King Ultrasonic CO KWL3215, User Manual

Page 1: ...KWL3215 KWL4215 King Ultrasonic CO LTD Ultrasonic Plastic Welder User s Manual ...

Page 2: ...hes without the consent of King Supersonic Co Ltd to avoid danger 7 Operating the machine by more than two people is strictly forbidden 8 Check screws in each section of the machine each month for tightness 9 Air pressure hoses should be checked every three months If any brittleness or abnormality is founded the hoses should be replaced immediately to avoid danger It is recommended to place all pi...

Page 3: ...ponents 3 Air Circuit Diagram III Operation Guidelines 1 Notes 2 Operating Principles 3 Mechanism Principles 4 Installation Procedures 5 Mold Adjustment Procedure 6 Ultrasonic Welding Steps Basic Steps for Using Ultrasonic Plastic Welder of King Ultrasonic CO LTD IV Circuit Diagram V Welding Problems and Solutions ...

Page 4: ...osition of Electric Components 24 Power Switch 25 Amplitude Gauge 26 Overload Indicator 27 Power Indicator 28 Amplitude Adjusting Button 29 Electrical Box 30 Earth Wire Socket 31 Power Cord 2 Name and Function of Body Components 1 Triplet Set A 5 16 air pressure hose is connected to a dry and clean air source to provide the machine with compressed air Note When the inside of the hose is half full ...

Page 5: ... the welding head In general the welding head has approx 1 2 wavelength and the material has good acoustic property and tensile strength Residual oxides are easily left on the work piece when using the welding head made of aluminum alloy However this problem can be solved with hard chromium or heatproof plastic film Note The welding head should not be modified without prior consent The spacer or e...

Page 6: ...rasonic wave inspection position when the power cord is unplugged 17 Counter Record the operating times of the work piece Press the black button to zero the counter 18 Rise Governor Rotate it anti clockwise to increase the rise speed or rotate it clockwise to decrease the rise speed of the vibrating cylinder Note The nut between knobs is used to lock the governor and should be tightened after adju...

Page 7: ...ed depending on the work 26 Overload Indicator It lights up and the operation stops when the ultrasonic oscillator of the machine operates abnormally 27 Power Indicator Indicate whether power is on or off 28 Amplitude Adjusting Button Select the appropriate output amplitude for the welding head to meet the requirements of the work piece 29 Electrical Box Accommodate the air pressure electrical con...

Page 8: ...d AC220V three phase 3P 32 Iron Male Connector Air pressure is delivered to the connector Ground Equipment A Equipment B Ultrasonic Equipment C Equipment A Equipment B Ultrasonic Equipment C Ground Ground Equipment A Equipment B Ultrasonic Equipment C ...

Page 9: ...8 Position of Components 3 4 5 18 19 7 8 25 16 15 14 13 20 11 12 26 27 24 17 31 22 23 22 Position of Components 10 Position of Components ...

Page 10: ...9 2 9 2 1 22 23 22 6 Position of Components ...

Page 11: ...10 組件位置圖 28 29 32 10 30 31 Position of Components ...

Page 12: ... 1 Copper Connector 1 4 2 Quick Bend 1 4 Ø8 3 Quick Bend 1 4 Ø8 4 Water filter FB300 5 Iron Male Connector 6 Oil Filler FL300 7 Pressure Governor R04 200 8 Pressure Gauge 1 4 9 Quick Bend 1 4 Ø8 10 Quick Bend 1 4 Ø8 11 Solenoid Valve ...

Page 13: ...20V 60Hz is transformed to 20Hz or 15KHz high voltage energy and then to mechanical vibration by the oscillator This mechanical vibration is then transmitted to the work piece via the spacer and welding head HF impact effect is produced on the contact of the work piece via air pressure The oscillator and spacer are accommodated in the vibrating cylinder and connected to the external welding head T...

Page 14: ...rop the body of the machine by about 5mm 10mm 6 Turn the pressure governor to increase the pressure higher than 3kg cm2 Tighten the fixed screws in a diagonal sequence Do not completely tighten the screw on any side at one time Then tighten the fixed nuts 7 Tighten the fixed handles of the large column and screw the fixed screws of the base 8 Push the emergency rise button to raise the welding hea...

Page 15: ...he surface such as painting electroplating and mold release agent 8 Ambient temperature of the work piece 9 Mold adjustment preciseness 10 Harmonization of different plastic materials 11 External and internal damping such as the obstruction of the gauge base or internal objects 12 Welding head design 13 Support design of the base 14 Amplitude of the welding head 15 Energy delivered to the work pie...

Page 16: ...e curing time Trial run Check the amplitude gauge Overload Display the amplitude with load 1 Decrease the pressure 2 Reduce the drop speed 3 Reduce the delay on time 4 Reduce the level of amplitude 5 Replace with a model with higher power Check the product Bad Good Bad Welding 1 Increase the welding time or pressure 2 Increase the level of amplitude 3 Replace with a model with higher power Over we...

Page 17: ... 250V 5W 100 2W 6 8 R12 BA159 BA 159 0 22 15A 15A 90 110 0 1uf 1000V 1M 1M 0 267uf 0 517uf 0 02uf 56 50 44 36 0 1 2W 120 1 2W 120 0 1uf 250V 0 1uf 250V 5W 15K 5W 15K 100uf 100V 100uf 100V 2W 6 8 2W 6 8 BA 159 BA159 BY 229 BY 329 0 01uf 630V 0 01uf 630V 5W 100 5W 100 5W 100 5W 100 BY299 BY329 BY299 BY329 I N4004 I N 4004 0 1uf 50V 2W ZY12 12V 2W ZY12 12V I N 4004 M Y 2 D C24 2N 6565 BT169 BC639 4N2...

Page 18: ...17 IV Control Wiring Diagram Control System Wiring Diagram ...

Page 19: ...e thickness of the joint face is not even The work piece is too tight Reduce the size of the energy conducting point Decrease the welding time Decrease the pressure Decrease the effect of the deformation Decrease the welding time Re design the joint face Check the operation conditions Reduce the bonding of the work piece Reduce The tolerance of the work piece The work piece can t be aligned after ...

Page 20: ...housing Move the internal parts away from energy area or change the press position Design and appliance to offset local energy The area outside the joint face of the work piece is molten or broken The interior angle is too sharp The vibration amplitude is too high The welding time is too long Internal stress Inappropriate operation conditions Blunt the sharp angle Reduce vibration amplitude Increa...

Page 21: ...te The backside of the rivet bottom is damaged The base has improper supports The pressure is too high Try to use a metal support for the base Reduce the pressure and place a metal plate between the rivet and base to dissipate heat and reduce the risk of danger After riveting the work piece remains loose The melted rivet does not completely cure before the pressure is removed The stroke of the wel...

Page 22: ...s are easily pulled out after embedding The bore size is improper and the plastic could not fully cover the embedded object After being completely embedded the object is continuously hammered with the welding head The nut is embedded under the plastic surface The inner diameter of the washer is bigger than the external diameter of the nut The screw is so long and it pushes the plastic and pulls ou...

Page 23: ...bed in a normal position The embedded object is blocked in the bore The lower part of the embedded object is inappropriately supported and the ultrasonic energy cannot be distributed over the plastic around the embedded object Reduce the pressure or delay on time The base should be firm and rigid and directly support the lower part of the bore The plastic fills up the nut bore The length of the em...

Page 24: ...o shorten the time The plastic material flows over the surface of the embedded object Embedded too deeply The welding time is too long There are too many conditions affecting the embedding Use the stopper nut to adjust the height Adjust the welding time The welding head temperature rises The amplitude is too high The temperature rises due to friction between metal pieces It is normal Reduce the am...

Page 25: ...dustrial Park Taipei 242 Taiwan TEL 886 2 22980299 16 Lines FAX 886 2 22980399 Taichung Branch No 22 2 Ln 171 Wenxin S 6th Rd Nantun Dist Taichung City408 Taiwan TEL 886 4 2223301 2223308 FAX 886 4 2223270 Tainan Branch No 356 Guoping Rd Anping District Tainan City 708 Taiwan TEL 886 6 2990566 2991134 FAX 886 6 2995295 Website http www ksonic com tw Rev 0601 ...