全自動(dòng)超聲波清洗機(jī)在實(shí)際應(yīng)用過(guò)程中，常面臨清洗效果、超聲波系統(tǒng)以及液體管理系統(tǒng)等多方面問(wèn)題，這些問(wèn)題不僅影響清洗效率與質(zhì)量，還可能導(dǎo)致設(shè)備故障，以下是對(duì)常見(jiàn)問(wèn)題的詳細(xì)分析及對(duì)應(yīng)的解決方案。

In practical applications, fully automatic ultrasonic cleaning machines often face various problems such as cleaning effectiveness, ultrasonic systems, and liquid management systems. These problems not only affect cleaning efficiency and quality, but may also lead to equipment failures. The following is a detailed analysis of common problems and corresponding solutions.

在清洗效果問(wèn)題上，清洗不徹底是較為突出的情況。其原因主要涉及超聲波頻率、清洗劑濃度和溫度控制三個(gè)方面。不同的清洗對(duì)象對(duì)應(yīng)著不同的超聲波頻率，若使用的 28kHz、40kHz、80kHz 等頻率與應(yīng)用場(chǎng)景不匹配，就無(wú)法達(dá)到理想的清洗效果；當(dāng)清洗劑濃度低于推薦值 15% 時(shí)，難以充分溶解和去除污垢；而溫度控制偏差若超出工藝要求的 ±5℃范圍，也會(huì)影響清洗的化學(xué)反應(yīng)和超聲波的空化效應(yīng)。針對(duì)工件表面損傷問(wèn)題，可采取一系列預(yù)防措施，對(duì)于脆性材料，改用≥80kHz 的高頻清洗方式，能夠在保證清洗效果的同時(shí)減少對(duì)工件的損傷；增加緩沖支架可有效減少清洗過(guò)程中工件的相互碰撞；對(duì)于精密件，將清洗時(shí)間嚴(yán)格控制在 3 分鐘以內(nèi)，避免過(guò)度清洗造成損壞。

In terms of cleaning effectiveness, incomplete cleaning is a prominent issue. The main reasons involve three aspects: ultrasonic frequency, cleaning agent concentration, and temperature control. Different cleaning objects correspond to different ultrasonic frequencies. If the frequencies used, such as 28kHz, 40kHz, 80kHz, etc., do not match the application scenario, the ideal cleaning effect cannot be achieved; When the concentration of the cleaning agent is lower than the recommended value of 15%, it is difficult to fully dissolve and remove dirt; If the temperature control deviation exceeds the ± 5 ℃ range required by the process, it will also affect the chemical reaction of cleaning and the cavitation effect of ultrasonic waves. A series of preventive measures can be taken to address the issue of surface damage to workpieces. For brittle materials, high-frequency cleaning methods with a frequency of ≥ 80kHz can be used to reduce damage to the workpiece while ensuring cleaning effectiveness; Adding buffer brackets can effectively reduce collisions between workpieces during the cleaning process; For precision parts, strictly control the cleaning time within 3 minutes to avoid damage caused by excessive cleaning.

超聲波系統(tǒng)故障主要體現(xiàn)在換能器效率下降和發(fā)生器報(bào)警兩方面。在換能器效率下降的診斷中，阻抗測(cè)試、絕緣電阻檢測(cè)和振幅檢測(cè)是重要手段。當(dāng)阻抗測(cè)試結(jié)果與正常值 50±5Ω 的偏差超過(guò) 10% 時(shí)，意味著換能器性能出現(xiàn)問(wèn)題，需要進(jìn)行更換；若絕緣電阻低于 10MΩ，應(yīng)立即停用設(shè)備，防止發(fā)生安全事故；當(dāng)振幅檢測(cè)值小于 25μm 時(shí)，則需對(duì)驅(qū)動(dòng)電路進(jìn)行檢查和修復(fù)。發(fā)生器報(bào)警時(shí)，不同的代碼對(duì)應(yīng)著不同的故障原因及處理方式。出現(xiàn) E01 過(guò)流保護(hù)代碼時(shí)，需仔細(xì)檢查換能器電纜是否存在短路情況；E02 過(guò)熱保護(hù)代碼提示應(yīng)及時(shí)清理散熱風(fēng)機(jī)的積塵，保證良好的散熱效果；當(dāng)出現(xiàn) E03 頻率失鎖代碼時(shí)，需重新匹配諧振電容，以恢復(fù)設(shè)備正常工作頻率。

Ultrasonic system failures mainly manifest in two aspects: decreased transducer efficiency and generator alarms. Impedance testing, insulation resistance testing, and amplitude testing are important methods for diagnosing the decrease in transducer efficiency. When the deviation between the impedance test result and the normal value of 50 ± 5 Ω exceeds 10%, it means that there is a problem with the performance of the transducer and it needs to be replaced; If the insulation resistance is lower than 10M Ω, the equipment should be immediately stopped to prevent safety accidents; When the amplitude detection value is less than 25 μ m, the driving circuit needs to be inspected and repaired. When the generator alarms, different codes correspond to different fault causes and handling methods. When the E01 overcurrent protection code appears, it is necessary to carefully check whether there is a short circuit in the transducer cable; E02 overheat protection code prompt: Clean the dust accumulation of the cooling fan in a timely manner to ensure good heat dissipation effect; When the E03 frequency loss lock code occurs, it is necessary to re match the resonant capacitor to restore the normal operating frequency of the equipment.

液體管理系統(tǒng)的常見(jiàn)問(wèn)題包括泡沫溢出和過(guò)濾系統(tǒng)堵塞。對(duì)于泡沫溢出問(wèn)題，可通過(guò)多種方式進(jìn)行控制，按 0.1%-0.3% 的比例添加消泡劑，能夠有效抑制泡沫產(chǎn)生；安裝液位傳感器并與補(bǔ)液系統(tǒng)聯(lián)動(dòng)，可根據(jù)液位變化自動(dòng)調(diào)節(jié)液體補(bǔ)充量，避免因液位過(guò)高導(dǎo)致泡沫溢出；將噴淋壓力優(yōu)化至 0.2-0.5MPa 的合理范圍，也有助于減少泡沫生成。在過(guò)濾系統(tǒng)堵塞的維護(hù)方面，初級(jí)過(guò)濾需每天清理目數(shù)≥200 的濾網(wǎng)，及時(shí)去除大顆粒雜質(zhì)；每月更換精度為 5μm 的精密濾芯，確保過(guò)濾效果；同時(shí)，每周進(jìn)行浮油排放，做好油水分離工作，以維持液體管理系統(tǒng)的正常運(yùn)行，保障清洗機(jī)的工作效率和清洗質(zhì)量。

Common problems with liquid management systems include foam spillage and clogged filtration systems. Foam overflow can be controlled by various ways. Adding defoamer at the proportion of 0.1% -0.3% can effectively inhibit the production of foam; The liquid level sensor is installed and linked with the liquid replenishing system. The liquid replenishing amount can be automatically adjusted according to the liquid level change to avoid foam overflow due to high liquid level; Optimizing the spray pressure to a reasonable range of 0.2-0.5MPa also helps to reduce the generation of foam. In terms of maintenance for clogged filtration systems, primary filtration requires daily cleaning of filter screens with a mesh size of ≥ 200 to promptly remove large particle impurities; Replace the precision filter element with a precision of 5 μ m every month to ensure the filtration effect; At the same time, perform weekly floating oil discharge and ensure proper oil-water separation to maintain the normal operation of the liquid management system and guarantee the efficiency and quality of the cleaning machine.

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