Emerson BRANSON Ultrasplice 40 Original Instructions Manual
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Emerson BRANSON Ultrasplice 40 Original Instructions Manual

Emerson BRANSON Ultrasplice 40 Original Instructions Manual

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I n s t r u c t i o n M a n u a l
Branson Ultrasonics Corp.
120 Park Ridge Road
Brookfield, CT 06804
(203) 796-0400
http://www.bransonultrasonics.com
Original Instructions
DCM00050 - REV. 02
Ultrasplice 40
Actuator

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  • Page 1 Original Instructions DCM00050 - REV. 02 Ultrasplice 40 Actuator I n s t r u c t i o n M a n u a l Branson Ultrasonics Corp. 120 Park Ridge Road Brookfield, CT 06804 (203) 796-0400 http://www.bransonultrasonics.com...
  • Page 2 DCM00050 REV. 02...

  • Page 3: Table Of Contents

    Table of Contents Chapter 1: Mechanical Actuator System Mechanical Actuator System ........2 Ultrasonic Stack Assembly .
  • Page 4 DCM00050 REV. 02...
  • Page 5 List of Figures Chapter 1: Mechanical Actuator System Figure 1.1 Model GUN 40 ..........2 Figure 1.2 Ultrasonic Stack Assembly .
  • Page 6 DCM00050 REV. 02...
  • Page 7 List of Tables Chapter 1: Mechanical Actuator System Table 1.1 Model GUN 40 Specifications........2 Table 1.2 Stack Removal Procedure .
  • Page 8 viii DCM00050 REV. 02...

  • Page 9: Chapter 1: Mechanical Actuator System

    Chapter 1: Mechanical Actuator System Mechanical Actuator System ....... . 2 Ultrasonic Stack Assembly .

  • Page 10: Mechanical Actuator System

    Mechanical Actuator System The Branson Model GUN 40 system is comprised of a power supply and control box, ultrasonic stack assembly, application tooling, and mechanical actuator. The mechanical actuator is the system that rigidly holds the converter, booster, and horn assembly known as the ultrasonic stack.

  • Page 11: Ultrasonic Stack Assembly

    Ultrasonic Stack Assembly Figure 1.2 Ultrasonic Stack Assembly Converter The 40 kHz electrical energy from the power supply is applied to the transducer element or converter, which transforms the high frequency electric current into high frequency mechanical vibrations at the same frequency. The heart of the converter is a lead- zirconate-titanate electrostrictive element that, when subjected to an alternating voltage expands and contracts.

  • Page 12: Figure 1.3 Parts Of The Ultrasonic Stack

    Figure 1.3 Parts of the Ultrasonic Stack The 40 kHz electrical energy from the power supply is applied to the transducer element or converter, which transforms the high frequency electric current into high frequency mechanical vibrations at the same frequency. The heart of the converter is a lead- zirconate-titanate electrostrictive element that, when subjected to an alternating voltage expands and contracts.

  • Page 13: Figure 1.4 Gathering Tool And Anvil

    Gathering Tool A Gathering Tool sweeps across the face of the Tip to collect the wire strands and forms the width of the compression chamber. Figure 1.4 Gathering Tool and Anvil 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.

  • Page 14: Figure 1.6 Flowchart Of The Ultrasonic Process (Splicing) Ultrasplice 40 Gun 40

    Figure 1.6 Flowchart of the Ultrasonic Process (splicing) Ultrasplice 40 GUN 40 DCM00050 REV. 02...

  • Page 15: Figure 1.7 Down Stop Adjustment

    Figure 1.7 Down Stop Adjustment 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: •...

  • Page 16: Table 1.2 Stack Removal Procedure

    DANGER Be sure that the power supply is off to prevent any possible electrical shock from the high voltage contact on the converter. 1.2.1 Stack Removal Table 1.2 Stack Removal Procedure Step Action Sample Remove the top cover and horn cover. Also disconnect the R.F.

  • Page 17: Table 1.3 Disassembly Of The Ultrasonic Stack Procedure

    Table 1.2 Stack Removal Procedure Step Action Sample Remove the four stack hold down bolts. Carefully lift the stack out by raising the converter and then sliding the stack back to free the tip of the horn from the tool block. With the Stack removed, place it in the optional stack mount block [H4A50011] to...

  • Page 18: Table 1.4 Assembly Of The Ultrasonic Stack Procedure

    Table 1.3 Disassembly of the Ultrasonic Stack Procedure Step Action Sample Clean, and polish away any roughness on the diaphragm springs or on the clamping faces of the booster. 1.2.3 Assembly of the Ultrasonic Stack Table 1.4 Assembly of the Ultrasonic Stack Procedure Step Action Sample...
  • Page 19 Table 1.4 Assembly of the Ultrasonic Stack Procedure Step Action Sample Apply and spread out an even coat of Molykote G-n paste (about equal to half a paper match head) to the booster face (the side with the stud) and the converter face.

  • Page 20: Table 1.5 Stack Installation Procedure

    1.2.4 Stack Installation Table 1.5 Stack Installation Procedure Step Action Sample 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. Then tighten the side with Spacer and hand tighten other side.
  • Page 21 Table 1.5 Stack Installation Procedure Step Action Sample With Tip to Tip Guide Squared up, Loosen the Gather screws and manually press the Gather Block down onto the Tip. The hand tightened Stack mount screws can now be tightened securely. Be sure that all four Stack screws are tightened evenly.
  • Page 22 Table 1.5 Stack Installation Procedure Step Action Sample Down Stop Adjustment. 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.

  • Page 23: Table 1.6 Other Tooling Gaps

    Table 1.5 Stack Installation Procedure Step Action Sample Gather to Anvil Gap Place a 0.001” shim between the Anvil and side of the gather block. Loosen the Gather adjusting Screw locknut. With the Gather Adjusting Screw, bring in the Gather Block until a slight drag is obtained.
  • Page 24 Table 1.6 Other Tooling Gaps Action Sample If the tip guide vertical adjustment is required. Loosen the Tip Clamp Screw and (2) Jack screw jam nuts. Turn the (2) Jack screws until the Tip Guide is even with the bottom of the Anvil.

  • Page 25: Encoder Board Calibration

    Encoder Board Calibration Figure 1.8 Encoder Board 1.3.1 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 the Touchscreen Controller Instruction Set).
  • Page 26 Optional Width Calibration • No voltage adjustment is required for the Terminator. Width Span Adjustment • From the controller “zero” the gather (step ref- Menu> Maintain> Width > Zero) • The gather will move to the zero width point. The controller then resets the zero point and opens the gather to 6 mm wide.
  • Page 27 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. The white filter element in the second assembly cannot be cleaned and must be replaced. Clogged filters will reduce the performance of equipment.
  • Page 28 Periodic Maintenance Signoff Sheet Date Machine was First put into Operation: _________ /________ /________ Name:__________________________ Signature:_______________________ Every Tool Rotation Every One Million Cycles Inspected Inspected Tool # of Vacuumed Surfaces Vacuumed Cleaned & Date Surfaces Calibrated Rotation? Cycles of Anvil, Cleaned Torqued Calibrated...

  • Page 29: Weld Development And Quality

    Weld Development and Quality ® When properly set up the ULTRASPLICE System will produce quality welds by simply placing parts into the fixture and actuating the foot switch or actuator start switch. CAUTION USE EXTREME CAUTION WHEN LOADING PARTS INTO THE FIXTURE SINCE A PINCH POINT MAY EXIST BETWEEN THE HORN AND ANVIL.

  • Page 30: Table 1.7 Proper Wire Insertion

    1.4.3 Proper Wire Insertion Table 1.7 Proper Wire Insertion Proper Wire Insertion Wires should be stripped to a dimension 2 mm Strip Length longer than the Tip/Anvil depth. Care should be taken to stack the wires vertically Placement in wherever possible to Welding zone ensure an optimum splice.
  • Page 31 strength make a minimum of 10 splices, pull test them and calculate the Cpk. If the Cpk is not satisfactory, examine the splice carefully to determine how it is failing. An underwelded splice will fail by separating at the weld. An overwelded splice will fail at the transition point of welded to unwelded wire.

  • Page 32: Figure 1.9 Percent Compaction Versus Tensile Strength

    1.4.4 Compaction vs. Tensile Strength Knowing that pull strength (tensile strength) directly relates to the ability of the splice to meet performance criteria the question becomes, “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 dimension which is 20% greater than their solid copper cross section, (refer to Figure 1.9...

  • Page 33: Table 1.8 Wire Splice Comparison Table

    1.4.5 Wire Splice Comparison Table 1.8 Wire Splice Comparison Table Ref. 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. OVER WELDED - Pressure and amplitude too high (flash &...
  • Page 34 Table 1.8 Wire Splice Comparison Table Ref. Photo of Condition Schematic Description SIDE SPLICE - Incorrect wire stacking in weld pocket. GOOD SPLICE 1.4.6 Spliced Wire Pull-Testing The weakest wire in tension of any splice is the wire with the smallest cross sectional area or gage.

  • Page 35: Emergency Stop

    1.4.7 Emergency Stop If there is a Emergency stop the red lights blink and the control will not operate until the Emergency stop fault is cleared. During an EMERGENCY STOP all equipment is returned and left at the home (rest) position and all pending motions and operations are canceled. All mechanical actions return to the ready mode after the emergency stop is canceled.

  • Page 36: Tool Kit

    Tool Kit Table 1.9 Tool Kit Qty Per Item # Description Branson P/N Comments Tool Kit (Optional Item) 40 KHz Torque Wrench 211-127 Purchase Separately Dial Indicator with (Optional Item) X3A50252 Modified Magnetic Base Purchase Separately Spanner Wrench 201-118-024 Spanner Wrench, 106-089A Modified Handle, Extension...

  • Page 37: File Attachments

    File Attachments Table 1.10 File Attachments File Description H4A00000 ULTRASPLICE 40 ASSEMBLY H4A00000-BOM ULTRASPLICE 40 BILL OF MATERIALS H4A00001 ULTRASPLICE 40 HOUSING ASSEMBLY H4A00002 ULTRASPLICE 40 GATHER ASSEMBLY H4A00003 ULTRASPLICE 40 LOWER ASSEMBLY H4A00004 ULTRASPLICE 40 FINAL ASSEMBLY H4A00008 VORTEC ASSEMBLY- BOM (OPTIONAL) H4A00014 ENCODER ASSEMBLY- BOM (OPTIONAL) DCM00050 REV.
  • Page 38 ULTRASPLICE 40 - STANDARD UNIT 1 OF 4 SHT QTY: WORK ORDER: DATE: UNLESS OTHERWISE STATED BRANSON ULTRASONICS CORP. FOR ALL SPECIFICATIONS SCALE: DIMENSIONS ARE IN INCHES [MM] AND TOLERANCES, REFER TO: METAL WELDING MATERIAL: DRAWN ON: ENGINEERING SPECIFICATION SEE NOTES FOR MFG.
  • Page 39 C L 1.4 34.9 TOOLING CENTERLINE 3.5 89.7 LOAD HEIGHT 4.34 110.2 9.0 228.8 2.75 69.9 10.84 275.4 3.61 91.6 0.6 14.3 4.0 102.5 4.0 102.5 0.2 5.6 2.3 58.7 ULTRASPLICE 40 - STANDARD UNIT M4x0.7 TAPPED HOLE 2 OF 4 SHT QTY: 6 PLACES WORK ORDER:...
  • Page 40 6.18 156.9 1.94 49.3 8.82 224.1 3.25 82.6 10.84 275.4 ULTRASPLICE 40 - WITH ENCODER OPTION 3 OF 4 SHT QTY: WORK ORDER: DATE: UNLESS OTHERWISE STATED BRANSON ULTRASONICS CORP. FOR ALL SPECIFICATIONS SCALE: DIMENSIONS ARE IN INCHES [MM] AND TOLERANCES, REFER TO: METAL WELDING MATERIAL: 11/10/09...
  • Page 41 4.34 110.2 3.75 95.3 4.77 121.0 ULTRASPLICE 40 - WITH VORTEC COOLER OPTION 4 OF 4 SHT QTY: WORK ORDER: DATE: UNLESS OTHERWISE STATED BRANSON ULTRASONICS CORP. FOR ALL SPECIFICATIONS SCALE: DIMENSIONS ARE IN INCHES [MM] AND TOLERANCES, REFER TO: METAL WELDING MATERIAL: 11/10/09...
  • Page 42 H4A00000 ULTRASPLICE 40 ASSEMBLY - BOM H4A00001 HOUSING ASSY, ULTRASPLICE 40 201-005 BUSHING,FLANGED FB-46-2 204-123 BEARING,ROLLER TORRINGTON 210-002 WASHER,TORRINGTON, TRA512 H4A50000 MAIN HOUSING, ULTRASPLICE H4A50006 ANVIL CLAMP H4A50007 TIP GUIDE CLAMP H4A50008 DOWN STOP SHAFT H4A50010 ANVIL ARM PIVOT PIN H4A50014 ANVIL ARM H4A50019...
  • Page 43 REVISIONS ZONE REV. DESCRIPTION DATE INITIAL RELEASE 5/3/06 ITEM NO. PART NUMBER DESCRIPTION QTY. 201-005 FLANGED BUSHING 204-123 7/16" NEEDLE BEARING 210-002 THRUST WASHER H4A50000 MAIN HOUSING US40 H4A50008 DOWN STOP SHAFT H4A50010 ANVIL ARM PIVOT H4A50014 ANVIL ARM H3A50101 SET SCREW MOD H3A50102 BUTTON, VESPEL...
  • Page 44 REVISIONS ZONE REV. DESCRIPTION DATE INITIAL RELEASE 5/3/06 ITEM NO. PART NUMBER DESCRIPTION QTY. 203-486 THUMB SCREW, M4 205-317 Air Cylinder 209-132 FITTING 27002-00-007 PIVOT PLATE 27002-00-009 PIVOT BUSHING H4A50017 STOP PLATE H4A50020 Gather Block H4A50031 ROD END, GATHER CYL. H4A50039 GATHER HOUSING H4A50040...
  • Page 45 REVISIONS ZONE REV. DESCRIPTION DATE INITIAL RELEASE 5/3/06 DETAIL A SCALE 1 : 1 ITEM NO. PART NUMBER DESCRIPTION H4A00003/QTY. 101-069 LOCKNUT 101-074 Strain Relief,Heyco #3200 205-314 TWDA 32 X 15 - HA 209-354 1/4 ST. FITTING 27002-00-015 ROD END, ANVIL ARM H4A50001 LOWER HOUSING, ULTRASPLICE 40 H4A50003...
  • Page 46 REVISIONS ZONE REV. DESCRIPTION DATE INITIAL RELEASE 5-3-06 100-087-417 WAS R4A50030, 100-095-168 WAS 18875 4-08-11 R4A50031, 100-095-169 WAS R4A50032. ITEM NO. PART NUMBER DESCRIPTION QTY. 101-065-612 CE LABEL 203-487 M4 SHOULDER BOLT 12.1 203-504 M4 X 4mm PAN HEAD 27002-00-035 STACK MOUNT WASHER H4A00005 STACK ASSEMBLY...
  • Page 47 REVISIONS ZONE REV. DESCRIPTION DATE INITIAL RELEASE ITEM NO. PART NUMBER DESCRIPTION QTY. 11008-08-132 COOLING BLOCK 104-057 Cooling Nozzle 104-087R Cooling, Connector 1/8NPT 104-109 Cooling, Hose 207-009 COOLER, VORTEC 207-075 FLOW CONTROL 209-034 FITTING,PLUG,1/8 NPT 209-055 Fiiting, Coupling 209-087 FITTING, 90 DEG. STREET 'L' 209-116 NIPPLE,CLOSE,1/8 NPT M4 x 30...
  • Page 48 REVISIONS ITEM NO. PART NUMBER DESCRIPTION H4A00014/QTY. ZONE REV. DESCRIPTION DATE 102-242-632R ASSY AMTECH ACTUATOR INTF BD INITIAL RELEASE UPDATED ASSEMBLY DRAWING 4/8/2016 211-823 M4 x 25MM STANDOFF H4A50025 ENCODER HOUSING BOTTOM COVER, ENCODER H4A50027 HOUSING H4A50028 ROD END H4A50029 HEIGHT ENCODER W/6"...
  • Page 49 DCM00050 REV. 02...

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