14 DCM00002 REV. 16
2.3 Overview of this Model
Figure 2.1 Metal Welding Power Supply
The Branson welder generates ultrasonic electrical energy through an ultrasonic converter
for welding metals. Several models are available, depending on the desired frequency (for
example, 20 kHz) or the desired power range (for example, 2.2 kW). The Touchscreen
Controller also contains a microprocessor-based controller module that provides for
control and monitoring of welding operations.
Ultrasonic Power Supply Module
Generates ultrasonic energy at the resonant frequency of the Converter-Booster-Horn
Stack. The Ultrasonic Power Supply Module contains five main circuits as follows:
• 320VDC Power Supply: Converts AC line voltage to +320VDC for the output power devices
• FET bridge: Switches the 320 VDC into ultrasonic pulses at the resonant frequency
• Output circuit: matches the impedance of the output power device to the Converter-Booster-
Horn- Stack; and provides feedback to the Control circuit
Control circuits: Perform the following functions:
• Provide drive signal to output power device
• Determine true percentage of ultrasonic power used over a range of amplitudes
• Allows control of the resonant frequency
• Control starting amplitude
System Protection: Protects the Power Supply by providing five levels of
protection:
• Voltage
• Current
• Phase
• Temperature
• Power
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