Universal Ultrasonic Generator for Welding

Abstract

The paper presents design and parameters of a multifunction ultrasonic generator manufactured by Tele and Radio Research Institute. Ecient 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 oating 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 eciency 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, 420 mA receiver and 010 V analog input enable the generator to monitor and control entire ultrasonic welding system without the need of a PLC unit.

Gradient Descent Metodu ile Ultrasonik Kaynak Sisteminin Frekans Optimizasyonu

“…In this way, it is aimed to increase efficiency [12]. The researchers designed more efficient ultrasonic welding machines by modelling ultrasonic welding machines [13]. In addition, studies have been carried out for ultrasonic frequency optimization [14].…”

“…The researchers designed more efficient ultrasonic welding machines by modelling ultrasonic welding machines [13]. In addition, studies have been carried out for ultrasonic frequency optimization [14]. When the studies are examined, it is seen that optimization studies have been carried out in many different aspects for ultrasonic welding machines.…”