Dukane iQ Series user manual Theory of Operation

iQ Series, Ultrasonic Hand Held Systems User’s Manual

Theory of Operation

Plastic welding is the most common application of ultrasonic assembly. To perform ultrasonic plastic welding, the vibrating tip is brought into contact with one of the work pieces. Pressure is applied and ultrasonic energy travels through the material generating frictional heat at the contact point of the two parts. The frictional heat melts a molded ridge of plastic on one of the pieces and the molten material flows between the two surfaces. When the vibration stops, the material solidifies forming a permanent bond.

Probe Configuration

A basic ultrasonic probe package consists of:

1.A probe which houses the transducer to convert the elec- trical energy supplied by the generator into mechanical vibrations.

2.A horn to transfer the mechanical vibrations from the probe to the parts to be welded.

Optional components include special replaceable tips which can be threaded on to the tip of the horn, and a booster to amplify the mechanical vibrations of the horn. A basic hand–held probe system is shown in Figure 6-2. The hand probe is easily identified by its trigger actuator and permanently attached cable. Normally a booster is not used with a hand probe as this increases the length and weight and reduces its versatility. The optional threaded titanium tip can be used when the application calls for a staking profile or a pointed spot weld. Replaceable tips are not commonly used in high–volume production environments.

 CAUTION Never use the hand probe if the cable insulating jacket is cut or damaged in any way.

Hand

Probe

Standard Custom

HornHorn

Tip

Figure 6–2Hand Probe, Horn and Tip

Page  36 Dukane Manual Part No. 403-577-01