Product Manual:
Sales Order
Customer
Create Date 11-23-2009 By MGD
Last Rev Date 12-27-2013 By LAW
Manual Include Instruction Sets Description
DCM01241-XX Special Information
|------------> DCM00003 General Information
|------------> DCM00056 MWX100
|------------> DCM00002 TouchScreen Controller
Special Actuator Controller
BRANSON Ultrasonics Corporation
41 Eagle Road
Danbury, Connecticut 06813-1961 U.S.A.
(203) 796-0400
http://www.bransonultrasonics.com
Instruction Set for Special Information Page 1 of 8
BRANSON Metal Welding
Product Manual- Special Information
Table of contents
Product Manual:……………………………………………………………………………….1
Table of Contents:…………………………………………………………..…………………2
Introduction:…………………………………………………………………………………...3
Using This Manual:……………………………………………………………………………4
Classification of Hazards:…..…………………………………………………… ……………4
System Specification Sheet:…..……………………………………………………………….5
Parameter Preset Information:…..……………………………………………………………..6
File Attachments:………………………………………………………………………………7
Special Instructions:……………………………………………………………………………8
Instruction Set for Special Information Page 2 of 8
BRANSON Metal Welding
Product Manual- Special Information
Introduction:
This is the product manual for your BRANSON Metal Welding ultrasonic welding system.
Several combined Instruction Sets form the contents of this manual. This section contains
information which relates most uniquely to you as the customer, your particular system and
application. It also documents other Instruction Sets used in the manual. The figure below
illustrates how the manual is organized.
BRANSON Metal Welding Product Manual
Special Information Instruction Set
General Information Instruction Set
Actuator Instruction Set
Controller Instruction Set
(Other) Instruction Set (s)
Instruction Set for Special Information Page 3 of 8
BRANSON Metal Welding
Product Manual- Special Information
Using this manual:
It is highly recommended that you read and understand the contents of this manual prior to
operating your BRANSON Metal Welding system. Each Instruction Set has a table of contents
and is intended to logically group information in a manner which the user will find convenient.
Classification of Hazards:
The safety indications in this manual are divided into different classes. The figure below shows
the assignment of symbols (pictograms) and signal words to the specific hazards and its potential
consequence.
PICTOGRAM SIGNAL
WORD
ATTENTION !
DANGER !
NOTE
A potentially dangerous situation
that could cause injury to persons
and serious damage to equipment.
A situation that may cause damage
to the equipment
Useful information, an application
hint or other important or useful
information.
DEFINITION
Instruction Set for Special Information Page 4 of 8
BRANSON Metal Welding
Actuator
Shuttle
Controller
Power Supply
PLC
Product Manual- Special Information
System Specification Sheet:
Sales Order
Customer
Create Date
Type
Serial Number Program No N/A
Type TouchScreen
Serial No
Firmware Type Welder
Firmware Version
Firmware Lang Multi Lingual
Type N/A
Serial Number N/A
Type N/A
Program Number N/A
Part Number Description
101-135-067R Converter
Horn
Tip
Tip Nut
Anvil
See Table 1 Booster, High Gain
To serve you better, please be aware of the following:
All tools have a 5 to 6 week lead time.
Prices are subject to change without notice.
An additional fee may be charged for expedited service.
MWX100
Type N/A
Instruction Set for Special Information Page 5 of 8
BRANSON Metal Welding
Product Manual- Special Information
Parameter Preset Information
Sales Order «SalesOrder»
Customer
«Customer»
Name or preset Number
Energy (joules)
Force (psi/bar)
Pressure (psi/bar)
Amplitude (microns)
Squeeze Time (ms)
Pre-Burst (ms)
Hold Time (ms)
Welding Parameters
After Burst Delay (ms)
After Burst Duration (ms)
Weld Time Min. (ms)
Weld Time Max. (ms)
Weld Power Min. (watts)
Weld Power Max. (watts)
Pre-Height Min. (mm)
Pre-Height Max.(mm)
Post Height Min.(mm)
Quality Monitoring
Post Height Max. (mm)
Name or preset Number
Energy (joules)
Force (psi/bar)
Pressure (psi/bar)
Amplitude (microns)
Squeeze Time (ms)
Pre-Burst (ms)
Hold Time (ms)
Welding Parameters
After Burst Delay (ms)
After Burst Duration (ms)
Weld Time Min. (ms)
Weld Time Max. (ms)
Weld Power Min. (watts)
Weld Power Max. (watts)
Pre-Height Min. (mm)
Pre-Height Max.(mm)
Post Height Min.(mm)
Quality Monitoring
Post Height Max. (mm)
Instruction Set for Special Information Page 6 of 8
BRANSON Metal Welding
Product Manual- Special Information
File Attachments:
Sales Order Customer
Description File
Assembly Drawing 159-132-341
File Attachments are included at the end of this instruction set.
Tooling Table:
The (computer) file name of this manual contains a two digit suffix number.
Example: DCM01241- ##. PDF
Use the suffix number from Table 1 to determine the Booster used on your welder.
DCM01241- Booster Type, Color Part Number Gain (ref only)
-01
-02
-03
-04
-05
-06
Super High Gain, Silver
High Gain, Gold
Medium High Gain, Blue
One-to-One, Red
Medium Low Gain, Blue
Low Gain, Black
Table 1
17100-00-416 2:1
17100-00-216 1.67:1
17100-00-316 1.17:1
17100-00-016 1:1
17100-00-516 0.75:1
17100-00-116 0.5:1
Instruction Set for Special Information Page 7 of 8
BRANSON Metal Welding
Product Manual- Special Information
Special Instructions:
Instruction Set for Special Information Page 8 of 8
BRANSON Metal Welding
Product Manual- General Information
General Information and Instructions
Document Number DCM00003
Last revised 03/27/2012 LAW
Use of this document is intended for use with all Branson Metal Welding products.
Branson Ultrasonics Corporation
41 Eagle Road
Danbury, Connecticut 06813-1961 U.S.A.
(203) 796-0400
(203) 796-0810 FAX
http://www.bransonultrasonics.com
This document is intended for use in conjunction with others to form a complete manual
for your Branson system.
Introduction:
This Instruction Set includes common information which relates to Branson products. It will help
you in setting up your system and to understand the fundamentals of the ultrasonic metal welding
process.
Portions of this section may be superseded by more specific and detailed information
provided in other Instruction Sets.
Instruction Set for General Information Page 1 of 30
BRANSON Metal Welding
Product Manual- General Information
Table of Contents
Introduction: ...............................................................................................................................1
Table of Contents ........................................................................................................................2
Thank You: .................................................................................................................................3
Warranty: ....................................................................................................................................4
Intended Use: ..............................................................................................................................5
Safety, Personal: .........................................................................................................................5
Safety Devices .........................................................................................................................5
Emergency Stops: ....................................................................................................................5
Safety Guidelines: ....................................................................................................................5
Maintenance Safety:.................................................................................................................6
Safety, System: ...........................................................................................................................6
System Protection Monitoring (SPM) ......................................................................................6
Thermal Switch........................................................................................................................6
Daily Functional Safety Checks: ..............................................................................................6
Unpacking, Handling & Installation: ...........................................................................................7
If damage has occurred: ...........................................................................................................7
System Location: .....................................................................................................................7
System Assembly: ...................................................................................................................7
Operating the System: .................................................................................................................8
Troubleshooting: .........................................................................................................................9
Weld Overload .........................................................................................................................9
Low Air Pressure .....................................................................................................................9
Ready Check ............................................................................................................................9
Troubleshooting Guide .......................................................................................................... 10
Periodic Maintenance ................................................................................................................ 13
Contacting Branson: .................................................................................................................. 14
Spare Parts & Replacement Tooling: ...................................................................................... 14
Questions or Problems: .......................................................................................................... 14
Returning Equipment: ............................................................................................................ 15
Return Authorization Form ................................................................................................. 16
New Applications: ................................................................................................................. 17
Evaluation Request Form .................................................................................................... 18
Terminology: ............................................................................................................................ 19
Ultrasonic Theory: .................................................................................................................... 24
What Is An Ultrasonic Weld?................................................................................................. 24
How Does It Work? ............................................................................................................... 24
Instruction Set for General Information Page 2 of 30
BRANSON Metal Welding
Product Manual- General Information
Thank You:
Thank you, and congratulations on selecting Branson MWX100/ ULTRASPLICE Systems for
your welding production. This system has been developed to produce the highest quality welds at
the lowest cost per weld.
If you should experience difficulty or have any recommendations for improvement, please do not
hesitate to contact us.
Please be advised that the MWX100/ ULTRASPLICE machine is protected under the United
States and International patents listed below. This operator’s manual is also protected by
copyright and may not be copied without prior written permission by Branson.
Trademarks
MWX100 and
ULTRASPLICE
Copyright
MWX100 Computer Software
and the MWX100 Manual
are registered trademarks of
Branson Ultrasonics Corporation
are copyrighted 1994,1995,1996,1997 by
Branson Ultrasonics Corporation
Instruction Set for General Information Page 3 of 30
BRANSON Metal Welding
Product Manual- General Information
Warranty:
Branson Ultrasonics warrants this equipment to be free from defects in material and
workmanship for one (1) year from date of original delivery by Branson or by an authorized
representative when used in accordance with written instructions. Any unit which proves
defective during this period will be repaired or replaced free of charge at the sole discretion of
Branson Ultrasonics, F.O.B. Danbury, Connecticut or an authorized repair station as advised by
Branson. This is the buyer’s sole and exclusive remedy. The defective unit must be returned
properly packed with all transportation charges prepaid.
Expendable tooling produced by Branson such as the horn, tip and anvil will wear at varying
rates depending upon the application and duty cycle. For this reason, Branson warrants that all
tooling complies with specifications on design and materials but cannot guarantee its useful life
for a fixed period of time.
The warranty provisions contained herein are expressly in lieu of all other warranties, express or
implied. THERE ARE NO IMPLIED WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE MADE IN CONNECTION WITH THE
EQUIPMENT TO BE DELIVERED THEREUNDER.
This warranty is limited to the original purchaser and is not transferable.
BRANSON Ultrasonics will not be liable for any consequential damages claimed in relation to
the purchase or warranty of the equipment to be delivered thereunder. Branson will not be liable
for any injury to persons or property caused directly or indirectly by the use of the equipment
delivered thereunder.
Horns fabricated by Branson for use in Branson equipment are manufactured to exacting
parameters and tuned to vibrate at the equipment’s ultrasonic operating frequency. An
improperly tuned horn can cause undue stress or damage to the converter and power supply.
Contact your Branson representative or Branson’s world headquarters in Danbury, Connecticut,
should you have any questions concerning horn qualifications.
Authorization to return equipment for repair is required. A Return Authorization Number must
be obtained from Branson’s Service Department. Equipment being returned for repair must be
packaged in the original carton(s) to protect it from damage and returned freight prepaid. Any
damage that is sustained as a result of improper packaging may void the warranty and is the
sole responsibility of the customer.
For questions relating to warranty or repair please contact our Repair Department.
Instruction Set for General Information Page 4 of 30
BRANSON Metal Welding
Product Manual- General Information
.
Intended Use:
This equipment is for the joining of metal parts using ultrasonic energy. A complete system
includes an actuator, controller and tooling (which delivers mechanical energy to the work
pieces). Some systems also include special fixturing and machine automation. Branson systems
may only be utilized to weld soft, ductile, metal parts together with Branson-supplied weld
tooling (such as horns, tips, anvils, and converters) unless an explicit, written, contrary
agreement between the ordering party and Branson has been consummated.
Safety, Personal:
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.
Emergency Stops:
In case of danger, hit the red, emergency stop which is found on the red, top portion of the foot
pedal. The actuator, power supply and related fixturing are returned to the “Home” position. If
dual anti-tie start buttons are used, there must be a red emergency stop associated in line. Free
access to the emergency stop button must be maintained.
Controller Cover
The power supply is equipped with a top cover which should only be removed for maintenance
and installation purposes.
Safety Guidelines:
For operating safety, please observe the following precautions:
• Plug the power supply into a grounded electrical supply to avoid electrical shock.
• Ensure that no one is in contact with system moving parts when operating.
• Keep hands away from the horn tip as high force and ultrasonic vibration can cause injury to
hands and fingers.
• Do not test ultrasonics when the converter is removed from the actuator. Without the
converter there is the danger of damage or shock.
• Before adjusting or repairing the ultrasonic stack or power supply, disconnect the line power.
• Any unauthorized modification of the units control circuitry or wiring may cause a
malfunction, which could result in injury to operating personnel.
• Do not operate the equipment until repairs and adjustments have been made and the
equipment is in good working order.
Instruction Set for General Information Page 5 of 30
BRANSON Metal Welding
Product Manual- General Information
Maintenance Safety:
Safety devices, especially covers, guards and ground cables should only be removed when it is
absolutely essential for the completion of maintenance work. If safety devices were removed
prior to starting maintenance work, be sure to re-install those devices after finishing the
maintenance work. The following installation and maintenance operations must be performed
prior to any disassembly of equipment:
• All system components must be disconnected from the main electrical supply
• Remove the plug from the main electrical supply and secure it from being re-inserted
accidentally.
• All system components must be disconnected from the main air supply
• Disconnect the air hose from the main air supply and release system air pressure via the
pressure regulator.
Safety, System:
System Protection Monitoring (SPM)
The SPM (System Protection Monitoring) stops ultrasonics when the power supply has been
overloaded or when inappropriate or defective horns are used.
Thermal Switch
A thermal switch is contained within the power supply to automatically disconnect power to the
machine if the unit gets too hot. This will occur if the exhaust fans from the generator are
inadvertently blocked or clogged.
Daily Functional Safety Checks:
• Check the machine tip and anvil for any signs of grinding, cracking, or galling that could be
the result of misalignment or tooling contact. Replace tooling that has excessive wear.
• Check for any loose material or debris in the welding cavity, cleaning it out.
• Check all parameter settings on the controller to ensure they are properly set for the weld to
be made.
• Drain water and contaminants from the airline filters as necessary
Instruction Set for General Information Page 6 of 30
BRANSON Metal Welding
Product Manual- General Information
Unpacking, Handling & Installation:
Unpack the Actuator and Touchscreen Controller. Remove the top cover of the power supply
and check if any components became loose during shipment.
If damage has occurred:
Notify the shipping company immediately. Retain packaging materials for inspection and
possible re-use.
System Location:
Locate the Touchscreen Controller in an area away from radiators or heating vents. Allow
sufficient clearance in back of the controller to access the connectors. Observe the following:
• Do not block the exhaust or air intake areas. Proper air circulation is necessary to maintain a
safe operating temperature.
• Only operate the controller within an ambient temperature range of 41°F to 122°F (5°C to
50°C).
• Verify that neither dust nor dirt are allowed to restrict the flow of air exhaust or air intake.
Clean the air ports as necessary.
If the temperature of the power supply exceeds the recommended operating range, a thermal
switch will stop ultrasonics and the power supply will display an Overload alarm. Ultrasonics
will remain off until the power supply cools to a safe operating temperature and the RESET
button is pressed.
If the environment is excessively dirty or oily, contact Branson for assistance. Special
Touchscreen Controller enclosures, filters (i.e. filter/separator/regulator), and other equipment
are available.
System Assembly:
Connect the actuator system per the Hookup diagram contained in the Special Information
Instruction Set. Verify that connections are complete and correct before proceeding. Plug the
Controller into a proper power source. See the Touchscreen Controller Instruction Set for power
specifications, plugs and receptacles used.
To prevent the possibility of an electrical shock, always plug the power supply into a
grounded power source. Be sure the power switch is in the Off position before making any
electrical connections.
Connect the system to a clean (5 micron air filter with 0.5 micron mist separator), dry, 80 psig
(5.5 bar) minimum air supply. See the Actuator Instruction Set for information on the set up of
application tooling and the use of this equipment for ultrasonic welding.
Instruction Set for General Information Page 7 of 30
BRANSON Metal Welding
Product Manual- General Information
Crash Gap Adjustment:
In most applications, adjustment of the gap between the ultrasonic Horn Tip and the Anvil is
factory set to prevent these surfaces from contacting each other when no parts to be welded are
present and the foot pedal is depressed. A poorly adjusted crash gap can cause serious damage to
the tooling. See the Actuator Instruction Set for proper setup instructions.
Operating the System:
With all proper connections made and with tooling properly set up, welding may be performed.
In most instances it is likely that Branson has developed weld settings for your application and
stored them as presets in the controller prior to shipping. See the Touchscreen Controller
Instruction Set for information on retrieving presets. For other weld parameter information
pertaining to your system, see the parameter preset page included in the Special Information
Instruction Set.
Instruction Set for General Information Page 8 of 30
BRANSON Metal Welding
Product Manual- General Information
Troubleshooting:
This section shows how to fix some of the possible errors and problems which may occur in
normal use of the MWX100/ Ultrasplice system.
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.
Hardware internal to the supply are controlling this function and it can not be defeated.
The control system analyzes the end of weld characteristics to check for overloads. If the system
determines an overload an alarm occurs. The control halts action until the system is reset.
Some of the possible causes for overloads are:
• The tool clearances are too small, horn and anvil touch during welding
• Excessive air pressure with low amplitude
• Defective Stack assembly
• Defective Power Transistors in power supply
Low Air Pressure
The control system and its components were designed to run with a clean air supply of from 90
to 120 psi. The control system monitors the air pressure from the low air pressure switch
(optional). The low pressure threshold is set from the controller. An alarm occurs when
incoming line pressure the drops below the set pressure.
Ready Check
The system undergoes a Ready Check operation at every startup, the end of every weld, and at
the exit of Setup mode. This procedure checks the height encoder position. If an incorrect height
value is returned, an alarm occurs.
Some of the possible causes of a Ready Check alarm are:
• The horn is stuck in the closed position
• Maintenance has moved the height encoder to an out of limit condition
• Defective encoder or electronics
• Encoder not plugged in to its connector
Instruction Set for General Information Page 9 of 30
BRANSON Metal Welding
Product Manual- General Information
Troubleshooting Guide
PROBLEM SOLUTION
System will not turn on. Power cable plugged in.
Power turned on at the outlet.
Check internal fuses on the Controller Line
Board.
Plant fuse fails or circuit breaker trips
when plugging the unit into an electrical
outlet.
Plant fuse fails or circuit breaker trips
during weld cycle
Line fuse fails. Check fuse current rating, replace if
Horn will not move down or up. System not connected to air supply.
Get Emergency Stop when system is
turned on.
No Sonics when test button is pressed. RF Cable connected.
No sonics during weld cycle Check all cable connections.
Overloads when welding Stack not tuned properly.
When touching the system you get a
slight electrical shock.
Inspect power cord, replace if shorted.
Check line filter, replace if failed.
Check current rating of the plant fuse or the
circuit breaker, replace if failed.
incompatible.
Check fan motor, replace if failed.
Air not turned on.
Check Emergency Stop Switch.
All cables properly connected.
Press red switch on foot pedal. (if system is
equipped with one)
Check RF cable for broken wire.
Ribbon cable in power supply between SPM and
programmer unplugged.
Check start cable for broken wires.
Check inside power supply for loose start cable
from rear of unit to programmer board.
Check thermo switch in power supply.
Tooling not set up properly.
Crash gap not set properly.
Tip nut cracked, replace if needed.
Check weld parameters.
Check stack interfaces for fretting.
Check for loose or failed horn or booster, tighten
or replace as necessary.
Inspect power cord, replace if needed.
Inspect system ground, repair if needed.
Instruction Set for General Information Page 10 of 30
BRANSON Metal Welding
Product Manual- General Information
Tooling heats up after machine runs a
while.
Low weld strength. Check weld parameters.
Excessive welding. Reset parameters.
Time limit error or peak power error
displayed after weld cycle.
Squealing sound during welding or when
test key is depressed
Weld heights are inconsistent Re-calibrate encoders with 1mm gauge.
Horn is stuck in down position Check air pressure.
Air leaking from machine. Ensure all air line connections are tight.
Unusual sound during weld cycle. Check tooling gap.
Cooling air is not turned on or is not on long
enough.
Cooling air is not directed at tooling.
Check tooling gaps.
Check knurl on tooling. If worn replace
tooling.
Increase Energy.
Check the Down stop adjustment.
Check for part contamination.
Ensure all hardware is tight.
Reset amplitude.
Reset pressure.
Measure and re-calibrate amplitude display.
Reset limits.
Check tip, rotate or replace if worn.
Check anvil for wear, rotate or replace if worn.
Check air pressure setting.
Check up stop for proper adjustment.
Process settings have to be opened up due to
part variance or limits should be adjusted
according to the part/wire being run.
Check anvil clamp for proper torque.
Check plate screws and tighten or replace.
Check cover plate screws and tighten.
Reset gaps.
Re-square horn/tip and reset gaps.
Reset horn tip and gap.
Ensure the connector for the encoder is tightly
plugged into the actuator card.
Ensure air lines are installed properly.
Check for kinks in air lines.
Check for cracked or broken air lines.
Check converter.
Check stack assembly.
Instruction Set for General Information Page 11 of 30
BRANSON Metal Welding
Product Manual- General Information
Squealing sound from power supply when
unit is turned on.
Maintenance counter alarm. Reset maintenance counter.
Actuator arm moves sluggish Check air lines for contamination.
System has READY CHECK message The horn is stuck in the closed position.
Time, height and energy inconsistent. Switch to energy mode & open height window.
Check cooling fans in rear of unit
NOTE: Air must be filtered to 5 microns and be
oil and water free.
Check solenoid valve, replace if needed.
Check air regulator.
Maintenance has moved the height encoder to
an out of limit condition.
Defective encoder or electronics.
Encoder not plugged into the actuator card.
Make some sample welds. Check the time and
the height of the welds for consistency. If the
time or weld thickness varies greatly, check the
air regulator.
Instruction Set for General Information Page 12 of 30
BRANSON Metal Welding
Product Manual- General Information
Periodic Maintenance
In order to maintain optimum operating conditions, it is important to perform various
maintenance and equipment inspections at periodic intervals. Please observe the following
recommendations.
Daily:
• Drain water and contaminants from the airline filters, if required.
Every Tool Rotation:
• Inspect the clamping surfaces of the Tip, the Tip Nut
and the Horn for fretting.
• Vacuum and clean out any copper residue or dirt in the actuator.
After one million cycles:
• Vacuum and clean inside of power supply
• Calibrate pressure regulator.
• Clean and torque the stack interface.
• Calibrate amplitude.
FSR Assembly
Air Filter/Separator/Regulator (Optional Branson Part #207-020) should be serviced after 1 year
or when a pressure drop of 15 psi is reached.
• Disconnect the air supply.
• Remove and clean out filter bowl with a clean rag.
• Replace the white filter element and re-assemble.
• Remove and clean out separator bowl with a clean rag.
• Replace brass-colored filter element and reassemble.
• Reconnect air supply.
Do not use solvent to clean filter bowls
Clean the air filter bowl with a mild household soap only. The bowl is made from a
polycarbonate material, which can rupture if exposed to synthetic lubricating oils solvents or
harsh chemicals. The bowl is rated for a maximum line pressure of 140 psig (1043 kPa) and a
maximum temperature of 120°F (49°C).
Instruction Set for General Information Page 13 of 30
BRANSON Metal Welding
Product Manual- General Information
Contacting Branson:
Spare Parts & Replacement Tooling:
Spare parts or replacement tooling for the ultrasonic welding system may be ordered directly
from Branson. A spare tooling specification sheet is included in the Special Information
Instruction Set. Additional part listings are contained in the Actuator and Touchscreen
Controller Instruction Set sections of this manual.
Branson will work with you and recommend components you need and should carry in inventory
based upon your manufacturing philosophy and or production needs. We will quote price,
delivery and can coordinate special arrangements such as expedited service or blanket orders.
When Ordering Spare or Replacement Parts have the purchasing agent Fax the order to us with
the following information provided:
• Purchase Order Number,
• Branson Part Number, Quantity, and Date Required,
• Ship To Information, (including “Ship to the Attention of”)
• Bill To Information
• Shipping Instructions, (such as air freight, truck, etc.)
• Special Instructions, (such as “Hold at Pick-Up Counter and Call” -- Be sure to provide a
name and a phone number)
Questions or Problems:
If you have any questions or are experiencing a problem, call the local Branson field sales and/or
service representative. He or she will be familiar with your equipment and application and, in
most cases, will be able to help you. He or she may have the replacement part you need, in
stock, that will return your system to operation in the shortest possible time.
If necessary, the representative will contact Branson for additional service and, in some cases,
will put you into contact with the appropriate personnel. If the local representative is unavailable,
please call us directly.
Before you call, take the following steps:
• Have this manual with you.
• Know how your system has been set up and equipped, including your MBOS version.
• Be able to describe the situation or problem.
• Have a list of steps that you have already taken.
• Have a list of spare parts in your inventory
• Have the name and phone number of the Local Branson Representative
Instruction Set for General Information Page 14 of 30
BRANSON Metal Welding
Product Manual- General Information
Returning Equipment:
In order to properly and efficiently handle an equipment return to Branson, the following
procedure must be followed. Contact your Local Sales Manager or Branson Customer Service
for assistance. Proper handling and identification of your equipment will expedite servicing
and/or return.
Using the Return Authorization Form, (next page), complete the following:
• Customer Information Section
• Description of Problem
• Equipment Information
Call Branson and Receive a Return Authorization Number (RA#) from Branson Customer
Service.
• Properly package the equipment to prevent damage
• Clearly mark the RA# on the outside of the package
• Include a copy of the completed Return Authorization Form inside the package
• Return general repairs by any convenient method. Send priority repairs via Air Freight
• Prepay the transportation charges, (FOB Danbury, CT)
Instruction Set for General Information Page 15 of 30
BRANSON Metal Welding
Product Manual- General Information
Return Authorization Form
Customer Information Authorization Information
Customer name: Return Authorization No:
Address:
Contact:
Phone:
Fax:
Description of Problem:
Equipment Information:
Machine Type:
Machine Serial Number:
Date of Original Purchase:
Part Number of Component:
PO Number for Repair:
Do not ship to Branson without an RA
number. Mark the RA number on the shipping
label. Please fax a copy of this completed
form to Branson Customer Service prior to
Shipping.
Assigned By:
Special Instructions:
For Branson Use Only
Under Warranty
Billable Repair
Charge Repair to Sales
Sold Replacement Part
Instruction Set for General Information Page 16 of 30
BRANSON Metal Welding
Product Manual- General Information
New Applications:
Branson is always eager to work with you on a new ultrasonic application. Whether it be a
manual workstation, a semi or fully automated system, Branson has the personnel and technical
competence to support your requirements. Branson’s application laboratory, product and
automation engineering, customer service and manufacturing capabilities are second to none.
Branson is the world leader in ultrasonic metal welding and our business philosophy is practiced
to assure customer success.
Application assistance is always available. For initial application review, contact your Local
Sales Manager who can indicate initial feasibility and assist you in completing the Ultrasonic
Weld Evaluation Request Form, (next page). Please complete one (1) request form for each
application.
Please copy the attached Ultrasonic Evaluation Request Form (next page), complete the
customer and application information section and forward it to Branson along with enough
component material to produce 24 assemblies, (if this is not practical please advise). A
feasibility evaluation will be performed and samples returned, for review, along with a system
quotation/ proposal. Be sure to include drawings of the completed assembly and include the
electrical, mechanical, and production requirements. Complete the form as completely as
possible. The Branson Sales Representative can assist you.
Instruction Set for General Information Page 17 of 30
BRANSON Metal Welding
Product Manual- General Information
Evaluation Request Form
Lab Application No: Date:
Please fill out this form with at least 24 samples parts for an ultrasonic weld analysis
Name:
Company:
Address:
City:
Telephone:
Component Description:
Part 1 Part 2
Material:
Hardness:
Plating:
Insulation:
Application Requirements:
Production Rate: (parts/hr)
Location tolerance: (in)
Is weld appearance important:
Pull Strength (lbs)
Drawing Notes:
This information to be completed by Branson
Representative:
Telephone:
Return samples to: Representative Customer
Sales Engineer:
Applications Engineer:
Instruction Set for General Information Page 18 of 30
BRANSON Metal Welding
Product Manual- General Information
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 for efficient 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. (Also See: AFTER BURST DELAY & AFTER BURST
DURATION)
After Burst Delay: The amount of time, in seconds, between the completion of the ultrasonic
welding cycle and the start of the AFTER BURST. (Also See: AFTER BURST & AFTER
BURST DURATION)
After Burst Duration: The amount of time, in seconds, that AFTER BURST energy is
delivered. (Also See: AFTER BURST & AFTER BURST DELAY)
Amplitude: Amplitude is the peak-to-peak displacement of mechanical motion as measured at
the face of the horn tip. Amplitude is measured in thousandths of an inch or in microns. (i.e. A
standard 40 kHz converter produces approximately .0004” or 10 microns of amplitude), Inches x
25,400 = microns. -- With ‘Advanced Power Supply’ this is adjustable depending on system
frequency and application tooling.
Anti-Node: The anti-node is the area of the horn and booster that exhibits maximum
longitudinal displacement and where the internal dynamic forces are equal to zero. This area is
at the face and back surface on half-wave technology.
Anvil: A device specially designed to grip the lower component and hold it stationary against
the energy of vibration(s) which allows a weld to be created.
Baud Rate: A communications measure describing the speed at which signals are transmitted
serially (the number of signal events per second).
BBRAM: Nonvolatile random access memory (battery back-up random access memory).
Equipped with long life built in batteries, this memory area preserves weld parameters and menu
settings when the system is powered off. (also known as BBR)
Booster: The central component of an ultrasonic stack assembly. A device which transfers
mechanical energy from the converter to the ultrasonic horn. The booster will, depending on
design, increase, decrease, or maintain the specific energy (amplitude) as received from the
converter.
Calibration: The process of adjusting a device to a known position for purposes of inspection
and/or monitoring position, direction, speed, and/or velocity.
Instruction Set for General Information Page 19 of 30
BRANSON Metal Welding
Product Manual- General Information
Clock: An electronic circuit that generates timing pulses to synchronize the operations of
various other circuits in a device(s).
Communications: Transmission of information between points of origin and reception without
alteration of the sequence and or structure of that information content.
Consumable Spare Tooling: The tooling portion of the ultrasonic system that wears and
requires replacement due to production use. This includes but is not limited to ultrasonic horns,
replaceable tips, anvil, and positioning mask. A Spare Tooling Specification Sheet is included
within the Operation Manual to document the spare tooling for a specific metal welding
application.
Continuous Sonics Mode: A system setting in which the power supply will deliver ultrasonic
electrical energy until the start signal is terminated.
Controller: The portion of the welding system that provides specific settings & instruction(s) to
the overall welding system.
Converter: A device which utilizes a lead-zirconate-titanate electrorestrictive element to
change high frequency electrical energy into high frequency mechanical energy.
Counter: A programmable device used to monitor system cycles and alert personnel when
specific conditions are met.
Data: Any representation(s) of instructions, characters, information, or analog quantities to
which meaning may be assigned
Default: A chosen system setting or parameter in which the system does not require external
data input. In some cases the default value will be changed based upon equipment use.
Dynamic Spring: An, adjustable, energy storage mechanism (shock absorber) which allows for
stack follow through upon engagement of application tooling with the work pieces to be welded.
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.
Energy Mode: A welding method in which the ultrasonic power supply is active until the
required amount of energy is delivered (See ENERGY)
Fixture: A device for positioning and or holding a component for assembly.
Force: The amount of mechanical pressure that is used to deliver, (bring down) the mechanical
actuator. This programmed force is also called TRIGGER FORCE and is used to engage the
knurl pattern into the component part(s) prior to the initiation of ultrasonic energy.
Instruction Set for General Information Page 20 of 30
BRANSON Metal Welding
Product Manual- General Information
Frequency: The number of complete oscillations per second expressed in Hertz (Hz) or
kilohertz (1 kilohertz = 1000 Hz). Typically 20 kHz or 40 kHz.
Gain: The ratio of the amplitude of motion produced by the converter and delivered by the horn
is called the gain. It is determined by the difference in mass on either side of the nodal point.
Hand Shaking: The procedure (signal exchange) when a connection is established between two
electronic devices. A common example is the signal exchange between a terminal and a
MODEM. These signals (hardware and software) are used to control the flow of data (start/stop)
between devices.
Height: A display value, in millimeters (mm), as registered by a linear encoder upon completion
of an ultrasonic welding cycle. -- Programmable, in millimeters, with Upper Control Limit &
Lower Control Limit
Height Encoder: A device utilized to monitor position, direction, speed, and/or velocity.
Horn: An acoustically designed metal tool that delivers mechanical energy from the converter/
booster into the work piece. Most applications utilize half wave technology, (40 kHz = 2.2” ±,
20 kHz = 5.5” ±).
Hold Time: The amount of time after delivery of ultrasonic energy until the stack tooling begins
to retract from the component material(s).
Joint: The welded surfaces
Linear Height Encoder: (See: Height Encoder)
Loading Meter: A meter which indicates the power drawn from the ultrasonic power supply.
Maintenance Counter: A programmable device used to alert production personnel of the need
to review/ inspect application tooling and/or the ultrasonic system for preventive maintenance
purposes. The device increments one (1) count for each system cycle. (See: Counters)
Mode: The method of operating the system (also see WELDING MODE)
Node: The node is the area of the horn, (and booster), that exhibits no longitudinal displacement
and where the internal dynamic forces are at the maximum. This area is in the center location on
half-wave technology.
Parameter(s): Programmable units used to control and or monitor the ultrasonic process. -Include but not limited to ENERGY, FORCE, PRESSURE, AMPLITUDE
Parts Counter: A programmable device used to monitor system cycles and alert personnel
when specific conditions are met. (See: Counters)
Instruction Set for General Information Page 21 of 30
BRANSON Metal Welding
Product Manual- General Information
Peak Power: Peak power is the maximum amount of power in watts that was required to keep
the ultrasonic stack in motion during the weld cycle.
Power: Power, measured in watts, is a function of pressure and amplitude. The amount of
power, (watts) required to keep the ultrasonic stack in motion is monitored and used to develop a
power curve. This power curve is used to calculate the amount of energy delivered/ dissipated,
(Watts = Joules / Time). The power as displayed on the control box is peak power.
Power Supply (Ultrasonic): An electronic device that converts 50/60 cycle electrical current
into 40 kHz, (40,000) or 20 kHz, (20,000) 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. The system will go into an overload condition in order to prevent system damage.
Preheight: A pre-sonic inspection display, in millimeters (mm), as registered by a linear
encoder prior to initiation of the ultrasonic welding cycle. -- Programmable, in millimeters, with
Upper Control Limit & Lower Control Limit
Presets: System memory available for storage and retrieval of welding parameters.
Pressure: The amount of mechanical pressure supplied to the ultrasonic stack assembly while
delivering ultrasonic energy to the components.
Quality Widows & Limits: Programmable values used by the system to compare actual
process data. Actual process data must be within limits or an alarm condition will exist.
Setup Mode: The condition the control box must be in prior to adjusting parameters, quality
windows, and/or any others settings except those contained within the Command Mode.
Squeeze Time : The amount of time after the ultrasonic tooling engages the component(s) and
before delivery of ultrasonic energy. -- Adjustable from 0 - 0.5 seconds
Stress: Stress is the amount of dynamic force per cross sectional area.
Time : Time is the duration of the ultrasonic, mechanical, activity. Time is a component used to
calculate the amount of ultrasonic energy delivered during a weld cycle, (Time = Joules / Watts).
Tip: Device specially designed to grip the upper component, to be welded, and to direct the
ultrasonic energy into the work piece, (Also: Horn Tip & Replaceable Horn Tip).
Tip Nut: Device specially designed to securely clamp a replaceable tip onto the horn.
Trigger Force: (See: Force)
Instruction Set for General Information Page 22 of 30
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