Ultrasonic welding product quality can not be stable, the most important factor is the output power can not be stable, so as to cause the formation of stable friction heat. And how to make the power output stable? 

Depends on: machine output power; HORN enlargement ratio; Pressure source; Voltage source and other four.

1. Machine output power +HORN expansion ratio = actual available power. From the point of view of planning and design, the stronger the output power of the machine is, the smaller the expansion of relative HORN is compared with the designed one when ultrasonic fusion is implemented for certain products.
Conversely, the smaller the output power of the machine is, the larger the expansion ratio of HORN's design is. For example: 2200W ultrasonic welding machine, HORN expansion ratio is 2.5 times. With a 3200W ultrasonic fusion machine, the HORN expansion ratio may only be 1.5 times. However, it is not emphasized that the output power of ultrasonic welding machine should be large, but to implement ultrasonic welding of a plastic product, give the most suitable environment for operation, which still need to consider the budget of cost, product functional requirements, welding standards and other considerations to plan a complete work of equipment and ultrasonic using skills.
2. After understanding the above key reasons affecting the quality of ultrasonic welding, the first step is to be familiar with and evaluate :(1) product quality requirements and functional standards; (2) Existing ultrasound equipment;
3. Determine the form and techniques of product design, such as ultrasonic waveguide fuse, product positioning and material). Since the available equipment resources are fixed, it is only right to use product design techniques to match the available equipment.
4, we have determined that there is no problem with human factors, but also the phenomenon of quality instability, the reason is only one: the influence of pressure and voltage. When we have been dealing with the phenomenon of unstable quality for many years, we also found that the quality standards that could not be reached during working hours unexpectedly reached the quality standards when everyone came off work and stopped using voltage and pressure at the same time. Therefore, it is also found that when multiple people or units use the same air pressure and voltage source, the air compressor will automatically fill the air when the air pressure in the air storage cylinder is lower than 2 ~ 4kg, which is a cause of error. And when the pressure source reaches the welding machine through the pipeline, due to the fast welding speed, the pressure of the first ultrasonic welding and the pressure of the second or third time remaining in the pipeline will also form errors, so that the periodic or non-periodic quality change will be formed. And the voltage is also due to the power company output for millions of people have the opportunity to use at the same time, the voltage drop generated at this time is not under our control, so the variable of pressure and voltage, really cause the change of energy output, and an important factor affecting precision quality. Of course it must be listed as a diagnostic item.

Solutions:
If the product quality requirements are relatively high, such as product requirements of less than 0.02m/m, or the fusion status of fusion wires is above 90%, the planning sequence must be:
1. Familiar with ultrasonic welding equipment;
2. Determine product functions;
3. Familiar with the corresponding relationship between ultrasonic wave and plastic welding;

4. Add voltage stabilizing devices as much as possible.