Ultrasonic Riveting 35kHz 1000W Staking Assembly for Automotive Interior Parts
Description:
Ultrasonic welding is widely used in the automotive industry. The sonotrode is correctly dimensioned through the use of finite element analysis (FEA). Applications range from interior components (side door trim, center console) to engine compartment components (cylinder head cover, engine covers), to lighting, filters and acoustic foams. Welders can be operated immediately without heat-up time. Cycle times are short, and energy consumption is low.
Conforming to the spirit of "Service First", ALTRASONIC provides lifetime maintenance to its products for as long as they are used by customers.
Principle:
The basic principle of ultrasonic riveting is to convert high-frequency electrical energy into high-frequency mechanical energy acting on thermoplastics in a reciprocating longitudinal movement, generating frictional heat at the plastic/plastic or plastic/metal interface, forming local melting, through controlled melting and shaping plastics. A boss or pin to lock another part.
During ultrasonic riveting, the control flow of molten plastic is used to lock another part (usually another plastic or metal). The preformed plastic pin passes through the hole in the part to be locked, and the high-frequency ultrasonic vibration from the welding head is transmitted to the upper part of the pin. The pin is melted due to the frictional heat and fills the cavity volume of the welding head, resulting in the locking of the spear head. Components. The plastic pin is gradually melted under continuous light pressure to form a rivet. The slight pressure of the horn causes the pin head to form a specific shape (as determined by the end structure of the horn). After the vibration stops, the plastic solidifies and a material is consolidated.
Specification:
| Item No. | HSW28 | HSW30 | HSW35 | HSW40 | HSW60 |
| Frequency | 28khz | 30khz | 35khz | 40khz | 60khz |
| Power | 1000W | 1200W | 1000W | 500W | 300W-500W |
| Horn | ≤12mm | ≤10mm | ≤10mm | ≤10mm | ≤10mm |
| Housing Diameter | 44mm | 44mm | 44mm | 44mm | 44mm |
| Weight of Welder | 1.0kg | 1.0kg | 1.0kg | 1.0kg | 1.0kg |
Advantage:
1. Uneven asymmetrical geometries can be welded.
2. Delicate component surfaces stay mark-free.
3. Short weld cycles between 100 and 300 milliseconds.
4. Targeted energy input protects sensitive electronic elements.
5. Different types of material can be welded or bonded by embedding.
6. Smaller machine footprint compared to other joining processes.
Application:
1. Lamp plastic riveting
The application of riveting technology in the internal circuit of the ceiling lamp in the car. The reserved studs on the plastic seat of the ceiling lamp pass through the pre-punching holes on the metal sheet, and then the metal plate conductors are riveted by the hemispherical round caps, and the parallelly placed metal pieces are separated by the vertical ribs to make them insulated and shackled. This can effectively prevent the vibration of the metal piece conductor from falling off, and fundamentally eliminate the short circuit phenomenon.
2. Door trim riveting
The trim panel skin component that is riveted to the press-formed wood fiber door frame uses an air core riveting column (tubular hot pile) for the outer flange riveting process. Due to the large contact area of the eversion edge and the high connection strength, the loosening, falling off or tearing caused by long-term vibration can be effectively avoided, so that the whole component can more effectively realize the functions of sound absorption, noise reduction and thermal insulation. Effectively improved the interior environment. In the narrow part near the edge, the vertical rib riveting process is adopted to increase the contact area of the rivet cap, and the phenomenon of tearing and falling off when the force is applied at the edge is prevented, thereby effectively overcoming the shortcoming of the poor stretching effect of the wood fiber board. , and finally combined with plastic parts into a structure.
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