Download Brochure WeldMaster C

WeldMaster™ C-Frame
Metal Spot Welder
The WeldMaster™ C-Frame I and
the WeldMaster™ C-Frame II
easily accommodate large metal
parts and enhance weld consistency, while significantly reducing
both weld energy and weld time.
General Description
Sonobond’s WeldMaster C-Frame I and
WeldMaster C-Frame II spot welders are
ideal for welding large metal parts, such as
those used in the mass production of aluminum automobile bodies. Both units produce
ultra-reliable, solid-state metallurgical
bonds without heat, current, fluxes, filler
materials, or other consumables. Although
the actual weld rate depends on the thickness and type of materials being joined, the
operation is usually completed in less than
1.5 seconds. The resulting welded joint
is usually as strong as the parent metals.
This technology also virtually eliminates the
problem of tips sticking to aluminum parts.
Both units have a microprocessor-controlled
2500-watt power supply, the patented
Wedge-Reed coupling system, and a Taper
Lock Tip that’s easily removed and replaced.
The tip vibrates to ultrasonically weld the
materials. The WeldMaster C-Frame I,
Model CF14-1, has a 14-inch throat depth
that accommodates a single head. The
WeldMaster C-Frame II has an 18-inch
throat depth. It is available with a single
head, Model CF18-1, or with a dual head,
Model CF18-2, that further reduces weld
time and energy. In order to better handle
large metal parts, both spot welders have
ample room between the tip and anvil, along
with the deep throat. The two units can be
operated by a robot arm that positions the
spot welder at desired weld locations.
WeldMaster™ C-Frame I and WeldMaster™ C-Frame II metal spot welders
Sonobond custom designs tooling to meet
each customer’s specific needs.
Features and Benefits
• Outputs 2500 watts of power to weld
non-ferrous similar and dissimilar
metal assemblies, including copper to
aluminum
• Effectively accommodates large metal
parts, such as those used in the automotive industry
• Produces ultra-reliable, solid-state metallurgical bonds without heat or current
• Requires no fluxes, filler material, or
other consumables
• Patented Wedge-Reed coupling system
assures precise, dependable welds
• Virtually eliminates the problem of tips
sticking to aluminum parts
(Continued on next page)
1191 McDermott Drive • West Chester, PA 19380 • Phone: 800-323-1269 • 610-696-4710 • Fax: 610-692-0674
Internet: www.SonobondUltrasonics.com • E-mail: [email protected]
© 2010 Sonobond Ultrasonics
WeldMaster™ C-Frame Metal Spot Welders
Features and Benefits
(continued from previous page)
• Heat-treated, tool steel Taper Lock Tips
can perform up to 200,000 welds without experiencing serious degradation
and can be easily removed and replaced
• Minimal operating and training costs
Operating Modes
TIME: In the Time Mode, the operator sets
a power level and weld time.
ENERGY: In the Energy Mode, the operator sets a power level, total energy in
joules, and a maximum weld time.
• Energy efficient and environmentallyfriendly
HEIGHT: In the Height Mode, the weld is
controlled by final weld thickness. The
operator sets a weld thickness in millimeters, a power level, and a maximum time.
• Easily incorporated into automated assembly equipment
Weldable Materials
• Little or no pre-cleaning of parts required
• Can be operated by robot arm
• Automatic frequency control for stable
operation
CF14-1 and CF18-1:
Aluminum 5xxx/6xxx 0.060” (1.5 mm)
Copper 1/2 hard 0.060” (1.5 mm)
Applications
Specifications
The Sonobond C-Frame I [Model CF14-1]
and C-Frame II [Models CF18-1 and CF182] are utilized in welding large metal parts,
such as those used for assembling aluminum automotive bodies. They can be bench
mounted or adapted for robot operation.
Theory of Operation
Both units use Sonobond’s patented
Wedge-Reed coupling system of high
vibratory force and low amplitude to ensure
precise, dependable welds. The two units
direct high-frequency, ultrasonic energy, via
a welding tip, to the surface between the
metals to be welded. The vibratory energy
disperses the oxides and surface films
between the work pieces. This creates a
true metallurgical weld without melting the
materials. In the case of Model CF18-2,
there are two ultrasonic heads. One head
powers the welding tip, while the other
head powers the anvil. This reduces the
weld energy and time by about half that
which is required for a single head.
The FC2016 power supply utilizes a pulse width
modulation amplifier with a feedback loop in
the directional coupler to control output power.
All weld parameters are adjusted, saved, and
recalled from the front panel of the power supply.
CF18-2: Aluminum 5xxx/6xxx 0.125” (3 mm)
Copper 1/2 hard 0.125” (3 mm)
Titanium Ti6Al4V 0.080” (2 mm)
Input Power
208 ± 10% VAC @ 15 amps, 1 phase
Air Requirements
100 psi @ 3 CFM clean dry air
Output Power
2,500 watts RMS into a 50 ohm resistive load
Databank
250 weld protocols
Weld Data Output
RS232 Port
Distance Measurement
Linear voltage displacement transducer (LVDT)
Throat Depth:
• Model CF14-1
• Model CF18-1 & CF18-2
14” (355 mm)
18” (457 mm)
Stroke (Tip Travel)
3” (76 mm)
Weld Force
Electro/pneumatic proportional regulator with feedback loop
Acoustic System
High force, low amplitude, Wedge-Reed with Taper Lock Tip
Transducer
Piezo-electric
Dimensions (approximate):
• Power Supply
• CF14 Welding Head
• CF18 Welding Head
8” (203 mm) high, 20” (508 mm) wide, 22” (559 mm) deep
33” (841 mm) high, 10” (257 mm) wide, 21” (530 mm) deep
36” (906 mm) high, 10” (257 mm) wide, 26” (663 mm) deep
Weight (approximate):
• Power Supply
• Welders: CF14-1
• CF18-1 & CF18-2
75 lbs (34 kg)
230 lbs (105 kg)
280 lbs (127 kg)
Specifications are provided for information only and are believed to be accurate. However, no responsibility is assumed by Sonobond Ultrasonics for their use. Ongoing product development and improvement
may cause changes without notice.
1191 McDermott Drive • West Chester, PA 19380 • Phone: 800-323-1269 • 610-696-4710 • Fax: 610-692-0674
Internet: www.SonobondUltrasonics.com • E-mail: [email protected]
© 2010 Sonobond Ultrasonics