In this article, we will share issues such as inconsistent welding results, surface damage, and damage to internal parts during welding, hoping to help you better cope with such unexpected challenges.
Situation 4: The welding results are inconsistent.
Reason: The tolerances of the workpiece are too large
Solution: Tighten the tolerance of the workpiece.
Reason: The change between the injection mold and the mold.
Countermeasures: Whether the welding statistics of the workpiece with a specific injection die are improved; Check the tolerances and dimensions of the workpiece; Check whether the mold is worn; Check the operating conditions.
Reason: Use of secondary materials or secondary plastic films.
Countermeasures: Check the material quality with the injection factory; review of operating conditions; Reduce the proportion of substandard materials; Improve the quality of defective materials.
Cause: The supply voltage changes.
Solution: Use a power supply regulator.
Cause: Drop in air pressure.
Solution: Increase the pressure of air output; ②.Device pressurized cylinder.
Reason: The proportion of additives is too high.
Solution: Reduce the additive; Check the operating conditions. Change the type of additive, that is, change the ** cone to a long line cone.
Cause: Uneven distribution of the additive.
Solution: Check the operating conditions; Check the mold design.
Reason: Poor quality of materials.
Solution: Check the operating condition meter.
Reason: Poor fit of the workpiece.
Solution: Check the size of the workpiece; Check the tolerances of the workpiece; Check the operating conditions.
Reason: Use materials with poor meltability.
Countermeasures: Refer to the plastic film fusing table and the inspection of the raw material supplier.
Reason: Use of substandard materials.
Countermeasures: Inspect the material with the injection factory; Check the operating conditions.
Situation 5: Surface damage.
Cause: Increased sonotrode temperature.
Solution: Tighten the tolerance of the workpiece. Check whether the sonotrode tool is loose; Reduced splicing time; Cool the sonotrode to dissipate heat; Inspect the interface between the sonotrode and the drive; Check whether the sonotrode is broken; If the sonotrode is titanium, replace it with aluminum; If the sonotrode is copper, reduce the magnification.
Cause: Partial bruising of the workpiece.
Solution: Check the size of the workpiece; Check the fit between the workpiece and the sonotrode.
Reason: Improper fitting of the workpiece and the fixture.
Solution: Check whether the support is appropriate; redesign of fixtures; Inspect the changes of the mold and the mold door workpiece.
Reason: Alumina (from the sonotrode head).
Solution: The sonotrode is treated with hard chrome; Use a thermoplastic film mold (bag).
Reason: Improper fitting of the sonotrode to the workpiece.
Solution: Check the size of the workpiece; Redo the new sonotrode head; Inspect the changes between the mold and the workpiece.
Cause: The splicing time is too long.
Countermeasures: Increase the pressure or amplitude to reduce the welding time; Adjust the buffer pressure.
Reason: Poor fit of the contact surface of the welding head, workpiece and base.
Solution: Check the parallelism between the workpiece of the welding head and the base; Check the fit between the sonotrode and the workpiece; Check the fit between the workpiece and the base; Where necessary, flatten the base.
Reason: The effect of workpiece deformation is too great.
Solution: Reduce the amount of deformation that affects it.
Cause: The splicing time is too long.
Solution: Reduce the splice time.
Cause: The size of the joint surface is uneven.
Solution: Redesign the joint surface; Check the operating conditions.
Reason: The workpiece is too tight.
Solution: Loosen the fit of the workpiece; Loosen the tolerances of the workpiece.
Situation 6: During welding, the internal parts are damaged.
Reason: The amplitude is too large.
Solution: Reduce the amplitude.
Cause: The splicing time is too long.
Countermeasures: Increase the amplitude or pressure to reduce the damage of the splice time; Adjust the buffering speed and delay time.
The reason: The workpiece absorbs too much energy.
Solution: Reduce the amplitude. Reduced stress; Reduced splice time; Use an energy controller.
Cause: Improper combination of parts, i.e. too close to the joint surface.
Solution: Determine the appropriate combination of internal parts; Move internal parts to avoid energy concentration areas or change crimping points; Design fixtures to offset local energy.
Situation 7: Melt or crack outside the joint surface of the workpiece.
Cause: The inner corners are too sharp.
Solution: Blunt the acute angle.
Cause: The amplitude is too large.
Solution: Blunt the acute angle.
Cause: The splicing time is too long.
Countermeasures: Increase the amplitude; increased pressure; Adjust the buffering speed and delay time.
Cause: Internal stress.
Solution: Check the injection conditions; Check the workpiece design.
Cause: Improper operating conditions.
Solution: Check the operating conditions;
Situation 8: Meltover in the center of the surface of the workpiece.
Cause: The amplitude is too large.
Solution: Reduce the amplitude.
Cause: The splicing time is too long.
Solution: Increase the amplitude or pressure to reduce the splicing time.
Reason: Feed port location.
Countermeasures: Check to change the feed inlet; Change the shape of the feed opening; Check the operating conditions. workpiece reinforced rib design; Increase the material thickness of the workpiece below the material opening.
Reason: Sonotrode shape and fit.
Solution: Change the sonotrode head; Check the fit between the sonotrode and the workpiece; Use a sonotrode with a downward-inclined cross-section.
Situation 9: Internal parts are fused.
Reason: The internal parts are made of the same material as the housing.
Solution: Change the material of the internal parts; The internal parts are solder masked.