100-214-276 Rev. 3
2-7
2000X aed Actuator
Chapter 2: Introduction to the 2000X aed Actuator
Instruction Manual
Welding Systems
2.5 Welding Systems
Ultrasonic Plastics Welding
Thermoplastic parts are welded ultrasonically by applying high-frequency vibrations to the parts
being assembled. The vibrations, through surface and intermolecular friction, produce a sharp
rise in temperature at the welding interface.
When the temperature is high enough to melt the plastic, there is a
flow
of material between the
parts. When the vibrations stop, the material solidifies under pressure and a weld results.
The Plastics Welding System
The welding system consists of a power supply, an actuator, and a converter-booster-horn stack.
The system can perform a variety of ultrasonic welding operations, including: inserting, staking,
spot welding, swaging, degating, and continuous operations. It is designed for use in automated,
semi-automated, and/or manual production systems.
Power Supply
The 2000X distance Power Supply converts conventional 50/60 Hz line current to high fre-
quency electrical energy. It also contains all the electronic controls and can be located remotely
from the Actuator. This allows the operator to adjust or reprogram the welding cycle remotely
from the Actuator and related welding, tooling, and parts-handling systems.
The 2000X distance Power Supply also contains a DC power supply for electrical power to oper-
ate the electrical components and control circuits in the power supply, and on the Actuator.
The Power Supply is configured with either an analog or digital UPS. The analog supply has one
preset which calls up the factory default setting.
The digital supply has a library of 20 locked presets which are accessible for various process
parameter modifications that are unique to the power supply itself. These modifications can be
named to reflect specific applications, and are loaded into memory prior to shipment from the
Branson factory. The parameters of the individual presets can be modified by a Branson repre-
sentative. Initally all 20 Presets are set to factory default. They are accessed via an RS232 link
to the system controller.
Converter
The converter is mounted in the actuator as part of the ultrasonic stack. The ultrasonic electrical
energy from the power supply is applied to the converter (sometimes called the transducer). This
transforms the high frequency electrical oscillations into mechanical vibrations at the same fre-
quency as the electrical oscillations. The heart of the converter are piezoelectric ceramic ele-
ments. When subjected to an alternating voltage, these elements alternately expand and contract,
resulting in better than 90% conversion of electrical to mechanical energy.
DOC EXPIRES 12PM 7/24/2012. Article or Material must comply with the requirements
stipulated by RoHS in its current version