Section 9 - Troubleshooting

Table 9–IWelding Process Troubleshooting

Problem

Symptom

Possible Cause

Recommended Solution

 

Excessive weld flash

Weld Time or Distance are too large

Reduce Weld Time or Distance

 

 

 

 

Overwelding

Welded assembly

Incorrect flash trap design

Evaluate and correct flash trap design

 

dimensions are too

 

 

 

small

 

 

 

 

 

 

 

Low strength weld

Weld Time or Distance are too small

Increase Weld Time or Distance

 

 

 

Underwelding

Welded assembly

Material difficult to weld due to low friction

Degrease joint interface to remove mold release

coefficient

agent

 

dimensions are too

 

 

 

 

large

 

Consider changing material (i..e.. avoid PTFE)

 

 

 

 

 

 

 

 

 

Warped parts

Check part dimensions

 

 

 

 

 

 

Uneven weld interface

Check molding process conditions

 

 

 

 

 

 

Fixture and part are not parallel

Level fixture where necessary

 

 

 

Check that tooling is true to table

 

 

 

 

 

 

Poor alignment of parts in tool and/or

Change part or tool dimensions

 

 

fixture

 

 

Excessive weld flash

 

Improve part tolerance due to cavity

 

Low weld strength

Insufficient fixture support

Check for parts shifting during welding

Nonuniform or

 

 

 

 

Provide features in parts for rotational driving (i..e..

inconsistent

Failure when leak

 

weld joints

 

drive ribs or cavities)

tested

 

 

 

 

 

Part walls flexing during weld

Redesign parts with reinforcing ribs and/or tongue-

 

 

 

Part failure in service

 

and-groove joints

 

 

Excessive filler or uneven distribution

Reduce amount of filler

 

 

 

Improve processing conditions to ensure even

 

 

 

distribution of filler

 

 

 

 

 

 

Moisture in parts

Prevent moisture absorption after molding prior to

 

 

 

welding

 

 

 

Dry parts before welding

 

 

 

 

 

 

Deceleration too low

Increase spin deceleration as high as possible (if

 

 

 

set too high, welder will fault with tracking errors)

 

 

Vertical speed too high

Reduce speed to decreased spin torque required

Final part

 

 

 

orientation

Parts not aligned

 

 

Poor tuning

Determine and enter tool inertia correctly into Setup

different from

properly

programmed

 

 

 

 

 

orientation

 

 

Contact DUKANE for special tuning requirements

 

 

 

 

 

 

Parts not held properly by tool or fixture

Ensure tooling does not allow excessive play

 

 

 

 

Dukane Manual Part No. 403-570-01

Page  75

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Dukane 403570-01 user manual Problem Symptom Possible Cause Recommended Solution

403570-01 specifications

The Dukane 403570-01 is a sophisticated ultrasonic welding machine renowned for its versatility and efficiency in various industrial applications. Designed with advanced technology, this model is favored in sectors such as automotive, medical, textiles, and consumer goods for its ability to provide consistent and reliable weld results.

One of the main features of the Dukane 403570-01 is its state-of-the-art ultrasonic transducer, which converts electrical energy into mechanical vibrations. This high-frequency sound wave technology allows for the joining of materials without the need for additional adhesives or fasteners, making it an environmentally friendly and cost-effective solution for manufacturers. The transducer operates at a frequency of 20 kHz, optimal for producing strong and durable welds.

In addition to its transducer, the 403570-01 is equipped with an advanced generator that provides precise control over the welding process. This generator adjusts the energy output based on the materials being welded and the specific application, ensuring optimal settings for each job. The machine also features a user-friendly control panel that allows operators to easily program and monitor welding parameters such as time, power, and pressure.

The 403570-01 is designed for ease of use and maintenance. Its modular design simplifies servicing and allows for quick replacement of components, ensuring minimum downtime. Additionally, the machine’s lightweight construction enhances portability, making it suitable for both dedicated production lines and on-the-spot repairs.

Another significant characteristic of the Dukane 403570-01 is its versatility in handling various materials, including plastics, metals, and composites. This flexibility opens up a wide array of welding applications, from assembling intricate medical devices to automotive components. Furthermore, it features integrated safety measures that protect both the operator and the machine, reducing the risk of accidents during operation.

In summary, the Dukane 403570-01 stands out due to its advanced ultrasonic technology, user-friendly controls, and versatility in handling various materials. With its robust design and efficient welding capabilities, it is an invaluable asset for manufacturers looking to enhance their production processes and maintain high-quality standards.