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超聲波焊接原理

超声波焊接时産品断裂怎么办

灵科超声波在服务市场的过程中，收集、总结了客户遇到最常见的问题。其中比较多的一条是：客户在检测超声波模具时发现，需要焊接的塑料件总是有断裂（非熔接部位）的情况，这样不仅导致了産品的不良、浪费人工材料，严重的还耽误了産品的交期、承担违约。不论是后期更换设备和服务商，还是边生产边改进，最终的损失都还是自己买单。

超声波焊接

那是什么原因导致産品在焊接过程中出现断裂呢？有的是焊接过程中操作上造成，有的是超声波焊接设备本身存在的问题。一起来看看超声波焊接机焊接时出现断的情况：産品为上下盖焊接，上面的小柱子并不参与焊接，但超声波模具需要避空。可能原因有以下几点：

1.定位工裝設計不合理

下定位工装设计尺寸偏大，塑料件放在里面有晃动，超声波焊接时産品有明显较大位移，使上焊头（掏空区域）碰到塑料柱。

超声波工装夹具

2、參數設置不合適

设定超声波提前超声，未压到産品前就超声，能量传递至塑料柱区域，也形成强烈的辐射振动

3、焊接能量輸出過大

超声波能量输出过大容易断，焊接时间是否过长、压力是否大了一点、産品压的太紧。

解決方法：

1、根據分析的原因，可能的解決方法有減少焊接時間或減少壓力或機頭後限位調高；

2、超聲波模具修改避空稍微大一點；更換超聲波發生器；調節超聲波模具位置等；

3、如果上述問題都解決不了，可能需要選擇頻率更高的超聲波焊接設備或重新設計超聲波模具，更換超聲波塑料焊接機的目的是選擇頻率更高/振幅小的高頻超聲波焊機，重新設計超聲波模具的目的是減少超聲波模具變比，減少能量輸出。

温馨提示：超声波焊接过程中，因不同産品焊接要求不同，对超声波焊接设备及工装夹具的要求便各不相同，在挑选设备及制作工装夹具的时候请优先参考專業的超聲波工廠。

超聲波焊接常見誤區

影響超聲波焊接的因素有哪些

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