The lack of an ultrasonic signal comprises one of the most basic, and yet, most frustrating issues surrounding ultrasonic welding equipment. A surprisingly wide array of issues can prompt this fundamental concern.
The power supply often forms the basis of ultrasonic signal issues. If the supply fails to send proper electrical energy to the converter, the necessary signal will fail to appear. Overheating sometimes underlies signal-related power supply concerns, especially if vents are covered or fans don't work properly. A blown power supply line fuse could also be to blame.
If the power supply has been deemed in working order, the solution may lie in the converter responsible for creating mechanical vibrations via electrical energy. A simple adjustment to the connection between the converter and the booster may do the trick, although the connection between the booster and the horn could also prove problematic.
Depending on the scope of the problem, part replacements may prove necessary. Such fixes may resolve sonics issues quickly — or they may reveal the need for additional repairs. As soon as you find the weak link in the chain, you can determine why your system lacks a signal and how the underlying issue can be prevented in the future.
A problematic horn will cause an overload error. If cracked, for example, the horn could draw excessive power, evidenced by an increase in necessary wattage. A diagnostic scan can prove invaluable, as internal cracks may not be visible to the naked eye, and thus, could be difficult for the average user to detect. Continuously running bad tooling will create more problems by taking out the equipment upstream.