In the operation of the ultrasonic welding machine, the three most common faults of the ultrasonic welding machine are: abnormal ultrasonic current overload, abnormal ultrasonic heating, and abnormal whistling of ultrasonic products. Here, we will focus on these three faults. Analysis and resolution.

 

Ultrasonic problem 1: Ultrasonic current overload is abnormal

When the generator sends out an overload alarm, it should be checked as follows:

1. Sometimes the no-load test is normal but not working normally. It may be that the internal sound energy components such as the welding head have changed, causing the sound energy to be transmitted poorly. Here is a relatively simple judgment method: hand touch method. The amplitude of the normal working welding head or horn surface is very uniform when working, and the hand feels velvety smooth. When the sound energy is not transmitted smoothly, there will be a feeling of bubbles or burrs on the hand. It is necessary to use the elimination method to eliminate the problematic parts. The same situation can also occur when the generator is abnormal. Normally, the input waveform of the transducer should be detected as a smooth sine wave. This phenomenon can also occur when there are spikes or abnormal waveforms on the sine wave. At this time, another pruning acoustic energy component can be used to replace it for identification.

2. Ultrasonic no-load test. If the working current is normal, it may be that the ultrasonic welding head has contacted objects that should not be touched or the parameter adjustment between the ultrasonic welding head and the welding seat has failed.

3. When the ultrasonic no-load test is abnormal, first observe whether the ultrasonic mold is cracked and whether the installation is firm, and then remove the welding head and perform no-load test to eliminate whether there is a problem with the transducer + horn, and proceed step by step. exclude. After eliminating the possibility of failure of the transducer + horn, replace the new welding head for judgment.

Ultrasonic problem 2: Ultrasonic heating is abnormal

Ultrasonic molds will have a certain degree of heat during work, which is caused by the loss of mechanical energy of the material itself and the heat conduction of ultrasonic objects. The standard for judging whether the ultrasonic mold heating is normal is that when there is no load (that is, not touching the workpiece), the ultrasonic wave should be continuously emitted for more than half an hour, and the temperature cannot exceed 50-70℃. Need to be replaced.

Ultrasonic problem three: abnormal howling occurs when the ultrasonic is working

When whistling occurs when the ultrasonic mold is working, the following reasons should be analyzed:

1. Whether the mold is in contact with objects that should not be in contact.

2. Whether the installation screws are loose.

3. Whether the ultrasonic mold has cracks.