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2.2
Overview of this Model
The 2000X Micro 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
The 2000X Micro 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. The 2000X Micro Actuator is designed with remotely-mountable pneumatic
controls. Operation of the 2000X Micro is controlled by inputs to the 2000X distance Power
Supply. Having remote pneumatic controls allows easier user access to the Actuator
settings, often important in automated systems. The pneumatics covered in this manual
refer to the Interface Box, which is calibrated to operate as a system with the Actuator. If
the Interface Box or Actuator are changed, the system must be fully recalibrated.
The Carriage and Slide System
The 2000X Micro 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 controls on the 2000X Micro are contained in the 2000X Interface Box,
which is connected to the Actuator with three (3)1/4-inch-OD poly tubing lines. The 2000X
Micro Actuator's carriage and sheet-metal enclosure contains the air cylinder, which
receives air pressure and control from the 2000X Interface Box. There is a pressure
sensor in the Interface Box to allow the power supply to read the regulated air pressure.
The air pressure regulator, solenoid valves, and air pressure gauge are found in the
Interface Box. Filtered factory air is connected to the 2000X Interface Box. The horn's rate
of descent is adjusted by the Downspeed control on the Interface Box. The rate of return
is fixed. For information on setting the Downspeed control, see
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/start signal can be
released. As melting of the plastic occurs, the S-Beam dynamic follow-through maintains
consistent force on the part, ensuring smooth, efficient transmission of ultrasonic energy
into the part.
100-412-182 REV. 06
1.5.3 Departments to
Contact).
2.4 Controls and
19
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