Vibration welding machines and equipment: Setup, Usage, and Troubleshooting for Professionals

Equipment Operation

You can operate the FW-801 Vibration welding machines and equipment according to the operation manual or according to Jfortune’s staff.

Use

Vibration friction welding is a new welding technology. It does not use other connections or self-consuming materials, such as adhesives, solvents, etc.
It can be a large number of all kinds of thermoplastic parts welded together, and only plastic parts themselves are welded together by welding process.

Almost all thermoplastic materials can be welded with vibration friction welding technology, whether they are injection molding, extrusion, pressure, foaming, or hot forming.
This binding method is particularly favorable for the crystallization of resins, e.g. aldehyde, nylon, thermoplastic resin, polyethylene and polypropylene.
Other materials, including cellulose, thermoplastic rubber, fillers, reinforced resins and plastics that show the properties of moisture absorption are also easily welded.

In either case, the two parts to be welded must be the same as the thermoplastic resin or the compatible resin.
Most heat plastic resin can be very good welding in the same material with their own, but there are also a number of different materials can be welded together, for example: polycarbonate on polypropylene, ABS on polypropylene.
But, in general, different materials can not be very good welding.

Misuse

In the daily production process there will be some inappropriate use of Vibration welding machines and equipment.
We again emphasize the prohibition of the following incorrect operation:

1. The vibration welding equipment does not allow any of the items stored at the top, otherwise there may be collapsed, damaged vibration welding machines and equipment structure, and even damage to the personnel on the site of the vibration welding machines and equipment.

2. The sound insulation cover on the front of the equipment safety door is not allowed to store any articles, and no personnel to rely on or sitting in front of the security door noise cover. Once the safety door is closed, the items stored in the front sound insulation cover can be dropped, resulting in damage to the goods and personnel injury.

Fixture

The fixture is designed according to the requirement of vibration welding machines and equipment by Jfortune.
If a customer wants to use a fixture designed by another company, please notify Jfortune to confirm whether the fixture is satisfied with the equipment requirements.
Jfortune is not responsible for the loss caused by the use of the fixture without the confirmation of Jfortune.
If you want to install or remove the fixtures provided by other companies, please follow the instructions.

Questions, Problems, Opinions

If you have any questions and comments, please contact us:

Suzhou Jfortune Precision Machinery Co., Ltd
Room 1715, Lejia Building 1, No.8 Jiarui Lane,
Suzhou Industrial Park. Suzhou, Jiangsu China.

Safety Warnings and Precautions

Please read the following carefully before installing and using the vibration welding machines and equipment:

Security Warning

1. In view of the great weight of the equipment, only professional person can use such as forklifts to move or install the device.

2. In order to prevent electric shock, vibration welding machines and equipment must be reliable grounding, grounding resistance must be in line with local relevant work industry safety regulations and shall be subject to periodic special inspection.

3. There is high pressure in the presence of vibration power, do not run the equipment in the electric control cabinet door open.

4. The main power supply must be cut off when the parts are replaced or repaired.

   

5. The vibration welding machines and equipment have taken into account the factors of safe operation in the design of any control circuit without the permission of the designer or the modification of a program may result in a false operation which causes the personal injury of the operator.

6. Don’t put the head, hands and arms in the drive fixture or the working table, the operation of the enormous pressure will cause damage.

7. Because there is pressure in the welding process, after pressing the vibration test key is not to use the hand to touch the vibration movable fixture.

8. In the maintenance or debugging equipment, removal of the safety device, in the maintenance or after the completion of the test must be reset immediately.

9. It takes about a minute for the capacitor to discharge and to measure the vibration before it is eliminated or repaired. The voltage of the movable power supply confirms that there is no residual current.

10. If the vibration welding machines and equipment are in the presence of possible defects or failures, it can’t be use before repaired.

Matters Need Attention

1. 1. After closing the main power supply for a minute to turn on the power supply. Often turn on or off the power supply will cause device failure of power supply and control circuit.

   2. The use of the oil specified in the manual, otherwise it will cause the solenoid valve, oil and hydraulic cylinders, etc.. Often to pay attention to the oil and pollutants. When there is an oil pollution in the air inlet, the air inlet of the drainage filter must be cleaned.

   3. In particular, it is necessary to point out that the upper fixture determines the frequency of vibration, so the weight must be satisfied specification requirements. Even if it is well designed, if the quality or strength of the fastening screw is not enough, or there is a tight lack of torque, which can cause the vibration of the head and the vibration power of overload or over amplitude.

   4. When changing the installation or replacement, always have to clean the mold, the vibration head, the surface of the work table.

   5. Before starting the vibration head, please adjust the vibration power supply. If it is not adjusted, it may cause vibration head or vibration power failure.

   6. Vibration power supply with overload protection circuit. When the vibration or operation of the power supply stop the vibration, please check the mold is in compliance with the requirements of technical specifications, mold installation is correct, whether the mold has cracks, etc..

   7. Confirm that the upper and lower fixtures are not in contact with each other, or the upper and lower position sensors, and the depth of the upper and lower fixtures in the process of increasing the working table. The sensor does not touch the working table. Contact will result in damage to the component.

   8. When the welding cycle is used in the test to test the vibration, please put the workpiece in the upper and lower fixture, check up and lower fixture direct contact.

   9. Please do not use metal to contact vibration head or fixture during vibration. Do not start the vibration welding machines and equipment without the fixture, this may cause damage to the power or vibration of the vibrator.

   10. Vibration welding machines and equipment for successful welding, but also depends on a lot of practical applications, such as the factors, such as vibration amplitude, pressure, welding time and holding time, design, size and components of welded reinforcement, etc.. Stay the changes of these factors in the production process can be changed to obtain the best welding results. Recommended after welding welding good parts carefully examined and tested to ensure their availability.

Important Explain

1. Open the packing box to install vibration welding machines and equipment must be careful to prevent damage to the machine, and need to check if the machine is damaged in transit. If there is damaged, please immediately with forwarders or Jfortune local agent contact of the representative. The transport forwarder shall be responsible for the damage or failure caused by the transport process, and shall the transport agent is notified to obtain a claim for any damage or malfunction.

2. Do not allow the vibration of the vibration head or fixture contact metal table and other metal parts, or vibration head and fixtures will be damaged.

3. Do not drive the vibration power when the vibration head is not on the clamp, because it may cause the vibration power failure.

4. The main power supply of the vibration welding machines and equipment shall be the delta type three-phase alternating current, if the device is not suitable for the power supply. Such as Y type coupling will cause vibration instability and vibration power failure. When the power supply is insufficient, the preparation will have the same problem.

5. Standard Specification for mould fastening screws for this type of vibration welding machines and equipment:

   • Screw specification: GB70-85 six angle M12xL

   • Screw length L:

     • Minimum length: gasket thickness + mold plate thickness +18

     • Maximum length: gasket thickness + vibration head inside the thread length + mold plate thickness -2mm

   • Screw number: at least 10

6. The following models using the tightening torque:

Specification for Inspection of Industrial Ground vibration welding machines and equipment

• Minimum grade of concrete strength: C30/37

• Bending / tensile strength: more than 0.5N/mm²

• Minimum thickness more than 16cm

• Concrete blocks should be designed as square and rectangular, length width ratio is less than 1.5.

• 30 times the minimum distance between the seam should be less than the thickness of the concrete block, such as the thickness of 16cm, minimum distance between seams should be less than 480cm.

• Plane of concrete: less than 2.5 per thousand

• The per meter length of concrete plane is less than 2.5mm

• Cleanliness: no acid, alkali, no pollution, no pollution and wear.

1 Prepare

The installation steps described in this section is for after training, and has certain skills for the technician.
Please do you have in the premise of vibration welding machines and equipment installation qualification to complete the following steps.
If you do not have this skill, service be assigned to other qualified employees to operate.

1.1 Unloading vibration welding machines and equipment

Be careful!
You need to use the capacity of at least more than 3000kg forklift or lifting equipment to unload and transport.
Considering the location of the center of gravity higher equipment, if the mobile device to another location, to prevent the equipment tipping.

Steps:

1. The fork forklift extends to the equipment chassis.

2. Unloading equipment.

1.2 Transport Equipment to the Installation Area

The installation area must meet the following requirements:

Table 1.1: The installation of regional environmental requirements

Be careful!
If the above conditions are not met, may cause damage to the vibration welding machines and equipment.
Do not operate the equipment is not closed under the condition of noise, high decibel noise can cause permanent hearing impairment.
Use a forklift or crane equipment will be transported to the installation area.

Claim Data

• The power of 3X380VAC, PE, N/50Hz

• The energy consumption of 14KVA

• The maximum current consumption of 21A

• The main switch (external) 50A

• Pneumatic system: rated pressure (site) 0.5-0.6MPa free oil

• Connector: 1/2″

• Pneumatic system: gas consumption is determined by the type of application

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