Medical nanosecond laser welding machine

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Product Description

Product Introduction

Core Component imported configuration

Core components: imported configuration

01 Customer Background and Pain Points

Amphenol, a U.S.-funded company, is an early manufacturer of communication and acoustic components. Its primary processes include injection molding, punching, and welding, and it predominantly uses copper materials. To enhance structural strength, it must weld a 0.1 mm-thick spring clip to a 0.8 mm-diameter copper post. The challenges encountered are:
1. Welding efficiency is extremely low: The original process involved single-sided, single-point welding, allowing only one weld point to be welded at a time, resulting in poor efficiency.
2. Weld strength does not meet specifications: Because the material is a copper alloy and the dimensions are too small, the weld joint lacks sufficient strength.
The customer is very frustrated by these two issues and has been unable to find a solution.

02 Customers have high requirements for the equipment

Amphenol found us online on October 16, 2019, discussed with our sales project engineer, and sought to customize a welding machine according to the following requirements:
1. Improve welding efficiency;
2. Reduce the number of fixture repairs;
3. Welding efficiency must be increased by 50% compared to the current level.
4. The yield rate must be increased by 30% over the current level.
5. Resolve the issue of welding instability;
According to the customer’s requirements, the existing standard spot welding machine simply cannot meet them. What should we do?

03 Custom development of the W150-F-J quasi-continuous laser welding machine according to customer requirements

Based on the customer’s requirements, the company’s R&D, welding processes, and sales departments jointly held a new project development meeting to discuss process design, tooling, structural layout, power delivery methods, and system configuration. They identified key risk factors, developed solutions for each, and finalized the overall direction and technical details as follows:
1. Prototype testing: The laser welding process engineer quickly fabricated a simple prototype fixture and used our existing medium-frequency welder to conduct trial tests. After five days of back-and-forth testing and tensile pull-out verification, the welding parameters were essentially finalized.
2. Equipment selection: The R&D engineer and the welding process engineer collaborated and calculated the required power based on the customer’s specifications, ultimately selecting the W150-QCW-J2 dual-head spot welder for earphones.
3. Equipment stability: Our company uses exclusively imported components for all core parts.
4. Equipment Advantages:
1) The double-head automatic spot welding machine we selected can weld two spots in a single cycle, increasing efficiency by more than 50% compared to the previous single-point model.
2) We have selected a special electrode material, which eliminates the occurrence of blowholes, resulting in a high yield rate, stable welds, and high strength that can match that of the base material; after welding, the weld can be directly pulled through the base material.
3) Easy to operate; ordinary workers can handle it, eliminating the need for professional welders and reducing labor costs.
4) When used with an automated positioning fixture, welding efficiency can be increased by 50% compared to the previous level.
5) Using dual-vibration lens welding results in a high yield rate, which can be increased by 30% compared to the previous method.
5. Delivery period: 25 working days.

04 Efficient design, timely delivery, professional service, and unanimous praise from customers

After finalizing the equipment technical specifications and signing the contract, Rayyang’s project manager promptly convened a production kickoff meeting to establish timelines for mechanical design, electrical design, machining, purchased components, assembly, and integrated testing, as well as for the customer’s on-site pre-acceptance, corrective actions, final inspection, and delivery. The team then used the ERP system to systematically issue work orders to each department and closely monitor and follow up on their progress.
After 35 working days, the Amphenol custom‑designed double‑head spot welder for Amphenol 7130 earphones successfully completed its aging tests. Following one day and one night of on‑site installation, commissioning, and training in operation, maintenance, and technical procedures conducted by our specialized after‑sales engineers, the equipment has been put into normal production and fully meets the customer’s acceptance criteria. Amphenol is highly satisfied with both the actual production output and welding performance of this machine; it has resolved their yield issues, improved welding efficiency, reduced labor costs, and earned our strong recognition and praise.

05 Meeting your customization needs is the mission of Raythink’s continued development.

Our customer base guides us,
What material do you need to weld?
What welding requirements? What welding process?
Do you need a fully automatic, semi-automatic, or assembly-line system?
Please feel free to raise any questions; LeiYang can provide “custom R&D” for you.

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