signal generator for ultrasonic welding - Page 1
Forum section: electronics / projects

author: meliharicii
author_rank: Contributor
timestamp: October 30, 2016, 02:36:49 pm
content: hi guys. i making ultrasonic welding machine. but my problem about signal generator. how is the make signal generator? i need the output 20kHz and 2000w. can you help me?thanks

author: LaserSteve
author_rank: Super Contributor
timestamp: October 30, 2016, 09:02:47 pm
content: Probably much easier to buy a recent Bronson Driver on EBay and repair it. You do need some sensing on the transducer end for system protection and tuning.STEVE

author: meliharicii
author_rank: Contributor
timestamp: October 30, 2016, 09:31:59 pm
content: Quote from: evb149 on October 30, 2016, 03:55:27 pmi got it.i need output 20khz sinus walve and nearly 2kW power.have you got any circuit this subject?

author: meliharicii
author_rank: Contributor
timestamp: October 30, 2016, 09:33:21 pm
content: Quote from: LaserSteve on October 30, 2016, 09:02:47 pmthank you. can you send me link about bronson driver?

author: richnormand
author_rank: Unknown
timestamp: October 30, 2016, 09:52:54 pm
content: You mean Branson ultrasonic welder stuff?http://www.ebay.com/sch/i.html?_from=R40&_trksid=p2050601.m570.l1313.TR3.TRC2.A0.H0.Xbranson+ultrasonic+welder.TRS0&_nkw=branson+ultrasonic+welder&_sacat=0

author: meliharicii
author_rank: Contributor
timestamp: October 30, 2016, 10:11:42 pm
content: Quote from: richnormand on October 30, 2016, 09:52:54 pmthank you. but this is so expensive. already i want to make myself. this is so important for me. my problem about signal generator. i using icl8038integrated.

author: danadak
author_rank: Super Contributor
timestamp: October 30, 2016, 11:49:28 pm
content: The critical part of the design is NOT the sinewave generator, its the2 KW inverter. This is a major design in terms of magnetics, layout,timing, safe area of components. If you have never done any powerdesign before this a very challenging design to tackle.I had the pleasure of calling on 3 very senior EEs that designed plasmacutting and welding equipment over many years. Each visit was generallya humbling experience.There are ap notes at Ixsys, IR, ST, etc.. on high power inverters,that would be a starting point.Good luck.Regards, Dana.

author: Marco
author_rank: Super Contributor
timestamp: October 31, 2016, 08:04:52 am
content: He can't afford not to be in resonance, the circuit needs to be resonant by design ... having to tune it all the time would be silly.That said, it all seems a bit optimistic.

author: meliharicii
author_rank: Contributor
timestamp: October 31, 2016, 01:19:58 pm
content: Quote from: Mechatrommer on October 31, 2016, 03:34:47 ami got it. Output voltage and current very low. i have 20kHz sine wawe. but i dont have enough power.

author: mikeselectricstuff
author_rank: Super Contributor
timestamp: October 31, 2016, 02:15:11 pm
content: It is highly unlikely you will be able to build one for less than you can buy something used unless you price your time extremely cheaply.Ultrasonic transducers are complex loads, and will be far from trivial to drive.

author: Marco
author_rank: Super Contributor
timestamp: October 31, 2016, 06:41:27 pm
content: Quote from: meliharicii on October 31, 2016, 01:19:58 pmYou'd need a full bridge driver at around 250V bus voltage to get 2 kW out of a 20 Ohm at resonance transducer ... assuming you drive it very near the resonant frequency (as I said, the system needs to be resonant by design).PS. are these transducers meant to be driven with the rectified mains as the bus voltage, so with 100 Hz modulation, and no PFC/isolation? It seems to end up nearly correct power wise.

author: meliharicii
author_rank: Contributor
timestamp: November 01, 2016, 07:19:27 pm
content: Quote from: Marco on October 31, 2016, 06:41:27 pmdid you mean this?

author: mikeselectricstuff
author_rank: Super Contributor
timestamp: November 01, 2016, 08:32:56 pm
content: Sorry but if you don't understand why that would not be remotely suitable you have zero chance of making a 2kW supply work. Just go buy something, seriously.

author: yli130
author_rank: Newbie
timestamp: February 27, 2022, 12:35:24 pm
content: Hi,Did you make one finally?