One. Ultrasonic Welding Machine
Principle: By using high-frequency vibration (20-40 kHz), frictional heat energy is generated between molecules to achieve local melting and connection of plastic components.
Technical features:
1.Applicable materials: Thermoplastic plastics such as ABS, PC, nylon, PP, etc.
2. Typical applications:
Interior components: dashboard components, various decorative panels, storage box covers, etc.
Exterior components: Headlamp covers, mudguards.
3. Advantages: Fast welding speed (0.1-1 second per cycle), suitable for mass production; No adhesive required, environmentally friendly, and with high joint strength.
4. Automation solution: It can be integrated with robots to achieve multi-station perforation welding (for example, multi-layer perforation welding of sound insulation cotton for car door panels).
Two. Hot Riveting Machine (Hot Riveting Machine
Principle: A hot riveting machine heats rivets or rivet columns to melt or soften them, and then applies pressure to deform them. A strong connection is formed after cooling.
Technical features
1. Application scenarios: It is suitable for components that require multi-point riveting, such as car door columns, instrument panel frames, etc.
2. Equipment Type:
Handheld: Flexible and suitable for small-batch and multi-specification products.
Fully automatic: Equipped with PLC control, it supports simultaneous processing of multiple rivet points (accuracy ± 0.02mm).
3. Advantages: The welding strength can reach over 90% of the raw material strength. Supports processing of irregular-shaped parts and convenient mold replacement.
Three. Hot Plate Welding Machine
Principle: A heating plate is used to melt the contact surfaces of plastic components, then they are pressed together and cooled to form a weld.
Technical features
1. Applicable products:
Large components: Headlamp assembly, radiator, air vents.
Complex curved surface components: intake manifold, fuel tank.
2. Technical advantages: Capable of welding ultra-thick plastic parts (10mm); The welding surface can be compensated for material allowance and has excellent air tightness.
Four. Other supporting equipment
1. Vibration friction welding machine
It is suitable for large irregular parts (such as fuel tanks and instrument panel frames), and welding is carried out through linear friction heat generation.
2. Rotary welding machine
Designed specifically for cylindrical components such as filter elements and bottle caps, it features high welding strength.
Five. Selection Suggestions
1. Material property matching
Ultrasonic welding is preferred for ABS/PC. For PP/PE, hot plate or hot riveting processes are preferred.
2. Production efficiency requirements:
Small-batch and diversified products: Handheld hot riveting machine, equipped with universal molds.
Large-scale production line: Robot ultrasonic welding station (capacity: 600 pieces per hour).
3. Precision control
Give priority to devices equipped with PLC+ touch screen that support parameter storage and traceability.
It is recommended to consult the specific product process requirements and request sample test data from the supplier (such as tensile strength and air tightness indicators). For professional solutions, please contact our Huazhuo Group.