{"id":949,"date":"2023-06-07T12:25:01","date_gmt":"2023-06-07T12:25:01","guid":{"rendered":"https:\/\/motorforum.rfidepc.com\/motor-manufacturers\/?p=949"},"modified":"2023-06-07T12:30:07","modified_gmt":"2023-06-07T12:30:07","slug":"summary-of-possible-faults-and-solutions-of-mask-machine-during-debugging-and-operation","status":"publish","type":"post","link":"https:\/\/motorforum.rfidepc.com\/motor-manufacturers\/summary-of-possible-faults-and-solutions-of-mask-machine-during-debugging-and-operation.html","title":{"rendered":"Summary of possible faults and solutions of mask machine during debugging and operation"},"content":{"rendered":"

Summary of possible faults and solutions of mask machine during debugging and operation. <\/span>Specializing in the production of optical vision (non-contact) automatic inspection equipment!<\/span><\/p>\n

Summary of possible faults and solutions of mask machine during debugging and operation<\/span><\/strong><\/a><\/h2>\n

What should I do if there is a problem with the mask machine equipment<\/strong><\/a> during the debugging process? Let’s solve this problem today.<\/span><\/p>\n

Below we list the faults that will occur during the debugging process or use of mask machine equipment, and analyze the reasons and give solutions, hoping to help you.<\/span><\/p>\n

Fault 1, uneven welding, workpiece distortion.<\/span><\/p>\n

Solution: 1. Check whether the workpiece size is different.<\/span><\/p>\n

2. Check whether the operating conditions cause deformation of the working object<\/span><\/p>\n

3. Adjust the buffer speed or pressure.<\/span><\/p>\n

Fault 2: The base support is unstable.<\/span><\/p>\n

Solution: 1. Improve the support point where necessary.<\/span><\/p>\n

2. Base redesign.<\/span><\/p>\n

3. Replace with a hard base<\/span><\/p>\n

4. If a large area of bakelite board is tilted, it needs to be reinforced.<\/span><\/p>\n

Fault 3: The contact surface of the welding head, base and workpiece is not even.<\/span><\/p>\n

Solution: 1. Redesign the guard point to make the height uniform.<\/span><\/p>\n

2. Adjust the horizontal screw.<\/span><\/p>\n

3. Check whether the conditions are true.<\/span><\/p>\n

4. Check the shape and size of the workpiece size.<\/span><\/p>\n

5. The side is bent, and the workpiece is ribbed<\/span><\/p>\n

6. Modify the metallurgical tools to avoid the workpiece bending outward.<\/span><\/p>\n

Fault 4, the workpiece error is too large.<\/span><\/p>\n

Solution: 1. Tighten the tolerance of the workpiece.<\/span><\/p>\n

2. Re-modify the workpiece size.<\/span><\/p>\n

3. Check the operating conditions (pressure, delay time, welding timing, curing timing, etc.).<\/span><\/p>\n

Fault five, uneven welding, improper alignment of the workpiece.<\/span><\/p>\n

Solution: 1. Check whether the workpiece is offset during welding.<\/span><\/p>\n

2. Check whether the workpiece is aligned when checking the combination<\/span><\/p>\n

3. Check the parallelism of welding heads, workpieces and metallurgical tools.<\/span><\/p>\n

Fault six, lack of close contact on the joint surface.<\/span><\/p>\n

Solution: 1. Check the size of the workpiece.<\/span><\/p>\n

2. Check the tolerance of the workpiece.<\/span><\/p>\n

3. Check the position of the ejector pin of the joint surface.<\/span><\/p>\n

4. Check the alignment of the workpiece assembly.<\/span><\/p>\n

5. Check whether the workpiece is dented.<\/span><\/p>\n

6. Check the fit between the workpiece and the welding head<\/span><\/p>\n

7. Check whether the support of the metallurgical tool is appropriate.<\/span><\/p>\n

Fault 7: The ultrasonic welding results are inconsistent<\/span><\/p>\n

(1) The proportion of fills is too high<\/span><\/p>\n

Solution: 1. Reduce the fill.<\/span><\/p>\n

2. Check the operating conditions.<\/span><\/p>\n

\"Summary<\/span><\/p>\n

Summary of possible faults and solutions of mask machine during debugging and operation<\/strong><\/span><\/p>\n

 <\/p>\n

3. Change the species category, that is, change the short-term cone into a long line cone.<\/span><\/p>\n

(2) Uneven distribution of fills<\/span><\/p>\n

Solution: 1. Check the operating conditions<\/span><\/p>\n

2. Check the mold design<\/span><\/p>\n

(3) The quality of materials is poor<\/span><\/p>\n

Check the operating conditions<\/span><\/p>\n

(4) The fit of the workpiece is not good<\/span><\/p>\n

Solution: 1. Check the size of the workpiece<\/span><\/p>\n

2. Check the workpiece tolerance<\/span><\/p>\n

3. Check the operating conditions<\/span><\/p>\n

Fault eight, turn on the main switch of the power supply, the fuse will be blown<\/span><\/p>\n

1. Ultrasonic power board short circuit;<\/span><\/p>\n

2. Rectifier bridge short circuit;<\/span><\/p>\n

3. The power current impact is large, and the fuse capacity is too small;<\/span><\/p>\n

Fault nine, excessive ultrasonic welding<\/span><\/p>\n

Cause analysis and solution: 1. The outer size of the working object after overmelting is different;<\/span><\/p>\n

2. There is too much damage to the appearance of the working object.<\/span><\/p>\n

3. Adjust the lowest point fine-tuning screw;<\/span><\/p>\n

4. Replace the lower amplitude sonotrode.<\/span><\/p>\n

5. The welding time is too long and wants to be shortened.<\/span><\/p>\n

Fault ten, press the welding button sonotrode and then fall, but does not rise after welding.<\/span><\/p>\n

Cause analysis and solution: 1. Insufficient air pressure;<\/span><\/p>\n

2. Poor solenoid valve;<\/span><\/p>\n

3. Adjust the air pressure;<\/span><\/p>\n

4. Maintenance program board;<\/span><\/p>\n

5. The time adjustment switch is damaged;<\/span><\/p>\n

Fault 11, the overload light is on during operation.<\/span><\/p>\n

\"servo<\/p>\n

servo motor<\/a> – Precision servo-electric cylinder<\/strong><\/span><\/p>\n

Cause analysis: 1. The sonotrode is loose;<\/span><\/p>\n

2. Improper frequency adjustment;<\/span><\/p>\n

3. The sonotrode is ruptured;<\/span><\/p>\n

4. Excessive pressure;<\/span><\/p>\n

5. The power of the machine is too small.<\/span><\/p>\n

Fault 12, the power indicator light is not on, the vibration box fan is weak, can not vibrate or the welding strength is weakened.<\/span><\/p>\n

Cause analysis: 1. Low power supply voltage;<\/span><\/p>\n

2. The input transformer is damaged;<\/span><\/p>\n

3. The power socket is in poor contact.<\/span><\/p>\n

Fault 13, press the welding button, the welding head immediately drops and rises without vibration when touching the processed object.<\/span><\/p>\n

Cause analysis: 1. The descent stroke has not reached the welding position;<\/span><\/p>\n

2. Poor contact of the stroke switch;<\/span><\/p>\n

3. Poor pressure trigger system.<\/span><\/p>\n

Fault 14, the impact of the sonotrode rising or falling is too great.<\/span><\/p>\n

Cause analysis: 1. The buffer adjustment is not suitable;<\/span><\/p>\n

2. Buffer adjustment locked;<\/span><\/p>\n

3. The descent speed is set too high;<\/span><\/p>\n

4. Poor cylinder cushioning.<\/span><\/p>\n

Fault 15, air pressure, power supply, and sonotrode are normal but cannot be started.<\/span><\/p>\n

Cause analysis: 1. Poor contact of the emergency rising button;<\/span><\/p>\n

2. Poor program control circuit;<\/span><\/p>\n

3. The start button is damaged;<\/span><\/p>\n

4. The solenoid valve is damaged.<\/span><\/p>\n

Fault 16: Too little energy is input to work.<\/span><\/p>\n

Cause analysis and solution: 1. Increase the pressure of use;<\/span><\/p>\n

2. Extend the welding time;<\/span><\/p>\n

3. Increase the amplitude;<\/span><\/p>\n

4. Use models with higher power;<\/span><\/p>\n

5. The ultrasonic welding head has poor resonance.<\/span><\/p>\n

Fault 17. Too much energy input to work.<\/span><\/p>\n

Cause analysis and solution: 1. Reduce the pressure of use;<\/span><\/p>\n

2. Reduce welding time;<\/span><\/p>\n

3. Reduce the number of amplitude segments;<\/span><\/p>\n

4. Slow down the decline rate of the sonotrode;<\/span><\/p>\n

5. Insufficient welding.<\/span><\/p>\n

Fault 18: Use of materials with poor ffusion.<\/span><\/p>\n

\"Precision<\/p>\n

Precision servo-electric cylinder – Application of stepper motor in mask machine<\/strong><\/span><\/a><\/p>\n

(1) Use secondary materials<\/span><\/p>\n

1. Check the materials with the factory.<\/span><\/p>\n

2. Check the operating conditions.<\/span><\/p>\n

(2) Surface damage: the temperature of the sonotrode rises<\/span><\/p>\n

1. Check whether the sonotrode screw is loose.<\/span><\/p>\n

2. Check whether the sonotrode tool is loose.<\/span><\/p>\n

3. Shorten the welding time.<\/span><\/p>\n

4. Make the welding head heat dissipation and cooling.<\/span><\/p>\n

5. Check the interface between the sonotrode and the transmission sub.<\/span><\/p>\n

6. Check whether the sonotrode is broken.<\/span><\/p>\n

7. If the welding head is titanium, replace it with aluminum.<\/span><\/p>\n

8. If the sonotrode is copper, reduce the magnification.<\/span><\/p>\n

(3) Local bruising of the workpiece<\/span><\/p>\n

1. Check the size of the workpiece.<\/span><\/p>\n

2. Check the fit between the workpiece and the welding head.<\/span><\/p>\n

(4) The workpiece is improperly fitted to the metallurgical tool.<\/span><\/p>\n

1. Check whether the support is appropriate.<\/span><\/p>\n

2. Redesign metallurgical tools.<\/span><\/p>\n

3. Check the changes of mold and mold door workpieces.<\/span><\/p>\n

(5) Surface damage: alumina (from the sonotrode).<\/span><\/p>\n

1. The welding head is treated with hard chrome.<\/span><\/p>\n

2. Use heatproof plastic film mold (bag).<\/span><\/p>\n

(6) Surface damage: improper fitting of the sonotrode and the workpiece.<\/span><\/p>\n

1. Check the size of the workpiece.<\/span><\/p>\n

2. Redo the new sonotrode.<\/span><\/p>\n

3. Check the changes between the mold and the workpiece between the mold.<\/span><\/p>\n

Fault 19. The current is large and overloaded (above 7A) during welding.<\/span><\/p>\n

Cause analysis: 1. High air pressure;<\/span><\/p>\n

2. The output gear is too large and the inrush current is large;<\/span><\/p>\n

3. The buffer is too small;<\/span><\/p>\n

4. High trigger pressure and long delay.<\/span><\/p>\n

Fault 20, no ultrasonic output, ultrasonic welding is not possible.<\/span><\/p>\n

Cause analysis: 1. The ultrasonic crystal plate is bad;<\/span><\/p>\n

2. The ultrasonic vibrating plate is bad;<\/span><\/p>\n

3. Welding overload protection;<\/span><\/p>\n

4. The output loop fuse is broken.<\/span><\/p>\n

5. The gear switch is 0 or the contact is not good;<\/span><\/p>\n

6. The output line is not well connected or short-circuited.<\/span><\/p>\n

Fault 21. The size of the joint surface is uneven.<\/span><\/p>\n

Solution: 1. Redesign the joint surface.<\/span><\/p>\n

2. Check the operating conditions.<\/span><\/p>\n

(1) The workpiece is too tight<\/span><\/p>\n

1. Relax the fit of the workpiece.<\/span><\/p>\n

2. Relax the tolerance of the workpiece.<\/span><\/p>\n

(2) The workpiece cannot be aligned after welding, and there is no alignment when the workpiece is combined.<\/span><\/p>\n

Solution: 1. Add a solid pile between the two workpieces.<\/span><\/p>\n

2. If possible, design the metallurgical tool to guide the correction.<\/span><\/p>\n

(3) Improper support of the base<\/span><\/p>\n

Solution: 1. Redesign the appropriate support tool to raise the base in the necessary place.<\/span><\/p>\n

2. If the bakelite board is tilted, add a hard bracket.<\/span><\/p>\n

(4) Bending of the side walls<\/span><\/p>\n

Solution: 1. Increase the ribs on the side wall of the workpiece.<\/span><\/p>\n

2. If the bakelite board is tilted, add a hard bracket.<\/span><\/p>\n

(5) The tolerance of the workpiece is too large<\/span><\/p>\n

Solution: 1. Tighten the workpiece tolerance.<\/span><\/p>\n

2. Check the operating conditions.<\/span><\/p>\n

(6) During welding, the internal parts are damaged and the welding time is too long.<\/span><\/p>\n

Solution: 1. Increase the amplitude or pressure to reduce the damage of welding time.<\/span><\/p>\n

2. Adjust the buffer speed and delay time.<\/span><\/p>\n

Fault 22. The welding time is too long.<\/span><\/p>\n

Solution: 1. Increase the pressure or amplitude to reduce the welding time.<\/span><\/p>\n

2. Adjust the buffer pressure.<\/span><\/p>\n

(1) The fit of the contact surface of the welding head, workpiece and base is poor.<\/span><\/p>\n

Solution: 1. Check the parallelism of the sonotrode workpiece and the base.<\/span><\/p>\n

2. Check the fit between the welding head and the workpiece.<\/span><\/p>\n

3. Check the fit between the workpiece and the base.<\/span><\/p>\n

4. In the necessary place, pad the base.<\/span><\/p>\n

(2) The influence of workpiece deformation is too great.<\/span><\/p>\n

Solution: 1. Reduce the amount of influence of deformation.<\/span><\/p>\n

(3) The welding time is too long<\/span><\/p>\n

Solution: 1. Reduce the welding time.<\/span><\/p>\n

(4) The workpiece absorbs too much energy<\/span><\/p>\n

Solution: Reduce the amplitude.<\/span><\/p>\n

1. Lock the welding head;<\/span><\/p>\n

2. Press the sound wave check button and adjust the sound wave adjustment screw to minimize the current indication;<\/span><\/p>\n

3. Replace the mold;<\/span><\/p>\n

4. Replace related parts;<\/span><\/p>\n

5. Overhaul the power tube;<\/span><\/p>\n

6. Overhaul the power amplifier circuit.<\/span><\/p>\n","protected":false},"excerpt":{"rendered":"

Summary of possible faults and solutions of mask machine during debugging and operation. Specializing in the production of optical vision (non-contact) automatic inspection equipment! Summary of possible faults and solutions of mask machine during debugging and operation What should I do if there is a problem with the mask machine equipment during the debugging process? […]<\/p>\n","protected":false},"author":1,"featured_media":952,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[1],"tags":[39],"class_list":["post-949","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-stepper-motor-technology-stepper-motor-drive-knowledge","tag-applications-of-stepper-motors"],"blocksy_meta":[],"_links":{"self":[{"href":"https:\/\/motorforum.rfidepc.com\/motor-manufacturers\/wp-json\/wp\/v2\/posts\/949","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/motorforum.rfidepc.com\/motor-manufacturers\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/motorforum.rfidepc.com\/motor-manufacturers\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/motorforum.rfidepc.com\/motor-manufacturers\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/motorforum.rfidepc.com\/motor-manufacturers\/wp-json\/wp\/v2\/comments?post=949"}],"version-history":[{"count":3,"href":"https:\/\/motorforum.rfidepc.com\/motor-manufacturers\/wp-json\/wp\/v2\/posts\/949\/revisions"}],"predecessor-version":[{"id":955,"href":"https:\/\/motorforum.rfidepc.com\/motor-manufacturers\/wp-json\/wp\/v2\/posts\/949\/revisions\/955"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/motorforum.rfidepc.com\/motor-manufacturers\/wp-json\/wp\/v2\/media\/952"}],"wp:attachment":[{"href":"https:\/\/motorforum.rfidepc.com\/motor-manufacturers\/wp-json\/wp\/v2\/media?parent=949"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/motorforum.rfidepc.com\/motor-manufacturers\/wp-json\/wp\/v2\/categories?post=949"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/motorforum.rfidepc.com\/motor-manufacturers\/wp-json\/wp\/v2\/tags?post=949"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}