What Are The Common Faults Of Ultrasonic Plastic Welding Machine And How To Solve Them?

1. Welding head (mold) damaged
Phenomenon: Uneven welding surface, product indentation or cracking
Reason: Unreasonable design of welding head (mismatched resonance frequency), material fatigue (micro cracks in aluminum alloy welding head after long-term use)
Solve:
Use a frequency analyzer to detect the natural frequency of the welding head (deviation should be less than ± 0.3kHz)
Replace titanium alloy/steel welding head (high load scenario)

2. Ultrasonic transducer/generator alarm
Phenomenon: Overload protection triggered (Error 05), no ultrasonic output
reason:
The insulation of the transducer is aging (impedance>5 Ω needs to be replaced)
Generator and transducer frequency mismatch (e.g. 15kHz generator with 20kHz transducer)
Solve:
Use LCR meter to detect the capacitance of the transducer (normal value ± 5% nominal value)
Re match generator (calibratable for automatic frequency tracking models)

3. Virtual soldering/over soldering
Phenomenon: Insufficient bonding strength or material carbonization
reason:
Incorrect amplitude selection (e.g. PP material requires 30 μ m amplitude, ABS requires 50 μ m amplitude)
Insufficient holding time (usually 0.5-2 seconds)
Solve:
Verify the actual output through an amplitude tester (such as Vibrometer)
Adjust parameters according to the melting point of the material (reference welding pressure=0.2-0.5MPa)