Production requirement

How the system addresses it

Programmable approach

Controlled speed and trigger conditions protect delicate parts and improve consistency.

Measured position

Collapse and final-position limits support dimensional and fault analysis.

Recipe flexibility

Named part programs store validated ultrasonic and motion settings.

Tier 1 evidence

Cycle data, alarms, access control and FAT samples support documented acceptance.

Application

Typical joining requirement

Precision plastic housing

Controlled collapse and cosmetic limits.

Automotive sensor or connector

Small joints with position and traceability requirements.

Filter / membrane assembly

Gentle programmable approach after exact-material trials.

Electrical component

Stake, insertion or weld with final-position monitoring.

Multi-variant production

Shared press with dedicated horn/fixture sets and recipes.

Configuration

Architecture

Best fit

DZ-3512F

35 kHz / 1200 W reference

Fine-feature and compact acoustic-tool applications.

DZ-2020F

20 kHz / 4000 W reference

Higher-power applications after acoustic review.

Standalone press

Manual loading

Dedicated production with guarded fixture.

Integrated station

Shuttle, rotary or line interface

Higher automation and poka-yoke scope.

Parameter

DZ-3512F

DZ-2020F

Reference model

DZ-3512F

DZ-2020F

Frequency

35 kHz

20 kHz

Rated ultrasonic power

1200 W

4000 W

Reference servo motor

400 W

400 W

Input power

220 VAC reference

220 VAC reference

Weld-time range

0.01-9.99 s

0.01-9.99 s

Reference time resolution/accuracy

±0.01 s stated legacy value

±0.01 s stated legacy value

Reference weight

150 kg

150 kg

Reference size (W×L×H)

700×500×1400 mm

700×500×1400 mm

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.

Position results

Trigger, collapse and final-position fields can be checked against recipe limits by controller scope.

Motion recipe

Approach, weld and retract speeds are stored with the ultrasonic parameters.

Cycle curves

Position and ultrasonic result data can support troubleshooting when the selected controller provides them.

Change control

Password levels and backup/restore protect validated settings.

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

Frequency / power

20 or 35 kHz reference configuration selected after application study.

Force sensing

Optional load cell or project-specific force monitoring.

Position sensing

Servo encoder and controller functions defined in the approved scope.

Tool change

Dedicated or quick-change horn/fixture with recipe and tool ID.

Data

Result storage, export, barcode and line interface by project requirement.

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

Part 3D, drawings and production samples

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

Exact material grades and fillers

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

Joint geometry and horn access

Required to complete the technical concept and remove quotation assumptions.

Collapse/final-position tolerance

Required to complete the technical concept and remove quotation assumptions.

Strength, seal and cosmetic acceptance

Defines measurable trial, FAT and SAT acceptance criteria.

Takt, data and line-interface requirements

Used to size stations, automation, changeover and capacity.

Question

Answer

What does the servo axis control?

It controls the press motion profile and position. The exact trigger, force and collapse functions depend on the selected sensing and controller package.

Does servo control eliminate the need for trials?

No. Trials remain essential because ultrasonic weldability depends on the resin, molded parts, joint, horn and fixture.

Which model is suitable for my part?

35 kHz often suits smaller precision features while 20 kHz supports larger tools and higher power, but final selection requires an acoustic and application review.

Can process data be exported?

Yes, when the required fields, format, storage period and interface are included in the project scope.

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.