Unstable quality of welded products, how to solve?

The main factor of unstable quality is that the output power can not be stabilized, in order to lead to the formation of stable friction heat energy. 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 other four items.

1, machine output power + HORN expansion ratio = the actual power available. It can be seen in a certain product implementation of ultrasonic welding, in terms of planning and design, the stronger the machine output power, the relative HORN expansion ratio is also designed to be smaller.

Conversely, the lower the output power of the machine, HORN designed to expand the ratio is also greater. For example: 2200W ultrasonic welding machine, HORN expansion ratio is 2.5 times. For a 3200W ultrasonic welding machine, the HORN expansion ratio may be as little as 1.5 times. However, not to emphasize the ultrasonic welding machine output power to be large, but to implement 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.

2, in the understanding of the above key reasons affecting the quality of ultrasonic welding, engineers in the design, the first should be familiar with and evaluate 1. product quality requirements and functional standards; 2. existing ultrasonic equipment. 3. decide the shape of the product design, and the environment to work;

3. Decide on the form and technique of product design (e.g., ultrasonic guide wire, product positioning, material). Since the available equipment resources have been fixed, it is necessary to use the product design skills to match the existing available equipment is correct.

4. When we are sure that there is no problem with human factors (1 ~ 2 items), the phenomenon of unstable quality will occur, and that is surely a fact: that is, the influence of air pressure and voltage. When we deal with the phenomenon of unstable quality over the years, we also find that the quality standard which cannot be achieved during working hours is unexpectedly achieved when everyone is off work and stops using voltage and air pressure at the same time. Therefore, it is also found that when many people or units use the common air pressure and voltage source, because the air compressor usually we will set the air pressure inside the air storage cylinder is lower than 2 ~ 4kg and then automatically pumped to fill this is a reason for the formation of the error. And the air pressure source through the pipeline to reach the fusion welding machine, due to the fusion welding speed, the first ultrasonic fusion of air pressure and the second or third time the air pressure stored in the pipeline also form an error, so 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, indeed, causing changes in energy output, and the important factors affecting the quality of precision. Of course, it must be listed as a diagnostic item.

Translated with DeepL.com (free version)