Models 4095 Press / 4096 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 Our systems have 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 all applicable instruction manuals carefully before you attempt to operate any equipment.
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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 4095 and 4096 are 40 kHz precision pneumatic actuators used for ultrasonic plastics assembly. The 4095 is a tabletop version, whereas the 4096 can be mounted on a bridge or rigid structural member for use with automated systems. Either can be supplied with the following GX-Series power supplies: ■ GXT . . . . . . .Weld by digital time ■ GXE . . . . . .Weld by digital time and/or constant energy ■ GXL . . . . . . .
“SONICS” ULTRASONIC ASSEMBLY SYSTEMS 50/60 Hz 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 V
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, or 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 85 psig. (586 kPa / 6 bar) at a minimum capacity of 2 CFM.
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 right, rear of the press head, using a hose having a minimum inside diameter of 1/8 inch (6 mm). 2.
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 12). 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 13 and 14, 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 Support the head before releasing the column clamps so that it cannot crash down or fly up. Ignoring this warning might result in injury and/or damage to the equipment and part being welded. 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 3-1/2".
7. Lock the two column clamps, tighten the converter housing door screws, and then tighten the fixture on the base plate. 8. Check for proper mating of fixture, parts, and horn. If the horn and part are not in parallel contact, shim the fixture or adjust leveling screws as required. 9. Set the PRESSURE regulator to a reading of 20 psig (140 kPa/1.4 bar) on the pressure gauge. (Turn the PRESSURE knob clockwise.) 10. To check that the horn and parts are properly aligned, the horn needs to be lowered.
OPERATION ACTUATION The 4095 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 at 4-7 psig. 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.
FINE ADJUSTMENTS UPPER LIMIT SWITCH The optional Upper Limit Switch is used as a safety interlock in automation to prevent the movement of material handling equipment (indexing) when the horn is down. It also initiates the movement of material handling equipment when the horn is up. UPPER LIMIT SWITCH The Upper Limit Switch is factory set and should be suitable for all applications. If for some reason you need to readjust it, observe the following procedure: 1.
BOOSTER SELECTION NOTE: Consult the Applications Manual or call our Applications Lab for proper booster selection. The first step in optimizing welding conditions is to select a booster which will provide the necessary amplitude. For parts one inch (25.4mm) in diameter or greater, start with a moderately high amplitude booster such as a gold. For smaller parts, start with a green booster.
STROKE SPEED ADJUSTMENT The velocity at which the horn descends and returns can be adjusted via the speed controls. These controls are factory adjusted for average operating conditions and should not require further adjustment. However, if a minor adjustment is necessary, adjust in small degrees. Turn clockwise to slow the extend speed, and counterclockwise to increase the return speed. The speed controls are 2 small threaded screws located at the top of the press and behind the air cylinder as shown below.
RE-ESTABLISHING PROPER BOOSTER / HORN INTERFACES To re-establish proper interfaces, follow these instructions: NOTE: Contact between the booster and horn should be parallel. When encountering symptoms such as loud noises or tuning difficulties, examine the booster / horn interfaces for parallelism, corrosion, galling or foreign deposits. Also check the tightness of the stud. DO NOT use anything coarser than 400 grit emery cloth. 1. Using open-ended wrenches, separate the booster from the horn.
MAINTENANCE REPAIRS / SERVICE If problems are encountered, contact our Service Department as follows: Phone: 1-800-745-1105 • 1-203-270-4600 Fax: 1-203-270-4610 E-Mail: service@sonicsandmaterials.com NOTE: If packing unit for return shipment, DO NOT use styrofoam “peanuts.” 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.
