Production requirement

How the system addresses it

Self-contained cell

Press, controls, fixture area and guarding are packaged in one station.

High-power range

15 kHz systems support larger acoustic tools after tuning and application trials.

Operator workflow

Dedicated loading height, fixture and two-hand/safety-door logic by risk review.

Expandable controls

Sensors, marking, result storage and line signals can be added by scope.

Application

Typical joining requirement

Large plastic housing

15 kHz joining with dedicated horn and supported fixture.

Automotive subassembly

Manual-load production with part and variant verification.

Appliance component

High-power weld, staking or insertion in a guarded station.

Industrial filter / enclosure

Application-specific weld after exact-material testing.

Standalone production island

Complete machine where line integration is not required.

Configuration

Architecture

Best fit

DZ-1532E station

15 kHz / 3200 W reference

Compact model in the enclosed family.

DZ-1542E station

15 kHz / 4200 W reference

Higher-power reference configuration.

DZ-1555E station

15 kHz / 5500 W reference

Largest legacy power configuration.

Custom enclosed cell

Project-specific

Fixture, guarding and controls adapted to the assembly.

Reference model

Frequency

Rated power

Reference weight

Reference size (W×L×H)

DZ-1532E

15 kHz

3200 W

300 kg

800×900×2000 mm

DZ-1542E

15 kHz

4200 W

350 kg

900×1000×2200 mm

DZ-1555E

15 kHz

5500 W

400 kg

900×1000×2200 mm

Common reference

15 kHz

Model dependent

Model dependent

220 VAC reference

Parameter

Engineering purpose

Frequency and acoustic tuning

Matches the horn, booster, converter and application; confirmed after acoustic design and trials.

Amplitude

Controls vibration displacement and heat generation; stored by recipe where the generator supports it.

Trigger force or trigger position

Defines when ultrasonic energy starts and reduces variation from part loading.

Weld mode

Time, energy, peak power, collapse/distance or absolute position, depending on controller and validation plan.

Weld force / air pressure

Influences interface contact, melt flow and final joint formation.

Hold time and hold force

Stabilizes the joint before the horn retracts.

Peak power and energy windows

Useful indicators for detecting missing parts, poor contact, tool wear or material variation.

Collapse or final position

Optional measured characteristic for applications requiring dimensional control.

Control element

Available project function

Recipe and access control

Named part programs, controlled editing rights and change history where required.

Cycle result

Pass/fail result based on agreed parameter limits, with clear alarm and recovery logic.

Process data

Time, energy, peak power, amplitude, force/pressure and position values available according to controller scope.

Part identification

Barcode, QR, RFID or manual selection options to prevent recipe/variant mismatch.

Tool and fixture status

Presence, home-position and service-life counters can be included in the control plan.

Line interface

Dry contacts, industrial Ethernet or customer-defined protocol; MES exchange is optional, not standard.

Safety status

Door, guard, emergency-stop and reset sequence are checked before weld enable.

Ultrasonic result

Time, energy, power and alarms are recorded according to generator capability.

Part loading

Presence, orientation and fixture confirmation reduce manual-loading errors.

Service access

Planned access supports acoustic-stack inspection and fixture maintenance.

Material or design factor

Application guidance

ABS, PC/ABS, PC, PS

Common ultrasonic candidates when joint geometry and cosmetics are suitable.

PP, PE and other semi-crystalline resins

Feasibility depends strongly on near/far-field distance, stiffness, joint design and fillers.

PA and filled engineering resins

Moisture, reinforcement level and horn wear must be reviewed during trials.

TPE/TPU or soft components

Often challenging; test the exact grade, thickness and support condition.

Dissimilar materials

Do not approve from generic resin names; validate chemical compatibility and melt behavior.

Option

Project scope

Enclosure

Guarded station with customer-defined safety device and optional sound treatment.

Loading

Front load, shuttle or ergonomic fixture arrangement.

Fixture

Custom nest, clamps, presence sensors and quick-change option.

Controls

Recipe, user access, result storage, barcode and line-ready signals.

Tooling

Tuned 15 kHz horn, booster and support fixture for the actual part.

Inspection

Vision, displacement, force, leak, pressure, flow or dimensional checks according to the CTQ plan.

Line communication

Signals or industrial network interface; MES connection only when explicitly included.

Safety

Interlocked guarding, safety doors/light curtains, emergency stops and safe reset concept to destination requirements.

Service package

Training, recommended spares, preventive-maintenance plan, remote support and optional on-site support.

Acceptance activity

Typical evidence

Documented scope review

Approved specification, layout, utilities, interfaces, cycle definition and exclusions.

Tool and datum verification

Part location, clamp support, tool identity and changeover checks.

Process-window trials

Representative production parts across agreed material and dimensional variation.

Quality checks

Agreed visual, dimensional, strength, leak, burst or functional test with defined limits.

Repeatability run

Quantity, run duration, operator conditions and acceptance method agreed before FAT.

Safety validation

Guarding, interlocks, emergency stops, reset behavior and maintenance access.

Data and alarm test

Recipes, access levels, pass/fail windows, alarms, identifiers and interface signals.

Training and handover

Operation, changeover, maintenance, backup/restore and agreed documentation.

Stage

Main input or activity

Output / decision

1. Application review

Parts, materials, joint, CTQs, takt and plant standards

Feasibility risks and missing inputs

2. Concept and quotation

Process choice, layout, tooling, controls, interfaces and exclusions

Approved technical and commercial scope

3. Trials and samples

Production-equivalent parts and agreed test method

Process window and sample evidence

4. Detailed engineering

3D design, risk review, I/O, safety and documentation plan

Customer design approval

5. Build and debug

Machine, tooling, programs and internal run-off

Ready-for-FAT review

6. FAT

Agreed parts, run quantity, quality checks, takt and documents

Punch list and shipment release

7. Installation and SAT

Utilities, setup, training and site acceptance run

Production handover by agreed scope

Please provide

Why it is needed

Part drawings and production samples

Used to check envelope, datums, access, tooling and machine layout.

Exact resin grades and joint design

Required for process feasibility and a grade-level trial plan.

Required horn size and access

Required to complete the technical concept and remove quotation assumptions.

Operator loading and ergonomic standard

Defines destination compliance, controls and responsibility boundaries.

Weld acceptance and cycle target

Defines measurable trial, FAT and SAT acceptance criteria.

Destination safety and electrical standard

Defines destination compliance, controls and responsibility boundaries.

Question

Answer

Is this really a desktop machine?

It is the legacy product name. The reference systems are floor-standing enclosed stations, as shown by their size and weight. A compact bench machine can be quoted separately if suitable.

Why use 15 kHz?

15 kHz can support larger horns and higher displacement for selected larger parts, but acoustic feasibility and audible-noise controls must be reviewed.

Does the enclosure reduce noise?

It can support acoustic treatment, but final sound performance depends on the process, guarding design, leaks, room and measurement method. No dB value is promised without testing.

Can the station be connected to a line later?

Signals and handling interfaces can be planned, but future integration requirements should be specified during the original design.

What information is required for an application review?

Please send part 3D data and drawings, exact resin grades, joint or stake details, production-equivalent samples if available, CTQ and test requirements, takt, annual volume, variant mix, utilities and plant standards.

Can Dizo Sonics test our real parts before quotation?

Yes. An application review and representative-part trials are recommended when feasibility, tooling concept or cycle assumptions need evidence. Trial scope, sample quantity and test method are agreed before testing.

How is the final cycle time confirmed?

The committed cycle is based on trials and a complete sequence study including loading, clamping, joining, cooling, inspection, data handling and unloading. Published reference cycles are not universal guarantees.

Which plastic materials can be processed?

Suitability is approved at exact-grade level. Resin chemistry, fillers, moisture, additives, color, recycled content, molded-part variation and joint design can all change the process window.

What documents are supplied with the machine?

The project handover package can include the approved specification and layout, electrical and pneumatic documentation, manuals, maintenance plan, spare-parts list, parameter backup, inspection records and FAT documents according to the contract.

Do you support FAT, installation and SAT?

Yes. FAT and SAT activities are defined in the project plan. Installation, training and on-site support depend on destination, responsibility split and the commercial scope.