Technical Guide: Maintenance and Calibration for the WS3100 Ultrasonic Bonder

1. Ultrasonic Transducer Calibration & Testing

The transducer is the heart of the WS3100. Over time, accumulated aluminum dust or a loose wedge can cause frequency drift.

• The Tightness Test: Use the Wedge Test button on the left panel. A properly seated and tightened wedge should show a power level at segment 11 or higher.

• Frequency Tracking: The WS3100 automatically tracks resonant frequency within the 56-63KHz range. If the machine fails to bond, check for Transducer Drift (limit is ≤ kHz).

• Wedge Installation: Always use the alignment block. Torque the M3 set screw until the wrench deforms by 15°. Crucial: Never handle the wedge with bare hands; skin oils carbonize under ultrasonic vibration, leading to bond failure.

2. Precision Wire Path Maintenance

In thick aluminum bonding (75μm-500μm), the wire path must be frictionless to prevent "loop sagging" or wire damage.

• Transducer Wire Hole: Use thick cotton thread soaked in high-purity alcohol. Pass it through the transducer hole and pull back and forth until the thread no longer turns black.

• Contact Cleaning: Weekly, clean the wire guide surface and contacts (Figure 14 in manual). Aluminum powder buildup here can cause Uncontrolled Wire Feed, leading to short circuits in power modules.

• Feed Rollers: Ensure the motor-driven rollers are free of debris to maintain consistent tension for 10mm and 49mm ID spools.

3. Critical Adjustment Checklist

When switching between wire diameters (e.g., moving from 100μm for FETs to 500μm for IGBTs), follow this sequence:

1. Zeroing/Reference Height: Perform a reference height detection to recalibrate the Z-axis home position.

2. Pressure Recalibration: Use the 10-turn precision potentiometer to adjust between the 30g-1200g range.

3. Cutter Force: Adjust the cutter solenoid so it cleanly shears the thick aluminum wire without hitting the workpiece.

4. Tail & Pull Adjustment: Fine-tune the "Auxiliary Break-off" travel to ensure a clean tail after the 2nd bond.

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