Summary of Contents for Branson Emerson Ultrasplice 40
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Original Instructions DCM00038 - REV. 08 Ultrasplice 40 Actuator O p e r a t i n g M a n u a l Branson Ultrasonics Corp. 120 Park Ridge Road Brookfield, CT 06804 (203) 796-0400 http://www.bransonultrasonics.com...
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Foreword Congratulations on your choice of a Branson system! The Branson Ultrasplice 40 Series system is process equipment for the joining of metal parts using ultrasonic energy. It is the newest generation of product using this sophisticated technology for a variety of customer applications. This Operating Manual is part of the documentation set for this system, and should be kept with the equipment.
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List of Tables Chapter 1: Safety and Support Chapter 2: The Ultrasplice 40 Actuator Table 2.1 Calculating Power ..........19 Table 2.2 Calculating Energy.
This chapter contains an explanation of the different Safety Notice symbols and icons found both in this manual and on the product itself and provides additional safety information for ultrasonic welding. This chapter also describes how to contact Branson Metal Welding for assistance.
General Precautions Take the following precautions before servicing the Controller: CAUTION Be sure the power switch is in the Off position before making any electrical connections. • To prevent the possibility of an electrical shock, always plug the Controller into a grounded power source •...
• 29 CFR 1910.212 OSHA General Requirements for all machines • 47 CFR Part 18 Federal Communications Commission • The Branson Ultrasplice 40 Actuator is designed to be in compliance with the following European standards as specified by the Directives issued by the European Parliament and The Council of the European Union: •...
Warranty For warranty information please reference the warranty section of Terms and Conditions found at: www.emerson.com/branson-terms-conditions. DCM00038 REV. 07...
How to Contact Branson Branson is here to help you. We appreciate your business and are interested in helping you successfully use our products. To contact Branson for help, use the following telephone numbers, or contact the field office nearest you.
To return equipment to Branson, you must first obtain an RGA number from a Branson representative, or the shipment may be delayed or refused. If you are returning equipment to Branson for repair, you must first call the Repair Returned Goods Authorization department to obtain a (RGA) number.
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8. For equipment not covered by warranty, to avoid delay, include a Purchase Order. Send a copy of this page with the equipment being returned for repair. 1.5.3 Contact Information Call your local Branson Metal Welding Representative, or contact Branson by calling (203) 796-0400. My Local Branson Representative's name is: _______________________________________________________________________...
Obtaining Replacement Parts You can reach Branson Parts Store at the following telephone numbers: • Direct Telephone Number: (203) 796-9807 • Fax number: (203) 926-2678 Many parts can be shipped the same day if ordered before 2:30 p.m., Eastern time.
Model Covered This manual contains instructions for installing, setting up and operating the Ultrasplice 40 Actuator. An Ultrasplice 40 Actuator requires a compatible Branson Metal Welding Controller to function, that is covered in separate manuals and user documents. 2.1.1 Controller Manual Set...
2.2.2 The Pneumatic System A pneumatic cylinder drives the anvil actuator to apply a precise pressure to the parts to be welded during the weld cycle. Pneumatic control is done by a compatible Branson Metal Welding Controller. 2.2.3 The Linear Encoder The linear encoder is a sensing device that tracks mechanical displacements related to the splice's resulting height and/or width.
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The horn is coated to further enhance tool life and to provide corrosion resistance. Since the horn is a vital part of the ultrasonic assembly system, it should not be altered without proper training and advice from Branson. 2.2.7...
Figure 2.2 Gather and Anvil Anvil Gather 2.2.8 Anvil The Anvil contains a serrated or knurled surface and is designed to hold the wires to be welded stationary against the lower component, which is vibrating at 40,000 Hz. The Anvil is supported on precision, roller bearings and applies the compressive force required to bond the wires.
Features The UltraSplice 40 is a complete 40 kHz, precision, light weight and portable, ultrasonic wire splicing system capable of producing perfect quality wire splices up to six square millimeters in cross section using an advanced 700 watt power supply. The Ultrasplice 40 ultrasonic wire splicer offers the following features: •...
Controls • Down Stop: The down stop is used to prevent contact between the Horn and Anvil if the welder is cycled without the part(s) to be welded. A minimum gap of 0.001 in (0.02mm) is recommended • Gather adjusting screw: Used to set the width of the compression chamber. Depending on the application the anvil will need to be set accordingly DCM00038 REV.
Ultrasonic Theory 2.5.1 What Is an Ultrasonic Weld? Ultrasonic welding joins metal parts by applying the energy of high frequency vibrations onto the interface area between the parts to be welded. 2.5.1.1 How Does It Work? Electrical Energy is transformed into high frequency mechanical vibration. This mechanical vibration is transferred to a welding tip through an acoustically tuned horn.
The power required to initiate and maintain vibration (motion) during the weld cycle can be defined as: Table 2.1 Calculating Power Where: • P = Power (watts) P = F x A x f • F = Force * (N) •...
Figure 2.5 Weld Power Graph for Clean Components, Dirty Components and when Part is Missing 2.5.4 Power The converter/ booster/ horn, (stack assembly), requires minimal electrical power to initiate and maintain motion (vibration) at a ‘no-load’ condition. As the mechanical load increases, the power required to maintain the mechanical vibration also increases.
2.5.5 Time The time required to deliver the necessary energy is defined as the Weld Time. For most welds, the time required will be less than one second. If more energy is required and all other weld parameters are maintained, the weld time will increase (Figure 2.7).
also increases. Subsequently, because of the increased Power less time is required deliver the same amount of Energy. This relationship is illustrated in the following power diagram (Figure 2.9): Figure 2.9 Amplitude’s Influence on Weld Power and Time 2.5.7 Resonant Frequency The ultrasonic tooling acts as a spring having node points and anti-node points.
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2.5.8 Avoiding an Overload Condition It is possible to increase the Amplitude and or the Pressure to a point where the power available is not adequate to initiate or maintain vibration under the given mechanical load. At this point, the power supply will stall resulting in an Overload condition. NOTICE Electronic circuits in the system will protect the power supply if an overload condition exists.
Terminology Actuator: A mechanical device which houses the converter/booster/horn (stack) assembly in a rigid mounting and is utilized to move the stack up or down. This allows for precise control of welding pressure while delivering mechanical vibrations from the ultrasonic stack to the work piece(s). After Burst: A short duration (burst) of ultrasonic energy that begins after completion of the AFTER BURST DELAY.
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Energy: Energy is the area beneath the ultrasonic power curve and is calculated in joules, (Watts X Seconds = Joules). When the ultrasonic welding system is setup in the “Weld In Energy” mode the system will deliver the amount of energy as programmed. NOTE: The maximum (default) time allowed for delivering ultrasonic energy is five (5) seconds.
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Power Supply (Ultrasonic): An electronic device that converts 50/60 cycle electrical current into 20 kHz, (20,000), 40 kHz (40,000), or 60 kHz, (60,000) cycles per second high frequency electrical energy. Power Supply Overload (Ultrasonic): The point or limit at which the amount of power in watts, required to keep the ultrasonic stack in motion, exceeds the available power from the power supply.
Shipping and Handling The Ultrasplice 40 actuator is a system of metal and electro-pneumatic components that move the ultrasonic tooling in the ultrasonic welding system and control aspects of the weld process. Many of its components can be harmed if the unit is dropped, shipped under improper conditions, or otherwise mishandled.
Receiving and Unpacking Branson Metal Welding actuator units are carefully checked and packed before dispatch. It is recommended, however, that you follow the inspection procedure below after delivery. To inspect the Ultrasplice 40 Actuator when it is delivered: Table 3.2...
Returning Equipment If you are returning equipment to Branson, please call your Branson Metal Welding Representative or Customer Service to receive approval to return goods to Branson. If you are returning equipment for repair refer to Chapter 1: Safety and...
About Installation This chapter is intended to help the installer with the basic installation and setup of your new Ultrasplice 40 system. This chapter will bring the reader to the point at which the system is functionally “ready to weld”. CAUTION The Controller is heavy.
Handling and Unpacking If there are any visible signs of damage to the shipping containers or the product, or you later discover hidden damage, take pictures, and NOTIFY YOUR CARRIER IMMEDIATELY. Save the packing material. 1. Unpack the Ultrasplice 40 components as soon as they arrive. Refer to the following procedures. 2.
Take Inventory of Small Parts Table 4.1 Standard small parts included with Controller and/or Actuator Part or Kit Description Comments (Optional Item) 211-127 40 kHz Torque Wrench Purchase Separately Dial Indicator with Modified Magnetic (Optional Item) X3A50252 Base Purchase Separately 201-118-024 Spanner Wrench Toolkit...
Installation Requirements 4.4.1 Location The actuator may be installed in a variety of positions. The Ultrasplice 40 is often manually operated using a foot switch, and so it can be installed at a safe and comfortable workbench height (approximately 30-36 inches) with the operator sitting or standing in front of the system.
4.4.3 Electrical Input Power Ratings Plug the Controller into a single-phase, grounded, 3-wire, 50 or 60 Hz power source. Table 4.4 lists the current and fuse ratings for the various models. Table 4.4 Input Power requirements Model Power Current Rating NEMA Connector 400 W 90V - 10 Amp Max.
Installation Steps 4.5.1 Mounting the Controller The Controller is designed to be placed on a workbench (rubber feet on bottom) within cable length limits of the actuator. It has two rear-mounted fans which draw cooling air from rear to front, which must be free from obstruction. Do not place the Controller on the floor or in other locations that will allow dust, dirt or contaminants to be drawn into the Controller.
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Performance and results can suffer if the RF cable is crushed, pinched, damaged or modified. Contact your Branson Representative if you have special cable requirements. In some cases, remote operation from a User I/O or a Remote Terminal can be used to solve a distance limitation.
Safety Devices The removal, bridging or disabling of safety devices is not condoned for production operation. Individual safety devices mentioned below may only be disabled if super- ordinate safety devices are employed in their place. 4.6.1 Emergency Stop In case of danger, hit the red, emergency stop Which is found on the red, top portion of the foot pedal.
Ultrasonic Stack Assembly Table 4.5 Ultrasonic Stack Assembly Procedure Action Reference • Clean shell, booster and converter faces and diaphragm surfaces with solvent to remove all contaminants and previously used paste • Place shell on clean bench, either flat side down •...
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Table 4.5 Ultrasonic Stack Assembly Procedure Action Reference • Place the assembled stack in a (optional) Benchtop stack mounting block • Using a spanner wrench on the horn, tighten to 175 in-lbs. • Tighten the converter to Booster to 150 in-lbs.
4.7.1 Installing the Stack in the Actuator The ultrasonic stack must first be assembled. To install the stack:. WARNING Make sure that the system power is turned off by disconnecting the power plug. Table 4.6 Mounting the Stack on the UltraSplice 40 Actuator Action Reference •...
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Table 4.6 Mounting the Stack on the UltraSplice 40 Actuator Action Reference • Loosen the gather assembly retaining screws but do not remove • Slide the gather assembly up and snug one screw to hold the gather assembly in its upper position •...
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Table 4.6 Mounting the Stack on the UltraSplice 40 Actuator Action Reference • Place Stack into the actuator • Carefully bring the tip portion under the gather block • Install the following: -Stack Space Plate -Upper Stack Mount & -Upper Brace •...
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Table 4.6 Mounting the Stack on the UltraSplice 40 Actuator Action Reference • Set tip guide gap by slightly loosening the Tip Glide clamp • Place a 0.001” Shim between the Tip and Tip Guide, as shown • Loosen the Tip Guide lock nut and slowly bring in the set screw until a slight drag is obtained on the shim •...
4.7.2 Down Stop Adjustment Table 4.7 Adjusting the Down Stop Action Reference • To adjust the anvil down stop, place a 0.001” to 0.002” shim between the tip and anvil as using a hex key wrench - turn the larger of the (2) socket head cap screws located on the side of the unit clockwise as needed •...
4.7.3 Setting Anvil Width Table 4.8 Setting Anvil Width Action Reference • Depending on the application, the Anvil Clamp Screw anvil will need to be set accordingly • Feeler Gages, Gage Pins and Drill Blanks are recommended for setting Anvil Width the required Anvil Width •...
4.7.4 Other Tooling Gaps Table 4.9 Other Tooling Gaps Action Reference • If needed, the Anvil Arm support screw can be adjusted, as shown to set the Anvil to tip gap • This is generally factory set Gather Adjusting Screw •...
Table 4.9 Other Tooling Gaps Action Reference • Completed Assembly 4.7.5 Rotating Tip Table 4.10 Rotating Tip Action Reference • The Tip can also be rotated or replaced without removing the stack • Remove the Tip Nut, Rotate the keyed Tip and re-install the Tip Nut NOTICE LEFT HAND THREADS...
Testing the Installation 4.8.1 Check Splicer Performance Ensure that nothing is touching the horn on all four sides. With the tooling disengaged and the welder unloaded, press the “SONICS” button on the Touchscreen controller for no longer than one second. If there is a loud squealing noise, the problem may be in the following areas: •...
Still Need Help? Branson is pleased that you chose our product and we are here for you! If you need parts or technical assistance with your Ultrasplice 40 system, call your local Branson Metal Welding representative or contact the Branson customer service by calling the appropriate department as indicated in 1.5.3 Contact...
Technical Specifications 5.1.1 Requirement Specifications The Ultrasplice 40 actuator requires compressed air. The factory air source must be “clean and dry air”, that is, without moisture or lubricants. The Actuator requires 70 psi minimum pressure for operation and cooling, and can require up to 80 psi maximum, depending on the application.
Actuator Controls This section describes how to operate a weld cycle using the Ultrasplice 40 Actuator. For more detailed information on making and altering settings, refer to your Controller Manual. CAUTION Keep fingers away from the splicing nest when setting up and operating the Actuator.
Initial Actuator Settings 6.2.1 Weld parameters To obtain quality welds each and every time, the correct combination of weld parameter settings must be developed. These parameters include: • Energy (Joules) • Weld Pressure, Pressure During Sonics (psi/bar) • Amplitude (Microns) •...
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6.2.5 Emergency Stop The emergency stop is found on the red, top portion of the foot pedal. When engaged it will prevent the actuator from running, and will also immediately terminate a weld cycle and cause the actuator to return to its “Home” position. It does not remove power from the system.
Operating the Actuator For detailed information about Ultrasplice 40 Actuator controls, refer to 2.4 Controls. 6.3.1 Check Welder Performance Ensure that nothing is touching the horn on all four sides. With the tooling disengaged and the welder unloaded, press the “SONICS” button on the Touchscreen controller for no longer than one second.
10%. Continue to follow this sequence until the splice looks good with no broken strands or flash. Once you have achieved a splice that appears good by following step 4 above, it is time to do some destructive testing. Pull test the splice according to recommended pull test technique.
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peel strength while decreasing the pull strength and therefore the ability of the splice to perform satisfactory. Table 6.2 Wire Splice Comparison Photo of Condition Schematic Description WIRE OVERLAP - Damaged or burnt insulation OVER WELDED - Wire not fully inserted into weld pocket UNDER WELDED - Pressure too low...
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Table 6.2 Wire Splice Comparison Photo of Condition Schematic Description FLASH - Gather gap too big SIDE SPLICE - Incorrect wire stacking in weld pocket GOOD SPLICE 6.3.4 Spliced Wire Pull-Testing The weakest wire in tension of any splice is the wire with the smallest cross sectional area or gage.
“How do I maximize tensile strength?” Studies at Branson on a range of wires in a 2 X 2 splice configuration clearly show that maximum tensile strength is achieved when the wires are welded and compacted to a...
1. Verify that the 9-pin footswitch cable is properly connected to the back of the Controller. 2. Power down and then power up the Controller to reset the system. 3. If the alarm persists, call Branson Support. See 1.5.3 Contact Information.
• Vacuum and clean out any copper residue or dirt in the actuator 7.1.2.3 Filter/Filter/Regulator – Disassembly Air Filter/Filter/Regulator (Optional component, Branson part# 207-020) should be serviced after 1 year or when a pressure drop of 15 psi is reached. • Disconnect the air supply •...
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• Replace brass-colored filter element number 5 and reassemble in reverse order • Remove housing on second filter in the same way in which the first housing was removed CAUTION DO NOT USE SOLVENT. • UNSCREW WHITE FILTER ASSEMBLY AND DISCARD NOTICE The brass-colored filter element in the first assembly may be cleaned in solvent, dried and re-used, if necessary.
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Table 7.1 Stack Removal Procedure Action Reference • Disconnect the R.F. cable from the converter and the system air supply from the back of the touchscreen controller • Remove the top cover and horn cover • Remove the Support Brace SUPPORT BRACE DCM00038 REV.
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Table 7.1 Stack Removal Procedure Action Reference • Loosen the gather assembly retaining screws but do not remove • Slide the gather assembly up and snug one screw to hold the gather assembly in its upper position • Remove the four stack hold down bolts •...
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Table 7.1 Stack Removal Procedure Action Reference • With the Stack removed, place it in the optional stack mount block [H4A50011] to remove the horn • Using a spanner wrench, turn the horn counter-clockwise and spin horn Table 7.2 Disassembly of the Ultrasonic Stack Action Reference •...
7.1.3.3 Reconditioning Tip and Nut Clamping Surfaces (Replaceable Tip Horns Only) After prolonged use, burrs may form on the clamping surfaces of the tooling. These burrs may be removed from the Tip and Tip Nut by polishing with 600 grit emery paper placed on a flat surface.
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Table 7.3 Rotating the Tip Action Reference Remove the Tip Nut, Rotate the keyed Tip and re-install the Tip Nut. NOTE: LEFT HAND THREADS Torque to 125 in-lbs. Completed Tooling Setup DCM00038 REV. 07...
FDA’s Good Manufacturing Practices, contact your Branson Metal Welding representative for additional information. 7.2.1 Encoder Board Calibration Encoder board calibration is factory set and generally does not need to be changed. Any calibration required due to tool wear or adjustment is built into the controller software and may be accomplished using touchscreen commands (refer to your power supply manual).
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7.2.1.2 Height Calibration CAUTION Read all steps completely and exercise caution as tooling moves during the calibration process. NOTICE Readings are consistently better if the calibration is done at 25 PSI. 1. Position a 1 mm shim on the tip. 2.
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7.2.1.3 Calibrate Width NOTICE Readings are consistently better if the calibration is done at 25 PSI. 1. Remove the top cover from the actuator and locate the actuator board. 2. From the Controller Maintenance Screen, press Zero button. The Gather will move to the zero width point.
Troubleshooting This section shows how to fix some of the possible errors and problems which may occur in normal use of the Ultrasplice 40 welding system. 7.3.1 Weld Overload Weld overloads are premature shut downs of the power supply. Overloads signify excessive loads and must be corrected if continued reliability of the equipment is to be maintained.
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Table 7.4 Troubleshooting Chart Problem Solution Plant fuse fails or circuit breaker Check current rating of the plant fuse or the trips during weld cycle circuit breaker, replace if failed. Check fuse current rating, replace if incompatible. Line fuse fails. Check fan motor, replace if failed.
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Table 7.4 Troubleshooting Chart Problem Solution Check weld parameters. Check tooling gaps. Check knurl on tooling. If worn replace tooling. Low weld strength. Increase Energy. Check the Down stop adjustment. Check for part contamination. Ensure all hardware is tight. Reset parameters. Reset amplitude.
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Table 7.4 Troubleshooting Chart Problem Solution Check tooling gap. Unusual sound during weld cycle. Check converter. Check stack assembly. Squealing sound from Controller Check cooling fans in rear of unit when unit is turned on. Maintenance counter alarm. Reset maintenance counter. Check air lines for contamination.
Parts Lists The following table lists items that are highly recommended to have readily available to prevent extended equipment down time and/or setup time. Table 7.5 Primary Spare Items Description EDP Number Linear Encoder H4A50029 Spring, Front Diaphragm 100-095-168 Spring, Rear Diaphragm 100-095-169 Converter Model 4TH 101-135-067R...
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