TL-24 US Welding Trblshoot

7/31/2019 TL-24 US Welding Trblshoot

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Ultrasonic Welding Trouble Shooting Guide

TechnologTL-24

PROBLEM PROBABLE CAUSES SOLUTIONS

Overweld Too much energy into the part. Reduce pressure, trigger orce and/or down speedWeld time too long. Reduce weld time/energy/ collapse.

Too much collapse. Change to lower ratio booster to reduce amplitude.

Digitally reduce the amplitude %.

Use Amplitude Proling.

Reduce down speed.

Change to lower gain horn i lowest booster is already in use.

Absolute distance too high. Recalibrate absolute distance and adjust.

Underweld Insucient energy into the part. Increase pressure, trigger, and/or down speed.

Insucient weld time. Increase weld time/energy/ collapse.Insucient amplitude. Use higher ratio booster to increase amplitude, i horn allows.

Change to higher gain horn i highest booster is already in use.

Energy loss into xture. I xture is urethane, change xture to rigid material such as

aluminum, stainless steel.

Evaluate part t in xture.

Presence o mold release. Eliminate use or clean parts ater molding.

Absolute distance too low. Increase absolute distance.

Moisture absorption by Dry parts as required.

hygroscopic material.

Non-uniform Warped part(s). Check part dimensions and fatness

weld around Check molding conditions.

Use higher trigger pressure.the joint

Non-uniorm horn ace amplitude. Have horn tested (and modied i needed) to establish uniormit

Lack o parallelism between horn, Shim xture where necessary, or level adjustable plate.

xture and part. Check part dimensions/fatness.

Insucient support in the xture. Check part t with horn using carbon paper.

Improve support in critical areas.

Change to a rigid xture.

I large sections o urethane are defecting, add rigid backup

y.


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Non-uniform

weld around

the joint(continued)

Inconsistent energy director height.

Wall fexure.

Knock-out pin location in joint area.

Improper alignment.

Non-uniorm horn contact.

Part tolerance.

Mold release.

Accumulation o llers in one area.

Moisture in joint area.

Correct mold to ensure uniorm energy director height.

Check molding conditions.

Add internal ribs to part.Increase wall thickness.

Modiy xture to prevent outward fexure.

Move knock-out pin location rom joint area.

Make sure knock-out pin marks are fush with surace.

Check or part shiting during welding.

Check alignment eatures in mating parts.

Check or parallelism o horn, part, and/or xture.

Check t o part to horn.

Check part t with horn using carbon paper.

Check or sinks.

Check or proper support in xture.

Tighten part tolerances.


Clean mating suraces.

I mold release is required, use a paintable/printable grade.


Reduce the amount o ller.

Use only short ber llers

Dry parts as required.

Inconsistent

weld results

part-to-part

Mold release.

Part tolerances.

Cavity-to-cavity variations.

Regrind/degraded plastic.

Clean mating suraces.

I mold release is required, use a paintable/printable grade.


Check part dimensions.


Run statistical study to see i a pattern develops with

certain cavity combinations.

Check part tolerances/dimensions.

Check or cavity wear.


Centralize gate location.

Check with molder or percentage o regrind


Reduce percentage o regrind (maintain below 10%).

Improve quality o regrind.


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Inconsistent

weld results

part-to-part(continued)

Drop in air line pressure.

Filler content too high.

Non-uniorm distribution o ller.

Incorrect joint design.

Poor part t.

Incompatible materials or resin

grades or lots.

Moisture in molded part.

(Usually nylon parts.)

Raise compressor output pressure.

Add surge tank with a check valve.

Check air supply line capacity vs. number o welders supplied.

Reduce percentage o ller.


Change type o ller, i.e., short- to long-glass bers.


Check mold design.

Redesign joint, check with Branson applications engineering.

Improve part dimensions.

Improve part tolerances.

Check molding conditions and improve.Check Branson Technical Inormation Sheet PW-1.

Check with resin supplier specications.

Check with Branson Applications Lab.

Receive parts dry-as-molded, bagged and sealed.

Dry parts, then weld.

Marking Lack o parallelism.

Shear intererence too great.

Energy director too large.

No joint design (butt suraces).

Improper t o part to xture.

Weld cycle is too long.

Readjust or parallelism between horn, part, and xture.

Check horn/part t.

Check part/xture t.

Level xture where necessary.

Reduce intererence.

Reduce energy director size.

Check or proper support.

Redesign xture.

Check or cavity-to-cavity variations.


Check or cavity-to-cavity variations.

Obtain a new horn.

Reduce weld time by adjusting amplitude and/or pressure.

Adjust Dynamic Triggering pressure.


4/6product nameTL-24


Marking

(continued)

Horn heats up.

Localized high spots in part.

Raised lettering.

Aluminum oxide (rom horn).

Overwelding: control mode

(time, energy, collapse or

absolute distance, peak power,

orce) too high.

Check or loose tip.

Reduce weld time. Cool horn with ambient or rerigerated air.

Check coupling between horn and booster.Visually check or cracked horn.

I horn is titanium, change to chrome-plated aluminum.


Check t o horn to part in xture.

Use polyethylene lm between horn and part.

Relieve horn.

Use recessed lettering where possible.

Chrome-plate or clear anodized horn and/or xture.

Use polyethylene lm between horn and part.

Readjust control parameters.

Flash (see also

non- uniform

welding)

Weld time too long.

Non-uniorm joint dimensions.

Energy director too large.

Shear intererence too great.

No joint design (butt suraces).

Reduce weld time.

Redimension joint.


Reduce size o energy director.

Reduce weld time.Reduce pressure.

Use textured surace.

Reduce amount o intererence.

Redesign joint to direct fash as required by application.

Misalignment

of welded

assembly

Lack o proper alignment eature

between mating parts.

Improper support in xture.

Wall fexure.

Add alignment eature to the mating part halves (i.e., pins and

sockets).

Redesign xture or proper support.

Shim xture where necessary.

I large sections o urethane are defecting, add rigid backup.

Add ribs or gussets to part.

Increase wall thickness.

I large sections o urethane are defecting, add rigid backup.


5/6


Misalignmentof welded

assembly

(continued)

Joint design improper dimension.

Part tolerance/poor molding.

Overwelding.

Redimension parts.



Reduce weld time/energy/pressure.

Internal

components

damaged during

welding

Too much energy into the part.

Long weld time.

Components improperly mounted, i.e.,

mounted too close to joint area, etc.

Location o components.

Reduce amplitude by changing to a lower gain booster, or utilize

Amplitude Proling.

Reduce pressure and/or down speed.

Reduce weld time/energy.

Adjust Dynamic Trigger pressure.

Investigate the use o alternate requencies.

Reduce weld time by adjusting amplitude and/or pressure.


Make sure internals are properly mounted.

Isolate internal components rom housing.

Move components away rom areas o high energy concentration.

Use nodally-mounted device to dampen energy locally.

Components should be in xture part.

Melting/fractureof part sections

outside of joint.

Too much energy into the part.

Sharp internal corners.

Excessive amplitude.

Internal stress.

Knit/fow lines.

Improper molding conditions.

Gate located near joint.

Reduce weld time.Decrease amplitude.

Decrease pressure.


Radius all sharp corners.

Reduce amplitude by changing to a lower gain booster, or

step amplitude.

Reduce horn amplitude i lowest booster is already in use.

Monitor/improve molding conditions.

Check part design.

Check molding process parameters.


Move gate area away rom joint.


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Technolog

Ultrasonic Welding Trouble Shooting Guide

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ISO CertificationsISO Certifications#22 Branson Ultrasonics Corporation 1999The Emerson logo is a trademark and service mark of EmersonElectric Co. Revised and printed in the U.S.A. 6/11

Branson Ultrasonics Corporation41 Eagle Road, Danbury, CT 06813-1961(203) 796-0400 Fax: (203) 796-9838www.bransonultrasonics.come-mail: [email protected]

Diaphragmming Excessive amplitude.

Long weld time.

Gate location.

Horn type and/or

placement.

Thin wall section.

Reduce amplitude.Utilize Amplitude Proling.

Reduce weld time by increasing amplitude and/or pressure.

Check gate placement.


Change shape o gate.

Add stiening ribs to the part.

Increase thickness o material on the underside o the gate area.

Eliminate horn contact over diaphragm area.

Check or horn/part t.

Use a horn with a nodal plunger.

Add vent hole in horn.

Increase wall thickness or add ribs.

Internal parts

welding

Internal parts same

material as housing.

Change material o internal part to incompatible material. Lubricate

internals.

Reposition internal parts to prevent contact during weld cycle.


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