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Sonics 4095 Instruction Manual

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Models
4095 Press /
4096 Actuator
I N S T R U C T I O N
M A N U A L
Sonics & Materials,
Inc.

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Summary of Contents for Sonics 4095

  • Page 1 Models 4095 Press / 4096 Actuator I N S T R U C T I O N M A N U A L Sonics & Materials, Inc.
  • Page 2 (41) (0) 22/364 1520 • (41) (0) 22/364 2161 fax www.sonics.biz • info@sonics.biz europe@sonicsandmaterials.ch Information contained in this manual is subject to change without notice. Sonics & Materials, Inc. is not responsible for any typographic errors. © Sonics & Materials, Inc. 2007 Printed in U.S.A.
  • Page 3 I N S T R U C T I O N M A N U A L • M O D E L 4 0 9 5 / 4 0 9 6 Go To Top Of Document...

  • Page 4: Table Of Contents

    T A B L E O F C O N T E N T S IMPORTANT SERVICE LITERATURE ......4 Manual Change Information .

  • Page 5: Important Service Literature

    I M P O R T A N T S E R V I C E L I T E R A T U R E The system supplied with this instruction manual is constructed of the finest material and the workmanship meets the highest manufacturing standards. It has been thoroughly tested and inspected before leaving the factory and when used in accordance with the procedures outlined in this manual, will provide you with many years of safe and dependable service.

  • Page 6: Unpacking And Inspection

    If the system or any unit is damaged, notify “Sonics.” “Sonics” will arrange for repair or replacement of damaged equipment without waiting for the claim against the carrier to be settled, provided a new purchase order is issued to cover the repair or replacement costs.

  • Page 7: Introduction

    I N T R O D U C T I O N The models 4095 and 4096 are 40 kHz precision pneumatic actuators used for ultrasonic plastics assembly. The 4095 is a tabletop version, whereas the 4096 can be mounted on a bridge or rigid structural member for use with automated systems.
  • Page 8 “SONICS” ULTRASONIC ASSEMBLY SYSTEMS 50/60 Hz Electrical power Power Supply/Generator Generates ultrasonic electrical energy (15/20/40 kHz) Ultrasonic electrical energy Actuator/Press Provides compressive force and mounting for Converter, Converter Booster, Horn assembly Transforms ultrasonic electrical energy to ultrasonic mechanical vibrations Ultrasonic Vibrations...

  • Page 9: Glossary Of Ultrasonic Terms

    MODEL 4096 MODEL 4095 I N S T R U C T I O N M A N U A L • M O D E L 4 0 9 5 / 4 0 9 6...

  • Page 10: Installation

    I N S T A L L A T I O N ELECTRICAL POWER The press is powered by the power supply. Consult your power supply instruction manual to determine power specifications. AIR SUPPLY The press requires a source of dry, filtered (5 micron), oil-free, compressed air capable of supplying a constant line pressure of 85 psig.

  • Page 11: Connections

    (6 mm). NOTE: Do not strain or kink the cables. When 2. Connect the RF and base (actuating) cables of the press (4095 only) to the going around corners, power supply. (Consult your power supply instruction manual for details.) allow as wide a bend as 3.

  • Page 12: Initial Equipment Setup

    I N I T I A L E Q U I P M E N T S E T U P ASSEMBLING AND MOUNTING CONVERTER, BOOSTER, AND HORN If the converter, booster, and horn are not already assembled, follow these instructions: 1.
  • Page 13 5. Using the 3/16” (4.7 mm) T-handle wrench provided, loosen (turn counterclockwise) the two cap screws screws on the hinged converter housing and open the door. 6. Place the converter / booster / horn assembly in the housing with the horn facing down.

  • Page 14: Horn And Fixture Alignment

    HORN AND FIXTURE ALIGNMENT For maximum productivity, the clearance between the horn and the part should be at a minimum. However, adequate clearance should be provided to enable easy loading and unloading of the part from the holding fixture. (The maximum stroke distance is 3-1/2".) Ensure that the horn does not contact the part when the head is close to the limit of its down travel distance.

  • Page 15: Positive Stop Adjustment

    7. Lock the two column clamps, tighten the converter housing door screws, and then tighten the fixture on the base plate. 8. Check for proper mating of fixture, parts, and horn. If the horn and part are not in parallel contact, shim the fixture or adjust leveling screws as required.

  • Page 16: Operation

    EMERGENCY STOP To abort the 4095 press during welding, simply press the red EMERGENCY STOP button located at the front center of the press base. Once the EMERGENCY STOP button has been depressed, the head will NOTE: Power supply retract and return to its “home”...

  • Page 17: Fine Adjustments

    F I N E A D J U S T M E N T S PRESSURE SWITCH ADJUSTMENT For systems mounted in the normal vertical position with downward travel, no adjustment should be necessary. The minimum trigger pressure is factory set at 4-7 psig.

  • Page 18: Upper Limit Switch

    F I N E A D J U S T M E N T S UPPER LIMIT SWITCH The optional Upper Limit Switch is used as a safety interlock in automation to prevent the movement of material handling equipment (indexing) when the horn is down.

  • Page 19: Booster Selection

    BOOSTER SELECTION The first step in optimizing welding conditions is to select a booster which will provide the necessary amplitude. For parts one inch (25.4mm) in diameter or greater, start with a moderately high amplitude booster such as a gold. For NOTE: Consult the smaller parts, start with a green booster.

  • Page 20: Stroke Speed Adjustment

    STROKE SPEED ADJUSTMENT The velocity at which the horn descends and returns can be adjusted via the speed controls. These controls are factory adjusted for average operating conditions and should not require further adjustment. However, if a minor adjustment is necessary, adjust in small degrees. Turn clockwise to slow the extend speed, and counterclockwise to increase the return speed.

  • Page 21: Re-Establishing Proper Booster/Horn Interfaces

    RE-ESTABLISHING PROPER BOOSTER / HORN INTERFACES To re-establish proper interfaces, follow these instructions: 1. Using open-ended wrenches, separate the booster from the horn. Clean each item and then examine interfaces for irregularities (scoring). NOTE: Contact between the booster 2. If irregularities are present, remove the stud. and horn should be 3.

  • Page 22: Maintenance

    M A I N T E N A N C E REPAIRS / SERVICE If problems are encountered, contact our Service Department as follows: Phone: 1-800-745-1105 • 1-203-270-4600 Fax: 1-203-270-4610 E-Mail: service@sonicsandmaterials.com NOTE: If packing unit It is suggested that a system in need of repair be sent back to the factory, with for return shipment, a written description pertaining to the nature of the problem.

  • Page 23: Warranty

    Ultrasonic welding horns constructed of titanium or aluminum are guaranteed against defects for a period of one year from date of shipment. “Sonics” will repair or replace a cracked or defective horn once without charge, if failure occurs within the warranty period.
  • Page 24 “Sonics” reserves the right not to warrant horns of unusual or experimental design which in our judgment are more likely to fail in use. This warranty does not cover equipment used for applications requiring metal- to-metal contact with weld time in excess of 1 second.
  • Page 25 Go To Top Of Document Sonics & Materials, Inc. Corporate Headquarters European Office 53 Church Hill Road • Newtown, CT 06470 USA 22 ch du Vernay • CH - 1196 Gland, Switzerland 203.270.4600 • 800.745.1105 • 203.270.4610 fax (41) (0) 22/364 1520 • (41) (0) 22/364 2161 fax www.sonicsandmaterials.com •...

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4096

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