Multi Head Spot Welding Machine for Fast, Precise Joining
Traditional welding techniques used for exterior car parts, like hot plate welding, MIR, resistance spot, and TIG welding, have many issues, such as thermal distortion, poor surface finishing, and high energy consumption.
Moreover, modern vehicles are designed with complex geometries and lightweight materials. Therefore, there is a rising need for more innovative welding assembly methods.
Multi head spot welding solves these problems by making the assembly process more efficient and durable. Dizo Global's ultrasonic multi-head welding machine boosts efficiency in vehicle production with its fast and effective welding mechanism. Let's know more about this multi head spot welding machine.
Table of Contents
How Does Ultrasonic Multi-head Welding Join Materials Without Heat?
How Does Dizo's Ultrasonic Multi-Head Welding Machine Work?
Applications of Ultrasonic Multi-head Welding Machine in the Automotive Industry
Why is Ultrasonic Multi-head Welding Better than Traditional Welding?
What are the Key Features of Dizo's Ultrasonic Multi-head Welding Machine?
Conclusion
FAQ's
How Does Ultrasonic Multi-head Welding Join Materials Without Heat?
Compared to the traditional methods that use external heat for joining the plastic parts, spot welding multi head uses frictional heat to soften the material and fuse it. It is a solid-state process and ideal for plastic and thin metals.
In a multi-head system, this process happens at multiple joints simultaneously, thanks to multiple horns or welding stations.
The components of the ultrasonic welding machine are:
- Generator: This part is used to turn the electrical power into high-frequency (15- 40 kHz) vibrations. Each head in the machine can have its own generator.
- Converter: Converter changes the high-frequency signals to mechanical vibrations that are used to create the bond through melting.
- Booster: The booster alters the amplitude of vibrations. It either decreases or increases the amplitude, depending on the design and quality of the material.
- Sonotrodes: Sonotrodes are the horns that apply mechanical vibrations directly to the surface. In multi-head ultrasonic welding, multiple horns operate at the same time, creating uniform welds at different points.
- Fixtures: Fixtures are used to hold the material tightly. Misalignment can lead to weak welds, so the parts must be positioned accurately.
In multi-head ultrasonic welding, all these components work together to bring impeccable results at a faster rate.
How Does Dizo's Ultrasonic Multi-Head Welding Machine Work?
Dizo's car exterior ultrasonic multi-head machine works by utilizing high-frequency (15-35 kHz) vibrations to weld different parts of vehicles simultaneously through its multi-head mechanism. Key steps in this process are the following:
Automated Parts Alignment
Smart sensors are used to adjust the parts before multi head spot welding. It makes sure, through advanced scanning, that the parts of the car are positioned correctly.
There is also a multi-sensor backup system in the machine. If one sensor fails, the others get to work without disturbing the cycle.
Multi-Head Welding Process
After loading the component in a fixed position, all the heads of the multi-head ultrasonic plastic welding machine are put in accurate positions. Then, all the heads apply ultrasonic vibrations at the same time, at different positions.
Each weld gets the same energy and pressure. In that way, there is a uniform weld quality at all points.
Closed-loop Quality Control
Quality is monitored throughout the process, which prevents any issues in the welding process. In case of any disturbance in the operation, the machine corrects the pressure or energy accordingly. It guarantees an efficient and clean weld.
With its high accuracy and fast processing, the multi-head reduces the production time up to 60-80%.
Applications of Ultrasonic Multi-head Welding Machine in the Automotive Industry
The multi-head ultrasonic plastic welding machine is truly a game changer in the automotive industry. Its applications include:
Exterior Components Welding
Vehicle external parts, like bumpers, lighting systems, or exterior trim, are welded with high efficiency through this method. It boosts the weld strength and visual appeal of the components equally.
Interior Components Welding
Multi-head welders create airtight, leak-proof seams in interior components like dashboards or door panels. Complex-shaped parts like glove boxes are welded with the help of adjustable head angles.
Large-Scale Production
As compared to single-head welders, advanced multi-head welding machines or dual head spot welders can handle large-scale production much more efficiently.
A single multi-head welding machine can weld 8-12 points at one time. It saves time, energy, and money.
Why is Ultrasonic Multi-head Welding Better than Traditional Welding?
Ultrasonic multi-head welding is normally preferred over the traditional methods due to its efficiency and higher production rate. Some of its benefits over traditional welding are the following:
Speed and Efficiency
Ultrasonic multi-head welding has a cycle time of about 0.1-1 second per weld, which makes it a faster and effective process than the traditional methods.
In traditional welding, adhesives, screws, and fasteners are used which are more slow processes as compared to the advanced multi-head technology.
Clean and Eco-Friendly
Another prominent feature of ultrasonic multi-head welding is that it's a completely eco-friendly process.
There is no risk of emission of dangerous chemicals in ultrasonic multi-head welding as compared to other techniques like Flux-cored arc welding.
Minimal Heat Distortion
Unlike other welding methods like hot-plate welding, ultrasonic multi-head welders apply heat at localized points, which prevents the other areas from thermal distortion.
Cost Saving
There is no need for external heat sources or consumables. There is less power consumption in ultrasonic multi-head welding compared to traditional methods. Therefore, it is a cost-effective solution for modern vehicles.
What are the Key Features of Dizo's Ultrasonic Multi-head Welding Machine?
The car exterior parts ultrasonic multi-head welding machine at Dizo Global outperforms its competitors because of its unique features. Here are the key features that make Dizo's Multi-head welding machine a reliable option:
Adjustable Welding Units
An important feature of this machine is its buffer stop system that assures perfect alignment and error-free bonding. Having a built-in 360-degree positioning mechanism, it allows the welding head to move in any direction according to the material shape.
The operators have complete control over monitoring the energy, pressure, and voltage input. It enables them to have a balance in applying pressure or heat as required.
Independent System Structure
This feature helps the machine to have stability in the fixed parts. It reduces the slight vibrations in the components, leading to more consistent bonding.
Moreover, it also ensures equal power and heat distribution during the operation. The result is finer, stronger, and cleaner welds.
Individual Head Angle Adjustment
When it comes to achieving a uniform quality and precision at all the weld points, it's important to align each head with 100% accuracy. That's what this feature ensures.
Each head angle can be adjusted to different shapes, which allows the machine to accurately work with rough surfaces.
Workpiece Detection and Alarms
Dizo Multi-head machine outperforms the traditional welding operations by having built-in smart alarms. These alarms monitor the whole process and give an indication in case of any imbalance in the operation.
This helps in the detection of misplaced components, rough surfaces, and gaps that can cause errors in the process.
Fast and Efficient Welding
By applying innovative technology, the ultrasonic multi-head machine at Dizo Global delivers both quality and speed. Smart sensors constantly monitor the weld quality and make instant adjustments if needed.
The amount of pressure and temperature is checked continuously and applied according to need.
Conclusion
Advanced welding solutions like multi-head welding machines have changed the way modern vehicles are designed.
Dizo Global's multi-head machine proves to be an ideal choice for automotive manufacturers. It is a cost-effective, eco-friendly, and fast welding machine that ensures the reliability and longevity of the vehicles.
FAQ's
1. Why is the multi-head welding process faster and more efficient than the single-head welding process?
Multi-head welding is faster because no repetition of the same cycle is required. All points are welded in a single operation simultaneously. Hence, it's a continuous process that saves both time and cost as compared to single-head welding.
2. Can ultrasonic welding manage large and complex-shaped exterior parts?
Yes. A multi-head welding machine can efficiently manage complex geometrical shapes. It allows adjustable welding angles according to the shape of the surface. That makes it an ideal choice for car exterior parts like bumpers, door panels, or fenders.
3. Is the ultrasonic welding technique environmentally friendly?
Ultrasonic welding uses 30-50% less energy compared to the heat-based welding process. Likewise, it doesn't emit harmful chemicals, fumes, or smoke. There is also minimal material waste in this method, which makes it eco-friendly.
4. Are there any limitations to ultrasonic welding?
While being a very fast and reliable welding technique, there are some limitations to ultrasonic welding as well. It works best only for plastics and thin metals. It struggles with thick metals and dissimilar materials. It also requires high initial costs, making it ideal for large-scale production only.
