Universal Ultrasonic Generator for Welding

• Authors: W. Kardyś , A. Milewski , P. Kogut , P. Kluk
• Languages of publication: EN

Abstracts

EN

The paper presents design and parameters of a multifunction ultrasonic generator manufactured by Tele and Radio Research Institute. Efficient usage of ultrasonic welding and cutting technology depends on the ability to precisely control process parameters and tune those parameters to suit particular needs. Ultrasonic generator is responsible for such control and tuning. Presented design incorporates powerful 32 bit Cortex M4 microcontroller with floating point unit which allows using modern signal processing methods to calculate parameters of ultrasonic stack in real time. Calculated parameters, especially impedance of the stack are used to estimate load level and identify phases of the welding process such as melting of the welded material. Precise control of the output signal is possible due to innovative design of the direct digital signal synthesis unit implemented in programmable logic device (CPLD). Resonant inverter topology of the generator front end ensures high electrical efficiency of the device. Designed generator is equipped with various communication interfaces such as USB host and slave, Ethernet, Bluetooth, CAN and RS485. Multiple digital inputs and outputs together with load cell interface, 4-20 mA receiver and 0-10 V analog input enable the generator to monitor and control entire ultrasonic welding system without the need of a PLC unit.

Keywords

EN

81.20.Vj; 43.35.-c; 43.35.+d; 77.65.Dq; 77.84.Cg; 85.50.-n

Discipline

• 81.20.Vj: Joining; welding
• 77.65.Dq: Acoustoelectric effects and surface acoustic waves (SAW) in piezoelectrics(see also 43.35.Pt Surface waves in solids and liquids—in Acoustics Appendix; for surface acoustic wave transducers, see 43.38.Rh—in Acoustics Appendix; for acousto-optical effects, see 78.20.hb, and 43.35.Sx—in Acoustics Appendix)
• 43.35.+d: Ultrasonics, quantum acoustics, and physical effects of sound
• 77.84.Cg: PZT ceramics and other titanates
• 85.50.-n: Dielectric, ferroelectric, and piezoelectric devices

• Publisher: Institute of Physics, Polish Academy of Sciences
• Journal: Acta Physica Polonica A
• Year: 2013
• Volume: 124
• Issue: 3
• Pages: 456-458

Dates

published

2013-09

Contributors

author

W. Kardyś

• Tele and Radio Research Institute, Ratuszowa 11, 03-450 Warsaw, Poland

author

A. Milewski

• Tele and Radio Research Institute, Ratuszowa 11, 03-450 Warsaw, Poland

author

P. Kogut

• Tele and Radio Research Institute, Ratuszowa 11, 03-450 Warsaw, Poland

author

P. Kluk

• Tele and Radio Research Institute, Ratuszowa 11, 03-450 Warsaw, Poland

References

• [1] W.P. Mason, Electromechanical Transducers and Wave Filters, 2nd ed., Van Nostrand, New York 1943
• [2] N. Mohan, T.M. Undeland, W.P. Robbins, Power Electronics, 3rd ed., Wiley, USA 2003
• [3] J. Chudorliński, W. Kardyś, Elektronika 51, 99 (2010) (in Polish)
• [4] W. Kardyś, P. Kogut, A. Milewski, Elektronika 53, 27 (2012) (in Polish)
• [5] P. Kluk, P. Wlazło, Elektronika 50, 70 (2009) (in Polish)
• [6] M. Brylski, Elektronika 51, 105 (2010) (in Polish)
• [7] P. Kluk, Elektronika 50, 79 (2009) (in Polish)
• [8] M. Brylski, Elektronika 51, 102 (2010) (in Polish)

Identifiers

DOI

10.12693/APhysPolA.124.456