Hands on Ultrasonics from Telsonic

24th November 2009
Posted By : ES Admin
Hands on Ultrasonics from Telsonic
As the use of ultrasonics for welding continues to expand, applications have become not only more diverse but complex and today it is not uncommon to find highly automated, multi sonotrode systems in many instances. Seeing the technology applied in this way clearly demonstrates the level of confidence that demanding industries such as medical device and automotive have in the process. It is interesting to note however that in many cases, the trust and confidence in the process was first established from demonstrations or prototype work, often using a simple hand held, single sonotrode unit.
Getting to grips with the process

Telsonic’s hand held ultrasonic welder, although simple in its configuration, is a powerful and highly flexible tool that can be applied to a multitude of tasks. When used in a development role the system can be quickly configured to produce test welds on prototype components. This allows the user to determine the suitability of the process for the application and even help establish indicative welding parameters and cycle time – useful information when considering the future production process.

The flexible configuration of the unit enables the hand tool to be mounted to a hand press in the vertical axis. This allows prototype and evaluation work to be taken to the next level, ensuring a consistent and predictable approach angle, operation to a fixed stop with automatic start and utilisation of the inbuilt generator timer. From this simple and portable approach often done at customer sites, trials can then be taken to the next step with powered, fully micro-process controlled weld delivery within the Telsonic Lab. Here, additional information such as height, distance and pressure can be obtained making it possible to generate a production specification for the welding process. By changing the sonotrode or tip, the same self tuning unit can be used to test different weld shape and size configurations.

Giving production a helping hand

There are also many cases where Telsonic’s hand held welding system is used as a production tool. Applied to low volume – high mix product ranges or large complex 3 dimensional components, the hand operated welding unit provides a quick, clean and efficient solution to many joining, welding and cutting tasks.

Ergonomics is a major consideration for all manual and semi automated processes and the Telsonic hand held ultrasonic welding system has been designed specifically with operators in mind. The low weight, just 1kg and slimline ‘grasp’ type grip with leaf switch operation, mean that the unit is easy and comfortable to use in either the horizontal or vertical attitude. Special configurations are also available to meet the needs of disabled users. The unit also has an attachment for counterbalanced hanger systems and a mounting point for pantograph use. The modest costs associated with the technology plus the ability to “pre-set” the welding time parameter, which helps de-skill the process, has seen the technology adopted in this configuration by companies involved in trade moulding, packaging, thermo-forming and plastics fabrication.

A further benefit of the hand held configuration is its ability to provide a valuable back up for automated production systems. Should an issue arise with one or more of the welding points within a production machine, the hand operated system will enable an operator to complete or re-work these specific welds, using the same welding parameters and enabling production to continue until repairs to the machine can be completed.

Whilst many companies continue to use the hand held unit as the mainstay of their production processes, others have used this configuration to grasp the technology, understand its many benefits, develop production level concepts and apply it in more sophisticated forms.

With a track record spanning over 40 years, Telsonic has been involved in the development and integration of ultrasonic technology into thousands of production systems. Companies wishing to consider ultrasonics for welding, cutting and cleaning applications will benefit from the unrivaled knowledge and experience gained by Telsonic’s engineers during this time.


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