Emerson 2000X Troubleshooting
Contents
1. Diaphragmming Excessive amplitude Reduce amplitude Utilize Amplitude Profiling Long weld time Reduce weld time by increasing amplitude and or pressure Gate location Check gate placement Check molding conditions Change shape of gate Add stiffening ribs to the part Increase thickness of material on the underside of the gate area Horn type and or Eliminate horn contact over diaphragm area placement Check for horn part fit Use a horn with a nodal plunger Add vent hole in horn be Thin wall section Increase wall thickness or add ribs Internal parts Internal parts same Change material of internal part to incompatible material Lubricate welding material as housing internals Reposition internal parts to prevent contact during weld cycle BRANSON Branson Ultrasonics Corporation 41 Eagle Road Danbury CT 06813 1961 203 796 0400 Fax 203 796 9838 www bransonultrasonics com e mail info bransonultrasonics com f ISO Certifications 22 Branson Ultrasonics Corporation 1999 The Emerson logo is a trademark and service mark of Emerson Electric Co Revised and printed in the U S A 6 112. Wall flexure SOLUTIONS Check for loose tip Reduce weld time Cool horn with ambient or refrigerated air Check coupling between horn and booster Visually check for cracked horn If horn is titanium change to chrome plated aluminum Check part dimensions Check fit of horn to part in fixture Use polyethylene film between horn and part Relieve horn Use recessed lettering where possible Chrome plate or clear anodized horn and or fixture Use polyethylene film between horn and part Readjust control parameters Reduce weld time Redimension joint Check molding conditions Reduce size of energy director Reduce weld time Reduce pressure Use textured surface Reduce amount of interference Redesign joint to direct flash as required by application Add alignment feature to the mating part halves i e pins and sockets Redesign fixture for proper support Shim fixture where necessary If large sections of urethane are deflecting add rigid backup Add ribs or gussets to part Increase wall thickness If large sections of urethane are deflecting add rigid backup PROBLEM Misalignment of welded assembly continued Internal components damaged during welding Melting fracture of part sections outside of joint PROBABLE CAUSES Joint design improper dimension Part tolerance poor molding Overwelding Too much energy into the part Long weld time Compo
3. glass fibers Check molding conditions Check mold design Redesign joint check with Branson applications engineering Improve part dimensions Improve part tolerances Check molding conditions and improve Check Branson Technical Information Sheet PW 1 Check with resin supplier specifications Check with Branson Applications Lab Receive parts dry as molded bagged and sealed Dry parts then weld Readjust for parallelism between horn part and fixture Check horn part fit Check part fixture fit Level fixture where necessary Reduce interference Reduce energy director size Check for proper support Redesign fixture Check for cavity to cavity variations Check part dimensions Check for cavity to cavity variations Obtain a new horn Reduce weld time by adjusting amplitude and or pressure Adjust Dynamic Triggering pressure PROBLEM Marking continued Flash see also non uniform welding Misalignment of welded assembly PROBABLE CAUSES Horn heats up Localized high spots in part Raised lettering Aluminum oxide from horn Overwelding control mode time energy collapse or absolute distance peak power force too high Weld time too long Non uniform joint dimensions Energy director too large Shear interference too great No joint design butt surfaces Lack of proper alignment feature between mating parts Improper support in fixture
4. If mold release is required use a paintable printable grade Check molding conditions Reduce the amount of filler Use only short fiber fillers Dry parts as required Clean mating surfaces If mold release is required use a paintable printable grade Tighten part tolerances Check part dimensions Check molding conditions Run statistical study to see if a pattern develops with certain cavity combinations Check part tolerances dimensions Check for cavity wear Check molding conditions Centralize gate location Check with molder for percentage of regrind Check molding conditions Reduce percentage of regrind maintain below 10 Improve quality of regrind PROBLEM Inconsistent weld results part to part continued Marking PROBABLE CAUSES Drop in air line pressure Filler content too high Non uniform distribution of filler Incorrect joint design Poor part fit Incompatible materials or resin grades or lots Moisture in molded part Usually nylon parts Lack of parallelism Shear interference too great Energy director too large No joint design butt surfaces Improper fit of part to fixture Weld cycle is too long SOLUTIONS Raise compressor output pressure Add surge tank with a check valve Check air supply line capacity vs number of welders supplied Reduce percentage of filler Check molding conditions Change type of filler i e short to long
5. Technolog TL 24 BRANSON Ultrasonic Welding Trouble Shooting Guide PROBLEM PROBABLE CAUSES SOLUTIONS Overweld Too much energy into the part Reduce pressure trigger force and or down speed Weld 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 Profiling Reduce down speed Change to lower gain horn if lowest booster is already in use Absolute distance too high Recalibrate absolute distance and adjust Underweld Insufficient energy into the part Increase pressure trigger and or down speed Insufficient weld time Increase weld time energy collapse Insufficient amplitude Use higher ratio booster to increase amplitude if horn allows Change to higher gain horn if highest booster is already in use Energy loss into fixture If fixture is urethane change fixture to rigid material such as aluminum stainless steel Evaluate part fit in fixture Presence of mold release Eliminate use or clean parts after 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 flatness weld around Check molding conditions the joint Use higher trigger pressure Non uniform horn face amplitude Have horn tested and modified if needed to establish uniformity Lack of parallelism b
6. etween horn Shim fixture where necessary or level adjustable plate fixture and part Check part dimensions flatness Insufficient support in the fixture Check part fit with horn using carbon paper Improve support in critical areas Change to a rigid fixture If large sections of urethane are deflecting add rigid backup S EMERSON Industrial Automation PROBLEM PROBABLE CAUSES Non uniform weld around the joint Wall flexure continued Knock out pin location in joint area Improper alignment Non uniform horn contact Part tolerance Mold release Accumulation of fillers in one area Moisture in joint area Inconsistent Mold release weld results part to part Part tolerances Cavity to cavity variations Regrind degraded plastic Inconsistent energy director height SOLUTIONS Correct mold to ensure uniform energy director height Check molding conditions Add internal ribs to part Increase wall thickness Modify fixture to prevent outward flexure Move knock out pin location from joint area Make sure knock out pin marks are flush with surface Check for part shifting during welding Check alignment features in mating parts Check for parallelism of horn part and or fixture Check fit of part to horn Check part fit with horn using carbon paper Check for sinks Check for proper support in fixture Tighten part tolerances Check molding conditions Clean mating surfaces
7. nents improperly mounted i e mounted too close to joint area etc Location of components Too much energy into the part Sharp internal corners Excessive amplitude Internal stress Knit flow lines Improper molding conditions Gate located near joint SOLUTIONS Redimension parts Tighten part tolerances Check molding conditions Reduce weld time energy pressure Reduce amplitude by changing to a lower gain booster or utilize Amplitude Profiling Reduce pressure and or down speed Reduce weld time energy Adjust Dynamic Trigger pressure Investigate the use of alternate frequencies Reduce weld time by adjusting amplitude and or pressure Adjust Dynamic Triggering pressure Make sure internals are properly mounted Isolate internal components from housing Move components away from areas of high energy concentration Use nodally mounted device to dampen energy locally Components should be in fixture part Reduce weld time Decrease amplitude Decrease pressure Adjust Dynamic Triggering pressure Radius all sharp corners Reduce amplitude by changing to a lower gain booster or step amplitude Reduce horn amplitude if lowest booster is already in use Monitor improve molding conditions Check part design Check molding process parameters Check molding conditions Move gate area away from joint Technolog TL 24 SOLUTIONS
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