Sonics H540 E - Manual (Page 9)

I N T R O D U C T I O N
Sonics’ hand held welders are portable 500 watt welders used for plastics
assembly that consist of an ultrasonic power supply and a hand gun. These
units are designed specifically for welding, staking, inserting and spot
welding applications (refer to the Applications section of this manual
beginning on page 26 for more information on these operations).
The model H520 is a 20 kHz power supply that comes with the CV55 hand
gun; the H530 is a 30 kHz power supply that comes with the CV53 hand gun.
The CV53/55 units are supplied with an integral 1/2" (12.7mm) diameter
titanium front driver with a replaceable flat face tip. (Other standard or
custom tips are available.)
The model H540 is a 40 kHz power supply that comes with the CVG54 hand
gun. The CVG54 hand gun is supplied with a removable horn designed
specifically for each customer’s requirements. The higher frequency and
lower amplitude of the 40 kHz system makes it ideal for welding small
assemblies that require gentler action.
The power supplies of all models feature autotune circuitry.
O V E R V I E W O F U L T R A S O N I C P L A S T I C S
A S S E M B L Y
WHAT IS ULTRASONICS?
Ultrasonics refers to vibrational waves with a frequency above the human
audible range which is usually above 18,000 cycles per second (Hz).
PRINCIPLE OF ULTRASONIC ASSEMBLY
The basic principle of ultrasonic assembly involves conversion of high
frequency electrical energy to high frequency mechanical energy in the form
of reciprocating vertical motion which, when applied to a thermoplastic,
generates frictional heat at the plastic/plastic or plastic/metal interface. In
ultrasonic welding, this frictional heat melts the plastic, allowing the two
surfaces to fuse together; in ultrasonic staking or insertion, the controlled
flow of molten plastic is used to capture or lock another material in place
(staking) or encapsulate a metal insert (insertion).
ULTRASONIC HAND HELD WELDERS
“Sonics” ultrasonic hand held welders are generally composed of the
following major elements: a power supply, hand gun (converter), and horn
(H540E only) as detailed in the diagram on the next page. A review of this
diagram will help you understand the basic elements involved in the
assembly process and their relation to each other.
8 I N S T R U C T I O N M A N U A L • H A N D H E L D W E L D E R S
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