Design ultrasonic power generators for welding machines using piezoelectric ceramic materials for welding on non-woven fabrics

Abstract

This paper presents the design and manufacture of ultrasonic emitters for welding machines using piezoelectric ceramic materials for welding on nonwoven fabrics. The ultrasonic vibrating membrane (UVB) used for the transducer is investigated to ensure that there are no cracks in the material structure. These parameters serve as the basis for evaluating the quality of the ultrasonic vibrating membrane in the fabrication of an oscillator for ultrasonic transducer welding (USTW). The ultrasonic power generator (USPG) is made of high-frequency components and power components to supply electrical oscillations to the UVB. This vibrating source must be compatible with the USTW to operate at maximum efficiency. Due to the influence of the manufacturing process and USTW usage environment, after operating for a long time, the resonant frequency (f_r) will be changed. Therefore, the USPG needs to monitor the frequency of the USTW automatically. Matching the impedance of USTW and USPG is very important to get the most out of USPG power. The fabrication results show that the use of high-resolution timer to generate the control frequency for USPG achieves high accuracy, with the largest error of 0.006% at 18401.12 Hz when surveyed in the range of 18 to 22 kHz. The parameters of control signal delay between two phases and pulse width also give very good results. Impedance-matching (IM) networks also show good exploitation of USPG when compared to USPG without IM.