Common Problems and Solutions of Ultrasonic Welding Machine
Problem 1: Burrs appear around the product after welding.
Solution for burrs on the right side:
Solution for burrs on the left side:
Problem 2: The welded thickness is too thin or too thick.
Solution:
The welded thickness can refer to: Ultrasonic Wire Harness Machine Welding Parameter Setting Table.
Problem 3: Some wires are not welded after product welding.
Solution:
Problem 4: Looseness or poor welding occurs after welding. Solution: Increase the amplitude, extend the welding time or increase the air pressure.
Problem 5: Sticking to the mold occurs after welding. Solution: Lengthen the shaking – off time, use secondary ultrasonic to shake off the product.
Problem 6: After welding, the electrical box gives an alarm for abnormal impedance or excessive power. Solution: Reduce the air pressure or decrease the amplitude.
Problem 7: Broken wires appear around the product after welding. Solution: Decrease the amplitude, shorten the welding time or reduce the air pressure.
Parameter Explanation:
- Delay time: The time to delay the triggering of ultrasonic waves.
- Welding time: The time to trigger ultrasonic welding.
- Welding energy: The energy value output by the ultrasonic wave. When the output energy value is equal to the set value, the ultrasonic output stops. The energy value range is 10 – 60000J.
- Cooling time: After the ultrasonic output stops, the time that the die head still presses on the product through air pressure.
- Shaking – off time: The time to shake off the welded workpiece stuck to the mold. (When the workpiece sticks to the mold after product welding, this problem can be solved by setting the shaking – off time.)
- Welding amplitude: Load amplitude. By adjusting the amplitude, the output power can be controlled. The amplitude of this model is adjustable from 1% – 100%.
- Control mode: Time mode / Energy mode.
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