Dukane iq series User Manual page 128

iQ
Series Ultrasonic Press System LE User's Manual
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Problem
Internal components of work piece damaged during welding.
Probable Cause
Excessive horn amplitude
Excessive exposure to ultrasound.
Too much energy transmitted into
the part.
The components are improperly
mounted (e.g., parts are mounted
too close to the joint area).
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Problem
Melting or fracturing of the part (outside of the joint area).
Probable Cause
Sharp internal corners/thin sections.
Excessive horn amplitude.
A long weld time.
Inherent stress.
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Page 120
Welding
Solution
Reduce the horn amplitude by changing to a lower gain
booster.
Dampen the excess horn amplitude.
Reduce the primary weld time and
increase the horn amplitude by changing to a higher gain
booster.
Reduce the horn amplitude.
Reduce the air pressure.
Reduce the weld time/primary weld characteristic.
Ensure that internal components are
mounted properly.
Isolate internal components from the part.
Move the internal components away from areas of high
energy.
Use an external device to dampen energy locally.
Solution
Radius all sharp corners.
Dampen motion for any damaged area, if possible.
Reduce the horn amplitude by changing to a lower gain
booster.
Decrease the weld time and
increase the horn amplitude and/or
the air pressure.
Check the molding conditions.
Check the part design.
Reduce the horn amplitude.
Dukane Manual Part No. 403-586-02
Continued