Precautions For Using The Transducer
As a professional manufacturer of high-power ultrasonic transducers, we are committed to providing customers with high-quality and reliable products. Due to the particularity of ultrasonic technology, our products rely on your careful cooperation and support to achieve their maximum function.
The main consideration when using an ultrasonic transducer is the matching with the input and output ends, followed by mechanical installation and matching dimensions. The frequency of the transducer is relatively intuitive. The frequency refers to the frequency measured by the transmission line method with a frequency (function) generator, millivoltmeter, oscilloscope, etc., or the frequency measured with a similar instrument such as a network impedance analyzer. Generally known as small signal frequency. The customer connects the transducer to the drive power supply through a cable, and the actual operating frequency is measured when there is no load or load after power on. Because the matching circuits of customers are different, the frequency of the same transducer in different driving power sources is different, and such frequency cannot be used as a basis for discussion.
1. Problems that easily occur during use
Common problems in use are chip cracking, weakness, overload, electrode ignition, electrode chip cracking, heat generation, wave leakage, and chip dislocation.
The causes of such problems can be classified into three categories. One is that there is a problem with the customer's drive power supply or mold and assembly. The second is that there is a problem with our transducer and horn. The third is that there is no problem with the products of both parties, but they do not match.
The first situation: there is a problem with the customer's drive power supply or mold
We recommend that customers actively find out the reasons, or communicate with our company's technical staff, and improve as soon as possible.
Case 2: There is a problem with our transducer and horn
This situation will also happen, but the possibility of discovery is relatively small. Our company specializes in producing all kinds of high-power ultrasonic transducers, and the quality of all products of the horn is at a high level in China. Moreover, with the ISO9000 quality certification system and strict craftsmanship and inspection, the quality of our transducer products is guaranteed. The pass rate of our products is 100%.
The third case: There is no problem with the products of both parties, but they do not match.
This is the most common, that is, the customer's drive power is good, the transducer is good, and the assembly is normal, but the parts do not match. The main parameters that cause the mismatch are the frequency and capacitance of the transducer. In view of this situation, the solution is for the customer to adjust the matching parameters of his drive power supply to suit our transducer. The second solution is for the customer to carefully study the parameters of his own chassis and the original transducer. All in all, as long as you can provide accurate parameter requirements, we can guarantee to provide you with a suitable transducer.
2. Precautions for assembly of various components
The main parts of the ultrasonic vibration system, such as transducers, horns, and tool heads, are connected by central bolts.
1. Check that the contact surface should be flat and smooth without scars. If there are scars, lightly polish with metallographic sandpaper above zero. It is required to be able to grind the defects flat without destroying the flatness of the contact surface.
2. Use a volatile and non-corrosive cleaning agent to clean the screws, screw holes and contact surfaces.
3. Thoroughly clean the screws, screw holes and contact surfaces.
4. All connecting screw holes should be perpendicular to the contact surface.
5. Apply a thin layer of butter or petroleum jelly on the contact surface before tightening, and be careful not to apply it to the connecting screws and screw holes.
6. Tighten the two parts carefully. Control the appropriate tightening torque according to the specifications of the connecting screws. When possible, it should be tightened appropriately.
7. If you loosen the joint surface again, you should not see any scars.
8. The vibration system has a uniform amplitude when touched by hand, no strange noise, and no local severe heating.
9. After working for a period of time, the joint surface should not be oxidized or ablated after re-opening, otherwise it means that the contact here is not good and the ultrasonic energy is lost seriously here.
3. The working temperature of the transducer
The transducer will generate heat when in use, which is mainly caused by three reasons. One is that the workpiece to be welded will heat up or the material processed by ultrasonic will heat up, or the mold (tool head) and the horn will heat up for a long time, and these heat will be transferred to the transducer. The second is the power loss of the transducer itself. Since 100% energy conversion efficiency cannot be achieved, the part of the energy lost must be converted into heat. The temperature rise will cause the parameter of the transducer to change and gradually deviate from the best matching state. What is more serious is that the temperature rise will cause the deterioration of the performance of the piezoelectric ceramic wafer. This in turn makes the transducer work worse and heat up faster, which is a vicious circle. Therefore, we must provide good cooling conditions for the transducer, which is generally air-cooled at room temperature; if necessary, cold air-cooling can also be used. Under normal conditions, the temperature rise caused by these two points is also normal, and under normal cooling conditions, there will be no major problems.
