Dukane iQ Series user manual Ultrasonic Horn

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Section 6 – Probes and Probe Stacks

Ultrasonic Horn

The horn transfers the ultrasonic mechanical vibrations (originating at the transducer in the probe housing) to the plastic parts through direct physical contact. The horn is precision machined and designed to vibrate at either 20kHz, 30kHz, 40kHz, 50kHz or 70kHz. The tuning is accomplished using electronic frequency measurement. Inherent variations in material composition prevent tuning by dimensional machining alone.

There are many different horn profile styles depending upon the process requirements. Factors which affect the horn design are the materials to be welded and the method of assembly. Horns are usually constructed from aluminum, hardened steel or titanium. As the frequency increases, vibration amplitude typically decreases, but internal stress in the horn increases. Higher frequencies are used for delicate parts that cannot handle a lot of amplitude. Some factors to keep in mind for high– frequency (e.g. 40kHz) ultrasonic welding versus low– frequency (e.g. 20kHz) ultrasonic welding are listed here.

1.Stress in the horn is higher at high frequencies.

2.Wear on the horn is greater at high frequencies.

3.Clean and flat mating surfaces between the horn, booster and transducer are more critical at high frequencies.

Booster

The function of a booster is to alter the gain (i.e. output amplitude) of the probe. A booster is amplifying if its gain is greater than one and reducing if its gain is less than one. A neutral or coupling booster is used to provide an additional clamping location for added probe stack stability. A probe designed to be mounted in a fixture along with a booster and horn is shown in Figure 6–3. This is commonly referred to as a stack. As indicated, the components are secured with threaded studs.

Probe

Housing

Booster

Horn

Figure 6–3Probe, Booster and Horn

Dukane Manual Part No. 403-577-01

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Contents User’s Manual Copyright Revision Revision HistorySummary Date This page intentionally left blank Contents This page intentionally left blank Introduction SectionThis page intentionally left blank Read This Manual First General User InformationDrawings and Tables Hand Probes Key FeaturesSystem Overview GeneratorHealth and Safety This page intentionally left blank Plastics Health Notice General ConsiderationsDomestic Power Grounding Electrical SafetyInternational Power Grounding Unpacking Placing RFI Grounding Connnecting Cables InstallationThis page intentionally left blank Placing UnpackingRFI Grounding AC Power Inlet Connecting Cables Quick Start Guide200/240 Volt Systems Power CordsUltrasound Output Pin 0V Output Common Pin 1 End of Weld AlarmPin 2 Any Fault Alarm System Outputs Optional ConnectionsControls This page intentionally left blank Front Panel Overview Power Switch/Circuit BreakerControl Keys System LCD Display Power Bar GraphArrow Keys + and KeysStarting a Weld Cycle Start-up SequenceStopping a Weld Cycle Manual Weld LCD Display OverviewSetup Maintenance Process Control SettingsThis page intentionally left blank Select the Welding Mode Process Controller SettingsTime key Navigate to Time ModeNavigating to Manual Mode Navigating Through the ModesKey Navigate to Energy ModeHold Amplitude AdjustmentHardware Settings System Information Hardware Settings, AdvancedSystem Information Free Run Frequency Advanced Settings40 % Introduction Setup MaintenanceNavigating Selecting a Setup Saving the Current SetupDeleting a Setup This page intentionally left blank Probes and Probe Stacks This page intentionally left blank Operating Notes Ultrasonic Probe OverviewCompressed Air Fitting In continuous duty Theory of Operation Ultrasonic Horn Attaching a Replaceable Tip to a Horn Stack AssemblyAttaching the Mounting Stud to a Horn or a Booster 5Stack Assembly Procedure In-lb Ft-lb KHz Stack Disassembly Removing the Mounting Stud from a Horn or Booster Booster Notes How to Tell the Booster Input End from the OutputTroubleshooting This page intentionally left blank No Ultrasonic Output System Power Output LevelWeak Welds Welding ProblemsInconsistent Welds Generator Fault Status Screens Manual Mode Pop-up Fault Status ScreensProcess Fault Status Screens Time and Energy Modes Options This page intentionally left blank IQ Hand Probe Options Foot Switch Kit Part NoBuzzer Kit Part No This page intentionally left blank Specifications This page intentionally left blank 1Generator Outline Drawing 2Probes Outline Drawings and Dimensions Operating Environment WeightsAC Power Requirements CE Marking Regulatory Agency ComplianceThis page intentionally left blank Outputs Interface This page intentionally left blank IQ Hand Probe Generator Rear Panel Detail This page intentionally left blank Contacting Dukane This page intentionally left blank Contacting Dukane Intelligent Assembly SolutionsIdentify Equipment This page intentionally left blank Appendices This page intentionally left blank Front Panel List of FiguresDescription List of TablesDukane ISO Part No - 577- 01