Rochester Industrial Services, Inc. is the exclusive distributor for ATCP in the United States and Canadian markets since June 25th, 2013.
Rochester Industrial Services is the industry leader on all types of industrial ultrasonic welding equipment repair.
Most manufacturers that use ultrasonic welding equipment fly blind when it comes to knowing the actual operating resonance frequency of their ultrasonic tooling...
Welcome the SonicSniffer…
The SonicSniffer will allow you to take an instant kHz frequency reading AT THE HORN that can be recorded on the production floor, allowing you to establish a resonating frequency baseline. Hourly or daily readings can instantly alert you that something is going wrong and possibly avoid an equipment failure.
|Machine||Date / Time||Action||Results|
|Welder 1||6-24-13 8:00am||Baseline reading||20,080 kHz|
|Baseline reading recorded and posted on welder 1
|Welder 1||6-25-13 2:00pm||Maintenance reading||20,070 kHz|
|Maintenance reading (in acceptable range)
|Welder 1||6-26-13 2:00pm||Maintenance reading||19,010 kHz|
|Maintenance reading (Out of Range)
|Maintenance manager is alerted and welder is inspected
Possible failures could be loose stack, converter joints, cracked horn, etc.
Don't fly blind!
It's simple to know your equipment's exact resonance frequency!
Time and time again Rochester Industrial Services has proven their ability to provide everything from emergency repairs for smaller, single use manufacturers all the way up to providing integrated repair and exchange programs for major corporations.
Rochester Industrial is not only a repair facility, we are your strategic partner. Ask yourself the following questions:
Can you call your repair house and talk to the tech that repaired your equipment and ask him specific questions about your machine?
With Rochester Industrial Services YOU CAN!
Does your repair house come to your site and do training seminars?
With Rochester Industrial Services WE DO!
Does your repair house provide you with solutions and root cause failure analysis, reduce down time, reduce costly repeat repairs, and save you money in the long run?
With Rochester Industrial Services WE DO!
SonicSniffer is a portable frequency meter for preventive maintenance of ultrasonic transducers and acoustic power sets, especially those used in ultrasonic cutting and welding. The SonicSniffer determines the working frequency of the acoustic set by analyzing the sound emitted by the equipment during operation.
CAPTION: The SonicSniffer measures the working frequency of the ultrasonic transducers and acoustic sets of power during operation.
|Frequency range||From 1 to 80 kHz, with 10 Hz resolution.|
|Frequency uncertainty (2σ):||± 8 Hz for signals with duration ≥ 0.35 ms.|
|Noise immunity:||≥ 105 dB for the range between 0 and 5 kHz.|
|Measurement distance:||From 1 in. (2.5 cm) to 4 ft. (1.2 m).|
|Memory:||01 (the last effective result).|
|Size - weight:||3/8 x 3/16 x 1/16 in - 1.6 oz. (50 g).|
Preventive maintenance on ultrasonic power equipment
Problems in ultrasonic systems cause inconvenience and loss that can be easily avoided with preventive maintenance. In general, the frequency deviations indicate degradation of the interfaces; loss of grip, or more serious problems such as cracks or wear. Some of these problems can be detected with tools such as SonicSniffer and resolved by simple procedures such as those described below.
In case of more complex problems, or when the goal is to manufacture elements of acoustic sets (eg sonotrodes or acoustic horns), it is essential to use more sophisticated tools like the TRZ Transducer Analyzer.
One of the most important symptoms in the set of acoustic problems is the decrease of its operating frequency. This decline may be caused by problems in the connection between the different parts of the assembly for clamping loss or failure, wear, or presence of cracks in the material. With preventive maintenance, these problems can be resolved without the need for specialized technical assistance, which will reduce maintenance costs and avoid the incidence of more serious problems in the future.
For high-quality welding equipment, a deviation of ± 50 Hz away from normal operating frequency implies the need for preventive maintenance of the acoustic set. Generally, the criterion is based on having a prior knowledge baseline of the operating parameters of each device whose characteristics must be monitored and recorded since the beginning of operation of the same.
Verification of interfaces
Once a change in frequency is detected, remove the components for verification of the interfaces. Be careful not to deform or scratch the parts during the disassembly process. Use special tools and avoid using a vice or other devices that would potentially alter the dimensions or shape of the components.
It is essential that the contact surfaces between the transducer and booster and between the booster and sonotrode are completely flat and parallel. The presence of regions without contact between these surfaces results in loss of power and efficiency.
A poor contact between surfaces usually evidenced by the appearance of dark rings due to wear and tear around the screw coupling that can be eliminated with reconditioning (see next diagram).
If any component of the interface presents irregularities or other evidence of severe loss of flatness, this problem should be fixed with machining and employing the TRZ Transducer Analyzer.
To retrieve the interfaces, use a new sheet of sandpaper glued water n ° 600 on a clean, flat surface (a mirror is the ideal base).
Carefully slide the component in one direction on the sandpaper twice consecutively. Do not apply pressure, as the pressure exerted by the weight of the piece is enough. NOTE: Take special care to avoid tilting the piece during this operation. Loss of flatness can compromise the piece.
Perform a second and a third phase, turning the part one third rotation (120 °) about its axis between each cycle, and performing two passes in each cycle. It is very important to keep the same number of passes over the sandpaper in each cycle.
Repeat this process until the contact surface can be recovered. This should not take more than 2 or 3 complete cycles.
Reassembling the Set
First clean all parts to eliminate all foreign material, oil, or grease deposited on the threads and surfaces, as well as the holes where the screws are inserted.
Do not use any lubricant on bolts or holes. Lubricant can cause the bolts to loosen during operation of the device causing frequency reduction and overheating.
Replace the screw, if worn or damaged, with the equivalent specified by the manufacturer.
The second step is to put the screws on the sonotrode and booster. For tightening, use a torque wrench with the torque reference values specified by the manufacturer or, if not available, the following default values:
The third step is assembling the parts of the acoustic set (Sonotrode-booster-converter). For this use the appropriate tools, including a torque wrench with the following values:
To complete the assembly, retest the operating frequency of the set after mounting on the welding equipment. The working frequency should now be within the accepted parameters. Otherwise, we are in presence of a more serious problem that can be caused by cracks or excessive wear. To solve these problems, contact Rochester Industrial Services.