安装与调试

1、使用前准备：

（1）本机应安装在坚固的平台或机架上，并远离暖气设备和其他热源，确保机器通风良好、环境干燥、清洁；

（2）工作前应先确定电源电压，采用电源自动稳压器，确保电源电压的稳定；

（3）应可靠接地。除电源进线的接地线外，机座后侧的铜螺钉应重复接地，接地电阻应不大于4欧姆；

（4）将主机上的控制电缆线和输出电缆线分别接插于电器箱背面的控制和输出插座上并旋紧；

（5）将气源管路接在机壳右后侧的滤清器上；

（6）检查整机各部紧固件，接插件，特别是电容器、保护板、程序板等插件是否有松动脱落。

2、上模具的安装：

擦净上模与变幅杆的接合面，把焊头装在变幅杆上，用随机勾形扳手拧紧（拧紧力矩约为25Nm）。

3、调试：

（1）初定气压在0.2~0.3MPa之间；

（2）检查急停按钮是否在旋出位置（若按下整机不动作）。接上电源并打开电源开关，此时机箱后的风扇开始工作；

（3）按“焊头下降”按钮，此时气缸带动换能器组下降，检查是否对正被焊接工件及气缸是否工作在缓冲区；

（4）按试验开关按钮，然后通过调整调谐器在顺钟向或逆钟向各45°角范围内，每次小量调整，把负载指示表的读数调至最小；

一般应小于1A算正常，若不能低于此值，应检查是否出故障。

[特别提示]：①试验超声波时，负载指示表并非表示功率输出大小，仅表示谐振程度（指示越低，谐振越佳）。如须较大振幅输出，可转动功率（振幅）调整钮至较高段数。但在发射超声波时，切不可改变振幅段数，以防高压电击；②负载表在空载发射超声波时，表示谐振程度；负载发射时表示输出能量大小；③正确的调谐非常重要，如果无法达到正常情况，请参照故障分析，不可勉强使用，以免损坏零件；④超声波试验开关一次按下时间不得超过3秒。

（5）调整延迟时间调节旋钮，使上模在下降至触着工件之前瞬间或压着工件后发射超声波；

（6）调整完毕后，对于一般工件，可按下述的初始条件进行试焊：

气动压力；0.2MPa

焊接时间：3（指示值）

保压时间：3（指示值）

延迟时间：3（指示值）

（7）按初始条件试焊接后，视被焊工件的熔接情况再参照下列方法进一步调整（详见第五章）。

Installation and Debugging

1.           Preparation before use

（1） Install the machine on a solid platform or a machine stand, and keep it away from heat source like heating facility, to ensure the equipment well ventilated and its environment dry and clean.

（2） Determine the power voltage before operation. Adopt automatic supply voltage regulator to guarantee the stability of supply voltage.

（3）  Should be well earthed. Except the earth wire of power supply, the bronze screw at the backside of the stand should be re-earthed and the earth resistance should be no more than 4Ω.

（4） Connect the control cable and output cable of main machine to the control socket and output socket at the backside of the electrical cabinet respectively and turn them tight.

（5） Connect the gas source pipeline to the filter at the right backside of the machine shell.

（6） Check whether any fastener or connector of the machine, especially capacitor, armor plate, and program plate, is loosened or falls off.

2.           Installation of upper die:

Clean the interface of upper die and amplitude-change rod, mount the horn onto the amplitude-change rod, and fasten it with machine’s auxiliary hook spanner（tightening torque is about 25Nm）.

3.           Debugging:

（1） Initial air pressure is between 0.2~0.3MPa;

（2） Check whether emergency stop button is at the unscrewing position（the machine has no action when pressing the button）. Connect to power supply, turn on the supply switch, and then the fan at the back of machine cabinet begins to rotate.

（3） Press “horn down” button, and air cylinder brings down the energy converter group, then check whether the welded work piece is aligned in place and air cylinder is working in the buffer zone.

（4） Press test switch button, tune with fine adjustment the readings of load indicator to the least by adjusting the tuner in clockwise or anticlockwise of 45° range.

The reading below 1A is normal. When the reading can not keep below this value, check whether there is any fault.

[Special attention]: ① When testing ultrasonic, load indicator does not indicator the power output but the resonance strength（the lower the reading is, the better the resonance is）. Turn power （amplitude）adjusting knob to the higher section when larger amplitude output is needed. Never change the amplitude section when emitting ultrasonic to avoid high voltage shock. ② Load indicator shows the resonance strength when emitting unloaded ultrasonic and the output energy when emitting loaded ultrasonic. ③ Proper tuning is very important. When normal condition can not be reached, please refer to fault analysis. Never forcedly use it in case parts are damaged. ④ Never press ultrasonic test switch for more than 3 seconds.

（5） Adjust delay-time adjusting knob to a state ultrasonic is emitted instantly when the upper die descends to touch or press work piece.

（6） After adjustment, make trial welding according to following initial condition for the ordinary work piece.

Air-power pressure: 0.2MPa

Welding time: 3（indicated value）

Pressure maintaining time: 3（indicated value）

Delay time: 3（indicated value）

（7） After try welding according to initial condition, make further adjustment according to the melting condition of work piece and the reference of following methods（see Chapter V for the details）.

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