Branson 2000X ao, Instruction Manual, Page: 35 / 112

100-214-281 Rev. 07 2-9
2000X ao Actuator Chapter 2: Introduction to the 2000X ao Actuator
Instruction Manual Welding Systems
Boosters are designed to resonate at the same frequency as the converter with which they are
used. Boosters are usually mounted at a nodal (minimum vibration) point of axial motion. This
minimizes the loss of energy and prevents vibration from being transmitted into the actuator.
Horn
The horn is selected or designed for a specific application. Each horn is tuned typically as a half-
wave section that applies the necessary force and vibration uniformly to the parts to be assem-
bled. It transfers ultrasonic vibrations from the converter to the workpiece. The horn is mounted
to the booster as part of the ultrasonic stack.
Depending on their profile, horns are referred to as stepped, conical, exponential, bar, or catenoi-
dal. The shape of the horn determines the amplitude at the face of the horn. Depending on the
application, horns can be made from titanium alloys, aluminum, or steel. Titanium alloys are the
best materials for horn fabrication due to their high level of strength and low loss. Aluminum
horns are usually chrome- or nickel-plated or hard-coated to reduce wear. Steel horns are for low
amplitude requiring hardness, such as ultrasonic insertion applications.
Dynamic Trigger Mechanism and Dynamic Follow Through
The Dynamic Trigger Mechanism assembly ensures that pressure is applied to the part prior to
the application of ultrasonic energy. This adjustable, pressure-activated device is located
between the air cylinder and the converter.
To maintain horn-to-part contact and force as the joint collapses, springs provide dynamic fol-
low-through. As the plastic melts, the springs extend to ensures smooth transmission of ultra-
sonic energy into the part.