What are the manifestations if the welding head of an ultrasonic welding machine is worn out?
When the welding head of an ultrasonic welding machine wears down, the most direct consequence is a significant decrease in welding quality, which may also be accompanied by abnormal equipment operation.
Core Performance Classification
- Welding Quality Issues
Weak Welds: Plastic parts are prone to detachment or cracking under stress because worn welding heads cannot effectively transmit ultrasonic energy.
Abnormal Weld Lines: Weld lines may be too wide, discontinuous, or show obvious overflow or material shortage.
Damage to Plastic Parts: Uneven welding head surfaces may scratch or damage the plastic part surface during welding, creating indentations or cracks.
- Abnormal Equipment Operation
Increased Noise: Wear on the welding head causes unstable vibration frequency, resulting in abnormal noises exceeding the normal range during operation.Increased Energy Consumption: To achieve the desired welding effect, the equipment needs to output more energy, which may be accompanied by an abnormal increase in current.
Triggered Protection Mechanisms: Some equipment may frequently trigger overload and overcurrent protection mechanisms due to energy transfer imbalances, leading to welding interruptions.
