Summary of possible failures and solutions of mask machine during debugging and operation

What should I do if there is a problem during the debugging of the mask machine equipment? Today, everyone will solve this problem. Below we enumerate the failures that may occur during the commissioning or use of the mask machine equipment, analyze the reasons, and give solutions, hoping to help everyone.

Fault 1. Uneven welding and distortion of the workpiece.

Solution: 1. Check whether the size of the workpiece is different.

2. Check whether the operating conditions cause deformation of the work

3. Adjust the buffer speed or pressure.

Fault two, the base support is not stable.

Solution: 1. Improve the support point where necessary.

2. The base is redesigned.

3. Replace with a hard base

4. If a large area of ​​the bakelite is inclined, it needs to be reinforced.

Trouble three, the contact surface of the welding head, base, and workpiece is not flat.

Solution: 1. Redesign the energy conservation point to make the height uniform.

2. Adjust the level screw.

3. Check whether the contrived conditions are true.

4. Check the shape and size of the workpiece size.

5. The side is curved, and the workpiece is ribbed

6. Modify the jig to avoid bending of the workpiece.

Fault four, the workpiece error is too large.

Solution: 1. Tighten the tolerance of the workpiece.

2. Re-modify the size of the workpiece.

3. Check the operating conditions (pressure, delay timing, welding timing, curing timing, etc.).

Fault five, uneven welding and improper alignment of the workpiece.

Solution: 1. Check whether the workpiece is offset during welding.

2. When checking the combination, whether the workpiece is aligned

3. Check the parallelism of welding heads, workpieces and jigs.

Fault six, the joint surface lacks close contact.

Solution: 1. Check the size of the workpiece.

2. Check the tolerance of the workpiece.

3. Check the position of the thimble on the joint surface.

4. Check the alignment of the workpiece assembly.

5. Check whether the workpiece is sunken.

6. Check the fit between the workpiece and the welding head

7. Check whether the support of the jig is appropriate.

Fault seven, the results of ultrasonic welding are inconsistent

(1) The proportion of filling materials is too high

Solution: 1. Lower the filling material.

2. Check the operating conditions.

3. Change the type of filling material, that is, change the short-line cone to the long-line cone.

(2) Uneven distribution of additives

Solution: 1. Check the operating conditions

2. Check the mold design

(3) Poor material quality

Check operating conditions

(4) Poor fit of the workpiece

Solution: 1. Check the size of the workpiece

2. Check the tolerance of the workpiece

3. Check the operating conditions

Fault eight, turn on the main power switch, the fuse is blown

1. The ultrasonic power board is short-circuited;

2. The rectifier bridge is short-circuited;

3. The start-up current has a large impact and the fuse capacity is too small;

Fault nine, excessive ultrasonic welding

Reason analysis and solutions: 1. The outer size of the work object after melting is different;

2. There is too much damage to the surface of the work.

3. Adjust the lowest point to fine-tune the screw;

4. Replace the welding head with a lower amplitude.

5. The welding time is too long to shorten.

Fault ten. Press the welding button and the welding head will drop, but it will not rise after welding.

Cause analysis and solutions: 1. Insufficient air pressure;

2. The solenoid valve is bad;

3. Adjust the air pressure;

4. Maintenance program board;

5. The time adjustment switch is damaged;

Fault eleven, the overload light is on during operation.

Reason analysis: 1. The welding head is loose;

2. Improper frequency adjustment;

3. The welding head is broken;

4. Excessive pressure;

5. The power of the machine is too small.

Fault twelve, the power indicator does not light up, the fan of the vibration box is weakened, cannot vibrate or the welding strength is weakened.

Reason analysis: 1. Low power supply voltage;

2. The input transformer is damaged;

3. Poor contact of the power socket.

Fault thirteen, press the welding button, the welding head will drop immediately and rise when the workpiece is not vibrated.

Reason analysis: 1. The descending stroke has not reached the welding position;

2. Poor contact of the travel switch;

3. Poor pressure trigger system.

Fault fourteen, the welding head rises or drops too much impact.

Reason analysis: 1. The buffer adjustment is inappropriate;

2. Buffer adjustment and lock up;

3. The descending speed is set too high;

4. The cylinder has poor cushioning.

Fault fifteen, the air pressure, power supply, and welding head are all normal but cannot be started.

Reason analysis: 1. Poor contact of the emergency up button;

2. The program control circuit is bad;

3. The start button is damaged;

4. The solenoid valve is damaged.

The sixteenth fault, the input energy is too little.

Reason analysis and solutions: 1. Increase the use pressure;

2. Lengthen the welding time;

3. Increase the amplitude;

4. Use models with higher power;

5. Poor resonance of the ultrasonic welding head.

Fault seventeen, too much energy input to work.

Reason analysis and solutions: 1. Reduce the pressure of use;

2. Reduce welding time;

3. Reduce the number of amplitude segments;

4. Slow down the descent speed of the welding head;

5. Insufficient welding.

Fault 18. Use materials with poor fusion properties.

(1) Use of secondary materials

1. Check the materials with the factory.

2. Check the operating conditions.

(2) Surface damage: the temperature of the welding head increases

1. Check whether the welding head screws are loose.

2. Check whether the welding head tool is loose.

3. Shorten the welding time.

4. Make the welding head radiate and cool.

5. Inspect the interface between the welding head and the transmission sub.

6. Check whether the welding head is broken.

7. If the welding head is made of titanium, replace it with aluminum.

8. If the welding head is made of copper, reduce the magnification.

(3) Partial bruises on the workpiece

1. Check the size of the workpiece.

2. Check the fit between the workpiece and the welding head.

(4) Improper fit between the workpiece and the jig.

1. Check if the support is appropriate.

2. Redesign the fixture.

3. Check the change of mold and mold door workpiece.

(5) Surface damage: alumina (from the welding head).

1. The welding head is treated with hard chromium.

2. Use anti-thermoplastic film molds (bags).

(6) Surface damage: improper fit between the welding head and the workpiece.

1. Check the size of the workpiece.

2. Redo new welding head.

3. Check the change of the workpiece between the mold and the mold.

Fault nineteen, the current is too large and overload (above 7A) during welding.

Reason analysis: 1. The air pressure is too high;

2. The output gear is too large and the impact current is large;

3. The buffer is too small;

4. High trigger pressure and long delay time.

Fault 20. There is no ultrasonic output and ultrasonic welding cannot be performed.

Reason analysis: 1. The ultrasonic crystal board is broken;

2. The ultrasonic vibration plate is broken;

3. Welding overload protection;

4. The output circuit fuse is broken.

5. The gear switch is at 0 position or the contact is not good;

6. The output line is not connected well or short-circuited.

Fault 21. The size of the joint surface is not uniform.

Solution: 1. Redesign the joint surface.

2. Check the operating conditions.

(1) The workpiece is too tight

1. Relax the fit of the workpiece.

2. Relax the tolerance of the workpiece.

(2) The workpiece cannot be aligned after welding, and the workpiece is not aligned when combined.

Solution: 1. Add a fixed pile between the two pieces of work.

2. If possible, design tools to correct.

(3) Improper support of the base

Solution: 1. Redesign the appropriate support fixture and raise the base where necessary.

2. If the bakelite is inclined, add a hard bracket.

(4) The side wall is bent

Solution: 1. Increase ribs on the side wall of the workpiece.

2. If the bakelite is inclined, add a hard bracket.

(5) The tolerance of the workpiece is too large

Solution: 1. Tighten the tolerance of the workpiece.

2. Check the operating conditions.

(6) During welding, the internal parts are damaged and the welding time is too long.

Solution: 1. Increase the amplitude or pressure to reduce damage to the welding time.

2. Adjust the buffer speed and delay time.

Fault 22, welding time is too long.

Solution: 1. Increase the pressure or amplitude to reduce the welding time.

2. Adjust the buffer pressure.

(1) The contact surface of the welding head, workpiece, and base is poor in fit.

Solution: 1. Check the parallelism between the welding head workpiece and the base.

2. Check the fit between the welding head and the workpiece.

3. Check the fit between the workpiece and the base.

4. Level up the base where necessary.

(2) The influence of workpiece deformation is too great.

Solution: 1. Reduce the influence of deformation.

(3) Welding time is too long

Solution: 1. Reduce splicing time.

(4) The workpiece absorbs too much energy

Solution: reduce the amplitude.

1. Lock the welding head;

2. Press the sonic check button and adjust the sonic adjustment screw to minimize the current indication;

3. Replace the mold;

4. Replace related parts;

5. Overhaul the power tube;

6. Overhaul the power amplifier circuit.