User`s manual

Section 8 – Troubleshooting
Dukane Part No. 403–556–03 Page 75
Welding
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Problem
Welding process not in control (inconsistent weld results on
a part-to-part basis) (continued).
Probable Cause Solution
Part dimensions vary due to mold Perform a statistical study to see if a pattern
cavity variations. develops with certain cavity combinations.
The resin contains regrind or degraded Consult with the molder.
plastic. Check the molding conditions.
Reduce the percentage of regrind.
Improve the quality of the regrind.
Fluctuations in the AC line voltage Upgrade to a generator with line
supplied to the generator. regulation.
Fluctuations in the air line pressure. Upgrade to a system with electronic pressure
regulation.
Add a surge tank with a check valve to the air line.
Raise the compressor output pressure.
The plastic’s ller content is too high. Reduce the percentage of ller in the plastic.
Check the processing conditions.
Change the type of ller (e.g., from short to long
glass bers).
The horn doesn’t t the part correctly. Check the part dimensions.
Check for cavity-to-cavity variations.
Obtain a new horn.
The weld cycle is too long. Reduce the weld cycle time and increase the horn
amplitude or air pressure.
Increase the dynamic trigger force.
There is a lack of parallelism between Check for parallelism between the horn,
the horn, part, and/or xture. part, and xture.
Check the horn/part t.
Check the part/xture t.
Level the xture, where necessary.
Rigid xture reects vibratory energy. Dampen the energy by using teon, neoprene, cork,
or urethane in the nest of the xture.
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