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2-8 100-214-281 Rev. 07
Chapter 2: Introduction to the 2000X ao Actuator
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 Series digital 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 Series Power Supply also contains a DC power supply for electrical power to operate
the electrical components and control circuits in the power supply, and on the Actuator.
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.
Booster
Success in ultrasonic assembly depends on the right amplitude of movement at the horn face.
Amplitude is a function of horn shape, which is largely determined by the size and form of the
parts to be assembled. The booster can be used as a mechanical transformer to increase or
decrease the amplitude of vibrations applied to the parts through the horn.
The booster is a resonant half-wave section of aluminum or titanium. It is mounted between the
converter and the horn, as part of the ultrasonic stack. It also provides a clamping point for rigid
stack mounting.