Most often seen problems during plastic welding

During the process of the ultrasonic welding process, there are three most frequently seen malfunctions: abnormal ultrasonic current over-load, abnormal ultrasonic heating, squealing noise coming from the area of the ultrasonic stack.

Trouble One: abnormal ultrasonic current over-load-when ultrasound generator gives an overload alarm, the inspection should be carried out as follows:

1 Conduct an ultrasound empty-load test, if the working current is normal, it is usually because that the welding head has come into touch with an object that is not supposed to be touched or the parameter adjustment between the welding horn and welding seat fails.

2 Conduct an ultrasound empty-load test, if there is anything abnormal with the test, first observe if there is any crack on the welding horn or if it is tightly fixated. If none, remove the welding horn and conduct the empty-load test again to see if it is the converter or booster problem, eliminate the possible problem step by step. If there is nothing wrong with the converter or booster, replace a welding horn to test again.

Trouble Two: unusual ultrasonic heating: the ultrasonic welding horn will certain have heating phenomenon while working, which are caused by the mechanical energy loss itself or the ultrasonic objects heating transmission. To define whether this welding horn heating is normal or not, its temperature should not exceed 50-70 centigrade degrees in a continuous ultrasound over half an hour under the empty-load situation, if the heating is serious, it is highly possible that the horn is damaged or the horn material is disqualified and needs to be replaced.

Trouble Three: Squealing sound coming from the welding horn while working. Normally, when this phenomenon appears, actions should be taken as follows:

1 Check if the welding horn has been in touched with any object that is not supposed to be touched

2 Check if the connecting screw is tightened

3 If there any crack on the horn surface

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