杜肯超声波介绍2017

Transducer/ Converter inside 换能器(内部)
Transducer/ Converter appearance 换能器外观
Hand Probe 手枪焊机
Generator/Process controller 发生器/控制器
Booster 调幅器
Stack Assembly 三联组组装
Applications
Troubleshooting
应用案例
常见问题分析
超声波原理及设备通识介绍 /us/Documents/DesignGuides/Guide%20To%20US%20Plastic%20Assembly.pdf
超声波组件介绍 /us/Documents/DesignGuides/Ultrasonic%20Probes.pdf
Industries That Use Ultrasonics 超声波应用行业
Medical医疗 Automotive汽车 Electronics电子 Consumer Products消费品 Toys玩具 Packaging包装 Appliance家用电器 Food食品加工
Systems Available 焊机系列
高频率设备的优势
• 高频率=低振幅 • 对于精密部件，柔和的熔接有利于焊
接控制的最优化 • 低噪音
Advantages of Higher Frequencies 高频率设备的优势
• High
frequency=low amplitude
高频率=低振幅 • Gentle welding provides maximum control on small delicate parts 振动比较柔和更适合精密的小零件 • Low noise低噪音
APP 下载 /us/mobileapp.htm
What is Ultrasonics? 什么是超声波
What is Ultrasonics? 什么是超声波
Ultrasonic welding employs mechanical vibrations which are typically above the range of human hearing. Humans can hear in the range of approximately 20 Hz – 18,000 Hz. (18 kHz.) Women can hear higher frequencies than men.超声波焊接的 波是机械振动波，完全在人耳所能听到范围以外 人类所能听到的频率范围是 20 Hz – 18,000 Hz. (18 kHz.) 相比之下女人听到的频率比男人略高.
Agenda议程
Process Theory Systems & Components Tooling- Fixture & Horn Technology Materials & Design Ultrasonic Techniques Machine Set-up considerations Process Control and monitoring 工艺理论 系统构成 工装夹具 材料及焊缝设计 超声应用 设备调试 工艺过程控制
Hot Air 热 风
Hot Shoe Extrusion 挤型
Electro Magnetic Welding 电磁焊
Direct Infrared
红外线 Laser激光
Inserting植入
Stake/Swage 铆接 Spot Weld点 焊 Fabric/Film织 物/膜材
Hot Tool 加热模具
“Amplitude振幅”
• A measurement of how far a component’s face moves during ultrasonic vibration 超声部件表面振动过程中的位移量 • Can refer to: transducer, booster, or horn 超声部件包含：换能器，调幅器，焊头 • The amplitude of the front of the horn is the most influential parameter responsible for heating of the plastic 焊头前端输出振幅是驱动塑料件生热最具影响的参数 • Measured commonly as a peak to peak value with units in microns. 通常计量波峰到波峰的微米数值
•Su Zhang, Country Manager, Dukane China •Fangxing Li, Senior RD & FAE , Dukane China •XiaoYan Hong, Sales Manager, Dukane China •Garden Liu, Project Manager, Dukane China
超声波焊接工艺
Introduction to Ultrasonic Plastics Assembly
杜肯公司及其全球战略 One World One Dukane
• Consistency in Product and Services throughout the world.全 球统一的产品和服务标准
Power Supply/ Generator 发生器/电箱
20,000 Hz 1300 Volts
50/60 Hz 120/240 VAC
换能器
0.0008” (20 μm) 20 kHz
X
调幅器 Gain
X
焊头 Gain
= 振幅
Conversion of Electrical Energy to Mechanical Motion 电能转化为机械振动能
Plug in the numbers to do the math and solve for BOOSTER GAIN: 将数值填入算式计算 调幅器 的GAIN值:
超声波Ultrasonic
旋转Spin
激光Laser
振动Vibration
热铆Thermal
热板Hotplate
Thermoplastic Welding Methods 热塑性塑料焊接方法
Friction 摩擦生热 Ultrasonics 超声波 Welding焊接 Surface Friction 表面摩擦 Spin welding 旋转焊接 Vibration 振动摩擦焊 接 Hotplate 热板 Staking铆接 Swaging 压形 Inserting镶埋 Thermal 热传导 Induction 电磁感应 Light-Based 光能
• Local Tooling and Support本地化的焊头底模和支持 • Global Communication.全球性的沟通网络
布拉格 ，捷克
芝加哥，美国 常州，中国
克雷塔罗，墨西哥
戈尔韦，爱尔兰
金奈，印度 = 设备制造厂
柏市，日本
维勒班，法国
3
Plastics Assembly/Processing 塑料装配
“Gain-振幅输出比”
•The ratio of output amplitude to input amplitude of a booster or horn 调幅器或焊头输出振幅与接收振幅的 比率
How to Determine Which Booster Ratio to Use 如何选择合适Gain值的调幅器
Spin Welding 旋转焊接机
Upper tool at approx. 3,000 rpm* 上模转速约 3,000 rpm*
*RPM based on part diameter. 转速取决于产品的直径
Vibration Welding 振动摩擦焊接机
240 Hz. @ approx. 1mm amplitude (horizontal) 频率240 Hz，振幅约1mm (水平)
Transducer Amplitude换能器振幅 .............. 20 μ (0.0008 inches) Resin amplitude requirement塑料件热熔所需振幅.... (i.e. Polycarbonate) 102 μ (0.004 inches) Horn gain factor焊头gain值........................ (.5” diameter exponential) 4:1
Horn 焊头
Plastic塑 料件 Fixture 底模
Hold time 保压时间
Why use Ultrasonics? 为什么要用超声波？
Advantages优势
No consumables Fast cycle Times Very accurate Highly repeatable Versatile equipment Parts are easily recycled Environmentally safe 无需添加物或辅材 速度快 精确 一致性，可重复 可灵活集成 产品易回收 无污染
• • • •
Hand Held Probe 便携式（手枪焊） Probe电箱及焊接单元 Press/Thruster 标准台式 Rotary 转盘式
焊机系列
• Custom/Automated
• 非标定制及自动化
Tooling, Horns & Fixtures 焊头与工装夹具
15, 20, 30, 35, 40, 50 kHz
System Components 系统组件
夹具 Fixture
超声波发生 器及控制器 Generator/C ontroller – iQ Series
机架 Press
焊头 Horn
系统构成 System Components
换能器
Transducer
调幅器 Booster
Conversion of Electrical Energy to Mechanical Motion 电能转化为机械振动能
20 kHz
Transducer Amplitude x Booster Gain x Horn Gain = STACK AMPLITUDE
Stack Amplitude Resin Amplitude Requirement Stack 振幅 塑料件热熔所需振幅
• • •
换能器振幅 x 调幅器 Gain x 焊头 Gain = STACK 振幅
How a Weld is achieved 超声波焊接过程分解
Parts in Fixture 产品放入底模 Horn Descends 焊头 下降
Horn Contact 焊头 接触
Pressure & Ultrasound Applied 压紧并发 超声
Hold Time 保压
Horn Retracts 焊头 缩回
Radio Frequency (Microwave)
射频
Hot Air热风
Hotplate and IR Welding 热板和红外线焊接
加热板温度约 288° C (550 ° F)
Thermal Staking 热铆机
Staking tool at approx. 204° C (400° F) 铆接模具 温度约 204° C (400° F)
Force applied upward 施压方向
Laser Welding 激光焊接机
Laser energy 光能
Force applied downward 施压方向
Ultrasonic Welding 超声波焊接机
Force appliultrasonic vibrations 往复振动
• Transducer换能器 • Booster调幅器 • Horn焊头
Horn & Fixture 焊头 & 底模
Ultrasonic Welding超声焊接
•Vibration振动 •Friction摩擦 •Heat生热 •Melt熔化 •Weld粘接 •U/S Off and Hold Cycle保压固化