2000 Series Ultrasonic Welding - Branson Ultrasonics BV

2000 Series Ultrasonic Welding
Hi-Tech Systems
Exclusively from BRANSON worldwide –
Second Generation Digital Power Supplies

Branson Worldwide – Best for Plastics
BRANSON offers a
wide range of successful
welding techniques,
based on the know-how
gathered in over
50 years on the global
Variable joining velocity leads to higher quality weld seams
The strength of a weld seam has been shown to depend to a high degree on the joining velocity
in relation to the meltdown during the welding process. This relationship determines the melt
flow characteristics and the thickness of the melted region and thus the strength and quality of
the weld seam. This leads to:
greater stability through increased bond layer thickness
improved visual appearance of the welded area
reduced ejection of particles
improved stress resistance, especially in plastics prone to tensional cracks
market. Simultaneously,
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.
Innovation:
Closed loop control
of joining velocity
Specific requirements are automatically identified
and taken into account.
This is achieved by the newly developed closed
loop control procedure, whereby a computer is
given a predefined constant velocity, and then
adjusts all other variables accordingly to maintain
it.
In addition to special software, this requires a
welding press with an attached servo drive,
which instantaneously respond to the signals
from the computer.
These innovative procedures from BRANSON
offer unique solutions to problems that would
typically arise when low viscosity plastics such
as PA or POM when welded, swaged or staked.
2000mc process controller
Section of a back pressure
valve made of PCU:
The macro photo shows a
pressure-tight step joint
incorporating flash
capturing cavities.
Amplitude and force profiling
Both methods control the joining process
using presets determined by empirical knowledge.
They indirectly ensure optimal welding
conditions, leading to a controlled melting in
the welding zone.
Amplitude profiling (pat.)
The 2000mc process controller varies the
amplitude of the horn according to certain
reference values (welding time, distance,
energy, power level), consequently 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 lowered, which leads to a controlled
melting of plastic in the joint area.
The 2000mc process controller consists of
state-of-the-art hard and software, and in
combination with a press unit and power
supply provides an ideal system for demanding
welding applications.
Software
The Windows NT operating system in conjunction
with a proprietary software package
gives you the following features:
4-channel operation: Up to 4 different welding
units can be controlled simultaneously.
Data capture: Data is collected during each
welding procedure, logged in a database, and
can instantly be graphically represented.
Application flexibility: The parameters for
each welding procedure (16 per welding unit)
can be set, altered and transmitted to the
power supply.
Resonance analysis: Allows the oscillating
unit to be analysed.
Autoscan: Allows important control parameters
and the resonance of the stack assembly to
be determined.

Innovation:
Top welding combinations from BRANSON
The following component combinations have the remarkable feature that they are entirely controlled by their process
controllers. With the System 2000 server, they also offer the user all possible operating modes. Even demanding welding
jobs can thus be precisely and individually tackled: it involves closed loop control as well as on-the-fly modulation of
amplitude and welding force.
Should the user not require the ability to vary the joining velocity, then the 2000pneumatic System will be more suitable.
System 2000pneumatic
The components of the pneumatically driven 2000aemc
welding press, such as the piston-pressure independent force
measuring system, proportional valve and linear distance encoder,
communicate with the 2000mc process controller and the
2000bdc ultrasound power supply. Mechanically, this welding
press is identical to the standard units, and therefore has a
modular design with a accuracy of operation.
The design also allows rapid changing of the stack assembly.
In addition to amplitude and force profiling, this combination
offers the following operating modes:
Time (Welding with preset time)
Metal contact (Welding until metal contact is achieved and
adjustable holding time afterwards)
Energy (Welding with preset energy level)
Peak power (Welding with preset power level)
All welding modes can be monitored using adjustable
limit values.
System 2000servo
The servo drive of the 2000servo welding press rapidly and
accurately acts on the control signals it receives during the
welding phase from the 2000mc process controller and the
2000sc controller.
This innovative concept implements closed loop control, in
addition to the standard operating modes and force and amplitude
profiling.
The press unit, whilst on the one hand being capable of producing
clamping forces of up to 750N (Servo 750-20), can also
carry out the most delicate of staking or swaging operations.
Its mechanical design and construction reflect these facts.
Further advantages of the servo press:
Instant process control by computer technology
(fluctuations of a compressed air supply are eliminated since
no pneumatic components are involved)
Precise reproducibility of the weld
High down speed feature due to variable RPM of the servo
motor
Collapse distance (Welding with preset distance)
The weld distance is not measured until the specified trigger
force is reached
Absolute distance (Welding with preset distance)
The complete stroke of the welding horn is measured.

Hi-tech systems ideal for use in series production
End-user advantages:
High quality seams of the produced components results in a longer life-span and greater robustness
Improved appearance of the components with no visible surface markings
Production advantages:
Optimised welding procedures, which are adjusted to the specific materials being processed, and resulting a consistent
production quality
Short welding times, long service life and minimal downtimes
The way:
Optimisation of the weld seam via the joining velocity, force profiling and amplitude profiling
Optimisation of the whole welding system via rapid adaptation of the welding process and its dynamics
Achtung!! Diese Seite wird schmaler
TeleService
All 2000mc process controllers
are fitted with a modem and
software that allows remote
servicing as standard.
We have thus laid the
groundwork for a global customer
service network that enables
us to service our machines and systems online.
Example of resonance analysis
World-wide exclusively by Branson –
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.
Expanded system Information: All parameters can be
accessed via the interface.
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
represented graphically.
The TeleService has many useful features:
Online support and advice when malfunctions due to
technical defects or incorrect use occur
Competent advice about user errors
Analysis of old welding data
Possibility of direct help when finding solutions for
specific applications
Online training of the system operators
Production of statistical analyses (SPC) with the 2000mc
statistic module
The TeleService thus has substantial advantages:
Minimisation of downtimes
Reduces workload on service personnel, allowing them to
work more effectively
Rapid assistance with production or in the laboratory
Accurate and effective planning of on-site service
Effective stockpiling of spare parts
Going well beyond conventional remote servicing sytems,
BRANSON will – if desired – also extend their service
package to onsite video monitoring.
The use of modern technology, backed up by the instant
availability of competent advisors, results in swift and effective
assistance, saving valuable time and costs.

Achtung!! Diese Seite wird schmaler
Welding combination for single operation
Components 2000pneumatic 2000servo
Digital Power Supply 2000bdc 2000bdc
Control 2000mc 2000mc / 2000sc
Press 2000aemc 2000servo
Operating modes
5 standard modes • •
Process control
Closed loop control of joining velocity
Force profiling • •
Amplitude profiling • •
Statistical process control (SPC) option option
Alarm and cycle counter • •
Alarm messages in text/Digital diagnostics • •
Digital amplitude control • •
Cycle parameters nonvolatile storage • •
Presets with free nameable infinitive infinitive
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 • •
Line/load regulation • •
RS 232 interface • •
Frequencies (kHz): 40 / 30 / 20 • •
Power levels (kW): 0.4 /0.8 / 1.1 / 1.5 / 2.2 / 3.3 / 4.0 • •
Actuator
Pneumatic drive
Servo drive
Proportional valve
Force measurement • •
Dynamic follow through
Two 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 • •
•
•
•
•
•
•
•
•

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 53-55 • D-63128 Dietzenbach
Telefon (0 60 74) 497-0 • Telefax (0 60 74) 497-199
Internet: www.branson.de
e-mail: info@branson.de
CH Tel. (022) 304 83 40 • Fax (022) 304 83 59
DK Tel. (032) 51 32 33 • Fax (032) 51 51 39
E Tel. (93) 5 86 05 00 • Fax (93) 5 88 22 58
F Tel. (1) 41 80 25 50 • Fax (1) 46 87 87 29
GB Tel. (0208) 5 61 44 22 • Fax (0208) 5 69 37 88
I Tel. (02) 66 08 17.1 • Fax (02) 66 08 17 97
NL Tel. (035) 609 81 11 • Fax (035) 609 81 20
Printed in Germany 0101/V 2.31 e
Subject to technical modifications