Sonics 4096 Actuator - Manual (Page 19)

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I N S T R U C T I O N M A N U A L • M O D E L 4 0 9 5 / 4 0 9 6
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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. Determine optimum amplitude by
welding a few parts, and repeat the procedure with boosters giving higher or
lower amplitude. If there appears to be little or no difference, use the booster
giving the highest amplitude.
Six standard boosters, color coded or engraved for ease of identification, are
available either to increase or decrease the amplitude.
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.
BOOSTER
Color Part No. Gain Amplitude Effect
Black BHN23TBK 2.50 Increase
Silver BHN23TSI 2.00 Increase
Gold BHN23GD 1.50 Increase
Brown BHN23BR 1.25 Increase
Green BHN23GR 0 No Change
Purple BHN23PU 0.75 Decrease
NOTE: Consult the
Applications Manual or
call our Applications
Lab for proper booster
selection.
High gain boosters,
such as silver and black
in combination with
high gain horns can
result in the horn
cracking or failing.
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