1
Safety Notes
1. The machine should be installed on a firm, flat surface.
2. The earth wires of the machine should be securely connected.
3. Do not modify any parts or lines of the machine without the
consent of King Supersonic Co., Ltd.
4. Do not use accessories that are not supplied by King
Supersonic Co., Ltd.
5. Do not push any button that should be pressed by both hands
with a toothpick or sharp-edged object for convenience.
6. Do not install footswitches 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 pipes once per year.)
10. During operation, do not lift the covers of the electronics box
or control box and cylinder to prevent high-voltage injury.
11. During operation, both hands should be placed around the
button and kept away from mold to avoid injury.
2
Table of Contents
I. Specifications
II. Component Description
(1) Component Position
(2) Name and Function of Body Components:
(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
3
I. Specifications
Model Frequency Power Welding
Capability
Compressed
Air
Dimension Power Source Weight
KWL-3215 15KHz 3200W 220m/m 9KG/cm2750*990*2060 220V/15A3P 300KG
KWL-4215 15KHz 4200W 250m/m 9KG/cm2750*990*2060 220V/20A3P 300KG
II. Component Description
(1) Component Position
(A) Position of Body Components
1. Triplet Set 2. Fixed Handle 3. Rise Buffer Adjusting
Screw
4. Drop Buffer Adjusting
Screw 5. Vibrating Cylinder 6. Stopper Screw
7. Spacer 8. Welding Head 9. Large Column
10. Base Plate 11. Pressure Gauge 12. Pressure Governor
13. Delay-on Timer 14. Welding Timer 15. Curing timer
16. Selector Switch 17. Counter 18. Rise Governor
19. Drop Governor 20. Hand Wheel For Height
Adjustment 21. Fixed Screw
22. Operator Push Buttons 23. Emergency Rise Button 32. Iron Male Connector
(B) Position 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 of water, rotate the button
anti-clockwise on the bottom of the cup to drain the water. The operation and life of
the air pressure parts will be adversely affected by bad compressed air. For example,
the governor may produce noise, or the solenoid valve may be blocked and therefore
can’t work…etc.
2. Fixed handle:
Secure the body onto the large column.
3. Rise Buffer Adjusting Screw:
Adjust the rise buffer rate of the welding head (at the point 14mm from the end of
the rise stroke). Rotate it clockwise to increase the buffer rate or rotate it
anti-clockwise to decrease the buffer rate.
4
4. Drop Buffer Adjusting Screw:
Adjust the drop buffer rate of the welding head (at the point 24mm from the end of
the drop stroke). Rotate it clockwise to increase the buffer rate or rotate it
anti-clockwise to decrease the buffer rate.
5. Vibrating Cylinder:
Accommodate and secure the oscillator and spacer to connect the welding head. The
vibrating cylinder is driven by an air cylinder. After the fixed screws are loosened,
the direction of the spacer and welding head can be changed.
6. Stopper Screw:
When welding, it is used to fine tune the drop of the welding head and adjust the
welding depth of the work-piece. When there is no work-piece on the base, it can
prevent the welding head from touching the base and causing damage.
7. Spacer:
Connect and secure the oscillator and welding head. The magnified amplitude of the
oscillator is delivered to the top of the welding head via the spacer.
8. Welding Head:
Ultrasonic wave energy is delivered to the work-piece via 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
electrical component could be damaged if the resonance frequency is changed
inappropriately.
9. Large Column:
Located behind the base plate to support the body.
10. Base Plate:
A workbench with 17 screw holes (M8P1.25) for securing.
11. Pressure Gauge:
Indicate the pressure of the air source.
12. Pressure Governor:
Adjust the air-source pressure entering the air cylinder.
Note: Before adjusting, pull the red collar out. After the adjustment is completed,
push it in to lock.
13. Delay-on Timer:
The time from the drop of the vibrating cylinder to transmission of the ultrasonic
wave. The ultrasonic transmission is usually set to start at the time when the welding
head touches the work-piece to match with the drop rate of the vibrating cylinder and
meet the buffer requirement.
5
14. Welding timer:
The time during which the ultrasonic wave is transmitting.
15. Curing Timer:
The time from stopping the ultrasonic transmission to when the vibrating cylinder
rises. During this time, the plastic is curing from its molten state with the pressure
being exerted on the work-piece.
16. Selector Switch:
a. Manual Operation:
When the operator presses two push buttons simultaneously with two hands, the
welding head drops together with the vibrating cylinder and remains at the drop
position. The welding head will rise together with the vibrating cylinder when
the emergency rise button is pushed.
b. Automatic Timing Operation:
When the operator presses two push buttons simultaneously with two hands, the
delay-on, melting, and curing timing operations will be carried out automatically.
c. Sonic Wave Inspection: Check if the ultrasonic wave is transmitted appropriately.
Note: Remember that the knob should not be set to the ultrasonic 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 adjustment.
19. Drop Governor:
Rotate it anti-clockwise to increase the drop speed or rotate it clockwise to decrease
the drop speed of the vibrating cylinder.
Note: Refer to 18.
20. Hand Wheel:
After loosening two fixed handles and rotating the hand wheel, the body will rise or
drop alongside the large column to adjust the height of the welding head.
21. Fixed Screw:
After the four fixed screws are loosened, the welding head can be rotated and
tightened after being aligned with the direction of the work-piece.
22. Operator Push Buttons:
When two operator push buttons are pressed with both hands, the system operates in
accordance with the setting of the selector switch.
Note: Do not push one button with a toothpick or sharp-edged object for
6
convenience.
23. Emergency Rise Button:
Upon pushing this button at any time, the ultrasonic transmission stops and the
vibrating cylinder returns to its original position immediately.
24. Power Switch:
Upon turning on this switch, the machine will be energized, indicators will light up,
and fans will run.
25. Amplitude Gauge:
It indicates the resonance level of the welding head when no load is exerted
(depending on the welding head and output level, the resonance is usually between
2.0~2.5) and indicates the level of the input power when the load is exerted
(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 control, and oscillating parts.
30. Earth Wire Socket: Refer to the “Correct Grounding Method” section.
Grounding is required to prevent leakage of current caused by electrostatic charge.
Correct grounding of the equipment and system is the prerequisite to ensure normal
operation of the production equipment. Always carry out the grounding in
accordance with (3).
7
(1) Wrong Grounding
(2) Wrong Grounding
31. Power Cord:
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
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III. Operation Guidelines:
(1) Notes:
1. During operation, do not open the door of the electrical box to avoid high-voltage
injury.
2. Carry out adequate grounding to avoid electrostatic charge.
3. During operation, both hands should be placed around the button and keep away from
the welding head to avoid injury.
4. When welding or embedding large work-pieces, wear earphones or industrial earplugs,
or put soundproof material around the machine body to reduce noise. Soundproof
products are available for your needs.
5. Pay more attention to ventilation equipment because some materials may produce
toxic gases under high temperature.
(2) Operating Principles:
When thermoplastic material is processed using the ultrasonic equipment, heat is produced
rapidly among molecules due to high-frequency friction on the contact surface of the
work-piece. The ultrasonic oscillation stops when the temperature is high enough to melt
the work-piece. The contact surface of the work-piece then cures gradually from its molten
state to complete the processing procedure.
(3) Mechanism Principles:
220V, 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. The rise and drop actions
are carried out based on preset conditions under the operation of the air-pressure system
and control circuit.
(4) Installation Procedures:
1. Set the selector switch to the Manual position.
2. Connect the power plug to an AC220V, three-phase power supply appropriately.
Note: For safety reasons, the machine should be properly grounded.
3. Clean air is directed into the triplet set through the air hose. Pull out the red collar on
the pressure governor and turn the pressure governor until the pressure gauge displays
about 1 bar to raise the vibrating cylinder.
Note: Keep the air source clean and dry, check the water level of the air cleaner regularly,
and drain water at any time if required.
4. Tighten the four fixed screws to secure the spacer.
5. Clean the contact surface between the welding head and the spacer. Use two wrenches
to tighten the screws.
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6. Before operation, always check the sonic wave to ensure the resonance between the
vibration system and oscillator, especially after the welding head is replaced or the
amplitude is changed.
(5) Mold Adjustment Procedure
To acquire the largest throughput, the distance between the welding head and the
work-piece should be as short as possible, but a sufficient space is required for the
placement and removal of the work-piece. Since the maximum stroke of the welding head
is 100 mm, make sure the work-piece will not touch the welding head when it reaches its
maximum stroke. The mold adjustment steps are described as follows:
1. Set the selector switch to the Manual position and turn the pressure governor to
maintain the minimum pressure that can raise the cylinder.
2. Place the work-piece on the base.
3. Release the fixed handles with your left hand. Turn the hand wheel to keep the distance
between the welding head and the work-piece more than 100mm (the max. stroke of the
welding head). Tighten the fixed handles.
4. Push the operator push buttons with both hands to drop the welding head.
5. Loosen the fixed screws and rotate the welding head to align with the work-piece. Then
rotate the hand wheel to drop the welding head to touch the work-piece. Finally, drop
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 head and rotate the stopper screw
so that it and the vibrating cylinder will not touch each other during the operation.
When there is no work-piece on the base, the stopper screw can stop the vibrating
cylinder to prevent the welding head from touching the base and causing damage.
Note: 1. The mold adjustment procedure described above is only for rough
adjustment. When precise mold adjustment is required, observation and
adjustment should be made carefully during the trial period. Or place carbon
paper and white paper between the welding head and work-piece. An
indentation will appear on the white paper. Then adjust the height of the base
depending on the depth of the indentation to ensure even exertion of force on
the work-piece.
2. Place copper plates with different thicknesses between the base and the
foundation to adjust the height of the base and make the work-piece align
with the welding head.
Remarks: The ultrasonic plastic processing is affected by the following factors:
1. Design of the contact or joint face
2. Design of the energy conducting point
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3. Plastic material
4. Shape and size of the work-piece
5. Distance between the contact surface and the welding head
6. Horizontal thickness of the sidewall and joint face
7. Cleaning and finishing of the 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-piece
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(6) Operating Procedures Ultrasonic Welding Steps
1. Select vibration amplitude, level
2. Adjust the frequency
3. Align the welding head, work-piece, and
base contact surface
1. Set the welding pressure
2. Set the rise and drop speed of the stroke
3. Set the delay-on time
4. Set the height adjustment screws
1. Set the welding time
2. Set the 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 hi
g
her
p
owe
r
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 welding
1. Reduce the welding time
and pressure
2. Reduce the level of
amplitude
Data Record
Level, pressure, delay-on, welding,
curing time
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V (Welding problems and solutions) (1) Welding
Problems Causes Solutions
Surface damage The shape of the welding head is
damaged.
The welding time is too long.
Bad bonding between the contact
surfaces of the welding head,
work-piece, and base.
Check the work-piece size.
Check the variation of the work-piece
between the molds.
Increase the pressure or amplitude to
reduce the welding time.
Adjust the buffer pressure.
Check if the welding head and base
are parallel.
Check the bonding between the
welding head and work-piece.
Check the bonding between the base
and work-piece.
Underlay the base, if required.
Burrs and flashes
over the joint face The energy conducting point is too
big.
Deformation of the work-piece may
have a great effect.
The welding time is too long.
The 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
welding.
When assembling, the work-piece is
not aligned.
The base has improper support.
The sidewall bends.
Bad design of the energy conducting
point.
Tolerance of the work-piece is too
high.
Add a stud between two work-pieces.
If possible, design a new gauge for
correction.
Re-design an appropriate support.
Underlay the base.
Add hard supports if the bakelite plate
tilts.
Add ribs to the sidewall of the
work-piece.
Add hard supports if the bakelite plate
tilts.
Re-design the energy conducting
point.
Reduce the tolerance of the
work-piece.
Check the operation conditions.
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Problems Causes Solutions
Internal parts are
damaged during
welding.
The amplitude is too high.
The welding time is too long.
The work-piece absorbs too much
energy. Inappropriate assembly of
the parts; i.e. the distance to the joint
face is too short.
Reduce the amplitude.
Increase the pressure or amplitude to
reduce the welding time.
Adjust the buffer or delay time.
Reduce the amplitude.
Reduce the pressure.
Reduce the welding time.
Use an energy controller.
Make sure the internal parts are
properly assembled.
Isolate the internal parts and 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.
Increase vibration amplitude.
Increase the pressure.
Adjust the buffer and delay time.
Review the ejecting conditions.
Review the work-piece conditions.
Check the operation conditions.
Internal parts are
fused. Internal parts have the same material
as the housing. Change the material of the internal
parts.
Apply anti-welding agent to the
internal parts.
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