[haihoang_boy]

Table of Contents
Introduction
Company Profile .................................................. .................................................. .....V
Chapter 1 Ultrasonic Basics
Process Definition .................................................. .................................................. ..1
How Ultrasonic Assembly Is Done.............................................. ..............................2
Ultrasonic Welding .................................................. .................................................. 2
Advantages of Ultrasonic Welding .................................................. ..........................3
System Components and Functions......................................... ................................4
Techniques for Applying the Energy to the Work.............................................. ......7

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Chapter 2 Plastics
Plastic Materials......................................... .................................................. ...............9
Compatibility of Materials .................................................. ......................................10
Hygroscopicity.................................... .................................................. ................... 11
Mold Release Agents .................................................. ............................................ 11
Lubricants .................................................. .................................................. ...........12
Plasticizers...................................... .................................................. ......................12
Fillers .................................................. .................................................. ..................12
Flame Retardants .................................................. .................................................1 3
Regrind .................................................. .................................................. ...............13
Colorants......................................... .................................................. ......................13
Resin Grade............................................. .................................................. .............13
Ultrasonic Weldability Compatibility Chart .................................................. ..........14
Ultrasonic Weldability Assembly Characteristics................................... ...............15
Chapter 3 Joint and Part Design
Basic Requirements .................................................. ...............................................17
The Energy Director.......................................... .................................................. ......18
The Step Joint............................................. .................................................. ..........21
The Tongue-and-Groove Joint .................................................. ..............................22
The Shear Joint............................................. .................................................. ........23
Part Design............................................ .................................................. ..................25
Near Field vs. Far Field Welding........................................... ..................................25
Parallel Contact........................................... .................................................. ..........26
Chapter 3 Joint and Part Design (continued)
Other Design Considerations.................................... ..............................................27
Sharp Corners .................................................. .................................................. ....27
Holes or Voids............................................. .................................................. ..........27
Appendages........................................ .................................................. ..................27
Diaphragmming .................................................. .................................................. ..28
Chapter 4 Other Assembly Techniques
Staking........................................... .................................................. ..........................29
The Standard Rosette Profile Stake............................................. ...........................30
The Dome Stake .................................................. .................................................. .31
The Hollow Stake .................................................. .................................................. 32
The Knurled Stake............................................. .................................................. ....32
The Flush Stake .................................................. .................................................. ..33
Stud Welding........................................... .................................................. ................33
Insertion......................................... .................................................. ..........................34
Swaging and Forming .................................................. ............................................35
Spot Welding........................................... .................................................. ................37
Degating.......................................... .................................................. .........................38
Scan Welding .................................................. .................................................. ........38
Bonding and Slitting.......................................... .................................................. .....39
Ultrasonic Bonding .................................................. ................................................39
Ultrasonic Slitting.......................................... .................................................. .........39
Chapter 5 Major Component Design
Generators........................................ .................................................. .......................41
AUTO-TRAC Tuning............................................ .................................................. ..43
Pulse-Width Modulation .................................................. ........................................44
Linear Ramp Variable Soft-Start............................................. .................................45
Microprocessor Control .................................................. .........................................45
Transducers....................................... .................................................. ......................47
Boosters .................................................. .................................................. ................49
Presses .................................................. .................................................. ..................50
Slide Assembly Design............................................ ................................................51
Force .................................................. .................................................. ...................51
The Bottom/Mechanical Stop .................................................. ................................53
Integrated vs. Modular Press Systems........................................... .........................54
Chapter 5 Major Component Design (continued)
Other Press Controls.......................................... .................................................. .....54
Pneumatic and Servo Comparison .................................................. ........................56
Horns .................................................. .................................................. ......................57
Gain .................................................. .................................................. .....................57
Horn Materials......................................... .................................................. ...............58
Slots............................................. .................................................. ..........................59
Composite/Compound Horns............................................. ......................................61
Contoured Horns............................................. .................................................. .......62
Replaceable Tips .................................................. ..............................................63
High Frequency Horn Design............................................ .......................................63
Tuning .................................................. .................................................. ..................64
Finite Element Analysis.......................................... .................................................. 65
Fixtures.......................................... .................................................. ...........................67
CAD Process from Data.............................................. ............................................68
Photos: Resilient, Rigid, Rigid Hold Down and Split Clamp, Contoured .................69
Chapter 6 Process Control
What Is Process Control? .................................................. ......................................71
Open-Loop (Time-Priority) Welding Systems .................................................. ......70
Closed-Loop (Energy-Priority) Welding Systems........................................... .......71
Microprocessor Control .................................................. .........................................75
iQ System Features - Pneumatic .................................................. ..........................76
Electronic Pressure Regulation .................................................. .............................76
Load Cell (Force Transducer)....................................... ...........................................76
Remote Setup Switching......................................... .................................................7 6
Sequencing........................................ .................................................. ....................76
Weld by Distance.......................................... .................................................. .........77
Dual Pressure .................................................. .................................................. .....78
iQ System Features - Servo .................................................. ..................................79
Sensing Start Distance and Sensing Speed .................................................. .........79
Start Motion at Force Drop.............................................. .........................................80
Weld Motion Type .................................................. .................................................. 80
Hold.............................................. .................................................. ..........................81
Teachable Top of Stroke Position.......................................... ...................................81
Position Teaching .................................................. .................................................. 82
Setup Switching .................................................. .................................................. ..82
Duplicating Process on Multiple Machines .................................................. ...........83
Chapter 6 Process Control (continued)
iQ Servo System Benefits .................................................. .....................................84
Weld and Hold Collapse Distance Control .................................................. ..........84
Rapid Speed Change............................................ .................................................8 4
Versatility .................................................. .................................................. ............85
Hold Phase............................................. .................................................. ..............85
Ease of Calibration....................................... .................................................. ........85
Welder Cloning is Easier .................................................. .....................................85
Rejects Reduced .................................................. .................................................8 5
Smaller Maintenance Costs .................................................. ................................86
Fewer Accidental Changes........................................... ..........................................86
Glossary .................................................. .................................................. 87
Ultrasonics Troubleshooting.................................................. .................91
Maintenance Troubleshooting.................................................. .............105
Product Support .................................................. ...................................109

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