Precise Mold Installation for Stable and Powerful Welding! The Golden Process for Ultrasonic Mold Installation and Debugging
I. Pre-Installation Preparation (Safety First)
1. Completely power down the equipment, shut off the air supply, and ensure the emergency stop button is pressed to eliminate accidental activation risks.
2. Verify the mold frequency matches the equipment (15K/20K), with no chipped corners, cracks, and intact threads.
3. Clean the transducer rod end face and mold contact surface-remove oil, metal shavings, and adhesive residue to ensure 100% energy transmission.
II. Core Mold Installation Steps
1. Hold the mold steadily with both hands. Align it vertically with the transducer rod threads and gently screw it in fully-avoid forcing or stripping threads.
2. Use a dedicated torque wrench to tighten to the specified torque. Secure fully without excessive force to prevent stripped threads or mold cracking.
3. After tightening, perform a no-load ultrasonic test: A clear, resonant sound without noise or vibration, coupled with stable current, indicates normal resonance.
4. Adjust the bottom mold to align horizontally with the welding head, ensuring even pressure and complete contact surface engagement.
5. Lightly press the workpiece to position it, secure the base mold, and complete overall alignment calibration.
III. Trial Welding and Mass Production
1. Perform an air pressure test first to confirm normal stroke and pressure.
2. Conduct trial welding on 1–3 pieces to inspect weld quality, appearance, and strength.
3. After fine-tuning parameters for stability, proceed to batch production.
IV. Prohibited Operations
- Do not install without cleaning
- Do not proceed to mass production without performing a no-load ultrasonic test
- Do not force welding with loose molds or significant leveling deviations
- Do not continue operation if abnormal noises or currents occur
Ultrasonic Mold Installation Checklist:
Power off, clean surfaces first, ensure vertical alignment without tilt.
Verify crisp ultrasonic signals without noise, level precisely before test welding.
Follow each step strictly-secure welds, high output!
