Welds, Spot Welds, Stakes, and Inserts

Here are two 500-watt hand-held ultrasonic welders for plastics assembly; a 20-kHz, Model H-520 and a 40-kHz, Model H-540. These compact and portable units are rugged, reliable, and easy to operate. They are designed specifically for welding, staking, inserting, and spot welding applications (see descriptions of applications).

The lightweight hand pieces are ideally suited for manual operations with low volume production requirements or for assembling parts with difficult to reach weld areas. The units consist of an ultrasonic power supply and a 1.5-lb hand gun. The 20-kHz hand guns are supplied with integral 1/2" diameter titanium front drivers with replaceable flat face tips. Other standard tips are available for various applications (see chart on page 54 for tip information). In addition, custom tips can be designed for specific applications. The 40-kHz hand gun is supplied with a removable horn designed specifically for each customer’s requirements.

Most manual applications can be performed with the 20-kHz model. However, the higher frequency and lower amplitude of the 40-kHz system makes it ideal for welding small assemblies that require gentler action. The hand gun systems operate at a standard 120 volts or optional 220 volts nominal input voltage.

The power supply features autotune circuitry which eliminates the need to retune the system each time it is turned on or when the horn/tip is changed. It also regulates the line voltage and provides constant amplitude throughout the welding process. The welders contain a microprocessor-based programmable timer for weld times from 0.1 to 9.9 seconds. Another function of the microprocessor is digital amplitude control. All of these beneficial features yield a more precise and repeatable cycle. Once set up, the user only needs to apply the tip of the hand gun to the parts being assembled and depress the switch on the gun’s housing to operate the welder.

These 500-watt welders contain two overload protection circuits, one for the power supply and the other for the converter. The systems overload circuit protects the power supply from exceeding its maximum wattage. The advanced converter protection circuit is designed to protect against excessive voltage or current caused by the application. With a response time of less than 2 micro-seconds, these circuits instantaneously prevent internal component damage to the power supply and converter.

Ultrasonic Welding Applications

Staking/Spot Welding Tips Standard threaded tips available for staking and spot welding are listed below.
Ordering Information (Specify tip required using code letter)
Examples: Staking Tip "A" indicates a tip used for staking a 1/32" solid boss with a high profile flared head. Spot Welding Tip "SA" indicates a tip used for spot welding 1/32" thick material. Flat, knurled and custom faced tips are available.

Pricing and Purchase on Abbeon.com.

Optional Accessories

Manual Press is available for assembling parts where production volume does not justify more expensive pneumatic presses. Provides a more controlled motion of the welder than is possible by just holding the hand gun, resulting in more consistent assemblies. This unit is available with foot switch or cam actuation. The trigger handle is removed from the hand gun housing when foot switch actuation is used. Model SD-M500 for 20 kHz and 40 kHz. Pricing and Purchase on Abbeon.com

Features

CV20 Ultrasonic Hand Gun Collar Adapter 0 to 18" Vertically Adjustable Head ½" Steel Tooling Plate 6" Throat Depth 3" Head Stroke

Spring Return Lever Arm Angle Iron Column Supports Through Holes for Work Bench Mounting Adjustable and Positive Stroke Stop Block X-Y Pattern Nest Fixture Mounting Holes on 47/16" and 7" Centers

Pneumatic Press is similar in style to the Manual Press. Contains dual anti-tie down palm buttons, a pressure regulator, and a pneumatic timer with all the required controls. Model SD-P500 for 20 KHz & 40 KHz (Call for pricing)

	Stapler attachment is ideally suited for sealing low production rate clam-shell packages. Supplied with two sealing patterns, the standard is a medium diamond knurl on one end and a coarse diamond knurl on the other. Model H520/CV553 for 20 kHz Pricing and Purchase on Abbeon.com
	Pistol Grip A lightweight ergonomic device that simply slips onto the hand guns. The operator activates the ultrasonics by pulling on the “trigger”. Model CV00524 for 20 kHz Model CV00544 for 40 kHz Pricing and Purchase on Abbeon.com.