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Troubleshooting and Maintenance of Ultrasound Welding Machine
Source: | Author:lihan | Publish time: 392 days ago | 372 Views | Share:
Ultrasound Welding Machine Analysis: It is generally believed that when the ultrasonic welding machine works, as long as the contact between the product and the die surface is accurate, the welding effect can be obtained. In fact, this is only a surface view. Since the ultrasonic wave is a friction vibration, it will produce the phenomenon of sound wave transmission. If we only observe the stability of hardware (model) and ignore the integrated mode of supersonic. The mode of wave operation will result in the result of losing all costs or misjudgement. Therefore, it is necessary to emphasize that the mode of operation of super-Shenbo welding is to transmit sound wave, so that the vibration friction can be converted into * energy and welded. At this time, the stability of the ultrasonic mould, the height of the product cross-section, the thickness, depth and material of the organization * will not be able to withstand the same pressure.

Troubleshooting and Maintenance of Ultrasound Welding Machine



Ultrasonic welding machine


Ultrasound Welding Machine Analysis: It is generally believed that when the ultrasonic welding machine works, as long as the contact between the product and the die surface is accurate, the welding effect can be obtained. In fact, this is only a surface view. Since the ultrasonic wave is a friction vibration, it will produce the phenomenon of sound wave transmission. If we only observe the stability of hardware (model) and ignore the integrated mode of supersonic. The mode of wave operation will result in the result of losing all costs or misjudgement. Therefore, it is necessary to emphasize that the mode of operation of super-Shenbo welding is to transmit sound wave, so that the vibration friction can be converted into * energy and welded. At this time, the stability of the ultrasonic mould, the height of the product cross-section, the thickness, depth and material of the organization * will not be able to withstand the same pressure.

On the other hand, the energy output by the mode (Horn) has its error value at every * point, not the same energy as that of the whole surface. As a whole, the potential * produces a difference in the degree of fusion of the product's weld wires. So * it has to be corrected. How to correct it is to rely on the horizontal screw of the ultrasonic welder itself, or stick thin tape or aluminium foil to overcome it.


The quality of ultrasonic welding products is unstable


Analysis of ultrasonic welding machine: The main factor of unstable quality is unstable output power, which leads to unstable friction heat energy. And how to make the power output stable? This depends on the output power of < 1 > machine, the expansion ratio of 2 HORN, 3 air pressure source, and 4 voltage source. 1. Output power + HORN enlargement ratio = actual available power. From this point of view, the stronger the output power of the machine is, the smaller the expansion of HORN is compared with that of the design. Conversely, the smaller the output power of the machine, the larger the expansion ratio of HORN design. For example, in 2200W ultrasonic welder, the expansion ratio of HORN is 2.5 times. When replaced with 3200W ultrasonic welder, the expansion ratio of HORN may be only 1.5 times. However, it is not emphasized that the output power of the welder of the ultrasonic welding machine should be high, but that when a plastic product is welded by the ultrasonic wave, it is necessary to give * suitable environmental operation. In the meantime, the budget of cost, the functional requirements of the product, the welding standard and other considerations should be taken into account to plan the complete working equipment and the use skills of the ultrasonic wave. 2. After understanding the key factors affecting the quality of ultrasonic welding, engineers should be familiar with and evaluate 1. Functional standards for product quality requirements; 2. Existing ultrasonic equipment; 3. Determining the shape and skills of product design, such as ultrasonic waveguide fuse, product positioning and material. Since available equipment resources are fixed, it is correct to use product design techniques to match existing available equipment. 4. When we determine that there are no human factors (1-2 items) in question, there will be mass instability. That's one thing: the effect of pressure and voltage. When we deal with the phenomenon of unstable quality for many years, we also find that the quality standard which can not be reached in working time is met unexpectedly when people are off work and most of the stopping voltage and air pressure are used at the same time. Therefore, it is also found that when many people or units use the common air pressure and voltage source, the air compressor usually sets the air pressure in the air storage tank below 2-4 kg and then automatically fills the air, which is an error cause. When the gas source passes through the pipeline to the welder, because of the fast welding speed, * the gas pressure of the first supersonic welding and the gas pressure of the second or third time remaining in the pipeline also form errors, which will result in periodic or non-periodic mass variation. Voltage is also due to the simultaneous use of power company output for millions of people. At this time, the voltage drop is not all we can control. So the variable of pressure and voltage really causes the change of energy output, which is an important factor affecting the precision quality. Of course * must be listed as a diagnostic item.


Countermeasure: In order to demand high quality products, such as below 0.02m/m for products or above 90 * for fusion conditions, design engineers should be familiar with ultrasonic fusion equipment according to their planning sequence, 2. Determine product functions, 3. Familiar with the corresponding relationship between ultrasonic and plastic fusion, 4. Adding voltage stabilizing equipment as far as possible.

The welding condition of ultrasonic welding machine is not suitable.


Ultrasound welding machine analysis: Ultrasound operating conditions refer to the output power (number of segments), pressure (dynamic pressure and static pressure) welding time, hardening time, delay time and other elements set. We take the supersonic waveguide fuse as an example. When we carry out ultrasonic welding, if the pressure is too high, the cylinder drops too fast, it is easy to flatten the supersonic waveguide fuse. Although it seems that the product has been close, the fuse line has been squeezed and sinked, and lost the effect of fuse-guiding, forming a forced fusion between plastic surface and surface, rather than a triangular point, so it produces a false fusion.


The output energy of ultrasonic welding machine is insufficient:


Ultrasound Welding Machine Analysis: When customers purchase Ultrasound Welding Machine, it is usually difficult to predict the future product development specifications, so they will encounter a larger product object beyond the Ultrasound Standard Welding. At this time, under the budget of no additional cost, only existing equipment can be used to operate production. In the case of using a small computer as a large object, the usual ways are to weld several times, increase the output power of the ultrasonic wave (increase section), or increase the welding time and pressure, etc. However, this also results in mass instability, because the voltage and pressure directly affect the stability of the output power of ultrasound. That is to say, the quality of products using ultrasound during working hours or rush hours is different from the stability of quality after work. However, if everyone uses ultrasound after work, it will not be efficient. Therefore, the countermeasure adopted at this time is to adopt a unique * cubic form of air pressure source; require products below 0.02m/m to install pressure stabilization equipment on the ultrasonic machine; adjust the number of output segments and increase power, but in general, the power output * can be well controlled between 2 and 4 segments in the ultrasonic operation. If * must work in 5 to 6 segments, the production time * must be shortened as far as possible to avoid parts and vibration. The loss of the mover. Increase the power amplifier (Horn Upper Module) expansion. But if the extended range * degree exceeds 4:1, it will have a great influence on Horn itself, sound wave and current.

The material of plastic products is not properly matched.


The melting point of each plastic material is different. For example, the melting point of ABS plastic material is about 115 C, the melting point of ABS plastic material is about 175 C, the temperature of PC is above 145 C, and PE is about 85 C. For example, the melting point gap between ABS and PE material is too big, so the ultrasonic melting is bound to be difficult. There is also a gap between ABS and PC, but the gap is not so big as the previous one, so it is still weldable. However, under the same power and energy expansion of ultrasound, different plastic materials have better bonding effect than the same material.


Lihan Machinery, a domestic supplier of ultrasonic equipment, has been focusing on the improvement of ultrasonic technology for 20 years. Its main businesses are: ultrasonic mask equipment, ultrasonic cotton shaping equipment, ultrasonic shearing/slicing/embossing/welding equipment. Lihan Machinery 24-hour Service Hotline: 400-6393-988