1. General Information - ultrasonic plastic welding machine
Contents
1. WEIHAI KAER SONIC POWER CO LTD http www kaer welder com USER MANUAL Version 1 0 High end Type Ultrasonic Welding Machine WEIHAI KAER SONIC POWER CO LTD http www kaer welder com 1 General Information JS series high accuracy ultrasonic welder is mainly used for secondary joining of thermoplastics Compared with other traditional processes such as gluing electric heat joining or screw tightening it has remarkable advantages like high productivity sound welding quality environmental protection and energy saving among others 2 Structural characteristics and Working principle JS series high accuracy ultrasonic welder converts the electric energy into ultrasonic energy through the ultrasonic transducer i e high frequency mechanical vibration energy with the frequency exceeding the threshold of human s auditory sense Conducted to the plastic work piece through the welding head such ultrasonic energy melts down the joint face of the plastic work piece after rubbing the joint face violently with ultrasonic frequency at the speed of tens of thousands of times per second and with certain amplitude The transient pressure maintained at the work piece after stopping vibration makes two pieces of weldment solidify together in the form of molecular interlinkage Generally the welding time is less than 1 second but the weld strength compares favorably with that of a weldment itself By adopting electronic program2. No electricity for power source please check to confirm b Bad contact between power line and outlet please make due repairing c If fuse of equipment power supply is blown please change fuse with regulated nominal value 2 If non logic action is found please make inspection as suggested below Contact our service staff if it still can t be solved a Check if connection of logic cable conductor is normal b If two operational buttons are well connected c If air supply is normal d If emergency stop is reset and any error exists 3 Inthe event of unstable logic control check and handle it as follows If not successful please contact our service department in case of failure a Caused by the interference due to too close distance between the logic wire and the power output wire b The logic wire or logic board is in contact with the ground wire or too close to the ground wire c The connecting plug in units of the logic wire are in bad contact d Power supply is impure with interference factors e Supply voltage fluctuates greatly 4 Unstable welding quality a Nonuniform shape dimensions or material quality of the weldment Address No 54 Dalian Road Torch Hi Tech Science Park Weihai city Shandong province China CHINA KAER Tel 86 631 5690111 Fax 86 631 5690222 E mail info whkcs com Zip 264209 WEIHAI KAER SONIC POWER CO LTD http www kaer welder com improper design of fusion fa
3. control JS series high accuracy ultrasonic welder has such features as high automation built in full automatic protective circuit easy and safe operation stable and reliable running etc JS series high accuracy ultrasonic welder is applicable for butt welding of thermoplastics With its welding head replaceable according to the customers requirements the welder can also be used for processing such as rivet welding spot welding embedding cutting etc External view and all parts introduction as follows Address No 54 Dalian Road Torch Hi Tech Science Park Weihai city Shandong province China CHINA KAER Tel 86 631 5690111 Fax 86 631 5690222 E mail info whkcs com Zip 264209 WEIHAI KAER SONIC POWER CO LTD http www kaer welder com pressure detection air pressure governor Address No 54 Dalian Road Torch Hi Tech Science Park Weihai city Shandong province China CHINA KAER Tel 86 631 5690111 Fax 86 631 5690222 E mail info whkcs com Zip 264209 WEIHAI KAER SONIC POWER CO LTD http www kaer welder com Frequency deviation gauge Frequency control ry a Main Technical Parameters fuse holder load gauge earth terminal Frequency deviation indication logic line plug Ultrasonic testing ultrasonic line plug 1 Operating voltage monophase AC220V 5 2 Apparent power of transducer O01500W o2000W o2600W o4200W 3 Ultrasonic frequency o15K
4. following screen Address No 54 Dalian Road Torch Hi Tech Science Park Weihai city Shandong province China CHINA KAER Tel 86 631 5690111 Fax 86 631 5690222 E mail info whkcs com Zip 264209 WEIHAI KAER SONIC POWER CO LTD http www kaer welder com TPE ie GDA FEl 10L Operating modes position mode Time mode system debug Run Count 100 Figure 1 The main interface As shown the control system has three kinds of operating modes When powered the system default is the last working mode the default mode of operation highlights such as the time mode above Working mode selection method After power on press the or v select one of the three operating modes the highlighted one is the selected mode Position model working process This model is the application mode of other types so omitted Time mode working process When choosing time mode just as shown in figure 1 that time mode in operating model highlights In the reset of STOP button press the Start button into the working process of time model as follows Start gt release weld head gt delay time to the can be set release ultrasound gt release time to can be set gt cooling gt pressure holding time to can be set gt run count value plus 1 gt weld head ascend gt time interval to can be set gt tick signals the end Attention In working process if press STOP ultrasonic output will be cut off and weld head auto asce
5. Hz oc20KHz 4 Power supply noise no more than 100Vp_p 5 Momentary interruption permission less than 10ms 6 Working temperature 0 50 C 7 Equipment Storage Temperature 10 60 C 8 Environment humidity 20 70 no condensation 9 No source of vibration environment 10 Dust free non corrosive gases environment 3 Equipment Installation The equipment should be installed on the solid table board with a space of 150mm in the rear Since the welder has relatively higher requirements for power supply unstable voltage will exert direct influence on the welding effect or in an even more serious case result in shortening service life of power generator or burning it Areas with unstable voltage require a voltage Address No 54 Dalian Road Torch Hi Tech Science Park Weihai city Shandong province China CHINA KAER Tel 86 631 5690111 Fax 86 631 5690222 E mail info whkcs com Zip 264209 WEIHAI KAER SONIC POWER CO LTD http www kaer welder com stabilizer with fluctuation of output voltage below 2 and the output power double the nominal power of the welder There should be no fire source around and well ventilated and the installation should be smooth Before operating the welder make sure to connect the ground wire properly with ground resistance less than 0 5ohm Never operate the welder without proper grounding Before switching on please make sure that proper power supply and air
6. ce improper selection of welder power and amplitude of welding head b Unstable supply voltage unstable air pressure of air supply c Occurrence of frequency deviation protection or overload protection during welding d Unstable outputting of ultrasonic e Because the power output of this welder is adjusted automatically according to the load improper adjustment of the limit screw or the moving stroke of the welding head exceeding allowable stroke of the welder may result in the reduction of power output 5 Occurrence of frequency deviation protection during welding a Improper adjustment of frequency Raise the frequency slightly to surmount the influence of frequency rising on the transducer system under the action of pressure Ensure stable degree of frequency deviation with slight changes during welding b Parameters of the components of transducer system are matchless which is generally caused by too high natural frequency of the acoustic welding head c Serious heating up of the transducer system d Too high welding pressure 6 Unstable output of ultrasonic and indication of high load but very faint sense of ultrasonic vibration are mainly caused by the automatic tracking system falling out of synchronism with the following causes a The working frequency deviates seriously which causes the failure of frequency tracking b The transducer system is damaged seriously or the parameters deviate seriously c O
7. d indicator lights gt Power switch the main power control gt Earth terminal earth resistance should be less than 0 5 ohms gt Signal output 4 pin airline outlet gt Logic signal Input 7 pin airline outlet 2 Ultrasonic generator ajustment Confirm that the logic signal line and ultrasonic wire are connected normally Turn on the power jog ultrasonic testing if the deviation indicator light please adjust frequency control knob and jog ultrasonic testing button until the deviation indicator does not light At this time continue to fine tune frequency control button until the deviation gauge pointers indicate the minimum if continue to increase or reduce the frequency control button the deviation gauge pointers will indicate a large number again Attention 1 When regulating jog the ultrasonic testing button do not continue to press 2 Ultrasonic generator is well ajusted when deviation gauge points the minimum usually within three cells in no load no pressure state the load gauge points within two cells If the load gauge points a large number please contact the manufacturer 3 The less in the potential difference between natural frequency of transducer and working frequency of generator the better 3 LCD display normal working information Operating mode The operating modes of this control system are shown as follows in Figure 1 Turned on the power normally press OK button to enter the
8. kcs com Zip 264209
9. mail info whkcs com Zip 264209 WEIHAI KAER SONIC POWER CO LTD http www kaer welder com noise occurs or transducer system heats to over 50 C during operation Only after returning to normal can the production be continued If temperature of transducer system is still on the high side continuous operation shall only be allowed after cooling it down In special situation forced heat elimination measures should be taken 10 If fuse of the machine is blown a fuse with regulated nominal value should be adopted If fuse is blown for several times the machine should be stopped immediately for inspection Only after an error errors is located and proper repairing is conducted can it be put into application 11 Ensure a clean air supply When air filter is half full of water immediate discharging should be made 12 Lubricate mechanical movable parts at regular intervals remove dust from electric cabinet regularly after a long time operation if equipment is not used proper dust cover should be chosen to cover them 13 If heat emission fan gets blocked from running stop immediately for inspection Continuous use will not be allowed until normal condition is resumed 14 Special staffs shall be designed for debugging and maintaining the equipment 15 Please feel free to contact us should any error occurs No continuous use or optional alteration is allowed Press the operational button with both hands for operation Foot
10. nd to the pointed time tick indicate but run count does not count System debug mode working process Address No 54 Dalian Road Torch Hi Tech Science Park Weihai city Shandong province China CHINA KAER Tel 86 631 5690111 Fax 86 631 5690222 E mail info whkcs com Zip 264209 WEIHAI KAER SONIC POWER CO LTD http www kaer welder com When choosing system debug mode just as shown in figure 1 that system debug mode highlights Working process is shown as follows In system debug mode press OK to enter the Figure 2 screen Press welding head ascends action self locking Press v welding head descends action self locking Press Test release ultrasound action is not self locking F 7H i Wa 1 a Phy gt we EMG meee litter l gt FERS mee RH 1 gt System debugk Welding head ascend amp descend Ultrasonic testing ultrasonic releasing Cancel return to Figure 2 system debug screen Press Return debug end return to the main screen Welding head ascend to pointed place buzzer sounds Or show no operation in 120S automatically return to the main screen Parameter setting Parameter setting mainly means various time parameters as following in Figure 3 Meanings of parameters set Delay time refers to in time mode the time from welding head start descend to the release of ultrasund Welding time refers to the time of releasing ultrasound Pressure holding time refers to
11. operated switch is not available for this machine Any consequences resulting from self modification or self setting shall not be our responsibility 5 Equipment Operating Instructions 1 Ultrasonic generator instrument gt Load gauge used for the actual load current direction of generator also used as output power instructions When the load sheet indicates a large number the generator automatically cuts off the power output and frequency deviation indicator lights gt Frequency deviation gauge the deviation of natural frequency of Address No 54 Dalian Road Torch Hi Tech Science Park Weihai city Shandong province China CHINA KAER Tel 86 631 5690111 Fax 86 631 5690222 E mail info whkcs com Zip 264209 WEIHAI KAER SONIC POWER CO LTD http www kaer welder com transducer and woking frequency of generator When frequency deviation gauge indicates a large number the generator automatically cuts off the power output and frequency deviation indicator lights gt Frequency adjustment knob used to adjust the frequency of generator gt Ultrasonic testing button jog the button for testing whether ultrasound and generator are normal Commonly used for equipment debugging gt Deviation indicator when the deviation of natural frequency of transducer and working frequency of generator is too large or the load current exceed the maximum limit current the generator automatically cuts off the power output an
12. ring bundle 3 Automatically memorize the last working model after each power on 4 Run count reset In the working screen press Return this count clears 1 Pressure Sensor Setting CEN wra T Display screen DLTI S D a OUT 2 OUT 2 light EB up amp down button Press set in the display screen will switch to display P 1 P 2 P 3 P 4 In them P 1 P 2 is pressure detection range value of out 1 P 3 P 4 is pressure detection OUT 1 light set Address No 54 Dalian Road Torch Hi Tech Science Park Weihai city Shandong province China ESAR Tel 86 631 5690111 Fax 86 631 5690222 E mail info whkcs com Zip 264209 WEIHAI KAER SONIC POWER CO LTD http www kaer welder com range value of out 2 This machine uses only one output output 1 so only setting P 1 the lowest pressure detection range value and setting P 2 the highest pressure detection range value Press set switch to P 1 press up and down button to change set value Change P 2 in the same way Speed Control Valve Increase in speed regulation of and decrease speed adjustment is used to adjust the cylinder lifting speed the actual work needed to be adjusted depending on the speed 6 Troubleshooting for Frequently Asked Questions and Equipment Maintenance 1 When turning on power switch power indicator doesnt light and fan doesnt run and no response is seen to operation then possible causes are as follows a
13. supply are used the cable wires have been connected correctly the limit of welding head has been well set and the hands and other parts are at safe operation position 4 Application Notice 1 User shall not alter welding head at option or it may change frequency parameters of transducer system which will result in damages to transducer system and ultrasonic power generating system 2 Never leave both hands under the welding head when the machine is in operation or is testing ultrasonic sound to guarantee operating safety for operators 3 No direct contact is allowed between the welding head and the machine base or other metal fixtures during operation or test to ensure safe operation of the equipment 4 No start up or operation of this equipment is allowed before reliable connection to earth 5 Start up or operation is prohibited where high temperature and high dust environment exist 6 Stable operational power supply is required while operation beyond the rated voltage is prohibited T Earplugs are recommended for a long term operator to avoid injury by noise pollution 8 Proper ventilation facilities should be made available when processing noxious plastic parts or those with peculiar smell 9 Stop and check the machine immediately in case any abnormal Address No 54 Dalian Road Torch Hi Tech Science Park Weihai city Shandong province China CHINA KAER Tel 86 631 5690111 Fax 86 631 5690222 E
14. the time of welding workpiece cooling after releasing ultrasound Interval time ii to the interval of permitting next Pacang after cooling Address No 54 Dalian Road Torch Hi Tech Science Park Weihai city Shandong province China Tel 86 631 5690111 Fax 86 631 5690222 E mail info whkcs com Zip 264209 CHINA KAER WEIHAI KAER SONIC POWER CO LTD http www kaer welder com Delay time 2 01s Welding time 1 70s Pressure holding time 0 92s Interval time 1 00s Figure 3 parameter setting screen Achieving method is as follows In time mode or position mode press OK to enter the parameter setting screen shown in Figure 3 The default screen shows delay time parameters Delay time font highlights By choosing A or v to select delay time welding time or pressure holding time Press OK to enter the parameter values to be set Click A or v to add or subtract the selected parameter value Parameter value range 0 19 99S Uninterruptable press or v to add or subtract parameter value by interval of 0 1s Uninterruptable click A and v to add or subtract parameter value by interval of 0 01s Click OK to return to parameter setting screen Click Back to return to the main screen Notice Others 1 The system enter non work screen if there is no continuous operation then it will automatically return to working screen after 120s 2 Wiring attention best to separate the input and output wi
15. ver high load while starting ultrasonic causes the failure of starting At this moment shorten the delay time to bring the triggering mode under the mode of advance triggering or reduce the pressure to lower the starting load 7 The following cases may be caused by the faults of the transducer system especially the acoustic welding head a High no load current and unstable ultrasonic b Particularly serious heating up of the welding head and squealing of the welding head while testing ultrasonic c Constant frequency deviation protection or overload protection invalid Address No 54 Dalian Road Torch Hi Tech Science Park Weihai city Shandong province China CHINA KAER Tel 86 631 5690111 Fax 86 631 5690222 E mail info whkcs com Zip 264209 WEIHAI KAER SONIC POWER CO LTD http www kaer welder com frequency adjusting 7 Special Statement a This manual is presented based on JS series high accuracy ultrasonic welder Part of its framework may not comply with the model you choose Therefore this manual is only for your reference with your concrete model subject to the real machine b Weihai Kaer Ultrasonic Engineering Co Ltd reserves the right for interpretation and revision for this manual This manual is subject to change without notice Address No 54 Dalian Road Torch Hi Tech Science Park Weihai city Shandong province China ESAR Tel 86 631 5690111 Fax 86 631 5690222 E mail info wh
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