The ultrasonic transducer is the core component of the ultrasonic welding machine. Its function is to convert high-frequency electrical signals into mechanical vibration energy, amplify the amplitude through the horn and transmit it to the welding mold, and finally achieve precision welding of materials. The performance of the transducer directly affects the welding efficiency, accuracy and equipment stability. If the transducer fails, it may cause loose welding, equipment shutdown or even component damage, seriously affecting production progress.

Analysis of the Causes of Failure of Boda Ultrasonic Transducer

1. Problems with the driving power supply, mold, or assembly

Power supply abnormality: unstable output voltage, frequency deviation or insufficient power of the driving power supply will cause the transducer to fail to work properly.

Poor mold matching: Improper design of welding mold (such as amplitude mismatch, contact surface wear), or loose assembly and poor contact between mold and transducer will weaken the energy transfer efficiency.

Assembly process defects: The connection between the transducer and the horn or the mold is not tightened or there are impurities, resulting in energy loss or local overheating.

2. Internal fault of the transducer and horn

Material aging: Under long-term high temperature and high pressure environment, piezoelectric ceramics or metal parts may fatigue, crack or debond.

Component damage: internal wire breakage, insulation damage or electrode corrosion, resulting in interruption of signal transmission.

Resonance frequency deviation: Due to wear or deformation, the natural frequency of the transducer does not match the frequency of the driving power supply, and effective resonance cannot be formed.

3. Parameter mismatch

Frequency deviation: The nominal frequency of the transducer is inconsistent with the actual driving frequency, resulting in low energy conversion efficiency.

Power overload: Long-term overload operation may cause the transducer to overheat, degrade in performance, or even burn out.

Impedance mismatch: The impedance between the transducer and the power supply and horn does not match, resulting in energy reflection and equipment loss.

Apsonic Ultrasonic Welding Machine Professional Maintenance Process

Apsonic provides a one-stop solution for transducer failures. The process is as follows:

1. Customer consultation

Collect information such as the equipment model, fault phenomenon, and operating environment of the Boda ultrasonic welding machine to preliminarily determine the scope of the fault.

2. On-site inspection

Engineers bring professional testing instruments (such as impedance analyzers and oscilloscopes) to the site to check the drive power supply, transducer, mold and connection lines.

3. Troubleshooting

Accurately locate fault points (such as piezoelectric ceramic failure and welding surface wear) through frequency scanning, impedance testing, amplitude measurement and other means.

4. Maintenance plan formulation

Provide repair or replacement suggestions based on the diagnosis results, clarify the repair cycle and cost, and ensure the customer's right to know.

5. Customer Confirmation

The customer reviews the maintenance plan and signs the maintenance agreement after confirmation.

6. Repair implementation

Transducer maintenance: Replace piezoelectric ceramics, repair debonded parts, and re-tune frequency.

Drive power calibration: adjust the output voltage, frequency and power to ensure matching with the transducer.

Mold optimization: repair worn surfaces, adjust amplitude matching, or customize new molds.

7. Debugging and testing

No-load test: Verify whether the transducer resonant frequency, impedance and heat generation meet the standards.

Load test: simulate the actual welding process to detect welding strength, weld surface uniformity and equipment stability.

8. Delivery and Use

Provide maintenance reports and operation suggestions, track equipment operation status, and ensure long-term stable operation.

Apsonnic Ultrasonic is an ultrasonic plastic welding equipment manufacturer dedicated to the research and development, manufacturing and digestion of Swiss technology of high-end ultrasonic plastic welding equipment. It has mastered more than 100 scientific research patents and is also the first company in China to master servo-controlled pressure ultrasonic welding technology. It has strong technical strength. It is widely used in medical equipment, electronic equipment, printing consumables, plastics, non-woven fabrics, packaging, auto parts and other fields, providing a large number of stable and high-quality ultrasonic plastic welding equipment and application solutions for various industries and enterprises at home and abroad.