How to adjust the current of the ultrasonic welding machine


The welding head is installed (must be locked firmly) otherwise it will cause ultrasonic abnormality, and in severe cases, it will burn the ultrasonic generator.
After the welding head is installed, turn on the power and immediately turn off the ultrasonic detection switch. Note that if the ammeter index is normal, it is within 1 ampere. If it is abnormally high, fine-tune the frequency. The normal current of a 2000 watt machine is below 1 ampere, 2000-3200 watt The current of the ultrasonic machine is generally less than 1.5A; if the ultrasonic mold is smaller, the current is generally slightly smaller. The mold is larger, and the corresponding no-load current will be larger, but it should not exceed this range;
1 An abnormal ultrasonic mold will also cause the ultrasonic current to increase, including: a self-made ultrasonic mold b ultrasonic mold cracks, this phenomenon generally occurs in the slot position of the mold 　
2 Excluding the problem of the mold, if the current is still too large, then the problem of the transducer + horn must be considered. Remove the ultrasonic vibration system and observe carefully to see if there are cracks on the surface or the piezoelectric ceramic lens is broken. In this case, you need a professional ultrasonic repairer to repair it.

The design and production of ultrasonic molds has a set of strict specifications, and ultrasonic molds cannot be made privately.
The ultrasonic control electric box can also be called an ultrasonic generator. In many cases, we often encounter problems caused by the high load current of the ultrasonic welding machine. What should we do if the current is too high?

Assuming that the ultrasonic current is large, we first need to distinguish whether the components of the ultrasonic generator itself are damaged and the current is large, or the current caused by the problem of the ultrasonic load output. First, remove the ultrasonic output line and test the current of the ultrasonic generator without load. Assuming it is normal, this indicates the defect composition of the ultrasonic vibration system.

The high current of the ultrasonic welding machine is generally caused by the mismatch between the ultrasonic vibration system of the ultrasonic transducer and the ultrasonic generator. We mainly check the following problems.

The loosening of the screw between the ultrasonic die and the transducer leads to high current. The solution is to tighten the ultrasonic die with a special wrench to see if the die is not locked.

If the ultrasonic mold or die head is damaged, the solution is to check whether there are cracks on the surface of the die head, or install it to other ultrasonic systems for detection.

It is normal to change the vibrator of the ultrasonic transducer or the ultrasonic die. Assuming that the current is too high after changing these two parts, this is a normal situation. This problem can be solved only by stopping the adjustment of the ultrasonic frequency.

Solution of excessive current in ultrasonic inspection of ultrasonic welding machine:

Make sure that the screws on the welding head are tightly locked (must be locked firmly) and the welding head and the transducer should be kept clean.