Models 1595 Press / 1596 Actuator I N S T R U C T I O N M A N U A L Sonics & Materials, Inc.
WARNING SAFETY PRECAUTIONS READ BEFORE INSTALLING OR USING THE EQUIPMENT This system has been designed to assure maximum operator safety. However, no design can completely protect against improper usage. For maximum safety and equipment protection, observe the following warnings at all times and read the instruction manual carefully before you attempt to operate the equipment. – The equipment has safety devices that require both hands to be on the palm buttons until the horn contacts the work piece.
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TABLE OF CONTENTS IMPORTANT SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Manual Change Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Visible Loss or Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Concealed Loss or Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 INTRODUCTION . . . . . . . . . . . . . . . . . . . . .
IMPORTANT SERVICE LITERATURE The system supplied with this instruction manual is constructed of the finest material and the workmanship meets the highest manufacturing standards. It has been thoroughly tested and inspected before leaving the factory and when used in accordance with the procedures outlined in this manual, will provide you with many years of safe and dependable service. NOTE: Please read carefully before operating the equipment, then forward to your service department.
UNPACKING AND INSPECTION NOTE: We recommend keeping all carton(s) and packing material in case it might be necessary to move the equipment, or to ship it for repair. Before unpacking the equipment, check the shipping carton for any visible damage. If you see any, be sure to follow the procedures described below under “Visible Loss or Damage.” Otherwise, proceed to remove the equipment from the carton. Before disposing of any packing material, check it carefully for small parts.
INTRODUCTION The models 1595 and 1596 are 15 kHz pneumatic actuators used for ultrasonic plastics assembly. The 1595 is a tabletop version, whereas the 1596 can be mounted on a bridge or rigid structural member for use with automated systems. Both models can be supplied with the following GXSeries power supplies: ■ GXT . . . . . . .Weld by digital time ■ GXE . . . . . .Weld by digital time and/or constant energy ■ GXL . . . . . . .
“SONICS” ULTRASONIC ASSEMBLY SYSTEMS 50/60Hz Electrical power Power Supply/Generator Generates ultrasonic electrical energy (15/20/40 kHz) Ultrasonic electrical energy Actuator/Press Provides compressive force and mounting for Converter, Booster, Horn assembly Converter Transforms ultrasonic electrical energy to ultrasonic mechanical vibrations Ultrasonic Vibrations Booster Increases or decreases amplitude Ultrasonic Vibrations Horn Contacts and transfers vibrational energy to plastic part Ultrasonic Vi
GLOSSARY OF ULTRASONIC TERMS POWER SUPPLY/GENERATOR – The solid state power supply converts standard 50/60 Hz electrical power to 15,000 Hz, 20,000 Hz, and 40,000 Hz (15/20/40 kHz) electrical energy. ACTUATOR/PRESS – The pneumatic actuator provides compressive force and mounting for the converter, booster, and horn assembly. The tabletop press consists of a base assembly, column and actuator (head).
INSTALLATION ELECTRICAL POWER The press is powered by the power supply. Consult your power supply instruction manual to determine power specifications. AIR SUPPLY The press requires a source of dry, filtered (5 micron), oil-free, compressed air capable of supplying a constant line pressure of 100 psig. (690 kPa / 7 bar) at a minimum capacity of 4 CFM (.1 cubic meters).
CONNECTIONS When making the initial connections, make sure all power is disconnected. NOTE: Do not strain or kink the cables. When going around corners, allow as wide a bend as possible. Do not run the cables parallel to any power line within a distance of less than 1 foot (304.8mm). 1. Connect the air supply source to the press air filter located at the bottom rear of the control panel, using a hose having a minimum inside diameter of 1/4 inch (6.4 mm). 2.
OPERATING PROCEDURES CONTROL PANEL Located to the right of the converter housing is a control panel with the following features: ❶ ❷ ❸ ❹ 1. Blue HEAD POSITION buttons (labeled “RAISE” and “LOWER”) which move the head up or down on the column when depressed. 2. Black and red SPEED CONTROL knobs which allow regulation of the speed at which the horn descends and returns (stroke speed). These controls are factory adjusted for average operating conditions.
INITIAL EQUIPMENT SETUP ASSEMBLING AND MOUNTING CONVERTER, BOOSTER, AND HORN If the converter, booster, and horn are not already assembled, follow these instructions: Never tighten the horn to the booster using the housing door as the upper wrench as this may cause damage to the booster and/or converter. 1. Clean the mating surfaces of the converter and booster, as well as the threaded stud and hole. Check that the stud is tight (see recommended torque requirements on page 13). 2.
5. Using the 3/16” (4.7 mm) T-handle wrench provided, loosen (turn counterclockwise) the two cap screws screws on the hinged converter housing and open the door. NOTE: When performing any of the operations described on this page and pages 14 and 15, DO NOT turn on the power supply. Never tighten the horn to the booster using the housing door as the upper wrench as this may cause damage to the booster and/or converter. 6.
HORN AND FIXTURE ALIGNMENT For maximum productivity, the clearance between the horn and the part should be at a minimum. However, adequate clearance should be provided to enable easy loading and unloading of the part from the holding fixture. The maximum stroke distance is 4" (optional 6" stroke available). Ensure that the head is not too close to the limit of its down travel distance. Otherwise, the horn may not have sufficient distance to travel downwards to achieve a full depth of weld.
6. Tighten the converter housing door screws, and then tighten the fixture on the base plate. 7. Check for proper mating of fixture, parts, and horn. If the horn and parts are not in parallel contact, shim the fixture or adjust leveling screws as required. Adjust the positive stop knob for proper weld depth (see below). 8. Set the UP PRESSURE regulator to a reading of 20 psig (140 kPa/1.4 bar) on the pressure gauge. (Turn the PRESSURE knob clockwise.
OPERATION ACTUATION The 1595 press is equipped with two maintained anti-repeat (non-tie-down) palm buttons, one located on the left and one on the right side of the base of the press. Both palm buttons must be pressed simultaneously to activate the press to cycle the welder. To operate the press, follow these simple steps: The equipment has safety devices that require both hands to be on the palm buttons until the horn contacts the workpiece. Do not defeat or modify these safety devices. 1.
FINE ADJUSTMENTS PRESSURE SWITCH ADJUSTMENT For systems mounted in the normal vertical position with downward travel, no adjustment should be necessary. The minimum trigger pressure is factory set to approximately 10-12 psig (69 kPa/.7 bar - 83 kPa/.8 bar). However, if the minimum trigger pressure requires recalibration or readjustment, observe the following procedure: 1. Maintain air pressure and unplug the power supply from the electrical source. 2. Remove the four screws holding the five-sided cover. 3.
UPPER LIMIT SWITCH The optional Upper Limit Switch may be used as a safety interlock in automation to prevent the movement of material handling equipment (indexing) when the horn is down. It also may be used to initiate the movement of material handling equipment when the horn is up. The Upper Limit Switch is located opposite the Pressure Switch. The Upper Limit Switch is factory set and should be suitable for all applications.
PRESSURE During the welding process, sufficient pressure should be applied to the part so that the mating surfaces contact each other. If the pressure is too low, the process will run inefficiently causing unnecessarily long weld time cycles, marking of the parts or poor welding. If the pressure is too high, the horn may stop vibrating, the part(s) might fracture, or the power supply might overload. Refer to the Applications manual for additional information on pressure settings.
5. Then, rotate the booster or horn 1/3 of a turn in a clockwise direction and then repeat step 4. 6. Repeat step 5. NOTE: Machining of booster / horn may alter the ability to tune the component to the system. System inoperation may occur. 7. Using wire brush, clean stud, then replace securely. Tighten new stud to the recommended torque specifications on page 13.
MAINTENANCE REPAIRS / SERVICE If problems are encountered, contact our Service Department as follows: Phone: 1-800-745-1105 • 1-203-270-4600 Fax: NOTE: If packing unit for return shipment, DO NOT use styrofoam “peanuts.” 1-203-270-4610 E-Mail: service@sonicsandmaterials.com It is suggested that a system in need of repair be sent back to the factory, with a written description pertaining to the nature of the problem. Always contact the factory for return authorization before shipping any instrument.
WARRANTY Sonics & Materials, Inc., hereinafter referred to as “Sonics,” warrants its products for a period of one year from the date of shipment against defect in material and workmanship under normal installation, use, and maintenance as described in the operating instructions which accompany such equipment.
“Sonics” reserves the right not to warrant horns of unusual or experimental design which in our judgment are more likely to fail in use. This warranty does not cover equipment used for applications requiring metalto-metal contact with weld time in excess of 1 second. Data supplied in the instruction manual has been verified and validated and is believed adequate for the intended use of the equipment.
Go To Top Of Document Sonics & Materials, Inc. Corporate Headquarters European Office 53 Church Hill Road • Newtown, CT 06470 USA 203.270.4600 • 800.745.1105 • 203.270.4610 fax www.sonicsandmaterials.com • info@sonicsandmaterials.com 22 ch du Vernay • CH - 1196 Gland, Switzerland (41) (0) 22/364 1520 • (41) (0) 22/364 2161 fax europe@sonicsandmaterials.
