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motion. This minimizes the loss of energy and prevents vibration from being transmitted
into the actuator.
Horn
The horn is selected or designed for a specific application. Each horn is tuned typically as
a half-wave section that applies the necessary force and vibration uniformly to the parts to
be assembled. It transfers ultrasonic vibrations from the converter to the workpiece. The
horn is mounted to the booster as part of the ultrasonic stack.
Depending on their profile, horns are referred to as stepped, conical, exponential, bar, or
catenoidal. The shape of the horn determines the amplitude at the face of the horn.
Depending on the application, horns can be made from titanium alloys, aluminum, or
steel. Titanium alloys are the best materials for horn fabrication due to their high level of
strength and low loss. Aluminum horns are usually chrome- or nickel-plated or hard-
coated to reduce wear. Steel horns are for low amplitude requiring hardness, such as
ultrasonic insertion applications.
S-Beam Dynamic Trigger Mechanism
The S-Beam Load Cell measures the force being applied to the part to trigger ultrasonics
and record the welding parameters. The Dynamic Trigger Mechanism ensures that
pressure is applied to the part prior to the application of ultrasonic energy. This
adjustable, pressure-activated device is located between the air cylinder and the
converter.
To maintain horn-to-part contact and force as the joint collapses, springs provide dynamic
follow-through. As the plastic melts, the springs extends to ensure smooth transmission of
ultrasonic energy into the part.
Encoder
The encoder measures the distance the horn has travelled. Depending on the power
supply settings, it can:
• Allow for distance welding in absolute and collapse modes
• Detect improper setup controls
• Monitor the distance data of the weld
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