Theory Of Operation; Probe Configuration; Hand Probe, Horn And Tip - Dukane iQ Series User Manual

User's Manual

Theory of Operation

Plastic welding is the most common application of
ultrasonic assembly. To perform ultrasonic plastic
welding, the vibrating tip is brought into contact with
one of the work pieces. Pressure is applied and ultrasonic
energy travels through the material generating frictional
heat at the contact point of the two parts. The frictional
heat melts a molded ridge of plastic on one of the pieces
and the molten material flows between the two surfaces.
When the vibration stops, the material solidifies forming a
permanent bond.

Probe Configuration

A basic ultrasonic probe package consists of —
1. A probe which houses the transducer to convert the elec-
trical energy supplied by the generator into mechanical
vibrations.
2. A horn to transfer the mechanical vibrations from the
probe to the parts to be welded.
Optional components include special replaceable tips
which can be threaded on to the tip of the horn, and a
booster to amplify the mechanical vibrations of the horn.
A basic hand–held probe system is shown in Figure 6-2.
The hand probe is easily identified by its trigger actuator
and permanently attached cable. Normally a booster is not
used with a hand probe as this increases the length and
weight and reduces its versatility. The optional threaded
titanium tip can be used when the application calls for
a staking profile or a pointed spot weld. Replaceable
tips are not commonly used in high–volume production
environments.
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Hand
Probe
Standard
Horn
Tip
Figure 6–2 Hand Probe, Horn and Tip
Dukane Manual Part No. 403-577-00
Custom
Horn