Modelling and Designing of Ultrasonic Welding Systems

This article presents the main stages and challenges in modelling and designing of modern ultrasonic welding and cutting systems. First, the key components of such a system, such as an ultrasonic stack (consisting of a high power ultrasonic transducer and a sonotrode) and a digitally controlled ultrasonic power supply with precise control of the output power, have been considered. Next, a concept of measurement system for verification and validation of mathematical models of ultrasonic stacks and its components has been presented. Finally, a method of ultrasonic stack e-diagnosis based on ultrasonic transducer electrical impedance measurement during welding and cutting process has been described.