Comparaison du soudage par ultrasons et du soudage laser dans la production de panneaux solaires

1. Esthétique du produit PK

Le soudage au laser consiste à utiliser un laser à haute énergie pour faire fondre le métal soudé afin de créer une connexion. Dans le soudage des plaques d'absorption de chaleur solaire, un point de soudure est soudé avec un intervalle de 3 à 5 mm. Le soudage au laser ne nécessite pas de pression sur la pièce soudée, la déformation globale est faible et les dommages de surface à la couche d'absorption de chaleur sont faibles, tandis que le soudage des métaux par ultrasons provoquera une déformation en forme d'onde sur la surface de la feuille en raison de la pression, bien que il peut être évité en gaufrant la surface Déformation, mais il formera toujours une marque de soudure d'environ 3 mm sur la surface de l'absorbeur de chaleur solaire. Par conséquent, l'apparence des produits de soudage au laser sera meilleure que celle du soudage des métaux par ultrasons. Dans ce tour de compétition, le soudage au laser est meilleur que le soudage des métaux par ultrasons.

2. Persistance PK

La résistance des joints de soudure au laser est faible et les joints de soudure sont faciles à casser lorsque la chaleur et le froid alternent fréquemment ou sont soumis à des forces externes. Le soudage des métaux par ultrasons utilise une pression verticale pour faire se chevaucher deux objets à souder, et ils sont combinés en une connexion solide par pression de vibration ultrasonique. Le temps de collage est court et la pièce de collage ne produit pas de défauts de structure coulée. Par conséquent, la position de soudage est uniforme et stable, et le métal ultrasonique Le soudage a réussi le test de flexion verticale à 90 degrés et il n'y a toujours pas de fracture. Dans ce tour de compétition, le soudage des métaux par ultrasons est meilleur que le soudage au laser.

3. Conductivité thermique PK

The use of laser welding will change the physical structure of the welded object, thereby affecting its electrical or thermal conductivity, and laser welding will result in a small heat conduction area between the metal sheet of the solar collector and the copper tube, which affects the heat transfer efficiency. Ultrasonic metal welding does not have this problem. Ultrasonic welding can reduce the temperature effect of the material to a lower level, so as not to change the metal structure. Therefore, the electrical conductivity or thermal conductivity after welding is extremely good, and the resistivity is extremely low or nearly zero. Ultrasonic metal welding has become conductive and thermally conductive material welding. It is a better choice, this performance can obviously produce advantages that cannot be achieved by laser welding when applied to flat panel solar collectors. According to the test, the transmission efficiency of ultrasonic metal welding products is about 3% higher than that of laser welding (that is, the water temperature is about 3% higher under the same working conditions). In this round of competition, ultrasonic metal welding is obviously better than laser welding.

4. Energy PK

As a representative product of low carbon, energy saving and environmental protection, solar water heaters are widely recognized by society and consumers. The energy consumption indicators in the production process have also attracted much attention. The welding of solar collectors is one of them. From the comparative analysis of welding principle, it can be known that ultrasonic metal welding can reduce the temperature effect of the material to a low level (the temperature of the welding zone does not exceed 50% of the melting temperature of the welded metal), so as not to change the metal structure, so it does not It will anneal the metal workpiece and does not require cooling water. In terms of energy consumption, ultrasonic welding can be carried out between the same type of metal and different types of metal, which consumes much less energy than laser welding. In this round of competition, ultrasonic metal welding is better than laser welding.

5. Cost PK

1. Equipment cost: Internationally, ultrasonic spot welding machine and laser welding machine are at the same price, but Minghe Ultrasonic Co., Ltd. has introduced the first fully automatic whole-plate ultrasonic metal welding in the solar thermal industry through the introduction of foreign technology and independent research and development. The machine has completely broken the situation that my country's high-precision ultrasonic welding equipment needs to rely on foreign imports, and has basically reduced the price of domestic ultrasonic welding machines by half. The purchase cost of a single device of ultrasonic metal welding machine is lower than that of laser welding machine, and the purchase ratio of the two is usually 300,000:1 million (the price of domestic laser welding machine is also falling rapidly, about 700,000). The laser welding machine generally has two laser welding heads, and the ultrasonic machine generally has one welding head. For the same capacity, compared with one laser welding machine, the ultrasonic is slightly better than the laser.

2. The cost of use: First, laser welding is suitable for thick materials, such as welding aluminum. The thickness of aluminum plate is generally selected as 0.4mm, while ultrasonic welding is suitable for thin products, such as aluminum plate. Generally, 0.2-0.3mm is enough. In terms of welding materials, ultrasonic is superior. The second is the cost of consumable parts. The consumable parts for laser welding are xenon lamps and filter elements, and the consumable parts for ultrasonic are welding heads. In general, laser welding consumables are cheaper than ultrasonic ones. Therefore, in this round of competition, ultrasonic metal welding is slightly better than laser welding.

6. Efficiency PK

The welding speed of ultrasonic metal welding is faster than laser welding: the typical ultrasonic metal welding speed is 8 m/min for copper welding and 12 m/min for aluminum welding. However, the currently selected process of ultrasonic welding is to roll grain and then weld, so a single machine Efficiency must be discounted. For the same production capacity, 2 ultrasonic welding machines are compared with 1 laser welding machine. In this comparison, ultrasonic is better than laser.