18 100-412-183 REV. 13
2.3 Features
2.3.1 The Welding System
The welding system consists of a DCX S Power Supply and a converter-booster-horn stack.
The system can perform ultrasonic welding, inserting, staking, spot welding, swaging,
degating, and continuous ultrasonic operations. It is designed for automated,
semi-automated and/or manual production operations.
2.3.2 The Power Supply
The DCX S Power Supply consists of an ultrasonic power supply assembly with a system
controller and user interfaces. The ultrasonic power supply assembly converts
conventional 50/60 Hz line current to 20 kHz, 30 kHz or 40 kHz electrical energy. The
system controller controls the welding system.
Listed below are the control features of the DCX S Power Supply ultrasonic welding system.
• Autotuning: Branson power supply tuning ensures that the system is running at peak efficiency
• Digital Amplitude Setting: This feature allows you to set the exact amplitude necessary for
your application, allowing increased range and setting repeatability over analog systems
• Frequency Offset: This process feature allows a user to set a frequency value, for certain
specific applications, where the force imparted on the fixture or anvil causes a frequency shift in
the stack’s operation. You should only use this feature when advised to do so by Branson
• Horn Signature: Using the DCX S Power Supply Web Page Interface, you may scan your
ultrasonic stack to view its operating frequency on your computer, using digital readouts and bar
graphs to give you the best picture of the stack’s operation
• LCD (Liquid Crystal Display): Provides a clear visual interface to monitor and configure the
system
• Membrane Keys: For high reliability and immunity from factory dust and oils
• Login ID Numbers: Allows for keeping track of user access to the DCX S Power Supply Web
Page Interface
• Ramp Starting: The starting of the DCX S Power Supply and horn is done at a rate that helps
reduce electrical and mechanical stress on the system. The horn start rate may be adjusted for
some tough-to-start applications
• Seek: Ensures operation at resonance; minimizes tuning errors; and operates the stack at low
amplitude (approximately 10%), then provides a means of sensing and storing the resonant
operating frequency value
• Start-up Diagnostics: At start-up, the controls test the major internal components
• Timed Seek: When enabled, will do a Seek once every minute to update horn resonant
frequency to memory. This is especially useful when the welding process affects the actual
temperature of the horn, causing a resonant frequency shift
• True Wattmeter: The controls on the power supply include a true wattmeter for accurate
measurement of power and energy
• Web Page Interface: Provides access, via Ethernet connection, to power supply information,
diagnostics, and configuration web pages
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