Application Instructions

Ultrasonic Resonant Units

Contents Page

1 Safety .................................................................................. 3
1.1 Appropriate application / bonded connection............................... 3
1.2 Safety regulations and instructions in case of danger................ 4
2 Process description of Ultrasonic Welding ...................... 5
2.1 Explanation terminology .................................................................... 5
2.2 Functional principle of Ultrasonic Welding .................................... 5
3 Design of a Resonant Unit ..................................................... 6
3.1. Design and function ............................................................................ 6
3.2. Converter ................................................................................................ 6
3.3 Boosters................................................................................................... 6
3.4 Intermediate Pieces ............................................................................. 7
3.4 Welding Horns........................................................................................ 7
4 Exchanging Ultrasonic Components.................................. 8
4.1 Instructions............................................................................................. 8
4.2 Removal of a Resonant Unit ............................................................... 8
4.2.1 Hand Welding Gun................................................................................... 8
4.2.2 Feed Unit................................................................................................... 8
4.3 Exchanging a Converter ...................................................................... 9
4.4 Exchanging a Booster........................................................................... 9
4.5 Exchanging a Welding Horn ............................................................... 9
4.6 Welding Horn lettering .....................................................................10
5 Fault Finding...................................................................... 11
5.1 High idling output...............................................................................11
5.2 Intensive noise development ..........................................................11
5.3 Warming of coupling surfaces .........................................................11
5.4 Crack formation on the Welding Horn...........................................11
5.5 Rework on Welding Horns ...............................................................12
5.6 Converter defect .................................................................................12
5.7 Overload Ultrasonic Generator........................................................12

Symbols and their meaning

Symbol indicates imminent danger. Therefore, read these text
Attention!
passages thoroughly. Be certain to follow the instructions
provided! Non-observance may cause serious hurts, death of
the worker and/or damages at the machine and accessories.
The pictogram will be replaced by concrete dangers through:
Dangerous electric tension

Hint ! Symbol gives you hints and pieces of advise, as well as the machine-

specific constraints which must be observed with certainty to assure
operation without error.
Symbol indicates further sources (handbooks, data sheets, etc.,) of

information for the topic concerned, or supplements them with an
example.

Abbreviations
MS Maschinenfabrik Spaichingen
US Ultrasonic
VE Feed unit

This document is for guidance only; Specifications are subject to change without notice.
© Maschinenfabrik Spaichingen GmbH

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 1 Safety
1.1 Appropriate application / bonded connection
Ultrasonic Resonant Units made by the Maschinenfabrik Spaichingen company are
exclusively intended for ultrasonic welding, and for the specified application in
special machines or in hand welding pistols.

Maschinenfabrik Spaichingen is unable to warrant secure operation and function

in one of the following cases:
 Use of parts which are not originated by MS (Ultrasonic generators, converters, boosters,
amplitude transformation pieces, sonotrodes)
 Unauthorized changes
 Use, installation, operation and maintenance in a different manner than described in
our manual
 Use of unsuitable or incompatible welding material
 Disregard of the security and operation hints, regulations for accident prevention and
legal regulations.
 Or any operation which is not in accordance with the regulations.

Should any of the above apply the guarantee is void.

Operate the Ultrasonic Resonant Units only according to

this operating instructions and the intended use.

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1.2 Safety regulations and instructions in case of danger
Please note the following
 the regulations for handling with electrical components acc. to IEC/EN 60204-1
 the valid safety and accident prevention regulations.

Therefore, first read all warnings, hints and instructions, so that you are protected against
avoidable dangers and operational errors.

CAUTION - to be observed with certainty!

The Resonant Unit may only be operated in a mounted
state (Special machine, hand welding pistol).

Beware of dangerous electric tension!

 Safety measures (e.g. converter casing, generator
casing) may not be removed.
 Do not open converter casing !
 Prior to replacement of the resonant unit, switch off
the Ultrasonic Generator.

Beware of high voltage fluctuations!

Make sure that the lock of the HF connector snaps firmly
into place.

Danger of burning!
Do not touch the sonotrode during/after welding process.

Do not plug in any HF plug or remove any HF plug from

the converter when the Ultrasonic Generator is switched
on.

Instructions
 Moisture or liquids penetrating into the converter can lead
to its damage.
 The compressed air for cooling the converter or the horn
has to be free of water and oil.
 Operate the horn only in combination with the converter type
intended for it, and if necessary with the booster or
intermediate piece.
 Contacting the horn with metallic parts during welding can
lead to damage of the horn, converter and generator.
 Avoid contacting any kind of objects with the Resonant Unit
during a welding cycle, apart from the surface to be welded.
 Do not exert torsional forces on the built-in Resonant Unit!
 Never fasten the converter on the casing or on the holding
ring of the booster.
 Use only original MS horns and adapter screws.
Drive in the adapter screws only manually and centre them
such that, in the mounted state, the undercut of the adapter-
screw sits in the middle between the coupling surface.
 Let a professional person undertake the manufacturing and
the machining of horns.

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 2 Process description of Ultrasonic Welding
2.1 Explanation of terminology
 (Vibration) amplitude
The amplitude is defined as the zero-to-peak value (half wavelength) of a longitudinal
vibration. The amplitude is given in µm.
The required amplitude value is based on sonic properties of plastic (amorphous, partial
crystalline) and on the application (e.g. welding, riveting, imbedding).

 Rivet Welding
The Ultrasonic rivet welding allows a positive joint of thermoplastic material or
thermoplastics with other material like duroplastic or metals.

 Surface welding
Surface welding with ultrasonics is used where a surface weld or an all-round seal weld is
required. A surface weld requires a certain design. The mating surfaces of the plastic parts
to be joined have to be provided with so-called directional power elements (ERG / energy
directors) to ensure a professional ultrasonic weld.

 Spot welding
Ultrasonic spot welding is mainly used where the mating surfaces have to be joined without
seam preparation. With spot welding the sonotrode tip goes through the upper part and
penetrates the lower part. Heat is generated on the contact surfaces of the components,
which melts the material and joins it together.
The displaced plastic flows upward and creates a ring-shaped elevation.

2.2 Process description

During a ultrasonic welding process, electrical energy is converted into vibration energy with
ultrasonic frequency and transmitted from a resonant unit (converter, booster and horn) onto
the workpiece.
The vibrations take the form of a stationary longitudinal wave, acting along the axis of the
resonant unit.
This hammering effect is transmitted onto the parts to be welded together.

The ultrasonic welding sequence can be subdivided into the following steps:
 The Ultrasonic Generator converts the mains voltage into a high-frequency electrical
AC voltage.
 AC voltage generated by the Ultrasonic Generator is fed to the converter.
The converter transforms this AC voltage into mechanical energy of the same frequency
(piezoelectric effect, axial vibrating direction).
 The booster purely mechanically transforms the output vibration amplitude from the converter
to the desired size of the amplitude (enlargement or reduction).
 The horn then transmits this vibration wavelength in combination with the press-on force
(welding pressure) onto the workpiece. Due to the transformation of the horn, an enlargement
of the amplitude occurs once more (exception: block horn).
The vibration energy thus induced in the workpiece is converted into heat by means of
friction in the welding zone.
 After switching off the ultrasonic energy the welded spot must cool down under sustained
welding pressure (dwell time), so that damage to the workpiece is ruled out.

Further information about the application technique of

ultrasonic welding is found in our training documentation or in
relevant professional literature.

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 3 Design of a Resonant Unit
3.1 Design and function
The resonant unit of (mechanical resonance unit of a Ultrasonic System) generally consists:
 an ultrasonic transformer (converter)
 a booster or an intermediate piece
 a horn.

Converter
Transforms the ultrasonic energy fed from the generator into mechanical
vibrations.

Booster
Performs mechanical enlargement or reduction of the amplitude for
adaptation to the working process.

Welding Horn
Transmits the vibration energy and press-on force.

These three single components are joined together by means of special set screws
(adapter screws). For a possibly efficient transmission of vibration energy, plane coupling
surfaces and sufficiently high tightening torque are necessary.
Depending upon the amplitude size required by the welding task, a booster can be rendered
dispensable if necessary.

3.2 Converter
The converter (ultrasonic transformer, transducer) is supposed to
convert the electrical energy into mechanical energy.

Technical Data:
 Efficiency η > 95%
 Made of titanium (high durability, even when large amplitudes are
transmitted)

Converter type Frequency Output Amplitude Protection Mounting

kHz W µm system
35/2000 S 30 2000 7,1 IP 54 rigid
35/1000 S 35 1000 6,0 IP 54 rigid

3.3 Boosters
The booster consists of a base body made of titanium and a holding
ring on which the entire resonant Unit is mounted in the feed unit of
the welding machine.
The booster is supposed to transform the vibration amplitude from the
converter into the size required by the horn and to transmit the
mechanical vibration energy generated in the converter to the horn.
The vibration amplitude of converters can be enlarged or reduced by
exchanging the boosters, and thus also the amplitude fed to the horn.

Technical Data:
 Made of titanium with transmission ratios of 2 :1 up to 1: 2.5

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3.4 Intermediate Pieces
The intermediate piece consists of a base body made of titanium.
Contrary to the booster, the intermediate piece has no holding ring.

Technical Data:
 Made of titanium with transmission ration of 1:1 up to 1: 1,5.

3.5 Welding Horns

The welding, riveting or imbedding tool termed as horn has to fulfil the following duties:
 amplitude enlargement (transformation of the amplitude)
 transmission of the ultrasonic energy onto the workpiece to be welded.

 formation during a shaping process (riveting, beading, swaging).

 necessary pressure transmission, in order establish good contact with the

workpieces to be welded.

Technical Data:
 Highly strong titanium and aluminium alloys are used for making horns.
 When carrying out ultrasonic riveting and ultrasonic welding of glass-fibre-reinforced
materials or when imbedding metals; hardened steel horns find application.

Welding Horn types

Round horn (RS)

Round-block-horn (RSBS)

Block horn (BS) - non-transforming

Knife horn (MS) - transforming

Carrier horn with 2 screw plugs (EZ)

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 4 Exchanging Ultrasonic Components
4.1 Instructions
Observe the safety instructions and danger warnings as

detailed in Chapter 1.2!
¯
ATTENTION!
Never fasten the converter on the casing  or on the holding ring
 of the booster

All coupling surfaces and threads must be perfectly clean, dry and free
of damages (no oil or grease).

Drive in the adapter screw
only manually and centre it such that, in

the mounted state, the undercut of the adapter-screw sits in the
middle between the coupling surfaces.

Exclusively use original MS-adapter screws.

Tightening torque Resonant Unit 30 kHz: 70 Nm

Tightening torque Resonant Unit 35 kHz: 40 Nm

4.2 Removal of a Resonant Unit

4.2.1 Hand Welding Gun
Remove the hand welding gun as detailed in the operating instructions of the machine
or in the instructions “Ulrasonic Hand Welding Gun..“.

4.2.2 Feed Unit

Observe the safety instructions and danger warnings as

detailed in the operating instructions of the
corresponding special machine.
Two different types of feed unit (front loader resp.
lateral loader) are employed.

Remove the four screws  so that the resonant unit can

be taken off the feed unit.

Depending on the position of the feed unit the

converter lid of the front loader resp. the converter
holder of the lateral loader have to be hold to avoid
that the resonant unit falls off.

Finally remove the HF-cable from the converter.

front loader lateral loader

When installing in the feed unit, ascertain the right

alignment of the horn!

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4.3 Exchanging a Converter

Use only the same type of converter.

 Dismount the vibration device from the feed unit or from the hand welding pistol.
 Clamp the horn in a vice or in a three-jaw chuck.
 Loosen the converter from the booster or from the horn with a suitable tool
(open-end wrench) by turning it counter-clockwise .
 Mount the new converter in the reverse order.

4.4 Exchanging a Booster

 Dismount the vibration device from the feed unit.
 Clamp the horn in a vice or in a three-jaw chuck.
 Loosen the converter from the booster by turning it with an open-end wrench in
counter-clockwise direction.
 Repeat the same process in case the booster is connected with the horn.
 Mount a new booster in the reverse order.

The described sequence applies also when exchanging an intermediate piece.

Use only boosters with the same transformation!

4.5 Exchanging a Horn

In case of a screwed plug with a contour or riveting

dome, ascertain the right alignment when screwing!

When installing in the feed unit, ascertain the right

alignment of the horn!
 Dismount the vibration device from the feed unit or from the manual welding pistol.
 Clamp the horn in a vice or in a three-jaw chuck.
 Loosen the booster or converter from the horn with a suitable tool (open-end wrench)
by turning it counter-clockwise.
 Mount the new horn in the reverse order.

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4.6 Welding Horn lettering
On each horn the serial number is punched with number punches.
On steel horns the serial number is engraved.

When reordering or in case of inquiries this serial number is to be quoted as well.

aaaa bbb cd
aaaa Last four numbers of the machine number.
Example: 1243 for machine 51.243
bb Serial number of the feed unit.
c Type of vibration device or feed unit
0 Single horn or carrier horn
1 With carrier horn: Consecutive numbering of the screwed plugs
(single sonotrode) starting with 1 from the left to the right side.
With tandem-feed unit: left sonotrode
2 With carrier horn: Consecutive numbering of the screwed plugs
(single sonotrode) starting with 1 from the left to the right side.
With tandem-feed unit: right sonotrode.
d Index
0 Original horn
1 - 9 Spare horns

Examples
51250 012 00 51250 028 11
1250 Machine 51.250 1250 Machine 51.250
012 The horn is installed in 028 The horn is installed in
feed unit 12 feed unit 28
0 Single horn or carrier horn 1 Horn 1 in case of tandem-feed unit
0 Original horn. or screwed plug 1 in case of carrier
horn
1 First spare horn.

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 5 Fault Finding
5.1 High idling output
Effect:
 intensive warming of converter and horn.
 failure of converter or horn.
 intensive noise development.
Possible causes and remedy
 Adapter screw not correctly centred/tightened. centre correctly or tighten properly.
 defective adapter screw. use a new adapter screw.
 unclean coupling surfaces. clean coupling surfaces.
 converter defective. check converter.
 crack on the horn. check horn for a visible crack.
 secondary frequencies on horn. send the horn for inspection to MS Co.

5.2 Intensive noise development

Effect:
 Ultrasonic welding not possible.
Possible causes and remedy
 the horn contacts metal. eliminate contact with metal.
 adapter screws not correctly centred/tightened. centre correctly or retighten properly.
 defective adapter screw. use a new adapter screw.
 threads unclean. clean thread.
 unclean coupling surfaces. clean coupling surfaces.
 crack on the horn. check horn for visible cracks.
 secondary frequencies on the horn. send horn for inspection to MS.

5.3 Warming of coupling surfaces

Possible causes and remedy
 adapter screws are not correctly tightened. tighten the horn, booster and converter
according to regulation.
 no original MS adapter screws used. use MS adapter screw.
 unclean or damaged coupling surfaces clean coupling surfaces and
eventually. authorise re-polishing.
 amplitudes unequal. check horn (visible crack?).
 high idling output. see 5.1.
 secondary frequencies on horn. send the horn for checking to MS.

5.4 Crack formation on the Welding Horn

Indication:
 intensive noise development when the test button on the Ultrasonic Generator is pressed.
 too high idling output when the test button on the Ultrasonic Generator is pressed.
 generator goes over to overload when the test button is pressed.
 welding performance constantly diminishes.
 linear texture interruption visible on the horn surface.
Possible causes and remedy
 the horn contacts metal. eliminate contact with metal.
 regardless of intensive noise development in send horn for inspection to MS.
the idling state, the horn was further operated.
 independent changes on the horn. see 5.5
 horn was used with a too high amplitude.

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5.5 Rework on Welding Horns
When face surfaces on horns are reworked the frequency rises.
Therefore, after reworking, the frequency of the horn can be outside the
permissible tolerances.
Even little rework on horns can
- seriously change the vibrating characteristic and thus substantially
shorten the durability of the horns.
- cause damage to the converter or lead to severe damage of the
Ultrasonic Generator.

Never perform changes by yourself, but rather delegate these duties to

a professional person.

5.6 Converter defect

Indication:
 generator switches over to overload when test button is pressed.
 intensive noise development when the test button is pressed.
 too high idling output when the test button is pressed.
 intensive warming of converter casing and on coupling area next to the booster
or next to the horn, in the case of a rigid converter.

Possible causes and remedy

 short circuit due to moisture in converter casing.
 regardless of more intensive noise development during idling, the vibration device was further
operated.
 defective horn was further operated
 metallic contact with the horn has effected a too high reaction on the converter.
replace the converter and send it to MS Co. for inspection.

5.7 Overload Ultrasonic Generator

Effect:
 Ultrasonic welding not possible.

Possible causes and remedy

 idling output too high. retighten adapter screws correctly.
exchange adapter screw.
check converter.
 no frequency found by Ultrasonic Generator. check horn (crack formation).
 welding pressure set too high. check the setting of welding pressure.
 amplitude set too high. check the setting of amplitude.
 secondary frequencies on the horn. send the horn for checking to MS.

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