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406.3TroubleshootingInpractice,bothmachineandapplicationrelatedfaultsmayoccur.Thefollowingchecklistdescribesthepossiblecausesofamalfunctionandhowitcanbecorrected,providedthatthesystemisingoodrepair.Asimpleruletofollowinmaintenanceistochangeparametersorcomponentsonebyone,andtoseetheresult,beforeproceedingtothenext.FaultsymptomPossiblecauseCorrectiveactionOverweldToomuchenergysupplied-Reduceweldpressuretothejointarea-Reduceweldtime-ReduceamplitudeInsufficientNotenoughenergysupplied-Increaseweldpressureweldtothejointarea-Increaseweldtime-IncreaseamplitudeRelativemotion-VerifythefixtureholdingthepartInconsistentweldWarpedparts-Checkpartdimensionsinthejointarea-Checkmouldingprocess-IncreaseweldpressureDeflectionofthewall-AddsupportingribstothewallsWeldingproblems-Checkfixturedesigninthetransverse-ProvideretainerlugsdirectiononthepartMisalignmentofupper-Checkpartdimensionswithlowerpart-Ifrequired,re-alignlowerfixture-Checkweldpressure41FaultsymptomPossiblecauseCorrectiveactionUnsatisfactory-Checkfixtureareasfixturesupportrequiringsupport-ModifyfixtureParttolerances-Compensatefortolerances-Changedimensioning-Checkpre-productionconditionsWeldqualityvariesParttolerances-Checkpartdimensionsfromparttopart-Checkpre-productionconditions-Providecompensation-HeattreatmentofpartsParttolerancesdueto-Checkpartdimensionsutilizationofandtolerancesmultiplemoulds-Checkwearofeachmould-Checkpre-productionconditionsormouldingtoolUseofrecycledmaterial-Reducerecycledresinportion-CheckqualityofrecycledresinIrregulardistribution-Checkpre-productionconditionsoffillers-CheckinjectionmouldingprocessImproper-Redesignjointdesign-ModifyexistingdesignImproperpart-Checkpartdimensionsanddimensionspre-productionconditionsWeldmarksPartisnotproperly-Checkalignmentofpartalignedinthefixtureinfixture-Modifyfixtureappropriately-Checkparttolerances42FaultsymptomPossiblecauseCorrectiveactionPaintedorstructured-Checkalignmentofpartsinsurfacesaredamagedfixture-Usefixturesuitableforthematerial-Providevacuumsuctionaidtothefixture-Provideclampdevices-CleanfixtureWeldmarksopposite-Reduceweldforcetheweldarea-Reduceweldpressure(visibleside)-IncreasewallthicknessFlashExcessiveweld-Reduceweldpressure-Reduceweldtime-ReduceamplitudeJointdesign-Provideflashtrap-Reducejointwidth-Changejointdesign/partgeometryWeldareastoolarge,-Providegroovesinthecausingexcessiveheatjointarea-ChangejointdesignPartsdisplacedPartsimproperly-Providealignmentaidsonafterweldingcenteredtheparts-ProvidealignmentpinswhicharecutoffduringweldingMisalignmentcaused-Modifyfixturebythefixture(providecompensationoralignment,asappropriate)Warpageofworkpieces-Addreinforcementsontheworkpiece(ribs)Parttolerances-Checkpre-productionconditions(compliancewithdimensionalspecifications)437.1BRANSONSoftwareAsignificantfactorindesigningweldablemouldingsisthematerial-specificdesignofthejointarea.Closelyconnectedfactors,viz.design,material,fixtureandmanufacturingprocess,willtonearly100percentdeterminethequalityandstrengthofthevibrationweld.Inthisconnection,thequalityofthefin-ishedpartisearlydeterminedbytheassemblytechniquechosenintheinitialdesignengineeringstage.ThisiswhereBRANSONsoftwarecomesinuseful.BRANSONsoftwareclaimstobeanactiveadvisorytoolapplicablebothtovibrationaswellasultrasonicweldingtechniques,inallrelevantstagesofthemanufacturingprocess.Thischallengeisindependentlymetbyofferingrealisticdesignsolutionswhichareinspired,beyondthelimitareaofwelding,bythetrendsoftheindustriesconcerned.Whereverproductcomponentsaresubsti-tutedbyplastic,thisadvisoryassistanceisimportantandrequested:Introducingasubstitutionofthiskind,thedesignengi-neermaypartiallysteponnewground,whereasthedesignspecificationsaretar-getedtowardsoptimizationinasmanyfieldsaspossible.7.CustomersupportDesignstages*Basictrials*Feasibility*Costs*MouldingtoolsDuedateManufacturingprocess*Logistics*ThefinishedpartisacompromiseofSpecificationsDesignandengineeringManufacturingcapital*Productioncontrol*Thesuccessofthefinishedpartdepends50percentontheengineeringstage.DesignspecificationsFunction+DesignEngineeringFinishedpart*ThiswhereBRANSONinvitesyourcooperation.7.2Thedevelopmenttowardsthefini-shedpartsBRANSON'sinternalApplicationBriefskeepthecompany'ssalesandprojectengineersabreastofthelatestnoteworthyfactsconcerningvibrationweldedthermo-plasticparts.Thefollowingpagesillustratesomeofthosehighlyinterestingapplica-tions,selectedfromamongahostofexistingvibration-weldedobjects.8.Applicationexamplesandfuturetrends45Fig.3646Fig.3747Abb.3848Abb.3949Abb.40