The welding principle of fully automatic wire bonding machines is based on ultrasonic vibration energy. During the welding process, the machine does not supply electric current to the workpiece, nor does it apply an external high-temperature heat source. Instead, ultrasonic-frequency mechanical vibration is converted into frictional work at the bonding interface. This friction causes limited temperature rise and plastic deformation on the metal surface. Under a static pressure, oxide films and surface impurities are squeezed out, and atomic-level bonding is formed between the same or dissimilar metals, resulting in a solid connection.
The advantages can be understood from several aspects:
- Controllable welding quality: With adjustable digital parameters for time, pressure, power, temperature, and arc shape, combined with high-precision visual positioning, the position and shape of each bond point can be stably controlled.
- Lower production cost: One operator can manage multiple machines at the same time, reducing defects and material waste caused by manual operation.
- Moderate energy consumption: The overall power consumption is similar to that of an ordinary manual wire bonder, making it suitable for long continuous operation.
- Good equipment durability: Key moving parts and welding tools are produced with high-precision machining, offering strong wear resistance and extended maintenance intervals. Hansheng Automation can custom-machine bonding tools, positioning fixtures, and other precision components according to customer requirements, helping to maintain bonding accuracy and equipment life.
- High production efficiency: Automated welding speed is significantly higher than traditional manual methods.
- Easy integration: The equipment is compact, requires little maintenance, and is suitable for automated LED packaging production lines.
- Good electrical conductivity after welding, with very low contact resistance.
- Low surface preparation requirements: Oxidized or electroplated surfaces can be welded directly.
- Short welding time, with no need for flux, shielding gas, or additional solder.
- No sparks or spatter during welding, meeting environmental and safety requirements.
