Abstract: An ultrasonic welding system including at least one sonic converter including a body and an ultrasonic horn, a vibrator disposed in the ultrasonic horn, a power source configured to provide electrical power to the vibrator, a driver mechanically coupled to the sonic converter, the driver being configured to drive the sonic converter, a controller including a detected power input and a driver control output, the driver control output being connected to a control input of the driver, and a first power monitor disposed at one of a vibrator power input and a power source output, and configured to provide a first measured power magnitude to the detected power input.

Abstract: A dual ultrasonic welder unit may be coupled to and carried by a mounting bracket including a base member extending in a an end of a robot arm and may include a first welder including a welding horn adjustable in a Z-axis direction by a first motor mounted within a mounting bar assembly of the first welder. The mounting bar assembly may be coupled to the base member and include a support for adjusting the location of the first welder in an X-axis direction by a second motor mounted to an extension member coupled to the base member and including a threaded member coupled to a follower member coupled to the mounting bar assembly. The dual ultrasonic welder may include a second ultrasonic welder fixedly coupled to the base member.

Abstract: A dual ultrasonic welder unit may be coupled to and carried by a mounting bracket including a base member extending in a an end of a robot arm and may include a first welder including a welding horn adjustable in a Z-axis direction by a first motor mounted within a mounting bar assembly of the first welder. The mounting bar assembly may be coupled to the base member and include a support for adjusting the location of the first welder in an X-axis direction by a second motor mounted to an extension member coupled to the base member and including a threaded member coupled to a follower member coupled to the mounting bar assembly. The dual ultrasonic welder may include a second ultrasonic welder fixedly coupled to the base member.

Abstract: An ultrasonic welder includes a housing having an ultrasonic transducer, a horn mounted to one end of the housing, a motor having a shaft, and a mounting assembly having a fastener such as a threaded screw. One screw end is coupled to the motor shaft to rotate as the motor shaft is being driven. The other screw end extends into a threaded screw receiver running within the housing. Upon rotating in one direction, the screw engages more threads of the screw receiver such that the housing with the horn move upward. Upon rotating in the other direction, the screw engages less threads of the screw receiver such that the housing with the horn moves downward. A linear transducer extends from the mounting assembly into the housing to monitor the horn position. A pair of guide shafts extend from the mounting assembly into the housing to stabilize the horn positioning.

Abstract: An ultrasonic welder includes a housing having an ultrasonic transducer, a horn mounted to one end of the housing, a motor having a shaft, and a mounting assembly having a fastener such as a threaded screw. One screw end is coupled to the motor shaft to rotate as the motor shaft is being driven. The other screw end extends into a threaded screw receiver running within the housing. Upon rotating in one direction, the screw engages more threads of the screw receiver such that the housing with the horn move upward. Upon rotating in the other direction, the screw engages less threads of the screw receiver such that the housing with the horn mover downward. A linear transducer extends from the mounting assembly into the housing to monitor the horn position. A pair of guide shafts extend from the mounting assembly into the housing to stabilize the horn positioning.