Production requirement

How the system addresses it

Production architecture

Rigid press and controlled pneumatics for repeatable automated cycles.

Application acoustic stack

Converter, booster and horn are tuned as one system for the project.

Recipe control

Amplitude, time, energy and result windows are protected by user level.

Integration ready

Fixtures, sensors, guarding, marking and line signals can be added by scope.

Application

Typical joining requirement

Automotive plastic component

Localized welding, staking or insertion on supported parts.

Appliance housing

Fast assembly without adhesive where joint design is suitable.

Filter and nonwoven assembly

Localized seams after material and contamination review.

Electrical enclosure

Housing, terminal and insert applications with fixture control.

Industrial plastic product

Production joining for compatible thermoplastic grades.

Configuration

Architecture

Best fit

20 kHz / 2000 W

DZ-2020E reference

General-purpose medium-power applications.

15 kHz / 2600 W

DZ-1526E reference

Larger horn or weld area after acoustic review.

15 kHz / 3200-4200 W

DZ-1532E / DZ-1542E

Higher-demand applications and larger presses.

15 kHz / 5500 W

DZ-1555E reference

High-power applications requiring engineering validation.

Reference model

Frequency

Rated power

Reference weight

Reference size (W×L×H)

DZ-1526E

15 kHz

2600 W

120 kg

700×800×1300 mm

DZ-2020E

20 kHz

2000 W

120 kg

700×800×1300 mm

DZ-1532E

15 kHz

3200 W

300 kg

800×1000×2000 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 or 20 kHz

Model dependent

Model dependent

220 VAC; amplitude 10-100% in 1% steps

Environment

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Reference operating range: -10 to 40 °C

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.

Generator result

Available weld time, energy, peak power and alarm fields depend on the selected controller.

Pressure stability

Regulation, pressure switch and optional transducer support the approved force condition.

Acoustic status

Frequency tracking, overload protection and stack checks protect the welding system.

Fixture interlock

Part presence, orientation and clamp status can prevent an incorrect cycle.

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

Press

Reference model or custom throat, daylight and stroke for the part and fixture.

Acoustic tooling

Titanium, aluminum or application-specific horn plus tuned booster and fixture.

Controls

Weld modes, parameter windows, recipes, access levels and result export by generator scope.

Cooling

Compressed-air or project-specific horn/fixture cooling for demanding duty cycles.

Automation

Shuttle, rotary, multi-head, robot or line integration when a standard press is not sufficient.

Poka-yoke

Part presence, orientation, variant, insert, fixture and tool verification.

Traceability

Barcode/QR/RFID, cycle-result storage and customer-defined data fields as an option.

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

Complete plastic-part drawings and samples

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

Exact resin grades, fillers and moisture condition

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

Joint or stake geometry

Required to complete the technical concept and remove quotation assumptions.

Required strength, seal or appearance standard

Defines measurable trial, FAT and SAT acceptance criteria.

Weld area and horn access

Required to complete the technical concept and remove quotation assumptions.

Takt, duty cycle and destination utilities

Used to size stations, automation, changeover and capacity.

Question

Answer

Should we choose 15 kHz or 20 kHz?

The decision depends on part size, horn geometry, material, joint and required amplitude. Lower frequency can suit larger tools, but the acoustic design must be calculated and tested.

Is a pneumatic machine repeatable enough for Tier 1 work?

It can be when the application, air system, fixture, recipe and monitoring plan are validated. Servo control is preferred when force-position profiles or tighter dimensional monitoring are required.

Are the legacy model dimensions final?

They are reference values from the existing product portfolio. The current quotation and approved general arrangement drawing control the delivered machine.

Can the machine be integrated into an automatic line?

Yes. Loading, fixtures, safety, signals and data exchange can be engineered as a custom station.

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.