HA-YS310 Basic Seminar PL ENG 170126 (MHa) PDF

Ultrasonic Welding for Plastics
Table of contents
1 Seminar Roadmap
2 Company Profile
3 Section 1: Understand the process
4 Section 2: Understand the machine
5 Section 3: Setup the welding
6 Section 4: Design weld parts
Ultrasonic Welding Basics 7 Section 5: Other applications

8 Your application
Basics
© Copyright Herrmann Ultraschall I 1 © Copyright Herrmann Ultraschall I Ultrasonic Welding Basics 2
Ultrasonic Welding for Plastics Ultrasonic Welding for Plastics

Table of contents Seminar Roadmap
1 Seminar Roadmap
2 Company Profile
7 Section 5: Other applications
8 Your application
© Copyright Herrmann Ultraschall I Ultrasonic Welding Basics 3 © Copyright Herrmann Ultraschall I Ultrasonic Welding Basics 4
Seminar Roadmap Seminar Roadmap
Section 1: Understand the process Section 2: Understand the machine

 What is a plastic weld?  By which machine elements are the process parameters realized?
 How can ultrasonic create a weld?  How does the trigger point definition work?
 What does influence this process?
 How does the machine respond?
 How do the process parameters influence the weld?

Section 3: Setup an ultrasonic weld Section 4: Joint design

 Setup a new weld program  What are the principles of a correct joint design?
 Assemble a sonic stack, setup an initial amplitude  What joint designs are proven? What are they designed for?
 Setup a fixture  How is the material influencing the process?
 Adjust the machine height, adjust the trigger point limits  Which materials can be welded?
 Adjust an initial force profile
 Improve welding quality
Section 5: Other ultrasonic applications Continuous support from the beginning – ULTRASONIC ENGINEERING
 Riveting
Idea SOP
 Cut & Seal
Design Process development
 Embedding of inserts
 Membrane welding Design
 Embossing Process planning / Equipment
 Beading
Setup & Trials
Manufacturing
Production
Spare parts
Quality Quality assurance

Table of contents 350 employees in 19 countries – 60 Mio. € sales (group)
1 Seminar Roadmap
2 Company Profile
8 Your application
Sales Structure Europe Sales Structure North America
Global Headquarters, Karlsbad

Tech-Center Upper Midwest Canada
Halmstad Tech-Center Tech-Center Boston, MA
Tech-Center
BeNeLux
Local Sales Office North West Coast Midwest Indiana, Ohio, Kentucky
Tech-Center Walsrode
Tech-Center Brno Tech-Center Irvine, CA
Tech-Center Wien Tech-Center Atlanta, GA
Poland
Czech Rep. Tech-Center Katowice North American Headquarters, Bartlett
Slovakia
Switzerland Austria Tech-Center Budapest Tech-Center
Tech-Center
Romania Tech-Center Istanbul
Rhône-Alpes Sales Office
Italy Tech-Center Modena
North Mexico
Tech-Center Mexico City

Tech-Center Barcelona Tech-Center Tel Aviv Carribean

Sales Structure Asia Company Profile
PLASTICS – welding moulded parts

Products:
 Serial welding machines HiQ
Tech-Center  Actuators VE SLIM LINE
Hwaseong-si
Eco Sonic Korea  Digital Generators in 20, 30 and 35kHz
Delhi  Customized machines ULTRALINE
Tech-Center Dongguan
 Ultrasonic components and fixtures
Mumbai Fields of applications:
Chennai Japan Headquarters, Kashiwa City
 Electronic industry
Tech-Center Bangalore
China Headquarters, Taicang  Medical
Tech-Center Kuala Lumpur
Herrmann ASEAN Tech-Center  Automotive
 IT/Telecommunication
Sales office
 Consumer and leisure goods
Company Profile Company Profile
NONWOVENS – high speed bonding systems PACKAGING – Ultrasonic sealing technology

Products: Products:
 Patented actuator units  Ultrasonic sealing systems
 Patented MICROGAP control for high speed applications  Seal modules
 Ultrasonic rotative systems  Ultrasonic components
 PIEZOGAP control system Fields of applications:
for cut & seal  Stand-up pouch (top seal, zipper, spout)
Fields of applications:  Longitudinal and cross sealing
 Nonwovens industry  Carton
 Extruded sheets  Blister bags, cups, bowls

 Cutting of food
 Textile industry
 Paper industry

Table of contents Section 1: Understand the process
1 Seminar Roadmap How does ultrasonic welding work?

2 Company Profile  What is a plastic weld?
3 Section 1: Understand the process  How can ultrasonics create a weld?
 What does influence this process?
 How does the machine respond?
 How do the process parameters influence the weld?
8 Your application
Section 1: Understand the process Section 1: Understand the process
Plastic welding Plastic welding

Observations: Observations: 2 N/mm²
 weld bead: indicates melt flow weld pressure
 re-crystallization of melt
 weld zone
 deformed spherolithes: indicates melt flow
 heat affected zone
 width of welding zone is dependent on weld
 Interesting: pressure (imagine the extremes)
amorphous and semi-crystalline areas can be seen
8 N/mm²
weld pressure

Melt flow creates bonding Function diagram of plastic welding

Initial Heat Cool
Welding without melt flow will just create melt create heat Vibration welding friction
stick, but not weld homogenous
weld Hotplate welding conduction
Create melt flow Ultrasonic welding

& press
Initial Heat Cool
compress melt HF welding
create force
Melt flow does create re- Em wave absorption
crystallization across the border Hot gas welding convection
What? How?
Laser welding light absorption
Whilst?
What is ultrasonic vibration? Ultrasonic welding – a quick look
Amplitude
Observations:
 The specific distance that the
sonotrode front surface moves forth  Short impacts
and back  welding 0,3 mm, barely perceptible
Frequency:
 The rate at which the sonic stack
expands and contracts
 20kHz = 20,000 times per sec.
 35kHz = 35,000 times per sec.

Ultrasonic welding – a close look Ultrasonic welding – not like this!

Observations: Observations:
 Vibration at the upper part  Melt flow
 Vibration at the lower part but only at the beginning  Melt flow is interrupted
 Particles flying
 Both parts are moving
 Melt flow, melt bead
Is the melt which has left the joint of any use?
 Melt starts at the tip, then expands
Functional diagram of ultrasonic welding More examples of damping

micro
create melt create heat damping
deformation
weld
Types of damping
 Elastic (no damping)
compress  Viscoelastic damping

melt = moderate heat creation
 Viscous damping
= efficient heat creation

Heat creation during US welding Heat is created…

Observations:
 heat appears first in the joint area
 the sonotrode interface gets warm
 weak areas get warm
 the entire body shows a very slight warming
 …most of all in the joint  …then at the sonotrode  …at weak areas
area interface (undesired)  …at the entire body
(undesired)
Questions Input and Output
 What can be observed in the plastic welding cross section?

 How does pressure affect the weld zone width?
 Why is melt flow important for plastic welding?
 Can you explain the „function diagram“ of plastic welding?
 Give some examples of heat creation in different welding processes.
 What is the mechanism behind heat creation in US welding? Vgl. DEU!!
 What different types of damping are there?
 Where is heat created in a US process and why?

Influences on US welding Input: Process parameters
Lid
Frequency Housing
Amplitude Sonotrode
Input Output Duration Holding time Fixture
Move down Trigger force Weld force Holding force Move up Ultrasonic
Startup Setup Input  Graph

 Frequency  Adjustment  Welding  Data
 Tooling of tooling parameters  Quality control
 Manufacturing  Weld parts  Welded part
 Material of weld parts
 Weld part design
Assemble Feed & Close Trigger Weld Hold Open Remove
Input: Welding parameters Output: Weld part
Two parameter sets: 1. Driving the speed Where is the patient?

 Frequency 90
on distance  Amplitude
 Weld force
Weld depth RPN [mm]
 (Trigger force)
on time
2. Driving the duration
 Weld mode STOP
 Shut off limit
Time (t)
Weld

Output: Weld graphs How to read a joining velocity profile

 joining velocity profile The „good“ joining velocity profile
 force profile  Should start immediately
Weld depth RPN [mm]

 power profile
To fit the real sonotrode movement
image the screen upside down Target:
< 50ms
 Continuous rising
Time (t)  Controlled speed
Target:
Joining profile does reflect 2-4mm/s
Joining profile does reflect the
the welding process
welding process
Welding
Output: Data Parameters

 Welding graphs are useful to analyze  What is a plastic weld?
individual welds or to compare  How can ultrasonic create a weld?
several welds for consistency  What does influence this process?
 Welding data is to compare  How does the machine respond?
thousands of weldings  How do the process parameters affect the weld? Know-how
Trigger Weld Hold
 Trigger point  t weld time  RPN+
measurement  E Energy Travel after hold time
 PPk Peak Power  MCT
 P+ Final Power Machine cycle time Output
 RPN Travel
Input
 ABS Position

Force does effect joining velocity Force does affect coupling

Too little velocity
 profile flattens out Too little coupling:
Weld depth RPN [mm]
 excessive weldtime to achieve weld  Surface damages

depth  Noisy weld
 increase weld force Increasing weld force:
 OR: use second weld force
Time (t)  improve coupling Starting point:
Note: trigger force is the „initial“ weld 2-4 N/mm
force  reduce surface damages
joint length
Too much velocity:  „deeper“ weld
Welding
 no accurate shut off Too much coupling:
resistance is
growing over RPN  no heat transfer within weld joint  Both weld parts are moving together
 reduce weld force Starting point:

 No weld effect in the joint
2-4 N/mm
joint length
Force does affect melt flow Frequency affects welding depth

Too little melt flow 20 kHz
 the low frequency ultrasonic wave travels deeply into the plastic
Weld depth RPN [mm]

 weak bonding 20 kHz
 can perform distant welds
 No melt compression („far field“, > 8mm) runs far
 increase weld force 35 kHz
Too much melt flow  the high frequency ultrasonic wave is absorbed early
Time (t)
 melt squeezed from the joint area  can perform only welds near the sonotrode coupling
 melt area width too small („near field“, < 6mm)
 irregular velocity profile 35 kHz
 irregular power profile early

damping
 reduce weld force Distant noise appears muffled

Amplitude does affect melt creation Note: Damping does affect melt creation

stress Tensile test diagram Too little amplitude Damping …
[N/mm²] break  no sufficient plastic (micro-) deformation W   E  Which fraction of the mechanical energy is
damping
 no sufficient damping transformed into heat?
material
amplitude  material isn‘t melting at all temperature … is temperature dependent
strain [%]
[°C]  Viscous melt has a much higher damping factor
= deformation  brittle melt appearance
by amplitude than a deformed plastic material
 slow joining velocity
 The heat creation is much more efficient
 increase amplitude
„Melt does create
Too much Amplitude more melt“
plastic  material is overheating plastic viscous damping
elastic
deformation  high joining velocity deformation  efficient
deformation Starting point: create create
 no damping  moderate  decrease amplitude  moderate heat creation
Refer to Section 4 Melt Heat
heat creation heat creation
Amplitude does affect coupling but also… Questions
Weld force Coupling  Why is the welding resistance increasing with RPN, what can we do about it?
 Smaller amplitudes are easier to  Why is too much joining velocity a problem?
couple with the weld part  What can bad coupling cause to the welding?
more  How does excessive force affect the melt flow?

speed  What happens with too little amplitude?
amplitude
 What is damping?
 Why is „melt creating more melt“ ?
 How can amplitude and force be used instead of each other?
Increase force and lower
same speed
amplitude – or vice versa
Better coupling

Table of contents Section 2: Understand the machine
1 Seminar Roadmap Machine elements

2 Company Profile
 By which machine elements are the process
3 Section 1: Understand the process parameters realized?
 How does the machine trigger the ultrasonic
4 Section 2: Understand the machine welding process?
8 Your application
Baustein 2: Die Maschine kennenlernen Section 2: Understand the machine
Amplitude – Ultrasonic Vibration Amplitude – How big is a micron?

Amplitude amplitude
 Human hair diameter:
 The specific distance that the sonotrode front ca. 100 µm
surface moves
 Ultrasound amplitude:
 Typical range is between 5µm and 50µm
10 µm to 50 µm
nodal points
Frequency: don‘t move
 The rate at which the sonic stack expands and
contracts
transversal
 20kHz = 20,000 times per sec
contraction
 35kHz = 35,000 times per sec  Typical: 30 µm

Section 2: Understand the machine Section 2: Understand the machine
Amplitude – sonotrode stack Resonance is ruling amplitude

Elements of the sonotrode stack: Resonance:
The excitation frequency is hitting the
Converter resonance frequency
It is driven by high frequency electrical power. It brings the
entire sonotrode stack into a resonance vibration. Resonance effect:
The amplitude of the resonator is much bigger
Booster than the amplitude of the exciter
It increases or decreases the given amplitude from the There are generators (exciter) in graded
converter. It enables to clamp the sonotrode stack to the frequencies: 20kHz, 30kHz, 35kHz
machine.
Each resonance frequency does require a
certain tooling length (multiples of ½ of a
Sonotrode
wavelength = ½ ). Thus only graded
It increases or decreases the amplitude. It transmits the US
sonotrodes exist
to the weld part. The length of the sonotrode is ruled by
resonance requirements. The lateral dimensions of sonotrodes are
limited
Converter – the engine of the stack Amplitude – Converter
 Piezoelectric crystals sandwiched between two titanium pieces oscillate (expand & contract) producing a  The converter receives a high frequency signal from the generator and converts it into mechanical
mechanical movement vibrations
 High frequency / high voltage electrical signal is causing the oscillation
amplitude
35 kHz 20 kHz

Amplitude – generator Amplitude transformation – booster
 The generator does supply the high frequency / high voltage signal for the converter  Solid piece of titanium, mounted between Mounting ring
 Amplitude programmable from 1% to 100% sonotrode and converter
 Automatic Amplitude Control: automatic compensation of sonotrode wear, load changes and temperature  Transforms the amplitude: incrementing or
changes. Amplitude consistency independent of supplied line voltage decrementing, depending on the mass ratio
 Amplitude is ramped up repeatable and to a consistent level  Different booster gains available
 Allows to mount the stack in the machine
High Frequency Signal e.g.

gain indicated on
Supply Voltage e.g. 50Hz
230V 20kHz the booster
Amplitude transformation – booster Amplitude – sonotrode

 Sonotrodes are acoustical tools and must be
Decreasing Gain custom-designed and tuned accordingly
 Sonotrodes must fit the part to be welded. They
20 kHz 1:0,8 1:1 transfer the sonic vibrations (amplitude) into the
plastic parts while applying a defined weld force
35 kHz 1:0,4 1:0,5 1:0,6 1:0,8 1:1  Sonotrodes are designed with a specific gain to
increase amplitude as required for the
Increasing Gain application
20 kHz 1:1,25 1:1,5 1:2 1:2,5 1:3  Sonotrode Materials:
- titanium
35 kHz 1:1,25 1:1,5 1:2 1:2,5 - aluminum
- steel alloy, hardened

Sonotrode – the ultrasonic tool Sonotrode – the ultrasonic tool

Sonotrodes are like instruments: they have to sound Available in three different materials:
right and you can't cut them short  Aluminum if the part is big or trials are required,
Available in a thousand shapes:  Titanium being the best resonating material,
 Steel for high durability
 Round or square
 stretched or compact Different coatings for wear protection and
 with a hole or solid with many special functions:
 vacuum channels
 with 3D-contours or flat
 double-length
 polished or with textures  Carrier-sonotrodes (composite /mother-daughter)
 with integrated down-holder
 with blades
 with non-stick-coating
 …
Which frequency is the right one? Pressure, force or stress?
 Each frequency has corresponding sonotrodes, stacks Pneumatic drive [bar]

and generators. The length of the tools is ruled by the (Pressure – counter pressure) x diameter Pneumatic pressure
resonance requirements = pneumatic force
Pneumatic pressure is not suitable to communicate [bar]
 System frequencies are available at 20kHz, 30kHz and parameters
35kHz [N] Friction
 Low frequencies can provide more power (20kHz: up to Sonotrode
6200W, 30kHz 1800W, 35kHz 1200W) (pneumatic force – sonotrode weight) [N] Force
= weld force [N]
 Low frequencies allow to realize bigger (20kHz up to
Suitable to compare parameters within a project
letter-format) and deeper cut (up to 10mm) tools
[N] Weight
 High frequencies tend to weld more carefully to the Joint area
weld part. Due to lower weights involved the machines Sonotrode force / joint area [N] weld force
can realize smaller forces (35kHz down to 10N) = join stress [N/mm²] [N/mm²] stress
Suitable to compare parameters throughout several projects

Force – Pneumatic drive Force – mechanical system

 Low friction pneumatic cylinder
 Weld Press includes single piece cast alloy
 Online Force control by pressure measurement: reliable, fast and square column frame construction
with long recalibration cycles
 Actuator mechanism with high-precision and low
 HiQ VARIO: proportional valve and weight compensation for small friction ball bearing system
forces
 HiQ DIALOG: proprietary HighMotionControl Valve Technology

provides precise closed-loop differential pressure and position
control. No throttles, no settings apart from what you can do in the
DIALOG screen
Linear encoder How does the TP detection work?

 The sonotrode is moving down. The movement is
HiQ DIALOG position stopped when the part is touched
(d)
 Non contact, non wear linear encoder  When no movement can be detected anymore, the
actual position of the sonotrode is recorded
 High resolution (1 µ) min limit
17,5 RPN
 If the position is within previously set tolerances, the
 High micro-linearity (10 µm) s=0 trigger point is set
17,98  Otherwise an error message is issued
 High repeatability
 No measurement delay 18,0
max limit
TRIGGER
 No need to calibrate
Time Activities
 Full stroke measurement (t)  Time is set t=0
Depth RPN is set s=0
Attention! t=0  US is started
Measurement!!
 Force is switched from trigger force to weld force

Electrical System – Controller Questions

HiQ DIALOG
 What is the special property of a sonotrode stacks nodal point? What use can that
 Industrial PC with Windows XP embedded operating system be for?
 All weld parameters are programmed via the 15” touch
screen  Compare a micron to distances of your daily life.
 Password level login  What elements does a sonotrode stack consist of?
 In-process quality control through six process windows  How does the „engine“ of a sonotrode stack work?
(min/max)
 Last 300 weld process data are stored internally
 How much amplitude does a converter provide?
 All weld process data can be transferred to an external PC  How can we increase or reduce the converters amplitude?
(via RS 232, Ethernet, USB)
 What is resonance? What are the consequences for ultrasonic sonotrodes?
 Optional DATARecorder software (up to 16 DIALOG touch
controllers can be connected to one external PC)  How does the trigger point detection work?
 Perfect usability and user-friendliness
Table of contents Section 3: Set up a new weld program
1 Seminar Roadmap Create a new weld program

2 Company Profile  Create a new weld program
 Define and install a sonotrode stack
 Set up fixture and sonotrode stack
4 Section 2: Understand the machine  Set up machine height and trigger point tolerances
5 Section 3: Setup the welding  Set up a first force profile
 Make a first weld
 Optimize weld quality
7 Section 5: Other applications  Ensure repeatability, look at weld table and select switch-off criteria (time, energy,
8 Your application depth, …)
 Set tolerances
 Problem-solving strategies
 Cycle-time optimization, hold time

Section 3: Set up a new weld program Section 3: Set up a new weld program
Create a new weld program Plan for an initial amplitude

On the DIALOG Screen…  You have the tools ready and want to calculate the amplitude?
 Open programming tab and enter the application list  You want to achieve a certain amplitude and need to determine the correct booster and
 Mark the „TEST“ memory and copy it. Enter a new name. If percentage?
you enclose the sonotrode number there will be no
mismatch Either way you use this easy formula:
 Uncheck the „protected“ checkbox, if necessary. Always A [µ]= AConverter x TBooster x TSonotrode x %Generator
protect your TEST memory so no changes can be done to it. AConverter depends on the generator type
It is a source for new memories only
TBooster fixed amplitude gain
 Back in the DIALOG screen the new memory name and
number will be indicated TSonotrode sonotrode gain
FGenerator amplitude setting on the generator
Amplitude calculation- starting point Amplitude calculation – Converter data
A [µ] = AConverter x TBooster x TSonotrode x %Generator A [µ] = AConverter x TBooster x TSonotrode x %Generator
 Different plastic materials require different weld amplitudes at a given frequency, see below  The provided amplitude of the converter is dependent on the generator used, see table
 Choose your desired amplitude from such a table or from previous welding reports.
Frequency
Material family Material Converter-
35 kHz 20 kHz Frequency Generator Power
Amplitude
Amorph ABS 14 µm 25 µm 20 kHz 2400 W 10,6 µm
PC 20 µm 30 µm 4800 W 12,0 µm
Semicristalline POM 32 µm 40 µm 6200 W 13,3 µm
PP 26 µm 38 µm 30 kHz 1800 W 7,5 µm
PA 6.6 35 µm 45 µm 35 kHz 1200 W 6,5 µm

Amplitude calculation – booster data Amplitude calculation – sonotrode gain
A [µ] = AConverter x TBooster x TSonotrode x %Generator A [µ] = AConverter x TBooster x TSonotrode x %Generator
 Different booster gains are available  Sonotrode gain is always bigger than 1:1
 Always cross-check the booster used with the limitations indicated on the sonotrode  Always cross-check the booster limitations indicated on the sonotrode with the booster used
Decreasing Gain HU5672
HU5672
Gain: HUI
1:1.6
Max Booster:
20 kHz 1:0,8 1:1 Sonotrode Gain.: HUI

1:2.5
Weight:
5.0 lbs
35 kHz gain 1:1.6

1:0,4 1:0,5 1:0,6 1:0,8 1:1
Max. Booster:
Increasing Gain 1:2.5
booster gain indicated on
20 kHz 1:1,25 1:1,5 1:2 1:2,5 1:3 Booster Weight:
the lower shaft
35 kHz 5.0 lbs
1:1,25 1:1,5 1:2 1:2,5 limitation
Assemble a sonic stack Assemble a sonic stack – Attention!

1. Clamp the sonotrode, see picture.  NEVER clamp the indexed tool mounting
2. Screw the booster into it, using the sonotrode studs.  NEVER clamp the booster on its ring
3. Remove the fastening plate from the tool quick change holder and place it over
the booster, then assemble the fastening plate with four screws.
Damages
4. Screw the converter in the booster
 Booster ring deformation, resulting in acoustic disturbances
5. Use a spanner (20kHz  32mm, 35kHz  18mm ) and fasten the converter.
Doing so, you‘ll fasten the entire stack. Care for the recommended assembly  Damage to the anti-rotation devices
torque values.
6. Once you have prepared a stack like this you just need to exchange it for
another. Do not disassemble in mass production.
Do in reverse for disassembly.

Assemble a sonic stack - booster Assemble a sonic stack – sonotrode studs
Upper mounting ring
Anti-
rotation
Fixing
Lower mounting ring O-Rings
screws
Vibration free mounting in the tooling mount

Transmission of the welding force from the pneumatic drive to the sonotrode
Prevents undesired rotation
Scan the new stack Setup the machine height
1. Connect the new stack with the earth wire and the HF-plug. Close the door. 1. Assemble the fixture preliminary to the machines baseplate. Feed a non-welded
2. Make sure you are in the correct memory. Go for the SETUP screen and press the SCAN button. The part.
generator will sweep through the frequency band to determine the resonance properties. 2. Open the clamps from the column of the machine. Then screw the machine to a
3. Press the TEST button and make sure the sonotrode does vibrate. Check the idle power and frequency position where the stroke can never hit the tools below.
while you press and take a record for preventive maintenance. 3. Go for the SETUP screen. Choose a moderate setup force and move the cylinder
4. If completed successfully you‘ll receive a message. Go for the PROGRAMMING screen, enter the all the way down, using the cycle start.
DETAILS and complete the weight, sonotrode number and booster gain information. 4. Check the distance reading is „--“. Otherwise the stop screw or an other obstacle
may prevent the full stroke.
5. Now screw the machine down until you reach the part, go on watching the
distance reading declining. Stop screwing when the distance reading is between
15 and 20 mm.

Align the trigger point limits Adjust an initial force profile

1. Go for the SETUP screen. Adjust a setup-force which is
1. Calculate the length of the joint in your weld
about right.
part in mm. Multiply by 3 and obtain an initial
2. Enter the blue TP button and adjust the TP tolerances to weld force starting point.
max + 0,5 mm and min – 0,5 mm.
2. Choose whatever weld mode.
3. Feed a new weld part in the fixture and move the unit
3. Go for the PROGRAMMING screen and adjust
down to it, using the cycle start. The machine will use the
the weld force accordingly.
adjusted setup force. The machine will record the
triggerpoint (TP). 4. Adjust the trigger force to approximately 2/3 of
this value.
4. When you reach the part, check the perfect matching of
sonotrode, weld part and fixture, then move the unit back. 5. Enter the DETAILS button and make sure the
second weld force is not used or is the same as
5. The machine will calculate new TP min and TP max limits
the first weld force.
from the recorded TP and the adjusted tolerances.
Perform an initial weld Example of a welding: weld graph

1. Open the PROGRAMMING screen.
2. You know exactly which depth the weld in your part was planned for?
F = force
-> Choose the RPN weld mode and adjust the shut off criteria according to your weld part design. You
may choose 0,5mm if you do not know more details. P = power
OR: You do not know which depth to run?
s = travel
-> Choose the TIME weld mode and adjust the shutoff criteria to 0,5s.
A = amplitude
 Adjust the hold time to 1s.
 Limit the weld time max limit to 0,5s or the RPN max limit to 0,5mm. f = frequency
 Feed new weld parts.
 Start the cycle and check the part.

Example of a welding: weld graph – after 25 ms Example of a welding: weld graph – after 50 ms
Amplitude: weld stack gets excitated, Amplitude: reaches 100%

amplitude builds up
Weld force: 100%
Force: switch from trigger to weld force
Power: continuous rise
Power: ramp up
Travel: energy director melts,
Travel: energy director starts to melt melt cushion builds up
Example of a welding: weld graph – after 75 ms Switch-of criteria

 Create a new weld program
 Define and install a sonotrode stack
 Set up fixture and sonotrode stack
Amplitude: stays constant
 Set up machine height and trigger point tolerances
Weld force: stays constant
 Set up a first force profile
Power: peak has been  Make a first weld
reached and levels in
 Optimize weld quality
Travel: continuous melt  Ensure repeatability, look at weld table and select switch-off criteria (time, energy, depth, …)
build- up
 Set tolerances
 Problem-solving strategies
 Cycle-time optimization, hold time

Weld Modes: Overview (details see next pages) Weld Mode: Time
Mode Criterion Description: Time Mode
Time The time duration that ultrasonics is applied
The ultrasonic signal is applied from the trigger point until the
► Used for uncritical applications, easy to use, provides little repeatability programmed weld time is reached. S1 > S2 > S3
s (mm)
Depth RPN Melt down distance (collapse), measured from the RPN = Reference Point Numeric (Trigger Point)
►Provides highly repeatable weld results especially for rigid plastic parts with a designed weld travel
To be considered:
Absolute Welding to a specified finished height regardless of trigger point
Distance ► Used when the assembly height of the part is the criteria (e.g. battery case for laptop)  This weld mode is easy to use
Energy The weld energy expended during the time that ultrasonics is applied  It is the least forgiving of all modes and does not compensate for
► Especially suitable when welding parts without a joint (extruded materials, films, textiles)
any plastic part variations
Peak Power The maximum output in watts during the weld process
►Used for various spot welding, staking and swaging applications  Parts are welded for the specified time regardless of the traveled
weld depth, energy used, or power output during the weld t (sec)
ADEPT Combines two or more of the above modes.
Ultrasonics ends as soon as one of the selected switch-off parameters is reached process
► Used when one weld mode is not sufficient, e.g. for applications with large part-to-part variations
 All parameters other than time fluctuate more or less from one
Continuous Generator runs sonotrode continuously
► Used to process roll stock materials at high speeds in a continuous operation
weld to the next
Pre-Trigger Turns on the ultrasonic signal (vibration) when the sonotrode begins to descend  Used for simple, little demanding and low end applications
► Allows “forming” operations (staking, swaging, etc.) with very low initial forces
Weld Mode: Depth RPN Weld Mode: Absolute Distance

Description: Description:
Depth RPN Mode Abs.Dist. Absolute Distance Mode
 The ultrasonic signal is applied from the trigger point (RPN) until the s (mm)  The ultrasonic signal is applied from the trigger point until the
t1 < t2 < t3 d (mm) t1 < t2 < t3
programmed weld depth is reached. programmed absolute distance is reached.
 Weld depth = melt down distance (collapse), measured from the RPN =  This results in consistent overall height of the welded assemblies.
Reference Point Numeric (trigger point).
To be considered:
 With the RPN Mode, the precise melt down distance from the trigger point
remains constant and insures a consistent amount of melt volume between  Parts are welded for the specified height regardless of the traveled
the two components. This results in a repeatable bond strength. weld depth, or energy used
t (sec) t (sec)
To be considered:  Compensates for cavity to cavity part dimensional variations,
 Compensates for fit variations (part to part), caused by cavity differences, maintaining a consistent finished assembly height
maintaining a consistent weld quality  Actual weld travel (melt volume) will be inconsistent resulting in
 Compensates for fit variations between parts and tooling (sonotrode/fixture) inconsistent weld quality
 The process becomes more stable and “forgiving” than with other weld  If parts are on the small side of tolerance (lower height), lower weld
modes (when welding rigid plastic parts with a defined joint) strength will occur
 RPN is the most common weld mode for consistent high quality welds  Can be used for inserting, or spot welding when an absolute height
of the fixture must be kept

Weld Mode: Energy Weld Mode: Peak Power

Description:
ENERGY Mode Description: Peak Power Output
The ultrasonic signal is applied from the trigger point until the programmed The ultrasonic signal is applied from the trigger point until the programmed peak Power (W) t1 < t2 < t3
Power (W)
weld energy is reached. The total amount of energy (watt x seconds) delivered E1 = E2 = E3 power value is reached.
to the part is programmed and controlled. The bigger the sonotrode contact area, the greater the ultrasonic power output.
To be considered:
To be considered:
 Welding by power relies upon the sonotrode design or the part design to
 Typically used when welding parts without a joint (extruded materials,
give a repeatable “spike” of power at the desired shut off point
films, textiles).
 Welding by energy can compensate for:  Spot welding of thin sheets, ultrasonic swaging, and staking of molded t (sec)
t (sec)
posts over incompatible materials (spring steel, PCB’s, etc.) are all
 Layer thickness variations  Ambient temperature variations examples of suitable peak power weld operations
 Coating thickness variations  Humidity variations  Sonotrode cooling (forced air) is often required to keep the peak power
 Material moisture content  Tooling wear output consistent. As sonotrodes heat up, their power requirement may
change
 Weld force variations
 Example: The spot welding sonotrode on the right will cause a power peak
 Excellent secondary control for the previous weld modes
when the wider part (behind the rivet detail) touches the plastic piece
Weld Mode: ADEPT (ADEPT = Absolute, Depth, Energy, Power, Time) Pre- Trigger Function
Description: ADEPT Mode Example Description:

Use of the ADEPT mode allows simultaneous control with multiple Depth RPN (mm) The ultrasonic signal is applied to the weld stack as the sonotrode Pre-Trigger Mode
t1 > t2 > t3
weld modes. starts descending.
Weld parameters can be any, or all, of the previous modes. The RPN trigger point which is essential for all previously discussed Power
Whichever parameter is reached first ends the welding cycle. weld modes is not existent. Therefore it is impossible to achieve a
(W)
repeatable weld.
A combination such as Depth RPN and Weld Time could control the
depth while simultaneously avoiding over-welding but still allow some
variation in depth within a programmed window. ”Normal” Trigger Mode
Time Tolerance
To be considered: Trigger Point t (sec.)
t (sec)  Used in processes such as part forming under extremely low
To be considered: forces, e.g., staking tiny parts or very thin wall sections
 ADEPT mode can provide the proper control during welding of parts with cavity to cavity variations and/or internal assembly variations that  Staking and inserting where no initial force is desirable
may not be controllable by any other mode  Used with older (analog) type generators in combination with
 If the cost of the assembly being welded is very high, multiple control modes can be used to prevent damage to internal and external pieces large sonotrodes to avoid a power “spike” (due to no load being
 Will allow the welding of parts/assemblies within multiple narrow process windows, controlled by multiple weld modes, while not rejecting applied to the sonotrode face) at start up
parts falling within those multiple windows

Table of contents Section 4: Design to manufacture
1 Seminar Roadmap Basic design rules

2 Company Profile
 What are the principles of a good joint design?
3 Section 1: Understand the process  What joint designs are proven?
What are they designed for?
 Which materials can be welded?
5 Section 3: Setup the welding How is the material influencing the process?
8 Your application
Section 4: Design to manufacture Section 4: Design to manufacture
Basic design rules 1. Energy director – why?

1. Energy director:
The „weakest point“ will take most of the deformation (because
define a place to start the weld
of this it doesn't matter too much which side it is located). This
2. Sonotrode contact:
allow the US to get to the weld area
2 will create a local heat source. Once some melt is created the
dampening efficiency does increase a lot. Good start!
3. Support: allow the bottom weld-part to resist 7
4. Melt encapsulation:
prevent the melt leaving the joint area 1 W/o ED there is no control where the hotspot appears. Random
5. Centering: assure a consistent alignment contact points and weaknesses will rule the weld.
„If you can‘t make
456
6. Volume and travel equilibration:
allow the part to travel and the melt to go somewhere them all – you W/o ED power, energy and weld-time required to start the
should know what
7. Prevent hard stop:
you miss.“
process are increased. Damages to the part are likely.
let the part sink into the melt during holding 3

1. Energy director – how? 2. Sonotrode contact – get the US in

 The ED angle is typically 90°. This has been Measure flatness when force is 1. US cannot travel around corners. Always imagine your
proven a good compromise between stiffness and applied part being a sponge, then simulate the deformation. If
sharpness. you can: get the US right over the welding joint.
h See table. 2. Easy one-level contact faces will allow best buy tooling
The height is ruled by the wall thickness. The base and safe setup.
of the ED should be at least 50% of the wall 3. Dedicated contact faces will allow the toolmaker to
thickness. focus his efforts on flatness and hide ejectors, gates,
R Care for sharpness, reduce the top radius smaller Material Part Height h labels and marking.
than 0,1mm. Ideally you plan for a venting in the size
4. Ultrasonic is damped the deeper it has to travel into
injection tool. Care for good melt flow during Rigid (e.g. Small 0,3 – 0,4
the plastic. Consider this for the amplitude required.
moulding. amorphous or with mm
Try to pull the joint as close as possible to the
GF) Big 0,5 – 0,7
! Flatness: The ED flatness should be below 1% of mm sonotrode.
each section. The A reference is the contact. PE, PP, PA without Small 0,5 – 0,7 5. Contact faces need to be 3x bigger than welding
GF mm
! Don‘t make any other portion of the weld part the cross-sections.
big 0,7 – 1,0
ED: Round all the internal corners up with an R0,2 mm
or even bigger.
3. Support – don‘t let the US out 4. Encapsulation – stop the fugitive

1. The support should transmit the forces from the fixture  Prevent the melt leaving the joint area: it will not
directly into the weld joint. Again: imagine a sponge. contribute to strength and debris may be unacceptable.
2. Don‘t let holes, steps or curves interrupt the force flow. An encapsulated joint is free of burr.
If you can't prevent it, the fixture needs to compensate  Strength will also increase because the melt will
for it.
distribute evenly within the channel.
3. Easy one-level support faces will allow best buy
tooling and safe setup.  The sealability does regularly require an encapsulation
of the melt.
4. Dedicated support faces will allow the toolmaker to
focus his efforts on flatness and hide ejectors, gates,  Amorphous plastics can achieve sufficient strength
labels and marking. without encapsulation due to their viscous melt.
5. Try to get the support as close to the joint as you can.  Both parts should be able to move against each other.
Can you preview a flange? A press fit is not suitable.
6. Support faces need to be 2x bigger than welding  If injection moulding or strength does require it: maybe
cross-sections. you can use a single-side encapsulation only?

Overview of different techniques Proven weld joint designs – overview
Welding Deforming, staking

Preferred joint designs
 step joint h1
 tongue & groove h2

α
 HU mash joint
 HU v-joint
Inserting Embedding
Trouble joint designs
 ED only
 45°shear joint
 flat shear joint
© Copyright Herrmann Ultraschall I Grundlagenseminar 111 © Copyright Herrmann Ultraschall I Ultrasonic Welding Basics 112
Preferred: step joint Preferred: Step Joint

Advantages:
 High strength
h1
 Suitable for shear & torsion force
 Self centering h2
 Cosmetically clean, melted material is contained in the joining area
 Optional decorative edge improves outward appearance
To consider:
 Dimension h2 > h1
 Melt could flow to the inside
possible
 Optimized sonotrode energy input through raised sonotrode contact surfaces decorative
directly above the joint areas edge
 Possible loose tolerances on large parts: addition of small ribs (spacers) might
be required to center large parts 0.1 – 0.2
mm

Preferred: Tongue & Groove Preferred: HU Mash Joint

Advantages: Advantages
 Full melt encapsulation resulting in maximum bonding strength  Full melt encapsulation resulting in maximum bond strength
 Suitable for shear & torsion forces  Suitable for shear & torsion forces
 Self centering, cosmetically clean α
 Self centering
 Reliable hermetic seals, material is contained in joining area
 Cosmetically clean, material is contained in Clearance
joining area should be in a range of  Especially suitable for
Nylon (PA) and Acetal (POM) resins
 No particulates generation 0,05mm to 0,1mm
To consider: To consider
 Joint design requires thicker walls  High ultrasonic energy required
 Optimized sonotrode energy input through raised sonotrode contact  Precision molding required
surfaces directly above the joint areas  Mash angle α provides important point contact (20° < α < 35 °)
 Possible loose tolerances on large parts: addition of small ribs  Possible loose tolerances on large parts: addition of small ribs (spacers) might be
(spacers) might be required to center large parts required to center large parts
Preferred: Mash joint Preferred: V-Joint

Advantages
 For wall thickness below 1mm
 Self-centering
 Good strength
 Good visual appearance
To consider
 Only for small parts
 Air can get enclosed into the joint
 Precise moulding required

Preferred: V-Joint Materials
 What are the principles of a good joint design?
 What joint designs are proven?
 What are they designed for?
 Which materials can be welded?
 How is the material influencing the process?
Section 4: Design to manufacture Table of contents
Which materials can be welded 1 Seminar Roadmap

 All thermoplastics can be welded (but PTFE). 2 Company Profile
 PC, PMMA, ABS and PVC can weld to each other
US key characteristics: 4 Section 2: Understand the machine

 E-Modulus: drives the US conduction and coupling 5 Section 3: Setup the welding
 Dampening: driving the heat creation
 Melting point: drives the energy requirement
 Melt flow index: defines the amount of melt staying in
front of the driven part 8 Your application
 !!! Additives: e.g. flame inhibitors,…
 !!! Moisture: most of all PA
 !!! Recycling: changing the key characteristics

Section 5: Other applications Section 5: Other applications
Applications NONWOVENS
 What has been done?
 What can be done?
PACKAGING PLASTICS

Automobile Medical applications

Covering discs, covers, bezels, cover plates, DAE- Ostomy, blood filters, spike membranes, filter
membranes, knobs, roller blinds, filter housings, cables, membranes, filter packages, flasks, electronic housings,
filter cartridges, liquid carriers, valve housings, gear handles, hearing aids, implants, infusion bags, plug
housings, handles, buckles, signs, rotors, lamp glasses, valves, cuvettes, Luer-Adapter, air filters, multiwells,
logos, brush holders, plugs, circuit boards, POF-ferrules, needle shields, seals, pens, prosthesis, rotative adapters,
embossing, pump housings, pump rotors, gear shift secretion containers, secretion bags, sensor housings,
covers, sensor housings, mesh carriers, graduated spouts, syringes, plugs, medical transfer systems, valve
collars, plug housings, contact plug, control housings, housings, obliteration elements, wells,…
diffusion discs, valve membranes, gears, indicators,
decorating rings, cable anchorage,…
Consumer, Electronics Examples: JOINING OF PLASTICS

Control elements, lids, displays, knobs, printer cartridges,
shower heads, electronic housings, power tool housings,
handles, cables, cable anchorages, electrical terminals,
buttons, guide light, blower wheels, motor brush holders,
original seals, circuit boards, pump rotors, switches,
relays, windows, sensor housing, toys, plugs, pens,
USB-sticks, valve housings, drains, water filter housing,
water tanks (coffee machine), toothbrushes,…

Examples: JOINING OF PLASTICS Examples: JOINING OF PLASTICS


Table of contents Your application
1 Seminar Roadmap
2 Company Profile
5
6
Section 3: Setup the welding
Section 4: Design weld parts Thank you!
8 Your application

Cutting edge technology worldwide
Global Headquarters North American Headquarters

Herrmann Ultraschalltechnik GmbH & Co. KG Herrmann Ultrasonics, Inc.
Descostraße 3–9 · 76307 Karlsbad, Germany 1261 Hardt Circle · Bartlett, IL 60103, USA
Tel. +49 7248 79-0 · www.herrmannultraschall.com www.herrmannultrasonics.com
China Headquarters Japan Headquarters

Herrmann Ultrasonics (Taicang) Co. Ltd. Herrmann Ultrasonic Japan Corporation
Build 20-B, No. 111, North Dongting Road, Taicang, KOIL 503-1, 148-2 Kashiwanoha Campus, 178-4 Wakashiba,
Jiangsu Province, China · www.herrmannchina.com Kashiwa City, Chiba 277-8519 · www.herrmannultrasonic.co.jp
© Copyright Herrmann Ultraschall I Ultrasonic Welding Basics 143

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Ultrasonic Welding for Plastics

Ultrasonic Welding Basics 7 Section 5: Other applications

© Copyright Herrmann Ultraschall I 1 © Copyright Herrmann Ultraschall I Ultrasonic Welding Basics 2

Ultrasonic Welding for Plastics Ultrasonic Welding for Plastics

Section 1: Understand the process Section 2: Understand the machine

 What does influence this process?

 How does the machine respond?

 How do the process parameters influence the weld?

Ultrasonic Welding for Plastics Ultrasonic Welding for Plastics

Section 3: Setup an ultrasonic weld Section 4: Joint design

Quality Quality assurance

Ultrasonic Welding for Plastics Ultrasonic Welding for Plastics

Global Headquarters, Karlsbad

Tech-Center Mexico City

Ultrasonic Welding for Plastics Ultrasonic Welding for Plastics

PLASTICS – welding moulded parts

NONWOVENS – high speed bonding systems PACKAGING – Ultrasonic sealing technology

 Extruded sheets  Blister bags, cups, bowls

Ultrasonic Welding for Plastics Ultrasonic Welding for Plastics

1 Seminar Roadmap How does ultrasonic welding work?

Plastic welding Plastic welding

Ultrasonic Welding for Plastics Ultrasonic Welding for Plastics

Melt flow creates bonding Function diagram of plastic welding

Create melt flow Ultrasonic welding

What is ultrasonic vibration? Ultrasonic welding – a quick look

Ultrasonic Welding for Plastics Ultrasonic Welding for Plastics

Ultrasonic welding – a close look Ultrasonic welding – not like this!

Functional diagram of ultrasonic welding More examples of damping

compress  Viscoelastic damping

Ultrasonic Welding for Plastics Ultrasonic Welding for Plastics

Heat creation during US welding Heat is created…

Questions Input and Output

 What can be observed in the plastic welding cross section?

Ultrasonic Welding for Plastics Ultrasonic Welding for Plastics

Influences on US welding Input: Process parameters

Startup Setup Input  Graph

Input: Welding parameters Output: Weld part

Two parameter sets: 1. Driving the speed Where is the patient?

Ultrasonic Welding for Plastics Ultrasonic Welding for Plastics

Output: Weld graphs How to read a joining velocity profile

Weld depth RPN [mm]

Output: Data Parameters

Ultrasonic Welding for Plastics Ultrasonic Welding for Plastics

Force does effect joining velocity Force does affect coupling

 excessive weldtime to achieve weld  Surface damages

 reduce weld force Starting point:

Force does affect melt flow Frequency affects welding depth

Weld depth RPN [mm]

 irregular velocity profile 35 kHz

 irregular power profile early

Ultrasonic Welding for Plastics Ultrasonic Welding for Plastics

Amplitude does affect coupling but also… Questions

more  How does excessive force affect the melt flow?

Ultrasonic Welding for Plastics Ultrasonic Welding for Plastics

1 Seminar Roadmap Machine elements

Amplitude – Ultrasonic Vibration Amplitude – How big is a micron?

Ultrasonic Welding for Plastics Ultrasonic Welding for Plastics

Amplitude – sonotrode stack Resonance is ruling amplitude

Converter – the engine of the stack Amplitude – Converter

Ultrasonic Welding for Plastics Ultrasonic Welding for Plastics

Amplitude – generator Amplitude transformation – booster

High Frequency Signal e.g.

Amplitude transformation – booster Amplitude – sonotrode