The working principle of high-frequency synchronous welding and cutting machines relies on high-frequency electromagnetic fields to induce molecular polarization and friction-generated heat in dielectric materials, combined with a pressure system to achieve simultaneous welding and cutting. The detailed process is as follows:
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1. High-Frequency Electromagnetic Field Induces Molecular Motion
Electric Field Generation by High-Frequency Oscillator
- The machine generates high-frequency electromagnetic fields (typically 27.12 MHz or 40.68 MHz, compliant with international industrial band standards) via an electron tube self-excited oscillator (e.g., vacuum tube).
- These fields act on processed materials (e.g., PVC, TPU, APET plastics), polarizing their internal molecules.
Friction-Based Heat Generation
- Under the high-frequency electric field, material molecules rapidly align with the field direction.
- The field’s rapid polarity reversal (millions of times per second) causes intense molecular friction, converting kinetic energy into heat.
- Localized temperatures surge to the material’s melting point (e.g., 120–200°C for PVC).
2. Pressure System for Synchronized Welding and Cutting
Welding Process
- Once the material reaches its melting point, the pressure system (e.g., hydraulic or pneumatic) drives upper and lower electrodes to clamp the material.
- Under pressure, molten molecules interpenetrate and bond, forming strong, seamless joints.
Synchronous Cutting
- Immediately after welding, the same pressure system or an auxiliary cutting module applies instantaneous high pressure (up to tens of tons) at the joint edges.
- Cutting and welding occur in one cycle, ensuring smooth, burr-free edges.
3. Synergistic Key Technologies
Low-Loss High-Frequency Resonator
- Uses European-standard coaxial resonators to minimize energy loss, ensuring stable field output and improving weld quality.
Spark Protection System
- Automatically shuts off the high-frequency circuit upon detecting sparks, preventing mold or material damage, and activates warning lights.
Frequency Stabilizer and Shielding
- Frequency stabilizer: Prevents frequency drift from operational or environmental interference, minimizing electrode/material wear.
- Shielding device: Reduces electromagnetic radiation to avoid disrupting nearby electronics.
4. Typical Applications
Automotive Interiors
- Produces sun visors, sunshades, cargo covers, and floor mats by welding composites (PVC, TPU) or dual-component acoustic foam.
- Ensures clean-cut edges that meet automotive industry standards (e.g., ISO 9001, TS 16949).
