Professional Documents
Culture Documents
1 Safety .................................................................................. 3
1.1 Appropriate application / bonded connection............................... 3
1.2 Safety regulations and instructions in case of danger................ 4
2 Process description of Ultrasonic Welding ...................... 5
2.1 Explanation terminology .................................................................... 5
2.2 Functional principle of Ultrasonic Welding .................................... 5
3 Design of a Resonant Unit ..................................................... 6
3.1. Design and function ............................................................................ 6
3.2. Converter ................................................................................................ 6
3.3 Boosters................................................................................................... 6
3.4 Intermediate Pieces ............................................................................. 7
3.4 Welding Horns........................................................................................ 7
4 Exchanging Ultrasonic Components.................................. 8
4.1 Instructions............................................................................................. 8
4.2 Removal of a Resonant Unit ............................................................... 8
4.2.1 Hand Welding Gun................................................................................... 8
4.2.2 Feed Unit................................................................................................... 8
4.3 Exchanging a Converter ...................................................................... 9
4.4 Exchanging a Booster........................................................................... 9
4.5 Exchanging a Welding Horn ............................................................... 9
4.6 Welding Horn lettering .....................................................................10
5 Fault Finding...................................................................... 11
5.1 High idling output...............................................................................11
5.2 Intensive noise development ..........................................................11
5.3 Warming of coupling surfaces .........................................................11
5.4 Crack formation on the Welding Horn...........................................11
5.5 Rework on Welding Horns ...............................................................12
5.6 Converter defect .................................................................................12
5.7 Overload Ultrasonic Generator........................................................12
Hint ! Symbol gives you hints and pieces of advise, as well as the machine-
specific constraints which must be observed with certainty to assure
operation without error.
Symbol indicates further sources (handbooks, data sheets, etc.,) of
information for the topic concerned, or supplements them with an
example.
Abbreviations
MS Maschinenfabrik Spaichingen
US Ultrasonic
VE Feed unit
This document is for guidance only; Specifications are subject to change without notice.
© Maschinenfabrik Spaichingen GmbH
MS-SCHWINGV3GB.doc Application Instructions for Ultrasonic Resonant Units Rev.: 01/2007 Page 2 - 12
1 Safety
1.1 Appropriate application / bonded connection
Ultrasonic Resonant Units made by the Maschinenfabrik Spaichingen company are
exclusively intended for ultrasonic welding, and for the specified application in
special machines or in hand welding pistols.
MS-SCHWINGV3GB.doc Application Instructions for Ultrasonic Resonant Units Rev.: 01/2007 Page 3 - 12
1.2 Safety regulations and instructions in case of danger
Please note the following
the regulations for handling with electrical components acc. to IEC/EN 60204-1
the valid safety and accident prevention regulations.
Therefore, first read all warnings, hints and instructions, so that you are protected against
avoidable dangers and operational errors.
Danger of burning!
Do not touch the sonotrode during/after welding process.
Instructions
Moisture or liquids penetrating into the converter can lead
to its damage.
The compressed air for cooling the converter or the horn
has to be free of water and oil.
Operate the horn only in combination with the converter type
intended for it, and if necessary with the booster or
intermediate piece.
Contacting the horn with metallic parts during welding can
lead to damage of the horn, converter and generator.
Avoid contacting any kind of objects with the Resonant Unit
during a welding cycle, apart from the surface to be welded.
Do not exert torsional forces on the built-in Resonant Unit!
Never fasten the converter on the casing or on the holding
ring of the booster.
Use only original MS horns and adapter screws.
Drive in the adapter screws only manually and centre them
such that, in the mounted state, the undercut of the adapter-
screw sits in the middle between the coupling surface.
Let a professional person undertake the manufacturing and
the machining of horns.
MS-SCHWINGV3GB.doc Application Instructions for Ultrasonic Resonant Units Rev.: 01/2007 Page 4 - 12
2 Process description of Ultrasonic Welding
2.1 Explanation of terminology
(Vibration) amplitude
The amplitude is defined as the zero-to-peak value (half wavelength) of a longitudinal
vibration. The amplitude is given in µm.
The required amplitude value is based on sonic properties of plastic (amorphous, partial
crystalline) and on the application (e.g. welding, riveting, imbedding).
Rivet Welding
The Ultrasonic rivet welding allows a positive joint of thermoplastic material or
thermoplastics with other material like duroplastic or metals.
Surface welding
Surface welding with ultrasonics is used where a surface weld or an all-round seal weld is
required. A surface weld requires a certain design. The mating surfaces of the plastic parts
to be joined have to be provided with so-called directional power elements (ERG / energy
directors) to ensure a professional ultrasonic weld.
Spot welding
Ultrasonic spot welding is mainly used where the mating surfaces have to be joined without
seam preparation. With spot welding the sonotrode tip goes through the upper part and
penetrates the lower part. Heat is generated on the contact surfaces of the components,
which melts the material and joins it together.
The displaced plastic flows upward and creates a ring-shaped elevation.
The ultrasonic welding sequence can be subdivided into the following steps:
The Ultrasonic Generator converts the mains voltage into a high-frequency electrical
AC voltage.
AC voltage generated by the Ultrasonic Generator is fed to the converter.
The converter transforms this AC voltage into mechanical energy of the same frequency
(piezoelectric effect, axial vibrating direction).
The booster purely mechanically transforms the output vibration amplitude from the converter
to the desired size of the amplitude (enlargement or reduction).
The horn then transmits this vibration wavelength in combination with the press-on force
(welding pressure) onto the workpiece. Due to the transformation of the horn, an enlargement
of the amplitude occurs once more (exception: block horn).
The vibration energy thus induced in the workpiece is converted into heat by means of
friction in the welding zone.
After switching off the ultrasonic energy the welded spot must cool down under sustained
welding pressure (dwell time), so that damage to the workpiece is ruled out.
MS-SCHWINGV3GB.doc Application Instructions for Ultrasonic Resonant Units Rev.: 01/2007 Page 5 - 12
3 Design of a Resonant Unit
3.1 Design and function
The resonant unit of (mechanical resonance unit of a Ultrasonic System) generally consists:
an ultrasonic transformer (converter)
a booster or an intermediate piece
a horn.
Converter
Transforms the ultrasonic energy fed from the generator into mechanical
vibrations.
Booster
Performs mechanical enlargement or reduction of the amplitude for
adaptation to the working process.
Welding Horn
Transmits the vibration energy and press-on force.
These three single components are joined together by means of special set screws
(adapter screws). For a possibly efficient transmission of vibration energy, plane coupling
surfaces and sufficiently high tightening torque are necessary.
Depending upon the amplitude size required by the welding task, a booster can be rendered
dispensable if necessary.
3.2 Converter
The converter (ultrasonic transformer, transducer) is supposed to
convert the electrical energy into mechanical energy.
Technical Data:
Efficiency η > 95%
Made of titanium (high durability, even when large amplitudes are
transmitted)
3.3 Boosters
The booster consists of a base body made of titanium and a holding
ring on which the entire resonant Unit is mounted in the feed unit of
the welding machine.
The booster is supposed to transform the vibration amplitude from the
converter into the size required by the horn and to transmit the
mechanical vibration energy generated in the converter to the horn.
The vibration amplitude of converters can be enlarged or reduced by
exchanging the boosters, and thus also the amplitude fed to the horn.
Technical Data:
Made of titanium with transmission ratios of 2 :1 up to 1: 2.5
MS-SCHWINGV3GB.doc Application Instructions for Ultrasonic Resonant Units Rev.: 01/2007 Page 6 - 12
3.4 Intermediate Pieces
The intermediate piece consists of a base body made of titanium.
Contrary to the booster, the intermediate piece has no holding ring.
Technical Data:
Made of titanium with transmission ration of 1:1 up to 1: 1,5.
Technical Data:
Highly strong titanium and aluminium alloys are used for making horns.
When carrying out ultrasonic riveting and ultrasonic welding of glass-fibre-reinforced
materials or when imbedding metals; hardened steel horns find application.
Round-block-horn (RSBS)
MS-SCHWINGV3GB.doc Application Instructions for Ultrasonic Resonant Units Rev.: 01/2007 Page 7 - 12
4 Exchanging Ultrasonic Components
4.1 Instructions
Observe the safety instructions and danger warnings as
detailed in Chapter 1.2!
¯
ATTENTION!
Never fasten the converter on the casing or on the holding ring
of the booster
All coupling surfaces and threads must be perfectly clean, dry and free
of damages (no oil or grease).
Drive in the adapter screw
only manually and centre it such that, in
the mounted state, the undercut of the adapter-screw sits in the
middle between the coupling surfaces.
MS-SCHWINGV3GB.doc Application Instructions for Ultrasonic Resonant Units Rev.: 01/2007 Page 8 - 12
4.3 Exchanging a Converter
Dismount the vibration device from the feed unit or from the hand welding pistol.
Clamp the horn in a vice or in a three-jaw chuck.
Loosen the converter from the booster or from the horn with a suitable tool
(open-end wrench) by turning it counter-clockwise .
Mount the new converter in the reverse order.
MS-SCHWINGV3GB.doc Application Instructions for Ultrasonic Resonant Units Rev.: 01/2007 Page 9 - 12
4.6 Welding Horn lettering
On each horn the serial number is punched with number punches.
On steel horns the serial number is engraved.
aaaa bbb cd
aaaa Last four numbers of the machine number.
Example: 1243 for machine 51.243
bb Serial number of the feed unit.
c Type of vibration device or feed unit
0
Single horn or carrier horn
1
With carrier horn: Consecutive numbering of the screwed plugs
(single sonotrode) starting with 1 from the left to the right side.
With tandem-feed unit: left sonotrode
2
With carrier horn: Consecutive numbering of the screwed plugs
(single sonotrode) starting with 1 from the left to the right side.
With tandem-feed unit: right sonotrode.
d Index
0
Original horn
1 - 9
Spare horns
Examples
51250 012 00 51250 028 11
1250
Machine 51.250 1250
Machine 51.250
012
The horn is installed in 028
The horn is installed in
feed unit 12 feed unit 28
0
Single horn or carrier horn 1
Horn 1 in case of tandem-feed unit
0
Original horn. or screwed plug 1 in case of carrier
horn
1
First spare horn.
MS-SCHWINGV3GB.doc Application Instructions for Ultrasonic Resonant Units Rev.: 01/2007 Page 10 - 12
5 Fault Finding
5.1 High idling output
Effect:
intensive warming of converter and horn.
failure of converter or horn.
intensive noise development.
Possible causes and remedy
Adapter screw not correctly centred/tightened.
centre correctly or tighten properly.
defective adapter screw.
use a new adapter screw.
unclean coupling surfaces.
clean coupling surfaces.
converter defective.
check converter.
crack on the horn.
check horn for a visible crack.
secondary frequencies on horn.
send the horn for inspection to MS Co.
MS-SCHWINGV3GB.doc Application Instructions for Ultrasonic Resonant Units Rev.: 01/2007 Page 11 - 12
5.5 Rework on Welding Horns
When face surfaces on horns are reworked the frequency rises.
Therefore, after reworking, the frequency of the horn can be outside the
permissible tolerances.
Even little rework on horns can
- seriously change the vibrating characteristic and thus substantially
shorten the durability of the horns.
- cause damage to the converter or lead to severe damage of the
Ultrasonic Generator.
MS-SCHWINGV3GB.doc Application Instructions for Ultrasonic Resonant Units Rev.: 01/2007 Page 12 - 12