First Welding Tests

Now, there is a time to test, if the generator is capable to heat the flexible vinyl foil significantly to weld it. The generator can be set easily. It can be started by external signal or internally, by the small arm on the probe top end. Operation stops in time set on the timer dial. For tuning, the mode is better to set as infinite, without time limit. Then, it is possible to start and stop generator manually and find the best output power using the tuning knob.

Before process.

Welded quite successfully.

Quite success, but overheat a little.

Finally, the maximal output power was found a quite big. The vinyl foil was welded in the time between 0.3 - 0.6 s. Sometimes, the heat was as high that the hole through was made. Sometimes, a gas was produced, which expanded and tore the weld apart. There is also problem with pointing accuracy, because due to ultrasonic vibration, there is very difficult to maintain the welded place, if the probe is hold by hands only.

The next research will be focused to more precise power setting, making better holder for accurate pointing and also it will be good to make another shape of the rod, where the energy will be distributed better.

Inside Generators

The electrical connection was inspected briefly and found pretty simple. There is no any integrated circuits inside, only simple power supply, oscillator and amplifier.

The front panel.

Timer dial in center, tuning knob and output power indicator on the left, then connectors for the probe and for the external triggering. On the right side, there are input and output power indicator lights, power switch and mode switches.

The rear panel.

Under the cover.

The probe.

The arm on the top end of the probe is equipped with a micro switch and can be used as an internal trigger.

The rod.

The rod can make spot about 6 mm in diameter. There are another rod shapes available at Honda Electronics, but we have this one only.

Artificial Japan Eectrical Network

Because of unique opportunity, I managed to obtain two old ultrasonic  generators from the scrap equipment of one local factory. Nobody knows what to do with them in comparison to many another useful devices they gave away, so the way to them was open. Now, the question is - could we use the generators for the flexible PVC material welding?

Connected transformers to produce a 96 V power.

At first, we need an electrical power. The generators was made by Honda Electronics and have power input for Japan network (maybe regulated), 100 V, 150 W. I don't have any regulation transformer and making stable transformer from 230 V to 100 V is expensive. So, I take four similar transformers to 24 V taken from four old VCRs I found in trash before many years. At the primary, I connected them in parallel to a 230 V. The secondary winding was then connected in series to get 96 V. When loaded to 150 W, there was no significant voltage drop. At last, the Japan outlet connector was added. I had it at my storage I don't know from.