What is a high-frequency welding machine?

What is a high-frequency welding machine?
High frequency welding machine is a plastic heat sealing equipment that uses a high-frequency electric field to oscillate the molecules inside the plastic and generate heat energy for the fusion of various products. Mainly used for: plastic fusion welding, welding, hot stamping, etc. mainly made of polyvinyl chloride (PVC). Blister packaging (including upper and lower double blister hot sealing and cutting edges, blister and cardboard hot sealing and cutting edges, etc.), automotive interior parts, seat cushions, trademarks, stationery, stickers, plastic covers, inflatable toys, footwear products, rain sails, umbrellas, raincoats, leather bags, nameplates, water beds, sunshades, door panels, various packaging bags, hand-held soft bags, etc., as well as the hot sealing processing of various concave convex switch patterns and letter texts. Simple devices can also be installed for hot stamping processing.
Product Introduction:
The high-power high-frequency welding machine uses high-voltage rectification self-excited electron tube oscillation to generate an electromagnetic field that causes plastic molecules to undergo changes. Under the action of external pressure and mold, it achieves functions such as welding, cutting, sealing, and embedding; Easy to understand and learn, with multiple times the efficiency of ordinary small machines, suitable for welding and cutting large plastic products. The process is simpler and the effect is more perfect.
Product features:
Pneumatic control, simple and convenient operation; Manual feeding and retrieval of materials; Welding and cutting are perfect and fast, with high efficiency and good craftsmanship; Suitable for welding and cutting large inflatable toys, car floor mats, sports equipment and other products.
The high frequency frequency mainly adopts the international industrial frequency band of 27.12mhz, which is consistent. The high-frequency electromagnetic wave adopts a device system independently developed by Jindian Company to avoid electromagnetic wave radiation interference, greatly reducing the direct radiation intensity of high-frequency electromagnetic waves on the human body. High frequency waves can be equipped with stepless heating devices according to the characteristics of the plastic and plastic products that need to be heat welded. The temperature can be adjusted according to the properties of the material, mainly for heating the surface of the mold. The high-frequency wave adopts the self current protection device system newly developed by Zui from Jindian Company, which can mainly protect high-frequency electronic tubes from unnecessary burning out caused by excessive current. High frequency wave adopts the latest American technology anti ignition device system, mainly using NL5557 high sensitivity spark device, which can instantly protect high-frequency molds from burning out due to excessive current.
Main uses
High frequency welding machine is mainly suitable for heat sealing packaging of pure PVC, TPU, EVA, or any soft and hard plastic, plastic, artificial leather, clothing fabrics containing 10% PVC.
Applicable scope
High frequency wave is mainly used in the medical supplies industry | plastic, plastic packaging industry | clothing embossing processing industry | automotive interior parts industry | inflatable toy industry | home goods industry and various plastic product processing and heat sealing, such as: vacuum blister sealing, PVC plastic blister sealing, PVC blister welding, PVC plastic blister welding, battery packaging sealing, hardware tool sealing, PEG vacuum blister sealing, vacuum cardboard sealing, USB packaging sealing, memory module packaging sealing, PVC blister welding, high frequency plastic fusion welding, high frequency plastic welding, high frequency plastic sealing, double-sided blister sealing, PVC Double sided bubble cover sealing, double-sided cardboard bubble shell sealing, cardboard bubble cover sealing, plastic plastic heat sealing, etc.
Double head hydraulic foot pedal high frequency machine
Product performance and characteristics
(1) Spark suppressor: When sparks are generated, this machine is equipped with a special electronic circuit that can automatically cut off high-frequency suppression sparks, reducing damage to molds and materials to a low level. At the same time, the warning light also lights up to alert.
(2) Avoidance of radio wave interference device: Equipped with high frequency stability and high frequency leakage magnetic pressure regulators, this device can prevent radio wave leakage from interfering with other electronic devices, such as televisions.
(3) Safety device: When the current exceeds the limit value, the overload current relay automatically protects the oscillating tube and rectifier. When the mechanical cooling is insufficient, it can automatically cut off the power supply and avoid accidents caused by improper operation.
(4) Special mechanical structure: Each model has undergone special design and assembly, and its strength is sufficient to handle any situation. The base never shakes, and the special parts are very lightweight to use.
(5) Easy to adjust synchronizer and special circuit: The high cycle power output is particularly strong, and can be adjusted according to the size of the mold and material thickness by the adjuster. Especially for special high cycle circuits, high stable output, strong output rate, and the ability to greatly reduce necessary welding time, improve product quality and output.
Applicable scope
Suitable for PVC or any soft and hard leather or fabric containing more than 30% for welding and indentation needs, such as shoes, trademarks, stickers, raincoats, rain sails, umbrellas, leather bags, handbags, stationery, inflatable toys, water beds, car cushions, sunshades, door bolts, clocks, electronics, toys, inflatable toys, locks, hardware, tools, trademarks, and other special hard shell vacuum packaging, especially to meet customer needs and design and construction.
Product advantages
Innovative model: The first machine tool combined with oscillation can reduce the footprint of the machine by 30% in limited space, shorten the high-frequency conveying circuit, improve output efficiency, and maintain stable oscillation frequency.
Efficient model: The overall innovative design, combined with ergonomics and professional technology, enables this machine to perform well in handling various plastic products without compromising quality and safety due to proficiency in operation.
Spark suppression and safety device: When sparks are generated, it can automatically cut off the high-frequency circuit to reduce damage to components and objects to a low level. When the current is overloaded, it can automatically cut off the oscillation tube and rectifier circuit, avoiding frequency drift caused by improper operation.
Professional configuration design: can avoid improper operation, prevent radio interference (such as television), and increase mechanical efficiency and work efficiency.
Drive mode: oil pressure.
Solution to interference problem of high-frequency welding machine
1. Spectral analysis of interference signals from high-frequency machines
The power output electronic tube of a high-frequency machine oscillates and outputs a signal, so its fundamental frequency stability is poor. It will fluctuate with changes in the temperature and working conditions inside the cabinet (output power adjustment, workpiece size, thickness, etc.). Although the variation is only a few tens of megahertz, there may be individual interference signals transferred from one channel to its adjacent channels.
The output power of the high-frequency machine is high, and the current of the high-voltage (3kV) DC power supply is also relatively high (about 1a). However, its high-voltage rectifier power supply is very simple, consisting of four 1a/10kV high-voltage silicon stacks and a 0.1 μ f/8kV filtering capacitor. Due to the small capacity of the filtering capacitor, the high-voltage DC power supply is actually a pulsating DC power supply of 100Hz. The high-frequency signal output by the high-frequency machine actually modulates an AC signal with a modulation level close to 100Hz, which has little adverse effect on the working performance of the high-frequency machine. However, it can reduce the power consumption of the electronic tube and extend its service life due to non equiamplitude oscillation signals. So the essence of high-frequency interference in televisions is a type of AC sound interference that modulates high-frequency signals. When the interference signal from the high-frequency machine is connected in series to the television, it will generate two wide horizontal bars of 100mHz AC sound modulation interference on the television screen. When the interference intensity is high, both horizontal bars will turn white. When the interference intensity is low, a network ripple (different from general AC sound interference) will be distributed within the two horizontal bars, and the accompanying sound will be 100mHz AC sound.
2. The interference signal propagation and intrusion of high-frequency machines in special cable TV trunk cables and user distribution mainlines are all laid along the outer wall of the user's housing, with cement poles only added in the open space, and not hung on the power poles in front and behind the user's house. Many trunk cables and user distribution mainlines pass only a few meters away from the high-frequency machine, and the distance is less than 1m (the length of the residential house is 10-20m, and the facilities machine on the second floor is generally installed inside the house. Steel strands are pulled outside the second floor wall to hang the cable, and the cable is approximately parallel to the high-frequency machine). Below, several levels of trunk amplifiers or first level user amplifiers are connected, or user distribution is directly carried out. If the interference signal of the high-frequency machine is first received by the main cable and then amplified by an amplifier before being distributed to the user's TV through the cable, then all TVs below will be affected by the interference of the high-frequency machine. But in reality, this is not the case. Usually, it is only sporadic and "wandering" interference. Users who are closer to the high-frequency machine have a higher proportion of complaints, while users who are slightly farther have a smaller proportion. Users who are 500m away from the high-frequency machine have not complained. This proves that the interference signal of the high-frequency machine does not first invade the main cable, and then (amplified by an amplifier) propagate through the cable to various televisions. Although the interference signal emitted by high-frequency machines is strong, the shielding loss of dry (main) cable (-12 or -9 physically foamed cable) can reach about 80dB, and the interference level invading the cable will not be very high, much lower than the TV signal level. The author used spectrum analysis to measure the interference level of the high-frequency machine at the end of an 80m long copper braided net covered cable with a -9 physical bubble. This is a user assigned mainline, with the high-frequency machine located 18m away from the user amplifier and 3m away from the cable (separated by a wall in the middle). During the measurement, the amplifier was powered off and the incoming cable was removed (connected to a 75 Ω load resistor). The interference level of the invading high-frequency machine was measured as follows: second harmonic<20dB, and the TV signal level was 42-60dB higher than it.
3. Measures to prevent and reduce high-frequency machine interference
(1) When building a factory, do a good job of system shielding. Use 0.3 galvanized sheet or small mesh wire mesh to shield the surrounding area. Insert 50mm iron pipes into the underground 2-3 meters, and connect the shielding mesh to the iron pipes every two meters. This way, high-frequency signals are not easily radiated from the factory, achieving the overall shielding effect.? (2) It is recommended to ground the high-frequency machine frame and casing well, strengthen the shielding of the body, and reduce the radiation of the body. It is recommended to use angle iron with a width of 50mm x 50mm or more and a length of not less than 2m to be inserted into the ground as a grounding body, and then connect the high-frequency machine frame and casing to the grounding body with a copper wire of 10mm2 or more. The connection should be as short as possible, not in circles, and avoid turning as much as possible. This can strengthen the shielding of the high-frequency machine body and reduce the intensity of interference signals radiating outward. If there are multiple high-frequency machines in the car (room), each high-frequency machine (or adjacent two) should have a ground wire buried nearby.
(3) Adjusting the position and direction of the high-frequency machine
If there are cables hanging on the exterior walls of the house, the high-frequency machine should be set at one end away from the cables. In addition, the ordinary high-frequency machine electronic tube case has two directions at right angles that are fixed on the galvanized angle iron frame with galvanized iron plates for shielding, which has weak radiation and should be directed towards the cable or nearby TV users in these two directions.
(4) Suggest purchasing and using anti-interference high-frequency machines
(5) Ensure proper grounding of the cable TV network and select the location of the cables
The amplifiers and steel wires near the high-frequency machine must be reliably grounded to enhance their shielding ability. When hanging cables on the exterior walls of buildings with high-frequency machines, they should be measured outside reinforced cement components (such as ring beams and cement floors), not on the outside of brick walls, as this will weaken the radiation on the cables.
(6) Adjust the position of the amplifier or cable
When the inlet cable of the amplifier is very close to the high-frequency machine (within 10m), the amplifier can be moved forward and the outlet cable can be moved closer to the high-frequency machine because the TV signal level here is high, which is conducive to increasing the level difference between the TV signal and intrusion interference, or adjusting the trunk cable to be slightly further away from the high-frequency machine.
(7) Ensure the reliability of cable joints
The connection between amplifiers should be made with straight through connectors as much as possible. The connectors for ordinary circuits should be made in a standardized and reliable manner, and special attention should be paid to the waterproofing of the connectors to avoid water ingress that may cause mold breakage of the outer conductor woven mesh, leading to poor shielding and interference signals in series.
(8) For users who are only within 20-30 meters of the high-frequency machine, the following measures can be taken: 1. Ensure or increase the user signal level, and ensure that the user entrance level of each channel is not less than 65dB, and try to increase it to 75-80dB. No user box is required for indoor use. The incoming cable is directly connected to the TV through a plug. If there are multiple televisions, a sealed branching device (such as Z106) or distributor is used to directly connect to the TV. The cables laid indoors by 3 users must be qualified or four shielded cables, and inferior cables are prohibited. Users within 10 meters of the high-frequency machine should use aluminum tube cables to enter the household. Try not to use plastic injection type plug wires for indoor televisions. 5. Make good plug wires and try not to use plastic injection type plug wires (their internal parts are easy to solder and not easy to detect). Use handmade four shielded cable plug wires. After receiving a user complaint about a malfunction, the first step is to try a new plug cable. If the problem is solved, cut off the plug of the user plug cable and redo it. Otherwise, check the indoor cables and joints, and even the outdoor cable joints
Maintenance and upkeep of high-frequency machines
1. Regularly inspect the water filter;
If there is dust on the machine, use compressed air to carefully blow clean the machine, but the main power must be turned off;
Fault: Before checking, be sure to turn off the main power supply, as there is voltage ranging from several thousand volts to tens of thousands of volts inside the machine.
Phenomenon 1: Common red lights (overload lights)
Reason:
a) Damaged insulation material of the lower mold;
b) There is dirt, dust, and moisture in the work object, vibration cylinder, or upper and lower molds that need to be cleaned;
c) Poor horizontal position of the upper and lower molds;
d) The upper and lower molds are not insulated and directly collide with each other;
e) Input power supply too high;
f) Damaged or loose vacuum tubes;
g) The electronic board for overcurrent protection is damaged, and the overcurrent protection board is the one with three main appliances;
h) The synchronizer is too large and the output is too high;
i) The working object is too large, exceeding the rated output of the same machine;
j) Temperature control malfunction;
k) High voltage capacitor damage;
l) The insulation column (upper template) is damaged.
Phenomenon 2: During high cycle output, the main power supply is disconnected or a fuse is burned out
Reason:
a) Vacuum tube malfunction
b) Transformer failure
c) High voltage rectifier board malfunction
d) Damaged three-phase magnetic switch
e) Short circuit faults in high-voltage transmission lines
f) Electric heating plate malfunction
Phenomenon 3: No output
Reason:
a) Poor switch contact
b) Line fault
c) Vacuum tube malfunction
Phenomenon 4: Poor working materials
Reason:
a) Poor adjustment;
b) Mold issues
c) There is a problem with the adhesive part (working object)
d) Insulation material too thick, insulation too high
Attention: When the mold is pressed down and touches the lower mold, the grounding copper plate must be pressed against the lower fixed plate, and the circular copper plate can be slightly deformed. If the grounding copper plate is not adjusted properly, this machine will not be able to work stably. When replacing molds of different heights, this grounding copper strip needs to be readjusted again.
2, High frequency wave and operation sequence
1. First, turn on the main switch of the three-phase power supply, and then turn on the power switch on the control box on the machine side. If there is a high cycle switch, do not turn it on temporarily. Then turn on the electric heating power switch. At this time, both the vacuum tube and the hot mold start to preheat.
2. Install insulation material on the lower mold, install the upper mold on the upper end, press the trial mold switch, and start debugging the joint position of the upper and lower molds. If the lower joint is poor, move the lower mold. If it is not level enough, adjust the four pillars of the upper mold.
3. After the mold is adjusted, adjust the three time controllers (if it is a pedal type machine, only the high cycle welding time). The falling time is the time when the upper mold runs to press the lower mold, the welding time is the output time, and the cooling time is the curing time. The above three times need to be flexibly applied without a fixed number of values.
4. If the mode is adjusted for the first time, the spacing of the homologous tuning needs to be adjusted to Zui width.
If the above operation has exceeded 10-15 minutes and the temperature has also reached the required level, turn on the high cycle switch and start the operation test.
6. During testing, if the effect is not ideal, slowly add the synchronizer and observe the screen flow meter (the value of the meter varies for different models, please refer to the manual). Check the product, and if it is not ideal, add or subtract a little bit of the synchronizer until it meets the requirements.
The effect of the finished product is determined by the following four aspects:
① Temperature ② homologous power output ③ pressure ④ output high cycle time. Please make flexible adjustments to the above four aspects.
3, High frequency welding machine and precautions
1. The machine must be equipped with a good grounding terminal (connected to the correct ground wire)
2. The machine is extremely sensitive to moisture and dust and needs to be placed in an appropriate workspace
3. The vacuum tube of the machine generates high heat, so it should not be placed next to the machine that generates high heat, nor should it be installed in a place directly irradiated by solar energy, as the above reasons will affect the heat dissipation function of the vacuum tube
4. If the machine is stopped for more than an hour and then restarted, it is necessary to wait for 10-15 minutes for the vacuum tube to preheat and protect its service life
5. The upper and lower ends (upper and lower molds) of the machine must not be directly touched together, and there must be insulation and working parts between them
6. During operation, when outputting high-frequency waves, remember not to touch the upper pole output terminal (i.e. upper mode), and do not attempt to directly measure the upper pole output terminal with meters, test meters, or other low-frequency or low-voltage instruments, as this may cause accidents to occur
7. Regularly inspect the insulation material of the lower extreme (lower mold). If there is any damage, burning, or breakdown, the insulation material should be replaced immediately. Otherwise, if the work continues, sparks will be generated and the process cannot be completed
8. If sparks frequently occur (when the upper and lower molds collide and output at high frequencies) without inspection and maintenance, it can cause damage to the machine parts and affect work
9. Work materials used for finished products should be kept away from moisture and dust as they can easily cause sparks
10. After turning on the power, the machine will hear the sound of the fan rotating (4kw, 5kw sound is smaller), which is used for vacuum tube heat dissipation. If the fan malfunctions, it must be repaired immediately, otherwise it will cause damage to the vacuum tube.
The processing customization of this product is, brand is Leehom, material is canvas, conveyor belt type is circular conveyor belt, suitable for environments that are heat resistant, wear-resistant, oil resistant, high temperature resistant, heat resistant, anti slip, moisture-proof, anti-static, and applicable to airport transportation