Big Linear Vibration Welding Machine Description
Linear Vibration Welding Machine is based on the principle of friction welding. Two plastic weldments that are pressed together, vibrating one of them to make a reciprocating displacement relative to the other, the displacement value can be up to 1.8 mm or 4 mm, the distance between the peak and peak is called the amplitude, and the vibration The frequency is 240 Hz, which generates frictional heat. It’s like rubbing two hands together.
In this process, one of the welded parts is mounted on the fixture of the elevating platform, and the other is placed on the driving fixture of the upper driving plate in the assembled position. The lifting platform moves up and down perpendicular to the vibrating head, and the servo system provides power and controls the pressure. The two parts must be pressed together by the clamping force of the lifting platform, which continues to act on the plastic part during the welding and holding cycle. Under pressure, the vibrating head vibrates and the plastic part is melted after a few seconds or dozens of seconds. This time is called “welding time.” The molten plastic is then cooled and solidified under pressure for a short period, which is called “hold time.” After the “hold time” is over, the lifting platform is lowered and returned to the unloading position (initial position).
Important Components
Big servo linear vibration welding machine consists of 9 main parts:
- Electrical control device
- Vibration source
- Frame
- Vibration Head
Vibration welding machines and equipment - Servo System
- Transmission System
- Soundproof Cover
- Base seat
- Pneumatic system
Among them, the electrical control device and the vibration source are installed in the electric control cabinet on the right side of the machine. The vibrating head, servo and all transmission machinery are mounted in the frame. A sound proof cover is placed over the linear vibration welding machine to prevent noise generated during vibration and to protect the operator. The front of the soundproof cover has a door that slides and opens in the vertical direction. There are two opposite doors on the back of the soundproof cover, allowing maintenance personnel to enter the inside of the vibration welding machine for maintenance.
Electrical control unit
The linear vibration welding machine’s electrical control unit consists of a programmable controller (PC), control relay, transformer and touch screen, and the user operates the machine on the touch screen. The PC controls the start and stop of the vibration source, the sequential operation of the servo system, and all machine functions.
Vibration power supply
The linear vibration welding machine’s vibration power supply mainly supplies electrical current to the drive coil of the vibrating head, causing the vibrating head to vibrate, so it is called a vibrating power source.
After the initial start-up and each time a new fixture is replaced, the operator must adjust the output frequency and output voltage of the vibrating power supply through the touch screen. The output frequency is used to tune the resonant frequency of the vibrating head, and the output voltage is used to tune the corresponding amplitude of the vibrating head.
There is a closed loop between the power supply and the induction coil of the vibrating head and the magnet for feedback of the amplitude of the vibration.
Machine Frame
The frame of the linear vibration welding machine is welded from a variety of structural steels. Except for the electric control cabinet, all the other mechanical, pneumatic and other parts are installed on the frame.
Due to complex affect from vibrating head’s horizontal alternating vibration load and the vertical tensile load which comes from the hydraulic system pressing the workpiece by lifting platform, the frame must have sufficient strength and overall stiffness.
The frame of the machine falls on the ground through four feet with rubber pads. The foot is adjustable. When the machine is installed, the height and level of the frame need to be adjusted so that the upper surface of the working platform achieves the required level accuracy (≤0.05mm/1000mm).
Vibration head
The linear vibration welding machine’s vibration head converts AC power into a bidirectional linear motion—vibration. It is mounted on a high-strength rubber mat on the machine frame which separates the vibration of the vibration head from the stationary frame.
The vibration head consists of a large cast iron frame, a spring, a set of drive assemblies and two drive coils. The springs are cantilevered beam springs that are fabricated from a single piece of high strength alloy steel. The top of each spring is screwed onto the cast iron frame. At the other end, the bottom of the spring is used to suspend the vibrating element (drive assembles and drive fixture).
The vibration head is based on the resonance of the spring assembly, so the motion of the vibration head is closely related to the pendulum motion. In the spring assembly system, one spring is fixed at one end and the other end is connected to the assembly. If the linear vibration welding machine’s system is tapped, the system will vibrate, and the frequency of the vibration is a function of spring mass and spring rate. This spring rate is called the spring constant. This frequency is called the natural or resonant frequency of the system. In order to let the system does work, electrical energy must be applied alternately to the solenoid. If the frequency of the applied electrical energy matches the natural frequency of the system, its energy consumption is minimal. Main performance parameters of the vibration head：
- Frequency range：110Hz
- Vibration range：0~3.6mm
- Drivable fixture weight： 130~160kg
- Drive board size： 1400（L）×550（W）mm
- Vibration head model：FW-3000
Machine servo system
The linear vibration welding machine’s servo system consists of a servo motor and a servo controller.
Its main performance parameters:
- Main motor rated power: 7.1KW
- Maximum table pressure available：2.5KN
Transmission system
The linear vibration welding machine’s transmission system consists of a lifting platform, two guide shafts, four linear bearings and a tight chain sprocket. The lifting platform is driven by a servo motor and performs vertical rise and drop movement along the guide shaft. During welding, the lower tool is mounted on the lifting platform, and the lower fixture for clamping the plastic part is mounted on the lower tool. The moving position of the lifting platform is determined by the displacement size.
soundproof cover
The outer casing of the soundproof cover is made of steel plate, and the inner wall is lined with sound absorbing material.
An active sliding door, also called a safety door, will be installed on the front of the soundproof cover. The door is mounted on the soundproof cover with four linear guides and two vertically mounted guide shafts. The up and down stroke is driven by a servo motor. The safety door is closed during welding. For non-welding time, the safety door is opened to remove the welded plastic parts. The inner wall of the safety door is also lined with a sound absorbing panel, and a sealing material is arranged between the safety door and the soundproof cover.
Pneumatic system
The linear vibration welding machine’s pneumatic system consists of an on-off valve (discharge valve), a pneumatic five-piece, a three-position five-way valve, a one-way throttle valve, a muffler, and a cylinder. The pneumatic system is mainly used to drive the movement of the mold fixture cylinder.
The air source of the pneumatic system is provided by the user and the pressure is 0.6 MPa.
Operator station
The big linear vibration welding machine area is marked as the operator station, i.e. the loading and unloading station, and the operator performs the specified manual production steps, loading individual components for welding.
loading and unloading station
Operator manual activity:
- loading a single part
- Press the start button.
- View the linear vibration welding machine’s controller on the right side of the operation table.
- After the welding is completed, remove the entire welded part.
Danger area
The marked area is the dangerous area, that is, the machine working area. During operating, the machine runs the following working steps: driving operation within the machine.
Machine working area：
*Travel and feed movements of component fixture and tool drive unit.
*Driving and feeding movement of the pressing device.
Big Linear Vibration Welding Machine Safety and protection device
Safety devices are part of the normal equipment state of the machine. They are used to protect personal life and health and safety. If the safety device is disabled, the careless behavior is fault-free.
Safety circuit
The linear vibration welding machine is equipped with the following safety circuits:
- Maintenance door safety
- Operator station’s emergency stop button, which is distributed under the operation panel and the man-machine interface operation panel (on the side of the electrical box).
- Operator station safety curtain。4.safety door
|
1 |
Safety switch behind the maintenance door |
|
2 |
emergency button |
|
3 |
safety curtain |
|
4 |
safety door |
Big Linear Vibration Welding Machine Operation and Commissioning
Safe Operation Guidelines
Safety Protection Devices
-
Initial commissioning is performed by Jfortune professionals after on-site installation.
-
Before first startup:
-
Remove all tools or foreign objects from the machine.
-
Check that all safety devices and emergency stop circuits are intact.
-
Ensure that no personnel are in the operation or hazardous areas.
-
Refer to the “Safety” section for detailed precautions.
-
Supply and Exhaust Interface
Electrical Connections
-
Incorrect connections may cause:
-
Unexpected machine activation.
-
Inability to control the device.
-
Reduced component lifespan.
-
Compressed Air Connection
-
Ensure the compressed air hose is securely connected to the maintenance unit.
-
The manual on/off valve must be opened for normal operation.
-
Confirm the working pressure is 6 bar on the pressure gauge.
Safety Function Checks
Improper safety device function can lead to life-threatening hazards.
Routine Inspection
-
Perform checks daily, before first use, and after long downtimes.
| Safety / Protection | Check Method | Expected Result |
|---|---|---|
| Emergency Stop Button | Press | All machine movements stop immediately |
| Safety Curtain | Shielded | Machine must not start |
| Door Safety Switch | Open maintenance door | Machine must not start |
Operation and Display Components
Machine Overview
Front View
| No. | Component |
|---|---|
| 1 | Tri-color Indicator Light |
| 2 | Touch Panel |
| 3 | Control Buttons |
| 4 | Start Button |
| 5 | Emergency Stop Button |
| 6 | Safety Curtain |
| 7 | Safety Door |
Control Interface
Reset Button
-
Function: Clear system faults.
Lighting Button
-
Function: Turns on internal lighting.
Run Ready Button
-
Function: Indicates control power is connected.
Three-Station Knob
-
Function: Switch between Manual, Automatic, and Tool Change modes.
Emergency Stop Button
-
Function: Pressing triggers an immediate stop to all machine movement.
-
Use only in emergencies where safety is at risk.
Unlock Method:
→ Turn the button clockwise and pull to reset.
Tri-Color Indicator Light
| Color | Status |
|---|---|
| 🔴 Red | Machine fault |
| 🟡 Yellow | Standby mode |
| 🟢 Green | Normal operation |
Manual Air Valve (Compressed Air Supply)
-
Risk: Hose whipping and stored pressure hazard.
-
Pneumatic components must be depressurized before maintenance.
-
Compressed air is controlled by a manual valve.
Maintenance Unit Components
| No. | Component |
|---|---|
| 1 | Switch Valve |
| 2 | Air Inlet |
| 3 | Filter Bowl |
| 4 | Pressure Adjustment Knob |
| 5 | Barometer |
| 6 | Drain for Water/Oil |
| 7 | Silencer |
Operating Instructions
Vibration Head Tuning
-
Each fixture has its resonant frequency, determined by:
-
Spring stiffness of the vibration head.
-
Weight of the upper fixture assembly.
-
-
Resonance minimizes the required drive energy.
Caution:
Do not test the vibration head without mounting the upper fixture.
Tuning is essential during fixture changes or troubleshooting.
Automatic Tuning of Vibration Head
-
The linear vibration welding machine system automatically adjusts the vibration frequency based on the mounted fixture and amplitude.
-
This ensures the system operates at its optimal resonant point.
Linear vibration welding machine Auto FM screen
If the fault indicator light is on during the auto-FM process, it indicates that the auto-FM has fault. After pressing the clear fault button and the fault indicator light is off, the auto-FM operation can be performed again. After the automatic frequency modulation is completed, it is generally possible to directly enter the working mode for welding the parts, and if necessary, manual frequency tuning can be used for adjustment.
Manual FM
- Press the manual FM button at the bottom of the screen to enter the manual FM At this time, which show in the frequency setting point column is the current working frequency of the machine.
- To reduce noise, you can close the safety door. Press the protection door close button, and then press the two cycle start buttons at the same time, the safety door rises, the off-indicator lights is on, indicating that the rise is in place, and the two cycle start buttons are released.
- To set the amplitude, change the amplitude in 01mm units by pressing the Amplitude Increase button or the Amplitude Reduction button at below of the Amplitude Setpoint button.
Another simpler method is to directly press the amplitude setting point key to display the digital input interface, and type in an amplitude value. The set value is displayed. Press ← button to confirm, the data is displayed, and the digital input interface is erased. The starting amplitude should be below 1.0 mm.
- Press the Start Vibration button and a sound will occur when the vibration head The vibrator indicator lights up to indicate that the linear vibration welding machine is on. Press this button again to stop the vibration.
- Observe the change of pointer in the load table. Fine tune the frequency near the automatic frequency that has been obtained. Press the frequency increase button or the frequency decrease button at below of the frequency setting point button to change the frequency in units of 0.1
Another simpler method is to directly press the frequency setting point key, display the digital input interface, and type a frequency value, the set value will be displayed, press ← key to confirm, the data is displayed, and the digital input interface is eliminated. At the beginning of the vibration, observe the change of the pointer in the load table, adjust the frequency to minimize the load, then gradually increase the amplitude, adjust the frequency until the pointer in the load table changes less, and the load is minimum (this process should be adjusted repeatedly until the load is minimum and the change is minimal). If the vibrator abnormality indicator light is on during this process, please wait 15 seconds and then press the clear fault button, then reduce the amplitude value as described above and then manually adjust the frequency.
