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Measurement Parameters of Ultrasonic

Oscillatory System during Welding
Thermoplastics
CONFERENCE PAPER JANUARY 2007
DOI: 10.1109/SIBEDM.2007.4292978 Source: IEEE Xplore

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1
MEASUREMENT PARAMETERS OF ULTRASONIC OSCILLATORY SYSTEM DURING WELDING
THERMOPLASTICS

Measurement Parameters of Ultrasonic

Oscillatory System during Welding
Thermoplastics
Alexey N.Slivin, Alexey D. Abramov, Denis S.Abramenko, Student Member, IEEE
Biysk Technological Institute (branch)
of Altay State Technical University after I.I. Polzunov, Biysk, Russia
Abstract - In the article the basic problems interfering
evolution of automatic-control systems by process ultrasonic
welding are analysed, measurements electric parameters of
ultrasonic oscillatory system during welding thermoplastics,
directed on search ways raise of strength a welded joint are
executed.

I. INTRODUCTION

LTRASONIC welding in modern conditions of

manufacture allows to solve many problems
connected with reception of the qualitative joint of any
thermoplastic materials. Ultrasonic welding, in most cases
in practice has successfully replaced thermal, highfrequency, frictional and other known ways of welding
[1].
Wide application of ultrasonic welding speaks that at
sampling optimum production engineering and the
necessary equipment development engineers and
industrial engineers are based on widely known
advantages and advantages of ultrasonic welding [5]:
1. An opportunity to carry out welding at temperatures
smaller temperatures of smelting welded thermoplastic
materials.
2. High quality of a welded joint.
3. An opportunity to carry out welding without
preliminary clearing welded surfaces of various pollution.
4.
Exclusion of excessive heating welded
thermoplastic materials, through local allocation of heat
in a weld zone.
5. To get a welded joint thermoplastic materials at
welding at a great distance from a point of feeding into of
energy that allows to carry out joints in remote places.
6. Absence of auxiliary glutinous components.
7. Durability of a welded joint to dissolvents, etc.

Listed above advantage of ultrasonic welding have led

to that at creation of new materials and products there is
no any more a question on sampling a way of their
welding. However, there is a some of problems which are
connected with automation process of ultrasonic welding.
Thus the main problem is definition of a time interval of
the ultrasonic affecting necessary for formation a welded
joint in thermoplastic polymeric materials.

The basic purpose now is development of automatic

ways of welding and improvement of quality of a welded
joint of products from thermoplastic polymeric materials.
II. PRODUCTION OF THE PROBLEM
During ultrasonic welding properties thermoplastic
materials (there is a softening and transition in a is
viscous-plastic condition) as a result of sorbtion of energy
of ultrasonic oscillations change. It leads to decrease
welding force, to warming up oscillatory system that
cause decrease of its Q-factor and to an error signal of the
oscillatory circuit. As a result, the resonant frequency and
an amplitude of oscillation of ultrasonic oscillatory system
(UOS) changes [1,4].
As a result of these destabilizing factors stability of a
process of ultrasonic welding and reception of a
qualitative welded joint gets special value.
Change of following parameters is usually made for
reception of a qualitative welded joint thermoplastic
materials at ultrasonic welding: amplitudes oscillation of
radiating surface UOS, magnitudes welding force and
durations of ultrasonic affecting. The variation in last
parameter has gained most a wide circulation.
At the automated ultrasonic welding limitation of a
time ultrasonic affecting is carried out by next ways:
1. Method on the fixed time assumes use of
ultrasonic affecting of constant duration at welding the
same products. Duration of ultrasonic affecting is from
preliminary experiments and is set on all weld cycles
equal, is usual by means of the electronic time relay [1].
2. Method on the fixed settlement at which
magnitude of deepening UOS in a welded detail or
deformation of a weld zone is saved by constant. At
achievement of the set deformation there is an automatic
termination of ultrasonic affecting and restriction of
moving UOS. Duration of a time of welding at this
method in each separate case can be various [8,11,14].
3. Method under the kinetic characteristic at which
is installed interconnection between an amplitude
oscillation of working end face UOS and change of
properties thermoplastic materials as a result sorbtion of
energy ultrasonic oscillations [9, 10, 12, 13]. Duration of
ultrasonic affecting proceeds till the moment of equality

2
MEASUREMENT PARAMETERS OF ULTRASONIC OSCILLATORY SYSTEM DURING WELDING
THERMOPLASTICS
of voltages and currents flowing through UOS with a
reference quantity certain by practical consideration.
At use of the circuit diagram of welding on the fixed
time the probability formation of a poor-quality welded
joint is defined by following parameters:
1. Instability of a resonant frequency and amplitude of
oscillation UOS;
2. Deviation of initial thickness of welded materials
from optimum;
3. Instability of weld conditions (temperature of a
waveguide and magnitude welding force).
4. Impurity of welded surfaces.
Not large changes of parameters of a welding regime,
geometry of details and properties of materials can lead to
that the demanded time of welding will appear more or
less time installed by the relay. Thus in the first case will
be observed skin weld, in second - burn weld. It instability
of the results gained at welding on the fixed time speaks.
Improvement of quality in this case are aimed to attain
due to maintenance of a constancy of parameters of a
welding regime, however it considerably complicates a
design of the equipment.
Unlike the circuit diagram of welding on the fixed
time at which sampling of duration of a welding time is
not connected absolutely not with education of a welded
joint, the circuit design of welding on the fixed
settlement is partially connected with kinetics of
education of a welded joint. In this case the probability of
implementation of a poor-quality welded joint is defined
by instability of initial thickness of welded materials.
Use of a welding method on the fixed settlement
assumes the certain deformation of a zone of a seam, that
sometimes happens is inadmissible owing to a decline of a
packaging of a product. The basic deficiencies of a way of
management process of ultrasonic welding (on the fixed
settlement) [8,11,14] is necessity of recustomizing of the
equipment for realization of welded joints from various on
properties and thickness of materials, and also presence of
various sensors (end switch, optical, end-of-stroke
sensors).
At ultrasonic welding with a batching of energy under
the kinetic characteristic the information on a
physicomechanical condition of welded materials is used
[1]. During ultrasonic welding there is a softening and
transition of a material in a plastic condition, magnitude
of a static compression pressure changes. Therefore the
square of contact of a welded material and welding tool
UOS changes. There is a change of an amplitude of
oscillation of oscillatory system and as consequence
change of a current, a voltage, a phase angle between
them, the power consumed UOS during welding. The
publications of authors [6,7,9,10,12] connected with
measurements on the electric side of the generator of
voltages and currents flowing through UOS, matching
speed or amplitude of ultrasonic oscillations in a material,
to a sign on a speed-up of a straining [8,11,14] materials
under a waveguide and the high-frequency energy [12]

consumed UOS are known. In the specified ways

measurement of the signal proportional to an amplitude of
oscillation and management of process of welding make
by comparison of signals with a reference quantity. Thus
a batching of energy carry out with high repeatability of
process.
The basic deficiencies of these ways of management is
that the offered criterion of definition of transition of a
material in a plastic condition during ultrasonic welding
is not to constants. Application of big static pressures
during ultrasonic welding lead to a damping of working
tool UOS, decrease of an amplitude of oscillation and
impossibility of the control of process ultrasonic welding.
Besides during welding there is a nonlinear change
properties of polymeric materials, heating UOS, decrease
of its resonant frequency and an amplitude of oscillation
during welding.
Because any of ways of management used now process
of ultrasonic welding to the full does not consider change
of parameters UOS, it is necessary to solve following
problems:
1. To execute measurements of electric parameters
UOS during ultrasonic welding.
2. To define the effect, changing properties of welded
materials on parameters UOS.
3. To research effect welding pressure on electric
parameters UOS.

III. RESULTS OF MEASUREMENT OF ELECTRIC PARAMETERS UOS

DURING WELDING
At research of process of ultrasonic welding it was used
UOS for welding thermoplastic, operating at a frequency
of 22 kHz, polypropylene weld specimens by thickness of
1,1 mm, lapped combined.
The measuring complex is developed for measurement
of electric parameters UOS during ultrasonic welding. In
figure 1 the block diagram of the measuring complex of
electric parameters UOS is presented.
The measuring complex is connected to a diagnostic
connector of the ultrasonic generator, and as in "rupture"
of a cable of UOS. Such connection provides an

fo, fo
Generator

U, I, f, (I,U)

Measuring
complex

U, I, f, (I,U)

UOS

Control
Control

Data

Computer
Fig. 1. Block diagram of measurement of parameters UOS.

opportunity of measurement of parameters following

signals:

3
MEASUREMENT PARAMETERS OF ULTRASONIC OSCILLATORY SYSTEM DURING WELDING
THERMOPLASTICS
1. Signal of basic frequency from the setting generator
sets working frequency UOS.
2. Feedback signal. Primary transformation of a signal
is carried out by the internal circuit diagram of the
generator. This signal is used in system of Automatic
Frequency control (AFC).
3. Voltage on oscillatory system.
4. Strength of current on oscillatory system.

(U,Os)

(I,U)
U
I

0
0

t, s

Fig. 2. Electric parameters UOS during welding without taking into

account effect of properties of materials (radiation in air).

(U,Os)

U
I
(I,U)

(U,Op)
0

Phase 1

Phase 2

Phase 3

t, s

Fig. 3. Electric parameters UOS during welding at constant pressure.

5 kg
0 kg
8 kg

10 kg

15 kg

0
1

t, s

Fig. 4. Dependence of amplitude of the current flowing through

piezoceramic elements UOS during welding at various weld pressure.

By means of these signals it is possible to compute

following parameters UOS:
1. Value of a voltage on oscillatory system.

4
MEASUREMENT PARAMETERS OF ULTRASONIC OSCILLATORY SYSTEM DURING WELDING
THERMOPLASTICS
2. Value of a current on oscillatory system.
3. Oscilation frequency UOS.
4. A phase difference of a voltage and a current on
oscillatory system.
5. A phase difference between two any periodic signals
(from the basic generator, a feedback, a current or a
voltage on oscillatory system).
For management of job of the measuring complex and
as recordings and processings of the measured
information
the
personal
computer
is
used.
Communication is carried out by means of protocol RS232.
During ultrasonic welding continuous measurement of
amplitude current of mechanical branch UOS I,
amplitudes of electric voltage U, a phase angle between a
voltage and current (I, U), a phase angle between a
voltage on oscillatory system and feedback signal (I,
Os), a phase angle between a voltage and a signal basic
frequencies (I, Op) was made (figure 2).
In figure 2 dependences of electric parameters UOS at
an absent material are presented (radiation to air).
During welding at an absent material value of current
I, voltage U and phase angles (I, U), (I, Op), (I,
Os) are saved by constants during all period of ultrasonic
affecting. In this case parameters UOS remain to
constants, because of absence of effect on oscillatory
system, changing properties of a welded material during
welding.
Dependences presented in figure 3 illustrate effect of
changing properties of a welded material in a weld zone
(a softening of a polymeric material and transition in a is
viscous-plastic condition) on electric parameters
oscillatory system. There is a change of following
magnitudes: I, U, (I, U), (I, Os) and (I,Op).
From dependences presented in figure 3 follows that
process of welding can be broken into 3 stages:
1. Change of a welded material from a solid condition
in is viscous-plastic. At this stage there is a decrease of
value of current I and voltage U on oscillatory system,
increase in a phase angle between a voltage and a current
(I,U), and values of phase angles (I,Os) and (I,Op)
remain practically constant.
2. The Is viscous-plastic condition. At this stage there
is maximum damping oscillatory system. Values of
current I and voltage U attain the minimal value, and
magnitude of a phase angle between a voltage and a
current (I,U) o n oscillatory system attains the maximum
value.
3. Change of a welded material from a is viscousplastic condition in is viscous-fluid. At this stage there is
an intensive smelting a material in a weld zone. Excesses
of the fused material start to be extruded from a weld zone
that reduces welding pressure on oscillatory system. There
is an increase in value of current I and voltage U on
oscillatory system, decrease of a phase angle between a
voltage and current (I, U).

One of key parameters of ultrasonic welding is welding

pressure.
In figure 4 some dependences of the current flowing
through piezoceramic elements oscillatory system at
welding of equal specimens on thickness from
polypropylene at changing welding pressure on a material
are presented.
From the presented dependences follows, that, at
welding equal specimens on thickness, curves of a current
can differ essentially from each other. It is connected, first
of all, with various force of welding pressures on welded
materials, both during the initial moment, and during all
process of welding.
Carried out researches have shown, that at effect of big
welding pressures there is strong damping UOS owing to
what it is not formed a qualitative welded joint. On the
other hand at small welding pressure also it is not formed
a qualitative welded joint, owing to insufficient energy
forwarded in a weld zone.
Thus, for implementation of the qualitative joint of
materials it is necessary to expel effect of instability
welding pressures at ultrasonic welding, i.e. to expel
distortions of curves of a current.
From the gained results necessity of search optimum
welding pressures during ultrasonic welding follows.
The further jobs will be directed on search of optimum
parameters of ultrasonic welding thermoplastic materials.
IV. CONCLUSION
As a result of the spent researches have been solved
following individual problems:
1. Measurements of electric parameters UOS during
ultrasonic welding are carried out;
2. Effect, changing properties of welded materials on
parameters UOS is determine;
3. Eeffect welding pressures on electric parameters
UOS Is researched;
4. Optimum regimes for implementation of ultrasonic
welding with the maximum effect are installed.
5. Criteria of automatic determination of optimum
regimes of ultrasonic welding of various materials in
various conditions are determined.

REFERENCES
[1] Volkov S.S., Cherniak B.J. Welding of plastic using
ultrasound, Chemistry.
[2] Volkov S.S., Orlov U.N., Astahova R.N. Welding
and agglutination of plastic. ., Machinery, 1972,
128 .
[3] Zaysev K.I., Matsuk L.N. Welding plastic. .,
Machinery, 1978.
[4] Holopov JU.V. Ultrasonic welding of plastic and
metals. "Mechanical engineering", 1988.
[5] Khmelev V.N., Slivin A.N., Barsukov R.V.,
Tsyganok S.N., Savin I.I., Shalunov A.V., Levin
S.V., Abramov A.D. "Development of the New

5
MEASUREMENT PARAMETERS OF ULTRASONIC OSCILLATORY SYSTEM DURING WELDING
THERMOPLASTICS
Principle of Batching of Energy at Ultrasonic
Welding and Creation of the Equipment for
Connection of Thermoplastic Materials", Intrnational
Workshops and Tutorials on Electron Devices and
Materials EDM'2006: Workshop Proceedings. Novosibirsk: NSTU, 2006.
[6] Patent the USSR 1315341 Control mode of a
ultrasonic welding.
[7] Patent the USSR 1627413 Control mode of a
ultrasonic welding.
[8] Patent the USSR 176381 Device for ultrasound
welding plastic.
[9] Patent the USSR 550225 Device of a proportioning
of energy at a ultrasonic welding.
[10] Patent the USSR 719835 Way of management of
process of a ultrasonic welding.
[11] Patent the USSR 753664 Device for ultrasonic
welding plastic. / Cherniak B.J., Bokov V.A.,
Lyashko F.E, Zvezdin G.A., Tizengauzen ...
[12] Patent the USSR 996140 Control mode of a
ultrasonic welding / Kozich ...
[13] RU, patent, 2220917 kl. 29 65/08. Method of
ultrasound welding thermoplastic / Lyashko F.E.,
Sokolova O.F.
[14] RU, patent, 2229382 kl. 29 65/08. Method of
ultrasound welding thermoplastic / Lyashko F.E.,
Sokolova O.F.
[15] RU, patent, 2247544 kl. A 61 B 18/00. A mode of
steering of process ultrasonic liposaction / Khmelev
V.N., Barsukov R.V., Tsyganok S.N., Slivin A.N.,
Rascals ..
Alexey N Slivin was born
in Biysk, Russia, 1976 He
received degree on information
measuring
engineering and
technologies from Altay State
Technical
University,
key
specialist of electronics. His
main research interest are
development of high-power
electronic
generators
for
ultrasonic technological welding.

Alexey D. Abramov was born

in Biysk, Russia, 1984. Post
graduated student of BTI. He is
received engineers degree from
BTI AltSTU at 2006. IEEE
Student Member. His main
research interest are development
of
high-power
electronic
generators
for
ultrasonic
technological welding.

Denis S. Abramenko post

graduated student of BTI. He is
received engineers degree from
BTI AltSTU at 2005. IEEE
Student Member.