The post Ultrasonic Composite horn – Sonotrode 320 x 280mm welding surface appeared first on Sonic-power.

This ultrasonic composite horn / sonotrode is designed in 23 kHz, with similar amplitude as 20 kHz, but the huge advantage of little sound to be heard in welding

Email : info@sonic-power.com

The ultrasonic composite horn / sonotrode is actually a half-wave coupled horns / sonotrode with two or more half-wave, tuned horns attached to it. This technology was first used in 1973. Because designs can often eliminate the need to invest in additional ultrasonic systems, they reduce equipment investment costs and minimize production time.

Composite ultrasonic horn / sonotrode designs are common on applications that cover a large surface area and on applications where there are multiple insertion, staking, or welding points. Some of automotive customers use composite ultrasonic sonotrodes / horns to attach insulator pads to door panels or similar,

Another common application that benefits from composite ultrasonic tooling is packaging (a vacuum-formed blister package). The ultrasonic composite horn / sonotrode saves manufacturers production time and costs, as it welds the package simultaneously at several different points, instead of using a multiple-head system or having an operator / machine ultrasonic weld each point separately.

Composite ultrasonic horns / sonotrodes are also  in applications where it’s difficult to create enough amplitude to weld. The amplitude at the face of a composite horn is higher than what could ever be achieved by a single large horn. The amplitude is designed into each of the individual half-wave horn attachments, not the coupler, a higher amplitude is generated at the weld area; this avoids causing excessive stress to the coupler horn.

Although composite horns / sonotrodes can eliminate the need for additional assembly systems, cut production times, and lower labor costs, they are more expensive than standard horns / sonotrodes. The added cost is due to the extra titanium or aluminum and machining time the composite horns require.

Typical ultrasonic composite horns / sonotrodes have aluminum couplers and titanium half-wave attachments. In addition to the expense of titanium, all of the half-wave attachments must be tuned within 50 cycles of each other. And they must be properly mounted onto the coupler horn. This design we have here is done with only aluminum.

The most common mounting method utilizes a 1/2 unf- or 3/8 unf stud at the top of the half-wave attachment; it’s screwed into a threaded hole at the output face of the coupler. In this case we have also used tuned titanium bolt. The bolt is mounted through the coupler; then the horn attachments are bolted to the coupler. The tuned bolt method is primarily used on composite horns that have two or more block horn / sonotrode attachments.

In addition to the extra metal and machining that’s required, composite horns have more design considerations than a standard ultrasonic horn / sonotrode. We always have to make sure the horn / sonotrode we are designing is balanced. But when we deal with composite ultrasonic  horns / sonotrodes, all of the ultrasonic horns / sonotrodes attachments have to be positioned evenly around the coupler, so the weight is evenly distributed. Sometimes the attachments are different lengths and different shapes, but you still have to keep the horn balanced.

But despite the added challenges in the design and manufacture of ultrasonic composite horns / sonotrodes, they have provided consistent performance and productivity for.

Sometimes a injected molded part cannot be welded without using of ultrasonic composite horn / sonotrode, therefore application can use a ultrasonic composite horn / sonotrode, the increase in productivity and the cost savings are so great that the initial added cost in tooling is more than justified.

The post Ultrasonic composite horn / Sonotrode 23 kHz appeared first on Sonic-power.

This ultrasonic composite horn / sonotrode is designed in 25 kHz, with similar amplitude as 20 kHz, but the huge advantage of very little sound to be heard in welding

Email : info@sonic-power.com

The ultrasonic composite horn / sonotrode is actually a half-wave coupled horns / sonotrode with two or more half-wave, tuned horns attached to it. This technology was first used in 1973. Because designs can often eliminate the need to invest in additional ultrasonic systems, they reduce equipment investment costs and minimize production time.

Composite ultrasonic horn / sonotrode designs are common on applications that cover a large surface area and on applications where there are multiple insertion, staking, or welding points. Some of automotive customers use composite ultrasonic sonotrodes / horns to attach insulator pads to door panels or similar,

Another common application that benefits from composite ultrasonic tooling is packaging (a vacuum-formed blister package). The ultrasonic composite horn / sonotrode saves manufacturers production time and costs, as it welds the package simultaneously at several different points, instead of using a multiple-head system or having an operator / machine ultrasonic weld each point separately.

Composite ultrasonic horns / sonotrodes are also  in applications where it’s difficult to create enough amplitude to weld. The amplitude at the face of a composite horn is higher than what could ever be achieved by a single large horn. The amplitude is designed into each of the individual half-wave horn attachments, not the coupler, a higher amplitude is generated at the weld area; this avoids causing excessive stress to the coupler horn.

Although composite horns / sonotrodes can eliminate the need for additional assembly systems, cut production times, and lower labor costs, they are more expensive than standard horns / sonotrodes. The added cost is due to the extra titanium or aluminum and machining time the composite horns require.

Typical ultrasonic composite horns / sonotrodes have aluminum couplers and titanium half-wave attachments. In addition to the expense of titanium, all of the half-wave attachments must be tuned within 50 cycles of each other. And they must be properly mounted onto the coupler horn. This design we have here is done with only aluminum.

The most common mounting method utilizes a 1/2 unf- or 3/8 unf stud at the top of the half-wave attachment; it’s screwed into a threaded hole at the output face of the coupler. In this case we have also used tuned titanium bolt. The bolt is mounted through the coupler; then the horn attachments are bolted to the coupler. The tuned bolt method is primarily used on composite horns that have two or more block horn / sonotrode attachments.

In addition to the extra metal and machining that’s required, composite horns have more design considerations than a standard ultrasonic horn / sonotrode. We always have to make sure the horn / sonotrode we are designing is balanced. But when we deal with composite ultrasonic  horns / sonotrodes, all of the ultrasonic horns / sonotrodes attachments have to be positioned evenly around the coupler, so the weight is evenly distributed. Sometimes the attachments are different lengths and different shapes, but you still have to keep the horn balanced.

But despite the added challenges in the design and manufacture of ultrasonic composite horns / sonotrodes, they have provided consistent performance and productivity for.

Sometimes a injected molded part cannot be welded without using of ultrasonic composite horn / sonotrode, therefore application can use a ultrasonic composite horn / sonotrode, the increase in productivity and the cost savings are so great that the initial added cost in tooling is more than justified.

The post Ultrasonic Composite horn / sonotrode 25 kHz appeared first on Sonic-power.

Ultrasonic Twin Head Sonotrode 25 kHz lenght 300 mm, with dual ultrasonic transducers, for ridgid mount

The World of Ultrasonic horns – Sonotrodes

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The World of Ultrasonic horns

Ultrasonic horns is a device commonly used for augmenting the oscillation displacement amplitude provided by an ultrasonic transducer operating at the low end of the ultrasonic frequency spectrum (commonly between 15 and 100 kHz).

The device is necessary because the ultrasonic amplitudes provided by the ultrasonic transducers them selves are insufficient for most practical applications of power ultrasound.

Another function of the ultrasonic horn is to efficiently transfer the acoustic ultrasonic energy from the ultrasonic transducer into the treated media, which may be solid for example, in ultrasonic welding, cutting or soldering or liquid.

The ultrasonic horn is commonly a solid metal rod with a round transverse cross-section and a variable-shape longitudinal cross-section – the ultrasonic rod horn. Another group includes the ultrasonic block horn, which has a large rectangular transverse cross-section and a variable-shape longitudinal cross-section, and more complex composite horns. The devices from this group are used with solid treated media. The length of the device must be such that there is mechanical resonance at the desired ultrasonic frequency of operation – one or multiple half wavelengths of ultrasound in the horn material, with sound speed dependence on the ultrasonic horn’s cross-section taken into account. In a common assembly, the ultrasonic horn is rigidly connected to the ultrasonic transducer using a threaded stud.

Ultrasonic horns may be classified by the following main features: Longitudinal cross-section shape – stepped, exponential, conical, catenoidal, Transverse cross-section shape – round, rectangular, Number of elements with different longitudinal cross-section profile – common and composite.

A composite ultrasonic horn has a transitional section with a certain longitudinal cross-section shape (non-cylindrical), positioned between cylindrical sections.

Frequently, an ultrasonic horn has a transitional section with a longitudinal cross-section profile that converges towards the output end. Thus, the ultrasonic horn’s longitudinal oscillation amplitude increases towards the output end, while the area of its transverse cross-section decreases. Ultrasonic horns of this type are used primarily as parts of various ultrasonic instruments for ultrasonic welding, soldering, cutting, making surgical tools, molten metal treatment, etc. Converging ultrasonic horns are also commonly included in laboratory liquid processors used for a variety of process studies, including ultrasonic sonochemical, ultrasonic emulsification, ultrasonic dispersing and many others.

Maximum achievable ultrasonic amplitude depends, primarily, on the properties of the material from which an ultrasonic horn is made as well as on the shape of its longitudinal cross-section.

The post Ultrasonic Sonotrode Twin Head, 25 kHz lenght 300 mm appeared first on Sonic-power.

Ultrasonic Titanium block horn 240 x 180mm, 20 kHz.

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Machined from aluminum or titanium, these horns are available up to 9″ x 12″. They require higher power units to run efficiently.

This Large titanium block horn is designed to have almost uniform amplitude across the entire surface, thus the weight of the horn is almost 7 kilos.

Extender horns (daughters horns as in composite horns) are sometimes attached to the face to weld applications requiring high amplitude.

The post Ultrasonic sonotrode Titanium block 240 x 180mm appeared first on Sonic-power.

An ultrasonic rotary horn intended to be excited at a frequency of from about 18 to about 60 kHz, which horn is a shaped, solid object having a rotational axis and a radial surface terminated by a first end and a second end.

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The horn is racially symmetrical. The thickness of the horn at the rotational axis is greater than the width of the horn at the radial surface. The diameter, width, and thickness of the horn are selected for a desired frequency so that the horn, upon being excited by ultrasonic energy at such frequency which is input at the rotational axis at, and substantially perpendicular to, one or both ends, is adapted to resonate in a manner such that:

• The excited end moves substantially in phase with the movement of the source of excitation.
• The opposing end, whether or not it is actively excited, moves substantially out of phase with the movement of the excited end.
• The radial work-contacting surface also moves substantially out of phase with the movement of the excited end.
• In addition, the first end and the second end have a substantially convex configuration which comprises a central, circular, flat portion which is concentric with the rotational axis and a generally concave portion from the flat portion to said radial
• The horn exhibits a single nodal point at its geometric center.
• Working ultrasonic rotating horns / sonotrode frequency: 20 kHz, 23 kHz, 25 kHz (sound of silence), 30 kHz, 35 kHz, 36 kHz, 40 kHz.and up to 80 kHz.
• Can be anodized, for even more ware

The post Ultrasonic Rotary horn – sonotrode, Titanium 30 kHz appeared first on Sonic-power.

Ultrasonic Titanium  horn Ø 200mm, 25 kHz.

Email : info@sonic-power.com

Machined from aluminum or titanium, these horns are available up to Ø 300mm. They require higher power units to run efficiently.

The World of Ultrasonic horns – Sonotrodes

Email : info@sonic-power.com
The World of Ultrasonic horns

Ultrasonic horns is a device commonly used for augmenting the oscillation displacement amplitude provided by an ultrasonic transducer operating at the low end of the ultrasonic frequency spectrum (commonly between 15 and 100 kHz).

The device is necessary because the ultrasonic amplitudes provided by the ultrasonic transducers them selves are insufficient for most practical applications of power ultrasound.

Another function of the ultrasonic horn is to efficiently transfer the acoustic ultrasonic energy from the ultrasonic transducer into the treated media, which may be solid for example, in ultrasonic welding, cutting or soldering or liquid.

The ultrasonic horn is commonly a solid metal rod with a round transverse cross-section and a variable-shape longitudinal cross-section – the ultrasonic rod horn. Another group includes the ultrasonic block horn, which has a large rectangular transverse cross-section and a variable-shape longitudinal cross-section, and more complex composite horns. The devices from this group are used with solid treated media. The length of the device must be such that there is mechanical resonance at the desired ultrasonic frequency of operation – one or multiple half wavelengths of ultrasound in the horn material, with sound speed dependence on the ultrasonic horn’s cross-section taken into account. In a common assembly, the ultrasonic horn is rigidly connected to the ultrasonic transducer using a threaded stud.

Ultrasonic horns may be classified by the following main features: Longitudinal cross-section shape – stepped, exponential, conical, catenoidal, Transverse cross-section shape – round, rectangular, Number of elements with different longitudinal cross-section profile – common and composite.

A composite ultrasonic horn has a transitional section with a certain longitudinal cross-section shape (non-cylindrical), positioned between cylindrical sections.

Frequently, an ultrasonic horn has a transitional section with a longitudinal cross-section profile that converges towards the output end. Thus, the ultrasonic horn’s longitudinal oscillation amplitude increases towards the output end, while the area of its transverse cross-section decreases. Ultrasonic horns of this type are used primarily as parts of various ultrasonic instruments for ultrasonic welding, soldering, cutting, making surgical tools, molten metal treatment, etc. Converging ultrasonic horns are also commonly included in laboratory liquid processors used for a variety of process studies, including ultrasonic sonochemical, ultrasonic emulsification, ultrasonic dispersing and many others.

Maximum achievable ultrasonic amplitude depends, primarily, on the properties of the material from which an ultrasonic horn is made as well as on the shape of its longitudinal cross-section.

The post Ultrasonic Titanium Horn 25 kHz Ø 200mm appeared first on Sonic-power.

Ultrasonic food cutting knifes in titanium halfwave cutting hight.

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These are the main features with ultrasonic food cutting knife, Can be used in continiuesly cutting on lines, with high speed.

• No sticking to the ultrasonic blade / horn / knife / sonotrode
• Perfect clean cut surface
• Compact equipment with a wide range of application
• Scalable machines adjustable to your needs, via our partners.
• Wide product variety of slicing without any tool changing, nougat – candy bar- cheese ect.
• No diameter, weight or thickness limits
• Easy to wash down, and easy to maintain
• Max. cutting width with 1 blade: 450 mm (20 kHz)
• Possibility to increase the cutting width with blades in series
• High speed slicing: 60 to 200 strokes / min. per blade
• Working blade frequency: 20 kHz, 23 kHz, 25 kHz (sound of silence), 30 kHz, 35 kHz, 36 kHz, and 40 kHz.
• Can be anodized, for even more easy cleaning and ware

The post Ultrasonic Knife horn with 3 knifes 25 kHz appeared first on Sonic-power.

35 kHz Ultrasonic titanium welding horn welding surface 100 x 40mm, with uniform amplitude

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A bar horn is a rectangular horn that is either un-slotted or slotted only through the thickness.

Special design techniques give optimum face amplitude uniformity. Bar horns generally has low-to-moderate gain (1:1 to 4:1). Bar horns are used for plunge and scan welding.

The post Ultrasonic welding horn – sonotrode welding surface 100 x 40mm appeared first on Sonic-power.

Ultrasonic Aluminum Bar Horn / sonotrode 350 x 70mm, 25 KHz, with uniform amplitude.

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Our unique designed high power ultrasonic converter allows us to make horns / sonotrodes in higher frequencies than normally.

This creates the advantage that no sound can be heard, we have named it “sound of silence”

A bar horn is a rectangular horn that is either un-slotted or slotted only through the thickness.

Special design techniques give optimum face amplitude uniformity. Bar horns generally has low-to-moderate gain (1:1 to 4:1). Bar horns are used for plunge and scan welding.

The post Ultrasonic Aluminum Bar Horn – sonotrode 350 x 70mm, 25 KHz appeared first on Sonic-power.