NONWOVENS Application Technology

Information de base
MICROBOND CSI – CDA-C25-G3
Herrmann Ultraschall
MICROBOND-C25-CDA
01 Requirements

02 MICROBOND System overview

03 Commissioning & setup

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Requirements

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Requirement for the installation
Requirement of the fixing point
The dimensioning of the screw-on point and the machine frame must be carried out in such a way that deformations and
vibrations do not negatively influence the regulation of the MICROBOND actuator. The forces and weights must be taken into
account when designing the mounting plate.

Limits
 5000N at Z axis
 500N at X axis Z axis

X axis

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Requirement for the installation
Requirement of the anvil
To ensure proper functioning of the control, the anvil roller must be installed according to the manufacturer's installation
instructions.
The anvil runout and the weld structure have a direct influence on the product quality.
The following points must be taken into account when designing the anvil and anvil bearings.

Limits
 synchronous rotation of the anvil with respect to the web material
 Concentricity of the rotary anvil drum of ≤ 5 μm
 contact pressure area of > 10%

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Commissioning & setup MICROBOND
Installation and alignment in the machine
Setup Axis offset
 Increase of the infeed angle using thick material or
high peak forces

 Adjustable by moving the anvil in production

direction or the VE MICROBOND against
production direction

 Depending from the anvil diameter in ~2-4mm

 Careful with coated sonotrodes (embedded

coating)!
Welding area
(wearing surface)

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Requirement for the installation
Requirement of the pneumatic installation
The quality of the compressed air supply network must comply at least to ISO 8573-1, class 2.4.2
Pneumatic plumbing of the converter cooling and the sonotrode cooling (option), as well as connection of the air cooling module
must be performed in accordance with the pneumatic schematics.

 Recommended supply pressure 5 – 6 bar

 Air consumption per converter > 96 l/min
 Ambient temperature ~30 °C
 Residual oil content 5 mg/m³
 Residual dust 8 mg/m³
 Residual water 6 g/m³

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Requirement for the installation
Requirement of the electrical installation
The electrical installation of the electrical cabinet, actuator, and the maintenance unit is dependent on the system configuration
as stated in the electrical schematics.

Electrical supply
 Supply voltage 400V AC 3/N/PE
 Mains frequency 50/60Hz

The power lines (HF lines and stepper motor lines) and the signal transmission lines (force sensor cable, trigger sensor cable,
metal contact ground, CAN bus lines) from the electrical cabinet to the actuators must also be laid separately.

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

02
MICROBOND
System overview

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Components and systems
MICROBOND actuator
Actuator unit CDA-C25-G3 6
7
16
1. Tooling holder CSI with ultrasonic stack
5 8
2. Force sensor connector
3. Metal contact connector
4. Eccentric adjustment 4
5. Transport eyelet
6. Main connector
3
7. Nameplate with serial no. 14
8. Stepper motor 17
15
9. Mounting screws for tooling holder + insulations 18
10. Screwing plate for tooling holder 9 13
11. Monorail
2
12. Carriages for monorail 19
12
13. Eccentric mechanic
14. Load cell 10
15. Parallel adjustment 11
16. Ball thread spindle 1
17. Homing sensor
18. Compression springs
19. Amplifire charger

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Components and systems
MICROBOND actuator
Specialties
 Movement works not linear
 In working position match 1Step = 0,3µm

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Components and systems
Charge amplifier – CMD600
Tasks of the charge amplifier
 Signal conditioning from piezo sensor
 Converts the signal to an analogue 0-10V

LED status
 RED: Reset
 GREEN: Measurement
 BLUE: Error

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Components and systems
VE MICROBOND
Tooling holder CSI
1. Jaw screws M8x30
2. Washer 8,4 14
10
3. CSI jaws
4. Sonotrode 15
9
5. Isolation plate
6. Tooling holder
3 11
7. Metal contact screw M5x12
8. Insulation shell short, 16mm
9. Insulation shell long, 83mm 1 12
10. Mounting screw M8x110
11. Mounting screw M8x40 13
12. Washer 8,4
13. Insulation washer 8
14. Support screws M6x100 16
15. Fender washer 6,4x15x1,5 7
6
16. CSI feed
5
2 4

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Components and systems
Overall system

High frequency cable

Force signal

CAN Bus

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Components and systems
Force/ Trigger Overview

Red = Forcesignal
Blue = Triggersignal Charge amplifier

SKM Modul

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Components and systems
Differences between SMR/ CDA
MICROBOND CSI – SMR-C10-G3 MICROBOND CSI – CDA-C25-G3

 Sensortype: DMS  Sensortype: Piezo

 Force working range: max 2500N  Force working range: max 4000N

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Components and systems
Parameter – MICROGap Controll
Special parameter MICROGap Controll
In order to ensure the proper functioning of the system, some parameters are important and must not be changed.
Actuator Specific Machine Parameter
 Synchronization: ON
Force Measurement Parameter
Special functions
 Measuring Range: 4000N
 Max. Force 7500N: ON
 Force Calibr. Pos.: 0 stp
 AC velocity: 200
 Filter type: 1000Hz
 Pos. US on: ON
 Sensor type: Piezo25
Controller Parameter
To setup this parameters it needs a service password
 P- Portion: 30 stp
 I-Portion: 5 stp
 I-Portion: 5 stp

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Components and systems
Parameter – Generator
Special parameter generator
In order to ensure the proper functioning of the system, some parameters are important and must not be changed.

Controller Parameter I Options

Force/ Frequency Offset: ON
Function I Trig. process contr.
Analog Input 4: ON
Trigger level: 2,5V
Diagnostic I Analog out
Virtual DAC: analog input 4

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

03
Commissioning & setup

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Commissioning & setup
Installation and alignment in the machine
Possible adjustiment options
 Z-axis (Moving direction of the sonotrode)
 U-axis (Tilting of the actuator)
 X-axis (in or against process direction)

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Commissioning & setup
Mechanical basic setting
Setup of the working position (Z-axis)
 The eccentric moves the toggle joint of the actuator unit
up or down. Thus, the optimum working position of the
sonotrode can be adjusted.
 Movement is +/-2mm
 The optimum working point in the process should be
between 7700 – 8000 steps.

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Commissioning & setup
Mechanical basic setting
Setup of the parallel adjustment (U-axis)
 The eccentric moves the toggle joint of the actuator right
and left. Thus, the optimum paralliusm of the sonotrode
and the anvil.
 Movement is +/-2mm

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Commissioning & setup
Mechanical basic setting
Parallel adjustment
unlock
(U-axis) via centering bolt
 Unlock the mounting screws, or
only the upper 4 when adjusting
finer.
unlock

 Use the parallel adjustment to tilt

the VE MICROBOND in the pivot keep closed
point

 use 2 feeler gauges 0,03mm -

0,05mm or pressure paper
(for open structures) to check the
correct setup

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Commissioning & setup
Mechanical basic setting
Pre-adjustment of trigger timing (mechanical)

 Install the trigger disc and the sensor

 Turn the anvil until the end of structure is in middle of the Sonotrode (see pic.)
 Adjust the disc that the end of the disc in the middle of the sensor

web direction

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Commissioning & setup
Basic setup sequence
 Remove eccentric handle completely back in starting position (away from anvil)
 Move stepper motor manually to position 8000 in setup mode
 Unlock mounting screws of the VE MICROBOND (keep the two lowers closed for fine adjustment)
 Adjust sonotrode to anvil parallel (use feeler gauges or pressure paper), therefore use eccentric handle
 Use eccentric handle until metal contact is reached and fix the handle with low force (250N)
 Execute automatic force calibration (turn the anvil until the LED of the charge amplifier shines red)
 Check force value at position 0 to 0N +/-5N (using automatic force check function)
 Possibly recheck metal contact position and inspect values again (use automatic metal contact position check function)
 Perform a scan of the sonotrode

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Commissioning & setup
Ultrasonic stack
 Work after exchange some parts like Generator/ Converter/ Booster or Sonotrode

Attention
It is important that:
 The stack are mount right (torque)
 Nothing touch the stack during the learn process
 The parts are not hot or cold

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Commissioning & setup
Adjustment of the trigger disk via UltraView
Requirements
 Anvil already installed
 Trigger disc are mount and roughly adjusted
 Actuator already installed
 Actuator are setup done
 Machine are able to run

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Commissioning & setup
UltraView
Adjustment of trigger position with UltraView
1. Start the Software
2. Connect with the generator
3. Start the production machine and speed up
4. Collect the data
5. Zoom in the welding process and analysis
6. Adjust the trigger disc how it necessary
7. Repeat step 4 -7 until is setup correctly
8. Start the production machine and speed up
and adjust the Force-/ Frequency Offset

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Commissioning & setup
Mechanical basic setting
 1. Button to change the language > (German/
English/ Italian )
 2. Button to connect to the set IP address
 3. Field to write the IP address
 4. Change the IP address on the current 1
connection
2
 5. Status of the connection
3
4
5

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Commissioning & setup
Adjustment of the trigger flank

 The end of the trigger signal should be at the end of the structure.
 The trigger signal has to end with the force like on the graph (green and light blue)
 This adjustment we have to do at full speed

 too close  Good  too far

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Commissioning & setup
Adjusting the force control

Force control
 With this offset it is possible to adjust that the
Amplitude are not higher then 120%
 Default value are 400
 Caution:
 Only in small steps (max. in 50)

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Commissioning & setup
Requirements for remote support
Requirements
 Stabel internet conecction
 Laptop with some software
 Ultraview
 TeamViewer
 Webex
 Ethernet cabel

© Copyright Herrmann Ultraschall I NONWOVENS Application Technology

Global Headquarters North America Headquarters
Herrmann Ultraschalltechnik GmbH & Co. KG Herrmann Ultrasonics, Inc. Bartlett, IL, USA
Descostraße 3–11 · 76307 Karlsbad, Germany
China Headquarters
Herrmann Ultrasonics Co. Ltd. Taicang, Jiangsu Province, China

Japan Headquarters
www.herrmannultraschall.com Herrmann Ultrasonic Japan Co. Ltd. Kashiwa City, Chiba, Japan