2000X aed Actuator
Instruction Manual
Chapter 2: Introduction to the 2000X aed Actuator
Models Covered
Chapter 2: Introduction to the 2000X aed
Actuator
2.1
Models Covered
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2.1.1
Power Supply Manual Set - - - - - - - - - - - - - - - - - - - 2-3
2.2
Overview of this Model
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2.3
Features of the System
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2.4
Controls and Indicators
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2.5
Welding Systems
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2.6
Glossary of Terms
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The 2000X Actuator provides motion, force, power (from the power supply), and cooling air to the ultrasonic stack assembly. The 2000X aed Actuator is designed to work with a Branson
2000X distance Power Supply.
2.1 Models Covered
This manual covers the Branson 2000X aed Actuator. The 2000X aed Actuator may be found in one of several configurations:
• An Actuator on a Column Support, Column and Ergonomic Base, also called a Stand on Base
(as seen on the following page)
• An Actuator on a Column Support, Column and Mounting Hub, sometimes called a Stand on
Hub
• An Actuator alone (not installed on a Column Support, and so on.). These are often used in custom or automated systems that provide a means of positioning the Actuator
This manual covers these configurations. A 2000X-series actuator requires a 2000X-series power supply to function, and that is covered in separate manuals and user documents.
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Models Covered
Figure 2-1 shows a Branson 2000X aed Actuator mounted on a column support which, in turn is mounted on a column, and is supported by the ergonomic base.
Figure 2.1
Left Side View of the 2000X aed Actuator
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Chapter 2: Introduction to the 2000X aed Actuator
Figure 2.2
Left Side View of the 2000X aed 15kHz Actuator
Overview of this Model
2.1.1 Power Supply Manual Set
The following documentation is available for the Branson 2000X-series Power Supplies that are compatible with the 2000X aed Actuator:
• 2000X distance Power Supply Instruction Manual (EDP 100-412-167)
• 2000-Series Installation Guide (EDP 100-214-226)
• 2000X distance Quick Start User’s Guide (EDP 100-412-169)
2.2 Overview of this Model
The 2000X aed Actuator is a compact, rigid unit designed for use in manual, semi-automated, and automated ultrasonic welding systems. The Actuator can be mounted directly on an I-beam
(or similar machine frame), or it can be mounted on a column and base with start switches and used in a manual or benchtop system. The Actuator is designed to be operated in an upright position, but is capable of running horizontally or inverted. If you are mounting your equipment in an inverted position, contact Branson for further recommendations. (See
1.5.3, Departments to
Contact,
on page 1-14.)
The 2000X aed Actuator requires a 2000X distance Power Supply for power and control of the
Actuator’s operation and to provide ultrasonic power to the Converter in the Actuator.
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Features of the System
2-4
The 2000X aed Actuator is designed with full, built-in pneumatic controls, and mechanical controls. Operation of the 2000X aed is controlled by inputs to the 2000X distance Power Supply.
The pneumatics covered in this manual refer to the remote box package sold by Branson. Some customers may require custom controls.
The Carriage and Slide System
The 2000X aed Actuator’s carriage is driven by a double-acting air cylinder. It is mounted on a linear ball-bearing slide. The slide system is based on eight sets of preloaded,
permanently lubricated
bearings and provides consistent, precise alignment of the horn, smooth linear motion, and long-term reliability.
The Pneumatic System
The pneumatic system included on the 2000X aed model is contained within the Actuator’s sheet-metal enclosure and consists of solenoid valves, an air cylinder, and a pressure regulator with an air pressure gauge. There is a pressure sensor in the actuator to allow the power supply to read the regulated air pressure. The horn’s rate of descent is adjusted by the Downspeed control on the front panel of the Actuator. The rate of return is fixed. For information on setting the
Downspeed control, see
Section 2.4: Controls and Indicators
.
Dynamic Triggering and Follow-Through
Many welding applications require force to be built up on the part before ultrasonic energy is activated. To achieve this, the Actuator contains a S-Beam load cell, located between the air cylinder and the converter, which initiates (triggers) ultrasonics after a preset force is applied to the part. Dynamic follow-through maintains a consistent force on the part during the weld collapse.
This system helps provide uniform weld quality.
The dynamic triggering and follow-through process operates as follows: upon activation of the operating cycle, the solenoid valve delivers regulated air to the upper portion of the cylinder, and exhausts air through the Downspeed control from the bottom of the cylinder, causing the horn to advance and contact the workpiece. When the load cell measurement of the force on the part indicates part contact, and the desired trigger force is reached, a signal is sent to the Power Supply, which then starts the weld cycle. At this time, the actuator locks into a cycle, timing begins, and the palm buttons can be released. As melting of the plastic occurs, the load cell dynamic follow through maintains consistent force on the part, ensuring smooth, efficient transmission of ultrasonic energy into the part.
2.3 Features of the System
Listed below are many features of the Branson 2000X-series ultrasonic welding system included in a 2000X aed Actuator and 2000X distance Power Supply.
•
Autotuning:
Branson Power Supply tuning ensures that the system is running at peak efficiency
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Features of the System
•
Amplitude Stepping:
A patented Branson process, controlled by the Power Supply.
At a specified time, energy, peak power, distance, or by external signal you can change the amplitude during the weld to control the flow of plastic. This feature helps ensure part consistency, higher strength parts and control of flash
•
Digital Horn Test Diagnostics:
In Test mode of the Power Supply, you can view the
Horn Test results in digital form, using digital readouts and bar graphs on the Power
Supply to give you the best picture of the stack’s operation
•
Pretrigger:
This feature allows you to set the system weld controls to turn the ultrasonics on
before
contact with the part
•
Afterburst:
This feature allows you to set the system weld controls to turn the ultrasonics on
after
the weld and hold steps to release parts from the horn
•
Control Limits:
With some power supply models, these secondary controls are used in conjunction with the main parameters of the weld parameters. These userprogrammed limits provide for adaptive control of the weld process
•
Process Alarm Display Showing Actual and Set Values:
When an alarm condition has occurred, you can view the value for the last weld and the suspect and reject settings you programmed into the controls
•
Post Weld Seek:
This system feature provides a short burst of energy at the end of the weld Hold and Afterburst steps to automatically retune the power supply, if required
•
Frequency Offset:
This process feature allows a user to set a frequency value, for certain specific applications, where the force imparted on the fixture or anvil causes a frequency shift in the Stack’s operation. You should only use this feature when advised to do so by Branson
•
English (USCS)/Metric Units:
This feature allows the welder to be set up in the local units in use
•
Startup Diagnostics:
At power supply startup, the controls test the major system components, including the Actuator and its controls
•
Weld Parameter Entry through Digital Keypad:
User Setup is direct and easy, by selecting the menu parameter by name and using the keypad to enter the precise value. The controls also support entry by incrementing existing values
•
System Information Screen:
This is a screen that will give you information about your welding system (e.g., cylinder size, stroke length, number of cycles). Refer to this screen when contacting Branson for service and support
•
Ramp Starting:
The starting of the 2000X-series power supply and horn is done at the optimum rate to reduce electrical and mechanical stress on the system. This also helps make some tough-to-start applications possible
•
True Wattmeter:
The controls on the power supply include a true wattmeter for accurate measurement of power and energy
•
S-Beam Load Cell/Dynamic Follow Through:
The load cell allows the ultrasonics to be triggered at a designated force input into the power supply
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Controls and Indicators
•
Encoder:
Allows the power supply to monitor the distance the horn has travelled, enabling the use of distance functions
•
Downspeed
: Controls the rate of descent and force build-up on the part
•
Pressure Sensor:
Allows the power supply to read the system pressure
2.4 Controls and Indicators
•
S-Beam Load Cell:
Provides an indication of the force on a part during a weld. This indication can be used to determine when to trigger ultrasonics and also to produce a force/distance graph of the operating cycle
The front panel controls on the 2000X aed Actuator are listed below.
•
Power Light:
Indicates that the Actuator is connected to the Power Supply and that the
Power Supply’s main power is on
•
Pressure Gauge:
Indicates the amount of factory air pressure applied to the cylinder; dual graduated at 0-100 psi and 0-700 kPa
•
Pressure Regulator:
Adjust the amount of air pressure applied to the cylinder; range of 5-
100 psig (35-700 kPa). Pull to set; push to lock
• Downspeed Control:
Downspeed knob controls the rate of descent and force buildup on the part to be welded
• Carriage Door:
Provides access to the converter-booster-horn stack; secured by four captive hex screws. Use a M5 T-handle wrench to tighten the cap screws for the 2000X aed
Actuator. Use a M8 T-handle wrench to tighten the cap screws for the 2000X aed 15kHz
Actuator
• Mechanical Stop:
Limits the stroke length to prevent the horn from contacting the fixture when no workpiece is in place; adjustment is approximately 0.07 in. (1.75 mm) per rotation for the 2000X aed 15kHz Actuator; adjustment is approximately 0.04 in. (1 mm) per rotation for 2000X Actuator; a locking ring keeps the setting from vibrating loose. Turning the knob clockwise increases the stroke length. There is an indicator on the side to provide a relative distance
The mechanical stop is not intended for welding by distance.
Turning the mechanical stop too far can cause it to come apart.
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Welding Systems
2.5 Welding Systems
Ultrasonic Plastics Welding
Thermoplastic parts are welded ultrasonically by applying high-frequency vibrations to the parts being assembled. The vibrations, through surface and intermolecular friction, produce a sharp rise in temperature at the welding interface.
When the temperature is high enough to melt the plastic, there is a flow
of material between the parts. When the vibrations stop, the material solidifies under pressure and a weld results.
The Plastics Welding System
The welding system consists of a power supply, an actuator, and a converter-booster-horn stack.
The system can perform a variety of ultrasonic welding operations, including: inserting, staking, spot welding, swaging, degating, and continuous operations. It is designed for use in automated, semi-automated, and/or manual production systems.
Power Supply
The 2000X distance Power Supply converts conventional 50/60 Hz line current to high frequency electrical energy. It also contains all the electronic controls and can be located remotely from the Actuator. This allows the operator to adjust or reprogram the welding cycle remotely from the Actuator and related welding, tooling, and parts-handling systems.
The 2000X distance Power Supply also contains a DC power supply for electrical power to operate the electrical components and control circuits in the power supply, and on the Actuator.
The Power Supply is configured with either an analog or digital UPS. The analog supply has one preset which calls up the factory default setting.
The digital supply has a library of 20 locked presets which are accessible for various process parameter modifications that are unique to the power supply itself. These modifications can be named to reflect specific applications, and are loaded into memory prior to shipment from the
Branson factory. The parameters of the individual presets can be modified by a Branson representative. Initially all 20 Presets are set to factory default. They are accessed via an RS232 link to the system controller.
Converter
The converter is mounted in the actuator as part of the ultrasonic stack. The ultrasonic electrical energy from the power supply is applied to the converter (sometimes called the transducer). This transforms the high frequency electrical oscillations into mechanical vibrations at the same frequency as the electrical oscillations. The heart of the converter are piezoelectric ceramic elements. When subjected to an alternating voltage, these elements alternately expand and contract, resulting in better than 90% conversion of electrical to mechanical energy.
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Welding Systems
Booster
Success in ultrasonic assembly depends on the right amplitude of movement at the horn face.
Amplitude is a function of horn shape, which is largely determined by the size and form of the parts to be assembled. The booster can be used as a mechanical transformer to increase or decrease the amplitude of vibrations applied to the parts through the horn.
The booster is a resonant half-wave section of aluminum or titanium. It is mounted between the converter and the horn, as part of the ultrasonic stack. It also provides a clamping point for rigid stack mounting.
Boosters are designed to resonate at the same frequency as the converter with which they are used. Boosters are usually mounted at a nodal (minimum vibration) point of axial motion. This minimizes the loss of energy and prevents vibration from being transmitted into the actuator.
Horn
The horn is selected or designed for a specific application. Each horn is tuned typically as a halfwave section that applies the necessary force and vibration uniformly to the parts to be assembled. It transfers ultrasonic vibrations from the converter to the workpiece. The horn is mounted to the booster as part of the ultrasonic stack.
Depending on their profile, horns are referred to as stepped, conical, exponential, bar, or catenoidal. The shape of the horn determines the amplitude at the face of the horn. Depending on the application, horns can be made from titanium alloys, aluminum, or steel. Titanium alloys are the best materials for horn fabrication due to their high level of strength and low loss. Aluminum horns are usually chrome- or nickel-plated or hard-coated to reduce wear. Steel horns are for low amplitude requiring hardness, such as ultrasonic insertion applications.
S-Beam Load Cell and Dynamic Follow Through
The S-Beam Load Cell measures the force being applied to the part to trigger ultrasonics and record the welding parameters. The load cell assembly ensures that pressure is applied to the part prior to the application of ultrasonic energy.
To maintain horn-to-part contact and force as the joint collapses, the load cell assembly provides dynamic follow-through. As the plastic melts, the load cell assembly ensures smooth transmission of ultrasonic energy into the part.
Encoder
The encoder measures the distance the horn has travelled. Depending on the power supply settings, it can:
• Allow for distance welding in absolute and collapse modes
• Detect improper setup controls
• Monitor the distance data of the weld
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Glossary of Terms
2.6 Glossary of Terms
The following terminology may be encountered when using or operating a 2000X-series ultrasonic welding system. Some of these terms may not be available in all Controls (Power Supply model) configurations:
AB Amplitude:
The amplitude at the horn face during the afterburst step.
AB Delay:
Time delay between the end of the hold and the start of the afterburst.
AB Time:
The duration of the afterburst.
Abort Current Printing:
Terminates the current printing request.
Absolute Cutoff:
Ends the ultrasonic portion of the cycle when the set absolute distance is reached.
Absolute Distance:
The distance the horn has travelled from home (ULS deactivation).
Absolute Mode:
A mode of operation in which the ultrasonic portion of the cycle is terminated when a user-specified distance from home has been reached.
Absolute Position:
The position of the actuator after clearing the Upper Limit Switch.
Actual:
A reported value that occurred during the weld cycle. The converse is the set parameter that was requested during the setup.
Afterburst:
Ultrasonic energy applied after the hold step. Used to break away sticking parts from the tooling.
Alarm Beeper:
An audible signal that sounds when a general alarm has occurred.
Amplitude:
The peak-to-peak movement at the horn face. Always expressed as a percentage of the maximum.
Amp A:
The amplitude applied to the part from the start of the weld to the step change.
Amp B:
The amplitude applied to the part from the step change to the end of the weld.
Amplitude Graph:
A graph of amplitude percentage plotted against time.
Amplitude Step:
A change in amplitude during the ultrasonic portion of the cycle.
Amp Control:
The ability to set amplitude digitally or by an external control.
Automatic:
A pretrigger condition indicating that pretrigger engages when the actuator leaves the upper limit switch.
Baud Rate:
The rate of data transmission over the serial communication port.
Beep:
An audible signal produced by the Branson control board. Used to alert the operator to an unexpected condition.
Cold Start:
A condition that restores a setup to its default values.
Collapse Distance:
The distance the horn has travelled from the trigger point of ultrasonics.
Collapse Mode:
A mode in which the ultrasonics portion of the cycle is terminated when a userspecified distance from the trigger point has been reached.
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Control Limits:
Additional parameters that determine the end of the ultrasonic portion of the cycle and the move to the hold state.
Converter:
The device that converts electrical energy into mechanical vibrations at a high frequency (an ultrasonic rate). The Converter is a central component of the welding system and is mounted in the Actuator.
Counters:
A record of the number of cycles run by category, for example, alarms, good parts, and so on, recorded in the Controls.
Digital Filter:
A smoothing technique used to provide more meaningful data.
Down Speed:
The user-definable speed of descent (percentage of maximum speed) during the down stroke of the Actuator.
Energy Mode:
A mode of operation in which ultrasonics are terminated at a user-specified energy value.
External Amplitude Control:
Enables you to access real-time amplitude control directly.
External Frequency Control:
Enables you to access real-time frequency control directly.
Form Feed:
When using a printer with the 2000Xd Power Supply to capture weld data, you can insert a form feed after print setup, print graph, or after reaching the number of lines per page.
Frequency:
The operating frequency of the ultrasonic stack. The frequency stored is measured at the end of the ultrasonic portion of the cycle (when ultrasonics are terminated).
Freq End:
The frequency at the end of the ultrasonic portion of the welding cycle (when ultrasonics are terminated).
F Actual:
The actual running frequency of the acoustic system.
F Memory:
The frequency stored in the Power Supply memory.
Frequency Offset:
An offset factor applied to the ultrasonic frequency stored in the Power Supply.
General Alarm:
An alarm that occurs due to system fault and/or tripping a limit.
Ground Det. Cutoff:
Ground Detect Cutoff. Immediately terminates the weld process, including the hold step, when a ground detect has occurred.
Gnd Det. Mode:
Ground Detect Mode, available in all models of 2000X power supplies. In this mode of operation, ultrasonics are terminated after detection of a ground condition between the horn and fixture or anvil.
Hold Force:
The force on the part during the hold portion of the cycle.
Hold Time:
The duration of the hold step.
Horn Down:
A mode in which ultrasonics are locked out and the user can advance the Actuator for setup and alignment.
Linear Encoder:
Provides carriage (horn) distance measurement during the Actuator cycle.
Lines per Page:
When using an optional Printer, the number of welds per printed page.
S-Beam Load Cell:
Provides force measurement for accurate ultrasonic triggering and graphing of force.
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Glossary of Terms
Main Menu:
The list of categories of features available in the software, as displayed on the front panel of the Power Supply. Accessible by using a power supply front-panel button.
Max Energy:
Maximum Energy. The maximum user-specified energy that produces a part without an alarm.
Min Energy:
Minimum Energy. The minimum user-specified energy that produces a part without an alarm.
Minus Limit:
The user-defined lower limit, or lower extreme of an acceptable range for a given parameter. See Control Limits in the Power Supply manual.
Parameter Range:
Valid range of parameters accepted for a particular setup.
Parameter Step:
Ability to dynamically change amplitude during the weld cycle.
Password:
A user-defined access code for the secure areas of the Power Supply’s user controls.
Password Protection:
Enables lock-out of the Power Supply’s weld parameter modification by using a user-defined password.
Peak Power Cutoff:
A power value that terminates the ultrasonics when peak power is not the primary control mode.
Pk Pwr Mode:
Peak Power Mode. A mode of operation in which ultrasonics are terminated at a user-specified power value in percentage of maximum.
Plus Limit:
The user-defined upper limit. See Control Limits, Suspect, Reject and Missing
Part Limits in the Power Supply manual.
Post Weld Seek:
Used to determine the operating frequency of the Stack, after the Hold and/or
Afterburst portion of the weld cycle. Ultrasonics are run at a low level (5%) amplitude during this step, and the frequency is stored to memory.
Power Graph:
A printed graph of power in percentage of maximum plotted against time.
Preset:
A method of saving the power supply’s user-set parameters to memory, for a given
Setup. The Power Supply model may allow multiple presets for easy recall of a Setup’s parameters, for a given part, process or operation. Presets can be labeled by the user or the system.
Preset Name:
The ability to name a preset in customer-defined terms. Not available in the
2000Xt Power Supply.
Pretrigger:
The setting that causes ultrasonics to start before contact with the part (or, before the set Trigger Force has been met).
Pretrig Amp:
Pretrigger Amplitude. The amplitude at the horn face during pretrigger.
Print on Alarm:
Allows the user to set up printing automatically when an alarm occurs.
Print on Sample:
Allows the user to set up printing automatically based on the number of cycles performed.
Ready Position:
State in which the welder is retracted to the home position and ready to receive the start signal, ready to operate.
Recall Preset:
Allows a user to activate a preset from memory for purposes of operation or modification.
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Glossary of Terms
Reject Limits:
User-definable limits at which the violating cycle is identified as having produced a bad part.
Required:
State used with limits indicating that a reset will be required when the limit is exceeded. The reset is accomplished by using the reset key on the front of the Power Supply.
Reset Required:
State used with limits indicating that a reset will be required when the limit is exceeded. The reset is accomplished by using the reset key on the front of the Power Supply.
Run Screen:
The screen showing weld status, alarms, weld count, and process information.
Available using a front-panel button on the Power Supply.
Save Preset:
Stores a programmed set of weld parameters as a Preset.
Scrub Time:
In Ground Detect mode, the amount of time after detection of a ground condition before the termination of ultrasonics, and end of the cycle.
Seek:
The activation of ultrasonics at a low-level (5%) amplitude, for the purpose of finding the resonant frequency of the Stack.
Serial Port:
A RS232 port provided to you for external data communications.
Step @ Energy:
User-definable point at which AmpA is changed to AmpB.
Step @ Ext Sig:
Allows you to shift either force or amplitude based upon an external signal.
Step @ Power:
User-definable point at which AmpA is changed to AmpB.
Step @ Time:
User-definable point at which AmpA is changed to AmpB.
Suspect Limits:
User-definable limits at which the resultant weld in a welding cycle is identified as potentially bad (suspect).
Test Scale:
The magnification of the power bar on the front panel of the Power Supply, useful for lower-power applications that want a more accurate (but smaller) scale.
Time Mode:
Terminates the ultrasonics at a user-specified time.
Timeout:
A time at which the ultrasonic energy terminates if the main control parameter has not been reached.
Trigger Beeper:
An audible signal sounded when the trigger force has been met, and the trigger switch is made.
Trig Delay:
Trigger Delay. A user-programmable time delay between engagement of the trigger switch and start of ultrasonics and ramping of force to the weld force.
User-defined Limits:
for process resultants, where - is the user-defined lower limit, and + is the user defined upper limit:
-/+ S/R Energy: The energy reached during the weld.
-/+ S/R Freq: The peak frequency reached during a weld.
-/+ S/R Power: The peak power as a percentage of the maximum reached during the weld.
-/+ S/R Abs D: The absolute distance reached during the weld from the Upper Limit
Switch.
-/+ S/R Col D: The collapse distance reached from trigger to end of weld.
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-/+ S/R Trg D: The distance at which the trigger occurred.
-/+ S/R Time: The weld time reached during the weld.
Weld Count:
Count of acceptable weld cycles.
Weld Energy:
The energy specified to be applied to the part during the weld cycle.
Weld History:
The last 50 weld summary data lines are saved.
Weld Scale:
The power bar LED scale during weld.
Weld State:
A screen message showing the current state of the welder during or before the process. The list of messages are shown in the Run Screen section.
Weld Results:
A one-line summary of information concerning the last weld cycle.
Weld Time:
The time for which ultrasonics are on.
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Glossary of Terms
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