1. Internal damage to ultrasonic transducers, amplitude rods, or welding heads.
Problem description: These three components are made of piezoelectric ceramics or metal materials, and may experience fatigue cracks, delamination (detachment of piezoelectric ceramic plates from metal parts), and other issues under long-term high-frequency vibration.
Consequences: Once internal damage occurs, it can cause drastic changes in the resonant frequency and impedance of the entire system. The generator cannot be matched to the correct resonance point, resulting in a sharp decrease in output efficiency. A large amount of energy is reflected back to the generator, causing overcurrent and overheating of the power transistor (IGBT) and burning out.
How to determine: Usually accompanied by abnormal noise (whistling, breaking sound), sudden deterioration of welding quality, or equipment detecting an "overload" alarm but not being taken seriously.

2. The voltage of the power grid is unstable.

Problem description: Sudden and drastic fluctuations in the voltage of the factory power grid (such as voltage surges or drops caused by the start and stop of large equipment), or encountering lightning surges.
Consequence: Excessive voltage can directly penetrate the components in the circuit, especially the filtering capacitors and power switching tubes. If the voltage is too low, it can cause an abnormal increase in current and may also lead to overheating and burning.

3. Cooling system malfunction.

Problem description: The fan inside the generator is damaged, the air vent is blocked by dust, or the ambient temperature is too high.
Consequence: When the ultrasonic generator is working, the power tube will generate a large amount of heat. If the heat dissipation is poor and heat accumulates, the temperature of the components will exceed their rated value, resulting in performance degradation or even thermal breakdown, causing permanent damage.