The causes and solutions of common faults in ultrasonic welding machines

Excessive fusion 】

Reason: Too much energy input for plastic parts

Solution:

1Reduce air pressure

2Reduce welding time

3Reduce the number of amplitude segments

4Replace the low magnification secondary rod
Inconsistent fusion effect 】

Reason:

1Changes in injection molds

2Using water pipe materials or secondary materials

3Changes in the proportion of added materials

Solution:

1Check if the injection mold is worn out

2Improve the materials used

3Fixed additive components
Plastic parts cracking and shaking 】

Reason:

1Excessive ultrasonic amplitude

2Insufficient strength of plastic parts

Solution:

1Select low magnification secondary pole

2Reduce output amplitude

3Plastic reinforcement or thickening
[Non fusion surface damage]

Reason:

1The contact surface between the welding head and the plastic does not match

2Concentrated ultrasonic damage

Solution:

1Repair the welding head and bottom mold to match the plastic part

2Repair welding heads and avoid empty spaces in relevant positions
Insufficient fusion 】

Reason: Too little energy input for plastic parts

Solution:

1Increase air pressure

2Extend welding time

3Increase the number of amplitude segments

4Replace the high magnification secondary pole

5Using higher power models
Surface perforation of plastic parts

 Reason:

1Insufficient ultrasonic amplitude caused by prolonged welding

2Concentrated ultrasonic damage

Solution:

1Increase output amplitude, reduce welding time, and replace higher power models if necessary

2The corresponding position of the welding head should be avoided from the air

3Strengthening the thickness or reinforcing ribs of plastic parts