Why does the ultrasonic welding machine fail, what are the common failures, and how to deal with them?

1. Turn on the power switch, the power indicator light is off, and there is no action.

Reasons: A. Poor contact between the power cord and the power socket; B. The power fuse of the machine is burnt.

  2. Turn on the power switch, the power indicator light is on, but there is no action, press the ultrasonic test button and there will be ultrasonic output.

Reason: A. The five-core wire connecting the base of the machine to the frame is open; B. The program circuit board of the machine is faulty.

3. Turn on the power switch, the power indicator light is on, but there is no action, and there is no ultrasonic output when pressing the ultrasonic test button.

Reasons: A. Check whether the emergency stop switch of the machine is pressed; B. The 110V or 24V power supply of the power transformer is abnormal; C. The program circuit board of the machine is faulty.

4. The machine works, but there is no ultrasonic output when pressing the ultrasonic test button and the work button.

Reasons: A. The 110V power supply of the power transformer is not normal; B. The 110V power line of the circuit board is disconnected.

5. The machine can work normally when the test button is pressed, but the machine does not work when the work button is pressed.

Reasons: A. The working switch is damaged; B. The five-core wire connecting the machine base and the frame is open.

6. When the ultrasonic test button is pressed, the indicated value of the power load meter is greater than 20% and cannot be adjusted down through the tuner.

Reasons: A. The transducer system is faulty; B. The power tube of the machine is burned.

7. The overload indicator light of the machine is on during welding, and the welding effect of the weldment is not ideal.

Reasons: A. The working air pressure of the machine is adjusted too much; B. The insertion weldment fits too tightly; C. The transducer system fails.

8. The welding effect of the weldment is not ideal, but the overload indicator light does not light up during welding, and the ultrasonic output is weak.

Reasons: A. The 24V power supply of the power transformer is abnormal, and the relay does not operate; B. The three-terminal voltage regulator LM7824 on the machine program board is damaged.

9. The welding effect of the weldment is not ideal, and the whistling sound can be heard by pressing the ultrasonic test button.

Cause: There is a problem with the assembly of the transducer system.

10. When the power switch is turned on, a weak whistling sound can be heard.

Reason: 1-2 power tubes on the circuit board were burned.

11. During the working process, the welding head is lowered, but there is no ultrasonic output, and the welding head does not reset.

Reasons: A. The air pressure adjustment of the machine is too small; B. The trigger preset button of the machine is damaged or improperly adjusted; C. The circuit board of the machine program board is faulty.

12. The ultrasonic output of the machine is normal, but the machine does not move.

Reasons: A. The air supply of the compressor pump is abnormal; B. The air circuit is blocked or the pneumatic components (solenoid valve, throttle valve or pressure regulating valve) are faulty.

13. The machine and transducer system are normal, but the welding effect is not ideal. Observe the power load meter when the machine is working, and the indicated value is less than 20%.

Reason: A. The descending stroke of the welding mold exceeds the allowable range of the equipment; B. The limit screw is not adjusted properly.

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