How to do if there are problems during debugging the mask machine equipment?

February 15, 2021

Here we list the masks machine equipment in the debugging process or in the process of use will appear in the failure, and analysis of the reasons, give the solution, hope to help you.

Fault one, uneven fusion, workpiece distortion and deformation.

1, check whether the size of the workpiece differences.
2, check whether the operating conditions cause deformation of the workpiece
3, adjust the buffer speed or pressure.

Fault two, the base support is not stable.

1、Improve the support point at the necessary place.
2、Redesign the base.
3、Change to hard base
4、If the large area of the bakelite is tilted, it needs to be reinforced.

Fault three, welding head, base, the workpiece contact surface is not flat paste.

1、Redesign the energy-saving point to make the height uniform.
2、Adjust the horizontal screw.
3、Check whether the manufacturing conditions are true.
4、Check the shape and size of the workpiece.
5、Side bending, workpiece with ribs
6、Modify the smelting tool to avoid bending the workpiece outward.

Fault 4, the workpiece error is too large.

1、Tighten the tolerance of the workpiece.
2、Revise the size of the workpiece.
3、Check the operating conditions (pressure, delay timing, fusion timing, curing timing, etc.).

Fault five, uneven fusion workpiece alignment is not appropriate.

1, check the fusion, the workpiece is not offset.
2, check the combination, the workpiece is aligned
3、Check the parallelism of the welding head, workpiece, and smelting tool.

Fault 6. Lack of close contact on the joint surface.

1、Check the size of the workpiece.

  1. Check the tolerance of the workpiece.
    3、Check the position of the ejector pin of the joint surface
    4、Check the alignment of the workpiece combination.
    5、Check whether the workpiece is depressed.
    6.Check the fit of workpiece and welding head
    7、Check whether the support of the smelting tool is appropriate.

Fault 7, ultrasonic welding results are inconsistent

(A) filler ratio is too high

1、Reduce the filler.
2, check the operating conditions.
3, change the type of filler, that is, the short line cone into a long line cone.

(B) uneven distribution of filler
1、Check the operation condition
2、Check the mold design

(C) Poor material quality

Check the operating conditions

(D) Poor workpiece fit

1、Check the workpiece size
2、Check the workpiece tolerance
3、Check the operating conditions

Fault eight, open the main power switch, the fuse is blown

  1. ultrasonic power board short circuit.
  2. rectifier bridge short circuit.
  3. the start-up current impact is very large, the fuse capacity is too small.

Fault nine, ultrasonic fusing excessive

Cause analysis and solutions.
1, after overfusion work object outside the size of different.
2, too much damage to the exterior of the workpiece.
3, adjust the lowest point trim screw.
4、Change the welding head with lower amplitude.
5, fusion time is too long to shorten.

Fault ten, press the fusion button welding head down, but not up after fusion.

Cause analysis and solutions.
1, insufficient air pressure.
2, bad solenoid valve.
3, adjust the air pressure.
4, maintenance of the program board.
5, time adjustment switch damage.

Fault eleven, operation in the overload light on.

Cause analysis.
1, loose welding head.
2, improper frequency adjustment.
3, the rupture of the welding head.
4, too much pressure.
5, the machine power is too small.

Fault twelve, the power indicator does not light up, the vibration box fan turns weak, can not send vibration or welding strength turns weak.

Cause analysis.
1, the power supply voltage is low.
2, input transformer damage.
3, poor contact with the power supply socket.

Fault 13, press the fusion button, the welding head then fell into the processing of the object did not vibrate that rise.

Cause analysis.
1, the downward stroke is not to the fusion position.
2, poor contact with the travel switch.
3, the pressure trigger system is not good.

Fault 14, the welding head up or down impact is too large.

Analysis of the causes.
1, the buffer adjustment is not appropriate.
2, buffer adjustment lockout.
3, the decline rate is set too high.
4, the cylinder buffer is not good.

Fault fifteen, air pressure, power supply, welding head are normal but can not start.

Cause analysis.
1, emergency rise button contact is poor.
2, the program control circuit is not good.
3, the start button is damaged.
4, the solenoid valve is damaged.

Fault sixteen, the input working energy is too little.

Cause analysis and solutions.
1, increase the use of pressure.
2, lengthening the fusion time.
3, increase the amplitude.
4, the use of larger power models.
5, poor resonance of the ultrasonic welding head.

Fault 17, the input work of too much energy.

Cause analysis and solutions.
1, reduce the use of pressure.
2, reduce the fusion time.
3, reduce the number of amplitude segments.
4, slow down the rate of descent of the welding head.
5、Insufficient fusion.

Fault 18, the use of poor fusion of materials.

(A) the use of sub-material
1、Check the material with the injection factory.
2, check the operating conditions.
(B) surface injury: the temperature of the welding head rises
1、Check whether the welding head screws are loose.
2、Check whether the welding head tool is loose.
3、Shorten the fusion time.
4、Make the welding head cooling.
5、Check the joint between the welding head and the transmission sub.
6、Check whether the welding head is broken.
7、If the weld head is titanium, replace it with aluminum material.
8、If the welding head is copper, then reduce the magnification.
(C) partial bruising of the workpiece
1、Check the size of the workpiece.
2、Check the fit of the workpiece and the welding head.
(D) The workpiece and the smelting tool fit improperly.
1、Check whether the support is appropriate.
2、Redesign the smelting tool.
3、Check the change of mold and mold door workpiece.
(E) Surface damage: aluminum oxide (from the welding head).
1、Welding head for hard chrome treatment.
2、Use heat-proof plastic film mold (bag).
(F) surface damage: welding head and the workpiece fit improperly.
1、Check the size of the workpiece.
2、Redo the new welding head.
3、Check the change of the workpiece between the mold and the mold.

Fault 19, welding current is too large, overload (7A or more).

Cause analysis.
1, high air pressure.
2, the output gear is too large, the impact current.
3, the buffer is too small.
4, high trigger pressure, long delay time.

Fault twenty, no ultrasonic output, can not be ultrasonic welding.

Cause analysis.
1, ultrasonic crystal board bad.
2, ultrasonic oscillation board bad.
3, welding overload protection.
4, output circuit fuse broken.
5, gear switch 0 position or bad contact.
6, the output line is not connected or short-circuit.

Fault twenty-one, the size of the joint surface is not uniform.

1、Redesign the jointing surface.
2、Check the operating conditions.

(A) The workpiece is too tight
1、Ease the fit of the workpiece.
2、Loosen the tolerance of the workpiece.
(B) The workpiece cannot be aligned after fusion, and the workpiece is not aligned when combined.
1、Increase the solid pile between two pieces of workpiece.
2、If possible, design the tool to guide the right.
(C) improper base support
1、Redesign the appropriate support smelter in the necessary place to pad the base.
2、If the bakelite is tilted, add a rigid support.
(D) sidewall bending
1、Add ribs to the side wall of the workpiece.
2、If the bakelite is tilted, add rigid bracket.
(E) The workpiece tolerance is too large
1、Tighten the workpiece tolerance.
2、Check the operating conditions.
(F) fusion welding, the internal parts are damaged, fusion time is too long.
1, increase the amplitude or pressure to reduce the fusion time damage.
2, adjust the buffer speed and delay time.
Fault twenty-two, the fusion time is too long.
1, increase the pressure or amplitude to reduce the fusion time.
2, adjust the buffer pressure.
(A) welding head, workpiece, base of the contact surface fit poorly.

1、Check the parallelism of the welding head workpiece and the base.
2、Check the fit of the welding head and workpiece.
3、Check the fit of the workpiece and the base.
4、In the necessary place, the pad flat base.

(2) The influence of workpiece deformation is too great.

Solution: 1. Reduce the amount of deformation.

(C) the fusion time is too long

Solutions: 1, reduce the fusion time.

(D) The workpiece absorbs too much energy

Solution: Reduce the amplitude.
1、Lock the welding head.
2, press the sound wave check button and adjust the sound wave adjustment screw so that the current indication is minimum.
3、Replace the mold.
4、Replace the relevant parts.
5、Overhaul the power tube.
6、Overhaul the power amplifier circuit.

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