Replacement Ultrasonic Converter For Branson Model 902J 101-135-047 With 910IW Plastic Welders

Replacement Converter for Branson Model 902J 101-135-047 for Using with 910IW Plastic Welders

Description:

All of the components used in construction of these Branson 902J replacement converters are all new, not recovered from scrapped units. The parts are made from certified materials in tightly controlled manufacturing processes, assembled and tested in a climate-controlled environment using carefully calibrated equipment, then properly aged and re-tested to ensure performance that duplicates the OEM part. The entire process is conducted in a ISO registered facility. Best of all, since the manufacturing process is so carefully controlled, durability is assured.

Replacement converter for Branson model 902J (101-135-047), for use with 910IW or IW+ intergrated benchtop welders or 905 or 910 D/M (500 and 1000 watt) power supplies using actuator or assembly stand units. These converters are made in a highly controlled and repeatable manner to duplicate the performance of the OEM models.

Specifications:

Ultrasonic vibrator and power supply matching operation?

There are four main aspects of matching the transducer to the driving power source, namely impedance matching, frequency matching, power matching, and capacitive reactance matching.

The most important of these are capacitive reactance and frequency. As mentioned above, because the ceramic piece is an insulator, you can almost understand that the transducer is not energized, it is just equivalent to a capacitor. To make the transducer work, it is actually applying an AC high voltage to the driver circuit to charge and discharge the capacitor. The piezoelectric ceramic sheet is synchronously stretched and deformed under the action of an alternating electric field to form a longitudinal vibration of the entire transducer, thereby driving the horn and the mold to vibrate. Therefore, if the capacitance is not well matched, the lighter is the transducer is weak, the welding is not strong; the heavy transducer is very hot, burning the electrode, burning the power of the high power tube. Our transducer products are accompanied by a product performance parameter table that shows the capacitance and frequency of each transducer. The driving power supply should adjust the parameters of the high voltage transformer, matching capacitor board, cellular coil, frequency modulation coil, etc. according to the capacitance of the transducer. Due to the sensitivity of the inductor and the capacitance, the power amplifier board, choke coil and other peripheral circuits also have an effect on the matching. And as the work progresses, the temperature of the transducer will rise, causing the capacitance to rise and the amount of change may exceed 50%. If the capacitor cannot be effectively matched, the phase difference between the current and voltage in the loop will be large. The power factor is very low and the virtual power is high. Look at the current is very large, but the transducer is weak, easy to heat, and the power device of the power supply is also prone to heat damage. It is likely that the transducer plate (ear) of the transducer is shattered or burned.

Frequency matching is also very important. This is primarily because the ultrasonic transducer can only operate at its resonant frequency point, so the drive power, horn, and welding tool (tool head) should all operate at this frequency. In general, we hope that this difference does not exceed ±0.1 kHz at most, and it is better to be smaller. We strongly recommend that the frequency of the matching welding die (welding head) be lower than the vibration sub-frequency by about 0.1 kHz (small signal frequency). That is to say, if the frequency of the original vibrator small signal measurement is 14.85 kHz, it is most ideal to measure the frequency after connecting the mold to 14.75 kHz. At the same time, it should be considered that after the ultrasonic transducer is connected to the horn and the die head, the resonance frequency peak of the system becomes very sharp, that is, the bandwidth is very narrow, the mechanical quality factor is large, and the frequency offset will cause the impedance to be very high. A big increase. Expressed on the drive power supply is the power supply (amplitude meter electric power) is large or overload protection. If it is just an empty load at this time, it is likely to cause the wafer to be misaligned, the wafer is broken or the center screw is broken.
Power matching and impedance matching are mainly based on the fact that the ultrasonic welding system is a gap type operation, the load changes greatly, and there must be sufficient power output during welding, and the minimum amplitude should be controlled at no load. Otherwise, as mentioned earlier, if the input is large at no load, the transducer is damaged. When the load is full, the power will not go up. It is still useless if the welding is not strong.

Replacement Converter for Branson Model 902J 101-135-047 for Using with 910IW Plastic Welders