Rps-sonic, consisted with a couple of young people who love ultrasonic very much.The founding members of RPS-SONIC have an average degree of Bachelor's degree or above. They have been in the ultrasonic industry for more than 5 years and have rich experience in ultrasound. The company's business philosophy is: Do not blindly promote any product, find the right product for the customer. So before each order, we will confirm all the details, including application details, equipment conditions, equipment specific information.

And we have the Professional import and export company， HangZhou LanBen Trade Co., Ltd, can export to any country wordwide.

Before year 2012, we only sale second branson / dukane / rinco / herrman/telsonic welding equipment , during these twenty year develop, we find, more and more people have problem with the core part of ultrasonic welding equipment -generator and transducer, so we decided to start our business of transducer and generator of our own transducer and generator. Many of the end user meet the transducer problem, they don’t know why transducer broken, and changing the expensive transducer one by one. Actually, one branson /dukane /rinco transducer can use 10~30 year, even the cheapest transducer can use about 5 years. So there must some reasons if your transducer broken in one year. That’s why we want build Rps-sonic, we need to help more end user to know more about transducer , to use ultrasonic equipment better, to save cost when meet problem.

The same to generator, Unreasonable operation may shorter the use-life of ultrasonic generator. So we have to make technical inquiry before operate ultrasonic welding machine. The key point of ultrasonic machine is resonance, only keep every part in resonance can make the system in best work environment.

Till now , we still have a lot of Branson /dukane/ rinco/ herrman telsonic welding machine, so that we can confirm every transducer/generator we made can matching to the original machine.

Of course we can make the transducer/generator replace for Branson /dukane/ rinco/ herrman telsonic welding machine, we can also make transducer/generator for any application of your ultrasonic equipment. We supply OEM service for oversea customers, we already have OEM customer in USA and German.

If you have any problem in ultrasonic area, welcome contact Rps-sonic.