How to solve the problem of unstable welding product quality?

Date:2016/3/21　Hits:10 Go back to the previous page

Keber Engineer Answer:
Good way to choose a large unit of ultrasonic welding equipment, for example, our Keber company products are very good.

The main reason for unstable quality is the unstable output power, which leads to the inability to form stable frictional heat energy. And how to make the power output stable?

This is determined by:
1, machine output power;
2, HORN expansion ratio;
3, air pressure source;
4, voltage source and so on four items.

Machine output power + HORN expansion ratio = actual available power. It can be seen that in a certain product implementation of ultrasonic welding, in terms of planning and design, the stronger the output power of the machine, the relative HORN expansion ratio is designed to be smaller. Example: For a 2200W ultrasonic welding machine, HORN's expansion ratio is 2.5 times. When switching to a 3200W ultrasonic welding machine, the expansion ratio of HORN may only be 1.5 times. However, it is not emphasized that the output power of ultrasonic welding machine should be large, but to implement the ultrasonic welding of a plastic product, give the appropriate environment for the operation, which still need to take into account the cost of the budget, the functional requirements of the product, welding standards and other considerations and then plan out the complete work of the equipment and the use of ultrasonic skills.
After understanding the various critical reasons affecting the quality of ultrasonic welding, when designing engineers should first familiarize themselves with and evaluate 1. the functional standards of product quality requirements 2. the existing ultrasonic equipment
Decide on the form and technique of product design (e.g., ultrasonic fusion line, product positioning, material). Since the available equipment resources are already fixed, it is only right to use product design techniques to match the available equipment.
If we are sure that there are no problems with the human factor (1 to 2 items), the fact that the quality is unstable is a certainty: the influence of air pressure and voltage. As we have dealt with the phenomenon of unstable quality for many years, we have also found that quality standards that could not be met during working hours were unexpectedly met when everyone was off duty and the voltage and air pressure were stopped at most of the same time. Therefore, it is also found that when multiple people or units use a common air pressure and voltage source, the air compressor usually sets the air pressure inside the air storage cylinder to be lower than 2 ~ 4kg before filling automatically, which is one of the reasons for the error. The air pressure source through the pipeline to reach the fusion welding machine, due to the fusion speed, the first ultrasonic fusion of air pressure and the second or third time the air pressure stored in the pipeline also formed an error, which will form a cyclical or non-cyclical quality variations. And the voltage is also due to the power company output at the same time for millions of people have the opportunity to use at the same time, at this time the resulting voltage drop is not under our control, so the variables of air pressure and voltage, which indeed cause changes in the energy output, and affect the quality of the important factors of precision. Certainly must be included as a diagnostic item.
Keber Engineer Response:
For higher quality, e.g. if the product pair needs to be below 0.02m/m, or if the fusion status of the wire needs to be above 90%, the design engineer, depending on the planning sequence, has to
1. familiarize with ultrasonic welding equipment;
2. Decide on the function of the product;
3. Familiarize yourself with the correspondence between ultrasonic and plastic welding;
4. add voltage stabilizing equipment as much as possible.