A new type of high power ultrasonic generator for welding and cutting processes

The paper presents a new type of high power ultrasonic generator for welding and cutting processes developed by the Tele & Radio Research Institute. The new generator can provide up to 5 kW of electrical power to an ultrasonic transducer in the frequency range of 16 kHz up to 60 kHz with regulation step down to 0.1 Hz. The device utilizes an innovative microcontroller with built-in high resolution timing blocks that enable direct synthesis of control signals for the generator's resonant converter, without the need of an external DDS unit or programmable device. This new approach to designing ultrasonic generators can benefit in greater flexibility and reliability of the device. New algorithms with cycle-by-cycle parameter control, and precise regulation of output frequency and power delivery, have been developed. Various parameters of ultrasonic stack, such as impedance and resonant frequency, are measured by the generator in real-time, and can be used for ultrasonic stack wear monitoring and fault detection.