Causes Of High Current in Ultrasonic Welding Equipment And Solutions

When ultrasonic welding equipment exhibits high current, it is necessary to distinguish whether the issue stems from damaged internal components or problems with the ultrasonic load output. A simple diagnostic method is to disconnect the ultrasonic output cable and test the generator's current under a no-load condition; if the current is normal, the fault lies within the ultrasonic vibration system.

Experience shows that high current in ultrasonic welding is often caused by a mismatch between the ultrasonic vibration system and the welding equipment. To address this, inspect the components of the vibration system for proper function, check for loose screw connections, and examine the equipment for cracks.
1. Loose screws connecting the ultrasonic welding equipment to the transducer can cause high current; this typically occurs in machines that have been in use for some time. The solution is to use a specialized wrench to tighten the ultrasonic horn (welding head) and ensure it is securely locked.
2. High current may occur after replacing the ultrasonic transducer or the vibrating components of the welding equipment; in such cases, the elevated current is considered normal.
3. Damage or cracking of the ultrasonic mold or horn-often resulting from prolonged use or excessive operation time-can also cause high current. To resolve this, inspect the surface of the horn for cracks or test the component by installing it on another ultrasonic system.