2000 Series Ultrasonic Welding

Transcription

1 2000 Series Ultrasonic Welding Modular Standard Components Exclusively from BRANSON worldwide Second Generation Digital Power Supplies

2 Branson Worldwide Best for Plastics BRANSON offers a wide range of successful welding techniques, based on the know-how gathered in over 2000 Series Digital Power Supplies These power supplies provide a future-proof system with the newest type of digital processor. They operate with frequencies of 20 khz, 30 khz or 40 khz having ouputs between 800 and 4000 Watts. The power supplies have varying formats, depending on their intended use. They can, in combination with the appropriate press units and actuators, be specifically configured to cater for all needs of the plastics joining industry. 50 years on the global market. Simultaneously, 2000f/aef Series Joining System Digital Power Supply Force modulation Force profiling Amplitude profiling Data management international presence is an important basis for our special consulting teams when analysing problems in key industries. It goes without saying that our customers can depend on our discretion in finding solutions. Blood filtering component made from PC. This macro shot clearly shows the pressure tight step joint that is ideal for this kind of application. One of the joint surface also incorporated an energy director. Special features of process control and digital power supplies*: Digital amplitude modulation Allows the amplitude to be precisely set between 10% and 100%. This is of particular importance to critical ultrasonic welding applications, where the amplitude is the most important variable. Force measurement Allows the trigger force to be set, as well as obtaining measurements for a higher reproducibility. Selectable starting time Four different starting rates of 10, 35, 80 and 105 milliseconds allow the start characteristics to be adjusted according to different horns. Automatic frequency tuning with memory The tuned operating frequency of the horn is stored at the end of each welding cycle. Active frequency regulation (AFR) This automatically sets the power supply to the optimal frequency. Mains voltage regulation (AVR) Correction for up to ± 15% variation in mains supply. Interface/ Port SPS controllers can be connected directly. * nicht in allen Modellen eingebaut

3 Exclusively from Branson worldwide Second generation Digital Power Supplies For the first time all control and regulation is carried out by a single microprocessor in the digital processing module. The completely digital design of the components has great advantages over analogue counterparts: Resonance analysis: Allows instant and continuous analysis of the oscillating unit, to determine if and why the resonance has been disrupted for example a damaged horn. Autoscan: Allows important control parameters and the resonance of the stack assembly to be determined. Further Information: All parameters can be accessed via the port. Application flexibility: The suite of applications for the hardware can be extended by specific software. RS232 Port: This port allows the power supply to communicate with other systems. Welding Charts: Each relevant welding parameter can be graphically represented. TeleService: Our service department has worldwide access to your power supply data via modem, for example if a hardware fault occurs. Determined welding data Specific operating modes for various welding applications Time mode (Welding with preset time) Metal contact mode (Welding until metal contact is achieved and adjustable holding time afterwards) Energy mode (Welding with preset energy level) Peak power mode (Welding with preset power level) All welding modes can be monitored using adjustable limit values. Collapse distance mode (Welding with preset distance) The weld distance is not measured until the specified trigger force is reached) Absolute distance mode (Welding with preset distance) The complete stroke of the welding horn is measured useful, for example, when the finished part is required to have a specified height. Example of resonance analysis Amplitude and force profiling Both methods control the joining process using presets determined by empirical knowledge. They thus indirectly ensure the optimal welding conditions, leading to controlled melting in the welding zone. Amplitude profiling (pat.) The amplitude is controlled according to reference values (welding time, distance, energy, power level), thus reducing the required plastification energy during the residual time. Amplitude profiling is suited to amorphous plastics; force profiling to partially crystalline thermoplastics. Force profiling Welding usually commences with a high energy, then, after a preset time interval in the millisecond range, it is significantly reduced. The energy being applied to the welding seam is thus reduced.

4 2000 Series pneumatic press units An intelligently conceived modular concept allows largely identical components to be used in different systems. Common construction criteria are: a compact precision linear slide system which provides smooth, accurate operation indexed tool changing system for quick changing of stack assemblies. Sound insulation cover (optional, will enclose the welding press if it is producing unacceptable sound levels). Achtung!! Diese Seite wird schmaler 2000ea/ae Series Joining System Digital Power Supply Amplitude profiling Data management Press units Comprised of a base plate, a rigid square column, enclosed actuator and various accessories. ae model: This model has an adjustable mechanical stop, a dynamic trigger assembly and upper limit switch. Combined with the t power supply it is capable of doing time mode welding, and in combination with the ea power supply it can additionally carry out energy and amplitude mode welding. aed model: This model incorporates the features of the ae model but has an additional linear encoder to accurately measure distance. In combination with the d power supply, this allows welding in distance mode (absolute or collapse). In addition, a measurement system directly measures the force acting on the parts to be welded. aef model: This press unit is mechanically identical to the aed model. An integrated proportional valve processes the weld and hold force control signals delivered by the power supply. Special feature of the welding press*: Dynamic force tracking system A compressed set of springs compensates for significant fluctuations and ensures a constant transfer of the ultrasonic energy. Force measurement Allows the exact triggering force to be set and measured. Optical measuring system measures the welding distance in increments of 0.01 mm. Precision air-pressure regulating device The air-pressure of the system is closely monitored, which allows the welding force to be reproducibly and accurately set. Regulated proportional valve The precision valve allows not only the speed of the welding tool actuator to be precisely defined, but is also responsible for the force profiling by modulating the force supplied in millisecond intervals. * not included in all models

5 Achtung!! Diese Seite wird schmaler Welding combination for single operation System Digital Power Supply 2000 series t ea d f Combined with press 2000 series ae ae aed aef Operating modes Time Ground detect Energy Peak power Distance (absolute/collapse) Process control Alarm and cycle counter Alarm messages in text/digital diagnostics Digital amplitude control Amplitude profiling Force profiling (3-levels) Cycle parameters nonvatile storage Presets with up to 16 nameable Printout 50 cycle history of all parameters Digitally settable downspeed Force measurement Language selection: engl. / germ. / french / ital. / span. Rapid traverse of actuator Selectable starting rate (ms): 10 / 35 / 80 / 105 Limits Digital Power Supply Autotune plus memory High cycle rate up to 200 line/load regulation Frequencies (khz): 40 / 30 / 20 Power levels (kw): 0.4 /0.8 / 1.1 / 1.5 / 2.2 / 3.3 / 4.0 Actuator Dynamic follow through Air cylinder sizes Force transducer Optical encoder Precision system air regulator Proportional valve with closed loop control Single 20 khz converter for all power levels Easy horn down function

6 Ultrasonic Welding Linear Vibration Welding Orbital Vibration Welding Hot Plate Welding Infrared Welding Laser Welding Spin Welding Industrial Cleaning BRANSON ULTRASCHALL Niederlassung der EMERSON Technologies GmbH & Co. Waldstraße D Dietzenbach Telefon ( ) Telefax ( ) Internet: CH Tel. (022) Fax (022) DK Tel. (032) Fax (032) E Tel. (93) Fax (93) F Tel. (1) Fax (1) GB Tel. (0208) Fax (0208) I Tel. (02) Fax (02) NL Tel. (035) Fax (035) Printed in Germany 0101/X 2.30 e Subject to technical modifications