28kHz Mask Straps Ultrasonic Welding Mask by Manual Spot Welding

• Application: Electronic
• Cooling Way: Air Cooling
• Control: Automatic
• Frequency Range: Low Frequency
• Electric Current: AC
• Style: Portable
• Model NO.: OKS-DH28K/35KHZ
• Power: Ultrasonic
• Transport Package: Carton Box/Foam
• Specification: 1500W/1000W/2000W
• Trademark: OKSULTRASONIC
• Origin: China
• HS Code: 854390
• Production Capacity: 10PCS/Per Month

Product Description

28KHZ Mask straps ultrasonic welding mask by manual spot welding 

Ultrasonic plastic welding machine

MODEL ULTRASONIC SERIES




INSTRUCTIONS

SPECIFICATION:

Frequency	35Khz/28khz
Output power	800W
Voltage	220-240VAC
Range of welding time	0.05-10/sec
Environment temperature	5-50ºC
Frequency tuning method	auto tuning
Automatic frequency adjustable range	±2
Moisture	≤85%RH
Currents	10A

CATALOG
PREFACE
CHAPTER1: working principle and electromechanical characteristics......................….1
CHAPTER2:Control function of ultrasonic welding system...............….....2
CHAPTER3:Machine installation and debugging.............................3
CHAPTER4: Adjustment of each part and preparation before melting.....................4~5
CHAPTER5 : Welding operation..............................…6
CHAPTER6: Matters needing attention..............................…7
CHAPTER7:Maintenance..............................…..8
CHAPTER8:Operation sequence diagram of ultrasonic welding................….…..9
CHAPTER9:Machine fault analysis and maintenance..................…... …..10
CHAPTER10:Parameters and specifications of ultrasonic welding machine........................11


Main products of the company

Specializing in the production and sales of ultrasonic plastic welding equipment, ultrasonic cleaning equipment, ultrasonic lace machine, ultrasonic nail equipment, high-frequency welding equipment, high-frequency heating machine, high-frequency synchronous fuse, multi-functional packaging and sealing equipment, metal spot welder, various brand transducers. Professional for various types of frequency ultrasonic, high frequency, multi-functional sealing packaging machine to make mold. Provide customer processing and leasing services, non-standard ultrasonic machine program. Maintain all brands of ultrasonic and high frequency equipment. Original accessories of all brands are sold. Second hand industrial equipment trading.







PREFACE
Ultrasonic plastic welding machine series is applicable to the fusion of thermoplastic products. This machine uses the principle of ultrasonic fusion to make the internal molecules of rubber vibrate to generate heat energy and fusion.
The oscillation cycle rate (20kHz ~ 15KHz) of this machine is in line with the international industrial band standard, and the output power of this machine is strong, and the automatic overload protection circuit protection device.
Please read this manual carefully before using the machine. If there are any defects or omissions in this manual, please contact our company.

Thank you for your cooperation!
Willing to work with you hand in hand to create tomorrow!







Chapter1  Working Principle And Electromechanical Characteristics

• Working Principle: the principle of ultrasonic welding is to produce high-voltage and high-frequency signals by the generator's self-excited oscillation. Under the high-frequency signals between the upper and lower electrodes, the processed plastic parts will polarize their internal molecules and generate heat by vigorous movement. The heat will be released to the welding shape under the pressure of the mold.
• Electromechanical Features:

1. Frequency stability: in strict accordance with the international radio interference Committee (CISPR), the machine adopts industrial band of 20kHz (or 15KHz), which is suitable for use in various regions, and is designed with frequency stabilizer and ultrasonic magnetic flux leakage suppressor to minimize external interference.
2. This machine adopts imported original electric ceramic transducer with strong output, high efficiency and good output waveform. It is equipped with famous high-power electronic tube with strong output, fast fusion and high working efficiency.
3. Unique design: the design of this machine is novel. It adopts electronic circuit automatic control and pneumatic actuator to complete all work processes, and the rising height of cylinder can be adjusted by corresponding time system, with even pressure and stable up and down. The time parameters of descending, welding, shaping and ascending are preset, electromagnetic counting, debugging and operation are simple and convenient, and novices are also easy to operate.
4. Current setting: the machine can set the required oscillation current with the help of an adjustable device and according to the size and thickness of the product, control the welding degree and ensure the consistency of the welding quality of the product.
5. Using solid-state full crystal ultrasonic vibration generator, it has strong vibration resistance, low power consumption, and can automatically track the cycle rate at the most suitable resonance frequency, so that the machine can be used for a long time.

 

1.  Safety protection: This machine is equipped with over-voltage and over-current protection device, which can automatically cut off the line in case of abnormal operation to protect the oscillating tube and rectifier, and avoid frequency drift caused by improper operation. All operating parts are provided with warning signs, both in Chinese and English, in line with international practice.
2. It is very convenient to change and adjust the welding head and die of transducer.
3. Genuine components: the procurement channel of the components of this machine is normal, all of which are genuine materials: Omron relay, Yadeke pneumatic components, and the transformer adopts CD structure, with large magnetic flux and small loss.        

 First pages






Chapter1 Control Function Of Ultrasonic Welding System
Model: 20kHz (or 15KHz) series
1,Pressure gauge: indication of working pressure.
2,Up buffer adjustment: the adjustment hole is located on the side of the machine, which can be adjusted properly to make the lifting inertia moderate.
3,Lowering buffer adjustment: the adjustment hole is located on the side of the machine, which can be adjusted properly to make the lifting inertia moderate.
4,Lowering speed adjustment: it is used to adjust the reasonable and appropriate lowering speed.
5,Setting of fusion time: adjust the length of fusion time, and vibrate for 0 ~ 9.99 seconds at the end of delay time.
6,Extension time setting: adjust the starting vibration time, and start vibration 0 ~ 9.99 seconds after the limit switch acts.
7,Power indicator: signal of power off.
8. Welding position window: check the condition of the plastic workpiece attached to the welding head during normal welding.
9. Body fixing handle: it is used to fix the body and support tightly.
10. Micro setting screw at the most paper point: it can be used to limit the rise and fall when the external dimension needs to be accurate during fusion.
11. Horizontal micro adjusting screw: adjust the four screws to make the welding head evenly attached to the plastic workpiece.
12. Emergency up button: for emergency up or manual up.
13. Welding down button: it is the action button for lowering in the automatic / manual operation mode.
14. Air pressure adjustment: working pressure adjustment and setting.
15. Counter: record the number of times of operation, with a zero return buckle.
16. Lowering speed adjustment: for adjusting the reasonable and appropriate lowering speed.
17. Selection switch (auto / manual / sound wave inspection) for automatic or manual operation, and button for no-load inspection of sound wave.
18. Setting of hardening time: adjust the end of vibration, and the cooling setting time of the melting part of plastic workpiece is between 0 and 9.99 seconds.

19. Working indicator light: signal display under working state.
20. Lifting hand wheel: it is used for lifting the whole machine body, with a stroke of about 5mm for each rotation.
21. Air filter: used for air filtration under air pressure.
22. Welding head: convey vibration energy to plastic workpiece for fusion.
               

Chapter III machine installation and commissioning
Machine installation and debugging:
1. Installation position: place the welding machine on the working platform, place the vibration box near the machine body, and make it easy for the operator to observe and adjust. The working table can bear the force of 120kg and the height is about 600-800mm. Besides, the machine shall not be placed in a place with severe moisture and dust, so as to avoid damage and leakage of components in the machine. Since there are heating devices (electronic tube, transformer) inside the machine, it should be kept away from the heat source for at least 1 meter, and the ventilation around the machine should be protected to facilitate heat dissipation.
2. Power supply installation: for the power supply voltage and input of the machine, please refer to the nameplate of the machine, and the ground wire must be installed. One end of the ground wire is grounded, and the other end is connected to the grounding knob behind the vibration generator to ensure safety. Please connect the power cord and plug behind the vibration generator to AC220V, 60 / 50Hz power supply.
3. Air supply: the completion of the mechanical action of the machine requires the promotion of compressed air. The machine needs to be equipped with air compressor of more than 1 ~ 2HP. Pay attention to adjust the pressure regulating valve so that the pressure indication is 4-6kg. Installation method of air source: lead the high-pressure air pressure pipe to clean and dry air pressure source and lock the air filter inlet joint on the fusion body with tube bundle.
4. Connection between the generator and the engine: connect the output cable plug and control cable plug of the engine to the outlet of the generator.



Chapter IV adjustment and preparation before fusion
1. Welding head
A. Wipe the cone, horn and head screw with alcohol or gasoline, then apply a thin layer of yellow grease on the head screw and the joint surface of the cone and head, and then lock the head screw on the head. Note: if there is any damage on the joint surface of expanding cone and welding head, the transmission efficiency of vibration will decrease, so it should be carefully maintained.
B. Turn the lifting hand wheel of the machine body to raise the machine body to a proper position (enlarge the space of the cone joint surface by about 300 mm
Fix 4 more welding head horizontal adjusting screws, and fix the expanding cone in the middle of its rotation range.
C. Rotate the welding head to enlarge the cone until it can not rotate.
D. Tighten the welding head by locking the backhand of the welding head (torque of about 300kg / cm2). At this time, pay special attention not to let the expanding cone rotate to prevent the twist of the turning tip. (if rotation is found, the 4 welding head horizontal adjusting screws shall be tightened again)
2. Erection of bottom formwork and adjustment of welding head
A. Adjustment preparation
(1) Open the air pressure source and adjust the pressure to 2KG/ CM2
(2) Place the bottom formwork on the base stably in the most convenient direction.
(3) There is a space of 100mm from the lifting hand wheel of the rotating machine to the working surface of the welding head.
(4) Turn on the main power switch on the vibration generator, and the power indicator will be on.
(5) Set the selection switch on the welding machine to the "manual" position.
(6) Inspect the depth of 100mm below the welding head to ensure the height of the welding head and the bottom mold.
B. Adjustment of welding head direction:
(1) Loosen the 4 horizontal adjusting screws, align the position of the welding head with the plastic workpiece, and turn the lifting hand wheel of the machine body to press the welding head onto the plastic workpiece.
(2) After adjusting the front and back of the bottom mold and the left and right positions to make the welding head fit the plastic workpiece, the bottom mold is in the most convenient operation direction.
C. Welding head horizontal adjustment:
(1) Tap around the welding head to make the welding head fit the plastic workpiece, fix 4 horizontal adjusting screws on average and then fix the bottom mold.
D. Height adjustment of welding head:
(1) Turn the lifting hand wheel of the machine body to lower the machine body to the welding position, align the red line of the window with the welding position, and tighten the fixing handle of the machine body, so that the machine body and the pillar are integrated.
(2) If the fusion of plastic parts is required to be confirmed for height, adjust the lowest trimming screw to the most appropriate position after the fusion of the ascending and descending cylinder.
E. Fusion preparation:
(1) Set the selection switch to the "manual" position, press the down / up button on the base, set the down speed and down / up buffer according to the situation, and adjust the working air pressure until there is no impact when lifting.
(2) According to the shape of the working object, set the number of output sections at appropriate positions. (test from low section to maintain service life) connect the sound wave inspection switch, and turn the sound adjustment screw to make the indication of vibration amplitude meter at the lowest mark. Note: press the sound wave inspection switch, and press three seconds to stop one second intermittent mode to maintain the vibrator life.

Chapter V welding operation
1, Welding operation: set welding, delay and hardening time
1. After finishing the above adjustment and preparation before welding, set the selector switch to the "automatic" position.
2. Press the down button of welding to test welding, and the welding machine can automatically work once.
3. Observe the working condition of welding and the shape of the work object after welding, adjust it to the welding head, bottom mold and reset the working pressure, sound wave output, welding time, try welding again, and adjust it repeatedly to the ideal welding condition of the work object. (the setting of delay time and hardening time shall be from a long time to an ideal condition. The setting of sound wave output and fusion time shall be set in a small and large increasing way to maintain the life of vibrator.)
4. After the ideal welding conditions are set, the operation can be carried out. Before production, the counter shall be reset to zero, sound wave inspection shall be conducted, and unnecessary items on the workbench shall be removed before operation.
2, Welding action description:
1. Welding head down: after the vibration generator is connected with the power supply and air source, press the two welding down buttons (weld) on the base, and the welding head will be down.
2. Delay time: when the welding head falls to the limit switch action, the delay time timer starts to count.
3. Weld time: at the end of the delay time, the weld time timer starts to count, and the vibrator is the same as the input vibration welding.
4. Hardening time: when the welding time is over, the hardening time timer starts to count.
5. Rise of welding head: when the hardening time is over, the welding head will rise, and the counter will accumulate once and complete one cycle action.


Chapter VI precautions
1. Please do not place the machine in a humid or dusty place. Do not place any fluid above the machine. Pay attention to the cleaning of the whole machine at ordinary times and wipe it at any time, but do not use liquid for cleaning.
2. Please do not press on the vibrating welding head to avoid burns. In case of danger during automatic operation, please press the emergency stop button.
3. Do not use the welding head not designed by our company on this machine.
4. During the sound wave inspection, when there is no load, the amplitude meter shall not exceed 1a. If it exceeds 1a, please adjust the sound wave adjusting screw. If it still cannot fall below 1A after adjustment, the welding head or the machine may be normal. Please contact our company for handling.
5. Press the sound wave inspection switch intermittently. Do not press it for more than three seconds to maintain the vibrator life.
6. During operation (with load), the amplitude shall not exceed the red area, (in the case of standard welding machine) if the pointer exceeds, to reduce the pressure, reduce the number of output sections, and adjust the sonic knob. If it cannot be lowered after adjustment, please contact our company for handling.
7. The vibration of this machine and the high-voltage line in the generator. Except for the adjustment of external operation, do not use the customer to do internal repair.
8. The welding head itself is determined by the fusion joint, and must match the resonance of the vibration system. Therefore, the welding head shall use the products designed and manufactured by our company to avoid damaging the vibration system.
9. This machine has a foot switch socket. Do not connect the foot switch for general operation, so as to maintain the safety of operators.
10. Pay attention to clean the air pressure source. If there is 1 / 2 water stagnation in the air filter of this machine, please remove it at any time. If there is too much water, the water of the air compressor must be removed from time to time.
11. The ground wire shall be grounded and shall not be connected to the power supply (ground wire) to prevent high-voltage leakage.
12. The vibrator and expanding cone shall not rotate more than 360 degrees to avoid breaking the high pressure line.

Chapter 7 maintenance
1. Welding head, bottom mold and plastic workpiece are always kept clean.
2. Regularly check whether the cable joint is loose.
3. Clean the air filter regularly. Use detergent or water instead of volatile flux.
4. Wipe the machine regularly, but do not use liquid for cleaning. Do not place heavy pressure or fluid above the vibration generator.
5. Keep the air in the workplace unblocked, and the surrounding temperature shall not be higher than 40 degrees (below 40 degrees).
6. The lifting sliding rod and rack shall be regularly smeared with yellow grease and kept clean.
7. When handling the machine, the vibration box shall be separated from the engine body (the cable socket shall be disassembled), and the handling shall be careful not to be impacted.
8. When it is not used for a long time, please wipe the appearance of the machine body clean, oil it for maintenance, cover it with a cover and place it in a dry and ventilated place.



















Chapter VIII ultrasonic operation sequence diagram




Chapter IX machine fault analysis and maintenance

	Fault phenomenon	Reason	Resolvent
1	Poor welding	1) Poor contact between welding head and bottom mold on plastic workpiece 2) Improper fusion time 3) Improper air pressure 4) Improper output power	1) Adjust the level of welding head and the position of bottom mold 2) Adjust welding time setting button 3) Adjust the pressure adjusting knob 4) Set the output adjustment at the appropriate band
2	Press the fusion button, and the welding head will drop immediately and rise when it touches the processed object without vibration	1) Falling stroke not reaching fusion position 2) Poor limit opening and closing	1) Turn the lifting hand wheel to make the welding position check the line alignment is at the welding position of the lifting cylinder. 2) Adjust its action position and change for repair
3	In operation Load light	1) Loose welding head 2) Improper wave adjustment 3) Broken welding head	1) Lock welding head 2) Readjust the sound wave 3) replacement
4	Press the welding button and the welding head will fall, but it will not rise after welding	1) Insufficient air pressure 2) Poor control circuit	1) Adjust air pressure 2) Time and space board replacement
5	The power indicator light is on, the fan of the vibration generator box turns weak, no vibration or welding turns weak	1) Insufficient supply voltage 2) Short circuit fuse blown 3) Poor contact of power socket	1) Change to a more stable power supply 2) Replace fuse 3) replacement
6	Air pressure, power supply and welding head are normal but cannot be operated	1) Poor contact of emergency up button 2) Poor control circuit	1) Check or replace 2) replacement
7	The impact of welding head rising or falling is too large	1) Emergency fit 2) Buffer adjustment locked 3) Lowering speed set too high	1) Readjust buffer 2) Check and adjust 3) Adjusting the lowering speed adjusting knob
8	Fusion fusion	1) The opening sizes of plastic workpieces after over melting are different 2) The surface of plastic workpieces is damaged a lot	1) Adjust the lowest micro survey screw 2) Replace the welding head with proper amplitude 3) Welding time is too long to be shortened
9	Turn on the main power switch and the fuse will be blown	Failure of generator body	Replacement

28KHZ Mask straps ultrasonic welding mask by manual spot welding