Sonics 4096 Actuator - Manual (Page 7)

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I N T R O D U C T I O N
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 . . . . . . .Weld by digital time, constant energy and/or distance*
*Requires optional linear encoder.
Both actuators are also compatible with E and F Series power supplies.
O V E R V I E W O F U L T R A S O N I C P L A S T I C S
A S S E M B L Y
WHAT IS ULTRASONICS?
Ultrasonics refers to vibrational waves with a frequency above the human
audible range which is usually above 18,000 cycles per second (Hz).
PRINCIPLE OF ULTRASONIC ASSEMBLY
The basic principle of ultrasonic assembly involves conversion of high
frequency electrical energy to high frequency mechanical energy in the form
of reciprocating vertical motion which, when applied to a thermoplastic,
generates frictional heat at the plastic/plastic or plastic/metal interface. In
ultrasonic welding, this frictional heat melts the plastic, allowing the two
surfaces to fuse together; in ultrasonic staking or insertion, the controlled flow
of molten plastic is used to capture or lock another material in place (staking)
or encapsulate a metal insert (insertion).
ULTRASONIC ASSEMBLY SYSTEMS
“Sonics” ultrasonic assembly systems are generally composed of the
following major elements: a power supply, converter, booster, horn, pneumatic
press and holding fixture, as detailed in the diagram on the next page. A
review of this diagram will help you understand the basic elements involved in
the assembly process and their relation to each other.
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